NDE PROCEDURE UT & MPI

CLIENT TPL Doc No. B224-CDU-TPL-000-PP-

HPCL RAJASTHAN REFINERY LTD. QD-PR0063-0002

PMC
EPCC 01 JOB NO B224 ENGINEERS INDIA LTD.
PROJECT Page.: 1 of 23
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HPCL RAJASTHAN REFINERY LIMITED

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BARMER, RAJASTHAN

PACKAGE NAME: Alloy Steel Ball Valves

VENDOR NAME: Niton Valves
VENDOR DOC. NO. NVI/UT/QC, NVI/MPI/QC
PO No.: 18868

HPCL RAJASTHAN REFINERY LTD

1. No Comments/Const. as per document
2. Proceed with Manufacturing

3. Rejected – Resubmit
R Retained for Records
V Void

0 06.03.2023 FOR APPROVAL HASAN YUSUF/AJAZ KADRI

CHECKED/ REVIEWED APPROVED
REV DATE PURPOSE PREPARED BY BY BY
 NDE PROCEDURE UT & MPI

CLIENT TPL Doc No. B224-CDU-TPL-000-PP-

HPCL RAJASTHAN REFINERY LTD. QD-PR0063-0002

PMC
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PROJECT Page.: 1 of 23
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Table of Contents
 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

PROCEDURE

FOR

ULTRASONIC

TESTING
REVISION STATUS

Rev . No. Date Description Prepared by Approved by

NDT Level III
00 11/01/2020 Original Nikhil Rasal K. Chatterjee
01 01/12/2021 Revision M. Hasanali K. Chatterjee

Activity Prepared By Approved By &Authorized By

Signature
With
Stamp

Name Mr. MADANIA HASANALI Mr. K. CHATTERJEE

(NITON) ASNT NDT Level-
ASNT NDT Level-III
Designation II
(UT, RT, MT, PT, ET, VT)
(UT, RT, MT, PT)
Date 01.12.2021 01.12.2021

Procedure for Ultrasonic Testing Proc. No. W-P-21-08 Rev. 01 Page 1 of 10

 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

1.0SCOPE :

1.1 This procedure covers pulse echo ultrasonic examination procedure of heat
treated carbon, low alloy steel forged/casting and welded materials by the
Normal (Longitudinal) beam and Angle (Shear) beam technique.
1.2 This practice is to be used whenever the inquiry, contract, order or specification
states that castings, forged steel round bar, overlay and welding, machining
surfaces etc. are to be subjected to ultrasonic examination.
1.3 UT in Place of RT For Forged Valve in Accordance With ASME B16.34

2.0 REFERENCE DOCUMENTS:

2.1 ASME Sec V, Article-4, 5 &23 for test procedure. (standard Specification)Edition -
2021
2.2 ASTM A609, A388, A435, A577 for Standard Practices Edition - 2019
2.3 ASNT SNT- TC-1A, for operator qualification. Edition – 2016
2.4 ISO 9712 for personnel qualification. Edition - 2012
2.5 ASME Sec VIII Div I, Appendix 12Edition - 2021
2.6 ASME B16.34 -2017 Edition, Mandatory Appendix IV Edition - 2020
2.7 ONGC Spec.2004A Rev.9 & FS 2009F Rev.8
2.8 API 6D Annexure – G Edition – 24th

3 ACCEPTANCE STANDARD:

3.1 For Welds, as per ASME Sec VIII Division -1 Appendix- 12.Edition – 2021
3.2 For forging acceptance standards as per ASTM A388, ASME B16.34,Mandatory
Appendix IV Edition – 2020
3.3 For Forging Plate acceptance standards as per ASTM A435/A577, ASME B16.34,
Mandatory Appendix IV Edition – 2020
3.4 For casting acceptance standards as per ASTM A609, ASME B16.34,Mandatory
Appendix IV Edition – 2020
3.5 ISO 5817 – acceptance criteria for NDT / quality level for imperfection.
3.6 API 6D as Per Annexure – G (Enclosed as Copy Annexure – G below) Edition – 24th

4 QUALIFICATIN OF PERSONNEL

4.1 As a minimum all personnel conducting UT shall be certified to NDT Level II of

ASNT SNT-TC-1A.

4.2 UT will be performed under the supervision of NDT Level II or equivalently

qualified Supervisor.

