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UNCONTROLLED IF PRINTED

UNCONTROLLED IF PRINTED 161Thorn Hill Road Warrendale, PA 15086-7527 TPG-AC7102/8 REV. A TRANSPORTATION & POWER

161Thorn Hill Road

Warrendale, PA 15086-7527

TPG-AC7102/8 REV. A

TRANSPORTATION & POWER GENERATION

AUDIT CRITERIA

Issued April 21, 2015

Revised 2016-01

Superseding Rev. NA

TO BE USED ON AUDITS STARTING ON OR AFTER 10-Apr-2016

Transportation and Power Generation

AUDIT CRITERIA FOR

Heat Treating - Pyrometry

1.

1.1

SCOPE

This checklist supplements TPG-AC7102. The checklist shall apply to

Suppliers seeking Transportation and Power Generation accreditation

for Heat Treating.

2.

2.1

2.1.1

2.1.2

2.1.3

2.1.4

PYROMETRY

General Requirements

Does the supplier have an internal procedure for Pyrometry addressing

all the aspects of the AMS 2750E and other customer specifications

applicable to their operations?

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?

Is there a system in place to review Pyrometry procedures and the

results (whether performed in-house or by an outside source) to ensure

that the AMS 2750E, or more stringent customer requirements are

being met?

Are there objective evidences of these reviews?

YES

YES

YES

YES

NO

NO

NO

NO

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3.

THERMOCOUPLES

3.1

Do the thermocouples and thermocouple wires meet the calibration

YES

NO

frequency, temperatures intervals and accuracy requirements of the

AMS 2750E, or more stringent customer requirements?

3.2

3.3

3.4

3.5

3.6

3.7

3.8

3.9

3.10

3.11

3.12

3.12.1

Are the thermocouples being calibrated throughout the range in which

they are to be used?

Are the actual calibration values and errors or correction factors

reported on the certification?

Are procedures in place to ensure that the base metal thermocouples

are only recalibrated when allowed by the AMS 2750E?

Are procedures in place to ensure that the base metal thermocouples

are only reused when allowed by AMS 2750E?

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 500°F?

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

requirements for any Type K and E thermocouples when used above

500°F?

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?

Does the supplier comply with the 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?

Does the internal procedure specify when the correction factors are to

be used?

Is the application of correction factors documented in clear and

unambiguous terms?

Does the supplier determine a replacement frequency of sensors

based on supporting data (SAT, TUS, recalibration data, etc.)?

Is there an internal procedure addressing this requirement?

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

3.13

Thermocouples Made from Rolls of Thermocouple Wire

SECTION 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

Are procedures in place to ensure that the thermocouples made from

YES

NO

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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 (1°F or 0.6°C for
primary and secondary standards; 2°F or 1.1°C for all other uses

including TUS)?

3.13.2

4.

4.1

4.1.1

4.1.2

4.2

4.2.1

4.2.2

4.2.3

4.2.4

Do records indicate compliance?

INSTRUMENTATION

Testing Instrumentation

Do all test instruments have a digital display and output, and meet the

readability, calibration frequency and the accuracy requirements of

Table 3 of AMS 2750E, or more stringent customer requirements?

Does the calibration of Primary, Secondary Standard and Field Test

Instruments meet the requirements of AMS 2750E or more stringent

customer requirements?

Process Instrument Calibration

Are the calibration accuracy and frequencies in accordance with the

requirements of AMS 2750E Table 3, or more stringent customer

requirements?

Are the calibrations performed on each furnace instrument that

qualifies the furnace for the particular instrument type?

Are the instruments checked for sensitivity during calibration to meet

AMS 2750DE Table 3, Footnote (4), or more stringent customer

requirements?

Do the instrument calibration records and stickers show conformance

to the requirements of AMS 2750E, or more stringent customer

requirements?

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

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4.3
Process Recorders including Electronic Data Collection
4.3.1
Do the furnace chart recorders meet the resolution requirements of
YES
NO

AMS 2750E Table 4, or more stringent customer requirements?

