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 oil field tubular.
3. APPLICABLE DOCUMENTS
The following specifications shall be referenced in this procedure.
API Spec 7 / 7G
T.H HILL DSI
ASME E709
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
ASNT LEVEL III
REVIEWED BY
: MARAN
DATE : 28TH MAY 2002 (REV)
REF : MT – CPS – 01 – RV1
PAGE : 01 OF 09
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 periodically or whether the
equipment is subjected to major electrical repair, periodic overhaul or damage. 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. Coil with 500 turns and minimum 10 amperes capacity
6.2. 10.000 amps C.D.S. unit
6.3. Ultra violet light
6.4. Ultra violet meter
6.5. Gauss meter ( 0 – 50 Gauss )
6.6. Ardrox / Magnaflux flourescent particles
The system verification requirement for all the items that are given below:
Coil and CDS shall be calibrated every 12 months. The ultra violet light meter shall be
calibrated every 12 months. The gauss meter shall be calibrated once in every year. Ultra
violet light intensity and bath concentration shall be checked and documented every day prior
commencing of job.
DOCUMENTED BY : BALAJI RAO
ASNT LEVEL III
REVIEWED BY
: MARAN
DATE : 28TH MAY 2002 (REV)
REF : MT – CPS – 01 –RV1
PAGE : 02 OF 09
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 MEDIUM
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 not be performed if the surface temperature of the part 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.
7.3. Ultra Violet Light – the ultra violet light should be calibrated everyday and a minimum
UV density should be 1000 m/w at 15 inches. If the UV bulb is to be replace re-calibration
should be carried out and all readings to be documented.
8. SURFACE PREPARATION
8.1. Satisfactory results are usually obtained when the surfaces are clean of all foreign
materials. However surface preparation by wire brushing / polishing 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, paints removers, wire brush
cleaning etc.
DOCUMENTED BY : BALAJI RAO
DATE : 28TH MAY 2002 (REV)
ASNT LEVEL III
REF : MT – CPS – 01 – RV1
REVIEWED BY
: MARAN
PAGE : 03 OF 09
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 prior to and during current application for
all magnetizing techniques.
10. MAGNETISING FIELD
10.1. When necessary to verify the adequacy or direction of the magnetic field, the magnetic
particle field indicator Burmah Castrol strip shall be used by positioning the strip on the
surface to be examined.
10.2. When using this indicator, a suitable flux or field strength is indicated when a clearly
defined line of particle forms across the copper face of the strip. The magnetic particles are
applied simultaneously with the magnetizing force.
10.3. When a clearly defined line of particles is not formed, or is not formed in the desired
directions, the magnetizing technique shall be changed or adjusted to obtain required test
sensitivity.
11. MAGNETIZING CURRENT
Rectified Alternating Current (Half or full wave) or direct current may be used.
DOCUMENTED BY : BALAJI RAO
ASNT LEVEL III
REVIEWED BY
: MA RAN
DATE : 28TH MAY 2002 (REV)
REF : MT – CPS – 01 – RV1
PAGE : 04 OF 09
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
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.
12.3. The sequence of magnetizing shall be circular magnetizing application for transverse
defect inspection.
12.4. A calibrated gauss meter should be used to mark the residual field before magnetizing
the tool to be inspected.
Reading should be above 25 gauss for proper magnetization.
13. MAGNETIZATION TECHNIQUES
13.1. Longtidunal Magnetization Techniques.
13.1.1 Magnetizing Procedure – For this technique, magnetizing is accomplished by passing
current through a multi – turn fixed coil (or cable) that is wrapped around the part or section
of the part to be examined. This produces a longitudinal magnetic field parallel to axis of the
coil.
13.1.2 Magnetic Field Strength – Direct or rectified current shall be used to magnetize parts
examined by the technique. The required field strength shall be calculated based on the
length (L) and the diameter (D) of the part in accordance with 13.1.2.1, 13.1.2.2. and
13.1.2.3. below. Inspection shall not exceed end 18 in. (460mm). A length of 18 in., shall be
used for the part (L) in calculating the required field strength.
DOCUMENTED BY : BALAJI RAO
ASNT LEVEL III
REVIEWED BY
: MARAN
DATE : 28TH MAY 2002 (REV)
REF : MT – CPS – 01 – RV1
PAGE : 05 OF 09
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
13.1.2.1. Parts with L/D Rations Equal to or Greater than 4. The magnetizing current shall be
within plus or minus 10% of the ampere – turns value determined as follows:
35.000
Ampere Turns = ----------(L/D) + 2
For example apart 10 in (250mm) long x 2 in (50mm) diameter has an L/D ratio of 5.
