NON-DESTRUCTIVE TESTING AND ACCEPTANCE STANDARDS

FOR STEAM TURBINE CASTINGS

1. SCOPEr
This Standard covers the manufacturing stages at which
inspection shall be carried out, the Inspection methods
and techniques, the quality control requirements and
standands of acceptance for major turbine castings, In-
cluding cylinders and steam chests, 1n chromium-molybde-
num, carbon-molybdenum and carbon steel.
The procedure for testing 1s as follows:-
I) Foundry quality control Clause 2
II) Manufacturing and Inspection stages " 3
III) Inspection techniques " 4
1v) Acceptance standards " 5
v ) Documentation " 6
vl) Release for despatch " 7
2. FOUNDRY QUALITY CONTROL:
The steel founder shall operate an adequate quality-con-
trol system 1n respect of all the procedures and tests
called for in this standard.
It shall be .the steel founder's responsibility to ensure
that all mandatory aspects of this standard are adhered
to and to certify the accuracy of all records and reports
submitted In accordance with clause 6.
3. MANUFACTURING AND INSPECTION STAGES:
3.1 Preliminary Inspection shall be carried out by the steel
founder after thorough cleaning, fettling and grinding
and, where called for, rough machining. At the discretion
* of the steel founder, progressive inspection procedures
may be adopted, provided that the condition of the cast-
Ing at each stage is adequate* for the effective applica-
tion of the Inspection technique employed.
 The following test methods shall be applied:
3.1.1 Overall visual Inspection in accordance with Clause 4.2
3.1.2 Magnetic particle .Inspection of all accesible surfaces 1n
accordance with clause 4.3
3.1.3 Overall ultrasonic inspection in accordance with Cl. 4.4
3.1.4 Radlographic inspection in accordance with clause 4.5 of
all fabrication weld preparation areas if called for by
the drawing or order and, at the steel founder's discre-
tion, on any shrinkage areas found by ultrasonic inspec-
tion to be unacceptable in terms of clause 5.1.2.4.
3.2 Excavation of defects
All defect Indications in excess of the limits defined in
clause 5 shall be repaired or submitted to BHEL for their
consideration and decision on a formal concession basis.
Where the arc-air technique 1s employed for the purpose
of excavation it shall be followed by grinding over the
whole excavated surface to a minimum depth of 1 mm prior
to the application of any subsequent Inspection.
Approval for welding must be obtained prior to commence-
ment of repair of defect excavations or build-up of scant
dimensions in the following cases:
Category 1 areas: All excavations or dimensional butter-
ing.
Category 2 areas: Excavations in excess of 18 mm depth or
60 cm2 area. Dimensional buttering in excess of 18 mm
depth.
- • • ' % • ' ' . . • " ;, • - • • . . - • ' ..'•/•;

All other weld repair excavations In Category 2 areas may

be undertaken at the discretion of the steel founder
without prior approval.
Visual and magnetic particle inspection shall be carried
out in accordance with clause 4.2 and 4.3 respectively on
all excavations on completion of preparation for welding.
This is an official inspection stage and it is the re-
sponsibility of the steel founder to notify BHEL, when
the casting is fully prepared for repair and available
for inspection.
3.3 Recording of defects and excavations
The foundry shall provide records of the following 1n the
form of sketches or photographs showing the location,
approximate shape and leading dimensions Including maxi-
mum depth:
3.3.1 Excavations In ateam chests and tee pieces
All excavations and areas to be built up by welding.
•%
In the case of an excavation associated with a fillet
radius and In excess of SOX of the thickness of the adja-
cent wall a more detailed record shall be provided,
preferably 1n the form of a supplementary sketch or
photographs* accurately describing Its position 1n rela-
tion to distinguishable permanent features of the cast-
Ing, Its contour, depths at several position, the minimum
wall thickness and the wall thickness at points Imme-
diately adjacent to the excavation.
3.3.2 Excavations In other castings
All excavations in excess of 18 mm depth or 80 cm* area.
3.3.3 Residual defects
All shrinkage areas not giving rise to excavations but
causing a reduction of 50% or more of the back-wall echo
or giving a signal amplitude 1n excess of 3 mm FBM (flat
bottom hole) equivalent.
All defects exceeding the acceptance limits but accepted
by BHEL on concession. •
3.4 Weld repairs
All weld repairs shall be carried out In accordance with
BS 4570: Part 1, or as otherwise agreed before commence-
ment of the repairs.
Detailed welding procedures shall be submitted 1n connec-
tion with all request for approval of welding repairs.
Where 11 1 s foundry practice to apply standard repair
procedures Identified by a reference number, each proce-
dure shall be submitted for Initial approval and the
reference number quoted 1n connection with any proposal
for subsequent use along with the request for approval of
the repair. Any change In any standard weld repair proce-
dure shall be notified to BHEL for re-confirmation of
approval.
Weld repair may be carried out with the casting 1n either
the annealed or normalised and tempered condition.
In the case of steam chests and tee-pieces 1n CrMoV the
post-weld heat treatment of major weld repairs shall
comprise complete normalising and tempering 1n accordance
with the heat treatment clause of the relevant material
specification. Subsequent minor repairs 1n steam chests
and tee-pieces and weld repairs generally on all other
castings shall be followed by stress relieving unless the
repairs are undertaken on the annealed casting. In such
cases the specified normalising and tempering shall be
applied.
3.5 Post-repai r i nsoecti on
All weld repairs shall be in the post-weld heat treated
conditin and ground to the requirements of clause 4.1
before re-Inspection.
Weld repairs shall be examined over the whole area of.the
repair and its vicinity as follows:
3.5.1 Visual inspection in accordance with clause 4.2.
i

