Table G1-1.

Effectiveness of Inspection for General Thinning

Inspection
Intrusive Non-intrusive
Effectiveness
Inspection Inspection
Category
A 50-100% examination of 50-100% ultrasonic
Highly Effective the surface (partial) scanning coverage
internals removed) and (automated or manual) or
accompanied by profile radiography
thickness measurements
B Normally 20% Normally 20% ultrasonic
Usually examination (no internals scanning coverage
Effective removed), and spot (automated or manual), or
external ultrasonic profile radiography, or
thickness measurements external spot thickness
(statistically validated)

C Visual examination 2-3% examination, spot

Fairly Effective without thickness external ultrasonic
measurements thickness measurements,
and little or no internal
visual examination
D External spot thickness Several thickness
Poorly Effective readings only measurements, and a
documented inspection
planning system
E No inspection Several thickness
Ineffective measurements taken only
externally, and a poorly
documented inspection
planning system

Appendix G-1 Page 1 of 13

 Table G1-2. Effectiveness of Inspection for Localized Thinning

Inspection
Intrusive Non-intrusive
Effectiveness
Inspection Inspection
Category
A 100% visual examination 50-100% coverage using
Highly Effective (with removal of internal automated ultrasonic
packing, trays, etc.) and scanning, or profile
thickness measurements radiography in areas
specified by a corrosion
engineer or other
knowledgeable specialist
B 100% visual examination 20% coverage using
Usually (with partial removal of automated ultrasonic
Effective the internals) including scanning, or 50% manual
manways, nozzles, etc. ultrasonic scanning, or 50%
and thickness profile radiography in areas
measurements specified by a corrosion
engineer or other
knowledgeable specialist
C Nominally 20% visual Nominally 20% coverage
Fairly Effective examination and spot using automated or manual
ultrasonic thickness ultrasonic scanning, or
measurements profile radiography, and
spot thickness
measurements at areas
specified by a corrosion
engineer or other
knowledgeable specialist
D No inspection Spot ultrasonic thickness
Poorly Effective measurements or profile
radiography without areas
being specified by a
corrosion engineer or other
knowledgeable specialist
E No inspection Spot ultrasonic thickness
Ineffective measurements without
areas being specified by a
corrosion engineer or other
knowledgeable specialist

Appendix G-1 Page 2 of 13

 Table G1-3. Effectiveness of Inspection for Caustic Cracking

Inspection
Intrusive Non-intrusive
Effectiveness
Inspection Inspection
Category
A Wet fluorescent Magnetic Shear wave ultrasonic
Highly Effective particle or dye penetrant testing of 25-100% of
testing of 25-100% of welds/cold bends; or
wields/cold bends; or Dye Radiographic testing of 50-
penetrant testing of 25- 100% of welds/cold bends
100% of welds/cold
bends
B Wet fluorescent Magnetic Shear wave ultrasonic
Usually particle or dye penetrant testing of 10-24% of
Effective testing of 10-24% of welds/cold bends; or
welds/cold bends; or Dye Radiographic testing of 25-
penetrant testing of 10- 49% of welds/cold bends
24% of welds/cold bends
C Magnetic particle or dye Shear wave ultrasonic
Fairly Effective penetrant testing of less testing of less than 10% of
than 10% of welds/cold welds/cold bends; or
bends; or Dye penetrant Radiographic testing of less
testing of less than 10% than 25% of welds/cold
of welds/cold bends bends
D Visual inspection Visual inspection for leaks
Poorly Effective
E No inspection No inspection
Ineffective

Appendix G-1 Page 3 of 13

 Table G1-4. Effectiveness of Inspection for Amine Cracking & Carbonate
Cracking

Inspection
Intrusive Non-intrusive
Effectiveness
Inspection Inspection
Category
A Wet fluorescent magnetic None
Highly Effective particle testing of 100%
of repair welds and 50-
100% of other welds/cold
bends
B Wet fluorescent magnetic Shear wave ultrasonic
Usually testing of 20-49% of testing of 50-100% of
Effective welds/cold bends welds/cold bends; or
Acoustic Emission testing
with follow-up shear wave
UT
C Wet fluorescent magnetic Shear wave ultrasonic
Fairly Effective particle testing of less testing of 20-49% of
than 20% of welds/cold welds/cold bends
bends; or Dry magnetic
particle testing of 50-
100% of welds/cold
bends; or Dye penetrant
testing of 50-100% of
welds/cold bends
D Dry magnetic particle Shear wave ultrasonic
Poorly Effective testing of less than 50% testing of less than 20% of
of welds/cold bends; or welds/cold bends; or
Dye penetrant testing of Radiographic testing; or
less than 50% of Visual inspection for leaks
welds/cold bends

