NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

GES I.06

EQUIPMENT AND TOOLS FOR NDT

Rev Date Description Checked Approved

0 1999 Issued for Implementation DL

Compiled by Teknica (UK) Ltd

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INDEX

SEC HEADING PAGE

1.0 SCOPE OF SPECIFICATION 4

1.1 Introduction 4
1.2 Scope of Supply 4
1.3 Other NOC Specifications 4

2.0 DEFINITIONS 4

2.1 Technical 4
2.2 Contractual 6

3.0 DESIGN 6

3.1 Codes and Standards 6

3.2 Exceptions 7

4.0 RADIOGRAPHY 7

4.1 Scope 7
4.2 Exceptions 7
4.3 Equipment and Materials 8
4.4 Safety Practices 11
4.5 Personnel Qualifications 12

5.0 ULTRASONIC EQUIPMENT 12

5.1 Scope 12
5.2 Introduction to Equipment and Operations 12
5.3 Apparatus 12
5.4 Calibration of Equipment 14
5.5 Examination Data Record 14
5.6 Reports 14
5.7 Personnel Requirements 14
5.8 Safety 14

6.0 LIQUID PENETRANT EQUIPMENT 14

6.1 Scope 14
6.2 Types of Material 15
6.3 Safety 16

7.0 MAGNETIC PARTICLE EQUIPMENT AND MATERIAL 16

7.1 Scope 16
7.2 Equipment 16
7.3 Magnetic Particle Materials 17
7.4 Maintenance and Calibration of Equipment 18
7.5 Safety 20

SEC HEADING PAG

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8.0 ELECTROMAGNETIC (EDDY CURRENT) EQUIPMENT 20

8.1 Scope 20
8.2 Apparatus 20
8.3 Testing 21
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1.0 SCOPE OF SPECIFICATION

1.1 Introduction

This specification covers the general requirements for the design, operation, inspection and testing of non-
destructive examination equipment intended to detect surface and internal discontinuities in materials,
welds, and fabricated parts and components.

1.2 Scope of Supply

The main equipment include radiographic (RT), ultrasonic (UT), liquid penetrant (PT), magnetic particle
(MT) and electromagnetic (eddy current ET) examination apparatus and materials.

It is the responsibility of the manufacturer and the user to ensure that the examination equipment supplied
or being used, conforms to the requirements of this specification.

1.3 Other NOC Specifications

Where indicated in this specification the following additional NOC Specifications shall apply:-

GES I.02 Inspection and NDT of Equipment in Operation

GES I.05 Acceptance Criteria for Non-Destructive Examination

GES W.07 Non-Destructive Testing

2.0 DEFINITIONS

2.1 Technical

The technical terms used in this specification are defined as follows:

Acceptance standard - A tube with artificial discontinuities specified in the applicable Eddy current product
standard used to establish the acceptance level.

Calibrated step wedge film - a radiograph with discrete density steps which is traceable to an international
standard.

Composite viewing - the viewing of two or more superimposed radiographs from a multiple film exposure.

Contrast sensitivity - the smallest contrast of luminance (or brightness) that is perceptible to the human eye
under specified conditions of adaptation luminance and target visual angle.

Densitometer - an instrument that measures optical density by measuring the intensity of transmitted or
reflected light; used to measure radiographic film density.

Designated wire - the specific wire that must be discernible in the radiographic image of a wire type image
quality indictor.

Eddy Current End Effect - The loss in sensitivity to discontinuities located near the extreme ends of the
tube as the ends of the tube enter or leave the test coil.

Equivalent penetrameter sensitivity (EPS) - that thickness of Image Quality Indicator (IQI) hole type
penetrameter expressed as a percentage of the part thickness, in which a 2T hole would be visible under the
same radiographic conditions. Note See IQI below.
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Essential hole - the specific hole that must be discernible in the radiographic image of an Image Quality
Indicator (IQI) hole type penetrameter. Note See IQI below.

Focal point - that area of the anode (target) of an X-ray tube which emits X-rays when bombarded with
electrons.

Half - value layer (HVL) - the thickness of an absorbing material required to reduce the intensity of a beam
of incident radiation to one half of its original intensity.

Image quality indicator (IQI):

Hole type - a rectangular plaque, made of material radiographically similar to that of the object being
radiographed, with small diameter holes (1T, 2T and 4T) used to check the image quality of the radiograph.
Wire type - at set of small diameter wires, made of material radiographically similar to that of the object
being radiographed, used to check the image quality of the radiograph.

Intensifying screen - material that is placed in direct contact with radiographic film in order to reduce the
exposure time (by emitting electrons or electromagnetic radiation in the visible light spectrum) and/or
improve film quality (by absorbing longer wavelength scattered radiation)

Line pairs - a line pair test pattern consisting of one or more pairs of equal width, high contrast lines and
spaces utilised to determine the maximum density of lines and spaces that can be successfully imaged. The
value is expressed in line pairs per millimetre.

Line pair resolution - the number of line pairs per unit distance that are detectable in an image.

