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RIS

Rail Industry Standard for NDT Processes on Rail Vehicles


This document is a voluntary standard, produced by
RSSB at the request of the industry. Duty holders
may choose to adopt it through internal
instructions/procedures or contract conditions.

Rail Industry Standard


Issue one March 2011
RIS-2701-RST

Published by:

RSSB
Block 2
Angel Square
1 Torrens Street
London
EC1V 1NY

© Copyright 2011
Rail Safety and Standards Board Limited
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Supersedes GMRT2005 Iss 3 on 04/06/2011
Rail Industry Standard for NDT Processes on Rail Vehicles

Issue Record
Issue Date Comments
One 5 March 2011 Original document
Replaces GM/RT2005 issue three

Revisions have not been marked by a vertical black line in this issue because the
document has been revised throughout.

Superseded or replaced documents


The following Railway Group documents are superseded or replaced, either in whole or in
part as indicated:

Superseded or replaced documents Sections Date when


superseded sections are
superseded
GM/RT2005 issue three June 2003 All 4 June 2011
Certification Processes for NDT Operatives,
Equipment and Facilities used for inspecting Rail
Vehicles

GM/RT2005 issue three ceases to be in force and is withdrawn as of 4 June 2011.

Supply
The authoritative version of this document is available at www.rgsonline.co.uk.
Uncontrolled copies of this document can be obtained from Communications, RSSB,
Block 2, Angel Square, 1 Torrens Street, London EC1V 1NY, telephone 020 3142 5400 or
e-mail enquirydesk@rssb.co.uk. Other Standards and associated documents can also be
viewed at www.rgsonline.co.uk.

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Rail Industry Standard for NDT Processes on Rail Vehicles

Contents
Section Description Page

Part 1 Introduction 4
1.1 Purpose of this document 4
1.2 Application of this document 4
1.3 Health and safety responsibilities 4
1.4 Copyright 4
1.5 Approval and authorisation of this document 5

Part 2 NDT Procedures 6


2.1 Approval and use of NDT procedures 6
2.2 Approval of new NDT techniques 7

Part 3 Requirements for Certification of NDT Equipment and Facilities 8


3.1 Equipment 8
3.2 Facilities 8

Part 4 Requirements for Certification of NDT Operatives 9


4.1 Rail vehicle wheelset axle testing by ultrasonic NDT technique 9
4.2 Rail vehicle wheelset axle testing by other NDT techniques 10
4.3 Other rail vehicle components 10

Appendices 11
Appendix A Recommendations for the Certification of NDT Equipment 11
Appendix B Recommendations for the Certification of NDT Facilities 12
Appendix C New NDT Techniques 13

Definitions 15

References 16

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Rail Industry Standard for NDT Processes on Rail Vehicles

Part 1 Introduction
1.1 Purpose of this document
1.1.1 This document is a voluntary standard on non-destructive testing (NDT)
processes used on rail vehicles, for the rail industry to use if they so choose.

1.1.2 This document sets out requirements and gives guidance for the certification of
operatives, equipment and facilities used to undertake NDT of components on rail
vehicles.

Specific responsibilities and compliance requirements are set out in 3.2.1 of


GM/RT2004.

1.1.3 The document is set out in the form of standard requirements followed by
guidance notes. Guidance notes are marked by a grey bar in the margin with the
letters GN and sequential numbering, to differentiate them from the standard
requirements to which they relate.

1.2 Application of this document


1.2.1 An infrastructure manager or a railway undertaking may choose to adopt all or
part of this document in company procedures or contract conditions. Where this
is the case the infrastructure manager or the railway undertaking will specify the
nature and extent of application.

1.2.2 Specific compliance requirements and dates have therefore not been specified
since these will be the subject of the internal procedures or contract conditions of
the companies which choose to adopt this standard.

1.3 Health and safety responsibilities


1.3.1 Users of documents published by Rail Safety and Standards Board (RSSB) are
reminded of the need to consider their own responsibilities to ensure health and
safety at work and their own duties under health and safety legislation. RSSB
does not warrant that compliance with all or any documents published by RSSB
is sufficient in itself to ensure safe systems of work or operation or to satisfy such
responsibilities or duties.

1.4 Copyright
1.4.1 Copyright in the Railway Group documents is owned by Rail Safety and
Standards Board Limited. All rights are hereby reserved. No Railway Group
document (in whole or in part) may be reproduced, stored in a retrieval system, or
transmitted, in any form or means, without the prior written permission of Rail
Safety and Standards Board Limited, or as expressly permitted by law.

1.4.2 RSSB members are granted copyright licence in accordance with the Constitution
Agreement relating to Rail Safety and Standards Board Limited.