4.3 All qualification certification shall within validity period as per ASNT SNT-TC-1A

Procedure for Ultrasonic Testing Proc. No. W-P-21-08 Rev. 01 Page 2 of 10

 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

5.0 PROCEDURE QUALIFICATION

When procedure qualification is specified, any changes in the essential variables
requirements, as listed in the Examination Variables Table, shall require re-
qualification of the written procedure by demonstration. A change of a requirement
identified as a nonessential variable, does not require requalification of the written
procedure. Any changes / deviations to this procedure or if a mandatory annexure is
required, will require revision and re-issue of this procedure. Any revision of either
essential or nonessential variables to this procedure, will as a minimum require
review and acceptance by the appointed NDT Level III.
EXAMINATION VARIABLES TABLE

Essential Non-essential Paragraph

No. Requirement
Variable Variable No.
Material types and configurations to be
examined, including thickness dimensions and
1 X - 3.2
product form
(casting, forgings, plate, etc)
The surfaces from which the examination shall X
2 - 7.0
be performed
Techniques(s) (straight beam, angle beam, X
3 - 17.0
contract, and/or immersion)
Angle(s) and mode(s) of wave propagation in X
4 - 17.2
the material
Search unit type(s), frequency(ies), and element X
5 - 9.2
sizes(s) / shapes(s)
Special search units, wedges, shoes, or saddles, X
6 - 17.2.3
when used
7 Ultrasonic instrument(s) X - 9.1
X 13.0 /
Calibration [calibration block(s) and
8 - 14.0 /
techniques(s)]
15.0

Procedure for Ultrasonic Testing Proc. No. W-P-21-08 Rev. 01 Page 3 of 10

 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

X 16.0 /
9 Directions and extent of scanning -
17.0
10 Scanning (manual vs. automatic) X - 15.0
X 18.0 /
11 Method of sizing indications -
19.0
Computer enhanced data acquisition, when X
12 - 20.0
used
13 Scan overlap (decrease only) X - 11.0
Personnel performance requirement, when X
14 - 3.1
required
15 Personnel qualification Requirements - X 4.0
Surface condition (examination surface, X 15.0 / 7.0
16 -
calibration block) / 8.0
17 Couplant: brand name or type - X 10.0
18 Post-examination cleaning Technique - X 7.3
Automatic alarm and/or recording equipment, X
19 - 20.0
when applicable
Records, including minimum calibration data to
20 - X 20.0
be recorded(e.g., instrument settings)

6.0 EQUIPMENT AND ACCESSORIES:

6.1 Extent of Examination: Extent of examination shall be as specified in approved

Engineering drawings and Quality Assurance Plan approved by Third Party
Inspection Agency/Customer. When procedure qualification is specified by the
referencing Code Section or range of values, shall require re-qualification of the
written procedure.
6.2 It is Operators responsibility to use ultrasonic instrument calibrated for
Horizontal and Vertical Screen Height and amplitude control linearity according
to ASME Sec V Article 4, Mandatory Appendix I and II.
6.3 All Instruments shall be approved by the inspector.
Recommended Model : MODSONIC

6.4 APPARATUS
6.4.1 An ultrasonic, pulsed, reflection type of instrument that is capable of
generating, receiving, and amplifying frequencies of at least 1 to 5 MHz.
6.4.2 The ultrasonic instrument shall provide linear presentation (within ±5%) for at
least 75% of the screen height (sweep line to top of screen). Linearity shall be
determined in accordance with Practice E 317 or Equivalent electronic means.

Procedure for Ultrasonic Testing Proc. No. W-P-21-08 Rev. 01 Page 4 of 10

 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

6.4.3 The Electronic apparatus shall contain a signal attenuator or calibrated gain
control that shall be accurate over useful range to ±10% of the nominal
attenuation or gain ratio to allow measurement of signals beyond the linear range
of the instrument.