3.5.2 Magnetic particle inspection in accordance with cl.4.3.

3.5.3 Ultrasonic inspection in accordance with clause 4.4.4. In
the case of recordable repairs the wholeof the weld and
heat affected zone shall be Inspected using a shear wave
technique capable of detecting subsurface cracking, lack
of fusion and lack of penetration.
3.5.4 Radiographic inspection at the discretion of the steel
founder or at the request of BHEL where further piarlfl-
cation of ultrasonic findings is necessary.
3.6 Final Inspection
After completion of all repairs arid all post weld heat
treatment a final inspection of the casting shall be
carried out by the steel founder.
This inspection shall comprise:
Overall visual inspection in accordance with clause 4.2.
Magnetic particle inspection of all accessible surfaces
in accordance with clause 4.3.
Completed records of this and all earlier inspections in
accordance with the requirments of clause 6 shal1 be
forwarded to BHEL together with notification that the
casting 1s aval1able for final Inspection by BHEL and
any other Inspecting authority nominated in the order. On
receipt of the completed inspection records , BHEL will
exercise their option to carry put such inspection as are
considered necessary to verify the foundry reports.
Clearance of the casting by other nominated inspecting
authorities shall be the responsibility of the steel
founder.
3-7 Repairs Subsequent to Final Inspection
Where unacceptable defects are disclosed on final Inspec-
tion the weld repairs and subsequent operations shall be
carried out in accordance with the clauses 3.2, 3.3, 3.4,
3.5 and 3.6.
3.0 Fabrication Welding
Fabrication welding shall not proceed before approval of
the weld design and procedures and, unless otherwise
agreed, acceptance by BHEL of all constituent castings in
accordance with clause 3.3.
Inspection of the fabrication welds shall be carried out
1n accordance with the appropriate BHEL Process Specifi-
cation called upon the order or drawing.
If furnace stress relieving 1s applied, magnetic particle
Inspection of all accessible surfaces of the castings
shall be repeated.
4. INSPECTION TECHNIQUES:
4.1 Surface Preparation
Prior to Inspection the test surfaces shall be cleaned
and fettled and be free from sand, blowholes, 'scale,
shrinkage, cracks and other surface Imperfections.
On rough machined areas the surface finish shall be6.3
(N9) or better as defined 1n BS 1134 : Part 1, but It •
should be noted that this does not overlde special sur-
face finish requirements In the specification for fabri-
cation welds called up by the order or drawing.
4-2 Visual Inspection
Visual examination shall be carried out to meet the
requirement of Clause 4.1.
4.3 Magnetic Particle Inspection Technique
Magnetic particle Inspection shall be carried out in
accordance with the requirements of AA 085 01 33 using
the current flow technique.
Unless otherwise agreed, DC or full or half wave recti-
fied AC, shall be used.
The prod technique Shall be employed in such a manner
that all surface defects Irrespective of direction are
detected, the prod spacing shall not exceeding 2OO mm.
A Berthold magnetic penetrameter set at position 2 or an
equivalent instrument shall be used to prove the effec-
tiveness of the magnetic field. For both the checking of
the fields strength and the examination of the weld the
sustained method shall be used in which the magnetic
particles are applied simultaneously with magnetisation
and magnetasing current is maintained for a short time
afterwards to allow adequate build up of particles. It 1s
important that magnetic Inks are well agitated before
application In order to ensure that the magnetic parti-
cles are in suspension.
 Each section magnetised arid sprayed shall be examined
before proceeding to the next.
Black magnetic ink- and powder shall be used m conjunc-
tion with a suitable white background paint. Strippable
paints are not acceptable. Water based inks shall con-
tain an aprppriate wetting agent. When fluorescent mag-
netic ink is employed, black light shall be used in
accordance with BS 4489. The magnetic ink or powder shall
conform to BS 4069, powder being permitted only on ex-
cavted areas and only by written agreement with BHEL.
41.4 Ultrasonic Inspection
4.4.1 Operators
Ultrasonic testing shall be carried out only by approved
operators. Each sub-contractor shall submit the names of
the opertars he intends to use, giving details of the
approvals obtained, to BHEL, Bhopal.
4.4.2 Equipment
The equipment characteristics and probes shall conform to
the requirements of AA 085 01 04.
4.4.3 Test probes \
These shall be selected from following.
2-3 MHZ 15-25 mm diameter combined double compression
wave probe.
4-5 MHZ 15 mm diameter combined double compression wave
probe.
2-3 MHZ 24 mm diameterr single compression wave probe.
