W912P522R0003 RTA TSpecs AppB-6.pdf

Quality Operating Procedure

IveyCooper

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 strength.

11.6 Examination Coverage: All examinations shall be conducted with sufficient overlap to ensure 100% coverage of area to be examined at the required sensitivity.

11.7 Small holes and openings leading to obscure passages or cavities shall be plugged or masked with suitable material to prevent test medium from coming in contact with components that may be damaged by particles or particle suspensions, unless prohibited by contract and/or code requirements.

11.8 Surface Contrast Enhancement: When coatings are temporarily applied to surface of test specimen, the coating shall only be in amounts sufficient to enhance particle contrast. When coatings are applied for particle contrast, it shall be demonstrated, in accordance with Paragraph 11.5, that indications can be detected through the enhancement coating.

12.0 Magnetization Techniques:

12.1 Longitudinal Magnetization Coil Technique: With this technique, magnetization is accomplished by passing current through a multiple-turn fixed coil (or cable) that is wrapped around the part or section of the part to be examined. This produces a longitudinal magnetic field parallel to the axis of the coil. If a fixed or pre-wound coil is used, the test specimen shall be placed near the inside surface of the coil during inspection. This is especially important if the coil opening is greater than ten times the cross-section of the test specimen (low fill factor coil).

12.1.1 When using the longitudinal technique in accordance with this procedure, direct or rectified magnetizing current shall be used. The required field strength shall be calculated based on the length (L) and the diameter (D) of the part in accordance with 1, 2, or as established in 3. below. Long parts shall be examined in sections not to exceed 18 inches (460 mm), and 18 inches (460 mm) shall be used for the part (L) in calculating the required field strength. For non-cylindrical parts, (D) shall be the maximum cross-sectional diagonal:

1. Parts with L/D Ratios Equal to or Greater than 4:

(Exception- for work to Military Standards use 12.1.1.2)

The magnetizing current shall be within +/- 10% of the ampere-turns value determined as follows:

Ampere-turns = 35,000 (L/D) + 2

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

For example, a part 10 inches (250 mm) long x 2 inches (50 mm) diameter has an L/D ratio of 5.

35,000 (5+2) = 5,000 ampere-turns

2. Parts with L/D Ratios Less Than 4 but not Less Than 2 and all work to Military Standards:

The magnetizing ampere-turns shall be within +/- 10% of the ampere-turns value as follows:

Ampere-turns = 45,000 L/D

3. Parts with L/D Ratios Less Than 2:

(Exception- for work to Military Standards use 12.1.1.2) An alternate form of magnetization shall be used.

12.1.2 Magnetizing Current: The current required to obtain the necessary magnetizing field strength shall be determined by dividing the ampere-turns obtained in steps 1 or 2 in Paragraph 12.2.1 by the number of turns in the coil as follows:

Amperes (meter reading) = ampere-turns turns

For example, if a 5-turn coil is used and the ampere-turns required are 5,000

5,000 5 = 1,000 amperes (+/- 10%)

12.2 Longitudinal Yoke Technique: With this technique, alternating or direct current electromagnetic yokes shall be used. This method shall only be used to detect discontinuities that are open to the surface of the test specimen. When possible, the yoke shall be rotated 90 degrees with respect to the original location and yoke leg placements shall overlap 1 (25mm) to 1 ½ inches (38mm) to assure all existing surface discontinuities are revealed. Leg spacing on yokes shall be 3 inches minimum and 8 inches maximum.

12.2.1 Each alternating current electromagnetic yoke shall have a lifting

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 power of at least 10 lb. (45kg) at the maximum pole spacing that will be used.

12.2.2 Each direct current yoke shall have a lifting power of at least 40 lb.

(181kg) at the maximum pole spacing that will be used.

12.3 Circular Magnetization Techniques: With this technique, magnetization is accomplished by passing current directly through the part to be examined or indirectly by use of a central conductor. This produces a circular magnetic field that is approximately perpendicular to the direction of current flow in the part.

12.3.1 When using the direct contact technique in accordance with this procedure, direct or rectified (half-wave rectified or full-wave rectified) magnetizing current shall be passed directly through the part being examined. The required current shall be determined using the following guidelines:

1. The current shall be 300 amp/in. (12 A/mm) to 800 amp/in. (31 A/mm) of outer diameter of part.

2. For parts with geometric shapes other than round, the greatest cross-sectional diagonal in a plane at right angles to the current flow shall determine the inches to be used in 12.3.1 (1).

3. If the current levels required for 12.3.1 cannot be obtained, the maximum current obtainable shall be used and the field adequacy shall be demonstrated in accordance with Paragraph 11.5.

12.3.2 When using the central conductor technique in accordance with this procedure, direct or rectified (half wave rectified or full wave rectified) current shall be used. The central conductor is used to examine the surfaces of ring or cylindrically shaped parts. The central conductor technique may also be used for examining the outside surfaces of these shapes. Where large diameter cylinders are to be examined, the conductor shall be positioned close to the internal surface of the cylinder. When the conductor is not centered, the circumference of the cylinder shall be used to determine the extent of the arc that may be examined for each conductor position.

12.3.3 The field strength required shall be equal to that determined in Paragraph 12.3.1 for a single turn central conductor. The magnetizing force shall be decreased in proportion to the number of times the central conductor cable passes through a hollow part. For example, if 6000 amperes are required to examine a part using a single central conductor, 3000 amperes are required when 2 turns of the through cable are used; and 1200 amperes are required if 5 turns are used. When the central conductor technique is used, magnetic field adequacy shall be verified using a magnetic particle field indicator in accordance with Paragraph 11.5. Note: All work to Military Standards must

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 be done using a single turn central conductor.

