GM PW 302 - Magnetic particle inspection of welded assemblies

INDUSTRY & FACILITIES

Pressure and Welding Technical Management Center

GM PW 302 - Magnetic particle inspection of welded

assemblies
*

App. Date 30/06/2003 Rev. 3 Order N° 302

Distr. Status Confidential - All rights Rev. Date 18/06/2003
reserved

Classification
Category 1 - Pressure and Welding technical Centre
Sub-category 4) Welding

Quality Actors

Editor(s) Cecile Sauphanor/FRA/VERITAS, Jean-Francois Adam/FRA/VERITAS, Patricia

Abecassis/FRA/VERITAS

Editor Manager Jean-Francois Adam/FRA/VERITAS

Checker Michel Clerjaud/FRA/VERITAS

Approval Manager Alain Chandeze/FRA/VERITAS

Distribution Manager Benedicte Godart/FRA/VERITAS

Master List Manager Benedicte Godart/FRA/VERITAS

Version Log
Revision Date Revision Number
18/06/03 3
18/06/03 3

Update of Master List Manager

Modification date Author Old value

Paper Complementary Distribution

Revision Sheet 000 of GM PW 302 Magnetic particle inspection of welded assemblies - rev. 3 - rev. date 18/06/2003

Revision Sheet

This document cancels and supersedes GM PW 302 - Rev. 2 (13/10/1998).

- Major modifications of the text due to the changement of the organization in Bureau Veritas, it is said
the creation of the Pressure and Welding Technical Management Centre in Bureau Veritas Paris-
Rennequin under the responsibility of Michel CLERJAUD who reports to Alain CHANDEZE.

- Modification of the paragraph 1.7.

- Complete modification of the other references in Part 1 - GENERAL.

- Also have been taken into account some dispositions connected with new PED organisation.
1.1 Purpose
The present Methodological Guide defines the general dispositions applicable to the magnetic particle
inspection of welded assemblies using wet process.

The inspection method described herein relates to magnetic particle inspections with electric current or a
magnetic field, directly applied to the assembly; detection is carried out with the help of a magnetic dye
(developer/indicator) applied to the zone to be inspected during the period ("continuous" process).

1.2 Scope of application

The instructions described hereinafter are applicable when magnetic particle inspection is carried out under
the supervision of Bureau Veritas, to the extent that the instructions are not in conflict with the requirements
or instructions delivered by the client.

Magnetic particle inspection is applicable to ferromagnetic steels, this includes those materials which, when
subject to a field of 2400 A/m, show an induction of at least one TESLA.

The present guide only covers the formalities for the discovery and the characterisation of surface defects
open or not.

The criteria for approval and acceptance should be defined by the client and should be the subject of a
separate and distinct document.

For french regulation applications, it might be refered to "BV France, PRT SD009", at the request of a foreign
office, if need. This demand will be considered, at each case, particularly by BV CTPS, which holds the
updated list of qualified inspectors.

1.3 Responsibility for implementation

The persons carrying out these inspections must be qualified and certified. In France, certification must be
granted in accordance with the COFREND system (Standard EN 473), at an appropriate level. Other regions
in Europe should ensure the qualifications of the operators comply with their national organisation (see annex
VIII of GM PW 127).

In accordance with this system, the inspections can be carried out by a "Level 1" operator on the condition
that a "Level 2" (or "Level 3") operator provided him with the technical instructions necessary to carry out the
inspections and present the results thereof.

The present document can be used as a basis for drafting the aforementioned instructions.

1.4 References

Other
- M.O.,
- PGG,
- Standard EN 473 Qualification and certification of NDT personnel - General principles.
- Standard EN 1290 Non destructive examination of welds - Magnetic particle examination of welds.
- Standard EN 1291 Non destructive examination of welds - Magnetic particle testing of welds - Acceptance
levels
- Standards EN 288-1, 288-2, 288-3 and 288-4 as examples (available in French, English and German and in
all EU languages from national standards institutes)
 - French AQUAP specification (applicable in case of repairs, please consult CTPS)
- general case (1-87)
- electron beam welding (1.88) (for these cases, please consult CTPS).
- local repairs made during welding for manufacture of new equipment or repairs of in-service equipment
(2.82) (for these cases, please consult CTPS)
- assemblies intended to fix on a wall a bolt-fitting, a string or a spacer (2.88) (for these cases, please
consult CTPS)
- manufacturing of stainless tubes fusion welded in specialised plants (for these cases, please consult
CTPS)

- Departmental order of 24 march 1978 as amended, concerning the use of welding in the repair of
pressure vessels manufactured under old French regulation, to take into account acceptance level of defects.

