INSPECTION

PROCEDURE

Title: MAGNETIC PARTICLE TESTING PROCEDURE

Doc Number: KTI-NDT-SOP-MT-003

Department: NDT Department
Section: Inspection Section
Effective Date 01-09-2019
Original Language English
Classification Secret
Standard ASME Sec. V

‫م‬.‫م‬.‫الشركة الكورية للفحص الفنى الشرق األوسط ذ‬

KOREAN TECHNO INSPECTION MIDDLE EAST CO. LLC

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APPROVAL
The signatures below certify that this management system procedure has been reviewed and accepted and
demonstrates that the signatories are aware of all the requirements contained herein and are committed to ensuring
their provision.
Name Signature Position Date

Prepared by GHULAM D CHOHAN NDT CO ORDINATOR

Reviewed &
ARIVAZHAGAN G NDT LEVEL III
Approved by

Authorized by AHMED RAAD MANAGING DIRECTOR

AMENDMENT RECORD
This Procedure is reviewed to ensure its continuing relevance to the systems and process that it describes. A summary
record of contextual additions or omissions is given below:
Page No. Context Revision Date
ALL Issued for Initial 00 20/10/2018
Reviewed and Approved as per latest edition and new standard
ALL 01 01/09/2019
format

COMPANY PROPRIETARY INFORMATION

The electronic version of this procedure is the latest revision. It is the responsibility of the individual to ensure that
any paper material is the current revision. The printed version of this manual is uncontrolled, except when provided
with a document reference number and revision in the field below:
Document Ref. KTI-NDT-SOP-MT-003 Rev 01

Uncontrolled Copy Controlled Copy √ Date 01/09/2019

Amendment Record Sheet
Present Amended Nature Brief
Amd. Clause Date of Page Reason for the
Rev. Issue Rev. Issue of description of Sign.
No. No. amendment No. amendment
No. No. No. No. change change

1 ALL 20/10/2018 ALL 00 01 -- -- --- --- --- ---

Reviewed and
approved as
per latest
2 ALL 01/09/2019 ALL 01 02 -- -- --- ---
edition and
new standard
format
Contents
1.0 PURPOSE...............................................................................................................4

2.0 REFERENCE (LATEST EDITIONS).................................................................4

3.0 PROCEDURE........................................................................................................4
3.1 PERSONNEL QUALIFICATION........................................................................................................4
3.2 PROCEDURE QUALIFICATION........................................................................................................4
3.3 ESSENTIAL AND NON-ESSENTIAL VARIABLES.........................................................................5
3.4 EQUIPMENT & MATERIAL...............................................................................................................6
3.5 MAGNETIC YOKE STRENGTH.........................................................................................................7
3.6 MAGNETIZING FIELD STRENGTH ADEQUACY & DIRECTION...............................................7
3.7 VISIBLE LIGHTING INTENSITY FOR VISUAL MAGNETIC PARTICLE
EXAMINATION................................................................................................................................................9
3.8 SPECIAL REQUIREMENT..................................................................................................................9
3.9 SURFACE PREPARATION.................................................................................................................9
3.10 APPLICATION OF MAGNETIC PARTICLES & MAGNETIZATION............................................9
3.11 TEMPERATURE REQUIRMENTS...................................................................................................10
3.12 AC YOKE METHOD..........................................................................................................................10
3.13 PERMANENT MAGNET METHOD.................................................................................................10
3.14 INSPECTION & RECORDING OF INDICATIONS.........................................................................11
3.15 ACCEPTANCE STANDARDS..........................................................................................................12
3.16 DEMAGNETIZATION.......................................................................................................................17
3.17 POST EXAMINATION CLEANING.................................................................................................17
3.18 REPORT FORMAT.............................................................................................................................18
3.19 ANNEXURE 1 ( MPI MAINTENANCE LOG).................................................................................19
1.0 PURPOSE

This procedure describes the methods and requirements for Magnetic Particle Examination of
ferromagnetic welds/components for detecting defects open to surface/near surface
discontinuities and whose geometry and sizes are suitable for carrying out the above method of
testing, using permanent magnet & AC yoke with wet magnetic particles in the vicinity of visible
light.