Location marker - a number or letter made of lead (Pb or other highly radiation attenuative material) that is
placed on an object being radiographed in order to provide traceability between a specific area on the
radiograph and the component.

Optical density step wedge - a radiographic image of a mechanical step wedge with precise thickness
increments and may be used to correlate optical film density to the thickness of material, also known as a
step tablet.

Optical line pair test pattern - a film image of a series of line pairs of various spatial frequencies (line pairs
per unit distance).

Radiographic examination - a nondestructive method for detecting discontinuities in materials and

components using penetrating radiation to produce an image on a recording medium.

Source - a machine or radioactive material that emits penetrating radiation.

Step wedge - device with discrete step thickness increments used to obtain a radiograph with discrete step
densities.

Sensitivity - a measure of the level of response from a discontinuity by a nondestructive examination.

Technique - a technique is a specific way of utilising a particular non destructive examination (NDE)
method.

Reference standard - a tube with artificial discontinuities used for establishing the Eddy current test
sensitivity setting and for periodically checking and adjusting sensitivity setting as required.

2.2 Contractual

The commercial terms used in this specification are defined as follows:

2.2.1 Owner
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The oil and gas company, an associate or subsidiary, who is the end user of the equipment and facilities.

2.2.2 Vendor

The company supplying the equipment and material.

2.2.3 Contractor

The main contractor for a defined piece of work.

2.2.4 Sub-Contractor

A company awarded a contract by a Vendor/Contractor to do part of the work awarded to the

Vendor/Contractor.

2.2.5 Inspection Authority

The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of this
specification and the Purchase Order/Contract.

2.2.6 Inspector

A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.

3.0 DESIGN

3.1 Codes and Standards

The design shall comply with this specification and the following codes and standards:

Unless specified otherwise in the Purchase Order/Contract, the current editions of the codes and standards
at the time of the order should be used.

ASTM E 94 Standard Guide for Radiographic Testing

ASTM E 142 Standard Method for Controlling Quality of Radiographic Testing

ASTM E 747 Standard Practice for Design, Manufacture, and Material Grouping
Classification of Wire Image Quality Indicators (IQI) Used for Radiology

ASTM E 999 Standard Guide for Controlling the Quality of Industrial Radiographic Film
Processing

ASTM E 1025 Standard Practice for Design, Manufacture, and Material Grouping
Classification of Hole-Type Image Quality Indicators (IQI) Used for Radiology

ASTM E 1079 Standard Practice for Calibration of Transmission Densitometers

ASTM E 1114 Standard Method for Determining the Focal Size of Iridium - 192 Industrial
Radiographic Sources

ASTM E 543 Practice For Agencies Performing Non-Destructive Testing

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ASTM E 1255 Standard Practice for Radioscopy

ASTM E 114 Recommended Practice for Ultrasonic Pulse-Echo Straight-Beam Testing by the
Contact Method

ASTM E 214 Standard Practice for Immersed Ultrasonic Examination by the Reflection
Method Using Pulse Longitudinal Waves

ASTM E 797 Standard Practice for Thickness Measurement by Manual Contact Ultrasonic
Method.

ASTM E 165 Standard Test Method for Liquid Penetrant Examination

ASTM E 709 Standard Guide for Magnetic Particle Examination

ASTM E 243 Standard Practice for Electromagnetic (Eddy Current) Testing of Seamless
Copper and Copper - Alloy Tubes

ASTM E 309 Standard Practice of Eddy - Current Examination of Steel Tubular Products
Using Magnetic Saturation

ASTM E 426 Standard Practice for Electromagnetic (Eddy-Current) Examination of Seamless

and Welded Tubular Products, Austenitic Stainless Steel and Similar Alloys.

ASTM E 543 Practice for Determining the Qualification of Non Destructive Testing Agencies.

3.2 Exceptions

This specification does not contain requirements or acceptance criteria for nondestructive examination, nor
directly reference qualifications in routine manufacturing operations.

4.0 RADIOGRAPHY

4.1 Scope

This section of the specification covers X-ray and gamma ray radiographic testing equipment as applied to
industrial situations with the use of radiographic film as a main recording medium.

4.2 Exceptions

Interpretation and acceptance standards are not covered by this specification, and no attempt has been made
to set standards of acceptance for any material or production process.

4.3 Equipment and Materials

4.3.1 Film

4.3.1.1 Selection

Radiographs shall be made using industrial radiographic film satisfying ASTM E 94. In any case, the films
selected must be capable of demonstrating the required image quality indications (IQI) sensitivity.

4.3.1.2 Processing

ASTM E 999 shall be used.

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4.3.2 Intensifying Screens

4.3.2.1 Metallic Foil Screens

Lead foil screens are commonly used in direct contact with the films, and depending upon their thickness,
and composition of the specimen material, will exhibit intensifying action at as low as 90keV.

For radiography using radioactive sources, the minimum thickness of the front lead screen shall be 0.005 in
(0.13mm) for Iridium-192 and 0.010 in (0.25mm) for Cobalt-60.

