Qc-006-24

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Procedure for Magnetic Particle Examination (Technique: Fluorescence Magnetic Particle Techniques)

Procedure Number & Revision

QC-006 Rev. 24

Revision Date:

04 - November - 2020

Activity

Name

Designation

Prepared By:

Kashyap Bhatt

NDT Level III (MT)

Reviewed By:

Pritesh Desai

Director Operations

Approved By:

Kashyap Bhatt

NDT Level III (MT)

Signature

Kashyap N. Bhatt

Director Operations

NDT Lc-'-'c! "! . . r;;: Pract;ce5>~7 & As pc: ASNT NDT Level ill ©W (ÿ° Certificate No. £3A|))proved By NDT Level ill (MT)

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This document revised 22 to Revision 23 for following points: Page Number/ Details of Changes Paragraph Number Reference of calibrated gauss meter added. 4.1

Kashyap N. Bhatt

mg** Director Operations

,

NDT Level ill ASNT NDT Level lil Certificate No. 99541

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rovedB,coul/0i)

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Details of Last Six Revisions of this Procedures (including this revision): Procedure Revision Number 18

Date of Revision

Developed By

Reviewed By

Approved By

dd-mm-yyyy 29-06-2016

NDT Level I

M.R.

NDT Level I

19

16-08-2016

20

03-03-2018

21

05-01-2019

22

21-10-2019

23

23-12-2019

24

04-11-2020

(MT) NDT Level I (MT) NDT Level I (MT) NDT Level I (MT) NDT Level I (MT) NDT Level I (MT) NDT Level I (MT)

M.R.

M.R.

Director Operations Director Operations Director Operations

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(MT) NDT Level I (MT) NDT Level I (MT) NDT Level I (MT) NDT Level I (MT) NDT Level I (MT) NDT Level I (MT)

Details of Validation of this Procedures and subsequent revisions of this procedure:

1. Procedure Qualification (process validation) of Revision 18 of this procedure was done on 25/July/2016 as per essential variables and non-essential variables specified in API-20D 2013 Edition on representative reference part with artificial discontinuity as well as with pie gauge as per Note mentioned in Paragraph 9.2.4 of API 20D of 2013 Specification . 2. No magnetic particle testing parameters were changed in Revision 19 to Revision 21 of this procedure. 3. Revision 21 was re-validated on 05-January-2019 and two separate documents devejoped as follows: a. Procedure validation records as per Paragraph 5.7.1.5 of API Q1 Specification - 9th Edition with Addendum 2. b. Procedure qualification records as per Paragraph 9.2 of API 20D -2013 Edition with Addendum - 1. 4. Revision 22 not required re-validation. 5. Revision 23 not required re-validation. 6. Revision 24 not required re-validation.

Kashyap N. Bhatt

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1 Scope 1.1 This procedure covers the examination requirements, examination and reporting criteria of wet continuous magnetic particle examination of ferromagnetic material. 1.2 This procedure includes magnetic particle examination with fluorescence magnetic

particle techniques. 1.3 This procedure is applicable to casting components, forging components as well as welded joints for equipments to be designed, manufactured and tested as per API 6A and other applicable Codes. 2

Reference Standards 2.1 API 6A - 21st Edition with Errata 1. 2.2 API 16C - 2nd Edition Addendum 1, Errata 4. 2.3 ASTM E 709 - 2015. 2.4ASME Boiler and Pressure Vessel Code: Section V, Nondestructive Examination, Article 7 - 2019 Edition.

3

Personal Requirement 3.1 The person performing the Magnetic Particle Examination shall be certified to NDT Level I (Magnetic Particle Testing) or NDT Level II (Magnetic Particle Testing) or NDT Level III (Magnetic Particle Testing) in accordance with Written Practice number QC023 - latest revision. 3.2 The person interpreting and evaluating the results the Magnetic Particle Examination shall be certified to NDT Level II (Magnetic Particle Testing) or NDT Level III (Magnetic Particle Testing) in accordance with Written Practice number QC-023 - latest revision.

4

Equipment and Accessories Requirements:

4.1 Following equipment and accessories are required for Magnetic Particle Examination as per this Procedure. Reference Paragraph Of This Equipment / Accessories Required

_

s/m 1. 2. 3.

4.

