engineering standards documents - nde – magnetic …

Issuer Area: North Atlantic Ontario OperationsTechnician Responsible: Name: Philippe Belzile, Registration: IO960805, Area: Materials Engineering & TestingTarget Audience: North Atlantic Ontario OperationsNeed of training: ( )YES ( X ) NO

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Engineering Standards Documents - NDE – MAGNETIC PARTICLESINSPECTION - TSSA(SPEC-83014)

NORTH ATLANTIC ENGINEERING & STUDIES DOCUMENTPGS-004743 – Engineering Standards Documents – NDE Magnetic Particles Inspection - TSSARev.: 00 - 10/14/2021

1.0 PURPOSE

This procedure outlines the requirements for the magnetic particle examination of ferro-magneticcastings, forgings, bars and weldments using an AC or DC electromagnetic yoke in accordance withthe following codes:

A.S.M.E. Section V, Article 7, latest editionA.S.M.E. Section VIII, Division 1, Appendix 6, latest editionA.S.M.E. Section V, SE 709, latest edition

2.0 APPLICATION

This specification, applies at any Vale locations indicated with approval on the cover page, with thefollowing exceptions:

2.1 EXCEPTIONS

None.

3.0 QUALIFICATION OF PERSONNEL

All personnel performing Magnetic Particle Inspection shall be qualified to CGSB (Canadian GeneralStandards Board) 48.9712 Level 2 or 3 or as required by the referencing code or specification.

4.0 MATERIALS

One of the following materials may be used,a) Wet fluorescent magnetic particleb) Wet visible magnetic particlec) Dry magnetic particle (red, black, yellow or light grey)d) White contrast paint

The particles shall be treated to impart color (fluorescent pigments, nonfluorescent pigments or both)in order to make them highly visible (contrasting) against the background of the surface beingexamined.

Dry and wet particles, including wet particle suspension vehicles, and particle concentrations shall bein accordance with SE-709.

Particles shall be used within the temperature range limitations set by the manufacturer.

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5.0 EQUIPMENT

Electromagnetic Yoke AC, DC or AC/DC with lift test verification within previous 12 months (ContourProbe Model B100 or equivalent. Pole separation should be < 6.5”)

Dry particles – Magnavis Dry Magnetic particles or equivalent

Wet particles – Visible – Magnaflux 7HF prepared bath or equivalent– Fluorescent – Magnaglo 14A Aqua glow or equivalent

Permanent magnetic yoke – Capable of lifting 40lbs. Must be checked daily prior to inspection. Poleseparation used should be less than, or equal to that used for calibration.

Black light (U/V light intensity ≥1000 uw/cm² - Calibrated within previous 12 months)

Black Light Meter (Ultra-Violet Product J221 or equivalent)

White light source (≥ 1000 lux)

White Light Meter

Residual Gauss Meter

Pie-Shaped Magnetic Particle Field Indicator / Artificial Flaw Shim (QQI)

6.0 CALIBRATION OF AC OR DC ELECTROMAGNETIC YOKE, OR PERMANENTMAGNET

The magnetizing power of yokes shall be verified prior to use each day the yoke is used. Themagnetizing power of yokes shall be verified whenever the yoke has been damaged or repaired.

Each alternating current electromagnetic yoke shall have a lifting power of at least 10 lb (4.5kg) at themaximum pole spacing, with contact similar to what will be used during the examination.

Each direct current or permanent magnetic yoke shall have a lifting power of at least 40 lb (18kg) atthe maximum pole spacing, with contact similar to what will be used during the examination.Each weight shall be weighed with a scale from a reputable manufacturer and stenciled with theapplicable nominal weight prior to first use. A weight need only be verified again if damaged in a mannerthat could have caused potential loss of material.

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7.0 LIGHTING CALIBRATION

7.1 BLACK LIGHT CALIBRATION

Check the electrical cables of the black light for any damage. Ensure the filter is clean and free of chipsor cracks.

A suitably calibrated black light or combination white light / black light meter Traceable to NIST(National Institute of Standards and Technology) with a valid calibration tag and the manufacturer’soperating instructions shall be used to check the black light intensity. Light meters shall be calibratedat least once a year or whenever a meter has been repaired. If meters have not been in use for oneyear or more, calibration shall be done before being used.

