Non-Destructive Testing

1. Non-Destructive Testing NDT Non-destructive Testing Approved for Public Release

2. Topics • Benefits and types of NDT • Electric Boat requirements • Results of Electric Boat NDT audits and typical deficiencies noted • Improving compliance Non-Destructive Testing Approved for Public Release

3. Benefits of NDT • NDT is, “an examination of an object which will not impair its future usefulness”. • NDT allows 100% examination of parts, welds, etc. when required. • Ensures compliance to specifications. • Prevents catastrophic failures. • NDT is a part of the Navy’s Level I and SUBSAFE programs. Non-Destructive Testing Approved for Public Release

4. 7 Major NDT Methods • Visual Testing (VT) • Liquid Penetrant (PT) • Magnetic Particle (MT) • Radiographic (RT) • Ultrasonic (UT) • Eddy Current (ET) • Material Verification (MV) Non-Destructive Testing Approved for Public Release

5. Topics • Benefits and Types of NDT • Electric Boat requirements • Results of Electric Boat NDT audits and typical deficiencies noted • Improving compliance Non-Destructive Testing Approved for Public Release

6. Electric Boat Requirements Methods that Electric Boat uses to invoke specific NDT requirements upon suppliers: • Standard Clauses in Purchase Order • Various Standards and Specifications (Military, Federal, ASTM, E.B. Specifications, etc.) • Electric Boat 2678, “Quality Control Requirements For Procured Material” (VPARS) Non-Destructive Testing Approved for Public Release

7. Electric Boat Requirements Non-Destructive Testing Approved for Public Release

8. Electric Boat Requirements Non-Destructive Testing Approved for Public Release

9. Electric Boat Requirements S/C 60-67 “Nondestructive Test Procedure Approval” • Requires suppliers to submit NDT procedures to EB for approval on a VPAR • Defines general requirements of NDT procedures • Applies to suppliers’ sub-tier NDT suppliers Non-Destructive Testing Approved for Public Release

10. Electric Boat Requirements • S/C 76-22A MT test reports • S/C 76-22B LP test reports • S/C 76-22C UT test reports • S/C 76-22F LP of K-Monel • S/C 76-22G 5x VT • S/C 76-22J VT test reports of castings • S/C 76-22H VT test reports for welds Non-Destructive Testing Approved for Public Release

11. Electric Boat Requirements • S/C 76-95 RT film retention by EB • S/C 76-24 Requirements for RT of castings • S/C 76-22L NDT IAW with drawings or spec Non-Destructive Testing Approved for Public Release

12. Topics • Benefits and Types of NDT • Electric Boat requirements • Results of Electric Boat NDT audits and typical deficiencies noted • Improving compliance Non-Destructive Testing Approved for Public Release

13. EB NDT Audit Results • Audited 65 of approximately 230 suppliers • Significant deficiencies noted in 29 audits • Poor audit performance rate of 44.6% Non-Destructive Testing Approved for Public Release

14. EB NDT AUDIT RESULTS Non-Destructive Testing Approved for Public Release

15. EB NDT Audit Results Categories of Deficiencies Inspector performance Qualifications Equipment Procedures Non-Destructive Testing Approved for Public Release

16. EB NDT Audit Results Inspector performance MT • 1 inch overlap not used during test • Incorrect use of field indicator • Incorrect removal of MT particles Non-Destructive Testing Approved for Public Release

17. EB NDT Audit Results Inspector performance PT • Incorrect pre-cleaning • Incomplete penetrant coverage • Improper drying of test surface during PT Non-Destructive Testing Approved for Public Release

18. EB NDT Audit Results Categories of Deficiencies Inspector performance Qualifications Equipment Procedures Non-Destructive Testing Approved for Public Release

19. EB NDT Audit Results Qualifications • Re-qualification by letter versus re-test • Inspectors qualified to AWS versus MIL-STD-271 • Wrong vision test administered • Vision test records incomplete-do not state with/without glasses • Number of test questions not in accordance with SNT-TC-1A Non-Destructive Testing Approved for Public Release

20. EB NDT Audit Results Categories of Deficiencies Inspector performance Qualifications Equipment Procedures Non-Destructive Testing Approved for Public Release

21. EB NDT Audit Results Equipment • UT equipment not calibrated properly • Gages for water temperature and pressure not calibrated during water washable PT • No field indicator at job site • No “blow ball” for removal to particles during MT Non-Destructive Testing Approved for Public Release

22. EB NDT Audit Results Categories of Deficiencies Inspector performance Qualifications Equipment Procedures Non-Destructive Testing Approved for Public Release

23. EB NDT Audit Results Procedures • Company Written Practice permits re-qualification by letter versus re-test • PT procedure does not address pre-cleaning • Procedure not approved per S/C 60-67 • Improper transfer of procedures Non-Destructive Testing Approved for Public Release

24. VPAR Approval EB EVALUATION AMC –PT-2 Rev. 1 4/30/03 with Tech No. 05-03 5/2/03 is approved for LPT of cladding to T9074-AD-GIB-010/1688 with acceptance to MIL-STD-2035 class 3 inboard, Class 1 for seating or seal area & class 2 for outboard surfaces as required by T9074-AD-GIB-010/1688. Reviewed to T9074-AS-GIB/271. Non-Destructive Testing Approved for Public Release

25. Topics • Benefits and Types of NDT • Electric Boat requirements • Results of Electric Boat NDT audits and typical deficiencies noted • Improving compliance Non-Destructive Testing Approved for Public Release

26. Improve Compliance Non-Destructive Testing Approved for Public Release

27. Improve Compliance Mil-Std-271 / Tech-Pub-271 is the top tier document over SNT-TC1A • Mil-Std-271 requires re-certification by re-examination vs. SNT-TC1A which allows recertification by satisfactory performance • Mil-Std-271 requires vision testing to Jaeger 1 lettering vs. SNT-TC1A which allows Jaeger 2 lettering Non-Destructive Testing Approved for Public Release

28. Improve Compliance Personnel Qualification Must be in accordance with Mil-Std-271 / Tech-Pub-271 Paragraph 1.6 in addition to the requirements of SNT-TC-1A, 2001. Non-Destructive Testing Approved for Public Release

29. Improve Compliance • Review your company’s “Written Practice” for compliance with BOTH Mil-Std-271 / Tech-Pub-271 and SNT-TC-1A • Inspectors’ performance must be audited periodically (recommended at least yearly) • Calibrate equipment (pressure gages, thermometers, etc.) Non-Destructive Testing Approved for Public Release

30. Improve Compliance • Transfer of NDT procedures from one activity to another activity is prohibited without specific NAVSEA approval Non-Destructive Testing Approved for Public Release

31. Improving Compliance • “The effectiveness of NDT depends upon the capabilities of the personnel who are responsible for and perform NDT”. • Questions regarding this presentation can be directed to Electric Boat Supplier Quality or Electric Boat NDT Engineering. Non-Destructive Testing Approved for Public Release

32. Conclusion Non-Destructive Testing Approved for Public Release

33. Conclusion The stakes are high! Given a choice we would rather answer a question than solve the problem Non-Destructive Testing Approved for Public Release