AC7114/1 REV.

AUDIT CRITERIA
161Thorn Hill Road Warrendale, PA 15086-7527

Issued 1997-07 Revised 2012-3 Superseding AC7114/1 Rev E

TO BE USED FOR AUDITS ON OR AFTER JULY 01, 2012 Nadcap AUDIT CRITERIA FOR NONDESTRUCTIVE TESTING FACILITY PENETRANT SURVEY

SCOPE
These Audit Criteria define the requirements for suppliers seeking Nadcap accreditation in Penetrant and are to be used as supplement to PRI AC7114. These criteria and the applicable User Prime Supplemental Checklists will ensure that NDT suppliers meet the requirements for Nadcap accreditation in Penetrant.

GENERAL 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 to the completeness 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 Task 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 do not 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/As 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 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 2012 Performance Review Institute. All rights reserved. t-frm-15

3-Jan-12

PRI

AC7114/1 Rev. F

-2-

2.1

References SAE Publications: AS7003 AMS 2644 QPL-SAE-AMS-2644 ASTM Publications: ASTM-E-1417 ASTM-E-1135 ASTM-D 95 Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15086-0001 Nadcap Program Requirements Inspection Material, Penetrant Qualified Products List, Inspection Material, Penetrant Available from ASTM, 100 Bar Harbor, Conshohocken, PA 19428-2959 Standard Practice for Liquid Penetrant Examination Test Method for Comparing the Brightness of Fluorescent Penetrant Test Method for Water in Petroleum Products and Bituminous Materials by Distillation

3
3.1

MATERIALS AND EQUIPMENT

Materials, Equipment Listing and Information The supplier shall complete and the auditor shall review, the supplier's provided materials and equipment listing, for adequacy, content and correctness. Attachments are for information only but shall be completed fully. NCRs shall not be written against attachments. (Attachment AC7114/1-A). Attachment

3.2

Material Certification 3.2.1 Is the manufacturers certification available for each batch of penetrant, emulsifier and developer in use, and is there evidence that they conform to the applicable AMS? Compliance Assessment Guidance: The last batch added to the tank defines the batch for the tank. YES NO

3.3

Material Identification 3.3.1 Are the contents of all containers (tanks/drums/bulbs) labeled with, or is there traceability to, the material and batch number(s)? YES NO

3.4

Equipment Arrangement 3.4.1 Are all tanks in a system arranged or covered to prevent mixing of materials? Compliance Assessment Guidance: N/A shall only be used when Method C or a spray system is the only method of application. YES NO N/A

4
4.1

PROCEDURES
NDT Facility Written Procedures 4.1.1 Is there a procedure, general or specific, for processing and inspection using the liquid penetrant method? YES NO

4.2

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. YES NO

PRI
4.3 Procedure / Technique

AC7114/1 Rev. F

-3-

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 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. 4.3.1 Traceability to the name and address of the facility performing the inspection? 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 4.3.3 Procedure identification number and the date the procedure was approved? A requirement that all personnel are qualified and certified to the required level for the activity undertaken and the applicable contract requirements? Part number and/or material to be examined? Complete processing parameters for the penetrant inspection materials including dwell times, application methods, drying times, concentration of emulsifiers, temperatures and controls to prevent excessive drying or overheating, as appropriate? 4.3.5.1 A requirement that components, penetrant, and ambient temperatures shall be maintained within the range of 50 F (10 C) to 125 F (52 C)? A requirement that rinse water temperatures are controlled within the range of 50F (10C) to 100 F (38C)? NOTE: N/A only if Method C is used YES NO YES NO YES NO

4.3.4 4.3.5

YES NO YES NO

YES NO

4.3.5.2

YES NO N/A

4.3.6

Method, Type and Sensitivity Level of Penetrant, Emulsifier, and Developer Form in accordance with AMS 2644? How hydrophilic emulsifier concentrations are established? What is the established concentration range as defined by the procedure? ________________________________________

YES NO

4.3.7

YES NO N/A

4.3.8 4.3.9 4.3.10

Identification of the components or areas within a component to be inspected? Address or provide traceability to customer acceptance criteria? Special equipment required including type and intensity of light if different from standard processing? Complete pre-cleaning and post-cleaning instructions, including cleaning materials, sequencing, times, concentrations and temperatures in accordance with customer requirements or reference to procedures containing such instructions? Compliance Assessment Guidance: Procedure may make reference to another procedure or to an outside source.

YES NO YES NO YES NO N/A

4.3.11

YES NO

PRI
4.3.12 4.3.13

AC7114/1 Rev. F
Description for the method of identifying inspection status? Method for control of software or programming used for automated processing equipment as applicable? Compliance Assessment Guidance: This would include software used to control automated systems. 4.3.14 All required process control tests and checks called out in section 5 of this checklist?