A ruler or tape measure measuring a minimum of 15 inches.

A darken area with an ambient white light of ≤ 20 lux is required when checking the black lightintensity and during in the actual inspection area as well.

Turn on the black light and allow 10 minutes for warm up.

Verify the ambient white light is ≤ 20 lux with the calibrated light meter.

Place the black light in the stand and adjust the height to 15 inches (380 mm) or hand hold the lightat a distance of 15 inches from the sensor surface of the meter.

Place the meter so that the sensor is directly centered in the black light beam.

Record the intensity of the black light. Black light intensity must be no less than 1000 μW/cm² at the15 inches distance. If the light does not meet the minimum requirements, the unit shall bequarantined until the condition may be rectified.

7.2 WHITE LIGHT CALIBRATION

The minimum light intensity shall be of 100 fc (1076 Lx). The light intensity, natural or supplementalwhite light source, shall be measured with a white light meter prior to the evaluation of indications ora verified light source shall be used. Verification of light sources is required on the surface to beexamined to ensure adequate sensitivity during the examination and evaluation of indications. Thelight source, technique used, and light level verification is required to be demonstrated only one time,documented, and maintained on file.

The white light source shall be verified with a calibrated white light meter. See appendix one forqualification of white light source

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8.0 FLUORESCENT MAGNETIC PARTICLE SOLUTION CHECKS

8.1 Fluorescent Magnetic Particle Suspension Bath

The magnetic particle concentration of the suspension shall be verified at the beginning of each 8 hour shift. The state of contamination shall be verified weekly. The bath shall be agitated before the test sample is drawn. The concentration level shall be held between 0.1 and 0.4 ml by adding magnetic particle powder or vehicle as necessary. The solid content as measured and any necessary correction shall be recorded and retained on file.

8.2 Settling Volume Check

When aerosols are not used, concentration of the suspension shall be checked using an ASTM 100ml settling tube as follows:

(a) Allow suspension to agitate and flow through the applicator for at least 30 minutes.

(b) Fill the ASTM Test Method D 96 pear-shaped centrifuge tube with a 1-mL stem (0.05-mL divisions) for fluorescent particle suspensions to the 100ml mark with the suspension directly from the applicator and demagnetize.

(c) Allow the sample to settle. Water-based suspensions require 30 minutes settling time and petroleum distillate suspensions require 60 minutes settling time.

(d) Read the height of precipitation in tube.

(e) The fluorescent suspension must read between 0.1 and 0.5 ml.

8.3 Contamination Check

Fluorescent suspensions shall be checked periodically for contaminants such as dirt, scale, oil, lint, loose fluorescent pigment, water (in the case of oil suspensions), and particle agglomerates which can adversely affect the performance of the magnetic particle examination process. The test for contamination shall be performed at least once per week.

(a) Carrier Contamination

For fluorescent baths, the liquid directly above the precipitate should be examined with fluorescent excitation light. The liquid will have a little fluorescence. Its color can be compared with a freshly made-up sample using the same materials or with an unused sample from the original bath that was retained for this purpose. If the “used” sample is noticeably more fluorescent than the comparison standard, the bath shall be replaced.

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(b) Particle Contamination

The graduated portion of the tube shall be examined under fluorescent excitation light for striations or bands, differences in color or appearance. Bands or striations may indicate contamination. If the total volume of the contaminates, including bands or striations exceeds 30% of the volume magnetic particles, or if the liquid is noticeably fluorescent, the bath shall be replaced.

9.0 APPLICATION OF PARTICLES

Dry Particles: Dry powder should be applied in such a manner that a light uniform dust-like coatingsettles on the surface to be tested, an applicator specifically designed for the purpose should beused. Dry powder must not be applied to a wet surface. Care should be taken in removing excesspowder from the surface by blowing the excess powder lightly while the magnetizing current ispresent. Accumulations of excess dry particles in examinations shall be removed with a light airstream from a bulb or syringe or other source of low pressure dry air.

