General workshop instructions

520530 - 8.0

4 Inspection and final manufacturing

4.1 Welding NDT (non-destructive testing)
4.1.1 Definition and basis for NDT
NDT includes the following kinds of test: Acoustic emission testing, eddy current testing, infrared
thermographic testing, leak testing (hyd. press. test excluded), strain gauge testing, PT, MT, RT, UT and
VT (direct unaided visual test and visual tests carried out during the application of another NDT method
are excluded) See EN ISO 9712:2013 (Non-destructive testing – Qualification and certification of NDT
personnel).
Non-destructive testing must be carried out in accordance with an internationally recognised standard.
For further instructions, see EN ISO 17635 (Non-destructive testing of welds – General rules for metallic
materials). It must be noted that the term VT is used only in connection with inspection of welding work.
4.1.2 Time of inspection
The inspection of welds must only be started after termination of any thermal straightening or heat
treatment. Where conditions dictate, inspection can be permitted before the final heat treatment; but
permission must be obtained from FLSmidth37).
Welds and materials with a latent possibility for the formation of hydrogen cracks or any other delayed
crack mechanisms must not be examined until at least 48 hours have passed. In case of doubt, please
contact FLSmidth.
4.1.3 Qualification/quality
NDT personnel must be qualified and certified to carry out NDT inspection jobs in accordance with EN ISO
9712:2013 (Non-destructive testing – Qualification and certification of personnel). The operator must be
certified to level 2. The operator certificate(s) have to be included in the final certified documentation.
Alternative corresponding internationally recognised standard may be agreed upon. The test equipment
and method must be suitable for the purpose.
Visual inspection may be conducted by inspectors not certified, however qualified.
NDT personnel and their qualifications shall be subject to written approval by FLSmidth37).
If no quality level reference is made on the drawings, the welding work and the extent of testing must be
done in a quality corresponding to quality level QA. See sub-section 2.3.3 and 2.7.
4.1.4 Extent and methods of testing
4.1.4.1 General notes
The quality level and the extent of testing of welds are defined by the quality levels, QA, QB or QC as
specified in Table 13. The normal test scope defined in Table 29 is compulsory and must be completed for
all deliveries of welded structures to FLSmidth.
It is the responsibility of the manufacturer to plan welding and NDT work so that required inspection /
examination can take place. Drawings showing NDT locations and extent of testing must be prepared by
the manufacturer and be available for the inspection, see sub-section 4.11.1.
When inspecting the structure it shall be ascertained that all welds have been completed and that they
are located as specified on the drawing(s) and that no welds show indications of excessive defects.
4.1.4.2 Test methods
Leakage test shall if demanded, but not detailed specified be executed by means of water or suitable
trace gas.
The test methods approved by FLSmidth for the inspection of welds are listed in the Table 28 below.
Welded seams must be examined by the use of suitable test methods.
The VT and PT/MT testing of raw materials for surface imperfections should precede the use of UT and RT
for detecting internal imperfections.

Method Abbreviation
Visual test VT
Magnetic particle inspection (MPI) MT
Liquid penetrant test PT
Radiographic test RT
Ultrasonic test UT
Table 28. Test methods and abbreviations, EN ISO 17635:2010.

37 Technical Query, see sub-section 1.3.3.

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 General workshop instructions
520530 - 8.0

4.1.4.3 Inspection lot

Welds perpendicular to each other must be included in the test lot. The test lot must include welds, so
that all welders on that particular job are represented in the NDT report on welds.
4.1.4.4 Lamination
Lamination in plate edge (flange on profiles included) prepared for QB or QC weld must not exist closer
than the greater of 50 mm or 4 x plate thickness. Detection of lamination shall be conducted by mean of
UT.
4.1.4.5 Inspection of welds
On drawings where the quality class has not been indicated, the extent of testing can in agreement with
the FLSmidth inspection be reduced from the given percentage to include VT only. See sub-section 2.7.
If imperfections are found:
• Causing non-compliance with the quality requirements, repairs must be made, and at the same
time the extent of testing must be increased from normal test to re-testing of the weld in
concern.
• In cases of non-compliance during re-testing, repairs must be made. At the same time, the
extent of testing must be increased to 100 % (repeated) re-test of the weld in concern.
• In cases of non-compliance during a 100 % test, repairs must be made and all repaired sections
of the welded seams must be examined 100 %.
For welding inspection the following requirements apply:

Exam
Quality level Method VT PT MT RT/UT
38), 39) 40)
FLS / (EN ISO 5817) Weld
type

Fillet 0
QA / (moderate D), normal test. 100 5 0
Butt 0
Fillet 41)
0
QA / (moderate D), re-testing. - 20
Butt 20
Fillet 41)
0
QA / (moderate D), repeated re-testing. - 100
Butt 100
42)
Fillet 0
QB / (intermediate C), normal test. 100 0 20
Butt 20

Fillet 0
QB / (intermediate C), re-test. - 0 100
Butt 100
42)
Fillet 0
QC / (stringent B), normal test 100 0 100
Butt 100
Table 29. Extent of weld testing. % of length of welded seams.

4.1.4.6 Where reasonable suspicion exists

FLSmidth reserves - without cost to FLSmidth - the right to call for an extraordinary increased quality
control (according to the choice of FLSmidth) of any item or any subject where reasonable suspicion exist
that defects or imperfections are present in the product. This reservation is valid not only for welding;
also imperfections in raw materials are covered by this clause (see e.g. sub-section 4.1.4.4).
Any imperfections detected during an extraordinary quality control must be evaluated and treated as if
they had been detected during a normal test according to Table 29.
4.1.5 Condition for detection and rejection of imperfection
4.1.5.1 General requirement
The detection and determination of the sizes of imperfections is highly dependent on inspection methods
and the methodology used. Inspection methods and the methodology must be chosen and carried out
according to an internationally recognised standard. The methods shall yield the detection,
characterization and size of imperfections, which all are required to determine the type of imperfection
and the acceptance/rejection mentioned in Table 32, EN ISO 5817:2014 as well as in the standards
mentioned in Table 30.

38 VT, visual test ascertains that the welding work has been completed and inspected according to EN ISO 17637:2011.
39 Measuring of weld dimension is included in VT according to EN ISO 5817 and EN ISO 17637/970.
40 Instead of RT the drawing may require UT. Otherwise UT/RT may be chosen optionally with regard to suitable thickness and weld characteristic.
41 Instead of PT the drawing may require MT. In this case the frequency test scope must follow what is required at PT. Otherwise PT/MT may be chosen
optionally.
42 UT shall apply 20% / 100% on fillet weld according to drawing requirement and EN ISO 17640:2011 (Non-destructive testing of welds - Ultrasonic testing
- Techniques, testing levels, and assessment) . Accept from FLSmidth inspection required.

40/63 The information transmitted by this document is the proprietary and confidential property of FLSmidth
and may not be duplicated, disclosed or utilized without written consent from FLSmidth.