W912P522R0003 RTA TSpecs AppB-3.pdf

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N° : H1039500 MKB 83‐325 F DC‐01

Cont. N° : 158400

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DOCUMENT TECHNIQUE Date : 03.12.2019

TECHNICAL DOCUMENT

Titre / Title : ROTOR POLE HANDLING DEVICE‐ INSPECTION REPORT

LOAD TEST REPORT

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RAPPORT D'ANOMALIE

ANOMALY REPORT

DER NC

AR CC

Detection Chantier/ Site Erection Fournisseur/ Supplier Inspection à la réception / As Found Garantie/ POC

(*) Obligation par le fournisseur de compléter cette information/Supplier must complete this mandatory information

Numéro Projet / Project N° Unité / Unit Fournisseur / Supplier Réf. Fournisseur / Supplier Ref. : Réf. Chantier / Site Ref. :

H1039500 01 LDV Consultants Inc.

Nom du Projet / Project Name (*) # OA / PO Ligne/Line TRA TRA200325 Rev. :

Old Hickory WBS # (Budget) : Responsabilité/Responsibility

No. Dessin / Drawing Rev. # Item Site

H1039500 MKB 83-325 F TB B 402

Titre d’anomalie / Anomaly Title : Rotor pole lifting device fitting issue QTÉ/QTY 2

É m et te u r

/ I ss u er

DESCRIPTION :

Rotor pole handling device key slot thickness wrong. We raised previously on site attached NCR TRA190735. We were not able using the rotor pole handling device because the wide of the key was not enough large. We didn't remarks at this moment that the thickness of the key was not enough larger on the device too. The rotor pole handling tool shown on drawing H-1039500 MKB 83-325 F TB rev. B have a slot dimension of 1.125'' and was fabricated at this dimension (see attached picture). The issue is that the rotor pole key thickness is 1.25'', see attached picture. The tool can be used considering this interference.

INSPECTEUR / INSPECTOR : Steeve Cossette DATE : 24-03-2020

TRAITEMENT SUGGERE / DISPOSITION PROPOSAL :

We suggest, if possible after calculation, to enlarge the slot on site and load test it on site. A Tennessee professional engineer letter will be necessary too for the new design.

PLEASE SEND WORD FORMAT ONLY TO : hydro.ncr@ge.com

À réapprovisionner / Re-Order (AR) À réparer / repair: GE Fourn/Supplier (NC) Accepté dans l’état / Use as is (NC)

À refaire / Rework (AR) Accepté matériel équivalent/ Use equivalent material (DER) Modif de la conception/ Design modif (NC)

Mise au rebut / Scrap (NC) Changement au contrat / Contract Change (CC) Autres/ Others

Type de défaut / Defect Type : (voir / see HN-LS-2-Q-T-052) Code : 20-4 A B C

G E

DETAILS DE LA DISPOSITION / DISPOSITION DETAILS :

Suggested disposition is acceptable. The affected part is not structural. Using a pencil grinder or a similar tool, remove material, about 1/8”, at the interference location and on the full width of the opening. Do paint touch-up with safety yellow paint after modifications. Since the affected part is not structural, no load test is required after the modification is done.

PRESCRIT PAR / PRESCRIBED BY : DATE : 2020-03-27

D is tr ib ut io n

Fournisseur / Supplier Client : Information Approbation / Approval Traitement/ treatment

PQL / SQL / BUYER Info Action Équipe GDT / GDT Team

Montage / Site Erection Info Action Autres / Others

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A pp ro ba tio n

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Section réservée pour Client et GE / For Client & GE use only Accepté / Accepted Commentaires / Comments :

Accepté tel que noté / Accepted as noted

Refusé / Rejected Signature :

Date :

Ré-inspecté par / Re-inspected by Date Ré-inspecté par / Re-inspected by : Client (Optionnel / Optional) Date

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NDT QUALIFICATION

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" Q /1, Sylvain Lemieux Cartes de qualifications

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212523552 Texte tapé à la machine Is a certified Welding Inspector Level II and satisfy CSA W178.2 standard ''Qualification of Welding Inspector'' Valid until February 28, 2021 This certification is valid for the following code(s) and/or standard(s):

CSA W47.1-09/W59-03

Expiration of recertification after 6 years February 28, 2021

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Nom Ville Province Secteur Méthod Niveau Expiration Date de la réactivation