6.5 ULTRASONIC INSTRUMENT

6.5.1 Type: Pulsed ultrasonic reflection instrument capable of generation,
receiving, and amplifying frequencies of at least 1 to 5 MHz
6.5.2 Voltage: Line voltage shall be suitably regulated by constant voltage
equipment and metal housing must be grounded to prevent electric shock.
6.5.3 Linearity: The Instrument must provide a linear presentation (within ±5%) of at
least 1.5 inch (40 mm) sweep to peak
6.5.4 Calibrated Gain Control of Attenuator: The instrument shall contain a
calibrated gain control or signal attenuator (Accurate within ±10%) which
will allow indications beyond the linear range of the instrument to be
measured.
6.5.5 Time Corrected Gain: The instrument shall be equipped to compensate for
signal decay with distance. A method should be available to equalize signal
response at different depths.

6.6 COUPLANT
Couplant must be selected that are not detrimental to the product or the process.
The couplant should be selected so that its viscosity is appropriate for the surface
finish of the part to be tested Mixture of oil and grease, wall paper paste or any
other similar material which permits satisfactory transmission of ultrasonic
energy should be used as couplant. The couplant used in calibration should be
used for the examination
Control of Contaminants (a-Couplants used on nickel base alloys shall not contain
more than 250 ppm of sulfur. (b) Couplants used on austenitic stainless steel or
titanium shall not contain more than 250 ppm of halides(chlorides plus fluorides)

6.0 CALIBRATION STANDARD:

A) For ultrasonic testing of Casting and Forging,

As per SA388 Back wall method will be used for setting test sensitivity.

B) For weld testing :

Miniature steel calibration block (V2 block) will be used for range calibration& angle
check.

ASME Reference block may be used for machine calibration, linearity check, etc. Refer
ASME Sec V, Article 4 & 5 for details of the calibration block.
Procedure for Ultrasonic Testing Proc. No. W-P-21-08 Rev. 01 Page 5 of 10
 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

For setting test sensitivity [DAC], three steel blocks [12.5, 25, 32 mm thick] prepared
from material similar to the test material with surface condition similar to the test
surface, with a 2.4 mm diameter hole drilled on the edge at a depth of ½ and ¾
thickness is recommended.
Transfer correction for test sensitivity will be used if the surface condition is very
different from the test material.
Only the required calibration holes as mentioned in the ASME reference block may be
incorporated in the Test block.
Block material shall be tested by ultrasonic method to ensure it is free from
discontinuities before drilling holes.

7.0 SURFACE PREPARATION:

7.1 Test Surface of material shall be free of material that will interfere with the
ultrasonic examination. They may be as cast, forge, and welded, blasted, ground
or machined. The Ultrasonic examination shall be conducted prior to machining
that prevents an effective examination of the casting / forging materials.
7.2 All surfaces to be inspected shall be free of scale, machining or grinding particles,
excessive paint thickness, dirt, or other foreign matter that may interfere with the
inspection.
7.3 The forging /casting shall be positioned such that the inspector has free access to
the back wall for the purpose of verifying change in contour.

8.0 SCANNING:

8.1 The rate of probe movement for examination shall not exceed 150 mm / second.
Each pass of the probe shall overlap a minimum of 10% of the probe dimension
parallel to the direction of the scan.
8.2 The scanning sensitivity level shall be set a minimum of 6 dB higher than the
reference level gain setting

8.3 Straight beam Scanning: Before performing angle beam Examinations of the
weld, the entire angle beam movement area shall be scanned with a longitudinal
wave to detect the presence of imperfections/lamination which can interfere with
the examination of the weld. Presence of all such discontinuities shall be
documented in the examination report. The fusion line of through plate is also
required to be examined with the same probe with the test sensitivity.

8.4 Angle beam scanning: The weld joint and the heat affected zone shall be 100%
examined with angle beam probes. Scanning shall be performed as described in
the 8.1. If any part of the weld area is not fully covered in the examination then
such areas shall be identified on the examination report

Procedure for Ultrasonic Testing Proc. No. W-P-21-08 Rev. 01 Page 6 of 10

 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

Recommended Angles: Up to 25mm 60º and 70ºdegree

Above 25 mm 60º and 45º degree

9.0 POST EXAMINATION CLEANING

When it is necessary to remove the used couplant for subsequent operations all
couplantshall be removed and cleaned.

10.0 DISCONTINUITY EVALUATION

10.1 All relevant discontinuities shall be confirmed and their position within the
weld cross-section and heat effected zone shall be determined by means of
graphical plot method by utilizing the maximum amplitude signal and beam
path.

10.2 The length of all recordable discontinuities shall be determined by 6 dB drop

method. All discontinuities shall be evaluated using the probe which produces
maximum signal amplitude.