12.4 Circular Magnetization Prod Technique: With this technique, magnetization is accomplished by pressing portable prod type electrical contacts against the surface in the area to be examined. A remote control switch, which may be built into the prod handles, shall be used to turn current on and off after proper prod positioning to avoid arcing at prod contact.

12.4.1 When using the prod technique in accordance with this procedure, direct or rectified magnetizing current shall be used. The current shall be 100 to 125 amp/in. of prod spacing for sections ¾ inch (19mm) thick or greater and all work to Military Standards. For sections less than ¾ inch (19mm) thick on non-military standard work, the current shall be 90 to 110 amp/in. of prod spacing.

12.4.2 Prod spacing shall not be less than 3 (76mm) inches or greater than 8 inches (203mm). The prods shall be rotated 90 degrees to the first placement and prod placements shall be overlapped from 1 inch (25mm) to 1 ½ inches (38mm) to assure complete coverage.

12.4.3 Great care shall be taken in maintaining prod tip cleanliness as to minimize the risk of overheating the test specimen at point of contact and to prevent arc burns. The prod tips that contact the part shall be aluminum, copper pads, or copper braid rather than solid copper.

12.5 Calibration of Equipment: Each piece of magnetizing equipment shall be calibrated every six months, or whenever the equipment has been damaged or repaired. The accuracy of the units’ meter shall be verified by equipment traceable to N.I.S.T. Comparative readings shall be taken at three levels of current output encompassing the usable range.

12.5.1 Electromagnetic yokes magnetizing power shall verified prior to use each day the yoke is used. Yokes shall be verified after any damage or repair to the yoke. Each A/C yoke shall meet the lifting requirements of Paragraph

12.2.1. Each D/C yoke shall meet the lifting requirements of Paragraph

12.2.2. The weights used to calibrate yokes shall be verified by the manufacturer and stenciled with the applicable weight. The weight shall only be verified again if damaged in a manner that may have caused potential loss of material.

13.0 Interpretation Of Results:

13.1 With non-fluorescent particles, the examination shall be carried out using visible light at a minimum intensity of 100 foot candles (1000 Lx), 200 foot candles

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 for Military Standards. Note: The above intensity requirements have been demonstrated using flashlights with two cells, AA, C, and D cell sizes, and drop lights of 75 watts and greater. Other light sources shall be demonstrated on a calibrated light meter prior to use.

13.2 With fluorescent particles, the examination shall be performed in accordance with Paragraph 9.7.

13.3 All indications revealed by Magnetic Particle inspection shall be evaluated in respect to the acceptance standards of the referencing Code Section or contract requirements.

Note: The size of the indication used for evaluation shall be the size or the particle accumulation and not necessarily the size of the discontinuity.

13.4 Indications revealed by Magnetic Particle inspection are not necessarily discontinuities, since irrelevant indications are sometimes encountered. Irrelevant or "false" indications are quite common, but may be easily identified. Some examples of such indications are:

1. Magnetic Writing: Indications are fuzzy and can be destroyed by demagnetization. These indications are caused by contact with other steel or magnets while magnetized.

2. Change in Section: The distribution of the magnetic field in an area of change in section (key-ways or drilled holes) of the test specimen is such that the test pattern is broad and fuzzy.

3. Flow Lines: These are large groups of parallel indications that occur in some forgings when magnetized with high currents.

13.5 Indications caused by marking methods such as scribe lines and vibro-etchings may be considered non-relevant unless the inspector has reason to believe that the marking is masking a relevant indication. Other areas with indications believed to be non-relevant shall be cleaned and re-examined or shall be re-inspected by other nondestructive test methods. If subsequent re-inspection reveals like indications, they shall be considered as relevant and shall be evaluated as discontinuities.

13.5.1 For work to Military Standards, if any indications (other than scribe lines and vibro-etchings) are believed to be non-relevant, the following methods may be used to prove non-relevancy:

1. Not less than 10 percent of each type of indication shall be explored by removing the surface roughness believed to have caused the type of indication to determine if defects are present. The absence of

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 indications by magnetic particle inspection after removal of the surface roughness shall be considered to prove that the indications were non-relevant with respect to actual defects. If reinspection reveals any indications, these and all of the original indications shall be considered relevant.

2. A liquid penetrant inspection after grinding to remove the surface roughness believed to have caused the indication.

3. Other methods approved by the authorized NAVSEA representative.

13.6 A linear indication is an indication with a length greater than 3 times the width.

13.7 A rounded indication is an indication that is circular or elliptical with a maximum length 3 times the width or less.

14.0 Acceptance Standards For Welds:

14.1 ASME Sections I, VIII Division I Appendix 6, B31.1, API-620, API-650 and API-653: Indications with major dimensions greater than 1/16 inch (1.6mm) shall be considered relevant. The following relevant indications are unacceptable:

1. All relevant linear indications.

2. All rounded indications with dimensions greater than 3/16" (4.8mm).

3. Four or more rounded indications in a line separated by 1/16" (1.6mm) or less edge to edge.

4. Applicable to ASME Section B31.1 and Section III only: Ten or more rounded indications in any 6 square inches (38.7cm) of surface with the major dimension of this area not to exceed 6 inches (152mm) with this area taken in the most unfavorable location relative to the indication being evaluated.

