NES 872 Part 4 Procedures For First Level Nickel Aluminium Bronze Castings - Category 1

Ministry of Defence
Defence Standard 02-872 Part 4

Issue 1 Publication Date 02 December 2002
Procedures for First Level Nickel

Aluminium Bronze Castings
Part 4
Inspections outside of Long Overhaul
Periods
Category 1
AMENDMENTS ISSUED SINCE PUBLICATION

AMD NO
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
D/DGFS(S)/SM511A/743/20/GEN-T memo
Feb 95
DEFENCE STANDARD 02-872

PROCEDURES FOR FIRST LEVEL NICKEL ALUMINIUM BRONZE CASTINGS
PART 4
ISSUE 1
INSPECTIONS OUTSIDE OF LONG OVERHAUL PERIOD
This Defence Standard

Is authorised for use in MOD contracts
By the Defence Procurement Agency
And the Warship Support Agency
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
DEF STAN 02-872 Pt 4 / Issue 1

SCOPE
1.
This procedure is to be used for in-service inspections carried out outside of the Long
Overhaul Period. This process is used to gauge the overall health of all Nickel Aluminium
Bronze (NAB) contained in the NAB Register of a submarine by detailed examination of a
sample of NAB castings.
2.
Castings are to be chosen for inspection from the assessments carried out using
NABWETLIFE or as requested by the Design Authority.
3.
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.
4.
Part 2 of this Defence Standard is to be used for the validation of all Submarine First Level
castings made of Nickel Aluminium Bronze (NAB) manufactured to Defence Standard 02747 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.
5.
Part 3 of this Defence Standard is to be used for the revalidation of Submarine First Level
castings made of Nickel Aluminium Bronze (NAB) manufactured to DGS 8520, DGS 348 or
Defence Standard 02-747 Part 1, 2 or 4 which have had service use involving contact with sea
water.
FOREWORD
Sponsorship
1.
This Defence Standard is sponsored by the Warship Support Agency, Ministry of Defence
(MOD).
2.
The complete Defence Standard 02-872 comprises:

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 in

writing of the circumstances.
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 publishing authority identified on Page 1 and those directly
applicable to a particular contract are to be dealt with using existing procedures.
5.
No alteration is to be made to this Defence Standard except by the issue of an authorized

amendment.
6.
Unless otherwise stated, reference in this Defence Standard to approval, approved, authorized
or similar terms, means the MOD in writing.
2
7.
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.
Extracts from British Standards within this Defence Standard have been included with the
permission of the British Standards Institution.
Conditions of Release
General
9.
This Defence Standard has been devised solely for the use of the MOD, and its contractors in
the execution of contracts for the MOD. To the extent permitted by law, the MOD hereby
excludes all liability whatsoever and howsoever arising (including but without limitation,
liability resulting from negligence) for any loss or damage however caused when 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 they are 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 to the Authority named in the tender or contract.
14.
When Defence Standards are incorporated into MOD contracts, users are responsible for their
correct application and for complying with contractual and other statutory requirements.
Compliance with an Defence Standards does not of itself confer immunity from legal
obligations.
Categories of Naval Defence Standard
15.
The Category of the Naval Defence Standards 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 parties
Operational 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 parties
Operational performance of the vessel, its systems or equipment.
Through life costs and support.
3
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.
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
British Standards Institution,

389 Chiswick High Road,
London, W4 4AL
b)
Defence Standards

An Executive Agency of the MoD
UK Defence Standardization,
Kentigern House, 65 Brown Street,
Glasgow G2 8EX
c)
Other documents
Tender or 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 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 Defence Standards may call 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 the 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 Standards has been written and is to be used taking into account the policy
stipulated in JSP430: MOD Ship Safety Management System Handbook.
Use of ARDROX 160 and silver nitrate solution

21.
Before using this Defence Standards in connection with Ardrox 160 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, eg 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 Standards.
24.
Ardrox 160 is a proprietary product and the manufacturers health and safety instructions must
be followed.
Additional information.
(There is no relevant information)

