Instructions IBUS-TD 16 page 1/26

ZBM ULTRA sp. z o.o.

IBUS-TD 16 Revision

IBUS-TD 16 Instructions on ultrasonic testing of welds 2-8 mm

thick at flat pieces and pipes

Replacement for: 07/4a.11

Replaced:

1 Introduction

1.1 Subject of the procedure

The following procedure describes the ultrasonic testing method for 2-8 mm thick butt

welds with application of the pulse-echo technique using transversal-wave detecting tandem probes, based on IBUS-TD-16 method.

1.2 Scope of application of the procedure

The procedure is applicable to testing of welds at pipes, pipelines and flat pieces. The

procedure has been subject to qualification by the Office of Technical Inspection and can be used for equipment covered by the technical inspection as specified in the repair and retrofit techniques for such equipment approved by the Office of Technical Inspection. Consent to application of the procedure on a case-by-case basis should be given each time by a competent engineering team with the Office of Technical Inspection. For other applications the procedure may be followed based on acceptance of interested parties.

The procedure is applicable to testing of:

welds in carbon steel and low-alloy steel,

welds in austenitic steel and other materials featuring an increased ultrasound wave attenuation provided that the requirement specified in point 2.5 is complied with,

welds in aluminum and its alloys.

1.3 Limitations to the scope of the procedure application

The provisions of the procedure shall not apply to the following:

welded joints with backing as well as the welds or their portions with false echoes caused by the weld geometry, e.g. angled welds, connector pipes, inserts, etc. The aforesaid limitation is not applicable to the weld face and root.

welded joints or their sectors yielding a negative VT result (acc. to the standard [3]).

1.4 Scope of testing

the primary objective of the tests performed according to this procedure is to select flawless welds and reject flawed welds. Consequently, the procedure requires testing 100% of all welds. A particularly high efficiency of tests performed according to this procedure ensures technical viability of such selection, which, in turn, is a precondition for reliable operation of the entire equipment (e.g. a power unit boiler, a large diameter pipeline, etc.). For more information on reliability of multi-component test items see [4],

for welding procedures ensuring high quality of welds and high process repeatability, the testing scope may be reduced to 30% of all welds. If not a single flawed weld is found among all the welds to be tested (30% of all welds), the entire batch (100% of all welds) shall be considered as flawless. If single flawed pieces are found (but not more than 5

Instructions IBUS-TD 16 page 2/26

pieces) and the metallographic testing can prove the flaws to be random findings related to face or/and root geometry errors and no other flaw was identified (lack of fusion, in particular), the whole batch (100%) shall be considered as flawless. In the remaining cases, the procedure requires testing 100% of all welds.

1.5 The scope of testing for equipment not covered by the technical inspection

When applying this procedure to tests on equipment not covered by the technical inspection, the testing objective may be formulated in a different way than in point 1.4. In such cases the scope of testing may be agreed upon between the interested parties.

2 Testing set

The testing set for tests performed according to this procedure consists of the following:

a flaw detector,

tandem probes and DAC curves for the same,

calibration block,

a probe water wetting system.

2.1 Flaw detector

The flaw detector must be provided with a confirmation of its current performance

parameters acc. to PN-EN 12668-1 ([1]). Moreover, the tandem probe's matching a given type of flaw detector must be

confirmed in writing. For application of the procedure, digital flaw detectors with DAC curve memory feature

are the most convenient.

2.2 Probes

2.2.1 The tests according to this procedure are performed with the use of ultrasound transversal-wave detecting tandem probes, with parameters listed in the Appendix No. 1.

2.2.2 For pipe circumferential weld testing, the probes should be formed to match the pipe diameter.

2.2.3 For a small number of welds tested on a one-off basis, it is possible to use a probe formed to match the next larger diameter in series specified in the Appendix No. 1.

2.2.4 For the tests performed according to this procedure it is recommended to use water-sprayed probes with a constant water supply during the tests. An alternative wetting method is allowed provided that a test with a positive result is performed (Appendix No. 8).

2.2.5 The probes require a confirmation of the current performance parameters as per the Appendix No. 9.

2.2.6 During the tests, the parameters of the probes used for the test should be checked periodically according to point 6.

Instructions IBUS-TD 16 page 3/26

2.3 Calibration block

Two types of calibration blocks shall be used - a simplified calibration block for the test

operators and a regular calibration block for verification and periodical tests of the probes according to the Appendix No. 2.

