ASTRON

MAGNETIC FLUX LEAKAGE TESTING(MFL)

SALALAH METHONAL COMPANY L.L.C (SEZ)

Magnetic Flux Leakage Testing (MFL)

Procedure

Document Number : AST-SMC-MFL-001

Date : 19-08-2018
Revision Number : 0

Prepared By Reviewed By Approved By

K.SRINIVASAN
NDT LEVEL –III
SUBHAM PUTHRAN (RT,UT,MT,ET)
ASNT LEVEL-II CERT No: 246900

Procedure Change
Rev Date Section Description
0 19.08.2018 Nil First Issue

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MAGNETIC FLUX LEAKAGE TESTING(MFL)

CONTENTS

1. PURPOSE

2. SCOPE

3. REFERENCES

4. MAGNETIC FLUX LEAKAGE PRINCIPLE

5. PERSONNEL

6. EQUIPMENT

7. PROBE PARAMETERS

8. PROCEDUE

9. CALIBRATION TUBE STANDARDS

10. SYSTEM CALIBRATION

11. PRIBE TRAVERSE SPEED

12. EXAMINATION TECHNIQUE

13. DATA RECORDING

14. DATA ANALYSING

15. REPORTING

16. SAFETY PRECAUTION

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MAGNETIC FLUX LEAKAGE TESTING(MFL)

1.0 PURPOSE

The purpose of this procedure is to provide guidelines to be followed during Magnetic Flux
Leakage (MFL) testing of ferromagnetic tubes.

2.0 SCOPE

The scope of this procedure covers the inspection of all types of heat exchanger/boiler
ferromagnetic tubing materials using computer based test equipment and data capture systems.

This procedure does not establish tube acceptance criteria; they must be specified by the client.

3.0 REFERENCES(Latest Edition)

3.1 ASME Section V, Article 16 : Magnetic Flex Leakage

3.2 ASNT –SNT-TC-1A : Recommended Practice for Personnel qualification and

Certification in Non-Destructive Testing

3.3 User’s Manual : Olympus Tech MS 5800

4.0 MAGNETIC FLUX LEAKAGE PRINCIPLE

Conventional eddy current testing cannot be applied to ferromagnetic tubes because of the
effect that the high levels of magnetic permeability have on the depth of penetration of the
eddy current field and on background noise level. This has been overcome in the partial
saturation magnetically biased eddy current principles.

The principles of the system are relatively simple. A probe on the end of a cable is pushed and
pulled through the tube, either manually or by means of a winch unit. The probe contains DC
magnetizing coils and AC eddy current sensor coils. This magnetizing coils partially magnetize the
tube wall and the defects are detected by the sensor coils as the probe is withdrawn from the
tube. The signals from the sensor coils are passed to the electronics unit where the signals are
processed and recorded for interpretation and storage.

5.0 PERSONNEL

5.1 Personnel analyzing test results shall be qualified and certified to MFL Level II minimum
in accordance with Astron written procedure, which in line with ASNT SNT-TC-1A.

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MAGNETIC FLUX LEAKAGE TESTING(MFL)

5.2 In addition to ECT Level II the personnel should have to undergo the equipment
manufacture/in house training program in the particular equipment for the operation &
interpretation of test results.

6.0 EQUIPMENT

MS5800MFL System

7.0 PROBE PARAMETERS

Choose the probe designated for the inside diameter of the tube. Never use a smaller nominal
size probe in a larger diameter tube.

Each probe to be used shall be identified by a unique serial number

8.0 PROCEDURE

8.1 BASIC INFORMATION REQUIREMENTS

The following minimum information is required prior to conducting an inspection:

Tube dimensions (Outside diameter, wall thickness, length)
Tube materials (Brass, Cu-Ni 90/10, carbon steel etc.)
Tube characteristicsStraight /‘U’ bends tubes
Scope of inspection(Number of tubes, inspection pattern)
Service (E.g., tube side – water / shell side – steam)
Types of wastage taking place(If known)
Recent tube failures (If any)
Review of previous inspection reports (If any)
Drawings, diagrams, maps or any other relevant information.

8.2 TUBE SHEET PREPARATION

Tube sheet drawings shall be marked up in such a way as to identify individual zones (if
required) and rows. The tube sheet of each heat exchanger shall be clearly marked in the
same manner to ensure traceability of each tube.

