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Bcit Slides mt2 Fall-2014 PDF
Bcit Slides mt2 Fall-2014 PDF
Level II
(CGSB 48-9712)
1. Principles of Magnets and Magnetic Fields
Theory of magnetic fields - Magnetic domains
The Earth's magnetic field resembles that of an enormous bar magnet. The field
lines emerge from the southern half of the earth and re-enter in the northern half.
The earth's magnetic field serves to deflect most of the solar wind, whose charged
particles would otherwise strip away the ozone layer that protects the Earth from
harmful ultraviolet radiation.
1. Principles of Magnets and Magnetic Fields
Theory of magnetic fields - Magnets
AC DC
Johann Carl Friedrich Gauss (30 April 1777 – 23 February 1855) German mathematician/physicist.
James Clerk Maxwell (June 13, 1831 - November 5, 1879) Scottish physicist
1. Principles of Magnets and Magnetic Fields
Theory of magnetism
Horseshoe magnet
with poles
1. Principles of Magnets and Magnetic Fields
Theory of magnetism
Laws of magnetism
- Like poles repel
- Unlike pole attract
1. Principles of Magnets and Magnetic Fields
Theory of magnetism
Ferromagnetic material have strong attraction and are able to retain magnetisation
after the magnetizing field is removed; especially hard or tool steel.
1. Principles of Magnets and Magnetic Fields
Theory of magnetism
Distance factors
- The further from the poles the weaker is the field
1. Principles of Magnets and Magnetic Fields
Theory of magnetism
Magnetic lines of force (flux) have the following characteristics:
- They form closed loops.
- They resemble rubber bands in that they will stretch and change shape under the
influence of any magnetic fields present.
- They return upon themselves and form close paths.
- They never cross.
- They seek the path of least resistance.
- They are most densely packed at the poles.
- They flow from north to south outside of the magnet and from south to north inside
the ferromagnetic material.
1. Principles of Magnets and Magnetic Fields
Theory of magnetism
Theory of magnetism
Theory of magnetism
Hans Christian Ørsted (14 August 1777 - 9 March 1851) Danish physicist
2. Characteristics of Magnetic Fields
Bar magnet has poles (N&S) and Ring magnet has no poles and
magnetic field outside the bar magnetic field are all internal
2. Characteristics of Magnetic Fields
Current Type
- Alternating current (AC) is the most basic source – single phase or 3-phase.
A A
- Direct current (DC) is either from a stored media (eg batteries, capacitors) or
converted from AC (eg. half-wave DC or full-wave DC)
A A A
Battery HWDC FWDC
t t t
2. Characteristics of Magnetic Fields
Alternating Current
Cyclic effects
- Due to cyclic nature of AC, the indication will appear to be “dancing” (particle
mobility) and hence better delectability.
Safety precautions
- Caution when using AC; high voltage and amperage
Source of current
- Generator or public utility will produce AC; 120V single phase or 440V 3-phase.
No rectifiers are required so the weight of the equipment is reduce, lighter and less
expensive; AC is also used for demagnetizers
2. Characteristics of Magnetic Fields
- Derived from AC (single phase) but taking only one half of the wave; hence there
is a pause between each half –wave (pulsating)
- Good for particle mobility (due to pulsating) and field penetration
2. Characteristics of Magnetic Fields
- Derived from AC (single phase) but taking both halves of the wave; hence there is
no pause between each half-wave.
- Good for field penetration but particle mobility is compromised.
2. Characteristics of Magnetic Fields
- Using 3-phase AC it is possible to use rectifiers to produce a FWDC that look very
close to pure DC (little ripples). It can be filtered to pure DC as shown below.
2. Characteristics of Magnetic Fields
Indications
- Anything that is revealed during the inspection
Imperfections
- Any anomalies (deviation from the design or specification)
Discontinuities
- Indications that are flaws (faults); which may or may not acceptable
Defects
- Discontinuity that does not comply to an acceptance criteria or accepted norms.
- It can be detrimental if put in service
Surface discontinuities
- Discontinuities that are located at or very close to the surface (1-3mm approx.)
Sub-surface discontinuities
- Discontinuities located below the surface (3-5mm approx.); may go deep but then
the indication may be too fuzzy to interpret.
