ge rail procedure for ultrasonic and visual · pdf file(2001 edition through the july 2002...

GE Transportation Rail Quality Specification

5/12/05 Procedure for Ultrasonic & Visual Inspection of Welds Rev. A

Author: V Ross / S Yesudas Approval: V Ross 84A215296DG

Issued: GETS Engineering 3/17/05 BUS. AREA: L COE DIST: 10 pt Sheet 1 of 21 This Drawing is the Property of GENERAL ELECTRIC COMPANY, TRANSPORTATION SYSTEMS DIVISION. This drawing is loaned upon the express condition that it shall not be reproduced in any manner, and shall be returned upon demand. It is submitted for evaluation purposes and it, and the information contained therein, shall not be otherwise used nor disclosed to third parties without written permission of General Electric Co.

GE RAIL PROCEDURE FOR

ULTRASONIC AND VISUAL INSPECTION

OF

LIGHT BOX BEAM STYLE LOCOMOTIVE PLATFORMS SPECIFIC CRITICAL WELD

JOINTS





LIST OF REVIEWERS

S. No. Name Section Date 1 Vince Ross Platform CoE 3/16/2005 2 William Ruprecht Quality 3/16/2005 3 Ray Stempka Manufacturing 3/16/2005

Table of Contents 1 SCOPE..................................................................................................................................... 3 2 ENGINEERING CODES, REFERENCE CODES & RECOMMENDED STANDARDS........... 3 3 PERSONNEL QUALIFICATION.............................................................................................. 3 4 PERSONNEL CERTIFICATION .............................................................................................. 3 5 VISUAL INSPECTION METHOD............................................................................................. 4 6 ULTRASONIC INSPECTION METHOD .................................................................................. 4 7 SCANNING METHOD.............................................................................................................. 4 8 COUPLANT.............................................................................................................................. 4 9 ULTRASONIC INSTRUMENTS............................................................................................... 5 10 GENERAL CALIBRATION REQUIREMENTS........................................................................ 9 11 ANGLE BEAM CALIBRATION ............................................................................................. 10 12 STRAIGHT BEAM CALIBRATION........................................................................................ 11 13 CALIBRATION CONFIRMATION.......................................................................................... 12 14 CONFIRMATION ACCEPTANCE VALUES.......................................................................... 12 15 EXAMINATION ...................................................................................................................... 12 16 EVALUATION ........................................................................................................................ 13 17 SIZING INDICATIONS........................................................................................................... 14 18 ACCEPTANCE CRITERIA .................................................................................................... 15 19 DOCUMENTATION ............................................................................................................... 15 20 TABLES AND FIGURES ....................................................................................................... 17 REVISION HISTORY

Rev

Change Author Date

0 Release to DRS S Yesudas 3/16/2005





A Visual Inspection Method added S Yesudas 5/12/2005 1 SCOPE This specification outlines the Procedure for ultrasonic and visual examination of welds. The ultrasonic procedure is specified for carbon steel, two (2) inches (50 mm) or less in thickness, capable of conducting ultrasound and having configurations that lend themselves to contact testing, as may be required by General Electric Specifications and other codes under which a component or system is being fabricated or constructed. General Electric Transportation certifies that this procedure meets the guidelines for ultrasonic inspection established by ASME Boiler and Pressure Vessel Code Section V Article 4. (2001 edition through the July 2002 addenda) All ultrasonic inspection shall be performed in strict accordance with individual job requirements. Where necessary, a separate procedure may be developed to assure conformance to job procedure specifications and customer requirements. 2 ENGINEERING CODES, REFERENCE CODES & RECOMMENDED

STANDARDS The latest revision of the following documents shall form part of this specification when not otherwise stated in General Electric Transportation’s contract or herein.

(a) ASME BPVC Section V - Section V Article 4 (b) ASNT - SNT-TC-1A 2001 edition (c) AWS - A 2.2 (d) ASTM/ASME - SE-213, SE-273, SE-797

3 PERSONNEL QUALIFICATION Personnel performing NDE in accordance with this specification shall meet the qualification requirements of SNT-TC-1A.

4 PERSONNEL CERTIFICATION Personnel meeting the qualification requirements of Section 3 shall have on file a copy of "Record of Personnel Certification". This record shall be retained on file for review by authorized customer representatives, upon request.

