AC7114-4 Rev G AUDIT CRITERIA FOR NONDESTRUCTIVE TESTING FACILITY FILM RADIOGRAPHY SURVEY

 AC7114/4 REV. REV. G

 AUDIT CRITERIA

Issued 1997-07 Revised 2013-7

161 Thorn Hill Road Warrendale, PA 15086-7527

Superseding AC7114/4 Rev F

TO BE USED ON OR AFTER A FTER NOVEMBER 3, 2013 Nadcap  AUDIT CRITERIA CRITERIA FOR NONDESTRUCTIV NONDESTRUCTIVE E TESTING TESTING FACILITY FILM RADIOGRAPHY SURVEY

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SCOPE These Audit Criteria define the requirements for s uppliers seeking Nadcap accreditation in Film Radiography and shall are to be used as a supplement to PRI AC7114. These criteria and the applicable User Prime Supplemental Checklists will ensure that NDT suppliers m eet the requirements for Nadcap accreditation in Film Radiography. Radiography. Note: This checklist checklist i s not applicable to film -less or digital radiography.

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GENERAL INFORMATION INFORMATION In completing this assessment, auditors are instructed to respond with a "Yes” or “No" to address compliance with each statement of requirement. For any negative responses, the auditor must clearly indicate in the NCR if the “No" reflects noncompliance with respect to existence, adequacy, and/or compliance. Existence relates to evidence of a documented procedure or policy, adequacy relates relates to the com pleteness of the procedure or policy, and compliance relates to evidence of effective implementation. This checklist includes the use of the word “shall” which indicates a clear requirement that must be met at all times. The word “may” indicates a possible resolution to a requirement or one recommended method to achieve a given requirement, but does not represent the only way to meet that requirement. In addition the checklist includes the term “Compliance Assessment Guidance”. This term is used to reflect the T ask Groups expectation when answering the checklist question as YES or N/A. The auditor must verify the list of procedures provided by the supplier at the time of the audit. Any corrections or updates to the list must be identified using notes, inserted at the applicable criterion.  All negative responses require a Nonconformance Report (NCR). Not Applicable (N/A) responses responses do not require require an explanation unless otherwise noted. There is only one plausible reason for an N/A, which is, that a particular operation or issue is not being used at the supplier. There are no N/A’s simply for a lack of a customer requirement. If a system is in use, then all questions pertaining to that system are applicable. If verification of results require documentation it shall be so noted in this checklist. The audit results shall not include any customer proprietary information. Technical information on parts which have been designated “Export Controlled – License Required” (EC-LR) cannot be input into eAuditNet. If auditors have any questions about this, they should contact the Staff Engineer for directions. GO FORWARD PLAN – Any new or revised procedure made after 4 December 2006 requires compliance to the following requirements. Procedures written written prior to this date shall be acceptable; however a system needs to be in place to ensure that changes reflect the current Nadcap requirements.

PRI operating procedures provide that "This report is published by PRI to advance the state of technical, engineering, and quality sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there from, is the sole responsibility of the user." PRI values your input. To provide feedback on this document, please contact the appropriate commodity staff engineer. (Contact information is located at http://www.eauditnet.com under “Contact Us”.) Copyright 2013 Performance Review Institute. All rights reserved. t-frm-15

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PRI 2.1

AC7114/4 Rev. G References

SAE Publications:

Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15086-0001.

 AS7003

Nadcap Program Program Requirements

 ASTM Publications: Publications:

Available from ASTM, ASTM, 100 Barr Barr Harbor Drive, Drive, West Conshohocken, PA 19428-2959, USA.

 ASTM-E-747

Practice for Design, Design, Manufacture, Manufacture, and Material Material Grouping Classification Classification of Wire Image Quality Indicators (IQI) Used for Radiology

 ASTM-E-1025  ASTM-E-1025

Practice for Design, Design, Manufacturer, Manufacturer, and Material Material Grouping Classification Classification of Hole-Type Image Quality Indicators (IQI) Used for Radiology

 ASTM-E-1742  ASTM-E-1742

Standard Practice Practice for Radiographic Radiographic Examination

 ASTM-E-1254  ASTM-E-1254

Guide for Storage Storage of Radiographs Radiographs and Unexposed Industrial Industrial Radiographic Radiographic Film

EN Publications:

Available from BSI, 389 Chiswick High Road, London W4 4AL. UK.

EN 462-1 EN 462-2 EN 462-3

Part 1: Image Quality Indicators (wire type) – Determination of Image Quality Value. Part 2: Image Quality Indicators (step hole type) – Determination of Image Quality Value. Part 3: Image Quality of Radiographs (wire type) –Image quality Classes for Ferrous Metals.

EN 462-4

Part 4: Experimental Evaluation of Image Quality Values and Image Quality Tables.

