The flawed specimens we produce are used for procedure qualifications, personnel qualifications, performance demonstrations and NDE training.

Transcription

1

2 INTRODUCTION TO FLAWSPEC The flawed specimens we produce are used for procedure qualifications, personnel qualifications, performance demonstrations and NDE training. Flawspec s corporate strategy and manufacturing processes were developed to satisfy the changing needs of industry. Industrial equipment construction and maintenance sectors demand greater innovation, technical advancements and increased efficiency. We have a vast knowledge of modern methods for pressure equipment construction, installation, inspection and testing. This enables us to design and manufacture flawed specimens which provide a very accurate simulation of the flaws found in new or in-service weldments. The flaw implanting techniques which we have developed enable us to deliver very high quality flaws with exacting tolerances. Flawspec s innovative processes and commitment to quality enable us to manufacture high quality specimens with delivery dates which fit your schedule. All flaw dimensions are guaranteed to conform to the specified tolerance level. TABLE OF CONTENTS Code Qualification Specimens... 2 Advance Training Specimens UT... 8 RT MT and PT Calibration Standards Custom Flawed Specimens Specifications Code Qualification and Advanced Training Specimens #1

3 CODE QUALIFICATION S Code qualification specimens are our core business. We excel at being the best resource for customers to use as a complete qualification supplier for both flawed specimens and calibration standards. We will produce the specimens required with guaranteed conformance to the required design and flaw sizing accuracy. These specimens are used for personnel qualification, procedure qualification and procedure demonstration in accordance with various codes, specifications and standards such as ASME, API, AWS, CSA etc. We have the ability to create flaws of less than 0.5mm in height if required by code. ULTRASONIC TESTING JOINT DIAMETER THICKNESS LENGTH APPROX. PIPE SV UT STD 12 4 UT XS 12 5 UT SCH UT STD UT XS UT SCH UT STD UT XS UT SCH UT STD UT XS UT STD UT XS UT STD UT XS UT STD 12 X UT XS 12 X JOINT DIAMETER THICKNESS LENGTH APPROX. TUBE SV UT UT UT UT UT UT UT UT #2

4 JOINT DIAMETER THICKNESS SIZE APPROX. PLATE SV UT-301 N/A X UT-302 N/A X UT-303 N/A X UT-304 N/A X UT-305 N/A X UT-306 N/A X PLATE DV UT-351 N/A X UT-352 N/A X UT-353 N/A X UT-354 N/A X UT-355 N/A X UT-356 N/A X JOINT DIAMETER THICKNESS SIZE APPROX. TEE SV UT-401 N/A X 6 X UT-402 N/A X 8 X UT-403 N/A X 10 X TEE DV UT-451 N/A X 6 X UT-452 N/A X 8 X UT-453 N/A X 10 X Y SV UT-501 N/A X 6 X UT-502 N/A X 8 X UT-503 N/A X 10 X Y DV UT-551 N/A X 6 X UT-552 N/A X 8 X UT-553 N/A X 10 X LAP FILLET UT-601 N/A PLATES 6 X 12 UT-602 N/A PLATES 8 X 12 UT-603 N/A PLATES 10 X #3

5 JOINT PENETRATION SIZE CARRIER PLATE SIZE NOZZLE SV UT XS X 6 LONG 16 X 16 X UT XS X 6 LONG 20 X 20 X UT XS X 12 LONG 20 X 20 X NOZZLE DV UT XS X 6 LONG 16 X 16 X UT XS X 6 LONG 20 X 20 X UT XS X 12 LONG 20 X 20 X NODE SV UT XS X 6 LONG 16 X 16 X UT XS X 6 LONG 20 X 20 X UT XS X 12 LONG 20 X 20 X NODE DV UT XS X 6 LONG 16 X 16 X UT XS X 6 LONG 20 X 20 X UT XS X 12 LONG 20 X 20 X NOTE: ROLLED PLATE OR PIPE IS AVAILABLE FOR NOZZLE OR NODE CARRIER PLATES. APPROX #4

