Evaluation of CEN Ultrasonic Testing

HSE
Health & Safety

Executive
Evaluation of CEN ultrasonic testing

standards for in-service inspection
Prepared by Mitsui Babcock for the

Health and Safety Executive 2005
RESEARCH REPORT 299
HSE
Health & Safety

Executive
Evaluation of CEN ultrasonic testing

standards for in-service inspection
NS Goujon and BWO Shepherd

Mitsui Babcock
Porterfield Road
Renfrew
Renfrewshire
PA4 8DJ
This report discusses the capability of European based UT procedures (which supersede the
equivalent British Standard, BS 3923) to detect service induced defects and looks at the limitations
which could have significant safety implications across a broad range of industrial sectors.
The aim of this project was to evaluate the capability of procedures based on the EN standards for inservice inspection. The project has concentrated on inherent capability with no blind trials, and
therefore complements projects like the PANI programme which has concentrated on human reliability
rather than procedure capability.
The work involved ultrasonic inspection of a number of testpieces containing both synthetic and real
service-induced defects (mainly cracks in welds). The project concentrated on detection, although
some sizing trials were also performed. A steering committee was established with representation
drawn from a variety of organisations to help direct and review the work.
Recommendations based both on the results of this project and the views of the Steering Committee
members are provided.
This report and the work it describes were funded by the Health and Safety Executive (HSE). Its
contents, including any opinions and/or conclusions expressed, are those of the authors alone and do
not necessarily reflect HSE policy.
HSE BOOKS
Crown copyright 2005

First published 2005
ISBN 0 7176 2945 7
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ii
Evaluation of CEN UT Standards for In-Service Inspection
Final Report
CONTENTS
SUMMARY
1.
INTRODUCTION
2.
STEERING COMMITTEE
2.1
MEMBERS
2.2
ISSUES RAISED BY THE COMMITTEE
3.
REVIEW OF MAIN DIFFERENCES BETWEEN BS 3923 AND
THE EN STANDARDS
3
3.1
REVIEW OF PREVIOUS ASSESSEMENT TRIALS
3.2
COMPARAISON OF STANDARDS
4.
EXPERIMENTAL INVESTIGATION
4.1
ULTRASONIC MODELLING
4.2
TESTPIECES
10
4.3
INSPECTION TECHNIQUE & PROCEDURE
10
4.4
RESULTS
11
4.5
DISCUSSION
22
5.
CONCLUSIONS
27
6.
RECOMMENDATIONS
30
7.
REFERENCES
31
APPENDIX A: EXAMINATION REQUIREMENTS
33
APPENDIX B: ULTRASONIC MODELLING
40
APPENDIX C: TESTPIECES
45
APPENDIX D: TRIALS RESULTS
48
iii
iv
Final Report
SUMMARY
This report describes the work carried out on the HSE funded project
Evaluation of CEN UT Standards for In-Service Inspection.
European standards covering pulse echo ultrasonic inspection of welds have
recently been issued, and supersede the equivalent British Standard BS 3923.
These standards (BS EN 1712; 1713; 1714), referred to below as EN
standards, are now specified by various manufacturing standards and are
intended to result in a more harmonised approach to in-manufacture
inspections within the EC.
There are no national or international UT standards specifically intended for inservice inspections.
It is therefore possible that in-service inspection
procedures will tend to be based by default on the new EN standards, just as
previously they were based (in the UK) on BS 3923 even though it had been
written largely with in-manufacture inspections in mind.
It is therefore important that the capability of EN based UT procedures to detect
and characterise service induced defects is properly understood, since
limitations (particularly reduced capability compared to BS 3923) could have
significant implications for plant safety and availability.
It should also be noted that more influence can be exerted over in-service
inspections since these are generally non-codified than over in-manufacture
inspections which are performed in accordance with internationally agreed
codes and standards.
The aim of this project was therefore to evaluate the capability of procedures
based on the EN standards for in-service inspection. The project has
concentrated on inherent capability with no blind trials, and therefore
complements projects like the PANI programme which has concentrated on
human reliability rather than procedure capability.
The work involved ultrasonic inspection of a number of testpieces containing
both synthetic and real service-induced defects (mainly cracks in welds). The
project concentrated on detection, although some sizing trials were also
performed. A steering committee was established with representation drawn
from a variety of organisations to help direct and review the work.
The recommendations based on the results of this project and the views of the
Steering Committee members are as follows:
BS EN 1714 should not be used as a stand alone procedure for in-service
inspection. In-service inspection should be performed in accordance with a
written procedure and work instruction / technique sheet which is more
prescriptive than this standard, and includes detailed specification of the scans
required, probe characteristics and reporting criteria. These should be based
on a knowledge of the defect and degradation types, locations, morphologies
and sizes of interest.
v
Final Report
In defining these requirements, consideration should be given to the following:

1. Although the BS EN amplitude report threshold of 32% DAC (10dB below
the DAC curve) may be appropriate for harmonising in-manufacture
inspections, a more sensitive threshold may be appropriate for in-service
inspections (even though all the defects studied exceeded this threshold
with at least one beam). Previous experience has demonstrated that a
report threshold of 10% DAC (20dB below the DAC curve) is sufficiently low
for most signals of interest to be reported (including tip diffracted signals)
but is still high enough to avoid false calls from noise. However there may
be cases where it is appropriate to report all indications detected above the
noise level.
2. Choice of beam angle is at least as important as choice of reporting
threshold. Both capability and reliability for defect detection will tend to
increase, the greater the number of different beam angles employed
(different probe angles and / or scan surfaces). The results from this project
suggest that for weld thicknesses below 20mm, a 70 scan should be
included for detection of opposite surface cracks oriented in the through wall
direction. An additional 45 scan is recommended for critical applications.
For greater thicknesses a 45 scan may provide increasingly better
capability than a 70 scan for the detection of such defects.
3. In this study, the 2MHz probes generally provided better capability for
detection than the 4MHz probes. However there may be circumstances
where 4MHz probes provide the better detection capability, for example it
can be easier to distinguish between defects at the weld root, and the root
bead reflection, when using higher resolution (higher frequency) probes.
4. A fixed root scan is highly recommended for inspection of welds with an
undressed root, where there is a requirement to detect defects near the
root, such as inner surface cracks.
5. The fixed amplitude method of measuring length described in BS EN 1712
(acceptance criteria) is not recommended for in-service inspection
applications. These should be based instead on the types of techniques
described in BS EN 583-5, e.g. 6dB drop sizing for defects longer than the
beam width.
6. Acceptance criteria should be agreed between the contracting parties.
vi
1.
Final Report
INTRODUCTION
This final report describes the work carried out on the HSE funded project
Evaluation of CEN UT Standards for In-Service Inspection.
European standards covering pulse echo ultrasonic inspection of welds have
recently been issued and supersede the equivalent British Standard, BS 3923
[1]
. These standards BS EN 1712 [2], BS EN 1713 [3] and BS EN 1714 [4], are
now specified by various manufacturing standards and are intended to result in
a more harmonised approach to in-manufacture inspections within the EC.
The implications for manufacturers and end-users of these European standards
(previously referred to as CEN standards, from now on referred to as EN
standards throughout this report) have previously been evaluated through a
TWI group sponsored project GSP 5657 [5], which involved Mitsui Babcock
performing part of the work. The project involved performing EN based
inspections on a selection of welded testpieces which contained predominantly
manufacturing defects such as lack of side-wall fusion, lack of inter-run fusion,
weld cracking, slag and porosity.
The main conclusion was that procedures based on EN standards were likely to
result in a lower detection rate than procedures based on BS 3923.
There are no national or international UT standards specifically intended for inservice inspections. It is therefore likely that in-service inspection procedures
will tend to be based by default on the new EN standards, just as previously
they were based (in the UK) on BS 3923 even though it had been written largely
with in-manufacture inspections in mind. Inspection capability can be very
sensitive to defect type so that the global capability for defects produced during
manufacture is unlikely to provide a true picture of the capability for service
induced cracks.
It is therefore important that the capability of EN based UT procedures to detect
and characterise service induced defects is properly understood, since
limitations (particularly reduced capability compared to BS 3923) could have
significant implications for plant safety and availability.
It should also be noted that more influence can be exerted over in-service
inspections since these are generally non-codified (EN is likely to be used as
an unofficial default) than over in-manufacture inspections which are
performed in accordance with internationally agreed codes and standards (EN
is mandatory).
The aim of this project was therefore to evaluate the capability of procedures
based on the EN standards for in-service inspection. The work has involved
ultrasonic inspection of testpieces containing both synthetic and real service
induced defects (mainly cracks). The project has concentrated on inherent
capability with no blind trials, and therefore complements projects like the PANI
programme which has concentrated on human reliability rather than procedure
capability.
2.
STEERING COMMITTEE
2.1
MEMBERS
Final Report
A steering committee was established with representation drawn from a variety

of organisations.
The membership of the steering committee was as follows:
Member
Organisation
Mr H Bainbridge
HSE
Mr R Lyon (Chairman)
RWE npower
Dr G Georgiou
Jacobi Consulting Ltd

(representing BINDT)
Mr R Gregory
ExxonMobil
Mr S Hewerdine
Oceaneering OIS
(latterly with Aker Kvaerner)
Dr B McGrath
Serco
Mr D Ritchie
Conoco Phillips Petroleum
Mr S Smalley replaced by Mr C Latter Royal & Sun Alliance /

/ Mr M Miller
Oceaneering (representing SAFed)
2.2
Mr A Kirkham, Dr L Morgan (MIC Ltd)
National Grid Transco
Dr B Shepherd
Mr O Shafi replaced by Ms NS Goujon
Mitsui Babcock
ISSUES RAISED BY THE COMMITTEE

The main areas of interest agreed at the beginning of the project were:
Testpiece thickness range: 10mm to 40mm (main interest up to 20mm)
Concentrate the work (around 80%) on surface breaking defects
Mainly cracks, but some interest in selective root corrosion
Butt, nozzle and attachment welds
Final Report
3.
REVIEW OF MAIN DIFFERENCES BETWEEN BS 3923 AND

THE EN STANDARDS
3.1
REVIEW OF PREVIOUS ASSESSEMENT TRIALS

Mitsui Babcock previously performed work as part of TWI group sponsored
project 5657 [5] to compare procedures based on BS 3923 and the draft EN
standards for manufacturing inspections. This involved applying both types of
procedures to production and test welds and also retrospectively analysing
previous inspection reports. As a part of the current workscope this previous
Mitsui Babcock work was reviewed.
Inspections with the BS EN 1714 standard reported and rejected considerably
fewer defects than with BS 3923. Most of the defects reported by the BS 3923
inspections but not by the EN inspections tended to be threadlike defects.
However there were cases where lack of side wall fusion defects were not
recordable by the EN standard, and were characterised as non-planar using the
EN cascade method for defect characterisation (which is the basis of BS EN
1713).
Further information on GSP 5657 and related projects is provided in references
[6] to [8].
3.2
COMPARAISON OF STANDARDS
3.2.1
Introduction
This section summarises the main differences between the European standard
BS EN 1714 and the superseded British standard BS 3923. Since BS EN 1712
defines evaluation levels and includes the description of the fixed amplitude
level technique for length measurement, it is also compared to BS 3923 where
appropriate.
These European standards are:
BS EN 1714: 1998 Non-destructive testing of welded joints Ultrasonic

testing of welded joints. This standard specifies methods for manual
ultrasonic testing of fusion welded joints in metallic materials equal to and
above 8mm thick which exhibit low ultrasonic attenuation. The standard
specifies four testing levels, each corresponding to a different probability of
detection of imperfections.
BS EN 1712: 1997 Non-destructive testing of welds Ultrasonic testing of

welded joints Acceptance levels. This standard specifies ultrasonic
acceptance levels, 2 and 3, for full penetration welded joints in ferritic steels
(with thicknesses from 8mm up to 100mm) which correspond to the quality
levels B and C of BS EN 25817 [9], in which flaws are accepted or rejected
principally on the basis of their ultrasonic echo amplitude and their length. It
also describes the fixed amplitude level technique for length measurement.
Final Report
The European standard BS EN 1713 was not considered. This standard defines
the classification of internal indications as planar or non-planar. It was studied
as a part of the previously referenced TWI GSP and some of the results are
summarised in reference [6].
The more general guidance on UT provided in BS EN 583 parts 1-5, references
[10] to [14], has not been studied in any detail.
The most stringent examination requirements for longitudinal indications in

various types of weld, that is examination level 1 under BS 3923 and
examination level C under BS EN 1714 are provided in Table A1 of Appendix
A1 (note that examination level D is more stringent than level C but is for
special applications, see section 3.2.3). The requirements for the testpieces
used for this study are provided in separate tables in Appendix A2.
3.2.2
Scope
The thickness ranges for which the standards apply are:
BS 3923: t 6mm and 150mm
BS EN 1714: t 8mm; no upper limit.
BS EN 1714 states that it can be applied directly as an inspection procedure

(although how this is practical given the range of options is not clear). BS 3923
states specifically that it does not in itself constitute a test specification.
3.2.3
Choice of examination / testing levels

Both standards have 3 examination levels providing different degrees of rigour
(+ 4th level for special applications). However:
BS 3923 examination levels differ in terms of both sensitivity and number of

techniques.
BS EN 1714 testing (the term examination has been dropped) levels differ
only in terms of number of techniques. Four testing levels are specified: A,
B, C and D. From testing level A to C, an increasing probability of detection
will be achieved (through additional scanning and/or surface dressing). The
quality level corresponding to this test level is defined in BS EN 25817 such
that: test level A corresponds to a quality level C (intermediate), test level B
corresponds to a quality level B (stringent), test level C is by agreement and
test level D is for special applications.
To achieve an examination level 1 under BS 3923, the component surfaces

must be dressed. BS EN 1714 is not prescriptive regarding surface
condition.
The highest level under which a butt joint (plates and pipes) inspection can
be carried out on an as-welded component, under BS 3923, is level 2B.
BS EN 1714 standard makes no distinction between as-welded and dressed

welds.
3.2.4
Final Report
Coverage / beam angles
3.2.4.1 Parent material inspection

As a part of the general requirement under BS 3923, the examination of the
parent material using a single or twin 0 probe should be carried out to achieve
a complete weld examination. Whether or not the parent material has been
ultrasonically tested previously, an examination shall be made after welding.
Under the BS EN standard, the parent material , in the scanning zone area,
shall be tested with 0 probes prior to or after welding, unless it can be
demonstrated that the angle probe testing of the weld will not be influenced by
the presence of the imperfections or high attenuation.
3.2.4.2 Weld inspection
The standards are broadly similar with the exception of:
The BS EN 1714 standard states that if individual sections of the testing

volume (which includes weld and parent material for at least 10mm on each
side of the weld) cannot be covered in at least one scanning direction or if
the angles of incidence with the opposite surface is less than 35 and
greater than 70 alternative UT or other NDT shall be agreed upon.
Removal of the weld cap may have to be considered.
There is no requirement in BS EN 1714 for a separate root scan.
Little guidance is provided in the BS EN 1714 standard on choice of beam

angle, other than that one of the beams should inspect the weld fusion faces
at as near as possible to normal incidence. (Clearly more appropriate for inmanufacture inspection than in-service inspection).
When there is a requirement for scanning both upper and lower surfaces
under the BS EN 1714 standard, there is no alternative proposed when
scanning access is restricted to the upper surface.
Under BS 3923, the most stringent inspection level (level 1) can only be
achieved for set-on connections if the bore of the nozzle/branch is
accessible and the root bead has been removed.
Unlike BS 3923, BS EN 1714 does not differentiate between single sided

and double-sided welds for plates and pipes and set-through nozzles.
3.2.5
Final Report
Sensitivities
The sensitivities provided in the tables below are for angled beam
examinations.
Note: SDH = side-drilled hole and in the case of BS 3923 scanning sensitivity,
+ means more sensitive.
3.2.5.1 BS 3923
Weld examination
Longitudinal defects
Transverse defects
Examination Level 1
Grass or at least DAC + 14dB
Grass or at least DAC + 20dB
Examination Level 2
3mm SDH DAC + 14dB
3mm SDH DAC + 14dB
Examination Level 3
3mm SDH DAC + 8dB
3mm SDH DAC + 8dB
Examination Level 4
Minimum scanning sensitivity Minimum scanning sensitivity

by agreement.
by agreement.
Table 3.1:
Minimum scanning sensitivity level under BS 3923.
Evaluation and Recording Level