EN 462-5

Part 5: Image Quality Indicators (duplex wire type) – Determination of Total Image Unsharpness Value.

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MATERIALS AND EQUIPMENT EQUIPMENT

3.1 3.1

Materials, Materials, Equipment Listi ng and Information

The supplier shall complete com plete and the auditor shall review, the Supplier’s provided Materials and Equipment Listing, for adequacy, adequacy, content and correctness. Attachments are for information information only but shall be completed fully. NCR’s shall not be written against attachments. attachments. (Attachment  AC7114/4-A).  AC7114/4-A).

4

PROCEDURES

4.1

NDT Facilit y Writ ten Procedur es

4.1.1

4.2

Is there a procedure, general or specific, for processing and inspection using the radiographic method?

 Attachment

YES NO

Approval

4.2.1

Does the procedure(s) indicate approval by the applicable Level 3? Compliance Assessment Guidance: The applicable Level 3 may be the Nadcap User, Nadcap User qualified or approved Level 3, internal Level 3 and/or external Level 3.

4.3

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Procedu re / Techniq ue

Does the written procedure, general or specific, contain the following information as a minimum? Compliance Assessment Guidance: The term, “procedure” may be synonymous with a technique, traveler or a route card, etc.  All non-technical requirements that have been flowed down solely by the baseline will only be required to be met if that in-use technique or process has been revised since the inception of the baseline on December 4, 2006. •

•

YES NO

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4.3.1

Traceability to the name and address of the facility performing inspection?

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YES NO

Compliance Assessment Guidance: In some cases it may not be necessary for the actual address as long as the facility is traceable to a unique identifier.

4.3.2

Procedure identification number and the date the procedure was approved?

YES NO

4.3.3

A requirement that all personnel are qualified and certified to the required level for the activity undertaken and the applicable contract requirements?

YES NO

4.3.4

The part name, part number and material?

YES NO

4.3.5

Materials required (i.e., tape, fixtures, etc.)?

YES NO N/A

4.3.6

Surface preparation (finishing and cleaning) including materials, processing times and metal removal, if required?

YES NO N/A

4.3.7

Applicable acceptance class, grade and zone in accordance with engineering drawing specification (accept/reject criteria and source of criteria)?

YES NO

4.3.8

Disposition of reports, films, and inspection records?

YES NO

4.3.9

Method of identifying inspection status after inspection?

YES NO

4.3.10

A sketch or photograph of the set-up for each view, showing film location relative to the part and radiation beam and location of IQI’s/penetrameters?

YES NO

4.3.11

Thickness ranges to be radiographed?

YES NO

4.3.12

Type and thickness of IQI’s/penetrameters, shims, and blocks?

4.3.13

Exposure parameters (KV, MA, and time)?

YES NO N/A YES NO

Compliance Assessment Guidance: For radioisotope sources, the isotope type, source strength, exposure time and source size.

4.3.14

Source-to-film distance (SFD)?

YES NO

4.3.15

Part-to-film distance (PFD)? (If not in intimate contact)

4.3.16

Angle between the central beam and the part or film?

YES NO

4.3.17

Film brand, type, and size?

YES NO

4.3.18

X-Ray machine used, manufacturer, model number, peak voltage rating, and effective focal spot size of the x-ray equipment to be used (i.e. large, sm all, dimension)?

YES NO

4.3.19

Method of monitoring backscatter radiation?

YES NO

YES NO N/A

Compliance Assessment Guidance: The method required to monitor backscatter varies with customer requirements. The supplier shall define the method and this method shall meet the supplier’s customer requirements.

4.3.20

Cassette/film holder type?

YES NO

4.3.21

Type and thickness of screens and film loading instructions?

YES NO

4.3.22

Blocking or masking materials and techniques, if used?

YES NO N/A

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4.3.23

Filter material, thickness, and location, if used?

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YES NO N/A

Compliance Assessment Guidance: Filters may be used as allowed by customer requirements, whenever the contrast reductions caused by the low-energy scattered radiation occurring on production radiographs are of a significant magnitude to cause difficulty in meeting the radiographic quality level or radiographic coverage requirements as specified in the contract, purchase order, or drawing.

4.3.24

Film viewing, film annotation (marking) and interpretation instructions?

YES NO

4.3.25

H & D film density range in the area of interest?

YES NO

4.3.26

H & D film density in the area of interest is within +30% to -15% of the plaque type penetrameters?

YES NO N/A

4.3.27

Radiographic quality/sensitivity level?

YES NO N/A

Compliance Assessment Guidance: May not be applicable to composites.

4.3.28

Film processing techniques and methods?

YES NO

4.3.29

Type and amount of backing material used, if required?

