A Sample: Ultrasonic Inspection Procedure

ULTRASONIC INSPECTION PROCEDURE
Reference: PROC/GEN/UT/02-729Pt5-C Issue:01 | Date of Issue: SAMPLE
Procedure For The Ultrasonic Testing

Of Castings To Def Stan 02-729 Pt.5
SAMPLE ONLY - NOT FOR PRODUCTION USE

FULL PROCEDURE AVAILABLE TO
PURCHASE FROM www.n-d-t.com
Authored By: A Sample PCN Level 3 (XXXXXX) Authorised For Use By:
Signed: A Sample Date: 21/06/20

Signed: Date:
Page 1 of 11
CONTENTS
1. Scope
2. References
3. Definitions & Abbreviations
4. Safety
5. Personnel Qualification
6. Identification And Datum Points
7. Equipment
8. Equipment Checks
9. Surface and Test Conditions
10. Extent of Inspection
11. Examination Procedure
12. Acceptance Standards
13. Reporting
14. Non-compliance Statement
15. Defect removal and re-testing
Appendix A – Procedure Revision History
Page 2 of 11
1. Scope
This procedure covers the ultrasonic inspection of cast products in accordance with Def Stan
02-729 Part 5.
This procedure shall only be used by people employed by or with written authorisation to work
on behalf of ABM NDT Limited, Sheffield.
This procedure is only to be used for the inspection of newly manufactured castings and does
not cover in-service inspection, however the procedure does cover items have been subject to
initial upgrading and repair work
This procedure does not cover any castings which have been extensively machined (i.e. into
finished components) except where proof machining/turning has taken place to improve surface
condition.
This procedure shall be carried out once all heat treatment operations have been completed
(excluding post weld repair stress relief) and at least 24 hours after the final heat treatment
operation has been completed.
2. References
This procedure makes reference to the following documents:-
DEF STAN 02-729 Iss. 2 Part 5 Requirements for non-destructive examination methods.
Part 5 Ultrasonics.
Def Stan 02-745 Part 2 Classification, Inspection Requirements and Acceptance

Standards for Castings, Part 2: Steel Castings.
Def Stan 02-863 Requirements for Classification, Dimensions, Tolerances

and General Standard of Acceptance for Copper and Nickel Alloy Castings.
BS EN ISO 9712:2012 Non-destructive Testing. Qualification and certification of

NDT personnel.
BS EN ISO 2400:2012 Non-Destructive testing - Ultrasonic Examination -

Specification for calibration block No. 1
BS EN 12668-1:2010 Non-destructive testing - Characterization and verification

of ultrasonic examination equipment - Part 1: Instruments
Page 3 of 11

of ultrasonic examination equipment - Part 2: Probes

of ultrasonic examination equipment - Part 3: Combined equipment
BS EN 1330-1:2014 Non-destructive testing - Terminology - List of general

terms
BS EN 1330-4:2010 Non-destructive testing - Terminology - Terms used in

ultrasonic testing
BS EN ISO 16811:2014 Non-destructive testing - Ultrasonic testing - Sensitivity

And Range Setting
3. Definitions & Abbreviations
As well as the terms defined in BS EN 1330-1 and BS EN 1330-4 this procedure uses the
following definitions:
PCN Personnel certification in Non-destructive testing

COSHH Control of substances hazardous to health
PPE Personal protective equipment
FBH Flat-bottom hole
SDH Side drilled hole
FSH Full screen height
DAC Distance-amplitude correction
DGS Distance gain scale
4. Safety
All consumables used shall have accompanying COSHH data sheets and shall be disposed of
in a way that is non-injurious to site personnel or to the environment.
Personnel working to this procedure shall at all times wear mandatory PPE; overalls, safety
boots, hard hat, high visibility clothing, safety eyewear.
Page 4 of 11
5. Personnel Qualifications
All personnel following this procedure must be currently certified by PCN to a minimum of Level
2 covering the ultrasonic testing of castings.
All personnel shall also hold a valid eyesight certificate (meeting the requirements of ISO 9712
Section 7.4) obtained within the last 12 months.
Documentation relating to ultrasonic operators employed by or working for the foundry/testing

company shall be kept on file at the administration offices for review purposes.
6. Identification And Datum Points
All castings tested shall be marked (either cast on or stamped) with a unique number for
identification purposes, this number shall be used as the datum point for reporting purposes.
7. Equipment
7.1 Electronic apparatus
An A-scan ultrasonic pulsed reflection type of instrument that is capable of generating, receiving
and amplifying frequencies of at least 1 to 6 MHz.
The ultrasonic flaw detector shall comply with the requirements of BS EN 12668-1 and have a
calibration certificate obtained within the last year.
7.2 Probes
Probe selection will depend on the geometry of the item to be examined, material type and grain
size, and the area of probe contact surface. The best near surface resolution will be obtained
using combined double compression wave probe and this characteristic is of value in the
examination of areas subject to subsequent machining. Generally the probe test frequency will
be in the range 2 – 6 MHz but a lower frequency may be necessary to overcome the effects of
material large grain structure and long beam path length.
Shear wave probe techniques are to be used where specified. On bored (or hollow) items where
the bore is inaccessible for examination with a compression probe an appropriate shear wave
technique is to be used. Shear wave is also to be used to cover areas where the shape of the
item prevents comprehensive examination by compression wave.
Other frequencies and sizes of search units may be used for evaluating and pinpointing
indications.
Page 5 of 11

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ULTRASONIC INSPECTION PROCEDURE

Reference: PROC/GEN/UT/02-729Pt5-C Issue:01 | Date of Issue: SAMPLE

Procedure For The Ultrasonic Testing

SAMPLE ONLY - NOT FOR PRODUCTION USE

Signed: A Sample Date: 21/06/20

3. Definitions & Abbreviations

6. Identification And Datum Points

9. Surface and Test Conditions

10. Extent of Inspection

11. Examination Procedure

12. Acceptance Standards

14. Non-compliance Statement

15. Defect removal and re-testing

Appendix A – Procedure Revision History

This procedure makes reference to the following documents:-

Def Stan 02-745 Part 2 Classification, Inspection Requirements and Acceptance

Def Stan 02-863 Requirements for Classification, Dimensions, Tolerances

BS EN ISO 9712:2012 Non-destructive Testing. Qualification and certification of

BS EN ISO 2400:2012 Non-Destructive testing - Ultrasonic Examination -

BS EN 12668-1:2010 Non-destructive testing - Characterization and verification

BS EN 12668-2:2010 Non-destructive testing - Characterization and verification

BS EN 12668-3:2013 Non-destructive testing - Characterization and verification

BS EN 1330-1:2014 Non-destructive testing - Terminology - List of general

BS EN 1330-4:2010 Non-destructive testing - Terminology - Terms used in

BS EN ISO 16811:2014 Non-destructive testing - Ultrasonic testing - Sensitivity

3. Definitions & Abbreviations

PCN Personnel certification in Non-destructive testing

Documentation relating to ultrasonic operators employed by or working for the foundry/testing

6. Identification And Datum Points

7.1 Electronic apparatus

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