Lei, Yu Milton ON

EMC

EMC

EMC

MT

PT

UT

15 aoûl 2020 15 août2020 15 août2020

15 août 2020 15 août2020 15 août2O21

Leibel, Mark Vaughan ON EMC

EMC

PT

MT

15 avr.202O 15 avr.2O2O

15 avr.2030 15 avr.2030

Leis, Brooklynn Newton ON XF 1 22 ocl.2023 22 oct.2028

Leitch, Kelly Edmonton AB EMC

EMC

MT

PT

15 juil. 2020 15 juil.2020

15 juil.2O22 15 juit.2024

Leitch, Robert W.D. Kitchener ON

EMC

EMC

EMC

EMC

RT

PT

MT

UT

15 mai 2020 15 mai 2020 15 mai 202O 15 mai 2020

15 mai 2020 15 mai 2020 15 mai 2020 15 mai 2020

Leith, David Campbell River

BC

EMC

EMC

MT

UT

15 dec.2023 15 dêc.2023

15 déc.2025 15 déc.2025

Lejeune, Francois Mirabel QC EMC PT 2 15 nov.2020 15 nov.2020

Lelievre, Stephen Sault Ste Marie

ON XF 1 2 aoû12021 2 août2026

Lemaire, Hugo Sherbrooke QC

EMC

EMC

MT

PT

15 mai 2020 15 mai 2021

15 mai 2024 15 mai 2026

Lemay, Francis Maniwaki oc XF 1 21 nov.2023 21 nov.2O28

LeMay, Danial Sherwood Park AB EMC

EMC

XF

MT

PT

27 nov.2023 15 avr.2020 15 avr.2O20

27 nov.2028 15 avr.2020 15 avr.2020

Lemczyk, Tomasz Enfield NS

EMC

XF

RT

16 sept. 2021 15 avr.2A20

16 sept.2021 15 avr.2023

Lemieux, David Trois- Rivieres QC

EMC

EMC

PT

MT

15 déc.2020 15 déc.202O

15 déc.2020 15 déc.2020

Lemieux, Dominique Edmonton AB EMC

EMC

XF

PT

MT

18 mars 2025 15févr.2O23 15févr.2O23

18 mars 2025 15 lêvr.2025 15 tévr.2025

Lemieux, Eric Normand Azilda ON XF 1 16 nov.2020 16 nov.2025

Lemieux, Jean- Francois Quebec QC

EMC

EMC

MT

UT

15 oct. 2020 15 ocl.2O2O

15 oct. 2020 15 oc|.2022

Lemieux, Jimmy Jonquiere QC EMC MT 2 15 juin 2023 15 juin 2026

Lemieux, Mario Saint- Hippolyte QC

EMC

EMC

EMC

MT

UT

PT

15 tévr.2022 15févr.2025 15févr.2025

15 févr.2022 15 févr. 2030 15 févr. 2030 lami^"- Q.,1.,^i^LVrrilgu^, Uyl [I Trois- Rivières

EMC

EMC

MT

PT

15 ianv.2O25 15 janv. 2025

1 5 janv. 2030 15janv.2030

Lemire, Marc- André Shawinigan QC

EMC

EMC

UT

MT

15 iuin 2023 15 juin 2023

15 juin 2025 15 juin 2026

Lemisko, William Saskatoon SK

EMC

EMC

EMC

EMC

PT

RT

UT

MT

15 août 2020 15 août2020 15 aoûl 2020 15 août 2020

'15 août 2020 I 5 août 2020 1 5 août 2020 15 août2020

Lemke, Aaron Dean Edmonton AB XF ,l 26 nov.2O24 26nov.2O24

Lenahan, Christopher Saskatoon SK XF 1 16 ocl.2024 16 ocl.2029

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212523552 Texte tapé à la machine January 15, 2025

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212523552 Texte tapé à la machine January 15, 2030

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NDT PROCEDURES

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Quality Operating Procedure

IveyCooper

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

11135 Dayton Pike Soddy Daisy, TN 37379 Phone: (423) 493-0097 Fax: (423) 435-9620

Procedure: 9-MT-1

For

Magnetic Particle Inspection And Acceptance Standards For Ferromagnetic Welds, Base Materials And Components

Revision Date Reviewed By Approved By Issue Date 6 8/31/15 8/31/15

Revision Description

1 Incorporate changes requested by customer “ Hale Iron” for NAVSEA work for compliance withT9074-AS-GIB-010/271 requirements which replaces Mil Std 271 Paragraphs: 2.5, 9. 5 .13, 9. 5. 25, 12.1.1. 1, 12.1.1.2, 12.1.1.3, 12.3.3, 12.4.1, 12. 5

13. 5, 13.5.1, 13.5.1.1, 13.5.1.2, 13.5.1.3

2 Revised para. 13.1 to read 100 foot candles.

3 Added 3.1, and 3.2; Revised 7.3 an 9.7.5, 13.1, 19.0, and Attachment 1 to comply with 2004 ASME Section V, Article 7, 2005 Addenda.

4 Revised para. 1.0 to reference para. 2.0, and paragraph 14.0 to read Appendix 6. Added para.

16.5.

5 Changed pH in para. 9.5.2 to read 7.0 to 10.5. Para. 41.1 #4 designates criteria for B31.1 and Section III use only. Added para. 14.3.1.

6 Revised 12.5.1 for calibration of yoke requirement to comply with 2015 ASME Section V, Article 7. Instructional note moved to 13.3. Updated 9.7 to include LED ultraviolet lighting.

References to ASME Section III removed. Updated form attached.

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

1.0 Scope:

Procedure 9-MT-1 contains the specified minimum requirements that shall be used in performing Magnetic Particle testing of ferromagnetic welds, base materials and components when Magnetic Particle inspection is required by contract requirements and/or code specifications. IveyCooper SERVICES, LLC, hereafter ICS, certifies that this procedure shall meet the minimum requirements of the applicable code or standard as listed in Paragraph 2.0 of this procedure. All Magnetic Particle inspection shall be performed in accordance with contract specifications and/or governing code requirements.

2.0 Applicable Codes and/or Requirements:

The following codes shall be made part of this procedure to the extent specified. The latest edition of the code shall be used unless otherwise required by contract.

