Magbooth_SOW_redacted.pdf

STATEMENT OF WORK

Magnetic Particle Inspection unit NSN 6635-00-361-4631

69 MXS GLOBAL HAWK

GRAND FORKS AIR FORCE BASE

GENERAL: The 69th Maintenance squadron is requesting a Magnetic Particle Inspection unit

NSN 6635-00-361-4631.

1. SET UP/TEARDOWN:

69th MXS requires the following item be delivered and installed to the following address within 120 calendar days after purchase: Grand Forks AFB, ND, 58207. The POCs for this delivery are TSgt Gonzalez and SSgt Schultz, who can be reached at 701-747-5721

2. REQUIREMENTS AND DETAILS:

NSN requirement is 6635-00-361-4631 per T.O. 33B-1-1. The unit must meet the requirements of Commercial Item Description A-A-5804B and Engineering Data List as listed below.

REFERE

NCE

PARA

REQUIREM

ENTS

REMARKS

CID 2 and

MPI Unit Visual inspection of all components to ensure all components of proper Size have been delivered as specified at contract award.

EDL 4

DD1423

Manual Presentation of Complete Manual.

Detailed inspection of equipment manual to ensure it contains the following requirements:

(A) Installation

(B) Operation

(C) Maintenance

(D) Parts catalog instructions

(E) Wiring Diagram

(F) Calibration Procedures and Adjustments.

CID 3.1.1

and 3.1.2

Ratings Ensure:

(A) The unit is capable of operating at an input power 200-240 VAC with 230 VAC nominal or 400-480 VAC with 460 VAC nominal, 50- 60 Hertz 3 phase. The unit shall have a press-to-test system indicating that the proper electricity connections have been made.

(B) The rated maximum output is at least 6000 amperes DC with not more than 6% ripple, and for AC is 5000 amperes.

CID 3.3 Magnetizing Current

Ensure the unit is capable of magnetizing work piece in the longitudinal and circular directions.

CID 3.4 Contact Head Ensure the usable distance between head and tailstocks for part contact at the maximum spacing is:

100 inches plus or minus 2 inches for Size II.

CID 3.2

and 3.4;

EDL 2b

Headstock Ensure:

(A) A fixed headstock and moveable tailstock is provided with a clamping device for supporting the work piece and providing electrical contact.

(B) Electrical contact is not made until the horizontal plunger shaft supporting the vertical contact plate assembly of the fixed headstock is pressurized to clamp the part firmly.

(C) It is fixed and located to the left of the operator.

(D) It supports and guides a horizontal plunger shaft, which supports the vertical contact plate assembly.

(E) Clamping of the work between contact plate assemblies is accomplished by means of an air cylinder attached to the plunger assembly of the headstock.

(F) The cylinder is double acting, driving the contact plate to the extended position and retracting the plate to the closed position.

(G) The direction of travel is controlled by a solenoid operated air valve, which in turn is controlled by a foot switch connected to the equipment through a flexible cord.

(H) Piston speed is controlled independently of the clamping force pressure through a needle valve arrangement.

(I) Air system controlling the cylinder speed and pressure is designed for an external air supply of at least 60 to 110 PSI.

(J) The unit has a moisture filter and pressure gauge installed in the feed air at the unit.

CID 3.2

and 3.4;

EDL 2a

Tailstock Visual inspection or as needed, physical measurement, Ensure:

(A) It is moveable to any position on the horizontal guide rails extending the full length of the unit.

(B) It has suitable guides to keep it in alignment, prevent canting, and facilitate movement and positioning.

(C) It is operated through a gear and rack system to afford movement in both directions.

(D) A positive lock is provided that is capable of holding the tailstock in a fixed position against the 300 lbs. headstock piston force.

(E) The locking device is designed to prevent damage to either the gear rack or lock if the tailstock is inadvertently cranked while in the locked position.

CID 3.2

and 3.4;

EDL 2a

Rails Visual inspection as needed, operational demonstration or physical measurement, Ensure:

(A) They are metal with the external surfaces having a smooth machine finish (64 RMS measured with a surface roughness gauge) and provides for coil and tailstock traverse.