4.3.2.2 Other Metallic Screen Materials

a) Lead oxide screens perform in a similar manner to lead foil screens except that their equivalence
in lead foil thickness approximates 0.0005in (0.013 mm).

b) Copper screens have somewhat less absorption and intensification than lead screens, but may
provide somewhat better radiographic sensitivity with energies above 1 MeV.

c) Gold, tantalum, or other heavy metal screens may be used in cases where lead cannot be used.

4.3.3 Fluorescent Screens

In general, for a given source for radiation, fluorescent screens shall be used only when the exposure
necessary without them would be prohibitively long. Good screen-film contact is essential for the
successful use of fluorescent screens.

4.3.4 Penetrameters (Image Quality Indicators - IQI)

4.3.4.1 Penetrameters shall be either the hole type or the wire type and shall be manufactured and identified in
accordance with the requirements or alternates allowed in ASTM E 1025 code (for hole type) and ASTM E
747 (for wire type) and Appendices.

4.3.4.2 Material Groups

Materials shall be designated in eight groups based on their radiographic absorption characteristics:
(1) magnesium (Mg), (2) aluminium (Al), and (3) titanium (Ti) for light metals, and for other metals and
alloys as follows:-

4. all carbon steel, low alloy steels, Type 300 series SS, and manganese - nickel - aluminium
bronze (Superston)
5. aluminium bronze or nickel - aluminium - bronze
6. nickel - chromium - iron alloy (Inconel, UNS No. N0660)
7. nickel - copper alloys (Monel series alloys ) or 70/30 copper-nickel alloy (Cupronickel)
8. all other nickel-copper, or copper-nickel alloys, and all brasses (copper-zinc alloys, and leaded
brasses).

The materials listed are in order of increasing radiation absorption.

4.3.5 Shims and Separate Blocks

Shims or separate blocks made of the same or radiographically similar materials (as defined in ASTM E
142) may be used to facilitate penetrameter positioning. There is no restriction on shim or separate block
thickness provided the penetrameter and area of interest 15% density tolerance requirements are met.

4.3.6 Radiographic Location and Identification Markers

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Lead numbers and letters shall be used to designate the part number and location number. The size and
thickness of the markers shall depend on the ability of the radiographic technique to image the markers on
the radiographs. As a general rule, markers 1/16 in(1.58mm) thick will suffice for most low energy (less
than 1MeV) X-ray and Iridium - 192 radiography; for higher energy radiography it may be necessary to use
markers that are 1/8 in (3.7mm) or more thick.

4.3.7 X-ray Calibration

4.3.7.1 Verification of Focal Spot Size

The equipment manufacturer's or supplier's publications, such as technical manuals, decay curves, or
written statements documenting the actual or maximum or focal spot size, shall be acceptable as source size
verification.

4.3.7.2 Determination of Focal Spot

For X-ray machines operating at 320 keV and less, the focal spot size may be determined by ASTM E
1114.

4.3.8 Radiation Sources

4.3.8.1 X - Ray Radiation

The radiographic technique shall demonstrate that the required radiographic sensitivity has been obtained.
The suitability of X-ray (i.e voltage and current levels) shall be demonstrated by attainment of required
penetrameter (IQI) sensitivity and complies with ASTM E 94.

4.3.8.2 Gamma Radiation

Isotope sources, when used, shall be capable of demonstrating the required radiographic sensitivity . The
recommended minimum thickness for which radioactive isotopes may be used is shown in Table 1,
whereas the overall radiographic sensitivity is primarily influenced by factors such as film selection,
intensifying screen selection, geometric unsharpness and film density.

Table 1.

Recommended Minimum Thickness for which Radioactive Isotopes may be used

Material Minimum Thickness

Iridium 192 Cobalt 60

Steel 0.75" (19mm) 1.50" (38.1mm)

Copper or High Nickel 0.65" (16.5mm) 1.30" (33mm)
Aluminium 2.50" (63.5mm)

The maximum thickness for the use of radioactive isotopes is primarily dictated by exposure time,
therefore, upper limits are not defined. The minimum recommended thickness limitation may be reduced
when the radiographic techniques used demonstrate that the required radiographic sensitivity has been
obtained.

4.3.9 Energy Selection

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In general, satisfactory results can normally be obtained for X-ray energies between 100 keV to 500 keV in
a range between 2.5 to 10 half value layers (HVL) of material thickness (see Table 2). This range may be
extended by as much as a factor of 2 in some situations for X-ray energies in the 1-25 MeV range primarily
because of reduced scatter (refer Table 3).

