E Proc Eng Bi 155 Rev 004

NOT PROTECTIVELY MARKED E/PROC/ENG/BI/155
Revision 004
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EDF Energy Nuclear Generation
Central Engineering Support Function

Branch Instruction
NDT Procedure for Ultrasonic Inspection of Ferritic and

Austenitic Forgings
Originated By: M Jenkinson Date: March 2018
Reviewed By: G Innes Date: March 2018
Reviewed By: P Heath Date: March 2018
Approved By: S Meikle Date: March 2018
REVISION AMENDMENT LEVEL OF USE DATE
004 General revision of the procedure. See Appendix H for the Reference Use March 2018
revision register
© 2018 Published in the United Kingdom by EDF Energy Nuclear Generation Ltd.
All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, including photocopying and recording,
without the written permission of the copyright holder, EDF Energy Nuclear Generation Ltd., application for which should be addressed to the
publisher. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. Requests for
copies of this document should be referred to Barnwood Document Centre, Location 12, EDF Energy Nuclear Generation Ltd., Barnett Way,
Barnwood, Gloucester GL4 3RS (Tel: 01452-652791). The electronic copy is the current issue and printing renders this document uncontrolled.
Controlled copy-holders will continue to receive updates as usual.
LIMITATION OF LIABILITY – Whilst EDF Energy Nuclear Generation Ltd. believes that the information given in this document is correct at the
date of publication it does not guarantee that this is so, nor that the information is suitable for any particular purpose. Users must therefore satisfy
themselves as to the suitability of the information for the purpose for which they require it and must make all checks they deem necessary to verify
the accuracy thereof. EDF Energy Nuclear Generation Ltd. shall not be liable for any loss or damage (except for death or personal injury caused by
negligence) arising from any use to which the information is put.
NOT PROTECTIVELY MARKED Template Ref: ENG/FORM/116 Revision 006

Parent Document: E/PROC/ENG/002
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CONTENTS
1 PURPOSE................................................................................................................................................4
2 SCOPE.....................................................................................................................................................4
3 RESPONSIBILITIES..............................................................................................................................4
3.1 Inspection Group Head..................................................................................................................4
3.2 NDT Inspection Engineer...............................................................................................................4
4 SAFETY ..................................................................................................................................................4
5 ITEMS FOR AGREEMENT ..................................................................................................................5
6 EXTENT OF INSPECTION ...................................................................................................................5
6.1 Cylindrical Solid Forging...............................................................................................................5
6.2 Cylindrical Hollow Forging ...........................................................................................................6
6.3 Rectangular Solid Forging..............................................................................................................6
6.4 Rectangular Hollow Forging ..........................................................................................................6
6.5 Near Surface Examination.............................................................................................................7
7 PRE-REQUISITES .................................................................................................................................7
7.1 Preparation of items to be tested....................................................................................................7
7.2 Deviation from Specification..........................................................................................................7
8 QUALIFICATION OF NDT PERSONNEL...........................................................................................7
8.1 New Forgings..................................................................................................................................7
8.2 In-Service Forgings ........................................................................................................................7
10 EQUIPMENT CHECKS AND CALIBRATION....................................................................................9
11 DISTANCE AMPLITUDE CORRECTION (DAC) CURVE.................................................................9
12 INSPECTION..........................................................................................................................................9
13 FORGING IDENTIFICATION, MARKING DATUM AND COORDINATE SYSTEM................... 10
13.1 Identification of Forging(s) to be tested....................................................................................... 10
13.2 Method of Marking...................................................................................................................... 10
13.3 Datum Points and Co-ordinate Systems ...................................................................................... 10
13.3.1 Longitudinal Measurements................................................................................................................ 10
13.3.2 Circumferential Measurements........................................................................................................... 10
14 VISUAL INSPECTION......................................................................................................................... 11
15 CROSS SECTIONAL DRAWINGS ..................................................................................................... 11
16 SCAN DESIGN...................................................................................................................................... 11
17 SCAN RESTRICTIONS ....................................................................................................................... 11
18 CORRECTION FOR ATTENUATION AND TRANSFER LOSS...................................................... 11
18.1 Shear Wave Losses....................................................................................................................... 12
18.2 Compression Wave Losses ............................................................................................................ 12
19 PERFORMING THE INSPECTION.................................................................................................... 12
20 CLASSIFICATION (QUALITY)........................................................................................................... 12
20.1 New Forgings................................................................................................................................ 12
20.2 In-Service Forgings ...................................................................................................................... 13
21 INSPECTION SENSITIVITY AND RECORDING LEVELS............................................................. 13
21.1 Recording Levels and Acceptance Criteria.................................................................................... 13
22 ASSESSMENT OF INDICATIONS ..................................................................................................... 13
22.1 Defect Sizing and Characterisation.............................................................................................. 14
22.2 Defect Recording.......................................................................................................................... 14
23 REPORTING CONTENTS................................................................................................................... 15

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23.1 Minimum Reporting Criteria ...................................................................................................... 15

23.2 Deviations from this Procedure and Test Restrictions ................................................................ 15
23.3 Additional Information if Applicable .......................................................................................... 15
24 DEFINITIONS ...................................................................................................................................... 16
25 REFERENCES...................................................................................................................................... 16
26 RECORDS............................................................................................................................................. 17
27 TABLES - QUALITY CLASSES, RECORDING LEVEL AND ACCEPTANCE CRITERIA .......... 17
APPENDIX A - RISK ASSESSMENT ........................................................................................................ 21
APPENDIX B - SITE CALIBRATION OF ULTRASONIC FLAW DETECTION EQUIPMENT .......... 23
APPENDIX C - SHEAR WAVE ATTENUATION AND TRANSFER LOSS MEASUREMENT ............ 26
APPENDIX D - ASSESSMENT OF INDICATIONS.................................................................................. 27
APPENDIX E - REPORTING SCAN RESTRICTIONS ............................................................................ 35
APPENDIX F - CAPABILITY STATEMENT............................................................................................ 37
APPENDIX G - QA INSPECTION CHECKLIST...................................................................................... 38
APPENDIX H - REVIEW/REVISION REGISTER ................................................................................... 39
DISTRIBUTION LIST................................................................................................................................. 39

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1 PURPOSE
This document gives general requirements and procedures for the manual ultrasonic inspection of forgings in
ferritic and austenitic steels.
2 SCOPE
The manual ultrasonic contact method is employed with A scan presentation. This procedure meets or
exceeds the criteria of BS EN 10228-3: 2016(1), “Non-destructive testing of steel forgings – Part 3:
Ultrasonic testing of ferritic and martensitic steel forgings” and BS EN 10228-4: 2016(2), “Non-destructive
testing of steel forgings – Part 4: Ultrasonic testing of austenitic and austenitic-ferritic stainless steel
forgings”
When a quality class is not specified, quality class 4 shall apply to ferritic forgings and quality class 3 to
austenitic forgings.
Turbine, rotor and generator forgings are not covered by this procedure.
For inspection on EDF Energy sites, certain items of information are to be provided by, and other matters are
to be agreed with via the nominated EDF Energy NDT Inspection Engineer.
The terms and definitions of BS EN ISO 5577: 2017(3), “Non-destructive testing - Ultrasonic testing -
Vocabulary” shall apply to this procedure.
3 RESPONSIBILITIES
3.1 Inspection Group Head

Appoint suitably qualified personnel to undertake review and revision when necessary and approve the
procedure for issue.
3.2 NDT Inspection Engineer

Ensure that the requirements of this instruction are met at their respective sites and catalogue any anomalies
or issues.
4 SAFETY
Users of this procedure are reminded of the following:
1. On EDF Energy sites all personnel using this procedure must work in accordance with all relevant
Statutory Regulations, EDF Energy Safety Rules and local Station Standing Instructions.
2. Safety requirements for contractors are detailed in the relevant contract documentation.
3. All personnel using either NDT or chemical materials shall work in a safe and responsible manner in
accordance with the requirements of the COSHH Regulations(4).
4. Portable electrical equipment shall be used only within the period of validity of an electrical safety
check (PAT test).
Prior to commencing any work under this procedure the risk assessment process detailed in Appendix A
shall be undertaken.

