LESER WORKS STANDARD Procedure for magnetic particle testing

LWN 331-03-EN page 1

Table of Contents
SUMMARY ........................................................................................................................................................ 2 1. 2. 3. 4. 5. GENERAL .................................................................................................................................................. 2 APPLICATION ........................................................................................................................................... 2 PURPOSE, DEFINITION............................................................................................................................ 2 TEST REFERENCES................................................................................................................................. 2 TEST PROCEDURES AT LESER ............................................................................................................. 3 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 6. 7. 8. 9. TEST INSTRUCTIONS ................................................................................................................................ 3 TEST DEPTH ............................................................................................................................................ 3 TESTING METHODS .................................................................................................................................. 3 TESTING FACILITY.................................................................................................................................... 3 TEST MEDIA, TEST AIDS ........................................................................................................................... 3 TEST PROCEDURE ................................................................................................................................... 4 DESCRIPTION OF INDICATIONS ................................................................................................................. 5 DE-MAGNETISATION ................................................................................................................................ 5

ACCEPTANCE CRITERIA (EVALUATION OF INDICATIONS) ............................................................... 5 QUALIFICATION OF THE TEST PERSONNEL ....................................................................................... 5 DOCUMENTATION, OPTION CODE ........................................................................................................ 5 STANDARD REFERENCES...................................................................................................................... 5

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LESER
GmbH & Co. KG

processed: La/Sa approved: refer to M 103600

edition: 26.06.07 replaces edition: 00.00.00

LESER WORKS STANDARD Procedure for magnetic particle testing Summary

LWN 331-03-EN page 2

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 H03 M44 Certificate LESER CGA (Certificate for Global Application) Inspection certificate 3.1 according to DIN EN 10204 Inspection certificate 3.1 acc. to DIN EN 10204: Magnetic particle testing Remarks

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 Gehuse von Ausrstungsteilen, Ausgabe Oktober 2004 Kap.6 Prfungen vor Inbetriebnahme Rules for Construction of Pressure Vessels, Division 1 UG -136 Minimum Requirements for Pressure Relief Valves UG-136 (f) Welding and other Requirements Founding - magnetic particle testing Non-destructive testing magnetic particle testing General foundations Non-destructive testing - penetrant testing and magnetic particle testing - Viewing conditions Non-destructive Examination, Addenda 2006 Article 7 - Magnetic Particle Examination

ASME Code, Section VIII Addenda 2006

DIN EN 1369 EN ISO 9934 DIN EN ISO 3059 ASME Code Section V

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LESER
GmbH & Co. KG

processed: La/Sa approved: refer to M 103600

edition: 26.06.07 replaces edition: 00.00.00

LESER WORKS STANDARD Procedure for magnetic particle testing

ASME B16.34-2004

LWN 331-03-EN page 3

LWN 221-03

Valves - Flanged, Threaded, and Welding End Mandatory Appendices II - Magnetic Particle Examination: Procedure and Acceptance Standards 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 99341, 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: Longitudinal magnetisation: Length of clamping: Max. tensile :

max. 2000A alternate current effectively 2800 A alternate current peak; max. 10 000 Aw, 1 T max.710 mm 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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LESER
GmbH & Co. KG

processed: La/Sa approved: refer to M 103600

edition: 26.06.07 replaces edition: 00.00.00

LESER WORKS STANDARD Procedure for magnetic particle testing

LWN 331-03-EN page 4

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 W / cm 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 postmagnetisation period has to be at least 1 second.
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LESER
GmbH & Co. KG

processed: La/Sa approved: refer to M 103600

edition: 26.06.07 replaces edition: 00.00.00

LESER WORKS STANDARD Procedure for magnetic particle testing

LWN 331-03-EN page 5

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 H03 M44 Certificate LESER CGA (Certificate for Global Application) Inspection certificate 3.1 according to DIN EN 10204 Inspection certificate 3.1 acc. to DIN EN 10204: Magnetic particle testing Remarks

optionally

9. Standard references
AD 2000-Merkblatt A4 DIN EN 1369 EN ISO 9934-1 EN ISO 9934-2 EN ISO 9934-3 DIN 1690 DIN EN 473 Gehuse von Ausrstungsteilen; Prfungen vor Inbetriebnahme Founding magnetic particle testing Non-destructive testing magnetic particle testing Part 1: General foundations Non-destructive testing magnetic particle testing Part 2: Test media Non-destructive testing magnetic particle testing - Part 3: Devices. Technical delivery conditions for castings made of metal materials Non-destructive testing - Qualification and certification of personnel used for non-destructive testing - General foundations Rules for Construction of Pressure Vessels, Division 1 Non-destructive Examination
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ASME Code, Section VIII ASME Code, Section V

LESER
GmbH & Co. KG

processed: La/Sa approved: refer to M 103600

edition: 26.06.07 replaces edition: 00.00.00

LESER WORKS STANDARD Procedure for magnetic particle testing

LWN 331-03-EN page 6

ASME B16.34

SNT-TC 1A LWN 287-99

Article 7- Magnetic Particle Examination Valves - Flanged, Threaded, and Welding End Mandatory Appendices II - Magnetic Particle Examination: Procedure and Acceptance Standards Personnel Qualification and Certification in non-destructive testing Regulative requirements regarding welding components for LESER safety valves

End of LWN

LESER
GmbH & Co. KG

processed: La/Sa approved: refer to M 103600

edition: 26.06.07 replaces edition: 00.00.00

T he S afety V alve
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.: LESER Job No.: LESER-Customers-No.: LESER-Contact: Fon: Fax: eMail:

xxx xxx xxx xxx + 49 (40) 25 165+ 49 (40) 25 165-500 xxx@leser.com

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. xxxx.xxxx Cold differential test pressure x,xx barg LESER Job No. xxx xxx,xx psig Pos.No. xx Option Code: Further SV-Info: xxx xxx Nominal size Inlet xxx xx Outlet xx Pressure rating Inlet xx Outlet xx

Tag No. xxx

Serial No.

Body material

Tested component
Pos. 1 Description xxx Material xxx Manufacturer xxx Heat No. / Batch xxx

2 Test reference
Magnetic particle testing acc. to: AD 2000-Merkblatt A4, chapter. 6 ASME Code, Section VIII Div 1, UG 136 LESER Works Standard LWN 331-03

3 Procedure 4 Test specification

Testing equipment: Testing method: Viewing conditions, exposure intensity: Test media: Test area: Qualification of the test personnel:

Magnetisation device, Universal test bench IFW 600-e Interflux GmbH SSW and JEW UV-A: Ee = 18 W/m; environment E < 20 Lux Interflux Water Suspendible Apelux Concentrate 1018 surface 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 Inspection Representative
This certification is written digitally and requires no handwritten signature. (Acc. to EN 10204, chapter 5)

Hohenwestedt, xx.xx.200x

LESER GmbH & Co. KG Hamburg HRA 82424

GF BoD Joachim Klaus, Martin Leser 20537 Hamburg, Wendenstr. 133 135 20506 Hamburg, P.O. Box 26 16 51 ( )

Fon +49 (40) 251 65-100 Fax +49 (40) 251 65-500 E-Mail sales@leser.com Internet www.leser.com

Bank HypoVereinsbank Hamburg BLZ 200 300 00, Konto Account 3203171 BIC: HYVEDEMM300 IBAN: DE64 2003 0000 0003 2031 71 USt-ID VAT-Reg DE 118840936

LESER The Safety Valve