CONTENTS
Page No
TITLE PAGE
SCOPE
FOREWORD
Sponsorship
Conditions of Release
Categories of Naval Defence Standard
Related Documents
Health and Safety
CONTENTS
SECTION
1.
1.1
1.2
1.3
1.4
GENERAL REQUIREMENTS
NABWETLIFE Code
Selection of Castings for Inspection
Identification
Pre-requisites
SECTION
2.
2.1
2.2
2.2.1
2.2.2
2.2.3
2.3
2.3.1
CLEANING OF CASTINGS
General
Shore Based Cleaning and General Etching
Cleaning Method 1
Cleaning Method 2
General Etching Method
In Situ Cleaning
In Situ Cleaning Method
9
9
9
10
10
10
11
11
SECTION
3.
3.1
3.2
3.3
3.4
3.4.1
3.4.2
3.5
3.6
3.7
3.8
SHORE BASED EXAMINATION FOR CORROSION

General
Visual Examination
Thickness Check
Detection of Corrosion
Detailed Etching Method
Ultrasonic Corrosion Detection
Removal of Corrosion
Post Dressing Thickness Gauging
Recording of Examination Results
Corrosion Limits
11
11
11
12
12
12
12
13
13
13
14
8
8
8
8
8
SECTION
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
INSPECTION ACCEPTANCE CRITERIA

Cleaning
Wall Thickness
Re-installation
Re-Stamping
Certification
Records
14
14
15
15
15
15
15
16
SECTION
5.
5.1
5.2
5.3
5.4
5.5
5.6
IN SITU EXAMINATIONS
In situ Cleaning
Ultrasonic Thickness Checks
In Situ Etching Method
Ultrasonic Corrosion Measurements
Records
Acceptance Criteria
16
16
16
16
17
17
17
ANNEX A.
RELATED DOCUMENTS
18
ANNEX B.
DEFINITIONS AND ABBREVIATIONS
19
ANNEX C.
PROCUREMENT CHECK LIST
20
ANNEX D
CASTING RECORD OF REVALIDATION INSPECTION
21
ANNEX E
REVALIDATION CERTIFICATE FOR NAB CASTINGS
22
ANNEX F
CHECK LIST FOR DOCUMENTS TO BE INCLUDED

IN THE QA PACK FOR REVALIDATED CASTINGS
23
ALPHABETICAL INDEX
24

1.
GENERAL REQUIREMENTS
Related Documents: DGS 8520, see also Annex A
1.1
a.
Extensive examinations have shown that the Nickel Aluminium Bronze (NAB)
castings used since the early 1960s are, to varying degrees, susceptible to normal
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.
Outside of Long Overhaul Period, examination of individual castings may be

required by Design Authority, for example high risk castings predicted by the
NABWETLIFE code, or to provide information to assist in the commission
extension safety justification and life extension safety justification.
NABWETLIFE Code
a.
1.2
Selection of Castings for Inspection

a.
1.3
Castings for inspection are to be selected by the Design Authority.
Identification
a.
1.4
NABWETLIFE is a computer code, written by MOD, which has been devised to

address the problem of how NAB corrosion affects the safe diving periods of
submarines. The aim of the program is to recommend when castings should be
removed/replaced outside of Long Overhaul Period to achieve the maximum safe
wetted life for a submarine. The high risk castings recommended by
NABWETLIFE are removed from the submarine at a suitable Upkeep Period eg
RAMP, and examined to the requirements of this specification.
Previously validated/revalidated castings should be stamped with a code which

uniquely identifies them. The code consists of the radiographic number which may
be preceded by the letters H or HA. The letters H and A indicate that the casting
has been heat treated and weld repaired respectively. Castings manufactured to
specifications subsequent to DGS 8520 will have their specification indicated,
followed by letters VAL and the date. The letters VAL and the date show that the
casting has been previously validated/revalidated on the date shown.
Pre-Requisites
a.
A casting examination control facility is required at the repair source, together

with a register of properly trained personnel who have the necessary experience to
carry out the procedures described in this Defence Standard. The Design Authority
will define what level of training and experience is necessary.

b.
The Examination Contractor is to demonstrate to the Design Authority that the

procedures necessary to control and document the application of this Defence
Standard are in place before work is carried out.
c.
The following documentation on each casting is to be made available to the

examination personnel prior to commencement of the examination:(1)
Drawings with dimensions and wall thicknesses
(2)
Casting radiographic interpretation sheets
(3)
Weld repair details
If the documentation is not available, advice is to be sought from the Design

