AC7102 8 pyrometry

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161Thorn Hill Road Warrendale, PA 15086-7527

AUDIT CRITERIA

AC7102/8 REV. NA

Issued 2014-01 Revised: 2014-05 Superseding NA

TO BE USED ON AUDITS STARTING ON OR AFTER 11-May-14

Nadcap

AUDIT CRITERIA FOR HEAT TREATING PYROMETRY

Editorial Revision: 14-May-14 para 5.3, 5.4, 6.7.1.q,

1. SCOPE 1.1 This checklist supplements AC7102. The checklist shall apply to Suppliers seeking

Nadcap accreditation for Heat Treating.

2. PYROMETRY 2.1 General Requirements 2.1.1 Does the supplier have an internal procedure, or procedures for Pyrometry addressing

all the aspects of AMS 2750E and other customer specifications applicable to their operations?

YES NO

2.1.2 Do all the test equipment and test thermocouples have current certifications traceable

to National Institute of Standards and Technology NIST, or other equivalent national certification agency?

YES NO

2.1.3 Is there a system in place to review Pyrometry procedures and the results of tests

(whether performed in-house or by an outside source) to ensure that AMS 2750E, or more stringent customer requirements are being met?

YES NO

2.1.4 Are there objective evidences of these reviews? YES NO 3. Thermocouples 3.1 Do the thermocouples and thermocouple wires meet the calibration frequency,

temperature intervals and accuracy requirements of AMS 2750E, or more stringent customer requirements? (U10)

YES NO

PRI AC7102/8 Revision NA - 2 -

3.2 Are the thermocouples being calibrated throughout the range in which they are to

be used? YES NO

3.3 Are the actual calibration values and errors or correction factors reported on the

certification? YES NO

3.4 Are procedures in place to ensure that base metal thermocouples are only

recalibrated when allowed by AMS 2750E? YES NO

3.5 Are procedures in place to ensure that thermocouples are only reused when

allowed by AMS 2750E? YES NO

3.6 Does the supplier comply with the re-calibration (or replacement) requirements for

nonexpendable thermocouples, including Type K and E, when used exclusively at or below 500F?

YES NO NA

3.7 Does the supplier comply with the re-use and depth of insertion requirements for

any Type K and E thermocouples when used above 500F? YES NO NA

3.8 Does the supplier comply with the U formula (except as allowed per AMS 2750E,

3.1.3.4 for TUS) when expendable test thermocouples are used for SAT and TUS testing? (U11)

YES NO NA

3.9 Does the supplier comply with AMS 2750E, paragraphs 3.1.5.2 and 3.1.5.3, or

more stringent customer requirements for the life usage of expendable and nonexpendable base metal load thermocouples?

YES NO

3.10 Does the internal procedure specify when the correction factors are to be used? YES NO 3.11 Is the application of correction factors documented in clear and unambiguous

terms? YES NO

3.12 Does the supplier determine a replacement frequency of sensors based on

supporting data (SAT, TUS, recalibration data, etc.)? YES NO

3.12.1 Is there an internal procedure addressing this requirement? YES NO 3.13 Thermocouples Made from Rolls of Thermocouple Wire NA 3.13.1 Are all rolls of thermocouple wire calibrated at both ends and the correction factor

determined to be the average of the two values at any calibration temperature? YES NO

3.13.2 Are procedures in place to ensure that the thermocouples made from rolls of

thermocouple wire are not used when the difference in end to end (front to back) correction factors at any test temperature exceed AMS 2750E or more stringent customer requirements (1F or 0.6C for primary and secondary standards; 2F or 1.1C for all other uses including TUS)?

YES NO

3.13.3 Do records indicate compliance? YES NO 4. Instrumentation 4.1 Testing Instrumentation 4.1.1 Do all test instruments have a digital display and output, and meet the readability, YES NO


calibration frequency and the accuracy requirements of Table 3 of AMS 2750E, or more stringent customer requirements?