14.2 AWS D1.1: The acceptance criteria shall be as follows unless otherwise specified by contract:

1. The welds shall have no cracks.

2. Thorough fusion shall exist between adjacent layers of weld metal and between weld metal and base metal.

3. Porosity:

a. Statically Loaded Non-tubular Connections: Complete joint penetration groove welds in butt joints transverse to the direction of computed tensile stress shall have no linear porosity. For all other groove welds and for fillet welds, the sum of linear porosity 1/32 inch

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

(1mm) or greater in diameter shall not exceed 3/8 inch (10mm) in any linear inch of weld and shall not exceed ¾ inch (19mm) in any 12 inch (305mm) length of weld.

b. Cyclically Loaded Non-tubular Connections and All Tubular Connections: The frequency of linear porosity in fillet welds shall not exceed one in each 4 inches (100mm) of weld length and the maximum diameter shall not exceed 3/32 inch (2mm). Exception: For fillet welds connecting stiffeners to web, the sum of the diameters of linear porosity shall not exceed 3/8 inch (10mm) in any linear inch of weld and shall not exceed ¾ inch (19mm) in 12 inch (305mm) length of weld. Complete joint penetration groove welds in butt joints transverse to the direction of computed tensile stress shall have no linear porosity. The frequency of linear porosity in all other groove welds shall not exceed one in 4 inches (100mm) of weld length and the maximum diameter shall not exceed 3/32 inch (2mm).

14.3 ASME Section B31.3: There shall be no cracks.

14.3.1 In-Process examination is a visual examination aided by the use of liquid penetrant or magnetic particle examinations and shall be conducted in conjunction with QOP 9-VT-1 paragraph 12.4.1 and Tables 6 and 7.

14.4 API-1104: Indications with major dimensions greater than 1/16 (1.6mm) inch shall be considered relevant. The following relevant indications are unacceptable:

1. Linear indications evaluated as crater or star cracks greater than 5/32 inch (4mm).

2. Linear indications evaluated as cracks other than crater or star cracks.

3. Incomplete fusion indications in excess of 1 inch in 12 inches of weld.

4. Porosity in pipe with an O.D. > than or = to 2.375 inches (60mm):

a. Length of any elongated indication exceeds 2 inches.

b. Aggregate length of indications exceeds 8% of weld length.

c. Width of elongated indication exceeds 1/16 inch.

5. Porosity in pipe with an O.D. < than 2.375 inches (60mm):

a. Length of elongated indication exceeds three times nominal wall thickness of the thinner section being joined.

b. Width of elongated indication is greater than 1/16 inch (1.6mm).

c. Aggregate length of indications exceeds 8% of weld length.

14.5 Mil Std-2035A: Welds shall meet the requirements of the applicable fabrication document and, unless otherwise specified, the following shall apply.

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

1. No linear indications, except undercut as listed in 2 and 3 below, greater than 1/16 inch in the weld and at least 1/2 inch of the adjacent base metal on each side of the weld.

2. Undercut in class 1 welds shall not exceed the lesser of 1/64 inch maximum depth measured from the unground adjacent base metal surface or ten (10) percent of the minimum thickness.

3. Undercut in class 2 and 3 welds shall not exceed the lesser of 1/32 inch or ten (10) percent of the minimum thickness. For base metal thickness 1/2 inch or greater, undercut up to 1/16 inch is allowed if the accumulated length of undercut exceeding 1/32 inch does not exceed the lesser of 15 percent of the joint length or 12 inches in any 36 inch length of weld.

4. Rounded indications 1/64 inch and less shall be disregarded for material thickness 3/16 inch and less. Rounded indications 1/32 inch and less shall be disregarded for material thickness greater than 3/16 inch. Non-linear or rounded indications meeting the standards of Figures 14-1 through 14-18 for 6 inch length of weld are acceptable. The maximum number of indications permissible for weld-length and weld-width different from that shown on Figures 14-1 through 14-18 shall be prorated. The maximum size shall not exceed the limits of Figure 14-19. When it is considered necessary for evaluation, Figure 14-19 may be used to determine the total indication area.

5. Aligned rounded indications shall be cause for rejection if one or more of the aligned indications is greater than 1/32 inch for class 1, greater than 1/16 inch for class 2, or greater than 3/32 inch for class 3.

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Figure 14-1

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Magnetic Particle Inspection

QOP 9-MT-1

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Figure 14-2

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Magnetic Particle Inspection

QOP 9-MT-1

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Figure 14-3

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Figure 14-4

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Magnetic Particle Inspection

QOP 9-MT-1

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Figure 14-5

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Figure 14-6

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Magnetic Particle Inspection

QOP 9-MT-1

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Figure 14-7

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Magnetic Particle Inspection

QOP 9-MT-1

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Figure 14-8

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Magnetic Particle Inspection

QOP 9-MT-1

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Figure 14-9

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Magnetic Particle Inspection

QOP 9-MT-1

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Figure 14-10

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Magnetic Particle Inspection

QOP 9-MT-1

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Figure 14-11

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Magnetic Particle Inspection

QOP 9-MT-1

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Figure 14-12

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Magnetic Particle Inspection

QOP 9-MT-1

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Figure 14-13

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Figure 14-14

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Figure 14-15

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Figure 14-16

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Figure 14-17

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Figure 14-18

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Figure 14-19

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

14.6 Unacceptable discontinuities shall be considered defects and may, upon the customer's approval, be eliminated provided:

1. Repair by welding is not required, when a defect is removed and the affected area is blended into the surrounding surface to avoid sharp notches, crevices or sharp corners.

2. After a defect is believed to have been removed, and prior to making repairs, the area shall be examined by NDE methods to insure defect removal.

3. After weld repairs and/or grinding, the repaired areas shall be re-examined by Magnetic Particle inspection and by all other methods of examination that were originally required for the affected area.

4. All surface and dimensional requirements are maintained.

Note: Any disputes concerning the acceptability of a defect shall be the customer's final responsibility.

15.0 Acceptance Standards For Castings:

15.1 Acceptance standards for castings shall be noted on the applicable fabrication document and, unless otherwise specified, the following shall apply for Mil Std- 2035A.

