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© Copyright 2011
Rail Safety and Standards Board Limited
Uncontrolled When Printed
Document comes into force 04/06/2011
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.
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
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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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.
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.
1.2.2 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.
1.4 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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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.
a) Scope.
b) Definitions.
c) References.
e) Personnel requirements.
f) Equipment requirements.
j) Method of testing.
k) Acceptance criteria.
l) Reporting.
GN05 NDT procedures for axles should include the requirements set out in GM/RT2466.
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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.
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.
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3.2 Facilities
3.2.1 The facilities used for NDT shall be approved for the use made of them.
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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. *
* 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).
4.1.2.2 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.
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GN18 The twelve-week period set out in 4.1.3.1 excludes periods of absence of less than one
month.
c) Axle familiarisation.
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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.
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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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.
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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.
b) Different operators.
c) Locations.
d) Orientation of application.
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.
GN51 Indications of defects should be clearly presented and capable of being 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.2.2 Implementation
GN62 Before use of a new NDT test technique, the following should be in place:
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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.
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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.
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