Job Procedure Magnetic Particle Testing Of Welds

Job Procedure for Magnetic Particle Testing of welds

Document No:

QHSE/ P 11/CNDT/JP47 /MTAPI 650

Rev

06

Issue Date

Prepared by:

Reviewed by:

Approved by:

Name & Signature: Vipin Kumar

Name & Signature: Prakriti Samanta

Name & Signature: Ganesh Babu

Date: 28.12.2017

Date:28.12.2017

Date: 28.12.2017

28.12.2017

Job Procedure for Magnetic Particle Testing Of welds

TABLE OF CONTENT SECTION

DESCRIPTION

PAGE NO.

AMENDMENT RECORD 1

SCOPE

2

PERSONNEL

3

SURFACE CONDITIONING

4

EQUIPMENT AND SUPPLIES

5

EXAMINATION

6

CALIBRATION

09

7

INTERPRETATION OF INDICATORS

09

8

EVALUATION OF INDICATIONS

04 05 05 05 06

09

9

ACCEPTANCE STANDARD (AS PER ASME SEC I. ASME SEC.VIII; DIV.1 & DIV.2,ASME B 31.1

10

10

REPAIR REQUIREMENTS

10

11

POST CLEANING

11

12

REPORTING SYSTEM

12

13

RECORDING SYSYTEM

12

14

Attachment -1

13

15

Attachment -2

14

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 2 of 14

Job Procedure for Magnetic Particle Testing Of welds

AMENDMENT RECORD Revision No.

Date of Amendment

Section / Checklist Amended

06

28 Dec 2017

Sec 1.8,12.0

05

26 Dec 2016

Name Amendment Details

Reviewed

Approved

Section in changes 1.8,12.0

Prakriti Samanta

Ganesh Babu

1.8,13 & annexure 2

Section - 1.8,13 & annexure 2

Prakriti Samanta

Ganesh Babu

All

Overall formatting and old Procedure Reference No. Aries/MT/API 650/03 changed to new number P 11/CNDT/JP47 MT-API 650

Prakriti Samanta

Ganesh Babu

04

03 Jan 2016

03

27 July 2013

Revised

Ganesh Babu

Ramasamy

02

16.11.2010

Revised

Jessen P.

Ramasamy

01

10.08.2009

Revised

Jessen P.

Ramasamy

00

10.08.2001

Initial Issue

Jessen P.

Ramasamy

All

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 3 of 14

Job Procedure for Magnetic Particle Testing Of welds

1.0

SCOPE 1.1 This work instruction provides the general requirements, methods, techniques and acceptance standards for wet powder examination using the continuous method of examination with AC electromagnetic yoke technique of ferromagnetic materials and welds such as LS, CS, nozzle / branch weld etc. where accessibility to yoke contact permits meaningful examination. 1.2

This work instruction is used to determine the presence of discontinuities such as cracks, slags, lack of fusion and penetration, lamination that are open to the surface.

1.3

Magnetic particle examination shall not be performed if the surface temperature of the part exceeding 125°F (52°C) for the wet particle examination. If temperature exceeds 125°F (52°C), separate procedure to be established by demonstration.

1.4

This work instruction shall be used as specified in the ITP or drawings.

1.5

ATTACHMENT 1 to this procedure details the essential and non-essential variables applicable for this procedure and their qualified range, this procedure is demonstrated to the satisfaction of AI as per T-150(a) of Section V & Certified by Manager QA/QC of Aries Group of Companies.

1.6

Any change in an essential variable shall require demonstration to AI and applicable revisions to this procedure & thereby recertification of the same.