E Visual inspection No inspection

Ineffective

Appendix G-1 Page 4 of 13

 Table G1-5. Effectiveness of Inspection for Sulfide Stress Cracking and
Hydrogen Stress Cracking
Inspection
Intrusive
Effectiveness
Inspection
Category
A Wet fluorescent magnetic
Highly Effective particle testing of 25-
100% of weldments
B Wet fluorescent magnetic
Usually particle testing of 10-24%
Effective of weldments; or Dry
magnetic particle testing
of 25-100% of
weldments; or Dye
penetrant testing of 25-
100% of weldments
C Wet fluorescent magnetic
Fairly Effective particle testing of less
than 10% of weldments;
or Dry magnetic particle
testing of less than 25%
of weldments; or Dye
penetrant testing of less
than 25% of weldments
D Visual inspection
Poorly Effective
E No inspection
Ineffective
Appendix G-1
Non-intrusive
Inspection
Shear wave ultrasonic
testing of 25-100% of
weldments, transverse and
parallel to the weld with the
weld cap removed; or
Acoustic Emission testing
with follow-up shear wave
UT
Shear wave ultrasonic
testing 10-24% of
weldments; Radiographic
testing of 50-100% of
weldments
Shear wave ultrasonic
testing of less than 10% of
weldments; Radiographic
testing of 20-49% of
weldments
Radiographic testing of less
than 20% of weldments
No inspection
Page 5 of 13
 Table G1-6. Effectiveness of Inspection for HIC/SOHIC and HIC/SOHIC-HF
Inspection
Intrusive Non-intrusive
Effectiveness
Inspection Inspection
Category
A Wet fluorescent magnetic None
Highly Effective particle testing of 50-100%
of weldments, plus
additional shear wave UT
for subsurface cracking
B Wet fluorescent magnetic Automated shear wave
Usually particle testing of 20-49% ultrasonic testing of 20-100%
Effective of weldments of weldments; or Acoustic
Emission testing with follow-up
shear wave UT
C Wet fluorescent magnetic Automated shear wave
Fairly Effective particle of less than 20% of ultrasonic testing of less than
weldments; or Dry 20% of weldments; or Manual
magnetic particle testing of shear wave ultrasonic testing
50-100% of weldments; or of 20-100% of weldments
Dye penetrant testing of
50-100% of weldments
D Dye penetrant testing of Manual shear wave ultrasonic
Poorly Effective less than 50% of testing of less than 20% of
weldments; Visual weldments
inspection for hydrogen
blisters
E No inspection Radiographic testing
Ineffective

Appendix G-1 Page 6 of 13

 Table G1-7. Effectiveness of Inspection for PTA*

Inspection Intrusive Non-intrusive

Effectiveness Inspection Inspection
Category
A Dye penetrant (25%+) Radiography (25%+)
Highly Effective Shear wave ultrasonics
(25%+)
B Dye penetrant testing Radiography approx. (5%)
Usually Shear wave ultrasonics
Effective (25%+)
C Dye penetrant (10%) Spot Radiography
Fairly Effective Spot shear wave ultrasonics
D Visual Visual for leaks
Poorly Effective

E No inspection No inspection
Ineffective

* There is no highly effective inspection without a minimum of partial

insulation removal and external VT and PT.

Table G1-8. Effectiveness of Inspection for ClSCC

Inspection
Intrusive Non-intrusive
Effectiveness
Inspection Inspection
Category
A Dye penetrant testing of Shear wave ultrasonic
Highly Effective 50% to 100% of testing of 25% to 100% of
weldments weldments, transverse and
parallel to the weld with the
weld cap removed
B Dye penetrant testing of Shear wave ultrasonic
Usually 25% to 50% of testing of 10% to 24% of
Effective weldments weldments, radiographic
testing of 50% to 100% of
weldments.
AE test with partial
insulation removal at PT
C Dye penetrant testing of Shear wave ultrasonic
Fairly Effective less than 25% of testing of less than 10% of
weldments weldments, radiographic
testing of 20% to 49% of
weldments
D Visual Visual for Leaks
Poorly Effective

Appendix G-1 Page 7 of 13

 E No inspection No inspection
Ineffective

Appendix G-1 Page 8 of 13

 Table G1-9. Inspection Effectiveness Guidelines for HTHA

Inspection
Effectiveness Typical Inspection Practices
Category
A None
Highly Effective
B Extensive Advanced Ultrasonic Backscatter
Usually Effective Technique (AUBT), spot AUBT based on stress
analysis or extensive in-situ metallography
C Spot AUBT or spot in-situ metallography
Fairly Effective
D Ultrasonic backscatter plus attenuation
Poorly Effective
E Attenuation only
Ineffective