The regular calibration block must be provided with a one-off parameter confirmation in a form of a performance certificate according to the Appendix No. 10.

2.4 DAC curves

A simplified standard is prepared for each type of identical welded joints and used to

make a DAC curve. DAC charts (curves) are drawn by plotting an echo amplitude from a hole having a standard diameter of Ø=1mm at least along three lengths. Based on an agreement by both parties, the testing criteria may be made more or less stringent by using a standard hole of Ø =0.7 mm or Ø =1.5 mm in diameter.

The flaw detector set-up parameters used for making the DAC curve must be maintained during the tests so that the DAC curve corresponds to the readings for an equivalent flaw.

2.5 DAC curves for highly attenuating materials

The DAC curves for highly attenuating materials are made as described in point 2.4

and additionally adjusted using a correction standard (Appendix No. 3).

2.6 Probe water wetting system

The probe water wetting system must ensure an adjustable constant water supply with

an addition of wetting agents (detergents) while the test surfaces must be kept in wet condition (Appendix No. 8).

2.7 Archivization of test results

The objective of the test result archivization for the time period declared by the testing

party or by both parties, in hard copies or as soft copy, is to keep the necessary information allowing for reproduction or repetition of the tests in the future. The content of the test report is presented as simplified (Appendix No. 6) and as full (Appendix 4). If possible, the use of simplified test report is recommended. An example of a simplified test report is shown in Appendix No. 7, whereas a full report is available in Appendix No. 5.

3 Tests

Requirements for the personnel. The test operators performing tests according to this procedure should hold at least a

Level 2 certificate as per PN-EN ISO 9712 (or a valid certificate as per PN-EN 473) or a certificate issued according to an equivalent system for a relevant industry sector.

The tests are performed in four stages, namely:

stage 1 (preliminary stage) - preparing, collecting and recording information on the test item (i.e. filling in the identification and descriptive part of the report - Appendix No. 4 or Appendix No. 6),

Instructions IBUS-TD 16 page 4/26

stage 2 - preparation for testing consists in making the testing equipment complete, setting up the flaw detector, providing access to the test item, preparing the test surfaces (point 3.1),

stage 3 - the testing proper and retesting after repairs (if any),

stage 4 - archivization of test results.

3.1 Preparation for testing

The test preparation should account for the following:

collecting, defining more specifically and establishing the information necessary for testing (see the relevant report sections in the Appendix No. 4 or the Appendix No. 6),

checking the set-up of the flaw detector and its equipment, preparation of the test items, accessibility for testing, etc. Record the relevant information under respective sections of the report (see the Appendix No. 5 or the Appendix No. 7),

alternatively, check the probe parameters.

3.2 Testing

The testing consists in the flaw detector set-up (scaling), moving the probe to perform

the test (3.2.3), assessing the test results and their recording in the test report. In a standard configuration the tests are performed on two sides unless the edges of the components prepared for welding are perpendicular (prepared without beveling) or the weld is accessible from one side only.

3.2.1 Flaw detector set-up

The flaw detector set-up consists in selecting the right DAC curve and the

corresponding settings, i.e. gain and time base. These parameters must be identical to those used for making the DAC curve (unless the flaw detector ensures invariable curve readings regardless of the position on the screen).

3.2.2 Probe connection

The TD probe is to be connected so that the front transducer functions as a transmitter

while the rear one operates as a receiver. At the same time, set the flaw detector up for operation with the tandem probe (disconnect the transmitter from the receiver).

3.2.3 Probe movements and screen watching

the probe movements are to be performed lengthwise as reciprocal motion (back and forth cycles repeated several times) combined with movements around the circumference,

the movements can be performed quite swiftly and dynamically, though in sections to test the whole weld volume several times,

while moving the probe watch the flaw detector screen and evaluate the echo readings as displayed on the screen and respond as described in point 4.

Instructions IBUS-TD 16 page 5/26

4 Weld quality evaluation

Echo readings below the DAC curve are considered as readings caused by noise. These are not subject to evaluation.

Echo readings above the DAC curve are considered as unacceptable flaws and these are impermissible readings.

5 Conclusion of the test

The tests shall be concluded with the preparation of a report in accordance with

Appendix 4 or Appendix 6 and archivization of this report in accordance with point 2.7.

