nes 872 part 2 procedures for first level nickel aluminium bronze castings - category 1

Procedures for First Level NickelAluminium Bronze Castings

Part 2

Validation

Ministry of Defence Defence Standard 02-872 Part 2

Issue 1 Publication Date 02 December 2002

Category 1

AMENDMENTS ISSUED SINCE PUBLICATION

AMD NO DATE OFISSUE

TEXT AFFECTED SIGNATURE &DATE

Revision Note

This Issue of this Standard has been prepared to incorporate changes to text and presentation.The technical content has been updated in line with current practice.

Historical Record

DPT 1311

1

DEFENCE STANDARD 02-872

PROCEDURES FOR FIRST LEVELNICKEL ALUMINIUM BRONZE CASTINGS

PART 2

ISSUE 1

VALIDATION

This Defence Standard

is authorised for use in MOD contracts

by the Defence Procurement Agency

and the Warship Support Agency

Published By:

Defence Procurement AgencyAn Executive Agency of the Ministry of DefenceUK Defence StandardizationKentigern House65 Brown StGlasgow G2 8EX

2

SCOPE

1. This specification is to be used for the validation of all Submarine First Level castings madeof Nickel Aluminium Bronze manufactured to Def Stan 02-747 Part 1, 2 or 4. It is to be usedto establish a baseline of data for any weld repairs, wall thickness measurements and theintegrity of the casting at manufacture.

2. Part 1 of this Defence Standard covers the policy for the recording and updating of NickelAluminium Bronze castings fitted in submarines to meet the First Level Quality Assurancerequirements in accordance with SSP 25.

3. Part 3 of this Defence Standard is to be used for the revalidation of Submarine First Levelcastings made of Nickel Aluminium Bronze manufactured to DGS 8520, DGS 348 or DefStan 02-747 Part 1, 2 or 4 which have had service use involving contact with sea water.

4. Part 4 of this Defence Standard is to be used for in-service inspections carried out outside ofthe Long Overhaul Period.

FOREWORDSponsorship

1. This Defence Standard (Def Stan) is sponsored by the Defence Procurement Agency, Ministryof Defence (MoD).

2. The complete Def Stan 02-872 comprises of:

Procedures for First Level Nickel Aluminium Bronze castings.

Part 1: Policy

Part 2: Validation

Part 3: Revalidation

Part 4: Inspections Outside of Long Overhaul Period

3. If it is found to be unsuitable for any particular requirement the MOD is to be informed inwriting of the circumstances.

4. Any user of this Defence Standard either within MOD or in industry may propose anamendment to it. Proposals for amendments that are not directly applicable to a particularcontract are to be made to the Sponsor of the Defence Standard and those directly applicableto a particular contract are to be dealt with using existing procedures or as specified in thecontract.

5. No alteration is to be made to this Defence Standard except by the issue of an authorizedamendment.

6. Unless otherwise stated, reference in this Defence Standard to approval, approved, authorizedor similar terms, means the Ministry of Defence in writing.

DEF STAN 02-872 Pt 2 / Issue 1

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7. Any significant amendments that may be made to this Defence Standard at a later date will beindicated by a vertical side line. Deletions will be indicated by 000 appearing at the end of theline interval.

8. This Defence Standard supersedes DPT 1311.

Conditions of Release

General

9. This Defence Standard has been prepared for the use of the Crown and its contractors in theexecution of contracts for the Crown. The Crown hereby excludes all liability (other thanliability for death or personal injury) whatsoever and howsoever arising (including but withoutlimitation, negligence on the part of the Crown, its servants or agents) for any loss or damagehowever caused where the Defence Standard is used for any other purpose.

10. This document is Crown Copyright and the information herein may be subject to Crown orthird party rights. It is not to be released, reproduced or published without written permissionof the MOD.

11. The Crown reserves the right to amend or modify the contents of this Defence Standardwithout consulting or informing any holder.

MoD Tender or Contract Process

12. This Defence Standard is the property of the Crown. Unless otherwise authorized in writingby the MOD, it must be returned on completion of the contract or submission of the tender inconnection with which it is issued.

