1602 Wagner Avenue

Erie, PA 16510

Title
Scope:

Radiographic Inspection of Steel Castings

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 Number: PS-1870

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

Drawing Revision: 2
Revision Reference No.:
2006E0267

Page 1 of 5

1602 Wagner Avenue

Erie, PA 16510

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 5th 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,
th
every 10 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 Number: PS-1870

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

Drawing Revision: 2
Revision Reference No.:
2006E0267

Page 2 of 5

1602 Wagner Avenue

Erie, PA 16510

Excerpt-Table1 of AD2000-W5
Quality Level
Allowable max.
Allowable max.
RT(4)
Working
Working Pressure
bar
Temperature
C
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 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
A Gas porosity
B Sand and Slag
C Shrinkage (all types)
D Cracks
E Hot Tears
F - Inserts

Maximum Severity Level

3
3
3
0
0
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 Number: PS-1870

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

Drawing Revision: 2
Revision Reference No.:
2006E0267

Page 3 of 5

1602 Wagner Avenue

Erie, PA 16510

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.

Drawing Number: PS-1870

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

Drawing Revision: 2
Revision Reference No.:
2006E0267

Page 4 of 5

Drawn By: GHW, 9/8/06

Approved By: JL, 9/8/06

Drawing Number: PS-1870

Revision Reference No.:
2006E0267

Page 5 of 5

Drawing Revision: 2

1602 Wagner Avenue

Erie, PA 16510