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5 ITEMS FOR AGREEMENT

Where this procedure is used by an organisation under contract to EDF Energy, as part of maintenance or
other work on installed plant, certain basic information is required prior to any inspection.
Items may be defined in detail in the contract specification or definition of the detail may be deferred for
agreement at the time the inspection is carried out.
Where applicable, the following shall be agreed with the Station Engineer and/or EDF Energy NDT Inspection
Engineer before inspection commences:
1. For new forgings the quality class required. When a quality class is not specified, quality class 4 shall apply
to ferritic forgings and quality class 3 to austenitic forgings.
2. Surface conditions, i.e. surface profile (variation in surface contour) and surface finish (machined or not
machined etc.).
3. Manufacturing or operation stage at which the inspection is to be carried out.
4. Item(s) to be tested.
5. Numbering/identification conventions for items to be tested.
6. Datum positions and co-ordinate systems for reporting position of defects.
7. Method of marking the component or area(s) to be tested.
8. Inspection consumables where appropriate.
9. Ultrasonic scans, angles to be employed and the extent of coverage of the inspection.
10. Types and orientations of defects to be searched for (e.g. longitudinal, transverse, internal bore cracking).
6 EXTENT OF INSPECTION
6.1 Cylindrical Solid Forging

100% volumetric scanning of a minimum of 180 around the forging periphery and along the entire length. If the
detection of near surface defects is required then the area of coverage shall be increased to 360°around the
forging periphery. Note. If access allows and the end face/s are flat and orthogonal, a 0° compression probe
shall be utilised to detect defects at right angles to the forging axis.,
0° Compression and shear
0° Compression

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6.2 Cylindrical Hollow Forging

100% volumetric scanning of 360 around the forging periphery and along the entire length. The shear wave
examination shall be carried out using a suitable angle probe to interrogate the internal bore surface for evidence
of discontinuities If the through wall thickness of the forging allows and the end face/s are flat and orthogonal, a
0° compression probe shall be utilised to detect defects at right angles to the forging axis.
6.3 Rectangular Solid Forging

Solid Forging: - 100% volumetric scanning from at least three mutually adjacent faces, including at least one
accessible end face with a compression probe (0).
0° Compression
6.4 Rectangular Hollow Forging

Bored Forging: - 100% volumetric scanning from all four major faces. The shear wave examination shall be
carried out using a suitable angle probe to interrogate the internal bore surface for evidence of discontinuities. If
access allows and the end face/s is flat and orthogonal, a 0° compression probe shall be utilised to detect defects
at right angles to the forging axis.
0° Compression

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6.5 Near Surface Examination

Near surface examination of forged products shall be carried out using twin crystal probes.
Note. The depth of penetration on a cylindrical forging for axial defects is limited as follows: -
Probe angle Max. depth of penetration Beam path to max. depth
38º 0.192 D 0.4 D
45º 0.146 D 0.35 D
60º 0.067 D 0.25 D
70º 0.030 D 0.17 D
D = outside diameter of forging
7 PRE-REQUISITES
7.1 Preparation of items to be tested

General Surface Profile
As Forged Surfaces
A forging in the as forged condition shall be free from loose scale and any other foreign matter that may interfere
with ultrasonic testing (e.g. rust, loose scale, dirt, paint, weld spatter etc.). Consideration shall be given to the
actual inspection quality class that can be achieved, in accordance with Section 27. Local variations in surface
contour may result in a gap between the probe and test surface. The minimum surface variation permitted will be
such that continuous probe coupling is maintained without any detriment to the test sensitivity.
Machined Surfaces
Machined surfaces shall have a surface finish of 6.3 µm Ra. or better. Local variations in surface contour
may result in a gap between the probe and test surface. Where the scanning surfaces are to be prepared prior
to test the error of form shall not be greater than 0.5 mm in any length of 50 mm. On straight sections this
shall be assessed by measuring the maximum gap which occurs under a 50 mm long straight edge placed on
the surface. On curved sections when using contoured probes, assessment shall be made by measuring the
maximum gap, which occurs under a 50mm long template curved to the nominal radius.
7.2 Deviation from Specification

Where geometric factors such as diameter changes and ovality, variable profile or physical obstructions prevent
attainment of the requirements of this section, the resulting restrictions and limitations on the inspection shall be
recorded in the inspection report as detailed in Section 17.
8 QUALIFICATION OF NDT PERSONNEL
8.1 New Forgings

NDT personnel shall be qualified, as a minimum to PCN Level 2 Ultrasonic testing category Forgings. This
shall be in accordance with and as identified in BEG/SPEC/ENG/PSPEC/038(5), Table A2 “Controlling the
quality of Non-destructive testing, Implementation of company standard BEG/SPEC/ENG/CTS/210(6)”.
8.2 In-Service Forgings

NDT personnel shall be qualified, as a minimum, to PCN level 2 Ultrasonic testing category Forgings. The
use of personnel qualified to PCN Level 2 Ultrasonic welds may be considered and must be approved by an
EDF Energy NDT Inspection Engineer prior to implementation.

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9. INSPECTION EQUIPMENT
Some or all of the following are required.
A portable standard flaw detector: complying with BS EN 12668-1: 2010(7), “Non-destructive testing –
Characterisation and verification of ultrasonic examination equipment – Part 1 Instruments”.
Single and twin crystal, 0 compression wave probes: 0.5 - 6MHz, 10mm and 25mm crystal diameter
complying with BS EN 12668-2: 2010(8), “Non-destructive testing – Characterisation and verification of
ultrasonic examination equipment – Part 2 Probes”.
Single and twin crystal shear wave probes: –0.5 - 6 MHz (Austenitic Forgings), 2 – 4 MHz (Ferritic
Forgings), 38, 45, 60 and 70, 10mm crystal diameter (or crystal area between 20mm2 and 625mm2),
complying with BS EN 12668-2(8).
On curved surfaces, it may be necessary to apply appropriate contouring to the contact surface of the probe
to achieve constant and reliable coupling or to meet the criterion of 0.5mm maximum gap, as specified in
Section 6.
Probes shall be contoured to match the inspection surface if: -
D  10a where D is the outside diameter of the component and a is the dimension of the
probe shoe to be contoured. Axial scans contour 90o to beam direction, circumferential scans contour
in line with beam direction. (Refer to figure below)
The above mentioned is a minimum requirement and shall be used for guidance only.
In practice contoured probes may be required for larger diameter components.
shear wave probe contoured for axial scan shear wave probe contoured for circumferential scan
Beam direction Beam direction
A2 type calibration block complying with the requirements of BS EN ISO 2400: 2012(9), “NDT –
Ultrasonic examination – Specification for calibration block No.1
A4 type calibration block complying with the requirements of BS EN ISO 7963: 2010(10), “Calibration
block No.2 for ultrasonic examination of welds
Suitable distance amplitude correction test blocks (DAC) complying with the requirements of BS EN ISO
16811: 2014(11), Annex B, “Non-destructive testing – Ultrasonic examination –Sensitivity and range setting”.
The DAC block shall be of the same material, or have a sound velocity of 5% of the material to be
inspected.
For shear wave probes, the distance amplitude test blocks shall have 3mm side drilled holes (SDH).
For compression probes the diameter of Flat Bottomed Holes (FBHs) used to construct the DAC curve shall be
dependent on the required quality class and the relative thickness of the forging being examined (Reference to
Section 27 Tables 1 and 3).
Contoured calibration blocks shall be used for calibrating contoured probes.
A non-corrosive couplant - Compatible with the items to be tested. The couplant employed should not
dissolve/remove the markings used to identify the weld and weld boundaries. Excess couplant shall be
removed and the component wiped clean following completion of test.

