Category 1
DATE OF
ISSUE
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
Published By:
Defence Procurement Agency
An Executive Agency of the Ministry of Defence
UK Defence Standardization
Kentigern House
65 Brown St
Glasgow G2 8EX
1
SCOPE
1.
This specification is to be used for the validation of all Submarine First Level castings made
of Nickel Aluminium Bronze manufactured to Def Stan 02-747 Part 1, 2 or 4. It is to be used
to establish a baseline of data for any weld repairs, wall thickness measurements and the
integrity of the casting at manufacture.
2.
Part 1 of this Defence Standard covers the policy for the recording and updating of Nickel
Aluminium Bronze castings fitted in submarines to meet the First Level Quality Assurance
requirements in accordance with SSP 25.
3.
Part 3 of this Defence Standard is to be used for the revalidation of Submarine First Level
castings made of Nickel Aluminium Bronze manufactured to DGS 8520, DGS 348 or Def
Stan 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 of
the Long Overhaul Period.
FOREWORD
Sponsorship
1.
This Defence Standard (Def Stan) is sponsored by the Defence Procurement Agency, Ministry
of Defence (MoD).
2.
Policy
Part 2:
Validation
Part 3:
Revalidation
Part 4:
3.
4.
Any user of this Defence Standard either within MOD or in industry may propose an
amendment to it. Proposals for amendments that are not directly applicable to a particular
contract are to be made to the Sponsor of the Defence Standard and those directly applicable
to a particular contract are to be dealt with using existing procedures or as specified in the
contract.
5.
6.
Unless otherwise stated, reference in this Defence Standard to approval, approved, authorized
or similar terms, means the Ministry of Defence in writing.
Any significant amendments that may be made to this Defence Standard at a later date will be
indicated by a vertical side line. Deletions will be indicated by 000 appearing at the end of the
line interval.
8.
9.
This Defence Standard has been prepared for the use of the Crown and its contractors in the
execution of contracts for the Crown. The Crown hereby excludes all liability (other than
liability for death or personal injury) whatsoever and howsoever arising (including but without
limitation, negligence on the part of the Crown, its servants or agents) for any loss or damage
however 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 or
third party rights. It is not to be released, reproduced or published without written permission
of the MOD.
11.
The Crown reserves the right to amend or modify the contents of this Defence Standard
without consulting or informing any holder.
MoD Tender or Contract Process
12.
This Defence Standard is the property of the Crown. Unless otherwise authorized in writing
by the MOD, it must be returned on completion of the contract or submission of the tender in
connection with which it is issued.
13.
When this Defence Standard is used in connection with a MOD tender or contract, the user is
to ensure that he is in possession of the appropriate version of each document, including
related documents, relevant to each particular tender or contract. Enquiries in this connection
may be made of the Authority named in the tender or contract.
14.
When Defence Standards are incorporated into contracts, users are responsible for their
correct application and for complying with contracts and any other statutory requirements.
Compliance with a Defence Standard does not of itself confer immunity from legal
obligations.
Categories of Naval Defence Standard
15.
The Category of the Naval Defence Standard has been determined using the following criteria:
a)
b)
c)
Related Documents
16.
In the tender and procurement processes the related documents in each Section and Annex A
can be obtained as follows:
a)
British Standards
b)
Defence Standards
c)
Other documents
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 sponsoring
Directorate and the Tender or Contract Sponsor.
18.
Prime Contractors are responsible for supplying their subcontractors with relevant
documentation, including specifications, standards and drawings.
Health and Safety
Warning
19.
This specification calls for the use of processes, substances and procedures that may be
injurious to health if adequate precautions are not taken. It refers only to technical suitability
and in no way absolves either the supplier or any user from statutory obligations relating to
health 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 policy
stipulated 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 contact
with 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 the
materials referred to in this Defence Standard.
24.
Ardrox 160 is a proprietary product and the manufacturers health and safety instructions must
be followed.
Additional Information
(There is no relevant information)
SCOPE
FOREWORD
Sponsorship
Conditions of Release
Related Documents
CONTENTS
SECTION
1.
GENERAL REQUIREMENTS
SECTION
2.
2.1
2.2
CLEANING OF CASTINGS
Cleaning and Etching
Visual Inspection
7
7
7
SECTION
3.