For level 1, all indications detected above grass shall be evaluated. For other
levels, only indications which exceed the DAC curve at the minimum scanning
sensitivity defined above shall be evaluated. Thus, for example, for a scanning
sensitivity of DAC +14dB, indications which exceed DAC 14dB (20% DAC) will
break the marked DAC curve and should be evaluated. Isolated point reflectors
are ignored unless their amplitude is above a specified level in which case they
are recorded. Indications which are above the evaluation threshold and
interpreted as being planar shall be recorded.
3.2.5.2 BS EN 1714 / BS EN 1712
Weld examination - BS EN 1714
Scanning sensitivity not specified. A choice of reference and evaluation levels
is given, see below, these are for both longitudinal and transverse defects.
Method 1: 3mm SDH
Reference level: 3mm SDH DAC

Evaluation level: Reference level - 10dB
Method 2: distance gain

Reference level: based on a Disc Shaped Reflector (DSR)
size (DGS)
dimension varies with the parent material thickness and the
(not covered by BS 3923) probe frequency used.
Method 3: 1mm deep Reference level: DAC curve for a 1mm deep rectangular
rectangular notch
notch.
Tandem testing
DDSR = 6mm (for all thicknesses)

Table 3.2:
Weld examination level under BS EN 1714.
Final Report
Recording Level - BS EN 1712
Recording level for methods 1 & 3:

o
Acceptance level 2: reference level 6dB (50% DAC)
Acceptance level 3: reference level 2dB (80% DAC).
Recording level for method 2:

o
Acceptance level 2: reference level
Acceptance level 3: reference level + 4dB
Recording level for tandem testing:

o
DDSR = 6mm (for all thicknesses)
Note that BS EN 1714 states that the amplitude of indications exceeding the
DAC -10dB (32% DAC) evaluation level shall be recorded and the length
determined (and also height if required). The BS EN 1712 recording level of
50% DAC (for acceptance level 2) appears to conflict with this. The BS EN
standards also equate DAC -10dB to 33% DAC, whereas it is in fact 31.6%
DAC. In this project we have taken the BS EN recording level to be 32% DAC.
3.2.6
Length measurement
3.2.6.1 BS 3923
Under BS 3923 the length measurement of an indication is typically performed
using the 6dB drop tip location technique (for defects larger than the beam
width).
Sizing of imperfections should be carried out at ranges not exceeding the halfskip range (except when agreed with the contracting parties).
3.2.6.2 BS EN 1714 / BS EN 1712
Under BS EN 1714:1998: the length of the indication, in either the longitudinal
or transverse direction shall, where possible, be determined using the technique
specified in the acceptance levels standard or 6dB drop tip location technique,
unless otherwise agreed. However, the BS EN 1712 acceptance standard
provides no choice since the 6dB drop method is not referenced.
The BS EN 1712:1997 (Acceptance levels) specifies that: the length of the
indication shall be determined by measuring the distance along the length over
which the echo amplitude is above the evaluation level, using the fixed
amplitude level technique described in Annex B of the standard. The technique
measures the lateral dimensions of an indication over which the echo is equal
to or greater than the evaluation level. To make a measurement the beam is
scanned over the indications, and the probe position and beam path range, at
which the echo has fallen to the evaluation level provide the extremities of the
measured defect length. A narrow beam width probe is suggested in order to
achieve a more accurate measurement or corrections for the influence of the
beam width may be performed.
7
3.2.7
Final Report
Other
BS EN 1714 (Section 12.3) recognises the difficulty of detecting subsurface

planar defects perpendicular to the surface. It recommends consideration of
specific testing techniques but does not provide further guidance.
BS 3923 does not recommend other techniques for such defects, except
that for double sided welds if the weld root before welding exceeds 3mm,
then either the tandem technique or a beam within 10 of normal to the root
face must be applied.
BS EN 1714 requires personnel to be familiar with testing problems

specifically associated with the type of weld joints to be tested.
Under BS 3923, the successful application of manual ultrasonic testing
depends on the knowledge and experience of the personnel responsible for
producing the test procedures, and the technical competence and ability of
the ultrasonic practitioner to carry out the procedural requirements and
interpret results.
It should be noted that the EN standard recommends as low a frequency for

initial testing (detection) as possible within the range 2MHz to 5MHz.
Under BS 3923 probes in the range 4MHz to 6MHz are preferable when the
parent examination is carried out in order to note possible variations in
attenuation in the material. There are no specific requirement when it comes
to the initial testing of the weld. The standard provides guidance in the
choice of probe frequency to be used for the weld inspection in relation to
the resolution, attenuation and coupling which can be achieved: better
resolution is achieved with higher frequency probes; at long ranges or in
more highly attenuative materials, shear probe frequency should be in the
range 2MHz to 3MHz. Lower frequency probes are noted as being more
tolerant of surface roughness.
4.
Final Report
EXPERIMENTAL INVESTIGATION
This section describes the following:
4.1
Ultrasonic modelling to help guide testpiece design
Sourcing of testpieces for trials
Techniques and procedures adopted for trials
Trials results
Discussion of results
ULTRASONIC MODELLING
In order to guide the design and selection of testpieces, some modelling of the
45 corner reflection response from vertical and tilted internal surface cracks
has been performed. The mathematical model of ultrasonic response is based
on elastic Kirchhoff theory applied to the case of the pulse-echo corner-effect
technique, where the intention is to detect defects close to the inner surface
using probes on the outer surface.
The results are presented in Appendix B. With reference to Figures B1 to B4
inclusive, the shapes of the corresponding families of curves are fairly similar
but with slightly higher amplitude for the 4MHz probe compared with the 2MHz
probe for untilted cracks, and slightly lower amplitude for tilted cracks (as
expected).
For the most part there are similar trends observed in both the 2MHz and 4MHz
output data sets. Within the approximate limits of 5 reflector tilt there is a
clear correspondence of increase in signal amplitude with increase in reflector
throughwall extent - this response does not appear to demonstrate any strong
bias with regard to sign of tilt. For both the 2MHz and 4MHz probes the
maximum response is obtained when the throughwall extent of the reflector is
largest (i.e. 5mm) and tilt is small or zero (i.e. vertical).
The mathematical model is based on specular reflection and therefore does not
take any account of diffraction by the top edge of the slot. It is expected that this
mechanism would become the dominant detection mechanism at increasing
angles of tilt.
The results indicate that for the situation modelled, defects exceeding 1mm in
height and tilted up to 20 should be above the evaluation threshold for both the
BS and EN standards. Note that these results assume that the weld cap does
not impose a restriction to scanning, and that there is no complication due to an
undressed root or counterbore.
4.2
Final Report
TESTPIECES
The work involved inspection of real or synthetic service induced defects within
a variety of plates, pipes, T-butts and nozzles. The testpieces were ferritic steel
testpieces of thickness range 10mm to 65mm. The testpiece list is provided in
Tables C1 and C2 in the Appendix C. The defect dimensions refer to intended
dimensions unless otherwise stated since sectioning was only performed on a
limited number of testpieces.
26 testpieces were used providing a total of 76 defects (4 of which were
erosion/corrosion simulated defects). Most of the defects were manufactured
the exceptions being the ten selected stress oriented hydrogen induced
cracking defects in the SOHIC pipe, the smooth thermal fatigue root crack in
pipe P257 and the two toe cracks of the furnace testpiece. Several of the
testpieces were provided by members of the Steering Committee (some of
which were lent from the PANI programme).
Note that the testpieces used for the study contain both in-service and
manufacturing type defects. Only defects representing service induced defects
are of main interest for this project.
4.3
INSPECTION TECHNIQUE & PROCEDURE

The inspections were generally carried out using 45, 60 and 70, 10mm
diameter crystal probes at both 2MHz and 4MHz frequencies, and scanning
from all available surfaces. Signal amplitude was recorded without applying any
threshold. It has therefore been possible to analyse the results to investigate
which defects exceed the EN evaluation threshold of 32% DAC as a function of
frequency and beam direction, and the extent to which lowering the evaluation
threshold increases the number of reportable defects.
Since the object of this project was to investigate procedure capability rather
than human reliability these trials were not blind, i.e. the operators were
informed of the location and types of defects in each testpiece.
The inspection was carried out using the following probes:
45, 2MHz, 10mm single crystal probe
45, 4MHz, 6x6mm single crystal sub-miniature probe
60, 4MHz, 6x6mm single crystal sub-miniature probe
70, 4MHz, 4x9mm twin crystal probe
10
4.4
Final Report
RESULTS
The results of the trials are presented in Appendix D. Note that most of the
defect dimensions refer to intended dimensions since only a limited number of
testpieces were sectioned. The sectioned testpieces include: three plates
(2557-003, 2557-004 and P2401), one pipe (P2301), one T-joint (P2201) and
two set-on nozzles (P2101 and P2102). This providing sectioning sizing
measurements for a total of 26 defects out of the 76 defects used for the study.
A summary of the results is provided in the following sub-sections. Note that
the comments relating to the BS 3923 standard refer to an examination level
2B. Refer to the schematic diagrams of Appendix A1 (Figure A1) when
references are made to a scanning side.
The BS and EN examination requirements specific to each testpiece used for
this study are provided in Appendix A2.
4.4.1
Detection
4.4.1.1 Plates
The results collected from the plates are summarised in the following tables.
TESTPIECES
COMMENTS
2557-003
(10mm thick)
(4MHz probes
only)
2557-004
(12mm thick)
Investigation of 4 embedded cracks.

Best responses from the twin 70 4MHz probe.
The presence of the weld cap restricted the coverage of the 45
(1/2 skip and full skip) and the 60 probes (1/2 skip).
Defect No3 (smooth crack) could have been missed using 60
4MHz probe as this probe provided responses of very low
amplitude. The full skip responses were just reaching the
recording threshold for the BS EN 1714 standard.
2MHz probes could not be applied as the testpiece was no
longer available (the testpiece has been sectioned).
The results show that the defects should have been detected and
reported using either the EN or the BS standard.
Investigation of 2 embedded cracks.
Best responses from the twin 70 4MHz probe.
The 45 probes provided poor results due to restricted coverage
created by the weld cap.
The 2MHz lower beam angle probes provided higher responses
than the 4MHz equivalents.
The results show that the two defects should have been detected
and reported using either BS EN 1714 or BS 3923. (Note that
under BS EN 1714, if restriction to one side of the weld, an
additional beam angle has to be used and if scanning cannot
cover the whole inspection volume alternative or supplementary
UT should be used or the weld reinforcement be removed).
The results from the dressed testpiece allowed for detection of
the defect by all the beam angles and provide responses above
the BS EN threshold of 32% DAC.
11
TESTPIECES
COMMENTS
TPF7
(14mm thick)
RSA/PLW/15/
ET001
(15mm thick)
Final Report
Investigation of 2 cracks: 1 toe crack and 1 at the root.

Best responses from the single 70 2MHz probe.
In general, the 2MHz probes provided higher responses than the
4MHz probes.
Defect No1 (Toe crack) was only detected from one side and at
full skip from the upper surface and at skip from the bottom
surface. A full skip examination is critical. The signal amplitudes
from the defect are 45% DAC.
Care must be taken to ensure total coverage of the weld volume.
The results show that due to the weld cap restriction, the
information on the defects is mainly provided from the full skip
scanning.
The results show that the defects should have been detected
and reported using either the EN or the BS standard.
Investigation of 7 upper surface breaking cracks:
3 transverse cracks and 4 longitudinal cracks (testpiece as
welded).
All the defects in this plate were upper surface breaking cracks,
three of which were transverse.
The inspection from the top side was carried out using full skip
and the inspection from the bottom side was carried out using
half skip.
A transfer correction of 15 dB was applied when inspecting from
the top side of the test plate to compensate for the zinc coating.
The transverse defects were still detectable from the upper
surface even though the weld cap was present. The signal
amplitude from defects 4 and 5 are all 28% DAC which is
below the reporting threshold of BS EN 1714. These defects
should have been reported under BS 3923 (even if most of the
responses were 20% DAC). Defect 6 would have been reported
under both standards if the 45 4 MHz probe was used.
Best responses from the 45 probes when scanning from the
upper surface.
Best responses from the single 70 2MHz probe when scanning
from the bottom surface (with the exception of defect 7, which is
not a toe crack, for which the 45 4MHz probe provided the best
response).
The 2MHz probes provide in general higher responses than the
4MHz probes.
12
TESTPIECES
COMMENTS
TPF1
(20mm thick)
PL8155
(20mm thick)
PL8153
(25mm thick)
PL8156
(25mm thick)
PL8157
(25mm thick)
Final Report
Investigation of 5 root cracks.

Defects of height 5mm were detected with a response 36%
DAC regardless of the probes angle and frequency.
The signal amplitude from the Defect 1 (height = 2mm) was
below the reporting threshold of BS EN 1714 for most of the
scans. Only the 60 and the 70 2MHz probes provided signal
amplitude above the BS EN recording threshold.
The signal amplitude from the Defect 2 (height = 3.5mm) was
below the reporting threshold of BS EN 1714 for the 45 2MHz
and 4MHz and for the 70 4MHz probe. The defect would have
been reported using all the probes under the BS standard (signal
at the limit of reportability using the 45 probes).
Best responses from the 70 2MHz probe.
4MHz probes.
Investigation of 1 toe crack.
Testpiece not inspected in full skip with the 70 probes.
2MHz probes.
The results show that the defect should have been detected and
Investigation of 2 cracks: 1 toe crack and 1 root crack.
Best responses from the 60 and 70 2MHz probes.
4MHz probes.
Investigation of 1 embedded crack.
4MHz probes.
Investigation of 1 toe crack.
Best responses from the single 60 and 70 2MHz probes.
4MHz probes.
13
TESTPIECES
COMMENTS
PL8158
(25mm thick)
PL8159
(30mm thick)
PL8160
(30mm thick)
P2401
(40mm thick)
P24T
(40mm thick)
Final Report

Best responses from the single 60 2MHz.
4MHz probes.
The signal amplitude of some of the indications was below the
reporting threshold of BS EN 1714 for some scans (but above BS
3923 threshold). However, this should not have prevented the
defects being reported.
Investigation of 1 transverse crack (testpiece dressed).
This transverse crack should have been reported regardless of
the standard used.
Investigation of 2 cracks: 1 root crack and 1 embedded crack.
4MHz probes.
and reported using either the BS EN 1714 or the BS 3923
standard.
Investigation of 1 upper surface breaking crack.
Testpiece could not be inspected in full skip with the 70 probes
due to restricted scanning surfaces.
4MHz probes.
and reported using either the BS EN 1714 or the BS 3923
standard.
14
Final Report
4.4.1.2 Pipes
The results collected from the pipes are summarised in the following tables:
TESTPIECES
COMMENTS
P2301
(11mm thick)
Investigation of 6 defects: 4 cracks (3 root cracks and 1 toe

crack) and 2 erosion/corrosion defects.
With the exception of the toe crack, all the defects were located
at the inner surface. The presence of the weld cap did not allow
coverage of the weld using the 45 at half skip. The investigation
range was therefore increased to 1.5 skip.
The results from all the defects show that the detection and the
reporting of the defects should have been the same regardless of
which standard was used for the inspection.
4MHz probes for the defects other than the erosion/corrosion
defects for which the 4MHz probes tended to provide higher
responses.
Cracks:
Best responses generally from the 70 2MHz probe.
4MHz probes.
reported using either BS EN 1714 or BS 3923 standard.
P23T
(11mm thick)
Erosion/corrosion defects:
2MHz probes. (May have been due to morphology of simulated
corrosion).
The weld geometry restricted the weld inspection from the cone
resulting in poor results. The indications were detected with
responses below 20% DAC which is below the reporting
threshold of both BS EN 1714 and BS 3923. This would have
prevented the defects being reported.
Investigation of one incomplete root penetration which simulates
a root corrosion defect.
The presence of the weld cap did not allow coverage of the weld
using the 45 at half skip. The investigation range was therefore
increased to 1.5 skip.
The indication was detected with responses above 40% DAC
which is above the reporting threshold of both BS EN 1714 and
BS 3923.
reported using either the BS EN 1714 or the BS 3923 standard.
15
TESTPIECES
COMMENTS
TPF6
(12.5mm thick)
SOHIC
(12.7mm thick)
TPF8
(35mm thick)
Final Report
Investigation of 4 cracks: 2 embedded cracks, 1 toe crack and 1

root crack.
4MHz probes.
Defect 6 (Toe crack) was only reported at full skip due to the
presence of the weld cap.
Investigation of 10 cracks - the cracks are in the parent material.
Best responses from the 0 probe.
The amplitude responses from the 0 probe (all above 40% DAC)
would have allowed all the detected defects to be reported with
either standard.
The maximum recorded level with the shear probes was 56%
DAC. Most of the recorded levels were below 32% DAC.
The highest responses from the shear probes were generally
provided by the 45 4MHz probe. Only four out of the ten defects
examined provided indication level 32% DAC. Nine out of ten
defects provided indication level 20% DAC using this probe.
All the detected defects (10 defects) would have exceeded the
reporting threshold of the BS 3923 standard using the 45 2MHz
probe and only one would have exceeded the reporting threshold
of the BS EN 1714 standard.
Seven out of ten defects would have exceeded the reporting
threshold of BS 3923 using the 60 2MHz probe and only one
would have exceeded the recording threshold of BS EN 1714.
Both the 60 and the 70, 4MHz probes provided indication level
below 14% DAC which is below the recording threshold of both
standards.
Investigation of 7 cracks: 1 HAZ crack, 3 root cracks and 3
embedded cracks.
Best responses from the 70 probes.
All the defects should have been reported using the 70 probes.
The detection was achieved from either side of the weld cap with
the exception of defect 4 (toe crack) which was only detected
from one side. The signal amplitudes from the indications were
all above 32% DAC with the 70 probes.
4MHz probes.
16
TESTPIECES
COMMENTS
P257
(65mm thick)
Final Report
Investigation of 1 smooth crack at the root.