6 Checking probe parameters

Every probe should be periodically tested to check if has maintained its parameters.

Consequently, upon receipt of a new probe, three DAC curves should be created using a normal calibration standard (for the hole, the inside notch and the outside notch) and recorded.

The probe should be examined daily before starting the tests. This examination involves a verification of echo levels at the characteristic points of the recorded DAC curves on a normal calibration standard. If the amplitude at any point differs by more than 6 dB, the examined probe can no longer be used for testing.

7 Related standards and documents

[1] PN-EN 12668-1:2010 Non-destructive testing. Characterization and verification of ultrasonic examination equipment. Part 1: Instruments.

[2] PN-EN ISO 9712:2012 Non-destructive testing. Qualification and certification of NDT personnel.

[3] PN-EN ISO 17637:2011 Non-destructive testing of welds. Visual testing of fusion-welded joints.

[4] W. Michnowski, J. Mierzwa, Niezawodność spoin małych grubości badanych ultradźwiękowo. Metoda IBUS-TD [Reliability of thin welds subject to ultrasonic testing. IBUS-TD method]. 12th IPPT-PAN Seminar, Zakopane 2006.

8 List of appendices

Appendix 1. Probe parameters and probe diameter range Appendix 2. Normal and simple calibration block Appendix 3. Correcting calibration block Appendix 4. Contents of a full test report in accordance with IBUS-TD instructions Appendix 5. Example of a full test report Appendix 6. Contents of a simple test report in accordance with IBUS-TD instructions Appendix 7. Example of a simple test report

Instructions IBUS-TD 16 page 6/26

Appendix 8. Probe wetting system test Appendix 9. Specimen certificate of parameters of tandem probes Appendix 10. Specimen certificate of normal calibration block preparation and examination Appendix 11. Specimen training certificate

Instructions IBUS-TD 16 page 7/26

Appendix 1. Probe parameters and probe diameter range

Shear-wave tandem probes (e.g. probes manufactured by ZBM ULTRA) must have the following parameters:

frequency: 4 MHz or 2 MHz for high-attenuation steel (e.g. austenitic steel),

two identical round transducers with a diameter of 7 mm, placed in line, one behind the other,

beam angle: 50-70°,

sound-insulating barrier between the transducers.

For pipe weld testing, the probes have to be profiled to the diameter of the pipe. The profile of the probe should optimally match the pipe diameter. However, it is permitted for a probe with a specific profile to be used for a certain range of diameters, as per the table below. - Table 1. Probe profiles and corresponding ranges of the diameters of the tested pipes

Item Diameter of probe profile Range of the diameters of the

tested pipes

1 Ø32 Ø 28 - Ø 32

2 Ø 44 Ø 32 – Ø 44

3 Ø 51 Ø 44 - Ø 51

4 Ø 63 Ø 51 - Ø 63

5 Ø 76 Ø 63 - Ø 76

6 Ø 89 Ø 76 - Ø 89

7 Ø 105 Ø 89 - Ø 105

8 Ø 125 Ø 105 - Ø 125

Instructions IBUS-TD 16 page 8/26

Appendix 2. Normal and simple calibration block

Simple calibration block

A simple calibration block can be prepared ad hoc by the person conducting the test, by drilling through the currently tested section of the plate or pipe in accordance with the drawings below (Figs. 1 and 2) or on a section of a plate or pipe identical to the section under test. The following conditions have to be met in order to use and prepare a simple calibration block.

Fig. 1. Calibration block for a flat element with thickness g, hole diameter Ø = 1mm (P –

direction of probe movement when determining the DAC curve)

Fig. 2. Calibration block for tests of pipe welds with thickness g, diameter D, hole diameter Ø

= 1mm (P – direction of probe movement when determining the DAC curve) Requirements for the preparation of simple calibration block

An important advantage of simple calibration block is their high similarity to the tested section of the weld, which makes them referential. The calibration blocks are made by drilling through the currently tested section of the plate or pipe in accordance with Figs. 1 and 2 or on a section of a plate or pipe identical to the section under test. In order for the simple calibration block to be correct:

the surface of the calibration block has to be identical or similar to the tested section with the weld;

the surface has to be free from corrosion damage, erosion damage or mechanical damage visible with the naked eye that would limit the contact area of the probe profiled

Instructions IBUS-TD 16 page 9/26

to pipes or of the flat probe on flat surfaces;

the reference hole has to be perpendicular to flat surfaces or to the generatrix and the tangent perpendicular to the generatrix for cylindrical surfaces.

