Procedure For Magnectic Flux Leakeage For QHSE/ P11/ ANDT/

Date: 18/08/2021
Tube Inspection JP06/ MFL/Gen

Rev # 03 Page 1 of 7

MAGNETIC FLUX LEAKAGE PROCEDURE FOR

TUBE INSPECTION.

Document
Rev Issue Date Prepared by: Reviewed by: Approved by:
No:
Name & Name &
Name & Signature:
Signature: Signature:
Lalith R. Vipin Shetty Ganeshbabu.M
Level-II Level-III Level-III
QHSE/ P11/
ANDT/ JP06/ 03 18/08/2021
MFL/Gen

Date: 18/08/2021 Date: 18/08/2021 Date: 18/08/2021

 Procedure For Magnectic Flux Leakeage For QHSE/ P11/ ANDT/
Date: 18/08/2021
Tube Inspection JP06/ MFL/Gen

Rev # 03 Page 2 of 7

Table of Content Page#

1. Scope ----------------------------------------------------------------------------------- 3

2. References------------------------------------------------------------------------------ 3

3. Personnel Qualification Requirements--------------------------------------------- 3

4. Principle of MFL System-------------------------------------------------------------- 3

5. Components of MFL System--------------------------------------------------------- 3

6. Pre Inspection Preparation---------------------------------------------------------- 3

7. Calibration Standard------------------------------------------------------------------ 4

8. Basic Information Requirements---------------------------------------------------- 4

9. Calibration ----------------------------------------------------------------------------- 4

10. Inspection of tubes-------------------------------------------------------------------- 4

11. Examination Technique -------------------------------------------------------------- 5

12. Data Recording------------------------------------------------------------------------ 5

13. Data Analysis-------------------------------------------------------------------------- 5

14. Acceptance Criteria------------------------------------------------------------------- 5

15. Reports Results----------------------------------------------------------------------- 5

16. Attachment -1------------------------------------------------------------------------- 6

17. Table - 1------------------------------------------------------------------------------- 7

 Procedure For Magnectic Flux Leakeage For QHSE/ P11/ ANDT/
Date: 18/08/2021
Tube Inspection JP06/ MFL/Gen

Rev # 03 Page 3 of 7

1.0 Scope:

This Procedure describes the method of applying Magnetic Flux Leakage (MFL) testing to test
Ferromagnetic heat exchanger, Air Cooler and Boiler tubes.

2.0 Referenced Documents:

a. RISS/EP/QC-01 – RISS Written Procedure for Training and certification Personnel

b. ANSI-CP-189 & ASNT SNT TC -1A- “ASNT Standard for Qualification and
Certification of Nondestructive Testing Personnel”
c. ASME Section V (2021 Edition) Article 16 – Non Destructive Testing- Magnetic Flux
Leakage Examination

3.0 Personnel Qualification Requirements:

The personnel who operate the MFL test equipment with the exception of the probe positioner
and puller technician shall be a minimum Level II in Magnetic Particle Testing Method.
Certification of the personnel shall be according to RISS Written Practice
The Result Evaluation of the MFL must be conducted by Personnel qualified to at least Level II

4.0 Principle of MFL System:

The basic principle of MFL system is belongs to the Permanent magnets. The two strong
permanent magnets coupled to a steel core, generate the magnetic field that saturates the tube
wall
An absolute coil (ABS) is wound around the core to measure magnetic field variation caused
by general wall loss
When small flaw is located between the two magnets the magnetic lines in the tube wall is
disturbed, resulting in a small amount of flux leakage into the inner tube. This flux leakage is
detected by the differential coil (LEAD), located between the magnets
A trailing coil (TRAIL), at the end of the probe, detects the residual magnetism

5.0 Components of the MFL System:

A computerized MS-5800 Multi-Function Non - destructive testing systems of M/s Olympus

NDT make along with a laptop computer running MFL and multiview software shall be used to
carry out the inspection. All results shall be recorded to hard disk and manual analysis was
conducted on screen

The system shall be consists of following three functional elements.

MFL probe selected based on the diameter and thickness of the tube as per the table.
Laptop with MFL software i.e. Multiview software
Wall loss adaptor
 Procedure For Magnectic Flux Leakeage For QHSE/ P11/ ANDT/
Date: 18/08/2021
Tube Inspection JP06/ MFL/Gen

Rev # 03 Page 4 of 7

6.0 Pre Inspection Preparation:

All tubes inner surface shall be adequately cleaned to remove any dust, loose foreign particles,
internal deposits or contaminations by a suitable process such as pressurized water jet cleaning.
It is also recommended to clean the outer surface of tube if possible.