13. When this Defence Standard is used in connection with a MOD tender or contract, the user isto ensure that he is in possession of the appropriate version of each document, includingrelated documents, relevant to each particular tender or contract. Enquiries in this connectionmay be made of the Authority named in the tender or contract.

14. When Defence Standards are incorporated into contracts, users are responsible for theircorrect application and for complying with contracts and any other statutory requirements.Compliance with a Defence Standard does not of itself confer immunity from legalobligations.

Categories of Naval Defence Standard

15. The Category of the Naval Defence Standard has been determined using the following criteria:

a) Category 1. If not applied may have a Critical affect on the following:Safety of the Vessel, its complement or third partiesOperational performance of the vessel, its systems or equipment.

b) Category 2. If not applied may have a Significant affect on the following;Safety of the Vessel, its complement or third partiesOperational performance of the vessel, its systems or equipment.Through life costs and support.

c) Category 3. If not applied may have a Minor affect on the following.MOD best practice and fleet commonality.Corporate experience and knowledge.Current support practice.


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Related Documents

16. In the tender and procurement processes the related documents in each Section and Annex Acan be obtained as follows:

a) British Standards British Standards Institution,389 Chiswick High Road, London, W4 4AL

b) Defence Standards Defence Procurement AgencyAn Executive Agency of the MoDUK Defence Standardization,Kentigern House, 65 Brown Street,Glasgow, G2 8EX

c) Other documents Tender of Contract Sponsor to advise. 17. All applications to Ministry Establishments for related documents are to quote the relevant

MOD Invitation to Tender or Contract Number and date, together with the sponsoringDirectorate and the Tender or Contract Sponsor.

18. Prime Contractors are responsible for supplying their subcontractors with relevantdocumentation, including specifications, standards and drawings.

Health and Safety

Warning

19. This specification calls for the use of processes, substances and procedures that may beinjurious to health if adequate precautions are not taken. It refers only to technical suitabilityand in no way absolves either the supplier or any user from statutory obligations relating tohealth and safety at any stage of manufacture or use. Where attention is drawn to hazards,those quoted may not necessarily be exhaustive.

20. This Defence Standard has been written and is to be used taking into account the policystipulated in JSP430: MOD Ship Safety Manual System Handbook.

Use of ARDROX 160 and Silver Nitrate solution

21. Before using this Defence Standard in conjunction with Ardrox and the silver nitrate solution,users should make themselves familiar with the precautionary measures set out in this Section.

22. Care is to be taken to ensure that the silver nitrate etching solution does not come into contactwith the skin or eyes, e.g. a face mask and rubber gloves must be worn.

23. Protective clothing should be worn and other measures taken as necessary in handling thematerials referred to in this Defence Standard.

24. Ardrox 160 is a proprietary product and the manufacturers health and safety instructions mustbe followed.

Additional Information

(There is no relevant information)


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CONTENTSPage No

TITLE PAGE 1

SCOPE 2

FOREWORD 2

Sponsorship 2

Conditions of Release 3

Related Documents 4

Health and Safety 4

CONTENTS 5

SECTION 1. GENERAL REQUIREMENTS 6

SECTION 2. CLEANING OF CASTINGS 72.1 Cleaning and Etching 72.2 Visual Inspection 7

SECTION 3. VALIDATION OF CASTINGS 83.1 General 83.2 Weld Repairs 83.3 Thickness Examination 83.4 Recording of Examination Results 8

SECTION 4. ACCEPTANCE CRITERIA 94.1 Weld Repairs 94.2 Wall Thickness 94.3 Quality Assurance Documentation 94.4 Stamping of castings 94.5 Records 10

ANNEX A. RELATED DOCUMENTS 11

ANNEX B. DEFINITIONS AND ABBREVIATIONS 12

ANNEX C. PROCUREMENT CHECK LIST 13

ANNEX D. VALIDATION CERTIFICATE FOR NAB CASTINGS 14

ANNEX E. CHECK LIST FOR DOCUMENTS TO BE INCLUDEDIN QA PACK FOR VALIDATED CASTINGS 15

ALPHABETICAL INDEX 16


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1. GENERAL REQUIREMENTS

Related Documents: Def Stan 02-747 Parts 1, 2 and 4, see also Annex A

a. Extensive examinations have shown that the Nickel Aluminium Bronze (NAB)castings used since the early 1960s are, to varying degrees, susceptible to normalcorrosion and selective phase attack by sea water. The selective phase corrosionoccurs under crevices and in the Heat Affected Zones (HAZ) of weld repairs. Thisdestroys the mechanical properties of the material without any obvious change in theappearance of the materials surface.