-4YES NO YES NO N/A

YES NO

PENETRANT PROCESS CONTROLS

Compliance Assessment Guidance: The following tests marked re-used are required when, and if, the materials are used from a tank, container or are sprayed and recovered. If materials are not recovered in any way, tests marked as reused are not applicable and shall be noted as such. If a particular system is not used by the supplier, (i.e., Post Emulsified, Lipophilic) then questions pertaining to that system are N/A and no explanation is required. 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 is expected to be evident and is 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. N/A YES NO YES NO YES NO YES NO

5.1

Penetrant Brightness Test (reused) 5.1.1 5.1.2 5.1.3 5.1.4 Is the fluorescent brightness of penetrant being tested at least quarterly? Is ASTM-E-1135 the standard test method used? Is the acceptable limit within 90 -110% of the unused standard? Are records of this test on file and do they indicate acceptable results? Compliance Assessment Guidance: The test results may indicate the exact percentage or simply state acceptable or some other term that denotes acceptance.

5.2

Water Content of Water-Washable Penetrant (reused) 5.2.1 Is the water content of water washable (Method A) penetrant being tested at least monthly? Is ASTM-D-95, Test Method D6304 or Karl Fischer test method used? Is the maximum acceptable limit 5%? Are records of this test on file and do they indicate acceptable results? Compliance Assessment Guidance: The test results may indicate the exact percentage or simply state acceptable or some other term that denotes acceptance.

N/A YES NO

5.2.2 5.2.3 5.2.4

YES NO YES NO YES NO

5.3

Water Content of Water-Based Penetrant (reused) 5.3.1 Is the water concentration of water based (Method A) penetrant being tested at least

N/A YES NO

PRI
weekly? 5.3.2 5.3.3

AC7114/1 Rev. F

-5-

Is a refractometer used to perform this test? Is the concentration in accordance with manufacturers recommendations? What is the current concentration percent? _______________

YES NO YES NO

5.3.4

Are records of this test on file and do they indicate acceptable results? Compliance Assessment Guidance: The test results may indicate the exact percentage or simply state acceptable or some other term that denotes acceptance.

YES NO

5.4

Water Content of Lipophilic Emulsifiers (reused) 5.4.1 Is the water content of in-use lipophilic (Method B) emulsifier being tested at least monthly? Is ASTM-D-95, Test Method D6304 or Karl Fischer test method used? Is the maximum acceptable limit 5%? Are records of this test on file and do they indicate acceptable results? Compliance Assessment Guidance: The test results may indicate the exact percentage or simply state acceptable or some other term that denotes acceptance.

N/A YES NO

5.4.2 5.4.3 5.4.4

YES NO YES NO YES NO

5.5

Concentration of Hydrophilic Emulsifiers 5.5.1 Concentration of in-use (Method D) hydrophilic emulsifiers (used from containers / tanks) 5.5.1.1 Is the concentration of in-use (Method D) hydrophilic emulsifiers being checked at least weekly or prior to use? Compliance Assessment Guidance: This test is required to be conducted at least prior to use in systems that experience a low volume of activity, but if used more often than once a week, weekly would be the minimum required frequency. 5.5.1.2 Does this maximum concentration percentage comply with QPL-AMS2644? What is the current concentration percent? _______________ 5.5.1.3 5.5.1.4 Is a refractometer used to perform this test? Has a correction graph(s) for in use emulsifier been established? Compliance Assessment Guidance: The graph shall have been prepared for each emulsifier in use and traceable to a specific refractometer as identified on the graph. A change in batch number does not necessitate a new graph. Graphs supplied by the manufacturer are not acceptable.

N/A N/A

YES NO

YES NO

YES NO YES NO

5.5.1.5

Is the variation of the concentration within +/- 3% points of the established nominal value?

YES NO

PRI

AC7114/1 Rev. F

-6-

Compliance Assessment Guidance: The nominal value must be set at least 3% points below the maximum concentration permitted by QPL-AMS2644. 5.5.1.6 5.5.1.7 Is the concentration verified upon initial mixing and when adjusted? Are records of this test on file and do they indicate acceptable results? Compliance Assessment Guidance: The actual percentage shall be recorded by the supplier or the reading from the refractometer if traceable to the percentage. Recording, OK or indicating a checkmark or other notation, is not acceptable. 5.5.1.8 Did the facility properly demonstrate this check? Compliance Assessment Guidance: a) The supplier shall be able to demonstrate the correct use of the refractometer in accordance with the manufacturers instructions and shall record the exact concentration or the refractometer reading traceable to the concentration. b) The refractometer shall be zeroed using water prior to use. 5.5.2 Concentration of spray (Method D) hydrophilic emulsifiers 5.5.2.1 5.5.2.2 Are concentrations for spray applications kept at or below 5%? Is the concentration of the spray hydrophilic emulsifiers being checked at least weekly or prior to use? Is a refractometer used to perform this test? Has a correction graph(s) for in use emulsifier been established? Compliance Assessment Guidance: The graph shall have been prepared for each emulsifier in use and traceable to a specific refractometer as identified on the graph. A change in batch number does not necessitate a new graph. Graphs supplied by the manufacturer are not acceptable. Compliance Assessment Guidance: The graph may be prepared by an external source but must meet the requirement defined above. 5.5.2.5 Is the concentration verified upon initial start up and when maintenance is performed? Are records of this test on file and do they indicate acceptable results? Compliance Assessment Guidance: The actual percentage shall be recorded by the supplier or the reading from the refractometer if traceable to the percentage. Recording, OK or indicating a checkmark or other notation, is not acceptable. 5.5.2.7 Did the facility properly demonstrate this check? Compliance Assessment Guidance: a) The supplier shall be able to demonstrate the correct use of the refractometer in accordance with the manufacturers instructions and shall YES NO YES NO N/A YES NO YES NO YES NO YES NO YES NO

5.5.2.3 5.5.2.4

YES NO YES NO

5.5.2.6

YES NO

PRI

AC7114/1 Rev. F
record the exact concentration or the refractometer reading traceable to the concentration. b) The refractometer shall be zeroed using water prior to use.