2.1 American Society For Mechanical Engineers (ASME):

1. SECTION I - Power Boilers

2. SECTION V - Nondestructive Examination

3. SECTION VIII - Pressure Vessels

4. B31.1 - Power Piping

5. B31.3 - Chemical Piping

2.2 American Society For Testing And Materials (ASTM):

1. E-109 - Dry Powder - Magnetic Particle Inspection

2. E-125 - Standard Reference Photographs for Magnetic

Particle Inspections of Ferrous Castings

3. E-709 - Magnetic Particle Examination

2.3 American Petroleum Institute (API):

1. API 620 - Low Pressure Storage Tanks

2. API 650 - Storage Tanks For Oil Storage

3. API 653 - Tank Inspection, Repair, Alteration, and

Reconstruction

4. API 1104 - Pipelines and Related Facilities

2.4 American Welding Society (AWS):

1. AWS D1.1 - Structural Welding

2.5 Military Standards (Mil Std):

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

1. NAVSEA - T9074-AS-GIB-010/271

2. Mil-Std - 6868 D

3. Mil-Std - 2035 A(SH)

3.0 Qualification Requirements:

3.1 Personnel

When Magnetic Particle inspection is to be performed in accordance with this procedure, personnel shall be qualified and certified as required by ICS QOP 18-1 or

QOP 18-2.

3.2 Procedure

When procedure qualification is specified, a change of a requirement identified as an essential variable in Table T-721 of ASME Section V, Article 7 shall require re-qualification of the written procedure by demonstration. A change of a requirement identified as a non-essential variable does not require re-qualification of the written procedure. All changes to this written procedure, whether essential or non-essential shall require revision or addendum to document change.

4.0 Safety Requirements:

4.1 When Magnetic Particle inspection is to be performed in accordance with this procedure, personnel shall make certain that the electrodes are firmly placed on the surface to be inspected prior to switching on the current and that the current is switched off prior to electrode removal to prevent arc strikes.

4.2 When Magnetic Particle inspection is to be performed in accordance with this procedure utilizing high intensity black-light, examiners shall wear safety goggles designed to absorb UV wavelength radiation.

5.0 Components For Inspection:

Ferromagnetic materials of all shapes and sizes may be examined by Magnetic Particle Testing provided the material is accessible and meets all code and/or contract requirements.

6.0 Time Of Inspection:

Final inspection shall be performed after weld or component is completed to code and/or contract specifications and final post weld heat treatment, unless otherwise specified by code and/or contract requirements.

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

7.0 Preparation Of Surface:

7.1 Welds: The weld surface and a minimum of one inch (25mm) on each side of the weld shall be dry and free of all dirt, grease, lint, scale, welding slag and spatter that could mask possible indications or interfere with interpretation.

7.2 Components: The surface to be examined shall be free of loose scale, oil, or grease. Cleaning may be accomplished using detergents, organic solvents, sand or grit blasting, etc. The method used to prepare surfaces for inspection shall be approved by code and/or contract requirements.

7.3 For “ASME Code” required inspections, all coatings must be removed prior to examination.

8.0 Magnetizing Current:

Alternating, direct, or rectified (half wave rectified or full wave rectified) current shall be used for magnetization during examination. The magnetic field must be of sufficient strength to indicate discontinuities that are unacceptable, and at the same time not be so strong as to cause excess particles to accumulate locally, possibly masking relevant indications. Alternating current shall be used for demagnetization after testing when required by code and/or contract specifications.

9.0 Magnetizing Equipment:

9.1 The following equipment shall be used for magnetization during examination:

1. 750 or 1,000 amp AC/DC half-wave low voltage machine

2. 3,000 or 4,000 amp AC/DC full-wave machine

3. Alternating current electromagnetic yoke

4. Direct current electromagnetic yoke

9.2 Cables: Size 2/0 or 4/0

9.3 Prods: Portable prod type electrical contacts usually with copper or brass tips and with a maximum open circuit voltage at prods of one (1) volt or less with a remote control switch which may be built into the handle.

9.4 Dry Magnetic Particle: Finely divided dry ferromagnetic particles manufactured by Magnaflux Corporation or equivalent. The particles shall possess high permeability and low retentivity characteristics. The particles are available in several colors and the color selected for each examination shall be one that provides the greatest contrast to the test specimen. The particles shall be applied to the test

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 specimen and excess particles removed in accordance with Paragraph 11.3.

9.5 Wet Magnetic Particle: Finely divided ferromagnetic particles manufactured by Magnaflux Corporation or equivalent. The particles shall possess high permeability and low retentivity characteristics. The particles shall be treated to impart color, fluorescent or non-fluorescent, such that they provide contrast to the test specimen. The particles shall be designed for use in a suspension vehicle. Low viscosity oil or conditioned water shall be used as the suspension vehicle. The suspension vehicle shall be applied to the test specimen in accordance with Paragraph 9.6.

9.5.1 Petroleum Distillate Vehicles: Low -viscosity light petroleum distillate vehicles shall possess the following characteristics:

1. Viscosity shall not exceed 3.0 cSt (3 mm squared/s) at 100 degrees F (37 C) and 5.0 cSt (5 mm squared/s) at the lowest temperature at which the vehicle will be used.