15.1.1 Linear indications: Castings surfaces shall be free of tears, or crack-like indications longer than 1/16 inch. Other indications, such as shrinkage, cavities, cold shuts, unfused chaplets, or internal chills, are acceptable if the maximum length and maximum number of the indications meet the standards of Table 15-1.

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Table 15-1 Linear indication acceptance standards for castings (in 36 square inches of area)

Description Class Maximum indication size, in.

Maximum number of indications

Finished machine surface

3/32 1/8

3/16

Rough ground surface

1/8 3/16 1/4

As-cast surface

3/16 1/4

5/16

Notes:

1. Casting surfaces shall be free of tears or crack-like indications longer than 1/16 inch. Any area containing a linear indication greater than 1/16 inch shall be cleaned and examined at 5X magnification or ground and reinspected as necessary to assure that it is not a crack or tear. In addition, the length of any indication shall not exceed ½ the material thickness at the location where the indication occurs.

2. Randomly distributed indications 1/16 inch and less shall not be counted.

3. The distance separating two longitudinally aligned linear indications shall be not less than 4 times D, where D is the length of the longer indication.

However, when the total length of the longitudinally aligned indications does not exceed the maximum length permitted for a single indication, these aligned indications shall be considered one indication, and shall not be cause for rejection.

4. The distance separating two linear indications not longitudinally aligned shall be not less than D, where D is the length of the longer indication.

5. For inspection areas of less than 36 square inches, the maximum number of indications shall be prorated.

6. The number of linear indications shall not exceed that permitted above, even if the area does not contain any non-linear indications.

15.1.2 Non-linear indications: Non-linear indications shall be evaluated to the requirements of Table 15-2.

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

Table 15-2 Non-linear indication acceptance standards for castings (in 36 square inches of area)

Description Class Maximum indication size, in.

Maximum number of indications

Finished machine surface

1/8 1/8

3/16

Rough ground surface

1/8 1/8 1/4

As-cast surface

1/8 1/4

5/16

Notes:

1. The maximum individual non-linear indication size shall be the major dimension of an indication. In addition, no indication shall exceed 1/2 the minimum design wall thickness at the location where the indication occurs.

2. Indications 1/16 inch and less shall not be counted.

3. For inspection areas of less than 36 square inches, the maximum number of indications shall be prorated.

4. Linear and non-linear indications permitted in Tables 15-1 and 15-2 may be present in the same 36 square inch inspection area. If an area contains less linear indications than permitted by Table 15-1, the maximum number of non-linear indications may be increased so that the combined total of linear and non-linear indications equals that of Tables 15-1 and 15-2. For example, class 1 finished machine surface permits six linear indications and eight non-linear indications for each 36 square inches of surface. If there were only two linear indications less than 3/32 inch length, then the non-linear indications may be increased to 12.

5. When the major dimension of a cluster of indications (four or more greater than 1/16 inch) does not exceed the maximum size permitted for a single indication, these clustered indications shall be considered as one indication, and shall not be cause for rejection. Scattered indications, separated from the cluster by 1/8 inch or more, shall not be considered as part of the cluster.

15.2 Repairs to defective areas shall be made in accordance with the applicable fabrication specification. Areas repaired by welding shall meet the applicable acceptance standard for welds.

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Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

15.3 Acceptance standards for forgings and wrought materials shall be in accordance with applicable material specification.

16.0 Demagnetization And Post Inspection Cleaning Of The Test Specimen:

16.1 When residual magnetization in the part could interfere with subsequent processing or usage, or if code and/or contract requirements stipulate, the test specimen shall be de-magnetized.

16.2 The current used to de-magnetize test specimen shall be in accordance with Paragraph 8.1.

16.3 De-magnetization shall be accomplished by subjecting the part to a field equal to or greater than that used to magnetize the part and in nearly the same direction, then continuously reversing the field direction gradually decreasing it to zero.

16.4 De-magnetization shall be performed by one of the following methods:

1. The part shall be moved through a high intensity (5000 to 10000 ampere turns) AC Coil and then slowly withdrawn from the field of the coil. The part shall enter the coil from a distance of 12 inches (300mm) and move steadily and slowly through the coil until it is at least 36 inches (900mm) beyond the coil.

2. An AC Yoke shall be placed on the surface of part, energized, and the legs moved around the area, then slowly withdrawn from the part while still energized.

16.5 When post examination cleaning of the test specimen is required by code and/or contract, the magnetic particle material shall be removed as soon as possible with a suitable cleaner/remover or other approved method as detailed in the contract.

17.0 Reports, Records And Identifications:

17.1 ICS shall submit a complete report of all Magnetic Particle examinations to the customer's authorized representative upon completion of each inspection and/or project. This report shall be made on ICS's Magnetic Particle Inspection Report (See Attachment 1). After completion of inspection and/or project, reports become the property of the customer.

17.2 As a minimum, the following information shall be noted on the inspection report:

1. Components or Welds Inspected and Component or Weld Identification

2. Inspection Procedure Identification and Acceptance Criteria

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3. Date of Inspection and Inspector's Name and Level Of Qualification

4. Inspection Results and Weld or Component Disposition

5. Magnetizing Equipment Used and Type of Magnetic Particles Used

6. Sketch or Photograph to Show Part Geometry, Method and Direction of Field.

18.0 Enforcement Of Procedures:

It shall be the responsibility of the Quality Control Manager of ICS to enforce the requirements of this procedure.