Fuzzy indication
Sharp indication
3. Effects of Discontinuities on Materials
DC flux – near and sub‐surface flaws
AC flux – surface flaws
3. Effects of Discontinuities on Materials
Design factors
Mechanical properties
- Properties like tensile strength, hardness and toughness will influence how the
material is use in fabrication and hence usage (service)
- Eg. for cold weather application (say below -40oC); a charpy test for toughness is
maybe required.
Part usage
- what is the part use for; how critical is the part?
- Eg. a turbine shaft may use a more sensitive technique such as wet florescent on
the wet bench
Michael Faraday (22 September 1791 – 25 August 1867) English physicist
4. Magnetization by Electric Current
Circular Field
Circular field
4. Magnetization by Electric Current
Circular Field
Head shot using
contact plates
4. Magnetization by Electric Current
Circular Field
Head shot using
contact plates
Head shot using
central conductor
4. Magnetization by Electric Current
Circular Field
Head shot using
contact plates
Head shot using
central conductor
4. Magnetization by Electric Current
Circular Field
Circular Field
Circular Field
Circular Field
Circular Field
Leech
Clamp
4. Magnetization by Electric Current
Circular Field
Circular Field
Circular Field
Current calculations
- Do some samples with the various equations
Direct contact
- Solid round part
- Solid rectangular part
- Solid irregular part
- Hollow part
Central conductor
- Hollow/ring part
- Irregular part
Prods
- Thickness and spacing
4. Magnetization by Electric Current
Circular Field
Circular Field
Circular Field
Circular Field
Circular Field
Circular Field
- DC increase is even
- AC the increase slow then rapid
- AC field concentrated near the surface
- AC has “skin effect” (good for surface
discontinuities),
- Field strength outside the conductor
decreases exponentially with distance
4. Magnetization by Electric Current
Circular Field
Safety precautions
- Ensure good contact; clean contacts
- Do not over-amp (too high current)
- Will prevent arcing (sparking) and over-heating
Longitudinal Field
Longitudinal Field
Longitudinal Field
Stationary coil Wrapped coil
Yoke
Portable coil
4. Magnetization by Electric Current
Longitudinal Field
Yoke – AC & DC
- Do not need calculation as amperage is note on unit (say 4Amps)
- Orientation is critical in yoke
4. Magnetization by Electric Current
Longitudinal Field
Longitudinal Field
Residual field n bar generated Residual field n bar generated
by slow break by quick break
4. Magnetization by Electric Current
Longitudinal Field
Advantages
- No direct induction so no arcing (sparking)
- Good for circumferential or transverse discontinuities
- Good portability (yoke)
Disadvantages
- Not good for longitudinal discontinuities (ie. parallel to field)
- For long part (more 15”-18”) need more than 1 shot for coverage.
4. Magnetization by Electric Current
Multi-directional magnetization
Combination of shots that will be used to inspect a part in one or two steps; usually
without re-positioning of the part. Eg. swinging field technique
- The two basic flux directions is achieved by the use of two phases of a three
phase mains supply.
- One phase is connected to the longitudinal flux generating system which can be
either a coil or a flux flow system. A second phase is used to generate
circumferential flux, usually by current flow through the work piece.
- As there is in sinusoidal A.C. a cyclic change in current value from zero to
maximum positive, down to zero, on to maximum negative and return to zero - fifty
times per second, and as there is a lag between the two phases, at any instant
there will be different amplitudes of longitudinal and circumferential fields.
4. Magnetization by Electric Current
Multi-directional magnetization
- Direct contact
- Coil
4. Magnetization by Electric Current
Multi-directional magnetization
Toroidal magnetization
Toroidal magnetization
Primary effect - magnetizing current (mag shot) produces a field surrounding the part
Secondary effect - circumferential current flow is developed within the test piece by the
collapsing field.
Tertiary effect - strong toroidal magnetic field is created as a product of the secondary
current flow within the part.
Discontinuities perpendicular to the field direction within the part may now be detected.
Toroidal magnetization
Use coil on a wet horizontal and a high permeability, low retentivity ferromagnetic
laminated core through part to concentrate the flux and make it perform more efficiently.
When coil is energized, a longitudinal field flows the laminated core and to some extent
in part.