Regulated field :
Welded constructions according to French regulation as follows :
- pressure equipment according to devree 99-1046 of December, 13th of 1999 transposing PED 97/23/EC
Directive which lists concerned equipment,
- transportable pressure equipment according to decree 2001-386 of May, 3rd of 2001 transposing TPED
1999/36/EC Directive, which lists is indicated in GM PW 402 § 2.1.
- simple pressure vessels according to decree of December, 14th of 1989 for application of 87-404/CEE
Directive
- equipment for transportation of dangerous goods according to ADR decree of June, 1st of 2001 modified,
- equipment for transportation of dangerous goods according to RID decree of June, 5th of 2001 modified,
- pipe-lines for transportation of fuel gases according to decree of May 11th of 1970,
- mains for distribution of fluids other than hydrocarbon and fuel gases.

All applicable document, cited in a precise standard.

1.5 Terminology
- MO Chapter 0. See section 2.1
- Standard EN 473 Qualification and certification of NDT personnel - General principles.
- Standard EN 1290 Non destructive examination of welds - Magnetic particle examination of welds
- Standard EN 1291 Non destructive examination of welds - Magnetic particle testing of welds - Acceptance
levels

1.6 Identification and filing

This guide, entitled "MAGNETIC PARTICLE INSPECTIONS OF WELDED ASSEMBLIES", is filed under the
reference GM PW 302 with other Methodologic Guides by the Metallurgy-Welding Manager in Pressure and
Welding Technical Management Centre, as stipulated in MO - 4.1 Continuous Improvement, Document
Management, §1.1.

1.7 Revision
This guide is revised at the warranted request of the Vice-President Quality or the Metallurgy-Welding
Manager of Pressure-Welding Technical Management Centre (CTPS) as stipulated in MO.

1.8 Distribution
This guide is made available to the organisation in charge of distribution by the Pressure and Welding
Technical Management Centre (CTPS) or the Metallurgy-Welding Manager (cf. PGG 012).

Section 1 - General dispositions

1.1. TIME OF INSPECTION

The inspections are carried out during the stages of manufacturing defined in the instructions
(specifications, codes, standards, regulations) provided by the client.

1.2. SCOPE OF INSPECTION

The zones to be inspected should be defined in the specifications submitted by the client. In the
absence of client specifications, Bureau Veritas can propose an appropriate inspection plan to the
client, which must be approved by the parties before being carried out.

1.3. PREPARING THE SURFACE

The surfaces must be clean, free of any grease, oil, sand, oxides, dust or flux or slag residue which
might prohibit on one hand the mobility of ferromagnetic particles of the dye, and on the other hand,
the interpretation of magnetic images.
Any grinding or machining of the surface which is necessary to remove the surface irregularities
(furrows, waves) must have the prior approval of the client.
To improve the visibility of the magnetic images a thin layer of white or light-colored paint is applied to
the area to be inspected.

1.4. OPERATING METHODS

The general principles to be followed are those defined in the standard EN 1290.
In certain cases, depending upon the type of contruction being inspected, it is necessary to define a
specific operating method in addition to the general instructions provided herein.
In this case, the operating method must be defined and approved by the parties prior to the
inspection.

1.5. SAFETY

The safety rules to be followed are those in force for both the materials and the products used.

Section 2 - Magnetization of the area to be inspected

Magnetization can be carried out according to two methods:

„ by running current directly into the assembly,
„ by running a magnetic field directly into the assembly.

The magnetic field must be of a sufficient intensity in order to allow the operator to work in an area
situated above the maximal value of magnetic permeability. For most ferromagnetic materials, this
condition is reached for a value of tangential field between 2000 and 4000 A/m.

2.1. MAGNETIZATION BY RUNNING CURRENT

2.1.1. Principle
 The direct passage of current in the assembly creates a magnetic field which runs across the
line joining the contact electrodes.
The defects will be better detected if their primary orientation is perpendicular to the direction
of the magnetic field, that is to say parallel to the line joining the contact electrodes.

2.1.2. Equipment
The generator must be capable of providing a current of a strong intensity under low
tension/voltage.
The current can be:
- AC,
- half-wave rectified,
- full-wave rectified,
- DC.
- The generator must be equiped with an ampmeter which measures the magnetization
current.
- The electrodes and the power switch must be designed so as to avoid the formation of
sparks between their extremities and the surface being inspected, as well as any
excessive heating of contact points.
These instructions are particularly important with respect to the inspection of carbon steel and
alloy steel which is sensitive to heat treatments.
An additional inspection of the contact points is recommended after the magnetic particle
inspection. This inspection can be carried out by dye penetrant inspection (See Procedural
Guide GM PW 301) and requires a slight grinding of the surface.
- The magnetization current must be turned on and shut off when the electrodes are in
contact with the surface. The generator therefore must be equipped with a command
allowing for this operation.