Authority.
d.
2.
Examination Contractors who find information on the castings which does not
correspond to that on the QA documentation should refer to the Design Authority
for advice on further action.
CLEANING OF CASTINGS
Related Documents: Def Stan 68-188, Def Stan 80-20, see also Annex A
2.1
2.2
General
a.
The sea water wetted surface of the castings will be covered with varying degrees
of bio fouling, calcareous deposits and redeposited copper which can be difficult
to remove.
b.
Any cleaning process must use methods which are not detrimental to the casting.
Special care should be taken to protect machined surfaces. Approved methods of
cleaning NAB castings include hydrojetting with or without entrained abrasives,
dry blasting with alumina grit and Chemical Dip. Metal will be removed with any
blasting process and care will be required to prevent damage to the casting. The
nozzle must be kept moving at all times i.e. castings should be swept blast and
machined surfaces must be masked.
c.
Suitable methods of cleaning are described in Clauses 2.2.1 and 2.2.2. The
contractors cleaning procedure and the training of operators must have Design
Authority written approval.
d.
Cleaning of castings must be carried out by staff who are suitably experienced.
e.
Where examination of castings is required outside of a Long Overhaul Period, it is

preferable for the casting to be removed from the submarine so that the examination
can be carried out at a suitably equipped shore based facility. However, where
castings are too large to remove from the submarine without a hull cut, in-situ
inspection may be required. Procedures to be followed for shore based inspection
are described in Clause 2.2 and Section 3. Procedures for in situ inspection are
described in Clause 2.3 and Section 5.
Shore Based Cleaning and General Etching

a.
The surfaces of the casting that have been in contact with sea water are to be
cleaned by an approved method, as described below. Cleaning Method 1 should be
9

used to remove all marine growth and surface corrosion products. This should be
followed by Cleaning Method 2 to provide clean, degreased surfaces for etching.
2.2.1
2.2.2
2.2.3
Cleaning Method 1
a.
Approved methods of mechanically cleaning NAB castings include hydrojetting

with or without entrained abrasives and dry blasting with alumina grit.
b.
Blasted surfaces are then to be lightly abraded with an emery disc or flap wheel to
remove all surface redeposited copper where present. Note that the etching
solution used to detect selective phase corrosion will give a false indication if
surface redeposited copper is still present.
Cleaning Method 2
a.
The casting is to be degreased either in a hot water detergent or in a cold agitated

solvent to Def Stan 68-188 or similar approved alternative for between 30 minutes
and 1 hour, or as advised by the manufacturers instructions.
b.
After degreasing, the casting is to be washed in hot fresh water i.a.w.

manufacturers instructions, until the degreasing solvent is removed.
c.
Paint can be removed by an additional dip in a chemical cleaner to Def Stan 80-20
or similar approved alternative for up to 8 hours after which the casting must
again be washed, this time in cold water.
General Etching Method

a.
On completion of cleaning, the casting is to be dipped for between 1 and 10

minutes in an approved brightening solution e.g. Ardrox 160 (available under
NSN 99 220 1162) or similar approved alternative. This process will etch the
surface of the casting, highlighting areas of weld repair, and selective phase
corrosion should these exist. The solution must be sufficiently fresh not to
contaminate the casting surface with redeposited copper. After removal from the
dip bath, the casting is to be thoroughly washed in cold fresh water to remove all
traces of the brightening solution.
b.
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
HAZ Corrosion
Plug/Crevice Corrosion
c.
- Dark Grey or Black

- Mid Grey
- Greyish Green
- Copper Colour or Greyish Green
A suitably experienced person (see Clause 1.4a) is to check that the casting is free
from surface redeposited copper before the examination for corrosion described in
Section 3 is carried out. The suitably experienced person is to advise when the
brightening solution requires changing, e.g. if it causes re-deposition of copper.
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.
10

2.3
2.3.1
3.
In Situ Cleaning
a.
In situ cleaning of castings will require procedures to identify the access restrictions,
the requirements for casting relocation, the proposed method of cleaning and the
required training / qualifications of staff. Particular attention will be required to
protect the surrounding components and the arrangements to be made for the
removal of debris.
b.
Written procedures are to be prepared and approved by the Design Authority to

cover the following.
(1)
Prerequisite requirements in accordance with Clause 1.4.
(2)
Work in way to prepare the casting for cleaning.
(3)
Protection of surrounding equipment such as heat exchangers tubes, electrical

and electronic equipment by suitable screening.
(4)
Containment and disposal of waste fluids / abrasive particles.
In Situ Cleaning Method

a.
The biofouling and surface redeposited copper is to be removed by a combination of

abrasive blasting, emery disc and flap wheels, as appropriate depending on access
restrictions and safe operation.
b.
Remote Visual Inspection (RVI) equipment may be necessary to aid cleaning and to
demonstrate the condition of the casting internal surfaces and to ensure freedom
from surface redeposited copper.
SHORE BASED ETCHING AND EXAMINATION FOR CORROSION