Table 2
Typical Steel HVL Thickness in Inches (mm) For
Common Energies

Energy Thickness, in (mm)

120 keV 0.10 (2.5)
150 keV 0.14 (3.6)
200 keV 0.20 (5.1)
250 keV 0.25 (6.4)
400 kV (Ir 192) 0.35 (8.9)
1 MeV 0.57 (14.5)
2 MeV (Co 60) 0.80 (20.3)
4 MeV 1.00 (25.4)
6 MeV 1.15 (29.2)
10 MeV 1.25 (31.8)
16 MeV and higher 1.30 (33.0)
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Table 3.
Approximate Radiographic Equivalence Factors For Several Metals
(Relative to Steel)

Metal Energy Level

100 keV 150 keV 220 keV 250 keV 400 keV 1MeV 2MeV 4 to 25 192 Ir 60 Co
MeV

Magnesium 0.05 0.05 0.08

Aluminium 0.08 0.12 0.18 0.35 0.35
Aluminium alloys 0.10 0.14 0.18 0.35 0.35
Titanium 0.54 0.54 0.71 0.9 0.9 0.9 0.9 0.9
Iron/all steels 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Copper 1.5 1.6 1.4 1.4 1.4 1.1 1.1 1.2 1.1 1.1
Zinc 1.4 1.3 1.3 1.2 1.1 1.0
Brass 1.4 1.3 1.3 1.2 1.1 1.0 1.1 1.0
Inconel X 1.4 1.3 1.3 1.3 1.3 1.3 1.3 1.3
Monel 1.7 1.2
Zironium 2.4 2.3 2.0 1.7 1.5 1.0 1.0 1.0 1.2 1.0
Lead 14.0 14.0 12.0 5.0 2.5 2.7 4.0 2.3
Hafnium 14.0 12.0 9.0 3.0
Uranium 20.0 16.0 12.0 4.0 3.9 12.6 3.4

4.3.10 Filters

Filters are uniform layers of material placed between the radiation source and the film, to absorb
preferentially the scattered radiation from the specimen. Normally lead foil and other metallic screens fulfil
this function.

4.3.11 Back - Scatter Protection

Normally, either or both the back lead screen and the lead contained in the back of the cassette or film
holder will furnish adequate protection against back-scattered radiation.

4.3.12 Film Holders and Cassettes

Film holders and cassettes shall be light-tight and made of flexible and durable materials, these can be
either metallic or non-metallic materials such as rubber, vinyl or plastic. If the film holder exhibits light
leaks, it shall be repaired before reuse or discarded.

4.3.13 Facilities for Viewing of Radiographs

Viewing facilities shall provide subdued background lighting of an intensity that will not cause
troublesome reflections, shadows, or glare on the radiograph. Equipment used to view radiographs for
interpretation shall provide a variable light source, sufficient for the essential penetrameter hole or
designated wire to be visible for specified density range. The viewing conditions shall be such that light
from around the outer edge of the radiograph or coming through low-density portions of the radiograph
does not interfere with interpretation.

4.4 Safety Practices

Problems of personnel protection against X-rays and gamma rays are not covered by this specification. It is
the responsibility of the user of the equipment to establish appropriate safety and health practices and
determine the applicability of regulatory limitations prior to use.
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4.5 Personnel Qualifications

Unless otherwise specified by a Owner and supplier agreement, all radiographic examination personnel
shall be qualified and certified in accordance with a non destructive testing agency as described in ASTM E
543.

5.0 ULTRASONIC EQUIPMENT

5.1 Scope

This section of specification covers ultrasonic examination equipment of materials by the pulso-echo
method using straight-beam longitudinal waves introduced by direct contact of the search unit with the
material being examined.

5.2 Introduction to Equipment and Operations

5.2.1 A series of electrical pulses is applied to a piezoelectric element (transducer) which converts these pulses to
mechanical energy in the form of pulsed waves at a nominal frequency. This transducer is mounted in a
holder so it can transmit the waves into the material through a suitable wear surface and couplant. The
assembly of transducer, holder, wear surface, and electrical connector comprise the search unit.

5.2.2 When pulsed energy is transmitted into materials, it travels in a direction normal to the contacted surface, and
is reflected back to the search unit by discontinuity or boundary interfaces which are parallel or near parallel to
the contacted surface. These echoes return to the search unit, where they are converted from mechanical to
electrical energy and are amplified by a receiver. The amplified echoes (signals) are usually presented in A-
scan display on a cathode ray tube (CRT), such that the entire round trip of pulsed energy within the resolution
of the system may be indicated along the horizontal base line of a CRT by vertical deflections corresponding
to echo amplitudes from each interface, including those of any intervening discontinuities.

5.3 Apparatus

Complete ultrasonic apparatus shall include the following:

5.3.1 Instrumentation

The ultrasonic instrument shall be capable of generating, receiving, and amplifying high-frequency
electrical pulses at such frequencies and energy levels required to perform a meaningful examination and to
provide a suitable readout.

5.3.2 Search Units

The ultrasonic search units shall be capable of transmitting and receiving ultrasound in the material at the
required frequencies and energy levels necessary for discontinuity detection. Typical search unit sizes
usually range from 1/8 in (3.2mm) in diameter to 11/8 in (28.6mm) in diameter with both smaller and
larger sizes available for specific applications. Search units may be fitted with special shoes for
appropriate applications. Special search units encompassing both a transmitter and a receiver as separate
piezoelectric elements are utilised to provide some degree of improved resolution near the examination
surface.

