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Non-Destructive Testing

Non-Destructive Testing. NDT. Approved for Public Release. Topics. Benefits and types of NDT Electric Boat requirements Results of Electric Boat NDT audits and typical deficiencies noted Improving compliance. Approved for Public Release. Benefits of NDT.

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Non-Destructive Testing

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  1. Non-Destructive Testing NDT Non-destructive Testing Approved for Public Release

  2. Topics • Benefits and types of NDT • Electric Boat requirements • Results of Electric Boat NDT audits and typical deficiencies noted • Improving compliance Non-Destructive Testing Approved for Public Release

  3. Benefits of NDT • NDT is, “an examination of an object which will not impair its future usefulness”. • NDT allows 100% examination of parts, welds, etc. when required. • Ensures compliance to specifications. • Prevents catastrophic failures. • NDT is a part of the Navy’s Level I and SUBSAFE programs. Non-Destructive Testing Approved for Public Release

  4. 7 Major NDT Methods • Visual Testing (VT) • Liquid Penetrant (PT) • Magnetic Particle (MT) • Radiographic (RT) • Ultrasonic (UT) • Eddy Current (ET) • Material Verification (MV) Non-Destructive Testing Approved for Public Release

  5. Topics • Benefits and Types of NDT • Electric Boat requirements • Results of Electric Boat NDT audits and typical deficiencies noted • Improving compliance Non-Destructive Testing Approved for Public Release

  6. Electric Boat Requirements Methods that Electric Boat uses to invoke specific NDT requirements upon suppliers: • Standard Clauses in Purchase Order • Various Standards and Specifications (Military, Federal, ASTM, E.B. Specifications, etc.) • Electric Boat 2678, “Quality Control Requirements For Procured Material” (VPARS) Non-Destructive Testing Approved for Public Release

  7. Electric Boat Requirements Non-Destructive Testing Approved for Public Release

  8. Electric Boat Requirements Non-Destructive Testing Approved for Public Release

  9. Electric Boat Requirements S/C 60-67 “Nondestructive Test Procedure Approval” • Requires suppliers to submit NDT procedures to EB for approval on a VPAR • Defines general requirements of NDT procedures • Applies to suppliers’ sub-tier NDT suppliers Non-Destructive Testing Approved for Public Release

  10. Electric Boat Requirements • S/C 76-22A MT test reports • S/C 76-22B LP test reports • S/C 76-22C UT test reports • S/C 76-22F LP of K-Monel • S/C 76-22G 5x VT • S/C 76-22J VT test reports of castings • S/C 76-22H VT test reports for welds Non-Destructive Testing Approved for Public Release

  11. Electric Boat Requirements • S/C 76-95 RT film retention by EB • S/C 76-24 Requirements for RT of castings • S/C 76-22L NDT IAW with drawings or spec Non-Destructive Testing Approved for Public Release

  12. Topics • Benefits and Types of NDT • Electric Boat requirements • Results of Electric Boat NDT audits and typical deficiencies noted • Improving compliance Non-Destructive Testing Approved for Public Release

  13. EB NDT Audit Results • Audited 65 of approximately 230 suppliers • Significant deficiencies noted in 29 audits • Poor audit performance rate of 44.6% Non-Destructive Testing Approved for Public Release

  14. EB NDT AUDIT RESULTS Non-Destructive Testing Approved for Public Release

  15. EB NDT Audit Results Categories of Deficiencies Inspector performance Qualifications Equipment Procedures Non-Destructive Testing Approved for Public Release

  16. EB NDT Audit Results Inspector performance MT • 1 inch overlap not used during test • Incorrect use of field indicator • Incorrect removal of MT particles Non-Destructive Testing Approved for Public Release

  17. EB NDT Audit Results Inspector performance PT • Incorrect pre-cleaning • Incomplete penetrant coverage • Improper drying of test surface during PT Non-Destructive Testing Approved for Public Release

  18. EB NDT Audit Results Categories of Deficiencies Inspector performance Qualifications Equipment Procedures Non-Destructive Testing Approved for Public Release

  19. EB NDT Audit Results Qualifications • Re-qualification by letter versus re-test • Inspectors qualified to AWS versus MIL-STD-271 • Wrong vision test administered • Vision test records incomplete-do not state with/without glasses • Number of test questions not in accordance with SNT-TC-1A Non-Destructive Testing Approved for Public Release

  20. EB NDT Audit Results Categories of Deficiencies Inspector performance Qualifications Equipment Procedures Non-Destructive Testing Approved for Public Release

  21. EB NDT Audit Results Equipment • UT equipment not calibrated properly • Gages for water temperature and pressure not calibrated during water washable PT • No field indicator at job site • No “blow ball” for removal to particles during MT Non-Destructive Testing Approved for Public Release

  22. EB NDT Audit Results Categories of Deficiencies Inspector performance Qualifications Equipment Procedures Non-Destructive Testing Approved for Public Release

  23. EB NDT Audit Results Procedures • Company Written Practice permits re-qualification by letter versus re-test • PT procedure does not address pre-cleaning • Procedure not approved per S/C 60-67 • Improper transfer of procedures Non-Destructive Testing Approved for Public Release

  24. VPAR Approval EB EVALUATION AMC –PT-2 Rev. 1 4/30/03 with Tech No. 05-03 5/2/03 is approved for LPT of cladding to T9074-AD-GIB-010/1688 with acceptance to MIL-STD-2035 class 3 inboard, Class 1 for seating or seal area & class 2 for outboard surfaces as required by T9074-AD-GIB-010/1688. Reviewed to T9074-AS-GIB/271. Non-Destructive Testing Approved for Public Release

  25. Topics • Benefits and Types of NDT • Electric Boat requirements • Results of Electric Boat NDT audits and typical deficiencies noted • Improving compliance Non-Destructive Testing Approved for Public Release

  26. Improve Compliance Non-Destructive Testing Approved for Public Release

  27. Improve Compliance Mil-Std-271 / Tech-Pub-271 is the top tier document over SNT-TC1A • Mil-Std-271 requires re-certification by re-examination vs. SNT-TC1A which allows recertification by satisfactory performance • Mil-Std-271 requires vision testing to Jaeger 1 lettering vs. SNT-TC1A which allows Jaeger 2 lettering Non-Destructive Testing Approved for Public Release

  28. Improve Compliance Personnel Qualification Must be in accordance with Mil-Std-271 / Tech-Pub-271 Paragraph 1.6 in addition to the requirements of SNT-TC-1A, 2001. Non-Destructive Testing Approved for Public Release

  29. Improve Compliance • Review your company’s “Written Practice” for compliance with BOTH Mil-Std-271 / Tech-Pub-271 and SNT-TC-1A • Inspectors’ performance must be audited periodically (recommended at least yearly) • Calibrate equipment (pressure gages, thermometers, etc.) Non-Destructive Testing Approved for Public Release

  30. Improve Compliance • Transfer of NDT procedures from one activity to another activity is prohibited without specific NAVSEA approval Non-Destructive Testing Approved for Public Release

  31. Improving Compliance • “The effectiveness of NDT depends upon the capabilities of the personnel who are responsible for and perform NDT”. • Questions regarding this presentation can be directed to Electric Boat Supplier Quality or Electric Boat NDT Engineering. Non-Destructive Testing Approved for Public Release

  32. Conclusion Non-Destructive Testing Approved for Public Release

  33. Conclusion The stakes are high! Given a choice we would rather answer a question than solve the problem Non-Destructive Testing Approved for Public Release

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