3.1
3.2
3.3
3.4
VALIDATION OF CASTINGS
General
Weld Repairs
Thickness Examination
Recording of Examination Results
8
8
8
8
8
SECTION
4.
4.1
4.2
4.3
4.4
4.5
ACCEPTANCE CRITERIA
Weld Repairs
Wall Thickness
Quality Assurance Documentation
Stamping of castings
Records
9
9
9
9
9
10
ANNEX A.
RELATED DOCUMENTS
11
ANNEX B.
12
ANNEX C.
13
ANNEX D.
14
ANNEX E.
15
ALPHABETICAL INDEX
16
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 normal
corrosion and selective phase attack by sea water. The selective phase corrosion
occurs under crevices and in the Heat Affected Zones (HAZ) of weld repairs. This
destroys the mechanical properties of the material without any obvious change in the
appearance of the materials surface.
b.
To limit the effect of this corrosion problem, it is necessary to examine NAB castings
prior to fitting in critical positions, and to carry out periodic examinations during
their life. These examinations are termed Validation and Revalidation
respectively.
c.
d.
All Submarine First Level sea wetted castings made of NAB manufactured to Def
Stan 02-747 Part 1, 2 or 4 are to be validated to the requirements of this Defence
Standard. 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 Def
Stan 02-747 Part 1, 2 or 4.
f.
g.
h.
The following record sheets are required for recording results and for certification by
personnel making the inspection:(1)
(2)
(3)
(4)
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
Castings are to be cleaned and etched to show up the weld repaired areas before
heat treatment is carried out.
b.
If a casting has been weld repaired in accordance with the requirements of Def
Stan 02-747 Part 4, or has not been weld repaired, then the etching process in
Clause 2.2d may be omitted.
c.
d.
e.
If the castings have been heat treated in error prior to validation, the oxide film on
the surface of castings may reduce the effectiveness of the etching process.
Castings therefore, which are weld repaired but which have been heat treated, may
be lightly shot blasted using fine glass beads prior to etching provided this is not
so severe as to materially damage machined surfaces.
NOTE: Due to the toxicity of Ardrox 160, contractors may prefer to use an alternative
general etching chemical, e.g. ferric chloride. Where such a change is proposed, prior
approval should be obtained from the Design Authority.
2.2
Visual Inspection
a.
In general, the appearance of the various exposed surfaces of the casting following
dipping in Ardrox 160 will be roughly as follows:
Weld metal
Parent Metal
3.
VALIDATION OF CASTINGS
Related Documents: Def Stan 02-747 Parts 1, 2 and 4, see also Annex A
3.1
3.2
General
a.
The main corrosion mechanism causing concern with NAB castings is selective
phase corrosion, which occurs under crevices and biofouling (plug corrosion), or
around weld repairs in the heat affected zone (HAZ corrosion). Selective phase
corrosion can penetrate the thickness of the casting at up to 1.1mm per year with
no apparent surface loss of metal.
b.
Information on the location and size of weld repairs on the wetted and non-wetted
surfaces, combined with wall thickness measurements, provides baseline data for
use during the through life monitoring process for NAB castings.
c.
If a casting has not been weld repaired, then the examination detailed in Clause
3.2 can be omitted.
Weld Repairs
a.
3.3
3.4
All areas of weld repair, in particular where the HAZ is exposed to sea water, are
to be sketched or photographed and sized so that each area is referenced to an
identifiable position on the casting. The depth of weld repair is also to be noted.
Thickness Examination
a.
Checks for wall thickness are to be carried out as laid out in Def Stan 02-747 Part
1, 2 or 4. In addition, the areas of weld repair noted in Clause 3.2 are to be
thickness checked and the results noted.
b.
The use of NDE methods such as ultrasonic examination for measuring wall
thickness must be supported by written procedures to a specification approved by
the Design Authority.
b.
The wall thickness values are to be recorded on a Wall Thickness Recording Sheet
in 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 available
from the Design Authority. If these are not available then general wall thicknesses
should be referenced to a gridded sketch at a spacing to be agreed with the Design
Authority, which gives sufficient detail to provide confidence on the general wall
thickness. For guidance the grid spacing will be typically 70 mm to 100 mm.
4.