b. To limit the effect of this corrosion problem, it is necessary to examine NAB castingsprior to fitting in critical positions, and to carry out periodic examinations duringtheir life. These examinations are termed Validation and Revalidationrespectively.

c. Validation of NAB castings is to be carried out during manufacture. Castings whichhave had any previous service use in contact with sea water to be revalidated inaccordance with Part 3 of this Defence Standard.

d. All Submarine First Level sea wetted castings made of NAB manufactured to DefStan 02-747 Part 1, 2 or 4 are to be validated to the requirements of this DefenceStandard. Contracts for new NAB castings are to state where validation is required.

e. The requirements of this standard are in addition to the requirements laid out in DefStan 02-747 Part 1, 2 or 4.

f. The Validation Contractor is to demonstrate to the Design Authority that theprocedures to control and document the application of this Defence Standard are inplace before work is carried out.

g. The following documentation is to be made available to the personnel making theinspection:-

(1) drawings with dimensions and wall thicknesses.(2) all non conformance documentation (concessions etc.) affecting casting

integrity.

h. The following record sheets are required for recording results and for certification bypersonnel making the inspection:-

(1) Weld Repair Recording Sheet(2) Gridded Sketch of casting(3) Wall Thickness Recording Sheet(4) Validation Certificate


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2. CLEANING OF CASTINGS

Related Documents: Def Stan 68-188, Def Stan 02-747 Part 4, Def Stan 02-872 Part 3,see also Annex A

2.1 Cleaning and Etching

a. Castings are to be cleaned and etched to show up the weld repaired areas beforeheat treatment is carried out.

b. If a casting has been weld repaired in accordance with the requirements of DefStan 02-747 Part 4, or has not been weld repaired, then the etching process inClause 2.2d may be omitted.

c. If the casting to be examined is contaminated with grease, then it is to bedegreased in a cold agitated solvent agent to Def Stan 68-188 or similar approvedalternative for between 30 minutes and one hour. On completion of degreasing, itis to be washed in hot water (80C - 90C) for several minutes until the degreasingsolvent is removed.

d. The casting is then to be dipped for between 5 and 10 minutes in an approvedbrightening solution e.g. Ardrox 160 (available under NSN 99 220 1162) orsimilar approved alternative. This process will etch the surface of the casting,highlighting areas of weld repair. The solution must be sufficiently fresh not tocontaminate the casting surface with redeposited copper. After removal from thedip bath, the casting is to be thoroughly washed in cold fresh water to remove alltraces of the brightening solution.

e. If the castings have been heat treated in error prior to validation, the oxide film onthe surface of castings may reduce the effectiveness of the etching process.Castings therefore, which are weld repaired but which have been heat treated, maybe lightly shot blasted using fine glass beads prior to etching provided this is notso severe as to materially damage machined surfaces.

NOTE: Due to the toxicity of Ardrox 160, contractors may prefer to use an alternativegeneral etching chemical, e.g. ferric chloride. Where such a change is proposed, priorapproval should be obtained from the Design Authority.

2.2 Visual Inspection

a. In general, the appearance of the various exposed surfaces of the casting followingdipping in Ardrox 160 will be roughly as follows:

Weld metal - Dark Grey or BlackParent Metal - Mid Grey


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3. VALIDATION OF CASTINGS


3.1 General

a. The main corrosion mechanism causing concern with NAB castings is selectivephase corrosion, which occurs under crevices and biofouling (plug corrosion), oraround weld repairs in the heat affected zone (HAZ corrosion). Selective phasecorrosion can penetrate the thickness of the casting at up to 1.1mm per year withno apparent surface loss of metal.

b. Information on the location and size of weld repairs on the wetted and non-wettedsurfaces, combined with wall thickness measurements, provides baseline data foruse during the through life monitoring process for NAB castings.

c. If a casting has not been weld repaired, then the examination detailed in Clause3.2 can be omitted.