2.0 REFERENCE (Latest Editions)

Ref. Title & Description Document No.

01 KTI Safety Manual KTI-HSEM-001-008
02 KTI Written Practice in compliance with SNT-TC-1A KTI-NDT-SOP-001
ASME Boiler & Pressure Vessel Code Section V, Non destructive -
03
Examination
ASME Boiler & Pressure Vessel Code Section VIII Div 1, Pressure -
04
Vessels
ASME Boiler & Pressure Vessel Code Section VIII Div 2, Design & -
05
Fabrication of Pressure Vessels
06 ASME Sec. IX -Qualification of Welding & Brazing -
07 ASME B31.3:, Chemical Plant and Petroleum Refinery Piping -
08 ASME B 31.1: – Power piping -
-
API 1104-Welding of Pipelines and facilities 21st Edition
09

3.0 PROCEDURE
3.1 PERSONNEL QUALIFICATION
Qualification
Personnel shall be qualified at least one of the following,
a) Personnel conducting the test shall be certified to ASNT Level II in Magnetic Particle Testing
in accordance with KTI Written Practice in compliance to SNT-TC-1A.
Vision
Personnel performing examination shall have vision, with correction if necessary, as follows:
a) Near vision acuity: capable of reading Jaeger J-2 or equivalent on standard chart at a
distance of not less than 30.5 cm (12 in). Test shall be administered annually.
b) Color contrast vision: color vision acuity per Ishihara charts, or shall be able to differentiate
the contrast among shades of grey used in method. Test shall be administered at five year
intervals.

3.2 PROCEDURE QUALIFICATION

Procedure Qualification shall be performed to meet the essential variables requirements of the
reference code before commencement of work. Any change in the essential variables shall need
a requalification of this procedure. Any change in essential or non- essential variables shall need
a revision of this procedure
3.3 ESSENTIAL AND NON-ESSENTIAL VARIABLES
Table – I

Requirements Essential Nonessential

Magnetizing Technique √ X

Magnetizing current type or amperage outside range specified by Article 7 of ASME

√ X
Sec V , 2013 or as previously qualified

Surface preparation √ X

Magnetic Particles (fluorescent/visible, color, particle size, wet/dry etc.) √ X

Method of particle application √ X

Method of excess particle removal √ X

Minimum light intensity √ X

Existing coating, greater than the thickness demonstrated √ X

Nonmagnetic surface contrast enhancement when utilized √ X

Performance Demonstration when required √ X

Examination part surface temperature outside of the temperature range

√ X
recommended by manufacturer of the particles or as previously qualified

Shape or size of the examination object X √

Equipment of the same type X √

Temperature (within those specified by manufacturer or as previously qualified X √

Demagnetizing technique X √

Post examination cleaning technique X √

Personnel qualification requirements X √

3.4 EQUIPMENT & MATERIAL

3.4.1 EQUIPMENT

Permanent magnets either fixed or adjustable pole shall have a lifting power capable of lifting
a test weight of 40 lbs. (18 kg.)

AC Yoke of reputable brands shall be used which can maintain magnetization periods of at
least 30 seconds. The yoke shall have articulated legs with pole spacing which are adaptable
to curved surfaces.

The following permanent magnet yokes or equivalent shall be used.

Yoke Type Make Model

Permanent Magnet yoke Magnaflux YM-5

EEC PY-1
Gammatec PM 2000
AC Magnetic Yoke EEC EF-2Y
Magnaflux Y7

3.4.2 CONSUMABLES
The following brands of MT consumables shall be used.
Table – II
Manufacture
Material Brand Group
r
Black Ink 7HF
Nonmagnetic Surface contrast Magnaflux MT1
WCP2
enhancement
Black Ink PFINDER 252 AEROSOL
Nonmagnetic Surface contrast PFINDER MT2
PFINDER 280 AEROSOL
enhancement
Black Ink MR76S
Nonmagnetic Surface contrast MR chemie MT3
MR72
enhancement
Black Ink BYCOTEST103
Nonmagnetic Surface contrast BYCOTEST MT4
BYCOTEST104A
enhancement
Black Ink Ardrox 800/3
Nonmagnetic Surface contrast Chemetall MT5
Ardrox8901W
enhancement
Black Ink Magna ink- BK Pradeep MT6

