AL ST 6 M INSTRUCTION HIN8241-QCI 04 | | 5; | REVISION PAGE - | Non destructive Testing by | ] eae Magnetic Particles | 00 | 44 PREPARED BY ‘APPROVED BY DATE RB pared Vou) chanera MayGAYE wll 10.04.2008 a NATURE OF MODIFICATION New Relesse | INDEX 1. oBvEcriV 41 | 1% CONDITION REQUEIRED FOR THE SURFACE TO BE ee 1 | INSPECTED AND METHOD OF REPAIR 6 Fea a 2. | ‘oCondlton required forthe suace tobe teted...6 IV. MATERIAL TO BE INSPECTED .. od Bueeoe oh bre sara . V. EQUIPMENT 2] |S COME ESTING # wal 2 | Xb INDICATIVE OUTLINE OF ON- POSITION. 6 aaa we | Xl. DESCRIPTION OF THE EXECUTION OF THE TESTING..7 Vi. TECHNIQUE OF MAGNETIZATION AND TYPE OF SL a ‘CURRENT 3 | xiv. FINAL CLEANING 9 {TECHNIQUE OF MAGNETIZATION 3.| ‘testing inthe areas of contacto the electrode wih the 1.1. Yoke. 3 Pa ee = 12. Eldkod 3. | XV. CRITERIONS OF ACCEPTANCE. 8 1.3, Oreet Contact and Centra Conductor 3. | t.welded joins. 9 1.4, Coil (code ASME, Section V, article 7)..... 4 41.1. Interpretation a Vi FERROAGNETIC PARTICLES .. wd | 42. Acceptable atern 8 4.09 Method. 4 | 13. Evaluation 10 2.Wet method | 14 Removal of acs and Repairs 0 pues g. | 2Castng, Forged, Laminated 40 73 eam 8. | XVLREPPORT nnn 40 Vil TEMPERATURE OF THE PART AND OF THE SUSPENSION OBJECTIVE This procedure seeks to standardize the routine of execution of the testing, through magnetic, particles, to be accomplished in welded joints, forged, laminated, castings. DOCUMENTS FOR REFERENCE Procedure for internal qualification of testing procedures for magnetic Particles - © ASME Section Y, article 7. ‘TH PROCEDURE 6k PROPERTY OF ALSTOM TSREPRODUCTION OR COMMUNICATION WITHOUT PREVOUS ALTHORZATIONISHOT ALOWEDALSTOM INSTRUCTION HINS241-QCI 04 Hydro India Non destructive testingby | | Magnetic Particles oo | 24 Ml. © ASME Section VIll, div. 1, Apendix 6: © ASME Section | © ASTM E 709, © CCHT0-3 QUALIFICATION OF THE OPERATORS "NDT! ‘The operators are trained and qualified as level Il in accordance with the requirements of SNT-TC-1 THE, or national System for qualification and certification (SNQ&C-END) - ABENDE, IV. MATERIAL TO BE INSPECTED . v. © Steel carbon: Welded joints , laminated, forged and castings © - Mattensitic Stainless steel: Castings, Laminated and Forged. IMPLEMENTS L 4. Yoke MAKE MODEL MAGNAFLUX Y7 (Articulated legs ) FERROCHEM 2501 (Articulated legs ) Electrods. MAKE MODEL RATING Magnaflux P.1500 1230 - 50 He FERROCHEM - 230V - 50Hz ‘TH PROCEDURES A PROPERTY OF ALSTOM ISREPRGCUCTION OR COMBMNICATICN WTHOUT PREMOUS AUTHORIZATIONS NOT ALLOWEDINSTRUCTION HIN8241-QCI 04 | ALSTOM pines : Non destructive testing by epee nee! Magnetic Particles oo | 3m Note: The tension should be measured, in open circuit of the apparel, which should not surpass Note: 25 V, to use copper ferrule. In case the tension value i superior to 25 V, the material of the ferrules of the electrodes should be of lead, steel, aluminum or bronze in order to avoid the copper penetration in the piece in testing VI. TECHNIQUE OF MAGNETIZATION AND TYPE OF CURRENT 1. TECHNIQUE OF MAGNETIZATION The techniques of Yoke will be used; Electrodes, direct contact, central driver or coil testing will be executed by'the Continuous method. 4.4. Yoke For the technique of Yoke alternating current” AC." should be used. 4.2. Electrod * © - For the below mentioned ‘technique, alternating current AC " should be used , for detection of superficial discontinuity and continuous current in half waves " HWDC *, for detection of superficial discontinuity and sub-superfcial, as mentioned below: : ‘Amperes x mm of ae z | Thickness ofthe | Piting between | Minimum spacing / maximum part ees between electrods Smaller 79mm 361044 A Bigger or equal to 75 to 200 mm 19 mm 4to 5A a) 5 A for carbon steel CCH-70 b) 7 A for martensitic 75 to 300 mm | stainless steel J 4.3. Direct contact and Central Conductor [__ Tested Diameter (mm) Ax Diameter in mm_ Upto 125 - 28 to 36 Bigger than 125 upto 260 20 to 28 Bigger than 250 upto 380 12to [Bigger than 380 © - With the use of central conductor, when’this is not centralized in the radius of the piece, the value to be used as diameter will be the distance from the conductor to the tested surface multiplied by two. Tis PROCEDURE 1s A PROPERTY OF ALSTOM TS REPRODUCTION CR CCARANICATIN WITHOUT PREWOUSAUTHORATONIS NOT ALLONEDINSTRUCTION HIN8241-QC1 04 ALSTOM Non destructive testingby [| | Hydro India Magnetic Particles oo | 4/4 ‘* = When the cable of the magnetization machine is used and it is_more than one turn, through the diameter of the part , the required value as per the table-above should be divided by the number of turns taken * For verification of the efficiency of the method mentioned above, the pattem should be used as shown ir the illustration 12(v). 1.4, Coil testing (code ASME, Section V, article 7). The amperage to be used with the coil technique should be as indicated below: Data: L= length of the coil jiameter of the coil A= amperage t= number of tums on the coil Formula No. 4 When a value same or bigger than fou be used 2s shown in the below formula obtained , withthe use in relation to LID, should At= 35000. +/ 10% (iD)+2 Formula No. 2 When a value smaller than four is obtained , but not inferior to two, with the use in relation UD, the formula to be used is shown below: At= 45000 +/-10% a) Note: the pattem shown inthe ilustaton 12 (should be used for verfcaton of the efficiency of the methods mentioned above. VII. PARTICLES FERROMAGNETIC 4. DRY METHOD MAKE ‘Type Colour 1 Grail Magnaflux * 3A Black 8A Red 246 Red FERROCHEM 247 Black 249) Grai "TS PROCECLRE S.A PROPERTY OF ALSTOM IG REPRODUGTION OR CoMlUMCATINWTHOUT PREMOUS ALTHORZATIONIS NOT ALLOWEDINSTRUCTION HIN8241-QCI 04 ALSTOM Non destructive testingby |“ | Hydro India - * Magnetic Particles 00. 5/11 2. WET METHOD 24, Coloured Make Type | Colour Vehicle Cone. NOC Black = 93671 Magnaflux NCE al CarrierliWater (*) 936g | 740A/P 7 |= Black i0g/_| | 446AII 5 Red : ( 10g/l | Ferrochem Tagc aval ae EG CarrierlWater (*) aoa 4146C/L 3 Red Ogil 2.2. Fluorescent a Under black light the following fluorescent ferromagnetic particles should be used) [ Make Type Vehicle Conc. aA 25 gil Magnafiux Wea] CatienllWater(”) Geen T34AIP 4 ~» _1.0g/ Ferrochem 13GPS CarienWater(*) gar a) For verification of the concentration of the suspension, a centrifuge tube should be used. ) This verification should ke made in each 8 working hours, in the suspension removed directly from the aplicador of this, through observation of the concentration of 100 mi of the suspension after 30 minutes. ¢) For the particles used under normal light, the volume of solid material should be in the strip from 1, 2 to 2. 4 ml i! d) For the particles used urider the black light, the volume of solid material should be in the strip of 0. 1 to 0.'4 ml e) When the middle of suspension is water, the following addictive should be used. { Make Type, Diluition Magnafiux WA2B 30 mi ] Note: the edie of each manufacturer shoul be used forthe sare manufacturers feromagnetc parties. Vill. TEMPERATURE OF THE PART AND OF THE SUSPENSION The temperature of the suspension of particles ferromagnetic, for the testing via humic . should not surpass 57 centigrade degrees. "4S PROCEDURES A PROPERTY OF ALSTOM TS REPROLUCTION OR CONERINICATON WV THOUTFREWOUS AUTHORZAIONISNOT ALLOWEDINSTRUCTION HIN8241-QCl 04° ALSTOM EVEN] -PRCE Non destructive testing by Bzolndi Magnetic Particles oo | 64 ‘The temperature of the surface of the piece to be tested should not be superior to a) 316 degrees centigrade , bya dry testing ; 'b) 57 degrees centigrade , by a wet testing ; IX. CONDITION REQUIRED FOR THE SURFACE TO BE TESTED AND METHOD OF REPAIR 4. Condition reauired for the surface to be tested. The surface in the area of interest should be clean, in such a way that there is no strange agent that reduces the mobility of the particles ferromagnetic. 