Template modelo técnico - Valeextportal.vale.com/eng/Sud/standards/pdf/SPEC-83014.pdf · Title: Template modelo técnico

ENGINEERING STANDARD SPECIFICATION Ontario

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ENGINEERING AND STUDIESMATERIALS ENGINEERINGNDE – MAGNETIC PARTICLE INSPECTION – GENERALPROCEDURE

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1.0 PURPOSE

This procedure outlines the requirements for the magnetic particle examination of ferro-magnetic castings, forgings, bars and weldments using an AC or DC electromagnetic yoke inaccordance with the 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 the following exceptions:

2.1 EXCEPTIONS

None.

3.0 QUALIFICATION OF PERSONNEL

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

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 pigmentsor both) in order to make them highly visible (contrasting) against the background of thesurface being examined.

Dry and wet particles, including wet particle suspension vehicles, and particle concentrationsshall be in 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(Contour Probe 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 toinspection. Pole separation 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 force of AC or DC electromagnetic yokes shall be checked at least once ayear, or whenever a yoke has been damaged. If a yoke has not been in use for a year ormore, a check shall be done prior to first use.

Each alternating current electromagnetic yoke shall have a lifting power of at least 10 lbs atthe maximum pole spacing that will be used.

Each direct current yoke shall have a lifting power of at least 40 lbs at the maximum polespacing that will be used.

The magnetizing force of a permanent yoke shall be checked prior to each inspection. Eachpermanent yoke shall have a lifting power of at least 40 lb at the maximum pole spacing thatwill be used.


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Each weight shall be weighed with a scale from a reputable manufacturer and stenciled withthe applicable nominal weight prior to first use. A weight need only be verified again ifdamaged in a manner that could have caused potential loss of material.

The calibration results shall be recorded and retained on file.

All equipment used for calibration purposes shall be calibrated once a year to a knownnational standard.

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 andfree of chips or cracks.

A suitably calibrated black light or combination white light / black light meter Traceable toNIST (National Institute of Standards and Technology) with a valid calibration tag and themanufacturer’s operating instructions shall be used to check the black light intensity. Lightmeters shall be calibrated at least once a year or whenever a meter has been repaired. Ifmeters have not been in use for one year or more, calibration shall be done before beingused.

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 blacklight intensity 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 holdthe light at 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.


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Record the intensity of the black light. Black light intensity must be no less than 1000μW/cm² at the 15 inches distance. If the light does not meet the minimum requirements, theunit shall be quarantined until the condition may be rectified.

7.2 WHITE LIGHT CALIBRATION

A minimum light intensity of 1000 lux is required on the surface to be examined to ensureadequate sensitivity during the examination and evaluation of indications. The light source,technique used, and light level verification is required to be demonstrated one time,documented, and maintained on file.

The white light source shall be verified with a calibrated white light meter. See appendix onefor qualification of white light source

8.0 FLUORESCENT MAGNETIC PARTICLE SOLUTION CHECKS

9.1 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.

9.2 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.


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

9.3 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.

(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-likecoating settles on the surface to be tested, an applicator specifically designed for thepurpose should be used. Dry powder must not be applied to a wet surface. Care should betaken in removing excess powder from the surface by blowing the excess powder lightlywhile the magnetizing current is present. Accumulations of excess dry particles inexaminations shall be removed with a light air stream from a bulb or syringe or other sourceof low pressure dry air.

Wet Particles: Fluorescent or non-fluorescent suspended in a recommended concentrationmay be applied by spraying or flowing over the part. When using the non-fluorescentparticles white paint should first be applied giving high contrast to the area being inspected.


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Visible wet suspension shall be contained in aerosols. When applying wet suspensions, themagnetizing current shall be turned on after the particles have been applied. Flow ofparticles shall stop with the application of current. Wet particles applied from aerosol spraycans may be applied before and/or after magnetizing current is applied. Wet particles maybe applied during the application of magnetizing current if they are not applied directly to theexamination area and are allowed to flow over the examination area or are applied directly tothe examination area with low velocities insufficient to remove accumulated particles.