MPI materials used in this wet visible continuous technique shall have good color contrast against
test surface, high permeability, low retentively and sufficiently fine.
Contrast paint shall be white in color and MPI Ink shall be black in color to provide color contrast
due to flux leakage from discontinuities.
Premixed with a suspending vehicle in a pressurized aerosol can shall be used.
Expired chemicals shall not be used for testing.
MPI materials shall meet the requirements of ASME Sec V Art. 7 / ASTM E-709. Product certificates
will include batch numbers

3.5 MAGNETIC YOKE STRENGTH

Permanent magnets shall have a lifting power capable of lifting a test weight of 40 lbs (18kg.)
at the maximum pole spacing. Permanent magnet shall be checked daily when in use. Lifting
test shall be witnessed, recorded and countersigned by Level II/Level III. Any yoke that does
not conform to the procedure test, shall not be used and shall be tagged so. The
magnetizing power of the magnetic yoke shall be checked at least once in a year and also
whenever the yoke has been damaged and repaired.

AC magnetic yoke shall have a lifting power capable of lifting a test weight of 10 lbs. (4.5kg).
This check shall be done daily when in use & Evidence of this test shall be provided. The plate
shall be weighed on a scale of the reputed manufacturer and stenciled on it prior to first use.
The weight need only be verified again if damaged in a manner that could have caused
potential lost of material.

Refer Annexure: 1 (MPI Maintenance Log)

3.6 MAGNETIZING FIELD STRENGTH ADEQUACY & DIRECTION

When it is necessary to verify the adequacy or direction of the magnetic field, the magnetic
particle field indicator as described in fig.1 or fig. 2 shown below shall be used. When using
the indicator as described in fig. 1, it should be positioned on the surface to be examined,
such that the copper plated side is away from the inspected side.

When using the indicator as described in fig. 2, it should be positioned on the surface to be
examined such that the artificial flaw side of the indicator is towards the inspected surface. A
suitable flux or field strength is indicated when a clearly defined line of magnetic particles
representing the 30% depth flaw appears on the indicator face when the magnetic particles
are applied simultaneously with the magnetizing force. This indicates the proper test
condition.

FIGURE – 1

Eight Carbon Steel PIE sections, furnace brazed

Non-ferrous handle of any convenient

Artificial Flaw (all segment interfaces)

Copper Plate, about 0.010 thick.

1/8”
Non-Ferrous union/ brazed.

Pie Shaped Magnetic Particle Field Indicator

FIGURE – 2

Artificial Flaw Shims

3.7 VISIBLE LIGHTING INTENSITY FOR VISUAL MAGNETIC PARTICLE
EXAMINATION

The intensity of the visible light (natural/artificial) at the surface of the part undergoing
examination should be a minimum of 1000 lux to enable interpretation of the result
accurately. A 100 W lamp at maximum of 0.5 meter distance gives the required light intensity.
This has been verified by demonstration using light meter. These light meters shall be
calibrated once in every year or whenever the meter has been repaired.

The light intensity on the surface of component shall be not less than that used in the
procedure qualification test.

3.8 SPECIAL REQUIREMENT

MPI shall be performed after post weld heat treatment when PWHT is required. If
enhancement coatings are to be used, the procedure shall be qualified as required by ASME
Sec. V, Article 7, T-741.2 and submitted for approval to CONTRACTOR/COMPANY.

3.9 SURFACE PREPARATION

3.9.1 Satisfactory results are usually obtained when the surface are in as welded, as rolled, as cast or
as forged condition. However, surface preparation by grinding or machining may be necessary where
surface irregularities could mask indications, due to discontinuities.
3.9.2 Prior to Magnetic Particle Inspection, the surfaces to be examined and the adjacent area
within at least 1" (25 mm) of the weld cap profile shall be dry, clean & free of all dirt, grease, lint,
scales, welding flux and spatter, oil or other extraneous matter that could interfere with the
examination. Cleaning may be accomplished using organic solvents, de-scaling solutions, paint
removers or grit blasting.

