IACS Rec-69-Rev2-Oct-2020-Ul (NDT)
IACS Rec-69-Rev2-Oct-2020-Ul (NDT)
69
3. Casting Condition
3.1 Heat Treatment
3.2 Surface Condition
6. Acceptance Criteria
6.1 Visual Inspection Testing
6.2 Surface Inspection Crack Detection
6.3 Volumetric Inspection Testing
7. Reporting
8. Rectification of Defects
Annex 1
Extent and methods of non-destructive testing examination to be applied to
typical hull steel castings.
1. General
No. 1.1.1 This document is intended to give general guidance on the extent, methods and
recommended quality levels applicable to the non-destructive testing examinations (NDT
69 NDE), of marine steel castings, except in those cases where alternative criteria have
(cont) been otherwise approved or specified.
1.1.2 Although no detailed guidelines are given for machinery components, the
requirements in these guidelines may apply correspondingly considering their
materials, kinds, shapes and stress conditions being subjected.
1.1.4 UR W8 or this Recommendation do not include every cast component type that
may be subject to Classification. In such cases where the particular component or type is
not included, appropriate national/international standards, or other Society requirements
may be applied, to determine the appropriate testing regime and defect acceptance
criteria.
1.1.5 These guidelines complement and reference the requirements of the following
UR’s - UR W8, UR W22, UR W29, UR A1, and UR W34, and contain general guidance
for the non-destructive testing methods, the extent of testing and the minimum
recommended quality levels that should be complied with unless otherwise approved or
specified.
1.1.7 Where intermediate inspections have been performed the manufacturer should
provide reports of the results upon the request of the Surveyor.
1.1.9 Where advanced ultrasonic testing methods are applied, e.g. PAUT or TOFD,
reference is made to UR W34, for general approach in adopting and application of these
advanced methods. Acceptance levels regarding accept/reject criteria are specified in
the applicable section in this Recommendation.
2.1.1 Personnel carrying out NDE are generally to be qualified and certified to
Level II of a recognised certification scheme such as EN 473, ISO9712 or SNT-TC-
1A. Personnel engaged in visual examination are to have sufficient knowledge and
experience, however, may be exempted from formal qualifications specified in this
Recommendation.
should align with the main requirements with those of ISO 9712 (apart from the
impartiality requirements of a certification body).
No.
2.1.2 2.1.3 Personnel responsible for the NDE NDT activity including approval of
69 procedures should be qualified and certified to Level III.
(cont)
2.1.4 The NDT personnel’s certificates and competence should comprise all industrial
sectors and techniques being applied by the manufacturer or its subcontractors.
Certificates should be made available to the Society for verification, when requested.
2.1.5 The operator carrying out the NDT and interpreting indications, should as a
minimum, be qualified and certified to Level II in the NDT method(s) concerned.
However, operators only undertaking the gathering of data using any NDT method and
not performing data interpretation or data analysis may be qualified and certified as
appropriate, at level I.
3. Casting Condition
3.2.1 Castings are to should be examined in the final delivery condition free from any
material such as scale, dirt, grease or paint that might affect the effectiveness
efficacy of the inspection. A thin coating of contrast paint is permissible when using
magnetic particle techniques. For surface inspection NDT methods, the surface quality
should be a minimum value of Ra ≤6.3 μm
3.2.2. Unless otherwise specified in the order, magnetic particle test shall be carried
out within 0.3mm of the final machined surface condition for AC techniques or within
0.8mm for DC techniques.
3.2.3. 3.2.2 Ultrasonic testing is to should be carried out after the castings have
been ground, machined or shot blasted to a suitable condition, with a minimum value
surface quality of Ra ≤12,5 μm. The surfaces of castings to be examined should be
such that adequate coupling can be established between the probe and the
casting and that excessive wear of the probe is avoided.
4.2.2 4.1.2 In addition to the areas identified in Annex 1, surface inspections shall
should be carried out in the following locations:
- at all accessible fillets and changes of section,
- in way of fabrication weld preparation, for a band width of 30mm,
- in way of chaplets,
- in way of weld repairs,
- at positions where surplus metal has been removed by flame
cutting, scarifying or arc-air gouging.