2. Shall have a minimum flash point of 200 degrees F (93C) so as to reduce risk of fire.

3. Shall be nonfluorescent if used with fluorescent particles.

4. Shall be non-reactive so as not to degrade suspended particles.

9.5.2 Water vehicles: Water may be used as the a suspension vehicle provided a suitable conditioning agent is added as to provide proper wetting and the following characteristics exist:

1. The vehicle shall have good wetting characteristics as to provide complete coverage of test specimen without evidence of de-wetting.

2. Shall not produce excessive foam that could interfere with the formation of indications.

3. Shall not be corrosive to test specimen or equipment in which it is used.

4. Viscosity shall not exceed 3 cSt (3 mm squared/s) at 100 degrees F (37C).

5. Shall be nonfluorescent if used with fluorescent particles.

6. Shall be non-reactive so as not to degrade suspended particles.

7. Shall have a pH balance between 7.0 and 10.5.

9.5.3 Bulk wet magnetic particle solutions shall be checked for content of ferromagnetic particles, discoloration and contamination at least once each day, when in use. Discoloration or contamination of the suspension with foreign materials that interfere with distribution, concentration, intensity, character or definition of the magnetic deposit shall require that the solution

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 container be drained, thoroughly cleaned and refilled with clean solution.

9.5.4 Concentration of bulk wet magnetic particle suspensions shall be checked prior to initial use by settling volume measurements and maintained on a daily basis. The concentration of suspended magnetic particles shall be checked in the following manner:

1. Allow re-circulating system to run for at least thirty minutes prior to testing the solution or shake container thoroughly to disperse particles in suspension.

2. Take a 100-ml portion of solution directly from hose or other device used to apply solution to test specimen, or from immersion tank, demagnetize and allow it to settle for 60 minutes for petroleum distillates or 30 minutes for water based solutions before reading.

3. The amount of particles settling at bottom of tube is indicative of particle concentration in the bath.

9.5.5 The concentration of the wet suspension shall be from 0.1 to 0.4-mL in a 100mL bath sample for fluorescent particles and from 1.2-mL to 2.4-mL in a 100-mL bath sample for non-fluorescent particles.

9.6 Wet magnetic particles, fluorescent or non-fluorescent, shall be applied to test specimen by spraying or flowing the solution over the area being examined.

9.7 With fluorescent particles, the examination is performed using ultraviolet light called black light. The following steps shall be taken when performing black light inspection:

1. Examination shall be performed in a darkened area.

2. The examiner shall remain in the darkened area a minimum of five minutes prior to performing the examination to enable his eyes to adapt to dark viewing.

3. The examiner shall not wear photochromic or permanently tinted lenses.

4. The black light shall be allowed to warm up for a minimum of five minutes prior to use or measurement of ultraviolet light intensity emitted.

Warm up minimum not required when LED ultraviolet light is used for examination.

5. The black light intensity at the surface of the test specimen shall be measured prior to use, at least once every eight hours, whenever the light power source is changed or interrupted, and upon completion of inspections.

6. A black light meter shall be used to measure black light intensity.

7. The black light intensity at the surface of the test specimen shall be a minimum of 1000 micro W/cm squared.

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

10.0 Temperature Of Test Specimen:

10.1 For Dry Magnetic Particle examination, the surface of the test specimen shall not exceed 600 degrees F (315C).

10.2 For Wet Magnetic Particle examination, the surface of the test specimen shall not exceed 135 degrees F (57C).

11.0 Sequence Of Operations:

11.1 Magnetic Particle Inspection shall be performed by the continuous method;

that is, the magnetizing current shall remain on while the test medium is being applied.

11.2 Direct or Indirect magnetization shall be used. Where the direct contact method is used, the magnetizing current is passed directly through the part creating a circular field within the part. Where the indirect method is used, a magnetic field is induced into the part creating a circular, longitudinal, or multidirectional magnetic field within the part.

11.3 Dry Continuous Technique: The flow of magnetic current shall be initiated prior to application of dry magnetic particles and terminated only after the application of powder has been completed and the excess powder has been removed. Dry magnetic powder shall be applied by means of a hand powder applicator in such a manner that a light, uniform, dust-like coating settles on the surface under test.

Excess particles shall be removed by means of dry air of sufficient force to remove the excess particles without disturbing those that are indicative of discontinuities.

Excess particles shall be removed by using a hand-actuated rubber bulb or specially designed applicator.

11.4 Wet Continuous Technique: Wet magnetic particles, fluorescent or non-fluorescent, shall meet requirements or Paragraph 9.5 and be applied to test specimen in accordance with Paragraph 9.6. The flow of magnetic current shall be initiated prior to application of wet magnetic particles and terminated only after the application of solution has been completed and the excess flow of solution has subsided.

11.5 Magnetic Field Adequacy: When it is necessary to verify magnetic field strength adequacy, a pie shaped magnetic field indicator shall be used. The indicator shall be positioned on test specimen so that the copper- plated side is away from surface of test specimen. When magnetic particles are applied simultaneously with the magnetizing force, a clearly defined line (or lines) of magnetic particles forming across the copper face of the indicator shall be considered evidence of suitable field

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6 strength.

11.6 Examination Coverage: All examinations shall be conducted with sufficient overlap to ensure 100% coverage of area to be examined at the required sensitivity.