Related Documents: Def Stan 02-872 Part 2, 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. The purpose of the procedures described in this
Section is to detect and establish the depth of selective phase corrosion.
b.
Castings are to be removed from the vessel, then cleaned and etched as per Clause
2.2.
Visual Examination
a.
The detailed visual examination of the casting after the etching described in
Clauses 2.2.3 and 3.4.1 is to be carried out by staff meeting the prerequisite in
Clause 1.4a. The location of selective phase corrosion will be around weld repairs
and under biofouling and crevices. It is imperative that all welds on sea water
wetted and non wetted surfaces are identified after general etching, referring to
Clause 2.2.3b. Previous QA documentation should be consulted to locate these
weld repairs which should be identified on the casting. Areas of plug corrosion
shall also be identified.
11

b.
3.3
3.4
3.4.1
3.4.2
Corrosion areas can be identified with the aid of 10% non-acidified silver nitrate
etch where necessary as per Clause 3.4.1.
Thickness Check
a.
Spot thickness checks are to be made over the casting body by an ultrasonic
method or calipers. Those regions where the wall thickness is found to be less
than 90% of the drawing wall thickness are to be logged on radiograph sketches
and reported to the Design Authority. These regions are to be inspected in
accordance with Clause 3.4.2c. All other regions are to be inspected in accordance
with Clause 3.4.2b.
b.
Where casting drawings are not available, NDE thickness readings are to be
forwarded to the Design Authority for advice.
Detection of Corrosion
a.
HAZ corrosion is typified by a narrow band of corrosion around weld repairs.

Areas of plug corrosion are visible following general etching (see Clause 2.2.3)
and can be seen as dimpling on polished surfaces (typically after 80 grit flap
wheel).
b.
To prepare the surface for detailed etching, the surface must be freshly abraded
typically with a flap wheel (80 grit) just prior (i.e. within one hour) to etching.
Detailed Etching Method

a.
Areas of selective phase corrosion can be identified by etching with fresh 10%
silver nitrate solution stored in a dark bottle to prevent deterioration by light. The
etch is preferably to be applied using a fine spray to moisten the metal surface.
Alternatively a soft brush may be used. Swabs may be used provided care is taken
to avoid contamination which can cause spurious results, (this usually means that
swabs are used only once on a single wipe).
b.
The silver nitrate etch will reveal regions of selective phase corrosion which turn
black. This is caused by silver depositing on any redeposited copper within the
regions of selective phase corrosion. Note that care is required to ensure that all
general surface redeposited copper is removed as this will also turn black and can
be confused with selective phase corrosion.
c.
Wash the etched areas thoroughly with fresh water to remove the etching
chemicals.
Ultrasonic Corrosion Detection

a.
Corroded areas are to be examined by a ZIPSCAN method, that has been agreed
with the Design Authority, to determine the depth of corrosion and remaining
sound wall thickness.
b.
All HAZ corrosion is to be examined 100%. Other corrosion patches extending

more than 10mm along the surface in any direction are to be examined 100%.
c.
In those regions which are identified as thinner than 90% of design wall thickness,
all corrosion is to be examined 100%.
12

d.
Corrosion penetration and casting wall thickness are to be recorded. Corrosion

location is to be logged on casting sketches with reference to the depth of
corrosion penetration.
e.
Any areas where the remaining uncorroded wall thickness is less than 90% of the
drawing wall thickness are to be reported to the Design Authority at the earliest
opportunity to enable further action to be determined.
WARNING: Ultrasonic NDE methods, have been used with limited success to
measure the depth of selective phase corrosion which has occurred at the HAZ. Total
reliability, however, is not guaranteed under all conditions and until a fully approved
reliable NDE method is available these techniques must be restricted to use as an aid for
detecting corrosion with confirmation of corrosion depth verified by an etch and grind
process.
3.5
3.6
a.
On completion of the examinations as per Clause 3.4, and after authorisation by

the Design Authority, corroded areas are to be ground out using suitable tooling
e.g. tungsten carbide burrs or grinding wheels.
b.
When all of the corrosion has been removed, this is to be verified by etching in
accordance with Clause 3.4.1
Post Dressing Thickness Gauging

a.
3.7
All areas where corrosion was present must be thickness gauged using callipers or
an approved ultrasonic technique when all the corrosion has been removed.
Recording of Examination Results

a.
A full report of the examination is to be submitted to the Design Authority. This is