3.10 APPLICATION OF MAGNETIC PARTICLES & MAGNETIZATION

Magnetic Particles shall be applied by aerosol spray cans on to the area of interest (about 4”
examination part). The Yoke is placed on the surface and switched on while the MPI ink is
flowing. Turn off the ink flow before switching off yoke. The duration of the magnetizing
current shall be sufficient enough to interpret indications. This is repeated with yoke placed
in such a way that magnetic lines are perpendicular to the earlier examination. Poles shall be
placed on area to be tested as described in figure 3.

The aerosol ‘spray can’ shall be shaken well before application to ensure the magnetic
particles are applied uniformly on the examination surface.

3.11 TEMPERATURE REQUIRMENTS

This method shall be generally used on all as welded joints and repaired areas at
temperatures not greater than 135˚ F (57˚C) of the part surface and of the suspension except
if otherwise specified by the actual medium manufacturer and in compliance with ASME Sec.
V Artcile-7.

Alternatively, the particles may be used outside the particle manufacturer’s recommendations
provided the procedure is qualified at proposed temperature to prove adequacy as required
by ASME V, Article 7, T-731.Pre-mixed aerosol cans of magnetic particles in a high flash point
blend of oils shall be used.

3.12 AC YOKE METHOD

Pre-mixed aerosol cans of magnetic particles in a high flash point blend of oils shall be used.
The operating sequence of the wet particle method shall be as follows:

a. White contrast paint shall be applied as a thin coat to the cleaned surface being tested.
The paint shall be allowed to dry.
b. The magnetic field shall be applied to the area under test by placing the yoke and
switching on the current flow with leg spacing between 75-150 mm as described in figure
3.
c. Good contacts of yoke shall be ensured on the test piece in order to avoid any electrical
sparking on the job and the current flow shall be switched on.
d. Magnetic particle ink shall be applied onto the area under examination while the current
flows on.
e. The magnetic field shall be held for sufficient time to allow particle migration before
withdrawing.
f. The examined surface shall be visually inspected for discontinuity indications.
g. The current flow shall be turned off before the removal of the yoke.
h. The yoke shall be relocated so that the magnetic field is perpendicular to the initial test
position and the above steps repeated.
i. When an indication is found, the above steps shall be performed at an axis perpendicular
to the axis of the indication in order to obtain maximum sensitivity.
j. All examinations shall be conducted with sufficient (approximately 50mm) overlap to
ensure 100% coverage at the required sensitivity.

3.13 PERMANENT MAGNET METHOD

a. White contrast paint shall be applied as a thin coat to the cleaned surface being tested.
The paint shall be allowed to dry.
b. Permanent yoke shall be placed on the test part and the magnetic field shall be applied to
the area under test as described in figure 3.
c. Magnetic particle ink shall be applied onto the area under examination while the part is
under magnetizing.
d. The magnetic field shall be held for sufficient time to allow particle migration before
withdrawing.
e. The examined surface shall be visually inspected for discontinuity indications.
f. The yoke shall be relocated so that the magnetic field is perpendicular to the initial test
position and the above steps repeated.
g. When an indication is found, the above steps shall be performed in an axis perpendicular
to the axis of the indication in order to obtain maximum sensitivity.
h. All examinations shall be conducted with sufficient (approximately 50mm) overlap to
ensure 100% coverage at the required sensitivity.