ACCEPTANCE CRITERIA
Related Documents: Def Stan 02-747 Parts 1, 2 and 4, see also Annex A
4.1
4.2
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 Repair
Recording Sheet.
Wall Thickness
a.
4.3
4.4
Wall thickness results are to comply with the drawing requirements and the
requirements laid out in Def Stan 02-747 Part 1, 2 or 4 as applicable.
Quality Assurance Documentation is to give the actual results of all tests carried out
in 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 out
to the requirements of this Defence Standard are to form part of the total QA
documentation 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 be
available for inspection by a MoD representative on request.
d.
e.
A check list for all the Quality Assurance documentation required for validated
Submarine First Level NAB castings is given in Annex E. A check list of this format
should be completed and submitted with the Quality Assurance documentation.
Stamping of Castings
a.
The officer signing the validation certificate is to witness the stamping of the casting.
b.
4.5
Records
a.
A copy of the Validation Certificate, together with copies of the full set of QA
records, including Weld Repair Recording Sheet, Wall Thickness Recording Sheet
and sketches/ photographs, are to accompany the casting. These are to be held by the
Through Life Records Contractor when the casting is fitted to the vessel, and are to
be available for future revalidation. The original documents are to be held by the
supplier / manufacturer until the casting is fitted to the vessel as a minimum. The
contract will state if the supplier / manufacturer is required to retain the documents
for a longer period.
b.
10
The following documents and publications are referred to in this Defence Standard:
JSP430
DGS 348
DGS 8520
SSP 25
11
For the purposes of this Defence Standard the following definitions and abbreviations apply:
Design Authority
First Level Quality Where the consequences of failure of a hull area, system or equipment are
Assured
such that it would lead to loss of the submarine, these areas, systems and
equipments will be classified First Level and additional Quality Assurance
measures 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
NSN
QA
Quality Assurance
Revalidation
Through Life
Records Contractor
Validation
12
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 a
particular application.
C.2
C.3
CHECK
No.
1
2
CLAUSE
No.
CHECK
State where NAB validation is required
State if the supplier / manufacturer is required
to retain casting QA documents for a specified
period.
13
1d
4.5a
or
NA
PART I - IDENTIFICATION
A.
F.
PIL No (VSN/
B.
G.
C.
H.
COMPONENT ADREFNO
D.
I.
MANUFACTURER
E.
COMPONENT DESCRIPTION
B.
C.
D.
E.
F.
DIMENSIONAL CHECKS
G.
H.
Signature
14
All certification and record sheets for the validated castings are to be annotated with the
appropriate ship fitting number or pump serial number (as applicable), description, and
unique 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 GRIDDED
SKETCH
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
15
P
A
Photographs 8, 9
Ardrox 4, 7
C
Certificate
Validation 6, 9, 14, 15
Concessions 6
Corrosion 6, 8
D
Design Authority 8
Drawings 6, 9
Degreasing 7
R
Radiograph number 9, 14, 15
Records Sheets
Wall Thickness 6. 8, 9
Weld Repair 6, 8, 9
S
Sketches 8, 9
Etching 7
First Level 6, 9
Ultrasonic Examination 8
H
Heat Affected Zone 6, 8
Heat Treatment 7
V
Validation 6, 7, 8, 9
Validation Contractor 6
I
W
Identification 9
Wall Thickness 6, 8, 9
Weld repairs 6, 7, 8, 9
Master Records 10
N
NDE 8
Nickel Aluminium Bronze 2, 6, 7, 8, 9
16
DStan Helpdesk
Tel 0141 224 2531/2
Fax 0141 224 2503
Internet e-mail enquiries@dstan.mod.uk
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 correct
application and for complying with contractual and statutory requirements. Compliance with
a 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 that
users of Defence Standards should ascertain that they are in possession of the latest issue or
amendment. Information on all Defence Standards is contained in Def Stan 00-00 Standards
for Defence Part 3 , Index of Standards for Defence Procurement Section 4 Index of Defence
Standards and Defence Specifications published annually and supplemented regularly by
Standards in Defence News (SID News). Any person who, when making use of a Defence
Standard encounters an inaccuracy or ambiguity is requested to notify the Directorate of
Standardization (DStan) without delay in order that the matter may be investigated and
appropriate action taken.