2, Method of Preparation , a) A cleaning should be made in the area of interest, with brush of steel manual or rotative, or by jet of sand or grantiles since this doesnt produce roughness that reduces the mobility of the particles ferromagnetic 'b) For cleaning of the surfaces, solvent should be used, C) In the case of welding , the area of interest should be considered the surface of the same, more 25 mm on each side, X. . INK OF CONTRAST When necessary, to minimize contrast problems between the particles ferromagnetic and the tested surface, to use contrast ink: The ink film, in its maximum thickness should not cause decrease of the sensibility of the inspection. ‘Make Type Minimum time for drying |[Ferochem 1204 5 minutes | [Magnafiux WOP-2 = 5 minutes J XI. INDICATIVE OUTLINE OF ON-POSITION . In the surface to be tested, in case required, References out of the testing area should be marked, in way to.assure that the specified job reposition is obeyed. At least two separate testing should be executed in each area and the lines of the magnetic flow of the second testing should be approximately perpendicular to those of the first testing, The crossing mentioned above can be obtained by the use of two different techniques , when necessary. "HS PROCEDURE If &PROFERTY OF ALSTOM II REPROCLCTON OR CONMUNCATION WITHOUT PREVIOUS AUTHORIZATIONSINSTRUCTION HIN8241-QCI 04 REVISION” | PAGE ALSTOM Non destructive testing by Hydro Indio Magnetic Particles oo | 741 XII. DESCRIPTION OF THE EXECUTION OF THE TESTING a) To Verify the material, forms and dimensions of the part to be tested b) To determine the apparatus/device/equipment type and the most appropriate technique for the execution of the testing (item V and VI). ) To determine the current type for the technique of the electrods, to verify its limits (item VI) d) To choose the more appropriate ferromagnetic particle, with the piece to be tested, seeking brightness of the atmosphere, contrast, format and dimensions of the piece (item Vib. ) To verify the temperature of the piece and of the suspension (item VIII). {) To Verify the available state of the surface to be tested (item IX). g) To determine the best outline of the overlapping for the piece to be tested. h) To execute the testing, to verify the need of demagnetization, to note down and to report the results obtained in the testing, noting down in the report item XV1). i) The magnetization: current should only be connected after the appropriate positioning of the electrods in the part and disconnect before the removal of these, in order to avoid opening of electric arch between the electrode and the part in inspection j) The ferrules of the electrods should be free from, grease, slag, oil, in order to allow the passage of the current to the part and to minimize the opening of electric arches. k)The execution of the testing should be in a continuous way, that is, applying the magnetic particles, removing the excess soon after and observing the indications, while the magnetization is being applied. 1) The removal of the excess of ferromagrietic particles, in the testing by dry method should be made through 4 blow of low speed; the use of jet of compressed air won't be allowed, {pin surface not darkened , common ferromagnetic particles should be used, under normal light, or fluorescent ferromagnetic particles under black light as requested. k) In darkened surface, particles fluorescent ferromagnetic should be used, under black light. 