Procedure No.

: OPS-PR-MPI-006-QP
Initial Issue Date : 20-Feb-2011
Revision No. : 00

Page 1 of 14
TITLE: MAGNETIC PARTICLE EXAMINATION

Company Name
GLOBAL INSPECTION SERVICES W.L.L.
Mailing Address P. O. Box 22410
DOHA QATAR

Telephone + (974) 4460 4550

Fax + (974) 4460 4054

Email technical.qa@gismea.com

Document Title MAGNETIC PARTICLE EXAMINATION

Document Ref. # OPS-PR-MPI-006-QP Revision 00

Client

Contract #

Project Description

00 Revised to incorporate Anup Nair M.R. Sarath Babu

20-Feb-2011 client comments Technical Support ASNT NDT Level III (184206)

Revision Date Revision Details Prepared By Reviewed and Approved By

 Procedure No. : OPS-PR-MPI-006-QP
Initial Issue Date : 20-Feb-2011
Revision No. : 00

Page 2 of 14
TITLE: MAGNETIC PARTICLE EXAMINATION

TABLE OF CONTENTS
1. SCOPE

2. QUALIFICATION OF PERSONNEL

3. REFERENCED CODES AND/OR DOCUMENTS

4. DEFINITIONS

5. SUMMARY OF TEST METHOD

6. CLASSIFICATION OF METHODS

7. SURFACE PREPARATION

8. INSPECTION MEDIUM

9. EQUIPMENT

10. EXAMINATION PROCEDURE

11. SAFETY

12. RECORDS

13. ACCEPTANCE CRITERIA

14. REPORT FORM

APPENDIX

I. Ultraviolet (UV) Light Intensity Log

 Procedure No. : OPS-PR-MPI-006-QP
Initial Issue Date : 20-Feb-2011
Revision No. : 00

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TITLE: MAGNETIC PARTICLE EXAMINATION
1. SCOPE:

1.1. This procedure establishes the minimum requirements for wet, fluorescent and visible methods
of magnetic particle examinations of welds and components intended for Installation project of
low pressure associated gas compressor at Halul Island. The methods covered in this
procedure can be effectively used when performing specific tests on welds and components
and detect surface and other discontinuities on or near the surfaces on a variety of
ferromagnetic materials.

1.2. Use of Magnetic Yoke is limited to the detection and evaluation of surface defects that are open
to the surface and other discontinuities on or near the surfaces of ferromagnetic materials. Use
of permanent magnets is prohibited by this procedure.

1.3. The approved procedure shall be qualified if required by the client for the following techniques,
when employed, on sample pieces of relevant geometry
1.3.1. Any technique to be used for examination of variable geometry welds
1.3.2. Flexible cable or coil techniques
1.3.3. Electromagnet (AC/DC)
1.3.4. Permanent magnet
1.3.5. Fluorescent technique
The qualification shall demonstrate satisfactory surface preparation, application of contrast
coating, adequate magnetization level and direction.

2. QUALIFICATION OF PERSONNEL:

2.1. All magnetic particle examination personnel shall be qualified and certified to Level II in
accordance with GLOBAL INSPECTION SERVICES (hereinafter called GIS) Written Practice
OPS-PR-WP-01, prepared in accordance with SNT - TC - 1A, 2001 Edition of ASNT and with a
minimum two years post certification experience.