6 CODE QUALIFICATION KITS All specimen kits for code qualification are available in carbon steel, 304 stainless steel or DMWs. ASME CODE CASE 2235 KIT 1 JOINT DIAMETER THICKNESS SIZE APPROX. UT-104 PIPE SV 4 STD UT-108 PIPE SV 6 XS UT-115 PIPE SV 12 XS UT-117 PIPE SV 24 XS 12 X NOTE: KIT CONSISTS OF 12 FLAWS ASME CODE CASE 2235 KIT 2 JOINT DIAMETER THICKNESS SIZE APPROX. UT-302 PLATE SV N/A X UT-305 PLATE SV N/A X UT-352 PLATE DV N/A X UT-355 PLATE DV N/A X NOTE: KIT CONSISTS OF 12 FLAWS ASME SECTION IX APPENDIX VII KIT JOINT DIAMETER THICKNESS SIZE APPROX. UT-302 PLATE SV N/A X UT-304 PLATE SV N/A X UT-352 PLATE DV N/A X UT-354 PLATE DV N/A X UT-103 PIPE SV 2 SCH UT-106 PIPE SV 4 SCH UT-109 PIPE SV 6 SCH UT-115 PIPE SV 12 XS NOTE: KIT CONSISTS OF 24 FLAWS ASME SECTION IX APPENDIX VIII KIT JOINT DIAMETER THICKNESS SIZE APPROX. UT-102 PIPE SV 2 XS 12 5 UT-105 PIPE SV 4 XS UT-108 PIPE SV 6 XS UT-115 PIPE SV 12 XS UT-117 PIPE SV 24 XS 12 X NOTE: KIT CONSISTS OF 22 UNFLAWED UNITS AND 10 FLAWED UNITS API UT-1 KIT JOINT DIAMETER THICKNESS SIZE APPROX. UT-108 PIPE SV 6 XS UT-115 PIPE SV 12 XS UT-302 PLATE SV N/A X UT-354 PLATE DV N/A X NOTE: KIT CONSISTS OF 12 FLAWS #5

7 QUALIFICATION FLAW TABLE FLAW # FLAW JOINT 1 LACK OF FUSION SUB SURFACE SV / DV 2 LACK OF FUSION SURFACE BREAKING SV / DV 3 LACK OF FUSION ROOT SV 4 LACK OF FUSION INTER-PASS SV / DV 5 INCOMPLETE PENETRATION SV 6 INCOMPLETE PENETRATION DV 11 TOE CRACK SV / DV 12 TOE CRACK FILLET 13 ROOT CRACK SV 14 CENTER LINE CRACK - SURFACE SV / DV 15 CENTER LINE CRACK SUB-SURFACE SV / DV 16 TRANSVERSE CRACK SURFACE SV / DV 17 TRANSVERSE CRACK SUB SURFACE SV / DV 18 BASE METAL CRACK SV / DV 33 POROSITY CLUSTER SUB-SURFACE SV / DV 34 POROSITY CLUSTER SUB-SURFACE FILLET 37 SLAG INCLUSION SUB-SURFACE SV / DV 38 SLAG INCLUSION SUB-SURFACE FILLET 39 TUNGSTEN INCLUSION SUB-SURFACE SV / DV 40 TUNGSTEN INCLUSION SUB-SURFACE FILLET 51 UNDERCUT SV / DV 52 UNDERCUT FILLET 56 LAMINATION BASE MATERIAL SV / DV - QUALIFICATION S ARE MANUFACTURED USING CRITICAL TOLERANCE FOR ALL FLAWS AND CONFORMANCE IS GUARANTEED. #6

8 ADVANCED TRAINING S Advanced training specimens are available for UT, RT, MT and PT Advanced training specimens are manufactured using standard tolerance for all flaws and conformance is guaranteed. All specimens contain 3 flaws. All plate specimens have a 12 weld length. Top quality carbon steel material is used for all advanced ultrasonic training specimens. Pipe: A106 Grade B Tube: SA 210-A1 Plate: SA 516 Grade 70 UT TRAINING S JOINT DIAMETER THICKNESS LENGTH APPROX. PIPE SV UT STD 12 4 UT XS 12 5 UT SCH UT STD UT XS UT SCH UT STD UT XS UT SCH UT STD UT XS UT STD UT XS UT STD UT XS UT STD 12 X UT XS 12 X JOINT DIAMETER THICKNESS LENGTH APPROX. TUBE SV UT UT UT UT UT UT UT UT #7