11.0EVALUATION STANDARD:
Any relevant discontinuity signal above 20% of the reference sensitivity shall be
investigated to the extent that the operator can determine the shape, identity, location
and evaluate in terms of the acceptance standard give below:

11.1 Procedure &acceptance Standard shall be as per ASME B 16.34 Appendix IV for
Castings and Forgings.

11.2 Straight Beam -

Indication which are equal to or exceed that obtained from a 6.4mm (0.25 in.)
diameter flat bottomed hole in a calibration test piece of thickness equal to the
defect depth are unacceptable.

11.3 Angle Beam -

Indication which are equal to or exceed those obtained from a 60 degree V-
notch, 25mm long and having a depth not greater than 5% of the nominal wall
thickness in a test piece are unacceptable.
Procedure for Ultrasonic Testing Proc. No. W-P-21-08 Rev. 01 Page 7 of 10
 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

11.4 Acceptance standard shall be as per ASME Sec VIII Div-I, Appendix 12 for
Weldings as per given below.
a) Indications characterized as cracks, lack of fusion or incomplete penetration
are unacceptable regardless of length.
b) Other imperfections are unacceptable if the indication exceed the reference
level amplitude and have lengths which exceed:

 ¼ in. (6mm) for t upto ¾ in. (19mm)

 1/3t for t ¾ in. to 2 ¼ in. (19mm to 57mm)
 ¾ in. (19mm) for t over 2 ¼ in (57mm)
12.0 REPORT

The UT report shall contain the following details -

i) Client Name
ii) Internal Work Order No.& PO No.
iii) Identification of the job.
iv) Date of Inspection
v) Code & Acceptance standards.
vi) Material type and thickness range of job.
vii) Technique of Method
viii) Area to be examined
ix) Equipment Details
x) Acceptance criteria
xi) Accept/Reject status-Remark
xii) UT Procedure No.
xiii) Operator name & signature.

UT evaluation report in the format enclosed as Annexure – A below.

Reviewed By Approved By Authorized By

NDT DEPT. ASNT NDT LEVEL-III QA/QC DEPT

Procedure for Ultrasonic Testing Proc. No. W-P-21-08 Rev. 01 Page 8 of 10

 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

ANNEXURE – G ( as per API 6D )

1. UT Of On 100% Of Critical Areas Of Castings

A. Examination Shall be carried out in accordance with ASME B16.34, Appendix IV.
B. Acceptance Shall be accordance with ASME B16.34, Appendix IV.

2. UT Of On 100% Of Accessible Areas Of Castings

A. Examination Shall be carried out in accordance with ASME B16.34, Appendix IV.
B. Acceptance Shall be accordance with ASME B16.34, Appendix IV.
C. ASME Sec. VIII Div. 1 Appendix 7

3. UT Of Forgings& Plate On 100% Of Surface Area

A. Examination Shall be carried out in accordance with ASME B16.34, Appendix IV.
B. Acceptance Shall be accordance with ASME B16.34, Appendix IV.

4. UT Of Full Penetration Welds On 100% Of Weld

A. Examination Shall be carried out in accordance with ASME BPCV, Section V, Article 4.
B. Acceptance Shall be accordance with ASME BPCV, Section VIII, Division 1, Appendix 12.

5. UT Of Weld Overlay On 100% Of Surface

A. Examination Shall be carried out in accordance with ASME BPCV, Section V, Article 4. Straight
Beam Method.
B. Acceptance Criteria Shall be accordance with ASME A578A/A578M Standard Level C.

Procedure for Ultrasonic Testing Proc. No. W-P-21-08 Rev. 01 Page 9 of 10

 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

ANNEXURE - A
F-P-21-09

ULTRASONIC EXAMINATION REPORT

Report No.:- Date:-DD/MM/YYYY W.O No.:-

CLIENT :-
PO. NO& Project Name:-
SPECIFICATION :-
Acceptance Standard :-
Procedure No. :-
Instrument :- MODSONIC Technique :- Pulse Echo by A Scan Couplant:- Machine Oil
Einstein II
Basic Reference Block :- ASTM-IIW-V2 Reflector Size :- Back Wall Echo 80 % / DAC
Sensitivity Setting :-+ 6db Recording Level :-20% Stage of Examination :- Final
Examination Surface :- Surface Condition :- Clean & Satisfactory
Extent of Examination :-100 % Scanning With 10 % Over Lap

