Developing Inspection Procedures from ASTM LPI …

1 Developing Inspection Procedures from astm LPI and MPI Standard Practices Aircra& Inspec-on and Maintenance- Higher Standards, Be9er Compliance 24-25 October, 2017. Coogee, NSW Dr Gary Mar<n, Paul Grosser and Malcolm Oakey NDT Procedures are a set of detailed instructions that enable an NDT technician to complete Inspection of critical aircraft components. Often these Procedures are produced by Original Equipment Manufacturers (OEM s), maintenance organisations and sometimes the Civil Aviation Safety Authority (CASA). What is an NDT Procedure? Is it just a list of operations to followed during an Inspection ? NO!!! It s a document that, if followed ensure not only the safety of the aircraK and NDT technician but permits traceability of results. Developing Inspection Procedures from astm LPI and MPI Standard Practices Recently CASA published Airworthiness Bulletin AWB 02-060 Issue 1 18 September 2017, NDT data - The use of during the course of maintenance.

2 This AWB applies to all aircraft and aeronautical products maintained in accordance with the 1988 Civil Aviation Regulations (CAR). The purpose of the AWB is to clarify: approval of Non Destructive Testing (NDT) data, the different ways NDT data can be presented, the precedence of different NDT data approvals, and how to control NDT data to ensure its proper use. Importantly CASA requires all non OEM NDT Procedures to have Civil Aviation Regulation (CAR), specifically CAR 2A, approval before they can become Approved Data. Developing Inspection Procedures from astm LPI and MPI Standard Practices Under the more recent 1998 Civil Aviation Safety Regulations (CASR) a Part 42 organisation, a Continuing Airworthiness Management Organisation (CAMO) is responsible for the airworthiness of the aircraft and it has the responsibility to ensure the Part 145 maintenance organisation, the Approved Maintenance Organisation (AMO) has the correct maintenance instructions.

3 The Part 145 AMO must ensure it has the correct maintenance instructions, in this case NDT Procedures . Either organisation can produce maintenance data as long as it is produced and approved as described in the respective Manual of Standards (MOS). This is a legal requirement under the regulations (CASR). Developing Inspection Procedures from astm LPI and MPI Standard Practices Where OEM Procedures are provided they must be used for the Inspection . OEM s often include the following in their Inspection Manuals: 3. References Magnetic Particle Inspection shall be carried out in accordance with Standard Practice for Magnetic Particle Examination astm E1444. astm -E-1417 is referenced when LPI is required. There are also examples where Inspection Procedures are not available or may be inappropriate for some components. Under the CAR 1988 CASA has approved a number of General Inspection Procedures for Liquid Penetrant Inspection and Magnetic Particle Inspection - attached to draft Civil Aviation Advisory Publication (CAAP) 33-02.

4 These Procedures may be considered approved maintenance data Developing Inspection Procedures from astm LPI and MPI Standard Practices Use of this maintenance data is subject to the following conditions : the maintenance data mentioned in paragraph 2A(2)(a), (b), (c) or (d) of CAR is inadequate for the purpose the person carrying out the maintenance on the aircraft, aircraft component or aircraft material first determines that the instructions are: o appropriate to the aircraft, aircraft component or aircraft material to be maintained o directly applicable to the maintenance that is to be carried out o not contrary to, or inconsistent with the manufacturer s data; or any other applicable approved maintenance data mentioned in regulation 2A of CAR. Some of the Procedures in the CAAP may be used in place of: Australian Standard (AS) 2062 American Society for Testing and Materials ( astm )-E-1417 or a European equivalent a generic European Standard for penetrant testing a Department of Defence standard for penetrant testing Developing Inspection Procedures from astm LPI and MPI Standard Practices These Procedures could also provide the basis for maintenance data developed under the 1988 CASR.

5 Material contained in the Draft CAAP 30-02 only covers the Inspection portion of the Inspection procedure. More material will be required to create a complete Inspection Procedure and this will be outlined later. Procedures developed for any components need to refer back to the requirements of the astm Standards upon which it must be based, either astm E 1417 or astm E 1417. Procedures may be drafted by an NDT Level 3 or by an NDT Level 2 Technician approved in the relevant method. Procedures should follow a consistent format and after drafting need to be reviewed by a Level 3 NDT Technician who may make amendments before approving the procedure. Under the 1988 CAR once the Level 3 has approved the Procedure it must be forwarded to CASA for CAR 2A (4) approval or to an authorised delegate for approval prior to use. Developing Inspection Procedures from astm LPI and MPI Standard Practices Procedure Format standard formats should be followed to ensure no steps are overlooked nor important material omitted.

