Acast_PS 1870_Rev_2

1602 Wagner Avenue Erie, PA 16510

Drawing Number: PS-1870

Drawing Revision: 2

Drawn By: GHW, 9/8/06 Approved By: JL, 9/8/06

Revision Reference No.: 2006E0267

Page 1 of 5

Title Radiographic Inspection of Steel Castings

Scope: This process specification covers the inspection of steel castings by outside vendors. This includes first piece sample qualification, process qualification and inspection of castings of qualified parts from suppliers.

Reference documents: Drawings attached. The qualification process and inspection for process for castings to be produced at a specified vendor will be as follows. No repair welding is permitted to meet acceptance of the First Piece Inspection or the Process Qualification. Map of Castings:

Large 1 Piece castings (10”-16”): The casting is divided into a grid defined by three sections axially and the flange (Axial 1-3 and Flange) in Section A-A on Page 4 and into ten 36° radial segments in the top view (Radial 1-10). There are also areas labeled Boss, Bottom, Pad 1 and Pad 2. NOTE: on 16” castings pad 1 and 2 are centered on the nozzle opening and Pad 1 is above the nozzle and Pad 2 is below the nozzle.

Large Ring Nozzle castings (8”-16”): The casting is divided into a grid defined by three sections axially (Axial 1-3) in Section A-A on Page 5 and into ten 36° radial segments in the top view (Radial 1-10). There are also areas labeled Boss, Pad 1 and Pad 2. NOTE: on 16” castings pad 1 and 2 are centered on the nozzle opening and Pad 1 is above the nozzle and Pad 2 is below the nozzle.

Large Base Castings (8”-16”): The casting is divided into a grid defined by 1 section axially and the 4 and into ten 36° radial segments in the top view (Radial 1-10). There are also areas labeled Boss, Bottom, Pad 1 and Pad 2.

Small 1 Piece castings (2”-6”): The casting is divided into a grid defined by one or two sections axially (as appropriate for the size of film used) and the flange (Axial 1-2 and Flange) in Section A-A on Page 6 and into 5 72° radial segments in the top view (Radial 1-5). There are also areas labeled Boss, Bottom, Pad 1 and Pad 2 (only 1 pad on 2” castings).

Misc. Pressure Castings: These castings include, but are not limited to RB bodies, cast covers, nozzle sections, etc. The casting is divided into a grid defined by three sections axially and the flange (Axial 1-3 and Flange) in Section A-A on Page 4 and into ten 36° radial segments in the top view (Radial 1-10). There are also areas labeled Boss, Bottom, Pad 1 and Pad 2.

First Piece (Sample) Inspection: The first sample (no more than two pieces) are to be inspected via 100% radiographic inspection (for the areas defined in the attached drawing(s)) using the acceptance criteria specified below. Radiographic reports are to



Drawing Revision: 2



Page 2 of 5

be submitted to FMC Engineering and Quality Control for approval prior of shipment of the castings. Process Qualification: Following approval of the first sample, the next 20 parts will be for the process being qualified via a partial radiograph of each of the parts. Two radiographs (180° apart, if applicable, must not be two adjacent sections) of each of the areas of the axial segments defined by the axial and radial grid (for example Axial 1 and Radial 1 and Axial 1 and Radial 5 – total of two radiographs) are to be radiographed on each of the castings. No two axial segments shall be located in the same radial segment on each casting. The boss, pad 1, pad 2, and the bottom shall be radiographed on every 5

th casting produced.

Areas radiographed shall not be repeated until each quadrant is inspected on castings produced. This is regardless of the number of castings per PO. Inspection of Qualified Castings: For line items with a quantity greater then 10, every 10

th casting must be radiographed (I.E. qty 40, 4 X-rays - qty 55, 5 X-rays). For

line items with a quantity less than 10, 1 casting is to be radiographed. Inspection procedure consists of two radiographs (180° apart, if applicable, must not be two adjacent sections) of each of the areas of the axial segments defined by the axial and radial grid (for example Axial 1 and Radial 1 and Axial 1 and Radial 5 – total of two radiographs) are to be radiographed on each of the castings. No two axial segments shall be located in the same radial segment on each casting. The boss, pad 1, pad 2, and the bottom shall be radiographed. Areas radiographed shall not be repeated until each quadrant is inspected on castings produced. This is regardless of the number of castings per PO. Any weld repair of castings shall be in accordance with PS-1875 Radiographic Inspection for Materials acc. to ASTM Standards: The castings shall be radiographed per Appendix 7-2 (c) of ASME Section VIII Division 1. All reports are to be certified by ASNT SNT-TC-1A Level 2 qualified individuals. Certification of individuals qualifications to ASNT SNT-TC-1A Level 2 are to be supplied upon request of FMC. Radiographic Inspection for Materials acc. to European DIN EN Standards: The scope of testing for steel castings is dependent of the Quality Level and stipulated in technical Bulletin W5 Table 2 of AD2000 Regulation. The Quality Level is defined in Table1 of AD2000-W5.



Drawing Revision: 2



Page 3 of 5

Excerpt-Table1 of AD2000-W5

Quality Level Allowable max. Working

Temperature °C

Allowable max. Working Pressure

bar

RT(4)

1(1)

Welding Ends 1 2 > 450 > 80 2 3 up to 450 up to 80 3

(1)Linear or alighned indications, when detected by surface testing are not permitted

(4)Radiographic examination RT in accordance with DIN EN 12680/acceptance criteria

in accordance with Appendix 1 AD 2000-Merkblatt All reports are to be certified by PED/ EN473 Level 2 qualified individuals. Certification of individuals qualifications to PED/ EN 473 Level 2 are to be supplied upon request of FMC. Acceptance Criteria are defined in technical Bulletin W5 Addendum 1 Table A1 of AD2000 Regulation. For castings having radiographed thickness up to 2 inches (51 mm), the radiographs shall be compared to those in ASTM E446, Standard Reference Radiographs for Steel Castings Up to 2 in. (51 mm) in Thickness. For castings having radiographed thickness 2 inches (51 mm) to 4 ½ in. (114 mm), the radiographs shall be compared to those in ASTM E186, Standard Reference Radiographs for Heavy Walled [2 to 4 1/2 in. (51 mm to 114 mm)] Steel Castings. The maximum acceptable severity levels for imperfections shall be as follows: Imperfection Category Maximum Severity Level A – Gas porosity 3 B – Sand and Slag 3 C – Shrinkage (all types) 3 D – Cracks 0 E – Hot Tears 0 F - Inserts 0 Deliverables: Certificate of conformance to this specification must be supplied with each shipment referencing the affected heat numbers, how many castings were inspected, and a signature of the 3d party inspector certifying conformance. Third party inspector can work for the same foundry, however, they must not report to/through production. Inspection results are to be kept by the supplier for a minimum of 7 years and be available for review by FMC personnel or their designate during an audit.



Drawing Revision: 2



Page 4 of 5

Heat number of the casting being x-rayed must be visible on the x-ray (lead letters or equivalent). Each casting that is x-rayed will be marked as such (indelible ink, etc.) so FMC can verify x-ray results. In the event of a major change to the patterns, the first part will be subjected to 100% x-ray. Assuming the part passes, you can resume the in-process inspection interval.

1602 W

agner

Avenue

E

rie, P

A 1

6510

Dra

win

g N

um

ber:

PS

-1870

Dra

win

g R

evis

ion:

2

Dra

wn B

y:

GH

W,

9/8

/06

Appro

ved B

y:

JL, 9/8

/06

R

evis

ion R

efe

rence N

o.:

2006E

0267

P

age 5

of

5

Documents

Acast_PS 1870_Rev_2