Best responses from the 45 probes.
The signal amplitudes from the indications were all very large
(above 140% DAC).
The defect would have been reported under BS EN 1714.
4.4.1.3 T-Joints
The results collected from the T-joints are summarised in the following tables:
TESTPIECES
COMMENTS
P2201
(20x10mm
thick)
Investigation of 7 defects: 4 cracks (3 root cracks and 1 toe

crack), 1 laminar tear and 2 erosion/corrosion defects.
The toe crack (defect 6) and the two erosion/corrosion defects
(defects 5 and 7) were not detected from the attachment plate.
Additional inspection was carried out from side F for defects 5, 6
and 7 (not required by either the EN or the BS standard).
The probe beam angle and frequency providing the best
responses is highly dependent on the defect being investigated
and the scan direction.
Cracks & laminar tear:

Best responses from the 45 2MHz and the 70 probes.
The toe crack was only detected from sides D, E and F, as
expected (see schematic diagram in Appendix D.3.1). The
defect would therefore have only been reportable under the BS
EN 1714 standard if examination level C or better was required,
as the examination only needs to be carried out from sides A
and B under examination level B. The defect would have been
reported under BS 3923.
With the exception of the toe crack, the reporting of the cracks
would have been the same regardless of which standard was
used for the inspection.
Erosion/corrosion defects:
Scanning restriction due to the weld cap prevented detection of
these small defects (3mm height) at 0.5 skip from side F.
To detect both defects the inspection has to be carried out from
the component plate.
17
TESTPIECES
COMMENTS
P22T
(20x10mm thick)
Furnace testpiece
(24x21.5mm thick)
Final Report
Investigation of 1 toe crack in the component plate.

The 2MHz probes provide higher responses than the 4MHz
probes.
The defect was detected only from the component plate surfaces
and would therefore not have been reported under BS EN 1714
examination level B.
Investigation of 2 toe cracks one in the furnace plate and one in
the tubeplate.
The inspection scans for this component would normally be
limited to surfaces B & D and C (0 inspection) - see schematic of
the testpiece Appendix D.3.3. The limitation is mainly due to
access restriction.
For this study, all the scanning surfaces were investigated to
maximise the amount of useful data available. To allow better
coverage, sub-miniature probes were used from surface A.
Defect No1 (Tubeplate crack):
Best response from surface B.
Best responses achieved using the 70 2MHz probe.
The 2MHz probes provide higher responses than the 4MHz
probes.
Reportable by both BS EN 1714 and BS 3923 standards.
Defect No2 (Furnace crack):
Best response from surface F. Note that inspection from
surface F is not required by either BS EN 1714 or the BS
3923 standard and is not included for the in-service
inspection. This result is unexpected since half skip from
surface D or E would normally be expected to be better. The
results may be due to the orientation of the defect or quality of
the scan surface in this particular testpiece.
The defect was only detected from sides D, E and F. It would
therefore have only be reportable under the BS EN 1714
standard if examination level C or better was required, as the
examination only needs to be carried out from sides A and B
under examination level B. The defect would have been
reported under BS 3923.
Best responses achieved using the 45 and 70 2MHz probes.
Therefore, both defects should have been reported under BS EN
1714 with an examination level C. If the requirement was to
examination level B, the defect in the furnace plate would not
have been reported. Both defects would have been reported
under BS 3923 (the 70 probes alone would have allowed the
detection of both defects.
18
Final Report
4.4.1.4 Nozzles
The results collected from the nozzles are summarised in the following tables:
TESTPIECES
COMMENTS
P2101
Set-on nozzle
(12mm thick)
P2102
Set-on nozzle
(12mm thick)
Investigation of 3 root cracks.

The restriction related to the weld cap limited the volume
coverage around the root for the 45 probes and (in some
instances) the 60 probes when scanning from the branch.
Inspection carried out from the outer surfaces of the branch (side
A) and the plate (side E not required by BS EN 1714 or BS
3923).
Difficult to resolve signals from the defect and those from the
root.
Inspection from the plate allows detection of the three defects
with amplitudes above 40% DAC.
Inspection from the branch allows detection of the three defects
with amplitudes at least 40% DAC using the 70 probes and
amplitudes at least 20% DAC using the 60 probes (with signals
not always maximised).
Best responses achieved using the 45 4MHz probe (from the
plate) and 70 4MHz probe (from the branch).
The results show that the defects would have been detected and
reported using either the BS EN 1714 or the BS 3923
(examination level 2) standard.
Investigation of 1 root crack and one toe crack (15 tilt).
The restriction related to the weld cap limited the volume
coverage around the root for the 45 probes.
Inspection carried out from the outer surfaces of the branch (side
A) and the plate (side E not required by BS EN 1714 or BS
3923).
root.
Best responses achieved using the 70 probes for the root crack
and the 45 4MHz probe for the toe crack.
Inspection from the branch and the plate allows detection of the
root crack with amplitudes above 40% DAC.
There are no responses from the plate scans which are between
20% DAC and 32% DAC. The toe crack would have been
reported if the inspection included scanning from the plate.
As no scanning from the component is required, the toe crack
would not have been reported under either standard.
19
TESTPIECES
COMMENTS
P21T
Set-on nozzle
(11mm thick)
4.4.2
Final Report
Investigation of 1 root crack.

Inspection carried out from the outer surface (side A) and the
inner surface (side B1) of the branch and from the outer surface
of the plate (side E).
Restriction was created by the weld cap limiting the volume
coverage when scanning from the branch and the plate.
Due to the restriction, the defect was only detected in full skip
from the branch side A and B1. The 60 probes detected the
defect from side A but the signal could not be maximised.
A 0 5MHz 10mm twin probe was used from the internal
surface of the plate. The defect was detected providing a signal
equivalent to 141% DAC.
Sub-miniature probes did not provide better results.
root.
Best responses achieved using the 70 4MHz probe.
The inspection from the outer surface of the branch (side A)
allows the detection of the defect with amplitudes of 100% DAC
with the 70 probes. The defect should have been reported
under both BS EN 1714 and BS 3923 standards.
Length measurement
In addition to the study on the amplitude response, length measurement was
carried out on selected testpieces: plates TPF7, PL8155, PL8156 and P24T;
pipes TPF6 and TPF8; T-joints P22T and the furnace testpiece, and the P21T
nozzle. This provided length measurement on 20 defects (that is on: 6 toe
cracks, 6 root cracks, 5 embedded cracks, 2 centreline cracks at surface and 1
HAZ crack).
The defect lengths were measured using both standards (that is, using the 6dB
drop technique and the fixed amplitude level technique) and compared to the
intended defects length.
The length of the indications was determined under BS 3923 using a 6dB drop
tip location technique (6dB drop from the last peak) and under BS EN 1712/ BS
EN 1714 by measuring the distance along the length over which the echo
amplitude is above the evaluation level.
The results from individual testpieces are provided in Appendix D. A summary
of the length measurement is provided in the table below (these results are
illustrated by the figures in Appendix D5 - note that none of the defects used for
this sizing exercise was sectioned).
20
Beam angle ()
Probe frequency (MHz)
Defect ref.
Final Report
45
2MHz
Intended BS
60
4MHz
2MHz
70
4MHz
2MHz
4MHz
EN
BS
EN
BS
EN
BS
EN
BS
EN
BS
EN
TPF6-3
14
14
15
15
11
13
15
14
15
15
17
14
14
TPF8-10
14
17
17
16
17
18
11
16
10
17
10
17
11
TPF8-9
15
17
15
17
14
19
17
19
16
19
17
18
16
P22T-1
15
14
14
15
15
14
14
15
14
14
14
14
13
TPF8-4
16
16
16
17
16
18
17
18
16
17
16
12
TPF6-6
17
20
20
20
21
18
20
18
18
17
17
16
21
TPF7-1
18
17
18
17
17
19
20
19
10
17
18
18
18
TPF6-1
18
16
17
18
18
18
22
19
19
TPF6-8
18
20
22
19
23
20
25
17
20
TPF8-5
18
20
19
18
20
17
20
19
22
20
18
18
21
TPF8-8
18
19
17
20
16
20
21
20
20
19
21
17
20
TPF8-11
18
17
17
17
19
17
21
17
19
22
23
18
23
TPF7-4
20
19
11
20
11
22
10
19
10
20
24
19
12
PL8155-1
20
19
22
20
21
22
22
22
20
21
23
22
22
PL8156-1
20
19
30
19
27
22
27
22
27
23
30
21
27
TPF8-7
20
21
24
20
23
21
28
19
30
20
31
22
30
P21T-2
20
18
18
15
17
15
20
20
P24T-1
47
50
50
49
54
48
49
48
53
51
56
50
25
Furnace-1
220
40+
40+
228 214 225 210 217 40+ 218 35+ 215 215 216 210
70
75
Furnace-2
220
220
20+
30+
30+
25+
20+
20+
214
214
212
215 10+ 210
20
20
18
20
10
10+7
Note: the reference in the table to BS refers to BS 3923 and EN refers to BS EN 1712.
Table 4.1: Defect Length including intended values and measurement values
using the 6dB drop technique and the fixed amplitude level technique.
Note: the signal amplitudes of the defects in the furnace testpieces were close
to threshold for some defects so reported length was segmented along full
length of defect.
4.4.3
Echodynamic pattern
The operators were asked to record the echodynamic pattern observed for the
individual beams used for each of the defects examined for length
measurement (see above section 4.4.2). The results for the relevant testpieces
are provided in Appendix D.
21
4.5
DISCUSSION
4.5.1
Detectability
Final Report
4.5.1.1 Plates and Pipes

There are little differences between the two standards as far as coverage is
concerned as they both specify that full coverage of the inspection volume
needs to be achieved in both cases. If there are access restrictions additional
scanning (or other NDT) is required to allow coverage (removal of the weld cap
may have to be considered to achieve better coverage). The EN standard is
more general, with very little specific requirements on scan directions or probe
type.
The fact that most of the defects were synthetic defects may have influenced
the detectability of the defects.
Detection of defects at the root was generally very hard. The geometric echo
related to the root bead made the differentiation between defect and root
difficult. The operators reported that some of the defects might not have been
detected under normal circumstances i.e., if the position of the defects were not
known. Therefore, a dedicated scan parallel to the root bead is strongly
recommended for root inspection.
All of the weld defects provided signal amplitudes which were above both EN
and BS report thresholds for at least one probe and scanning direction.
However since the EN standard provides little guidance on the selection of
probes or beam direction, it is reliant on the operator using an appropriate
technique, or a procedure being available which specifies appropriate
techniques.
One pipe, the SOHIC testpiece, contained stress oriented hydrogen induced
cracking (SOHIC) located in the parent material. Due to the thickness of the
testpiece, the scanning requirements for weld defects are very similar for both
the EN and the BS standard with the exception of the scanning sensitivity. The
amplitude responses from the defects were mostly below 32% DAC. Therefore,
these defects may not have been reported under the EN standard. Moreover,
the best responses from the defects were obtained with a 0 probe. The
amplitude responses from the 0 probe were all above 40% DAC which would
have allowed all the defects to be reported with both standards. However, under
the EN standard, the inspection of the parent material with a 0 probe does not
need to be carried out if the inspection was carried out prior to welding.
According to both standards, if there is a restriction to one side of the weld a
second probe must be used and total coverage of the weld volume must be
ensured. Therefore, all the weld defects from the plate and pipe testpieces used
for the study should have been reported regardless of the standard used
(provided an appropriate beam angle was used).
The 2MHz probes provided in general higher responses than the 4MHz probes
for testpieces 14mm thick and above. However, the results showed that the
responses from the erosion/corrosion defects were slightly higher with the
4MHz probes. Also, there may be circumstances where 4MHz probes provide
22
Final Report
better detection capability, for example it can be easier to distinguish between

defects at the weld root, and the root bead reflection, when using higher
resolution (higher frequency) probes.
For the defects and testpieces studied, the 70 probes provided best overall
performance for thicknesses up to 20mm, suggesting that a 70 probe should
be included as a minimum for this thickness range.
4.5.1.2 T-joints
Under BS EN 1714 examination level B, scanning with angled beams needs
only to be carried out from the two faces of the attachment plate (see Table A3
& Figure A1 of Appendix A). No scanning from the component is required.
Therefore, defects at the upper and rear surface of the component plate cannot
be detected. This is in contradiction with the required volume coverage as
stated in the European standard since, by limiting the inspection to the
attachment plate surfaces, the coverage of the inspection volume of the
attachment welds cannot be achieved.
The results from this study highlighted this point. For example, defects such as
toe cracks and erosion/corrosion defects would not have been reported under
the BS EN 1714 standard. The EN standard specifies a 0 scan from the main
component surface (opposite surface from the attachment). This is certainly
appropriate for manufacturing inspections, to detect e.g. lack of fusion between
the attachment weld and the main component. However, for in-service
inspection, angle beam scans to detect cracks initiating at the weld toes and
propagating into the main component would be more appropriate (access
permitting).
In general, it is difficult to identify the best probe to allow the detection of the
defects as it varies with the type and position of defect being inspected.
4.5.1.3 Nozzles
All the nozzles inspected for this work had thicknesses below 15mm.
The scanning requirements for the testpieces are summarised in Table A4 of
Appendix A2. BS 3923 level 1 does not cover set-on nozzles less than 15mm
thick. The requirements under the examination level 2 are: to scan from the
branch to full skip using two angles and an independent root scan with one
angle scanning from side A (if the root bead is removed, the separate root scan
can be omitted).
The requirement for the EN standard is that the inspection has to be carried out
from one of the nozzle surfaces toward the shell (scan from side A to 1.25 skip
or side B1 to 0.5 skip). There is no requirement for scanning from the shell.
Therefore, inspection from the shell is not required under either of the standards
which is a major omission for in-service inspection.
The geometry and the weld finish often restricted the coverage for the 45 and
60 beams. The 70 beams would have allowed the detection and reporting of
23
Final Report
all the root defects with responses >40% DAC from the branch. They would
have therefore been reported under both standards.
Difficulty was reported in resolving signals from the root crack and those from
the root.
However, the toe defects would not have been reported under either of the
standards as inspection from the plate is not required. The results show that the
responses from the defects with the 70 beams scanning from the plate would
have provided responses >45% DAC which is above the reporting threshold of
both standards.
4.5.2
Length measurement
Length measurement using the fixed amplitude level technique of the EN
standard can vary depending on the beam angle and frequency used, since
length measurement is related to the defect response at the evaluation level.
Defects for which the response varies below the evaluation level along their
length can be reported as a succession of smaller defects. For example, defect
furnace-2 length was reported as three discrete short lengths when using the
60 probes.
The length measurement using the fixed amplitude level technique of the EN
standard for the two longest defects (furnace-1 and furnace-2 both having a
length of 220mm) varies from 150mm to 215mm for furnace-1 and 30mm to
50mm furnace-2 depending on the probe used (the 70 probes provided the
larger values).
The variation as a function of probe in measured length for the defects of
intended length 14mm to 20mm (this excludes the three longest defects),
illustrated by Figures 4.1 and 4.2, are:
L being the intended length value,
with the British Standard: L - 3mm to L + 4mm
with the European Standard: L - 22mm to L + 11mm
The standard deviations of the difference between the length measured using
the 6dB drop technique and the fixed amplitude level technique were
calculated. The calculation was carried out for all the defects and for the defects
of intended length between 14mm and 20mm only. The results are provided in
Table 4.2 below. Note that the measured length of the defects in the furnace
testpiece used for the calculation were the addition of the segmented lengths,
when appropriate.
Probe characterisation
45
2MHz
45
4MHz
60
2MHz
60
4MHz
70
2MHz
70
4MHz
standard deviation
(including all the testpieces)
42.6
37.7
49.1
48.4
37.2
37.1
standard deviation
(excluding the three longest defects)
3.6
3.6
5.1
5.0
4.0
4.1
Table 4.2:
Standard deviation of the difference between the length measured