When coil is de-energized, this field collapses and induces a circumferential current into
part. This in turn induces a strong toroidal field surrounding the part in a radial direction
Magnetic flux during
magnetizing pulse is
concentrated in core
inserted through test
object
4. Magnetization by Electric Current
Toroidal magnetization
Use a tabletop transformer fixture connected to the wet horizontal machine or portable
MT machine using a standard clamp block
wet continuous method can be use and be removed from the machine when not
needed
Table top, closed loop transformer
fixture showing close proximity of
primary and secondary (ring shaped test
object) windings with core
4. Magnetization by Electric Current
Multi-directional magnetization
Multi-directional magnetization
Multi-directional magnetization
Multi-directional magnetization
Pie gage
Shims (QQI)
Hall effect
meter
5. Selection proper method of magnetization
Examples:-
- Weld
- Shaft/bolt
- Small casting (landing gear)
- Large casting (bonnet)
6. Inspection materials
Inspection particles
The magnetic particles used for MPI is essentially iron fillings with a dye (make it more
visible): -
- Wet particles: suspended in a liquid (vehicle or media)
- Dry particles: just particles and dye.
Inspection particles
The magnetic particles used for MPI is essentially iron fillings with a dye (make it more
visible): -
- Wet particles: suspended in a liquid (vehicle or media)
- Dry particles (powder): just particles and dye.
Contrast
- state of being strikingly different from something else, typically something in close
association
- dye makes an indication more visible to the human eye
- different colored dyes; blue, yellow, and green, but it seemed that the red dye
resulted in best response to visible observation
- term "contrast ratio" is generally used to express "seeability"
- white dye on a white background, the contrast ratio would be one-to-one; no
contrast between the dye and the background.
- red dye, the contrast ratio is said to be six-to-one, making that contrast very
noticeable on a white background surface
- contrast ratio of a fluorescent dye is said to be forty-to-one
- hence, fluorescent penetrant produces a much higher degree of "seeability" or
sensitivity as compared to visible dye penetrants
6. Inspection materials
Particles in suspension:-
- particles suspended in a vehicle such as water or light petroleum distillate applied
by flowing. spraying. or pouring
- available in both fluorescent and non-fluorescent concentrates
- premixed with suspending vehicle by the supplier. but usually supplied as dry
concentrate (powder) or paste concentrate (to be mixed by the user)
- suspensions normally used in wet horizontal MPI equipment; dispensed from an
aerosol or other dispensers
Product Name: BAYOL 35
Product Description: lsoparaffinic
Hydrocarbon
Intended Use: Solvent
6. Inspection materials
Advantages of suspension:-
- small size (7C black: 20microns; 14A: 6microns); more sensitive than dry powder
- able to remain in discontinuities until they are removed
- contrast is invariably higher with wet fluorescent
Disadvantages of suspension
- Hard to remove; oil remnant not good for processes (eg. welding)
- Handling procedures; especially with flammable liquid (petroleum distillate)
- Mixing suspension; additives for water vehicle
- Odor and ventilation requirements
6. Inspection materials
Note: use of a reference concentration when new suspension is mixed
6. Inspection materials
trough
6. Inspection materials
Centrifuge tubes
- Visible : with 1.5ml stem
- Florescent: with 1.0ml stem
visible florescent
7. Principles of Demagnetization
Hysteresis loop/curve
- magnetic hysteresis loop or curve is a graph that plots magnetizing force and
magnetic field strength
- use magnetising and de-magnetising procedures
7. Principles of Demagnetization
Hysteresis loop/curve
Permeability:
μ
7. Principles of Demagnetization
Hysteresis loop/curve
Hysteresis loop/curve
Soft steel:-
- Thin hysteresis loop
- High permeability
- Low reluctance
- Low coercive force
- Low residual magnetic field
- Low retentivity
Hard steel:-
- Wide hysteresis loop
- Low permeability
- High reluctance
- High coercive force
- High residual magnetic field
- High retentivity
7. Principles of Demagnetization
Residual magnetism
When the magnetising current is removed not all the magnetic field is removed (see
hysteresis loop/curve)
- Same direction and weaker than the magnetic field
- A stronger magnetic field will overcome a weaker one (useful when de-mag circ
field)
Residual magnetism
Gaussmeter
7. Principles of Demagnetization
Residual magnetism
Methods of demagnetization
AC Coil Method
- AC flows in one direction (“-”) and then the opposite direction (“+”)
- at every cycle the current is reduced
- that means the current is reversing (AC) and reducing with each cycle
- If coil does not have a reducing current rheostat; pull part way from the coil
7. Principles of Demagnetization
Methods of demagnetization
DC Coil Method
- DC does not flow in like AC, so to reverse the direction it has to be done
mechanically (ie reverse the DC current or flip the part)
- reduce first then reverse
- at least 10 reversals but not more than 30 (1 reversal per second)
- DC de-magnetisation is more penetrating than AC; better for large part
Part that have been de-magnetised should be stored in the East-West direction; so
that it does not pick up the earth’s field.