9 JOINT DIAMETER THICKNESS SIZE APPROX. PLATE SV UT-301 N/A X UT-302 N/A X UT-303 N/A X UT-304 N/A X UT-305 N/A X UT-306 N/A X PLATE DV UT-351 N/A X UT-352 N/A X UT-353 N/A X UT-354 N/A X UT-355 N/A X UT-356 N/A X JOINT DIAMETER THICKNESS SIZE APPROX. TEE SV UT-401 N/A X 6 X UT-402 N/A X 8 X UT-403 N/A X 10 X 12 TEE DV UT-451 N/A X 6 X UT-452 N/A X 8 X UT-453 N/A X 10 X Y SV UT-501 N/A X 6 X UT-502 N/A X 8 X UT-503 N/A X 10 X #8

10 JOINT DIAMETER THICKNESS SIZE APPROX. WEIGHT(LBS Y DV UT-551 N/A X 6 X UT-552 N/A X 8 X UT-553 N/A X 10 X LAP FILLET UT-601 N/A PLATES 6 X 12 UT-602 N/A PLATES 8 X 12 UT-603 N/A PLATES 10 X JOINT PENETRATION CARRIER PLATE SIZE APPROX. SIZE NOZZLE SV UT XS X 6 LONG 16 X 16 X UT XS X 6 LONG 20 X 20 X UT XS X 12 LONG 20 X 20 X NOZZLE DV UT XS X 6 LONG 16 X 16 X UT XS X 6 LONG 20 X 20 X UT XS X 12 LONG 20 X 20 X NODE SV UT XS X 6 LONG 16 X 16 X UT XS X 6 LONG 20 X 20 X UT XS X 12 LONG 20 X 20 X NODE DV UT XS X 6 LONG 16 X 16 X UT XS X 6 LONG 20 X 20 X UT XS X 12 LONG 20 X 20 X NOTE: ROLLED PLATE OR PIPE IS AVAILABLE FOR NOZZLE OR NODE CARRIER PLATES. #9

11 UT TRAINING KIT 1 JOINT DIAMETER THICKNESS SIZE APPROX. UT-104 PIPE SV 4 STD UT-108 PIPE SV 6 XS UT-115 PIPE SV 12 XS UT-117 PIPE SV 24 XS 12 X NOTE: KIT CONSISTS OF 12 FLAWS UT TRAINING KIT 2 JOINT DIAMETER THICKNESS SIZE APPROX. UT-302 PLATE SV N/A X UT-305 PLATE SV N/A X UT-352 PLATE DV N/A X UT-355 PLATE DV N/A X NOTE: KIT CONSISTS OF 12 FLAWS UT TRAINING KIT 3 JOINT DIAMETER THICKNESS SIZE APPROX. UT-104 PIPE SV 4 STD UT-108 PIPE SV 6 XS UT-302 PLATE SV N/A X UT-355 PLATE DV N/A X NOTE: KIT CONSISTS OF 12 FLAWS UT TRAINING KIT 4 JOINT DIAMETER THICKNESS SIZE APPROX. UT-402 TEE SV N/A X 8 X UT-452 TEE DV N/A X 8 X UT-502 Y SV N/A X 8 X UT-552 Y DV N/A X 8 X UT-602 LAP FILLET N/A X NOTE: KIT CONSISTS OF 15 FLAWS UT TRAINING KIT 5 JOINT PENETRATION SIZE FLAT CARRIER PLATE SIZE APPROX. UT-652 NOZZLE DV 4 XS X 6 LONG 20 X 20 X UT-652 NOZZLE DV 8 XS X 12 LONG 20 X 20 X UT-602 NODE DV 4 XS X 6 LONG 20 X 20 X UT-602 NODE DV 8 XS X 12 LONG 20 X 20 X NOTE: KIT CONSISTS OF 15 FLAWS #10