1.4.3 In circumstances where Rail Safety and Standards Board Limited has granted a
particular person or organisation permission to copy extracts from Railway Group
documents, Rail Safety and Standards Board Limited accepts no responsibility
for, nor any liability in connection with, the use of such extracts, or any claims
arising there from. This disclaimer applies to all forms of media in which extracts
from Railway Group documents may be reproduced.

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1.5 Approval and authorisation of this document


1.5.1 The content of this document was approved by Rolling Stock Standards
Committee on 21 January 2011.

1.5.2 This document was authorised by RSSB on 27 January 2011.

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Part 2 NDT Procedures


2.1 Approval and use of NDT procedures
2.1.1 NDT of rail vehicle components
2.1.1.1 All NDT of rail vehicle components shall be in accordance with an approved NDT
procedure.

2.1.2 Qualification of author


2.1.2.1 NDT procedures shall be prepared by personnel who are qualified to level 2 or
level 3 in the appropriate method.

GN01 An explanation of the various levels of qualification is set out in 4.3.1.

2.1.3 Scope of NDT procedure


GN02 An analysis should be undertaken to determine the minimum required detectable defect
size of the NDT procedure. The analysis should take into account the frequency of
inspection and the expected stress levels in the component being tested.

GN03 The railway undertaking should ensure the areas of the components to be tested, the
defect levels to be detected, the rejection criteria and periodicities of inspection are
defined. Any limitations of the methods to be used should also be identified.

2.1.4 Requirements for NDT procedures


GN04 NDT procedures should include, as a minimum, the following:

a) Scope.

b) Definitions.

c) References.

d) Health and safety information / precautions.

e) Personnel requirements.

f) Equipment requirements.

g) Equipment control calibration.

h) Surface preparation method, if applicable.

j) Method of testing.

k) Acceptance criteria.

l) Reporting.

m) Post-test cleaning and control of residual effect, including, for example,


demagnetisation.

n) Post-test surface protection.

GN05 NDT procedures for axles should include the requirements set out in GM/RT2466.

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2.1.5 Validation of NDT procedures


2.1.5.1 Validation and approval of the NDT procedure shall be performed by personnel
qualified to level 3 in the proposed NDT technique, as set out in BS EN 473:2008.

GN06 NDT procedures should be validated and approved by personnel in accordance with
auditable procedures that incorporate the guidance given in 2.1.6.

2.1.5.2 The person approving the NDT procedure shall not be the author of the
procedure.

2.1.6 Validation process


GN07 A validation process should be undertaken to check that the defect sizes specified can be
detected in the areas defined using the processes in the documented procedure.

GN08 The validation process should be undertaken using the equipment, facilities and methods
defined in the NDT procedure on a full-size representative test piece.

GN09 The validation of ultrasonic axle testing procedures should use a full-size test piece that
includes all components being fitted that have an effect on the ultrasonic signals, such as
wheels, gear wheels and axle mounted brake discs.

GN10 Where a NDT procedure uses an earlier procedure as its basis, the validation can be
restricted solely to the technical justification of the effects of the changes made from the
original procedure. The evidence used should be formally documented and retained for
future scrutiny.

2.1.7 Endorsement of procedures


GN11 The validated NDT procedure should be endorsed to state that it has been approved by a
technically competent authority.

GN12 Where the process technique is covered by an American Society of Non-Destructive


Testing (ASNT) scheme, then the approval of the procedure should be by an ASNT
Level 3. The UK manual ultrasonic axle testing (UAT) process should be approved by a
person certificated to personnel certification in non-destructive testing (PCN) Level 3.

2.2 Approval of new NDT techniques


2.2.1 Approval
2.2.1.1 New NDT techniques shall be approved by a technically competent authority that
should, as a minimum, include the recommendations set out in Appendix C.

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Part 3 Requirements for Certification of NDT Equipment


and Facilities
3.1 Equipment
3.1.1 Equipment used for NDT shall be manufactured in accordance with relevant
procedures / standards and compatible with the appropriate validation
documentation used.

GN13 Appendix A contains recommendations for the certification of NDT equipment.

3.2 Facilities
3.2.1 The facilities used for NDT shall be approved for the use made of them.

GN14 Appendix B contains recommendatons for the approval of NDT facilities.

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Part 4 Requirements for Certification of NDT Operatives


4.1 Rail vehicle wheelset axle testing by ultrasonic NDT technique
4.1.1 Training
4.1.1.1 Operatives who undertake manual ultrasonic NDT axle testing of railway
wheelset axles shall undergo a course of training covering the relevant methods
and successfully pass an examination in accordance with BS EN 473:2008 at an
examination centre approved by a certification body.