2.2. The examination shall be performed, evaluated and interpreted by a MT Level II qualified
personnel.

3. REFERENCED CODES AND/OR STANDARDS

3.1. ASME Boiler and Pressure Vessels Code Section V, Article 7 (2007 Ed.)

3.2. ASTM-Metal Test Methods and Analytical Procedures Vol: 03.03 Non-Destructive Testing

3.2.1. ASTM - E 709/01 Standard Guide for Magnetic Particle Examination

3.2.2. ASTM - E 1444/05 Standard Practice for Magnetic Particle Examination

3.3. ES-S-60 QP Specification for the Non Destructive Testing of Welds

3.4. ES-5.14.0010 Specification for the fabrication, Inspection and installation of Carbon,
Carbon Manganese and Low Alloy Ferrite Process Pipe work.
 Procedure No. : OPS-PR-MPI-006-QP
Initial Issue Date : 20-Feb-2011
Revision No. : 00

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TITLE: MAGNETIC PARTICLE EXAMINATION
4. DEFINITIONS:

4.1. Magnetic Particles

Finely divided ferromagnetic particles capable of being individually magnetized and attracted to
distortions in a magnetic field.

4.2. Magnetic Field

The volume within and surrounding either a magnetized part or a current-carrying conductor
wherein a magnetic force is exerted.

4.3. Wet Method

A method of MT that uses finely divided magnetic particles suspended in a liquid vehicle as the
indicating material. The particles may be either fluorescent or nonfluorescent. The suspensions
are liberally applied to the test object by flowing the liquid over the test object.

4.4. Circular Method of Magnetization

A low voltage, high amperage current is passed through the item being inspected or through a
central conductor which passes through a hollow part of the test object. The magnetic flux
induced by this current in the test object is at right angles to the direction of current flow. Either
the wet method of testing may utilize the circular magnetization

4.5. Longitudinal Magnetization

A low voltage, high amperage current is passed through a solenoid (an electrical conductor
formed into a circular coil), which is placed around the item being tested. The current induces a
magnetic flux longitudinally within the coil and within the part being tested. Longitudinal
magnetization can also be induced by the use of a yoke. A yoke is a C-shaped piece of soft
magnetic material around which is wrapped a coil carrying the magnetizing current. When a
part is placed across the opening of the C-shape, it produces a magnetic field wherein the lines
of force traverse the part in a direction essentially parallel with its longitudinal axis.

4.6. Continuous Method

When the magnetic particles are applied during the time the magnetizing current is applied is
known as the continuous method.

4.7. Residual Method

The application of the magnetic particles after the magnetizing current has stopped flowing and
the residual magnetic field is used to form indications is known as the residual method.

4.8. Relevant indication

An indication resulting from a discontinuity requiring evaluation.

4.9. Magnetic Particle Indications

Surface discontinuities produce sharp and distinct patterns while near-surface
discontinuities produce less distinct indications, broad, rather than sharp.
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TITLE: MAGNETIC PARTICLE EXAMINATION
5. SUMMARY OF TEST METHOD

5.1. This is a non-destructive test method based on the principle that magnetic lines of force, when
present in ferromagnetic materials, will be distorted by a change in material continuity, such as
a sharp dimensional change or a discontinuity. A discontinuity lying open to or close to the
surface of a magnetized test part, causes the distortion of the flux lines at the surface. This
condition is termed as "flux leakage". When fine magnetic particles are distributed evenly over
the area of discontinuity where flux leakage exists, they will be held in place. The accumulation
of particles at points of flux leakage will be visible under proper lighting conditions and are
characteristic of the type of discontinuity that is detected. Maximum sensitivity exists for
discontinuities at the surface. It diminishes rapidly with the increasing depth of subsurface
discontinuities. Discontinuities oriented parallel to the lines of force will remain essentially
undetected. Therefore, to detect discontinuities of random orientation, it usually necessary to
magnetize the part twice or more to induce magnetic lines of force in a suitable direction in
order to perform an adequate examination.

6. CLASSIFICATION OF METHODS

6.1. Detailed sequence of magnetic particle examination methods and technique of magnetization
are given in the following paragraphs. Paragraph 10 covers magnetic particle examination of
welds or base metal by the alternating or direct current electromagnet yokes method.

