Engineering & Construction: Magnetic Particle Test Procedure [PDF]

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MAGNETIC PARTICLE TEST PROCEDURE

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Engineering & construction

MAGNETIC PARTICLE TEST PROCEDURE Document No. DES-1744-QA&QC-05 Purchase Order No.: Equipment/Material: Stack

REV

DATE

DESCRIPTION

PREPARED

CHECKED

00

11-9-2013

FOR FINAL/ CERTIFIED

B

12/2/2013

A

22/7/2012

Issued for client review

RONAK MEHTA

RONAK MEHTA

SAKET KUMAR

Issued for client review

RONAK MEHTA

RONAK MEHTA

SAKET KUMAR

DESCON ENGINEERING FZE

APPROVED

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MAGNETIC PARTICLE TEST PROCEDURE TABLE OF CONTENT

SR. NO

CONTENTS

1.

SCOPE

2.

PERSONNEL

3.

EQUIPMENT AND SUPPLIES

4.

EXAMINATION

5.

INTERPRETATION OF INDICATION

6.

EVALUATION OF INDICATION

7.

ACCEPTANCE STANDARD

8.

REPAIR REQUIREMENTS

9.

DEMAGNETIZATION

10.

POST EXAMINATION CLEANING

11.

LIGIT METER

12.

REPORTING SYSTEM ATTACHMENT - 1 ATTACHMENT – 2

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MAGNETIC PARTICLE TEST PROCEDURE

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QUALITY CONTROL PROCEDURE FOR MAGNETIC PARTICLE EXAMINATION

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1.0

MAGNETIC PARTICLE TEST PROCEDURE

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SCOPE 1.1

This procedure provides the general requirements, methods, techniques and acceptance standards for wet powder examination using the continuous method of examination using AC electromagnetic yoke technique on ferromagnetic materials and welds and where accessibility to yoke contact permits meaningful examination. This procedure is applicable for materials having thickness more than 6 mm.

1.2

This procedure is used to determine the presence of discontinuities which are open to examination surface.

1.3

This procedure is applicable when the temperature of material and wet powder does not exceed 5oC to 52oC.

1.4

This procedure shall be used when specified in the ITP or drawings

1.5

ATTACHMENT 2 to this procedure details the essential and non essential variables applicable for this procedure and their qualified range established by demonstration of this procedure to the satisfaction of AI and certified by NDE Level III as per Article 1, ASME Section V T-150 requirements.

1.6

Any change in an essential variable shall require re-qualification and certification of this procedure by demonstration to AI and applicable revisions to this procedure.

1.7

Any change in the non-essential variable does not require re-qualification but may require revisions to this procedure. REFERENCE DOCUMENT: Saudi Aramco Specification No: SAEP -1145, SAEP-1142 Material Requisition of Hamworthy: MR 1970/07 REV 03 32-SAMSS-004, 32-SAMSS-029 Codes and standards (Latest Edition-2011): ASME SEC-V Edition-2011 Addenda 2011a 2.0

PERSONNEL 2.1

Personnel performing and evaluating examination to this procedure shall be qualified and certified according to Descon written practice, which meets the requirement of SNT-TC-1A (2006 Edition).

2.2

Personnel performing Magnetic Particle Examination - MT Level I / lI Personnel evaluating Magnetic Particle Examination - MT Level II / III

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3.0

MAGNETIC PARTICLE TEST PROCEDURE

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EQUIPMENT AND SUPPLIES 3.1

Temple stick / Surface thermometer to check the examination surface temperature.

3.2

AC Electro-magnetic Yoke suitable to operate on single phase supply.

 

Each alternating current Electro-magnetic yoke shall have a minimum lifting capacity of 10 lbs. (4.5 kg) at minimum and maximum pole spacing that will be used Standard weights of suitable size shall be used to verify this adequacy. These standard weights shall be weighed with scale from a reputable manufacturer and stenciled or otherwise marked with the applicable nominal weight prior to first use. A weight need only be verified again if damaged in a manner that could have caused potential loss material.



This check shall be carried out during the demonstration of this procedure and at least once every year or earlier whenever the yoke is damaged & repaired or when there is a doubt on the its lifting capacity.

3.3

Magnetic Particle Pie Field Indicator to determine the level & direction of magnetic flux density.

