Nondestructive Testing Reference Standards:

Utilization, Manufacturing and Custom

Applications

Phil Herman
Presenter: Phil Herman,
President/CEO
PH Tool Reference Standards, LLC.

Company founded in 1973 as manufacturer of molds

Investment in EDM technology in late 1970’s led to
NDT work

Pioneer in artificial defect machining in pipe and tube

Twenty years as executive leader of company

Recognized leader in manufacture of Reference
Standards and Calibration Blocks
Presenter: Phil Herman,
President/CEO
PH Tool Reference Standards, LLC.

Current job
 Oversee operations, work with OEMs and
industry experts on new block designs, support
sales to end-user clients and dealers worldwide
 Unique opportunity to support numerous
industries including, Oil and Gas, Power
Generation, Aerospace, Primary Metals, Dept.
of Defense, R&D, and many more

Purpose of Presentation

 What are Reference Standards?

 Distinction between Reference Standards

and Calibration Blocks

 How are each used?

 Critical aspects of manufacture and

inspection

 Interesting Custom Applications and the

latest in standard designs
Some OIL and GAS industry FAST FACTS:
• America’s oil and natural gas industry supports 9.2
million jobs and comprises 7.5 percent of GDP.

• The national average annual salary for oil and gas

exploration and production is $96,844 or about $47
per hour – more than double the average annual
salary of all occupations.

• From 2004-2007, the oil and natural gas industry

was responsible for creating nearly 2 million
additional domestic jobs.

Copyright 2010 – American Petroleum Institute, all rights

reserved. API Communications: 2010-174 | 10.15.10 | PDF
Some OIL and GAS industry FAST FACTS:

• The U.S. consumes about 19.5 million

barrels/day. A barrel of oil contains 42
gallons. So, that’s 820 million gallons of oil
per day divided by 300 million, which gives a
per person, per day consumption of
approximately 2.7 gallons, which equals
approximately 2 barrels of oil per month,
per person.

Copyright 2010 – American Petroleum Institute, all rights

reserved. API Communications: 2010-174 | 10.15.10 | PDF
 The Role of NDT in the Oil and Gas industry
• No matter how we get at it, we need to get it to a refinery and
ultimately to the consumer.
• This must be done in the safest manner possible.
• Nondestructive Testing (NDT) ensures that this critical goal is
achieved.
• Much of the equipment in our industry is metal and metals fail.
• NDT helps owners and operators to locate items of potential
failure before they create problems.
• Cracking, Corrosion, Pitting, Wall Loss, and more.
 What are Reference Standards?
• Since real or actual flawed specimens are difficult
to obtain and even more difficult to quantify, NDT
Reference Standards serve a vital role.

• They are actual items to be inspected into which

artificial, precise defects are introduced via
machining methods.

• The defects represent a variety of undesirable

conditions in varying degrees of severity.

• In this way, Reference Standards provide

repeatable NDT inspection results that allow
inspection personnel to make accept/reject
decisions.
 What are Reference Standards?
Here are a few examples:

• Pipes with EDM notches, flat-bottom

or side-drilled holes
• Tubes with notches on ID and OD, pits,
wear
• Lifting gear with simulated cracking
• Threaded Couplers
• Turbine Blades

Some examples of Reference Standards

ASME Sec. V Article 4 Angle Beam Pipe Standards with 10% deep flaws for UT

Some examples of Reference Standards

Diesel Piston in aluminum with EDM slots machined in combustion bowl for Eddy Current

Some examples of Reference Standards

Forged alloy steel nozzle with OD and ID notches for Ultrasonic Inspection
 What are Calibration Blocks?
• A non-representative block containing precision-
machined geometries (thicknesses, radii, angles,
holes and slots) that are used to calibrate or set-up
NDT equipment.
• Block used to “standardize” NDT instruments,
thereby ensuring proper function, and the ability to
perform the required inspection with confidence.
• Without calibration standards, NDT personnel are
unable to move forward with the inspection
process.
• Both calibration blocks and reference standards
must be manufactured with utmost care and
accuracy. A poorly-manufactured or uncertified
standard puts subsequent testing in doubt.
• Manufacturers ensure dimensional integrity
through an array of QA requirements that ensure
“traceability to national standards” such as NIST.
 What are Calibration Blocks?

• A few examples:
– Step Blocks for ultrasonic thickness
calibration
– IIW Test Blocks for angle beam
verification, distance calibration,
sensitivity and more
– Horizontal and Vertical Linearity
blocks
– ASTM flat-bottom hole blocks

Some examples of Calibration Blocks

Two types of Ultrasonic Thickness Blocks for accurate instrument calibration


Some examples of Calibration Blocks

IIW-Type 2 Ultrasonic Test Block


Some examples of Calibration Blocks

ASTM E 428 Flat Bottom Hole Distance Amplitude set of 19 blocks with #3 (3/64”) FBH
Critical aspects of Manufacturing and Inspection

Electrical Discharge Machining in manufacturing

simulated flaws/defects

The process of manufacturing EDM Notch Reference

Standards

Conventional Machining of Calibration Blocks

Electrical Discharge Machining (EDM)
• EDM is a metalworking operation utilizing spark
erosion for precise shaping of the metal workpiece.
The workpiece (anode) and electrical tool (electrode)
are submerged in a bath of dielectric fluid and brought
closer together until the voltage overcomes the
insulating effect of the fluid, causing a spark between
the electrode and workpiece. Consecutive discharges
produce a series of micro-craters on the workpiece
until the desired shape is achieved.

