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REFERENCE BLOCKSFOR NDTExperts in manufacturing customisedblocks with induced flaws

TECHNO LOGY CENTRE

Reference Blocks for NDTCONTENTSINTRODUCTION4TRAINING KITS5FLAWED SPECIMEN TESTS8STANDARD FLAWED SPECIMENS11CUSTOM SPECIMENSAND MOCK UPS21ASME XI APPENDIX VII SET24ASME XI APPENDIX VIII SET25DISSIMILAR WELDS26BEND TEST27BOILER TUBES28CRACK SIZING BARS29CASTING AND FORGING FLAWS30STANDARD UT CALIBRATIONBLOCKS31PDI REFERENCE BLOCKS33CUSTOM REFERENCE BLOCKS34CORROSION AND EROSION35NON-DESTRUCTIVE TEST ADDITIVEMANUFACTURING BLOCKS FORAPPLICATION OF RADIOGRAPHYAND ULTRASOUND TECHNIQUES363

IDONIAL Technology CentreINTRODUCTIONIDONIAL was established in 2019 as a result of the merger of the ITMA and PRODINTEC centers with 28 and 14 years ofexperience respectively, which have opted to join efforts to address new challenges and provide our customers withtailor-made solutions related to the development of materials, advanced manufacturing and the digital industry throughtechnological development and innovation.For this purpose, the centre has a wide technological offer oriented to the needs of companies applicable to a wide rangeof industrial sectors and with an expert and multidisciplinary team with an interest in development and innovation.Steel andmetallic alloysBiofabricationAdditiveManufacturingDigital IndustrySmart products andactive materialsRefractories,ceramics andraw materialsNumericalsimulationWeldingand joiningtechnologiesSurfaces andcoatingsIDONIAL’s key lines of workOur experience in research and development in the field of steel and metallic alloys together with welding and joiningtechnologies makes IDONIAL a reference center in provides a service for manufacturing of reference blocks for NonDestructive Tests, with induced defects.Flawed specimens are manufactured through a wide set of techniques available at IDONIAL workshop and labs, includingmicromachining, EDM or controlling welding parameters. Size and location of each flaw is made and then supplied withdocumentation with all details for customers.4

Reference Blocks for NDTTRAINING KITSIDONIAL is providing a set of reference blocks with different weld flaws, for flaw detection, interpretation andsizing by NDT inspection agencies for training purposes.RECOMMENDED FORD Introduction to weld flaws. Detection, interpretation and sizing.KIT CONTENTSD 10 miniature flawed specimens, each one with oneflawD Flaw location detailsD Testing and acceptance criteriaD Macro sectionsRELEVANT FOR THE FOLLOWING NDTDDDDDUltrasonic, TOFD and Phased Array testingMagnetic particle testingPenetrant testingVisual testingRadiographic testingMATERIALSD Steels: Carbon, C-Mn Structural, High T-P, Cr-Mn,Cr-Mo-V, Corrosion and Wear resistant, CryogenicSteels D Stainless SteelD CastingsD Aluminium and light alloysKits are sent in a durable case to avoid failures during delivery.KIT TYPES AND CONTENTSDEMONSTRATION KIT (IT1319DK) - 13 KGThe 1 tee and 9 plate specimens are a variety of piecescarefully selected from each of the other kits in order toprovide an overview of flaw types and their detection using various non-destructive testing techniques.ULTRASONIC KIT (IT1219) - 12 KGThe 1 tee and 9 plate specimens contain a selection ofcommonly occurring surface-breaking and weld-bodyflaws.MAGNETIC PARTICLE (IT1237M) & PENETRANT KIT(IT1237P) - 12 KGThe 3 tee and 7 plate specimens contain a selection ofcommonly occurring surface-breaking flaws.VISUAL KIT (IT1237V) - 12 KGThe 3 tee and 7 plate specimens contain a selection ofcommonly occurring visual welding flaws and irregularities.RADIOGRAPHIC KIT (IT1219V) - 12 KGThe 1 tee and 9 plate specimens contain a selection ofcommonly occurring surface-breaking and weld-bodyflaws.WELD FLAW IDENTIFICATION KIT (IT730ID) - 7 KGContains 30 macro sections showing flaws in cross section.5

IDONIAL Technology CentreFLAWS IN EACH KITAcronymName1MT KITPT KITTOE CRACKMTPT1ATOE CRACKMTPT1BTOE CRACKMTPT1CTOE CRACK (FULL PEN)2ROOT CRACK3SIDE WALL CRACK4CENTRE LINE CRACK SURFACE5CENTRE LINE CRACK WELD BODY6POROSITY WELD BODY6APOROSITY SURFACE BREAKING76PieceVT KITDEMOKITUT KITDMUTRT KITUTMTPTMTPTDMUTRTUTDMUTRTSLAGDMUTRT8LACK OF SIDE WALL FUSIONDMUT9LACK OF ROOT FUSIONMTMTPTPTVT