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Additions: Surface contour measurement and plotting aids such as needle a profile gauge, beam-profiles,
ruler, and protractor.
10 EQUIPMENT CHECKS AND CALIBRATION

Routine function checks shall be carried out on the flaw detector and probe combination prior to use.
These checks shall be recorded. Reference to Appendix B gives further details.
Daily Checks
1. Probe Condition (Physical state and external aspects, flatness etc).
2. Probe Angle (Shear wave probes only).
3. Probe Beam Profile (Shear wave probes only).
4. Probe Pulse Duration.
5. Reference Sensitivity.
6. Probe Signal to noise Ratio.
Weekly Checks
1. Flaw Detector Linearity of Equipment Gain.
2. Flaw Detector Time Base Linearity.
11 DISTANCE AMPLITUDE CORRECTION (DAC) CURVE

Where a Distance Amplitude Correction (DAC) curve is required to set scanning sensitivity and recording
threshold, the relevant curve or curves shall be constructed in accordance with BS EN ISO 16811(11). For
shear wave probes 3mm diameter side-drilled holes and for compression probes FBHs shall be used. For the
70° shear wave near-surface scan, the DAC curve shall be constructed using at least three 3mm diameter
side-drilled holes.
The working range of the DAC curve shall be between 80% and 20% of full screen height. If the DAC curve
falls below 20% of full screen height then a further curve shall be constructed to cover the longer range.
At the sensitivity used for preparation of the DAC curve the “grass level” should be approximately 26dB
lower than the DAC curve over its full working range.
The sensitivity at which the DAC curve is constructed shall be recorded as the Primary Reference Gain
(PRG) and referenced to the A2 or A4 test block and recorded as follows: -
0o Compression Wave Probes
The reference sensitivity shall be the calibrated gain control setting with the first back wall echo from the
20mm thick A4 test block set at 80% full screen height (T20), or the first back wall echo from the 25mm
thick A2 block at 80% full screen height (T25).
Shear Wave Probes
The reference sensitivity shall be the calibrated gain control setting with the maximised echo from the 50mm
radius of an A4 test block set at 80% full screen height (R50), or the echo from the 100mm radius of an A2
block set at 80% full screen height (R100).
12 INSPECTION
Technique sheets may be produced where specific details such as datum positions, area of examination,
supplementary scans, probes or sensitivity etc. are required. These will be produced and controlled in
accordance with E/PROC/ENG/BI/005(12), “Production and control of NDT procedures and technique

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sheets”. For inspections on an EDF Energy site where an EDF Energy NDT Inspection Engineer has been
nominated, their guidance should be sought in preparing additional technique sheets.
Note. Each inspection shall be designed to detect all imperfections within the examined volume.
13 FORGING IDENTIFICATION, MARKING DATUM AND COORDINATE SYSTEM
13.1 Identification of Forging(s) to be tested

Each forging and/or inspection area shall be clearly and uniquely identified. Wherever possible the Station
numbering/identification conventions shall be adopted. The identification shall be marked on the test area and
on the drawing. Where reports of previous inspections are available, the same identification shall be used.
13.2 Method of Marking

Where the operator is to determine and mark datum points and/or measurement directions, the marking shall be
done in such a way as not to interfere with the inspection. The method of marking shall be compatible with the
item under test. The positions and directions shall be identified in the inspection report; wherever possible they
shall be clarified by reference to permanent features and fixtures of the item itself and, where appropriate,
surrounding plant.
13.3 Datum Points and Co-ordinate Systems

Datum point(s) shall be clearly marked and co-ordinate systems specified. Datum positions shall be consistent
with those used for any previous NDT.
The following conventions shall be used whenever possible.
13.3.1 Longitudinal Measurements

Datum Point
The datum point shall be one end face of the forging. The end face shall be defined as that face of the forging,
which has the smallest surface area, e.g. the end of the shaft. For forgings having a complex shape or where only
a section is to be examined, a suitable feature or section change shall be used. For components having a defined
flow through the forging, the upstream end shall be used as the datum.
Direction of Measurement
Measurements upstream of the datum shall be negative, measurements downstream shall be positive. The
direction of measurement employed shall be clearly identified and recorded on the inspection report. If probe
stand-off and echo range data is to be tabulated, then the scan direction must be included (e.g. looking upstream /
downstream, towards the reactor).
13.3.2 Circumferential Measurements

Datum Point
For a fixed forging in horizontal or inclined locations the datum point shall be the 12 o'clock (top dead centre)
position.
For a rotating forging, a suitable datum point shall be determined and marked using an indelible marker. This
position shall be recorded in the inspection report relative to some feature (e.g. keyway, locating pin or
permanent attachment).
Direction of Measurement
For a fixed forging the positive circumferential direction shall be clockwise looking from the fixed longitudinal
datum end or in the direction of flow if applicable.

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For a rotating forging the positive circumferential direction shall be the direction of rotation when measured
from the datum point.
14 VISUAL INSPECTION
Visually inspect the surface of the forging for adequacy of preparation, scanning obstructions or
imperfections. Record and report all findings.
15 CROSS SECTIONAL DRAWINGS

Cross-sectional drawings of the forging, showing the critical inspection areas shall be provided or drawn up prior
to the inspection. These shall detail the surface profile, bore profile if applicable and relative thickness of
individual sections. Where applicable the flow direction shall also be identified.
One representative cross-sectional drawing will be required if the geometry of the forging is consistent along its
length.
16 SCAN DESIGN
Scanning shall be designed to achieve the best possible coverage of the forging volume and as a minimum shall
incorporate the requirements of Section 6 and the following requirements: -
1. 0 compression beam to assess forging thickness and changes of section.
2. Forging thickness less than 40mm shall be examined using twin crystal 0 probes.
3. Forging thickness 40mm or greater shall be examined using single and twin crystal 0 probes.
4. Standard angle probes are preferred, using direct scans at shortest possible beam paths.
5. Where required, hollow sections shall be examined around the whole outside surface in both directions
circumferentially with a suitable angle probe to locate longitudinal bore cracking along the entire length of
the forging.
6. Where required, hollow sections shall be examined around the whole outside surface in both directions
axially with a suitable angle probe to locate transverse bore cracking along the entire length of the forging.
7. Twin crystal angle beam probes shall be used to locate near surface cracks.
8. Where 100% coverage is required scanning shall be carried out using a scan pattern or scan lines which
overlap by not less than 10% of the crystal diameter
9. Where grid coverage is specified the grid line separation shall be, as a minimum, equal to the material
thickness up to a limit of 200mm.
Details of the scan design shall be included in the inspection report.
17 SCAN RESTRICTIONS
When restrictions to scanning affect coverage, caused either by local features, forging geometry or incorrect
surface preparation, they shall be reported fully.
Full size cross-sectional drawings shall be constructed at representative positions, the scanning achieved shall be
marked on the drawings and any areas of limited coverage shall be clearly identified.
Details of the scan restrictions shall be included in the inspection report, See Appendix E.
18 CORRECTION FOR ATTENUATION AND TRANSFER LOSS

Both shear and normal wave attenuation and transfer losses shall be compensated for by the following methods.

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18.1 Shear Wave Losses

Attenuation shall be assumed as zero for beams passing through material of thickness less than or equal to 25
mm.
For beams passing through material of thickness greater than 25 mm, the total attenuation and transfer loss shall
be measured as described in Appendix C, and the resulting mean value used in setting inspection sensitivity as
described in Section 20. All readings shall be included in the report.
18.2 Compression Wave Losses

Attenuation shall be assumed to be zero for beams passing through material of thickness less than or equal to 25
mm.
For forging inspection where the beam passes through material of thickness greater than 25 mm, the attenuation
shall be calculated from the formula.
Δ =N2BWE - (N1BWE + 6) dB
Where N1BWE is the gain required to raise the first parent material back wall echo to a given screen height, and
N2BWE is the gain required to raise the second back wall echo to the same screen height.
Attenuation shall be measured at the longitudinal datum point and also at a point mid-way along the forging
length or at 1000mm intervals along the forging length, whichever is shorter. The average value shall be
calculated and be used in setting the inspection sensitivity as described in Section 21. All readings shall be
included in the report.
Note Transfer loss is automatically compensated for in applying the above formula.
For both shear and compression waves, situations where the measured total losses exceed 6dB are outside the
scope of this procedure. An EDF Energy NDT Inspection Engineer may consider the use of lower frequency
probes. If used, these will be specified in a technique sheet that shall be provided together with a justification
statement.
19 PERFORMING THE INSPECTION

The cross-sectional drawings produced and scan designs as defined in Sections 15 and 16 shall be used to carry
out an inspection which obtains the fullest possible coverage of the forging.
It is the responsibility of the technician to ensure that the flaw detector working range is checked and is adequate
for the inspection coverage.
In all cases the scanning speed shall be sufficiently slow to maintain adequate coupling and shall not exceed 150
mm/seconds.
20 CLASSIFICATION (QUALITY)
20.1 New Forgings

The applicable quality class, as detailed in Section 27, shall be agreed between EDF Energy and the supplier.
When a quality class is not specified, quality class 4 shall apply to ferritic forgings and quality class 3 shall
apply to austenitic forgings (Class 4 and 3 are the most stringent).
Section 27, Table’s numbered 1 to 4 detail the appropriate recording levels and acceptance criteria that shall
be applied to the respective quality class chosen.
For critical components a more stringent test regime may be required. This shall be subject to prior
agreement by a nominated EDF Energy NDT Inspection Engineer.
Several quality classes may be applied to a forging or parts of a forging. Where agreed, recording/evaluation
levels and acceptance criteria different from those detailed below may be used.