Sinker EDM Wire EDM

(Electrode in yellow) (Electrode in yellow)
Advantages of EDM over conventional “chip-making”
machining methods in making NDT Standards:

• The ability to machine extremely narrow

notches (under .001”)

• The ability to access hard-to-reach locations

such as pipe/tube IDs without the need to
section the workpiece.

• The ability to hold very close dimensional

tolerances.

• The ability to machine harder materials and

exotic alloys.
Advantages of EDM over conventional “chip-making”
machining methods in making NDT Standards:

• The ability to machine irregular shapes not

otherwise possible.

• All conductive materials are able to be

EDM'd. EDM notches can be machined on
both the OD and ID of pipe and tube.
Notches can be machined on IDs as small as
0.040".
 Typical EDM Notch process
• Item arrives at PH Tool and is uniquely identified.

• Drawings are prepared.

• Workpiece layout is completed.

• EDM parameters are established based on notch

requirements/alloy/product shape/size.

• EDM Electrodes are made.

• Workpiece is fixtured on EDM table.

• EDM test-cut may be performed.

• “Real” notch is machined. (EDM’ers say “burned”)

 The EDM process (continued)…
• Electrode is retracted and the replication material is
mixed and applied.

• Replica (two-part silicone product) is cross-sectioned

and examined at high-magnification (135 to 270X) on
Video Measurement System.

• Notch “As-built” dimensions are recorded on the

replica holder.

• Additional notches are machined.

• Certification Report providing NIST traceability is

prepared.

• Standard is prepared for return shipment to

customer.
Item arrives at PH Tool and is uniquely
identified.
EDM Electrodes are made.
 Examples of EDM Electrodes

• ID Notch electrodes for tubing standards

More examples of EDM Electrodes
Workpiece is fixtured on EDM table
EDM Notch is “burned”
More Notches…
Replication Material is mixed and applied
to notch
Replica is cross-sectioned and examined at
high-magnification (135 to 270X) on Video
Measurement System.
 Conventional Machining of
Calibration Blocks
• Order raw material (maintain heat no.
traceability)
• UT pre-scan of material
• Designer writes CNC mill program
• Saw/mill/grind to make “CNC blank”
• CNC machining center profiles block
and peck drills holes
• CNC engrave serial no., alloy, description
• Hand finish
• Final Inspection and place in inventory
• Logo application
• Certification to NIST
Standard Test Blocks
UT of material

Machining of IIW
blanks

CNC program and

verification
 Standard Test Blocks
Profile milling
of Angle Beam
block on CNC

Peck-
Peck-drilling of
IIW-
IIW-Type 1
block on CNC
Standard Test Blocks

Polishing and
hand finishing

Test Block Inventory

 Standard Test Blocks

Logo and Serial No.

application on Laser
Engraving System

Block Serial Nos.

are engraved for
traceability and
tie-
tie-in to
Certification
Report

Custom applications and the latest trends
in reference standard and cal block design

Smaller flaws (notches, FBHs, micro-holes)

Embedded or Sub-surface Flaws to meet ASME

Code Cases for Qualification Blocks

Longer, heavier standards (pipe and bar) for UT

Faster turnaround times/Emergency services

Stringent QA requirements and NIST traceability as

“home-made” standards are exposed in audits
 Cross-section of weld-embedded flaw
machined by EDM (shows height and width)
 Cross-section of weld-embedded flaw
machined by EDM (shows height and length)
 Variation from the “Standard” theme
DSC blocks with radiussed
scanning surfaces

Double-
Double-
wide IIW-
IIW-
type 2
block for
wide
transducers

Special wide step blocks in

titanium alloy

Special thickness step blocks

 Standards for Automated and Robotic
Inspection systems require a higher level
of precision.

Boeing Delta IV AUSS

Special thickness standard
with relieved steps
measuring 1”1” x 8”
8” at .020”
.020”
to .400”
.400” thickness.
 Corrosion Samples can be made using
electrodes cast from actual, in-service
corroded sections of aircraft skin or pipeline.

EDM corrosion is indistinguishable

from real corrosion.
 Ultra-Narrow EDM Notches

EDM notches for Magnetic Particle

Inspection measuring less than 0.001”
0.001”
wide at depths up to .012”
.012” in SPS
fasteners
 Microholes for Liquid Penetrant Test Props

Typical Micro-
Micro-holes are .004-
.004-.006”
.006” diameter x
.008-
.008-.010”
.010” deep.
Holes can be machined in welds in plate, pipe,
and fasteners. For Personnel qualification.
EDM Starter Notches for Crack propagation
 Questions

Phil Herman
President/CEO
PH Tool Reference Standards, LLC
Telford, PA
267-203-1600
phil@phtool.com
www.phtool.com