©2012 Rolls-Royce plc

The information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any

purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc.

This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given

concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or

any of its subsidiary or associated companies.

Ve

rsio

n 2

Feb

20

12

Global NDT Specifications

Change Awareness

Insert filename

Develop Global Specifications and Standards

Generic Controlling Documentation

Common Engineering Language Single Database

Standardised Design and Materials Selection Culture

Determine Corporate Best Practice

Maximise the use of Industry Standards (AMS etc.)

Identify Cost Reduction Opportunities

Reduce Documentation Complexity

Generate Supplier Friendly Systems

Enable Supply Chain Simplification

Facilitate Global Design Make Capability

Assist Global Procurement Material Strategy

vision

Insert filename

Materials: MSRR EMS RRMS

Processes: RPS EPS RRP

Quality: RQS EIS RRQ

Outcome Based Documents

Non-prescriptive „driven by outcome‟ Specifications (except NDT)

Parameter/Method Definition placed on Supplier (except NDT)

Industry Standard Friendly

Industry Standard Aligned

Paragraph Format – Similar to other Industry Standards

Global Specs to be used where Industry Standard does not satisfy

Requirements

philosophy

Go

Fo

rward

Insert filename

A ‘Go-Forward’ Implementation Strategy

Global Specifications will be used on all future engine projects

The first engine to call out Global Specifications is Trent XWB

NDT Rationalised Process Specifications (RPS‟s) will be replaced by RR

Process (RRP) specifications on 2nd May 2012.

implementation

Trent XWB powering the AirbusXWB

Insert filename

publication

Insert filename

family of NDT specs RRP58000

Technical Control of Non Destructive

Testing

RRP58001

Ultrasonic Immersion Inspection of

Rectilinear Machined Forms

RRP58002

Ultrasonic Examination of Billet and

Bar Material for Sub Surface Defects

RRP58003

Fluorescent Penetrant Inspection

RRP58004

Magnetic Particle Inspection

RRP58005

Training & Approval of NDT

Personnel

RRP58006

Radiographic Inspection

RRP58007

Visual Inspection

RRP58008

Method for Construction of Ultrasonic

Limitation Diagrams

RRP58009

Digital Radiography

RPS906

RPS705

RPS707

RPS702

RPS700

RPS908

RPS704

RPS709

RPS907

RPS720

Insert filename

Change The following RPS’s will be issued as cancelled on 2nd May 2012:

RPS700, 702, 704, 705, 707, 709, 720, 906, 908.

Each cancelled RPS will direct you to the RRP that supersedes it ensuring that

existing documentation flow down is not broken.

Facilities approved per the RPS will automatically be considered approved per

the relevant RRP.

NDT personnel trained and approved per a RPS will not require re-training

other than via this ppt.

Supplier level 3 personnel approved to control per RPS906 remain approved to

control NDT per RR58000.

Legacy NDT technique instructions remain valid. Application of the NDT

process and its control and maintenance must be in accordance with the

relevant RRP. Where there is a conflict between NDT technique instruction and

RRP, the NDT technique instruction shall be re-issued and re-approved in line

with RRP58000.

Insert filename

RRP58000 Technical Control of Non Destructive Testing

Requirements for planning and sequencing of NDT operations specified within

RRP58000.

Requirement for a QCTP specified within RRP58000. Rules and QCTP now

contained within RR QMS and available from RR when required.

Requirements for NDT technique instructions specified within RRP58000.

Requirements and technique instructions for NDT methods not covered by an

RRP now incorporated within RR QMS.

Guide to NDT inspection capability, limitations and constraints now

incorporated within RR QMS.

Requirements for carrying probability of detection (POD) experiments now

incorporated within RR QMS.

Requirements for control of NDT at External Suppliers is specified within

RRP58000.

Continued.......

RR QMS = Rolls-Royce Quality management System

Insert filename

RRP58000 Technical Control of Non Destructive Testing

Vision requirements are now specified within RRP58005 – Training & Approval

of NDT Personnel.

Requirements for reduced radiological examination levels on castings is now

contained in RRP58006 – Radiographic Inspection and RRP58009 – Digital

Radiography.