1) The Examiner should stay in the darkened area for at least 5 minute for familiarization with the atmosphere before the beginning of the exam. m)For the use, the lamp emitting’ the black light, should be heated up for at least 5 minutes, before the beginning of the testing. n)The black light should have a fitter for ultraviolet radiation, to allow the light passage’ with wavelength in the strip from 3300 to 3900 A. The intensity of black light in the testing surface should be proven through a sensitive meter to the light ultra-violet, that operates in a spectrum centered to 3650 A, it should be same or superior to 1000 mWicm?. it can also be proven for the use of the indicator of the magnetic field as, illustration 12(v), in the conditions of execution of the rehearsal for the verification of the indications of the patter. that appear cleatly visible. P) The proof should be made at least once in & (eight) hours and whenever the work place is changed. ‘Ts PROCECURE Is A PROPERTY OF ALSTOM I REPRODUCTION OR COMBIICATON WITHOUT PREMCUS ELTHORATIONISNOT ALLOWEDINSTRUCTION HIN8241-QC104 | ALSTOM EEN] PROF Non destructive testing by nyo) eae Magnetic Particles oo | 31 ‘q)The magnatising force of Yoke, should be gauged for determination of its minimum capacity ‘of mass rising, with the maximum spacing among poles thet must used, being the minimum capacity of 4.5 Kg. for alternating current -Yoke Eletromagnetic that should be proven, at least every 8 hours, change of the work place or when itis damaged. 1) The calibration of the amp.meters should be made annually and the real reading should be inside of a strip of +/ - 10% of the real value. s) The verification of the adaptation of the testing should be done in the beginning of each continuous work, using the indicator of magnetic field, in the limits of the useful area of inspection. Eight low carbon steel pie sections furnace brazed together & copper plated De ‘Nonferrous handle Eight artificial defects, Nonferrous trunions [0:7Smm Copper plate - 0.25mm, +/- 0.025mm —— Indicator of Magnetic field [= i FIGURE 12(v) XII, DEMAGNETIZATION The demagnetization should be done, when requested in the plan of quality, drawing or specification, due to interferences of the residual magnetization to affect the subsequent operations or in the operation of the part. "is PROCEDURE I A PROPERTY GF ALSTOM. TS REFRCOICTIONCR COMMLNICATION WITHOUT PREVIOUS AUTHOREZATIONIS NOTAINSTRUCTION HIN8241-QCI 04 ALSTOM ee Non destructive testing by eons Magnetic, Particles oo | om XIV. FINAL CLEANING the part 1a) In case that in the points of contact of the electrods with the part in testing appear signs of arch opening, these should be removed and later. the area should be tested by magnetic particles (technique of Yoke) or penetrating liquids, when these affect th subsequent operations or the operation of the part 1. Testing b) The signs of opening of the arch, should be removed, through grinding , or even with. stuffing of weld, 2s necessary. c) In case of the finished machined surface , where painting is not required , it should be protected with anti-corrosive oil. XV. CRITERIONS OF ACCEPTANCE 4. Welded joints When requested by the plan of quality, the use of the code ASME, Section Vill, division 1, appendix 8 or ASME Section | TO 260 the criterion should be used as shown below: ‘An indication originating from discontinutty is an evidence of mechanical imperfection, but only indications with larger dimensions than 1. 6 mm should be considered important 1.1. Interpretation 1a) Lineal Indications are thoSe that have the largest length than three times the width; bb) Round Indications are those with elliptic or iregular circular format, where the length is ‘same or smaller by three times the width. ¢) Any questionable indication or doubtful should be re-tested to determine if itis or not an important indication. . 