(B) They are sufficiently sturdy to accommodate a static load equal to

1500 lbs. concentrated over an area equivalent to the tailstock base at any point along the rails (A steel block weighing 1500 lbs. and having a footprint the same as the tailstock, is placed on the rail system and the deflection measured by use of a dial indicator supported from the floor – deflection shall not be greater than ½ inch).

CID 3.2,

3.3, and

3.6, EDL

2a

Operating Controls and Indicators

Visual inspection or as needed, operational demonstration, Ensure the following are located in the unit to permit operator manipulation/viewing from the inspection station.

Foot Switch – a double action foot switch for air cylinder operation.

Speed Control Valve – controls the speed of the headstock clamping action.

Regulated Valve – controls the headstock clamping force.

Pump Switch – turns on and off the circulating pump.

Contact Coil Selector Switch – two-position switch that enables selection of contact or coil method of magnetization.

AC/DC Selector Switch – two position switch that enables selection of either AC or DC magnetizing and demagnetizing current.

Current Control Dial – calibrated infinitely variable control that regulates the current output for magnetizing current.

Magnetizing Current Push Button Switch – momentary switch that initiates a timed “shot” of two magnetizing currents. Switch to be located as specified in Magnetizing Current Push bar topic below.

Magnetizing Current Push bar –

(1) Heavy duty metal bars enable the operator to depress a magnetizing current push button from any position at the inspection station. The unit will be set up with an 18 inch copper bar between the heads and a current of 1000 amps selected.

(2) The switch actuator on the push bar assemblies is disengaged by sliding and rotating, reverting the unit to push button operation. The arms actuating the push button switches will be rotated to prevent activation of the switches by the push bar and the switches is activated as in (1) above.

Demagnetizing Current Push Button Switch – supplied so that it will only initiate the demagnetizing cycle and selection of AC or DC will be made by selection of the proper AC/DC selector switch.

Fan Switches – turns on and turns off the housing vent fans. Check for proper operation.

White Light Switch – turns the hood housing white light on and off.

AC Ammeter – indicates AC root mean square (RMS) amperes at the coil or contacts. Connect a digital voltmeter reading RMS across the shunt, read and converted to AC amperes.

(1) The meter is of the digital type capable of measuring zero to maximum output and the machine output will be varied.

(2) The meter incorporates a sample and hold display i.e., it displays the magnetizing and demagnetizing current value until either the magnetizing or demagnetizing current push button is depressed or power to the unit is terminated. In each case, the meter will retain the previous reading until the magnetizing/demagnetizing current is activated for the next cycle. The meter will not retain this reading if power is lost to the equipment.

DC Ammeter – indicates DC (full wave rectified AC) magnetizing amperes at the coil or contacts. The same meter circuit is used for both AC/DC indications procedure for testing is the same as that used to test the AC meter circuit. The meter is of the sample and hold type capable of measuring 0 to maximum output.

Function Indicators – displays that indicate the following are in progress:

(A) Magnetizing

(B) Demagnetizing

(1) A pushbutton switch on the console is supplied and these buttons internally lit to indicate magnetizing, demagnetizing, and a single light indicating power on.

(2) An additional indicator to indicate that the line switch is provided.

Tailstock Locking Control – locks the tailstock in any position along the rails. The coil positioned along the rails in several positions and the locking system engaged. A piece of material clamped between the head and tailstock and maximum clamping pressure applied. The coil shall not move when magnetically energized.

Tailstock Crank Handle – moves the tailstock to any position along the rails.

Hand Spray Nozzle – distributes the ferromagnetic particle bath over the part to be inspected. Distribute magnetic particle bath over the copper bar to prove its capability.

Air Pressure Gauge – measures the air pressure to the cylinder of the headstock clamping mechanism. Gauge readings indicate pressure directed to the headstock.

Hose pressure Regulating Cock – regulates the flow of ferromagnetic particle bath through the hose. A valve shall be provided in the line supplying magnetic particle bath that regulates the flow.

