agnetic Particle Examination (MT) LEVEL -II Training Course Prepared by Dr. Samir Saad General Manager Cutech Arabia LLCAA) About the Author Dr. Samir Saad General Manager Cutech Arabia LLC Experience: 17 Years (Oil and Gas) Skills & Expertise Welding and Welding Inspection + Non-Destructive Testing Material Technology In Service & On-stream Inspection * Corrosion and Management Asset Integrity Management DrSamir Saad Education Certification M.S. and Ph.D. degrees in Welding Engineering Technology. Bachelor of Mechanical Engineering Professional Certification ASME Authorized Inspector (Al), Soller and Pressure Vessel ‘ASNT NDT LEVEL I In 14 methods, ASNT 10: 190902 Visual and Optical Testing (VT), 7. Magnetic ux leakage Testing (MFL), 1 2 Radiographic Testing (RT), 8. inferred thermal testing (IR), 3. Uttasonie Testing (UT), 8. Leak Testing (LT, 4. Liguid Penetrant Testing (PT), 10, Acoustic Emission Testing (AE) 5. Magnetic Testing (MT), 11, Neutron Radiography (NR) 8. Electromagnetic Testing ET), ‘AWS-CWEng. - Certified Welding Engineer, ID NO. 17010046, ‘AWS-CWE - Gertied Welding Educator, ID NO. 1902001 E. ‘AWS-CWI- Certified Welding inspector, ID NO. 19021321 ‘AWS-CWS - Cerfied Welding Supervisor, ID NO. 20020008, 'AWS-CWSR - Certfed Welding Sales Representative, ID NO. 2003000R CSWIP 3.2.2 - Senior Welding inspector Personal, ID NO.74305, BGAS-CSWIP-Painting Inspector Grade 2-BGAS, 10:589730. [APL 510- Pressure Vessel Inspector ID NO. 35376. [API 570. Process Piping Inspector ID NO. 38328, ‘API 853. aboveground storage tank inspector ID NO. 36171, [APL RP 580 -Risk-Based inspection professional ID NO. 52784 [APP 871- Corrosion and Materials Professional ID NO. 58359 ‘API 896 - Refractory Personnel, ID NO. 94784 [API S77 - Welding Inspection and Metallurgy, ID NO. 94785, [API SIFE-Source Inspector Feed Equipment, ID NO. 95780 ‘Lead aualtor according to 180 9001:2015 from IRC.Xt Qualification and Certification Requirements 3 Introduction to NDT Xf Introduction to Magnetic Particle Inspection XE Physics x Equipment and Materials xt Testing Practices Xt Example Indications xt Magnetic Particle Testing Acceptance Criteria XE,ASME SECT. V, Article 7i£The following documents outline personnel qualification and certification requirements: 1. ASNT Recommended Practice No. SNT-TC-1A. 2. ANSI/ASNT CP-189: Standard for Qualification and Certification of Nondestructive Personnel. 3. ACCP: ASNT Central Certification Program. 4. NAS 410, National Aerospace Standard Certification and Qualification of Nondestructive Testing Personnel.SX Training and Qualification Process: % % 1. Certification of NDT personnel is the responsibility of the employer ‘A person who is in the process of training and qualification is considered a trainee. Three Basic Levels of Qualification LEVEL | — is qualified to perform specific calibrations, specific tests, and specific evaluations. The NDT Level | should receive the necessary instruction and supervision from a certified NDT Level Il or Ml individual. LEVEL II — is qualified to set up and calibrate equipment and to interpret and evaluate results with respect to codes, standards and specifications, LEVEL Ill — must be capable and responsible for establishing techniques, interpreting codes, and designating the test method and technique to be used. The NDT Level Il in the methods in which certified, should be capable of training and examining NDT Level | and II personnel for certification in those methods.Lt Qualification Requirements: 1. Organized training (required class hours). Required testing (general, specific, practical). Education (depends on written practice). Experience (documented hours). Physical attributes to perform examinations (vision acuity and color contrast test performed annually). XX Certification ‘% Certification is a written testimony that an individual has met all the qualifications of a company’s written practice.Xf Nondestructive testing methods are used for the following reasons: 1, 2 3. 4. i 6. 7. 