MPI Bench Manual for Magnetic Particle Inspection

FERROCHEM NDT SYSTEMS PVT. LTD. Plot No. C-98, Additional Jejuri Industrial Area, M.I.D.C.
, Village : Jejuri, Taluka : Purandar, Dist. :- Pune 412 303, Tel. No. 0091 9272230385, 9272230386 E.Mail : ferro@pn2.vsnl.net.in; ferrochem@yahoo.in Web : www.ferrochemndtsystems.com
USERS MANUAL
MPI BENCH
Name of the Buyer : M/s. Usai Forge (P) Ltd., Hyderabad.
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FERROCHEM NDT SYSTEMS PVT. LTD. Plot No. C-98, Additional Jejuri Industrial Area, M.I.D.C., Village : Jejuri, Taluka : Purandar, Dist. :- Pune 412 303, Tel. No. 0091 9272230385, 9272230386 E.Mail : ferro@pn2.vsnl.net.in; ferrochem@yahoo.in Web : www.ferrochemndtsystems.com
CONTENTS
Sr. No. 1 2 3 4 5 6 7
Contents Preface Introduction about MPI Description of MPI Bench Installation of the MPI Bench Trouble Shooting Circuit Diagram Warranty Certificate
Page No. 1 2 4 8 9 10 11
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Congratulations for purchasing MPI Bench from FerroChem NDT Systems Pvt. Ltd. Pune, India FerroChem has designed the Equipment especially for your application keeping in mind the most desirable features to achieve the best performance for years together without any failure. We are sure you will appreciate the quality and performance. The Manual systematically presents all the features, operations, maintenance, electrical circuit and components, etc. for a smooth operation. Please carefully follow the instructions given in this manual for achieving trouble free operation. Thank You, For FerroChem NDT Systems Pvt. Ltd.
A. L. Datar (Director)
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INTRODUCTION TO MPI Magnetic Particle Inspection [MPI]: The Magnetic Particle Inspection method of Non-Destructive Testing is one of the five major methods for locating surface and subsurface discontinuities in ferromagnetic materials. The basic technique:Magnetic Particle Inspection involves magnetizing an object to a flux density that causes magnetic flux leakage from discontinuities. Powdered ferromagnetic materials are then sprinkled over the surface through the leakage field. Magnetic materials are held over discontinuities and form an outline of the discontinuity indicating its location, size, shape and the extent. Uses:The common defects such as cracks, laps, seams, inclusions, etc. are detected by MPI Material like bars, billets rods, forgings, castings, finished and semi-finished materials, welds, and in-service parts are tested for defect detection by Magnetic particle Inspection. MPI cannot be applied to Non-magnetic materials metals and alloys such as Copper, Brass, Aluminum, and austenitic stainless steels. Application:Five essential steps of applying MPI method are: 1. Surface Preparation The surface should be smooth and clean. It should be free from dirt, rust, oil or grease and any non-conducting coating.. Surface Preparation can be done with wire brush or by shot blasting or by other means.
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2. Magnetization Both Circular and Longitudinal magnetization methods are used for testing. Circular Magnetization involves passing Current [AC or HWDC] through the component for detection of defects in longitudinal direction. Longitudinal Magnetization involves holding the component in Magnetizing Coil for detection of defects in transverse direction. Combined Magnetization involves magnetizing both circular and longitudinal way to detect cracks in both longitudinal and transverse direction simultaneously. 3. Application of Magnetic Particles Bath i.e. Magnetic Particles suspended in Test Oil, is applied by spraying on to the surface. A circulation tank and spraying arrangement is provided on the equipment. 4. Inspection Inspection of the surface for locating accumulation of particles follows immediately. When using Fluorescent Particles provision of a Dark Room and UV/Black light source becomes essential. Cracks appear as brilliant yellowgreen lines when viewed under UV/Black light. 5. Demagnetization and Cleaning Inspected components are demagnetized by passing through a demagnetizing coil and are cleaned before dispatching for further processing.
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Description of the MPI BENCH The MPI Bench supplied to you consists of the following: Types of magnetization available Circular : Circular Magnetization being provided thorough a Central Conductor, i.e. a solid copper rod of 25 mm square and length 1100 mm. Central Conductor should be threaded thorough the component, which will be resting on a fixture being provided along with the equipment. Longitudinal: Longitudinal Magnetization being provided though two, three turn copper coils provided on both the ends of the equipment. The coils are mounted on moving platforms, with locking facility, which will enable movement of the coils on the bed, in such a way that the coils can be fixed at a desirable distance between each other. The coils are energized though a separately provided current generator to generate a combined field of 6000 KA (6 KAT) maximum. Combined: Combined Magnetization will be provided through simultaneous operation of both the circular and the longitudinal magnetization. This can be achieved thorough a selector switch. The magnetic field being induced will be a resultant of both the Circular and the Longitudinal Magnetizations. AC