GN15 The recognised certification body in the UK for ultrasonic axle testing is the British Institute
for NDT, which owns and operates the PCN Certification Scheme.

4.1.1.2 Training programmes for operatives covering ultrasonic axle testing of rail vehicle
axles shall include the following minimum requirements:

a) Calibration procedures.

b) Axle familiarisation.

c) Classical trajectories. *

d) Trace pattern prediction.*

e) Axle scanning techniques.

* The elements identified are not required for operatives exclusively operating
semi-automated procedures which do not require personnel to interpret the test
results. The training programme therefore may be of reduced duration. The
certificate of competence (railway axles) issued to such operatives shall clearly
indicate the limited scope.

4.1.1.3 The training programme covering both practical and theory for level 1 applicants
shall be a minimum of 80 hours.

GN16 There are other training requirements set out in the PCN manual which are recommended
as best practice to be followed.

4.1.1.4 The training for operators of semi-automatic axle testing equipment should be to
a scheme approved by an independent technically competent authority.

GN17 Where specialist semi-automatic axle testing equipment is used and a level 1 or level 2
qualification in ultrasonic axle testing is required by the NDT operator, it is permissible for
the training programme to be job specific in accordance with SNT-TC-1A:2006 (see GN20)
and approved by an independent technically competent authority (see 3.1 for equipment
requirements).

4.1.2 Reassessment of newly qualified operatives


4.1.2.1 Within three months of gaining a certificate of competence in ultrasonic axle
testing of rail vehicle axles, new certificated holders shall be reassessed to
ensure that they are correctly interpreting the techniques and documentation.

4.1.2.2 Reassessment, in the context of this document, shall be a practical ‘on site’
evaluation of an operative’s ability to carry out axle testing to the required
standards.

4.1.2.3 Operators holding a level 1 certificate of competence shall be reassessed by


operatives certificated to level 2 or 3. Operators holding a level 2 certificate of
competence shall be reassessed by operatives certificated to level 3. The
reassessor shall be qualified in the appropriate technique.

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4.1.3 Validity of certification and maintenance of competence


4.1.3.1 NDT operatives shall maintain their competence in the ultrasonic testing of rail
vehicle axles and undertake re-certification at the following frequency:

a) Operatives undertaking a minimum of 60 hours ultrasonic axle testing in


each twelve-week period – certification is valid for one year.

b) Operatives undertaking a minimum of 30 hours ultrasonic axle testing in


each twelve-week period using semi-automated techniques where the
operative is not required to interpret the results of the tests – certification is
valid for two years.

GN18 The twelve-week period set out in 4.1.3.1 excludes periods of absence of less than one
month.

GN19 Auditable records of NDT operatives’ qualifications should be maintained to demonstrate


that competence is being maintained in accordance with the requirements set out in this
document. Where an operator has not maintained competence, as set out in 4.1.3.1, a
technical competent authority should determine if a further assessment or re-training is
required. When operators have not maintained their competence beyond 12 months then
PCN should be advised and the necessary actions implemented.

4.1.4 Re-certification periodicity


4.1.4.1 NDT operatives shall have their certificates renewed at periods of a maximum of
five years as set out in BS EN 473:2008.

4.2 Rail vehicle wheelset axle testing by other NDT techniques


4.2.1 The training programmes for NDT operatives that test rail vehicle wheelset axles,
by other than ultrasonic testing, shall include the following minimum
requirements:

a) Compliance in accordance with BS EN 473:2008. Where a


BS EN 473:2008 scheme is not available or feasible a SNT-TC-1A:2006
company training scheme is permissible.

b) Calibration procedures appropriate to the technique.

c) Axle familiarisation.

d) Defect and scanning techniques appropriate to the technique.

GN20 The certification of operatives should be in accordance with BS EN 473:2008 or


appropriate SNT-TC-1A:2006 scheme.

4.3 Other rail vehicle components


4.3.1 Operatives that test components other than rail vehicle wheelset axles shall be
trained and certificated in accordance with PCN / BS EN 473:2008 or
SNT-TC-1A:2006, by an organisation accredited by a nationally recognised body
or in accordance with the ASNT scheme. In this instance the qualification levels
shall be as follows:

a) Level 2 – alternatively the holder of a level 2 certificate issued by an ASNT


level 3 certificate holder, within a written practice following the guidelines
published in SNT-TC-1A:2006.

b) Level 3 – alternatively the holder of a level 3 certificate issued by the


ASNT.

GN21 The validity of certificates should be in accordance with PCN / BS EN 473:2008 or


SNT-TC-1A:2006 (companies written practice) as appropriate.