- The electrodes must be applied perpendicularly to the surface to be inspected.

 2.1.3. Regulating the magnetization current
- The intensity of the magnetization current and the distance between electrodes shall
be defined in the instructions or the code submitted by the client.
- In the absence of specific instructions the:

TYPE OF CURRENT
effective intensity 40/50 (A)
AC
average intensity 25/32 (A)
Half-wave rectified
average intensity 36/45 (A)
Full-wave rectified

The distance between electrodes shall not be less than 7.5 cm. or greater than 30 cm.

- A verification of operating conditions (intensity and distance between electrodes) shall be

carried out with the use of a magnetization reference.

2.2. MAGNETIZATION BY RUNNING A MAGNETIC FIELD DIRECTLY INTO THE

ASSEMBLY
- The magnetization of the area to be inspected is carried out with an electromagnet equiped with
mobile poles held manually and applied to the surface of the assembly.
- The magnetic circuit of the electromagnet is closed by/at the area being inspected which is
subject to a "longitudinal" magnetic field.
- The defects will be more easily detected if their principal orientation is perpendicular to the
magnetic field, that is to say perpendicular to the line connecting the poles.

2.2.1. Equipment
The lifting strength of the electro-magnetic apparatus measured with the aid of a
dynamometer must be, at least:

- 45 N, if the electromagnet is supplied with alternative current

- 180 N, if the electromagnet is supplied with direct current with distances between the
poles measuring between 7.5 and 25 cm. These distances correspond to the
distances between the axes of the poles.

2.2.2. Regulating the magnetization current

The detection sensitivity must at least be equal to that of magnetization by running current
directly to the assembly.
A verification of operating conditions shall be carried out with the help of a magnetization
reference or a measure of the tangential field according to the conditions provided in the
standard EN 1290.

Section 3 - Production of the magnetic image

The magnetic dye is made up of a ferromagnetic powder of fine and even grains, attracted by the magnet and
suspended in a neutral dye which has no effect on the powder or on the area to be inspected.
- The concentration of the magnetic powder must be in conformity with the guidelines provided
band must be at least equal to 5 g/liter of solution for colored powders which are visible in normal
light.
- For inspections occurring under ultraviolet lighting, powders composed of grains of ferromagnetic
nucleus with a fluorescent covering.

The concentration of such powders can vary between 0.5 and 2 g/liter of solution.
- The neutral dye which is transparent and light in color must sufficiently wet the powder in order to
assure its effective suspension in the dye.

The limitations for use with respect to temperature are provided by the manufacturer and must be
followed in all cases.

Section 4 - Verification of magnetization conditions with the help of a

reference

4.1. The inspection conditions must be verified in the beginning of each inspection and each time the
inspection is modified in any way.

This global verification of the sensitivity is carried out by placing a magnetization reference on the
area to be inspected.

To do this, one of the following is used:

- either the Reference described in the standard EN 1290, § 5.4.2,
- or the ASME reference in the shape of an octogon composed of eight triangular sections
assembled by brazing and dipped in copper (ASME V, Art. 7).

4.2. The surface of the magnetization reference should be adapted, if necessary, to the curves of the
surface to be inspected to allow the induction lines to pass from the material to the reference, with as
little contact as possible with the air.

4.3. The magnetization reference shall also be used to define the scope of the zone subject to
magnetization for the inspection conditions chosen and, consequently the maximum incline of the
defects detected in relation to the line joining the electrodes or the poles.

The width of the area being inspected should also be verified, following a direction which runs across
the line connecting the contacts and the zone near the contacts, generally considered as a troubled
zone which distorts the magnetic indications.

Section 5 - Performance of the magnetic particle inspections

5.1. CHOOSING THE MAGNETIZATION METHOD

- The choice as to which method of magnetization to be used shall be made by the client.
 - In the absence of specific directions, the operator carrying out the inspection shall choose the
method which is most appropriate with respect to the elements to be inspected and the defects to
be detected.

The method of magnetization by running a magnetic field is recommended when the inspection is
carried out following a heat/thermal treatment on carbon steel or alloy steel, which are sensitive to
heat treatments.

5.2. POSITIONING THE CONTACTS

- The positioning of the contacts on the surface shall be carried out so as to assure a thorough
inspection of the weld, plus an area of 20 mm on either side of the seam.
- The successive positions of the contacts should allow total coverage of the areas to be
inspected, following at least two perpendicular directions of the magnetic fields which have been
created.