Therefore.
35.000
----------- = 5.000 ampere turns
(5+2)
13.1.2.2. Parts with L/D rations less than 4 but no less than 2. The magnetizing ampere turns
shall be within plus or minus10% of the ampere turns valued determined as follows:
45.000
Ampere Turns = ----------(L/D)
13.1.2.3. Magnetizing Current: The current required to obtain the necessary, magnetic field
strength shall be determined by dividing the ampere turn obtained in steps 13.1.2.1 or
13.1.2.2 above by the number of turns in the coil as follows:
Ampere Turns
Ampere (meter reading) = -----------------Turns
DOCUMENTED BY : BALAJI RAO
ASNT LEVEL III
REVIEWED BY
: MARAN
DATE : 28TH MAY 2002 (REV)
REF : MT – CPS – 01 – RV1
PAGE : 06 OF 09
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
For example, if a 5 turn coil is used and the ampere turns required are 5.000 used.
5.000
----------- = 1.000 amperes (plus or minus 10%)
5
13.2. Circular Magnetization Technique.
13.2. Central Conductor Technique.
13.2.1. Magnetizing Procedure. For this technique, a central conductor is used to examine
the internal and external surfaces of tubular. For tubular of diameter more than 7” to be
examined, the conductors shall be positioned close to the center of the tubular.
13.2.2. Magnetizing Current. The field strength required shall be determined as given below.
1)
For parts with outer diameters up to 5 in (125mm) 600 to 900 amp/in of diameter shall
be used.
2)
For parts with outer diameters over 5 in (125mm) up to 10 in (250mm) 400 to 600
amp/in of diameter shall be used.
3)
For parts with outer diameters over 10 in (250mm) up to 15 in (380mm) 300 to 400
amp/in of diameter shall be used.
4)
For parts with outer diameter over 15 in (380mm) 100 to 330 amp/in of diameter shall
be used.
DOCUMENTED BY : BALAJI RAO
ASNT LEVEL III
REVIEWED BY
: MARAN
DATE : 28TH MAY 2002 (REV)
REF : MT – CPS – 01 – RV1
PAGE : 07 OF 09
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
14. DEMAGNETIZATION
14.1. Demagnetization shall be performed on tubular whenever is required.
14.2. Demagnetization may be accomplished by one of the following methods.
14.2.1. A.C. Withdrawal – This method is accomplished by with drawing the part from the
field of a high intensity alternating current coil. Care should be taken that the part is
completely removed from the influence of the coil before demagnetize is turn off, otherwise
the demagnetize will have the effect of magnetizing the part.
14.2.2. Decreasing A.C. – This method is accomplished by the used of consecutive steps of
reserved and reduced direct magnetization down to a negligible value. This method required
equipment for reserving the current and simultaneously for reducing it in 25 or more small
increments.
14.2.3. Where it is possible De-mag coil can be used for demagnetization.
14.2.4. Any one of the above method of demagnetization is acceptable as long as the tubular
is demagnetized to a level of below 25 gauss.
15. EVALUATION OF INDICATIONS
15.1. All indications shall be evaluated in terms of the respective acceptance standards used.
15.2. Any crack on the threads is cause for rejection and no removing of cracks by polishing
is allowed.
15.2.1. 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.
15.3. Relevant indications are those that result from mechanical discontinuities.
DOCUMENTED BY : BALAJI RAO
ASNT LEVEL III
REVIEWED BY
: MARAN
DATE : 28TH MAY 2002 (REV)
REF : MT – CPS – 01 – RV1
PAGE : 08 OF 09
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
16. MAPPING OF INDICATIONS
16.1. Relevant indications shall be marked on the components with a suitable marker to easily
identify the indications exact location to expedite repairing where possible.
17. RECORDS AND REPORT
17.1. Result of magnetic particle examinations will be recorded on AKURA reports. This
shall include the following information.
17.2. Tubular type, size, weight, type of connection, type of magnetization being used,
equipment being used for magnetization and result of examinations.
18. CUSTOMER REQUIREMENTS
Any requirements given by the customer for that particular order shall be supersede the
contents of this procedure.
DOCUMENTED BY : BALAJI RAO
ASNT LEVEL III
REVIEWED BY
: MARAN
DATE : 28TH MAY 2002 (REV)
REF : MT – CPS – 01 – RV1
PAGE : 09 OF \09