FIGURE 3

10% overlap

P1
P1 P2 P2

90o

Weld Distance between

P1 & P2
3" to 6"

P1 P2 P2
P1
3.14 INSPECTION & RECORDING OF INDICATIONS
a. All indications shall be evaluated whether it is relevant, non-relevant, or false indications.

b. Indications will be revealed by the retention of magnetic particles. All such indications are
not necessarily imperfections, however, excessive surface roughness, magnetic permeability
variations (such as at the edge of the HAZ) etc., may produce similar indications.

c. An indication is the evidence of an imperfection. Only indications which have any dimension
equal to more than 1/16 in. shall be considered relevant.

d. True (relevant) indications are caused by leakage fields due to discontinuities in the
specimen.

e. Non- relevant indications are caused by leakage fields other than the discontinuities such as
change in sections, change in permeability, magnetic writing, and false lines from excess
magnetization etc.

f. False indications are those that are mechanically held on by gravity with no relation
whatever to the leakage field. For example- dirt, grease, surface irregularities etc.

g. Rejectable indications shall be marked by suitable means on the part itself and shall be
recorded on a sketch, if required and be attached to the MPI report form.

h. Relevant indications only shall be considered for evaluation.

i. An indication shall be regarded as non-relevant, unless evidence is given that it is of no

significance for the evaluation of the part.

j. The examination shall be repeated using new test parameters when non-relevant indications
could mask relevant ones or when broad areas of particle accumulation occur.

3.15 ACCEPTANCE STANDARDS

Acceptance or rejection of indications observed during Magnetic Particle inspection shall be

based on the applicable Codes & Standards.
1.1.1 EVALUATION AND ACCEPTANCE CRITERIA AS PER ASME B31.3

CRITERIA DETAILS

Symbol Measure Acceptable value limits

A Extent of imperfection Zero (no evident imperfection)

B Depth of incomplete penetration ≤1mm (1/32 in.) and ≤0.2 Tw

Cumulative length of incomplete ≤38mm (1.5 in.) in any 152mm(6 in.) weld length
penetration

Depth of lake of fusion and incomplete

C ≤0.2 Tw
penetration

Cumulative length of lake of fusion and

≤38mm (1.5 in.) in any 152mm(6 in.) weld length
incomplete penetration [Note(7)]

D Size and distribution of internal porosity See BPV Code, Section Ⅷ, Division 1, Appendix 4

For Tw ≤6mm (1/4 in.),limit is same as D

E Size and distribution of internal porosity
For Tw ＞6mm (1/4 in.),limit is 1.5 X D
Slag inclusion , tungsten
inclusion or elongated
indication
F ≤Tw/3
Individual length
≤2.5mm (3/32 in.) and ≤Tw/3
Individual width
Cumulative length ≤Tw in any 12 Tw weld length

Slag inclusion , tungsten

inclusion or elongated
indication
G
Individual length ≤2Tw
Individual width ≤3mm (1/8 in.) and ≤Tw/2
Cumulative length ≤4Tw in any 152mm(6 in.) weld length

H Depth of undercut ≤1mm (1/32 in.) and ≤Tw/4

I Depth of undercut ≤1.5mm(1/16 in.) and ≤[Tw/4 or 1mm(1/32 in.)]

J Surface roughness ≤500 min. Ra per ASME B46.1

K Depth of root surface concavity Total joint thickness, incl. weld reinf. ≥Tw

Height of reinforcement or internal For Tw, mm(in.) Height, mm(in.)

protrusion
≤6(1/4) ≤1.5(1/16)
[Note (8)] in any plane through the weld
L shall be within limits of the applicable ＞6(1/4),≤13(1/2) ≤3(1/8)
height value in the tabulation at right. ＞13(1/2),≤25(1) ≤4(5/32)
Weld metal shall merge smoothly into the
component surfaces. ＞25(1) ≤5(3/16)

Height of reinforcement or internal

M protrusion Limit is 2L
[Note (8)] as described in L.

Tw = Nominal wall thickness of the thinner of two components joined by a butt weld.

Notes:

(1) Criteria given are for required examination. More stringent Criteria may be specified in
the engineering design.

(2) Longitudinal groove weld includes straight and spiral seam. Criteria are not intended
to apply to welds made in accordance with a standard listed in Table A-1 Table
326.1.

(3) Fillet weld includes socket and seal welds, and attachment welds for slip-on flanges,
branch reinforcement and supports.
(4) Branch connection weld includes pressure containing welds in branches and fabricated
laps.