7. SURFACE PREPARATION

7.1. Surface Condition:

Surface of the part to be tested shall be free of all dirt, grease, lint, scale, welding flux and
splatters, oil or other extraneous matters that could interfere with the examination. Thin non-
conductive coatings such as paints may not hamper the formation of indications; however in the
area electrical contacts they must be removed in order to avoid sparking. As-welded, as-rolled,
as-cast or as-forged surfaces shall be subject to MT provided they are clean and surface
irregularities do not exist. Part surface temperature shall not exceed a maximum shall not
exceed 122F for particle suspensions prepared in oil vehicles.

7.2. Surface Cleaning:

Cleaning may be accomplished using solvents, paint removers, sand or grit blasting, wire-
brushing etc. If required the surface shall be dressed out with light grinding to remove
roughness or irregularities. The grinding direction shall not coincide with the expected flaw
orientation. When testing a local area, such as a weld, the area 1" (25mm) adjacent to all side
of the area of interest to be examined shall also be cleaned to the extent necessary to permit
detection of indications.

8. INSPECTION MEDIUM

The magnetic particles used for wet magnetic particle examination techniques shall be of finely
divided ferromagnetic material of high permeability and low retentivity, free from contaminants like
rust, grease, paint, dirt or other material which might interfere with their proper functioning. They
shall be of such shape, size and color as to provide adequate sensitivity and contrast for the
intended use.
 Procedure No. : OPS-PR-MPI-006-QP
Initial Issue Date : 20-Feb-2011
Revision No. : 00

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TITLE: MAGNETIC PARTICLE EXAMINATION

8.1. The Wet method particles used shall be either black or red color, readily available aerosol cans.
The selection of particular color shall be one that contrasts most with the test surface. The wet
particle inspection shall also utilize fluorescent particles which are readily available in aerosol
spray cans.

9. EQUIPMENT/CONSUMABLES

9.1. Selection of a specific type of equipment shall depend on the intended application and
technique adopted. This procedure shall describe only the use of Yoke method.

9.2. Yokes utilizing alternating currents for magnetization shall be employed viz. Magnaflux Y6 or
Gammatec or Contour Probe (Parker), etc. Yokes used shall be checked at least every six
months or whenever the yoke has been damaged, for its magnetizing force.

9.3. AC Yokes lifting power shall be checked at the beginning of each shift, by lifting a 10 lb (4.5 kg)
weight at the maximum pole spacing that will be used, and the results of the test recorded in the
calibration log.

9.4. Direct current electromagnetic yokes lifting power shall be checked at the beginning of each
shift shall be checked daily prior to use by lifting a 40 lb (18 kg) weight at the maximum pole
spacing that will be used, and the results of the test recorded in the calibration log.

9.5. Each weight shall be weighed with a scale from reputable manufacturer and stenciled prior to
first use. A weight need only be verified again if damaged in a manner that could have caused
potential loss of material.

9.6. Ultraviolet light, portable type capable of providing required intensity shall be employed for wet
fluorescent magnetic particle examination.

9.7. Light meters, both visible and fluorescent (black) light meters, shall be calibrated at least every
six months or whenever the meter has been repaired.

9.8. Consumables used shall belong to the same manufacturer and family of particular type of
magnetic particle used. The following family of magnetic particle materials (or equivalent) shall
be used:

Method Manufacturer Contrast Paint Particles

Wet Fluorescent CHEMETALL ARDROX 8532
Wet Visible CHEMETALL ARDROX 8901W ARDROX 800/3

10. EXAMINATION PROCEDURE

Magnetic Particle Inspection of welds or base metal by wet particle Yoke method:
 Procedure No. : OPS-PR-MPI-006-QP
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Revision No. : 00

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TITLE: MAGNETIC PARTICLE EXAMINATION
10.1. Surface temperature: Before performing the examination it shall be verified that the
temperature of the part shall not exceed 122 F for wet particle examinations.

10.2. Surface condition: The examination surface shall be free of dirt, scale grease, flake type rust,
sand, oily films or other interfering extraneous matters that may hamper proper inspection and
evaluation. It shall be verified that any required operations such as heat treatment, grinding,
machining etc. shall be completed before the MT examination is performed. Inspection of all
welds shall include a band of base metal at least one inch wide on each side of the weld.