Procedure Paragraph No.: 9.0 White Light Source Paragraph No.: 9.0 Calibrated Photometer For verification of job Temperature meter for measuring temperature of temperature within useful surface. temperature range for material. Paragraph No. 8.0 grinding wheel with brush, Grinder Wire

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Electromagnetic Yoke Magnetic Field Indicator U]traviolet lamp with filter Calibrated Ultraviolet light intensity measuring meter. Ferromagnetic powder suspension. ASTM Pear Shape Tube. Calibrated dimension measuring instrument Slotted Shim CX-230 type Calibrated Gauss Meter

5. 6. 7. 8. 9. 10. 11. 12. 13.

5

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Paragraph No. 6.0 Paragraph No. 11.0 Paragraph No. 6.0. Paragraph No. 6.0, 9.0. Paragraph No. 7.0. Paragraph No. 7.0. Paragraph No.: 12 & 13 Paragraph No. 11.0 Paragraph No. 15.0

Safety Requirements:

5.1 As a minimum, safety requirements mentioned in following table must be followed. In addition to safety requirements mentioned in following table, all other applicable safety requirements applicable at manufacturing shop or site shall be followed.

S/N# 1.

Safety Requirements Electrical Safety

2.

Personnel Safety

3.

Fire Safety

Remarks a. The cables used with ultraviolet lamp as well as electromagnetic yoke must be shock proof with proper connectors. The connecters shall be connected to electric plug having proper earthling for preventing shock._ a. The incandescent lamp whenever used must be used in glass envelop having shielding on top side for preventing glare in operator's eyes. b. The ultraviolet lamp must always use with filter. The filter shall have any crack. c. The ultraviolet lamp must always face down. d. Avoid direct contact on ultraviolet light on eyes and skin. e. Hand gloves for preventing direct contact of hand skin with ferromagnetic material or test surface. f. Nose mask for preventing air bon parting entering in inertia of operator. g. Wear safety shoes and safety helmet. h. Wear safety belt during working at height. _ a. Pre-mixed bath samples or oil vehicle for wet ferromagnetic particle suspension are flammable. They must be stored in dry and cooled place having storage temperature range specified by the manufacturer. b. Material Safety Data Sheet specified by the pre-mixed ferromagnetic suspension bath material manufacturer must be followed.

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c. Pre-mixed ferromagnetic bath suspension or oil based wet suspension must be protected from welding arc, grinding spark etc, which can cause fire.

_

6. Magnetic Particle Testing Equipment

6.1 6.2

Electromagnetic yoke, capable of working with AC as well as HWDC/DC mode shall be used for examination. The lifting force relates to the electromagnetic strength of the yoke. The magnetizing force of a yoke shall be checked by determining its lifting power on a steel plate as follows:

Type Current

AC DC

Minimum Yoke Lifting Force Yoke Pole Leg Spacing 4 to 6 inch to 2 4 inch. (100 to 150 mm) (50 to 100 mm) 4.5 Kg = 23.0 Kg 13.5 Kg

6.3

The lifting power of electromagnetic yoke shall be check daily prior to first use. If the electromagnetic yoke has not used continuous three months or more, then also the lifting power of electromagnetic yoke shall be checked every three months during such not used period. Such verification shall be documented. The lifting power of the electromagnetic yoke shall also be checked whenever yoke has undergone any maintenance or part replacement.

6.4

Ultraviolet Light:

6.4.1 The Ultraviolet Light (UV-A Light) used during examination shall have minimum intensity of 1000 p W/ cm2 at the examination surface. Intensity of ultraviolet light at examination surface shall be verified each time prior to starting magnetic particle examination. 6.4.2 The Ultraviolet Light (UV-A Light) shall be used with constant voltage 6.4.3

6.4.4

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supply transformer. The ultraviolet lamp of UV-A Light must have protective filter for avoiding very low wavelength ultraviolet light. The UV-A light shall operate in the range between 330 nm to 400 nm. The Ultraviolet Light shall be warmed up for time period as specified by ultraviolet light manufacturer.

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7. Magnetic Particle Testing Material

7.1 Fluorescence Magnetic Particles, glow with a bright yellow-green color when view under black light and suspended in water or kerosene with the concentration of 0.1 mL to 0.4 mL in 100 mL of bath sample shall be used. Pear shaped centrifuge tube shall be used for measuring concentration of ferromagnetic particles in the suspension. 7.2 Ferromagnetic particles used for magnetic particle examination must be free from impurities. 7.3 Following magnetic particle testing material shall be used:

_

S/N#

Magnetic Particle Testing Material

Make

Product Code

1.