11.7 Small holes and openings leading to obscure passages or cavities shall be plugged or masked with suitable material to prevent test medium from coming in contact with components that may be damaged by particles or particle suspensions, unless prohibited by contract and/or code requirements.

11.8 Surface Contrast Enhancement: When coatings are temporarily applied to surface of test specimen, the coating shall only be in amounts sufficient to enhance particle contrast. When coatings are applied for particle contrast, it shall be demonstrated, in accordance with Paragraph 11.5, that indications can be detected through the enhancement coating.

12.0 Magnetization Techniques:

12.1 Longitudinal Magnetization Coil Technique: With this technique, magnetization is accomplished by passing current through a multiple-turn fixed coil (or cable) that is wrapped around the part or section of the part to be examined. This produces a longitudinal magnetic field parallel to the axis of the coil. If a fixed or pre-wound coil is used, the test specimen shall be placed near the inside surface of the coil during inspection. This is especially important if the coil opening is greater than ten times the cross-section of the test specimen (low fill factor coil).

12.1.1 When using the longitudinal technique in accordance with this procedure, direct or rectified magnetizing current shall be used. The required field strength shall be calculated based on the length (L) and the diameter (D) of the part in accordance with 1, 2, or as established in 3. below. Long parts shall be examined in sections not to exceed 18 inches (460 mm), and 18 inches (460 mm) shall be used for the part (L) in calculating the required field strength. For non-cylindrical parts, (D) shall be the maximum cross-sectional diagonal:

1. Parts with L/D Ratios Equal to or Greater than 4:

(Exception- for work to Military Standards use 12.1.1.2)

The magnetizing current shall be within +/- 10% of the ampere-turns value determined as follows:

Ampere-turns = 35,000 (L/D) + 2

SERVICES, LLC

Magnetic Particle Inspection

QOP 9-MT-1

Revision: 6

For example, a part 10 inches (250 mm) long x 2 inches (50 mm) diameter has an L/D ratio of 5.

35,000 (5+2) = 5,000 ampere-turns

2. Parts with L/D Ratios Less Than 4 but not Less Than 2 and all work to Military Standards:

The magnetizing ampere-turns shall be within +/- 10% of the ampere-turns value as follows:

Ampere-turns = 45,000 L/D

3. Parts with L/D Ratios Less Than 2:

(Exception- for work to Military Standards use 12.1.1.2) An alternate form of magnetization shall be used.

12.1.2 Magnetizing Current: The current required to obtain the necessary magnetizing field strength shall be determined by dividing the ampere-turns obtained in steps 1 or 2 in Paragraph 12.2.1 by the number of turns in the coil as follows:

Amperes (meter reading) = ampere-turns turns

For example, if a 5-turn coil is used and the ampere-turns required are 5,000

5,000 5 = 1,000 amperes (+/- 10%)

12.2 Longitudinal Yoke Technique: With this technique, alternating or direct current electromagnetic yokes shall be used. This method shall only be used to detect discontinuities that are open to the surface of the test specimen. When possible, the yoke shall be rotated 90 degrees with respect to the original location and yoke leg placements shall overlap 1 (25mm) to 1 ½ inches (38mm) to assure all existing surface discontinuities are revealed. Leg spacing on yokes shall be 3 inches minimum and 8 inches maximum.

12.2.1 Each alternating current electromagnetic yoke shall have a lifting

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12.2.2 Each direct current yoke shall have a lifting power of at least 40 lb.

(181kg) at the maximum pole spacing that will be used.

12.3 Circular Magnetization Techniques: With this technique, magnetization is accomplished by passing current directly through the part to be examined or indirectly by use of a central conductor. This produces a circular magnetic field that is approximately perpendicular to the direction of current flow in the part.

12.3.1 When using the direct contact technique in accordance with this procedure, direct or rectified (half-wave rectified or full-wave rectified) magnetizing current shall be passed directly through the part being examined. The required current shall be determined using the following guidelines:

1. The current shall be 300 amp/in. (12 A/mm) to 800 amp/in. (31 A/mm) of outer diameter of part.

2. For parts with geometric shapes other than round, the greatest cross-sectional diagonal in a plane at right angles to the current flow shall determine the inches to be used in 12.3.1 (1).

3. If the current levels required for 12.3.1 cannot be obtained, the maximum current obtainable shall be used and the field adequacy shall be demonstrated in accordance with Paragraph 11.5.

12.3.2 When using the central conductor technique in accordance with this procedure, direct or rectified (half wave rectified or full wave rectified) current shall be used. The central conductor is used to examine the surfaces of ring or cylindrically shaped parts. The central conductor technique may also be used for examining the outside surfaces of these shapes. Where large diameter cylinders are to be examined, the conductor shall be positioned close to the internal surface of the cylinder. When the conductor is not centered, the circumference of the cylinder shall be used to determine the extent of the arc that may be examined for each conductor position.

12.3.3 The field strength required shall be equal to that determined in Paragraph 12.3.1 for a single turn central conductor. The magnetizing force shall be decreased in proportion to the number of times the central conductor cable passes through a hollow part. For example, if 6000 amperes are required to examine a part using a single central conductor, 3000 amperes are required when 2 turns of the through cable are used; and 1200 amperes are required if 5 turns are used. When the central conductor technique is used, magnetic field adequacy shall be verified using a magnetic particle field indicator in accordance with Paragraph 11.5. Note: All work to Military Standards must

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12.4 Circular Magnetization Prod Technique: With this technique, magnetization is accomplished by pressing portable prod type electrical contacts against the surface in the area to be examined. A remote control switch, which may be built into the prod handles, shall be used to turn current on and off after proper prod positioning to avoid arcing at prod contact.