3.2 Weld Repairs

a. All areas of weld repair, in particular where the HAZ is exposed to sea water, areto be sketched or photographed and sized so that each area is referenced to anidentifiable position on the casting. The depth of weld repair is also to be noted.

3.3 Thickness Examination

a. Checks for wall thickness are to be carried out as laid out in Def Stan 02-747 Part1, 2 or 4. In addition, the areas of weld repair noted in Clause 3.2 are to bethickness checked and the results noted.

b. The use of NDE methods such as ultrasonic examination for measuring wallthickness must be supported by written procedures to a specification approved bythe Design Authority.

3.4 Recording of Examination Results

a. Each weld repair is to be given a number, which is to be marked on the weldrepair sketch and cross referenced to the Weld Repair Recording Sheet.

b. The wall thickness values are to be recorded on a Wall Thickness Recording Sheetin such a way that they are cross-referenced to a grid based sketch.

c. Grid based thickness sketches for the larger NAB castings should be availablefrom the Design Authority. If these are not available then general wall thicknessesshould be referenced to a gridded sketch at a spacing to be agreed with the DesignAuthority, which gives sufficient detail to provide confidence on the general wallthickness. For guidance the grid spacing will be typically 70 mm to 100 mm.


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4. ACCEPTANCE CRITERIA


4.1 Weld Repairs

a. All weld repairs are to meet the requirements of Def Stan 02-747 Part 2 or 4.

b. All weld repairs are to be sketched, sized and recorded on the Weld RepairRecording Sheet.

4.2 Wall Thickness

a. Wall thickness results are to comply with the drawing requirements and therequirements laid out in Def Stan 02-747 Part 1, 2 or 4 as applicable.

4.3 Quality Assurance Documentation

a. Quality Assurance Documentation is to give the actual results of all tests carried outin accordance with the requirements of Def Stan 02-747 Part 1, 2 or 4 as applicable,and is to include details of the weld procedure and weld consumables employed.

b. Records and sketches of the weld repair and wall thickness examinations carried outto the requirements of this Defence Standard are to form part of the total QAdocumentation for the casting.

c. All record sheets are to be annotated with the castings ship fitting number,description, and unique radiograph number. Records are to be retained and are to beavailable for inspection by a MoD representative on request.

d. On completion of the examination, a Validation Certificate is to be completed in theformat of Annex D. Completion of the NDE to the requirements of Defence Standard02-747 Part 1, 2 or 4 is to be documented on the Validation Certificate.

e. A check list for all the Quality Assurance documentation required for validatedSubmarine First Level NAB castings is given in Annex E. A check list of this formatshould be completed and submitted with the Quality Assurance documentation.

4.4 Stamping of Castings

a. The officer signing the validation certificate is to witness the stamping of the casting.

b. In addition to the identification requirements given in Def Stan 02-747 Part 1, 2 or 4,castings validated to the requirements of this specification are to be stamped on theflange edge H as a prefix to the radiograph number if heat treated duringmanufacture and also A if weld repaired. The letters VAL followed by the date areto be stamped as a suffix to the radiograph number.


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4.5 Records

a. A copy of the Validation Certificate, together with copies of the full set of QArecords, including Weld Repair Recording Sheet, Wall Thickness Recording Sheetand sketches/ photographs, are to accompany the casting. These are to be held by theThrough Life Records Contractor when the casting is fitted to the vessel, and are tobe available for future revalidation. The original documents are to be held by thesupplier / manufacturer until the casting is fitted to the vessel as a minimum. Thecontract will state if the supplier / manufacturer is required to retain the documentsfor a longer period.

b. The Through Life Records Contractor is to hold the master records.


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ANNEX A.

RELATED DOCUMENTS

A1. The following documents and publications are referred to in this Defence Standard:

JSP430 MOD Ship Safety Management System Handbook

Def Stan 68-188 Emulsifier for solvent cleaner

Def Stan 02-747 Requirements for Nickel Aluminium Bronze Castings and ingots

Part 1 - Nickel Aluminium Bronze (Naval alloy) centrifugal castings andingots

Part 2 - Nickel Aluminium Bronze (Naval alloy) sand castings and ingots

Part 4 - Nickel Aluminium Bronze (Naval alloy) sand castings withwelding restricted to the non-wetted surface (Class I and II castings only)

Def Stan 02-872 Procedure for First Level Nickel Aluminium Bronze Castings

Part 1 - Policy

Part 3 - Revalidation

Part 4 - Inspections Outside of Long Overhaul PeriodDGS 348 Cast Nickel Aluminium Bronze

DGS 8520 Cast Nickel Aluminium Bronze

SSP 25 Quality Assurance for Safety in Submarines


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ANNEX B.