1.7

Any change in the non-essential variable does not require re-qualification but may require revisions to this procedure

1.8

Reference Documents:

Current Applicable Edition of the following documents are referred: ASME -BPVC Section V-2017 Edition

6

ASME-BPVC-Section VIII Division 1 & 2-2017 Edition ASME-BPVC-Section I –Edition 2015 API 653-5TH Edition 2014-Tank Inspection, Repair, Alteration ASNT SNT TC 1A-2011 & 2016 Edition API 650 – 12 TH Edition 2013-Welded Tanks for Oil Storage

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 4 of 14

Job Procedure for Magnetic Particle Testing Of welds

2.0

PERSONNEL 2.1

Personnel performing examination to this work instruction shall be qualified and certified according to Aries Group Of Companies, Document No.which meets the requirement of SNT-TC-1A.

2.2

Personnel performing magnetic particle examination - MT Level II Personnel evaluating magnetic particle examination

2.3

- MT Level II / III.

Personnel As per API 650 8.2.3, Magnetic Particle Examiners shall pass an annual vision test using Jaeger 2 at a distance not less than 12 inches, and shall also be subject to an annual color-contrast test.

3.0

SURFACE CONDITIONING Satisfactory results are obtained when the surfaces are in the as welded, as rolled, as cast or as forged conditions. However surface preparation by grinding / machining may be necessary where surface irregularities could mask indications due to discontinuities. Prior to magnetic particle examination, the surface to be examined and all adjacent areas within at least 25.4mm (1 inch) shall be dry and free of all dirt, grease, lint, scale, welding flux and spatter, oil or other extraneous matter that could interfere with the examination. Cleaning shall be done using organic solvents. The procedure shall be qualified and established in case surface coating of any sort exceeds 50 micron.

4.0

EQUIPMENT AND SUPPLIES 4.1 EM Yokes (electromagnetic) utilizing AC current shall be used for the detection of the discontinuities open to the surface. 4.2 Temple-Stick or Infra-Red thermometer for surface temperature measurement. 4.3 Magnetic Particle Pie Field Indicator to determine the direction of magnetic flux density.

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 5 of 14

Job Procedure for Magnetic Particle Testing Of welds

4.4 Light Meter, to ensure minimum required light Intensity. (1000Lux). The light meter shall be calibrated at least once in a year or whenever the meter has been repeated. 4.5 It was observed that a 60W/220V bulb gives sufficient light intensity (1000 Lux) at a distance of 250mm (10”). 5.0

EXAMINATION 5.1 Examination Medium. 5.1.1 Wet visible ferromagnetic particles of the approved supplier shall be used. The color of the particle shall provide adequate contrast with the surface being examined. The white light intensity at the inspection surface shall be minimum of 1000lux (100 foot-candles). Illumination (natural or supplemental white light) of the examination surface shall be required for the evaluation of indications. The minimum light intensity shall be 1000 lux (100 fc). The light intensity, natural or supplemental white light source, shall be measured with a white light meter prior to the evaluation of indications or a verified light source shall be used. Verification of light sources is required to be demonstrated one time, documented, and maintained in the file

SUPPLIER MAGNAFLUX

MATERIAL White Contrast Paint

PRODUCT WCP-2

Detecting Media (MPI Ink)

SUPPLIER Chemetall

MATERIAL White Contrast Paint Detecting Media (MPI Ink)

7HF

PRODUCT Supramor-4 7HF WCP712

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 6 of 14

Job Procedure for Magnetic Particle Testing Of welds

Any change in material from the above list shall require procedure demonstration. 5.2 Method of Examination. Examination shall be done by continuous magnetization method, i.e. the magnetizing current remains “ON” while the examination medium is being applied and two or three more shots are applied before interpretation while the excess medium is being removed. 5.3

Examination Coverage All examination shall be conducted with sufficient overlap to assure 100% coverage at the established sensitivity. The weld and at least 13 mm (1/2”) of the base material on each side of the weld shall be examined where possible.