If a part is to be heat treated (say pass the Curie temperature); demagnetisation may
not be required.
7. Principles of Demagnetization
Methods of demagnetization
AC Yoke Method
- With AC yoke move the yoke away from the part while the current is on
8. Magnetic particle testing equipment
Equipment-selection considerations
- Purpose/area of test
- Spot inspection and small area: yoke
- Whole casting, full exam: bench or multi-directional unit
8. Magnetic particle testing equipment
- should be capable of handling large and heavy parts with cranes or forrklift
- flexibility in use; both circular and longitudinal field or both
- need for stationary equipment; better coverage; penetration (DC); efficient on large
repeat quantities; better sensitivity with wet florescent
- use of accessories/attachments; coils, central conductor with black light for greater
sensitivity
8. Magnetic particle testing equipment
behavior of human eye vs illumination level
8. Magnetic particle testing equipment
white‐light meter
black‐light meter black & white‐light meter
* minimum UV-A output for a black light SHALL be 1000 μW/cm2 measured at a
distance of 15” from the outside face of the filter.
9. Type of discontinuities detected by MPT
Types of discontinuities
Inherent discontinuities/flaws
- usually formed when the metal is molten
- inherent wrought flaws are related to melting and solidification of original ingot
before forming into slabs, blooms an billets
- inherent casting flaws relates to melting, casting and solidification of a cast article;
caused by variable such as inadequate feeding, gating, excessive pouring
temperature or entrapped gases
Processing discontinuities/flaws
- related to various processes like machining, forming, extruding, rolling, welding,
heat treating and plating
Services discontinuities/flaws
- relates to various in-service conditions like stress, corrosion, erosion and fatigue
9. Type of discontinuities detected by MPT
Product form:-
- Bursts (Forgings)
- Cold Shuts (Castings)
- Cracks (All Product Forms)
- Hot Tear (Castings)
- Inclusions (All Product Forms)
- Lamination (Plate, Pipe)
- Laps (Forgings)
- Porosity (Castings)
- Seams(Bar, Pipe)
9. Type of discontinuities detected by MPT
Welding:-
- Burn Through
- Cracks
- Excessive/Inadequate Reinforcement
- Inclusions (Slag/Tungsten)
- Incomplete Fusion
- Incomplete penetration
- Misalignment
- Overlap
- Porosity
- Root Concavity
- Undercut
9. Type of discontinuities detected by MPT
Relevant Indications
- are produced by leakage fields which are the result of discontinuities.
- require evaluation with regard to acceptance standard/criteria
Non-relevant indications
- can occur singly or in patterns as a result of leakage fields created by conditions
that require no evaluation such as changes in section (like keyways and drilled
holes), inherent material properties (like the edge of a bimetallic weld), magnetic
writing etc.
False Indications
- are not the result of magnetic forces
- examples are particles held mechanically or by gravity in shallow depressions or
particles held by rust or scale on the surface.
10. Interpretation and evaluation of indications
Indications - pictures
Cracks
10. Interpretation and evaluation of indications
Indications - pictures
Flakes/scabs
10. Interpretation and evaluation of indications
Indications - pictures
Forging burst
10. Interpretation and evaluation of indications
Indications - pictures
Lamination
10. Interpretation and evaluation of indications
Indications - pictures
Cold shuts
10. Interpretation and evaluation of indications
Indications - pictures
Porosity
10. Interpretation and evaluation of indications
Indications - pictures
Shrinkage
10. Interpretation and evaluation of indications
Indications - pictures
Blowholes (pipes)
10. Interpretation and evaluation of indications
Indications - pictures
Inclusions
10. Interpretation and evaluation of indications
Indications - pictures
Hot tears
10. Interpretation and evaluation of indications
Indications - pictures
Corrosion
10. Interpretation and evaluation of indications
Indications - pictures
Wear/erosion
10. Interpretation and evaluation of indications
Indications - pictures
Wear/erosion
10. Interpretation and evaluation of indications
Indications - pictures
Interpretation:-
- determination of a magnetic particle indication's source and relevancy (distinguish
between relevant and non-relevant indications)
Evaluation:-
- process of determining the magnitude and significance of a discontinuity causing
an indication after it has been interpreted as being relevant.