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Appendix A Recommendations for the Certification of NDT


Equipment
A.1 Recommendations for the certification of NDT equipment
GN22 NDT equipment should be approved by a technically competent authority and issued with a
certificate of type approval after satisfactory assessment to the appropriate standards. The
certificate should clearly state the make, model and modification level of the NDT
equipment and identify the scope of application of the equipment.

GN23 Where equipment is approved to a national standard (BS or EN) then such approval
documentation satisfies the certification recommendations set out in this document.

GN24 NDT equipment should be assessed and, if successful, issued with a certificate of type
approval for the conditions identified below:

a) New equipment.

b) Existing equipment that has been modified or changed.

GN25 The assessment of the NDT equipment should define the approval processes that are to
be satisfied to demonstrate the equipment functions in accordance with its requirements.
The capability for detecting required defect sizes and, where required, locations, should be
defined by a technically competent authority, the defect size should be consistent with the
component design requirements. The assessments should be undertaken on a
representative sample with real defects, where possible, or simulated defects of the
appropriate size, taking consideration of the limitations of using simulated defects.

GN26 In addition, ultrasonic NDT equipment should be assessed in accordance with the
requirements set out in BS EN 12668 series.

GN27 The means of indicating the presence of a defect should be clear and unambiguous.
Defect identification should incorporate a means of identifying the location of the defect in
the component.

GN28 NDT equipment should be assessed in all applications, environments and situations where
it could be used in service.

GN29 NDT equipment should be suitable for the environment in which it will operate. Portable
equipment should be packaged in appropriate enclosures and provided with adequate
carrying facilities.

GN30 The NDT test equipment and any part that comes into contact with the component being
tested should not damage the component.

GN31 The calibration and periodic checks of the NDT test equipment should be approved by the
technically competent authority as being adequate for the equipment application.

GN32 The NDT testing equipment employed in semi-automatic processes should provide results
that will not require interpretation by a trained operator.

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Appendix B Recommendations for the Certification of NDT


Facilities
B.1 Recommendations for the certification of NDT facilities
GN33 NDT facilities that support the use of NDT equipment provided at a site, or NDT equipment
that is used at more that one location, should be approved by an organisation accredited
by a nationally recognised body and have a certificate of approval issued to the standard
required by BS EN ISO / IEC 17024:2003.

GN34 Before a certificate of approval is issued for a facility, the applicant organisation should
demonstrate the capability to undertake the procedures for which approval is sought.

GN35 The scope of approval for NDT testing facilities should include use of, and compliance with,
approved procedures, qualified operatives and certificated equipment.

GN36 The NDT testing facility assessment should include a special process audit of the NDT
facilities by a competent technical authority NDT specialist in the applicable technique.

GN37 An NDT facility assessment by an independent assessor should be completed at least


every two years to re-certify the facility.

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Appendix C New NDT Techniques


C.1 Approval of new NDT techniques
C.1.1 Approval
GN38 New NDT techniques that are to be applied to safety-critical components should be
approved by a technically competent authority and should, as a minimum, include the
recommendations set out in C.1.2 to C.1.9.

C.1.2 Defects
GN39 The length, depth, shape, profile and orientation of the defect that the equipment can
identify in test samples should be declared. The defect of the specified size should be
identified in a full-size representative test piece.

GN40 The equipment should be evaluated on components in the condition that the test will
routinely be applied.

GN41 The NDT test system should be able to clearly identify the location of defects in the
components.

GN42 Any limiting conditions of the component being tested that restrict the application of the
process and achievement of identifying the declared defects should be defined.

GN43 The materials to which the technique is to be applied should be identified and any
limitations associated with the conditions or surface coatings declared.

C.1.3 Demonstration
GN44 The NDT test system should be proven to identify a defect of known dimensions introduced
into a component. The defect size should be confirmed using an existing proven NDT
technique.

GN45 Blind trials should be undertaken to identify defects in component parts that have
previously been rejected by a proven technique. Where the new technique has greater
sensitivity (defect size) than the comparison technique, then all defects identified by the
comparison technique should be detected by the new technique.

C.1.4 Repeatability / probability


GN46 The process / technique should have a declared probability of detection (POD) including
the effects of varying conditions, including (this list is not exhaustive):

a) Different period of use.

b) Different operators.

c) Locations.

d) Orientation of application.

e) Variation in the components.

f) Environmental conditions within the declared limitations of the technique.

GN47 Blind trials should be undertaken to compare the POD of the new technique with that of an
established one. Where a POD is claimed that is greater than the comparison technique, a
different technique should be used to verify defects identified by the new technique but not
by the previous.

