WIXLIB

SONASPECTIONEXPERTS INMANUFACTURINGFLAWED SPECIMENSAND MOCK-UPSImproving the world through engineeringManufactured in the UK & USA

INTRODUCTIONSonaspection is the longest established manufacturer of flawed specimens in the Non-Destructive Testing(NDT) industry, starting in 1980 and have developed many well recognised ‘industry standard’ flawmanufacture and implanting techniques.Having led the field in flaw manufacture, Sonaspection are internationally accepted as the standard for NDTtraining and qualification and have sold their products to all the major performance demonstration, trainingand qualification centres around the world. Sonaspection’s samples are also used in procedural and equipmentdevelopment in NDT.High quality flaws are achieved by a combination of Sonaspection’s first class workmanship and craft,a unique blend of welding and NDT skills, plus a full understanding of the product.Sonaspection’s flawed specimens contain purposely induced real flaws which are accurately sized andlocated. Each specimen is supplied with documentation detailing flaw types, sizes and location.CONTENTSEducational kitsFlawed specimen setsStandard specimen setsUltrasonic specimensMagnetic and penetrant specimensVisual specimensRadiographic specimensStandard specificationsCustom specimens and mock upsASME XI appendix setsDissimilar weldsBoiler tubes and Sizing barsCasting and forging flawsFlawed forging specimensStandard UT calibration blocksPDI reference blocksCustom reference blocksCorrosion and erosionPage 3-4Page 5-6Page 7Page 8Page 9Page 10Page 11Page 12Page 13-16Page 17Page 19Page 20Page 21Page 22Page 23-24Page 25Page 26Page 27LOCATIONSSonaspection benefit from having manufacturing facilities in both Lancaster, UK and Concord, North Carolina,USA, providing increased capacity and flexibility to meet the needs of our customers around the world.W sonaspection.comUK (Head office)10 WoodgateWhite Lund Industrial EstateLancasterLA3 3PQUnited KingdomUSA6851 Belt RoadConcordNC 28027USAT 44 (0)1524 34991E sonaspection@imeche.orgT 1 704-262-3387E sonaspection usa@imeche.org2

EDUCATIONAL KITSA set of miniature welds, macro sections and photo-radiographs to demonstrate the principles of flawdetection, flaw interpretation and basic sizing.RECOMMENDED FOR t *OUSPEVDUJPO UP XFME nBXT t %FNPOTUSBUF QSJODJQMFT PG nBX EFUFDUJPO t %FNPOTUSBUF UZQJDBM nBX SFTQPOTFT t %FNPOTUSBUF QSJODJQMFT PG nBX JOUFSQSFUBUJPO t #BTJD nBX TJ[JOHMETHODS t %FNPOTUSBUJPO LJU DPWFSJOH BMM NFUIPET t 6MUSBTPOJD UFTUJOH t .BHOFUJD QBSUJDMF UFTUJOH t 1FOFUSBOU UFTUJOH t 7JTVBM UFTUJOH t 3BEJPHSBQIJD UFTUJOHKIT CONTENTS t NJOJBUVSF nBXFE TQFDJNFOT FBDI implanted with one flaw t 'MBX MPDBUJPO EFUBJMT t 5FTUJOH BOE BDDFQUBODF DSJUFSJB t 1IPUP SBEJPHSBQIT XIFSF BQQMJDBCMF for each specimen t .BDSP TFDUJPOT t .BHOJGZJOH HMBTT t FSUJmDBUF PG DPOGPSNBODFMATERIALS t BSCPO 4UFFM t 4UBJOMFTT 4UFFM t "MVNJOJVNKits are presented in a durable polypropylene casewith high density black molded inserts.KIT TYPES AND CONTENTSDEMONSTRATION KIT (KTCS91) - 13 KG/29 lbsThe 1 tee and 9 plate specimens are a variety ofpieces carefully selected from each of the otherkits in order to provide an overview of flaw typesand their detection using various non-destructivetesting techniques.ULTRASONIC KIT (KTCS86) - 12 KG/26 lbsThe 1 tee and 9 plate specimens contain aselection of commonly occurring surface-breakingand weld-body flaws.VISUAL KIT (KTCS87) - 12 KG/26 lbsThe 3 tee and 7 plate specimens contain a selectionof commonly occurring visual welding flaws andirregularities.MAGNETIC PARTICLE (KTCS88) & PENETRANT KIT(KTCS89) - 12 KG/26 lbsThe 3 tee and 7 plate specimens contain a selectionof commonly occurring surface-breaking flaws.RADIOGRAPHIC KIT (KTCS90) - 12 KG/26 lbsThe 1 tee and 9 plate specimens contain aselection of commonly occurring surface-breakingand weld-body flaws.WELD FLAW IDENTIFICATION KIT (KTCS92)- 7 KG/15 lbsContains 30 macro sections showing flaws in crosssection.Image: Visiual KitThis kit contains 10 macro sections of various flaws3

