National Seminar & Exhibition on Non-Destructive Evaluation, NDE 2014, Pune, December 4-6, 2014 (NDE-India 2014)

Vol.20 No.6 (June 2015) - The e-Journal of Nondestructive Testing - ISSN 1435-4934
www.ndt.net/?id=17891

Demonstration Of NDE Procedures – Why, What And How?

Prakash D. Tamhankar1,a , Pradeep Kumar2,b and M onish Vadhavkar3,c
1,2,3
Insight Quality Services, 507/508, Siddharth Towers, S. No. 12/3 B,
Kothrud, Pune – 411029, India
a b
Email: prakash.tamhankar@iqs-ndt.org, pradeep.kumar@iqs-ndt.org,
c
monish.vadhavkar@iqs-ndt.org

Abstract

Non-destructive Examination (NDE) is carried out as per a written procedure. The procedure is a
must as per most codes. Procedures give assurance of quality to customers. Procedures give
confidence of repeatable consistent results.

A procedure is incomplete without its qualification. Qualification is done through demonstration of

the procedure. Demonstration validates the procedure. Codes, and many times customers, specify
demonstration.

Demonstration requirements may vary. ASM E codes refer to their Section V Article 1 for general
demonstration requirements. Clause T-150 is important. Other parts of this code may specify other
requirements. For example, Radiographic examination procedure demonstration in Section VIII
Division 1 talks about a very simple method.

M ethodology of demonstration is important but may vary. Use of calibrated equipment is essential.
Consumables used need to have certificates as specified by the code. Personnel performing
demonstration shall be as specified in the procedure.

Test pieces used in demonstration are very important. They represent the material and jobs specified
in the scope of the procedure. The samples have to be with flaws. They need to qualify the range
specified as per the procedure. Naturally flawed samples are preferred. Quantity to be tested may be
specified by the code.

Documentation of demonstration is critical. Equipment calibration certificates, consumable

certificates, qualification certificates of personnel, master reports of the samples, reports of
demonstration and summaries, and other supporting documents for all these are required. These are
to be well controlled and are auditable during ASM E audits.

The Level III controlling and supervising the demonstration, and the Inspector witnessing the
demonstration, play important roles in the demonstration of procedures.

Keywords: Procedure, Demonstration, Qualification, Demonstration requirements, Equipment,

Personnel, Test specimens or samples, Documentation.
A successful Nondestructive Examination requires basically three things; approved / qualified
procedures, calibrated equipments and qualified personnel. This paper discusses the requirements
for qualifying a procedure. M ethodology of demonstration is important but may vary. When
carrying out demonstration there are some prerequisites which need to be considered. These are

1) Approved procedure- All NDE procedure used on the job shall be approved by NDE Level III.
NDE Level III shall select a suitable technique according to the job requirement. All essential and
non essential variables shall be mentioned on the procedures. Some values in the procedure may
have to be changed after the demonstration.

2) All instruments used in the procedure needs to be calibrated preferably traceable to the national
standard. Calibration certificates shall be made available to the review of NDE Level III and
Authorized Inspector.

3) All personnel performing and evaluating NDE shall be qualified and certified in accordance with
the requirements of the code accepted Editionof ASNT SNT-TC-1A or CP 189 or as acceptable to
the code. The personnel performing NDE shall be competent in the applicable method /Technique.

4) Flawed Sample – Test specimens used in demonstration are very important. They represent the
material and jobs specified in the scope of the procedure. There should be a flawed sample which
shall be approved by NDE Level III. These flaws may be artificial or Natural. Usually natural flaws
are preferred. When selecting the sample NDE Level III should select in such a way that it should
resemble the expected flaw in the actual job base on process like welding and forming. Test
specimen having flaws whose size; location, orientation; quantity and characterization have been
determined prior to demonstration should be known only to the supervising Level III Examiner.

The referencing Code Section shall be consulted for the following specific detailed requirements:

(a) Personnel certification requirements or prerequisites for qualification under the

requirements of this Article
(b) Examination planning, including the extent of examination
(c) Acceptance criteria for evaluating flaws identified during examination
(d) Level of rigor required for qualification
(e) Examination sensitivity, such as probability of detection and sizing accuracy
(f) Records, and record retention requirements

In deciding the NDE requirements for a job, there are various factors to be considered like whether
the requirements of any NDE are given by the referencing code, and if the referencing code requires
NDE according to a particular standard.

In general, most codes and most methods will prescribe a written procedure requirement. There are
certain exceptions, like Radiographic examination as per Section VIII Div. 1 of ASM E B & PV
code, where a procedure is exempted. ASM E B & PV code requires the procedures to be
demonstrated and qualified before use. The demonstration has to be done to the satisfaction of the
Inspector.

Procedure demonstration is defined in article 1 of section V as: A written procedure is

demonstrated, to the satisfaction of the Inspector, by applying the examination method using the
employer’s written nondestructive examination procedure to display compliance with the
requirements of this Section.
Procedure qualification is defined as: A written nondestructive examination procedure is qualified
in accordance with the detailed requirements of the referencing Code Section.

When we go through the various requirements of section V, we understand that a number of

variables are involved in all examinations. M ost of the times, these variables are listed in the
articles. The variables, as the name goes, have full potential to change the results of the
examinations, and therefore, need to be controlled. The code differentiates the variables as essential
and non-essential. A common misconception about non-essential variables is that they need not be
included in the written procedure. Actually, they need to be very much there in the procedure. The
word non-essential is related to their significance. When there is a change in any non-essential
variable, the procedure has to be revised, but need not be redemonstrated and requalified. Whereas,
a change in essential variable needs the procedure to be revised, redemonstrated and requalified.