using the 6dB drop technique and the fixed amplitude level technique.
24
Final Report
35
Intended length
smaller length recorded
larger length recorded
30
Length (mm)
25
20
15
10
0
1
10
11
12
13
14
15
16
17
Defect
Figure 4.1: Variation of length measured using the 6dB drop technique
(for defects of intended length between 14mm and 20mm).
35
Intended length
smaller length recorded
larger length recorded
30
Length (mm)
25
20
15
10
0
1
10
11
12
13
14
15
16
17
Defect
Figure 4.2: Variation of length measured using the fixed amplitude level technique
(for defects of intended length between 14mm and 20mm).
25
Final Report
In general, the experimental results show (regardless of the probe angle and
frequency used) that the lengths measured using the 6dB drop technique of the
British Standard are very close to the intended values. However, the results
collected using the fixed amplitude level technique of the BS EN 1712 show
more discrepancies against the intended length values. Moreover, the error of
measurement seems to increase with defect length and long defects, where the
amplitude fluctuates about the BS EN evaluation level along their length, can be
reported as segmented (note that the study only included three long defects, of
intended length: one 47mm long and two 220mm long).
The accuracy of defect length measurement depends on the shape of the
defect and its size. This is particularly the case for the EN fixed amplitude
technique, since parts of the defect which provide responses below the
evaluation threshold of 32% DAC will not be included in the measured length.
This can be put into perspective by considering the results from testpiece TPF1
which contained a number of vertical surface breaking cracks. Defect 1 was of
nominal height 2mm and out of six probes (45, 60, 70 each at 2MHz and
4MHz), it was only above 32%DAC for one (70 2MHz) and was borderline for
one (60 2MHz). If the length of this type of defect was measured using the EN
fixed amplitude technique, it is therefore possible that parts of the defect below
2mm height would not be included in the measured length.
These results are consistent with a more detailed study of length sizing
methods performed by TWI [15] on a variety of defect types. Fixed amplitude
techniques were reported to be less subject to operator variability than the 6dB
drop (from the last peak) method, but more prone to gross deviations from
length measured by radiography. Note that undersizing is generally of more
concern than oversizing.
4.5.3
Echodynamic pattern
The patterns recorded were all as expected with the exception of two cracks
which exhibited a pattern 2 instead of pattern 3. These two cracks were two inservice cracks from a T-joint testpiece (furnace testpiece, see Appendix D.3.3).
This helps to confirm that the intended defects are indeed planar.
26
5.
Final Report
CONCLUSIONS
The data generated from the test samples show that the defects should have
been reported in most cases with both BS 3923 and BS EN 1714 standards
(referred to below as BS and EN respectively). However choice of probes
played an important part in the detection of the defects. Defects that were
missed or below the EN report threshold with one probe were often reportable
with another. The orientation and size of the defect both influence the detection
capability. The EN standard does not include a requirement for a separate root
scan to be performed. Inspection with a root scan made detection easier on
samples with an undressed root. An operator with limited experience may miss
root defects without a root scan.
Care must be taken when choosing the probes to use for the inspection. The
choice of probe(s) to be used for the detection of the defects under the EN
standard is even more critical than for the BS standard since the report
threshold is higher (less stringent). The results from this study show that in most
cases 2MHz has provided higher response than 4MHz, although this may not
be the case under other circumstances. A 70 probe should be included to
inspect components of thickness 20mm or less.
Maximum coverage of the inspection volume of interest must be achieved.
Note that both the BS and EN standards specify that this should include the
whole weld volume. However for in-service inspection there might be no need
to inspect the full weld, but only those parts where service induced defects
could occur depending on whether or not there is a need to detect or monitor
defects produced during manufacture. Dressing of the weld cap and root
improves the reliability of the inspection.
Inappropriate choice of probes or scan surfaces using the EN standard could
result in defects being missed (it provides less guidance than the BS standard).
Moreover, the results from the T-joints and the nozzles studied showed that a
literal interpretation of the EN minimum requirements (which limit scans to the
branch/attachment) prevents the detection of defects extending into the main
component. Defects such as toe cracks growing from the attachment welds as
well as erosion/corrosion defects created at the inner surface of the component
could therefore be missed under the EN standard.
The requirement for parent material inspection prior to weld inspection with a 0
probe is not compulsory with the EN standard as long as the inspection was
performed before or after welding. This information would not generally be
available to those performing in-service inspection. In any event, if 0 inspection
is not performed because it was already done at the manufacturing stage, it
could lead to service induced laminar cracking in the parent material being
missed.
The error in length measurement (compared to intended length) using the EN
1712 standard (acceptance criteria) was up to +11/-22 mm compared to an
error of +4/-3 mm using the BS standard. As the length measurement technique
specified by this EN standard is directly related to the defect response at the
inspection level, length measurement is dependent on the probe used. Due to
the variation of the signal amplitude along the defect, longer defects can be
27
Final Report
reported as segmented. Much of the guidance on defect characterisation and

sizing which was in the BS standard is incorporated in BS EN 583-5 (Reference
14). These methods are considered preferable to those specified in BS EN
standards 1712 and 1713.
Results from the testpieces demonstrated that for a given probe angle, defects
were either not reportable by either standard, or above the reporting threshold
for both. There were very few instances where signal amplitude from a weld
defect was between the BS and EN report thresholds.
Note that it is important to distinguish between reportable and detectable. A
defect might not be reportable because its signal response does not exceed the
reporting criteria. However it may still be detectable because its signal
amplitude is sufficiently above the noise level for it to be visible to the operator.
An operator who detects an indication will normally manipulate the probe so as
to maximise the signal and determine whether it exceeds the evaluation / report
threshold.
If an amplitude report threshold is required for ISI to avoid too many nonrelevant indications being reported, previous experience has shown that a
threshold of 10% DAC is sufficiently low for most signals of interest (including
tip diffracted signals) to be reported. (BS 3923 specifies a threshold of 10%
DAC for high integrity inspections, and 20% for medium integrity inspections for
quality control purposes. EN specifies a level of 32%)
This project deliberately concentrated on the inherent capability of the EN
standard rather than human reliability issues (such as those investigated in the
PANI programmes). It is not straightforward to determine the influence of
reliability on whether a given defect would still have been reported during blind
trials or site inspections, since this is likely to depend primarily on whether it
would have been detected in the first place, rather than how successful the
operator was at maximising its signal and comparing it to the reporting
threshold.
The EN standard regularly refers to the required specification for guidance on
which techniques to use, i.e. it assumes the customer or some other party has
already specified some requirements. The EN standard states that it will
normally satisfy the need for a written procedure. However, it is not very
prescriptive, and can be difficult to interpret. One particular area where
confusion can rise is over quality levels and examination levels.
It should also be noted that the analysis performed in this project has been
based on a literal interpretation of the EN standard. It is important that those
responsible for specifying and performing ultrasonic in-service inspection do not
feel constrained to blindly following the EN standard (or, unless with good
reason, any other generic standard). Although the scope of the EN standard
does not discriminate between application for in-manufacture and in-service
inspection purposes, it is much more appropriate as a generic standard for
harmonising in-manufacture inspections, than for in-service inspection.
For in-service inspection, it is important that those responsible for specifying
and performing the inspection take due account of the types, locations,
morphologies and sizes of defects of concern for each specific application.
28
Final Report
This is needed in order to determine the most appropriate scan surfaces, probe
types and reporting criteria. In fact it may be appropriate for all defects or
degradation to be reported during ISI regardless of signal amplitude (i.e. no
amplitude threshold). This is because even a small defect may be of interest if
it provides early warning of degradation, and recording such defects allows
growth to be monitored during subsequent inspections.
29
6.
Final Report
RECOMMENDATIONS
The following are based on the results of this project and the views of the
Steering Committee members.
BS EN 1714 should not be used as a stand alone procedure for in-service
inspection. In-service inspection should be performed in accordance with a
written procedure and work instruction / technique sheet which is more
prescriptive than this standard, and includes detailed specification of the scans
required, probe characteristics and reporting criteria. These should be based
on a knowledge of the defect and degradation types, locations, morphologies
and sizes of interest.
In defining these requirements, consideration should be given to the following:
1. Although the BS EN amplitude report threshold of 32% DAC (10dB
below the DAC curve) may be appropriate for harmonising inmanufacture inspections, a more sensitive threshold may be appropriate
for in-service inspections (even though all the defects studied exceeded
this threshold with at least one beam). Previous experience has
demonstrated that a report threshold of 10% DAC (20dB below the DAC
curve) is sufficiently low for most signals of interest to be reported
(including tip diffracted signals) but is still high enough to avoid false
calls from noise. However there may be cases where it is appropriate to
report all indications detected above the noise level.
2. Choice of beam angle is at least as important as choice of reporting
threshold. Both capability and reliability for defect detection will tend to
increase, the greater the number of different beam angles employed
(different probe angles and / or scan surfaces). The results from this
project suggest that for weld thicknesses below 20mm, a 70 scan
should be included for detection of opposite surface cracks oriented in
the through wall direction. An additional 45 scan is recommended for
critical applications. For greater thicknesses a 45 scan may provide
increasingly better capability than a 70 scan for the detection of such
defects.
3. In this study, the 2MHz probes generally provided better capability for
detection than the 4MHz probes. However there may be circumstances
where 4MHz probes provide the better detection capability, for example
it can be easier to distinguish between defects at the weld root, and the
root bead reflection, when using higher resolution (higher frequency)
probes.
4. A fixed root scan is highly recommended for inspection of welds with an
undressed root, where there is a requirement to detect defects near the
root, such as inner surface cracks.
5. The fixed amplitude method of measuring length described in BS EN
1712 (acceptance criteria) is not recommended for in-service inspection
applications. These should be based instead on the types of techniques
described in BS EN 583-5, e.g. 6dB drop sizing for defects longer than
the beam width.
6. Acceptance criteria should be agreed between the contracting parties.
30
7.
Final Report
REFERENCES
[1]
BS 3923 Part 1 1986 - Ultrasonic examination of welds Methods for

manual examination of fusion welds in ferritic steels.
[2]
BS EN 1712:1997 Non-destructive testing of welds Ultrasonic

testing of welded joints Acceptance levels.
[3]
BS EN 1713:1998 Non-destructive testing of welds Ultrasonic

testing Characterisation of indications in welds.
[4]
BS EN 1714:1998 Non-destructive testing of welded joints

Ultrasonic testing of welded joints.
[5]
Georgiou, G A : Adopting European Ultrasonic Standards for High

Quality Fabrications: Implications for Manufacturers and End Users
TWI Final Report 5657/10/95 for GSP 5657, December 1995.
[6]
Georgiou, G A and Mudge, P J: 'Proposed European Ultrasonic

Procedures and Acceptance Criteria for High Quality Fabricators:
Their Evaluation and their Implementation'. INSIGHT, European
Issue,
October 1994, Vol. 36 No 10, pp 792-793.
[7]
Georgiou, G A and Mudge, P J: 'An Evaluation of Proposed CEN

Ultrasonic Methods for the Inspection and Sectioning of Fusion Welds
in Ferritic Steels'. Proceedings of the 6th European Conference on
Non-Destructive Testing, Nice, France, 24-28 October 1994, Vol. 1,
pp 117-121.
[8]
Georgiou G A: 'A Comparison of European Ultrasonic NDT National

Standards for Pressure Vessels with Proposed European Standards.
(Proceedings of ICPVT '95, Paris, October 1995, No 32).
[9]
BS EN 25817:1992 Arc-welded joints in steel Guidance on quality

levels for imperfections.
[10]
BS EN 583-1:1999
examination;
Part 1: General principles.
Non-destructive
testing
Ultrasonic
[11]
BS EN 583-2:2001 Non-destructive
examination;
Part 2: Sensitivity and range setting.
testing
Ultrasonic
[12]
BS EN 583-3:1997 Non-destructive
examination;
Part 3: Transmission technique.
testing
Ultrasonic
[13]
BS EN 583-4:2002 Non-destructive testing Ultrasonic

examination;
Part 4: Examination for discontinuities perpendicular to the surface.
31
Final Report
[14]
BS EN 583-5:2001 Non-destructive testing

examination;
Part 5: Characterisation and sizing of discontinuities.
[15]
Georgiou, G A, Hayward, K S: 'Ultrasonic Techniques for Sizing Flaw

Lengths'. British Journal of Non-Destructive Testing, November
(1991)
Vol. 33 No 11 pp 545-548.
32
Ultrasonic
APPENDIX A: EXAMINATION REQUIREMENTS
33
Final Report
Final Report
A1. MOST
STRINGENT
REQUIREMENTS
FOR
LONGITUDINAL
INDICATIONS - EXAMINATION UNDER BS 3923 (LEVEL 1) AND BS
EN 1714 (LEVEL C)
The following table summarises the most stringent requirements for longitudinal
indications only, in various types of weld: for examination level 1 for BS 3923
and examination level C for BS EN 1714.
Note 1: Although the probability of detection achieved with a testing level C

is greater than the one achieved with testing level B, according to BS EN 25817
[9], quality level B is still categorised as stringent.
Note 2: The examination of butt joints - plates and pipes - under BS 3923
level 2B is as per BS 3923 Level 1 without the separate near surface scans
from sides A, B C and D (see Figure A1). If the weld of the component is a
single sided weld the scans are only performed from the upper surface (sides A
& B) with two angles at 0.5 skip and one angle at 1 skip.
34
Parent material
Scanning
(1)
thickness (mm)
side
Butt joint plates and pipes
NA
6t<8
A&B
or
C&D
8t<15
and
E or F
15t<50
50t100
100<t150
t>150
T-joint
8t<10
10t<15
A&B
or
C&D
and
E or F
BS EN 1714
Probe Scanning
angle
coverage
NA
NA
1.25 skip
1.25 skip
Number
of scans
(2)
(2)(3)
1.25 skip
Not relevant
1.25 skip
d+e
Not relevant
A&B
D&E
(8)
and C
2
1
1
0.75 skip
d+e
Not relevant
A&B
t>100
D&E
(8)
and C
Set-through nozzle joint
(A or B)
and
8t<15
(D or E)
and C
(A or B)
and
15t<40
(D or E)
and C
3
1
1
0.75 skip
d+e
Not relevant
50t100
40t100
(A and B)
and
(D and E)
and C
3
7
15t<40
d or e
Not relevant
0.5 skip
d or e
Not relevant
0.5 skip
2
d+e
Not relevant
A&B
and
E
A&B
and
(4) (5)
(4) (5)
&D
C
1 skip
3
+ Root scan
0.5 skip
13
(or 7)
+ Root scans
(with separate near

surface scans from
each side)
and E
1
(6)
(7)
NA
NA
NA
C&D&E
and
A and B
(or B)
Not Specified
2
2
0.5 skip
1 skip
C&D&E
and
A and B
1
0.5 skip
2
NA
7 (or 5)
+ Root scan for singlesided welds only
7
+ Root scan for singlesided welds only
NA
NA
NA
NA
H&G
or
(9)
E &D
and
(9)
C
and
A
and
B
and
(9)
(F1 and F2)
(only if bore not
accessible)
1 skip
0.5 skip
Not relevant
0.5 skip
1 skip
Not Specified
(9)
NA
9
(9)
(or 8)
NA
A or
B1
and C
1.25 skip
0.5 skip
Not relevant
40t<50
50t<100
Number of scans
1.25 skip
t>100
Set-on nozzle joint
8t<15
BS 3923
Scanning
Probe angle
coverage
As for 15t<50 mm - see note

