Good Practices User Guide -

7/28/2019 Good Practices User Guide -

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TABLE OF CONTENTS

Topic sheet M01 General points

Main processes of magnetic particles testing

Topic sheet M02 Products used for manual inspection

Accessories and devices for quality control for manual

inspection of magnetic particles testing

Topic sheet M03 Constraints and environmental risks

Risks for the operator associated with the implementation ofmagnetic particles inspection

Topic sheet M04 Approach to reduce the environmental footprint of the magnetic

particles testing

Practices to minimize risks of accidents

Improvements for a greener manual magnetic particles testing

Other techniques for improving magnetic particles testing

Coordinator Associated Beneficiaries


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General points

Magnetic ParticlesTesting

Magnetic particlestesting can only beperformed onferromagneticmaterial

This techniqueallows the detectionof surface orunderlying defects

Magnetic particles testing (MT) is a method of non-destructive testing whichconsists of developed an intense magnetic flux inside a ferromagnetic material.With the penetrant testing, this technique represent 50% of the non-destructivefield.

During the magnetization of a ferromagnetic part, a defect close to the surfacedisturbs the magnetic field lines, creating a leakage flow highlighted by usingmagnetic particles which can be dry powders or in suspension in an aqueous ororganic liqueur.

The defect appears as a magnetic indication visible to the naked eye underwhite or UV light (particles with fluorescent pigments). To optimize its detection,the defect direction should be perpendicular or slightly disoriented comparedwith the direction of the created magnetic field.

Magnetic particles testing reveals surface defects, such as : Cracks. Lacks of fusion. Forging folds.

This technique does not allow to detect porosity or pitting (holes).

Magnetic particles testing requires the use of chemicals almost at every step ofthe implementation.

Change in section Defect

Local modification of the trajectoryLarge variation of field

North South

TopicSheet

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TopicSheet

Main process of magnetic particlestesting

M01

They are different processes of magnetization:

Longitudinal magnetization(detection of transverse defects)

Transverse magnetization(detection of longitudinal defects)

Solenoid

Electromagnet

Electric current flowing directly

into the part

Circumferential magnetization

by mean of a central conductor

Magnetization using handheldelectrodes

Magnetic particlestesting bench:

Can detect

longitudinal defectsby current flowing in

the part

Can detecttransverse defects by

magnetic flux flowingin the part

Solenoid

Electromagnetic

field lines

Electromagnetic field lines

Electromagnet

Electromagneticfield lines

Electromagnetic field lines

Conductor



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Products used for manual inspection

Magnetic products:

Magnetic particles are oriented along the leakage flux, allowing defectdetection.

Magnetic products used: dry powders, organic or aqueous magneticinks.

Contrasting paints:

In the case of a white light inspection, application of a white contrastingpaint to increase the sensitivity of defects detection.

Product packagings:

Aerosol cans. Bulk.

Application methods of magnetic indicators:

Spraying magnetic inks. Powdering for dry powder indicators.


Types of products:

Cleaning products:

Cleaning products are used in order to facilitate the mobility of magneticparticles on the surface of the part and to prevent the appearance of

spurious magnetic images. Main cleaner products used: ethyl acetate, acetone, isopropyl alcohol,

... There are other types of cleaning processes: chemical, mechanical

(blasting, sandblasting). They are generally not allowed or implementedwith great caution (may occasionally plug the defects).

TopicSheet

M02


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Accessories and devices for qualitycontrol for the manual inspection ofmagnetic particles testing.

Accessories :

Equipments for magnetization by magnetic flux:

Electromagnets : Directly mains supply or power supply bytransformer or batteries.

Coils : - Magnetization or demagnetization coils.- Possibility of using coils with quick openingand closing system.

Devices for quality control:

Magnetic field measurement and quality control of the magnetization:

Ensure that the magnetic field strength is optimal for the detection ofthe defects

Luxmeter and UV radiometer :

Allow to ensure that the control is carried out under recommendedlighting conditions.

Contact electrodes for electrical current flowing in the part.

Electric power source (electric current generator) :

Can generate electric currents of different intensities, frequencies andwaveform depending on the parts to control.

Lighting equipments :

White lighting. UV lighting (fluorescent penetrant testing).