Simple calibration blocks are made by the testing personnel, and their conformity to the

requirements of the IBUS-TD 16 procedure is certified by the operator, who includes a suitable note in the test report.

Normal calibration block

IBUS-W normal calibration block may be purchased at ZBM ULTRA, and their conformity to the requirements of the IBUS-TD procedure is certified (certificate), complete with an enclosed drawing (Appendix 10). IBUS-W calibration blocks can also be prepared by the testing personnel themselves, and their conformity to the requirements of the IBUS-TD 16 procedure is certified by the operator, who issues the certificate as per the appendix (Appendix 10).

Fig. 3. IBUS-WR normal calibration block

Fig. 4. IBUS-WP normal calibration block

Instructions IBUS-TD 16 page 10/26

Requirements for the preparation of normal calibration block

These calibration blocks are used for validation (examination) of probe parameters and for verification of parameters in the tests. They are made in accordance with the drawing (Fig. 3 or Fig. 4), from a material with acoustic parameters comparable to the acoustic parameters of the material under test. In order for the normal calibration block to be correct:

the tolerances for calibration block dimensions in Fig. 3 and Fig. 4 are ±0.1 mm;

the surface of the calibration block is ground to Hz 0.63.

It is deemed that the acoustic parameters are comparable if the ultrasonic wave velocities are different by no more than ±0.5%, and suppression – by no more than ±3 dB. the reference hole has to be perpendicular to the generatrix and the tangent perpendicular to the generatrix for cylindrical surfaces. Every calibration block should have a certificate indicating that it has been prepared and tested in accordance with IBUS-TD instructions.

Instructions IBUS-TD 16 page 11/26

Appendix 3. Correcting calibration block

A sample correcting calibration standard is depicted in Fig. 5. This calibration block is used for correction during tests of welds from austenitic steel.

Fig. 5. Photograph of a correcting calibration block. 1 - 1.5mm reference hole, 2 - reference

hole in the middle of the weld, 3 - weld section with a ground face and root, 4 -tandem probe, type 2TD67 7x7

The correcting calibration block is used to accordingly correct the sensitivity of the DAC

curve. In order to do this, it is necessary to create a DAC curve for a hole drilled in the material (1 in the drawing). Then, a hole with the same diameter is drilled in the grinded fragment of the weld. The next step is to compare the indications for the hole in the weld with the DAC curve created for the hole in the material. The differences should be adjusted until the indications for the opening in the weld overlap with the prepared DAC curve. The adjustment cannot exceed 6 dB.

Instructions IBUS-TD 16 page 12/26

Appendix 4. Contents of a full test report in accordance with IBUS-TD instructions

The weld test report has been prepared based on the PN-EN ISO 17640 standard, with

certain modifications, and it should contain the following data: 1. General data, including the following information: a) particulars of the client (name, address); b) identification of the object under test:

name of the object under test,

product material and shape,

weld location,

weld identification (number) or sketch,

dimensions (weld thickness and length) or outside diameter and pipe wall thickness,

reference to the welding procedure specifications, specification and heat treatment,

stage of production,

surface condition,

temperature of the object; c) contract requirements, e.g. specifications, guidelines, special arrangements, etc.; d) place and date of testing; e) name of the testing body, name and certificate of the person conducting the test; f) name of the verifying body. 2. Devices

a) ultrasonic flaw detector – manufacturer, type, identification number; b) ultrasonic probes – manufacturer, type, nominal frequency, angle of incidence and

identification number; c) identification of reference blocks, including their sketch; d) couplant. 3. Testing method a) testing levels – put: NOT APPLICABLE, reference to testing procedures – put: IBUS-TD; b) extent of testing – put: as indicated by the length of the DAC curve; c) location of the scanning areas – put: as indicated by the length of the DAC curve; d) location of reference points and information about the coordinate system:

if the repair involves the cutting out of the entire weld, put: NOT APPLICABLE; otherwise, specify the origin of the “X” axis and the coordinate system in accordance with point 12.4 of PN-EN ISO 17640, limited to the “X” axis;

e) timebase range; f) identification of probe positions (as indicated in the appendix) – four positions are

permitted for flat welds, and two positions are permitted for pipe welds (left and right side);

g) method and values used for sensitivity setting:

gain setting for reference levels,

values used for transfer corrections – corrections are applied only for austenitic steel;