Reference Blocks for NDTFLAWS IN EACH KITVT KITDEMOKITROOT CONCAVITYVTDM11INCOMPLETE ROOTPENETRATION SVVT12OVER PENETRATIONVT13INCOMPLETE ROOTPENETRATION DV14LAMINATIONMTPT14ALAMINATION WELDPREPARATIONMTPT14BLAMINATION15IRREGULAR ROOT PENETRATIONVT16WELD SPATTERVT17UNDERCUTVT18EXCESS CAPVT21CRACK SUBSURFACE WELD CAPREMOVED22CONCAVE CAPVT23UNEVEN LEG LENGTHVTAcronymName10PieceMT KITPT KITUT KITRT KITRTUTRTRTUTUTMTPTDMRTRTDMRTDMDM7

IDONIAL Technology CentreFLAWED SPECIMEN TESTSManufacturing of a set of reference blocks for practicaltraining using different NDT techniques is provided byIDONIAL. The aim is to facilitate practical training andimprove skills on flaw detection, sizing and interpretation.Sets are delivered with specimens including one or twoflaws, the best approach to let operators acquire such desired skills using NDT.RECOMMENDED FORD Introduction to basic flaw detection, sizing and interpretationD Analysing weld geometriesSET CONTENTSDDDDD10 Small flawed specimensEach specimen containing 1 or 2 flawsFlaw location detailsTesting and acceptance criteriaCertificate of conformanceUT/TOFD/Phase Array SetDescriptionThicknessWidth1 Plates110202 Plates110203 Plates110204 Plates1,51020MT/PT & VT SetDescriptionThicknessWidth7 Plates0,610203 Plates0,61020RELEVANT FOR THE FOLLOWING NDTDDDDDUltrasonic, TOFD and Phased Array testingMagnetic particle testingPenetrant testingVisual testingRadiographic testingDimensions above in cm.Sets are sent in a durable case to avoid failures duringdelivery.8LengthLengthRT SetDescriptionThicknessWidthLength4 Plates110204 Plates1,510202 Plates11020

Reference Blocks for NDTDIMENSIONS OF INDIVIDUAL SPECIMENS T/PT & VTRT & TERIALSCARBON STEELSTAINLESS sYesSET TYPESPECIMEN DETAILSDescriptionDimensions (in cms)Flaw length range0.3 to 6Flaw height range0.05 to 1.5Flaw size tolerance 0.3Specimen size tolerance 15%Specimen thickness tolerance 10%Specimen diameter tolerance 10%9

IDONIAL Technology CentreFLAW TYPES Planar Flaws (Toe Crack, TransverseCrack, Root Crack, Centre-line Crack,Side Wall Crack, Lack of side Wall fusion, lamination, crater crack). Root Conditions (Incomplete penetration, Irregular root penetration, rootconcavity, lack of root fusion, burnthrough, over penetration). Volumetric Flaws (Porosity, Surfaceporosity, Slag, Tungsten Inc). Other Weld conditions (Excess cap,Weld spatter, Mismatch, Cold lap, Concave cap, undercut, Incomplete Weldfill).10

Reference Blocks for NDTSTANDARD FLAWED SPECIMENSThe design phase and all the manufacturing processes involved in the development of Standard Flawed Specimensare being done following the requirements of all known internationally recognised Qualification Programme. Thus,IDONIAL provides customers with reliable specimens fortraining and qualification on weld flaw detection, sizingand interpretation. Weld sizes and geometries are representing the most common settings.IDONIAL provides either set of flawed specimens or individually.INDIVIDUAL SPECIMENSContain three different flaw types. All of them are differentin size, tags and are supported with NDT reports and acceptance/rejection criteria.RECOMMENDED SETSIDONIAL can arrange a selection of specimens representing the above mentioned settings, including all flaws,with 1-5 flaws per unit and with a total weld length of over350 cm.CUSTOM SETSCustomers can define the sets following the needs coming from recognised qualification schemes, such as API,ACCP, etc.11

IDONIAL Technology CentreULTRASONIC SPECIMENSINDIVIDUAL SPECIMENSSpecimen typePart NumberIT-UT-14PlateWeld preparation typeApprox dimensions (cms)DiameterThicknessSizeApprox -19–330x4431IT-UT-15IT-UT-20PipeIT-UT-2181.230 long7151.230 long14IT-UT-22152.530 long28IT-UT-23201.230 long18IT-UT-24202.530 long37IT-UT-25301.230 long27IT-UT-26302.530 zzleIT-UT-33Penetration (Diameter x Thickness)10x1.2Carrier plate(L x W x .250x50x2.54350x50x2.554IT-UT-3620x1.2NodeStub (Diameter x Thickness)Carrier plate(L x W x 2

Reference Blocks for NDTFLAW TYPES for UT Specimens Planar Flaws: Toe Crack, TransverseCrack, Root Crack, Centre-line Crack,Side Wall Crack, Lack of side Wall fusion, lamination. Root Conditions: Incomplete penetration (SV), incomplete penetration (DV),lack of root fusion. Volumetric Flaws: Slag.RECOMMENDED SETSSpecimen TypesSet 2IT-UT-39ContentsApprox Weight (Kg)3 x UC-151 x UC-163 x UC-17Specimen TypesSet 5IT-UT-422292 x UC-20"2 x UC-372 x UC-381931 x UC-24Set 7IT-UT-441 x UC-161 x UC-191 x UC-251 x UC-241 x UC-261 x UC-254 x UC-271 x UC-262 x UC-282 x UC-292 x UC-302291931 x UC-211 x UC-22Set 4IT-UT-412 x UC-342 x UC-36Set 6IT-UT-433 x UC-191 x UC-23Approx Weight (Kg)2 x UC-332 x UC-352 x UC-18Set 3IT-UT-40Contents2112111 x UC-271 x UC-301 x UC-3113