to include casting sketches showing the location of corrosion, referenced to the
depth of corrosion penetration and casting wall thickness.
b.
In addition, a Casting Record of Revalidation Inspection, an example of which is

at Annex D, should be filled in. A separate sheet should be filled in for each
casting. This is used to supply the information required to carry out life
assessment. The following information should be included in the Table:
(1)
The casting description, unique number and previous QA document number

are to be logged at the top of the table.
(2)
All weld repairs and other defects where corrosion has been removed are to
be given a number which will be marked on the casting using a felt tip
marker and logged in column 1 of the Table. Note that all areas of corrosion
should be logged, including any grooving at O seals. Grooving or pitting at
'O' seals is a special case to be referred to the Design Authority.
(3)
Details of weld repairs on sea water wetted surfaces, obtained from previous
QA documentation, are to be entered in column 2 of the Table next to
defects identified in column 1. Note that some weld repairs may not have
resulted in corrosion but confirmation of this is required. A sketch or
photograph of areas of corrosion, with identification numbers as referenced
in column 1 of the Table, is to accompany the Table.
13
3.8
4.
(4)
Grid based thickness scans for the larger NAB castings should be available
with the QA documentation in accordance with Part 2 of this Defence
Standard. If these are not available then general wall thicknesses should be
measured on a gridded sketch at a spacing to be agreed with the Design
Authority. The measurements should give sufficient detail to provide
confidence on the general wall thickness. For guidance the grid spacing will
be typically 70 mm to 100 mm.
(5)
On the castings, measure the maximum surface length 'A' in any one
direction and the maximum depth 'B' for each defect and record these on the
Table in columns 4 and 5.
(6)
Using a calibrated ultrasonic probe or callipers, measure the thinnest wall

adjacent to the defect, i.e. measure the wall thickness prior to the grinding
out of the defect. This defect free wall thickness 'C' is to be recorded in
column 6 of the Table. Subtracting the defect depth 'B' from this will give
the remaining wall thickness 'D', where D=(C-B), see column 7 of the Table.
This can be confirmed by measuring directly the remaining wall thickness
'D'.
(7)
Complete columns 8 to 10 in the Casting Record of Revalidation Inspection

Table.
Corrosion Limits
a.
Using the results reported in accordance with Clause 3.7, the Design Authority is
to decide if the rates of corrosion for the boat sample of NAB castings are within
acceptable limits. The acceptable limits allow the submarine to continue
unrestricted operations to the end of her planned commission or until the next
planned NAB Inspection. If the rates of corrosion found in the sample are higher
than expected, further Inspections may be immediately required or subsequent
operations with diving restrictions might be advised by the Design Authority.
Where corrosion has been higher than expected, a safety assessment is to be made
for future operations of the submarine, identifying any operational restrictions as
necessary.
b.
It must be remembered that even if all the Inspected castings are replaced (because
of high corrosion rates), the submarine cannot be returned to unrestricted service
without such a safety assessment as there may be other castings in the vessel that
also exhibit these high corrosion rates.
c.
When corrosion is found to be negligible and the casting meets the revalidation
criteria, the casting should be revalidated in accordance with Section 4 of this
Defence Standard and returned to service or stores if applicable.
INSPECTION ACCEPTANCE CRITERIA

Related Documents: Def Stan 02-824, Def Stan 02-872 Parts 2 & 3, MOD Form 77, see
also Annex A
4.1
Cleaning
a.
The casting has been satisfactorily cleaned when all fouling and redeposited
copper has been removed. Acceptance is to be confirmed by suitably trained
personnel.
14

4.2
a.
4.3
4.4
4.5
Corrosion has been removed when there are no indications of selective phase
corrosion turning black after etching with 10% silver nitrate etch. Acceptance
must be confirmed by suitably trained personnel (see Clause 1.4a).
Wall Thickness
a.
Corrosion free castings with a wall thickness above 90% of the drawing wall
thickness are acceptable, as specified in Part 3 of this Defence Standard.
b.
The Design Authority is to determine whether further corrosion is to be removed

from castings once the wall thickness has been reduced to 90% of the original
value in way of corrosion.
c.
Castings whose thickness has been reduced to less than 90% of the drawing
thickness must be referred to the Design Authority. These castings are only to be
installed into a submarine following receipt of an approved Concession (MOD
Form 77 - Revised 7/91) issued by the Design Authority.
Re-installation
a.
Acceptable castings are to be re-installed after the examinations are complete if