As for 15t<50 mm - see note
NA
1
1
2
1
1
40t<50
Scanning side
(1)
NA
A and B
(8)
and C
A&B
D&E
(8)
and C
15t<40
Final Report
A and
B1
and C
1.25 skip
0.5 skip
Not relevant
Not covered for Not covered Not covered

Level 1
for Level 1
for Level 1
A and
1 skip
2
B1 & B2 and
0.5 skip
(10)
1 (or 2)
(10)
C
Not relevant
1
&E
Not Specified
A and
1
1 skip
(11)
B1 & B2 &
1 (or 2)
0.5 skip
1
B3 and
Not Specified
(11)
1
C and
Not relevant
E and F
1
Not Specified
Table A1:
Most stringent examination level for longitudinal indications under
BS 3923 (examination level 1) and under BS EN 1714 (examination level C).
35
Not covered for

Level 1
(10)
6 (or 7)
(11)
7 (or 8)
Final Report
Notes related to Table A1:

(1)
See the following schematic diagrams, Figure A1, for scanning sides
identification.
(2)
The surface of the weld cap shall comply with the requirements for scanning
surface preparation. This may require dressing of the weld cap. However, for
single sided circumferential pipe welds the outside cap only is to be dressed.
(3)
Additional testing by tandem technique by special agreement.
(4)
On thickness less than 35mm lower surface scan not required.
(5)
If the weld of the component is a single sided weld the scans are only
performed from the upper surface (sides A & B) with a full skip and two
angles, separate near surface scans are also carried out with one angle from
side A and Side B.
Total number of scans = 6.
(6)
If the weld of the component is a single sided weld the scans are only
performed from the upper surface (sides A & B) with 1/2 skip and two angles,
separate near surface scans are also carried out with one angle from side A
and Side B.
Total number of scans = 6.
(7)
Only applicable to double sided welds.
(8)
To be substituted by tandem technique from A and B if C is not possible.
(9)
If the bore of the component is not accessible then scans from sides C, E &
D can not be carried out and scans from the weld fillet surfaces have to be
carried out.
(10)
If the bore of the component is not accessible then scanning from C is not
possible and an extra probe is used from side B2.
(11)
If the bore of the component is not accessible then scanning from C is not
possible and an extra probe is used from side B1 and B2.
36
Side A
Side E
Final Report
Side B
Attachment
Side A
Side D
Side F
Side B
Side C
Butt joints plates and pipes
Side F
d
Side D
e
Side E
Side C
T-joints
Nozzle
Side G
Side D
Side F1
45
Side A
Side A
Nozzle
Side B1
Shell/plate
Side C
Side B
Side F2
45
Side H
Side E
Side F
Shell/plate
Side D
Set-through nozzle joints
Figure A1:
Side B3
Side E
Side B2
0
Side C
Set-on nozzle joints
Schematic diagram defining the scan surfaces
37
A2.
Final Report
REQUIREMENTS FOR THE TESTPIECES USED FOR THIS STUDY (ACCORDING TO STANDARDS)
BS 3923 - Level 2B
Scanning
from
Thickness (mm)
10< t <15
Prep
15 t < 40
t = 65
BS EN 1714 Level C
Probe
Scanning
Coverage
angle
from
BS EN 1714 level B
Probe
Scanning
Coverage
angle
from
Probe
angle
Coverage
PLATES/PIPES
2557-003
2557-004
P2301
P23T
SOHIC
TPF6
TPF7
RSA/PLW/15/ET
P2401
P24T
TPF8
TPF1*
PL8153*
PL8155*
PL8156*
PL8157*
PL8158*
PL8159
PL8160
P257
A+B
(+ root scan)
A+B
(+ root scan)
A+B
+C+D
(+ root scan)
A+B
FS
(A + B)
or (C + D)
and
E or F
(A + B)
or (C + D)
and
E or F
1.25 FS
(A + B)
or (C + D)
1.25 FS
1.25 FS
(A + B)
or (C + D)
1.25 FS
FS
1/2S
2
1
1/2S
FS
(+ root scan)
Table A2:
Examination requirement for the testpieces used for this study Plates and pipes.
38
(1 if
testpiece*
and
frequency
<3MHz)
Final Report
BS 3923 - Level 1
Scanning
from
BS 3923 - Level 2
Probe
Scanning
Coverage
angle
from
BS EN 1714 Level C
Probe
angle
Coverage
BS EN 1714 level B
Scanning Probe
Scanning
Coverage
from
angle
from
Probe
angle
Coverage
Thickness
T-JOINTS
(mm)
20 < t < 24
C +D +E
1/2S
C +D +E
1/2S
C +D +E
1.25 FS
1.25 FS
P2201
P22T
+ (A + B)
FURNACE
(or B)
FS
+ (A + B)
(or B)
FS
+A+B
1.25 FS
+A+B
1.25 FS
(+ root scan)
(+ root scan)
Table A3:
Examination requirement for the testpieces used for this study T-joints.
BS 3923 - Level 2
Thickness
(mm)
t = 12
BS EN 1714 Level C
BS EN 1714 level B
Scanning
from
Probe
angle
Coverage
Scanning
from
Probe
angle
Coverage
Scanning
from
Probe
angle
Coverage
A
(+ root scan)
FS
A
or B1
and C
3
3
1
1.25 FS
1/2S
NR
A
or B1
2
2
1.25 FS
1/2S
NOZZLES
P2101
P2102
P21T
Table A4:
Examination requirement for the testpieces used for this study Nozzles.
39
Final Report
APPENDIX B: ULTRASONIC MODELLING

- RESULTS FROM THE CORNER EFFECT KIRCHHOFF PROGRAM
40
B1.
Final Report
RESULTS FOR 2MHZ CORNER EFFECT
B1.1 Fixed input values
Ultrasonic transducer is 10 mm diameter, transverse wave, single crystal

operating at 2MHz.
Component is a 20 mm thick ferritic steel plate.
Rectangular slot is 10 mm long.
Reference level of 0 dB is 100% fsh DAC based upon a 3 mm sdh.
Scan line step size is 1 mm.
B1.2 Output data corresponding to variable input of Tilt and Height of

slot
The results are presented in Table B1 and Table B2.
B1.3 Graphical analysis of results at 2MHz
Figure B1: Ultrasonic response (% DAC) as a function of Height of Slot from back-wall.
Figure B2: Ultrasonic response (% DAC) as a function of Angle of Tilt.
41
Height
Tilt
Final Report
-20
-15
-10
-5
-2
+2
+5
+10
+15
+20
1 mm
-0.04
1.02
1.08
1.54
1.65
1.68
1.68
1.60
1.22
0.64
-0.25
2 mm
2.35
4.61
5.96
7.07
7.33
7.36
7.28
6.95
5.56
3.48
0.37
3 mm
-0.13
4.81
8.03
9.93
10.31
10.26
9.98
9.05
5.65
0.25
-9.57
4 mm
-2.64
4.10
9.06
11.64
12.05
11.83
11.19
9.14
3.06
-4.63
-2.40
5 mm
-2.98
3.79
9.54
12.69
12.63
12.52
11.32
8.13
0.84
-0.19
-2.59
Table B1: Peak amplitude response relative to reference level at 0 dB as calculated by program - Values in dB.
Height
Tilt
-20
-15
-10
-5
-2
+2
+5
+10
+15
+20
1 mm
100%
112%
113%
119%
121%
121%
121%
120%
115%
108%
97%
2 mm
131%
170%
199%
226%
233%
233%
231%
223%
190%
149%
104%
3 mm
99%
174%
252%
314%
328%
326%
316%
283%
192%
103%
32%
4 mm
74%
160%
284%
382%
400%
390%
363%
286%
142%
59%
76%
5 mm
71%
155%
300%
431%
428%
423%
368%
255%
110%
98%
74%
Table B2: Peak amplitude response converted in % fsh where 100% fsh corresponds to 100% DAC.
42
B2.
Final Report
RESULTS FOR 4MHZ CORNER EFFECT
B2.1 Fixed input values
Ultrasonic transducer is 10 mm diameter, transverse wave, single crystal

operating at 4MHz.
Component is a 20 mm thick ferritic steel plate.
Rectangular slot is 10 mm long.
Reference level of 0 dB is 100% fsh DAC based upon a 3 mm sdh.
Scan line step size is 1 mm.
B2.2 Output data corresponding to variable input of Tilt and Height of

slot
The results are presented in Table B3 and Table B4.
B2.3 Graphical analysis of results at 4MHz
Figure B3: Ultrasonic response (% DAC) as a function of Height of Slot from back-wall.
Figure B4: Ultrasonic response (% DAC) as a function of Angle of Tilt.
43
Height
Tilt
Final Report
-20
-15
-10
-5
-2
+2
+5
+10
+15
+20
1 mm
-1.20
1.69
3.32
4.58
4.93
5.02
4.99
4.74
3.48
1.46
-1.44
2 mm
-8.44
-6.66
4.17
8.76
9.90
10.12
9.92
8.77
3.53
-7.66
-6.99
3 mm
-6.02
-2.50
-0.49
9.66
11.96
12.35
11.84
9.06
-2.17
-1.95
-6.83
4 mm
-4.65
-2.32
0.70
9.14
12.88
13.47
12.55
7.76
-0.15
-4.50
-4.90
5 mm
-4.77
-2.35
2.33
8.15
13.36
14.14
12.63
6.69
0.95
-3.14
-8.02
Table B3: Peak amplitude response relative to reference level at 0 dB as calculated by program - Values in dB.
Height
Tilt
-20
-15
-10
-5
-2
+2
+5
+10
+15
+20
1 mm
87%
121%
147%
169%
176%
178%
178%
173%
149%
118%
85%
2 mm
38%
46%
162%
274%
313%
321%
313%
274%
150%
41%
45%
3 mm
50%
75%
95%
304%
396%
414%
391%
284%
78%
80%
46%
4 mm
59%
77%
108%
286%
441%
472%
424%
244%
98%
60%
57%
5 mm
58%
76%
131%
256%
466%
509%
428%
216%
112%
70%
40%
Table B4: Peak amplitude response to converted in % fsh where 100% fsh corresponds to 100% DAC
44
APPENDIX C: TESTPIECES
45
Final Report
Testpiece
ID
1.
2.
3.
4.
5.
6.
2557-003
2557-004 *
TPF7
Type
Prep
Plate
Plate
Plate
RSA/PLW/
15/ET001
TPF1
Plate
Plate
PL8155
Dimensions
Plate
V
V
Surface
Dia.
OD
(mm)
NA
NA
NA
NA
NA
NA
T
(mm)
10
12
15
15
20
20
Defect
L
(mm)
300
300
300
1000
370
300
Defect ID
Tilt / Width
()
Height
(mm)
Length
(mm)
Weld
Final Report
24
Comments
2557-003-1
5.6
2557-003-2
4.6
2557-003-3
2.7
2557-003-4
4.1
2557-004-2
5.2
22
Centre line crack
2557-004-4
3.8
15
Centre line crack
TPF7-1
30
18
Toe crack
13.5
S
Centre line crack

Centre line crack
15.5
S
Smooth crack
Centre line crack
TPF7-4
15
20
Root crack
RSA/PLW-1
Toe crack
RSA/PLW-2
15
Toe crack
RSA/PLW-3
25
Toe crack
RSA/PLW-4
Transverse crack
RSA/PLW-5
15
Transverse crack
RSA/PLW-6
24
Transverse crack
RSA/PLW-7
14
Crack
TPF1-1
Root crack
TPF1-2
12
Root crack
TPF1-3
20
Root crack
TPF1-4
32
Root crack
Root crack
TPF1-5
10
40
PL8155-1
NI
NI
20
Toe crack
PL8153-1
NI
NI
33
Toe crack
7.
PL8153
Plate
XX
NA
25
300
PL8153-3
NI
NI
22
Root crack
8.
PL8156
Plate
NA
25
300
PL8156-1
NI
NI
20
Centre line crack
9.
PL8157
Plate
XX
NA
25
300
PL8157-3
NI
NI
20
Toe crack
10.
PL8158
Plate
XX
NA
25
300
PL8158-1
NI
NI
25
Sidewall crack
11.
PL8159
Plate
NA
30
300
PL8159-1
NI
NI
20
Centre line crack
12.
PL8160
Plate
XX
NA
30
300
PL8160-3
NI
NI
18
Transverse crack
P2401-1
7.7
P2401-3
4.8
P24T-1
13.
P2401
14.
P24T
Plate
NA
40
NI
Plate
NA
40
NI
30
Root crack
29
Centre line crack
47
Centre line crack
Both surfaces as welded; X bottom surface dressed; X upper surface dressed; XX Both surfaces dressed
*
This testpiece was rescanned with 2MHz probes after the testpiece cap was dressed.
S
Defect sectioned/ sectioned value.
NA
Not Applicable
NI
No Information
Table C1: Summary of the testpieces information
46
Testpiece
ID
15.
P2301
Type
Prep
Pipe
Dimensions
Surface
Dia.
OD
(mm)
168
T
(mm)
11
Defect
L
(mm)
NI
Defect ID
Tilt / Width
()
Height
(mm)
Lenght
(mm)
Weld
Final Report
P2301-A1
13
6.6
14
Root crack
P2301-B1 20+30 3.1
17
Root crack
24
Root crack
25
Erosion/Corrosion
20
Erosion/Corrosion
17.
18.
19.
20.
21.
P23T
Pipe
TPF6
Pipe
SOHIC
TPF8
Furnace
boiler
26.
P2102
P21T
NI
23.
25.
NI
(Set-on)
P22T
P2101
Pipe
Pipe
22.
24.
Pipe
P257
P2201
(Set-on)
T
(Set-on)
Nozzle
(Set-on)
Nozzle
(Set-on)
Nozzle
(Set-on)
168
457
610
457
NA
NA
11
12.5
12.7
35
65
20x10
NI
300
457
300
65
NI
NA
20x10
NI
NA
21.5/24
NI
168
12
NI
168
12
NI
150
11
NI
P2301-C1
P2301-D1
NA 2x3
P2301-D2
NA 2x2.5
P2301-D3
16.
Comments
15
9.1
4.2
19
Toe crack
P23T-2
NI
28
Incomplete root
penetration
TPF6-1
15
18
Crack
TPF6-3
20
14
Crack
TPF6-6
37.5
17
Toe crack
TPF6-8
18
Root crack
SOHIC-1/10
NI
NI
NI
Stress Oriented
Hydrogen Induced
Cracking
TPF8-4
15
16
TPF8-5
18
TPF8-7
TPF8-8
15
TPF8-9
10
TPF8-10
TPF8-11
P257-1
NI
HAZ Crack
Root crack
Tight planar smooth

20
root defect
18
Rough planar
15
Rough planar
14
Rough planar
18
Root crack
NI
NI
Smooth root crack
14
Laminar tear
40
Root crack (LOP)
P2201-2
20
P2201-3
45
P2201-4
25
P2201-5
NA 3x3
P2201-6
25
P2201-7
NA 2.7x1
P2201-9
40
P22T-1
NI
15
Toe crack
Furnace-1
NI
220
Toe crack
Furnace-2
NI
220
Toe crack
P2101-3
7.1
18
Root crack
P2101-4
2.8
12
Root crack
P2101-5
5.7
13
Root crack
P2102-1
7.1
11
Root crack
5.6
13
Toe crack
20
Root crack
P2102-2
15
P21T-2
NI
3.6
5.1
4
28
Root crack
15
Erosion/Corrosion
18
Toe crack
30
Erosion/Corrosion
22 ncomplete root crack
4.5
Both surfaces as welded; X bottom surface dressed; X upper surface dressed; XX Both surfaces dressed
S
Defect sectioned/ sectioned value.
NA
Not Applicable
NI
No Information
Table C2: Summary of the testpieces information (continued)
47
APPENDIX D: TRIALS RESULTS
48
Final Report
D1.
Final Report
PLATES
D1.1 Testpiece 2557-003

