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MAGNETIC PARTICLE EXAMINATION PROCEDURE FOR WELDS IN

API 1104 carbon steel pipelinesPROC. NO.:IMSN/MT/11

REV. NO.:0

DATE:June 1, 2010

PAGE:Page 11 of 11

1. SCOPE

1.1 This procedure covers the performance of Magnetic Particle Examination and evaluation against applicable acceptance standards for ferromagnetic welds (including their heat-affected zone) using combination of Yoke magnetization technique with non-fluorescent wet particles.

1.2 This procedure is not intended to replace visual examination but will act as supplementary NDE method for finding open to the surface discontinuities.1.3 This procedure is applicable in the performance of magnetic particle examination by PT. Inti Mutu Sejahtera Nusantara (IMSN).

1.4 Weld configurations to be examined, including thickness dimensions and base material product form shall follow Customers Drawing Requirements or NDE Map.1.5 This procedure only applicable for pipelines with outside diameter above 4 inch.2. CODES AND REFERENCES

2.1 API 1104 Welding of Pipelines and Related Facilities - 20th Edition, November 2005.

2.2 ASME Pressure Piping Code B31.8 Gas Transmission and Distribution Piping Systems, 2007 Edition.

2.3 ASME Pressure Piping Code B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids, 2006 Edition.2.4 ASTM E-709 Standard Guide for Magnetic Particle Testing, 2008 Edition.2.5 IMSNs NDE Personnel Qualification and Certification Procedure Doc. No.: IMSN/WP/01 Revision 0.3. PERSONNEL QUALIFICATION

Magnetic particle examination shall be performed by qualified and certified personnel in accordance with IMSNs NDE Personnel Qualification and Certification Procedure Doc. No.: IMSN/WP/01 Revision 0 which is in compliance with SNT-TC-1A 2006 Edition.4. EQUIPMENT AND MATERIALS4.1 Magnetizing Equipment

Equipment used under this procedure shall be Alternating Current (AC) Yokes or Direct Current (DC) Yokes or Permanent Yokes type. The equipment shall satisfactorily meet the requirement defined in Par. 6.2 of this procedure.Table 1 Magnetic Particle Examination MediumManufacturerWhite Contrasting PaintPrepared Black Ink BathTemp. Range

MAGNAFLUXWCP-27HF5C 52C

CHEMETALL-ELYWCP-722SUPRAMOR 45C 52C

CIRCLE SYSTEMMI-GLOW WCPCIRCLESAFE 820AX5C 52C

4.1 Examination MediumTable 1 shall be used in the performance of Magnetic Particle Examination under this procedure. At all times, valid materials certificates shall be available to any concerning parties for verification between the batch number stated in the certificate against the one printed on the aerosol cans.

5. SURFACE PREPARATION5.1 Examination shall be conducted on uncoated (free from non-magnetic coatings) surfaces.5.2 Surface preparation by grinding or machining may be necessary where surface irregularities could mask discontinuities indications by non-relevant indications.5.3 Cleaning shall be accomplished using either detergents, organic solvents, de-scaling solutions, paint removers (for painted surface) or sand blasting.5.4 Prior to magnetic particle examination, the surface to be examined and all adjacent areas within at least 1 inch (25 mm) shall be dry and free from dirt, grease, lint, scale, welding flux and spatter, oil, or any non-magnetic coating.5.5 Temperature on surface of the part to be examined shall be controlled within those specified in Table 1.6. CALIBRATION6.1 Calibration of Lifting Weight Standard

Each lifting weight standard shall be weighed with a scale from a reputable manufacturer or independent laboratory and stenciled with the applicable nominal weight. A certificate of the lifting standard stating its nominal weight shall be maintained on file. A weight standard need only be calibrated again if damaged in a manner that could have caused potential loss of material.

6.2 Calibration of Electromagnetic Yokes

6.2.1 Each AC yoke shall be able to lift a standard weight of at least 10 lb (4.5 kg) at minimum 6 inch pole spacing that will be used for minimum of 3 seconds. This calibration shall be verified every year or whenever the electromagnetic yoke is suspected to have been damaged or after being repaired. At the minimum, the last calibration report (see Exhibit B) from that one that is presently applicable shall be maintained on file.