PROBE CRYSTAL SIZE FREQUENCY

Normal Probe 10 mm 2 MHz
T.R 10 mm 4 MHz
Angle (45⁰/60⁰/70⁰) 8 X 9mm 4 MHz
JOB DETAILS:-
Item No. ITEM DESCRIPTION Valve Sr. No. / Heat No. QTY. REMARKS

TEST RESULT:-

ASNT LEVEL - II

Procedure for Ultrasonic Testing Proc. No. W-P-21-08 Rev. 01 Page 10 of 10

 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

PROCEDURE

FOR

MAGNETIC PARTICLE

TESTING
REVISION STATUS

Rev . No. Date Description Prepared by Approved by

NDT Level III
00 11/01/2020 Original Nikhil Rasal K. Chatterjee
01 01/12/2021 Revision M. Hasanali K. Chatterjee

Activity Prepared By Approved By & Authorized By

Signature
With
Stamp

Name Mr. MADANIA HASANALI Mr. K. CHATTERJEE

(NITON) ASNT NDT Level-II ASNT NDT Level-III
Designation
(UT, RT, MT, PT) (UT, RT, MT, PT, ET, VT)
Date 01.12.2021 01.12.2021

Procedure for Magnetic Particle Testing Proc. No.- W-P-21-09 Rev. 01 Page 1 of 11
 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

1.0 SCOPE

This general Magnetic Particle Testing procedure is intended to be descriptive for both
dry and wet (continuous) magnetic particle examination, a non-destructive method for
detecting cracks and other discontinuities at or near the surface in ferromagnetic
materials. This procedure is in accordance with following documents and any other
applicable code and client Specification.

2.0 REFERENCE DOCUMENTS

I) ASME Sec V, Article-7, 25 for test procedure – Edition - 2021

II) ASTM E709/ ASTM A275 / MSS SP : 53 - Edition - 2019
III) ASNT SNT -TC- 1A, for operator qualification - Edition – 2020 / Latest
IV) ISO 9712 for personnel qualification - Edition - 2012
V) ASME Section VIII Div-I Appendix 6 - Edition - 2021
VI) ASME B 16.34 Mandatory Appendix II - Edition – 2020
VII) ONGC Spec.2009F Rev.8 & FS 2004A Rev.9
VIII) ASME Sec V, Article-7 Table T-721 - Edition – 2021
IX) API 6D Annexure – G - Edition – 24th

3.0 PERSONNEL QUALIFICATION

I) As a minimum all personnel conducting MPT shall be certified to NDT Level II as

per ASNT SNT-TC-1A and it shall be performed under the supervision of NDT
Level II or equivalent qualified supervisor.
II) Evaluation & Report shall be reviewed by certified NDT Level II as per
ASNT SNT-TC-1A
III) All qualification certification shall within valid period

3.1 PROCEDURE QUALIFICATION

When procedure qualification is specified, any changes in the essential variables

requirements, as listed in the Examination Variables Table, shall require re-
qualification of the written procedure by demonstration. A change of a requirement
identified as a non essential variable, does not require re-qualification of the written
procedure. Any changes / deviations to this procedure or if a mandatory annexure is
required, will require revision and re-issue of this procedure. Any revision of either
essential or non essential variables to this procedure, will as a minimum require
review and acceptance by the appointed NDT Level III.

Procedure for Magnetic Particle Testing Proc. No.- W-P-21-09 Rev. 01 Page 2 of 11
 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

EXAMINATION VARIABLES TABLE

Non-
Essential
Requirement Essential Paragraph No.
Variable
Variable
Magnetizing technique X 12.1 / 12.2
Magnetizing current type or amperage outside
range specified by this article or as previously X 11.1 / 11.2
qualified
Surface preparation X 8.0
Magnetic particle (fluorescent / visible, color,
X 7.0
particle size, wet / dry)
12.1 / 12.1.2 /
Method of particle application X
12.1.5
Minimum light intensity X 10.0
Existing coatings, greater than the thickness
X NA
demonstrated
Nonmagnetic surface contrast enhancement,
X 12.1.2
when utilized
Performance demonstration, when required X 6.0
Examination part surface temperature outside
of the
temperature range recommended by the X 9.0
manufacturer of
the particles or as previously qualified
Shape or size of the examination object X NA
Equipment of the same type X 11.0
Temperature (within those specified by
X NA
manufacturer or as previously qualified)
Demagnetizing technique X 15.0
Post examination cleaning technique X 16.0
Personnel qualification requirements X 4.1.1 / 4.1.2