4-5 MHZ 24 mm diameter single compression wave probe.
2-3 MH Z 10 mm diameter single compression wave probe.
2-5 MHZ 45" Twin and single shear wave probe.
/
2-5 MH_£* 60*
-
Twin and single shear wave .probe.
2-5 MH Z 70" Twin shear wave probe.
4.4.4 Inspection of the Casting
The foundry shall take full account of the moulding and
feeding method in planning the ultrasonic coverage and
all necessary .details of the method shall be made avail-
able to BHEL at the ultrasonic inspection stage.
 The whole of the casting shall be covered by overlapping
scans with compression probes. This examination shall be
supplemented by a thorough shear wave profile examination
of locations where the method or the casting gives rise
to features which may cause Internal planar defects e.g
raisers, chills, fillets, brackets, bosses and changes in
section.
The 2-3 MHZ combined double compression wave probe shall
be used:
4.4.4.1 On wall thickness less than 50 mm.
4.4.4.2 On sections that are accessible from one side only but
this shall be supported by a single crystal compression
wave probe at depths greater than 50 mm.
4.4.4.3 From both the outer and. Inner surfaces, (where ac-
cessible) 1f areas of shrinkage -are disclosed, in order
to determine the relative loss of section and depth of
sound metal below the testing surface. For this purpose
the limits of the defect shall be taken as the points at
which Its signal is distinguishable from the background
noise level.
4.4.4.4 On Internal surfaces of category 1 zones.(See fig.1)
Twin 45* and 60* shear wave probes shall be used to a
depth of 80mm and single shear wave probes beyond this
depth.
4.4.5 Scanning sensitivity
DCS scales may be used for setting compression wave scan-
ning sensitivity and evaluation of Indications 1n rela-
tion to the acceptance standard but where these are not
available a distance amplitude curve shall be plotted
using test blocks containing drilled flat bottomed holes
of.diameters corresponding to the level of acceptance.
In order to compensate for differences in surface condi-
tion and attenuation between the test block and the
casting, the sensitivity shall be adjusted by the dif-
ference in dB between the back wall Indication amplitude
on the casting and that on the same thickness of the test
block (I.e.taken at a position away from the Influence of
the flat bottomed hole).
When using shear wave probes the sensitivity shall be
such tht a grass level of 2-3mm is obtained at the maxi-
mum depth to be tested..'•'.
4.4.6 Attenuation
Measurements shall be made on the body of the casting
using a 4MHz compression wave probe. The signal height
from a 3mm diameter flat bottomed hole at the back wall
distance shall be at least 8dB higher than 'grass' level.
If a DGS scale 1s not available a test block containing
the appropriate size of hole may be used provided that
the sensitivity Is adjusted on the casting as directed 1n
clause 4.4.5. '
4.4.7 Inspection of Weld Preparation Areas
In the case of fabrication weld sites indicated on the
drawing an ultrasonic examinatin shall be carried out as
follows:
(a) From €he end face and outside diameter using a 4-5
MHz combined double compression wave probe to a
depth of 50mm and a single probe below this depth.
(b) From the outside diameter using a 4-5 MHz 60*
miniature twin shear wave probe scanning in the
axial direction towards the end face. The sensitivi-
ty shall be such that a grass level of 2-3mm is
obtained at the maximum depth.
(c) As is (b) but scanning circumferentially in both
directions. "
(d) If the wall thickness exceeds 60mm then repeat re-
quirement of (b) and (c) using a 60* miniature
single shear wave probe.
Each indication observed shall be thoroughly Investigated
to establish whether it has "travelling" features typical
of radical cracking. A l l such indication and thlr dimen-
sions shall be recorded irrespective of signal amplitude.
4.5 Radiographic Inspection
Radiographic Inspection shall be carried out as appro-
priate (See clause 3.1.4), in accordance with AA 085 01
40. Either X-rays or gamma rays may be used as a source
of radiation. The geometric unsharpness shall be the
smallest, consistent with practicable exposure times.
5. ACCEPTANCE STANDARD:
5.1 Entire Casting
. Note: The references to Categories 1 and 2 below, refer
to the critical and non-critical parts of the casting as
designated on the casting drawing or otherwise defined.
* " •' •". ' ..
5.1.1 Magnetic Particle Inspection
Linear discontinuities are acceptable provided that they
do not exceed the limits 1n table 1 and are not associat-
ed with or part of sub-surface defect.
Table 1 Linear discontinuities
«»*«V«IB>«V««B(*W«BB«VMMBW^M«*aW*«flHiWWI ^ «t«V<«^«^B^M^M^«^M«V ••••*••» ^BW^M«W «•••••• ^M^KI^^M^B ^•^•^•^••M ^M «M ^B ••••••_

