PROCESS SPECIFICATION

GE Energy P3C-AL-0003
Materials and Processes Engineering

Page 1 of 13

MAGNETIC PARTICLE INSPECTION OF STEAM TURBINE

AND GENERATOR COMPONENTS

D O C U M E N T REVISION S T A T U S : DETERMINED BY THE LAST ENTRY IN T H E "REV" A N D " D A T E " C O L U M N

REV. DESCRIPTION SIGNATURE REV. DATE

COMPLETELY REVISED SPECIFICATION; ALLOWED

QUALITY INDICATORS OTHER THAN GE TAPER BLOCK;
UPDATED COMMUNICATION; OMITTED TECHNICAL
LESSONS; STANDARDIZED CALIBRATION REQUIREMENTS;
PCI NO. 04018167. (RW BERGMAN) CRTRIPEPI 2004 NOV 02
B REVISED THE ACCEPTABLE RESIDUAL MAGNETIC FIELD
VALUES FROM +/ 3 GAUSS TO +/-8 GAUSS, EXCEPT ON
INNER DIAMETERS; PCI NO. 05030978. (JR VIERTL) CRTRIPEPI 2006 JAN 20

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PROPRIETARYINFORMATION - THIS DOCUMENT CONTAINS

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PREPARED BY:
J.R. Viertl
ORIG. ISSUE DATE:
December 22, 1966
DT-2.3C
 P3C-AL-0003 GE Energy Page 2 of 13
REV. B Materials and Processes Engineering

MAGNETIC PARTICLE INSPECTION OF STEAM TURBINE

AND GENERATOR COMPONENTS

1.1 This process specification outlines the procedures to be followed and the
acceptance standards to be applied by qualified personnel of the Steam
Turbine-Generator Manufacturing Department, or approved inspection sources,
when performing Magnetic Particle inspections.

1.2 This specification shall apply to raw material, in-process material, finished materials,
and welds, regardless of heat treatment state.
1.3 It is not the intent of this instruction to detail acceptance standards for individual
Steam Turbine - Generator components except shells.
1.4 Communication
1.4.1 External Supplier (See Definition)
1.4.1.1 General Electric Company - Energy Sourcing is the authorized interface
for all communication between GE and the External Supplier. All
questions or requests for additional information shall be submitted to GE
Energy for clarification. Conflicts between applicable Specifications
and/or drawings shall be submitted to GE Energy for resolution by
Engineering.

1.4.2 Internal Supplier (See Definition)

1.4.2.1 All communication, including questions or requests for additional
information, shall be submitted to Materials and Processes Engineering -
Low Temperature Materials Development Engineering (LTMDE).
1.5 Requests For Deviations - Requests for deviations to the requirements of this
specification shall be submitted as follows:
1.5.1 External Supplier - To PSSO by SDR.
1.5.2 Internal Supplier - To the appropriate Engineering personnel by QCR.

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 P3C-AL-0003 GE Enerav Page 3 of 13
REV. B Materials and Processes Engineering

2. APPLICABLE DOCUMENTS
2.1 The following documents shall form a part of this specification to the extent specified
herein. Unless otherwise indicated, the latest issue shall apply.
2.1.1 General Electric Company

P3C-AL-0012 Magnetic Particle and Liquid Penetrant Tests Acceptance

Standards for Stationary Components for Steam Turbine
P3C-AL-0032 Magnetic Particle and Liquid Penetrant Tests Acceptance
Standards for Turbine Rotating Components
P3C-AL-0039Q Qualification and Certification of Liquid Penetrant Testing
and Magnetic Particle Testing Personnel

P28A-AL-0203 Nondestructive Testing Process Qualification and

Approval
2.1.2 American Society for Non-Destructive Testing

Recommended Practice No. SNT-TC-1A

3. DEFINITIONS
3.1 Personnel
3.1.1 Purchaser - GE Energy or its Business Associate.
3.1.2 External Supplier - The corporation, company, partnership, sole proprietorship
or individual engaged to perform the process covered by this Specification.
3.1.3 Internal Supplier - Any GE Power Generation Manufacturing Department.
3.1.4 Supplier-As used herein, unless specifically designated, refers to either an
External or an Internal Supplier.
3.2 Specification Deviation Documents
3.2.1 Applicable to External Supplier
3.2.1.1 Supplier Deviation Request (SDR) - A method for the documentation,
approval and control of a waiver for materials, processes, or dimensions
which deviate from Purchase Order documents (drawings, specifications,
engineering instructions, etc.).