-7-

5.6

Dry Developer Characteristics (Form a) 5.6.1 Is the dry developer being checked at least daily or prior to use? Compliance Assessment Guidance: All systems employing dry developer must be checked at least for caking; this includes spray on systems and portable bulbs or blowers. This may be visually verified or demonstrated by system performance. 5.6.2 Does the check for recycled dry developer ensure the developer has not picked up excessive fluorescent material (10 or more fluorescent specks observed in a 4 inch/10cm circle), when tested utilizing the same method used for applying developer to hardware? Compliance Assessment Guidance: For the purpose of this check, recycled refers to any material that is drawn from a source where some or all of the remaining material is returned to that source. The test panel selected shall be nonfluorescent and non-reflective and have a working surface color which provides a good contrast with the developer powder. Note: some spray systems actually return material to the source. The auditor shall verify that a system labeled as not recycled is as such in actual performance. The holding tanks for dry developer shall be verified for lack of fluorescent material when possible. 5.6.3 Does the check ensure that the developer is not caked? (applicable to recycled and closed systems) Are records of this test on file and do they indicate acceptable results? Compliance Assessment Guidance: Records indicating OK or some other check mark are acceptable for this test. 5.6.5 Did the facility properly demonstrate this check?

N/A YES NO

YES NO N/A

YES NO

5.6.4

YES NO

YES NO N/A YES NO YES NO YES NO YES NO

5.7

Concentration of Aqueous Developer (Soluble [Form b] & Suspended [Form c]) 5.7.1 5.7.2 5.7.3 5.7.4 Is the concentration of in-use Form b and Form c developer being checked at least weekly? Is a hydrometer and a specific gravity chart being used for this test? Are the acceptance limits in accordance with manufacturers instructions? Are records of this test on file and do they indicate acceptable results? Compliance Assessment Guidance: Records indicating OK or some other check mark are acceptable. 5.7.5 Did the facility properly demonstrate this check?

YES NO N/A YES NO YES NO YES NO

5.8

Characteristics of Aqueous Developer (Soluble [Form b] & Suspended [Form c]) 5.8.1 5.8.2 5.8.3 Is the aqueous developer checked at least daily or prior to use for fluorescence by immersing a clean 3x10 inch (7.5x25 cm) aluminum panel into the developer? Does the aqueous developer uniformly wet the test panel? Is the aqueous developer coated panel free from fluorescent contamination?

PRI

AC7114/1 Rev. F

-8-

5.8.4

Are records of this test on file and do they indicate acceptable results? Compliance Assessment Guidance: Records indicating OK or some other check mark are acceptable.

YES NO

5.8.5 5.8.6

Did the facility properly demonstrate this check? If Aqueous soluble developers were used in combination with type I, Method A penetrant, was specific customer documentation or approval on file?

YES NO YES NO N/A

5.9

Penetrant System Performance 5.9.1 Has the supplier performed an initial check to establish a baseline for each known defect standard and material in use? Compliance Assessment Guidance: The supplier shall perform an initial check with all new materials to establish a baseline for each known defect standard and material in use. This check shall be performed utilizing a color photograph approximately 1:1, whose background does not interfere with the comparison or by direct comparison of used versus unused materials; to record the baseline performance. The requirement is that the performance of the in use materials can not fall below that of the unused materials. Therefore a baseline performance must be established to compare to the daily results. The requirement for a photo does not apply when directly comparing new and in use materials utilizing two identical test panels. (example: NiCr Panels) NOTE: The establishment of the baseline photo may be performed by an external source providing that the color photo is representative of the panel when run at the suppliers facility. The outside source shall process the panel utilizing the same penetrant materials and test parameters as the supplier and produce a color photo of approximately 1:1 scale. 5.9.2 Is the penetrant system performance checked at least daily or prior to use? Compliance Assessment Guidance: The check is intended to be performed at least prior to use, that is if the system is not used every day, the check would not be required to be performed every day. This check includes all in use materials, recycled and not recycled. Note: This includes materials sprayed to waste but is not applicable to solvent removable penetrant utilized from sealed aerosol containers. 5.9.3 Are records of this test on file and do they indicate acceptable results? Compliance Assessment Guidance: Results of the system performance test, utilizing the in-use materials, must indicate the same number and appearance (e.g. size, etc.) of the flaws detected originally when the baseline was established. Example: If 4 stars of a certain size and appearance are originally detected, then the same number and appearance of the stars is expected each subsequent test and the actual number must be recorded. This comparison shall be made utilizing a color photograph (approximately 1:1, whose back ground does not interfere with the comparison) or by direct comparison of used versus unused materials. 5.9.4 Did the facility properly demonstrate this check? Compliance Assessment Guidance: The objective of the system performance test is that it be used as a comparison tool. That comparison day to day may either be performed utilizing the same system parameters as the original (i.e. materials, dwell times, temperatures, etc), or may be processed in the same manner as production components, but the method of processing shall be proceduralised. The system performance test shall be witnessed by the auditor with all aspects performed properly. Does the procedure address the actions to be taken when the sensitivity or performance of the in-use materials falls below the performance of the unused YES NO YES NO YES NO YES NO