IDONIAL Technology CentreMAGNETIC AND PENETRANT SPECIMENSINDIVIDUAL SPECIMENSSpecimen typePart NumberWeld preparation typeApprox dimensions (cms)DiameterThicknessSizeApprox weigth(Kg)–130 x 2058120 Long415120 0 Long10IT-MS-0530120 Long22–115 x 15 x 307–115 x 15 x 307TeeIT-MS-06YIT-MS-07NozzlePenetration (Diameter x Thickness)Carrier plate (L x W x T)IT-MS-0810 x 140 x 40 x 1.217IT-MS-0920 x 140 x 40 x 1.222NodeStub (Diameter x Thickness)Carrier plate (L x W x T)IT-MS-1020 x 140 x 40 x 1.232IT-MS-1125 x 140 x 40 x 1.237IT-PS-01–130 x 205IT-PS-028120 Long4IT-PS-0315120 Long8IT-PS-0420120 Long10IT-PS-0530120 Long22IT-PS-06–115 x 15 x 307IT-PS-07–115 x 15 x 307Penetration (Diameter x Thickness)Carrier plate (L x W x T)IT-PS-0810 x 140 x 40 x 1.217IT-PS-0920 x 140 x 40 x 1.222Stub (Diameter x Thickness)Carrier plate (L x W x T)IT-PS-1020 x 140 x 40 x 1.232IT-PS-1125 x 140 x 40 x 1.23714

Reference Blocks for NDTFLAW TYPES for MT PT Specimens Planar Flaws: Toe Crack, TransverseCrack, Root Crack, Centre-line Cracksurface, Side Wall Crack, Crater Crack. Root Conditions: Lack of root fusion.HAZ Crack. Volumetric Flaws: Surface Porosity.RECOMMENDED SETSIT-MS-12IT-PS-12MagneticPenetrant1 x IT-MS-011 x IT-PS-012 x IT-MS-032 x IT-PS-032 x IT-MS-052 x IT-PS-051 x IT-MS-061 x IT-PS-061 x IT-MS-071 x IT-PS-07Approx Weight (kgs)7015

IDONIAL Technology CentreVISUAL SPECIMENSINDIVIDUAL SPECIMENSSpecimen typePart NumberApprox weigth(Kg)Approx dimensions (cms)Weld preparation typeDiameterThicknessSize–130 X 2058120 Long4IT-VS-0315120 Long8IT-VS-0420120 Long10IT-VS-0530120 Long22–115 x 15 x 307–115 x 15 x zzlePenetration (Diameter x Thickness)Carrier plate (L x W x T)IT-VS-0810 x 140 x 40 x 1.217IT-VS-0920 x 140 x 40 x 1.222Stub (Diameter x Thickness)Carrier plate (L x W x T)IT-VS-1020 x 140 x 40 x 1.232IT-VS-1125 x 140 x 40 x 1.237Node16

Reference Blocks for NDTFLAW TYPES for VT Specimens Planar Flaws: Crater Crack. Root Conditions: Lack of Root fusion,Root concavity, Excess penetration, Incomplete penetration, Irregular penetration. Volumetric Flaws: Surface Porosity. Other Weld conditions: Undercut, Excessive Cap, Concave Cap, Weld Spatter.RECOMMENDED SETSIT-VS-122 x IT-VS-012 x IT-VS-031 x IT-VS-05Approx Weight (kgs)451 x IT-VS-061 x IT-VS-0717

IDONIAL Technology CentreSECURE SPECIMENSSpecimens are similar to the ones shown in the individual section, by delivery is different, in order to separate samplesfrom reports.RADIOGRAPHIC SPECIMENSINDIVIDUAL SPECIMENSSpecimen typePart NumberIT-RS-01PlateIT-RS-02Weld preparation typeApprox dimensions (cms)DiameterThicknessSizeApprox weigth(Kg)–0.630 x 203–130 x 205IT-RS-03–1.530 x 207IT-RS-04–230 x 209IT-RS-05–2.530 x 2013IT-RS-06–330 x 2014–0.630 x 203IT-RS-08IT-RS-07Plate–130 x 205IT-RS-09–1.530 x 207IT-RS-10–230 x 209IT-RS-11–2.530 x 2013IT-RS-12–330 x 20142.50.320 Long0.3IT-RS-1450.520 Long1IT-RS-1580.620 Long2IT-RS-13PipeIT-RS-16150.620 Long4IT-RS-17151.220 Long8IT-RS-18201.220 Long11IT-RS-1920220 Long18IT-RS-20301.220 Long17IT-RS-21302.520 Long3318