12 UT TRAINING FLAW TABLE FLAW # FLAW JOINT 1 LACK OF FUSION SUB SURFACE SV / DV 2 LACK OF FUSION SURFACE BREAKING SV / DV 3 LACK OF FUSION ROOT SV 4 LACK OF FUSION INTER-PASS SV / DV 5 INCOMPLETE PENETRATION SV 6 INCOMPLETE PENETRATION DV 11 TOE CRACK SV / DV 12 TOE CRACK FILLET 13 ROOT CRACK SV 14 CENTER LINE CRACK - SURFACE SV / DV 15 CENTER LINE CRACK SUB-SURFACE SV / DV 16 TRANSVERSE CRACK SURFACE SV / DV 17 TRANSVERSE CRACK SUB SURFACE SV / DV 18 BASE METAL CRACK SV / DV 33 POROSITY CLUSTER SUB-SURFACE SV / DV 34 POROSITY CLUSTER SUB-SURFACE FILLET 37 SLAG INCLUSION SUB-SURFACE SV / DV 38 SLAG INCLUSION SUB-SURFACE FILLET 39 TUNGSTEN INCLUSION SUB-SURFACE SV / DV 40 TUNGSTEN INCLUSION SUB-SURFACE FILLET 51 UNDERCUT SV / DV 52 UNDERCUT FILLET 56 LAMINATION BASE MATERIAL SV / DV -ALL S ARE AVAILABLE IN OTHER MATERIAL GRADES, DIMENSIONS OR JOINT S AS CUSTOM S. PLEASE REQUEST A SPECIFIC QUOTE. #11

13 RT TRAINING S JOINT DIAMETER THICKNESS LENGTH APPROX. PIPE SV RT STD 12 4 RT XS 12 5 RT STD RT XS RT STD RT XS RT STD RT XS RT STD RT STD JOINT DIAMETER THICKNESS LENGTH APPROX. TUBE SV RT RT RT JOINT DIAMETER THICKNESS SIZE APPROX. PLATE SV RT-301 N/A X RT-302 N/A X RT-303 N/A X RT-304 N/A X RT-305 N/A X PLATE DV RT-351 N/A X RT-352 N/A X RT-353 N/A X RT-354 N/A X RT-355 N/A X #12

14 RT TRAINING KIT 1 JOINT DIAMETER THICKNESS SIZE APPROX. RT-101 PIPE SV 2 STD 12 4 RT-102 PIPE SV 2 XS 12 5 RT-104 PIPE SV 4 STD RT-105 PIPE SV 4 XS RT-107 PIPE SV 6 STD RT-110 PIPE SV 8 STD NOTE: KIT CONSISTS OF 18 FLAWS RT TRAINING KIT 2 JOINT DIAMETER THICKNESS SIZE APPROX. RT-302 PLATE SV N/A X RT-305 PLATE SV N/A X RT-352 PLATE DV N/A X RT-355 PLATE DV N/A X NOTE: KIT CONSISTS OF 12 FLAWS RT TRAINING FLAW TABLE FLAW # FLAW JOINT 5 INCOMPLETE PENETRATION SV 6 INCOMPLETE PENETRATION DV 11 TOE CRACK SV / DV 13 ROOT CRACK SV 14 CENTER LINE CRACK - SURFACE SV /DV 15 CENTER LINE CRACK SUB-SURFACE SV / DV 33 POROSITY CLUSTER SUB-SURFACE SV / DV 37 SLAG INCLUSION SUB-SURFACE SV / DV 39 TUNGSTEN INCLUSION SUB-SURFACE SV / DV 53 MIS-ALIGNMENT SV 54 EXCESS PENETRATION - ROOT SV 55 ROOT CONCAVITY SV -ALL S ARE AVAILABLE IN OTHER MATERIAL GRADES, DIMENSIONS OR JOINT S AS CUSTOM S. PLEASE REQUEST A SPECIFIC QUOTE. #13

15 MT AND PT TRAINING S MT and PT Specimens are available in either Carbon Steel or 304 Stainless Steel. JOINT DIAMETER THICKNESS LENGTH APPROX. PIPE SV MT/PT STD 12 4 MT/PT STD MT/PT STD MT/PT STD MT/PT STD MT/PT STD JOINT DIAMETER THICKNESS LENGTH APPROX. TUBE SV MT/PT MT/PT MT/PT JOINT DIAMETER THICKNESS SIZE APPROX. PLATE SV MT/PT-301 N/A X MT/PT-302 N/A X 12 PLATE DV MT/PT-351 N/A X 12 MT/PT-352 N/A X JOINT DIAMETER THICKNESS SIZE APPROX. TEE SV MT/PT-401 N/A X 6 X TEE DV MT/PT-451 N/A X 6 X #14