5.9.5

YES NO

PRI
materials? 5.10

AC7114/1 Rev. F

-9-

Known Defect Standard Maintenance / Degradation 5.10.1 Are there maintenance procedures in place that assure that cleaning of the known defect standards, between usage, is adequate and that physical changes in the standard that make it unsuitable for use, can be detected? Compliance Assessment Guidance: The procedure must define what is actually done by the supplier. The auditor shall require that the technician demonstrate that the panel or test standard is clean and indication free prior to performance of the test. Unless defined by supplemental requirements, this does not require application of developer. 5.10.2 Is a degradation check performed for the known defect standard at least annually? Compliance Assessment Guidance: This check must be performed by comparing the original results obtained utilizing all new materials to the current results, also using all new materials. This check is a check of the defect standard, not of the system. It shall be performed utilizing measurements with the actual measurement of the largest dimension of each indication being recorded. The degradation check is not applicable if the defect standard is replaced before the requirement comes due or for known defect standards where a direct comparison of new versus in-use materials is made on a daily basis. 5.10.3 Is the stated tolerance for the degradation check +/- 30% of the baseline measurement? YES NO N/A YES NO N/A YES NO

5.11

Penetrant Contamination Check (Reused) 5.11.1 Is a visual assessment performed on the penetrant for contamination at least daily? Compliance Assessment Guidance: This test may be performed in any way that allows contamination to be detected in the penetrant material, and the method used shall be specified in the suppliers procedure. Determine if any of the following conditions are evident; precipitates, waxy deposits, white coloration, separation of constituents, surface scum, or any other evidence of contamination or breakdown. When any of the above conditions are detected the material shall be discarded or modified in accordance with the manufacturers instructions. 5.11.2 Are records of this check on file and do they indicate acceptable results? Compliance Assessment Guidance: Records indicating OK or some other check mark are acceptable.

N/A YES NO

YES NO

5.12

Dryer Controls 5.12.1 Is the dryer oven controlled to a tolerance of +/-15 F (8.3C) or better? Compliance Assessment Guidance: It is expected that the auditor shall verify the performance is acceptable via the calibration certificate. The calibration certificate at a minimum shall indicate the set point, the maximum temperature reached during a cycle, and the minimum temperature reached during a cycle. In addition the variation shall be recorded from the set point and shall meet the required tolerance. This is a calibration of temperature variation with time. The dryer temperature shall not vary more than +/-15 F (8.3C) from the set value. The minimum test period used for the calibration shall be representative of the duration of a drying cycle. 5.12.2 Is the temperature controlling device calibrated at a minimum of one point within its

N/A YES NO

YES NO

PRI
range of use?

AC7114/1 Rev. F

- 10 -

Compliance Assessment Guidance: If the temperature controlling device is to be calibrated at one point, then that point shall be the point of use for that dryer. If multiple points are used, then they shall encompass the range of use for that dryer. Example: The dryer should not be calibrated at 130F (54C), 140F (60C) and 150F (66C) and then used at 160F (71C). 5.12.3 Is the calibration performed at least quarterly or with adequate documentation, extended to no more than every 6 months? Compliance Assessment Guidance: The calibration shall be performed at least quarterly or extended as allowed by the governing standard but not to exceed 6 months and only when 4 consecutive acceptable calibrations and adequate documentation is available to support the decreased frequency. 5.12.4 5.12.5 Is the calibration current? Is there a temperature indicator for the dryer and is it calibrated to a tolerance of +/10 F (5.6C ) or better? Is the temperature indicator calibrated at a minimum of one point within its range of use? Compliance Assessment Guidance: If the indicator is to be calibrated at one point, then that point shall be the point of use for that dryer. If multiple points are used, then they shall encompass the range of use for that dryer. Example: The dryer should not be calibrated at 130F (54C), 140F (60C) and 150F (66C) and then used at 160F (71C). 5.12.7 Is the calibration performed at least quarterly or with adequate documentation, extended to no more than every 6 months? Compliance Assessment Guidance: The calibration shall be performed at least quarterly or extended as allowed by the governing standard but not to exceed 6 months and only when 4 consecutive acceptable calibrations and adequate documentation is available to support the decreased frequency. 5.12.8 5.13 Is the calibration current? YES NO YES NO YES NO YES NO YES NO

5.12.6

YES NO

Black Light Meters and Measurements 5.13.1 Is a digital meter, with a spectral sensitivity from 320-400 nm, utilized to verify black light intensity? Is calibration of the meter being performed at least semi-annually or, with adequate documentation, extended as allowed by the governing standard but not to exceed 12 months when 4 consecutive acceptable calibrations and adequate documentation is available to support the decreased frequency? Is calibration performed at a minimum of three points to establish linearity? Compliance Assessment Guidance: No specific values need to be used. YES NO

5.13.2

YES NO

5.13.3

YES NO

PRI

AC7114/1 Rev. F

- 11 -

5.13.4

Is the light meter accurate to within 5% of the standard reading? Compliance Assessment Guidance: Note that 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.