1.2. Pattern of acceptance . This pattern of acceptance should be applied, except if other more restrictive pattem is specified for @ specific material or application within this division. "HS PROCEDURE 1s PROPERTY OF ALSTOM ITS REPRODUCTION OR COMMANCATION WITHOUT PREMOUSAUTHOAATIONIS NOT ALLONEDINSTRUCTION HIN8241-QCI 04 | ALSTOM Non destructive testing by Poa al Hydro India Magnetic Particles 00 10/44 4.3. Evaluation Every tested surface should be free from: a) Important linear Indication; b) Rounded indication larger than 4.7 mm. )Four or more important indications, in separate line for 1.6. mm, or minus, form comer to corner ; a) The originating indication of indication of an imperfection, can be larger than the imperfection that caused her, however, the size to be taken as base for the evaluation of ‘acceptance is the size of the indiation (accumulation of particles) and not the size of the imperfection. 1.4. Removal of defects and repairs All the defects surpassing the limits indicated above and in the acceptance criterion, should be removed before executing the repair, should assure that the same were eliminated, using the testing for magnetic particles, After the repairs for welding , the repaifed surface, more 25 mm. adjacent to the repair, should be prepared to make @ new testing for magnetic particles, in accordance with the same procedure applied initially The areas where there is no need of repair for welding , one should have the surface polished with emery, in @ manner to avoid the incision in the surface. 2. Gasting , Forged , Laminate ‘That which is indicated in the plan of the quality should be applied, it ennotates technique of the material or drawing, XVI. REPORT Ex:R1, R2, R3, All the important indications should be registered, as well as all the referring essential information of the testing in the report form; according to model (enclosure 01). In case there are indications to repair the conclusion of the-report it should be repair, In the reevaluation of the repaired area a new report should be emitted with the same ‘number of the original report, accompanied by the letter" R* plus the number" 1" and so (on and so forth, how many times the repair persists Former. :R1, R2, R3, "TS PROCEDURES A PROPERTY OF ALSTOM TS REPRODUCTION OR COMMUNICATION WITHOUT PREVOUSALTHORZATION SNOT ALINSTRUCTION HIN8241-QCI 04 ALSTOM REVSION | PAGE - Non destructive testing by pigilnge } Magnetic Particles oo | 4414 Enclosure 01 ALSTOM TEST REPORT PAGE 10F1 THYORO INDIR MAGNETIC PARTICLE TESTING Customer Insp./Test No. Dt tem TTP/QAP No. Drawing No. Rev P.O. No: liem/Operation No. Quontity ‘WAS No, ‘Material Iden Test Site HeotTreatment:ElYes + CJNo . CUNA | Exient of Test: Material Surface Condition Welding Process Welder No. Procedure Ref ‘Material Thickness ‘Acceptance Standard TEST DATA Equipment [Magnetic Ink: Colour Fluorescence Test Method Wel Dy Manufacturer of det. ile ‘Magnetisation ‘Measured Ufing Force: . | Background paint Prod Specing [Curent ACG RWOC oO DC Inspection Method] Confinvous ChRernant | Magnefsaion Time: | Demagnefiaton: | D¥es EIN Illumination : [] Visible det. media [] Fluorescence | Magnetic Field Strength : | Magnetising | Curent ‘Measured Black light: Mominafien:() Day ight CI Ugh Point C Black Light TEST RESULT: 1 No Remarks [Remarks (se below) Remarks according to addilional sketch Sign Dote ‘CONCLUSION: O_Approved D_Not Approved NAME NAME [SIGNATURE : ‘SIGNATURE & DATE & DATE Customer Representative HI Inspector Flommat No PINBDATICIOU-O4 Rev, OT Ot OSTO2P "HS PROCEDUREIGA PROPERTY OF ALSTOM. TS REPRODUCTION OR CONMLNCATION WITHOUT PREVIOUS AUTHORZATION SNOT ALLOWED