Current wave forms available
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Method of current control and effect on waveform
Current Control for Circular Magnetization ( Central Conductor) can be achieved by using two Six Step Control Switches. One of the switches will be to control current in lower range ( Approximately 3000 Amp.) and other to control current in higher range (3000 Amp. to 6000 Amp.). Thus the current control will be manual through 12 Step Control Switch. The current control will have no effect on waveform. Current Control for Longitudinal Magnetization: Current Control for Longitudinal Magnetization can be achieved through a Six Step Control Switch. All switches are provided on the Control Board on right hand top side of the body of the equipment. The current control will have no effect on waveform. Current Control for Combined Magnetization: It is recommended to adjust magnetization levels for Circular and Longitudinal Magnetization individually through controls as described above. While operating the equipment on combined magnetization the individual adjustments are not disturbed, but the selector switch is moved to the position marked as Combined magnetization. Circular Magnetization : Low Range 0 to 3000 Amp. in Six Steps. High Range 3000 to 6000 Amp. in Six Steps. Incremental Step 500 Amp. Longitudinal Magnetization: 0 to 6 KAT in Six Steps. Incremental Step 0.8 to 1.0 KAT
Working range and incremental setting steps
Monitoring of magnetizing current(s) Magnetizing duration range Duty cycle at maximum output
Through Six Steps Switch Controls Adjustable between 0.5 to 5 Seconds 2 Seconds ON and 6 Seconds OFF, 25%
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Maximum current ON time Open circuit voltage Uo (RMS) Short circuit current I k (RMS) Rated current I r (RMS)
2 Seconds 22 Volts (Approx.) 6000 Amp. (Max.) for Circular Magnetization 130 Amp.
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Cross sectional dimensions of poles
Maximum clamping length Method of clamping Compressed air pressure Maximum dimension between headstocks and bed Maximum test piece diameter Maximum mass of test piece (supported and unsupported) Type of usable detection media (water -/ oil-based) Schematic layout of the equipment (current generator, control panel, location of the detection medium reservoir)
Components are not being clamped between poles. Central Conductor is clamped between poles. Pole dimensions are 25 mm x 75 mm. Pneumatic Cylinders are employed to establish a firm contact between Central Conductor and Pole. 1000 mm Pneumatic Cylinders are employed to establish a firm contact between Central Conductor and Pole. 5 Kg/cm2 ( Minimum) 100 mm 180 mm 70 Kgs. Supported Water based florescent powder i.e. FerroChem Make Product 134C/P-7 or 135C.1/L-2. The Equipment has a main frame of size : 1600 x 600 x 800 mm (LxBxH). On top of the main frame is Bed, which supports stocks at two ends and coils, which move on the same. Below the bed is a Tray which collects excess circulation fluid and sends it back to a reservoir of 20 ltr capacity. Current generator, two numbers, Control Panel, Timers, Switches are placed below the tray. For easy access, doors are provided on all sides. The back doors have louvers for ventilation. On the left side of the equipment conical reservoir of size : 600 x 600 mm is fitted. A foldable dark room is provided on the top of the equipment with curtains. The dark room folds with a press of lever. When folded, components can be loaded with help of over head crane. When un-folded inspection can be carried out after drawing curtains of the front side. Mains Switch is located on the right side. Control panel is on the right top portion at the front of the equipment. Current control and
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type of magnetization can be achieved through use of switches provided there. Type of meter (digital, analog) Accuracy and resolution of meter Electrical supply requirements at maximum current output (voltage, phases, frequency and current) Overall dimensions of equipment Equipment mass, in kilograms. Analog Meter. Accuracy +/- 10%, Resolution: 150 Amp. (Approx) 415 V, 3 Phase, + N, 50 Hz, 150 Amp.
1900 mm x 1300 mm x 2100 mm (LxBxH) 1000 Kgs. (Approx.)
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Characteristics of Coils : Number of turns Maximum achievable ampere turns Length of the coil Internal diameter of the coil or length of sides if the coil is rectangular Number of Turns 3 x 2 6000 AT 1.6 meters (Approx.) Internal diameter of the coil 300 mm
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Installation of the MPI Bench: Our Team of Engineers will visit your place once the Bench arrives at your premises. We will need the following from you. Clear space for keeping the Bench. Electrical Power Supply Compressed Air Main Cable 2750 x 1550 x 2300 mm. 3-phase +1N 415 Volts, 125 Amps. 5 Kg./cm2 Minimum Not provided