EACH KIT CONTAINS THE FOLLOWING FLAWS AS INDICATEDMT KitPT KitVT Kit Demo Kit UT KitDMRT KitWeld IDKitDef 1Toe CrackMTPTWDef 1AToe CrackMTPTDef 1BToe CrackMTPTDef 1CToe Crack (Full Pen)Def 2Root CrackMTPTDef 3Side Wall CrackDef 4Centre Line Crack SurfaceMTPTDef 5Centre Line Crack Weld BodyDef 6Porosity Weld BodyDef 6APorosity Surface BreakingDef 7SlagDef 8Lack of Side Wall FusionDef 9Lack of Root FusionDef 10Root ConcavityVTDef 11Incomplete Root Penetration SVVTDef 12Over PenetrationVTDef 13Incomplete Root Penetration DVDef 14LaminationMTPTWDef 14ALamination Weld PreparationMTPTWDef 14BLaminationDef 15Irregular Root PenetrationVTDef 16Weld SpatterVTDef 17UndercutVTDef 18Excess CapVTDef 19Mismatch PlateDef 20Misalignment PlateDef 21Crack Surface BreakingDef 21ACrack Subsurface Cap RemovedDef 22Concave CapDef 22AIncomplete Weld FillDef 23Uneven Leg LengthsDef 26Lack of Inter Run FusionWDef PTDMMTWVTWWVT4W

FLAWED SPECIMEN SETSBASIC WELD FLAW EVALUATIONA set of small lightweight and convenient to handle welds specimens, each containing either one or two flawswith a minimum of 18 flaws per set. The sets are designed for practical training, to provide an introduction toflaw detection, sizing and interpretation.RECOMMENDED FOR t *OUSPEVDUJPO UP CBTJD nBX EFUFDUJPO t *OUSPEVDUJPO UP CBTJD nBX TJ[JOH t *OUSPEVDUJPO UP CBTJD nBX JOUFSQSFUBUJPO t 4JNQMF XFME HFPNFUSJFT.5 15 75 4&5 0/5&/54DescriptionSET CONTENTS t TNBMM nBXFE TQFDJNFOT t "WFSBHF SFBM nBXT t 'MBX MPDBUJPO EFUBJMT t 5FTUJOH BOE BDDFQUBODF DSJUFSJB t FSUJmDBUF PG DPOGPSNBODFThickness7 Plates0.6 3 Tees0.6 WidthLength10 (4)20 (8)10 (4)20 (8)WidthLength10 (4)20 (8)10 (4)20 (8)10 (4)20 (8)RT SET CONTENTSDescriptionMETHODS t 6MUSBTPOJD UFTUJOH '4 4 ,( MCT t .BHOFUJD 1BSUJDMF '4 4 ,( MCT t 1FOFUSBOU 5FTUJOH '4 4 ,( MCT t 7JTVBM 5FTUJOH '4 4 ,( MCT t 3BEJPHSBQIJD 5FTUJOH '4 4 ,( MCTThickness4 Plates14 Plates1.52 Pipes1 UT SET CONTENTSDescriptionWidthLength1 Tee1 10 (4)20 (8)3 Plates1 10 (4)20 (8)4 Plates1.510 (4)20 (8)2 Pipes110 (4)20 (8)Thickness Dimensions above are in cm (inch)Each set is presented in a durable polypropylene case with high density black molded inserts.INDIVIDUAL SPECIMENS DIMENSIONS: CM (INCH)SpecimenThickness8JEUI %JB8JEUI %JBLength.5 15 7535 65Pipe (SV)1-10 (4)20 (8)NoYesPipe (SV)1.8 -15 (6)20 (8)NoYesTee (SV)0.6 10 (4)/ "20 (8)YesNoTee (SV)110 (4)/ "20 (8)NoYesPlate0.610 (4)/ "20 (8)YesNoPlate110 (4)NA20 (8)NoYesPlate1.5 10 (4)NA20 (8)NoYesPlate2.5 (1)15 (6)NA25 (10)NoYes 5