TopicSheet

M02



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TopicSheet

M03

Products used for magnetic particles testing present significant risks to theoperator and the environment. These products are:

In general flammable (organic products) and explosives (spray cans). Toxic to the aquatic environment. Hazardous to health operators (must not be inhaled / ingested or in

contact with eyes or skin). Usually contain volatile organic compounds (VOCs) with a potentially

greenhouse effect.

In general, the magnetic particles testing operation produces a largequantity of wastes (effluent, rags, empty cardboard packing).

Ecological impact of penetrant and magnetic particles testing in France peryear:

100 000 tons of organic products. 200 000 tons of waste. MkWh 1000 is 200 million tons CO

2equivalent.

In Europe : these figures are multiplied almost by 10.

Environmental challenges and objectives of the Green Testing project:

Reduce environmental pressures (energy consumption, greenhousegases and VOCs emission, waste production by 20% to 30%),potential risks to operators health and arduousness tasks.

Reduce drastically inspection costs (from 20% to 40%). Reduce environmental pollution (by 90%) through the provision of

alternative technologies.

VOCs are the cause of the ozone layer destruction. The ISO14001 and the related European Directives, lead each companyto reduce its VOC emissions.

The implementation of magnetic particles inspection required large amount

of energy particularly for magnetization and demagnetization of parts.

Constraints and environmental risks



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Risks due to electric and magnetic fields: Indirect risks : fires, explosions, projection of ferromagnetic objects Direct risks : modification the electrocardiogram, malaise (high intensity

fields), health effects(decrease of melatonin secretion, leukemia, immunesystem changes, visual disturbances)

Low frequency electromagnetic fields (less than 100 kHz) are

classified as potentially carcinogenic to humans (group 2B).However, it has not been possible so far to establish a causal linkbetween exposures and occurrence of leukemia.However, studies are insufficient to conclude definitively whetherthe carcinogenicity of low frequencies electromagnetic fields.

Indirect risks: Risks associated with handling parts (parts dropping, fingers jamming).

Risk of burns associated with current flow in parts and hot parts.

Electrical hazards : Electrocution hazards due to the use of both electrical sources and the

water simultaneously to achieve the magnetic particles inspection.

Risks of explosion due to spray cans: Care must be taken when using aerosols near direct heat sources

(welding, hot parts, for example) because of the flammability ofmaterials used and the risk of explosion of spray cans.

Risks related to vapours exposure of magnetic particles testing materials(solvents and organic products):

Exposure to solvent and organic product vapours is deemed hazardousto health.

Risks related to UV radiation:: Skin aging and cancer.

Eyes problems(cataract).

TopicSheet

M03Risks for the operator associated with theimplementation of magnetic particlesinspection



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FactsheetApproach to reduce the environmentalfootprint of the magnetic particles testing04

1

TopicSheet

M04

To manage the environment in everyday life:

Generally speaking, companies must invest in a policy of proactive protection, forexample by setting up an Environmental Management System (EMS).

The eco approach within the company has been built according to a structuredset of steps and controlled at each level of their implementation.

Making an environment diagnosis :

Waste diagnosis: waste management by controlling the processing

costs; waste reduction and establishment of a sorting and selectivecollection at the source ...

Energy diagnosis: hunt wasting; energy saving solutions; energyrecovery solutions (heat).

Gaseous and liquid effluents diagnosis: optimized choice costs /performances of the treatment system ; reducing the amount ofeffluents at the source ; reusing treated wash water; recoveringexcess of used materials.

Other possible diagnoses: dusts and particles; odors; noises.

To inform and educate the different agents or stakeholders

Monitoring: nuisance registry to record incidents occurred and responsesrelative to the environment feedback.



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Approach to reduce the environmentalfootprint of the magnetic particles testing

fvrier 2012

To reduce incomings and outgoings:

In every industrial process, all incoming and outgoing parts have a greater orlesser impact on the environment, that it is necessary to minimize as possible.

The incomings:

Cleaning products. Products required for the implementation of the magnetic particles

testing process (contrasting paint, magnetic inks or dry magneticpowders).

Electrical energy required mainly for magnetization operations ofparts.

Water used for cleaning operations and to prepare dilute solutionsready for use (magnetic inks).

The outgoings:

Wastes (cartons, empty spray cans, rags and papers, damagedcontrol equipments : UV or white lightings, electrical cables used forthe magnetization,).

