TWI-UT-Forgings Procedure for Level 3

Ultrasonic Inspection of Wrought Products MF/PCN/1 RevO

Example procedure

This document specifies the specific method for ultrasonicinspection of Steel wrought bar stock to the requirements

of BS EN 10228-3 Ultrasonic testing of ferritic ormartensitic steel forgings.

Ultrasonic Inspection of Wrought ProductsGH/PCN/1 Rev 0

Compiled By: Joe BloggsPCN level 3 123321

Approved By: A N OtherPCN Level 3 123456

^ ^ i c ^ w r ^ f r V f t T T & T S ? ^

1CERTIFICATION SCHEME FOR PERSONNELCERTIFICATION IN NON DESTRUCTIVE TESTINGCANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS


Example procedure

2 CONTENTS LIST

Para Heading PageTitle 1

1 Contents 22 Scope 33 Reference Documents 34 Terminology and Abbreviations 35 Personnel 36 Safety 37 Equipment 38 Surface Condition 49 Performing the Test 410 Sensitivity and Range setting 411 Acceptance criteria and sizing 512 Post Inspection 513 Reporting and recording indications 514 Non-conforming products 6

Appendix 1- Test Block 7Appendix 2- Reporting format 8Appendix 3- Ultrasonic Technique sheets 9



Example procedure

SCOPE:This document specifies the specific method for ultrasonic inspection of Steel wrought bar stock to therequirements of BS EN 10228-3 Ultrasonic testing of ferritic or martensitic steel forgings.

REFERENCESISO 9712 Qualification and certification of NDT personnelBS EN 1330-2 NDT Terminology Part 2 Terms common to the NDT methodBS EN1330-4 Glossary of terms used in non-destructive testing: Ultrasonic testing.BS EN 12668-1 Non-destructive testing- Characterisation and verification of ultrasonic examinationequipment -Parts 3BS EN 583-1 Non-destructive testing -Ultrasonic examination Part 1: General principlesBS 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 ofdiscontinuitiesBS EN 2400 Non-destructive testing- Specification 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 certification,\C distance amplitude correction

Standards terms shall be detailed in BS EN 1330-2 BS EN 1330-4wz

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 certified to PCN; level 2 (ISO 9712) in wrought products and authorised inthe inspection method shall perform theTJIfrasonic inspection to this procedure.

Only ultrasonic technician certified to PCN Level 3 (ISO 9712) in wrought products and authorised inthe inspection method shall supervise the inspection.

All authorised technicians shall have a current eye certification complying with the requirements ofPCN PSL/44 Jaeger J1 X Roman N 4.5 and couloir vision shall be sufficient to distinguish contrastbetween the colour and shade used in the NDT method concerned by the employer Ichihara (17plate 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.

EQUIPMENTEquipment: Ultrasonic equipment instrument shall fulfil the requirements of BS EN 12668-1

Ultrasonic Probes: The probes shall fulfil the requirements of EN 12668-2 and normal frequencyrange of 1 Mhz to 6 Mhz. Probe selection The probes used are specified on the job specific techniquesheet.

Calibration Blocks: The calibration blocks used shall conform the requirements of BS EN 1223 andBS EN 10228-3.

Coupling media: Different coupling may be used but their type shall be compatible with the materialsto be examined.Example-Contact paste:-Oil



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-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 bookfor recording information.

SURFACE CONDITIONScanning surfaces shall be free from paint, no-adhering scale, dry coupling, surface irregularities orany other material which could reduce coupling efficiency 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 finished machined condition. Surface transfer shall be assessed using2 off 45° probes compensation shall be made as follows £ 2dB no compensation £ 2db ^12dB adjustaccordingly. > 12dB inform the NDT supervisor and do not carry out inspection until the differences isbelow 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 specified areas of specific 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 eachinspection to allow repeatability of the test.

PERFORMING THE TESTThe combined equipment (flaw detector and probes) shall be calibrated and checked in accordancewith the requirements detailed in BS EN 12668-3.

Subclause Title Frequency of checking3.2.1 Linearity of time-based Weekly3.2.2 Linearity of equipment gain Weekly3.3.1 Probe index Daily3.3.2 Beam angle Daily3.4.2 Physical state and external

aspectsDaily

3.4.3 Sensitivity and signal-to-noiseratio

Weekly

3.4.4 Pulse duration Weekly

Sensitivity shall be sufficient to ensure the detection of the smallest discontinuity required by therecording/ 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 probesa) DAC using a 2mm flat bottomed hole

Shear Probesa) DAC using a 3mm diameter side drilled hole

Calcification of discontinuitiesDiscontinuities shall be classified according to their echo dynamic patterns as follows.

a) Point discontinuities dimensions equal to or less than 6dbb) Extended discontinuities dimensions greater than 6db



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c) Isolated discontinuities: the distance between points corresponding to the maxima of theindications of adjacent discontinuity

d) Grouped discontinuities: The distance between points corresponding to a maximum of theindications of adjacent discontinuities.

ACCEPTANCE CRITERIAThe applicable quality class shall be agreed between the purchaser and the supplier. Unlessotherwise 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 probesEquivalent flat bottom hole £2ratio R for rapid backwall echo reduction < 0.6

Acceptance criteria isolated point type discontinues £ 3Extended or grouped point discontinues £ 2

Quality Classes 4 recording level and acceptance criteria class 4 for shear wave probes using DACtechnique2mhz 30% DAC4mhz 50% DAC

Quality Classes 4 recording level and acceptance criteria for shear wave probes using DAC techniqueisolated discontinuities2mhz 60% DAC4mhz100%DAC

Extended or grouped point type discontinuities2mhz 30% DAC4mhz 50% DAC

Sizing based on 3mm diameter hole.

SizingWhere the extent of a discontinuity is required to be evaluated then any of the following may be used

a) 6db-drop techniqueb) 20db-drop techniquec) Maximum amplitude technique.

The preferred sizing technique shall be stated on the specific technique

POST-TEST PROCEDURE

All parts shall be cleaned of ultrasonic coupling after test and the protective coatings shall be restoredto eliminate the effect of corrosion.

REPORTINGAll tests shall be subject of a written report which shall include the following information as a minimumrequirement:

a) Name of supplierb) Order numberc) Identification of forging under examinationd) Scope of examination: examination zones and applicable quality levele) Stage of manufacturef) Surface conditiong) Equipment used (flaw detector, probes calibration and reference block)h) Technique used to set sensitivityi) Reference to the standards EN 10228-3j) Results of examination



Example procedure

k) Location, classification and amplitude( in term of FBH-equivalent diameter or in present of SDH)I) Details of any restrictionsm) Daten) Name, qualification and signature of operator.

All recordable indication shall be recorded on a schematic drawing showing depth and area.

NON-CONFORMING PRODUCTSAll parts found to be out size the acceptance criteria shall be quarantined and labelled. The suspectarea shall be marked as per procedure GH/NDT Rep/1.



Example procedure

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CERTIFICATION SCHEME FOR PERSONNELCERTIFICATION IN NON DESTRUCTIVE TESTINGCANDIDATE ANSWER SHEET LEVEL 3 UT FORGINGS


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 tU 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 Specification Technique sheet

Equipment Used Probes

Calibration blocks

Surface condition Surface transfer

Sensitivity Setting0456070

Defect location Amplitude

Details of restrictionsReport Issued By J Bloggs Approved ByNDT Qualification PCN L3 200F NDT QualificationSignature Signature

Date of Inspection Date Approved



Example procedure

Appendix 3 Ultrasonic Technique GH/ PCN/1 issue 0
