MT Unit Product Description EZPT 0119 20Aug19.pdf

PD-AFLCMC-EZPT-19-01

20 August 2019

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

PRODUCT DESCRIPTION

MAGNETIC PARTICLE INSPECTION UNITS, 52 INCH & 100 INCH

1. SCOPE. This Product Description (PD) covers 52 inch and 100 inch wet horizontal magnetic particle inspection units, which will be capable of performing conventional magnetization of ferromagnetic parts.

2. CLASSIFICATION. The magnetic particle inspection units shall be of the following sizes:

Size I: 52 inch Size II: 100 inch

3. SALIENT CHARACTERISTICS.

3.1 General. It shall provide alternating current (AC) and full wave rectified direct current (DC) from a three-phase AC power supply.

3.1.1 The 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 are made.

3.1.2 The rated maximum output shall be at least DC 6000 amperes with not more than 6% ripple, and for AC is 5000 amperes.

3.1.3 The unit shall be self-contained requiring only connections for electrical and compressed air supply for operation.

3.2 The unit shall be capable of performing magnetic particle inspection processes as described in ASTM E1444.

3.3 The unit shall be capable of magnetizing a work piece in the longitudinal and circular directions.

Beneficial comments, recommendations, additions, deletions, clarifications, etc., and any data which may improve this document should be sent to: AFLCMC/EZPT, 5259 Warehouse Road, Bldg 2211; Room 1, Tinker AFB OK 73145-3307 or email to aflcmc-ezpt-ndio@us.af.mil.

http://www.assistdocs.com/search/document_details.cfm?ident_number=110060&StartRow=1&PaginatorPageNumber=1&doc%5Fnumber=1444&status%5Fall=ON&search%5Fmethod=BASIC mailto:aflcmc-ezpt-ndio@us.af.mil

1 August 2019

3.4 The usable distance between fixed headstock and moveable tailstock (with clamping device for supporting the work piece and providing electrical contact) at the maximum spacing shall be:

Size I 52 +/- 2 inches Size II 100 +/- 2 inches

3.5 The overall length of the unit shall be as follows:

Size I no greater than 73 inches Size II no greater than 124 inches

3.6. Instruments for inspection shall be conveniently located to permit the operator manipulation and viewing from the inspection station.

3.6.1 Digital ammeter shall display AC root mean square (RMS) amperes or DC amperes at the coil or contact. The meter shall incorporate a sample and hold the display that will reset after magnetizing or demagnetizing current push button is depressed.

3.6.2 The current control shall be continuously variable.

3.6.3 The magnetization activation switch shall be of a type that can be activated by a knee/hip push bar. The push bar shall not exceed a height of 36 inches.

3.6.4 The magnetization time shall be variable from 0.20 to 2.0 seconds.

3.6.5 The headstock pressurization shall be activated by a maintained foot switch

3.6.6 The coil shall be rail mounted, have a minimum inside diameter of 16 inches, and be capable of producing 15,000 Ampere-turns AC and DC.

3.7 The unit shall be capable of demagnetizing any work piece previously magnetized by the same unit to less than three gauss in any directions. Both automatic reversing DC and AC ramp demagnetization capabilities shall be built into the unit.

3.8 The operating air pressure range shall be at least 60 to 110 PSI.

3.9 The equipment shall be capable of operating at a 2% duty cycle at maximum output indefinitely without damage to any components.

3.10 Electrical systems components, devices, wiring and insulation shall be suitable for voltages, current and duty characteristics of the circuits in which they are used and shall meet the applicable requirements of the National Electrical Manufactures Association (NEMA).

3.11 Accessories. The following accessories shall be included:

3.11.1 A copper rod one inch in diameter by eighteen inches in length that will provide a low resistance path for determining magnetizing current through the contact heads.

3.11.2 Four auxiliary cables consisting of two No. 4/0 extra flexible insulated conductors with each cable being 15 feet in length, and two No. 2/0 extra flexible insulated cable conductors with each being 10 feet in length. Each conductor shall have a 4/0 connector on each end and shall have a suitable heavy duty, oil-resisting insulation.

3.11.3 Contact clamps consist of two spring-loaded clamps suitable for use with the equipment in circular magnetizing of parts by passing current through the parts. The cable clamps connect to the 4/0 cables and the cables connect to the contactor block placed between the head and tailstock.