10.3. Lighting: For wet nonfluorescent particle examination, adequate visible light shall be available.
It shall be a minimum of 100 foot candles (1000 lux) and measured by a lux meter on a daily
basis. For fluorescent particle examination, the testing shall be performed in a darkened area
with an ambient light intensity of 1 foot candles (10 lux) maximum. The black light used shall be
allowed to warm up for a minimum of 5 min. prior to use or measurement of the intensity of the
ultraviolet light emitted. The black light intensity shall be measured with a black light meter prior
to use, whenever the lights power source is interrupted or changed, and at the completion of
the examination or series of examinations. A minimum of 1000W/cm on the surface of the
part being examined shall be required. The black light intensity shall be measured once in 4 hr,
whenever the workstation is changed, or after change of filter or bulb. The readings shall be
recorded on a log sheet and kept with the black light unit at all times and monitored for intensity
fading before each usage.

10.3.1. The examiner shall be in the darkened area for at least five (5) min. prior to performing
fluorescent magnetic particle examination to enable his eyes to adapt to dark viewing.
Glass or lenses worn by examiners shall not be photosensitive.

10.3.2. Reflectors and filters should be checked and cleaned prior to use. Cracked or broken
filters shall not be used.

10.4. Magnetizing current: This method shall be used only to detect surface discontinuities using
alternating current.

10.5. Magnetizing technique: Continuous magnetization technique shall be adopted when

employing this method i.e. the magnetizing current shall be "on" throughout the process of
application of the magnetic particles on the test part.

10.6. Examination Medium: Wet magnetic particles shall be employed.

10.6.1. Wet particles used shall be either fluorescent or non-fluorescent black ink-typ.

10.6.2. The contour yoke leg spacing shall suit the shape of the part being tested, being neither
too close nor too far off. Pie-Shaped Magnetic Field Indicator shall be used in the yoke
technique to determine the field strength and direction of magnetic field. Burma Castrol
type II flaw indicator (or other type approved by client) and portable field strength meters
shall be used on each weld examined.
 Procedure No. : OPS-PR-MPI-006-QP
Initial Issue Date : 20-Feb-2011
Revision No. : 00

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TITLE: MAGNETIC PARTICLE EXAMINATION
10.7. Direction of Magnetization: Two separate examinations shall be carried out on each area.
The yoke shall be placed so that the magnetic field generated during one examination is
approximately perpendicular to the field during the other. Discontinuities across a weld bead
shall be detected by placing the contact surfaces of the yoke at an angle of 30-45 degrees from
the long axis of the weld. The field indicators may be used to find the direction of the magnetic
flux as well.

10.8. Wet Particle Examination: The yoke shall be positioned and the examination medium liberally
applied to all surfaces of the part. The instant the bath stream is removed from the part, the
magnetizing current shall be applied. Indications are then to be noted either visibly for non-
fluorescent particles or with the help of a black light for fluorescent particles. The current shall
then be turned off and the yoke repositioned for subsequent examination (perpendicular to the
first) of the area.

When non-fluorescent wet black inks are used, the surface of the part being examined shall be
checked for adequate color contrast. If contrast is inadequate, it shall be improved by spraying
initially with a very thin coat of white contrast paint and then with the black ink.

10.9. Examination Coverage: All examinations shall be conducted with sufficient field overlap to
ensure 100% coverage. The degree of overlap of successive areas during examination shall
be 25% minimum. Yoke leg spacing shall be between a minimum of 3 inches and a maximum
of 6 inches. The area to be examined shall be limited to a maximum distance of one-fourth of
the pole spacing on either side of a centerline joining the two yoke poles.

10.10. Excess Particle Removal: The examination current shall be maintained while removing
excess particles. Care shall be taken not to disturb or blow away any lightly held particle
patterns.