4.2.3 4.1.3 Ultrasonic testing shall should be carried out in the zones indicated in
Annex 1 and also at the following locations:
- in way of all accessible fillets and at pronounced changes of section.
- in way of fabrication weld preparations for a distance of 50mm from the edge.
- in way of weld repairs where the original defect was detected by
ultrasonic testing.
- in way of riser positions,
- in way of machined areas particularly those subject to further machining such
as bolt hole positions.
4.1.4 In the case of castings such as rudder horns, which may have a large surface
area still untested after the above inspections have been applied, an additional
ultrasonic inspection of the untested areas should be made along continuous
perpendicular grid lines on nominal 225 mm centres, scanning from one surface only.
5. Examination Procedures
5.1.1 Steel castings nominated for NDE NDT shall should be subjected to a 100%
visual examination of all accessible surfaces by the manufacturer and made available
to the Surveyor. Lighting Viewing conditions at the inspected surfaces shall should be
in accordance with a nationally or internationally recognised standard. Unless
otherwise agreed, the visual and surface crack detection inspections are to should be
carried out in the presence of the Surveyor.
testing and liquid penetrant testing are to should comply with recognised national
or international standards. Magnetic particle testing inspection will be carried out in
No. preference is preferable to liquid penetrant testing except in the following cases;
69 - austenitic stainless steels,
(cont) - interpretation of open visual or magnetic particle indications,
- at the instruction of the Surveyor, where a particular need for penetrant testing
has been identified.
5.2.2 For magnetic particle testing, attention is to be paid to the contact between the
casting and the clamping devices of stationary magnetisation benches in order to avoid
local overheating or burning damage in its surface. Prods shall should not be permitted
on finished machined items. Note that the use of solid copper at the prod tips must be
avoided due to the risk of copper penetration contamination into the casting. The pole
of the magnets should have close contact with the component.
5.2.3 5.2.4 When indications have been detected as a result of the surface
inspection, acceptance or rejection is to should be decided in accordance with
Section 6.
5.3.2 In some cases, due to the shape, nature, complexity of casting, or defect type
or orientation, there may be a need for radiographic testing. In such cases,
radiographic testing may be carried out on the basis of prior agreement with the
Classification Society. Where radiographic testing is to be applied, national or
international standards for both the testing method, and the quality or severity level to be
applied, should be agreed with the Classification Society.
Guidance on standards:
ASTM E446 – 15
ASTM E186 – 15 (2019) e1
ASTM E280 – 15 (2019) e1
ISO 4993:2015
A suitable quality level for marine castings would normally be severity level 2 or 3 (of
the above standards), depending on the location zone and type of casting. Other
severity levels may be applied, and should be agreed with the Classification Society
5.3.2 5.3.3 Only those areas shown in the agreed inspection plan should need to be
tested, however, the inspections may reveal indications that require further evaluation,
No. or an extension of testing. In such cases, this should be agreed with the Classification
69 Society. The plan should include those locations nominated in section 4.2.3 together
with the scanning zones identified for the relevant casting in Annex 1.
(cont)
5.3.3 5.3.4 Ultrasonic scans are to should be made using a 0o probe of 1 - 4MHz
(usually 2MHz) frequency, and angle probes, where required. Whenever possible
scanning is to be performed from both surfaces of the casting and from surfaces
perpendicular to each other.
5.3.4 5.3.5 The backwall echo obtained on parallel sections should be used to
monitor variations in probe coupling and material attenuation. Any reduction in the
amplitude of the back wall echo without evidence of intervening defects due to
material properties should be corrected. Attenuation in excess of 30dB/m could be
indicative of an unsatisfactory annealing heat treatment, and may render the
effectiveness of the testing as unsuitable. In such cases of excessive attenuation, this
should be investigated, and suitable mitigation measures carried out for effective
ultrasonic testing to continue, where possible.