Instructions IBUS-TD 16 page 13/26

h) reference levels: indication for a hole with a diameter of 1 mm, perpendicular to the

tested surface or indication of a different reference hole diameter; i) result of the parent material test – put: not tested; j) standard for acceptance levels – put: IBUS-TD; k) deviations from these instructions or contract requirements. 4. Test results a) if the repair involves the complete cutting out of the weld – only GOOD/BAD; b) for other welds – table or sketch (graphical representation) representing the recorded

indications with amplitude exceeding the acceptance level, specifying the following:

coordinates of the indication (coordinate X),

length of the indication,

maximum echo amplitude,

result of evaluation in accordance with the specified acceptance levels: bad weld.

If no indications with an amplitude higher than the acceptance level have been recorded, replace the list of indications with the following: “No indications with an amplitude higher than the acceptance level have been recorded”.

In most cases, the test involves a number of welds of the given object, for which most of the elements of the report are constant. In such situations, a summary report should be prepared. The first part of such a report should contain all elements common to each of the tested welds, and point 4 should include the elements characteristic to the individual welds complete with the test results.

Instructions IBUS-TD 16 page 14/26

Appendix 5. Example of a full test report.

REPORT NO. 56/12/2009 For:

Fabryka Wagon S.A., ul. Roweckiego 5, Bydgoszcz Relating to:

Ultrasonic test of pipe welds in accordance with IBUS-TD For (client): as above

No. of the order (contract) dated: November 10, 2009, ref. No.:

Head of the testing group: Jan Nowak Qualification certificate acc. PN-EN ISO 9712:

UT 3 .....................................

Signature

Wrocław, September 13th, 2016 (place and date of the Report)

Instructions IBUS-TD 16 page 15/26

I. General data Name of the object under test: 3M boiler Product material and shape: tubes Reference to the welding procedure specifications, specification and heat treatment: none Stage of production: 10 h after welding Surface condition: cleaned Temperature of the object: 23 Celsius degrees Contract requirements: test 30% of all welds Place and date of testing: Wrocław, September 13th, 2016 Name of the testing body: ZBM Ultra Name and certificate of the person conducting the test: Jan Kowalski, Certificate No. 1231 Name of the verifying body: internal verification II. Devices

ultrasonic instrument ultrasonic probes

manufacturer: ZBM ULTRA type: CUD15 identification number: 15001 certificate number:

probe 1: manufacturer: ZBM ULTRA type: 4TD67 nominal frequency: 4MHz actual angle of incidence: 67 diameter of probe profile: 55-75 mm certificate number: 23421/II/2010

Identification of reference blocks, including their sketch: a simple calibration standard has been prepared from the material under test in accordance with IBUS-TD instructions Couplant: water with detergent

III. Testing method Testing levels: NOT APPLICABLE Reference to testing procedures: IBUS-TD Extent of testing: as indicated by the length of the DAC curve Location of the scanning areas: as indicated by the length of the DAC curve Location of reference points and information about the coordinate system: NOT APPLICABLE Timebase range: 0-12 cm Identification of probe positions: A and B Method and values used for sensitivity setting:

gain setting for reference levels: 34 dB

values used for transfer corrections: 0 dB (not used) Reference level: indication for a hole with a diameter of 1 mm, perpendicular to the tested surface Result of the parent material test: not tested Standard for acceptance levels: IBUS-TD Deviations from these instructions or contract requirements: none Acceptance level: reference level – 3 dB

Instructions IBUS-TD 16 page 16/26

IV. Test results

7 out of the 21 available welds were tested, two of which had been repaired. During the tests, 5 welds were determined to be good and 2 welds were determined to be bad.