5.3.3 Couplant

A couplant, usually a liquid or semi-liquid, is required between the face of the search unit and the
examination surface to permit the transmittance of ultrasound from the search unit into the material under
test. Typical couplants include water, cellulose gel, oil, and grease. Corrosion inhibitors or wetting agents
or both may be used. Couplants must be selected which are not detrimental to the product or the process.
The couplant used in calibration shall be used for the examination.
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5.3.3.1 The couplant shall be selected so that its viscosity is appropriate for the surface finish of the material to be
examined. The examination of rough surface generally requires a high viscosity couplant.

Table 4 shows a range of oils of varying viscosity, for on use surfaces of different roughness.

Table 4
Suggested Viscosities - Oil Couplants

NOTE: The table is a guide only and is not meant to exclude the use of a particular couplant
that is found to work satisfactorily on a particular surface.

Approximate Surface Roughness Equivalent Couplant Viscosity,

Average (Ra) µin (µm) Weight Motor Oil

5-100 (0.1-2.5) SAE 10

50-200 (1.3-5.1) SAE 20
100-400(2.5-10.2) SAE 30
250-700(6.4-17.8) SAE 40
Over 700 (Over 18) cup grease

5.3.3.2 At elevated temperatures, heat resistant coupling materials such as silicone oils, gels, or greases shall be
used. Furthermore at elevated temperatures intermittent contact of the search unit with an auxiliary cooling
surface may be necessary to avoid temperature changes that affect the ultrasonic wave characteristics of the
search unit. At high temperatures certain couplants based on inorganic salts or thermoplastic organic
materials, high temperature resistant materials, and search units that are not damaged by high temperatures
may be required.

5.3.3.3 Where constant couplings over large areas are needed, as in automated examination, or where severe
changes in surface roughness are found, other couplants such as liquid gap coupling will usually provide a
better examination. In this case, the search unit does not contact the examination surface but is separated
by a distance of about 0.2 in (0.5mm) filled with couplant. Liquid flowing through the search unit fills the
gap. The flowing liquid provides the coupling path and has the additional advantage of cooling the search
unit if the examination surface is hot.

5.3.3.4 An alternative means of direct contact coupling is provided by the wheel search unit. The search unit is
mounted at the required angle to a stationary axle about which rotates a liquid filled flexible tyre. A
minimum amount of couplant provides ultrasonic transmission into the examination surface since the
elastic tyre material is in rolling contact and conforms closely to the surface.

5.3.4 Reference Standards - The item under examination may itself provide an adequate standard, using the
height of the back wall echo for reference. For more quantitative information, machined artificial reflectors
(discontinuities) or charts representing distance-amplitude relationships, of known reflector sizes, for a
particular search unit and material, may be used for calibration. These artificial reflectors may be in the
form of flat-bottom holes, side-drilled holes, or slots. The surface finish of the reference standard shall be
similar to the surface finish of the item under examination. The reference standard material and the
production material shall be acoustically similar (in velocity and attenuation). The reference standard
selected shall be used by the examiner as the basis for signal comparisons.

For bond/unbond (fusion/lack of fusion) examinations, a reference standard shall be used similar to the
production item being examined containing areas representing both bonded (fused) and unbonded (lack of
fusion) conditions if geometry and material permit.

5.4 Calibration of Equipment

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Calibration with respect to reference standards shall be periodically checked to ensure that the ultrasonic
system calibration is not changing. As a minimum, the calibration shall be checked each time there is a
change of operators, when search units are changed, when new batteries are installed, when equipment
operating from one power source is changed to another power source, or when improper operation is
suspected.

5.5 Examination Data Record

5.5.1 The following data shall be recorded as a minimum for future reference at the time of each examination:

a) Part number identification,

b) Operator's name and level (if certified),
c) Instrument description, make, model and serial number,
d) Setup - Couplant, cable type and length, manual/automatic scanning,
e) Search unit description - Type, size, frequency, special shoes,
f) Reference standards (and calibration data required to duplicate the examination),
g) Indication of information as specified by the applicable specification, or results of the
examination (number, classification, and location of discontinuities). For bond/unbond
(fusion/lack of fusion) examinations the extent of unbond (lack of fusion) or bond (fusion) shall
be reported

5.6 Report

When required by the Owner, a report shall be prepared and shall include all the Examination Data Records
and the date of the tests.

5.7 Personnel Requirements

Qualification and certifying documentation from appropriate agencies, for all operators performing
ultrasonic examination, shall be made available to the Owner upon request.

5.8 Safety

This standard does not purport to address the safety problems associated with the use of hazardous
materials and equipment. It is the responsibility of the user to consult and establish appropriate safety and
health practices from relevant equipment manufacturers.

6.0 LIQUID PENETRANT EQUIPMENT

6.1 Scope

Liquid penetrant nondestructive testing materials are utilised for detecting discontinuities that are open to
the surface such as cracks, seams, laps, cold shuts, laminations, through leaks, or lack of fusion. They can
be effectively used in the examination of nonporous, metallic materials, both ferrous and non-ferrous, and a
variety of non metallic materials.

Penetrant materials shall meet the requirements of ASME V, Article 6 for sulphur and halogen content
regardless of the type of material to be examined.