19.0 Attachment 1:

Magnetic Particle Inspection Report (Sample Report)

IveyCooper Magnetic Particle Inspection Report Page 40 of 40 SERVICES, LLC Sample Report 9-MT-1 Attachment 1

11135 Dayton Pike Soddy Daisy, TN 37379 Phone: (423) 493-0097 Fax: (423) 435-9620

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Visual Inspection

ASME / API / AWWA

QOP 9-VT-1

Revision: 6

Procedure: 9-VT-1

For

Visual Inspection And Acceptance Standards For Welds And Base Materials�

Revision Date Reviewed By Approved By Issue Date Original 2/2/01 6/25/01

1 3/18/05 3/18/05 2 5/03/05 5/03/05 3 3/26/06 3/27/06 4 6/6/07 6/7/07 5 3/13/08 3/14/08 6 11/5/08 11/7/08

Revision Description 1 Revised light intensity requirements in paragraph 10.3.

2 Revised AWS D1.1 Acceptance Criteria to conform to 2004 edition paragraphs 12.7, 12.8, inserted table 10 and table 11 and 12.9 footnotes.

3 Revised 3.1, 3.2, 10.3, 15.0, and Attachment 1 to meet 2004 ASME Section V, Article 9, 2005 Addenda.

4 Added 12.8 AWS D9.1M/D9.1: 2006 Visual Inspection of Production Arc Welding and corrected the formatting throughout.

5 Revised para. 12.1 #8 to read .70; para. 12.2 #7 concavity criteria revised, #8 to read .70; para. 12.3 #6 to read Any other, #8 to read .70. Revised para. 12.4.1 and 12.4.1.1 to include in-process inspection and added tables 6 and 7 B31.3 acceptance criteria.

Added In-Process inspection report in Attachment 1. Added para. 12.9. Added AWWA D100-05 acceptance criteria.

6 Revised AWWA D100-05 acceptance criteria.

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Visual Inspection

ASME / API / AWWA

QOP 9-VT-1

Revision: 6

1.0 Scope:

Procedure 9-VT-1 contains the specified minimum requirements that shall be used in performing Visual testing of welds, base materials and components when Visual inspection is required by contract requirements and/or code specifications. IveyCooper SERVICES, LLC, hereafter ICS, certifies that this procedure shall meet the minimum requirements of the applicable code or standard as listed in 2.0 of this procedure. All Visual inspections shall be performed in accordance with contract specifications and/or governing code requirements.

2.0 Applicable Codes And/Or Requirements:

The following codes shall be made part of this procedure to the extent specified. The latest edition of the code shall be used unless otherwise required by contract.

2.1 American Society Of Mechanical Engineers (ASME):

1. SECTION I - Power Boilers

2. SECTION III - Nuclear Power Plant Components

3. SECTION V - Nondestructive Examination

4. SECTION VIII - Pressure Vessels

5. B31.1 - Power Piping

6. B31.3 - Chemical Piping

2.2 American Petroleum Institute (API):

1. API 620 - Low Pressure Storage Tanks

2. API 650 - Storage Tanks for Oil Storage

3. API 653 - Tank Inspection, Repair, Alteration, and

Reconstruction

4. API 1104 - Pipelines and Related Facilities

2.3 American Welding Society (AWS):

1. AWS D1.1 - Structural Welding

2. AWS D9.1 � Sheet Metal Welding

2.4 American Water Works Association (AWWA):

1. AWWA D100-05

3.0 Qualification Requirements:

3.1 Personnel

When Visual inspection is to be performed in accordance with this procedure, personnel shall be qualified and certified as required by ICS QOP 18-1 or QOP 18-2. Certified Welding Inspectors, shall

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Visual Inspection

ASME / API / AWWA

QOP 9-VT-1

Revision: 6 be qualified and certified as required by AWS QC-1.

3.2 Procedure

When procedure qualification is specified, a change of a requirement identified as an essential variable in Table T-921 of ASME Section V, Article 9 shall require re-qualification of the written procedure by demonstration. A change of a requirement identified as a non-essential variable does not require re-qualification of the written procedure. All changes to this written procedure, whether essential or non-essential shall require revision or addendum to document change.

4.0 Safety Requirements:

When Visual inspection is to be performed in accordance with this procedure, personnel shall comply with the safety standards set forth by code and/or contract. As a minimum, the following safety factors shall be considered.

1. Welding can cause extremely high local temperatures. Care shall be taken to avoid contact of any part of the body with high temperature surfaces.

2. Eye protection shall be worn in areas where welding, grinding, or chipping is taking place.

3. Where welding is being performed in the vicinity of Visual inspections, care shall be taken to avoid looking toward welding arc to minimize possibility of damage to eyes.

5.0 Components For Inspection:

Visual inspection may be performed on welds and materials of all shapes and sizes provided the material is accessible and meets all code and/or contract requirements.

6.0 Time Of Inspection:

6.1 Visual inspection may be required at any step in the welding process. It may be specified by code and/or contract to perform Visual inspection on base materials prior to fit-up, alignment and spacing of mated materials, and the weld at any stage of completion.

6.2 Final inspection shall be performed after weld or component is completed to code and/or contract specifications and final post weld heat treatment, unless otherwise specified by code and/or contract requirements.

7.0 Preparation Of Surface:

7.1 Welds: The weld surface and a minimum of one inch (25mm) on each side of the weld shall be free of all rust, scale, slag, sand, welding flux, weld spatter, paint, oil or other extraneous materials that could mask surface discontinuities or interfere with interpretation.

7.2 Components: The surface to be examined shall be free of loose scale, oil, or grease. Cleaning may be accomplished using detergents, organic solvents, sand or grit blasting, etc. The method used to

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7.3 Generally, surfaces will be considered suitable for visual inspection in the as welded, as cast, or as forged condition without grinding, providing this does not interfere with interpretation. All welds shall blend smoothly into the base metal. Stainless steel brushes shall be used when brushing austenitic steels or nickel base alloys and shall not have had previous use on carbon or low alloy steels.

