Ultrasonic Inspection of Wrought Products MF/PCN/1 RevO

Example procedure
This document species the specic method for ultrasonic
inspection of Steel wrought bar stock to the requirements
of BS EN 10228-3 Ultrasonic testing of ferritic or
martensitic steel forgings.
Ultrasonic Inspection of Wrought Products
GH/PCN/1 Rev 0
Compiled By: Joe Bloggs
PCN level 3 123321
Approved By: A N Other
PCN Level 3 123456
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1
CERTIFICATION SCHEME FOR PERSONNEL
CERTIFICATION IN NON DESTRUCTIVE TESTING
CANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS
Ultrasonic Inspection of Wrought Products MF/PCN/1 RevO
Example procedure
2 CONTENTS LIST
Para
Heading Page
Title
1
1 Contents
2
2
Scope 3
3
Reference Documents
3
4
Terminology and Abbreviations 3
5 Personnel
3
6
Safety
3
7
Equipment
3
8 Surface Condition
4
9
Performing the Test
4
10
Sensitivity and Range setting
4
11
Acceptance criteria and sizing
5
12 Post Inspection 5
13
Reporting and recording indications
5
14
Non-conforming products
6
Appendix 1- Test Block
7
Appendix 2- Reporting format
8
Appendix 3- Ultrasonic Technique sheets
9
2
CERTIFICATION SCHEME FOR PERSONNEL
CERTIFICATION IN NON DESTRUCTIVE TESTING
CANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS
Ultrasonic Inspection of Wrought Products MF/PCN/1 RevO
Example procedure
SCOPE:
This document species the specic method for ultrasonic inspection of Steel wrought bar stock to the
requirements of BS EN 10228-3 Ultrasonic testing of ferritic or martensitic steel forgings.
REFERENCES
ISO 9712 Qualication and certication of NDT personnel
BS EN 1330-2 NDT Terminology Part 2 Terms common to the NDT method
BS EN1330-4 Glossary of terms used in non-destructive testing: Ultrasonic testing.
BS EN 12668-1 Non-destructive testing- Characterisation and verication of ultrasonic examination
equipment -Parts 3
BS EN 583-1 Non-destructive testing -Ultrasonic examination Part 1: General principles
BS EN 583-3 Non-destructive testing -Ultrasonic examination Part 3: Transmission technique.
BS EN 583-5 Non-destructive testing -Ultrasonic examination Part 5: Characterisation and sizing of
discontinuities
BS EN 2400 Non-destructive testing- Specication for calibration block No.1
_ BS EN 10228-3 Non-destructive testing of steel forgings: Ultrasonic testing of ferritic or martensitic
^ A/steel forgings
vfyd PCN : Personnel certication
,\C distance amplitude correction
Standards terms shall be detailed in BS EN 1330-2 BS EN 1330-4
wz
13246 Technical information covering material type and acceptance standard.
If the product does not conform to the technical information sheet 13246 the technician shall inform
!^the NDT supervisor who will carry out further investigation.
N D T P E R S O N N E L : 7 - ^
Only Ultrasonic technician certied to PCN; level 2 (ISO 9712) in wrought products and authorised in
the inspection method shall perform theTJIfrasonic inspection to this procedure.
Only ultrasonic technician certied to PCN Level 3 (ISO 9712) in wrought products and authorised in
the inspection method shall supervise the inspection.
All authorised technicians shall have a current eye certication complying with the requirements of
PCN PSL/44 Jaeger J1 X Roman N 4.5 and couloir vision shall be sufcient to distinguish contrast
between the colour and shade used in the NDT method concerned by the employer Ichihara (17
plate min)
SAFETY:
All technicians shall perform the inspection to the requirement of the companies SSOW 1243
All relevant PPE shall be worn to carry out the inspection safely.
EQUIPMENT
Equipment: Ultrasonic equipment instrument shall full the requirements of BS EN 12668-1
Ultrasonic Probes: The probes shall full the requirements of EN 12668-2 and normal frequency
range of 1 Mhz to 6 Mhz. Probe selection The probes used are specied on the job specic technique
sheet.
Calibration Blocks: The calibration blocks used shall conform the requirements of BS EN 1223 and
BS EN 10228-3.
Coupling media: Different coupling may be used but their type shall be compatible with the materials
to be examined.
Example
-Contact paste:
-Oil
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CERTIFICATION SCHEME FOR PERSONNEL
CERTIFICATION IN NON DESTRUCTIVE TESTING
CANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS
Ultrasonic Inspection of Wrought Products MF/PCN/1 RevO
Example procedure
-Grease
The coupling media used for the calibration of equipment shall be the same as the inspection.
Ancillary equipment: The technician shall ensure that they have ruler, UT plotters, pen and note book
for recording information.
SURFACE CONDITION
Scanning surfaces shall be free from paint, no-adhering scale, dry coupling, surface irregularities or
any other material which could reduce coupling efciency or hinder the movement of the probe.
Surface finish shall be compatible with the requirement of class 1 EN 10228-3 6.3 Mm.
The part shall be tested in the nished machined condition. Surface transfer shall be assessed using
2 off 45 probes compensation shall be made as follows 2dB no compensation 2db ^12dB adjust
accordingly. > 12dB inform the NDT supervisor and do not carry out inspection until the differences is
below the 12db requirement
Scanning shall be performed using manual pulse-echo technique.
Manual scanning speed shall not exceed 150mm/s
100% scanning coverage shall be performed over the specied areas of specic technique sheet.
Each scan shall be overlapped by 10% of the effective probe diameter.