Wet Particles: Fluorescent or non-fluorescent suspended in a recommended concentration may beapplied by spraying or flowing over the part. When using the non-fluorescent particles white paintshould first be applied giving high contrast to the area being inspected. Visible wet suspension shallbe contained in aerosols. When applying wet suspensions, the magnetizing current shall be turnedon after the particles have been applied. Flow of particles shall stop with the application of current.Wet particles applied from aerosol spray cans or pump sprayers may be applied before and/or duringmagnetizing current application.

10.0 EXTENT AND METHOD

The AC method shall only be applied to detect discontinuities that are open to the surface of the part.

There are no restrictions to the size and shapes of the items to be examined

Prior to magnetic particle examination, the surface to be examined and any adjacent area within atleast 1" (25 mm) of the surface to be examined shall be dry and free of any dirt, grease, lint, scale,welding flux, spatter, oil, or other extraneous matter that could interfere with the examination.Satisfactory results may generally be obtained, when the surfaces are in the as-rolled, as-forged, oras-cast condition. However, surface preparation by grinding or machining may be necessary in somecases where surface irregularities could otherwise mask the indication of discontinuities.

Cleaning may be accomplished by detergents, organic solvents, descaling, solutions, paint removers,vapor degreasing, sand or grit blasting, or ultrasonic cleaning methods.

Inspection shall be done using the continuous method, that is, particles are applied while themagnetizing force is present. Each area to be inspected requires the yoke to be placed in twodirections at 90° to each other with sufficient overlap (75mm to 150mm) to ensure complete coverage.

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1.) Position yoke, switch on current.2.) Apply particles to form a light, uniform coating on the examination surface.3.) Switch current off4.) Remove yoke5.) Inspect6.) Reposition the yoke following technique “A”, “B”, or “C” (see Appendix)

Fluorescent magnetic particles inspection is performed using an ultraviolet light (nominalwavelength is 365 nm), called UV-A light.

The examination shall be performed as follows:

(a) It shall be performed in a darkened area with a maximum ambient white light level of 2 fc (21.5 lx)measured with a calibrated white light meter at the examination surface.

(b) Examiners shall be in a darkened area for at least 5 min prior to performing examinations toenable their eyes to adapt to dark viewing. Glasses or lenses worn by examiners shall not bephotosensitive.

(c) The examination area shall be illuminated with UV-A lights that operate in the range between 320nm and 400 nm.

(d) UVA lights shall achieve a minimum of 1000 μW/cm2 on the surface of the part being examinedthroughout the examination.

(e) Reflectors, filters, glasses, and lenses should be checked and, if necessary, cleaned prior to use.Cracked or broken reflectors, filters, glasses, or lenses shall be replaced immediately.

(f) The UV-A light intensity shall be measured with a UV-A light meter prior to use, whenever thelight’s power source is interrupted or changed, and at the completion of the examination or series ofexaminations.

(g) Mercury vapor arc lamps produce UV-A wavelengths mainly at a peak wavelength of 365 nm forinducing fluorescence. LED UV-A sources using a single UV-A LED or an array of UV-A LEDs shallhave emission characteristics comparable to those of other UV-A sources. LED UV-A sources shallmeet the requirements of SE-2297 and SE-3022. LED UV-A light sources shall be certified asmeeting the requirements of SE-3022 and/or ASTM E3022.

10.1 Nonmagnetic Surface Contrast Enhancement

Nonmagnetic surface contrasts may be applied by the examiner to uncoated surfaces, only in amounts sufficient to enhance particle contrast. When nonmagnetic surface contrast enhancement is used, it shall be demonstrated that indications can be detected through the enhancement. Thickness measurement of this nonmagnetic surface contrast enhancement is not required.

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10.2 Magnetic Particle Examination Using The AC Yoke Technique on Ferritic Materials Coated With Nonmagnetic Coatings

The requirements of ASME V, Article 7, Mandatory Appendix I are to be adhered to when inspecting through an existing nonmagnetic coating on the part to be inspected.

10.3 Direction of Magnetization

Whichever method is used to produce magnetization, the maximum sensitivity is to linearindications that are perpendicular to the lines of flux. Each area of the part being examinedshall be magnetized at least twice so that the lines of flux from one examination areperpendicular to the second.