8. . To ensure product integrity and reliability. . To avoid test object failure, prevent accidents and save lives. . To make user profits. To ensure customer satisfaction. . To aid in better product design. . To lower manufacturers’ costs. . To maintain uniform quality levels. |. To ensure operations readiness.i | Surface Surface/sub-surface and Volumetric 1Visual Testing(VT) 1.Radiography Testing(RT) 2.Magnetic Particle Testing (MT) 2.Ultrasonic Testing(UT) ( surface and near surface , applied on only ferromagnetic material) 3. Penetrant Testing (PT) (any defects open to surface) 4, Eddy Current (ET) ( surface and near surface)Xf Introduction Magnetic particle testing is: 1. Cost effective. 2. Simple. 3. Fast. 4. The most reliable nondestructive testing method for detecting surface and near surface discontinuities. 5. Able to detect discontinuities in ferromagnetic materials that are not open to the surface. 6. An easier method in terms of cleaning than liquid penetrant testing.x4 Theories 1. Magnetic particle testing will reveal surface and slightly subsurface discontinuities in ferromagnetic materials. 2. Other nondestructive testing methods, usually liquid penetrant or eddy current testing, must be used to test materials not strongly attracted to a magnet. 3.Magnetic particle testing may be used for raw material, in-process during manufacturing to prevent further manufacturing expense for test objects containing discontinuities, and to repair internal discontinuities such as cracks at the root of a weld. 4.Final product testing is used on the final test object to prevent test objects with discontinuities from entering service. 5.Maintenance tests are used for in-service discontinuities that may have been formed by overloading or fatigue cycles.Xt Magnetic Particle Test O The magnetic particle test consists of six basic operations: 1. Clean the surface to be tested. 2. Establish a suitable magnetic flux in two directions at 90° in the test object axis. 3. Apply magnetic particles in either a dry powder or a liquid suspension. 4. Test the object for discontinuities under suitable lighting conditions. 5. Interpret and evaluate the test indications. 6. Demagnetize, if necessary.O Magnetic Particle Test 8 Contrast paint Magnet & Ink Resultxt Magnetic Domains 1. Materials that can be magnetized have submicroscopic regions called magnetic domains that will have positive and negative polarity at opposite ends if magnetized, 2. If a material is not annette, the magnetic domains are randomly aligned. Rowedoaage HAA 3. When the material is subjected to an indirectly induced magnetic external field or if current is passed directly through the test object, the magnetic domains align themselves and form a north and south pole in the test object. PSISPISO SCC CO N s OeoeeoeoceoooXf Magnetic Domains 4. When all of the domains are aligned, the material is said to be magnetically saturated. 5. When a material is magnetically saturated, no additional amount of external magnetization force will cause an increase in its internal level of magnetization. ‘SO'SSSSSO SS Ss HOCSSSSEeosd Magnetized Material( Principles of Magnetic Particle Testing ) Xf Magnetic Poles Magnets will have two or more opposite polarity poles, called north and south poles. ite poles attract each other. Attract QO These poles are where the magnetic lines of force leave or enter the magnet. Se Opposite poles 6/26/2000 attracting repellingxe Characteristics of Magnetic Fields (QQ The Magnetic lines of force have the following important properties: 1. Magnetic lines of force form continuous loops that are never broken. _ 2. Magnetic lines of force never cross each other. 3. Magnetic lines of force are strongest and most dense at the poles. 4. Their density decreases with increasing distance from the poles. 5. Magnetic lines of force always seek the shortest path of least resistance which is through metal. 6. They seek the path of least magnetic resistance or reluctance in completing their loop which is the shortest distance through metal. 7. Magnetic lines of force only enter or leave the poles of a magnet. 