Electrical Interconnection – rigid copper bus bars for high amperage electrical connections between the power pack and the inspection station.

Longitudinal Magnetizing Coil –

(1) Use for longitudinal magnetization/ demagnetization energized by low voltage high amperage current. Connect the digital voltmeter across the input terminals and the machine energized to 3000 amps. Read the voltage along with the amperage on the unit magnetization current meter.

(2) Rail mounted and capable of being positively locked in any position on the rails.

(3) Coil on a roller assembly that prevents canting and permits easy, one-handed movement along the rails. Unlocked and moved from one end of the test bed to the other and move easily without canting.

(4) Current supplied to the coil through number 4/0 extra flexible cables attached to the rigid bus bars extending from the coil horizontally toward the rear of the table.

(5) Coil opening large enough to clear the contact plate assembly when not in use capable of resting at the extreme left, in order that the contact plate assembly on the headstock will extend beyond the face of the coil.

(6) Length through the window opening not to exceed 5 inches.

(7) Open area or inner diameter of the coil not to exceed the specified size by at least ¼ inch. Inside diameter of the coil, 16 inches. Measure at the narrowest part of the coil.

(8) Coil capable of delivering at least 15,000 ampere-turns, AC and DC.

Set the magnetic particle unit first on AC and 3000 amps, the unit energized and the current multiplied by the number of turns in the coil.

The resulting number shall not be less than 15000 – repeat test using DC test position.

AC Receptacle – Locate a standard plug receptacle furnishing 115 V AC on the control panel to permit connection of an auxiliary device requiring up to 450 watts input.

Demagnetizing Capability –

(1) Demagnetizing facilities is built into the equipment.

(2) Demagnetizing current is high amperage, low voltage reversing DC and AC decrement.

(3) The demagnetizing current decrement select is automatic or operator selectable.

(4) The maximum demagnetizing current is sufficient to demagnetize parts by the output specified. Magnetize a steel bar 1 inch diameter 12 inches long and then demagnetize and check using a magnetometer to assure demagnetization.

(5) The pushbutton switch for the automatic demagnetizing cycle when momentarily depressed initiates the automatic demagnetizing cycle. When the demagnetizing cycle has been completed, the cycle stops automatically.

(6) The equipment is designed to allow the demagnetizing current to flow either through the contact heads or mounted coil as controlled by the transfer switch relay.

(7) The demagnetizing current capable of being started at any value from 10 to 100% of the machine rating.

(8) The following demagnetizing controls (may have dual function) located on the control panel:

(A) Demagnetizing switch (start) button.

(B) Contact-coil transfer switch.

(C) Current control dial.

(D) AC/DC selector switch Duty Cycle – The equipment capable of operating at a duty cycle listed below without damage to any of the components.

(A) 10 seconds on, 3 minutes off, maximum amperage 40%.

(B) 5 seconds on, 4 minutes off, maximum amperage 100%. To assure compliance, see tests performed in paragraph 4.3.

CID 3.2

and 3.11.5;

EDL 2a

Contact Plate Visual inspection or as needed, operational demonstration or physical measurement, Ensure:

(A) The headstock contact plate unit is consisting of a suitable metal backing plate, a 3/16 inch or more copper contact plate and a ¼ inch or more lead contact plate.

(B) The tailstock contact plate is consist of a 3/16 inch or more copper plate and a ¼ inch or more lead plate properly grounded and mounted on a suitable structure.

(C) Contact plates are at least 6 inches wide and 6 inches high.

(D) The headstock contact plate assembly is securely mounted to the plunger and the tailstock contact plate assembly securely mounted to the tailstock body.

(E) The lead plates are secured by at least one screw at top center. If one screw is used, the lower edge is retained behind the contact plate shelf.

(F) Electrical connections to the headstock contact plate are copper bar with a cross section equivalent to two 4/0 cables.

(G) Where a threaded copper bar is used, a backing nut is provided.

(H) Electrical connections to the tailstock contact plate are two 4/0 extra flexible copper cables (Each contact plate shall be equipped with a shelf and a removable “V” type support).