NDT code of ethics now defined within RRP58005 – Training & Approval of

NDT Personnel.

Requirements for performance assessment of NDT inspection personnel is now

specified within RRP58005 – Training & Approval of NDT Personnel.

Human factors within NDT is specified within RRP58000 appendix C.

Insert filename

RRP58001 Ultrasonic Immersion Inspection of Rectilinear Machined Forms

No significant changes.

Changes to immersion tank calibration will be revised back to RPS705

requirements at next revision.

Insert filename

RRP58002 Ultrasonic Examination of Billet and Bar Material for Sub Surface

Defects

No significant changes

Application: Flow chart removed, now contained within RPS 920/12

GENERAL INSPECTION REQUIREMENTS: References to AMS-STD-2154,

ASTM E 428 & AMS 2628 for calibration standards added. Paragraph on

Probes removed.

Acoustic compatibility measurement changed

AUTOMATIC INSPECTION: Paragraph added to clarify on which material

classes this method shall be employed. Paragraph added to control water path.

Paragraphs (covering Flaw Detector, Monitor Gates, DAC, Recording, Alarm

Systems, Couplant and Inspection Sensitivity) moved to General Inspection

Requirements section

Continued……

Insert filename

RRP58002 Ultrasonic Examination of Billet and Bar Material for Sub Surface

Defects

MANUAL INSPECTION: Paragraph added to clarify on which material classes

this method shall be employed. Reference to AMS-STD-2154 for transducers

added.

CONTROL CHECKS & MAINTENANCE: Instrument calibration & scan

speed/index calibration interval changed to 12-monthly.

TABLE 2 QUALITY STANDARDS: Title changed to “Rejection and Alarm

Threshold Levels Based on Material Class”. Note added for titanium alloys

where AMS2628 is used.

Insert filename

RRP58003 Fluorescent Penetrant Inspection

Control preparation section has been amended to remove RPS references and

replace with RRP51000.

RPS702 states the facility ambient temperature range however does not state

how this is to be controlled whereas RRP58003 now requires temperature

verification of both facilities and processing solutions if it is suspected that the

ambient temperature fall out of the specified range.

Removal of the maximum penetrant contact time of 1 hour

Change from 4 minute maximum emulsification time to 2 minutes unless

otherwise approved by the Rolls-Royce Technical Authority

The maximum 5 lux requirement for inspection areas has been removed

Continued……

Insert filename

RRP58003

Fluorescent Penetrant Inspection

Frequency of calibration of automatic lines changed from quarterly to

annually.

Amended mandatory default drying requirements of 120oC (248oF) for 1 hour

to “unless otherwise agreed by Rolls-Royce Technical Authority”.

Section on Non Aqueous developer (NAWD) amended with reference to

“localised application” removed.

Minimum number of indications per penetrant type for the initial calibration of

PSM5 panel amended to comply with ASTM 1417.

14

Insert filename

RRP58004 Magnetic Particle Inspection

Inspection Techniques

Change from historical approach of generating “machine transferrable”

inspection techniques by formulation, to “machine specific” techniques by on-

machine trial. Technique instruction to reference specific machine/ equipment

and parameters used. Reduced emphasis on current waveform relationships.

Inspection techniques to be verified by demonstration of presence of adequate

flux density for all parts (not limited to parts of Critical classification, complex

geometry and focus inspection).

Verification of Flux Density

Verification of flux density to be demonstrated on all surfaces (chamfers, radii

etc. not required where adjacent surfaces demonstrated).

Verification of adequate flux density may be made using gaussmeter for

circular magnetisation. Longitudinal magnetisation requires artificial shim.

Continued……

Insert filename

RRP58004 Magnetic Particle Inspection

Min. gaussmeter reading 30 gauss at part surface. Readings greater than 50

gauss acceptable providing background fluorescence satisfactory.

Artificial shims to be in accordance with AS 5371 (“QQIs”).

Particle Application

Magnetisation time of min. 2 secs. may be accumulative and comprise multiple

shots of 0.5 secs.