GN48 The results of the NDT test should be consistent and the indications for a specific defect
should not vary for different test scenarios.

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C.1.5 Calibration
GN49 Calibration processes for the equipment should be clearly identified and easily applied by
the operator.

C.1.6 Ease of use


GN50 Test equipment should be capable of being set up by an operator or, where the equipment
is portable, assembled and set up.

GN51 Indications of defects should be clearly presented and capable of being interpreted.

GN52 The results should be clearly presented and easily interpreted.

GN53 Where the test results are presented in a form that does not require interpretation the
output should clearly specify the results.

GN54 Where the operator is required to interpret the test results, sufficient clear instructions
should be provided to permit the operator to interpret the results correctly.

GN55 The application of the process and analysis of outputs should take into consideration
human factors, including, for example, ease of use, risk of fatigue, and interpretation of
results.

GN56 The NDT test equipment should be suitable for the environment in which it will operate.
Portable equipment should be packaged in appropriate enclosures and provided with
adequate carrying facilities.

GN57 The test equipment and any part that comes into contact with the component being tested
should not damage the component.

C.1.7 Materials
GN58 Where materials are used that have the potential to be hazardous, then suitable warnings
and protection should be identified. This information should be made available to all
operatives.

C.1.8 Expertise
GN59 The operator knowledge and skills required to successfully operate the system should be
commensurate with those required for existing NDT techniques.

C.1.9 Report
GN60 Test results and demonstrations should be summarised in a report which documents the
evidence gathered.

C.2 Use of new NDT techniques


C.2.1 Training
GN61 The training and certification programmes for operatives using new techniques should be
set out and included as part of the approval submission.

C.2.2 Implementation
GN62 Before use of a new NDT test technique, the following should be in place:

a) Procedures to implement the new techniques as set out in Part 2.

b) Certification of operatives as set out in Part 4.

c) Certification of equipment as set out in 3.1.

d) Certification of facilities as set out in 3.2.

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Definitions
Certification body
A qualified body with authority to issue certificates and administer procedures for NDT
operatives according to the requirements of BS EN473:2008 and
BS EN ISO / IEC 17021:2006 that has been accredited by a nationally recognised body.

Facility
For the purposes of this document only, any depot, workshop, location or mobile apparatus
regularly used to undertake NDT of safety-critical components fitted to rolling stock.

Level 1
For the purposes of this document only, level 1 is the category of qualification that an
individual has demonstrated competence to be certificated at that level by an organisation
accredited to issue level 1 certification in accordance with BS EN 473:2008 and
BS EN ISO / IEC 17021:2006.

Level 2
For the purposes of this document only, level 2 is the category of qualification that an
individual has demonstrated competence to be certificated at that level by an organisation
accredited to issue level 2 certification in accordance with BS EN 473:2008 and
BS EN ISO / IEC 17021:2006.

Level 3
For the purposes of this document only, level 3 is the category of qualification that an
individual has demonstrated competence to be certificated at that level by an organisation
accredited to issue level 3 certification in accordance with BS EN 473:2008 and
BS EN ISO / IEC 17021:2006.

Non-destructive testing
Non-destructive testing (NDT) is the method of testing materials for fitness for purpose
without causing them harm.

Procedure
An approved document that specifies the method to be applied for a specific testing
regime, including the equipment, calibration requirements, areas to be examined,
orientation of the component and the pass / fail criteria.

Semi-automatic process (for NDT)


A NDT process that once commenced will complete the examination of the component
without intervention from the operative.

Technically competent authority


A company, or person, having proven competence in a particular technology or process
and able to act in an independent and impartial manner. With relation to this document
there is to be at least one member of staff certificated to level 3 in the appropriate NDT
method.

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References
The Catalogue of Railway Group Standards and the Railway Group Standards DVD give
the current issue number and status of documents published by RSSB. This information is
also available from www.rgsonline.co.uk.

RGSC 01 Railway Group Standards Code


RGSC 02 The Standards Manual

Documents referenced in the text


Railway Group Standards
GM/RT2004 Rail Vehicle Maintenance
GM/RT2466 Railway Wheelsets
Other references
BS EN 473:2008 Non-destructive testing. Qualification and certification of
NDT personnel – General Principles
BS EN 12668 series Non-destructive testing - Characterisation and verification of
ultrasonic examination equipment
BS EN ISO / IEC 17021:2006 Conformity assessment - Requirements for bodies providing
audit and certification of management systems
BS EN ISO / IEC 17024:2003 Conformity assessment - General requirements for bodies
operating certification of persons
SNT-TC-1A:2006 Personnel Qualification and Certification in Nondestructive
Testing

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