All examinations shall be conducted with sufficient overlap to assure 100% coverage at therequired sensitivity.

When it is necessary to verify the adequacy of magnetic field strength, it shall be verified byusing a magnetic particle field indicator (Pie Gauge) or artificial flaw shim(s). The gauge orshim(s) will be positioned on the surface to be examined during magnetization. Adequacy of asuitable flux or field strength is indicated when a clearly defined line of magnetic particles formacross the face of the indicator or shim. When there is no line of particles in the desireddirection the magnetizing technique shall be changed or adjusted.

10.4 Demagnetization

When residual magnetism in the part could interfere with subsequent processing or usage, thepart shall be demagnetized any time after completion of the examination. Alternating currentyokes may be used for local demagnetization by placing the poles on the surface, moving themaround the area, and slowly withdrawing the yoke while it is still energized.

11.0 EVALUATION OF INDICATIONS

All indications shall be evaluated in terms of the acceptance standards of the referencing codesection.

Discontinuities on or near the surface are indicated by retention of the examination medium.However localized surface irregularities due to machining marks or other surface conditions mayproduce false indications.

Broad areas of particle accumulation, which might mask indications from discontinuities, areprohibited, and such areas shall be cleaned and reexamined.

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 threetimes its width.Any questionable or doubtful indications shall be reexamined to determine whether or not they arerelevant.

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11.1 Indications

Indications will be revealed by retention of magnetic particles. All such indications are not necessarily imperfections, however, since excessive surface roughness, magnetic permeability variations (such as at the edge of heat affected zones), etc., may produce similar indications.

11.2 Valid Indications

All valid indications formed by magnetic particle examination are the result of magnetic leakage fields. Indications may be relevant, nonrelevant, or false.

11.3. Relevant Indications

Relevant indications are produced by leakage fields which is the result of discontinuities.Relevant indications require evaluation with regard to the acceptance

standards agreed upon between the manufacturer/ test agency and the purchaser.

11.4 Nonrelevant Indications

Nonrelevant indications can occur singly or in patterns as a result of leakage fields created by conditions that require no evaluation such as changes in section (like keyways and drilled holes), inherent material properties (like the edge of a bimetallic weld), magnetic writing, etc.

11.5 False Indications

False indications are not the result of magnetic forces. Examples are particles held mechanically or by gravity in shallow depressions or particles held by rust or scale on the surface.

12.0 ACCEPTANCE

In the absence of a code requirement, these acceptance standards shall apply:

All surfaces to be examined shall be free of:

(a) relevant linear indications;

(b) relevant rounded indications greater than 3/16 inch;

(c) four for more relevant rounded indications in a line separated by 1/16 inch or less, edge to edge;

(d) an indication of an imperfection may be larger than the imperfection that causes it, however, the size of the indications is basis for acceptance evaluation.

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13.0 POST CLEANING

When post cleaning is required by the procedure, all traces of the examination material shall beremoved as soon as practical using a process that that does not adversely affect the part.

14.0 REPORTING

Report shall include at least the following:

1) Contract Reference (Customer PO #, W.O. etc.) 2) Date of examination 3) Items examined 4) Quantity of items examined. 5) Identification of items examined e.g. Part #, Heat # Serial # 6) Map or record of indications (acceptable or rejectable as specified by the referencingcode section – As a minimum, rejectable indications shall record type of indication, location, andextent.) 7) Examination personnel identity and qualification level 8) A technique sketch showing coverage 9) Equipment used (Lighting equipment, Magnetic particle equipment and current, and particletype used) 10) Procedure identification and revision 11) Material and thickness (Only required for A.S.M.E. code required inspections) 12) Acceptance standard including revision status and date 13) If a technique qualification is required, description and drawings or sketches of thequalification specimen, including coating thickness measurements, and flaw dimensions, and results

The report shall be signed by a qualified Level 2 or 3 person (as per this procedure) certifying thatinterpretation was made in accordance with the procedure.