Fluorescence magnetic powder for mixing in kerosene for preparing magnetic particle testing bath concentration for temperature up to 48°C. _

MAGNAFLUX

MAGNAFLUXMG410

7.5 Concentration of Magnetic Particle Suspension: 7.5.1 Bath concentration shall be determined by settling volume through the use of an ASTM pear-shaped centrifuge tube with a 1-mL stem (0.05 mL division) for fluorescence particles. The settling time shall be 60 minutes for non aqueous suspension (oil suspension). The volume setting out at the bottom of the tube is indicative of the particle concentration in the

bath. 7.5.2 If the bath concentration is low in particle content, add the sufficient amount of particle materials to obtain desired concentration; if the suspension is high in the material add sufficient water to obtained desired concentration. 7.5.3 If the settled particle appears to be loose agglomerates rather than a solid layer, take a second sample. If still agglomerated, the particles may have bacome magnetized; and shall be replaced 8

Part Preparation 8.1 The surface of the part to be examined shall be clean, dry and free of contaminates such as oil, grease, loose rust, loose sand, loose scale, lint, thin paint, welding fluxes, weld spatter etc. 8.2 Surface preparation shall be done by either wire brush or by grinding or by

8.3 8.4

machining process. Magnetic Particle Testing shall be performed after final heat treatment and final machining operation. The temperature of the test surface shall be within the temperature range heÿ, specified by the mangntic particle testing chemicals manufacturers. I

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temperature shall be measured by the calibrated surface temperature measuring

8.5

9

instrument. Before magnetic particle examination is conducted, a check of the examination surface shall be conducted to locate any surface discontinuity openings which may not attract and hold magnetic particles because of their width.

Lighting Requirements:

9.1

9.2 9.3

Wet Fluorescent Magnetic particle Testing shall be carried out in well darkened area, with minimum 1000 microwatt / cm2 ultraviolet light (UV-A Light) intensity at examination surface. As far as practical, wet fluorescent magnetic particle examination shall be performed in hood covered with black light. Maximum allowable white light at examination surface shall be 20 Lux during wet fluorescent magnetic particle testing. Light intensity shall be measured at the beginning of examination and at every interval of four hours of continuous use. Both ultraviolet light (UV-A Light) intensity meter as well as white light intensity meter shall be calibrated prior to first use and at maximum interval of 6 months thereafter. The light meter shall also be calibrated whenever the light meter has undergone any maintenance or part replacement.

10 Part Magnetizing and Application of Medium (As Per Continuous Method) 10.1 The person pe'rforming magnetic particle examination as well as the inspector shall be in the darkened area for at least 5 minutes just before the examination if testing is to be carried out with wet fluorescence magnetic particle testing. 10.2 The current used during Magnetic Particle Testing shall be HWDC/DC as specified on electromagnetic yoke. 10.3 Magnetic particle suspensions shall be applied by spraying 10.4 The magnetizing current shall be turned on after the particles have been applied. The flow of particle shall be stopped with the application of current. 10.5 Wet particles may be applied during the application of magnetizing current, if they are not applied directly on examination surface and are allowed to flow over examination area. Ferromagnetic particles will be attracted to leakage flux on the examination surface and will form an indication. Excess ferromagnetic particles will be flow away with suspension. 10.6 At least two separate examinations shall be performed on each area by placing electromagnetic yoke in minimum two perpendicular directions such that during the second examination, the lines of magnetic flux shall be established approximately perpendicular to those during the first examination on area under examination. 10.7 Magnetic particle examination shall be performed with sufficient overlap (minimum 15% or 25 mm whichever is higher).

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11 Verification of Magnetic Field Strength: 11.1 The pie type magnetic field indicator shall be used for verifying presence and direction of established magnetic field. The pie gauge shall be as per Figure 14 of ASTM E-709. 11.2 Adequacy of established magnetic field shall be verified with CX-230 type Slotted Shim as specified in Paragraph 20.8.5.2 of ASTM E-709 and Appendix X2 of ASTM E709. Shims are placed in the area(s) of interest with notches toward the surface of the part being examined. Shims shall be taped or glued such that the defective side of shim shall be in contact with examination surface during verification of adequacy of established magnetic field. Use enough shims or place the shims in multiple area to ensure proper field direction and strength area obtained. 11.3 A suitable field strength is indicated when a clearly defined line of magnetic particles forms across the established magnetic field (checked as per Paragraph 11.2 above) when the magnetic particles are applied simultaneously with the magnetizing