3.4

The following brands of magnetic particle powder & white contrast paint SUPPLIER

MATERIAL

PRODUCT

White Contrast Background Paint

WCP-2

Wet Powder (in aerosol can) Black Color

7HF

MAGNAFLUX

Any change in material from the above list shall require procedure demonstration. 3.3

4.0

The materials shall be used within the expiry dates mentioned on the spray cans. Batch Test Certificates are not required. They can however be made available when specifically required by the contract or specifications.

EXAMINATION 4.1

Surface Preparation

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4.1.1 Surfaces to be examined may be in the as welded, as rolled, as cast or as forged condition. Grinding may be necessary in certain cases where surface irregularities could mask unacceptable discontinuities. 4.2

Pre-Examination Cleaning

4.2.1 The surface to be examined and all the adjacent areas within at least 1 in. (25 mm) shall be cleaned by mechanical means and organic solvent to remove any dart, grease, lint, scale, welding flux or spatter, oil or other matter which could interfere with the examination. 4.3

Surface Contrast Enhancement

4.3.1 A thin uniform layer of nonmagnetic surface contrast paint (WCP-2) on uncoated examination surface may be applied temporarily only in amounts sufficient to enhance particle contrast, it shall be demonstrated that the indications can be detected through the enhancement coating as per para T150 of ASME Section V Article 1. Actual thickness measurement of this nonmagnetic contrast enhancement coating is not required. 4.4

Method of examination

4.4.1 Examination shall be done by continuous magnetization method, i.e. the magnetizing current remains “ON” while the examination medium is being applied. 4.5

Examination coverage

4.5.1 Examination shall be conducted with sufficient overlap to ensure 100% coverage. The weld and at least 12.7 mm (1/2”) of the base material on each side of the weld shall be examined where possible. 4.6

Direction of magnetization

4.6.1 At least two(2) separate examinations shall be performed on each area to be examined. During the second examination, the lines of magnetic flux lines shall be approx. perpendicular to those used during the first examination. 4.6.2 The level and direction of flux density can be established before examination using a magnetic pie field indicator. 4.7

Magnetization & application of particles

4.7.1 Yoke shall be positioned with both legs in full contact with the inspection surface as far as practicable. (Shall have a spacing not less than 75mm(3 inch) and not greater than 200mm(8”)) The effective width of magnetizing field is 1/4th of the yoke spacing on each side of a line through the yoke centers.

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4.7.2 The current shall be turned “ON” after the yoke has been properly positioned on the examination surface by a control switch built into yoke handles and the particles applied while magnetization in ON. Flux level can be varied by a control knob (if available) to a desirable degree as assessed by the field indicator. 4.7.3 Wet particles are designed to be suspended in a vehicle contained in a light petroleum based distillate with a wetting agent additive at a given concentration and applied to the test surface by spraying as available in pre-mixed spray cans. It is best for detection of small discontinuities as the suspension allows the particles to float to the leakage field. 4.7.4 Particles shall be applied sparingly with spray can in such a manner that a light, uniform coating settles upon the surface to be examined. 4.8

Examination Temperature

The temperature of the Consumables and the surface of the part to be examined shall be between 5º C (40º F) to 52ºC (125º F). (The part & Consumables shall lieu as per Consumables Manufacturers recommendations) 5.0

6.0

INTERPRETATION OF INDICATIONS 5.1

All examination shall be performed in natural or artificial white light. The white light intensity at the inspection surface shall be minimum of 100 foot-candles (1000 Lux).

5.2

The interpretation shall identify if an indication as false, non relevant, or relevant. False and non relevant indications shall be proven as false or non relevant. Interpretation shall be carried out to identify the locations of indications and the character of the indication.

5.3

Surface discontinuities are indicated by accumulations of magnetic particles which should contrast with the examination surface. The color of the magnetic particles shall be sufficiently different than the color of the examination surface.

5.4

Linear indications are those having a length greater than 3 times the width.

5.5

Rounded indications are those of circular or elliptical shape with a length equal to or less than 3 times the width.

EVALUATION OF INDICATIONS 6.1

All indications shall be evaluated in terms of the acceptance standards of the referencing Code Section given below. Discontinuities on or near the surface are indicated by retention of the examination medium. However, localized surface irregularities due to machining marks or other surface conditions may

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produce false indications. Broad areas of particle accumulation, which might mask indications from discontinuities, are prohibited, and such areas shall be cleaned and reexamined.