Appendix G-1 Page 9 of 13

Table G1-10. CUI for Carbon and Low Alloy Steels Inspection Categories
Inspection
Insulation
Effectiveness
Removed
Category
A  Remove >95% of the
Highly Effective insulation
AND
 visual inspection of the
exposed surface area with
follow-up by UT, RT or pit
gauge is required
B For the total surface area:
Usually  >95% external visual
Effective inspection prior to
removal of insulation
AND
 remove >60% of total
surface area of insulation
including suspect areas
AND
 visual inspection of the
exposed surface area with
follow-up by UT, RT or pit
gauge as required
C For the total surface area:
Fairly Effective  >95% external visual
inspection prior to
removal of insulation
AND
 remove >30% of total
surface area of insulation
including suspect areas
AND
 visual inspection of the
exposed surface area with
follow-up by UT, RT or pit
gauge as required
 >95% external visual
D inspection prior to
Poorly Effective removal of insulation
AND
 remove >5% of total
surface area of insulation
including suspect areas
AND
 visual inspection of the
Appendix G-1
Insulation Not
Removed
For the total surface
area:
 >95% profile or real-
time radiography
For the total surface
area:
 >95% external visual
inspection
AND
 follow-up with profile
or real time
radiography of >60%
of total surface area
of insulation including
suspect areas
For the total surface
area:
 >95% external visual
inspection
AND
 follow-up with profile
or real time
radiography of >30%
of total surface area
of insulation including
suspect areas
For the total surface
area:
 >95% external visual
inspection
AND
 follow-up with profile
or real time
radiography of >5%
Page 10 of 13
 exposed surface area with of total surface area
follow-up by UT, RT or pit of insulation including
gauge as required suspect areas

E  <5% insulation removal No inspection or

Ineffective and inspection ineffective inspection
OR technique or <95%
 no inspection or visual inspection
ineffective inspection
technique

Table G1-11. External SCC of Austenitic Stainless Steel Inspection Categories

Inspection
Effectiveness Inspection
Category
A For the total surface area:
Highly Effective  >95% dye penetrant or eddy current test with UT
follow-up of relevant indications
B For the total surface area
Usually Effective  >60% dye penetrant or eddy current testing with UT
follow-up of all relevant indications
C For the total surface area
Fairly Effective  >30% dye penetrant or eddy current testing with UT
follow-up of all relevant indications
D For the total surface area
Poorly Effective >5% dye penetrant or eddy current testing with UT
follow-up of all relevant indications
E Less than “D” effectiveness or no inspection or
Ineffective ineffective inspection technique used

Appendix G-1 Page 11 of 13

 Table G1-12. CUI for Stainless Steels Inspection Categories

Inspection
Effectiveness Intrusive Inspection Non-intrusive
Category Inspection
A For the total surface area: No inspection techniques
Highly Effective  >95% dye penetrant or yet available meet
eddy current test with requirements of "A".
UT follow-up of
relevant indications.
B For the total surface area: For the total surface area:
Usually Effective  >60% dye penetrant or  >95% automated or
eddy current testing manual ultrasonic
with UT follow-up of all scanning
relevant indications. OR
 AE testing with 100%
follow-up of relevant
indications.
C For the total surface area: For the total surface area:
Fairly Effective  >30% dye penetrant or  >67% automated or
eddy current testing manual ultrasonic
with UT follow-up of all scanning
relevant indications.
D For the total surface area: For the total surface area:
Poorly Effective  >5% dye penetrant or  >30% automated or
eddy current testing manual ultrasonic
with UT follow-up of all scanning
relevant indications OR
 >60% radiographic
testing
E Less than “D” Less than “D”
Ineffective effectiveness or no effectiveness or no
inspection or ineffective inspection or ineffective
inspection technique used inspection technique used

Appendix G-1 Page 12 of 13

 Table G1-13. Inspection Effectiveness for External Damage

Inspection
Effectiveness Inspection
Category
A Visual inspection of >95% of the exposed surface area
Highly Effective with follow-up by UT, RT or pit gauge as required
B Visual inspection of >60% of the exposed surface area
Usually Effective with follow-up by UT, RT or pit gauge as required
C Visual inspection of >30% of the exposed surface area
Fairly Effective with follow-up by UT, RT or pit gauge as required
D Visual inspection of >5% of the exposed surface area
Poorly Effective with follow-up by UT, RT or pit gauge as required
E Visual inspection of >5% of the exposed surface area
Ineffective with follow-up by UT, RT or pit gauge as required

Table G1-14. Guidelines for Assigning Inspection Effectiveness for Furnace Tube

Inspection
Effectiveness Inspection
Category
A Visual inspection, UT thickness measurements of all
Highly Effective tubes and strapping at UT measurement locations.
FMR at various locations
B Visual inspection, UT thickness measurements of all
Usually Effective tubes
C Visual inspection with UT thickness measurements of
Fairly Effective 75% of the tubes
D Visual inspection with spot UT measurements
Poorly Effective
E Visual
Ineffective

Appendix G-1 Page 13 of 13