Magnetic particle testing procedure-EN & ASME

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Toolfab Engineering Industries (P) Ltd

Magnetic Particle Testing Procedure

Document No. : TF/NDT/MT/004
Rev. : 00
Date : 30/08/2017

Prepared By Reviewed By APPROVED BY (Level Approved By(Level III-

III-SUPPLIER) SUZLON)

Name: Name: Name: Name: Mr. Salai

T.PRABHAKARAN P.BHARATHRAJ A.Katesan& S. Sridhar
Sign : Sign :
Sign : Sign :

Date: Date:
Date: 30.08.2017 Date:30.08.2017

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Magnetic particle testing procedure-EN & ASME
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List of changes

Rev. No Date Page No. Class No. New Changes

Contents:

Sr.No Description Page no

10.00 SCOPE 3
20.00 REFERENCE CODES & STANDARDS 3
30.00 PERSONNEL QUALIFICATION 3
40.00 DEFINITIONS 3
50.00 SUMMARY OF TEST METHOD 4
60.00 CLASSIFICATION OF METHODS 4
70.00 SURFACE PREPARATION 4
80.00 INSPECTION MEDIUM 5
90.00 EQUIPMENT& CONSUMABLES 5
100.00 EXAMINATION PROCEDURE 5
110.00 SAFETY 8
120.00 ACCEPTANCE CRITERIA 9
130.00 RECORDS 9

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Magnetic particle testing procedure-EN & ASME
10.0
SCOPE: logo
This procedure describes the minimum requirementsof Magnetic Particle Examinations for both dry and wet,
visible method for detecting cracks and other discontinuities at or near surface in ferromagnetic materials.

20.0 REFERENCE CODES & STANDARDS:

ASME.Sec.V. Art.7 : Boiler and Pressure Vessels Code for Magnetic Particle Testing
ASTM.SE.709 : Standard guide for Magnetic Particle Examination.
ASNT.SNT.TC.1A /EN ISO 9712 : Recommended Practice for Personnel certification of NDT.
ISO 17638 : Non-Destructive testing of weld MPT.
ISO 23278 : Acceptance Criteria
ASME Sec VIII Div.1 (Appx.06) : Acceptance Criteria
CQA: TTU: G-QAX 032: NDT Procedure Manual

30.0 PERSONNEL QUALIFICATION:

Personnel performing Magnetic Particle testing in accordance with this procedure shall hold a valid certification
to a minimum level II as per. ASNT SNT – TC – 1A or EN ISO 9712

40.0 DEFINITIONS:

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

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

40.30 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 non-fluorescent. The suspensions are liberally
applied to the test object by flowing the liquid over the test object.

40.40 Dry Method: A method of MT that uses finely divided ferromagnetic particles as the indicating material. The
particles are non-fluorescent and are applied to the test object in such a manner that a fine, dust like coating
settles on the surface being examined.

40.50 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 or dry
method of testing may utilize the circular magnetization

40.60 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.

40.70 Continuous Method: When the magnetic particles (wet or dry) are applied during the time the magnetizing
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Magnetic particle testing procedure-EN & ASME
current is applied is known as the continuous method.
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40.80 Residual Method: The application of the magnetic particles (wet or dry) after the magnetizing current has
stopped flowing and the residual magnetic field is used to form indications is known as the residual method.

40.90 Relevant indication: An indication resulting from a discontinuity requiring evaluation.

40.100 Magnetic Particle Indications: Surface discontinuities produce sharp and distinct patterns while near-
surface discontinuities produce less distinct indications, broad, rather than sharp.

50.0 SUMMARY OF TEST METHOD

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.

60.0 CLASSIFICATION OF METHODS

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.

70.0 SURFACE PREPARATION

Surface Temperature: Before performing the examination it shall be verified that the temperature of the Particle
shall not exceed 600°F (316°C) for dry particle examination and 135° F (57°C) for wet particle examinations.

70.10 Surface Condition:

a) Surface of the part shall be as-welded, as-rolled, as-cast or as-forged surfaces conditions
b) Prior to Magnetic Particle Examination, the surface of the part to be tested and all adjacent areas within at
least 1 in shall be free of all dirt, grease, lint, scale, welding flux and splatters, oil or other matters that could mask
indications due to discontinuities.

70.20 Surface Cleaning:

Cleaning may be accomplished using solvents, paint removers, sand or grit blasting, wire-brushing etc. 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.

80.0 INSPECTION MEDIUM

The magnetic particles used for either dry or wet magnetic particle examination techniques shall be of finely
divided ferromagnetic material of high permeability and low retentively, free from contaminants like rust, grease,

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Magnetic particle testing procedure-EN & ASME
paint, dirt or other material which might interfere with their proper functioning. They shall be of such
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shape, size and colour as to provide adequate sensitivity and contrast for the intended use.

The Dry method particles used shall be of grey or red colour. The choice of colour shall be based on maximum
contrast with the part being examined.

The Wet method particles used shall be either black or red colour, readily available aerosol cans.

The selection of particular colour shall be one that contrasts most with the test surface. As the wet magnetic
particles are finer in nature than the particles used for dry methods, they shall be employed in the detection of
smaller discontinuities. The wet particle inspection shall also utilize fluorescent particles which are readily
available in aerosol spray cans.