6.2.2 Each DC yoke shall be able to lift a standard weight of at least 40 lb (18 kg) at minimum 6 inch pole spacing that will be used for minimum of 3 seconds. This calibration shall be verified every year or whenever the electromagnetic yoke is suspected to have been damaged or after being repaired. At the minimum, the last calibration report (see Exhibit B) from that one that is presently applicable shall be maintained on file.

6.2.3 Each permanent yoke shall be able to lift a standard weight of at least 40 lb (18 kg) at the maximum pole spacing that will be used. This calibration shall be verified daily prior to use. This check doesnt have to be maintained on file.

6.3 Calibration of Visible Light Meter

Visible light meter shall be calibrated at least once a year or whenever the meter has gone through major repair. If meters have not been in used for one year or more, calibration shall be done before being used. At the minimum, the last calibration report from the one that is presently applicable shall be maintained on file.

7. EXAMINATION PROCEDURE7.1 Viewing Conditions

A minimum light intensity of 100 fc (1000 lx) is required on the surface to be examined to ensure adequate sensitivity during the examination and evaluation of indications.

7.2 Surface Contrast Enhancement

Surface contrast enhancer shall be applied temporarily to uncoated surfaces only in the amounts sufficient to enhance viewing contrast. The material used as contrast enhancer shall be of the white paint type and shall follow those specified in Table 1 for each particle manufacturer. After surface preparation in accordance with Par. 5, shake the contrasting paint to ensure uniform distribution of particles. Apply a uniform thin film of the contrasting paint to the test surface. Wait at least 30 seconds to allow the contrasting paint film to dry. Apply magnetic particles to the examination surface.7.3 Method of Examination

Examination shall be done by the continuous method; that is, wet magnetic particles applied from the aerosol spray cans may be applied before and/or after magnetizing current is applied. Accumulation of excess particles during examination shall be removed by blowing or other source of low pressure dry air. The examination current or power shall be maintained for at least 3 seconds while removing the excess particles. Observe any indications formed.

Figure 1 Yoke Placement and Orientation for Detection of Flaws [in mm]7.4 Direction of Magnetization

At least two separate examinations shall be performed on each area. During the second examination, the line of magnetic flux shall be approximately perpendicular to those used during the first examination. Figure 1 shows example of typical yoke placement, poles configuration and orientation for detection of flaws.

7.5 Magnetizing Field Adequacy and Direction

All examinations shall be conducted with sufficient overlap to assure 100% coverage at the required sensitivity. Yokes overlap shall not exceed that detailed in Figure 1. Verification of magnetic field adequacy due to reduction of contact surface between the yoke leg and the part, a magnetic flux strip indicator (Burmah Castrol Type 1 containing three artificial defects) shall be used. Attach one flux indicator on the part surface under examination so that its length is at right angles to the direction of the applied flux. Magnetize the work piece by the use of the same pole spacing and contact area as the ones to be used for the examination. The magnetization time shall not be less than 3 seconds. While the work piece is being magnetized apply the magnetic particles. It is essential that the application of magnetic particles stops before the end of magnetization. The direction and field adequacy of the induced magnetic field is seen readily from the response of the flux indicators. The exact direction can be checked by re-orientating the indicators with respect to the direction of the field. The direction and field adequacy are considered sufficient when 3 (three) lines on the strip are clearly defined.

7.6 Evaluation of Indication(s)

Discontinuities are indicated by retention of the examination medium. However, localized surface irregularities due to machining marks, magnetic permeability variations such as at the edge of heat affected zones or other surface condition may produce non-relevant indications. Broad areas of particle accumulation, which might mask indications from discontinuities, are prohibited, and such areas shall be cleaned and reexamined.

8. ACCEPTANCE STANDARDS

An indication of an imperfection may be larger than the imperfection that causes it; however the size of the indication is the basis for acceptance evaluation.