YES NO

5.13.5

Is the calibration current? Compliance Assessment Guidance: The light meter shall be accurate to within 5% of the standard reading. Note that 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.

YES NO

5.13.6

Is the black light meter traceable to calibration data? Compliance Assessment Guidance: To meet this requirement, the meter shall be serialized, stickered or otherwise identifiable to the calibration data.

YES NO

5.13.7

Is the black light intensity of the inspection light(s) checked at least daily, prior to use and after equipment maintenance? Is the minimum acceptable limit 1200 W/cm2 at 15 inches (38cm)? Compliance Assessment Guidance: Borescope intensity shall be a minimum of 1000 W/cm2 at the inspection surface as measured from the inspection distance.

YES NO

5.13.8

YES NO

5.13.9

Are records of this check on file and do they indicate acceptable results? Compliance Assessment Guidance: The actual light intensity shall be recorded for this check; OK or some other mark is not acceptable.

YES NO

5.13.10

Did the facility properly demonstrate this check? Compliance Assessment Guidance: The auditor shall observe the check of the black light intensity being conducted.

YES NO

5.13.11

Are the black light reflectors and filters clean and in good condition?

YES NO

5.14

White Light Meters and Measurements 5.14.1 Is the calibration of the meter performed at least semi-annually or, with adequate documentation, extended as allowed by the governing standard but not to exceed 12 months when 4 consecutive acceptable calibrations and adequate documentation is available to support the decreased frequency? Is calibration performed at a minimum of three points to establish linearity? Compliance Assessment Guidance: No specific values need to be used. 5.14.3 Is the light meter accurate to within 5% of the standard reading? Compliance Assessment Guidance: Note that 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. YES NO YES NO

5.14.2

YES NO

PRI

AC7114/1 Rev. F

- 12 -

5.14.4

Is the calibration current? Compliance Assessment Guidance: The light meter shall be accurate to within 5% of the standard reading. Note that 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.

YES NO

5.14.5

Is the white light meter traceable to calibration data? Compliance Assessment Guidance: To meet this requirement, the meter shall be serialized, stickered or otherwise identifiable to the calibration data.

YES NO

5.14.6

Is ambient white light level in the inspection area, controlled for Type I penetrant, not to exceed 2 ft-candles (20 lux) as measured at the examination surface? Compliance Assessment Guidance: This measurement is taken in the darkened inspection area to include the examination surface with the black lights operating in the fixed position of 15 inches (38 cm).

YES NO

5.14.7

Is this check being performed at least weekly, prior to use and after equipment maintenance? Are records of this check on file and do they indicate acceptable results? Compliance Assessment Guidance: The actual light intensity shall be recorded for this check, OK or some other mark is not acceptable.

YES NO

5.14.8

YES NO

5.14.9 5.15

Did the facility properly demonstrate this check?

YES NO

Timing Devices 5.15.1 Are timing devices that are used to monitor penetrant, emulsifier and developer dwell times calibrated at a minimum of one point at least annually using a calibration traceable to NIST or other National Standard? YES NO

5.16

Water Temperature Monitor 5.16.1 Are water temperature indicators calibrated at a minimum of one point in the range of use at least semi-annually using a calibration traceable to NIST or other National Standard? N/A if only Method C is utilized. Compliance Assessment Guidance: The indicator (gage) utilized to control this process must have a measurement range sufficient to provide adequate resolution of the desired readings. YES NO N/A

5.17

Pressure Monitors 5.17.1 Are water pressure indicators calibrated at a minimum of one point in the range of use at least semi-annually using a calibration traceable to NIST or other National Standard? N/A if only Method C is utilized. Compliance Assessment Guidance: The indicator (gage) utilized to control this process must have a measurement range sufficient to provide adequate resolution of the desired readings. YES NO N/A

PRI

AC7114/1 Rev. F

- 13 -

5.17.2

Are air pressure indicators calibrated at a minimum of one point in the range of use at least semi-annually using a calibration traceable to NIST or other National Standard? Compliance Assessment Guidance: The indicator (gage) utilized to control this process must have a measurement range sufficient to provide adequate resolution of the desired readings.

YES NO N/A

COMPLIANCE
Compliance Assessment Guidance: The supplier shall perform representative inspections from current production 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 penetrant line 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. Witness the facilitys 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. 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 suppliers facility. a. Copy of completed technique card or supplier procedure with evidence of customer approval if required. Copy of the applicable shop traveler or work order. 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.

b. c.

A. Customer

Compliance End User

YES NO

PRI

AC7114/1 Rev. F

- 14 -

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

Penetrant Type:

Method:

Sensitivity Level:

Developer Form:

Inspectors

Level(s):

PRI
B. Customer

AC7114/1 Rev. F
Compliance End User

- 15 YES NO

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

Penetrant Type:

Method:

Sensitivity Level:

Developer Form:

PRI

AC7114/1 Rev. F

- 16 -

Inspectors

Level(s):

C. Customer

Compliance End User

YES NO

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

Penetrant Type:

Method:

Sensitivity Level:

PRI

AC7114/1 Rev. F

- 17 -

Developer Form:

Inspectors

Level(s):

6.2

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 to provide at least one set of compliance documentation for each of the suppliers Nadcap User customer base. If all of the suppliers Nadcap customers were represented in the actual compliance audits, then this section is N/A. Note: EC-LR materials shall not leave the suppliers facility. a. Copy of completed technique card or supplier procedure with evidence of customer approval if required. Copy of completed shop traveler or work order. 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.