force. 11.4 Slotted Shim can also be used to for verifying presence and direction of established magnetic field in place of pie gauge. 12 Interpretation Indications 12.1 All valid indications formed by magnetic particle examination are the result of magnetic flux leakage fields. Indications may be relevant, non-relevant or false. 12.2 A relevant indication are produced by flux leakage fields which are having any dimension greater than 1.5 mm and are result of discontinuities. 12.3 A linear relevant indication is one having length (major dimension) equal to or greater than three times the width (minor dimension). 12.4 A rounded indication is one of circular or elliptical shape with the length (major dimension) less than three times the width (minor dimension). 12.5 Inherent indications not associated with surface rupture (i.e. magnetic permeability variations, non-metallic stringers) shall be considered as non-relevant. 12.6 If indications are believed to be non-relevant, they shall be examined by liquid penetrant surface NDE methods in accordance with ASTM E165, or removed and re¬ inspected, to prove their non-relevancy.

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13 Evaluation of Indications For Acceptance 13.1 Refer overleaf table for interpretation and evaluation criteria for acceptance of Magnetic particle examination results:

Sr. No.

Job specification

Reference Annexure Number of this procedure for interpretation and evaluation of Magnetic particle Examination

1. 2.

API 6A Specification API 16C Specification

Annexure A Annexure B

13.2 If the customer purchase order specification requires stringent acceptance criteria then specified in above table for applicable job specification then the same shall be followed in that job. 13.3 If the customer purchase order specification requires liberal acceptance criteria then specified in above table then also as a minimum acceptance criteria specified in above table shall be followed for applicable job specification. 13 Recording of Indications 13.1 The permanent records of the location, direction and frequency of indication will be made by sketching the indication location, length and frequency. 14 Reporting 14.1 Reporting of Magnetic Particle Examination shall be as per report format number: JFC-F-QC-05 Latest Revision.

15 Demagnetization: 15.1 After completion of magnetic particle testing as well as interpretation and evaluation of indications, the demagnetization process shall be performed if the residual magnetic field of the test surface found more than 3 Gauss. 15.2 Demagnetization shall be performed by pulling the electromagnetic yoke to minimum 92 cm away from test surface and simultaneous tilting the electromagnetic yoke while AC current is flowing from electromagnetic yoke. 15.3 The residual magnetic field shall be maximum 3 Gauss in the test surface after demagnetization process. 15.4 The gauss meter must have accuracy of 1 Gauss. The gauss meter shall be calibrated prior to first use and at maximum interval of 6 months thereafter. The gauss meter shall also be calibrated whenever it has undergone any maintenance or part

replacement.

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ANNEXURE A: Details of interpretation and evaluation for Magnetic Particle Examination as per API 6A Specification:

Following criteria shall be applied when drawing / purchase order specification / job specification requires Magnetic Particle examination as per API 6A Specification: 1.0 Interpretation of indications observed during Magnetic Particle Examination: 1.1 An indication is the evidence of a mechanical imperfection. An indication of an imperfection may be larger than the imperfection that caused it, however the size of the indication is the basis for acceptance evaluation. 1.2 Only indications with major dimensions greater than 1.5 mm shall be considered relevant. 1.3 A linear relevant indication is one having length (major dimension) equal to or greater than three times the width (minor dimension). 1.4 A rounded indication is one of circular or elliptical shape with the length (major dimension) less than three times the width (minor dimension). 1.5 If indications are believed to be non-relevant, they shall be examined by liquid penetrant surface NDE methods in accordance with ASTM E165, or removed and re¬ inspected, to prove their non-relevancy. 2. Acceptance Criteria: Sr. No.

Job Description

Acceptance Criteria Details

2.1

Material - Surface NDE: Magnetic Particle Examination

For PSL 3 / 3G, magnetic particle examination shall be performed by wet fluorescent

2.2

Weld - Surface NDE: Magnetic Particle examination

technique. The following acceptance criteria shall apply: a. No relevant linear indication. b. No relevant rounded indication with a major dimension equal to or greater than 5 mm. c. No more than 10 relevant indications in any continuous 40 cm2 area. d. No four (or more) relevant rounded indications in a line separated by less than 1.6 mm (edge-to-edge). e. No relevant indications in pressure contact sealing surface. _ Examination shall include a minimum of 13 mm of adjacent base metal on both sides of the weld. For PSL 3 / 3G, magnetic particle examination shall be performed by wet fluorescent technique. The following acceptance criteria shall apply: a. No relevant linear indication. b. No rounded indication greater than 3 mm for welds whose depth is 16 mm or less or no rounded indication greater than 5 mm for welds whose depth is greater than 16 mm. c. No more than 10 relevant indications in any continuous 40 cm2 area. d. No four (or more) relevant rounded indications in a line separated by less than 1.6 mm (edge-to-edge). e. No relevant indications in pressure contact sealing surface.