8.0 Equipment For Use:

Visual inspection may be aided by use of tools specifically designed for this purpose. One or more of the following tools may be required as an inspection aid.

1. Fit-up Gauge: For measuring alignment of mated surfaces.

2. Fillet Weld Gauge: For measuring sizes of fillet welds.

3. Depth Gauge: For measuring depth of undercut or pitting.

4. Borescope: For remote viewing of weld root or other inaccessible welds.

5. Mirrors: To improve angle of vision.

6. Supplemental White Light: To meet illumination requirements at test specimen.

9.0 Temperature Of Part:

9.1 Completed welds shall be cooled to ambient temperature prior to final visual examination. This shall be a natural cooling unaided by forced cold air or quenching.

9.2 Surface temperature of welds or components that are completed and have previously cooled to ambient temperature, shall meet code and/or contract requirements prior to visual inspection

10.0 Sequence Of Operations:

10.1 Prior to welding, visual examination shall include the following:

1. Weld Joint Preparation, Dimensions

2. Alignment and Fit-Up of mated materials

3. Cleanliness

4. Verify Base Materials and Consumable Materials being used are correct

5. Verify qualification of welding procedures and welding operators

10.2 Adequacy of the final visual examination shall be demonstrated by detection of a fine line 1/32 inch or less in width placed on the surface to be examined, or simulated on a test mock up or like component. The line or artificial flaw shall be placed in the least discernible location of the test specimen.

10.3 Visual examination shall be conducted directly when access is sufficient to place the eye within 24 inches of the surface to be examined and at an angle not less than 30 degrees to the surface. Mirrors may be used to improve the angle of vision and aids such as magnifying lenses may

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Revision: 6 be used to improve the examination. Natural and/or artificial lighting shall be provided to illuminate the area to be examined. A minimum 100 foot-candles intensity shall be used.

Note: The above intensity requirements have been demonstrated using flashlights with two (2) cells, AA, C, and D cell sizes, and drop lights of 75 watts and greater. Other light sources shall be demonstrated on a calibrated light meter prior to use.

10.4 Where access is limited, remote inspection tools shall be used. Remote visual examination aids may include mirrors, borescopes, telescopes, video cameras or other suitable instruments, that can resolve the equivalent of inspection results obtained by direct visual inspection. Remote Visual inspection shall demonstrate resolution capabilities equal to or greater than that obtainable by direct Visual examination.

10.5 Welding processes, such as tack welds that will be part of the final weld, shall be examined at 5x magnification.

10.6 Completed welds and areas of interest shall be examined for the following:

1. Cracks, blowholes, porosity, overlap and incomplete fusion, incomplete penetration (when accessible), and weld reinforcement.

2. Weld spatter, arc Strikes, and oxides.

3. Size of legs or weld throat of fillet welds.

4. Contour and finish of surfaces.

5. Undercutting.

10.7 Repairs will be inspected in accordance with the repair procedure and as a minimum to the degree specified in this procedure.

11.0 Interpretation Of Results:

11.1 All indications revealed by visual inspection shall be evaluated in respect to the acceptance standards of the referencing Code Section or contract requirements.

11.2 A linear indication is an indication with a length greater than 3 times the width.

11.3 A rounded indication is an indication that is circular or elliptical with a maximum length 3 times the width or less.

12.0 Acceptance Standards:

12.1 ASME Section I:

1. Alignment Tolerance of mated materials shall be in accordance with Table 1.

2. Maximum weld reinforcement on each face shall be in accordance with Table 2.

3. Butt welds shall be free of incomplete penetration (where accessible), incomplete fusion and cracks that are open to the surface.

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4. Weld grooves shall be completely filled so that the surface of the weld metal is not below the surface of the base metal.

5. The weld surface shall be free of coarse ripples, grooves, overlaps, abrupt ridges, and valleys to avoid stress risers.

6. Undercut shall not exceed 1/32 inch or 10% of the wall thickness, whichever is less.

7. Concavity shall not exceed .093 inch or 20%, whichever is less, of the thinner of the sections being joined provided the conditions of 4 above are met. The contour of the concavity shall blend smoothly and the weld thickness of the weld be at least equal to the thinner of the sections being joined.

8. For fillet welds, the throat dimension shall not be less than .70 times the nominal thickness of the weld and undercut shall not exceed the limits of number 6 above.

Table 1 Section Thickness, in. Longitudinal Circumferential

Up to 1/2, incl. 1/4 t 1/4 t Over 1/2 to 3/4, incl. 1/8 in. 1/4 t Over 3/4 to 1 1/2, incl. 1/8 in. 3/16 in.

Over 1 1/2 to 2, incl. 1/8 in. 1/8 t

Over 2 Lesser of 1/16 t Lesser of 1/8 t or 3/8 in. or 3/4 in.

Table 2 Maximum Reinforcement, in.

Circumferential Joints Nominal Thickness, in. in Pipe and Tubing Other Welds

Up to 1/8 3/32 3/32 Over 1/8 to 3/16, incl. 1/8 3/32 Over 3/16 to 1/2, incl. 5/32 3/32 Over 1/2 to 1, incl. 3/16 3/32 Over 1 to 2, incl. 1/4 1/8 Over 2 to 3, incl. * 5/32 Over 3 to 4, incl. * 7/32 Over 4 to 5, incl. * 1/4 Over 5 * 5/16

* The greater of 1/4 in. or 1/8 times the width of the weld in inches.