(I) The center of pressure of the contact plate corresponds to the centerline of the magnetizing coil provided with the unit.

CID 3.2

and 3.11.5;

EDL 2a

Contact Shelf Visual inspection or as needed, physical measurement, ensure:

(A) It is suitably supported electrically insulated material no less than ½ x 1-1/2 x 6 inches with the 1-1/2 side horizontal.

(B) It incorporates provision for mounting the V notch shelf for copper braid pads.

(C) It is capable of supporting a concentrated 100 lb. load with no deflection.

(D) A V notch shelf is supplied and suitably supported electrically insulated material not less than ½ inch thick and designed to support parts up to 6 inches in diameter.

(E) The V notch support contains two mounting pins and that the pins are positioned 2-1/2 inches on each side of shelf centerline.

CID 3.2,

3.4, and 3.11.5;

Braid Pad Assemblies

Visual inspection or as needed, operational demonstration or physical measurement, ensure:

EDL 2a (A) Two replaceable copper braid pad assemblies are provided with each unit.

(B) The assemblies consist of two outer faces of copper braid with a neoprene pad at least 4 x 5 x ½ inches thick between the faces.

(C) Each face is at least 4-1/2 x 5-1/2 inches wide.

(D) Each face consists of 4 layers of 48 x 17 x 0.0126 copper braid.

(E) The braid faces are clamped together to form a good electrical contact by folding copper sheet over all cut edges and that the copper sheet measures at least ½ inch on each side after folding and extends the full length of the cut edge.

(F) The copper braid pad is mounted on a block of electrical insulating material similar in size and shape to the base of the V notch shelf, including the mounting pins.

Design and method of attaching the copper braid pad to the mounting shelf is such that when positioned on the contact plate shelf the copper braid is against the contact plate.

CID 3.2

and 3.11.6;

EDL 2a

Holding Tank

Visual inspection or as needed, operational demonstration or physical measurement, ensure:

(A) The main frame contains a tank for the inspection medium suspension.

(B) The tank shall permit solution mixing and/or agitation and collect the solution sprayed or flowed on the part to be inspected.

(C) Fabricated from 304 stainless steel (attach cert of material to this report).

(1) At least 14-gauge.

(2) Tungsten inert gas welded.

(3) Lip extending the full length of the frame.

(4) Triangular depressed fluid storage bin.

(5) Extend the full length of the processing area.

(6) Splash panel that extends at least 2 inches above the grill on all four sides.

(7) Corners rounded and the top of the splash panels if not turned shall be protected.

CID 3.2;

EDL 2a

Grill Visual inspection or as needed, physical measurement, ensure:

(A) The tank is covered between the front edge and rail and rear edge and rail by a readily removable grill.

(B) It is constructed of longitudinal horizontal number 2 grade or better hardwood slats. The slats are not less than ¾ x 2 inches in cross section with the 2 inches face vertical.

(C) The slats are suitably spaced (not greater than 3/8 inch) and assembled to form sections easily handled by one person.

(D) Slats are at least 2 sections.

(E) A corrosion resistant screen not larger than ¼ inch mesh shall be installed under each section of wood.

CID 3.2;

EDL 2a

Sump Screen Visual inspection or as needed, operational demonstration, ensure:

(A) A sump screen of #10 mesh or finer shall be provided to exclude foreign particles from entering the sump.

(B) Removal of the screen for cleaning purposes is easily accomplished without the removal of any fasteners or a large portion of the grill.

(C) Sump screen shall not be adversely affected by corrosion or deterioration from water or mineral oils.

CID 3.2

and 3.11.6;

EDL 2a

Circulation Pump

Visual inspection or as needed, operational demonstration, ensure:

(A) It is a low-pressure type entirely suitable for handling a suspension of ferromagnetic particles in the inspection medium.

(B) It is electric motor driven with a rotation speed of 1800 RPM or less.

(C) It is compact and easily accessible.

(D) The design of the pumping system precludes its building up a pressure in excess of 12 PSI at the hose discharge and precludes stalling or damage from grit or chips.