YES NO N/A

4.3.30

Additional information for special applications such as in-motion radiographs?

YES NO N/A

4.3.31

Geometric un-sharpness (Ug)?

4.3.32

Requirement that contrast be determined by measuring the difference in density of the film through the IQI and the adjacent material per ASTM-E-1742 Figure 2?

YES NO YES NO N/A

Compliance Assessment Guidance: The minimum density difference shown in F igure 2 shall be achieved between the IQI and the base metal for radiographic quality levels 1 and 2. This shall be carried out and verified during the initial technique development in accordance with the supplier’s procedure. This value does not need to be recorded. If the auditor suspects that the contrast does not meet the requirements they shall verify the contrast during the compliance job. Measuring contrast difference does not apply to composite/sandwich structures or when wire type IQI’s are used.

4.3.33 4.4

YES NO

Identification

4.4.1

5

All required process controls called out in section 5 of this checklist?

Does the facility have a procedure by which parts and radiographs are identified and correlated?

YES NO

NDT PROCESS CONTROL Compliance Assessment Guidance: •

•

Where equipment is not used for a period in excess of the check frequency, the check shall be performed immediately prior to use. If the following process control checks are performed at the supplier, adequate procedural coverage and documentation of said tests and results are expected to be evident and are to be reviewed by the auditor. If the tests are performed by an external source, the auditor is expected to review evidence of flow-down (i.e., a Purchase Order) with the appropriate information to include at a minimum; traceability to the required test and the standard used. In addition an adequate certification or other document is required to document the results of the tests.

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Film Processi ng Area

5.1.1

5.1.2 5.2

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Is the facility equipped with an adequate darkroom/film processing area for the loading of the film holders and development of film without producing nonconforming radiographs? Is the film processing equipment adequate for performing production processing?

Automatic Processor

5.2.1

Is the automatic processor maintained within the processor and chemical manufacturer’s specified temperature, processing speed, replenishment rates, and concentrations?

YES NO

YES NO N/A YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined. The developer temperature shall be verified prior to use.

5.2.2

Is the processor performance tested daily, or prior to use, when solutions are changed and when malfunction is suspected?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined. This shall be accomplished using either: a. PMC strips supplied by the manufacturer. The PMC strips shall be used in accordance with the manufacturers’ instructions apart from the following: the step used shall be between 2.0D and 2.5D. b. Pre-exposed (does not preclude the use of film exposed that day) filmstrips, using light, X-ray or Gamma rays. The pre-exposed film can be produced using a suitable block of metal of uniform thickness or a stepped metal wedge. The strip may include an unexposed area of film for monitoring the base fog. The technique including the exposure parameters and method of preventing s cattered radiation and undercutting used shall be detailed in a procedure. A control film, processed through fr eshly mixed seasoned developer shall be produced and the control film densities measured and recorded, establishing nominal control values. To monitor the processor performance, a monitor film shall be processed through the automatic processor. The monitor film density shall be measured in the same area as the control film and compared to the control film densities.

5.2.3

Are the results recorded within ± 10% film density required of original standard radiograph?

YES NO

Compliance Assessment Guidance: Records of this c heck shall be on file and indicate acceptable results within ±10%. The actual value shall be recorded for this check, “OK” or some other mark is not acceptable. A procedure shall detail the steps to be taken to correct the problem if the monitor film is out of tolerance this shall include the processing of another monitor film to verify that the problem has been corrected.

5.2.4

Is the base fog check performed and recorded daily or prior to use? Compliance Assessment Guidance: A representative sample of f ilm utilized shall be checked, it is not necessary to perform the check for each class of film in use. This requirement shall be procedurally defined. Records of this check shall be on file and indicate acceptable results. The actual value shall be recorded for this check, “OK” or some other mark is not acceptable.

YES NO

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5.2.5

Is the maximum base fog limited to 0.30D for class I, II and special film systems?

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YES NO

Compliance Assessment Guidance: A procedure shall detail the steps to be taken to correct the problem if the monitor film is out of tolerance this shall include the processing of another monitor film to verify that the problem has been corrected.

5.2.6

Has a batch of film been dedicated to the processor performance test?

YES NO N/A

Compliance Assessment Guidance: Applies when using pre-exposed filmstrips.

5.2.7

Does the control film have at least one area with a density between 2.0D and 2.5D?

YES NO

5.2.8

Are monitor film(s) retained for a minimum of 4 weeks for audit purposes?

YES NO

5.2.9

Is the automatic processor cleaned and maintained in accordance with manufacturer’s recommendations?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined. Records of the cleaning and maintenance shall be on f ile. Records indicating “OK” or some other check mark are acceptable for this test. 5.3

Manual Processi ng

5.3.1

Is the process performance tested daily, or prior to use, when solutions are changed and when malfunction is suspected?