5.4

Magnetization technique. The part under examination shall be subjected to continuous magnetization during which particles are being applied and inspection is made before the magnetizing current is turned “OFF”. The magnetizing power of yoke(s) shall be verified prior to use each day the yoke is used

5.4.1 Direction of Magnetization: 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. 5.4.2 Assessment of Level & Direction of Magnetization; the direction of flux density shall be measured before evaluation with a magnetic pie field indicator. When a clearly defined line of particle is not formed on the pie indicator, the magnetizing technique shall be changed and to be established by demonstration. 5.5

Examination Procedure

5.5.1 EM Yoke Technique (for Longitudinal Magnetization) a. EM Yokes shall be positioned with both legs in full contact with the inspection surface as far as practicable and shall have a spacing not less than 75mm (3 inch) or greater than 200mm(8 inch). The effective width of

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 7 of 14

Job Procedure for Magnetic Particle Testing Of welds

magnetizing field is 1/4th of the yoke spacing on each side of a line through the yoke centers. The magnetizing power of yokes shall be verified prior to use each day the yoke is used b.

The current shall be turned “ON” after the EM yokes have been properly positioned on the examination surface by a remote control switch built into yoke handles and the particles applied while magnetizing.

5.5.2 Application of Magnetic Particle a.The white contrast paint in the aerosol can shall be applied on the surface of examination in such a manner that a light uniform coating is produced. b. 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 very small discontinuities as the suspension allows the particles to float to the leakage field. 5.5.3 Removal of Magnetic particles: Wet type particle used and hence this is not applicable 5.5.4 Demagnetization a.Magnetization with AC yoke has an advantage of a self-demagnetizing effect. b. Demagnetization is not mandatory if the component is large enough which will not pose any problems to subsequent fabrication operation. 5.5.5 Light Intensity. a.Calibrated white light meter shall be used to establish the light intensity required for examination. A 60W/220V bulb gives sufficient light intensity (1000 Lux) at a distance of 250mm (10”). b. 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. If the meter has not been in use for one year or more, recalibration shall be done prior to use. Illumination (natural or supplemental white light) of the examination surface shall be required for the evaluation of indications. The minimum light intensity shall be 1000 lux (100 fc). The light intensity, natural or supplemental white light source, Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 8 of 14

Job Procedure for Magnetic Particle Testing Of welds

shall be measured with a white light meter prior to the evaluation of indications or a verified light source shall be used. Verification of light sources is required to be demonstrated one time, documented, and maintained in the file 6.0

CALIBRATION 6.1 Yoke calibration: Each alternating current Electro-magnetic yoke shall have minimum lifting force of 10 lbs. (4.5 kg) at maximum pole spacing that will be used. The magnetizing power of yokes shall be verified prior to use each day the yoke is used. 6.2 Test weight calibration: Standard weights prepared for this purpose 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. 6.3 Light meter calibration: 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. If the meter has not been in use for one year or more, recalibration shall be done before being used

7.0

INTERPRETATION OF INDICATORS. 7.1 All examinations shall be performed with adequate light source. 7.2 Observation of the formation of indication shall be done during the application of particles. Drawings that show the details of joints will help the NDE personnel to interpret and recognize the particle pattern. 7.3 Surface preparation by grinding may be necessary where surface irregularities could mask relevant indications.

8.0

EVALUATION OF INDICATION a. Mechanical discontinuities such as surface roughness, dirt, oils and grease at the surface will be indicated by the retention of the examination medium and can cause false indications.

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 9 of 14

Job Procedure for Magnetic Particle Testing Of welds

b. Any indication that is believed to be non-relevant shall be regarded as an imperfection unless it is shown by re-examination by the same method or by the use of other appropriate NDE method and/or by surface conditioning that no unacceptable imperfection is present. c. True indications are caused by mechanical imperfections in the weld and the adjacent base metal. Relevant indications are those having a dimension greater than 1.5mm (1/16 in). d. Linear indications are those having a length greater than 3 times the width e. Rounded indications are those of circular or elliptical shape with a length equal to or less than 3 times the width. 9.0

ACCEPTANCE STANDARD (AS PER ASME SEC.VIII DIV.1 App-6) 9.1

All welds such as LS, CS including pressure part fillets, such as welds joining nipple/stub/branch to drum, header, pipelines shall be free of the following relevant indications: 9.1.1 All cracks and relevant linear imperfections. 9.1.2 Lack of fusion. 9.1.3 Relevant rounded indications with dimension greater than5mm (3/16 in). 9.1.4 In-line porosity i.e. four (4) or more relevant porosity indications separated by 1.5mm(1/16 in) or less edge to edge.