Installation: Our team of experts will visit your premises for installation and commissioning of the MPI Bench as and when it reaches the premises. The team will spend enough time to ensure that the MPI Bench runs to your satisfaction for initial run and will train the operators and Maintenance Staff for its smooth running in future. Calibration: MPI Bench will be supplied duly calibrated meeting the requirements of relevant ASTM Standard. Guarantee and Warranty: In addition to aforesaid precautions for good running of the MPI Bench, we also provide guarantee and warranty against workmanship for the MPI Bench. After Sales Service: Kindly note that we provide all After Sales Services such as Calibration and supply of Accessories such as Copper Mesh Pads, Centrifuge Tube, Residual Field Indicator, Magnetic Powders, etc. Training: As a part of customer care, we will arrange free of cost training program at site for your personnel, at the time of installation, for those who will be responsible for maintenance and calibration of your MPI Bench. Installation: Our team of experts will visit your premises for installation commissioning of the MPI Bench as and when it reaches the premises. team will spend enough time to ensure that the MPI Bench runs to satisfaction of the user for initial run and will train the operators Maintenance Staff for smooth running of the MPI Bench in future. and The the and
Guarantee and Warranty: In addition to aforesaid precautions for good running of the equipment, we also provide guarantee and warranty against workmanship for the MPI Bench.
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After Sales Service: Kindly note that we provide all After Sales Services such as Calibration and supply of Accessories such as Copper Mesh Pads, Centrifuge Tube, Residual Field Indicator, Magnetic Powders, etc. Training: As a part of customer care, we will arrange free of cost training program at site for your personnel, at the time of installation, for those who will be responsible for maintenance and calibration of your MPI Bench. TROUBLE SHOOTING You are advised to contact FerroChem immediately, in case of any trouble either with MPI Bench. Contact Person: Mr. Rahul Jadhav, Mr. Vishwas Shinde; Mr. Jitendra Barse Name and Address: M/S FerroChem NDT Systems Pvt. Ltd., Plot No. C-98, Addl. Jejuri MIDC, Village Jejuri, Taluka Purandar, Dist. Pune 412 303. Maharashtra, INDIA. Telephone: 0091 92722 30385 / 30386 / 17690 / 00829 E-Mail: ferro@pn2.vsnl.net.in; ferrochem@yahoo.in Working Hours: 9.00 AM to 5.30 PM Monday to Friday Weekly off: Saturdays and Sundays. Above is applicable for both Office and Factory. After Office Hours and for Emergency: Contact, Mr. A. L. Datar, Director, Cell No 09822546909 Please note that our Warrantee and Guarantee stands canceled if either of MPI Bench is opened and an attempt is made to correct the defect without our written permission; either by you or by your representative.
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Circuit Diagram
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WARRANTY CERTIFICATE
This is to certify that the equipment described below is warranted for period of 12 months from the date of dispatch against all manufacturing defects, faulty material and bad workmanship. This warrantee will not cover any fragile electrical items like Chokes, and Mains Indicator Lamp, polycarbonate cover, etc; and bought out items such as Contactors, Fuses, Diodes, Timers, Meters, etc. Most of the electrical are bought out items. They are purchased from reputed makes, which are manufactured as per IS and other International Standards. Please note that we do not manufacture these items, hence they are not covered under manufactures warranty. It is our observation of many years that if properly used; the components do not give problem in the normal running. Moving contacts have a life of one million operations and are required to be replaced after that period. Working conditions govern the life of the components. Warranty can be given from manufacturing view point. If any defective material is noticed during the above period, the defective material shall be replaced or rectified free of cost within a reasonable time. Model Equipment Sr. No Month of Manufacture Delivery Challan No & Date Invoice No & Date Customer P.O. No & Date 6000 Amp. Bench Type Machine 11331122256120510 May - 2012 83143 Date : 08/06/2012 C0150 Date : 08/06/2012 Usai Forge (P) Ltd. Kamineni, 4th Floor, King Koti, Hyderabad 500 001. A.P. India. 40110089 Date : 07/03/2012
For FerroChem NDT Systems Pvt. Ltd.
Authorized Signatory
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MPI Bench Manual for Magnetic Particle Inspection

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FERROCHEM NDT SYSTEMS PVT. LTD. Plot No. C-98, Additional Jejuri Industrial Area, M.I.D.C.

Name of the Buyer : M/s. Usai Forge (P) Ltd., Hyderabad.

Current wave forms available

Method of current control and effect on waveform

Working range and incremental setting steps

Cross sectional dimensions of poles

1900 mm x 1300 mm x 2100 mm (LxBxH) 1000 Kgs. (Approx.)

For FerroChem NDT Systems Pvt. Ltd.

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