4.1.2 Does the calibration of Primary, Secondary Standard and Field Test Instruments

meet the requirements of AMS 2750E or more stringent customer requirements? YES NO

4.2 Process Instrument Calibration 4.2.1 Are the calibration accuracy and frequencies in accordance with the requirements

of AMS 2750E Table 3, or more stringent customer requirements? YES NO

4.2.2 Are the calibrations performed on each furnace instrument that qualifies the furnace

for the particular instrument type? (U11) YES NO

4.2.3 Are the instruments checked for sensitivity during calibration to meet AMS 2750E

Table 3, Footnote (4), or more stringent customer requirements? YES NO

4.2.4 Do the instrument calibration records and stickers show conformance to the

requirements of AMS 2750E, or more stringent customer requirements? YES NO

4.3 Process Recorders including Electronic Data Collection 4.3.1 Does the Process recording system meet the resolution requirements of AMS

2750E Table 4, or more stringent customer requirements? YES NO

4.3.2 Do recorder printing and chart speeds meet the requirements of AMS 2750E Table

5, or more stringent customer requirements? YES NO

4.3.3 Are the chart (circular and/or strip) recorders speed(s) verified annually as a

minimum? YES NO NA

4.3.4 Are the chart (circular and/or strip) recorders speed(s) accurate within 3 minutes

per hour? YES NO NA

4.4 Furnace Classes and Instrumentation Types 4.4.1 Do the testing frequencies and tolerances meet the requirements of AMS 2750E for

the applicable Furnace Class and Instrumentation Type? (See Figure 2 and Tables 6, 7, 8, and 9)

YES NO

4.4.2 Are the furnaces instrumented for the Instrumentation Type identified by the

supplier? (See Figure 3) YES NO

4.4.3 Are refrigeration and quenching systems properly instrumented to meet AMS

2750E, paragraph 3.3.3, or more stringent customer requirements? YES NO NA

5. System Accuracy Test (SAT) 5.1 General 5.1.1 Does the internal SAT procedure conform to the requirements of AMS 2750E, or

more stringent customer requirements for the specific method used by the supplier? (U14)

YES NO

5.2 System Accuracy Test (SAT) Waiver (Note: Not all customer Primes allow the waiver).

NA

5.2.1 If the SAT Waiver is utilized, do the procedures and practices meet all of the YES NO


requirements of AMS 2750E section 3.4.7? 5.3 System Accuracy Test (SAT) Practice NA 5.3.1 Are the SATs performed on the temperature control and recording systems

required by the applicable instrumentation type, as well as any additional recording systems used for product acceptance in each control zone of each piece of thermal processing equipment used for production heat treatments?

YES NO

5.3.2 Are the SATs performed upon installation and periodically thereafter in accordance

with the requirements of AMS 2750E, Tables 6 or 7, or more stringent customer requirements, including any applicable frequency reductions? (The SATs frequencies are based upon equipment class and instrumentation type).

YES NO

5.3.3 Is a SAT performed after any maintenance that could affect the SAT result?

(Examples include replacement of the thermocouple(s) and re-calibration of the instrument that resulted in an adjustment to the instrument).

YES NO

5.4 System Accuracy Test (SAT) Methods NA 5.4.1 Are the displayed temperature indication and recording of the sensor being tested,

with appropriate offsets or correction factors, at any operating temperature, compared with the corrected temperature indication of the test sensor on a test instrument?

YES NO

5.4.2 Do records indicate that: a. The thermocouple correction factors are stated unambiguously and used

correctly? YES NO

b. The furnace identification, the set point, test thermocouple measurement,

furnace thermocouple indication, and the difference after correction factors are applied, including all other information required by AMS 2750E paragraph 3.4.8.1 or more stringent customer requirements?

YES NO

c. Any required corrective actions are documented and the furnace re-tested

after any required adjustments? YES NO

d. Any frequency reductions are adequately documented and justified? (U11) YES NO e. Do SAT results meet the requirements of all applicable specifications? YES NO 5.4.3 If the alternate SAT method specified in AMS 2750E, paragraph 3.4.6 is utilized, is it

documented and does it meet specification requirements? (Note: Not all customer Primes allow the alternate method).

YES NO NA

5.5 System Accuracy Test (SAT) Resident Test Thermocouple NA 5.5.1 Is there an internal procedure documenting the use of resident test thermocouples,

including periodic verification of their position? YES NO

5.5.2 Are the furnace (or load) thermocouple and the resident SAT thermocouple two

different thermocouple types? (It is not allowed to use Type R thermocouple as a resident SAT thermocouple against Type S control thermocouple, or vice versa, due to similarity of both thermocouples metal chemistry).