10.0 EXTENT AND METHOD

The AC method shall only be applied to detect discontinuities that are open to the surface ofthe 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 areawithin at least 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 interferewith the examination. Satisfactory results may generally be obtained, when the surfaces arein the as-rolled, as-forged, or as-cast condition. However, surface preparation by grinding ormachining may be necessary in some cases where surface irregularities could otherwisemask the indication of discontinuities.

Cleaning may be accomplished by detergents, organic solvents, descaling, solutions, paintremovers, 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 intwo directions at 90° to each other with sufficient overlap (75mm to 150mm) to ensurecomplete coverage.

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 particle inspection is performed using an ultraviolet light (nominalwavelength is 365 nm), called black light. The examination shall be performed as follows:

(a) It shall be performed in a darkened area. (b) Examiners shall be in a darkened area for at least 5 min prior to performing


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examinations to enable their eyes to adapt to dark viewing. Glasses or lenses worn by examiners shall not be photochromic or exhibit any fluorescence. (c) Black lights shall achieve a minimum of 1000 uW/cm² on the surface of the part being examined throughout the examination. (d) 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. (e) The black light intensity shall be measured with a black light meter prior to use, whenever the light’s power source is interrupted or changed, and at the completion of the examination or series of examinations. Follow the blacklight meter manufacturers’ instructions for use of the meter. Light meters shall be calibrated at least once a year or whenever a meter has been repaired. If meters have not been in use for one year or more, calibration shall be done before being used.

11.1 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.

11.2 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.

11.3 Direction of Magnetization

Whichever method is used to produce magnetization, the maximum sensitivity is tolinear indications that are perpendicular to the lines of flux. Each area of the part beingexamined shall be magnetized at least twice so that the lines of flux from oneexamination are perpendicular to the second.

All examinations shall be conducted with sufficient overlap to assure 100% coverage atthe required sensitivity.

When it is necessary to verify the adequacy of magnetic field strength, it shall beverified by using a magnetic particle field indicator (Pie Gauge) or artificial flaw shim(s).The gauge or shim(s) will be positioned on the surface to be examined during


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magnetization. Adequacy of a suitable flux or field strength is indicated when a clearlydefined line of magnetic particles form across the face of the indicator or shim. Whenthere is no line of particles in the desired direction the magnetizing technique shall bechanged or adjusted.

11.4 Demagnetization

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

11.0 EVALUATION OF INDICATIONS

All indications shall be evaluated in terms of the acceptance standards of the referencingcode section.

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 conditionsmay produce 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 thanthree times its width.

Any questionable or doubtful indications shall be reexamined to determine whether or notthey are relevant.

12.1 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.


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12.2 Valid Indications

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

12.3. Relevant Indications

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

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

12.4 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.

12.5 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.

13.0 POST CLEANING


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When post cleaning is required by the procedure, all traces of the examination material shallbe removed 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 thereferencing code section – As a minimum, rejectable indications shall record type ofindication, location, and extent.) 7) Examination personnel identity and qualification level 8) A technique sketch showing coverage 9) Equipment used (Lighting equipment, Magnetic particle equipment and current, andparticle type 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, andresults

The report shall be signed by a qualified Level 2 or 3 person (as per this procedure)certifying that interpretation 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), identifiedas an essential variable, shall require requalification of the written procedure bydemonstration. A change of a requirement identified as a nonessential variable does notrequire requalification of the written procedure. All changes of essential or nonessentialvariables from those specified within the written procedure shall require revision of, or anaddendum 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 haveinstructions and procedures 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. Thisrisk assessment has been documented and is available through Central Engineering.

Rev Revision Notes RiskCode

Approvedby

Reviewedby

Issue DateYYYY/MM/DD

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

2

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

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

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


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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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Template modelo técnico - Valeextportal.vale.com/eng/Sud/standards/pdf/SPEC-83014.pdf · Title: Template modelo técnico