Feature of Discontinuity Category 1 Category 2

Length of Discontinuity 6mm 10mm
10mm
Separation between
discontinuities
In line 6x length
length of 4x length of
longer longer
longer
Lateral 3x length of 2x length of
longer longer
Aggregate length in a 20mm 30mm.
*frame 10 cm x 16 cm.
* Placed in the most unfavourable position.
5.1.2 Ultrasonic Inspection
The following conditions shall be considered unaccept-
able.
5.1.2.1 Any planar defect having a measurable dimension normal
(or approximately normal) to the surface greater than 3mm
' irrespective of- signal amplitude. .
5.1.2.2 Indications of shrinkable "tailing" or worm holing which
occur-within 16 mm of either the casting surface or a
subsequently finish machined internal or external sur-
face. ,
5.1.2.3 Attenuation in excess of the limits defined in clause
4.4.6.
5.1.2.4 Any shrinkage Indication which causes a reduction of back
wall echo of 50X or more and exceeds any one of the
•'••;> parameters A, C, D, E or F of Table 2 or 3.
Where geometry of section precludes the use of the back
wall echo for location and plotting of shrinkage a signal
level of 3 mm FBH equivalent shall be used instead.
5.1.2.5 Any isolated indications exceeding any one of the parame-
ters B, C, D, E or F of Tables 2 or 3.
 Shrinkage defects exceeding the limits given 1n tables 2
or 3, in respect of signal amplitude and/or loss of back-
wall echo only, may.be radiographed and will be accepted
if the shrinkage Intensity does not exceed the standards
laid down in clause 5.1.3. The permissible area of defect
shall be as defined 1n the ultrasonic standard.
Table 2. Category 1 areas
- ,
Parameter : * Zone : *Zones : * Zones
: : • . . . • - . ,.-;•:'••. • ' : • .-1 / . . •.: 2 & 3 : 4

A-Reduction of back wall 90% 75X Not Applicable

. echo
B- single amplitude 10 mm FBH* 6 mm FBH+ 3.00mm FBH+
parallel section
C- Thickness of defect 15X wall 10X wall Not
thickness thickness Applicable
D- Max. dimension of 100 mm 75 mm 12.00 mm
defect
> ' •
E-Area of defect Not 10 cma 0.25 cma
applicable
F- Total, area in - 200 cm2 65 cm* 2.50 cm2
1000 cm* frame

Table 3. Category 2 areas

Parameter *Zone * Zones

1 2 &3

A- Reduction of backwall echo 90X 75X

./
B- Single amplitude - parallel 10 mm FBH+ 6 mm FBH+
sections
C- Thickness of defect 15X wall 10% wall
thickness thickness
D- Max. dimension of defect Unl1 mi ted 100 mm
E- Area of defect Unl imlted 100 cm8
F- Total area in 1000 cm2 frame Unl i mi ted 100 cm"
 Note : Where a defect .lies 1n two adjacent zones, exclud-
ing zone 4, the limits defind for the outer zone, shall
apply and total defect thickness shall not exceed 15X
* See fig. 1 for description of zones.
+ Flat bottom hole equivalent.
5.1.3 Radioaraphic Inspection
Shrinkage defects in excess of clause 5.1.2.4 which on
radiographic Inspection exceed the Units given in Table
4 are unacceptable.
Table 4. Shrinkage defects

Severity level
Wall region * Zone 1 * .Zones 2-ft 3
A.S.T.M Standard E186 : E280 E186 : E280
Wall thickness - mm < 75 : 75 - 115 : >115 <115 : 2:115
Class C type (1) 4 : 5 : 5 2 : 2
(2) 4 : 4 : 4 2 : 2
(3) 3 : 3 ; 3 2 : 2

* See * fig. 1 for description

• .
of zones.
.

5.2 Weld preparations

5.2.1 Magnetic particle inspection
* . • . i • . ' : . - ' . ' '

Cracks and non-metallic inclusions are unacceptable.

5.2.2 Ultrasonic Inspection
The following conditions shall be considered unaccept-
able:
5.2.2.1 Any condition within the machined length giving rise to
clusters of Indications whose amplitude are equivalent to
a 1mm ideal reflector or greater.
5.2.2.2 Any radial planar defects exhibiting "travelling" Indica-
-•' . . . . tions. • • . ' . • '' • • '" •' •. •;• ' • ' • • .:'•"•• •'. • .
5.2.2.3 Attenuation in excess of the limits definedin clause
5.4.6.
5.2.3.4 Any indication greater than 3mm ideal reflector within 25
mm of the final weld preparation face.
5.2.3 Radiographic Inspection
The following conditions shall be considered unaccept-
able:
Shrinkage, porosity, sand and slag Inclusion defects
outside the limits of ASTM class 1 ( E186 or E 280).
5.3 Weld Repairs
The following conditions shall be considered unaccept-
able:
5.3.1 Magnetic Particle Inspection
Any indication that can be Identified as a crack.
5.3.2 Ultrasonic Inspection
Zones 3 and 4 of Category 1 areas
5.3.2.1 Defects with a radial dimension greater than 3 mm.
5.3.2.2 Indication greater than 3mm flat bottom hole equivalent
measured on compression wave test.
Zones 1 and 2 Category 1 and all zones of Category 2
areas
5.3.2.3 Defects with a radial dimension greater than 3mm within 6
»
mm of final surface. . ' . " • . '

5.3.2.4 Defects with a radial dimension greaterthan 6mm.

5.3.2.5 Defects with a radial dimension greater than 3mm and
exceeding 30 mm in length.
5.3.2.6 Indication greater than 6 mm flat bottom hole equivalent
measured on compression wave test.
6. DOCUMENTATION
6.1 . General
A statement signed by a responsible person in the found-
ry quality control department shall be provided in report
form for each examination carried out. This report shall
give identification of the component, the manufacturing
and inspection stages at which examination has been car-
ried out (as called for in clasue 3) and the area tested.
Additional information requirements regarding technigues,
materials and equipment used, specific to the particular
inspection method, are detailed in the following clauses.
6.2 Magnetic Particle Inspection
The following details shall be included in addition to
those in clause 6..1 .
a) Equipment used.
b) Current used.
c) Prod spacing used.
d) Magnetic fluid or powder used.
e) Name of operator.
f) Results of examination.
g) Date of examination.
6.3 Ultrasonic Inspection
The report shall include the following details in addi-
tion to the requirements in clause 6.1
a) Equipment and Serial Number
b) Test probes, frequency, crystal dimensions and probe
angles (where applicable).
c) Test sensitivity.
•d) Maximum attenuation reading obtained on body of cast-
ing.
e) Record of examination before and after weld repair
(including sketches or photographs).
f) Date of examination.
g) Name of operator.
B.4 Radiograph1c Inspection
a) Technique, including shooting sketch.
b) X-ray set/Isotope used.
c) Kilovoltage/Source Strength.
d) Focal spot/ Source Dimension.
e) FFD/SFD.
f) Film used.
g) Screens used,
h) Exposure.
 j) Sensitivity obtained.
k) I.Q.I used.
1) Film density.
m) Identification.
n) Rad1ograph1c report.
o) Date of examination.
p) Name of radiographer.
•* . - • • . ~ . '
6.5 Weld repair sketches and procedures
Weld repair sketches together with the weld procedure
employed shall be provided in line with the requirments
of clauses 3.1, 3.2 and 3.4.
7. RELEASE FOR DESPATCH

Castings shall not be despatched by the foundry until

Instructions are received from BHEL 1n writing or by Fax/
telex. This permission will only be given on receipt of a
complete and satisfactory set records and after any
necessary monitoring by BHEL or their customer.