Examinations shall be conducted by personnel





(a) Certified as Level I and directly supervised by a Level II or III individual. or

(b) Certified as Level II or III. Only Level II or III individuals shall be

permitted to perform final evaluation of inspection results. 5 VISUAL INSPECTION METHOD Prior to welding, butt joints and fillet weld joints shall be checked for proper alignment and root opening in accordance with G.E. Locomotive welding procedures. Prior to ultrasonic inspection all completed welds shall be visually inspected for their full extent to the acceptance limits specified in Table 3 and Figures 2 and 3. 6 ULTRASONIC INSPECTION METHOD Only pulse-echo type equipment utilizing A-scan presentation shall be used for ultrasonic examination. Pulse echo testing shall be conducted using the following methods.

(a) Angle Beam Testing - The sound enters the material at an angle of approximately 40 to 70 degrees.

(b) Straight Beam Testing - The sound enters the material perpendicular

to the test surface. 7 SCANNING METHOD Scanning shall be performed manually by moving the transducer in a direct path or by moving the material in a direct path with the search unit stationary. All scanning shall be performed at a uniform rate of speed determined at the time of the test so that discontinuities relative to the quality of the material can be detected. A maximum scanning rate of 6 inches per second is to be used. The transducer shall be placed in intimate contact with the test surface. A minimum of 10 percent transducer overlap will be used in the scan pattern for 100% coverage. 8 COUPLANT For the sound to be transmitted into the material, the surfaces of the transducer and the material must be coupled with a sound transmission medium.





Couplant, with all additives, shall not be detrimental to the material being examined. The same couplant shall be used for calibration and examination. Consideration shall be given in the selection of couplant to minimize post-inspection cleaning requirements. Examples of acceptable, commercially available couplants permitted by this procedure are as follows:

Exogel 20 or 30 Echogel Exosen 20 or 30 Glycerin Hamikleer

9 ULTRASONIC INSTRUMENTS The examination shall be conducted with an ultrasonic pulse reflection system generating frequencies over the range of at least 1 to 6 MHz, and shall be equipped with a stepped gain control in units of 2.0 dB or less. Other frequencies may be used if equal or better sensitivity can be demonstrated. Basic instrument Calibration / Qualification shall be performed and documented at intervals not to exceed three (3) months or prior to use thereafter or whenever maintenance is performed which affects the equipment function as follows:

1. Screen height linearity shall be evaluated in accordance with Mandatory

Appendix I of ASME BPVC Section V Article 4. The ultrasonic instrument shall provide linear vertical presentation within +/- 5% of the full screen height for 20% to 80% of the calibrated screen height (base line to the maximum calibrated screen point). The screen height linearity shall be measured and at the time of calibration.

2. Amplitude control linearity shall be evaluated in accordance with Mandatory

Appendix II of ASME BPVC Section V Article 4. The ultrasonic instrument shall utilize an amplitude control accurate over its full useful range to 20% of the nominal amplitude ratio, to allow the measurement of indications beyond the linear range of the vertical display on the screen. The amplitude control linearity shall be measured and recorded at the time of calibration.





3. If the instrument has a damping control, it may be used if it does not reduce

the sensitivity of the examination.

4. The reject control shall be in the "off" position for all examinations unless it can be demonstrated that it does not affect the linearity of the examination.

5. The following ultrasonic instruments (or equivalent) with calibrated gain

(Attenuator) control may be used:

“A” scan presentation:

Krautkramer Branson Model – USK – 5 Krautkramer Branson Model – USK – 7S Krautkramer Branson Model – USL – 36 Krautkramer Branson Model – USL – 37 Krautkramer Branson Model – USL – 38 Krautkramer Branson Model – USL – 48 Krautkramer Branson Model – USD – 10 Krautkramer Branson Model – USIP – 10 Krautkramer Branson Model – USIP – 11 Krautkramer Branson Model – USIP – 12 Krautkramer Branson Model – USN – 50 Krautkramer Branson Model – USN – 36 Automation Industries – M–90 Automation Industries – QC–400 Panametrics Model 2300 – Epoch III Sonic Mark I Sonic Mark II

9.1 Search Units (Transducers)

Search Units may contain either single or dual transducer elements.

Search units with contoured contact wedges may be used to aid ultrasonic coupling. Inspections shall be done with the same contact wedges used during calibration.

Transducer incident angle shall be verified utilizing an IIW block prior to calibration and inspection.