N/A YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined. This shall be accomplished using: a. PMC strips supplied by the manufacturer . The PMC strips shall be used in accordance with the manufacturers’ instructions apart f rom the following: the step used shall be between 2.0D and 2.5D. b. Pre-exposed filmstrips, using light, X-ray or Gamma rays. The pre-exposed (does not preclude the use of film exposed that day) f ilm can be produced using a suitable block of metal of uniform thickness or a st epped metal wedge. The strip shall include an unexposed area of film for monitoring the base f og. The technique including the exposure parameters and method of preventing sc attered radiation and undercutting used shall be detailed in a procedure. A control film, processed through freshly mixed seasoned developer shall be produced and t he control film densities measured and recorded, establishing nominal control values. To monitor the processor performance, a monitor film shall be processed through the manual processor. The monitor film density shall be measured in the same area as the control film and compared to the control film densities.

5.3.2

Are the results recorded within ± 10% film density required of original standard radiograph?

YES NO

Compliance Assessment Guidance: The actual value shall be recorded f or this check, “OK” or some other mark is not acceptable. A procedure shall detail the steps to be taken to correct the problem if the monitor film is out of tolerance this shall include the processing of another monitor film to verify that the problem has been corrected.

5.3.3

Is the base fog check performed and recorded monthly or prior to use?

YES NO

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Compliance Assessment Guidance: A representative sample of film utilized shall be checked, it is not necessary to perform the check for each class of film in use. This requirement shall be procedurally defined. Records of this check shall be on file and indicate acceptable results The actual value shall be recorded for this check, “OK” or some other mark is not acceptable.

5.3.4

Is the maximum base fog limited to 0.30D for class I, II and special film systems?

YES NO

Compliance Assessment Guidance: A procedure shall detail the steps to be taken to correct the problem if the monitor film is out of tolerance this shall include the processing of another monitor film to verify that the problem has been corrected.

5.3.5

Has a batch of film been dedicated to the process performance test?

YES NO N/A

Compliance Assessment Guidance: Applies when using pre-exposed filmstrips.

5.3.6

Does the control film have at least one area with a density between 2.0D and 2.5D?

YES NO

5.3.7

Is a film processing log maintained showing number, sizes and dates of film processed?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined. The actual value shall be recorded for this check, “OK” or some other mark is not acceptable.

5.3.8

Is a log maintained showing replenishment dates and mixing dates of new solution?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined. The actual dates shall be recorded for this check, “OK” or some other mark is not acceptable.

5.3.9

Are manual processing times adjusted in accordance with manufacturer’s instructions to compensate for fluctuations in temperature and reduction in batch strength of processing solutions?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined.

5.3.10

Are developer solution temperatures maintained within manufacturer’s specified temperature range, checked and recorded prior to use?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined. The actual values shall be recorded for this check, “OK” or some other mark is not acceptable.

5.3.11

Is a timer with an audible alarm available and calibrated for manual processing to monitor processing times?

YES NO

Compliance Assessment Guidance: The timing device shall be calibrated at least annually. Any calibration traceable to an acceptable national source is acceptable for these timing devices. 5.4

Radiogr aphic Materials

5.4.1

Is the storage of film and chemicals adequate to ensure no adverse effects on radiograph quality? Compliance Assessment Guidance: All unexposed films in the manufacturer containers whether unopened or in use shall be stored with the films on edge. The s torage temperature should be between 40°F [4.4°C] and 75°F [24°C] at a relative humidity

YES NO

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range of 30 to 60 %. This requirement shall be procedurally defined. If the auditor or supplier suspects that the temperature or humidity is out of this range, the temperature and humidity must be verified. Films may be stored at lower temperatures than 40°F [4.4°C] in unopened containers, if allowed by the customer. Prior to use the cold film shall be allowed to stabilize at room temperature before opening the containers. This requirement shall be procedurally defined. Storage facilities f or unexposed films should provide adequate protection from penetrating radiation.

5.4.2

Is production radiographic film within shelf life?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined.

5.4.3

Are cassettes and other film holders free from conditions that would interfere with interpretation of film?

YES NO

Compliance Assessment Guidance: Film holders and cassettes shall be examined prior to use for cracks or other defects to minimize the likelihood of light leaks. This requirement shall be procedurally defined.

5.4.4

Are screens free from any cracks, creases, scratches, or foreign material that could render undesirable non-relevant images on the film?

YES NO N/A

Compliance Assessment Guidance: Screens shall be examined prior to use for cracks, creases, scratches, or foreign material that could render undesirable non-relevant images on the film. This requirement shall be procedurally defined. 5.5

Image Quality Indic ators

N/A

This section may be answered N/A only when IQI’s are not required by t he governing specification.