N/A

b. c.

A. Customer

Compliance End User

YES NO

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

Internal Procedure(s):

Revision(s)

PRI

AC7114/1 Rev. F

- 18 -

Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

Part Number:

Revision

Penetrant Type:

Method:

Sensitivity Level:

Developer Form:

Inspectors

Level(s):

Date Performed:

B. Customer

Compliance End User

YES NO N/A

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

Process Specification(s):

Revision(s)

PRI

AC7114/1 Rev. F

- 19 -

Internal Procedure(s):

Revision(s)

Acceptance Specification(s) / Drawing Notes:

Revision(s)

Class and/or Grade (if applicable)

Part Description:

Part Number:

Revision

Penetrant Type:

Method:

Sensitivity Level:

Developer Form:

Inspectors

Level(s):

Date Performed:

C. Customer

Compliance End User

YES NO N/A

Purchase Order Number:

Work Order Number:

Lot / Batch / Serial Number:

PRI

AC7114/1 Rev. F

- 20 -

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

Penetrant Type:

Method:

Sensitivity Level:

Developer Form:

Inspectors

Level(s):

Date Performed:

6.3

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 specifications and revisions as required by the contract document? Compliance Assessment Guidance: This will be confirmed by the auditor by reviewing the customer P.O. and End User drawing if available. YES NO

6.3.2

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

YES NO N/A

PRI

AC7114/1 Rev. F

- 21 -

6.3.3

Were the applicable requirements, procedures and acceptance criteria made available to the penetrant inspectors? Compliance Assessment Guidance: Work instructions/routings/shop travelers/techniques/procedures, acceptance criteria and unique customer requirements shall be available to the inspectors. The term available means that these documents are within easy access by the technicians. These documents are available and are used to perform the inspections, not used from memory.

YES NO

6.3.4

If written procedures, and or techniques, require review and/or approval by the Cognizant Engineering Organization, is that approval evident? Compliance Assessment Guidance: This shall be investigated and confirmed by the auditor by reviewing the last ten part numbers shipped.

YES NO N/A

6.3.5

If applicable, are part specific drawing inspection and/or acceptance notes being flowed down and followed by the inspectors? Was there evidence of compliance to the document control procedure? If applicable, are all specifications, drawings, procedures or technique changes authorized? Auditor to confirm approval. Compliance Assessment Guidance: The auditor shall review the documents for any unauthorized changes.

YES NO N/A

6.3.6 6.3.7

YES NO YES NO N/A

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 6.4.1.2 6.4.1.3 6.4.1.4 Part number / Material Identification? Specification reference? Inspection acceptance requirements? Correct sequence of operations? YES NO YES NO YES NO YES NO

6.5

Pre-Cleaning Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation. 6.5.1 Are parts being cleaned in accordance with applicable work instructions/procedure? Compliance Assessment Guidance: There shall be a procedure that addresses the cleaning materials, sequence, times, concentrations and temperatures in accordance with customer requirements. 6.5.2 Were all parts clean? Compliance Assessment Guidance: Parts shall be cleaned in accordance with customer requirements. The auditor shall confirm the cleanliness of the parts prior to YES NO YES NO

PRI

AC7114/1 Rev. F
inspection by whatever means are available and reasonable.

- 22 -

6.6

Pre-Penetrant Etching Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation. 6.6.1 Is there a procedure that addresses etching materials, sequence, times, concentrations and temperatures in accordance with customer requirements? If required, were all parts etched? Compliance Assessment Guidance: All parts shall be properly etched if applicable. The auditor shall determine applicability based on a review of the purchase order, specification, customer instruction, etc. 6.6.3 If required, is an outside source used? If so, identify the source name and location: ______________________________________________ 6.6.4 If required, was the source performing etch (internal or external) approved by the customer?

N/A

YES NO

6.6.2

YES NO N/A

YES NO N/A

YES NO N/A

6.7

Penetrant Application Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation. 6.7.1 Are components, penetrant, and ambient temperatures maintained within the range of 50 F (10 C) to 125 F (52 C)? Compliance Assessment Guidance: If the auditor or supplier suspects that the temperature is out of this range, the temperature must be verified. 6.7.2 6.7.3 Is a calibrated timing device used to monitor penetrant dwell time? Are parts dry prior to penetrant application? Compliance Assessment Guidance: It is expected that a dry condition be confirmed by the auditor. YES NO YES NO YES NO

6.7.4

Are penetrant application operations controlled to ensure complete coverage of areas to be inspected? Compliance Assessment Guidance: It is expected that adequate and complete coverage be confirmed by the auditor by whatever means is suitable.

YES NO

6.7.5

Was the correct method, type, and level of penetrant used? Compliance Assessment Guidance: The auditor shall confirm these issues by researching the appropriate customer specifications and documentation.

