g
Distributed Power Quality Management System
Part Cleanliness Standard
STD-02-0860
Rev: 4.01
Uncontrolled Copy; Printed on 1/26/17
Document Revision Chart
#.#
3.0
Section Modified and Revision Description
Converted to DP format; Clarified titles of Tables 1 to 3;
Updated 4.6 and reference (7.0 and where applicable)
Removed STD-05-0852 (obsolete) from 4.4.2 and 7.1
4.0
4.1
Date
08/05/09
04/01/16
Author
R. Mrazek
A. Eyers/W. Chen
10/05/16
W. Chen
1.0
Purpose
1.1
The purpose of this standard is to define the part cleanliness requirement goals for
engine ready components. Component cleanliness directly correlates to break in
damage and long term reliability.
2.0
Scope
2.1
This procedure applies to all purchased and manufactured parts that are ready for
assembly into an engine. This standard supersedes all other cleanliness requirements.
If this standard conflicts with any cited reference, this standard takes precedence.
This standard does not apply to rough castings or components in process.
2.2
The sampling procedures are defined in WGSCM 283.
2.3
The cleanliness requirements are grouped by engine families.
2.4
Parts as purchased shall meet the visual cleanliness of P28A-AL-0002 and residual
magnetism requirements of STD-02-0864.
3.0
Definitions
3.1
Visual Cleanliness – Free of abrasive debris or adhesive wear observable without any
optical correction beyond 20/20 corrective lenses.



All machined and fabricated parts are to be delivered clean, free of rust without
chips, dirt, grit or debris that can be detected visually. All sharp edges and corners
are to be broken and chamfered without violating print dimensions.
Castings shall be leak proof, free of sand, scale, rust, steel shot, gates, fins and
casting defects per MSS SP-55 “Casting Defect Acceptance”.
Forgings shall be free of rust, scale, and excessive flash.
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PAGE 1 OF 8
g
Distributed Power Quality Management System
Part Cleanliness Standard
STD-02-0860
Rev: 4.01
Uncontrolled Copy; Printed on 1/26/17


Finished parts are to be free of residual magnetism that attracts metal chips.
Allowable magnetic levels are described in STD-02-0864, Magnetism Specification
for Engine Parts”.
Pipes, elbows and fittings shall be cleaned to remove all scale, foreign material,
and processing compounds prior to final surface examination. The cleaning
process shall not injure the surface finish, material properties or the metallurgical
structure. The cleaned fittings shall be protected against the normal hazards of
shipping.
3.2
Cleanliness Level – An established maximum allowable amount of contamination in a
given area or volume, or on a component.
3.3
Contamination – Unwanted material.
3.4
Particle Size – The maximum linear dimension of the particle.
3.5
Significant Surface – Any surface of a component which is required to meet an
established cleanliness level.
3.6
Engine Ready - A part, which can be removed from its packaging, meets this
cleanliness standard, with only a wipe with a clean cloth to remove rust preventative
residue and be assembled into an engine.
3.7
Abrasive – An inorganic material that within normal engine service can cut, scratch or
cause abrasive wear of other metallic engine parts. Includes materials such as steel
chips, sand, aluminum oxide, aluminum, shot, cast iron, steel bristles, etc.
3.8
Metallic – Includes inorganic materials such as iron, steel, brass, copper, etc.
3.9
Graphite Smears – Black residue from graphite flakes found on the surface of cast iron
which continues to leech after several cleaning cycles.
4.0
Requirements
4.1
Cleanliness of Components/ Air Passages/ Oil Passages/Coolant System
4.1.1
All parts, identified in this specification, must be able to meet this cleanliness standard
if they are to be assembled into an engine.
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PAGE 2 OF 8
g
Distributed Power Quality Management System
Part Cleanliness Standard
STD-02-0860
Rev: 4.01
Uncontrolled Copy; Printed on 1/26/17
4.1.2
Graphite smears from cast iron castings are permissible.
4.1.3
This specification is not a substitute for visual cleanliness. If a part or assembly is
visually dirty it must be Q-traked per the Process Map, Nonconforming Material,
cleaned and cleanliness verified and deemed engine ready prior to assembly.
4.1.4
This specification only applies to components that are deemed engine ready.
Components that are in process are not required to meet these criteria. Parts cleaned
by WED are required to meet these criteria after final wash and at time of final
assembly. Assembly production leaders are responsible for maintaining all part
cleanliness from receipt in the assembly area until the engine is shipped.