4.0.SURFACE PREPARATION

The surface to be examined and all adjacent areas minimum 25mm (1”) should be
essentially clean, dry and free of contaminations such as oil, grease, rust, scale, paint,
welding flux and spatters or other interfering conditions. Cleaning of the test surface
may be accomplished by detergents, organic solvents, or mechanical means.

Procedure for Magnetic Particle Testing Proc. No.- W-P-21-09 Rev. 01 Page 3 of 11
 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

5.0EQUIPMENTS

A suitable and appropriate means for producing the necessary magnetic flux in the
part.

5.1 ELECTRO MAGNETICYOKES

I) AC electromagnetic yokes provide effective means of part magnetization for the
detection of surface discontinuities.
II) HWDC electromagnetic yokes provide an effective means for near surface
discontinuities as well.
III) The magnetizing force of a yoke will be tested by determining its lifting power
on a steel plate. AC yokes should have a lifting force of at least 10lb (4.5Kg) and
DC yokes 40lb (18.1 Kg) at the maximum pole spacing used.
IV) The magnetizing force of yokes shall be checked at least once in a year, or
whenever a yoke has been damaged.

5.2 PRODS

I) The prod electrodes (generally solid copper or braided copper tips) are first
pressed firmly against the test part the magnetizing current is then passed
through the prod and into the area of the part in contact with prods. This
establishes a circular magnetic field in the part around and between each prod
electrode.
II) AC limits the prod technique to the detection of surface discontinuities. HWDC is
most desirable since it will detect both surface and sub-surface discontinuities.
The prod technique will be used with dry magnetic particles due to better
mobility. Wet particles will be generally not used with prod technique because
of potential electrical and flammability hazards.
III) Care will be taken to maintain clean prod tips to minimize heating at the point of
contact on to prevent arc strikes and local overheating. Steel, aluminum or
copper braded tips prod or pad rather than the solid copper tips prod will be
used, where the possibility of copper penetration exist. Open circuit voltage
shall not exceed 25V.
IV) A remote control switch, built into the prod handles shall be provided to permit
the current to be turned on after the prods have been properly placed and to
turn it off before the prods are removed to minimize arcing.
V) Prod spacing shall not exceed 8 in. (200 mm) & Shall not be less than 3 in. (75
mm)
VI) A magnetizing current from 90-110 Amp/in. of prod spacing for material under
19mm and 100-125 Amp/in. from material over 19mm will be used.
VII) The equipment employed shall be maintained in proper working order. The
frequency of verification calibration shall be every six months as per Table-2,
Procedure for Magnetic Particle Testing Proc. No.- W-P-21-09 Rev. 01 Page 4 of 11
 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

SE-709 ASME Sec V or otherwise whenever malfunction is suspected. The

record of this will be maintained.
VIII) Prod tip shall be kept clean and dressed.

6.0 MAGNETIC PARTICLE

I) The particles used in either dry or wet. Magnetic particles will be finely divided
ferro magnetic materials which have been treated to impart colour. These
particles should have high permeability to have ease in magnetizing and
attraction to the discontinuity and low retentivity to avoid magnetic
agglomeration.
II) Dry magnetic particles examination shall not be performed if the surface
temperature of parts is exceed 6000F (3150C).
III) The dry particles employed will be of reddish brown colour, a thin coating of
contrast paint shall be used, where necessary and examination will be done
under white light.
IV) The wet particle employed will be of Black colour and will be suspended in
kerosene or water for non fluorescent method, the concentration of particles
shall be between 1.2 to 2.4 ml in 100 ml bath concentration.
V) The temperature of wet particle suspension and the surface of the parts shall
not exceed 1350F (570C).