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20.2 In-Service Forgings

For in-service forgings, the recording level shall be based on quality class 4 for ferritic and class 3, for
austenitic material as detailed in Section 27. The acceptance criteria stated however should be used for
guidance only, with all recordable indications (pattern 1, 2, 3 and 4) being reported and referred for further
assessment through the EDF Energy NDT Inspection Engineer.
21 INSPECTION SENSITIVITY AND RECORDING LEVELS

Compression Wave Probes
Test sensitivity for scans with 0 compression probes shall be the gain setting used to construct the DAC
(PRG) plus an additional 6dB and any applicable attenuation value (Δ).
New Forgings: -The diameter of flat-bottomed holes used to construct the DAC curve shall be dependent on the
required quality class and the relative thickness of the forging being examined (Reference to Section 27 Tables 1
and 3).
In-service Forgings: - A block with 2mm (minimum) diameter flat-bottomed holes shall be used to construct
the DAC curve (PRG).
Shear wave Probes
The test sensitivity for scans with angled shear wave probes shall be the gain setting used to construct the DAC
(PRG), plus an additional 6dB and any applicable attenuation value (Δ).
New and In-service Forgings: - 3mm diameter of side drilled holes shall be used to construct the DAC curve.
21.1 Recording Levels and Acceptance Criteria

New Forgings: - All indications evident at the test sensitivity shall be investigated and characterised to
determine its shape and orientation, refer to Appendix D. The indications can then be assessed and recorded in
accordance with the criteria detailed in Section 27.
In-Service Forgings: - All indications evident at the test sensitivity shall be investigated and characterised to
determine its shape and orientation, refer to Appendix D. The indications can then be assessed using Section 27
for guidance and referred to the EDF Energy NDT Inspection Engineer.
Compression Wave Probes
All indications exceeding DAC at the scanning sensitivity shall be evaluated by probe movement, the
appropriate sizing method and recorded in the inspection report.
Shear Wave Probes
All indications exceeding DAC at the scanning sensitivity shall be evaluated by probe movement, the
appropriate sizing method and recorded in the inspection report.
Note. The recording level shall be reduced to 60% DAC (-5dB) at the scanning sensitivity for 2MHz probes for
ferritic material and 1MHz for austenitic material.
22 ASSESSMENT OF INDICATIONS
Defect evaluation and characterisation shall be performed generally in accordance with the ultrasonic
scanning and probe movement techniques defined in BS EN ISO 16827:2014(13), “Non-destructive testing –
Ultrasonic testing –Characterization and sizing of discontinuities”. Reference to Appendix C.

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22.1 Defect Sizing and Characterisation

For reportable indications exhibiting pattern l behaviour in the through-thickness direction, the length shall
be determined by the 6dB drop method.
The through-wall size and length of all reportable indications exhibiting pattern 2, 3a/b or 4 behaviour shall
be determined as follows:
1. Pattern 2 - measured using the 6dB drop method.
2. Pattern 3a/b or 4 - measured using the maximum amplitude or 20dB drop method. The method used shall
be recorded on the test report.
The maximum amplitude of all reportable indications shall be recorded as the number (±) relative to the
DAC curve at the test sensitivity.
Notes:
(i) Closely spaced pattern l indications can be mistaken as pattern 3 or 4; therefore care must be
taken when characterising these indications.
(ii) The edge echoes from large smooth planar defects can appear as two individual pattern 1
indications.
(iii) Guidance on the resolution of smooth single peak, irregular single peak and irregular
multi-peak echoes is given in Appendix D, figures 2 to 7.
(iv) There is a risk of measuring ultrasonic beam width rather than actual defect size when using
wide beams (especially 70° probes at long ranges).
If there is any doubt over the nature of indications, or if definitive characterisation requires additional scans
with different probes, the NDT Inspection Engineer shall be informed.
Results from all probes shall be combined to confirm the nature, orientation, position and size of the
indication. Defects shall be characterised as follows: -
22.2 Defect Recording

The position of all reportable defect indications shall be recorded following the above conventions. In addition
the following basic information shall be recorded for each indication.
1. Defect Length.
2. Defect Width.
3. Radial extent of the defect.
4. Depth to the top edge of the defect from the outer surface.
5. Scan direction and probe used for assessing the defect.
All measurements shall be in mm.

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23 REPORTING CONTENTS
23.1 Minimum Reporting Criteria

A report shall be prepared for each forging. The report shall contain, as a minimum, the following information: -
1. The location of the test, e.g. Supplier’s works, Power Station, Reactor No.
2. The name of the organisation carrying out the test.
3. The operator's name and qualifications.
4. Identification of the forging(s) tested.
5. Extent of inspection i.e. extent of area tested, forging length.
6. Procedure reference and issue number and if applicable reference and issue number(s) of technique sheet(s).
7. The date of test.
8. Details of all equipment including flaw detector and probes used, plus a record that performance checks
required under Appendix B were carried out.
9. Couplant used.
10. Reference sensitivities (T20/T25/R50/R100) and test sensitivities employed for each range zone (flaw
detector gain settings).
11. All attenuation measurements and the resultant mean attenuation value.
12. Inspection design for the particular forging geometry inspected, including areas of limited coverage due to
surface flatness, parent material quality, geometry, or access problems.
13. Details of all reportable indications, including their positions in relation to the datum(s) and co-ordinate
system(s) defined in Section 13, their depth, their length and the amplitude of each indication expressed as a
number of dB above the DAC level.
14. Where the defect has been sized using probe movement techniques the defect shall be shown on a full size
cross-sectional drawing, indicating the through wall dimension of the defect. A table of the stand-off and
range measurements, together with the stand-off datum, shall be included.
23.2 Deviations from this Procedure and Test Restrictions

1. Details of all areas where the surface preparation did not meet the specification.
2. Full details of any test limitation or restriction to be shown to scale on a sketch with relevant measurements
and dimensions relating to datum position.
3. Full details of any test restrictions such as geometric reflections at a similar range, defects within the
dead zone of the probe and counter bores. These may be discounted at the time of test, but must be
reported as they affect the capability of the procedure.
4. Changes of equipment or sensitivities to those specified.
5. Any ambient conditions such as temperature, lighting or physical position that affect the application of
the inspection.
23.3 Additional Information if Applicable

1. The stage of operation or manufacture at which the inspection took place.
2. Sentencing of the item(s) against the Acceptance Standard if required.

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24 DEFINITIONS
Station Engineer A member of EDF Energy staff nominated to provide Plant information or
agree to certain items/conditions/ as identified above.
EDF Energy NDT A member of EDF Energy staff with expertise in NDT, nominated to provide
Inspection Engineer information or agree to certain items/conditions as identified above and to advise
or arbitrate on technical matters which may arise before, during or on completion
of the inspection and subsequent reporting.
BWE Back Wall Echo
DAC Distance Amplitude Curve
PRG Primary Reference Gain
FBH Flat Bottomed Hole
EFBH Equivalent Flat Bottomed Hole
25 REFERENCES
1) BS EN 10228-3: 2016 Non-destructive testing of steel forgings – Part 3: Ultrasonic
testing of ferritic and martensitic steel forgings
2) BS EN 10228-4: 2016 Non-destructive testing of steel forgings – Part 4: Ultrasonic
testing of austenitic and austenitic-ferritic steel forgings.
3) BS EN ISO 5577: 2017 Non-destructive testing – Ultrasonic testing – Vocabulary
4) COSHH Regulations Control of Substances Hazardous to Health Regulations
5) BEG/SPEC/ENG/PSPEC/038 Controlling the Quality of Non-Destructive Testing,
Implementation of Company Standard. CTS 210
6) BEG/SPEC/ENG/CTS/210 Controlling the Quality of Non Destructive Testing
7) BS EN 12668-1: 2010 Non-destructive testing – Characterisation and verification of
ultrasonic examination equipment – Part 1 Instruments.
ultrasonic examination equipment – Part 2 Probes
9) BS EN ISO 2400: 2012 Non-destructive testing. Ultrasonic testing. Specification for
calibration block No. 1
10) BS EN ISO 7963: 2010 Non-destructive testing. Ultrasonic testing. Specification for
calibration block No. 2
11) BS EN ISO 16811: 2014 Non-destructive testing – Ultrasonic examination –
Sensitivity and range setting
12) E/PROC/ENG/BI/005 Production and Control of NDT Procedures and Technique
Sheets
13) BS EN ISO 16827: 2014 Non-destructive testing – Ultrasonic examination
Characterization and sizing of discontinuities.
ultrasonic examination equipment – Part 3 combined
equipment
15) BEG/SPEC/SHE/COP/016 Code of Practice – Risk Assessment