4.2
Cleanliness Acceptance Criteria Tables
4.2.1
Cleanliness of critical engine components is determined by a sampling procedure
which is used to quantify the amount of debris on surfaces. Acceptance criteria are
identified in Tables 1 thru 3. The sampling procedure and data collection method is
described in WGSCM283. Tables identify maximum particle size for metallic and
abrasive particles only. The maximum foreign metallic particles and abrasive particles
only are listed for bushings and journal bearings.
4.2.2.1 The size listed is the largest dimension measured on any given abrasive, ferrous, and
metallic particles only.
4.2.2.2 Parts not specifically listed in Tables 2 and 3 shall have the maximum particle size and
maximum dirt mass determined by the relevant significant surface area and fluid in
contact with the surface as given in Table 1. Unlisted exhaust gas surfaces, painted
surfaces and surfaces exterior to the engine are excluded.
Table 1 – Cleanliness Acceptance Criteria by Surface Contact Fluid Type
Oil/Fuel
Air
Coolant
Maximum Particle Size, mm (Inch)
0.5 (.020)
1.0 (.039)
1.5 (.060)
Dirt Mass per 1ft2, mg
25
50
70
Table 2 – Cleanliness Classification
1
2
3
4
0.2
0.4
0.5
1.0
(.008)
(.016)
(.020)
(.035)
Cleanliness Class
Maximum Particle Size,
mm (inch)
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5
1.5
(.060)
6
Visually
Clean
PAGE 3 OF 8
g
Distributed Power Quality Management System
Part Cleanliness Standard
STD-02-0860
Rev: 4.01
Uncontrolled Copy; Printed on 1/26/17
Dirt Mass per 1000 cm2,
10
25
25
50
70
mg
Table 3 – Maximum Allowable Cleanliness Classes for VHP, AT, VGF, APG 1000/2000/3000
APG2000 VHP, AT, VGF
System/Component
APG3000
APG1000
Oil Circuit
Crankcase (Machined Oil Surfaces and Passages to Bearings
1
4
and Nozzles)
Crankcase (Cast Oil surfaces/Inner surfaces – oil splash)
2
4
Pan, Oil (internal area)
2
4
Crankcase Lower Covers (internal area)
2
4
Crankcase Upper Covers (internal area)
1
4
Crankshaft Ass’y (Includes counterweights/fasteners, timing
1
3
gear/fasteners)
Bearing, Main Lower & Upper Half
1
3
Bearing, CS Main #1 Thrust
1
3
Bearing Cap
1
3
Cylinder Liner
1
4
Anti-Polishing Ring
1
Connecting Rod Ass’y
1
3
Bearing, Connecting Rod
1
3
Piston
1
3
Piston Rings
1
3
Piston Pin
1
3
Nozzle, Oil Spray
1
Camshaft
1
3
Bushing, Camshaft
1
3
Support, Bearing Sub- Ass’y
2
3
Plate, Clamping
2
Bearing, Camshaft Thrust
2
3
Shaft, Accessory Drive – camshaft
2
3
Shim / Disc, Timing Gear
2
3
Gear, Idler
2
3
Gear, Camshaft Timing
2
3
Tappet, Valve Housing
1
3
Pin, Tappet Roller
1
3
Roller, Tappet
1
3
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Distributed Power Quality Management System
Part Cleanliness Standard
STD-02-0860
Rev: 4.01
Uncontrolled Copy; Printed on 1/26/17
System/Component
Head Cylinder (Machined and Completed Assembly-Oil
passage, Top oil surface, Valve Bores, Bottom Surface)
Shaft, Rocker Arm
Rocker Arm, Inlet and Exhaust
Support, Rocker Arm
Tube, Rocker Arm Oil Supply
Prechamber Assembly
Rocker Cover (Internal surface)
Lube Oil Module – Internal Surfaces (Includes Oil Filter Ass’y, Oil
Cooler, Transfer connections)
Oil Pump (Internal Passages)
Cover Plate, Free End (Oil Circuit Only)
Housing, Free End (Oil Circuit Only)
Flywheel Housing (Oil Side Only)
Tube, Flywheel Housing to Lube Oil Module
Connection, Flywheel Housing to Oil Pan
Turbocharger Bracket (Oil Passages Only)
Tube, Turbocharger Oil Supply
Gas Circuit
Adaptor, Main & PCC Gas Valve
Fuel Inlet – models with fuel injectors
Diffuser, Gas
Fuel Components
Tube, Gas, PCC Manifold
Flexible Connection, Main Gas Pipe
Check Value Ass’y
Prechamber Gas Feed Manifold (Inner Passages & Ports)
Tube, Prechamber gas valve to Prechamber
Head, Cylinder (Machined and Completed) Assembly – gas
passages)
Manifold, Gas
Air System (Internal Surfaces)
Charge Air Cooler Ass’y / Intercooler
Bellows – Fuel Inlet
Bellows – Air Intake Side
Bellows – Exhaust pre-turbo
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APG2000
APG3000
1
VHP, AT, VGF
APG1000
4
1
1
1
1
1
1
1
3
3
3
3
3
3
3
1
2
2
2
2
2
1
1
3
3
3
3
3
3
3
3
1
1
1