there is sufficient time during the Upkeep Period.
b.
Castings which are deemed unacceptable by the Design Authority are to be

replaced with castings validated in accordance with Part 2 of this Defence
Standard a previously revalidated casting to Part 3 of this Defence Standard, or a
Copper Nickel Chromium casting to Def Stan 02-824.
Re-Stamping
a.
The officer witnessing the stamping of the casting is to sign the Revalidation
Certificate. A line is to be stamped through the previous validation date and the
new date stamped as a suffix to the original number.
NOTE: Pressure castings are not to be stamped on the highly stressed region e.g.
Critical Test Regions of the castings. The stamping should be positioned on low stress
areas as indicated below.
i. Valve bodies should be stamped at the edge of the cover flange or in the
absence of a prominent cover flange then as close to the cover position as
possible. Failing this another flange should be stamped, but stamping on hull
flanges is to be avoided.
ii. Flange fittings to be stamped on a flange edge.
iii. Unflanged fittings to be stamped on an area that is thicker than the minimum
acceptable wall thickness.
4.6
Certification
a.
All castings that are to be re-installed are to be re-stamped in accordance with

Clause 4.5, and issued with a Revalidation Certificate in the format of Annex E.
15
4.7
Records
a.
A full report of the shore based corrosion examination, including wall thickness
records, sketches / photographs, and, the Casting Record of Revalidation
Inspection Table, see Annex D, is to be submitted to the Design Authority.
b.
If the casting is re-installed in the submarine, a copy of the Revalidation

Certificate and QA certificate of compliance, together with copies of the full set of
QA records, as listed in Annex F, 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 revalidations.
c.
The Through Life Records Contractor is to hold the master records.
5.
IN SITU EXAMINATIONS
5.1
In Situ Cleaning
a.
5.2
5.3
To be carried out in accordance with Clause 2.3.
Ultrasonic Thickness Checks

a.
In-situ thickness gauging using calipers or an approved ultrasonic technique may

be required by the Design Authority on selected castings, e.g. as an input to life
assessment for Commission Extension and Life Extension studies.
b.
Wall thickness results 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 wall thicknesses are to
be measured on a gridded sketch at a spacing to be agreed with the Design
Authority. The measurements should give sufficient detail to provide confidence
on the general wall thickness. For guidance the grid spacing will be typically 70
mm to 100 mm.
In Situ Etching Method

a.
Etching to reveal corroded areas is to be by the application of a fresh 10% silver

nitrate solution. Etching is to be carried out within one hour of dry abrading the
surface, as the surface develops an oxide film resistant to etch solutions after a
period of time. Precautions will be required to ensure that the etch can be
contained and not run into crevices which cannot be flushed.
b.
Wash the etched areas thoroughly with fresh water to remove the etching
chemicals.
c.
Ultrasonic thickness checks will be required to maintain a record of the level of

dressing.
16

5.4
5.5
5.6
Ultrasonic Corrosion Measurements

a.
In situ ultrasonic corrosion measurements using a NDE Time-of-Fight method

(e.g. ZIPSCAN) may be required by the Design Authority on selected castings to
be used as a guide to the condition of the castings.
b.
The procedure for NDE corrosion measurement is to be agreed with the Design
Authority.
Records
a.
The format for recording the results of the work specified to be undertaken by the
Design Authority is to be in accordance with Clause 3.7.
b.
All records must contain the unique radiographic number for the casting and are to
be forwarded to the Design Authority.
c.
A copy of all the records is to be passed to the Through Life Records Contractor,
and is to be available for future revalidations.
d.
The Through Life Records Contractor is to hold the master records.
Acceptance Criteria
a.
The records from Clause 5.5 are to be assessed by the Design Authority for
acceptability, as appropriate.
17

ANNEX A.
RELATED DOCUMENTS
A1.
The following documents and publications are referred to in this Defence Standard:
JSP 430
MOD Ship Safety Management System Handbook
DGS 348
Cast Nickel Aluminium Bronze
DGS 8520
Cast Nickel Aluminium Bronze
Def Stan 02-747
Requirements for Nickel Aluminium Bronze Castings and ingots

Part 1 - Nickel Aluminium Bronze (Naval alloy) centrifugal castings and
ingots
Part 2 - Nickel Aluminium Bronze (Naval alloy) sand castings and ingots
Def Stan 02-824
Part 4 - Nickel Aluminium Bronze (Naval alloy) sand castings with

welding restricted to the non-wetted surface (Class I and II castings only)
Copper Nickel Chromium sand castings and ingots
Def Stan 02-872
Procedure for First Level Nickel Aluminium Bronze Castings