5.5.1

Are penetrameters or other image quality indicators (IQI’s) procured and traceable to the appropriate certifications?

YES NO

Compliance Assessment Guidance: The certification shall meet ASTM-E-1742, ASTME-1025, ASTM-E-747, European standard EN 462 or customer requirements and shall be verified upon receipt. The certificate shall be stored for the life of the penetrameters/IQI and in accordance with the company quality record retention procedure.

5.5.2

Are penetrameters or other image quality indicators (IQI’s) of the proper material and sizes as required by the cognizant engineering organization available? Compliance Assessment Guidance: Penetrameters or other image quality indicators (IQI’s) shall be defined in the technique or procedure.  Alternate types of IQI’s or modifications to the types specified above are only permitted upon approval of the cognizant engineering organization. Details of the design, materials designation, and thickness identification of t he IQI’s shall be in the written procedure, or documented on a drawing that shall be referenced in the written procedure. Materials shall be considered radiographically similar if the following requirements are satisfied. Two blocks of equal thickness, one of the material to radiographed and one of the material of which the IQI’s are made, shall be exposed together on the same film at the lowest energy level to be used for production radiographs. If the film density of the IQI material to be radiographed is within the range from 0 to +15% of the material to be radiographed, it shall be considered radiographically similar. The film density readings shall be between 2.0D and 4.0D for both materials. The IQI’s of a •

•

•

YES NO

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lower density may be used.

5.5.3

Are penetrameters or IQI’s well maintained and properly identified, and if applicable, are holes kept clean and verified prior to use?

YES NO

Compliance Assessment Guidance: Penetrameters or IQI’s shall be examined prior to use for any damage that may affect its use. This requirement shall be procedurally defined. 5.6

Film Viewing Area

5.6.1

Is the viewing area clean (e.g., free of dust, dirt, and liquids) and conducive to proper film interpretation?

YES NO

Compliance Assessment Guidance: Subdued lighting in the viewing room is prefer red rather than total darkness. Background illumination lighting shall be arranged such that light reflections do not interfere with review of radiographs.

5.6.2

Is the film viewing area checked semi-annually to ensure a maximum ambient light of (3 ft candles / 30 lux), and are the results recorded?

YES NO

Compliance Assessment Guidance: Light levels shall be measured at t he viewer surface, with the viewer off. This requirement shall be procedurally defined. The ambient light value shall be recorded for this check, “OK” or some other mark is not acceptable.

5.6.3

Are viewers equipped to prevent damage to the film from heat?

YES NO

Compliance Assessment Guidance: Film viewers shall be equipped with a fan, blower, or other means to provide s tabile temperature at the viewing port to avoid damaging the radiographic film while viewing.

5.6.4

Are viewers equipped with light diffusing glass to provide a uniform reading surface of the viewing screen?

YES NO N/A

Compliance Assessment Guidance: Not applicable to high intensity viewers.

5.6.5

Is a calibrated white light meter used for checking illuminator brightness?

YES NO N/A

Compliance Assessment Guidance: This requirement shall be procedurally defined. Where dual purpose meters ar e utilized, the meter shall be calibrated in t hose units where used. Therefore if the meter is used in both Lux and Candelas, then the meter would have to be calibrated in both units. This question would only be answered N/A if the illuminator brightness was checked by an outside agency.

5.6.5.1

Is calibration of the meter being performed at least annually?

YES NO N/A

5.6.5.2

Has the calibration been performed at a minimum of three points to establish linearity?

YES NO N/A

5.6.5.3

Is the light meter accurate to within ± 5% of standard reading?

YES NO N/A

Compliance Assessment Guidance: The value of ±5% is in reference to a comparison of the light meter being calibrated to another calibrated (traceable to NIST or other National Standard) light meter. It is not meant to represent a “true” ±5% calibration tolerance.

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5.6.5.4

Is the white light meter traceable to the calibration data?

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YES NO N/A

Compliance Assessment Guidance: The meter shall be serialized, stickered or otherwise identifiable to the calibration data.

5.6.6

Does the facility have a system for checking illuminator brightness?

YES NO

5.6.7

Is viewer intensity verified when procured, a bulb is replaced or when maintenance is performed and is this recorded?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined. The intensity value shall be recorded for this check, “OK” or some other mark is not acceptable.

5.6.8

Is each viewer posted with its maximum viewing density?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined.

5.6.9

Are maximum viewing densities determined by a standardized procedure?

5.6.10

If used, do scales & reticules (eye loupe comparators) have initial certifications?

YES NO YES NO N/A

Compliance Assessment Guidance: The certification shall be verified upon receipt. The certificate shall be stored for the life of the device and in accordance with the company quality record retention procedure.