The datum point for each inspection shall conform to the technique sheet and be marked for each
inspection to allow repeatability of the test.
PERFORMING THE TEST
The combined equipment (aw detector and probes) shall be calibrated and checked in accordance
with the requirements detailed in BS EN 12668-3.
Subclause
Title
Frequency of checking
3.2.1
Linearity of time-based
Weekly
3.2.2
Linearity of equipment gain
Weekly
3.3.1 Probe index Daily
3.3.2 Beam angle Daily
3.4.2
Physical state and external
aspects
Daily
3.4.3
Sensitivity and signal-to-noise
ratio
Weekly
3.4.4 Pulse duration
Weekly
Sensitivity shall be sufcient to ensure the detection of the smallest discontinuity required by the
recording/ evaluation levels for the particular quality level and class.
The technique to be used to evaluate discontinuities shall carried out using a DAC curve
Normal probes
a) DAC using a 2mm at bottomed hole
Shear Probes
a) DAC using a 3mm diameter side drilled hole
Calcication of discontinuities
Discontinuities shall be classied according to their echo dynamic patterns as follows.
a) Point discontinuities dimensions equal to or less than 6db
b) Extended discontinuities dimensions greater than 6db
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CERTIFICATION SCHEME FOR PERSONNEL
CERTIFICATION IN NON DESTRUCTIVE TESTING
CANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS
Ultrasonic Inspection of Wrought Products MF/PCN/1 RevO
Example procedure
c) Isolated discontinuities: the distance between points corresponding to the maxima of the
indications of adjacent discontinuity
d) Grouped discontinuities: The distance between points corresponding to a maximum of the
indications of adjacent discontinuities.
ACCEPTANCE CRITERIA
The applicable quality class shall be agreed between the purchaser and the supplier. Unless
otherwise agreed the following acceptance shall conforming to the requirement of EN 10228-3 table 5
Quality Classes 4 recording level and acceptance criteria for normal probes
Equivalent flat bottom hole 2
ratio R for rapid backwall echo reduction < 0.6
Acceptance criteria isolated point type discontinues 3
Extended or grouped point discontinues 2
Quality Classes 4 recording level and acceptance criteria class 4 for shear wave probes using DAC
technique
2mhz 30% DAC
4mhz 50% DAC
Quality Classes 4 recording level and acceptance criteria for shear wave probes using DAC technique
isolated discontinuities
2mhz 60% DAC
4mhz100%DAC
Extended or grouped point type discontinuities
2mhz 30% DAC
4mhz 50% DAC
Sizing based on 3mm diameter hole.
Sizing
Where the extent of a discontinuity is required to be evaluated then any of the following may be used
a) 6db-drop technique
b) 20db-drop technique
c) Maximum amplitude technique.
The preferred sizing technique shall be stated on the specic technique
POST-TEST PROCEDURE
All parts shall be cleaned of ultrasonic coupling after test and the protective coatings shall be restored
to eliminate the effect of corrosion.
REPORTING
All tests shall be subject of a written report which shall include the following information as a minimum
requirement:
a) Name of supplier
b) Order number
c) Identication of forging under examination
d) Scope of examination: examination zones and applicable quality level
e) Stage of manufacture
f) Surface condition
g) Equipment used (aw detector, probes calibration and reference block)
h) Technique used to set sensitivity
i) Reference to the standards EN 10228-3
j) Results of examination
5
CERTIFICATION SCHEME FOR PERSONNEL
CERTIFICATION IN NON DESTRUCTIVE TESTING
CANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS
Ultrasonic Inspection of Wrought Products MF/PCN/1 RevO
Example procedure
k) Location, classication and amplitude( in term of FBH-equivalent diameter or in present of SDH)
I) Details of any restrictions
m) Date
n) Name, qualication and signature of operator.
All recordable indication shall be recorded on a schematic drawing showing depth and area.
NON-CONFORMING PRODUCTS
All parts found to be out size the acceptance criteria shall be quarantined and labelled. The suspect
area shall be marked as per procedure GH/NDT Rep/1.
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CERTIFICATION SCHEME FOR PERSONNEL
CERTIFICATION IN NON DESTRUCTIVE TESTING
CANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS
Ultrasonic Inspection of Wrought Products MF/PCN/1 RevO
Example procedure
A p p e n d i x 1 Te s t B l o c k
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CERTIFICATION SCHEME FOR PERSONNEL
CERTIFICATION IN NON DESTRUCTIVE TESTING
CANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS
Ultrasonic Inspection of Wrought Products MF/PCN/1 RevO
Example procedure
A p p e n d i x 2 R e p o r t i n g f o r m a t
U l t r a s o n i c R e p o r t s h e e t U T / G H / 1 r e v 1
Company Name:
Order No
Specimen Number
Location
Part Description
Area to be Inspected
Applicable Specication
Technique sheet
Equipment Used
Probes
Calibration blocks
Surface condition Surface transfer
Sensitivity Setting
0
45
60
70
Defect location
Amplitude
Details of restrictions
Report Issued By
J Bloggs Approved By
NDT Qualication
PCN L3 200F NDT Qualication
Signature Signature
Date of Inspection Date Approved
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CERTIFICATION SCHEME FOR PERSONNEL
CERTIFICATION IN NON DESTRUCTIVE TESTING
CANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS
Ultrasonic Inspection of Wrought Products MF/PCN/1 RevO
Example procedure
Appendix 3 Ultrasonic Technique GH/ PCN/1 issue 0
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CERTIFICATION SCHEME FOR PERSONNEL
CERTIFICATION IN NON DESTRUCTIVE TESTING
CANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS