NON-DESTRUCTIVE EXAMINATION AND STANDARD OF

ACCEPTANCE-GENERAL FORGED COMPONENTS

1. SCOPE:
This standard covers the non-destructive testing pro-
cedures and standards of acceptance applicable to general
forged components such as couplings, spacers and thrust
collars. The tests shall be carried out by the supplier
after machining to the drawing dimensions.
For the requirements for rotors, shafts and discs refer-
ence should be made to AA 085 01 02 and to BP 085 01 87
for forged pipe-work stub pieces.
2. REFERENCES:
B.S. 405S, BS 6072, BS 4124, BS EN 10228-3.
3. SUMMARY OF PROCEDURE:
i) Surface Finish
ii) N.D.T. Procedure
i i i) Acceptance Standards
iv) Recording of Results.
4. PROCEDURE:
4.1 Surface Finish:
j
All surfaces shall be machined to a finish of 6.3 urn Ra or
better, produced by a broad-nosed tool to ensure a surface
adequate for ultrasonic and magnetic particle inspection.
4.2 N..D.T. Procedure:
4.2.1 Visual Examination:
All surfaces shall be visually examined in a clean condi-
tion and any defects observed shall be reported.
4.2.2 Magnetic Particle Inspection:
All surfaces shall be examined. Testing equipment, condi-
tions and procedures shall be in accordance with,88:6072.
Techniques shall be such as to detect defects in any
direction. Testing materials in the form of dry powders
and water based inks are not acceptable. Application of
magnetic particles shall be by the continuous method
described in BS 4124 a portable flux indicator shall be
used to demonstrate attainment of an adequate field
strength. The Berthold magnetic flux indicator used on
setting 2 is recommended. The attention of operations
shall be drawn to the precautions described in BS:6072 to
minimise arcing and excessive heating of the forging
surface at the point of prod contact.
4.2.3 Ultrasonic Inspection:
Testing equipment shall comply with BS:4124/BS EN 10228-3.
The forging shall be scanned on all external surfaces
using single crystal longitudinal wave probes with a
frequency of 4-5 MHz. Combined double probes shall also
be used to cover the near zones. Other probes, as appro-
priate, shall be used to explore and evaluate unfavourably
oriented defects. A test block shall be available in
ultrasonically similar steel containing 3 mm flat bottomed
holes at varying depths for setting of sensitivity and
evaluation of indications. The scanning sensitivity shall
ba established by obtaining a half screen echo from a 3 mm
flat bottom hole at the maximum testing distance and
increasing the sensitivity fay 12 dBs.
All indications in excess of half screen height shall be
recorded. Groups of indications in excess of quarter
screen height shall be recorded.
4.3 Acceptance Standards:
4.3.1 Visual and Magnetic Particle Inspection:
Cracks are unacceptable.
Other linear threadlike defects continuous of fragmented
upto 6 mm in length and separated by 3 x L, where L is the
length of the largest defect, are acceptable provided
there are not more than three such defects in any area 150
mm x 150 mm.
Any indications outside these levels may be cause for
rejection but may be referred to the purchaser for conces-
sion.
4.3.2 Ultrasonic Inspection:
Isolated defects upto 3 mm flat bottom hole with no probe
movement are acceptable.
Groups of defects giving maximum indication greater than
half screen height at the testing sensitivity, ad individ-
ual defects with probe movement in excess.of that estab-
lished as appropriate for a 3 mm flat bottom hole at the
relevant depth may be cause for rejection but may be
referred to the Purchaser for concession.
5. RECORDING-OF RESULTS & REPORTING:

The results of the examination shall be reported on BHEL "

(Bhopal) N.D.T. Inspection Report Sheets 1 and 2 copies of
which are reproduced in Annexure 1 and Annexure 2.
 ANNEXURE-I

Inspection Procedure Acceptance Standard

Contract Ref.No. Coding
Contract Name P.F No.
Drawing No. Item Description
Supplier's Name Supplier
Supplier's NOT Report Ref.

Magnetic particle/Visual Examination

Equipment Description

Current

Prods/Coil

Amps/Inch/Turns

Prod. Spacing

Magnetic Ink

Area Examined

Results of Examination

Operator Date
 ANNEXURE-II

Ultrasonic Examination
Flaw Detector

Surface Condition Coup!ant

Test Conditions

Pulse Energy

linealibrated Cain
Single/Double
Frequency MHz
Size mm
Probes
Make
Calib'd Test Block dBs
Atten. (Ref.Sensitivity)
Setting _.
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uuaii.odioiUlYiuy uuo

Record of Indications
The position of defect indications shall be shown on a sketch.
Defect Distance from Estimated Estimated Calib'd Atten
No. test surface length F.B.H Setting to give
mm. (state drop Equivalent 50% FSH at Ref.
off) mm. mm. Sensitivity.

Operator Approvals Date