6 A typical standard format for surface method NDT Procedures is: 1. Procedure designation - A unique identifier for a stand-alone document. Including aircraft type, Inspection Method, Inspection by name or number, issue number and date. eg: ATTAR/B200/LPI/wing spars 1 issue 1 dated 13 October 2017. Provision for revision must be made. 2. Procedure title - A clear concise statement, including aircraft type, Inspection method and approximate location of the Inspection . The title should be in bold type larger than normal text. authority A table including Author, Position of the Author and signature, Date of Issue, Regulatory Authority Approval, Number, Name and Signature. 4. Introduction a paragraph briefly outlining reason for Inspection linking it to an Airworthiness Directive (AD) or similar. Use photographs or diagrams showing Inspection location within the aircraft or component Developing Inspection Procedures from astm LPI and MPI Standard Practices 5.

7 Scope a paragraph indicating what the procedure is applicable to, what type of defects, and minimum detectable defects sought. Detection reliability should be included here. 6. Personnel qualification and level - Refers to the NAS 410 level; Trainee, Level 1 Limited, Level 1, 2 or 3 classification of the NDI Technician eligible to carry out the Procedure. 7. References Include all relevant references, astm E 1444, here. 8. Safety - All safety requirements covering equipment, consumables and site must be included. 9. Equipment - A list of equipment required to carry out the Inspection , covers both plant and consumables, including lighting requirements and sensitivity levels where applicable. General equipment such as rags and marking pens etc need not be listed. 10. Pre- Inspection requirements - A list of what has to be done to the aircraft or component prior to the commencement of the Inspection .

8 Any process that may cause deformation of the surface must be avoided. Developing Inspection Procedures from astm LPI and MPI Standard Practices 11. Inspection - This is a set of detailed instructions on how to perform the Inspection . The use of photographs and diagrams is encouraged where possible. 12. Acceptance/Rejection Criteria - A clear statement of what discontinuities are acceptable and or unacceptable. 13. Post Inspection Requirements - This is generally a short statement to ensure all equipment used to carry out the Inspection is removed from the aircraft. Post cleaning requirements are included here. 14. Reporting Requirements for recording and reporting of the Inspection results are detailed here. 15. Annexes - Annexes are used to include supporting information from another source or defect logging diagrams etc. if appropriate. Developing Inspection Procedures from astm LPI and MPI Standard Practices astm Standard Practice and Draft CAAP 30-02 The astm Standard Practices contain information that may not be relevant to every Inspection which is why a Level 3 is required to review and approve Procedures before they are sent for regulatory authority approval.

9 The following is a interpreta<on guide of some of the specific statements in the astm which we hope will enable the produc<on of workable Procedures from those statements, giving due considera<on to the part to be inspected and the defects sought. It is not exhaustive and further assistance may be required. Developing Inspection Procedures from astm LPI and MPI Standard Practices astm E1444 - 16 Standard Practice for Magnetic Particle Examination. This covers all magnetic particle inspections and is therefore going to contain much more information than required in any one Inspection procedure. Head shot on bench Camshaft cracking Coil shot on bench In the aircraft industry most magnetic particle Inspection is done on a bench with a head, central conductor or coil. Though the draft CAAP does permit the use of electromagnetic yokes. Developing Inspection Procedures from astm LPI and MPI Standard Practices Magne<c par<cle carrier may be water but it does require the addi<on of both surfactants and corrosion inhibitors - Safer Hydrocarbon based carrier is easier to work with and does not have foaming or corrosion issues.

10 Magnetic particle concentration is critical care needed to ensure it is always within the specified range - regular concentration checks. When working with electromagne<c yokes the consumables normally come in Cer<ficated aerosol cans - par<cle concentra<on checks are not required. Any procedure using them must include a reminder to adequately shake the cans to ensure appropriate par<cle distribu<on. Developing Inspection Procedures from astm LPI and MPI Standard Practices Clause To ensure the detection of discontinuities in any direction, each part must be magnetized in a minimum of two directions at approximately right angles to each other. Depending on part geometry, this may be circular magnetization in two or more directions, multiple circular and longitudinal magnetization, or longitudinal magnetization in two or more directions. If the discontinuity sought is known then magnetisation only needs to be at right angles to the known orientation.