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16) ENG/FORM/151 Daily Ultrasonic equipment function checks

17) BEG/SPEC/OPS/036A Procedure Use & Adherence (PU&A)
26 RECORDS
Record Template Record Requirement Record Record Retention Storage Security

Title No./Identifier No./Identifier for Record Originator Owner Period Location Classification
or Link to
Record
Inspection OMD W.O.C. No. Procedural Inspection Station Lifetime AMS Not
Report Group Protectively
Marked
27 TABLES - QUALITY CLASSES, RECORDING LEVEL AND ACCEPTANCE

CRITERIA
Table 1: Ferritic Forgings – Normal Probes
Quality class
Parameter
1 2 3 4
Recording level
Equivalent Flat Bottomed Holes (EFBH) >8 >5 >3 >2
Ratio R for rapid BWE reduction <0.1 <0.3 <0.5 <0.6
Acceptance criteria
EFBH (isolated point type discontinuities) deq <12 <8 <5 <3
EFBH (extended or grouped point discontinuities) <8 <5 <3 <2

deq = Diameter of equivalent FBH
R = Fn/Fo,n
where:
n = 1 for t >60mm n = 2 for t < 60mm
Fn = amplitude (screen height) of the nth reduced BWE
Fo,n = amplitude(screen height of the nth BWE in the nearest discontinuity free
area in the same range as Fn
If the reduction in BWE exceeds the recording level, this shall be further investigated.
Ratio R applies only to rapid reduction of BWE caused by the presence
of a discontinuity
CLASSIFICATION OF DISCONTINUITIES
a) Point discontinuity
Echo-dynamic pattern 1 and/or dimension equal to or less than -6dB beam width.
b) Extended discontinuity

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Echo-dynamic pattern 2 and/or dimension equal to or less than -6dB beam width.
c) Isolated discontinuities
The distance d, between points corresponding to the maxima of the indications of adjacent discontinuities
exceeds 40mm.
d) Grouped discontinuities
The distance d, between points corresponding to the maxima of the indications of adjacent discontinuities is
less than or equal to 40mm.
Table 2: Ferritic Forgings – Shear Wave Probes
Quality Nominal test Recording level Acceptance criteria
class Frequency % DAC Isolated Extended or
MHz discontinuities grouped
% DAC Point type
discontinuities
%DAC
Shear wave scanning does not apply to quality class 1
1
2 1 50 100 50
2 100 200 100
3 2 50 100 50
4 100 200 100
4 2 30 60 30
4 50 100 50
A DAC based on 3mm side drilled holes shall be constructed for each frequency of probe
The indication amplitude in dB relative to the DAC is given below
Table 2a: dB Amplitude of Indication Relative to % DAC
% DAC Amplitude of indication relative to DAC ( dB)

25 -12
30 -10
50 -6
60 -4
100 0
200 +6
400 +12

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Table 3: Austenitic Forgings - Normal probes

Forging Recording level Acceptance criteria for
thickness deq mm
t mm Isolated discontinuities Extended or grouped
deq mm discontinuities
deqmm
Class 1
t < 75 >5 <8 <5
75 < t < 250 >8 <11 <8
250 < t < 400 >14 <19 <14

Indication with an Indication with a total loss of BWE. A total loss
T > 400 80% reduction of of BWE is to be considered when its amplitude
BWE becomes less than 5% of its initial value,
measured near the indication or less than or equal
to grass
Class 2
t < 75 >3 <5 <3
75 < t < 250 >5 <8 <5
250 < t < 400 >8 <11 <8
400 < t < 600 >11 <15 <11

Indication with an Indication with a total loss of BWE (as above)
T > 600 80% reduction of
BWE
Class 3
t < 75 >2 <3 <2
75 < t < 250 >3 <5 <3
250 < t < 400 >5 <8 <5
400 < t < 600 >8 <11 <8

Indication with an Indication with a total loss of BWE (as above)
T > 600 80% reduction of
BWE

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Table 4: Austenitic Forgings - Shear Wave Probes

Acceptance criteria for
Forging Nominal test Recording level
thickness Frequency %DAC Isolated Extended or
mm MHz discontinuities grouped
% DAC discontinuities
% DAC
1 30 60 30
t < 75
2 50 100 50
1 50 100 50
75 < t < 250
2 100 200 100
1 100 200 100

250 < t < 400
2 200 400 200
Based on 3mm side drilled hole DAC

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Appendix A - Risk Assessment

This risk assessment covers the processes involved for the inspection of EDF Energy Plant items using
Ultrasonic Inspection processes by EDF Energy Inspection Group Staff, or its approved suppliers, whilst
working on EDF Energy sites.
It is a requirement of the Health & Safety at Work Act, Regulations 3 and 4 to provide sufficient information
to persons other than employees to ensure their Health and Safety.
Company Specification BEG/SPEC/SHE/COP/016(15), Risk Assessment Process, requires that all identified
tasks be adequately assessed to identify significant Hazards and specify reasonable control measures.
Contractor’s staff or others can use this information but must fulfil their own responsibilities to their
employees under the act.
Task Pre-Job brief (PJB)
Before commencing any work to this procedure on an EDF Energy site, users must carry out an appropriate
PJB in line with the requirements of the Time Out for Personal Safety (TOPS) principles. It is the
responsibility of individuals and those in charge of work parties to conduct their work activities in such a
manner as to ensure their own safety and that of others. Users must be aware of the risks and the control
measures required to minimise the potential hazards involved with this process.
A pre-job brief is a two-way discussion conducted prior to carrying out a task to ensure that the requirements
of the task are fully understood. The type of briefing shall be proportional to the task and the risks associated
with the task and can be either a self-brief, green card brief or written brief. Before commencing any work a
review of the task and conditions identified in the PJB are as discussed. Any deviation from those discussed
at the PJB shall be brought to the attention of the Supervisor or, if not available, the EDF Energy NDT
Inspection Engineer.
Note: In addition to the hazards mentioned below. The inspections may be performed in areas which are
either confined space and/or designated as R2/C2 or R3/C2. These areas may be identified as having
‘Significant Risk’ status and therefore specific additional control measures will be applied.
The main hazards associated with the application of this inspection method are:
1) Heavy and awkwardly shaped test blocks can be easily dropped, especially when coated with couplant,
or may fall if not safely located.
2) Electric shock from portable electrical equipment.
3) Slippery surfaces/grip from the presence of ultrasonic couplant.
The following control measures shall be taken to minimise hazards:

1) All test and calibration blocks must be cleaned after use.
2) When moving test and calibration blocks use appropriate cases or carrying boxes, do not carry sharp
edged blocks in a bag that is likely to tear and allow the block to fall out.
3) Make sure test and calibration blocks are safely and securely positioned at all times. When working out
on the plant use lanyards, where applicable and do not balance unsecured blocks on pipework or uneven
surfaces.
4) Clean couplant off the component after inspection and mop up any spillages.
5) All electrical equipment shall have a current Portable Appliance Test (PAT) certificate/sticker.
6) Suitably Qualified and Experienced Personnel to carry out the inspection.
7) Personal Protective Equipment (P.P.E.) to be used.
8) Always use 3 points of contact when using ladders.
9) Check validity of scafftags before using scaffolding and also check the structure meets your access
requirements.