Comparison techniques
- In addition to standards; comparative pictures maybe used for evaluation (eg.
ASTM E125 : Standard Reference Photographs for Magnetic Particle Indications
on Ferrous Castings)
- In some instances actual reference standards (known defective part) may be used
at the start of a run to check the system
10. Interpretation and evaluation of indications
Evaluation techniques
Specifications
- Specifications usually details what is to be performed (eg. scope, calibrations,
types of shots, coverage, test parameters, personnel certification etc.)
- Most end user will have specification outline their NDE requirements and will
usually reference standards and codes (eg Dow Chemicals specifications for
pressure vessels references ASME codes; AugustaWestland references BS/EN
standards)
Certifications
- company certification may be required to ensure that the facility or shop is capable
of performing the required inspection to the end user requirements (eg ASME
certification or CWB 178)
- personnel certification is required to attest to the technician’s qualification
(capability) to performed the inspection and evaluate the indications found – which
maybe in-house (SNT-TC-1A), end user specific (AugustaWestland), or nationally
accredited (eg. CGSB)
10. Interpretation and evaluation of indications
Defect Appraisal
History of part
- Weld on pressure vessel
Manufacturing process
- SMAW, ground smooth
Use of part
- Waste water/chemicals
Use of tolerances
- No linear indication > 1/16”
10. Interpretation and evaluation of indications
Defect Appraisal
History of part
- Casting (new)
Manufacturing process
- Sand cast, sand blasted surface
Use of part
- Fitting for a hub
Use of tolerances
- max acceptable 0.3” ( 8 mm) long for
materials up to 0.5” (13 mm) thick”
11. Standards,, specifications,
p , codes and reports
p
Standard CAN/CGSB 48.9712
- “Non
Non-destructive
destructive testing
testing- Qualification and certification of NDT personnel
personnel”
- 2014 edition; published by CSA
- Scope:-
This International Standard specifies requirements for principles for the
qualification and certification of personnel who perform industrial non
non-
destructive testing (NDT)
- Methods:
a) acoustic emission testing;
b) eddy current testing;
c) infrared thermographic testing;
d) leak testing (hydraulic pressure tests excluded);
e) magnetic testing;
f) penetrant testing;
g) radiographic testing;
h) strain gauge testing;
i) ultrasonic testing;
j) visual testing (direct unaided visual tests and visual tests carried out during the
application of another NDT method are excluded)
* Go thru some of the standard relating to MT certification
11. Standards,, specifications,
p , codes and reports
p
Standards, specifications and codes
Codes
- generally the top-tier documents, providing a set of rules that specify the minimum acceptable
level of safety for manufactured, fabricated or constructed objects
- may incorporate regulatory requirements and will often refer out to standards or specifications
for specific details on additional requirements not specified in the Code itself
- examples: ASME Boiler and Pressure Vessel Code (B&PVC) and AWS D1.1 Structural
Welding Code – Steel
Standards
- documents
d t th
thatt establish
t bli h engineering
i i or ttechnical
h i l requirements
i t for
f products,
d t practices,
ti
methods or operations
- example those that provide requirements for performing NDT (eg ASTM E709 : Standard
Guide for Magnetic Particle Testing, and ASTM E 1444, Standard Practice for Magnetic
Particle Testing)
g)
Specifications
- provide specific requirements for materials, components or services
- often generated by private companies (owners/end-users) to address additional requirements
applicable
li bl to a specific
ifi product
d or application
li i
- often listed in procurement agreements or contract documents as additional requirements
above and beyond code or standard requirements
11. Standards,, specifications,
p , codes and reports
p
Standards, specifications and codes
NDT Procedures
- written by companies to describe how an NDT method is carried out in the facility and/or a
specific project or contract
- reference codes, standards and/or specifications that may be required for the NDT work to be
p
performed
Written/work instructions
- step by step instructions on how a specific NDT task is to be performed
Technique sheets
- detailed steps and/or sequences of operations for a specific NDT task
- will include specific inspection parameters for the NDT task
Reports
- written testimony of the NDT work performed and the outcome (eg. accept/reject)
- include inspection parameters including acceptance criteria
- may include sketches or pictures showing area tested or for disposition (eg repair/scrap)
- i l d ttechnician’s
include h i i ’ name and d certification
tifi ti
11. Standards,, specifications,
p , codes and reports
p
Standards, specifications and codes
Defining
f the scope off the examination
- The scope of the examination has to be defined from the start – ie. what is to be
performed (eg RT or UT), the area(s) or part/component to be inspected, what
standard/specification/code to use, acceptance standard/criteria to evaluate the
i di i
indications to, personnell certification
ifi i etc.