Now controlling the variables means not letting the variables go off beyond or under certain limits.
The limits are specified in the codes. But what is the confidence that a written procedure will run
well and give the desired results? How to ascertain that particular discontinuities will be identified
by this procedure? One way is to actually perform the examination as per the procedure, and prove
it. But what shall we do with the variables when performing this examination? Obviously, we will
be performing with some fixed values of the variables. The best practice is to do various
examinations during the demonstration, using the limiting values of the variables, so that we are
able to establish that the procedure will still work with any value within these limits. This is called
establishing a range of variables. With such demonstration, we are giving the confidence to the
Inspector and to the customer that the procedure works well.

It is the responsibility of the M anufacturer, fabricator, or installer to establish non-destructive

examination procedures and personnel qualification and certification procedures conforming to the
referenced requirements.

As per article 1 of section V, when required by the referencing Code Section, a personnel
demonstration may be usedto verify the ability of the person to apply the examination procedure.
When Article 1 is directly referenced, the qualification of the person can be as per SNT-TC-1A or
ANSI/ASNT CP-189. Other National or international central certification programs may be used.
When the referencing Code Section does not specify qualifications or does not refer to Article 1
directly, in such cases qualification may involve a personnel demonstration to show the competency
of the personnel performing the examinations. This means that sometimes the demonstration is not
only to ensure that the procedure is technically correct to identify discontinuities, but it also proves
the ability of the performer.

The demonstration shall be performed under the control and supervision of a Level III Examiner
who is qualified and certified for performing the examination method and technique specified by the
procedure, and shall be witnessed by the Inspector. The supervising Level III may be an employee
of the qualifying organization or a subcontractor organization. The Level III will monitor the
demonstration, and guide regarding all the aspects. It is his responsibility to ensure that the finer
points of the examination are not missed out and carried out so as to give a clear result of the
demonstration. In actual job, the same way we need to ensure that the finer points are not missed.

At least one specimen having flaws whose size, location, orientation, quantity, and characterization
have been determined prior to the demonstration and are known only by the supervising Level III
Examiner shall be tested. The Level III preferably shall carry out the examination on the specimen
himself to get the details of the flaws. Care must be exercised by the Level III to keep the master
reports only to himself, which is important. Demonstrations can be done on flawed specimens
purchased from renowned suppliers. In such cases, full reports are available with the specimens.
The Level III shall be extra careful in such case, as the report can be easily available to others from
other sources, and the same samples may be used many times in other demonstrations. The
maintenance of these samples is also equally important.

The demonstration has to be done by a Level II or Level III Examiner, other than the supervising
Level III, who is qualified and certified to perform the examination method and technique specified
by the written procedure. The demonstrator shall have a good knowledge of the procedure and
technique to be performed. He/she should be conversant with the requirements and the variables.
The knowledge of the demonstrator gives a good confidence to the Inspector and customer even on
the procedure. In the same manner, we have to ensure that the detection of discontinuity is not
missed in the job.

As per section VIII division 1, a procedure for Radiographic examination is not essential. Hence the
requirement of demonstration is also diluted. Demonstration of density and penetrameter image
requirements is considered to comply with Section V requirements. This is so because when density
and sensitivity requirements are met, it means that the radiograph is interpretable, and the technique
employed was correct. The defect catching capacity is hence proved.

Ultrasonic examination demonstration is required when working as per Section VIII div 2. This is
critical, and good samples are a must.

Penetrant examination demonstration is critical. The demonstration has numerous variables. The
techniques could be more than one, and demonstration is required for every technique. For example,
procedure may be for solvent removable and water washable penetrants. The scope of the procedure
could be for welds, ground welds, machined parts etc. This means we have to demonstrate on each
such specimen. The timings between steps are variables. M inimum and maximum time after pre-
cleaning, after excess penetrant removal, minimum penetrant dwell time, and start and limiting
timings for interpretation – all have to be demonstrated. This makes the demonstration a long one,
but takes care of all variables in practice. Care must be taken in water washable technique not to
repeat tests on the same specimen a number of times. The indications may get weaker and weaker in
such a case.

M agnetic particle examination demonstration, when compared to penetrant examination

demonstration, is simpler. The equipment used is yoke most of the times. It could be AC, DC or
permanent magnet yoke. Specimens may differ as per the scope of the procedure. Calibration of the
yoke with regards to lifting power is a must. The variables regarding timings are absent, and hence
the demonstration is quicker.

In both penetrant examination and M agnetic particle examination, light demonstration is a must.
White light requirement for both is the same, and one common demonstration is sufficient.
Calibration of the lux meter is important. When done with a lamp, care should be taken to consider
the ambient light falling on the luxmeter, or the demonstration shall be done in dark space.

M ost of the codes require procedure demonstration to be witnessed by Authorized Inspector.

Customer also may witness the procedure demonstration. Documents relating to the procedure
needs to be properly prepared satisfying all the code requirements and shall be properly maintained.
It will be helpful in convincing the customer that the procedure is adequate enough to identify the
discontinuities in the job.
Documentation of the procedure demonstration shall include the following:

(a) The technical justification document

(b) NDE procedures, including the essential variables applied
(c) Description of the equipment used, including the calibration records
(d) Description of the specimens used to perform the demonstration
(e) Certification of acceptable completion of the performance demonstration.
The certification may be issued separately for the equipment/procedure and the
individual.

So all the NDE Procedures should be demonstrated with a flawed specimen with the approval of
NDE Level III and also should be controlled by NDE Level III. Procedure is always incomplete
unless we demonstrate or qualify it. The actual testing on the job is always incomplete unless we
implement the demonstrated procedure effectively.

Re fe re nce s:

[1] ASME BPVC Section VIII Division I, Edition 2013

[2] ASME BPVC Section V, Edition 2013
[3] SNT -T C-1A Edition 2006