12.4.1 When using the prod technique in accordance with this procedure, direct or rectified magnetizing current shall be used. The current shall be 100 to 125 amp/in. of prod spacing for sections ¾ inch (19mm) thick or greater and all work to Military Standards. For sections less than ¾ inch (19mm) thick on non-military standard work, the current shall be 90 to 110 amp/in. of prod spacing.

12.4.2 Prod spacing shall not be less than 3 (76mm) inches or greater than 8 inches (203mm). The prods shall be rotated 90 degrees to the first placement and prod placements shall be overlapped from 1 inch (25mm) to 1 ½ inches (38mm) to assure complete coverage.

12.4.3 Great care shall be taken in maintaining prod tip cleanliness as to minimize the risk of overheating the test specimen at point of contact and to prevent arc burns. The prod tips that contact the part shall be aluminum, copper pads, or copper braid rather than solid copper.

12.5 Calibration of Equipment: Each piece of magnetizing equipment shall be calibrated every six months, or whenever the equipment has been damaged or repaired. The accuracy of the units’ meter shall be verified by equipment traceable to N.I.S.T. Comparative readings shall be taken at three levels of current output encompassing the usable range.

12.5.1 Electromagnetic yokes magnetizing power shall verified prior to use each day the yoke is used. Yokes shall be verified after any damage or repair to the yoke. Each A/C yoke shall meet the lifting requirements of Paragraph

12.2.1. Each D/C yoke shall meet the lifting requirements of Paragraph

12.2.2. The weights used to calibrate yokes shall be verified by the manufacturer and stenciled with the applicable weight. The weight shall only be verified again if damaged in a manner that may have caused potential loss of material.

13.0 Interpretation Of Results:

13.1 With non-fluorescent particles, the examination shall be carried out using visible light at a minimum intensity of 100 foot candles (1000 Lx), 200 foot candles

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13.2 With fluorescent particles, the examination shall be performed in accordance with Paragraph 9.7.

13.3 All indications revealed by Magnetic Particle inspection shall be evaluated in respect to the acceptance standards of the referencing Code Section or contract requirements.

Note: The size of the indication used for evaluation shall be the size or the particle accumulation and not necessarily the size of the discontinuity.

13.4 Indications revealed by Magnetic Particle inspection are not necessarily discontinuities, since irrelevant indications are sometimes encountered. Irrelevant or "false" indications are quite common, but may be easily identified. Some examples of such indications are:

1. Magnetic Writing: Indications are fuzzy and can be destroyed by demagnetization. These indications are caused by contact with other steel or magnets while magnetized.

2. Change in Section: The distribution of the magnetic field in an area of change in section (key-ways or drilled holes) of the test specimen is such that the test pattern is broad and fuzzy.

3. Flow Lines: These are large groups of parallel indications that occur in some forgings when magnetized with high currents.

13.5 Indications caused by marking methods such as scribe lines and vibro-etchings may be considered non-relevant unless the inspector has reason to believe that the marking is masking a relevant indication. Other areas with indications believed to be non-relevant shall be cleaned and re-examined or shall be re-inspected by other nondestructive test methods. If subsequent re-inspection reveals like indications, they shall be considered as relevant and shall be evaluated as discontinuities.

13.5.1 For work to Military Standards, if any indications (other than scribe lines and vibro-etchings) are believed to be non-relevant, the following methods may be used to prove non-relevancy:

1. Not less than 10 percent of each type of indication shall be explored by removing the surface roughness believed to have caused the type of indication to determine if defects are present. The absence of

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2. A liquid penetrant inspection after grinding to remove the surface roughness believed to have caused the indication.

3. Other methods approved by the authorized NAVSEA representative.

13.6 A linear indication is an indication with a length greater than 3 times the width.

13.7 A rounded indication is an indication that is circular or elliptical with a maximum length 3 times the width or less.

14.0 Acceptance Standards For Welds:

14.1 ASME Sections I, VIII Division I Appendix 6, B31.1, API-620, API-650 and API-653: Indications with major dimensions greater than 1/16 inch (1.6mm) shall be considered relevant. The following relevant indications are unacceptable:

1. All relevant linear indications.

2. All rounded indications with dimensions greater than 3/16" (4.8mm).

3. Four or more rounded indications in a line separated by 1/16" (1.6mm) or less edge to edge.

4. Applicable to ASME Section B31.1 and Section III only: Ten or more rounded indications in any 6 square inches (38.7cm) of surface with the major dimension of this area not to exceed 6 inches (152mm) with this area taken in the most unfavorable location relative to the indication being evaluated.