7.0

6.2

Indications will be revealed by retention of magnetic particles. All such indications are not necessarily imperfections, however, since excessive surface roughness, magnetic permeability variations (such as at the edge of heat affected zones) etc., may produce similar indications.

6.3

An indication of an imperfection may be larger than the imperfection that causes it; however, the size of the indication is the basis for acceptance evaluation. Only indications which have any dimension greater than 1⁄16 in. (1.5 mm) shall be considered relevant. Any questionable or doubtful indications shall be reexamined to determine whether or not they are relevant.

ACCEPTANCE STANDARD 7.1

Acceptance standard shall be as required by the applicable construction Code such as ASME Code Section I, Section VIII DIV-1 or 2 and ASME B 31.1

7.2   

The following acceptance criteria meet the requirements of the above Codes: All cracks and relevant linear indications. Relevant rounded indications with dimension greater than 3/16 in. (5.0 mm) In-line porosity i.e. four (4) or more relevant porosity indications separated by 1/16 in. (1.5 mm) or less edge to edge.

 In addition, the following criteria shall be applicable for ASME B 31.1 items 

7.3

8.0

Ten (10) or more rounded indications in any 6 sq.in. (3870 mm2) of surface with the major dimension of this area not to exceed 6 in. (150 mm) with the area taken in the most unfavorable location relative to the indications being evaluated. For non-load bearing attachment welds as determined by Design Engineer where this examination is required, the area shall be examined to an extent of 10% of total length or as described on the applicable drawings. The acceptance criteria shall be that the examination area should be essentially free of cracks. Rounded indications are not a factor in acceptability of welds. However, in case of appreciable number & size of rounded indications rectifications and reexaminations may be required.

REPAIR REQUIREMENTS Unacceptable imperfections shall be repaired and reexamination made to assure removal or reduction to an acceptable size. Whenever an imperfection is repaired by chipping or grinding and subsequent repair by welding is not required, the excavated area shall be blended into the surrounding surface so as to avoid sharp notches, crevices, or corners. Where welding is required after repair of an imperfection, the area

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shall be cleaned and welding performed in accordance with a qualified welding procedure. Treatment of indications believed nonrelevant: Any indication which is believed to be nonrelevant shall be regarded as an imperfection unless it is shown by reexamination by the same method or by the use of other nondestructive methods and/or by surface conditioning that no unacceptable imperfection is present. Examination of areas from which defects have been removed: After a defect is thought to have been removed and prior to making weld repairs, the area shall be examined by suitable methods to ensure it has been removed or reduced to an acceptably sized imperfection. Reexamination of Repair areas. After repairs have been made, the repaired area shall be blended into the surrounding surface so as to avoid sharp notches, crevices, or corners and reexamined by the liquid penetrant method and by all other methods of examination that were originally required for the affected area, except that, when the depth of repair is less than the radiographic sensitivity required, reradiography may be omitted. 9.0

10.0

DEMAGNETIZATION 9.1

When residual magnetism in the part could interfere with subsequent processing or usage, the part shall be demagnetized any time after completion of the examination.

9.2

Magnetization with AC yoke has an advantage of a self-demagnetizing effect.

9.3

Demagnetization is not mandatory if it does not pose any problems to subsequent fabrication operation.

POST EXAMINATION CLEANING 10.1

11.0

Post examination cleaning is necessary only in those cases where residual magnetic particles could interfere with subsequent processing or with service requirements. If post cleaning is deemed necessary it shall be done promptly after evaluation by coarse water rinsing or water spray or solvent wiping, which does not adversely affect the part.

LIGHT METER 11.1

Calibrated white light meter was used to establish the light intensity required for examination. It was observed that a 100W/220V bulb gives sufficient light intensity (1000 Lux) at a distance of 300mm.

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11.2

The white light meter shall be calibrated at least once in a year or whenever the meter has been damaged or repaired or there is a doubt on the accuracy of the meter.

11.3

If the meter has not been in use for one year or more, calibration shall be done before being used.

11.4

Calibrated white light meter shall be used when it is required to establish the required light intensity for any other light source and distance.

12.0 REPORTING SYSTEM Examination results shall be reported on the attached form (ATTACHMENT 1). ATTACHMENT – 1

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