The nominal frequency shall be from 1 MHz to 5 MHz, unless variables such as production material grain structure require the use of other frequencies to assure adequate penetration or better resolution.





9.2 Calibration Block

9.2.1 Basic Calibration Blocks

The material from which the block is fabricated shall be of the same product form, and material specification or equivalent P-number grouping, and heat treatment as the material being examined. P-number materials for calibration blocks of P-nos. 1, 3, 4, and 5 materials are considered equivalent. See Figure 1 for the Basic Calibration Block(s).

The surface finish on the scanning surface of the block shall be representative of the scanning surface finish on the component to be examined.

9.2.2 Calibration Block Quality

Prior to fabrication the block material shall be completely examined with a straight beam search unit. Areas that contain an indication exceeding the remaining back-wall reflection shall be excluded from the beam paths required to reach the various calibration reflectors.

9.2.3 Heat Treatment

Calibration blocks shall receive at least the minimum tempering treatment required by the material specification for the type and grade

9.2.4 Block Curvature

For examinations in materials where the examination surface diameter is greater than 20 inches a block of essentially the same diameter curvature, or alternatively, a flat basic calibration block, may be used.

9.2.5 Materials with convex diameters 20 inch and less

For examinations in materials where the examination surface diameter is equal to or less than 20 inches, a curved block shall be used. Except where otherwise stated in this procedure a single curved basic calibration block may be used for examinations in the range of curvature from 0.9 to 1.5 times the basic calibration block diameter. See Figure 2 (ASME BPVC Section V Art. 4 Figure T-434.1.7.2) for any diameter range.





9.2.6 Materials with concave diameters 20 inch and over

As an alternate to the requirements of Section 8.2.4, when examining from the convex surface by the straight beam contact technique, ASME BPVC Section V Art. 4 Non-mandatory Appendix G may be used to determine the necessary gain correction factor.

9.2.7 Block Thickness When two or more base material thicknesses are involved, the calibration block thickness shall be determined by the average thickness of the weld.

9.2.8 Block Range When the block thickness +/- 1 inch spans two weld thickness ranges as shown in Figure 1, the block's use shall be acceptable in those portions of each thickness range covered by 1 inch.

9.2.9 Alternate Block Design As an alternate, calibration blocks may be constructed as shown in ASME BPVC Section V Art. 4 Non-mandatory Appendix J Figure J-431. 10 GENERAL CALIBRATION REQUIREMENTS

10.1 Ultrasonic System Calibrations shall include the complete ultrasonic system and shall be performed prior to use of the system in the thickness range under examination.

10.2 Calibration Surface Calibrations shall be performed from the surface (convex or concave) corresponding to the surface of the material from which the examination will be performed.

10.3 Couplant The same couplant to be used during the examination shall be used for calibration.





10.4 Contact Wedges The same contact wedges to be used during the examination shall be used for calibration.

10.5 Instrument Controls Any control, which affects instrument linearity (e.g., filters, reject, or clipping), shall be in the same position for calibration, calibration checks, instrument linearity checks, and examination. 10.6 Temperature For contact examination, the temperature differential between the calibration block and the examination surfaces shall be within 25o F.

11 ANGLE BEAM CALIBRATION

1. Position the search unit on the BCB (Figure 1) for the maximum response from the first indication from the 1/4 T side drilled hole. Adjust the left edge of this indication to line 2 on the screen with the delay control.

2. Position the search unit for the maximum response from the first indication from

the 3/4 T side drilled hole. Adjust the left edge of this indication to line 6 on the screen with the range control.

3. Repeat delay and range control adjustments until the 1/4 T and 3/4 T hole

reflections start at sweep lines 2 and 6. 4. Position the search unit for maximum response from the square notch on the

opposite surface. The indication will appear near sweep line 8.

5. Two divisions on the sweep equal 1/4 T. 6. Adjust the sensitivity control to provide an 80% (plus or minus 5% of full screen

height) of full screen indication from the maximum response from the hole with the highest amplitude response. Mark the peak of the indication on the screen with a grease pencil.





7. Without adjusting the sensitivity control position the search unit for maximum response from the remaining two holes and mark the maximum response on the CRT in a like manner.

8. Position the search unit for maximum amplitude response from the 3/4 T hole

indication after the beam has bounced from the opposite surface. The indication should appear at sweep line 10. Mark the peak on the screen for the 5/4 T position.

