331-03-en magnetic particle testing

L E S E R W O R K S S T A N D A R D L W N 3 3 1 - 0 3 - E N Procedure for magnetic particle testing page 1

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L E S E R processed: La/Sa edition: 26.06.07GmbH & Co. KG approved: refer to ÄM 103600 replaces edition: 00.00.00

Table of Contents SUMMARY ........................................................................................................................................................ 2

1. GENERAL .................................................................................................................................................. 2

2. APPLICATION ........................................................................................................................................... 2

3. PURPOSE, DEFINITION............................................................................................................................ 2

4. TEST REFERENCES................................................................................................................................. 2

5. TEST PROCEDURES AT LESER ............................................................................................................. 3 5.1 TEST INSTRUCTIONS................................................................................................................................ 3 5.2 TEST DEPTH............................................................................................................................................ 3 5.3 TESTING METHODS.................................................................................................................................. 3 5.4 TESTING FACILITY.................................................................................................................................... 3 5.5 TEST MEDIA, TEST AIDS ........................................................................................................................... 3 5.6 TEST PROCEDURE................................................................................................................................... 4 5.7 DESCRIPTION OF INDICATIONS ................................................................................................................. 5 5.8 DE-MAGNETISATION ................................................................................................................................ 5

6. ACCEPTANCE CRITERIA (EVALUATION OF INDICATIONS) ............................................................... 5

7. QUALIFICATION OF THE TEST PERSONNEL ....................................................................................... 5

8. DOCUMENTATION, OPTION CODE ........................................................................................................ 5

9. STANDARD REFERENCES...................................................................................................................... 5


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Summary Purpose of the magnetic particle examination is to detect the presence of fissures/cracks in the surface (magnetic particle examination) and in the surfaces of adjacent areas. The magnetic particle examination will not be applied in case of:

− Bodies > DN 125 / 4“ − Stainless steel materials − Non-ferrous metals and non-metals

The issue of a certificate that the test has been carried out can be ordered with:

Option code Certificate Remarks

H03 LESER CGA (Certificate for Global Application) – Inspection certificate 3.1 according to DIN EN 10204

M44 Inspection certificate 3.1 acc. to DIN EN 10204: Magnetic particle testing

optionally

1. General This LWN (LESER Works Standard) does list the standard specification and describes the procedure during the magnetic particle examination at LESER and its documentation. 2. Application The magnetic particle examination is carried out by LESER on ferromagnetic iron and cast steel samples independent of the shape and on the welding seams. 3. Purpose, definition The magnetic particle examination is a procedure to detect fissures/cracks in the surface (surface crack testing) and in the surfaces of adjacent areas up to a depth of 2 - 2.5 mm of ferromagnetic materials and belongs to the group of non-destructive tests. After magnetisation the test sample is treated in different procedures with a test media with contrasting effect. Exposure to UV light enables the detection of faults. 4. Test references The following standards were included at LESER for magnetic particle testing: AD 2000-Merkblatt A4 Gehäuse von Ausrüstungsteilen, Ausgabe Oktober 2004 Kap.6 Prüfungen vor Inbetriebnahme ASME Code, Section VIII Rules for Construction of Pressure Vessels, Division 1 Addenda 2006 UG -136 Minimum Requirements for Pressure Relief Valves

UG-136 (f) Welding and other Requirements DIN EN 1369 Founding - magnetic particle testing EN ISO 9934 Non-destructive testing – magnetic particle testing - General foundations DIN EN ISO 3059 Non-destructive testing - penetrant testing and magnetic particle

testing - Viewing conditions ASME Code Section V Non-destructive Examination, Addenda 2006 Article 7 - Magnetic Particle Examination


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ASME B16.34-2004 Valves - Flanged, Threaded, and Welding End Mandatory Appendices II - Magnetic Particle Examination: Procedure and Acceptance Standards LWN 221-03 Magnetic particle testing, testing at LESER 5. Test procedures at LESER

5.1 Test instructions The magnetic particle examination has to be carried out in accordance with DIN EN ISO 9934-1, chapter 6 according to a written test instruction. This specification will determine the test parameters in such a way that the test can be repeated in same manner.

5.2 Test depth Due to the maximum tensile diameter at the magnetising appliance at LESER we will test parts up to a size of DN 125 / 4“. Larger parts are exposed to penetrant testing.

5.3 Testing methods The different types of magnetic particle examination differ in the type of magnetisation and the type of test media applied to show the stray field. LESER applies the following magnetisation procedures: - SSW: magnetisation by alternating current, solenoidal magnetisation - JEW: magnetisation by direct current, longitudinal magnetisation The test media used is a fluorescent fluid test media.