14.2 AWS D1.1: The acceptance criteria shall be as follows unless otherwise specified by contract:

1. The welds shall have no cracks.

2. Thorough fusion shall exist between adjacent layers of weld metal and between weld metal and base metal.

3. Porosity:

a. Statically Loaded Non-tubular Connections: Complete joint penetration groove welds in butt joints transverse to the direction of computed tensile stress shall have no linear porosity. For all other groove welds and for fillet welds, the sum of linear porosity 1/32 inch

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(1mm) or greater in diameter shall not exceed 3/8 inch (10mm) in any linear inch of weld and shall not exceed ¾ inch (19mm) in any 12 inch (305mm) length of weld.

b. Cyclically Loaded Non-tubular Connections and All Tubular Connections: The frequency of linear porosity in fillet welds shall not exceed one in each 4 inches (100mm) of weld length and the maximum diameter shall not exceed 3/32 inch (2mm). Exception: For fillet welds connecting stiffeners to web, the sum of the diameters of linear porosity shall not exceed 3/8 inch (10mm) in any linear inch of weld and shall not exceed ¾ inch (19mm) in 12 inch (305mm) length of weld. Complete joint penetration groove welds in butt joints transverse to the direction of computed tensile stress shall have no linear porosity. The frequency of linear porosity in all other groove welds shall not exceed one in 4 inches (100mm) of weld length and the maximum diameter shall not exceed 3/32 inch (2mm).

14.3 ASME Section B31.3: There shall be no cracks.

14.3.1 In-Process examination is a visual examination aided by the use of liquid penetrant or magnetic particle examinations and shall be conducted in conjunction with QOP 9-VT-1 paragraph 12.4.1 and Tables 6 and 7.

14.4 API-1104: Indications with major dimensions greater than 1/16 (1.6mm) inch shall be considered relevant. The following relevant indications are unacceptable:

1. Linear indications evaluated as crater or star cracks greater than 5/32 inch (4mm).

2. Linear indications evaluated as cracks other than crater or star cracks.

3. Incomplete fusion indications in excess of 1 inch in 12 inches of weld.

4. Porosity in pipe with an O.D. > than or = to 2.375 inches (60mm):

a. Length of any elongated indication exceeds 2 inches.

b. Aggregate length of indications exceeds 8% of weld length.

c. Width of elongated indication exceeds 1/16 inch.

5. Porosity in pipe with an O.D. < than 2.375 inches (60mm):

a. Length of elongated indication exceeds three times nominal wall thickness of the thinner section being joined.

b. Width of elongated indication is greater than 1/16 inch (1.6mm).

c. Aggregate length of indications exceeds 8% of weld length.

14.5 Mil Std-2035A: Welds shall meet the requirements of the applicable fabrication document and, unless otherwise specified, the following shall apply.

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1. No linear indications, except undercut as listed in 2 and 3 below, greater than 1/16 inch in the weld and at least 1/2 inch of the adjacent base metal on each side of the weld.

2. Undercut in class 1 welds shall not exceed the lesser of 1/64 inch maximum depth measured from the unground adjacent base metal surface or ten (10) percent of the minimum thickness.

3. Undercut in class 2 and 3 welds shall not exceed the lesser of 1/32 inch or ten (10) percent of the minimum thickness. For base metal thickness 1/2 inch or greater, undercut up to 1/16 inch is allowed if the accumulated length of undercut exceeding 1/32 inch does not exceed the lesser of 15 percent of the joint length or 12 inches in any 36 inch length of weld.

4. Rounded indications 1/64 inch and less shall be disregarded for material thickness 3/16 inch and less. Rounded indications 1/32 inch and less shall be disregarded for material thickness greater than 3/16 inch. Non-linear or rounded indications meeting the standards of Figures 14-1 through 14-18 for 6 inch length of weld are acceptable. The maximum number of indications permissible for weld-length and weld-width different from that shown on Figures 14-1 through 14-18 shall be prorated. The maximum size shall not exceed the limits of Figure 14-19. When it is considered necessary for evaluation, Figure 14-19 may be used to determine the total indication area.

5. Aligned rounded indications shall be cause for rejection if one or more of the aligned indications is greater than 1/32 inch for class 1, greater than 1/16 inch for class 2, or greater than 3/32 inch for class 3.

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Figure 14-1

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Figure 14-2

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Figure 14-3

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Figure 14-4

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Figure 14-5

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Figure 14-6

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Figure 14-7

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Figure 14-8

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Figure 14-9

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Figure 14-10

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Figure 14-11

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Figure 14-12

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Figure 14-13

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Figure 14-14

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Figure 14-15

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Figure 14-16

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Figure 14-17

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Figure 14-18

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Figure 14-19

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14.6 Unacceptable discontinuities shall be considered defects and may, upon the customer's approval, be eliminated provided:

1. Repair by welding is not required, when a defect is removed and the affected area is blended into the surrounding surface to avoid sharp notches, crevices or sharp corners.

2. After a defect is believed to have been removed, and prior to making repairs, the area shall be examined by NDE methods to insure defect removal.

3. After weld repairs and/or grinding, the repaired areas shall be re-examined by Magnetic Particle inspection and by all other methods of examination that were originally required for the affected area.

4. All surface and dimensional requirements are maintained.

Note: Any disputes concerning the acceptability of a defect shall be the customer's final responsibility.

15.0 Acceptance Standards For Castings:

15.1 Acceptance standards for castings shall be noted on the applicable fabrication document and, unless otherwise specified, the following shall apply for Mil Std- 2035A.