12.2 ASME Sect. VIII:

1. Alignment Tolerance of mated materials shall be in accordance with Table 3.

2. Maximum weld reinforcement on each face shall be in accordance with Table 4.

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3. Butt welds shall be free of incomplete penetration (where accessible), incomplete fusion and cracks that open to the surface.

4. Weld grooves shall be completely filled so that the surface of the weld metal is not below the surface of the base metal.

5. The weld surface shall be free of coarse ripples, grooves, overlaps, abrupt ridges, and valleys to avoid stress risers.

6. Undercut shall not exceed 1/32 inch or 10% of the wall thickness, whichever is less.

7. Concavity shall be permitted only when the resulting thickness is equal to the thinner of the sections being joined provided the conditions of number 4 above are met. The contour of the concavity shall blend smoothly and the weld thickness of the weld be at least equal to the thinner of the sections being joined.

8. The throat dimension shall not be less than .70 times the nominal thickness of the fillet weld.

Undercut shall not exceed the limits of number 6 above.

Table 3 Joint Categories

Section Thickness, in. A B, C, & D

Up to 1/2, incl. 1/4 t 1/4 t Over 1/2 to 3/4, incl. 1/8 in. 1/4 t Over 3/4 to 1 1/2, incl. 1/8 in. 3/16 in.

Over 1 1/2 to 2, incl. 1/8 in. 1/8 t Over 2 Lesser of 1/16 t Lesser of 1/8 t or 3/8 in. or 3/4 in.

Table 4 Maximum Reinforcement, in.

Material Nominal Category B & C Thickness, in. Butt Welds Other Welds

Less Than 3/32 3/32 1/32 3/32 to 3/16, incl. 1/8 1/16 Over 3/16 to 1/2, incl. 5/32 3/32 Over 1/2 to 1, incl. 3/16 3/32 Over 1 to 2, incl. 1/4 1/8 Over 2 to 3, incl. 1/4 5/32 Over 3 to 4, incl. 1/4 7/32 Over 4 to 5, incl. 1/4 1/4 Over 5 5/16 5/16

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12.3 ASME B31.1:

1. Alignment tolerance for mated material shall not exceed 1/16 inch unless the piping design specifically states a different allowable misalignment.

2. Maximum reinforcement shall be in accordance with Table 5.

3. There shall be no cracks on external surface (or internal when accessible).

4. No surface undercut greater than 1/32 inch in depth.

5. No incomplete fusion open to surface or incomplete penetration (when accessible).

6. Any other linear indications greater than 3/16 inch.

7. Surface porosity with rounded indications having dimensions greater than 3/16 inch or four or more rounded indications separated by 1/16 inch or less edge to edge in any direction.

8. For fillet welds, the throat dimension shall not be less than .70 times the nominal thickness of the weld and undercut shall not exceed the limits of number 4 above.

9. Concavity is allowed on the weld root provided the weld thickness is at least as thick as the thinner of the sections being joined. The contour of the concavity shall blend smoothly and the weld thickness of the weld be at least equal to the thinner of the sections being joined.

Table 5 Maximum Thickness of Reinforcement

For Design Temperature, in.

Material Nominal Thickness, in. >750 degrees F 350 to 750 degrees F < 350 degrees F

Up to 1/8, incl. 1/16 3/32 3/16 Over 1/8 to 3/16, incl. 1/16 1/8 3/16 Over 3/16 to 1/2, incl. 1/16 5/32 3/16 Over 1/2 to 1, incl. 3/32 3/16 3/16 Over 1 to 2, incl. 1/8 1/4 1/4 Over 2 5/32 * *

* The greater of 1/4 inch or 1/8 times the width of the weld in inches.

Notes:

1. For double welded butt joints, this limitation on reinforcement given above shall apply separately to both inside and outside surfaces of the joint.

2. For single welded butt joints, the reinforcement limits given above shall apply to the outside surface of the joint only.

3. The thickness of weld reinforcement shall be based on the thickness of the thinner of the materials being joined.

4. The weld reinforcement thickness shall be determined from the higher the abutting surfaces involved.

5. Weld reinforcement may be removed if so desired.

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12.4 ASME B31.3:

1. Extent of misalignment for mated materials shall be stated in the engineering design or WPS.

2. The weld surface shall be free of coarse ripples, grooves, overlaps, abrupt ridges, and valleys to avoid stress risers.

3. Weld grooves shall be completely filled so that the surface of the weld metal is not below the surface of the base metal.

4. Tables 6 and 7 give detailed information regarding acceptance criteria.

12.4.1 In-Process Examination

In-Process examination is a visual examination of the welding process from joint preparation to finished joint aided by liquid penetrant or magnetic particle examinations.

The customer shall determine if and when the use of liquid penetrant or magnetic particle examination is required by engineering design. The In-Process examination shall be conducted utilizing the current revision of this procedure and when applicable QOP 9- PT-1 or QOP 9-MT-1. The following items are to be examined during the In-Process examination:

1. Joint preparation and cleanliness

2. Preheating

3. Fit-up, joint clearance and internal alignment prior to joining

4. Variables specified by the joining procedure, including filler material, position and electrode

5. Condition of the root pass after cleaning �external and, where applicable, internal-aided by liquid penetrant or magnetic particle examination when specified in the engineering design

6. Slag removal and weld condition between passes

7. Appearance of the finished joint

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Table 6 B31.3 Acceptance Criteria for Welds and Examination Methods for Evaluating Weld Imperfections

Criteria (A to M) for Types of Welds and for Service Conditions Examination Methods

Normal and Category M Fluid

Service

Severe Cyclic Conditions

Category D Fluid Service

Type of Weld Type of Weld Type of Weld

G ir th , M ite r

G ro ov e

B ra nc h

(N ot

2)