_

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Sr. No.

Job Description

Acceptance Criteria Details

2.3

Repair Weld PSL 2 and PSL3/3G (Paragraph 7.4.2.2.13 for PSL 2 and PSL 3 /3G)

Examination shall include a minimum of 13 mm of adjacent base metal on all sides of the weld. Surface preparation for welding shall be examined prior to welding to ensure defect removal to acceptable level method and acceptance criteria shall be as per raw 2.2 above. The following acceptance criteria shall apply: a. No relevant linear indication. b. No rounded indication greater than 3 mm for welds whose depth is 16 mm or less or no rounded indication greater than 5 mm for welds whose depth is greater than 16 mm. c. No more than 10 relevant indications in any continuous 40 cm2 area. d. No four (or more) relevant rounded indications in a line separated by less than 1.6 mm (edge-to-edge). e. No relevant indications in pressure contact sealing surface. _

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Certificate No. 99541

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ANNEXURE B: Details of interpretation and evaluation for Magnetic Particle Examination as per API 16C Specification:

Following criteria shall be applied when drawing / purchase order specification specification requires Magnetic Particle examination as per API 16C Specification:

/

job

1.0 Interpretation of indications observed during Magnetic Particle Examination: 1.1 An indication is the evidence of a mechanical imperfection. An indication of an imperfection may be larger than the imperfection that caused it, however the size of the indication is the basis for acceptance evaluation. 1.2 Only indications with major dimensions greater than 1.5 mm shall be considered

relevant. 1.3 A linear relevant indication is one having length (major dimension) equal to or greater than three times the width (minor dimension). 1.4 A rounded indication is one of circular or elliptical shape with the length (major dimension) less than three times the width (minor dimension). 1.5 If indications are believed to be non-relevant, they shall be examined by liquid penetrant surface NDE methods in accordance with ASTM E165, or removed and re-inspected, to prove their non-relevancy. 2.0 Acceptance Criteria: Sr. No.

Job Description

2.1

Material (Paragraph 7.4.6.9.2.5)

2.2

Surface NDE: Particle examination (Paragraph 7.4.6.11.3.3 and 7.6.9.2)

Weld

-

Magnetic

Acceptance Criteria Details

Following acceptance criteria shall be applied: a. No Relevant Linear indication. b. No relevant rounded indication with a major dimension equal to or greater than 4.8 mm. c. No more than ten relevant indications in any continues 152.4 mm (6 Inch) square area. d. Four or more relevant indications in a line separated by less than 1.6 mm (edge to edge) are unacceptable. e. No relevant indication in pressure contact sealing surface. Examination shall include a minimum of 13 mm of adjacent base metal on both sides of the weld. Following acceptance criteria shall be applied: a. No Relevant Linear indication. b. No rounded indication greater than 3.2 mm for weld whose depth is 15.9 mm or less and 4.8 mm for weld whose depth is greater than 15.9 mm. c. No more than ten relevant indications in any continues 152.4 mm (6 Inch) square area. d. Four or more relevant indications in a line separated by less than 1.6 mm (edge to edge) are unacceptable. e. No relevant indication in pressure contact sealing surface. _

...

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Sr. No.

Job Description

Acceptance Criteria Details

2.3

Defect removal area prior to weld repair (Paragraph 7.4.6.12) Repair weld (Paragraph 7.4.6.12.)

Surfaces prepared for repair welding shall be examined prior to welding to ensure defect removal of acceptable levels.

2.4

Examination shall include a minimum of 13 mm of adjacent base metal on all sides of the weld. The following acceptance criteria shall apply: Following acceptance criteria shall be applied: a. No Relevant Linear indication. b. No rounded indication greater than 3.2 mm for weld whose depth is 15.9 mm or less and 4.8 mm for weld whose depth is greater than 15.9 mm. c. No more than ten relevant indications in any continues 152.4 mm (6 Inch) square area. d. Four or more relevant indications in a line separated by less than 1.6 mm (edge to edge) are unacceptable. e. No relevant indication in pressure contact sealing surface.

_

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