YES NO

6.7.6 6.7.7 6.7.8

Were the parts properly drained to prevent pooling? Was the correct penetrant dwell time utilized as specified by customer requirements? If parts exceeded the maximum dwell time, was penetrant reapplied?

YES NO YES NO YES NO N/A

PRI

AC7114/1 Rev. F

- 23 -

6.8

Use of Emulsifier Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation. 6.8.1 Is a calibrated timing device used to monitor emulsification time? List Emulsification Time .

N/A

YES NO

Compliance Assessment Guidance: The emulsification time used shall be recorded by the auditor. 6.8.2 Are methods of application and removal of emulsifiers properly controlled? Compliance Assessment Guidance: It is expected that the auditor shall watch these operations carefully to detect discrepancies. 6.8.3 6.8.4 Was the correct emulsifier utilized? If hydrophilic emulsifier was used, were the pre-rinse parameters controlled? (e.g., temperature, pressure, etc.) Compliance Assessment Guidance: It is expected that parameters such as: temperature, pressure, etc, be observed and evaluated by the auditor. 6.8.5 Was the entire part flooded with water prior to reaching the maximum emulsification time? YES NO YES NO YES NO N/A YES NO

6.9

Penetrant Removal Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation. Some questions will be N/A if only method C is utilized. 6.9.1 6.9.2 Is the rinse water controlled to provide a coarse spray? Is the rinse water temperature controlled within the range of 50F (10C) to 100 F (38C)? Is the rinse water pressure controlled to 40 psi (275 kPa) maximum? YES NO N/A YES NO N/A

6.9.3

YES NO N/A

6.9.4

Is the water pressure and temperature monitored at least daily or prior to use? Compliance Assessment Guidance: This check does not need to be recorded, however the auditor is expected to verify compliance by witnessing the check being performed without prompting.

YES NO N/A

6.9.5

Is penetrant removal, for manual stations, verified under appropriate lighting? Compliance Assessment Guidance: N/A shall only be used where an automated system is used. Is over and under washing/removal controlled? Compliance Assessment Guidance: Removal, using water, removers and solvents shall be controlled. The auditor shall observe all removal processes. The appearance of the part at final inspection may also provide evidence of correct removal. Wash distance of 12 inches (30 cm) where possible, application of

YES NO N/A

6.9.6

YES NO

PRI

AC7114/1 Rev. F
removers and the use of solvents are included as this issue applies to all washing and removal methods. 6.9.7 If used, is the air pressure on the hydro-air nozzle controlled to 25 psi (170 kPa) maximum and monitored at least daily or prior to use? Compliance Assessment Guidance: This check does not need to be recorded, however the auditor is expected to verify compliance by witnessing the check being performed without prompting.

- 24 -

YES NO N/A

6.10

Developer Application Compliance Assessment Guidance: Developer is required unless specific and clear customer allowance has been given. When developer is not used, the auditor shall provide an explanation. Section 6.10 is required to be answered in all cases where developer is used. In addition, the following sections 6.11, 6.12 and 6.13 will be required when that particular material is used; otherwise those sections not used are N/A with no explanation being required. The auditor shall verify compliance to each of these requirements by direct observation. 6.10.1 Was the developer utilized in accordance with the applicable customer requirements? Compliance Assessment Guidance: The auditor shall confirm this issue by researching the appropriate specifications and documentation. 6.10.2 Is a calibrated timing device used to monitor developer dwell time? Compliance Assessment Guidance: A timing device shall be calibrated at a minimum of one point at least annually. Any calibration traceable to an acceptable national source is acceptable for these timing devices. 6.10.3 Was the developing time in accordance with applicable customer requirements? Compliance Assessment Guidance: The auditor shall confirm this issue by researching the appropriate specifications and documentation. 6.10.4 When applying developer, are the parts completely covered? Compliance Assessment Guidance: When applying developer, the parts or the areas to be inspected as applicable shall be completely covered with a thin and uniform developer layer. This issue shall be observed and confirmed by the auditor. 6.10.5 Are dwell times (in minutes) used by the supplier within the ranges noted below? Please note all used. An explanation is not required for not used. Compliance Assessment Guidance: 20 to 120 minutes is between 10 to 240 minutes. The auditor shall include materials utilized for the wipe-off technique when completing section 6.10.5. If form d is utilized for wipe-off only, the auditor should answer yes with an explanation.

N/A

YES NO

YES NO

YES NO

YES NO

YES NO N/A Form: a Form: b Form: c Minimum Dwell Time: 10 Maximum Dwell Time: 240 YES NO N/A Minimum Dwell Time: 10 Maximum Dwell Time: 120 YES NO N/A Minimum Dwell Time: 10 Maximum Dwell Time: 120 YES NO N/A

PRI
Form: d 6.11

AC7114/1 Rev. F
Minimum Dwell Time: 10 Maximum Dwell Time: 60

- 25 -

Dry Developer (Form a) Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation. 6.11.1 Are all parts dried in accordance with customer requirements? Compliance Assessment Guidance: The auditor shall confirm this issue by researching the appropriate specifications and documentation. If a dryer is used, the set temperature used shall take into consideration the tolerance of the dryer. 6.11.2 Are methods for applying developer and removing excess developer properly controlled? If air was used to remove excess dry developer, was it controlled to 5 psi (34 kPa) or less?