9. Connect the screen marks for the side drilled holes to provide the distance

amplitude curve (DAC) 12 STRAIGHT BEAM CALIBRATION

1. Position the search unit for the maximum response from the first indication from the 1/4 T side drilled hole. Adjust the left edge of this indication to line 2 on the screen with the delay control.

2. Position the search unit for the maximum response from the first indication from

the 3/4 T side drilled hole. Adjust the left edge of this indication to line 6 on the screen with the range control.

3. Repeat delay and range control adjustments until the 1/4 T and 3/4 T hole

reflections start at sweep lines 2 and 6.

4. Position for maximum response from the hole which gives the highest amplitude.

5. Adjust the sensitivity control to provide an 80% (plus or minus 5% of full screen height) of full screen indication from the hole. Mark the peak of the indication on the screen with a grease pencil.

6. Without adjusting the sensitivity control, position the search unit for maximum

response from the remaining two holes and mark the maximum response on the CRT in a like manner.

7. Connect the screen marks for the side drilled holes to provide the distance

amplitude curve.





13 CALIBRATION CONFIRMATION

13.1 System Changes When any part of the examination system is changed, a calibration check shall be made on the calibration block to verify that distance range points and sensitivity setting(s) satisfy Section 10 and/or Section 11 of this specification document. 13.2 Periodic Examination Checks A calibration check on at least one of the reflectors in the calibration block shall be made at the finish of each examination or series of examinations, every 4 hours during examination, and when examination personnel are changed. The distance range points and sensitivity setting(s) recorded shall satisfy the requirements of Section 10 and/or Section 11 of this specification document.

14 CONFIRMATION ACCEPTANCE VALUES

14.1 Distance Range Points If any distance range point has moved on the sweep line by more than 10% of the distance reading or 5% of full sweep (whichever is greater), correct the distance range calibration and note the correction in the examination record. All recorded indications since the last valid calibration or calibration check shall be reexamined and their values shall be changed on the data sheets or re-recorded.

14.2 Sensitivity Settings If any sensitivity setting has changed by more than 20% or 2 dB of the amplitude, correct the sensitivity calibration and note the correction in the examination record. If the sensitivity setting has decreased, all data sheets since the last valid calibration or calibration check shall be marked void and the area covered by the voided data shall be reexamined. If the sensitivity has increased, all recorded indications since the last valid calibration or calibration check shall be reexamined and their values shall be changed on the data sheets or re-recorded.

15 EXAMINATION

Angle beam scanning shall be performed for reflectors oriented parallel and transverse to the weld as follows:





15.1 Parallel Reflectors The angle beam shall be directed at approximate right angles to the weld axis in two directions where possible. The search unit shall be manipulated so that the ultrasonic energy passes through the required volumes of weld and adjacent base metal. The scanning shall be performed at a gain setting at least two times the primary reference level. Evaluation shall be performed with respect to the primary reference level. The search unit shall be rotated 180 degrees and the examination repeated. 15.2 Transverse Reflectors The angle beam shall be essentially parallel to the weld axis. The search unit shall be manipulated so that the ultrasonic energy passes through the required volumes of weld and adjacent base metal specified by the referencing code. The scanning shall be performed at a gain setting at least two times the primary reference level. Transducer scanning movement shall be in accordance with Section 6 of this specification document. 15.3 Straight beam scanning shall be performed as follows: Straight beam scanning of the adjacent base metal shall be performed to detect reflectors that might affect interpretation of angle beam results, and is not to be used as acceptance-rejection examination. Locations and areas of such reflectors shall be recorded on the inspection report.

The weld and base metal shall be scanned, to the extent possible with straight beam search unit. The scanning shall be performed at a gain setting of at least two times the primary reference level. Evaluation shall be performed with respect to the primary reference level. Transducer scanning movement shall be in accordance with Section 6 of this specification document. 16 EVALUATION

For examinations using DAC calibrations, any imperfection with an indication amplitude in excess of 20% of DAC shall be investigated to the extent that it can be evaluated in terms of the acceptance of this specification.