5.6.10.1 5.6.11

Is the condition verified prior to use and documented at least annually?

Is exposed film maintained in an environment that prevents deterioration (excessive heat, humidity, UV light)?

YES NO N/A YES NO N/A

Compliance Assessment Guidance: All exposed films shall be stored in some form of enclosures to exclude dirt and protect them against physical deterioration and damage. This requirement shall be procedurally defined. The st orage temperature should not exceed 100°F [38°C] at a relative humidity range of 30 to 60 %. This requirement shall be procedurally defined. If the auditor or supplier suspects that the temperature or humidity is out of this range, the temperature and humidity must be verified.

5.6.12

Are finished radiographs permanently identified with the following information as required? Compliance Assessment Guidance: Unless otherwise specified by the purchase order or contract, the supplier may use an alpha, numeric or alpha-numeric identification traceable to the following information:

5.6.12.1

The NDT facility name or identifier?

YES NO

5.6.12.2

Part number/serial number or control number?

YES NO

5.6.12.3

The date exposed?

YES NO

5.6.12.4

The view number? (when more than one view)

YES NO N/A

5.6.12.5

Location markers? (if applicable)

YES NO N/A

5.6.12.6

Lot number? (if applicable)

YES NO N/A

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5.6.12.7

R1, R2, R3 etc.? (if repair or rework radiographs)

YES NO N/A

5.6.12.8

Film side IQI identified with an “F” by the IQI? (if applicable)

YES NO N/A

Is the available densitometer capable of measuring H & D densities up to 4.0D with a density unit resolution of 0.02D?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined.

5.6.14

Does the facility maintain density filmstrips traceable to NIST, National Standards or equivalent, for calibration of densitometers?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined.

5.6.15

Are working filmstrips verified to NIST, National Standards or equivalent or replaced annually?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined. I f verification is performed, the value’s shall be recorded for this check, “OK” or some other mark is not acceptable. Note: The terms “working” and “master” film strips for all intents and purposes may be the same film strip.

5.6.16

Is calibration of the densitometer verified with the known density strip performed each shift when in use and/or when maintenance is performed, and are the results recorded?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined.

5.6.17

Are readings taken at a minimum of three points covering low, medium and high densities and are they within ± 0.05D of the density strip?

YES NO

Compliance Assessment Guidance: Example: Any calibration point chosen for low density in the range of 0.1D to 1.0D, medium density in the r ange of 1.0D to 3.0D and high density in the range of 3.0D to 4.0D is acceptable. This r equirement shall be procedurally defined.

5.6.18

Is documented evidence of checks and values for the densitometer available?

YES NO

Compliance Assessment Guidance: Recording “OK” or indicating a c heckmark or other notation is not acceptable.

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COMPLIANCE Compliance Assessment Guidance: The supplier shall perform r epresentative inspections from current pr oduction to determine compliance with these requirements. These parts shall be selected to represent a variety of Nadcap participating customer requirements and several different types of processing equipment if more than one radiographic system is in use at this facility. Borrowing hardware from one company to another to demonstrate compliance is not acceptable; unless there is objective evidence the design authority has authorized movement of the hardware to the company undergoing the audit. Investigate the purchase order specifications to identify any customer unique acceptance, process control, or procedure requirements applicable to these parts. If composites are processed, at least one job will include composites. Witness the facility's ability to perform inspection of these parts in accordance with the requirements. If there are trainees being utilized by the facility, it is expected that the auditor makes every attempt to witness them performing in a compliance job. It is expected that the auditor shall review and follow traceability from the purchase order to completion of the NDT process or final certification by reviewing as a minimum the items listed below. The auditor shall verify that the process applied complies with the procedural system established by the company in terms of flow down, customer specification retrieval (as applicable), inspection identification, etc.

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a) Purchase Order b) Drawing (if applicable) c) Work Order d) Process Specifications and Revision e) Internal Procedures and Revision f) Lot / Batch / Serial Number: g) Applicable Procedures / Techniques / Work Instructions h) Travelers / Route Cards i) Inspection Log 6.1

Provide the following documentation for auditor review for each of the parts being tested during the compliance portion of the audit: Note: EC-LR materials shall not leave the supplier’s facility. a) Copy of completed technique card or supplier procedure with evidence of customer approval if required. b) Copy of completed shop traveler or work order. c) If neither a or b above indicate the process and acceptance standard and their revision status, then the document that shows the link to this data shall also be reviewed. Compliance End User

 A. Customer

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

 Acceptance Specification(s) / Drawing Notes:

Part Description:

Revision(s)

Class and/or Grade (if applicable)

YES NO

PRI

AC7114/4 Rev. G

Part Number:

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Revision

Inspectors

Level(s):