9.2 For non-load bearing attachment welds as determined by Design Engineer shall be essentially free of cracks, rounded indications is not a factor in acceptability of welds. However, in case of appreciable number & size of rounded indications rectification and re-examinations required. 10.0

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,

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 10 of 14

Job Procedure for Magnetic Particle Testing Of welds

crevices, or corners. Where welding is required after repair of an imperfection, the area shall be cleaned and welding performed in accordance with a qualified welding procedure. Treatment of indications believed non-relevant: Any indication which is believed to be non-relevant 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, re-radiography may be omitted. 11.0

POST EXAMINATION CLEANING When post examination cleaning is required, it should be conducted as soon as practical using a process that does not adversely affect the part. LIGHT METER Calibrated white light meter was used to establish the light intensity required for examination. It was observed that a 60W/220V bulb gives sufficient light intensity (1000 Lux) at a distance of 250mm (10”).

a. 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. b. Calibrated white light meter shall be used when it is required to establish the required light intensity for any other light source and distance. c. 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 Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 11 of 14

Job Procedure for Magnetic Particle Testing Of welds

meter. If the meter has not been in use for one year or more, recalibration shall be done before being used 12.0

REPORTING SYSTEM (Ref: Aries /AMES/MT-01 Rev 00) Examination results shall be reported in Form No: 02 (ATTACHMENT) this shall

6

include as a minimum: a)

Procedure No. And revision

b)

Magnetic particle equipment and type of current

c)

Type of magnetic particle (Wet-Visible)

d)

Examination personnel identity / qualification level

e)

Map or record of indication

f)

Material and thickness

g)

Lighting equipment

h)

Date and time examinations were performed

13.0

RECORDING SYSTEM

All reports shall be retained for a minimum period of three (3) years unless otherwise Specified in the Code or Contract Bid requirement and will be a part of documentation.

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 12 of 14

Job Procedure for Magnetic Particle Testing Of welds

ATTACHMENT -1 Requirements of a Magnetic Particle Examination Procedure (Table-721)

No. 1

Requirement Magnetizing Technique

2

Magnetizing current type or amperage outside range

Essential Variable X

Non-Essential variable ---

X

---

specified by this article or as previously qualified (Eg. AC Yoke) 3

Surface preparation

X

---

4

Magnetic particle (fluorescent/visible, color, particle

X

---

size, wet/dry) 5

Method of particle application – Eg. Spray

X

---

6

Method of excess particle removal

X

---

7

Minimum light intensity

X

---

8

Existing coatings – Eg. None

X

---

9

Nonmagnetic surface contrast enhancement, when

X

---

utilized 10

Performance demonstration, when required

X

---

11

Examination part surface temperature outside of the

X

---

temperature range recommended by the manufacture of the particles or as previously qualified. 12

Shape or size of the examination object

---

X

13

Equipment of the same type

---

X

14

Temperature (within those specified by manufacturer

---

X

or as previously qualified) 15

Demagnetizing technique

---

X

16

Post examination cleaning technique

---

X

17

Personnel qualification requirements

---

X

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 13 of 14

Job Procedure for Magnetic Particle Testing Of welds

ATTACHMENT 2 (Sample Report Form) 6

Doc. Ref.: QHSE/P 11/CNDT/JP47/MT-API 650 Job Procedure for Magnetic Particle Testing | Rev No: 06 | Date: 28.12.2017

Page 14 of 14