DEFINITIONS AND ABBREVIATIONS

B1. For the purposes of this Defence Standard the following definitions and abbreviations apply:

Design Authority Authority within MOD with design responsibility for the equipment

First Level QualityAssured

Where the consequences of failure of a hull area, system or equipment aresuch that it would lead to loss of the submarine, these areas, systems andequipments will be classified First Level and additional Quality Assurancemeasures will be implemented. SSP 25 refers.

HAZ Heat Affected Zone around a weld.

NAB Nickel Aluminium Bronze to DGS 8520, DGS 348 or Def Stan 02-747

NDE Non Destructive Examination

NSN NATO Stock Number

QA Quality Assurance

Revalidation Examination of used NAB castings during their life to the requirements ofPart 3 of this Defence Standard to determine the castings fitness for furtherservice

Through LifeRecords Contractor

Facility contracted to maintain the QA records for castings through life

Validation The Post manufacture examination of new NAB castings prior to fitting incritical positions to the requirements of this part of this Defence Standard


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ANNEX C.

PROCUREMENT CHECK LIST

Notes:C.1 This check list is to ensure that certain aspects of this Naval Engineering

Standard are consulted when preparing a Procurement Specification for aparticular application.

C.2 Clauses where a preference for an option is to be used or where specific data isto be added are included in the Check List.

C.3 Each item is to be marked either:

= includedNA = not applicable

CHECKNo. CHECK

CLAUSENo.

orNA

1 State where NAB validation is required 1d2 State if the supplier / manufacturer is required

to retain casting QA documents for a specifiedperiod.

4.5a


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ANNEX D

VALIDATION CERTIFICATE FOR NAB CASTINGS

PART I - IDENTIFICATION

A. EQUIPMENT SERIAL No. F. PIL No (VSN/ )

B. UNIQUE RADIOGRAPH No. G. PIL LINE ENTRY No

C. COMPONENT DRAWING No. H. COMPONENT ADREFNO

D. SHIP FITTING No. (e.g. BS 123) I. MANUFACTURER

E. COMPONENT DESCRIPTION MATERIAL SPEC. (DEFSTAN 02-747 Pt. 1, 2 OR 4)

PART II REPAIR AND VALIDATION Signature

A. WELD AREAS MAPPED (a, b, c, etc)

B. WALL THICKNESS CHECK

C. SUBSEQUENT WELD REPAIR

D. COMPONENT HEAT TREATED

E. COMPONENT RADIOGRAPHED AND LIQUID PENETRANT EXAMINED

F. DIMENSIONAL CHECKS

G. WELD AREAS RE-MACHINED

H. INTERNAL WELD REPAIRS/ HAZ EXPOSED TO SEA WATER

Indicate action taken by signature (or NA if not applicable in appropriate box).

CONCESSION NOS

CONCESSIONS GRANTED FOR ABOVE COMPONENT

I certify that the above NAB casting has been validated in accordance with Def Stan 02-872

Part 2 and stamped *

SIGNATURE

NAME IN BLOCK LETTERS

AUTHORITY/DEPT

DATE

* FULL CASTING IDENTIFICATION TO THE REQUIREMENTS OF DEF STAN 02-747 PART1, 2 OR 4 AND DEF STAN 02-872 PART 2 TO BE INSERTED


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ANNEX E

CHECK LIST FOR DOCUMENTS TO BE INCLUDED IN QA PACK FOR VALIDATEDCASTINGS

E1. All certification and record sheets for the validated castings are to be annotated with theappropriate ship fitting number or pump serial number (as applicable), description, andunique radiograph number.