6.1 CONSUMABLES

I) The test consumables shall be in accordance with the applicable Clients’

specification. This test procedure uses a visible solvent white contrast spray
paint in combination with a wet, non-fluorescent, solvent-suspended magnetic
particle ink spray.
II) A certified statement from the manufacturer of the test consumables, stating
that the batch numbers and the chemical content are in accordance with ASTM
E 709 standard, shall be made available whenever required for verification and
the records shall be maintained.
III) Consumables shall be used in sets purchased from the same manufacturer.
IV) The family of test consumables used shall be demonstrated for the effectiveness
of the test system by its ability to detect known discontinuities. If the family of
test consumables are changed then the demonstration shall be conducted again
to verify effectiveness.

Procedure for Magnetic Particle Testing Proc. No.- W-P-21-09 Rev. 01 Page 5 of 11
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Brand Name

PRADEEP NDT – WC23

SPRAY FILL – SC23
MAGNA FLUX –
WHITE CONTRAST PAINT – 7HF

V) Storage of test consumables shall be as per the manufacturer’s recommendation

and shall be used within the shelf life specified.

7.0SENSITIVITY

The magnetic field indicator (Pie Shaped) will be used to check the adequacy of field
strength and direction of part magnetization. When a clearly defined test pattern in the
indicator is not formed, or not formed in the desired direction, the magnetizing
technique will be changed or adjusted.

8.0 TECHNIQUE

After surface preparation as per point4.0 of this procedure, a thin and fine coating of
contrast paint will be applied (where necessary)
The visible light intensity at the surface of the part under inspection shall be minimum
of 100 fc (1076 lux).

I) DRY CONTINEOUS METHOD.

The flow of magnetizing current will be initiated prior to application of dry
magnetic powder and terminated after the application of powder has been
completed and any excess has been blown off. Usually, Specially designed
powder Blowers & Hand Powder applicators are employed.

II) WET CONTINEOUS METHOD.

In this method the part will bath with the examination medium and terminating
the bath application immediately prior to cutting off of the magnetizing current. A

Procedure for Magnetic Particle Testing Proc. No.- W-P-21-09 Rev. 01 Page 6 of 11
 NITON VALVE IND.PVT.LTD. & VALVINOX S.R.L

slight overlap is allowed. The magnetizing current duration will be ½ s for each
magnetizing pulse (shot), with two or more shots given to the part.
To assure that all the existing discontinuities are revealed, inspection will be done
in two directions, approximately 90 to each other, with a minimum overlap of
10% with 100% coverage of inspection area at required sensitivity.

9.0 INTERPRTATION

9.1CASTINGS

Surface indications determined by magnetic particle examination shall be

compared with those indicated in ASTM E125, Standard Reference Photographs for
Magnetic particle Indications on Ferrous castings, and shall be removed if they
exceed the following limits.

Type Degree
I - Linear discontinuities All
(Hot tears and cracks)
II - Shrinkage 2
III - Inclusions 3
IV - Chills and chaplets 1
V - Porosity 1

9.2 Other Components (Forgings, Bolting, Welds, bevel weld Ends)

All surfaces examined shall be free from

a) Relevant linear indications,
b) Relevant rounded indications greater than 3/16 in.(5 mm)
c) Four or relevant rounded indications in a line separated by 1/16 in. or less edge
to edge.

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Note: 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 lessthan three times its
width.
9.3All the indication formed by magnetic particle examination is the result of magnetic
flux leakage fields. Indications may be relevant or non relevant.

NON REJECTABLE INDICATIONS: Can occur singly or in the patterns as a result of flux
leakage fields created by condition that require no evaluation such as change in
section, inherent material properties, magnetic writing etc.

REJECTABLE INDICATIONS: Are produced flux leakage field which are the result of
discontinuity.

10.0 ACCEPTANCE CRITERIA

The acceptability of parts examined by this method will be as per Procedure &
Acceptance Standard for Castings, forgings and rolled or wrought materials shall be as
per ASME B16.34 Mandatory Appendix II (API 6D Annexure – G (Enclosed as Copy
Annexure – G below)

11.0DEMAGNETIZATION

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

12.0 DOCUMENTATION

A. Recording of Non Rejectable Indication:

Non-Rejectable Indication shall be recorded as specified by the referencing
code section.

B. Recording of Rejectable Indication:

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

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13.0REPORT–

The Magnetic Particle test report shall contain the following details.....