Testpiece Description
Flaw No
1
2
3
4
Comments
Centre line crack

24
Centre line crack
13.5
Smooth crack
9
Centre line crack
15.5
Testpiece thickness = 10mm.
* Sectioning result
Side A
Flaw
Distance from
Height*
datum (mm)
(mm)
5.6
229
4.6
170
2.7
113
4.1
50
Testpiece as welded.
Flaw Length*
(mm)
Flaw Type
Side B
Side A
Manual UT Inspection Results

Upper surface
Probe
45
4MHz
60
4MHz
70
4MHz
Single
70
4MHz
Twin
Def.
No
1
2
3
4
1
2
3
4
1
2
3
4
1
2
3
4
Side A
Skip
FS
NF
NF
NF
NF
NF
NF
NF
NF
80
63
36
32
63
90
70
28
NF
45
NF
80
50
100
32
141
141
100
125
282
282
400
178
562
FS = Full Skip
NF = Not Found
Bottom Surface
Side B
FS+
&*2FS Skip
36
141*
32
125*
-
NF
NF
NF
NF
NF
NF
NF
NF
80
90
32
125
63
159
36
125
Side B
FS
50
45
NF
25
100
100
36
45
125
90
90
159
501
178
282
282
Side A
FS+
&*2FS Skip
NF
80*
32
36
-
NF
NF
NF
NF
36
28
20
50
100
100
63
80
100
70
90
70
FS
45
112
32
125
50
63
56
159
251
159
159
159
400
282
316
200
Side B
FS+
&*2FS Skip
NF
NF
NF
NF
-
NF
NF
NF
NF
100
63
20
32
125
90
45
80
159
112
56
90
Note: The inspection was not carried out using 2MHz probes.
This testpiece is no longer available
49
FS
FS+
70
50
50
50
100
159
56
56
224
251
159
282
282
447
316
355
NF
70
NF
50
-
Final Report
D1.2 Testpiece 2557-004

Flaw No
Flaw
Height*
(mm)
5.2
3.8
Flaw Length*
(mm)
Flaw Type
2
4
Distance from
datum (mm)
Centre line crack

22
Centre line crack
15
Testpiece thickness = 12mm
Testpiece as welded for the first set of data.
Comments
Testpiece weld cap dressed for the second set of data.
* Sectioning result.
Side A
167
50
Side B

First set of data
Upper surface
Probe
Def.
No
Side A
Bottom Surface
Side B
Side A
Side B
Skip
FS
FS
+
Skip
FS
FS
+
Skip
FS
FS
+
Skip
FS
FS
+
NF
50
141
NF
25
100
NF
20
112
NF
16
25
NF
NF
316
NF
NF
178
NF
NF
178
NF
NF
125
40
112
NF
125
100
63
80
63
80
45
125
25
63
50
20
141
70
4MHz
Single
100
159
70
159
125
125
70
141
400
NF
400
NF
28
355
14
355
70
4MHz
Twin
159
178
80
178
178
112
100
224
355
NF
631
NF
18
282
18
282
45
4MHz
60
4MHz
FS = Full Skip
NF = Not Found
50
Final Report
Second set of data

In order to compare the performances of the 2MHz and the 4MHz probes, the
inspection was carried out again. As the original operator was not available, a
different operator carried out the inspection using all the probes.
Note that the inspection was only carried out from the upper surface which had
been flushed since the inspection above.
Upper surface
Defect
No
Probe
Side A
Side B
Skip
Full Skip
Skip
Full Skip
45
2MHz
Single
NF
125
100
112
251
NF
178
NF
45
4MHz
Single
36
80
56
80
200
NF
80
NF
60
2MHz
Single
100
125
125
100
112
NF
224
NF
60
4MHz
Single
32
125
100
112
90
NF
100
NF
70
2MHz
Single
141
80
80
100
159
NF
251
NF
70
4MHz
Single
70
178
100
125
282
NF
251
NF
100
224
112
159
251
NF
316
NF
70
2
4MHz
4
Twin
NF = Not Found
51
Final Report
D1.3 Testpiece TPF7

Flaw No
1
4
Comments
Flaw Type
Flaw Length
(mm)
Toe crack
18
Crack
20
Testpiece as welded
Flaw
Height
(mm)
3
4
Weld/Specimen cross section(s)

Side A
Side B
Side A
Side B
52
Distance from
datum (mm)
52
230
Final Report

Defect 1
Upper surface
Probe
Side A
Side B
Length
Bottom Surface
Side A
Side B
Upper surface
Side A
Bottom Surface
Side B
Side A
Side B
Full Full Full Full

BS EN BS EN BS EN BS EN
Skip Skip Skip Skip Skip Skip Skip Skip
45
NF NF NF
2MHz
80
Pattern
Defect Detection (% DAC)
NF NF 100 NF NF NF 18 15 NF NF 17 18 3A
45
NF NF NF 100 NF NF
4MHz
80 NF NF NF 18 15 NF NF 17 17 3A
60
NF NF NF
2MHz
63
NF NF
80 NF NF NF 19 16 NF NF 19 20 3A
60
NF NF NF
4MHz
63
NF NF
45 NF NF NF 20 14 NF NF 19 10 3A
70
NF NF NF
2MHz
63
NF NF 125 NF NF NF 17 20 NF NF 17 18 3A
70
NF NF NF
4MHz
50
NF NF
63 NF NF NF 20 10 NF NF 18 18 3A
NF = Not Found
BS refers to BS 3923 and EN refers to BS EN 1712.
Defect 4
Upper surface
Probe
Side A
Side B
Length
Bottom Surface
Side A
Side B
Upper surface
Side A
Bottom Surface
Side B
Side A
Side B
Full Full Full Full

45
NF
2MHz
63
Pattern
NF NF NF
63
NF NF 12 11 NF NF 19 13 NF NF 3A
45
NF NF NF NF NF
4MHz
56
NF NF NF NF NF NF 20 11 NF NF 3A
60
NF
2MHz
50
NF NF
32
56
NF NF 20 12 NF NF 22 10 NF NF 3A
60
NF
4MHz
56
NF
25
80
NF 40 19 10 14
70
80
2MHz
NF 200 NF 125 NF
70 112 18 22 20 24 21 22 19 18 3A
70
36
4MHz
NF
56
70
25
NF
45
36
56 18
19 10 19
19 12 20 11 21
NF = Not Found.
S = Half skip
FS = Full skip
53
3A
3A
Final Report
D1.4 Testpiece RSA/PLW/15/ET 001

Flaw No
1
2
3
4
5
6
7
Comments
Flaw Type
Flaw
Length
(mm)
5
15
25
Flaw
Height
(mm)
1
2
3
Toe crack
Toe crack
Toe crack
Transverse
6
1
crack
Transverse
15
2
crack
Transverse
24
3
crack
Crack
14
2
Rough zinc coating on the top side.
Distance
from datum
(mm)
100
850
450
Tilt against
normal
(deg)
1
5
4
225
750
300
651
0
All the flaws are at the upper surface with no ligament.

1000
RSA/PLw/15/E
T/001
o>
o
>
Top side (coated)

2
54
Final Report

The inspection from the top side was carried out using full skip and the
inspection from the bottom side was carried out using half skip.
A transfer correction of 15 dB was applied when inspecting the top side of the
test plate to compensate for the zinc coating.
Transverse defects 5 and 6 were detected when scanning on the weld cap,
even though the weld cap was as-welded.
Defect 1
Probe
Frequency
(MHz)
Top side scan (full skip)
Bottom side scan (1/2skip)
Operator 1
Operator 2
Operator 1
Operator 2
45
56
56
40
36
45
56
56
32
32
60
25
20
25
25
60
NF
NF
40
36
70
NF
NF
45
40
NF
NF
25
25
70
4
NF = Not Found
Defect 2

Probe
Frequency
(MHz)
Operator 1
Operator 2
Operator 1
Operator 2
45
100
90
80
80
45
80
90
90
70
60
45
50
80
90
60
11
10
80
80
70
NF
NF
100
100
NF
NF
63
63
70
4
NF = Not Found
55
Final Report
Defect 3
Probe
Frequency
(MHz)
Operator 1
Operator 2
Operator 1
Operator 2
45
80
90
90
100
45
80
80
70
80
60
19
18
80
80
60
10
100
90
70
NF
NF
90
90
NF
NF
100
100
70
4
NF = Not Found
Defect 4

Probe
Frequency
(MHz)
Operator 1
Operator 2
Operator 1
Operator 2
45
20
20
28
28
45
20
20
14
13
60
18
NF
11
11
60
NF
18
13
11
70
NF
NF
20
20
NF
NF
11
11
70
4
NF = Not Found
56
Final Report
Defect 5
Probe
Frequency
(MHz)
Operator 1
Operator 2
Operator 1
Operator 2
45
20
20
20
20
45
10
11
10
10
60
20
20
11
11
60
NF
NF
11
11
70
NF
NF
20
20
NF
NF
20
20
70
4
NF = Not Found
Defect 6

Probe
Frequency
(MHz)
Operator 1
Operator 2
Operator 1
Operator 2
45
28
32
28
28
45
50
45
22
20
60
25
28
11
10
60
NF
NF
11
10
70
NF
NF
70
63
NF
NF
36
45
70
4
NF = Not Found
Defect 7

Probe
Frequency
(MHz)
Operator 1
Operator 2
Operator 1
Operator 2
45
50
50
45
40
45
45
45
70
70
60
50
45
45
40
60
NF
NF
63
56
70
NF
NF
40
40
NF
NF
40
40
70
4
NF = Not Found
57
Final Report
D1.5 Testpiece TPF1

Flaw No.
1
2
3
4
5
Comments
Flaw type
Flaw Length
(mm)
Flaw Height
(mm)
Root Crack
8
2
Root Crack
12
3.5
Root Crack
20
5
Root Crack
33
8
Root Crack
40
10
Testpiece cap removed and undressed root.
20
60
Flaw 1
3.5
Flaw 2
Flaw 3
Flaw 4
10
Flaw 5
58
Position
From Datum
(mm)
50
100
150
210
280
Final Report

Tested from one surface both sides of the weld with 2MHz and 4MHz probes
and 45, 60 & 70 angles.
Defect 1
Probe
Frequency
(MHz)
Operator 1
Operator 2
45
Less than 10% DAC
Less than 10% DAC
45
Less than 10% DAC
Less than 10% DAC
60
32
32
60
16
16
70
50
40
70
20
22
The 450 probe would not detect defect 1 with an undressed weld cap.
Defect 2
Probe
Frequency
(MHz)
Operator 1
Operator 2
45
Less than 20% DAC
Less than 20% DAC
45
Less than 20% DAC
Less than 18% DAC
60
45
50
60
40
36
70
50
40
70
20
25
The 450 probe would not detect defect 2 with an undressed weld cap.
Defect 3
Probe
Frequency
(MHz)
Operator 1
Operator 2
45
50
50
45
36
36
60
56
56
60
50
50
70
50
50
70
56
56
The 45 probe would detect defect 3 with an undressed weld cap. Beyond half
skip 10% DAC with 4 MHz probe and 28% with the 2 MHz.
59
Final Report
Defect 4
Probe
Frequency
(MHz)
Operator 1
Operator 2
45
63
50
45
50
50
60
70
56
60
63
70
70
100
100
70
63
63
Defect 5
Probe
Frequency
(MHz)
Operator 1
Operator 2
45
100
90
45
100
100
60
100
100
60
100
100
70
100
112
70
100
100
Test plate TP1 was examined with a fixed root scan using a 45 probe. Half to
full skip using 45 and 60 probes and half skip with the 70 probe.
If TP1 had a weld cap a fixed root scan would be difficult. There was difficultly
to find the maximum response from defect and root. There was also difficulty to
distinguish between root and defect indications.
60
Final Report
D1.6 Testpiece PL8155

Flaw No
Flaw Type
Distance from datum

(mm)
45
Flaw Length (mm)
Toe crack
20
Testpiece upper weld cap removed, bottom weld cap as welded.
Comments

Side B
Side A
1

Defect 1
Upper surface
Probe
Side A
Length
Bottom Surface
Side B
Side A
Upper surface
Side B
Side A
Side B
Bottom Surface
Side A
Side B
Full Full Full Full

Pattern
45
NF
2MHz
NF
NF
50
NF
NF 112 NF NF NF
19
20
NF NF
20
22
3A
45
NF
4MHz
NF
NF
80
NF
NF 100 NF NF NF
19
18
NF NF
20
21
3A
60
100
2MHz
50
80
32
90
NF
56
NF
19
22
20
21
19
23
20
22
3A
60
45
4MHz
125
70
45
112 NF
70
NF
19
21
19
15
20
20
20
20
3A
70
178
2MHz
63
125
90
20
23
19
18
20
24
19
21
3A
70
100
4MHz
16
200
63
20
22
NA NA
20
22
19
20
3A
NF = Not Found.
NA = Not Appropriate
61
Final Report

Flaw No
Flaw Type
1
3
Flaw Length (mm)
Toe crack
33
Root crack
22
Testpiece cap and root removed
Comments
Distance from datum

(mm)
69
260

Side B
Side A
1

Upper surface
Probe
Defect
No
Side A
Bottom Surface
Side B
Side A
Side B
Skip
Full
Skip
Skip
Full
Skip
Skip
Full
Skip
Skip
Full
Skip
45
2MHz
56
355
125
251
282
90
200
282
282
112
45
90
100
355
25
159
45
4MHz
22
141
50
141
90
90
112
80
100
40
56
70
32
112
11
80
60
2MHz
90
125
159
159
251
178
178
316
159
159
178
100
178
141
50
112
60
4MHz
28
125
80
159
125
56
141
159
63
80
100
28
56
63
16
100
70
2MHz
178
316
178
112
251
70
251
56
70
4MHz
36
90
141
200
125
178
112
50
62
Final Report

Flaw No
Flaw Length
(mm)
20
Flaw Type
Distance from
datum (mm)
35
Centre-line crack
Testpiece upper weld cap removed, bottom weld cap as welded.
Comments

Side B
Side A
1

Defect 1
Upper surface
Probe
Side A
Side B
Length
Bottom Surface
Side A
Side B
Upper surface
Side A
Side B
Bottom Surface
Side A
Side B
Full Full Full Full

Pattern
45
32
2MHz
159
70
282
80
125 200 80
21
27
21
29
22
29
21
30
3A
45
25
4MHz
100
16
90
50
100
90
40
19
19
21
24
24
24
22
27
3A
60
28
2MHz
100 112 125 159
80
125 90
21
27
25
26
21
27
19
26
3A
60
20
4MHz
141
100
90
50
63
21
25
21
25
21
27
20
25
3A
70
56
2MHz
141 159 224
80
100 178 316 24
24
24
26
24
28
23
30
3A
70
40
4MHz
141 159 112
80
40
21
22
26
24
26
23
27
3A
80
80
200 178 25
63
Final Report

Flaw No
Flaw Type
Distance from
datum (mm)
245
Flaw Length (mm)
Toe crack
20
Testpiece top and bottom weld caps removed.
Comments

Side A
Side B
3

Upper surface
Probe
Defect
No
Side A
Bottom Surface
Side B
Side A
Side B
Skip
Full
Skip
Skip
Full
Skip
Skip
Full
Skip
Skip
Full
Skip
45
2MHz
63
400
32
501
NF
178
50
251
45
4MHz
32
251
32
200
18
141
32
159
60
2MHz
100
100
125
100
112
80
90
200
60
4MHz
36
112
28
90
45
100
80
63
70
2MHz
141
251
141
282
70
4MHz
63
200
178
355
NF = Not Found
64
Final Report