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MAGNETIC FLUX LEAKAGE TESTING(MFL)

8.3 TUBE CLEANLINESS

The technician shall ensure that the tube cleanliness satisfies the requirements.
Scale and other deposits will reduce the sensitivity of the inspection technique and
thereby
adversely affect test results.

Any deposit that doesn’t affect the thermal efficiency of an exchanger, to

a great extent is suitable for MFL testing.

9.0 CALIBRATION TUBE STANDARDS

9.1 Calibration tube standards for Magnetic Flux Leakage testing shall comply with the
requirement of manufactures recommendations.
9.2 The calibration tube standards shall be manufactured from a length of tubing of the same
nominal size and material as that to be examined. The intent of the calibration tube
standard is to establish and verify system response and to act as a guide in data analysis.
9.3 The standard should contain a sample of the expected damage, natural or artificial and
reference.
9.4 Wherever possible tubing with natural defects, typical of the tubing under test, should be
used to evaluate the sensitivity and accuracy of the inspection technique.

10.0 SYSTEM CALIBRATION

10.1 The test equipment shall be calibrated in accordance with a work instruction or
technique detailing
signal settings and amplitudes as well as data capture settings. Any change in probe,
extension
cable, test instrument or any other part of the examination system hardware shall be
cause for re- calibration.

10.2 The test equipment response shall be checked and verified by use of the calibration tube
standard as follows:
Prior to starting of examination
At least once every two hours
At each change of operator
At any time that malfunctioning is suspected
At the beginning and end of each work shift

10.3 If, during any check, it is determined that the test equipment is out of calibration (as
defined by the work instruction) the equipment shall be re-calibrated and a new data file
opened.

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MAGNETIC FLUX LEAKAGE TESTING(MFL)

10.4 The data analyst shall determine which tubes, if any, are to be re-examined.

10.5 It is the responsibility of the data capture technician to ensure that the data is of the
quality required by the relevant procedure and/or as defined by the data analyst.

11.0 PROBE TRAVERSE SPEED

The maximum probe traverse speed is limited by the frequency response of the electronic
system.
The ideal traverse speed is between 0.5-1.0 meters per second but not critical.

12.0 EXAMINATION TECHNIQUE

Information is gathered whilst withdrawing the probe from the tube. The withdrawing shall be by
hand,
the technician shall ensure that an even speed is maintained.

13.0 DATA RECORDING

For the purposes of this procedure all test results will be recorded on suitable data acquisition
systems.
Each trace shall be identified according to zone/row/tube number as applicable.

14.0 DATA ANALYSIS

14.1 Analysis of all data shall be conducted by at least ASNT Level II operator qualified
in Eddy Current Testing and in house trained for the operation of the equipment and
interpretation of test results.

14.2 All indications shall be evaluated. Indication types that must be reported shall be
characterized using the frequencies or frequency mixes which were qualified.

14.3 All data recorded during acquisition shall be stored on suitable media together with
the analysis reports.

15.0 REPORTING

The following minimum information shall become part of the permanent record of the
inspection:
Owner
Plant site

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MAGNETIC FLUX LEAKAGE TESTING(MFL)

Heat exchanger identification

Test equipment serial number
Calibration standard serial number
Size and type of probes
Operators and analysts identification and certification level.

A written report shall be produced after each completed inspection and shall include but
not be limited to the following:

INTRODUCTION :General outline of the survey including dates of inspection and

inspection
procedure.

PURPOSE :Specific purpose for the inspection including all specification

relating to unit in question

SCOPE : Details of the extent of the survey.

RESULTS: : Details of defects detected and severity thereof as well as other

relevant details of the inspection.

DISCUSSION: : (Optional) Statistical and general information.

CONCLUSION: : Overall state of heat exchanger, possible trends and

recommendations for future inspections.

APPENDICES : As required to augment report, eg. Tables, tube sheet drawings,

photographs etc.

16.0 SAFETY PRECATIONS

The equipment is being operated with 100-240 Volt AC, 50-60 Hz electrical power supply.
It is the responsibility of the technician to take all precautions while handling the
equipment, such as checking loses connections, checking the cable for free of damage
and keeping the equipment away from the water contact to prevent electrical shock.

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