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 P3C-AL-0003 GE Energy Page 4 of 13
REV. B Materials and Processes Engineering

3.2.2 Applicable to Internal Supplier

3.2.2.1 Quality Control Report (QCR) - GE Manufacturing Department non-
conformance report initiated during processing through the factory. The
QCR used by Manufacturing to document non-conformance to governing
documents and request disposition and corrective action.

3.3 Technical Terms

3.3.1 Continuous Method - The continuous method of magnetic particle testing is

performed by applying a magnetic field before application of the magnetic
particles and then allowing particle flow to stop before removing the magnetic
field.

3.3.2 Circular Magnetization - Circular magnetization is created by inducing a circular

magnetic field in a piece such that the magnetic lines of force take the form of
concentric rings about the axis of the current. This may be accomplished by
passing current directly through the test specimen (direct circular) or by
passing current through a central conductor and including the circular field into
the test specimen (indirect circular). Circular magnetization will be used for
detection of discontinuities in materials whose axes are approximately parallel
or up to 45° to the direction of the current.

3.3.3 Defect - A relevant indication in a material whose size and/or location, as

defined and evaluated by these acceptance standards, would be detrimental to
the function of the turbine component.
3.3.4 Discontinuity - A physical break or abrupt non-uniformity in the microstructure
of the material.

3.3.5 False Indication - An indication created by mechanical attraction or gravity.

Some examples of false indications are surface roughness, extraneous
material on the surface and/or contamination.

3.3.6 Longitudinal Magnetization - Longitudinal magnetization, created via a coil,

consists of inducing a magnetic field in the specimen such that the magnetic
lines of force extending through the piece are approximately parallel to the axis
of the magnetizing coil. Longitudinal magnetization will be used for detection of
discontinuities in material whose axes are approximately transverse or up to
45° to the axis of the coil.

3.3.7 Magnetic Particle Indication - A build-up or accumulation of magnetic particles

on the surface of the test specimen.

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3.3.8 Non-Relevant Indication - An indication, created by a magnetic leakage field,

which is not due to a discontinuity in the material and thus will not have a
detrimental effect on the function of the part. Some examples of non-relevant
indications are structural design features of the component, permeability
changes, dissimilar materials and excessive magnetization.

3.3.9 Relevant Indication - An indication which is due to a discontinuity in the

material.

4. ENGINEERING REQUIREMENTS
4.1 The test surface shall be clean and free from oil, grease, sand, loose rust, scale, lint,
'thick' paint, weld flux and spatter, and contamination which will interfere with the
mobility of the magnetic particles and mask relevant indications or create false
indications.

4.1.1 Thin nonconductive coatings, such as paint or plating, less than 4 mils thick will
not normally interfere with the formation of indications.
4.1.2 All coatings must be removed in the areas where electrical contact will be
made.

4.2 If needed, a surface may be cleaned by pressure blasting, provided this will not
interfere with subsequent tests.
4.3 If false indications are noted due to surface conditions such as weld deposits or
burned in sand, the surface shall be cleaned of these conditions and the part re-
tested.
4.4 Chemical cleaners used for surface preparation shall not contain chlorine, sulfur, or
caustics.
4.5 A surface finish not exceeding 250 micro inches AA (0.0064 mm) is required.
4.6 Qualification Package - The Supplier shall submit two (2) copies of the FPQ
documentation for review/approval.
4.7 Upon receipt of written notification for FPQ, the Supplier is approved for production
of the qualified part. The MPP shall be "FROZEN", not to be changed without
approval of a new MPP.