7.0 Calibration Standard:

Calibration tube shall be manufactured from a tubing of the same material specification, same
heat treatment and same nominal size and thickness. The calibration tube shall be manufactured
according to the sketch provided in Attachment-1

8.0 Basic Information Requirements:

The following minimum information is required prior to conducting an inspection

· Tube dimensions – Outside diameter, Wall thickness and length

· Tube Materials
· Tube characteristics – Finned, ‘U’ bends, swaged, etc..,
· Scope of inspection – No of tubes, inspection pattern
· Review of previous inspection reports ( If any)
· Drawing, Diagrams, Maps or any other relevant information

9.0 Calibration:

The calibration standard tube shall be used for equipment calibration as per following steps.

· The wall loss adapter is placed between the probe and MS5800 to integrate the voltage
across the absolute coil
· Check wall loss adapter drift periodically
· The RESET button sets the integrator output to zero. During the inspection RESET is
recommended every 10 tubes
· When insert the probe into the tube in order to reduce the electromagnetic noise. Hold the
RESET button and click the Balance

The test equipment response shall be checked and verified by use of the calibration tube
standard as follows

· At least every two hours

· At each change of operator
· At any time that malfunctioning is suspected
 Procedure For Magnectic Flux Leakeage For QHSE/ P11/ ANDT/
Date: 18/08/2021
Tube Inspection JP06/ MFL/Gen

Rev # 03 Page 5 of 7

If during any check, it is determined that the test equipment is out of calibration (as defined by
the work instruction) the equipment shall be re calibrated and a new data file opened. The data
analyst shall determine which tubes, if any are to be reexamined.
It is the responsibility of the data capture technician to ensure that the data is of the quality
required by the relevant procedure or as defined by the data analyst.

10.0 Inspection of tubes:

· The inspection is conducted with the probe located at the fair end of the tube. The assembly
is pushed to the end of the tube by feeding the hose through the tube
· To start the inspection the assembly is gradually pulled along the tube towards the operator.
· The above procedure can be repeated for as many tubes are to be inspected during the
operating session. The equipment dismantled procedures are to be inspected during the
operating session. The equipment dismantle procedure are the reverse of those carried out
during the setup of the inspection
· The Pulling speed of the probe shall be kept constant during the inspection. The pulling
speed shall be kept same as the speed of the calibration.(maximum speed is 1m/s)

11.0 Examination Technique:

· In all techniques measurements are taken whilst withdrawing the probe. The pushing and
withdrawing shall be done manually.
· The technician shall ensure that an even speed is maintained

12.0 Data Recording:

For the purpose of this procedure all test results will be recorded on suitable data acquisition
system
· Each data storage unit shall contain the following information
· Positive identification of the item under test
· Data storage unit number
· A reference to the contents
· Data
· Probe identification

Each trace shall be identified according to zone / row / column and tube number as applicable

13.0 Data Analysis:

All indications shall be evaluated based on the client’s acceptance criteria.

Analysis of all data shall be conducted by NDT level II qualified in data analysis.

All indications shall be evaluated. Signal amplitude and phase shall be taken into account
whenever defect indications are evaluated using the absolute or differential modes.
All indication must be evaluated and defects classified in a category of wall loss as follows
 Procedure For Magnectic Flux Leakeage For QHSE/ P11/ ANDT/
Date: 18/08/2021
Tube Inspection JP06/ MFL/Gen

Rev # 03 Page 6 of 7

· 0% - 20% Wall thickness loss

· 21% - 40% Wall thickness loss
· 41% - 50% Wall thickness loss
· >50% Wall thickness loss

The default setup already includes defects codes and depth curves

· PIT is measured on the LEAD channel (for small OD or ID indications)

· WLL is measured on the ABS channel (for Large area indications)
· ID_PIT is measured on the TRAIL channel (for small ID indications)

Reporting of indication shall be in accordance with attachment 1, and shall be recorded on the
report format

14.0 Acceptance Criteria:

The acceptance criteria or rejection of tubes based on wall loss is at the discretion of the client.

15.0 Reporting Results:

· Reporting shall be prepared with the information gathered using the computer data files
· Report all tubes wall with a wall loss reading, percentage of wall loss and carto diagram
with wall loss and all reports issued to the clients shall Be signed by the person performing
the inspection
 Procedure For Magnectic Flux Leakeage For QHSE/ P11/ ANDT/
Date: 18/08/2021
Tube Inspection JP06/ MFL/Gen

Rev # 03 Page 7 of 7

Attachment-1: Calibration tube sketch

 Procedure For Magnectic Flux Leakeage For QHSE/ P11/ ANDT/
Date: 18/08/2021
Tube Inspection JP06/ MFL/Gen

Rev # 03 Page 8 of 7

Table -1: Selection of MFL Probes.