Flaw No
Flaw Type
Distance from
datum (mm)
50
Flaw Length (mm)
Sidewall crack
25
Comments

Side B
Side A
2
3
1

Upper surface
Probe
Defect
No
Side A
Bottom Surface
Side B
Side A
Side B
Skip
Full
Skip
Skip
Full
Skip
Skip
Full
Skip
Skip
Full
Skip
45
2MHz
159
178
40
178
70
447
112
200
45
4MHz
100
63
32
63
16
141
63
25
60
2MHz
282
224
251
562
112
316
355
501
60
4MHz
316
70
316
501
25
282
316
316
70
2MHz
141
282
125
200
70
4MHz
316
125
100
90
65
Final Report

Flaw No
1
Flaw Length
(mm)
20
Flaw Type
Distance from
datum (mm)
85
Centre-line crack
Testpiece top weld cap as welded and bottom weld cap removed.
Comments

Side A
Side B
3

Upper surface
Probe
Defect
No
Side A
Bottom Surface
Side B
Side A
Side B
Skip
Full
Skip
Skip
Full
Skip
Skip
Full
Skip
Skip
Full
Skip
45
2MHz
501
NF
224
NF
36
501
32
316
45
4MHz
178
NF
125
NF
32
224
25
112
60
2MHz
200
NF
70
NF
63
90
45
63
60
4MHz
178
NF
50
NF
32
100
20
40
70
2MHz
200
80
141
80
70
4MHz
178
100
125
50
NF = Not Found (Includes signal not maximised or signal maximised at skip)
66
Final Report

Flaw No
3
Flaw Length
(mm)
18
Flaw Type
Distance from
datum (mm)
160
Transverse crack
Comments

Side A
Side B
2
1
3

Upper surface
Probe
Defect
No
Side A
Bottom Surface
Side B
Side A
Side B
Skip
Full
Skip
Skip
Full
Skip
Skip
Full
Skip
Skip
Full
Skip
45
2MHz
501 A
NF
708 T
NF
NF
631 A
NF
708 T
45
4MHz
200 A
NF
400 T
NF
NF
355 A
NF
891 T
60
2MHz
125 A
NF
224 T
NF
45 A
100 A
50 T
100 T
60
4MHz
159 A
NF
282 T
NF
NF
125 A
NF
400 T
70
2MHz
100 A
NF
178 T
NF
141 A
NF
316 T
NF
70
4MHz
159 A
NF
200 T
NF
70 A
NF
56 T
562 T
NF = Not Found
= Away from datum
67
= Toward datum
Final Report
D1.13 Testpiece P2401

Flaw No
1
3
Comments
Flaw Length Flaw Height* Distance from

(mm)
(mm)
datum (mm)
Root crack
30
7.7
23
Centre line crack
29
4.8
122
Testpiece thickness = 40mm. Testpiece as-welded.
* Sectioning result
Flaw Type
Side A
Side B
Side A
Side B

Defect 1
Probe
Frequency
(MHz)
Side A
Side B
1/2 skip
Full skip
1/2 skip
Full skip
45
100
NF
200
NF
45
70
NF
100
NF
60
200
NF
159
NF
60
178
NF
141
NF
70
178
178
63
63
70
4
NF = Not Found
Defect 3
Probe
Frequency
(MHz)
Side A
Side B
1/2 skip
Full skip
1/2 skip
Full skip
45
63
56
40
63
45
50
36
40
36
60
56
100
90
63
60
36
63
80
36
70
112
159
70
70
63
68
Final Report
D1.14 Testpiece P24T

Flaw No
Flaw Type
Centre line crack
Flaw Length
(mm)
47
Flaw Height
(mm)
6
Distance from
datum (mm)
68
Testpiece thickness =40mm. Testpiece as-welded (weld cap width

27mm)
Comments
Weld/Specimen cross section

Side B
Side A

Defect 1
Upper surface
Probe
Side A
Length
Bottom Surface
Side B
Side A
Upper surface
Side B
Side A
Full Full Full Full

BS
Bottom Surface
Side B
Side A
Side B
EN
BS
EN
BS
EN
BS
EN
Pattern
45
2MHz
NF 100 NF 100 224 NF 200 NF
49
6
7
7
50
3
7
12
50
50
51
52
45
4MHz
NF
40
NF
40
159 NF 141 NF
47
6
6
6
50
2
5
10
49
54
48
50
60
2MHz
NF
50
NF
40
141 NF 159 NF
51
10
6
48
10
49
59
48
49
60
4MHz
NF
45
NF
25
100 NF 100 NF
46
10
47
48
53
49
49
70
2MHz
22(1)
(2)
13(1)
(2)
90
NF
80
NF
47
46
51
56
52
54
70
4MHz
NF
(2)
NF
(2)
50
NF
50
NF
50
25
50
20
Notes:
(1)
The signals from the defect provided by the 70 2MHz probe could not be maximised.
The full skip measurement could not be achieved using the 70 probes due to
the restricted scanning surfaces.
(2)
NF = Not Found
- = No length measured
69
D2.
Final Report
PIPES SECTIONS

General over view of the testpiece
Cone
Weld
Weld
Weld
B
Weld
A
Elbow
Section
C
Section
A
Section
B
Flaw Type
Flaw
Length*
(mm)
Flaw
Height*
(mm)
Flaw
Tilt* ()
Distance
from
datum
(mm)
Root crack
14
6.6
13
305
Root crack
17
3.1
20 to 30
288
Root crack
24
9.1
148
Erosion/Corrosion
25
2x3
NA
20
Erosion/Corrosion
20
2 x 2.5
NA
293
Toe crack
19
4.2
15
348
Weld
Reference
Flaw
No
Comments
6 sch 80 Pipe section.

168mm pipe, testpiece thickness = 11mm.
Testpiece as-welded.
* From sectioning report.
70
Final Report

Weld A
Weld B
Section A
Elbow
Section B
Section A
Section C
Section B
Weld C
Weld D
Cone
Section C
2
71
3
1
Final Report

Note: NF = Not Found
Weld A Defect 1
Probe
Frequency
(MHz)
Scan from the elbow

Operator 1
Scan from pipe section A
Operator 2
Operator 1
Operator 2
1/2 skip skip+1/2 1/2 skip skip+1/2 1/2 skip skip+1/2 1/2 skip skip+1/2
45
NF
80
NF
80
NF
141
NF
141
45
NF
50
NF
50
NF
45
NF
56
60
159
NF
200
NF
100
NF
100
NF
60
125
NF
141
NF
80
NF
63
NF
70
90
NF
90
NF
141
NF
141
NF
70
40
NF
40
NF
112
NF
100
NF
Weld B Defect 1
Probe
Frequency
(MHz)
Scan from Butt B side A

Operator 1
Operator 2
Scan from Butt B side C

Operator 1
Operator 2
45
NF
80
NF
70
NF
90
NF
90
45
NF
70
NF
70
NF
80
NF
70
60
90
NF
90
NF
56
NF
50
NF
60
56
NF
50
NF
56
NF
56
NF
70
125
NF
141
NF
56
NF
56
NF
70
100
NF
100
NF
80
NF
90
NF
Weld C Defect 1
Probe
Frequency
(MHz)
Scan from Butt C side B

Operator 1
Operator 2
Scan from side D

Operator 1
Operator 2
45
NF
80
NF
90
NF
50
NF
50
45
NF
80
NF
90
NF
40
NF
40
60
90
NF
70
NF
90
NF
70
NF
60
56
NF
70
NF
56
NF
63
NF
70
125
NF
112
NF
125
NF
125
NF
70
112
NF
112
NF
125
NF
125
NF
72
Final Report
Weld D
Defect 1
Probe
Frequency
(MHz)
Scan from Butt D side C

Operator 1
Operator 2
1/2 skip skip+1/2 1/2 skip skip+1/2
Scan from Cone side

Operator 1
Operator 2
1/2 skip
1/2 skip
45
NF
112
NF
100
NF
NF
45
NF
70
NF
70
NF
NF
60
40
NF
50
NF
NF
NF
60
80
NF
56
NF
NF
NF
70
18
NF
18
NF
11
11
70
40
NF
40
NF
11
16
Defect 2
Probe
Frequency
(MHz)
Scan from side C

Operator 1
Scan from Cone side
Operator 2
1/2 skip skip+1/2 1/2 skip skip+1/2
Operator 1
Operator 2
1/2 skip
1/2 skip
45
NF
100
NF
100
NF
NF
45
NF
70
NF
56
NF
NF
60
56
NF
56
NF
NF
NF
60
90
NF
70
NF
NF
NF
70
32
NF
32
NF
14
14
70
90
NF
100
NF
18
16
Defect 3
Probe
Frequency
(MHz)
Scan from side C
Scan from Cone side
Operator 1
Operator 2
Operator 1
Operator 2
Full skip
Full skip
Full skip
Full skip
45
178
282
32
32
45
45
50
14
16
60
112
141
100
112
60
100
112
45
40
70
100
112
50
50
70
100
100
28
28
73
Final Report
D2.2 Testpiece P23T

Flaw No
2
Comments
Flaw Length
(mm)
Flaw Type
Flaw Height
(mm)
Distance from
datum (mm)
Incomplete root
28
5
penetration
168 OD pipe section. Testpiece thickness = 11mm.
Testpiece as-welded.
72
General over view of the testpiece
Weld
A
Weld
B
Section B
Centre
Section A

Weld A - Defect 1
Section A
Centre

Probe
Frequency
(MHz)
Scan from Section A
Scan from Centre
Skip
Full
Skip
1+
Skip
Skip
Full
Skip
1+
Skip
45
NF
63
400
NF
63
400
45
NF
40
159
NF
50
200
60
56
141
63
100
60
80
125
141
141
70
125
90
125
90
70
100
63
125
100
NF = Not Found
74
Final Report
D2.3 Testpiece TPF6

Flaw No
1
3
6
8
Comments
Flaw Length
Flaw Height
(mm)
(mm)
Crack
18
3
Crack
14
3
Toe crack
17
3
Root crack
18
3
Testpiece thickness = 12.5mm, OD = 457mm
Flaw Type

Side A
Side B
75
Distance from
datum (mm)
53
212
478
629
Final Report

Upper surface
Defect
No

Side A
Side B
skip Full skip skip Full skip
45
2MHz
45
4MHz
60
2MHz
60
4MHz
70
2MHz
70
4MHz
Length
BS
EN
Intended
Pattern
Probe
NF
NF
NF
NF
NF
NF
18
NF
NF
159
NF
NF
14
15
14
3A
NF
NF
NF
159
20
20
17
3A
NF
NF
NF
NF
NF
NF
18
NF
NF
NF
NF
NF
NF
NF
18
NF
NF
63
NF
NF
15
11
14
3A
NF
NF
NF
100
20
21
17
3A
NF
NF
NF
NF
NF
NF
18
NF
NF
11
NF
90
16
17
18
3A
NF
70
NF
NF
13
15
14
3A
NF
50
NF
100
18
20
17
3A
32
NF
125
NF
20
22
18
3B
NF
32
NF
90
18
18
18
3A
NF
70
NF
NF
14
15
14
3A
NF
56
NF
80
18
18
17
3A
38
NF
40
NF
19
23
18
3B
100
28
112
141
18
22
18
3A
16
141
45
NF
15
17
14
3A
NF
50
NF
112
17
17
17
3A
141
NF
316
NF
20
25
18
3B
63
28
50
200
19
19
18
3A
16
45
25
NF
14
14
14
3A
NF
20
NF
45
16
21
17
3A
112
NF
70
NF
17
20
18
3B
NF = Not Found
76
Final Report
D2.4 Testpiece SOHIC

Advantica pipe testpiece containing stress oriented hydrogen induced cracking
(SOHIC)Pipe section 610mm OD x 12.7mm thick
Scanning from the upper surface
Toward
datum
Away from
datum
Toward
datum
Away from
datum
skip Full skip skip Full skip skip Full skip skip Full skip
Probe
Defect
No
45 2MHz
28
25
20
18
25
25
20
18
20
20
20
20
45
36
32
36
32
32
32
32
56
36
28
63
22
22
20
25
25
22
36
36
22
22
28
28
25
25
25
25
25
25
25
25
28
28
25
28
20
16
20
16
32
20
25
25
20
20
25
25
20
18
20
18
20
18
25
25
20
18
20
18
10
20
20
22
22
18
11
14
Probe
Defect
No
45 4MHz
60 2MHz
60 4MHz
20
13
20
20
10
20
20
20
20
18
20
18
18
10
28
25
20
20
14
13
22
22
22
18
13
32
25
28
28
14
10
11
20
16
20
20
14
14
14
16
14
14
14
14
10
13
14
14
13
A 70 4MHz probe was also used. All the indications were below 10% DAC.
A 0, 5MHz probe provide the following results, scanning from the upper
surface at Skip.
Defect No
10
% DAC
60
60
60
78
78
80
75
80
80
40
77
Final Report
D2.5 Testpiece TPF8

Flaw No
4
5
7
8
9
10
11
Comments
Flaw Type
Flaw Length
(mm)
Flaw Height
(mm)
HAZ crack
16
Root crack
18
Tight planar smooth
20
root defect
Rough planar
18
Rough planar
15
Rough planar
14
Root crack
18
Testpiece thickness = 35mm, OD = 355mm
4
2
6
672
4
4
4
4
767
859
960
1048

Side A
Side B
78
Distance
from datum
(mm)
368
451
Final Report

Upper surface
Defect
Probe
No
45
2MHz
45
4MHz
60
2MHz
60
4MHz
Side A
Side B
Length
skip
Full skip
skip
Full skip
BS
EN
Intended
NF
NF
NF
50
16
16
16
100
NF
80
NF
20
19
18
282
NF
224
NF
21
24
20
NF
NF
NF
70
19
17
18
NF
32
NF
45
17
15
15
10
NF
100
NF
40
17
17
14
11
100
NF
224
NF
17
17
18
NF
NF
NF
50
17
16
16
90
NF
56
NF
18
20
18
125
NF
125
NF
20
23
20
NF
NF
NF
50
20
16
18
NF
32
NF
25
17
14
15
10
NF
90
NF
16
16
17
14
11
70
NF
159
NF
17
19
18
NF
NF
20
56
18
17
16
178
NF
80
NF
17
20
18
400
NF
316
NF
21
28
20
90
NF
32
63
20
21
18
112
80
50
90
19
17
15
10
56
70
25
40
18
11
14
11
125
NF
125
NF
17
21
18
NF
NF
NF
28
18
NA
16
125
NF
80
NF
19
22
18
631
NF
316
NF
19
30
20
70
NF
20
70
20
20
18
80
63
80
125
19
16
15
10
40
80
40
NF
16
10
14
11
125
NF
251
NF
17
NF = Not Found
NA = Not Appropriate
19
18
79
Final Report
Upper surface
Defect
Probe
No
70
2MHz
70
4MHz
Side A
Side B
Length
skip
Full skip
skip
Full skip
BS
EN
Intended
NF
100
16
17
16
200
159
20
18
18
501
224
20
31
20
141
32
19
21
18
100
63
19
17
15
10
80
70
17
10
14
11
159
100
22
23
18
NF
60
16
12
16
251
125
18
21
18
400
251
22
30
20
178
36
17
20
18
125
125
18
16
15
10
63
45
17
11
14
11
125
159
18
23
18
NF = Not Found
80
Final Report
D2.6 Testpiece P257

Flaw No
Flaw Type
Smooth root crack
Comments
Flaw Length
(mm)
39
Distance from
datum (mm)
-
Pipe section. Testpiece thickness = 65mm. Testpiece weld cap

removed
3.8

Upper surface
Probe
Defect No
Side A
Side B
skip
Full skip
skip
Full skip
45
2MHz
708
NF
447
NF
45
4MHz
891
NF
447
NF
60
2MHz
200
NF
141
NF
60
4MHz
200
NF
141
NF
70
2MHz
200
NF
NS
NF
70
4MHz
159
NF
NS
NF
NF = Not Found
NS = No Scanning distance
81
D3.
Final Report
T JOINTS