MATERIALSSPECIMEN DETAILSCarbon SteelStainless SteelDescriptionAluminiumSet TypeDimensions: cm (inch)to 1.8Flaw length range10.3 to 0.6UltrasonicYesYesYesFlaw height rangeVisualYes--Flaw size toleranceMagneticYes--Specimen size tolerance or - 15%PenetrantYesYesYesSpecimen thickness tolerance or - 10%RadiographicYesYesYesSpecimen diameter tolerance or - 10% or - 0.3 FLAW TABLEPLANAR FLAWSROOTCONDITIONSVOLUMETRICFLAWSOTHER WELDCONDITIONSToe crackSide wall crackIncomplete penetrationPorosityExcess capTransverse crackLack of sidewall fusionIrregular rootpenetrationSurface porosityWeld spatterTransverse crack(Embedded)Centre-line crackweld bodyRoot concavitySlagMismatchRoot crackLaminationIncomplete penetrationTungsten IncCold lapCentre-linecrack surfaceCrater crackLack of root fusionConcave capBurn throughUndercutOver penetrationIncomplete weld fill(Surface breaking)6

STANDARD FLAWEDSPECIMENSADVANCED WELD FLAW EVALUATIONStandard Flawed Specimens are designed and manufactured to meet the requirements of all knowninternationally recognised Qualification Programme.t "EWBODFE USBJOJOH BOE QSBDUJDF QSJPS UP RVBMJmDBUJPOT PO - Flaw detection- Flaw sizing- Flaw interpretationt 3FBMJTUJD TJ[F XFMETt PNNPO XFME HFPNFUSJFTSonaspection flawed specimens are avaliable either individually or in sets.INDIVIDUAL SPECIMENSContain three different flaw types and are: t "MM EJGGFSFOU TJ[FT t 6OJRVFMZ OVNCFSFE t 4VQQMJFE XJUI /%5 SFQPSUT t 4VQQMJFE XJUI BDDFQUBODF SFKFDUJPO DSJUFSJBRECOMMENDED SETS t POUBJO B TFMFDUJPO PG JOEJWJEVBM TQFDJNFOT as above, with an average of three flaws perspecimen t POUBJO BU MFBTU POF FYBNQMF PG FBDI nBX type listed in the flaw table t POUBJO B NJOJNVN UPUBM XFME MFOHUI PG 360cm (144”)CUSTOM SETSManufactured specifically for recognised qualification schemes - for example ASNT, ACCP and APIFor Level II training, practice and qualification i.e. ACCP, SNT-TC-IA, BS EN ISO 9712, API and others.STANDARD FLAWED SPECIMEN7