6.2 Types of Materials

6.2.1 General

A family of liquid penetrant examination materials would typically consist of the penetrant (fluorescent or
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visible types) with or without separate emulsifiers, solvent removers and developers. The materials shall be
applied strictly in accordance with the Manufacturer’s recommendations and intermixing of materials from
various manufacturers in not permitted. The procedure generally involves cleaning the part and then the
application of a penetrant over the surface to be inspected. After sufficient time has elapsed the penetrant is
removed by wiping or washing with an appropriate solvent, with or with the help of an emulsifier, and
finally the developer applied. After sufficient time has elapsed for the developer to draw out the penetrant
from any defects, the object is viewed under a suitable light source, which in the case of fluorescent
penetrant requires an ultraviolet light. The development stage is sometimes omitted when a flourescent
penetrant is used.

6.2.2 Penetrants

Penetrants are generally one of three basic types;

6.2.2.1 Post-Emulsifiable Penetrants cannot be removed by water rinsing alone and require the application of an
emulsifier to make them soluble in water. The proper emulsification time must be experimentally
established and maintained to ensure that over-emulsification does not occur, resulting in loss of penetrant
within flaws.

6.2.2.2 Water-Washable Penetrants are designed to be directly water-washable from the surface of the test part,
after a suitable penetrant dwell time. Because the emulsifier is `built-in' to the water-washable penetrant, it
is extremely important to exercise proper process control in removal of excess surface penetrant to ensure
against overwashing. Water-washable penetrants can be washed out of discontinuities if the rinsing step is
too long or too vigorous. Some penetrants are less resistant to overwashing than others.

6.2.2.3 Solvent-Removable Penetrants are designed so that the majority of the excess penetrant can be removed,
simply by wiping, with the help of a little additional solvent if required. To minimise removal of penetrant
from defects, care shall be taken to avoid the use of excess solvent. Flushing the surface with solvent to
remove the excess penetrant is prohibited.

6.2.3 Emulsifiers

6.2.3.1 Lipophilic Emulsifiers are oil-miscible liquids used to emulsify the excess oily penetrant on the surface of
the part, rendering it water-washable. The rate of diffusion establishes the emulsification time. They are
either slow-or fast-acting, depending on their viscosity and chemical composition, and also the surface
roughness of the area being examined.

6.2.3.2 Hydrophilic Emulsifiers are water-miscible liquids used to emulsify the excess oily fluorescent penetrant
on the surface of the part, rendering it water-washable. These water-base emulsifiers (detergent-type
removers) are supplied as concentrates to be diluted with water and used as a dip or spray. The
concentration, use and maintenance shall be in accordance with manufacturer's recommendations.

6.2.4 Solvent Removers

These function by dissolving the excess penetrant, making it possible to wipe the surface clean.

6.2.5 Developers.

Developers operate by drawing the penetrant out of surface defects, through a blotting action, thus
increasing the visibility of the indications.

6.2.5.1 Dry Powder Developers are used as supplied, that is free-flowing, non-caking powder. Care shall be taken
not to contaminate the developer with fluorescent penetrant, as the penetrant specks can appear as
indications.

6.2.5.2 Aqueous Developers consist of dry powder particles either suspended or dissolved in water. The
concentration, use and maintenance shall be in accordance with manufacturer's recommendations.
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6.2.5.3 Nonaqueous Wet Developers are supplied as suspensions of developer particles in a nonaqueous solvent
carrier ready for use as supplied. Nonaqueous, wet developers form a coating on the surface of the part
when dried, which serves as the developing medium.

6.2.5.4 Liquid Film Developers are solutions or colloidal suspensions of resins/polymer in a suitable carrier. These
developers will form a transparent or translucent coating on the surface of the part. Certain types of film
developer may be stripped from the part and retained for record purposes.

6.3 Safety

Liquid penetrant examination materials may be flammable or emit hazardous and toxic vapours. All
manufacturer's instructions and precautionary notices shall be strictly adhered to.

7.0 MAGNETIC PARTICLE EQUIPMENT AND MATERIALS

7.1 Scope

There are various types of magnetic particles available for use in magnetic particle examination. They are
available as dry powders (fluorescent and nonfluorescent) ready for use as supplied, powder concentrates
(fluorescent and nonfluorescent) for dispersion in water or suspending light petroleum distillates, magnetic
slurries/paints, and magnetic polymer dispersions.

When the material to be examined has been properly magnetised, the accumulations of magnetic particles
at the points of flux leakage are indicators of surface or near-surface discontinuities.

7.2 Equipment

With the exception of a permanent magnet, all equipment will require a power source capable of delivering
the required current levels to produce the magnetic field. The current used dictates the sizes of cables and
the capability of relays, switching contacts, meters and rectifier if the power source is alternating current.

7.2.1 Yokes

Yokes are usually C-shaped electromagnets which induce a magnetic field between the poles (legs) and are
used for local magnetisation. Many portable yokes have articulated legs (poles) that allow the legs to be
adjusted to contact irregular surfaces or two surfaces that join at an angle.

Permanent magnets are also available, but their use is restricted by limitations imposed on their magnetic
field generating capacity.