Reflectors evaluated as laminar reflectors in the base material which interfere with scanning of examination volumes shall require the angle beam examination technique to be modified such that the maximum feasible volume is examined, and shall be noted in the record of the examination. Planar imperfections (through wall) should be evaluated at an incident angle of less than 10 degrees. Where this is not possible, an additional gain shall be added in accordance with Table 1. For the purposes of Table 1 planar imperfections shall be considered to lie along the welding preparation faces. The probe angle shall be the actual measured angle, not the nominal angle. 17 SIZING INDICATIONS When determining the length of an indication, greater in length than the active transducer width, manipulate the transducer to give the maximum amplitude from the reflector. Adjust amplitude to 80% screen height. Slide the transducer horizontally in one direction until the amplitude of the indication drops to 40% screen height. Mark the indication at the midpoint of the transducer. Repeat the sequence in the opposite direction and again mark the indication at the midpoint of the transducer. The length between marks is representative of the length of the indication. When determining the length of an indication, smaller in length than the active transducer width, manipulate the transducer to give the maximum amplitude from the reflector. Adjust amplitude to 80% screen height. Slide the transducer horizontally in one direction until the amplitude of the indication is no longer detectable. Slide the transducer back toward the indication horizontally until the amplitude of the indication increases to 40% screen height. Mark the indication at the midpoint of the transducer. Repeat the sequence in the opposite direction and again mark the indication at the midpoint of the transducer. The length between marks is representative of the length of the indication. To determine the extent of a through-wall (Planar) type indication manipulate the transducer to give the maximum amplitude from the reflector. Adjust amplitude to 80% screen height. Read and record the sweep reading to the reflector. Slide the transducer toward the reflector (forward) until the amplitude of the reflector falls to 40% screen height. Read and record the sweep reading to the reflector. Repeat the process moving away (back) from the reflector and read and record the sweep reading to the reflector.

When calibrated in accordance with Section 10 of this document, the minimum and maximum depths can be determined directly from the positions of the 40% reflectors on the sweep line.





When necessary to determine percent of wall thickness subtract the minimum sweep reading from the maximum sweep reading and divide by the sweep reading for one complete wall thickness (8 on the sweep line). Multiply by 100 and record as percent of wall. Example - If the 40% minimum sweep was at 2 and the maximum 40% sweep was at 3.5 the percent of wall would be:

3.5 - 2 = 1.5 1.5 / 8 = 0.1875 0.1875 X 100 = 18.75%

18 ACCEPTANCE CRITERIA The acceptance will be based on an ASME calibration block with a .6 dia hole. Crack, lack of fusion or lack of penetration are grounds for rejection. Any indication other than porosity within 1” of the edge will be grounds for rejection. Linear indications greater than ¼ T in length will be grounds for rejection. Cumulative length of the defects must not exceed T in length of 12 T and indications must be separated by 2 T. Note: plate thickness (if a plates of different thicknesses are welded together use then T=thickness of thinner plate) 19 DOCUMENTATION

Non-rejectable indications exceeding 20% DAC shall be recorded on the inspection report. Rejectable indications shall be recorded. As a minimum, the type of indication (i.e., crack, lamination, inclusion, etc.), location, and extent (i.e., length and through-wall dimension) shall be recorded. When a test piece is finished, an inspection record shall be prepared using an Ultrasonic Inspection Report containing the information listed below. This record shall become a part of the complete inspection package and shall list the following information:

a. NDE Contractor b. Purchase Order Number c. Procedure Specification and revision d. Technique Specification e. Component Identification f. Identification of material or volume scanned





g. Surface(s) from which examination was conducted including surface condition

h. Inspection Evaluation Results i. map or record of rejectable indications detected or areas cleared j. Areas of restricted access or inaccessible areas k. Inspector and qualification level l. Date and time of Inspection m. Ultrasonic Instrument Model and S/N n. Frequency of Test o. Transducer Model, S/N, and Size & Angle(s) p. Couplant used, brand name or type q. Calibration Block Identification r. Instrument reference level gain and, if used, damping and reject

settings(s)

The following additional records shall be supplied with the inspection package when requested by the Customer:

a. One copy of technician certifications for the technician performing the work.

b. One copy of the basic equipment qualification certification required by Section 8 of this document.





20 TABLES AND FIGURES

Figure 1





Legend for Figures 2, Figure 3, Table 1

L1 or L2 = Length or maximum dimensions of an individual imperfection measured parallel to axis of the weld L = Sum of lengths of imperfections in stated weld length H = Height (or Depth) of imperfection T = Thickness of base material (thinner of different) D = Size (diameter) of rounded imperfections S = Size of filler weld (Leg dimension)

Table 1





Table 3





Figure 2





Figure 3

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