Part 1 Policy
Part 2 Validation
Def Stan 68-188

Def Stan 80-20
Part 3 Revalidation
Emulsifier for solvent cleaner
MOD Form 77
Cleaning compound, solvent, cold bath type, for metal (cresylic acid/
dichloromethane)
Concession Application
SSP 25
Quality Assurance for Safety in Submarines
Memo D/DGFS(S)/SM511A/743/20/GEN-T dated February 1995
18

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
Examination
Organization contracted to carry out the examination of the castings
Contractor
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
NABWETLIFE
NDE
MOD in-house code for determining the life of NAB castings based on
statistical analysis
Non Destructive Examination
NSN
NATO Stock Number
QA
Quality Assurance
RAMP
Revalidation Assisted Maintenance Period. This replaces the obsolete term

RUP (Revalidation Upkeep Period).
Examination of used NAB castings during their life to the requirements of
Part 3 of this Defence Standard to determine the castings fitness for further
service
Organization contracted to maintain the QA records for NAB castings
through life
Examination of new NAB castings prior to fitting in critical positions to the
requirements of Part 2 of this Defence Standard.
Proprietary time of flight ultrasonic examination technique developed by
AEA which has been used for the detection of selective phase corrosion
Revalidation
Through Life
Records Contractor
Validation
ZIPSCAN
19

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
Clauses where a preference for an option is to be used or where specific data is

to be added are included in the Check List.
C.3
Each item is to be marked either:

= included
NA = not applicable
CHECK
No.
CLAUSE
No.
CHECK
20
or
NA
ANNEX D.
CASTING RECORD OF REVALIDATION INSPECTION
Revalidation Date
Material
Casting Unique Radiographic

Number
Previous Radiographic No. (if

different)
Component Description
1
Defect
ID No
21
Radiograph
Type of
position
Defect
numbers for
e.g. HAZ,
weld repairs
Plug,
(see previous
QA documents) O Seal
4
Defect
Length
(mm)
A
Defect Depth (mm) Defect Free

Wall
Thickness
Ultrasonic Etch &
(mm)
Grind
10
Remaining
Wall
Thickness
(mm)
Drawing
Wall -10%
(mm)
D>E =
D=(C-B)
Action:
Accept,
Reject,
Refer to Design
Authority
D<E = x
DEF STAN 02-872 Part 4 / Issue 1
Completed by .................................... Date ...................

ANNEX E.
REVALIDATION 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
SPECIFICATION
PART II - REVALIDATION ACTION
Signature
A.
ALL PREVIOUS CONCESSIONS ASSESSED
B.
CLEANED ETCHED AND GROUND TO DETECT CORROSION
C.
THICKNESS RECORDS IN WAY OF CORRODED AREAS ATTACHED
D.
CASTING RECORD OF REVALIDATION INSPECTION TABLE COMPLETED FOR

ALL DEFECTS AND ATTACHED WITH SKETCH.
PART III - RECLAMATION AND REVALIDATION

A.
PREVIOUS VALIDATION DOCUMENTATION SCRUTINIZED
B.
SUBSEQUENT WELD REPAIR
C.
COMPONENT RADIOGRAPHED AND DP EXAMINED
D.
DIMENSIONAL CHECKS
E.
WELD AREAS RE-MACHINED
F.
INTERNAL WELD REPAIRS
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 revalidated in accordance with Def Stan 02872 Part 3 and stamped *
SIGNATURE
NAME IN BLOCK LETTERS
AUTHORITY/DEPT
DATE
* CASTING IDENTIFICATION TO BE INSERTED
22
ANNEX F.
CHECK LIST FOR DOCUMENTS TO BE INCLUDED IN QA PACK FOR
REVALIDATED CASTINGS
F.1.
All certification and record sheets for the revalidated castings are to be annotated with
the appropriate ship fitting number or pump serial number (as applicable), description,
and unique radiographic 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
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
REVALIDATION CERTIFICATE
CASTING RECORD OF REVALIDATION INSPECTION TABLE
All QA records complete:
SIGNATURE
NAME IN BLOCK LETTERS
AUTHORITY/DEPT
DATE
23
ALPHABETICAL INDEX
(Note: Page Numbers are given)
Abbreviations 19
Acceptance 14, 16
Alumina grit 10
NABWETLIFE 2, 8
Photographs 16
Biofouling 11
Quality Assurance Documentation 9, 11, 13
Casting
Copper Nickel Chromium 15
Nickel Aluminium Bronze 2, 8
Cleaning 10, 11, 15, 16
Concessions 15
Corrosion 8, 9, 10, 11, 12, 13, 15
Radiographic number 8, 16
Redeposited copper 9, 10, 12, 15
Related Documents 4, 18
Revalidation Certificate 15, 22
Silver Nitrate 15
Sketches 11, 12, 15, 16
Design Authority 2, 8, 9, 11, 12,