5.4 Testing facility

At LESER the magnetic particle examination is carried out with a magnetisation device (Universal test bench IFW 600-e, applicable in accordance with DIN 54130). Technical data Solenoidal magnetisation: max. 2000A alternate current effectively 2800 A alternate current peak; Longitudinal magnetisation: max. 10 000 Aw, ≥ 1 T Length of clamping: max.710 mm Max. tensile Ø: 320 mm

5.5 Test media, test aids

• characteristics and selection of fluid testing agents The characteristics of the test media has to comply with the specifications of DIN EN ISO 9934-2 Fluorescent test media (a suspension of fluorescent particles in a watery carrier fluid) have normally the highest sensitivity. This is why LESER uses a fluorescent test media.

• Examination of test media, test aids A control of the test media sensitivity has to be carried out regularly during and before the test with suitable calibration devices in accordance with DIN EN ISO 9934-2. The control facilities used to monitor the test fluid are: - the ASTM sedimentation glass and - the MTU calibration device (comparison device no. 3).

• Irradiation, viewing conditions Fluorescent procedure. UV light


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The magnetic particle examination requires controlled conditions for the monitoring indications. (in accordance with DIN EN ISO 3059) At LESER the monitoring of indications is carried out using a fluorescent system (UV light). Measuring the exposure intensity The UV-A exposure intensity has to be determined with an UV-A exposure gauge on the testing surface at operational conditions. Measurements may only be carried out after the light has been stabilised (not less than 10 minutes after being switched on).

Specifications The test sample s put under UV-A exposure in a darkened room. The UV-A exposure intensity on the testing surface has to be larger than 1000 μW / cm² and the exposure intensity of the environment has to be smaller than 20 Lux. Before the test the eyes of the tester have to adapt to the lower environmental light for a time.

Control and verification The UV-A exposure system (UV light) is tested every six months using a UV-2500II UV exposure intensity gauge. The calibration of the exposure gauge has to be carried out using a monochromatic beam with a wavelength of 365nm and may not exceed 24 months.

5.6 Test procedure

Surface preparation, surface condition Fault detection is also dependent on surface conditions. Dirt particles can hinder the agility of the magnetic powder particles. The testing area has to be free of dirt, loose rust particles, tinder, sweat spots, grease, oil and other foreign bodies that could influence the testing sensitivity. The required surface condition can be ascertained by blasting, grinding or mechanical processing. There has to be a sufficient visual contrast between the indicator and the surface.

Inserting the test sample The test sample should be placed securely and gently onto the V reference. After that the test sample be clamped in. After the test media has been evenly mixed, the test can commence.

Magnetisation Magnetisation techniques, magnetisation conditions

To enable the detection of inhomogenities on the entire testing surface and in all directions you can apply combined magnetisation techniques: Setting up the magnetisation required for the indication of longitudinal flaws (solenoidal magnetisation) is done by direct current. Setting up the magnetisation required for the indication transverse flaws (longitudinal magnetisation) is done by alternate current.

Combined test After setting up the intensity of the solenoidal magnetisation of the testing bench as described in the “Operations Manual“, the combined test of flaws in any direction can commence.

Magnetisation control (Proof of magnetisation) The solenoidal magnetisation of the testing bench is monitored by the inbuilt contact measuring instruments. If the magnetisation control reacts frequently the test has to be stopped and the cause of the fault has to be removed.

Application of test media The test media has to be applied shortly before and during the magnetisation. The test sample is rinsed for 3 seconds with a handheld hose, whereby the test fluid quantity can be controlled. It has to be ascertained that the magnetisation period has to be longer than the handheld hose, in order to avoid that indication that have formed do not get flushed away. This so-called post-magnetisation period has to be at least 1 second.


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Exposure of the testing surface, evaluation and registration of indications The test sample is exposed to UV-A light in a darkened room and is checked for cracks and fissures. It has to be ascertained that the indication of flaws after magnetisation are not destroyed before evaluation and registration.

5.7 Description of indications It has to be differentiated between linear and non-linear indications and between single indications and groups of indications.

5.8 De-magnetisation

After the test has been completed there can be some residual magnetism in the test sample. Should this influence the further use of the sample, the test sample has to be de-magnetised and it should be free of indications resulting from previous testing (cleaned).