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Providing the above control measures have been implemented correctly; the hazards identified in
carrying out work to this procedure and the degree of risk associated has been assessed. The risks
scores are within the category of 1 to 10.
 Fatalities E1 E2 E3 E4 E4
 Terminal ill health condition
 Long term widespread damage or loss E 10 14 21 23 25
 Major fire-explosion / gas-vapour leak

(poisonous)
 Permanent disability D1 D2 D3 D4 D5
 Significant long term health effects
D
 Major damage or loss 9 13 18 22 24
Fire / minor gas – poisonous component release

 Lost Time Injury (LTI) C1 C2 C3 C4 C5
 Health issue requiring time of work, significant
pain C 4 7 17 19 20
 Significant property / plant damage or loss
 RIDDOR reportable
 Medical Treatment Injury B1 B2 B3 B4 B5
 Health issue requiring physiotherapy or
counselling, moderate pain B 2 5 8 15 16
 Short term local damage or loss
 Minor fire / non-poisonous component release
 First Aid Treatment (minor cuts or grazes) A1 A2 A3 A4 A5
 Minor health issue, slight pain (no time of work)
A
 Very limited property /plant damage or loss 1 3 6 11 12
1 2 3 4 5
Very Very
Unlikely Possible Likely
Unlikely Likely
Likelihood of Occurrence
Score Risk Action
25 - 21 Intolerable Risk Eliminate
20 - 13 Intolerable Risk Manage
12 - 11 Intolerable Risk Procedural Solutions
10 - 9 Tolerable Risk Contingency Procedures
8-1 Tolerable Risk Review Periodically
Report any safety issues to the EDF Energy NDT Engineer or Station Engineer.

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Appendix B - Site Calibration of Ultrasonic Flaw Detection Equipment

B.1 PURPOSE
This appendix describes the methods to be used to calibrate manual ultrasonic flaw detection equipment prior
to carrying out inspections at site.
B.2 APPLICABLE STANDARDS AND REFERENCES

The following British and European Standards are applicable for the following:
1. BS EN ISO 2400(9) – Specification for calibration block No. 1 (formerly A2 block).
2. BS EN ISO 7963(10) – Specification for calibration block No. 2 (formerly A4 block).
3. BS EN 12668-3(14) – Combined equipment checks.
B.3 PRECAUTIONS
Care should be exercised in making the required measurements, as these are used to make judgements on the
equipment's overall performance.
B.4 PROCEDURE
Prior to any inspections being carried out the following equipment checks shall be carried out. The checks
detailed in Sections B4.1 and B4.2 shall be recorded on ENG/FORM/151(16) ‘Daily Ultrasonic equipment
function checks’. The latest revision can be found on CDMS.
B.4.1 Weekly Checks

The flaw detector type and serial number shall be recorded, and the following checks made. Any probe or
flaw detector combination shall have these checks carried out prior to use, providing no such checks have
been made within the preceding seven days.
B.4.1.1 Linearity of Equipment Gain

For this check any standard calibration block and any probe employed during subsequent inspection can be
used. The flaw detector controls for frequency range pulse energy etc. shall be switched to the positions used
during testing. Variable suppression and swept gain controls shall be switched to “off”.
1) Position the probe on the calibration block to obtain a reflected signal from a small reflector e.g. 3mm
hole in the DAC block.
2) Adjust the gain to set this signal to 80% full screen height and note the calibrated gain control (dB).
3) Increase the gain by 2dB and confirm the signal rises to more than full screen height (101%).
4) Restore the gain to 80% full screen height and then reduce it by 6dB. Confirm that the signal falls to
approximately 40% screen height.
5) Reduce the gain by three further 6dB increments and confirm that the signal amplitude falls respectively
to 20%, 10% and 5% screen height.

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The acceptable tolerance limits are given in the table below:

Gain dB Expected screen height (%) Limits
+2 101 Not less than 95%

0 80 (reference line)
-6 40 37% to 43%
-12 20 17% to 23%
-18 10 8% to 12%
-24 5 Visible, below 8%
B.4.1.2 Time Base Linearity

For this check an A4 or A2 standard calibration block and any normal compression probe employed during
subsequent inspection can be used. The linearity shall be checked over a range at least equal to which is to be
used in subsequent inspections.
1) Place the probe on calibration block in a position where the range to the last back-wall signal is equal to
or exceeds the range over which the linearity has to be checked.
2) Adjust the time-base so that the first and sixth back-wall echoes coincide with the first and last scale
marks respectively.
3) In turn bring each signal up to 80% full screen height and check the leading edge lines up with the
appropriate graticule line.
4) Check that any deviations from the ideal positions of any of the signals are within the specified tolerance
of 2% of full screen width.
B.4.2 Daily Checks

The following checks shall be carried out prior to use each day.
B.4.2.1 System Checks – Physical State and External Aspects

Visually inspect the outside of the ultrasonic flaw detector, probes, cables and calibration blocks for physical
damage or wear which could influence the system’s current operation or future reliability. In particular
inspect the face of the probes for physical damage or wear. Check all cables and connectors to ensure good
stable electrical contact.
B.4.2.2 System Checks – Pulse Duration

This check can be done during calibration for inspection using the same cables and settings as per the
inspection.
1) Place the probe on the calibration block and set the reflected signal to 80% full screen height.
2) Measure the pulse width of the signal on the calibrated time base. As a guide this will be approximately
4mm for a 4/5MHz compression wave probe at 10% FSH.
B.4.2.3 System Checks – Signal-to-Noise Ratio

This simple check identifies deterioration in the performance of the combined equipment and is only
intended to monitor the continuing performance of equipment that has been previously shown to operate
satisfactorily.

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1) Using a standard calibration block obtain and maximise a signal from a transverse hole.
2) Adjust the calibrated gain control to set this signal to 20% full screen height and note the gain setting.
3) Remove the probe from the calibration block and wipe the probe face dry.
4) With the probe not in contact, increase the calibrated gain control until the overall system noise at the
same range as the hole signal reaches 20% full screen height. Note this gain setting.
5) The difference between the first and second gain measurements (dB) gives the signal-to-noise ratio.
The signal-to-noise ratio shall be within 6dB of the base measurement made by the user.
B.4.2.4 System Checks – Recording of Checks and Base Values

The following information shall be recorded each day prior to use.
1) Full identification of flaw detector.
2) Identification of each probe to be used.
For each probe:

1) Frequency.
2) T100/40/20/25, Gain (dB) needed to raise to full screen height the signal from the 20/25/40/100mm
thickness for compression waves on an A2 or A4 block.
3) Pulse Duration as B4.2.2.
4) Physical State as B4.2.1.
5) Signal/Noise as B4.2.3.
On a weekly basis a record shall be made of the Amplifier and Time Base linearity checks.
B.4.3 Range and Sensitivity Calibration

Calibration of the range and sensitivity of the equipment shall be carried out prior to each examination. Checks
to confirm these settings shall be performed at least every 4 hours and on completion of the examination. Checks
shall also be carried out whenever a system parameter is changed or changes in the equipment settings are
suspected. If deviations are found during these checks the corrections given in the table below shall be carried
out.
Sensitivity
Deviations  4dB The setting shall be corrected before the examination is continued.
Reduction in Setting shall be corrected and all examinations carried out with the
Sensitivity > 4dB equipment over the previous period shall be repeated.
Increase in Setting shall be corrected and all recorded indications shall be re-
Sensitivity > 4dB examined.
Range
Deviations  2% of The setting shall be corrected before the examination is continued.

the range
Deviations > 2% of Setting shall be corrected and examinations carried out with the
the range equipment over the previous period shall be repeated.
Any probe or flaw detector that is thought to be defective shall not be used for any inspections and either
disposed of (probes) or marked for repair or re-calibration (flaw detector).