Weld identification (number) in accordance with sketch 1

Weld location

Dimensions (outside diameter, thickness in mm)

Test result Notes

3 as per drawing 3a d = 60, g = 4 good

4 as per drawing 3a d = 60, g = 4 bad

8 as per drawing 3a d = 60, g = 4 good after repair

9 as per drawing 3a d = 60, g = 4 good after repair

10 as per drawing 3a d = 60, g = 4 good

12 as per drawing 3a d = 60, g = 4 good

13 as per drawing 3a d = 60, g = 4 bad

Instructions IBUS-TD 16 page 17/26

Appendix 6. Contents of a simple test report in accordance with IBUS-TD instructions

The simple weld test report should contain the following data:

1. General data, including the following information: a) particulars of the client (name, address); b) identification of the object under test:

name of the object under test,

product material and shape,

identification of the welds under test – weld location and/or weld identification (number) or sketch,

dimensions (weld thickness and length) or outside diameter and pipe wall thickness, c) contract requirements (e.g. additional arrangements); d) place and date of testing; e) name of the testing body, name and certificate of the person conducting the test; f) name of the verifying body. The identification of the welds under test and their dimensions may be included in the test results. 2. Devices a) ultrasonic flaw detector – manufacturer, type, identification number; b) ultrasonic probes – manufacturer, type, nominal frequency, angle of incidence and

identification number; c) identification of reference blocks, including their sketch; d) couplant. 3. Testing method a) location of reference points and information about the coordinate system:

if the repair involves the cutting-out of the entire weld, put: NOT APPLICABLE,

otherwise, specify the origin (zero point) of the “X” axis. b) values used for transfer corrections – corrections are applied only for austenitic steel; c) reference hole diameter.

Instructions IBUS-TD 16 page 18/26

4. Test results

The test results for a single weld should be presented as follows: a) if the repair involves the complete cutting-out of the weld – only GOOD/BAD; b) for other welds – table or sketch representing the recorded indications with amplitude

exceeding the acceptance level, specifying the following:

coordinates of the indication (coordinate X),

length of the indication,

maximum echo amplitude,

result of evaluation in accordance with the specified acceptance levels: bad weld.

If the test concerns more than one weld, the test results for the individual welds may be presented in a summary form enabling an unambiguous identification of the test result for the individual welds (e.g. in the form of a list).

Instructions IBUS-TD 16 page 19/26

Appendix 7. Example of a simple test report.

REPORT NO. 56/03/2010 For:

Fabryka Wagon S.A., ul. Jana Roweckiego 5, 53-621 Wrocław

Relating to:

Ultrasonic test of pipe welds in accordance with IBUS-TD

For (client):

as above

No. of the order (contract) dated: February 20th, 2010, ref. No.: A34

Head of the testing group: Jan Nowak Qualification certificate as per standard PN-EN ISO 9712:

UT 2 .................................

Signature

Wrocław, September 13th, 2016 (place and date of the Report)

Instructions IBUS-TD 16 page 20/26

I. General data Name of the object under test: economizer in boiler K3 at level 2 Product material and shape: steel pipes (regular steel) Contract requirements:

Test the entire bundle 4, consisting of the following:

131 welds with a size of 38/4 (outside diameter/thickness in mm)

48 welds with a size of 67/6

9 welds with a size of 98/6 Place and date of testing: Wrocław, September 13, 2016 Name of the testing body: ZBM Ultra Name and certificate of the person conducting the test: Jan Kowalski, IBUS-TD Certificate No. 1231 II. Devices

ultrasonic flaw detector ultrasonic probes

manufacturer: ZBM ULTRA type: CUD15 identification number: 15001 certificate number: 54/III/2009

probe 1: manufacturer: ZBM ULTRA type: 4TD67 7x7 Ф38 U9008 certificate number: 425/II/2010

probe 2: manufacturer: ZBM ULTRA type: 4TD67 7x7 Ф67 U9018 certificate number: 426/II/2010

probe 3: manufacturer: ZBM ULTRA type: 4TD67 7x7 Ф97 U9012 certificate number: 429/II/2010

Identification of reference (calibration) standards, including their sketch: a simple calibration standard has been prepared from the material under test in accordance with IBUS-TD instructions Couplant: water with detergent

III. Testing method a) location of reference points and information about the coordinate system: NOT

APPLICABLE b) values used for transfer corrections: NOT APPLICABLE c) reference hole diameter: 1 mm

IV. Test results

Instructions IBUS-TD 16 page 21/26

The following number of welds in bundle 4 have been tested under the contract.

Dimensions (outside diameter, thickness in

mm)

Number of tested welds

Number of corrected welds

Total number of welds

89/4 128 9 131

67/6 48 3 48

98/6 9 0 9

3 welds with a size of 38/4, marked on the enclosed sketch, have not been tested because they were inaccessible. All of the tested welds are good.