10.11. Evaluation of Indications: All indications shall be evaluated in accordance with the specified
acceptance criteria or special examination instructions. Indications believed to be non relevant
shall be reexamined for verification. The non-relevant indications are quite common and since
they are true particle buildups, they are difficult to distinguish from buildups that are caused by
flaws. Hence a careful evaluation to properly interpret the test results shall be adopted.
Examples of certain non-relevant indications are as follows:

10.11.1. Magnetic Writing: Usually associated with parts displaying good residual characteristics
in the magnetized state. If such parts are in contact with the other steel or magnets it
gives rise to a leakage at points of contact and consequently a magnetic particle
indication. The indications appear fuzzy or intermittent and broad caused by loosely held
particles and will be destroyed by demagnetization.

10.11.2. Effects of Over magnetization: The indications are broad and fuzzy and are caused by
particles adhering at leakage fields around sharp corners, ridges or other surface
irregularities subjected to over magnetization.

10.11.3. Changes in Magnetic Characteristics: Configurations that result in a restriction of the

magnetic field are a cause of non-relevant indications. Internal notches such as splines,
threads, grooves or keyways are typical of such restrictive configurations.
 Procedure No. : OPS-PR-MPI-006-QP
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TITLE: MAGNETIC PARTICLE EXAMINATION
Abrupt changes in magnetic properties, such as those between weld metal and base
metal or between two dissimilar base metals, result in non-relevant indications.
Changes in permeability in certain areas can create leakage flux resulting in the
formation of non-relevant indications. Indications due to change in permeability are:
isolated cold work, hard or soft spots, boundaries of heat treated sections and
segregation of alloying elements in a weld deposit.

10.11.4. Others: If other indications are believed to be non relevant, at least 10% of each type of
indication shall be evaluated by removing the surface roughness or other conditions
believed to have caused the indication, to determine if defects are present. If defects
are absent upon re-inspection by magnetic particle examination after removal of surface
roughness, it indicates that the patterns formed were non relevant in nature with respect
to true defects. However if re-inspection reveals any indications, these and all original
indications shall be considered to be relevant and shall be evaluated in accordance with
the applicable acceptance standards.

10.12. Demagnetization: Since the method employs the usage of alternating magnetizing current as
a magnetizing force, residual magnetism shall not be appreciable enough to subject the part
being tested for demagnetization.

When the presence of residual magnetism within the part could interfere with subsequent
processing or usage, the part shall be demagnetized.

In general demagnetization is accomplished by subjecting the part to a field equal to or

greater than that used to magnetize the part, then continuously reversing the field direction
while gradually reducing it to zero. Any of the following methods may be adapted to parts
requiring demagnetization:
10.12.1. Alternating-current yokes may be used be used for local demagnetization by placing the
poles on the surface, moving them around the area, and slowly withdrawing the A/C
yoke while it is still energized.
10.12.2. The effectiveness of demagnetizing operations shall be verified using a calibrated
magnetic field meter. If the deflection of the meter pointer exceeds more than 2 scale
divisions (2 gauss), the part shall be demagnetized within these limits.
10.13. Post Cleaning: When the examination has been completed the welds and the adjacent wet
affected areas shall be cleaned by flushing with solvent. Other suitable cleaning techniques
may be used if they will not interfere with subsequent requirements. All residual magnetic
particle materials shall be removed from the part in accordance with project requirements.

11. SAFETY

11.1. The minimum safety requirements when performing magnetic particle inspection shall be:
11.1.1. Wet method solutions with a petroleum distillate vehicle are highly volatile, relatively toxic
and may cause skin irritation. Use adequate ventilation and avoid prolonged skin contact.