4.3.2

4.3.3

4.3.4

4.4

4.4.1

4.4.2

4.4.3

Do recorder printing and chart speeds meet the requirements of AMS

2750E Table 5, or more stringent customer requirements?

Are the chart (circular and/or strip) recorder’s speed(s) verified annually

as a minimum?

Are the chart (circular and/or strip) recorder’s speed(s) accurate within

±3 minutes per hour?

YES

YES

YES

Furnace Classes and Instrumentation Types

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)

Are the furnaces instrumented for the Instrumentation Type identified

by the supplier? (See Figure 3)

Are refrigeration and quenching systems properly instrumented to meet

AMS 2750E, paragraph 3.3.3, or more stringent customer

requirements?

YES

YES

YES

NO

NO

NO

NO

NO

NO

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5.

SYSTEM ACCURACY TEST (SAT)

5.1

General

5.1.1

5.2

5.2.1

5.3

5.3.1

5.3.2

5.3.3

5.4

5.4.1

5.4.2

5.4.2.1

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?

System Accuracy Test (SAT) Waiver

If the SAT Waiver is utilized, do the procedures and practices meet all

of the requirements of AMS 2750E section 3.4.7?

System Accuracy Test (SAT) Practice

Are the SAT’s 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?

Are the SAT’s 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 SAT’s frequencies are based upon

equipment class and instrumentation type).

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).

System Accuracy Test (SAT) Methods

Are the uncorrected 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?

Do records indicate that:

The thermocouple correction factors are stated unambiguously and

used correctly?

YES

NO

SECTION NA

YES

NO

SECTION NA

YES

YES

YES

NO

NO

NO

SECTION NA

YES

YES

YES

NO

NO

NO

5.4.2.2 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

5.4.2.3 Any required corrective actions are documented and the furnace re-

YES

NO

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5.4.2.4

5.4.2.5

5.4.3

5.5

5.5.1

5.5.2

5.5.3

5.5.4

tested after any required adjustments?

Any frequency reductions are adequately documented and justified?

Do SAT results meet the requirements of all applicable specifications?

If the alternate SAT method specified in AMS 2750E, paragraph 3.4.6

is utilized, is it documented and does it meet specification

requirements?

System Accuracy Test (SAT) Resident Test Thermocouple

Is there an internal procedure documenting the use of resident test

thermocouples, including periodic verification of their position?

Are the furnace (or load) control 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).

Are resident SAT thermocouples only Type N, R or S when used at

temperatures exceeding 500°F (260°C), and nonexpendable if exposed

to temperatures above 1000°F (538°C)?

Are resident SAT thermocouples subject to the replacement or

recalibration frequency specified in AMS 2750E, or more stringent

customer requirements?

YES

YES

YES

NO

NO

NO

NA

SECTION NA

YES

YES

YES

YES

NO

NO

NO

NO

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6. TEMPERATURE UNIFORMITY SURVEY (TUS)

6.1

6.1.1

6.1.2

6.1.3

6.2

6.2.1

6.2.2

6.2.3

6.2.4

6.2.5

6.2.6

General

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?

Are initial TUS’s performed prior to production or after any repair or

modification that might have altered the temperature uniformity

characteristics? (Examples are noted in AMS 2750E, paragraph 3.5.3)

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?

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

appropriate QA documentation as to whether an initial TUS is required?

Load Condition (for TUS)

Is the load condition for the performance of the initial TUS on each

furnace documented?

Is each successive TUS performed with the same type of load

condition as the initial one?

If the heats sinks are used, do they meet the requirements of AMS

2750E paragraph 3.5.10.1 for placement and thickness?

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?

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

during the TUS?

Is the number and placement of thermocouples used for the TUS as

required per AMS 2750E, or more stringent customer requirements?

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NA

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6.3

Initial TUS

6.3.1

Do the initial test temperatures include the highest and lowest

YES

NO

temperatures for which the equipment will be used for each qualified

operating range?