Compliance End User

B. Customer

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

 Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

Part Number:

Revision

YES NO

PRI

AC7114/4 Rev. G

Inspectors

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Level(s):

Compliance End User

C. Customer

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

 Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

Part Number:

Inspectors

Revision

Level(s):

YES NO

PRI

6.2

AC7114/4 Rev. G

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If applicable and in conjunction with the preceding, the supplier shall also provide an additional three paperwork compliance jobs across the Nadcap User base. Provide the following documentation for auditor review for each of these jobs: Note: The goal is provide at least one set of compliance documentation for each of the supplier’s Nadcap User customer base. If all of the supplier’s Nadcap customers were represented in the actual compliance audits, then this section is N/A. Note: EC-LR materials shall not leave the supplier’s facility.

N/A

a. Copy of completed technique card or supplier procedure with evidence of customer approval if required. b. Copy of completed shop traveler or work order. c. If neither a or b above indicate the process and acceptance standard and their revision status, then the document that shows the link to this data shall also be reviewed. Compliance End User

 A. Customer

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

 Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

YES NO

PRI

AC7114/4 Rev. G

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Part Description:

Part Number:

Inspectors

Revision

Level(s):

Date Performed:

Compliance End User

B. Customer

YES NO N/A

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

 Acceptance Specification(s) / Drawing Notes:

Part Description:

Revision(s)

Class and/or Grade (if applicable)

PRI

AC7114/4 Rev. G

Part Number:

Inspectors

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Revision

Level(s):

Date Performed:

Compliance

C. Customer

YES NO N/A

End User

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

 Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

Part Number:

Revision

PRI

AC7114/4 Rev. G Inspectors

6.3

Level(s):

- 18 Date Performed:

Customer Specifications Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation.

6.3.1

Is the facility using the appropriate specification(s) and revision(s) as required by the contract document?

YES NO

Compliance Assessment Guidance: This shall be confirmed by t he auditor by reviewing the customer P.O and End User drawing if available.

6.3.2

If the facility is working to any deviations, have they been approved by the customer?

YES NO N/A

Compliance Assessment Guidance: The auditor will confirm documented customer approval; this may be in the form of a written communication, technique approval or by a formal deviation from the End User.

6.3.3

Were the applicable work instructions / routings / shop travelers / techniques / procedures, acceptance standard and unique customer requirements made available to the radiographic inspectors?

YES NO

Compliance Assessment Guidance: The term, “available” means that these documents are within easy access by t he technicians. These documents are available and are used to perform the inspections, not used from memory.

6.3.4

If written procedures and/or techniques require review and/or approval by the Cognizant Engineering Organization, is that approval evident?

YES NO N/A

Compliance Assessment Guidance: This shall be investigated and confirmed by the auditor by reviewing the last ten parts shipped.

6.3.5

If applicable, are part specific drawing inspection and/or acceptance notes being flowed down and followed by the inspectors?

6.3.6

Was there evidence of compliance to the document control procedure?

6.3.7

If applicable, were any and all specification, drawing, procedure or technique changes authorized?

YES NO N/A

YES NO YES NO N/A

Compliance Assessment Guidance: Auditor to confirm approval. 6.4

Inspection Process Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation.

6.4.1

Do applicable Work Orders/Shop Travelers and Technique Cards contain or provide traceability to the following as a minimum? 6.4.1.1

Part number / material identification?

YES NO

6.4.1.2

Specification reference?

YES NO

6.4.1.3

Inspection acceptance requirements?

YES NO

PRI

AC7114/4 Rev. G 6.4.1.4

6.5

Correct sequence of operations?

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Part Setup and Expos ure Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation.

6.6

6.5.1

Were the correct film/film holder/screens used as defined by the technique?

YES NO

6.5.2

Were parts properly positioned on the film as defined by the technique?

YES NO

6.5.3

Were identifiers and markers utilized properly as defined by the technique?

YES NO

6.5.4

Were the correct exposure parameters set and used as defined by the technique?

YES NO

6.5.5

Was IQI selection and placement as defined by the technique?

YES NO N/A

6.5.6

Was a sufficient number of IQI’s used to represent the material thickness range as defined by the technique?

YES NO N/A

6.5.7

Were the correct shims used as defined by the technique?

YES NO N/A

6.5.8

Was backscatter monitored per customer requirements?

YES NO N/A

Film Processing Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation.

6.6.1

Was the film processed to the established times and conditions?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined.

6.6.2

Did film processing equipment and dark room procedures yield developed film that is free of stains, scratches, light streaks, fogging, or other artifacts, which might interfere with film interpretation?

YES NO

Compliance Assessment Guidance: This issue shall be investigated and confirmed by the auditor. 6.7

Film Viewing Compliance Assessment Guidance: The following evaluation process shall be determined by direct observation, and by researching the specifications, procedures and other customer documents that are applicable and required to reach an educated answer to each question.

