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K2, Narayani Apartments, Velan Nagar, Valasaravakkam, Chennai 600 087. Phone : 044 2486 4481 Fax : 044 2377 4125 044 2486 4836 E-mail : sisins@hotmail.com

TITLE: MAGNETIC PARTICLE EXAMINATION 1.0 SCOPE This procedure describes the techniques and acceptance criteria for wet magnetic particle examination carried out on steel casting, forging, wrought materials, Bars and welds, API 6A equipment **. Magnetic particle examination is used on ferromagnetic materials for detecting the presence of discontinuities located at or near the surface. 2.0 APPLICABLE SPECIFICATIONS 2.1 This specification meets the requirement of: ASME Boiler and Pressure Vessel Code Section V. ASTM E 709 API 6A SNT TC 1A

2.2 Unless otherwise specified, the acceptance standard for discontinuities shall be ANSI B16. 34 Annex C for castings, forgings, wrought materials and bars ; ASME Boiler and Pressure Vessel Code Section VIII Division I appendix 6 for welds 3.0 EQUIPMENT Any of the following or equipment can be used. 3.1 Portable magnetic particle equipment AC/HWDC type of M/S. Ormspavan India.

3.2 Portable Electro Magnetic Yoke. Full wave rectified coil / central conductor or Bench magnetising unit / prod unit using half wave rectified AC of M/S. Flaw check Devices, India. 3.3 Portable Magnetic particle equipment AC/HWDC type of M/S. Magnafield Control Ltd, Pune. A remote control switch, built into the prod handles, is provided to permit the Current to be turned on after the prods have been properly placed and turn it off before the prods are removed in order to minimise arcing. Prepared by Approved by

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SOUTHERN INSPECTION SERVICES

K2, Narayani Apartments, Velan Nagar, Valasaravakkam, Chennai 600 087. Phone : 044 2486 4481 Fax : 044 2377 4125 044 2486 4836 E-mail : sisins@hotmail.com

3.4 Calibration of equipment : 3.4.1 Frequency : The equipment shall be calibrated once a year or whenever the equipment is subjected to major electrical repair or damage. 3.4.2 Procedure : The accuracy of the units meter shall be verified by an equipment traceable to National Standards. Comparative readings shall be taken for three different current output level encompassing the usable range. 3.4.3 Tolerance : The units meter reading shall not deviate by more than 10% of full scale relative to the actual current value as shown by the test meter. 4.0 INSPECTION MEDIUM 4.1 Wet non fluorescent Magnetic particle of following shall be used . 1. Supraflux 2. Magnaflux Concentrated paste from M/s. Ferroflux Products Pune.

7C Black powder Product from Magnaflux, USA Repacked and Marketed by M/s. Nagar juna Signode LTd. Hyderabad. 4.2 Wet Magnetic Particle are suspended in kerosene and applied to the test surface by flowing, spraying or pouring. 4.3 Bath Concentration of Magnetic Particle Suspensions : 4.3.1 The initial bath concentration of suspended magnetic particle should be as specified or as recommended by the manufacturer and should be checked by settling volume measurement and maintained at the specified concentration on daily basis. Prepared by Approved by

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SOUTHERN INSPECTION SERVICES

K2, Narayani Apartments, Velan Nagar, Valasaravakkam, Chennai 600 087. Phone : 044 2486 4481 Fax : 044 2377 4125 044 2486 4836 E-mail : sisins@hotmail.com

4.3.2

Bath concentration is determined by measuring its setting volume through the use a pearshaped centrifuge tube.!00 ml of thoroughly mixed sample is taken in the centrifuge tube and allowed to settle for approximately 30 minutes.The volume setting out at the bottom is indicative of the particle concentration . The setting volume shall be from 1.2 to 2.4 ml per 100 ml.of bath sample or as specified by the manufacturer. If the settled particles appear to be loose agglomerates rather than a solid layer, a second sample shall be taken. If still the particles appear to be agglomerated, The suspension shall be replaced since the particles may have become magnetized.

4.3.3 4.3.4

5.0 SENSITIVITY CHECK OF THE EQUIPMENT The sensitively of the magnetic particle examination system shall be evaluated using pie gauges & Referrence block. 6.0 SURFACE PREPARATION The surface being inspected shall be dry and clean. It shall be free from oil, sand, loose rust, thick paint, scale, welding flux and weld splatter. 7.0 INSPECTION TECHNIQUE 7.1 The area shall be circularly magnetized by means of contact electrodes or prods. 7.2 Magnetic Field Strength : 7.2.1 Prod Method

7.2.1.1 Casting and Weldments : A magnetizing current of 90 to 110 amperes per 1 in. (25mm) of prod spacing is used for material under 3/4 in. (19mm) thick and 100 to 125 amperes per 1 in (25 mm ) of prod spacing is used for materials 3/4 in (19 mm ) and over in thickness . Prepared by Approved by

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SOUTHERN INSPECTION SERVICES

K2, Narayani Apartments, Velan Nagar, Valasaravakkam, Chennai 600 087. Phone : 044 2486 4481 Fax : 044 2377 4125 044 2486 4836 E-mail : sisins@hotmail.com