6.3.2

6.4

6.4.1

6.4.2

6.4.3

6.5

6.5.1

6.5.2

6.5.2.1

6.5.2.2

If the highest and lowest test temperatures are more than 600*F (or

335°C) apart, are additional tests performed at one or more

intermediate test temperatures so that test temperatures are not more

than 600*F (or 335°C) apart?

Periodic TUS

For any operating range greater than 600°F (335°C), are periodic tests

performed at a temperature(s) within 300°F (170°C) of the maximum

and 300°F (170°C) of the minimum of each qualified operating range

and there are no more than 600°F (335°C) increments between

adjacent test temperatures, for each range as defined during the initial

survey?

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

uniformity survey at the minimum and maximum temperature of each

qualified operating range?

Are the TUS’s performed at the frequencies required by AMS 2750E

Tables 8 or 9, or more stringent customer requirements?

Temperature Uniformity Test Methods

Does the TUS recorder or data logger output the TUS data in a digital

format?

Are readings taken:

Before the first test or furnace sensor reaches the lower tolerance of

the test range?

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

the test range?

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

NA

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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
YES
NO
included as part of the TUS record?
6.5.5
Is the actual uniformity of the furnace calculated and compared to the
YES
NO
furnace uniformity requirement?
6.5.6
If the TUS records indicate catastrophic failure of test thermocouple(s),
YES
NO
NA
are the failure(s) within acceptable limits allowed by AMS 2750D
paragraph 3.5.16, or more stringent customer requirements?
6.5.7
Do the TUS results meet the requirements of all applicable
YES
NO
specifications for each individual piece of equipment surveyed during
the audit?
6.6
Offsetting
SECTION 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
YES
NO
customer requirements?
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
YES
NO
NA
technicians?
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
YES
NO
intentional offsets?
6.7
Temperature Uniformity Survey Documentation
6.7.1
Does the documentation of the performed TUS includes as a minimum:
6.7.1.1 Furnace identification name or number?
YES
NO
6.7.1.2 Survey temperatures?
YES
NO
6.7.1.3 TUS sensor and location identification including a detailed diagram,
description or photograph(s) of any load or rack used?
YES
NO
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6.7.1.4 Time and temperature data from all recorded sensors required for
YES
NO

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furnace instrumentation type for all zones tested (Reference AMS 2750
Rev. E section 3.5.13.3.2)?
6.7.1.5 Correction factors for TUS sensors at each survey temperature?
YES
NO

6.7.1.6

6.7.1.7

As found and as left TUS offsets (if used in production)?

YES

YES

NO

NO

Corrected or uncorrected readings of all TUS sensors at each survey

temperature?

6.7.1.8

6.7.1.9

6.7.1.10

6.7.1.11

6.7.1.12

6.7.1.13

6.7.1.14

6.7.1.15

6.7.1.16

6.7.1.17

6.7.2

6.7.3

6.7.4

(Readings shall be identified as corrected or uncorrected).

Testing company identification (if not performed in-house)?

Signature for the testing company (if not performed in-house)?

Identification of technician performing the survey?

Survey start date and time?

Survey end date and time?

Survey test instrument identification number?

Indications of the test pass or fail?

When required, documentation of furnace survey sensor failures (see

3.5.16)?

Summary of corrected plus and minus TUS readings at each test

temperature after stabilization?

Quality Organization approval

Are test instrument correction factors for each channel at each survey

temperature used?

Are control and/or monitoring sensor readings and corrected TUS

sensor readings within the applicable positive temperature tolerance at

any time?

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

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NO

NA

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7.

LABORATORY FURNACE

SECTION NA

7.1

Are the laboratory furnaces, used for response to heat treating testing

YES

NO

7.2

8.

8.1

8.2

8.3

8.4

8.5

8.6

per material specifications (when a load sensor is used) tested to the

requirements of AMS 2750E paragraph 3.6?

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?

QUALITY ASSURANCE PROVISIONS

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?

Is the corrective action documented including the actions taken to bring

the instrument/sensor/test into compliance?

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?

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?

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?

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

the appropriate corrective actions taken, documented and maintained

on file?

YES

YES

YES

YES

YES

YES

YES

NO

NO

NO

NO

NO

NO

NO

NA