6.7.1

Was film verified for proper identification, density, and quality level?

YES NO

6.7.2

Was the area of interest clearly defined and viewable on the finished radiograph?

YES NO

6.7.3

Did the inspectors allow sufficient time after entering the viewing area for eye adaptation or re-adaptation before interpreting radiographs?

YES NO

Compliance Assessment Guidance: The inspectors shall wait sufficient time, but, not less than 1 minute, after entering the viewing area, before interpreting radiographs to ensure that the features of the IQI are visible and the required sensitivity is displayed. If the eyes are momentarily subjected to the full brightness of the illuminator at least 30 seconds re-adaptation shall be required. There shall be no extraneous light sources that could interfere with inspection or distract the operator. (eg densitometer)

PRI

AC7114/4 Rev. G

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 A timing device is required for eye adaptation monitoring, but evidence of calibration is not required.

6.7.4

Was the specific acceptance criteria properly understood by the inspector?

6.7.5

Compliance Assessment Guidance: All indications (artifacts and discontinuities) shall be evaluated. Unless otherwise verified, radiographs exhibiting artif acts in the area of interest greater than the acceptance criteria shall be re-shot. Borderline indications shall show evidence of evaluation. The auditor shall ver ify evidence that all border line indications have been evaluated. Reference radiographs (such as ASTM E155) shall not be used for anything other t han acceptance criteria unless specified by the customer. Were relevant indications / artifacts in the area of interest identified and recorded?

YES NO

YES NO N/A

Compliance Assessment Guidance: All indications (artifacts and discontinuities) shall be evaluated. Unless otherwise verified, radiographs exhibiting artif acts in the area of interest greater than the acceptance criteria shall be re-shot. Borderline indications shall show evidence of evaluation. The auditor shall verif y evidence that all border line indications have been evaluated.

6.7.6

Was the film free of any signs of scatter radiation or improper exposure technique?

YES NO

6.7.7

W as the film free of any evidence of improper film handling?

YES NO

6.7.8

Was film properly sorted and cataloged so it is easy to locate?

YES NO

Compliance Assessment Guidance: This requirement shall be procedurally defined.

6.7.9

Was the H & D film density of the area of interest within +30% / -15% of the plaque type penetrameters density, when used?

YES NO N/A

6.7.10

Is the film contrast determined by measuring the difference in density of the film through the IQI and the adjacent material per ASTM-E-1742?

YES NO N/A

Compliance Assessment Guidance: The minimum density difference shown in t he applicable figure shall be achieved between the IQI and t he base metal for radiographic quality levels 1 and 2. This test shall be performed each time radiographic exposure parameters change, i.e., a new technique is used. Measuring contrast difference does not apply to composite/sandwich structures or when wire type IQI’s are used.

6.7.11

If film is retained by the supplier, compare with films of the same part taken in the past.

N/A

6.7.11.1

Was the film retrievable?

YES NO

6.7.11.2

Do the films exhibit consistent density, sensitivity and area of interest?

YES NO

6.7.11.3

Is there evidence of evaluation of all relevant indications and traceability to the archived film? Part # / Lot # / Serial # / Control # ________________________________

YES NO

 ____________________________________________________________  ____________________________________________________________ 6.8

Inspector Qualification

6.8.1

Were the inspection personnel certified to the correct levels for the work they were

YES NO

PRI

AC7114/4 Rev. G

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performing? Compliance Assessment Guidance: This includes all pertinent functions within the radiographic method. In regard to personnel who only process film with no additional radiographic functions; the requirement is that those individuals be qualified and/or certified in accordance with the supplier’s writt en procedure as approved by the Level 3. This shall be verified by review of the certification records.

6.8.2

6.8.3

Were all non-certified or in-training personnel observed performing radiography properly supervised? Compliance Assessment Guidance: This shall be determined by direct observation. Were all personnel who require near vision correction to pass the visual acuity exam wearing vision correction for detection and evaluation purposes during testing/inspections? Yes No

YES NO N/A

YES NO N/A

Compliance Assessment Guidance: The auditor shall verify that corrective lenses were used if required. N/A only w here none of the inspection personnel witnessed working required correction lenses. 6.9

6.10

Inspection Status

6.9.1

Are symbols and/or marking methods used to denote radiographic inspection status?

YES NO

6.9.2

Were all inspection results properly recorded and traceable to the parts?

YES NO

Repair and/or Rework

6.10.1

If applicable, are repair and/or rework film traceable to the original part defect, and identified with a letter “R1, R2, R3, etc.”? Compliance Assessment Guidance: This requirement shall be procedurally defined.

YES NO N/A