(5) These imperfections are evaluated only for welds ≤3/14 in. (5mm) in nominal
thickness.

(6) Where two limiting values are separated by "and" the lesser of the values determines
acceptance. Where two sets of values is separated by "or" the larger value is
acceptable. T is the nominal wall thickness of the thinner of two components joined by
a butt weld.

(7) Tightly butted unfused root faces are unacceptable.

(8) For groove welds, height is the lesser of the measurements made from the surfaces of
the adjacent components; both reinforcement and internal protrusion are permitted in
a weld. For fillet welds, height is measured from the theoretical throat; internal
protrusion does not apply

(9) No crack is acceptable

API 1104 ACCEPTANCE CRITERIA

Any indication with a maximum dimension of 1.6 mm (1/16 in.) or less shall be classified as non
relevant.

Relevant indications shall be unacceptable when any of the following conditions exist:

a. Linear indications evaluated as crater cracks or star cracks exceed 4 mm (5/32 in.) in length.

b. Linear indications evaluated as cracks other than crater cracks or star cracks.

c. Linear indications are evaluated as incomplete IF and exceed 25 mm (1 in.) in total length in a
continuous 300 mm (12 in.) length of weld or 8% of the weld length.

Rounded indications shall be evaluated as follows:

Rounded indications (Porosity-Individual or scattered porosity) shall be unacceptable when any of

the following conditions exist:

a. The size of the individual pore exceeds 1/8 in. (3 mm).

b. The size of an individual pore exceeds 25% of nominal wall thickness joined.

Cluster Porosity [CP] that occurs in any pass except finish pass shall comply with the above
mentioned dimensions. CP that occurs in the finish pass shall be unacceptable when any of the
following condition exists:

i. The diameter of the cluster exceeds ½ in. (13 mm).

ii. The aggregate length of CP in any12 in. (300 mm) continuous weld length exceeds ½ in. (13
mm).
ASME B31.1 ACCEPTANCE CRITERIA
All indications observed during testing shall be evaluated according to the B31.1.

Terminology

a. Relevant indications- indications with major dimensions greater than 1.6 mm

b. Linear indications – an indication having a length greater than three times the width
c. Rounded indication – an indication or circular or elliptical shape with the length equal to less
than three times the width
Acceptance standard

All surfaces to be examined shall be free of

a. Any cracks or linear indications

b. Rounded indications with dimensions greater than 5 mm
c. Four or more rounded indications in a line separated by 2 mm or less edge to edge
d. Ten or more rounded indications in any 3870 mm 2 of surface with major dimension of this
area not to exceed 150 mm with the area taken in most unfavourable location relative to the
indications being evaluated.

ASME Section VIII Div I (As per Appendix 8)

Terminology

a. Relevant indications- indications with major dimensions greater than 1.6 mm

b. Linear indications – an indication having a length greater than three times the width
c. Rounded indication – an indication or circular or elliptical shape with the length equal to less
than three times the width
Any indications, which are believed to be non relevant, shall be regarded as an imperfection
unless it is shown by re-examination by the same method or by the use of other non-
destructive methods and / or by surface conditioning that no unacceptable imperfection is
present.

Acceptance standard

Indications in excess of the limits specified below are unacceptable

a. Relevant linear indications

b. Relevant rounded indications greater than 4.8 mm
c. Four or more relevant rounded indications in a line separated by 1.6 mm or less edge to edge.

3.16 DEMAGNETIZATION

Demagnetization shall be carried out when residual magnetism in the part could interfere
with subsequent processing or usage. E.g. welding or when required by the specific
requirements of project specifications. Technique shall be specified when demagnetization is
required. When MPI is done on bevel ends/ welds ends, Residual magnetism shall be checked
using a calibrated Gauss meter. In the event that residual magnetism in excess of ± 2 Gauss
detected in the test object, demagnetization is required to be done.
3.17 POST EXAMINATION CLEANING

Post examination, cleaning shall be carried out as per the project specific requirements if
required.
3.18 REPORT FORMAT

3.19 ANNEXURE 1 ( MPI MAINTENANCE LOG)