(E) It is self-draining or provided with an external drain cock.

(F) The pump motor operates satisfactorily at 50 and 60 Hz without excessive temperature rise.

(G) The pump motor is provided with suitable protection against overload and short circuit.

(H) Suitable oil resistant flexible hoses at least ½ inch nominal inside diameter are used.

(I) Hose does not extend more than 18 inches below the grill.

(J) Hose does not have threaded fittings to attach to the pump discharge line beneath the grill and onside of the splash rail.

(K) Hoses shall be provided with a lever type hand valve at the discharge end.

CID 3.6.1 Ammeters Ensure it indicates the magnetizing/ demagnetizing current flowing into the coil or between the heads by checking with a calibrated shunt placed between the contact plates and the voltage developed across the shunt read out on a digital voltmeter.

CID

3.11.2

Auxiliary Cables

Through visual inspection and physical measurement, ensure:

(A) Two auxiliary cables consist of 4/0 extra flexible insulated conductors each 15 feet long and have a 4/0 connector on each end. The insulation is heavy duty oil- resistant.

(B) Two auxiliary cables consist of 2/0 extra flexible insulated conductors, each 10-foot long and have a 4/0 connector on each end.

The insulation is heavy duty oil-resistant.

CID 3.2

and 3.11.2;

EDL 2a, 2c

Contact Clamps nsure:

(A) Contact clamps consist of two spring-loaded clamps suitable for use with the equipment in circularly magnetizing parts by passing current through the parts. The cable clamps connected to the 4/0 cables and the cables connected to the contactor block placed between the head and tailstock. The clamps will be clamped to a steel bar and current passed through the bar

(B) The clamps have insulated handles.

(C) The clamps are equipped with 4/0 connectors to allow connection of the auxiliary cables to the current supply.

CID 3.2

and 3.11.6;

EDL 2a

Circulation Pump

Visual inspection or as needed, operational demonstration, ensure:

(A) It is a low-pressure type entirely suitable for handling a suspension of ferromagnetic particles in the inspection medium.

(B) It is electric motor driven with a rotation speed of 1800 RPM or less (inspection of motor data plate).

(C) It is compact and easily accessible.

(D) The design of the pumping system precludes its building up a pressure in excess of 12 PSI at the hose discharge and precludes stalling or damage from grit or chips (A 0-25 PSI pressure gauge will be installed in place of the hose nozzle and the pump turned on. Pressure shall not exceed 12 PSI).

(E) It is self-draining or provided with an external drain cock.

(F) The pump motor operates satisfactorily at 50 and 60 Hz without excessive temperature rise.

(G) The pump motor is provided with suitable protection against overload and short circuit.

(H) Suitable oil resistant flexible hoses at least ½ inch nominal inside diameter are used.

(I) These hoses do not extend more than 18 inches below the grill.

(J) These hoses does not have threaded fittings to attach to the pump discharge line beneath the grill and onside of the splash rail.

(K) These hoses shall be provided with a lever type hand valve at the discharge end.

CID

3.11.1

Copper Rod Through visual inspection and physical measurement, ensure a copper rod 1inch in diameter and 18 inches long is provided with the equipment for use in checking the magnetizing current through the contact heads.

CID 3.2

and 3.11.4;

EDL 2a

Canopy Through visual inspection, physical measurement, or demonstration, ensure:

(A) It is consist of:

(1) A steel frame.

(2) A commercial light-darkening fabric.

(B) The canopy fabric is waterproof and solvent resistant.

(C) It is fire retardant (certificate of conformance).

(D) It forms an enclosure and folds back to facilitate the entry of parts from an overhead position.

(E) The canopy frame is designed and constructed so that it can easily be handled by one person standing in front of the unit. The canopy will be folded and unfolded to demonstrate this capability.

(F) Fold and unfold is accomplished in one operation (see E above).

(G) When the canopy is extended, the frame is not supported or restricted by the fabric.

(H) The canopy edges extend at least 8 inches below the top of the splash rail.

(I) The front center of the canopy is split to facilitate entry of personnel.