QA CERTIFICATE OF COMPLIANCE

CHEMICAL ANALYSIS RESULTS RECORD SHEET

MECHANICAL TESTS RESULTS RECORD SHEET

VISUAL INSPECTION RESULTS RECORD SHEET

LIQUID PENETRANT RESULTS RECORD SHEET

RADIOGRAPHY/ULTRASONIC RESULTS RECORD SHEET

HEAT TREATMENT CERTIFICATE

PRESSURE TEST RESULTS RECORD SHEET/ CERTIFICATE OF COMPLIANCE

VALIDATION CERTIFICATE

GRIDDED SKETCH FOR WALL THICKNESSES

WALL THICKNESS RECORDING SHEET CROSS-REFERENCED TO GRIDDEDSKETCH

SKETCH/PHOTOGRAPH OF WELD REPAIRS

WELD REPAIR RECORDING SHEET CROSS-REFERENCED TO SKETCH/PHOTOGRAPH

All QA records complete: SIGNATURE

NAME IN BLOCK LETTERS

AUTHORITY/DEPT

DATE


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AArdrox 4, 7

CCertificate

Validation 6, 9, 14, 15Concessions 6Corrosion 6, 8

DDesign Authority 8Drawings 6, 9Degreasing 7

EEtching 7

FFirst Level 6, 9

HHeat Affected Zone 6, 8Heat Treatment 7

IIdentification 9

MMaster Records 10

NNDE 8Nickel Aluminium Bronze 2, 6, 7, 8, 9

PPhotographs 8, 9

QQuality Assurance Documentation 9

RRadiograph number 9, 14, 15Records Sheets

Wall Thickness 6. 8, 9Weld Repair 6, 8, 9

SSketches 8, 9

TThrough Life Records Contractor 9

UUltrasonic Examination 8

VValidation 6, 7, 8, 9Validation Contractor 6

WWall Thickness 6, 8, 9Weld repairs 6, 7, 8, 9


ALPHABETICAL INDEX(Note: Page Numbers are given)

Inside Rear Cover

Crown Copyright 2002

Copying Only as Agreed with DStan

Defence Standards are Published by and Obtainable from:

Defence Procurement AgencyAn Executive Agency of The Ministry of Defence

UK Defence StandardizationKentigern House65 Brown Street

GLASGOW G2 8EX

DStan Helpdesk

Tel 0141 224 2531/2 Fax 0141 224 2503

Internet e-mail [email protected]

File Reference

The DStan file reference relating to work on this standard is D/DStan/69/02/872 Pt 2.

Contract Requirements

When Defence Standards are incorporated into contracts users are responsible for their correctapplication and for complying with contractual and statutory requirements. Compliance witha Defence Standard does not in itself confer immunity from legal obligations.

Revision of Defence Standards

Defence Standards are revised as necessary by up issue or amendment. It is important thatusers of Defence Standards should ascertain that they are in possession of the latest issue oramendment. Information on all Defence Standards is contained in Def Stan 00-00 Standardsfor Defence Part 3 , Index of Standards for Defence Procurement Section 4 Index of DefenceStandards and Defence Specifications published annually and supplemented regularly byStandards in Defence News (SID News). Any person who, when making use of a DefenceStandard encounters an inaccuracy or ambiguity is requested to notify the Directorate ofStandardization (DStan) without delay in order that the matter may be investigated andappropriate action taken.

CONTENTSSCOPEFOREWORDSponsorshipConditions of ReleaseRelated DocumentsHealth and Safety1. GENERAL REQUIREMENTS2. CLEANING OF CASTINGS2.1 Cleaning and Etching2.2 Visual Inspection

3. VALIDATION OF CASTINGS3.1 General3.2 Weld Repairs3.3 Thickness Examination3.4 Recording of Examination Results

4. ACCEPTANCE CRITERIA4.1 Weld Repairs4.2 Wall Thickness4.3 Quality Assurance Documentation4.4 Stamping of Castings4.5 Records

ANNEX A. RELATED DOCUMENTSANNEX B. DEFINITIONS AND ABBREVIATIONSANNEX C. PROCUREMENT CHECK LISTANNEX D VALIDATION CERTIFICATE FOR NAB CASTINGSANNEX E CHECK LIST FOR DOCUMENTS TO BE INCLUDED IN QA PACK FOR VALIDATED CASTINGSALPHABETICAL INDEX