5.3.5 5.3.6 Machined surfaces, especially those in the vicinity of riser locations and in
the bores of stern boss castings, should also be subject to a near surface
(approximately 25mm) scan using a twin crystal 0o probe.
5.3.6 5.3.7 In the examinations of those zones nominated for ultrasonic examination
the reference sensitivity for the 0° probe is to should be established against a 6mm
diameter disk reflector. Sensitivity can be calibrated either against 6mm diameter flat
bottomed hole(s) in a reference block (or series of blocks) corresponding to the
thickness of the casting provided that a transfer correction is made, using the DAC
(distance-amplitude-correction) method, or, as a preferred alternative, by using the
DGS (distance-gain-size) method.
5.3.8 The reference sensitivity of angle probes (where required for testing)
should be established against an appropriate 6mm reflector (e.g. reference
reflectors angled perpendicular to the sound beam) for the DAC method, or
equivalent using the DGS method.
5.3.9 The DGS diagrams issued by a probe manufacturer identify the difference in dB
between the amplitude of a back wall echo and that expected from a 6mm diameter
disk reflector. By adding this difference to the sensitivity level initially set by adjusting
a back wall echo to a reference height eg e.g. 80%, the amended reference level will
6. Acceptance Criteria
6.1.1 All castings shall should be free of cracks, crack-like indications, hot tears, cold
shuts or other injurious detrimental indications. Thickness of the remains of
sprues or risers is to should be within the casting dimensional tolerance.
6.1.2 Additional magnetic particle, dye penetrant or ultrasonic testing may be required
for a more detailed evaluation of surface irregularities at the request of the
Surveyor.
6.2.2 For the purpose of evaluating indications, the surface is to should be divided
into reference band length of 150 mm for level MT1/PT1 and into reference areas of
22500mm2 for level MT2/PT2. The band length and/or area shall should be taken in the
most unfavourable location relative to the indications being evaluated.
6.2.3 The following quality levels recommended for magnetic particle testing
(MT) and/or liquid penetrant testing (PT) are;
Level MT1/PT1 - fabrication weld preparation and weld repairs.
Level MT2/PT2 - other locations nominated for surface crack detection inspection in
Annex 1.
No.
The allowable numbers and sizes of indications in the reference band length and/or
69 area are given in Table 1. The required quality level should be shown on the
(cont) manufacturer’s inspection plan. Cracks and hot tears should are not be accepted.
acceptable.
1)
MT1/PT1 4 in 150 mm Non-linear 4 5
1)
length Linear 4 3
1)
Aligned 4 3
area Linear 6 5
Aligned 6 5
6.3.1 Acceptance criteria for ultrasonic testing are identified in Table 2 as UT1 and
UT2. As stated in 4.2.1 the quality levels applicable to the zones to be examined are to
should be identified on an inspection plan. The following quality levels are nominated
for the castings identified in Annex 1.
6.3.2 For near surface testing (to an approximate depth of 25 mm) twin crystal 0o
(normal beam) probe should be used, plus a 0o probe (usually single crystal beyond a
depth of 25 mm) for the remaining volume.
6.3.2 6.3.3 Ultrasonic acceptance criteria for other casting areas not nominated in
Annex 1 will should be subject to special consideration based on the anticipated stress
levels and the type, size and position of the discontinuity.
6.3.4 Table 2 describes the acceptance criteria for both methods of applied
sensitivity (DGS and DAC)
6.3.5 DGS and DAC methods may be used for determining sensitivity. The DAC
method for normal beam probes may be based on a 6.0mm diameter reflector or flat
bottomed hole (FBH). A DAC curve should be produced using reference blocks
containing 6.0mm FBH reflectors over a range representative of the inspection thickness,
after adjustment for transfer and attenuation losses,
6.3.6 For quality level UT 1, any discontinuity producing a signal amplitude in excess
of the 6.0 mm DAC curve is unacceptable.
6.3.7 For quality level UT2, the sensitivity may be based on actual size FBH (of 12mm
and 15 mm) or based on equivalent 6mm FBH, and the sensitivity adjusted to obtain
equivalent amplitudes, as described in 6.3.8.