Instructions IBUS-TD 16 page 22/26

Appendix 8. Probe wetting system test

In order to achieve the necessary high probability of imperfection (defect) detection, the profile of the probe has to match the pipe (2.2.2), and (this is particularly important) the probe wetting system has to be tested. The wetting system with continuous feeding of water with detergent is the best system, and it does not have to be tested. However, other solutions have to be tested.

The test of the probe wetting system is performed to determine if there is sufficient acoustic coupling between the probe and the tested element when moving the probe in the manner required in the test. Good wetting depends on several parameters of the couplants used for wetting, e.g.: liquids, gels, greases, oils, etc.

The most important parameters of these couplants are: wettability (contact angle 6), spreadability, viscosity, etc. Only couplants with parameters matching both surfaces, i.e. the tested surface and probe surface, give good results. Test

Fig. 6 depicts the DAC curve and the echoes from the hole in the simple calibration block (Appendix 2). The probe should be moved several times along the generatrix and along the circumference, and the generated echoes should be observed. These movements (of which there should be no more than 30) should be performed without manually adding the wetting couplant. The proposed wetting couplant and/or its feeding system is disqualified if the echo amplitudes during these movements are different from the DAC curve by more than ±3 dB. Note

Oil derivative couplants (and their synthetic equivalents) and fats are on the opposite side of the wettability spectrum to water-based couplants.

They must never be used together. Surfaces “contaminated” with one of these couplants have to be thoroughly washed before the other couplant can be applied.

PL EN

stal-000 steel-000

Fig. 6. Echoes from the hole in the calibration block

Instructions IBUS-TD 16 page 23/26

Appendix 9. Specimen certificate of parameters of tandem probes

CERTIFICATE NO. XXX OF THE PREPARATION AND EXAMINATION OF TANDEM ULTRASONIC PROBES

Based on the results of probe tests carried out on mm/dd/yyyy in accordance with IBUS-TD-16 Ultrasonic Weld Testing Instructions and in accordance with standard PN-EN ISO/IEC 17025 – point 5.4.4, it has been found that: the parameters of the ultrasonic probes indicated in table 1 conform to the requirements of the IBUS-TD Instructions, which conforms to the requirements of point 5.4.4 of standard PN-EN ISO/IEC 17025. This certificate is valid for two years, i.e. until mm/dd/yyyy, after which the probes should again be subject to periodic tests.

Prepared by: Full name Reviewed and approved by: Full name Qualification Certificate Place and date

Certificate issued for: Name and address of the company

Table 1

Item Probe symbol Serial number Notes

1

2

…

Instructions IBUS-TD 16 page 24/26

Appendix 10. Specimen certificate of normal calibration standard preparation and examination

CERTIFICATE NO. XX/MM/YY OF THE PREPARATION

AND EXAMINATION OF normal ultrasonic calibration standards for the calibration of tandem probes in accordance with IBUS-TD 16 instructions

Based on the results of the tests carried out on mm/dd/yyyy in accordance with IBUS-TD 16, it has been found that: the parameters of the normal ultrasonic calibration standards indicated in Table 1 conform to the requirements of IBUS-TD 16 Instructions This certificate is issued for an indefinite period, provided that the calibration standard has not suffered visible mechanical damage.

Prepared by: full name

Reviewed and approved by: full name, certificate

Place and date Table 1

Item Calibration standard symbol Serial number Notes (e.g. flat, profiled to the pipe, etc.)

1

2

…

Certificate issued for: name and address of the company Measurement results (DAC curves) have been enclosed.

Instructions IBUS-TD 16 page 25/26

Appendix 11.

CERTIFICATE NO. XX/XX.XX/X OF TRAINING in the IBUS-TD 16 method

It is hereby certified that Mr.

Jan Kowalski has been trained in the independent performance of ultrasonic weld tests using the IBUS-TD 16 method. Mr. Jan Kowalski has successfully completed the verification tests provided for in the training program. The certificate is issued under the license provided by ZBM ULTRA sp. z o.o. to name and address of the company. Mr. Jan Kowalski holds personal identity card No. AAA111222 and level-2 ultrasonic testing certificate No. UT2/123 issued by XXX. The training was conducted using the following flaw detectors:

CUD15, manufactured by ZBM ULTRA.

The training was conducted by: full name of the trainer Qualification certificate as per PN-EN ISO 9712, signature.

Wrocław, September 13th, 2016