8. Magnetic lines of force are called magnetic flux.xe Characteristics of Magnetic Fields CA The Magnetic lines of force have the following important properties: 9. Ifa barmagnet is broken or cracked, new magnetic poles are formed. 10. Acircular magnet with no irregularities has no poles. 11. Magnetic poles will attract magnetic particles.x Magnetized Ring C2 There will be no poles to attract magnetic particles if a uniform ring contains a circular magnetic field. O Acrack 90° from the magnetic field direction will create poles and an external flux leakage field that will attract magnetic particles and form an indication. Magnetic field is Magnetic poles of entirely within, leakage field will thus no external attract magnetic particles.xy Bar Magnet 1 The horseshoe magnet has north and south poles just like a bar magnet but the magnet is curved so the poles lie in the same plane. (| O Ifa bar magnet was placed across the end of a horseshoe magnet or if a magnet was formed in the shape of a ring, the lines of magnetic force would not even need to enter the air \ C Ifa horseshoe magnet is straightened to a bar magnet, it illustrates a longitudinally magnetized bar. Atransverse machined notch or crack in a longitudinally magnetized bar will cause new poles with a flux leakage field that will attract particles. () Magnetic particlesEo! Magnetic Flux Leakage C Ifthe magnet is just cracked but not broken completely in two, a north and south pole will form at each edge of the crack. Q The magnetic field exits the north pole and reenters the at the south pole. Q The magnetic field spreads out when it encounter the small air gap created by the crack because the air cannot support as much magnetic field per unit volume as the magnet can. When the field spreads out, it appears to leak out of the material and, thus, it is called a flux leakage field. O Ifiron particles are sprinkled on a cracked magnet, the particles will be attracted to and cluster not only at the poles at the ends of the magnet but also at the poles at the edges of the crack. none panncies FLUX LEAKAGE "Eo! Magnetic Flux Leakage O Magnetic particle testing is based on the principle that magnetic flux lines will be disrupted by a discontinuity, and Q Adiscontinuity will interfere with the magnetic field and form north and south poles. G2 this distortion will cause some of the flux lines to exit and reenter the test object forming poles at the discontinuity. Q This is called magnetic flux leakage and will attract fine magnetic particles that form an indication outline of the discontinuity. Magnetic particlesXt Effects of Discontinuities on Materials O Field Direction / Discontinuity Detection > Discontinuities located in the direction of current flow have the highest probability of detection. > Discontinuities perpendicular to the magnetic lines of force have the highest probability of detection. » Ifthe magnetic lines of force is parallel to the Discontinuities, the field will see little disruption and no flux leakage field will be produce Flux Leakage > Itis critical to establish a magnetic field in two 90° directions in all areas of the test object and to use the proper current to detect discontinuities.Xt Effects of Discontinuities on Materials O Field Direction / Discontinuity Detection > Adiscontinuity that is 45° to 90° from the magnetic field direction will disrupt the magnetic field and will create new poles. These poles will attract small particles and form an indication if an adequate magnetic field is used for testing. Irregular Cracks May Show Magnetic / Longitudinal Ses Field Crack Will Show Mik tice SicaXt Effects of Discontinuities on Materials O Surface Discontinuities > If linear and 90° from the magnetic field direction, discontinuities will form poles and a leakage field that will attract magnetic particles and form a visible indication Leakage field. » Surface discontinuity indications are sharp and well defined. O Scratches > Scratches sometimes attract particles in a very strong field, and the field strength may have to be reduced to verify there is no deeper discontinuity present.Xt Effects of Discontinuities on Materials O Subsurface Discontinuities > Subsurface