13, 15, 16
Drawings 9, 13
Through Life Records Contractor 16
HAZ 8, 10, 12
Etching 9, 10, 11, 12
U
Ultrasonics 12, 13, 16
First Level 2
Wall Thickness 2, 9, 11, 12, 13, 14, 15,

16
H
Health and Safety 4
ZIPSCAN 12, 16
Identification 8, 13
L
Life assessment 13, 16
24
Inside Rear Cover
Crown Copyright 2002

Copying Only as Agreed with DStan
Defence Standards are Published by and Obtainable from:

An Executive Agency of The Ministry of Defence
UK Defence Standardization
Kentigern House
65 Brown Street
GLASGOW G2 8EX
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 4.
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.

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Ministry of Defence

Defence Standard 02-872 Part 4

Procedures for First Level Nickel

AMENDMENTS ISSUED SINCE PUBLICATION

DEFENCE STANDARD 02-872

This Defence Standard

DEF STAN 02-872 Pt 4 / Issue 1

The complete Defence Standard 02-872 comprises:

Inspections Outside of Long Overhaul Period

If it is found to be unsuitable for any particular requirement the MOD is to be informed in

No alteration is to be made to this Defence Standard except by the issue of an authorized

DEF STAN 02-872 Pt 4 / Issue 1

Category 1. If not applied may have a Critical affect on the following:

Category 2. If not applied may have a Significant affect on the following;

DEF STAN 02-872 Pt 4 / Issue 1

Category 3. If not applied may have a Minor affect on the following.

British Standards Institution,

Defence Procurement Agency

Tender or Contract Sponsor to advise.

Health and Safety

DEF STAN 02-872 Pt 4 / Issue 1

Use of ARDROX 160 and silver nitrate solution

DEF STAN 02-872 Pt 4 / Issue 1

Categories of Naval Defence Standard

Health and Safety

SHORE BASED EXAMINATION FOR CORROSION

DEF STAN 02-872 Pt 4 / Issue 1

INSPECTION ACCEPTANCE CRITERIA

DEFINITIONS AND ABBREVIATIONS

PROCUREMENT CHECK LIST

CASTING RECORD OF REVALIDATION INSPECTION

REVALIDATION CERTIFICATE FOR NAB CASTINGS

CHECK LIST FOR DOCUMENTS TO BE INCLUDED

DEF STAN 02-872 Pt 4 / Issue 1

To limit the effect of this corrosion problem, it is necessary to examine NAB

Outside of Long Overhaul Period, examination of individual castings may be

Selection of Castings for Inspection

Castings for inspection are to be selected by the Design Authority.

NABWETLIFE is a computer code, written by MOD, which has been devised to

Previously validated/revalidated castings should be stamped with a code which

A casting examination control facility is required at the repair source, together

DEF STAN 02-872 Pt 4 / Issue 1

The Examination Contractor is to demonstrate to the Design Authority that the

The following documentation on each casting is to be made available to the

Drawings with dimensions and wall thicknesses

Casting radiographic interpretation sheets

Weld repair details

If the documentation is not available, advice is to be sought from the Design

Where examination of castings is required outside of a Long Overhaul Period, it is

Shore Based Cleaning and General Etching

DEF STAN 02-872 Pt 4 / Issue 1

Approved methods of mechanically cleaning NAB castings include hydrojetting

The casting is to be degreased either in a hot water detergent or in a cold agitated

After degreasing, the casting is to be washed in hot fresh water i.a.w.

General Etching Method

On completion of cleaning, the casting is to be dipped for between 1 and 10

- Dark Grey or Black

DEF STAN 02-872 Pt 4 / Issue 1

Written procedures are to be prepared and approved by the Design Authority to

Prerequisite requirements in accordance with Clause 1.4.

Work in way to prepare the casting for cleaning.

Protection of surrounding equipment such as heat exchangers tubes, electrical

Containment and disposal of waste fluids / abrasive particles.