I) Client
II) Purchase order No.
III) Project Name
IV) Date of test & Report
V) Material
VI) Job Identification
VII) Area to be examined
VIII) Method
IX) Equipment Details
X) Surface preparation/Condition
XI) Magnetizing current
XII) Direction of Magnetic field (Longitudinal/Circular)
XIII) Manufacture & Type of Magnetic Particle.
XIV) MPT Procedure No.
XV) Acceptance criteria
XVI) Accept/Reject status-Remark
XVII) Operator name & signature.
MPT evaluation report in the format enclosed as Annexure- below.

14.0 POST EXAMINATION CLEANING

When post – examination cleaning is required, it should be conducted as soon as
practical using a process that does not adversely affect the part.

Reviewed By Approved By Authorized By

NDT DEPT. ASNT NDT LEVEL-III QA/QC DEPT

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ANNEXURE – G ( as per API 6D )

1. MPT On 100% Of Castings On External & Internal Surface

Per ASME BPCV, Sections V & VIII
A. Examination Shall be carried out in accordance with ASME BPCV, Section V, Article 7.

B. Acceptance Shall be accordance with ASME BPCV, Section VIII, Division 1, Appendix 7.
2. MPT On 100% Of Castings On External & Internal Surface Area
Per ASME bB16.34 Modified.
A. Examination Shall be carried out in accordance with ASME B16.34, Appendix II.

B. Acceptance Shall be accordance with ASME B16.34, Appendix II, except Round or
Linear indication shall not exceed 5mm (0.197 in)
3. MPT On 100% Of Bolting Surface Area
A. Examination Shall be carried out in accordance with ASME BPCV, Section V, Article 7.

B. Acceptance Shall be accordance with ASME BPCV, Section VIII, Division 1, Appendix 6

4. MPT On 100% Of Machined Surface

A. Examination Shall be carried out in accordance with ASME BPCV, Section V, Article 7.

B. Acceptance Shall be accordance with ASME BPCV, Section VIII, Division 1, Appendix 6

5. MPT On 100% Of Sealing (Including Seating) Surface

A. Examination Shall be carried out in accordance with ASME BPCV, Section V, Article 7.

B. Acceptance Shall be accordance with ASME BPCV, Section VIII, Division 1, Appendix 6
(In addition to the stated acceptance criteria, No Rounded or Linear indication in pressure-
contact sealing surfaces are allowed)
6. MPT Of Forgings On 100% Of Surface Area
A. Examination Shall be carried out in accordance with ASME BPCV, Section V, Article 7.
B. Acceptance Shall be accordance with ASME BPCV, Section VIII, Division 1, Appendix 6

7. MPT Of Welds On 100% Of Weld Surface Area

A. Examination Shall be carried out in accordance with ASME BPCV, Section V, Article 7.
B. Acceptance Shall be accordance with ASME BPCV, Section VIII, Division 1, Appendix 6

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ANNEXURE
F-P-21-08 Rev.01

MAGNETIC PARTICLE TEST REPORT FORMAT

Report No. : NVI/MPI/---------- Date:DD/MM/YYYY

Client : M/s. ------------------
P.O. No. &Date:---------------------- DT.---------------
Procedure No.: W-P-21-09 Rev. - 01
Material : ASTM :---------

Light Intensity :Lux

Material Temp. :

Sr. PO. Sr.

DESCRIPTION Valve Sr.No. QTY (Nos)
No. No.

Process Based: ASTM : E709/A275( Casting / Forging )

Equipment Used : Yoke of C Equipments.
Model No. & Sr. No.: MEY-2 Yoke & MEY-2/B218
Lifting Capacity : 4.5 kg AC Mode
Current: 230 Volts AC.
Method : Wet Visible (Black Ink)-Make – Pradeep)
Field Verification: By PIE Gauge.
Acceptance Standard : MSS: SP-53 /ASME B 16.34 / ASME SEC VIII DIV-I, APPENDIX-6

Testing method : Cleaning of the Casting/Forging ----------------------- Surface was carried

to make the area dry and free from dust and oil. Current was
switched on Black Magnetic powder was sprayed simultaneously
while the current was on. Placement of the yoke legs was done on
two adjacent directions 90 Degree apart. The distance between
the two legs limited to maximum of 6”. All accessible areas of the
job were inspected.

Observation :---------------------------------------------------------

Remarks: Above mentioned item is -------------- in Magnetic Particle Testing

For, QUALITY DEPT.

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