3.11.4 An LED UV-A inspection lamp for reviewing fluorescent magnetic particle indications shall be provided.

3.11.4.1 UV-A inspection lamps employed to fluoresce the inspection medium shall have an initial minimum intensity of 1000 microwatts per square centimeter at 15 inches. The UV-A lamp wavelength shall be in the range of 320 to 380 nanometers (nm), with a peak intensity of 365 nm. UV-A inspection lamps shall be 110-120VAC mains powered. Except the UV-A lamp lens itself, no part of the UV-A lamp may exceed 120 °F in operation to prevent injury to personnel. LED UV-A lamps are to be used unless otherwise specified, and shall meet requirements of ASTM E3022-18 and TO 33B-1-1.

3.11.4.2 The lamp shall be mounted on a swivel bracket that shall permit the light to be directed at the parts under inspection. The lamp is connected to a line cord at least as long as the unit’s length that can be wound on an enclosed spring-loaded reel. It shall be readily retractable and extendable to any desired length between head and tailstock positions without adjustment at the reel.

3.11.5 A hood suitable for fluorescent inspections including flame retardant curtains, a white light source and ventilation fan shall be provided.

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

3.11.6 A set of replaceable copper braid pads for the headstock and tailstock contact plates.

3.11.7 A tank suitable for holding the suspension and particles with a hose long enough to reach the entire inspection area, and a nonmagnetic low pressure spray nozzle.

3.11.8 An agitation system capable of maintaining magnetic particles in suspension.

3.11.9 The unit shall be delivered with all equipment necessary for immediate operation (e.g.

circuit breaker box, air pressure regulator, air filter).

4. CALIBRATION CERTIFICATE. Calibration of ammeter to +/- 5% at full amperage, using National Institute of Standards and Testing (NIST) traceable standard, by the manufacturer is required.

5. MANUAL. One paper copy and one electronic copy (CD-ROM) of the commercial operation and maintenance instructions, part catalog, wiring diagram, installation procedures (including calibration procedures and adjustments, as applicable) following MIL-PRF-32216 shall be shipped with each item. An electronic copy of the manual(s) shall be delivered to the Contracting Officer for distribution to the Equipment Specialist and Cognizant Engineer.

6. WARRANTY. The unit shall be supplied with the commercial warranty or a one-year warranty on parts and labor, whichever is longer. Information on warranty expiration, conditions, and point of contact shall be shipped with each item.

7. APPROVED ITEMS. The contractor shall maintain the same configuration on all delivered units and technical manuals for this order. Any deviations shall be approved in advance.

8. PRODUCT CONFORMANCE

8.1 Product conformance. The products provided shall meet the salient characteristics of this Product Description, conform to the producer’s own drawings, specifications, standards and quality assurance practices, and be the same product offered for sale in the commercial market. The government reserves the right to require proof of such conformance.

8.2 Conformance testing. The government may perform acceptance testing of one item to the characteristics of section 3.

9. PACKAGING. Preservation, packing and marking shall be specified in the contract or order. The unit should be packaged to withstand 30 days outside storage without damage. Drain valves on unit shall be left open.

10. NOTES.

10.1 Metric products. Products manufactured to metric dimensions will be considered on an equal basis with those manufactured using inch-pound units, provided they fall within the tolerances specified in conversion tables contained in the latest version of FED-STD-376 and all other requirements of this CID are met. If the manufacturer elects to use metric dimensions as the basis upon which to derive or base a mechanical feature, a request shall be made to the contracting officer to determine if the product is acceptable. The contracting officer has the option of accepting or rejecting the product.

10.2 Source of Documents.

10.2.1 ASTM documents may be obtained at ASTM International - Standards Worldwide or from American Society for Testing and Materials, 100 Barr Harbor Drive, West Conshohocken, PA 19428-2959.

10.2.2 NEMA documents may be obtained at nema.org or from National Electrical Manufacturers Association, 1300 North 17th Street Suite 1752, Rosslyn, Virginia 22209.

10.2.3 Copies of TO 33B-1-1 are available online at

https://www.tinker.af.mil/Home/Technical-Orders/

10.2.4 Copies of government documents are available online at https://quicksearch.dla.mil/qsText.aspx

10.3 Ordering data.

a) Title, number, and date of this PD.

b) Specify special packaging requirements.

c) Contracting officer may request proof of certification of commercial item prior to first contract delivery.

10.4 Subject term (key word) listing.

a) Ferromagnetic

b) Inspection Unit

c) Magnetic Particle http://www.astm.org/cgi-bin/SoftCart.exe/index.shtml?E%2Bmystore http://www.astm.org/cgi-bin/SoftCart.exe/index.shtml?E%2Bmystore https://www.tinker.af.mil/Home/Technical-Orders/ https://quicksearch.dla.mil/qsText.aspx