1
1
1
1
1
1
2
2
2
2
2
2
2
2
4
1
4
2
1
2
4
4
PAGE 5 OF 8
g
Distributed Power Quality Management System
Part Cleanliness Standard
STD-02-0860
Rev: 4.01
Uncontrolled Copy; Printed on 1/26/17
System/Component
Bellows – Exhaust post turbo
Turbocharger (Air Side)
Air Induction Components
Air Intake Filter/Housing
Air Inlet Tube (into Turbocharger)
Air Inlet Tubes (after Turbo into) manifold)
Bracket, Turbocharger (Air passages) Only)
Multiduct (Air Passage Only)
Intake Manifold
Head, Cylinder(Machined and Completed Ass’y-air passages)
Wastegate
Coolant System
Crankcase (water passage only)
Water Pipes
Thermostat Housing
Dual Water Pump
Multiduct (water passage only)
Bracket, Turbocharger (Water passages only)
Head, Cylinder (Machined and Completed assembly – coolant
passage)
Exterior Surfaces
Painted Surfaces all parts
Post Turbine Exhaust Bellows
Exterior Surfaces
APG2000
APG3000
5
1
1
1
2
2
2
2
2
2
VHP, AT, VGF
APG1000
5
2
4
4
4
4
4
4
3
3
3
3
3
3
2
5
5
5
5
5
5
5
6
6
6
6
6
6
4.3
Drawing Designation
4.3.1
Absence of a cleanliness notation on the drawing does not exclude a part from this
standard. Drawings and routings shall have cleanliness class requirements call out per
STD-02-0113 (e.g. - "Cleanliness Class 1 per STD-02-0860”).
4.4
Packaging
4.4.1
The organization shall preserve the conformity of product during internal processing
and delivery to the intended destination. This preservation shall include identification,
handling, packaging, storage and protection. Preservation shall also apply to the
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g
Distributed Power Quality Management System
Part Cleanliness Standard
STD-02-0860
Rev: 4.01
Uncontrolled Copy; Printed on 1/26/17
constituent parts of a product. All parts under this standard must be packaged to
maintain cleanliness until packaging is removed for final assembly.
4.4.2
All purchased parts must be packaged by the supplier in conformance with STD-050852P28A-AL-0002, and parts subject to this standard shall be packaged to maintain
the specified cleanliness for 3 months after receipt at GE.
4.4.3
The end and/or other openings of tubing, fittings, pipe, and elbows subject to this
standard shall be packaged with barrier protection to ensure cleanliness of interior
surfaces.
4.4.4
Packages of parts with a cleanliness significant surface opened at GE for inspection, to
remove single items from lot packages, or any other reason shall be repackaged to
meet the original package requirements or as designated by GE Packaging Engineer.
4.5
Exclusions
4.5.1
The following products are excluded from this standard:


CFR engine systems/parts.
Service parts for obsolete product lines.
4.6
Quality
4.6.1
A process control plan shall be in place for GE final wash systems for core critical
parts, crankcase, crankshafts, connecting rods, cylinder heads and pistons, and for all
parts with cleanliness designated as a key design feature on the part drawing.
4.6.2
Qualification of parts with a cleanliness significant surface, which require a part
process control plan, shall show a final wash operation within the part process control
plan and manufacturing process plan (MPP) per P28A-AL-0002.
5.0
Quality Standards
5.1
Document Control - N/A
5.2
Quality Records – N/A
5.3
Monitoring, Measuring and Continuous Improvement - N/A
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g
Distributed Power Quality Management System
Part Cleanliness Standard
STD-02-0860
Rev: 4.01
Uncontrolled Copy; Printed on 1/26/17
6.0
Responsibilities
N/A
7.0
References
7.1
General Electric Company
PWQMS 4.2.4
Record Control
PW-501
Supplier Deviation and Request for Information Process
DP003
Document Control
P28A-AL-0002
Supplier Quality Requirements
WGSCM 283
Millipore Cleanliness Test Procedures
STD-02-0113
Standard Material Specification Practices
STD-02-0864
Magnetism Specification for Engine Parts
STD-05-0852
Supplier Quality Manual
QOP-02-0411
Noble Parts
7.2
External
MSS SP-55
Visual Method for Evaluation of Surface Irregularities
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PAGE 8 OF 8