90.0 EQUIPMENT/CONSUMABLES

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.

Permanent Yoke and A/C or D/C electromagnetic Yokes which have articulated legs that allow the legs to be
adjusted to contact irregular surfaces or two surfaces that join at an angle Yokes used shall be checked at least
once in a year or whenever the yoke has been damaged, for its magnetizing force.

AC Yoke’s shall be checked daily prior to use by lifting a 10 lb. (4.5 kg) weight at the maximum pole spacing that
will be used.

Direct current electromagnetic yokes shall be checked daily prior to use by lifting a 40 lb. (18 kg) weight at the
maximum pole spacing that will be used.

Permanent Yoke shall be checked daily prior to use by lifting a 40 lb. (18 kg) weight at the maximum pole spacing
that will be used.

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

Visible Light meters shall be calibrated at least every six months or whenever the meter has been repaired.

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:

100.0 EXAMINATION PROCEDURE

Magnetic Particle Inspection of welds or base metal by visible dry or wet particle Yoke method:

100.10 Surface temperature: Before performing the examination it shall be verified that the temperature of the
part shall not exceed 600F (316˚C) for dry particle examinations and135F (57˚C) for wet particle examinations.

100.20 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.

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100.30
Lighting: For dry particle and wet non-fluorescent particle examination, adequate visible light shall be logo
available. It shall be a minimum of 100 foot candles (1000 lux) and measured by a lux meter on a daily basis.

100.40 Magnetizing current: This method shall be used only to detect surface discontinuities using alternating
current yoke, direct current yoke or Permanent yoke which have articulated legs that allow the legs to be adjusted
to contact irregular surfaces or two surfaces that join at an angle.

100.50 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.

100.60 Examination Medium: Either dry or wet magnetic particles shall be employed.

100.60.1Dry particles (non-fluorescent) when used with alternating current for magnetization, are superior for
detection of surface cracks that are not exceptionally tight or fine.

100.60.2 Wet particles used shall be non-fluorescent black ink-type. They are better than dry for detection of very
fine surface discontinuities.

100.60.3The 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 (Refer Annexure: A) shall be used in the yoke technique to determine
the field strength and direction of magnetic field.

100.70 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.

100. 80 Dry Particle Examination: The yoke shall be positioned on the surface to be examined and the
magnetizing current turned on. The particles are then dusted lightly over the surface. Indications shall then be
noted. The current shall then be turned off and the yoke repositioned for subsequent examination (perpendicular
to the first) of the area.

100.90 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 visibly for non-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 colour 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.

100.100Examination Coverage: All examinations shall be conducted with sufficient field overlap to ensure 100%
coverage. 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 centreline
joining the two yoke poles.

100.110Excess Particle Removal: Accumulation of excess dry particles shall be removed with a gentle air stream
from a bulb or syringe or other source of low pressure dry air. 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.

100.120Evaluation of Indications:

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Magnetic particle testing procedure-EN & ASME
a) All indications shall be evaluated in accordance with Table 6.1 of AWS.D1.1M acceptance criteria or
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special examination instructions. Indications believed to be non-relevant shall be re-examined for verification.

b) The non-relevant indications are quite common and since they are true particle build-ups, they are difficult to
distinguish from build-ups 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:

100.120.1 Treatment of imperfections believed non-relevant

Any indication which 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 non-destructive methods and/or by surface conditioning
that no unacceptable defect is present.

100.120.2 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.

100.120.3 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.

100.130 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.

100.140 Changes in Magnetic Characteristics:

a) 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.

b) 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.

100.150 Others:

a) 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.

b) 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.

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100.160 Demagnetization:

a) 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.

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

c) 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:

d) 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.

e) 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.

100.170 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.

110.0 SAFETY

The minimum safety requirements when performing magnetic particle inspection shall be:
a) 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.

b) Aerosol cans should be kept out of direct sunlight or areas in excess of 130 F.

c) Care shall be taken with any electrical equipment used.

d) Adequate and correct PPE to be used at all times, i.e. gloves, respirator (face mask).

e) Ensure MSDS is available and it is read and understood by all.

120.0 ACCEPTANCE CRITERIA

AS PER ASME Sec VIII Div. Appendix 6

All surfaces to be examined shall be free of:

(a) Relevant linear indications

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(b)
Relevant rounded indications greater than 3/16” inches (5mm) logo
(c) Four or more relevant rounded indications in a line separated by 1/16” (1.5mm) or less (edge to edge).

AS PER EN ISO 23278

130.0 RECORDS

130.10 Non-relevant Indications shall be recorded as specified by the referencing Code Section.

130.20 Relevant 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.

130.30 The following information shall be recorded for each examination:

a) Procedure identification and revision

b) Equipment and type of current
c) Magnetic particles (visible or fluorescent, wet or dry)
d) Material and thickness
e) Lighting equipment
f) Record of indications
g) Examination personnel identity, qualification level
h) Dateand time examinations were performed.

Report Format: As per customer recommended (CQA: TTU: F-QAX144 Latest Rev.)

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