Acceptance Standards for weld parts and their base metal fabricated according to API 1104 shall be as described below. Any indication with a maximum dimension of 1.5 mm or less shall be classified as non-relevant. Any larger indication believed to be non-relevant shall be regarded as relevant until re-examined by magnetic particle other nondestructive examination method to determine whether or not an actual imperfection exist. The surface may be re-conditioned before examination. After an indication is determined to be non-relevant, other non-relevant indications of the same type need not be re-examined.Relevant indications are those caused by imperfections. Linear indications are those in which the length is more than three times the width. Rounded indications are those in which the length is three times the width or less.Relevant indications shall be considered as defects should any of the following conditions exist:

a. Linear indications which are evaluated as crater cracks or star cracks and exceed 4 mm in length.

b. Linear indications which are evaluated as cracks other than crater cracks or star cracks.

c. Linear indications which are evaluated as IF and exceed 25 mm in total length in a continuous 300 mm length of weld or 8% of the weld length.

d. Rounded indications shall be evaluated according to the criteria of Paragraph 9.3.9.2 and 9.3.9.3 of API 1104 (see Exhibit C) as applicable. For evaluation purposes, the maximum dimension of a rounded indication shall be considered its size.9. EXAMINATION OF AREAS FROM WHICH IMPERFECTION HAVE BEEN REMOVED

Upon request, the area in which the defect has been removed (prior to making weld repairs) shall be re-examined in accordance with this procedure to ensure that the defect has been removed or reduced to acceptable size of imperfection.

10. RE-EXAMINATION OF REPAIRED AREA

After the weld is completed and the surface has been smoothly finished, the re-examination of repaired area shall be performed in accordance with this procedure.

11. DEMAGNETIZATION

Unless specified in the contracting documents, demagnetization is not necessary to be done. If the part is to be heat treated after examination, it is also not necessary to conduct demagnetization of the part previously examined.

12. POST EXAMINATION CLEANING

Unless directed otherwise by contracting documents, all parts and objects that have been examined by magnetic particle method are not necessary to be cleaned. When required by contracting document, post examination cleaning should be conducted as soon as practical using a process that doesnt adversely affect the part. Typical post examination cleaning employed are: Drying of wet particles and subsequent removal by brushing or with compressed air.

Removal of wet particles by flushing it with acetone.

13. EXAMINATION REPORT

All relevant and rejectable indications shall be recorded. As a minimum, the type of indications as defined in this procedure, location and extent (length or diameter or aligned) shall be recorded on Magnetic Particle Examination Report form as shown in Exhibit A of this procedure. The record shall be stored for a period as specified in the contracting documents.

14. SAFETY PRECAUTIONS

14.1 Care shall be exercised during examination for magnetic particle materials which are relatively toxic and highly flammable.14.2 Manufacturers directions shall be followed at all times.14.3 Smoking is prohibited while performing magnetic particle examination.14.4 Electrical hazards like opened electrical wire from lighting source or magnetizing equipment and the presence of short circuiting medium shall be treated with care.14.5 Material Safety Data Sheet (MSDS) for each magnetic particle materials shall be consulted in determining the proper method for the disposal of used pressurized spray cans and liquid residue waste.Exhibit A MAGNETIC PARTICLE EXAMINATION REPORT FORM

Exhibit B ELECTROMAGNETIC YOKE CALIBRATION REPORT FORMPERIODIC CALIBRATION OF ELECTROMAGNETIC YOKES

Yoke's make and model:

Yoke's serial no.:

Referenced weight standard ID:

YOKE'S LIFTING POWER TEST RESULT

POWER SOURCEREFERENCED WEIGHTPOLE SPACINGLIFTING TIMERESULT

This is to confirm that the instrument above meets the requirement of PT. Inti Mutu Sejahtera Nusantara Document No.: IMSN/MT/11 Rev. 0

Calibrated by :

Date of Calibration:

Next recommended calibration:

Exhibit C Excerpt from API 1104 Par. 9.3.9.2 and Par. 9.3.9.3