Establishing specifications
- Owner/end-user (engineer) will put forward a specification that will be deployed in
conjunction
j ti with
ith the
th contractual
t t l NDT workk tto b
be performed
f d
Establishing reports
- A written testimony of the inspection is usually required in any inspection to
document the inspection work performed
Technical
T h i l requirements
i off reports
- A report will include the parameter used in the inspection (eg. project, part #,
code/specification used, procedure used, equipment, environment, inspection
settings, personnel name and certification etc.)
- Corrective actions
- An acceptable part is usually put into use or work to proceed; while and
unacceptable one will be disposition by the owner/end-user (eg. re-work, repair,
scrap, use as is
i etc.)
t )
11. Standards,, specifications,
p , codes and reports
p
Reports
What was
inspected
Whatt was
Wh
found
What was
the result &
Who performed disposition
the inspection
11. Standards,, specifications,
p , codes and reports
p
Review of Specification/Standard/Code
- In order to get the right results; all the equipment and accessories used must be
functioning properly
- Either it has to be calibrated or attested that it complies with the specification,
standard and/or code that is specified for the NDT work
- C lib i ffrequency iis usually
Calibration ll specified
ifi d iin the
h codes,
d standards
d d and/or
d/
specifications
ASTM E709
12. Quality
y control of equipment
q p and processes
p
Proper functioning of equipment and accessories
- Aircraft
f related checks
Helicopter
specification
12. Quality
y control of equipment
q p and processes
p
Proper magnetic particles and bath suspension
Technique sheets
- detailed steps and/or sequences of
operations for a specific NDT task
- ensure everyone does the work the
same way
- ensure quality of the work
performed as technique sheets
have to approve prior to use
- consistent
i t t outcome
t or results
lt
12. Quality
y control of equipment
q p and processes
p
Process control
Control of wet method p
particle concentration
- Brilliance and contamination
- in-use ink (bath) shall be checked under UV-A against the reference sample stored ; any of
the following conditions are unacceptable and shall require replacement of the in-use ink
- a noticeable reduction in the fluorescent brightness of the in-use ink relative to the
reference
f sample,
l
- clouding of the in-use ink (bath) carrier fluid to the extent that the markings on the flask
between 5ml and 25ml cannot be seen through the carrier fluid,
- milky white or bluish white fluorescence of the carrier fluid (due to oil or grease
contamination).)
Calibration
C off current output using shunts
- accuracy of the equipment ammeter shall be verified with a calibrated ammeter shunt
connected to the head and tail stock contacts
- comparative readings shall be taken at least at three levels of output current encompassing the
usable range of the equipment
- The equipment meter reading shall not deviate from the current level indicated by the shunt by
more than ±50 A or ±10% of the actual ammeter output of the magnetising equipment,
whichever is the greater
Quick
Q break test
- use a quick-break tester or a suitable oscilloscope
13. Instruction writing
g
Written Instructions
Ability to prepare a detailed NDT instruction providing written step by step information
f
on the testing of a sample and to provide the instruction by application
- Step-by-step review of how to write a sample written instruction
- Shall include:
a. A description
d i i off the
h test specimen.
i
b. A list of equipment, reference standards and accessories used.
c. A description of the calibration procedures specific for the test specimen.
d. A description of the inspection procedures specific for the test specimen.
e. The
Th iinstrument
t t settings
tti att the
th time
ti off inspection.
i ti
f. A report of the results.