16 JOINT DIAMETER THICKNESS SIZE APPROX. Y SV MT/PT-501 N/A X 6 X Y DV MT/PT-551 N/A X 6 X LAP FILLET MT/PT-601 N/A PLATES 6 X MT/PT TRAINING KIT 1 JOINT DIAMETER THICKNESS SIZE APPROX. MT/PT-104 PIPE SV 4 STD MT/PT-107 PIPE SV 6 STD MT/PT-302 PLATE SV N/A X MT/PT-352 PLATE DV N/A X NOTE: KIT CONSISTS OF 12 FLAWS MT/PT TRAINING KIT 2 JOINT DIAMETER THICKNESS SIZE APPROX. MT/PT-401 TEE SV N/A X 6 X MT/PT-451 TEE DV N/A X 6 X MT/PT-501 Y SV N/A X 6 X MT/PT-551 Y DV N/A X 6 X MT/PT-601 LAP FILLET N/A X12 53 NOTE: KIT CONSISTS OF 15 FLAWS MT AND PT TRAINING FLAW TABLE FLAW # FLAW JOINT 2 LACK OF FUSION SURFACE BREAKING SV / DV 3 LACK OF FUSION ROOT SV 5 INCOMPLETE PENETRATION SV 11 TOE CRACK SV / DV #15

17 FLAW # FLAW JOINT 12 TOE CRACK FILLET 13 ROOT CRACK SV 14 CENTER LINE CRACK - SURFACE SV / DV 16 TRANSVERSE CRACK SURFACE SV / DV 18 BASE METAL CRACK SV / DV 31 POROSITY CLUSTER- SURFACE SV / DV 32 POROSITY CLUSTER- SURFACE FILLET -ALL S ARE AVAILABLE IN OTHER MATERIAL GRADES, DIMENSIONS OR JOINT S AS CUSTOM S. PLEASE REQUEST A SPECIFIC QUOTE. CALIBRATION STANDARDS Calibration standards and reference blocks are designed and manufactured in accordance with your specific code requirements. Capabilities Include: EDM notching Conventional machining Exotic materials Complex geometries Rolling / forming / bending Corrosion resistant overlay or cladding GTAW, SMAW, GMAW, FCAW and SAW processes PWHT NDE All calibration standards and reference blocks are supplied with a CAD drawing and a material test report for all fully traceable materials used. #16

18 CUSTOM FLAWED S Any specimen required which is not included in our current product line can be designed manufactured as a custom specimen. Their applications included: Performance and procedure demonstration in accordance with ASME, API and AWS. In-Service cracking. Production mock-ups. Custom flawed specimens can be manufactured from ASME Material Groupings P1 to P45 for any application required: Piping Plate Tubing Nozzles Castings Forgings Pressure Vessels Capabilities Include: DMWs Corrosion resistant overlay or cladding Butter layers Machining of complex joint configurations GTAW, SMAW, GMAW, FCAW and SAW processes PWHT NDE Note: Customer supplied material can also be used. #17

19 SPECIFICATIONS CODE QUALIFICATION AND ADVANCED TRAINING S MATERIALS Code Qualification Specimens and Advanced Training Specimens are manufactured using top quality Carbon Steel and 304 Stainless Steel. FLAW DIMENSION TOLERANCE Tolerance Level Flaw Height Flaw Length Standard +/- 1mm (0.039 ) +/- 2mm (0.079 ) Critical +/- 0.5mm (0.020 ) +/- 1mm (0.039 ) SURFACE FINISH Base materials are buffed smooth leaving mill scale intact. Welds are left in the as-welded condition. Additional machining, grinding or polishing available upon request. CORROSION PROTECTION A clear corrosion resistant coating is applied to completed specimens. DOCUMENTATION PROVIDED CAD drawings - As Built Certificate of Conformance MTRs for base materials MTRs for filler metals NDE reports as required #18

20