N/A

YES NO

YES NO

6.11.3

YES NO N/A

6.12

Aqueous Developer (Form b & c) Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation. 6.12.1 6.12.2 Was the excess water removed from the parts prior to developer application? Are methods for applying developer and removing excess developer properly controlled? Compliance Assessment Guidance: The auditor shall observe that the proper techniques are employed. 6.12.3 Are all parts dried in accordance with customer requirements? Compliance Assessment Guidance: The auditor shall confirm this issue by researching the appropriate specifications and documentation. If a dryer is used, the set temperature used shall take into consideration the tolerance of the dryer.

N/A

YES NO YES NO

YES NO

6.13

Non-Aqueous Developer (Form d) Compliance Assessment Guidance: The auditor shall verify compliance to each of these requirements by direct observation. The auditor shall include the wipe-off technique when answering section 6.13. 6.13.1 Are all parts dried in accordance with customer requirements? Compliance Assessment Guidance: The auditor shall confirm this issue by researching the appropriate specifications and documentation. 6.13.2 Are methods for applying developer properly controlled? Compliance Assessment Guidance: The auditor shall observe that a thin even layer of developer is applied and is not in excess.

N/A

YES NO

YES NO

6.14

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

PRI

AC7114/1 Rev. F

- 26 -

6.14.1 6.14.2

Are magnification/viewing aids available for evaluating indications? Are calibrated/verified measuring devices in accordance with customer requirements utilized? Compliance Assessment Guidance: The auditor shall confirm this by researching the appropriate specifications and documentation.

YES NO YES NO

6.14.3

Is the Inspection area free of fluorescent material or other contamination that may interfere with the inspection process? Compliance Assessment Guidance: This would include the area where parts are evaluated, spills on the floor, tables or other areas where penetrant materials may come in contact with parts and baskets, trays, etc. used to hold parts. The auditor is expected to evaluate the area as a whole and determine if any detrimental contamination is present that would interfere with the inspection of parts.

YES NO

6.15

Evaluation 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. 6.15.1 For Type I inspection, did inspectors allow at least 1 minute to condition their eyes to the darkness before conducting the inspection? Compliance Assessment Guidance: Inspectors shall allow at least 1 minute to condition their eyes to the darkness when coming in from ambient lighting. Adaptation time during inspection and evaluation is not required unless otherwise specified by the customer. A timing device is required for eye adaptation monitoring, but evidence of calibration is not required. 6.15.2 Did the inspector adhere to the requirement of not wearing permanently darkened or photo-chromatic eye glasses? Compliance Assessment Guidance: This is not intended to prohibit the use of eyeglasses with lenses treated to absorb ultraviolet light. 6.15.3 For Type I inspection, was the light intensity at the inspection surface at the time of this survey at least 1200 W/cm2? If required, did the inspector properly evaluate every indication and reject parts containing relevant indications that exceeded the acceptance limits? Compliance Assessment Guidance: The auditor is expected to confirm understanding by whatever means are required. This may be possible by observation or, in some cases, may require the auditor to ask the inspector(s) questions regarding the criteria and how it is to be used. 6.15.5 Were the indications wiped with a solvent dampened swab or brush in accordance with customer requirements? Compliance Assessment Guidance: For the purpose of this checklist, the term swab shall include lint-free cloth. 6.15.6 If redeveloped, was the redevelopment time, for acceptance, adequate to meet customer requirements? YES NO N/A YES NO N/A YES NO YES NO YES NO

6.15.4

YES NO N/A

PRI

AC7114/1 Rev. F

- 27 -

6.15.7 6.15.8 6.15.9

Were all rejectable indications marked on the part and/or appropriately documented? Was all pertinent paperwork traceable to the part? Were the specific accept/reject criteria properly understood by the inspector? Compliance Assessment Guidance: The auditor is expected to confirm understanding by whatever means are required. This may be possible by observation or, in some cases, may require the auditor to ask the inspector(s) questions regarding the criteria and how it is to be used.

YES NO N/A YES NO YES NO

6.15.10

Did the accept/reject criteria properly reflect the customer criteria? Compliance Assessment Guidance: This will be confirmed by the auditor by reviewing the customer P.O and End User drawing if available.

YES NO

6.16

Post Cleaning Compliance Assessment Guidance: The auditor shall verify compliance to this requirement by direct observation. 6.16.1 6.16.2 If required was an adequate post process cleaning operation performed? After inspection and appropriate cleaning, were parts properly protected from corrosion or damage? YES NO N/A YES NO N/A

6.17

Inspector Qualification 6.17.1 Were the inspection personnel certified to the correct levels for the work they were performing? Compliance Assessment Guidance: This shall be verified by review of the certification records. 6.17.2 Were all non-certified or in-training personnel observed performing PT operations properly supervised? Compliance Assessment Guidance: This shall be determined by direct observation. YES NO N/A YES NO

6.18

Inspection Status 6.18.1 6.18.2 Are symbols and/or marking methods used to denote penetrant inspection status? Were all inspection results properly recorded and traceable to the parts? YES NO YES NO