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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 APPROVED
00 11-9-2013 FOR FINAL/ CERTIFIED


B 12/2/2013 Issued for client review RONAK MEHTA RONAK MEHTA SAKET KUMAR
A 22/7/2012 Issued for client review RONAK MEHTA RONAK MEHTA SAKET KUMAR
DESCON ENGINEERING FZE

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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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QUALITY CONTROL PROCEDURE

FOR

MAGNETIC PARTICLE EXAMINATION

























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1.0 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 5
o
C to 52
o
C.
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 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



MAGNAFLUX



White Contrast
Background Paint

Wet Powder (in aerosol can)
Black Color

WCP-2


7HF


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

3.3 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.

4.0 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 T-
150 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 5 C (40 F) to 52C (125 F). (The part & Consumables shall lieu as per
Consumables Manufacturers recommendations)

5.0 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.
6.0 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.

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 116 in. (1.5 mm) shall
be considered relevant. Any questionable or doubtful indications shall be
reexamined to determine whether or not they are relevant.

7.0 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
Ten (10) or more rounded indications in any 6 sq.in. (3870 mm
2
) 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.
7.3 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 re-
examinations may be required.

8.0 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 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.

10.0 POST EXAMINATION CLEANING

10.1 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.

11.0 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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