15.0 PROCEDURE QUALIFICATION

When procedure qualification is specified by the referencing Code Section, a change of arequirement in Table T-721, of ASME V, Article 7 (see page 13 of this procedure), identified as anessential variable, shall require requalification of the written procedure by demonstration. A change ofa requirement identified as a nonessential variable does not require requalification of the writtenprocedure. All changes of essential or nonessential variables from those specified within the writtenprocedure shall require revision of, or an addendum to, the written procedure.

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TABLE T-721 FROM ASME V, ARTICLE 7

16.0 REFERENCE DOCUMENTATION

The following documents were used in the development of this document or have instructions andprocedures applicable to it. They shall be used in their most recent revision.

A.S.M.E. Section V, Article 7A.S.M.E. Section VIII, Division 1, Appendix 6A.S.M.E. Section V, SE 709.

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17.0 REVISION AND TRANSITION NOTES

Revision notes describe: what was changed, and if applicable, why it was changed, and the plan toimplement the change, including whether changes are retroactive.Note: The revision notes are a summary of the changes and may not necessarily be a complete list.

A risk code is entered for each revision and if applicable, the revision notes will describe how riskwas addressed for the revision.

RiskCode Risk Category

A This revision is a minor change and/or introduces no risk.

B Risk has been addressed for this revision by the reviewer and approver. Low risk or no new hazards identified.

C For this revision, a PHR or other risk management tool has been used to address risk and minimize hazards.This risk assessment has been documented and is available through Central Engineering.

Rev Revision Notes RiskCode

Approvedby

Reviewedby

Issue DateYYYY/MM/DD

1a Document format and entire content revised. Previousnumber 018-00. A P. Belzile J. Lech 2012/06/06

2a

Converted all light measurement from foot-candles to lux.Revised the following sections to comply with TSSA leadauditor’s requirements:Section 6.0: Added details for Electromagnetic and

permanent magnet Yoke, dry/wetparticles, black light.

Section 8.0: Added the calibration requirement for thewhite light source.Section 11.0: Added details to meet the requirements ofASME sect. V.Section 12.0: Removed 1/16 inch limitation. Added

wording to define discontinuities andadditional requirements to reexamineareas of broad particles examination

Section 13.0: Added reference to code acceptancestandards.Section 15.0: Added ASME code requirements forreports.

A P. Belzile A. Akerman 2012/11/22

3a SPEC Reviewed 2016 – Regional Approvals removed, noother changes A P. Belzile A. Nadeau 2016/12/15

4a Document Format Updated - 5 yr Review P. Belzile A. Nadeau 2020/04/21

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00

New specification created in 2021 when the ValeEngineering Standards Document System wastransitioned to SISPAV. It replaces the SPEC Series ofEngineering Standards.Revised the following sections to comply ASME sectionV:Section 6.0: Yoke magnetizing check frequency.Section 7.2:Updated white light requirements.Section 9.0: Updated wet particles application.Section 10.0: Fluorescent magnetic particles section

A P. Belzile B. Nixon 2021/10/14

Issued By: Jerry Lech

Certification: CGSB 48-9712, MPI Level 3

Date: Dec. 28, 2011

Signature:

Approved By Philippe Belzile

Certification:P. Eng. (On)

Date: January 18th 2012

Signature:

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18.0 APPENDIX

Magnetic Particle Sample Technique

Technique "A" Technique "B"

Technique "C"

2

1

4

2

3 4

1

3

2

1

3

6 5

2

6

1

4

7

5

3

4

7

3

1

55

3

2

4

4

2

1

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Qualification of white light source

Inspection of visible (colour contrast) indications must be carried out where light at theinspection surface is at a minimum intensity of 1000 lux. The light may be measured with awhite light meter at the time of inspection. Alternatively, a source may be qualified as per thefollowing method:

Equipment

White light: Light source (describe) __________________________________________

Light meter: Serial Number: _______________ Calibration due date: _____________

1.) Set the meter in a stationary location2.) Place the light in front of the meter sensor and retract while observing the light output

on the meter.3.) Stop retraction when the meter reads 1000 lux. Record the distance. The light is

qualified inspection use at a maximum distance as noted.

White light source is qualified for use at a maximum distance of ___________ cm.

_________________________________Technician (Signature)

_________________________________Technician (Print name)

_________________________________Date

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Demonstrated procedures to Authorized Inspector

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