Flaw
No
Flaw type
Flaw
length*
(mm)
2
3
4
5
6
7
Flaw
height*
(mm)
Flaw Tilt* ()
Laminar tear
14
6
20 wrt component
Root crack (LOP)*
40
2
45 wrt plate
Root crack
28
3.6
25 wrt plate
Erosion/corrosion
15
3x3
NA
Toe crack
18
5.1
25 wrt component
Erosion/corrosion
30
2.7 x 1
NA
Incomplete root
22
4
40 wrt plate
9
crack (LOP)*
Testpiece as welded. All flaws are mechanical.
Comments Dimensions: 1000 x 20 x 10mm.
* From sectioning report
Side A
Attachment
plate
Side B
Side F
Component
Side D
Side E
82
Distance
from
datum
(mm)
107
301
491
430
914
355
213
Final Report

Defect 2
Probe
Frequency
(MHz)
45
112
112
45
100
100
60
50
50
60
32
32
70
63
63
70
36
45
Operator 1
Side
A
Side
B
Side
D
Operator 2
Side
E
Side
F
Side
A
Side
B
Side
D
Side
E
Side
F
Defect 3
Probe
Frequency
(MHz)
45
20
40
20
36
45
25
10
25
60
125
10
159
13
60
80
13
63
16
70
200
13
224
16
70
200
18
178
18
Operator 1
Operator 2
Side
A
Side
B
Side
D
Side
E
Side
F
Side
A
Side
B
Side
D
Side
E
Side
F
Defect 4
Probe
Frequency
(MHz)
45
20
178
20
200
45
159
10
159
60
178
56
200
60
60
141
80
125
90
70
224
32
251
32
70
251
45
316
40
Operator 1
Operator 2
Side
A
Side
B
Side
D
Side
E
Side
F
Side
A
Side
B
Side
D
Side
E
Side
F
83
Final Report
Defect 5
Probe
Frequency
(MHz)
45
56
50
NF
50
50
45
32
63
NF
32
56
60
16
25
NF
16
25
60
20
40
NF
20
45
70
20
45
NF
20
45
4
NF = Not Found.
28
50
NF
28
45
70
Operator 1
Operator 2
Side
A
Side
B
Side
D
Side
E
Side
F
Side
A
Side
B
Side
D
Side
E
Side
F
Defect 6
Probe
Frequency
(MHz)
45
141
125
159
159
45
112
125
112
178
60
90
178
63
90
178
70
60
100
112
125
100
141
125
70
200
159
90
200
159
100
70
200
125
56
178
159
50
Operator 1
Operator 2
Side
A
Side
B
Side
D
Side
E
Side
F
Side
A
Side
B
Side
D
Side
E
Side
F
Defect 7
Probe
Frequency
(MHz)
45
80
50
NF
80
50
45
45
32
NF
40
32
60
28
28
NF
28
28
60
25
40
NF
25
36
70
20
32
NF
20
32
4
NF = Not Found.
32
32
NF
32
32
70
Operator 1
Operator 2
Side
A
Side
B
Side
D
Side
E
Side
F
Side
A
Side
B
Side
D
Side
E
Side
F
84
Final Report
Defect 9
Probe
Frequency
(MHz)
45
63
112
63
100
45
25
80
25
90
60
159
63
141
56
60
159
63
159
63
70
125
70
178
56
70
141
56
224
63
Operator 1
Operator 2
Side
A
Side
B
Side
D
Side
E
Side
F
Side
A
Side
B
Side
D
Side
E
Side
F
85
Final Report
D3.2 Testpiece P22T

Flaw No
Flaw type
Flaw length
(mm)
Flaw height
(mm)
Toe crack
15
Testpiece as welded. Mechanical flaw.
Dimensions: 1000 x 20 x 10mm.
Comments
Distance
from datum
(mm)
33
Attachment
Side A
Side B
Side F
Component
Side D
Side E

Side A Side B
Side D Side E
Length (mm)
Side F
skip
skip
skip
FS
BS
EN
Pattern
Frequency
(MHz)
Probe
Defect 1
45
90
141
NF
125
14
14
45
63
90
NF
80
15
15
60
80
125
NF
100
14
14
60
100
63
141(3)
10(1)
40(2)
63
15
14
70
125
125
NF
125
14
14
70
90
125
10
100
14
13
NF = Not Found.
(1)
Could not be maximised.
(2)
Sub-miniature probe used
(3)
Not a direct reflection from the defect.
86
Final Report
D3.3 Furnace Testpiece

Flaw No
1
2
Comments
Flaw length
Flaw height (mm)
(mm)
In-service crack
220
2
In-service crack
220
4
Testpiece as welded. Tfurnace=21.5mm, Ttubeplate=24mm.
Flaw type

Side E
Side D
Furnace
DEFECT 2
Side F
Side C
DEFECT 1
Side B
Side A
Tubeplate

Defect 1
Side
A*
45
80
228
214
45
45
63
225
210
60
100
217
40+40+70
60
20
45
218
40+35+75
70
141
215
215
70
100
216
210
Side
B
Side
D
Side
E
Side
F
BS
EN
Pattern
Frequency
(MHz)
Length (mm)
Probe
* Sub-miniature probes were used
87
Final Report
Defect 2
Side
A
45
70
36
20
100*
220
20+10
45
50
50
36
159*
215
20+10+
10+7
60
28
56
80
210
20+20
60
40
36
63
212
25+18
70
22
63
100
214
30+20
70
50
56
50
214
30+20
Side
B
Side
D
Side
E
Side
F
BS
EN
Pattern
Frequency
(MHz)
Length (mm)
Probe
* Not a direct reflection from the defect.
88
D4.
Final Report
NOZZLES

Flaw No
3
4
5
Comments
Flaw tilt wrt

Flaw
Flaw
the nozzle*
length*
height*
(mm)
(mm)
()
Root crack
18
7.1
9
Root crack
11
2.8
3
Root crack
13
5.7
0
Dimensions: Diameter 168 x 12 mm.
Flaw type
Distance
from datum
(mm)
397
305
397
Branch
Side A
Side E
Plate/component

Frequency (MHz)
Probe
Defect 3
Scan from the branch (side A)
Operator 1
Scan from the plate (side E)
Operator 2
skip Full skip skip+1/2 skip Full skip skip+1/2
Operator 1
Operator 2
Full skip
Full skip
45
NF
NF
28
NF
NF
28
200
200
45
NF
NF
45
NF
NF
45
355
224
60
100
100
100
100
100
100
60
100
80
80
63
70
40
70
178
178
178
178
70
178
125
159
159
NF = Not Found
89
Final Report
Frequency (MHz)
Probe
Defect 4
Scan from the plate
(side E)

Operator 1
Operator 2
Operator 1 Operator 2
Full skip
Full skip
45
NF
NF
28
NF
NF
28
100
100
45
NF
NF
18
NF
NF
20
125
100
60
20
36
28
45
45
56
60
36
63
45
90
50
45
70
40
50
80
70
70
112
100
100
100
NF = Not Found
Frequency (MHz)
Probe
Defect 5
Scan from the plate
(side E)

Operator 1
Operator 2
Operator 1 Operator 2
Full skip
Full skip
45
NF
NF
125
NF
NF
112
141
125
45
NF
NF
125
NF
NF
125
159
159
60
50
40
70
50
45
45
60
50
50
56
56
45
50
70
112
100
90
90
70
141
141
100
100
NF = Not Found
90
Final Report

Flaw No
1
2
Comments
Flaw
Flaw tilt*
height*
()
(mm)
Root crack
11
7.1
0 wrt nozzle
Toe crack
13
5.6
15 wrt component
Dimensions: Diameter 168 x 12 mm.
Flaw length*
(mm)
Flaw type
Distance
from datum
(mm)
0
209
Branch/
nozzle
Side A
Side E
Plate/ component

Defect 1
Probe
Frequency
(MHz)
Scan from the branch

(side A)
Scan from the plate

(side E)
1/2 skip Full skip skip+1/2
Full skip
45
NF
NF
56
70
45
NF
NF
70
70
60
63
40
40
60
63
70
56
70
63
NF
125
70
125
NF
90
NF = Not Found
91
Final Report
Defect 2
Probe
Frequency
(MHz)

(side A)
Scan from the plate

(side E)
1/2 skip
Full skip
1/2 skip
Full skip
45
NF
100
45
NF
125
60
16*
80
60
16*
70
70
56
50
70
45
16
NF = Not Found
* Not maximised
92
Final Report
D4.3 Testpiece P21T

Flaw length
Flaw height
(mm)
(mm)
2
Root crack
20
4.5
Testpiece as welded. Mechanical flaw.
Comments
Dimensions: OD 150 x 11 x 12mm.
Weld/Specimen cross section
Flaw No
Flaw type
Distance from
datum (mm)
55
Side A
Side B1
Branch
26mm
Side E
Plate
12mm

Defect 2
45
45
60
2
4
Scan from
the branch
(Side B1)
Scan from
the plate
(Side E)
1/2
skip
Full
skip
skip+
1/2
1/2
skip
Full
skip
1/2
skip
Full
skip
BS
EN
NF
NF
NF(1)
NF
NF
NF
NF
NA
NA
NA
NF
(1)
NF
NF
NF
NF
NA
NA
NA
NF
Length
(mm)

(Side A)
NF
NF
Pattern
Frequency
(MHz)
Probe
36
(2)
NF
NF
NF
NF
18
(2)
NF
NF
NF
NF
18
15
60
NF
63
70
NF
100
NF
90
NF
NF
17
15
70
NF
100
NF
100
NF
NF
20
20
A 0 5MHz 10mm twin probe was used from the internal surface
of the plate. The defect was detected providing a signal equivalent
to 141% DAC.
Comments
None of the beams can reach the defect at 0.5 skip. Sub-miniature
probes did not provide better results.
Difficult to resolve signals from the defect and those from the root.
(1)
NF = Not Found.
Reflection at the cap (2) Could not be maximised.
93
Final Report
D5. SUMMARY OF THE RESULTS FROM THE LENGTH MEASUREMENT
60
250
50
BS
200
EN
40
Length (mm)
20
150
100
P24T-1
P21T-2
TPF8-7
PL8156-1
PL8155-1
TPF7-4
TPF8-11
TPF8-8
TPF8-5
TPF6-8
TPF6-1
TPF7-1
TPF6-6
P22T-1
TPF8-4
TPF8-9
0
TPF8-10
50
TPF6-3
10
Furnace-2*
30
Furnace-1
Length (mm)
Intended
Defect reference
* The defect length used is the sum of the reported discrete lengths
Figure D1: Length measurement - 45, 2MHz probe.
60
250
50
200
BS
EN
40
Length (mm)
30
20
150
100
50
10
P24T-1
P21T-2
TPF8-7
PL8156-1
PL8155-1
TPF7-4
TPF8-11
TPF8-8
TPF8-5
TPF6-8
TPF6-1
TPF7-1
TPF6-6
TPF8-4
P22T-1
TPF8-9
TPF8-10
TPF6-3
Defect reference
94
Furnace-2*
Furnace-1
Length (mm)
Intended
Final Report
60
250
50
200
EN
40
30
20
150
100
Furnace-1*
P24T-1
P21T-2
TPF8-7
PL8156-1
PL8155-1
TPF7-4
TPF8-11
TPF8-8
TPF8-5
TPF6-8
TPF6-1
TPF7-1
TPF6-6
TPF8-4
P22T-1
0
TPF8-9
TPF8-10
50
TPF6-3
10
Defect reference
Furnace-2*
BS
Length (mm)
Length (mm)
Intended
60
250
50
BS
200
EN
40
Length (mm)
Length (mm)
Intended
30
150
100
20
50
10
95
Furnace-2*
P24T-1
P21T-2
TPF8-7
PL8156-1
PL8155-1
TPF7-4
TPF8-11
TPF8-8
TPF8-5
TPF6-8
TPF6-1
TPF7-1
TPF6-6
TPF8-4
P22T-1
TPF8-9
TPF8-10
TPF6-3
Defect reference
Furnace-1*
Final Report
60
250
50
200
EN
Length (mm)
30
20
150
100
Furnace-1
P24T-1
P21T-2
TPF8-7
PL8156-1
PL8155-1
TPF7-4
TPF8-11
TPF8-8
TPF8-5
TPF6-8
TPF6-1
TPF7-1
TPF6-6
TPF8-4
0
P22T-1
0
TPF8-9
50
TPF8-10
10
Furnace-2*
BS
40
TPF6-3
Length (mm)
Intended
Defect reference
250
60
200
Intended
40
BS
EN
Length (mm)
30
20
150
100
50
10
0
Defect reference
96
P24T-1
D f
Furnace-2*
P21T-2
TPF8-7
PL8156-1
PL8155-1
TPF7-4
TPF8-11
TPF8-8
TPF8-5
TPF6-8
TPF6-1
TPF7-1
TPF6-6
TPF8-4
P22T-1
TPF8-9
TPF8-10
TPF6-3
Furnace-1
Length (mm)
50
Printed and published by the Health and Safety Executive

C30 1/98
Printed and published by the Health and Safety Executive
C1.10
06/05
ISBN 0-7176-2945-7
RR 299
25.00
9 78071 7 62945 9

Evaluation of CEN Ultrasonic Testing

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Evaluation of CEN Ultrasonic Testing

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HSE

Health & Safety

Evaluation of CEN ultrasonic testing

Prepared by Mitsui Babcock for the

RESEARCH REPORT 299

Health & Safety

Evaluation of CEN ultrasonic testing

NS Goujon and BWO Shepherd

Crown copyright 2005

Evaluation of CEN UT Standards for In-Service Inspection

ISSUES RAISED BY THE COMMITTEE

REVIEW OF PREVIOUS ASSESSEMENT TRIALS

INSPECTION TECHNIQUE & PROCEDURE

APPENDIX A: EXAMINATION REQUIREMENTS

APPENDIX B: ULTRASONIC MODELLING

APPENDIX D: TRIALS RESULTS

Evaluation of CEN UT Standards for In-Service Inspection

Evaluation of CEN UT Standards for In-Service Inspection

In defining these requirements, consideration should be given to the following:

Evaluation of CEN UT Standards for In-Service Inspection

Evaluation of CEN UT Standards for In-Service Inspection

A steering committee was established with representation drawn from a variety

Jacobi Consulting Ltd

Conoco Phillips Petroleum

Mr S Smalley replaced by Mr C Latter Royal & Sun Alliance /

Mr A Kirkham, Dr L Morgan (MIC Ltd)

National Grid Transco

ISSUES RAISED BY THE COMMITTEE

Testpiece thickness range: 10mm to 40mm (main interest up to 20mm)

Concentrate the work (around 80%) on surface breaking defects

Mainly cracks, but some interest in selective root corrosion

Butt, nozzle and attachment welds

Evaluation of CEN UT Standards for In-Service Inspection

REVIEW OF MAIN DIFFERENCES BETWEEN BS 3923 AND

REVIEW OF PREVIOUS ASSESSEMENT TRIALS

BS EN 1714: 1998 Non-destructive testing of welded joints Ultrasonic

BS EN 1712: 1997 Non-destructive testing of welds Ultrasonic testing of

Evaluation of CEN UT Standards for In-Service Inspection

The most stringent examination requirements for longitudinal indications in

BS 3923: t 6mm and 150mm

BS EN 1714: t 8mm; no upper limit.

BS EN 1714 states that it can be applied directly as an inspection procedure

Choice of examination / testing levels

BS 3923 examination levels differ in terms of both sensitivity and number of

To achieve an examination level 1 under BS 3923, the component surfaces

BS EN 1714 standard makes no distinction between as-welded and dressed

Evaluation of CEN UT Standards for In-Service Inspection

Coverage / beam angles

3.2.4.1 Parent material inspection

The BS EN 1714 standard states that if individual sections of the testing

There is no requirement in BS EN 1714 for a separate root scan.

Little guidance is provided in the BS EN 1714 standard on choice of beam

Unlike BS 3923, BS EN 1714 does not differentiate between single sided

Evaluation of CEN UT Standards for In-Service Inspection

Grass or at least DAC + 14dB

Grass or at least DAC + 20dB

3mm SDH DAC + 14dB

3mm SDH DAC + 14dB

3mm SDH DAC + 8dB

3mm SDH DAC + 8dB

Minimum scanning sensitivity Minimum scanning sensitivity

Minimum scanning sensitivity level under BS 3923.

Evaluation and Recording Level

Reference level: 3mm SDH DAC