L on gi tu di na l G ro ov e (N ot

3)

Fi lle t ( N ot

4)

G ir th , M ite r

G ro ov e

B ra nc h

(N ot e 2)

L on gi tu di na l G ro ov e (N ot e

3) Fi lle t (

N ot ir th a nd M ite r

G ro ov e

L on gi tu di na l G ro ov e (N ot

3)

Fi lle t ( N ot nc h

C on ne ct io n

(N ot

2)

Weld Imperfection

V isu al

R ad io gr ap hy

M ag ne tic

P ar tic le iq ui d

Pe ne tr an t

A

E

H

N/A

K

E

D

F

J

D

F

C

C

I

Crack

Lack of Fusion

Incomplete Penetration

Internal Porosity

Internal slag inclusion, tungsten inclusion, or elongated indication

Undercutting

Surface porosity or exposed slag inclusion (Note 5)

Surface Finish

Concave Root Surface

Weld Reinforcement or internal protrusion

X

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Table 7 Symbol Measure Acceptable Value Limits [Note (6)]

A Extent of imperfection Zero (no evident imperfection)

B Depth of incomplete penetration <1 m (1/32 in) and <0.2 T w Cumulative length of incomplete penetration < 38 mm (1.5 in.) in any 150 mm (6 in) weld length

C Depth of lack of fusion and incomplete penetration < 0.2 T w Cumulative length of lack of fusion and incomplete penetration < 38 mm (1.5 in) in any 150 mm (b in) weld length [Note (7)]

D Size and distribution of internal porosity See BPV Code, Section VIII, Division 1, Appendix 4

E Size and distribution of internal porosity For T w <6 mm (1/4 in.), limit is same as D For T w> b mm (1/4 in), limit is 1.5 x D

F Slag inclusion, tungsten inclusion, or elongated indication Individual length <2 T w Individual width < 2.5 mm (3/32 in) and < T w/3 Cumulative length < T w in any 12 T w weld length

G Slag inclusion, tungsten inclusion, or elongated indication Individual length < 2 T w Individual width < 3 mm (1/8 in) and < T w/2 Cumulative length < 4 T w in any 150 mm (6 in.) weld length

H Depth of undercut < 1 mm (1/32 in.) and < T w/4

I Depth of undercut < 1.5 mm (1/16 in,) and <[T w/4 or 1 mm (1/32 in)]

J Surface roughness < 500 min. Ra per ASME B46.1

K Depth of root surface concavity Total joint thickness, incl. weld reinf.,> T w

L Height of reinforcement or internal protrusion [Note (8)] For T w, mm (in) Height, mm (in) in any plane through the weld shall be within limits of the applicable height value in the tabulation at right, except < 6(1/4) <1.5 (1/16) as provided in Note (9). Weld metal shall merge >6 (1/4), < 13 (1/2) < 3 (1/8) smoothly into the component surfaces. >13 (1/2), < 25 (1) < 4 (5/32)

> 25 (1) < 5 (3/16)

M Height of reinforcement or internal protrusion [Note (8)] Limit is twice the value applicable for L above as described in L. Note (9) does not apply.

X = Examination method generally used NA = Not applicable ... = Examination not generally used

Notes follow on next page

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Notes:

(1) Criteria given are for required examination. More stringent criteria may be specified in the engineering design.

(2) Longitudinal groove weld includes straight and spiral seam.

(3) Fillet weld includes socket and seal welds, and attachment welds for slip-on flanges, branch reinforcement, and supports.

(4) Branch connection weld includes pressure-containing welds in branches and fabricated laps.

(5) These imperfections are evaluated only for welds less than 3/16 inch in nominal thickness.

(6) Where two limiting values are separated by "and," the lesser of the values determines acceptance. Where two sets of values are separated by "or," the larger value is acceptable.

Tw is the nominal wall thickness of the thinner of two components joined by a butt weld.

(7) Tightly butted unfused root faces are unacceptable.

(8) For groove welds, height is the lesser of the measurements made from the surfaces of the adjacent components; both reinforcement and Internal protrusion are permitted in a weld. For fillet welds, height is measured from the theoretical throat; internal protrusion does not apply.

(9) For welds in aluminum alloy only, Internal protrusion shall not exceed the following values:

(a) for thickness less than or equal to 5/64 inch: 1/16 inch

(b) for thickness > 5/64 inch and less than or equal to ¼ inch: 3/32 inch For external reinforcement and for greater thicknesses, see the tabulation for Symbol L.

12.5 API-1104:

1. Extent of misalignment for mated materials shall be stated in the engineering design or WPS.

2. Weld grooves shall be completely filled so that the surface of the weld metal is not below the surface of the base metal.

3. Root concavity is allowed provided the weld thickness is equal to or greater than the thinner of the sections being joined.

4. Weld reinforcement on each face shall not exceed 1/16 inch unless otherwise specified in WPS.

5. Undercut less than or equal to 1/64 inch in depth shall not exceed 2 inches or 2 inches aggregate length in a 12 inch length of weld. No undercut greater than 1/32 shall be permitted.

6. Incomplete penetration shall not exceed 1 inch and an aggregate length of 1 inch in 12 inch weld length or 8% of weld length. Where incomplete penetration is due to mis-match, it shall not exceed 2 inches and an

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7. There shall be no cracks on external surface (or internal when accessible).

12.6 API-620, API-650, and API-653:

1. Butt welds shall be free of incomplete penetration (where accessible), incomplete fusion and cracks that are open to the surface.

2. Welds shall be free of surface porosity exceeding one (1) cluster in a 4 inch length of weld and no cluster shall exceed 3/32 inch.

3. Undercut…