7.2.1.2 Forgings, Wrought Materials and Bars : A magnetising current of 75 to 100 amperes per 1 in. (25 mm ) of Prod spacing is used for materials under in ( 19 mm) thick and 100 to 125 amperes per 1 in .(25mm) of prod spacing is used for materials 3/4 in ( 19 mm) and over in thickness. 7.2.1.3 Prod spacing should not exceed 8 in.(200mm). Prod spacing less than 3 in. (75 mm) is usually not practical due to banding of particles around prods. Care shall be taken to prevent local overheating or burning of the surface being examined. 7.2.1.4 Two separate examination shall be carried out in each area. The second examination shall be performed with prods approximately at right angles to the current flow used for the first examination in that area. 7.2.2 Head Shot Method A magnetising current of 700 to 900 amps/1 inch (25mm) on part diameter upto 5 in (125mm), from 500 to 700 amp/1 in. (25 mm) on dia over 5 in.(125 mm ) and upto 15 in. (375 mm). In case of hollow parts the thickness shall be the criteria for selecting the current rating. 7.3 The examination is carried out by continuous method as described below :

The inspection medium is applied over the surface to provide an abundant source of suspended particles on surface. The inspection medium will be spread over the surface. using a wash bottle after thoroughly agitating the bath. The temperature of the suspension shall not exited 50* C . The batch application is terminated simultaneously with the initiation of magnetising current. Thus there is no application of inspection medium while the magnetising current is flowing. 8.0 EVALUATION OF INDICATIONS 8.1 Discontinuities at or near the surface would be indicated by the retention of the inspection medium. 8.2 All the indications are not necessarily defects, since certain metallurgical Discontinuities and magnetic permeability variations may produce similar indications which are not relevant to the detection of unacceptable discontinuities. These Prepared by Approved by

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K2, Narayani Apartments, Velan Nagar, Valasaravakkam, Chennai 600 087. Phone : 044 2486 4481 Fax : 044 2377 4125 044 2486 4836 E-mail : sisins@hotmail.com

non relevant indications shall be re-examined destructive test method such as penetrant testing. 8.3

by any other suitable non-

Relevant indications are those which result from mechanical discontinuities. Only those indications with major dimension greater than 1.6 mm shall be considered relevant.

9.0 ACCEPTANCE CRITERIA 9.1 Castings : Maximum acceptable indications are as follows : 9.1.1 Linear Indication : a) b) c) 0.3 in. (8mm) long for materials upto 0.5 in. (13mm) thick ; 0.5 in. (13mm) long for materials 0.5 in. to 1 in. (13mm to 25mm) thick 0.7 in. (18mm) long for materials over 1 in. (25mm) thick;

For linear indications, the indications must be separated by a distance greater than the length of an acceptable indication. A linear indication is one with length in excess of three times the width. 9.1.2 Rounded indications : a) b) 0.3in (8mm) dia materials upto 0.5 in. (13mm) thick; 0.5 in. (13mm ) dia materials over 0.5 in. (13mm ) thick.

Four or more rounded indications in a line separate by 0.06 in.(1.5mm) or less edge to edge are unacceptable. Rounded indications are those which are not defined as linear indications. 9.2 Forgings and Rolled or Wrought Materials : Maximum acceptable indications are as follows : Prepared by Approved by

9.2.1

Linear indications :

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a) 0.2 in. (5mm) long for materials 0.5 in .(13mm) or less thick; b) 0.4 in. (10mm ) long for materials over 0.5 in. to 1 in (13mm to 25 mm ) thick; c) 0.6 in. (15mm) long for materials over 1 in . (25 mm) thick. For linear indications, the indications must be separated by a distance greater than the length of an acceptable indication. A linear indication is one with length in excess of three times the width. 9.2.2 Rounded indications : a) b) 0.2 in. (5mm) dia for materials upto 0.5 in. (13mm) thick; 0.3 in. (8mm) dia for materials over 0.5 in. (13mm) thick.

For or more rounded indications in a line separated by 0.06 in (1.5mm) or less edge are unacceptable. Rounded indications are those which are not defined as linear indications. 0909 9.3 Welds : All surface examined shall be free of : a) b) c) relevant linear indications relevant rounded indications greater than 3/16 in Four or more relevant rounded indication in a line separated by 1/16 in. or less edge to edge.

A linear indication is one having a length greater than three times the width. A Rounded indication is one of circular or elliptical shape with a length Equal to or less than three times its width. Prepared by Approved by

10.0

DEMAGNETISATION

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K2, Narayani Apartments, Velan Nagar, Valasaravakkam, Chennai 600 087. Phone : 044 2486 4481 Fax : 044 2377 4125 044 2486 4836 E-mail : sisins@hotmail.com

Unless otherwise specified in work order , demenetistion carried out. 11.0 POST EXAMINATION CLEANING

shall not be

When inspection is concluded, the magnetic indicating material shall be remove by any suitable means leaving the product in a dry and clean condition. 12.0 PERSONNEL 12.1 12.0 Personnel performing inspection in accordance with this specification shall be qualified to at least level I as per ASNT requirement RECORD A record to results along with procedure parameters shall be maintained by level I inspector. Prepared by Approved by