15.1.1 Linear indications: Castings surfaces shall be free of tears, or crack-like indications longer than 1/16 inch. Other indications, such as shrinkage, cavities, cold shuts, unfused chaplets, or internal chills, are acceptable if the maximum length and maximum number of the indications meet the standards of Table 15-1.

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Table 15-1 Linear indication acceptance standards for castings (in 36 square inches of area)

Description Class Maximum indication size, in.

Maximum number of indications

Finished machine surface

3/32 1/8

3/16

Rough ground surface

1/8 3/16 1/4

As-cast surface

3/16 1/4

5/16

Notes:

1. Casting surfaces shall be free of tears or crack-like indications longer than 1/16 inch. Any area containing a linear indication greater than 1/16 inch shall be cleaned and examined at 5X magnification or ground and reinspected as necessary to assure that it is not a crack or tear. In addition, the length of any indication shall not exceed ½ the material thickness at the location where the indication occurs.

2. Randomly distributed indications 1/16 inch and less shall not be counted.

3. The distance separating two longitudinally aligned linear indications shall be not less than 4 times D, where D is the length of the longer indication.

However, when the total length of the longitudinally aligned indications does not exceed the maximum length permitted for a single indication, these aligned indications shall be considered one indication, and shall not be cause for rejection.

4. The distance separating two linear indications not longitudinally aligned shall be not less than D, where D is the length of the longer indication.

5. For inspection areas of less than 36 square inches, the maximum number of indications shall be prorated.

6. The number of linear indications shall not exceed that permitted above, even if the area does not contain any non-linear indications.

15.1.2 Non-linear indications: Non-linear indications shall be evaluated to the requirements of Table 15-2.

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Table 15-2 Non-linear indication acceptance standards for castings (in 36 square inches of area)

Description Class Maximum indication size, in.

Maximum number of indications

Finished machine surface

1/8 1/8

3/16

Rough ground surface

1/8 1/8 1/4

As-cast surface

1/8 1/4

5/16

Notes:

1. The maximum individual non-linear indication size shall be the major dimension of an indication. In addition, no indication shall exceed 1/2 the minimum design wall thickness at the location where the indication occurs.

2. Indications 1/16 inch and less shall not be counted.

3. For inspection areas of less than 36 square inches, the maximum number of indications shall be prorated.

4. Linear and non-linear indications permitted in Tables 15-1 and 15-2 may be present in the same 36 square inch inspection area. If an area contains less linear indications than permitted by Table 15-1, the maximum number of non-linear indications may be increased so that the combined total of linear and non-linear indications equals that of Tables 15-1 and 15-2. For example, class 1 finished machine surface permits six linear indications and eight non-linear indications for each 36 square inches of surface. If there were only two linear indications less than 3/32 inch length, then the non-linear indications may be increased to 12.

5. When the major dimension of a cluster of indications (four or more greater than 1/16 inch) does not exceed the maximum size permitted for a single indication, these clustered indications shall be considered as one indication, and shall not be cause for rejection. Scattered indications, separated from the cluster by 1/8 inch or more, shall not be considered as part of the cluster.

15.2 Repairs to defective areas shall be made in accordance with the applicable fabrication specification. Areas repaired by welding shall meet the applicable acceptance standard for welds.

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15.3 Acceptance standards for forgings and wrought materials shall be in accordance with applicable material specification.

16.0 Demagnetization And Post Inspection Cleaning Of The Test Specimen:

16.1 When residual magnetization in the part could interfere with subsequent processing or usage, or if code and/or contract requirements stipulate, the test specimen shall be de-magnetized.

16.2 The current used to de-magnetize test specimen shall be in accordance with Paragraph 8.1.

16.3 De-magnetization shall be accomplished by subjecting the part to a field equal to or greater than that used to magnetize the part and in nearly the same direction, then continuously reversing the field direction gradually decreasing it to zero.

16.4 De-magnetization shall be performed by one of the following methods:

1. The part shall be moved through a high intensity (5000 to 10000 ampere turns) AC Coil and then slowly withdrawn from the field of the coil. The part shall enter the coil from a distance of 12 inches (300mm) and move steadily and slowly through the coil until it is at least 36 inches (900mm) beyond the coil.

2. An AC Yoke shall be placed on the surface of part, energized, and the legs moved around the area, then slowly withdrawn from the part while still energized.

16.5 When post examination cleaning of the test specimen is required by code and/or contract, the magnetic particle material shall be removed as soon as possible with a suitable cleaner/remover or other approved method as detailed in the contract.

17.0 Reports, Records And Identifications:

17.1 ICS shall submit a complete report of all Magnetic Particle examinations to the customer's authorized representative upon completion of each inspection and/or project. This report shall be made on ICS's Magnetic Particle Inspection Report (See Attachment 1). After completion of inspection and/or project, reports become the property of the customer.

17.2 As a minimum, the following information shall be noted on the inspection report:

1. Components or Welds Inspected and Component or Weld Identification

2. Inspection Procedure Identification and Acceptance Criteria

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3. Date of Inspection and Inspector's Name and Level Of Qualification

4. Inspection Results and Weld or Component Disposition

5. Magnetizing Equipment Used and Type of Magnetic Particles Used

6. Sketch or Photograph to Show Part Geometry, Method and Direction of Field.

18.0 Enforcement Of Procedures:

It shall be the responsibility…