YES NO

5.5.3 Are resident SAT thermocouples only Type B, N, R or S when used at temperatures YES NO


exceeding 500F (260C), and nonexpendable if exposed to temperatures above 1000F (538C)?

5.5.4 Are resident SAT thermocouples subject to the replacement or recalibration

frequency specified in AMS 2750E, or more stringent customer requirements? YES NO

6. Temperature Uniformity Survey (TUS) NA 6.1 General 6.1.1 Does the internal TUS procedure conform to the requirements of AMS 2750E, or

more stringent customer requirements for the specific method used by the supplier? YES NO

6.1.2 Are initial TUSs performed prior to production or after any furnace modification or

adjustment, that could have altered the temperature uniformity characteristics? (Examples are noted in AMS 2750E, paragraph 3.5.3)

YES NO

6.1.3 Do procedures and documentation exist to demonstrate that test frequencies and

test temperatures meet AMS 2750E paragraph 3.5.5, 3.5.6, 3.5.7 and Table 8 or 9, or more stringent customer requirements, on both periodic and annual basis?

YES NO

6.1.4 Are all furnace modifications and repairs documented in a log with the appropriate

QA documentation as to whether an initial TUS is required? YES NO

6.2 Load Condition (for TUS) 6.2.1 Is the load condition for the performance of the initial TUS on each furnace

documented? YES NO

6.2.2 Is each successive TUS performed with the same type of load condition as the

initial one? YES NO

6.2.3 If heats sinks are used, do they meet the requirements of AMS 2750E paragraph

3.5.10.1 for placement and thickness? YES NO NA

6.2.4 Do operating parameters during the TUS reflect the normal operating parameters

for the particular furnace, including the atmosphere, except as allowed by AMS 2750E paragraph 3.5.11?

YES NO

6.2.5 Does the supplier have a detailed diagram of the test sensors location during the

TUS? YES NO

6.2.6 Is the number and placement of thermocouples used for the TUS as required per

AMS 2750E, or more stringent customer requirements? YES NO

6.3 Initial TUS 6.3.1 Do the initial test temperatures include the highest and lowest temperatures for

which the equipment will be used for each qualified operating range? YES NO

6.3.2

If the highest and lowest test temperatures are more than 600F (or 335C) apart, are additional tests performed at one or more intermediate test temperatures so that test temperatures are not more than 600F (or 335C) apart? (U11)

YES NO NA

6.4 Periodic TUS 6.4.1 For any operating range greater than 600F (335C), are periodic tests performed at

a temperature(s) within 300F (170C) of the maximum and 300F (170C) of the YES NO


minimum of each qualified operating range and there are no more than 600F (335C) increments between adjacent test temperatures, for each range as defined during the initial survey? (U11)

6.4.2 Does the supplier, at least once each calendar year, perform a temperature

uniformity survey at the minimum and maximum temperature of each qualified operating range?

YES NO

6.4.3 Are the TUSs performed at the frequencies required by AMS 2750E Tables 8 or 9,

or more stringent customer requirements? (U11) YES NO

6.5 Temperature Uniformity Test Methods 6.5.1 Does the TUS recorder or data logger output the TUS data in a digital format? YES NO 6.5.2 Are readings taken: a. Before the first test or furnace sensor reaches the lower tolerance of the test

range? YES NO

b. Frequently enough (maximum 2 minutes) to detect any overshooting of the

test range? YES NO

6.5.3 After the temperatures have stabilized, are the test readings taken at 2 minute

intervals maximum for a minimum of 30 minutes? YES NO

6.5.4 Are temperatures indicated by all furnace thermocouples recorded and included as

part of the TUS record? (U11 & U13) YES NO

6.5.5 Is the actual uniformity of the furnace calculated and compared to the furnace

uniformity requirement? YES NO

6.5.6 If the TUS records indicate failure of test thermocouple(s), are the failure(s) within

acceptable limits allowed by AMS 2750E paragraph 3.5.16, or more stringent customer requirements?