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Appendix C - Shear Wave Attenuation and Transfer Loss Measurement

The total V-path shear wave attenuation and transfer loss shall be measured using two 45o single crystal
shear wave probes, 10mm diameter, 4-5 MHz.
To assist in this measurement a mechanical jig can be used to ensure the ultrasonic probes are positioned and
aligned correctly.
1. Calibrate the flaw detector time base to an appropriate range.
2. Using the two 45 single crystal shear wave probes in the transmit/receive mode and the A2 test block;
obtain a full skip response (V-path) from the 25mm dimension.
3. Maximise the response and adjust the echo to 80% full screen height and record the gain setting (AdB).
4. Move the probes to the test piece and, at 8 equi-spaced positions along the length of the forging,
maximise the V-path response and adjust the echo to 80% full screen height. Record the gain setting
(BdB) and measure the thickness (‘x’ mm) at each position.
5. Calculate the average gain setting and thickness (BAvdB and xAvmm). The material thickness should be
measured using the 0° compression probe at 8 equi-spaced positions around the forging.
6. Select the appropriate compensation (CdB) from the following table:-
Average Material Thickness Compensation

(xAvmm) (CdB)
5 to 25 0
25 0
30 1
35 2
40 3
50 4
60 6
70 8
80 9
90 11
100 13
110 15
120 17
1. Calculate the total attenuation and transfer loss, Δ, from the following formula:-
Δ = BAV – (A + C) dB

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Appendix D - Assessment of Indications

All indications exceeding the reporting threshold shall be investigated to determine the nature, shape and size
of the reflector.
This section gives details of probe movement techniques, echo dynamic patterns and sizing methods to be
used in accordance with BS EN ISO 16827: 2014(13), “Non-destructive testing –Ultrasonic examination
Characterisation and sizing of discontinuities”.
Defect Shape and Orientation
The discontinuity/reflector may be categorised as one of the following:
Point, i.e. has no significant extent in any direction.
Elongated, i.e. has significant extent in one direction only.
Planar, i.e. has significant extent in two directions.
Volumetric, i.e. has significant extent in three directions.
By using echo dynamic patterns, directional reflectivity and other parameters such as location, orientation,
multiple indications, discontinuity type and orientation may be established as one of the following:
Point (a) Spherical.
(b) Planar.
Elongated (a) Cylindrical.
(b) Planar.
Large (a) Volumetric.
(b) Smooth planar.
(c) Rough planar.
Multiple (a) Spherical.
(b) Planar.
Defect Reflectivity
This term describes the variation in echo amplitude from a reflector in relation to the angle at which the
ultrasonic beam is incident on it. Discontinuities that show relatively constant echo heights over a wide range
of incident angles are said to have low directional reflectivity, and vice versa.
The echo height from a discontinuity depends upon its size, orientation and surface contour. By measuring
the echo height from different directions and angles (taking into account the effects of range on echo height)
it is possible to assess these characteristics.
For example, a reflector that shows a very low directional reflectivity is likely to be spherical. Conversely, a
discontinuity that shows a very high directional reflectivity is likely to be a large smooth planar reflector
lying perpendicular to the beam angle at which the maximum echo height was observed.
The directional reflectivity of very small flat reflectors is relatively low and increases with the size of the
reflector until it approaches the ultrasonic beam width. This effect can be used to help estimate the size of a
discontinuity.
Defect Echo dynamic Pattern
All indications exceeding the reporting threshold shall be investigated by probe movement and the echo
dynamic pattern defined as l, 2, 3, 4. The following figures give examples of each echo dynamic pattern.
Note. For assessment and acceptance to Section 27, all indications shall be classed as either pattern 1 or 2.

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Figure 1, Pattern 1 ultrasonic response
Reflector
Typical lateral and axial) scans give single peak short envelope
pattern 1 signal response.
Amplitude Variation in peak signal amplitude

with probe movement
A-scan
Range Probe position
Reflector
Typical lateral and axial scans give single peak extended envelope
pattern 2 signal response.
Amplitude Variation in peak signal amplitude

with probe movement
A-scan

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Note: When measuring smooth planar defects at oblique incidence, pattern 1 responses by tip diffraction
off its two extremities can sometimes be observed.
Figure 3, Pattern 3a ultrasonic response
Reflector
Typical lateral) and axial scans give a single but ragged echo that may
fluctuate by more than 6dB.
Amplitude Variation in peak signal

amplitudes with probe movement
A-scan

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Figure 4, Pattern 3b ultrasonic response
Reflector
Typical lateral and axial scans give a travelling echo extended train of
signals that may fluctuate by more than 6dB.
Amplitude Variation in peak and subsidiary signal

A-scan amplitudes with probe movement
showing
the pulse
envelope

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Reflector
Typical lateral and axial scans give a cluster signals that may or may not
be resolved and rise and fall at random with probe movement.
Amplitude Variation in peak and subsidiary signal

A-scan amplitudes with probe movement
Long range echoes Short range echoes
If there is any doubt over the nature of indications, this should be reported to the EDF Energy NDT Site
Team Leader for further investigation.

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Defect Resolution
The following criteria shall apply to determine whether defects are isolated or connected.
Figure 6a, Defects along the beam axis
Relevant threshold
Defect echo type (a) may only be classified as discrete if the two echoes remain
separated at the reporting threshold throughout the complete scan.
Figure 6b, Defects oblique to the beam axis
Relevant threshold
Defect echo type (b) may only be classified as discrete if the two echoes remain
Figure 6c, Defects normal to the beam axis
Relevant threshold
Defect echo type (c) may only be classified as discrete if the two echo envelopes remain

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Figure 6d, Extended irregular echo envelopes
Defect 1 a
b
c
Defect 2
d
Single Peak Echo

b d
a
Relevant threshold
Defect 1 Defect 2
c
Multi-Peak Echo
b d
a
Relevant threshold
Defect 2
Defect 1
Defect echo envelope type (d) may only be classified as discrete defects if the echo
envelopes remain separated at the reporting threshold.

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Combination of Defect Signal Data

By combining the data determined from the probe movement techniques it is possible to identify the basic
shape / type of the discontinuity.
The greater the number of angles from which the discontinuity is interrogated the greater the accuracy.
It is important to note that the best probe for sizing could well be the probe giving the best possible
resolution of the defect response. This will normally be at oblique incidence and not therefore the probe
giving the highest amplitude.
The table below summarises all features of typical responses of all discontinuity types and shapes.
Table 5:
Shape/ Type Echo dynamic patterns Directional Remarks

Reflectivity
Transverse Lateral
Movement Movement
Point Pattern 1 Pattern 1 Very low Point location

spherical
Point planar Pattern 1 Pattern 1 Moderate Point location only
Elongated Pattern 1 Pattern 2 Very low in transverse Point location by

cylindrical plane. High in lateral transverse movement
plane (see note)
Elongated Pattern 1 Pattern 2 Moderate in transverse Ends may be
planar plane. High in lateral individually located by
plane (see note) lateral movement
Large Pattern 3 Pattern 2 or Moderate in transverse Approximate outline
volumetric Pattern 3 plane. Moderate in generally possible
lateral plane (see note)
Large smooth Pattern 2 Pattern 2 Very High Ends may be
planar individually located
Large rough Pattern 3 Pattern 3 Moderate Location of individual
planar facets and ends
generally possible
Multiple Pattern 4 Pattern 4 Very low Location of edges of
spherical cluster generally
possible
Multiple Pattern 4 Pattern 4 Moderate
planar
Note: The transverse and lateral plane are defined as follows:
Transverse plane – perpendicular to the major axis of the discontinuity, or to a specified
direction
Lateral plane – parallel to the major axis of the discontinuity, or at right angles to the
transverse plane

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Appendix E - Reporting Scan Restrictions

An important factor in the determining forging integrity is the accurate assessment of inspection coverage
achieved during an ultrasonic inspection.
Probe scanning may be restricted due to various factors and can result in a limited test where the inspection
coverage shown on the ‘scan design sheet’ is not fully achieved.
Scanning can be limited due to the following:
 Forging design such change of section etc.
 Obstructions such as adjacent pipework or thermocouples etc.
 External profile such as excavations and welds associated with attachments etc.
 Internal profile due to forging design such as bore throttling etc.
All scan restrictions need to be clearly and concisely recorded on inspection reports to enable an accurate
assessment of inspection coverage.
To establish a uniform method of recording scan restrictions this appendix gives details of how they shall be
annotated.
 Axial and circumferential scan restrictions will be treated separately and not superimposed.
 Full size cross-sectional drawings shall be constructed at representative positions, the scanning
achieved shall be marked on the drawings and areas of limited coverage that remain shall be clearly
identified.
 The extent or length of any scan restriction shall be recorded relevant to a designated datum.
Figures E1 and E2 show examples of a restriction. The scan designs and the resultant test restrictions shown are
for example purposes and should be used only as a general guide.
1. FORGING SECTION CHANGE - COMPRESSION SCAN

Example shows a forging configuration
Scanning on change of section not achieved.
Denotes area not scanned.

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FORGING SECTION CHANGE – SHEAR WAVE SCAN
Example shows a forging configuration

Scanning on change of section not achieved.
Denotes area scanned from one side only.
Denotes area not scanned from either direction.