Sewages and residual cleaning products contaminated by organic orsolid debris (magnetic inks, residual oil and grease).

Other possible nuisances:

Odors caused by chemicals used or from effluent treatment plant. Noise due to control devices (ventilation noise of magnetization

equipment) Noise due to the handling parts in production control plant (falling of

parts in the waste / good containers at the end of the testing line forexample).

Electric, magnetic and electromagnetic fields implemented in themagnetic particles testing, knowing that the demagnetizationoperations of parts at the end of the inspection generate additionalenvironmental pollution (electrical and magnetic fields) equivalent tothose of the magnetization.

TopicSheet

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Practices to minimize risk of accidentsand impact on operators health

Solutions to reduce risks of accident:

Collective protective equipments:

Ventilation and purifying of atmosphere at the workplace. To delimit / or mark the access to dangerous areas. Protection by recording a dangerous function during interventions. Identification of dangerous products to prevent inadvertent use. Hazard signs To delimit work areas.

Personal protective equipments:

Safety shoes and helmets. Goggles. Gloves, protective clothes.

Masks or breathing equipments . Hearing protection (falling of parts in the scrap good containers at the end

of the testing line for example).

Give a sens of responsability at the operators :

To take into consideration the user sheet of chemicals (by referencingto the company doctor who has at disposal the health and safetysheets ).

To know the location of the fire extinguishers and their functionaryuse.

Dont leave tools or parts on ground in the workshop. To keep working equipment and accessories at their place and clean

the working place.

TopicSheet

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TopicSheet

Improvements for a greener manualmagnetic particles testing 03

Ecologic inspection

products

Spray systems:

To prefer rechargeable spray systems (with an adapted spray nozzle andmechanical pressure by pumping):

Waste quantity reduced. Quantity of MPI products reduced by 4 compared to the use of an

aerosol. Does not require propulsive gas.

Magnetic particles products:

Purchase products in bulk rather than spray cans:

Diminution of the quantities of packaging and aerosol cans.

Give priority to water-based products rather than organic-based products:

Reduction of VOC emissions. Non-flammable products. Effluent treatment simplified and maintenance costs reduced (low

fouling). Eliminating inherent risks due to the use of organic solvents (harmful,

vapors, skin irritation, ...).

Lighting systems:

Preferred LED (white light or UV) to conventional bulbs: Greater light intensity.

Energy consumption 50 times smaller than for mercury vapor lamps(2.5 W instead of 100W). Longer life (over 10,000 hours). Less hazardous waste to the environment (especially mercury vapor

lamps UV lamps).


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Improvements for a greener manualmagnetic particles testing

Ecologic inspectionproducts

Magnetization systems and demagnetization system:

To improve the effectiveness of controls through better magnetic couplingbetween the magnetization system and the inspected part:

To match, for exemple the size of the coil to one of the part. To ensure the regular maintenance of the magnetizing benches as

well as their accessories and testing equipment (i.e. heating of cablesand control materials (heating cables due to poor electrical contactsfor the circulation of the current in the parts).

To allows substantial energy savings.

Using equipment of new generation, generating low frequencies:

Reduces energy consumption (reduction of harmonics, cos close to1, no heat losses in the thyristors).

Reducing exposure to risk by lowering the electromagnetic Maxwellfrequency).

Use of inspection kit powered with batteries:

Ergonomic system, lighter than a conventional electromagnet. Operator Safety: for inspection in elevation and inside metallic

enclosures.

Effluent recovery systems :

Using cleaning fountains with recycling of cleaning products by debrisfiltration:

Reduces the amount of solvent required for cleaning.

Use of recovery equipment and wastewater filtration (activated carbon): Prevents the spread of effluents into the environment and allows their

treatment.

Use vacuum and filtering systems of organic vapors: Prevents the spread of toxic vapours into the atmosphere. Protects the operator against toxic vapours inhalation.

TopicSheet

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TopicSheet

Other techniques for improving magneticparticles testing

M04

Low frequency magnetic particles testing:

Advantages of this technique: Allow to detect deeper defects. Better contrast of magnetic indications. To limit operators exposure by using a low frequency magnetization

(the acceptability thresholds are higher).

Magnetic particles testing without contact by rotary field can beused with low frequency magnetic field.

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Good Practices User Guide -