7.2.2 Prods

Prods are used for local magnetisation by direct contact with the specimen under examination, contact tips
are generally made of aluminium, copper braid, or copper pads.

A remote-control switch, built into the prod handles, shall be provided to permit the current to be turned on
after the prods have been properly placed and to turn it off before the prods are removed in order to
minimise arcing (arc burns).

7.2.3 Black Light Generating Equipment

The black light generating equipment must be capable of developing the required wavelengths of 330 to
390nm with an intensity at the examination surface not less than 1000 MW/cm² when measured with a
suitable black light meter. Suitable filters shall be employed to remove the extraneous visible light emitted
by black light.
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7.3 Magnetic Particle Materials

7.3.1 Particle Types

The particles used in either dry or wet magnetic particle examination techniques are basically finely divided
ferromagnetic materials which have been treated to impart colour (fluorescent and nonfluorescent) in order
to make them highly visible (contrasting) against the background of the surface being examined. The
particles are designed for use either as a free flowing dry powder or for suspension at a given concentration
in a suitable liquid medium.

7.3.2 Particle Characteristics

The magnetic particles must have high permeability to allow ease of magnetising and attraction to the
discontinuity and low retentivity so they will not be attracted (magnetic agglomeration) to each other.
Control of particle size and shape is required to obtain consistent results. The particles shall be nontoxic,
free from rust, grease, paint, dirt and other deleterious materials that might interfere with their use; Both
dry and wet particles are considered safe when used in accordance with the manufacturer's instructions.
They generally afford a very low hazard potential with regard to flammability and toxicity.

7.3.3 Dry Particles

Dry magnetic powders are designed to be used by spraying or dusting directly onto the surface of the part
being examined. They are generally used on an expendable basis although the particles may be collected
and reused. This practice shall be avoided however, as it is difficult to maintain particle size and control
contamination. Dry powders may also be used under extreme environmental conditions. They are not
affected by cold; therefore examination can be carried out at temperatures that would thicken or freeze wet
baths. They are also heat resistant; some powders may be usable at temperatures up to 600°F (315°C).
Some coloured, organic coatings applied to dry particles to improve contrast lose their colour at
temperatures this high, making the contrast less effective. Fluorescent dry particles cannot be used at this
high a temperature; the manufacturer shall be contacted for the temperature limitation or tests shall be run.

7.3.4 Wet Particle Systems

Wet magnetic particles are designed to be suspended in a vehicle such as water or light petroleum distillate
at a given concentration for application to the test surface by flowing, spraying, or pouring. They are
available in both fluorescent and non fluorescent concentrates. In some cases the particles are premixed
with the suspending vehicle by the supplier, but usually the particles are supplied as a dry concentrate or
paste concentrate which is mixed with the distillate or water by the user. The suspensions are normally
used in wet horizontal magnetic particle equipment in which the suspension is retained in a reservoir and
recirculated for continuous use. The suspension may also be used on an expendable basis dispensed from
an aerosol.

7.4 Maintenance and Calibration of Equipment

7.4.1 The magnetic particle equipment employed shall be maintained in proper working order at all times. The
frequency of verification calibration, usually every six months, see Table 5, or whenever a malfunction is
suspected, shall be specified in the written procedures of the testing facility. Records of the checks and
results provide useful information for quality control purposes and shall be maintained. In addition, any or
all of the tests described shall be performed whenever a malfunction of the system is suspected.
Calibration tests shall be conducted in accordance with the specifications or documents that are applicable.

Table 5
Recommended Verification Intervals

Item Maximum Time Between

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Verifications
Lighting:
1 week
Visible light intensity 1 week
Black light intensity 1 week
Background visible light intensity 1 day

Wet particle concentration 8h or every shift change

Wet particle contamination 1 week

Water break test 1 day
Equipment calibration/check:
Ammeter accuracy 6 months
Timer control 6 months
Quick break 6 months
Dead weight check 6 months
Light meter checks 6 months

NOTE - The maximum time between verifications may be extended when substantiated by
actual technical stability/reliability data.

7.4.2 Equipment Checks

The following tests are recommended for ensuring the accuracy of magnetic particle magnetising
equipment.

7.4.2.1 Ammeter Accuracy

The equipment meter reading shall be compared to those of a control test meter incorporating a shunt or
current transformer, connected to monitor the output current. The accuracy of the entire control test meter
arrangement shall be verified at six-month intervals or as agreed upon between the Owner and Supplier.

Comparative readings shall be taken at a minimum of three output levels encompassing the usable range.
The equipment meter reading shall not deviate by more than ± 10% of full scale relative to the actual
current values as shown by the test meter. Caution: When measuring half-wave rectified AC, the direct
current reading of a conventional DC test meter reading must be doubled.

7.4.2.2 Timer Control Check

On equipment utilising a timer to control the duration of the current flow, the timer shall be checked for
accuracy as specified in Table 7 or whenever a malfunction is suspected.

7.4.2.3 Magnetic Field Quick Break Check

On equipment that has a quick break feature, the functioning of this circuit shall be checked and verified.
This test may be performed using a suitable oscilloscope or a simple test device usually available from the
manufacturer. On electronic power packs or machines, failure to achieve indication of a "quick break"
would indicate that a malfunction exists in the energising circuit.