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Appendix F - CAPABILITY STATEMENT

The capabilities claimed for this procedure can be found in Section 11 of report SERCO/TAS/19750/R01 –
Capability statement for EDF Energy NDT procedure E/PROC/ENG/BI/155 for Ultrasonic inspection of
Ferritic and Austenitic forgings. This report is available for review on CDMS but an extract has been added
below.
1. The inspection sensitivity/indication recording threshold for 0° compression wave probes is too low
to allow the target 3mm diameter Type 1 defects (isolated pores, inclusions and segregation) to be
detected in all cases. For 2MHz probes, detection should be adequate for all ferritic forging
thicknesses and for austenitic forgings up to 75mm thickness. Detection at 4MHz frequency is not
possible for any case.
2. The inspection sensitivity/indication recording thresholds for angled shear wave probes is too low to
allow Type 1 defects to be reliably detected. There is a marginal detection capability indicated for
Quality Class 4 ferritic forgings up to 50mm thickness with a 2MHz probe, but the margin of +1.3dB
relative to the indication recording threshold is insufficient to ensure reliable detection.
3. The inspection sensitivity/indication recording threshold for 0° compression wave probes is more
than sufficient to allow the target 12mm long x 3mm diameter Type 2 defects (stringers) to be
reliably detected in all but one case (QC 3 austenitic forging 400mm < t ≤ 600mm) with the 4MHz
probe frequency. At 2MHz probe frequency the target stringer would be detected in all cases.
4. For angled shear wave probes and Quality Class 4 ferritic forgings, the peak amplitude response of a
target 12mm long x 3mm diameter stringer can be expected to be approximately 12dB above the
indication recording threshold, which is more than sufficient to guarantee reliable detection. For
Quality Class 3 austenitic forgings, detection of a 12mm long x 3mm diameter stringer is
straightforward except for forgings with thicknesses between 250mm and 400mm inspected with
2MHz probes, where detection is only marginal at best.
5. Type 3 (lamination) defects with dimensions of 12mm long x 3mm wide and skews and tilts of up to
+/- 5° should be readily detectable with 0° compression wave probes in Quality Class 4 ferritic
forgings and Quality Class 3 austenitic forgings up to 400mm in thickness. Beyond that, inspection
becomes progressively less certain as thickness increases, especially for forgings with ultrasonically
noisy material.
6. Type 4 defects (surface-breaking cracks) which are insonified by beams which have traversed the
forging material should be reliably detected if angles of incidence of 45° ±10° or 0° ± 10° can be
achieved. This conclusion also applies for Quality Class 4 ferritic forgings if the defects are tilted
and skewed within the limits of the defect description. For Quality Class 3 austenitic forgings and
defects that are tilted and skewed within the limits of the defect description this conclusion holds for
1MHz probes but detection becomes marginal as the probe angle approaches 60°. This conclusion is
supported by experimental data from the PANI exercises for ferritic forgings.
7. Cracks which are detected by probes on the same surface of the crack at short range should be
reliably detected at 11.5dB and 4dB above the indication recording threshold with 2MHz and 4MHz
angled shear wave probes respectively in the case of ferritic forgings. In the case of austenitic
forgings these cracks should be reliably detected at least 11.5dB above the indication recording
threshold with 1MHz angled shear wave probes and by 7dB with 2MHz probes.

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Appendix G - QA Inspection Checklist

The principles of BEG/SPEC/OPS/036A(16) shall apply during the use of this procedure. This procedure is
considered ‘reference use, medium risk, medium control’. The EDF-Energy preferred method of place-
keeping is circle and slash. A process designed to help the procedure user track completion of procedure
steps to ensure that all necessary steps are performed and in the correct sequence. To assist in this
requirement a ‘QA Inspection Checklist’ is provided below.
STEP PROCEDURAL REQUIREMENTS SECTION STATUS

In progress = √
Completed = √
1 SAFETY 4
Pre-job brief App A
TOPS / Risk Assessment App A
2 INSPECTION PRE-REQUISITES 7
Component preparation 7.1
3 QUALIFICATION OF OPERATOR/S 8
Operator SQEP’d for task 8.1 & 8.2
4 EQUIPMENT AND CONSUMABLES 9
Equipment as specified 9
Equipment checks 10 & App B
Consumables as specified 9
5 INSPECTION PROCEDURE 12 & 19
Initial Inspection requirements 11, 19 & 21
Equipment set-up, calibration and sensitivity 11 & App B
6 ASSESSMENT OF INDICATIONS 22
Reporting Threshold 27
Recording Indications 22.1
7 REPORTING OF RESULTS 23
Minimum reporting criteria 23.1
Location:
Component ID:
Operator:
Date:

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Appendix H - Review/Revision Register
Issue / Revision Amendment

E/PROC/ENG/BI/155
First Issue.
Revision 000, March 2006
E/PROC/ENG/BI/155 Format revised and minor amendments for clarity.
Revision 001, March 2009 Capability statement added.
Forging Inspection drawings added for clarity.
Drawings added to demonstrate probe contouring.
Additional text added to clarify datums, recording levels and acceptance
criteria.
E/PROC/ENG/BI/155
Classification of discontinuities added from BS EN 10228-3 & 4.
Table 2a updated to cover full range quoted in EN Standards.
Minor changes to table 3.
Risk assessment updated.
Scan Restriction Guidance added.
Minor amendments to layout.
EN Standards updated.
Qualification requirements amended.
E/PROC/ENG/BI/155
Circumferential probe contouring requirements amended.
Defect characterisation changed in line with current EN Standards.
Risk Assessment updated in line with procedures.
Capability statement summary added.
Minor amendments to layout
E/PROC/ENG/BI/155
Standards updated
Revision 004. March 2018
QA Inspection Checklist Added
DISTRIBUTION LIST
None


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NOT PROTECTIVELY MARKED E/PROC/ENG/BI/155

EDF Energy Nuclear Generation

Central Engineering Support Function

NDT Procedure for Ultrasonic Inspection of Ferritic and

Originated By: M Jenkinson Date: March 2018

Reviewed By: G Innes Date: March 2018

Reviewed By: P Heath Date: March 2018

Approved By: S Meikle Date: March 2018

REVISION AMENDMENT LEVEL OF USE DATE

NOT PROTECTIVELY MARKED Template Ref: ENG/FORM/116 Revision 006

NOT PROTECTIVELY MARKED Template Ref: ENG/FORM/116 Revision 006

23.1 Minimum Reporting Criteria ...................................................................................................... 15

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3.1 Inspection Group Head

3.2 NDT Inspection Engineer

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5 ITEMS FOR AGREEMENT

6.1 Cylindrical Solid Forging

NOT PROTECTIVELY MARKED Template Ref: ENG/FORM/116 Revision 006

6.2 Cylindrical Hollow Forging

0° Compression and shear

6.3 Rectangular Solid Forging

0° Compression and shear

6.4 Rectangular Hollow Forging

0° Compression and shear

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6.5 Near Surface Examination

7.1 Preparation of items to be tested

7.2 Deviation from Specification

8 QUALIFICATION OF NDT PERSONNEL

8.1 New Forgings

8.2 In-Service Forgings

NOT PROTECTIVELY MARKED Template Ref: ENG/FORM/116 Revision 006

Beam direction Beam direction

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10 EQUIPMENT CHECKS AND CALIBRATION

11 DISTANCE AMPLITUDE CORRECTION (DAC) CURVE

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13 FORGING IDENTIFICATION, MARKING DATUM AND COORDINATE SYSTEM

13.1 Identification of Forging(s) to be tested

13.2 Method of Marking

13.3 Datum Points and Co-ordinate Systems

13.3.1 Longitudinal Measurements

13.3.2 Circumferential Measurements

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15 CROSS SECTIONAL DRAWINGS

18 CORRECTION FOR ATTENUATION AND TRANSFER LOSS

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18.1 Shear Wave Losses

18.2 Compression Wave Losses

19 PERFORMING THE INSPECTION

20.1 New Forgings

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20.2 In-Service Forgings

21 INSPECTION SENSITIVITY AND RECORDING LEVELS

21.1 Recording Levels and Acceptance Criteria

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22.1 Defect Sizing and Characterisation

22.2 Defect Recording

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23.1 Minimum Reporting Criteria

23.2 Deviations from this Procedure and Test Restrictions

23.3 Additional Information if Applicable