Quality assurance manual operating procedures for magnetic particle inspection purpose


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PT. AKURA BINA CITRA
Perkantoran Liga Mas Indah Kav. 9 Lt. 2, Pancoran Indah I, Jl. Raya Pasar Minggu, Jakarta 12760

Phone : (62-21) 922-4606, 794-8138 Fax : (62-21) 798-7714 E-mail : akura@cbn.net.id

QUALITY ASSURANCE MANUAL


OPERATING PROCEDURES FOR

MAGNETIC PARTICLE INSPECTION

1. PURPOSE



To provide instruction for the Magnetic Particle examination of items listed in para 2.0 by qualified and certified AKURA personnel.
2. SCOPE
This procedure shall be utilized in the performance of Magnetic Particle examination of ferromagnetic lifting equipment, welds on oil field equipment, welds on tubular etc.
3. APPLICABLE DOCUMENTS
The following specifications shall be referenced in this procedure.

ASTM E - 709

ASME V

API RP 8B

T.H HILL DSI LIFTING EQUIPMENTS
4. PERSONNEL QUALIFICATION
4.1 Personnel performing and interpreting magnetic particle examination shall be qualified in accordance with ASNT recommended practice.
5. RESPONSIBILITIES
5.1 NDE Level II

An NDE level II individual shall be qualified to set up and calibrate equipment and to interpret and evaluate results with respect to applicable codes, standard and specifications.

The NDE level II shall be thoroughly familiar with scope and limitations of the methods for

Which the individual is qualified and shall exercise assigned responsibility for on the job training and guidance of trainees and NDE level I personnel. The NDE level II shall be able to prepare written instructions and to organize and report the result of the tests.



DOCUMENTED BY : BALAJI RAO DATE : 28TH MAY 2002 (REV)

ASNT LEVEL III REF : MT – CPS – 02 – RV1

REVIEWED BY : MARAN PAGE : 01 OF 06

PT. AKURA BINA CITRA
Perkantoran Liga Mas Indah Kav. 9 Lt. 2, Pancoran Indah I, Jl. Raya Pasar Minggu, Jakarta 12760

Phone : (62-21) 922-4606, 794-8138 Fax : (62-21) 798-7714 E-mail : akura@cbn.net.id

QUALITY ASSURANCE MANUAL


OPERATING PROCEDURES FOR

MAGNETIC PARTICLE INSPECTION
5.2 NDE Level I

An NDE level 1 individual shall be qualified to properly perform specific calibrations, specific tests and specific evaluation for acceptance or rejection determinations, according to written instructions and to record results. The NDE level I shall receive necessary instructions or supervision from certified NDE level II or NDE level III personnel.
5.3 NDE Trainee

NDE trainee is an individual who shall work as an assistant to NDE level II and to receive job training.
6. EQUIPMENT QUALIFICATION
Each piece of magnetizing equipment shall be calibrated at least once a year or whether the equipment is subjected to major electrical repair, periodic overhaul or damage. If equipment has not been in use for a year or more, calibration shall be done prior to first use. Calibration shall be performed in accordance with ASTM E 709.
The following consumable / equipment or their equivalent may be used to perform magnetic particle testing.
6.1. Magnaflux white contrast paint WPG 2

6.2. Magnaflux magnetic ink. 7HF

6.3. Magnaflux Y6 Yoke

6.4. Dry powder

6.5. Magnaflux fluorescent particles

6.6. Ultra violet light and meter
The ultra violet light intensity shall be checked for minimum intensity of 1000 micro watt / cm square and this check shall be performed every day of operation. The bath concentration shall be checked every time a fresh batch is made. The UV meter shall be calibrated every 12 months. The gauss meter shall be calibrated every year. The yoke shall be calibrated once a year against a certified 10 pound lifting block.

DOCUMENTED BY : BALAJI RAO DATE : 28TH MAY 2002 (REV)

ASNT LEVEL III REF : MT – CPS – 02 – RV1

REVIEWED BY : MARAN PAGE : 02 OF 06

PT. AKURA BINA CITRA
Perkantoran Liga Mas Indah Kav. 9 Lt. 2, Pancoran Indah I, Jl. Raya Pasar Minggu, Jakarta 12760

Phone : (62-21) 922-4606, 794-8138 Fax : (62-21) 798-7714 E-mail : akura@cbn.net.id

QUALITY ASSURANCE MANUAL


OPERATING PROCEDURES FOR

MAGNETIC PARTICLE INSPECTION
7. EXAMINATION MATERIAL
7.1. The finely divided ferromagnetic particles used for the examination shall meet the following requirements :
7.1.1. Dry Particle – If dry particles are used, the color of the particle (Magnaflux Dry Gray Powder) shall provide adequate contrast with the surface being examined. Magnetic particle examination shall not be performed if the surface temperature of the parts exceeds 51 degree C.

7.1.2. Wet Particle – If wet particles are used the color of the particles shall provide contrast with the surface being examined. The particles shall be suspended in a suitable liquid medium in the concentration recommended in 7.2. The temperature of the wet particle suspension and the surface of the part shall not exceed 51 degree C.
7.2. Bath Strength – the strength or concentration of the magnetic particles in the bath must be maintained at the proper level if inspection results are to reliable and consistent. This bath is normally checked by the use of a pear shaped centrifuge tube. A 100ml portion of the bath is taken from the hose or nozzle and allowed to settle for 25 minutes. The volume settling out at the bottom of the tube is indicative of the particle concentration. The recommended concentration from a 100 ml sample is 0.20 to 0.40 ml / 100ml for fluorescent particles.
8. SURFACE PREPARATION
8.1. Satisfactory results are usually obtained when the surface are in the as – welded, as – condition. However surface preparation by grinding or machining may be necessary where surface irregularities could mask indications due to discontinue.