YES NO NA

6.5.7 Do the TUS results meet the requirements of all applicable specifications for each

individual piece of equipment surveyed during the audit? YES NO

6.6 Offsetting NA Note: Offsetting may be applied either by internal electronic adjustment or by

manual offset of the set point as long as the method is clearly documented and followed, and complies with the specific customer requirements.

6.6.1 Is there a procedure that specifies the use of offsets? YES NO 6.6.2 Is the procedure in accordance with AMS 2750E, or more stringent customer

requirements? YES NO

6.6.3 Do records indicate that the procedure is followed? YES NO 6.6.4 Are manual offset tables clearly posted and visible to the operator? YES NO NA 6.6.5 Are electronic offsets documented and available to calibration technicians? YES NO NA 6.6.6 Does documentation exist to verify that the offsets were applied? YES NO


6.6.7 Does the procedure address how to account for and reintroduce any intentional

offsets? YES NO

6.7 Temperature Uniformity Survey Documentation 6.7.1 Does the documentation of the performed TUS includes as a minimum: a. Furnace identification name or number? YES NO b. Survey temperatures? YES NO c. TUS sensor and location identification including a detailed diagram,

description or photograph(s) of any load or rack used? YES NO

d. Time and temperature data from all recorded sensors required for furnace

instrumentation type for all zones tested (Reference AMS 2750 Rev. E section 3.5.13.3.2)?

YES NO

e. Correction factors for TUS sensors at each survey temperature? YES NO f. As found and as left TUS offsets (if used in production)? YES NO NA g. Corrected or uncorrected readings of all TUS sensors at each survey

temperature? (Readings shall be identified as corrected or uncorrected).

YES NO

h. Testing company identification (if not performed in-house)? YES NO NA i. Signature for the testing company (if not performed in-house)? YES NO NA j. Identification of technician performing the survey? YES NO k. Survey start date and time? YES NO l. Survey end date and time? YES NO m. Survey test instrument identification number? YES NO n. Indications of the test pass or fail? YES NO o. When required, documentation of furnace survey sensor failures (see 3.5.16)? YES NO NA p. Summary of corrected plus and minus TUS readings at each test temperature

after stabilization? YES NO

q. Quality Organization approval YES NO 6.7.2

Are test instrument correction factors for each channel at each survey temperature used?

YES

NO

6.7.3 Are control and/or monitoring sensor readings and corrected TUS sensor readings

within the applicable positive temperature tolerance at any time? YES NO

6.7.4 Are all readings of all TUS sensors and control or monitoring sensors within the

temperature tolerance requirements during the soak period except as allowed by AMS2750E para 3.5.16?

YES NO


7. Laboratory Furnace NA 7.1 Are the laboratory furnaces, used for response to heat treating testing per material

specifications (when a load sensor is used) tested to the requirements of AMS 2750E paragraph 3.6?

YES NO

7.2 Are laboratory furnaces, used for response to heat treating testing per material

specifications (when a load sensor is not used) tested as required for the production equipment?

YES NO

8. Quality Assurance Provisions 8.1 Does the internal procedure require that, if any instrument/sensor/test fails to meet

test requirements, or that has exceeded its test interval including any applicable permissible extension period (See AMS 2750E Table 10, or more stringent customer requirements), that the applicable equipment is taken out of service?

YES NO

8.2 Is the corrective action documented including the actions taken to bring the

instrument/sensor/test into compliance? YES NO

8.3 Does the internal procedure require that, in the event of any test failure or out-of-

tolerance condition, an evaluation of the possible effects of the non-conformance on product processed since the last successful corresponding test is performed and documented per established material review procedures?

YES NO

8.4 Does the internal procedure require that if the TUS results show a deviation of more

than the maximum allowed by specification, the cause of the difference is determined, corrected, and the equipment is re-tested before additional thermal processing in that equipment is performed, or corrected using an offset when allowed?

YES NO

8.5 Does the internal procedure require that the supplier document the evaluation of the

TUS failure and determine if parts processed were affected by any out of tolerance condition?

YES NO

8.6 If potential product impact is discovered by a test or TUS failure, are the appropriate

corrective actions taken, documented and maintained on file? YES NO NA

AC7102 8 pyrometry

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