If a magnetic image seems to be extremely tilted in relation to the direction of the magnetic field, a
complementary examination shall be carried out by creating a field, the direction of which shall be
perpendicular to primary direction of the magnetic image.
- As a general rule, the inspection of the weld is carried out by placing the contacts on both sides of
the seam, as illustrated hereafter, and by assuring sufficient coverage to examine the zones to be
inspected in accordance with homogenous magnetization conditions.
 DIFFERENT POSITIONS OF THE CONTACTS

5.3. ADJUSTMENT OF THE MAGNETIZATION AND SPACING BETWEEN THE

CONTACTS

- These adjustments are specified in the instructions or the code submitted by the client.
- In the absence of instructions the operator shall determine the inspection conditions following
tests carried out according to the directions provided in section 2.1.3. or 2.2.2. hereinabove.

5.4. APPLYING THE MAGNETIC DYE (DEVELOPER/INDICATOR)

- The client shall choose the magnetic dye to be used for the inspection. If the client fails to
specify its choice of magnetic dye, the choice shall be made by the operator, after having
consulted the client.

This choice must be made in accordance with the surfaces being inspected and the temperature of
the assemblies.
- The magnetic dye shall only be applied for the period of magnetization, plus a few additional
seconds.

It is recommended that operator wet the area to be inspected prior to magnetization in order to
facilitate the even application of the magnetic dye.
 - The dye, which has a tendancy to settle, must be sufficiently mixed to assure its homogeneity.
- The magnetic dye is applied by spraying, but the operator must not use an excessively strong
jet.

5.5. VERIFICATION OF THE INSPECTION CONDITIONS

- The inspection conditions must be verified with the help of magnetization gauge described in
section 8.1 hereinabove.

These verifications must be carried out regularly during the course of an inspection.
- The scope of the inspection zone for each positionning of the contacts must also be verified
with a gauge (See section 4.3 hereinabove).

5.6. OBSERVING MAGNETIC IMAGES

- The observation should be carried out during and after the end of magnetization and should
occur under normal lighting for colored powders and under highly ultraviolet lighting for
fluroescent powders.
- The lighting used should be the same as that used for the adjustments and verifications, with
the help of a magnetization reference.

Precautions must be taken to avoid both reflections occurring as a result of a light which is centered
on a shiny surface and surrounding lighting which is excessively intense.

Note Not all magnetic images correspond to actuel defects. In fact, results can appear due to
surface irregularities, excessive roughness, an excessive variation of magnetic permeability of
the HAZ (Heat Affected Zone) or the boundary line of the weld (notably on alloy steel or steels
with a high carbon content),or an increased value of the magnetic scope, etc.
In case of uncertainty, additional investigations will be carried out following an improvement of
the surface and a modification of the magnetization conditions.

5.7. DEMAGNETIZATION

Following the inspection and at the request of the client, the parts inspected can be demagnetized,
using an appropriate method (thermal effect or magnetization cycles).

Section 6 - Inspection Report

The inspection report, which should be based upon the sample report attached in Appendix II, should include
all of the following information:
- Details regarding the weld which was inspected: type of steel, type of assembly, identify the weld
on a construction plan or according to a diagram set forth by the operator carrying out the
inspection
- Reference documents: diagrams, codes, specifications
- Evaluation criteria submitted by the client
 - Stage of the inspections: before or after heat treatment
- Scope of inspection: percentage
- State of the surface: rough, sanded, grinded, polished, shot-blasted , brushed, planed (totally or
smoothed)
- Equipment used: brand, type
- Magnetization gauge used
- Type, color and brand of developer/indicator
- Type of lighting
- Operating Conditions
„ intensity of magnetization
„ spacing between contacts
- Scope of the magnetized zone for each position of the contacts, accompanied by a drawing
indicating the successive positions in order to assure the complete inspection under two
perpendicular directions.
- The results of the analysis with drawings indicating the position and the dimension of the
inacceptable indications in light of the criteria submitted by the client.
- The eventual demagnetization
- Date and location at which the examination occurred
- Name, title and qualification of the operator, the person writing the report and the inspector
- Bureau Veritas' general conditions

A copy of the report is sent to the client and is also kept on file for a period of at least five years.

Appendix 1 - Non-destructive testing magnetic particle inspection

general control principles

STANDARD EN 1290

(Not enclosed in Lotus-Notes but easily available from your standards organisation. Essential documents held by
operational offices (cf. § 1.4 of the present document).

Appendix 2 - Magnetic particle examination Report

(Form AdME 7622)