11.1.2. Aerosol cans should be kept out of direct sunlight or areas in excess of 130 F.
11.1.3. Care shall be taken with any electrical equipment used.
11.1.4. Adequate and correct PPE to be used at all times, i.e. gloves, respirator (face mask).
11.1.5. Ensure MSDS is available and it is read and understood by all.
 Procedure No. : OPS-PR-MPI-006-QP
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TITLE: MAGNETIC PARTICLE EXAMINATION
12. RECORDS

12.1. Nonrejectable Indications shall be recorded as specified by the referencing Code Section.

12.2. Rejectable Indications shall be recorded. As a minimum, the type of indications (rounded or
linear), location and extent (length or diameter or aligned) shall be recorded.

12.3. The following information shall be recorded for each examination:

12.3.1. procedure identification and revision Stage of inspection

12.3.2. equipment and type of current
12.3.3. magnetic particles (visible or fluorescent)
12.3.4. material and thickness
12.3.5. lighting equipment
12.3.6. Technique used and essential parameters
12.3.7. record of indications
12.3.8. examination personnel identity, qualification level
12.3.9. Date and time examinations were performed.

13. ACCEPTANCE CRITERIA

13.1. The indication of a discontinuity may be larger than the actual discontinuity that causes it,
however, the size of the indication and not the size of the discontinuity is the basis for
acceptance or rejection.

13.2. Arc strikes outside of the weld preparations shall not be acceptable. Where these are
determined during inspection, the arc strikes shall be grounded out to a smooth profile and
subjected to MPI.

13.3. Acceptance criteria for examinations performed shall be based on ES.5.14.0010 table-6 either
ES.5.14.0020 Table-6 or ASME Sec VIII, Division 1, Appendix-6 as stipulated by specification.
 Procedure No. : OPS-PR-MPI-006-QP
Initial Issue Date : 20-Feb-2011
Revision No. : 00

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TITLE: MAGNETIC PARTICLE EXAMINATION
Acceptance criteria ES.5.14.0010 table-6

ACCEPTANCE CRITERIA FOR WELDS TO ASME SECTION VIII, DIV. 1 Appendix 6

1. Evaluation of Indications

An indication is the evidence of a mechanical imperfection. Only indications with major dimensions
greater than 1/16 in. shall be considered relevant.

1.1. A linear indication is one having a length greater than three times its width.

1.2. A rounded indication is one of circular or elliptical shape with a length equal to or less than
three times its width.

1.3. Any questionable or doubtful indications shall be reexamined to determine whether or not they
are relevant.

2. Acceptance Standards

These acceptance standards shall apply unless other standards are specified for specific
applications within this Division. All surfaces to be examined shall free of:

2.1. relevant linear indications;

2.2. relevant rounded indications greater than 3/16 in. (4.8 mm);
 Procedure No. : OPS-PR-MPI-006-QP
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2.3. four or more rounded indications in a line separated by 1/16 inch (1.6mm) or less (edge to
edge);

2.4. 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.

3. Treatment of imperfections believed non-relevant

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 defect is present.

4. 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 the defect has been removed or reduced to an acceptably
sized imperfection.

Field indicator
 Procedure No. : OPS-PR-MPI-006-QP
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Revision No. : 00

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TITLE: MAGNETIC PARTICLE EXAMINATION

14. REPORT FORM

Appendix I
 Procedure No. : OPS-PR-MPI-006-QP
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Ultraviolet (UV) Light Intensity Log

UV Light Manufacturer: UV Light Model:

UV Light Sr. No.: Calibration dated:

Date Intensity @ 15 inches Technician Date Intensity @ 15 inches Technician

Notes:
1. The ultraviolet light intensity at the examination surface shall be measured:
a. At least every 4 hours
b. Whenever the work location is changed
c. After changing a filter or bulb
d. After a UV light unit failure

2. If UV meter reads lower than 1000W/cm, clean the filter as required and re-measure. If still below
1000W/cm, replace the bulb.

3. UV light intensity shall be minimum 1000W/cm at 15 inches in a darkened area and 3000W/cm
at 15 inches in other areas of ambient white light which exceed 2 ft candles.