ULTRASONIC SPECIMENSINDIVIDUAL SPECIMENSSpecimen TypeFLAW TABLEWeld Preparation TypePart -33UC-34Diameter prox Dimensions:cm (inch)(or nearest commercial size)/ "/ "/ "0.6 1.2 2.5 (1)30x30 (12x12)30x30 (12x12)30x40 (12x16)4 (9)8 (18)23 (51)/ "/ "/ "8 (3)15 (6)15 (6)20 (8)20 (8)30 (12)30 (12)/ "/ "2 2.5 (1)3 (1 )1.2 1.2 2.5 (1)1.2 2.5 (1)1.2 2.5 (1)2 2.5 (1)30x30 (12x12)30x40 (12x16)30x44 (12x17 )30 (12) long30 (12) long30 (12) long30 (12) long30 (12) long30 (12) long30 (12) long15x15x30 (6x6x12)20x20x30 (8x8x12)14 (31)23 (51)31 (68)7 (15)14 (30)28 (62)18 (39)37 (82)27 (59)56 (122)14 (31)23 (51)/ "/ "/ "/ "2.5 (1)3 (1 )2.5 (1)3 (1 )20x20x30 (8x8x12)22x22x30 (9x9x12)20x20x30 (8x8x12)22x22x30 (9x9x12)23 (51)31 (68)23 (51)31 (68)Carrier Plate DimensionsL x W x Thickness10x1.2 (4x )20x1.2 (8x )50x50x2.5 (20x20x1)50x50x2.5 (20x20x1)43 (94)54 (120)10x1.2 (4x )20x1.2 (8x )50x50x2.5 (20x20x1)50x50x2.5 (20x20x1)43 (94)54 (120)StubDia x ThickCarrier Plate DimensionsL x W x Thickness20x2 (8x )25x2 (10x )Toe crackRoot crackSide ration(DV)PorosityLack ofroot fusionPenetrationDia x Thick NodeSizeApproxWeightkg (lb)50x50x2.5 (20x20x1) 75 (165)50x50x2.5 (20x20x1) 103 (228)LaminationLack of sidewall fusionSlagRECOMMENDED SETSSpecimen TypesContentsApproxWeight kg (lb)229 (505)Set 2UC-393 x UC-151 x UC-163 x UC-172 x UC-183 x UC-19Set 3UC-402 x UC-201 x UC-211 x UC-221 x UC-231 x UC-241 x UC-251 x UC-26193 (426)4 x UC-272 x UC-282 x UC-292 x UC-30211 (464)Set 4UC-418Specimen TypesContentsSet 5UC-422 x UC-332 x UC-342 x UC-352 x UC-36Set 6UC-432 x UC-372 x UC-38Set 7UC-441 x UC-161 x UC-191 x UC-241 x UC-251 x UC-261 x UC-271 x UC-301 x UC-31ApproxWeight kg (lb)412 (907)357 (786)242 (532)

MAGNETIC AND PENETRANT SPECIMENSFLAW TABLEINDIVIDUAL SPECIMENSSpecimen TypeWeld Preparation TypeApprox Dimensions:cm (inch)Diameter ThicknessPart No.Toe crackSizeApproxWeightkg (lb)(or nearest commercial size)PlateMC-01MC-02 PipeMC-03MC-04MC-05/ "1 30x20 (12x12)5 (10)Root crack8 (3)15 (6)20 (8)30 (12)1111 20 (8) long20 (8) long20 (8) long20 (8) long4 (9)8 (17)10 (21)22 (48)Centreline cracksurface TeeMC-06/ "1 15x15x30 (6x6x12)7 (15)/ "1 15x15x30 (6x6x12)7 PC-03PC-04PC-05PenetrationDia x ThickCarrier Plate DimensionsL x W x Thickness 10x1 (4x )20x1 (8x )40x40x1.2 (16x16x )40x40x1.2 (16x16x )StubDia x ThickCarrier Plate DimensionsL x W x Thickness20x1 (8x )25x1 (10x )40x40x1.2 (16x16x )40x40x1.2 (16x16x )32 (70)37 (81) 17 (38)22 (49)/ "1 30x20 (12x12)5 (10)Pipe8 (3)15 (6)20 (8)30 (12)1111 20 (8) long20 (8) long20 (8) long20 (8) long4 (9)8 (17)10 (21)22 (48)/ "1 15x15x30 (6x6x12)7 (15)/ "1 15x15x30 (6x6x12)7 (15) ationDia x ThickCarrier Plate DimensionsL x W x Thickness10x1 (4x )20x1 (8x )40x40x1.2 (16x16x )40x40x1.2 (16x16x )StubDia x ThickCarrier Plate DimensionsL x W x Thickness20x1 (8x )25x1 (10x )40x40x1.2 (16x16x )40x40x1.2 (16x16x )17 (38)22 (49)32 (70)37 (81)RECOMMENDED SETMC-12Magnetic1 x MC-012 x MC-032 x MC-051 x MC-061 x MC-079PC-12Penetrant1 x PC-012 x PC-032 x PC-051 x PC-061 x PC-07SurfaceporosityLack ofroot fusionHAZ crackPlate Transversecrack(surfacebreaking)ApproxWeight kg (lb)70 (155)Cratercrack