(J) The split edges overlap at least 4 inches to preclude the entrance of outside light.

(K) The canopy is equipped with a ventilating fan and white light illuminator.

(L) The ventilator fan has sufficient capability to provide a minimum of 15 air changes per hour. Calculate the area within the canopy and the fans check with an air flow meter to assure compliance.

(M) The fan and white light function independently of each other.

(N) Two fan units are provided.

(O) It shall not allow more than 2 foot-candles (20 lux) of ambient light into the inspection area.

CID 3.2

and 3.11.3;

EDL 2a

Black Light Through visual inspection, physical measurement, or demonstration, ensure:

(A) It is of the spot type.

(B) Equipped with a black light filter with a peak transmission of 365 nm plus or minus 1.0% (certificate of performance).

(C) Intensity is at least 1000 microwatts per square centimeter at a distance of 15 inches from the bulb.

CID 3.2

and 3.11.3;

EDL 2a

Lamp Housing

Through visual inspection or demonstration, ensure:

(A) It is enclosed in a metal housing fabricated with a pistol-grip handle.

(B) The lamp and filter are capable of being changed without the use of tools (accomplish an actual lamp and filter replacement).

(C) The housing is sufficiently light tight so that the visible light emitted by the lamp does not interfere with the fluorescence of the inspection material.

CID 3.2

and 3.11.3;

EDL 2a

Line Cord Through visual inspection ensure:

(A) It is at least as long as the unit’s length.

(B) It could be wounded on an enclosed spring-loaded reel.

(C) It is readily retractable and extends to any desired length between head and tailstock positions without adjustment at the reel.

CID 3.2

and 3.11.3;

EDL 2a

Light Support

Through visual inspection or demonstration, ensure:

(A) It is supplied.

(B) It is easily demounted or removed without special tools.

(C) The support contains adjustable swivel brackets that permit the light to be directed or aimed toward the part to be inspected.

(D) The red light is readily demounted or removed from the adjustable brackets without removal of any fasteners or fixtures.

CID 3.2

and 3.10;

Ground Through visual inspection and ohmmeter check, ensure the lamp housing and transformer are electrically grounded.

EDL 2a

CID 3.2

and 3.11.8;

EDL 2a

Plug Through visual inspection, ensure a parallel blade 3 wire grounding-type attachment plug is provided.

CID 3.2

and 3.11.7;

EDL 2a

Agitation System

Visual inspection or as needed, operational demonstration or physical measurement, ensure:

(A) It is provided to agitate and maintain the ferromagnetic particles in suspension.

(B) The system is adequate to uniformly mix particles and vehicle during suspension makeup, agitate and uniformly distribute particles in uniform suspension during operation.

(C) No fittings interfere with proper agitation.

CID 3.2

and 3.11.7;

EDL 2a

Agitation/ Distribution Tests

Visual inspection or as needed, operational demonstration or physical measurement, ensure:

(A) With the procedure as stated:

(1) A measured volume of kerosene (135 degrees Fahrenheit flash point or higher, at least ¾ storage tank capacity) is placed in the storage tank.

(2) A measured quantity of fluorescent magnetic particles to produce a reading of 0.5 ml per 100 ml is added to the tank.

(3) Mixing or agitation is with the pump agitation system.

(4) The mixture is agitated for 30 minutes and a 100 ml sample taken using the centrifuge tube.

(5) The mixture concentration shall be adjusted to produce a reading of

0.5 ml of solid in a 100 ml sample (If a powder or kerosene is added, an additional 30 minutes will be allowed for agitation).

(6) Shut off pump and agitation system and let stand for at least 20 hours.

(7) At the end of 20 hours or more, start the pump and run for 30 minutes and test 100 ml sample for concentration.

(8) The particle concentration shall be the same as the previous reading.

(B) The distributor is clear of the tank sides by not less than 0.375 of an inch and shall be easily removable for cleaning and repair.

(C) The system is manufactured of materials, which are not unduly affected, by corrosion or other deterioration from water or mineral oils or by interaction with other components of the system.