7.4.2.4 Equipment Current Output Check

To ensure the continued accuracy of the equipment, ammeter readings at each transformer tap shall be
made with a calibrated ammeter-shunt combination. This accessory is placed in series with the contacts.
The equipment shunt shall not be used to check the machine of which it is a part. For infinite current
control units (non-tap switch), settings at 500-A intervals shall be used. Variations exceeding ±10% from
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the equipment ammeter readings shall indicate that the equipment needs service or repair.

7.4.2.5 Internal Short Circuit Check

Magnetic particle equipment shall be checked periodically for internal short circuiting. With the equipment
set for maximum amperage output, any deflection of the ammeter when the current is activated with no
conductor between the contacts is an indication of an internal short circuit.

7.4.2.6 Electromagnetic Yoke Lifting Force Test

The magnetising force of a yoke (or a permanent magnet) shall be tested by determining its lifting power
on a steel plate. See Table 6. The lifting force relates to the electromagnetic strength of the yoke.

Table 6
Minimum Yoke Lifting Force

Yoke Pole Leg Spacing

Type Current 50 to 100 mm 100 to 150mm

(2 to 4 in) (4 to 6 in)

AC 45 N(10lb) 225 N (50lb)

DC 135N (30lb)

7.4.2.7 Powder Blower

The performance of powder blowers used to apply the dry magnetic particles shall be checked at routine
intervals or whenever a malfunction is suspected. The check shall be made on a representative test part.
The blower shall coat the area under test with a light, uniform dust-like coating of dry magnetic particles
and have sufficient force to remove the excess particles without disturbing those particles that are evidence
of indications. Necessary adjustments to the blower's flow rate or air velocity shall be made in accordance
with the manufacture's recommendations.

7.5 Safety

7.5.1 Those involved with hands-on magnetic particle examination exposure to hazards include:

7.5.1.1 Electric Shock and Burns

Electric short circuits can cause shock and particularly burns from the high amperages at relatively low
voltages that are used. Equipment handling water suspensions shall have good electrical grounds.

7.5.1.2 Flying Particles

Magnetic particles can enter the eyes and ears when applying them to a vertical or overhead surface or
when cleaning an examined surface with compressed air. Dry particles are easy to inhale and the use of a
dust respirator is recommended.

7.5.1.3 Ultraviolet Light Exposure

Ultraviolet light in excess of 1000 µW/cm² can adversely affect the eyes and skin. Safety goggles designed
to absorb UV wavelength radiation are suggested where high intensity black light is used.

7.5.1.4 Materials and Concentrates

The safe handling of magnetic particles and concentrates shall be governed by the suppler's Material Safety
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Data Sheets (MSDS).

8.0 ELECTROMAGNETIC (EDDY CURRENT) EQUIPMENT

8.1 Scope

The electromagnetic (eddy current) shall include a detector, phase discriminator, filter circuits, and
signalling devices as required for the particular application.

8.2 Apparatus

8.2.1 The electronic apparatus shall be capable of energising the test coil (see below) with alternating currents of
suitable frequencies (for example, 1kHz to 125 kHz), and shall be capable of sensing the changes in the
electromagnetic response of the coils. Electrical signals produced in this manner are processed so as to
actuate an audio or visual signalling device or mechanical marker which produces a record.

8.2.2 The apparatus shall be calibrated with an appropriate reference standard to ensure that the equipment is
operating at the proper level of sensitivity, with the following considerations:

a) Primary reference standards employed for this purpose shall be prepared and used in accordance
with the methods described in Appendix A1, ASME PV Section 5.

b) Equivalent secondary reference standards, prepared and used in accordance with methods
described in Appendix A2, ASME PV Section 5, also may be employed for standardising

c) Reference standards shall be of the same alloy, temper, and dimensions as the tube material to
be tested.

8.2.3 Test Coils

Test coils shall be capable of inducing current in the tube and sensing changes in the electrical
characteristics of the tube.

8.2.4 Driving Mechanism

A mechanical means of passing the tube through the test coil with minimum vibration of the test coil or the
tube shall be employed. The device shall maintain the tube substantially concentric with the electrical
centre of the test coil. A uniform speed (±5.0% speed variation maximum) shall be maintained.

8.2.5 End Effect Suppression Device

A means capable of suppressing the signals produced at the ends of the tube material shall be employed.
Individual suppler's shall specify when an end effect suppression device is mandatory.

8.3 Testing

8.3.1 Testing of the apparatus using the appropriate reference standards shall be conducted at least every four (4)
hour during continuous operation, or whenever improper functioning of the testing apparatus is suspected.
If improper functioning occurs, the apparatus shall be restandardised in accordance with paragraph 8.2.2.

8.3.2 Testing shall not be conducted unless the equipment can be set to the levels required.

8.3.3 For practical applications, reference standards also may be employed to establish quality control levels.

8.3.4 The equipment manufacturer shall select test parameters consistent for the product, unless otherwise agreed
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upon between manufacturer and Owner.

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