Residual ink application allowed for geometric constraints and complex features

(e.g. splines, threads) where leakage field particle build up occurs.

Magnetisation Methods

Use of toroidal magnetisation technique permitted.

Multi-directional magnetisation allowed for standard bolts. Else specific

authorisation required.

Offset threading bar method of determination per ASTM E1444.

Continued……

Insert filename

17

RRP58004 Magnetic Particle Inspection

Coil magnetisation formulas based on requirements of ASTM E1444. Ampere

turns values 70% of ASTM E1444. Field strength greater than RPS 700,

qualified by shims.

Demagnetisation requirements “outcome based” i.e. method acceptable where

remaining field strength value < 3 gauss. No initial demagnetisation required

where field strength < 3 gauss.

Control Checks

For AS5282/ Ketos Ring amperage values required quoted in RRP 58004, in

line with ASTME 1444.

Requirement to carry out low end output stability/ repeatability check.

Magnetic field quick break check.

Calibration requirements for Hall effect gaussmeter (3 positions).

Internal short check (not required if manufacturer certifies as such).

Insert filename

RRP58005 Training and Approval of NDT Personnel

Requirements for a code of ethics to be included in the written practice added

from RPS906.

Requirement for suppliers in countries where a NANDTB exists, NDT

qualifications must come under the control of the NANDTB.

Performance review guidelines and requirements added from RPS906.

Sample template added for performance review of personnel.

Insert filename

RRP58006 Radiographic Inspection

• Reduced Radiological Examination for castings removed from RPS906 and

added into RRP58006

• All previous references to RPS720 have been changed to RRP58009

• Record retention for double scrutiny added

• Section added to mandate sensitivity checks at least each shift

• Section added to mandate backscatter checks at least at the beginning of each

shift

• Section added in to allow for technique modifications and the use of multiple x-

ray units

• Section added to allow for additional radiography following section reduction

Insert filename

RRP58007 Visual Inspection

• No significant differences

Insert filename

RRP58008 Method for Constructing Ultrasonic Limitation Diagrams

RPS 907 will not be cancelled as it will continue to be relevant to legacy parts.

New rules have been defined for determining inspection category.

Inspection category is now determined by the number of scans interrogating a

specific volume. No priority given to normal to surface scans.

There are now only three inspection categories:-

Category A – Full Inspection

Four or more ultrasonic scans interrogate a given point within the volume of the

finished component.

Category B – Limited Inspection

Between one and three ultrasonic scans interrogate a given point within the

volume of the finished component.

Category C – No inspection

No ultrasonic scans interrogate a given point within the volume of the finished

component.

Insert filename

RRP58009 Digital Radiography

• Reduced Radiological Examination for castings removed from RPS906 and

added into RRP58006

• All previous references to RPS720 have been changed to RRP58009

• Record retention for double scrutiny added

• Section added to mandate sensitivity checks at least each shift

• Section added to mandate backscatter checks at least at the beginning of each

shift for CR.

• Section added to allow for additional radiography following section reduction

• Section added to recognise and make allowances for automated systems

Insert filename

Now What?

All internal Rolls-Royce Level 3 Controllers and Supplier level 3‟s approved to

control NDT per RPS906 Section B are required to ensure that all NDT personnel

under their control are made aware of the change summarised herein, i.e. are

taken through this presentation.

Evidence of this awareness training must be documented, i,e, when, where, personnel

trained, trained by, acknowledgement signature of all parties.

All internal Rolls-Royce Level 3 Controllers and Supplier level 3‟s approved to

control NDT per RPS906 Section B should use the time between now and „Go

Live‟ date to prepare for implementation.

Implementation date is effective 2 May 2012 when the relevant RPS‟s will be

superseded by RRP‟s.

Note: There may be a slight delay between implementation date and availability of the re-

issued „cancellation‟ RPS‟s on the Supplier Portal.

Rolls-Royce will allow a 2 month transition period from „Go Live‟ date, i.e. RRP‟s

fully implemented by 2nd July 2012.

Do refer to transition instructions on the cancellation RPS documents.

23