6. Acceptance criteria (evaluation of indications) The indications have to be evaluated by size and frequency and are being evaluated in accordance with additional evaluation specifications of DIN EN 1369, ASME 16.34-2004 regarding the quality of the casting, and in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99. The tested parts are marked with the marking OFR. (OFR = surface crack testing)

7. Qualification of the test personnel The personnel for the magnetic particle examination will be qualified and certified in accordance with EN 473 and SNT-TC 1A. The level of qualification of personnel involved in magnetic particle examination is equal to the LESER non-destructive testing training: MT Level 1 and 2. 8. Documentation, Option Code The issue of a certificate that the test has been carried out can be ordered with:

Option code Certificate Remarks

H03 LESER CGA (Certificate for Global Application) – Inspection certificate 3.1 according to DIN EN 10204

M44 Inspection certificate 3.1 acc. to DIN EN 10204: Magnetic particle testing

optionally

9. Standard references AD 2000-Merkblatt A4 Gehäuse von Ausrüstungsteilen; Prüfungen vor Inbetriebnahme DIN EN 1369 Founding – magnetic particle testing EN ISO 9934-1 Non-destructive testing – magnetic particle testing - Part 1: General foundations EN ISO 9934-2 Non-destructive testing – magnetic particle testing -

Part 2: Test media EN ISO 9934-3 Non-destructive testing – magnetic particle testing - Part 3: Devices. DIN 1690 Technical delivery conditions for castings made of metal materials DIN EN 473 Non-destructive testing - Qualification and certification of personnel used for non-destructive testing - General foundations ASME Code, Section VIII Rules for Construction of Pressure Vessels, Division 1 ASME Code, Section V Non-destructive Examination


End of LWN


Article 7- Magnetic Particle Examination ASME B16.34 Valves - Flanged, Threaded, and Welding End Mandatory Appendices II - Magnetic Particle Examination: Procedure and Acceptance Standards SNT-TC 1A Personnel Qualification and Certification in non-destructive testing LWN 287-99 Regulative requirements regarding welding components for LESER

safety valves

The Safety Valve

LESER GmbH & Co. KG Hamburg HRA 82424 Fon +49 (40) 251 65-100 Bank HypoVereinsbank Hamburg LESER – The Safety Valve GF · BoD Joachim Klaus, Martin Leser Fax +49 (40) 251 65-500 BLZ 200 300 00, Konto · Account 3203171 20537 Hamburg, Wendenstr. 133 – 135 E-Mail [email protected] BIC: HYVEDEMM300 20506 Hamburg, P.O. Box 26 16 51 ( ) Internet www.leser.com IBAN: DE64 2003 0000 0003 2031 71

Inspection certificate 3.1 according to DIN EN 10204 MAGNETIC PARTICLE TESTING [Option code M44] LESER GmbH & Co. KG Postfach 26 16 51 20506 Hamburg, Germany

. . Customer Order No.: xxx

LESER – Job – No.: xxx . . LESER-Customers-No.: xxx

LESER-Contact: xxx

Fon: + 49 (40) 25 165-

Fax: + 49 (40) 25 165-500

eMail: [email protected]

This LESER inspection certificate confirms that the test object was tested according to the undermentioned test references. 1 Test object xxx xxx xxx

Art.-No. Cold differential test pressure Option Code: xxx

xxxx.xxxx x,xx barg xxx,xx psig Further SV-Info: xxx

Nominal size Pressure rating Tag – No. LESER – Job – No.

Pos.- No. Serial – No. Body material

Inlet Outlet Inlet Outlet

xxx xxx xx xxx xx xx xx xx

Tested component

Pos. Description Material Manufacturer Heat No. / Batch

1 xxx xxx xxx xxx

2 Test reference Magnetic particle testing acc. to: AD 2000-Merkblatt A4, chapter. 6 ASME Code, Section VIII Div 1, UG 136

3 Procedure LESER Works Standard LWN 331-03

4 Test specification Testing equipment: Magnetisation device, Universal test bench IFW 600-e Interflux GmbH Testing method: SSW and JEW Viewing conditions, exposure intensity: UV-A: Ee = 18 W/m²; environment E < 20 Lux Test media: Interflux Water Suspendible Apelux – Concentrate 1018 Test area: surface Qualification of the test personnel: MT Level I, MT Level II (DIN EN 473 and SNT-TC 1A)

5 Acceptance criteria The indications have to be evaluated by size and frequency. Regarding the quality the castings will be evaluated in accordance with DIN EN 1369 and ASME B16.34. The evaluation at the welding seams will be carried out in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99.

6 Test result The test was realised without any objection. The requirements of the test references are fulfilled.

Manfred Orlowski Hohenwestedt, xx.xx.200x Inspection Representative

This certification is written digitally and requires no handwritten signature. (Acc. to EN 10204, chapter 5)

USt-ID · VAT-Reg DE 118840936

331-03-en magnetic particle testing

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