6.3.8 For use of FBH of 6mm for setting sensitivity, adjustment of signal amplitudes
(measured in dB above 6mm DAC) can be determined for 12mm and 15mm FBH
reflectors: to be DAC + 12dB and DAC + 16dB (plus any compensation for transfer and
attenuation losses). This is illustrated in Figure 1. The increase in dB to the indicated
levels represent the equivalent FBH sizes (for 12 mm and 15mm), and their respective
corresponding ultrasonic response amplitudes.
No.
69
(cont)
Figure 1 DAC curve produced from 6.0mm FBH reflector and DAC curves
adjusted to represent equivalent 12.0mm and 15.0mm FBH reflectors.
The bottom curve (DAC) represents a sensitivity based on 6mm FBH, and the two
additional curves (DAC + 12 and DAC + 16dB) above this represent the equivalent
sensitivities converted for larger FBH’s (12mm and 15mm).
When scanning using these curves, and applying Table 2 acceptance criteria, for UT2,
any indication below DAC +12mm should be disregarded, and any indication above DAC
+16mm should be rejected.
Any indication between these two curves should be evaluated according to its size, as
per Table 2.
Table 2 Ultrasonic Acceptance Criteria for steel castings – Using DGS or DAC
system
No.
69 Quality Level Allowable disc Max. Allowable length
(cont) shape according Maximum size of linear all
1)
to DGS [mm] or number of relevant indications
5), 6)
diameter of FBH indications to [mm]3
according to be registered2
4)
DAC2), 3) Curve
[mm]
UT1 >6 0 0
UT2 12-15 5 50
>15 0 0
Notes:
1) DGS: distance-gain size.
2) DAC: Distance Amplitude Correction
3) The corresponding DAC level to each of the FBH reflectors is at 100% DAC
2 4) grouped in an area measuring 300 x 300 mm
3 5) measured on the scanning surface
6) the measured indication is regarded as the longest dimension, as measured
in the scanning process
6.3.9 The maximum number of indications to be registered and the maximum length
of indications permissible for quality level 2 (as stated in Table 2) apply to normal probes.
6.3.11 Any signal between 12 + 15 curve should be evaluated for length of defect,
and referred to table 2 for acceptance
7. Reporting
7.1 General
(10) Test standards used. including reference to the appropriate tables for
acceptance purposes
(11) Results, including documentation regarding the repair and testing history (as
appropriate);
- flaw detector probes probe type, size, angle and frequency (and any adaptions
to probes for curved surfaces), calibration and reference blocks, sensitivity
method (including reflector size, transfer correction), maximum scanning rate
(mm/s), and couplant used.
8. Rectification of Defects
8.1 Indications that exceed the requirements of Table 1 and Table 2, should be
classed as defects, and should be repaired or rejected as appropriate, according to
Classification Society Rules.
8.3 Complete removal of the defect should be proved by magnetic particle testing or
penetrant testing, as appropriate.
No.
69 8.4 Castings which are repaired should be examined by the same method as
at initial inspection, as well as by any additional methods as requested by the
(cont) Surveyor.
8.1.2 Weld repairs should be suitably classified. Major repairs are those;
- where the depth is greater than 25% of the wall thickness or 25mm whichever
is less,
- where the total weld area on a casting exceeds 2% of the casting surface
noting that where a distance between two welds is less than their average width, they
are to be considered as one weld.
Major repairs require the approval of the Classification Society before the repair is
carried out. The repair should be carried out before final furnace heat treatment.
Minor repairs do not usually require the approval of the Classification Society but
should be recorded on a weld repair sketch as a part of the manufacturing procedure
documents. These repairs should be carried out before final furnace heat treatment.
Cosmetic repairs do not require the approval of the Classification Society but should
be recorded on a weld repair sketch. These repairs may be carried out after final
furnace heat treatment but are subject to a local stress relief heat treatment.
- on un-machined surfaces where the depth of defect removal is not over 15mm
or 10% of wall thickness, whichever is less, and the length of the removed part is not
(cont)
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