8.2. Prior to magnetic particle examination, the surface to be examined and all adjacent areas within at least 1 inch (25mm) shall be dry and free of all dirt, grease, lint, scale, welding flux and spatter, oil or other extraneous matter that could interfere with the examination.
8.3. Cleaning may be accomplished using organic solvents, de scaling solutions, paints removers, vapor degreasing, sand or grit blasting.

DOCUMENTED BY : BALAJI RAO DATE : 28TH MAY 2002 (REV)

ASNT LEVEL III REF : MT – CPS – 02 – RV1

REVIEWED BY : MARAN PAGE : 03 OF 06

PT. AKURA BINA CITRA
Perkantoran Liga Mas Indah Kav. 9 Lt. 2, Pancoran Indah I, Jl. Raya Pasar Minggu, Jakarta 12760

Phone : (62-21) 922-4606, 794-8138 Fax : (62-21) 798-7714 E-mail : akura@cbn.net.id

QUALITY ASSURANCE MANUAL


OPERATING PROCEDURES FOR

MAGNETIC PARTICLE INSPECTION

9. PARTICLE APPLICATION
9.1. Dry particles shall be applied in such a way as to provide a light and uniform covering over the entire surface to be examined. Excess particles shall be removed using a gentle air blast. Care should be taken in blowing off excess powder so as not to disturb indications.
9.2. Wet suspensions shall be applied by spraying.
9.3. Dry or wet magnetic particles shall be applied during current application.
10. MAGNETISING FIELD VERIFICATION
10.1. When it is necessary to verify the adequacy or direction of the magnetic field, the Burma Castrol magnetic particle field indicator shall be used by positioning the indicator on the surface to be examined.
10.2. When using this indicator, a suitable flux or field strength is indicated when clearly defined line of particle forms across the copper face of the indicator.
10.3. When a clearly defined line of particles is not formed, or is not formed in the desired directions, the magnetizing techniques shall be changed or adjusted to obtain required test sensitivity.
11. MAGNETIZING CURRENT
Alternating current or direct current shall be used.
12. DIRECTION OF MAGNETIZATION
12.1. At least two separate examinations shall be performed on each area. During the second examination, the lines of magnetic flux shall be approximately perpendicular to those used during the first examination.
12.2. All examination shall be conducted with sufficient overlap to assure 100% coverage at the required test sensitivity.
DOCUMENTED BY : BALAJI RAO DATE : 28TH MAY 2002 (REV)

ASNT LEVEL III REF : MT – CPS – 02 – RV1

REVIEWED BY : MARAN PAGE : 04 OF 06

PT. AKURA BINA CITRA
Perkantoran Liga Mas Indah Kav. 9 Lt. 2, Pancoran Indah I, Jl. Raya Pasar Minggu, Jakarta 12760

Phone : (62-21) 922-4606, 794-8138 Fax : (62-21) 798-7714 E-mail : akura@cbn.net.id

QUALITY ASSURANCE MANUAL


OPERATING PROCEDURES FOR

MAGNETIC PARTICLE INSPECTION
13. MAGNETIZATION TECHNIQUES
13.1. Yoke - Technique
13.1.1. Application - This method shall only be applied to discontinuities that are open to the surface of the part.
13.2. Magnetizing Procedure – For this technique alternating or direct current electro magnetic yokes or permanent magnet yokes shall be used. This lifting power should be 10 pounds for AC yoke and 40 pounds for DC permanent magnet yoke.

A proper calibrated test block to be used and block needs to be calibrated every 2 years.
14. DEMAGNETIZATION
14.1. Demagnetization do not need to be performed since the remnant field is very small.
15. EXTENT OF EXAMINATION
The examination areas shall be as indicated in the customer requirements or as per the applicable specification used.
16. EVALUATION OF INDICATIONS
16.1. All indications shall be evaluated in terms of the acceptance standards of the applicable code section, to the specific client specification.
16.2. Any indication believed to be non relevant shall be regarded as relevant until the indication is either eliminated by surface conditioning or demonstrated to be non relevant by other means.
16.3. Relevant indications are those that result from mechanical discontinuities.
DOCUMENTED BY : BALAJI RAO DATE : 28TH MAY 2002 (REV)

ASNT LEVEL III REF : MT – CPS – 02 – RV1

REVIEWED BY : MARAN PAGE : 05 OF 06

PT. AKURA BINA CITRA
Perkantoran Liga Mas Indah Kav. 9 Lt. 2, Pancoran Indah I, Jl. Raya Pasar Minggu, Jakarta 12760

Phone : (62-21) 922-4606, 794-8138 Fax : (62-21) 798-7714 E-mail : akura@cbn.net.id

QUALITY ASSURANCE MANUAL


OPERATING PROCEDURES FOR

MAGNETIC PARTICLE INSPECTION
17. MAPPING OF INDICATIONS
17.1. All relevant indications shall be marked on the components with a suitable marker to easily identify the indications exact location to expedite repairing where possible.
18. RECORDS AND REPORT
18.1. Result of magnetic particle examinations will be recorded on MT inspection reports. This shall include the following information.
18.2. Materials, shapes or sizes to be examined, type of magnetizing being used, equipment being used for magnetization, magnetic particle used – manufacture, color, wet, dry. Magnetization current, demagnetization and sketches or a chart indicating coverage..
19. CUSTOMER REQUIREMENTS
Any requirements given for a particular order shall supersede the requirements given in this procedure.

DOCUMENTED BY : BALAJI RAO DATE : 28TH MAY 2002 (REV)

ASNT LEVEL III REF : MT – CPS – 02 – RV1

REVIEWED BY : MARAN PAGE : 06 OF 06

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