discontinuities are broad and fuzzy and more easily blown or rinsed away than a deep surface indication. Particle buildup at leakage field: Leakage Field from Surface and Subsurface Discontinuities > Subsurface discontinuities are more difficult to detect unless larger than 0.15 cm (0.06 in.) and especially if more than 0.15 cm (0.06 in.) deep when direct current must be used.sh Quantifying Magnetic Properties Magnetic Field Strength (Magnetic force) (H) > Amagnetic field strength of 1 A/m is produced at the center of a single circular conductor with a 1 meter diameter carrying a steady current of 1 ampere. Q Magnetic flux density (B) » Magnetic flux density is the number of lines passing transversely through a unit area (gauss). Quantity SI Units SI Units CGS Units (Sommerfeld) (Kennelly) (Gaussian) Field Alm Am oersteds (Magnetization Porc) Flux Density tesla tesla gauss Magnetic weber weber Magnetization erg/Oe-cm?xt Units of Measure and Terminology Q Each magnetic particle testing procedure and technique must specify which units of measurement are to be used and how the measurement is to be accomplished. Quantity SI Units ‘SI Units CGS Units (Sommerfeld) (Kennelly) (Gaussian) Alm Alm oersted Field is Flux Density tesla tesla (Magnetic Induction) Flux weber weber Magnetization Alm -ves Magnetic Hysteresis O Amagnetic hysteresis loop or curve is a graph that plots magnetic flux density (B) and magnetic field strength (H). Itis often referred to as the B-H loop. (a) (b) Zero flux density A Residual magnetism Saturation 77 Saturation Zero magnetic: y field | Point Point 0 6/26/2000ves Magnetic Hysteresis 6726/2000ves Magnetic Hysteresis B Fux Densty =B Speake oirection 6/26/2000 rsaa The Hysteresis Loop and Magnetic Properties 2 Retentivity (Point b) > itis materials ability to retain a certain amount of residual magnetic field when the magnetizing force is removed after achieving saturation. Residual Magnetism or Residual Flux (Point b) > the magnetic flux density that remains in a material when the ‘magnetizing force is zero. Note that residual magnetism and retentivity are the same when the material has been magnetized to the saturation point, O Coercive Force(Point c) > The amount of reverse magnetic field which must be applied to ‘a magnetic material to make the magnetic flux return to zero. O Reluctance > Is the opposition that a ferromagnetic material shows to the establishment of a magnetic field. > Reluctance is analogous to the resistance in an electrical otal DrSamir Saaa Magnetic Permeability QO Permeability > is how easily a material can be magnetized. > permeability is measured in henries per meter (H/m or H-m-1), or equivalently in newtons per ampere squared The lepe ot te unetnat (N-A-2). > More specifically, itis the ratio between the flux density and the magnetizing force. n=B/H [Wecetasive = [Wcmaterian / LLeiey Mo air = 4m * 10-7 Ht or N-AP?,xe Magnetic Permeability O Magnetic properties and hysteresis loops vary between materials, material conditions, shape, chemical composition, microstructure and grain size. Q The following figure shows permeability curves of (a) high permeability (easy to magnetize) and (b) low permeability (hard to magnetize) material. (b) Saturation @ L Saturation point, Flux density Flux density 6/26/2000Xf Magnetic Permeability Q (a) is a hysterisis loop for a low permeability (hard to magnetize) - Lower Permeability - Higher Retentivity - Higher Coercivity - Higher Reluctance - Higher Residual Magnetism b) O (b) is a hysterisis loop for a high permeability (easy to oo - Higher Permeability - Lower Retentivity - Lower Coercivity - Lower Reluctance bower Residual Magnetism Residualae Effect of Materials on Electromagnetic Fields Q Materials with high permeability (soft or low carbon steel) > will have a stronger magnetic field strength at a given magnetizing force than material with lower permeability (high carbon or hard material). (a) Residual magnetism (b) Residual magnetism Flux density Coercive force (High carbon or hardened steel). Coercive force Flux density {Soft or annealed low carbon steel)