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 P3C-AL-0003 GE Enerav Page 6 of 13
REV. B Materials and Processes Engineering

5. PERSONNEL QUALIFICATION

5.1 Non-destructive testing shall be performed by personnel qualified as NDT

Inspectors, Level II, in accordance with the recommendations of SNT-TC-1A.
Internal suppliers shall be qualified per P3C-AL-0039Q. External suppliers shall be
qualified to P28A-AL-0203.
6. EQUIPMENT
6.1 Magnetic particle testing equipment shall produce either half-wave rectified direct
current (HWDC), full-wave rectified direct current, or full-wave direct current (FWDC)
capable of supplying sufficient amperage and type of amperage as defined in the
requirements of this instruction and the specific instruction being applied. A typical
apparatus will be a wet horizontal machine. A built-in demagnetization circuit, or a
separate demagnetization coil, will be necessary when demagnetization is required.

6.1.1 A DC electromagnetic yoke may be used for localized inspections. An AC

electromagnetic yoke may be utilized for localized inspections where only the
detection of surface discontinuities are of interest.
6.1.2 With the exception of demagnetization, the use of AC current is not permitted
when using a wet method unless specified in a specific process instruction or
with approval from Materials and Processes Engineering - Low Temperature
Materials Development Engineering (LTMDE).

6.1.3 The use of DC or FWDC current is not permitted when using the dry method
unless specified in a specific process instruction or with approval from
Materials and Processes Engineering - Low Temperature Materials
Development Engineering (LTMDE).

6.2 Magnetic particle testing equipment shall be checked for accuracy at the time of
purchase, at an interval not to exceed twelve months, and whenever electrical
maintenance is performed which may affect the equipment accuracy. The
equipment meter reading shall not deviate by more than ±10% relative to the actual
current values as shown by the calibration meter.

6.2.1 An external ammeter may be used in place of the magnetic particle testing
unit's internal ammeter. The external ammeter shall be checked for accuracy at
the time of purchase, at an interval not to exceed twelve months, and
whenever electrical maintenance is performed which may affect the equipment
accuracy. The external ammeter reading shall not deviate by more than ±10%
relative to the actual current values as shown by the calibration meter.

6.3 The ammeter shall be positioned such that it can be monitored continuously during
the application of the magnetizing current.

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 P3C-AL-0003 GE Energy Page 7 of 13
REV. B Materials and Processes Engineering

6.4 The magnetic particle equipment shall have suitable switches for convenient control
of the magnetizing current.

6.5 Magnetization may be accomplished using flexible cables. Cables shall be inspected
before each use to ensure that they are in good condition. Special attention shall be
paid to the condition of the cable's shield. Look for areas where the shield may have
melted or been cut at any point where the cable will be in contact with the part being
tested.

6.6 Magnetic yokes shall be checked for accuracy at the time of purchase, and at an
interval not to exceed twelve months. Magnetic yokes are checked by testing their
lifting power using calibrated steel plates. AC yokes shall lift at least 10 lbs, and DC
yokes shall lift at least 40 lbs. The maximum pole spacing shall be used for this test.

6.7 Magnetic Particles

6.7.1 For visible magnetic particles, the color of the particles shall be selected to
yield the highest contrast with the part. The lighting shall meet the requirements
of 6.8.2.

6.7.2 For fluorescent magnetic particles, an ultraviolet light is required. This light
shall meet the requirements of 6.8.1.

6.7.3 When using a dry magnetic particle method, the particles are applied using a
dry powder applicator. The particles may be mobilized once applied to the part
using an air bulb or equivalent source which will provide a low velocity, low
pressure air flow. All application and mobilizing of particles must be done while
the current is being applied using the true continuous method.

6.7.4 When using a wet magnetic particle method, the particles must be suspended
in a medium (typically water or a petroleum distillate).

6.7.4.1 If a petroleum distillate is to be used as the vehicle, it should be checked

during the settling test in Para. 6.7.4.3 for natural fluorescence with an
ultraviolet light (kerosene and Carrier II do not need to be checked). The
natural fluorescence shall not interfere with the detection of magnetic
particle indications.

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 P3C-AL-0003 GE Enerav Page 8 of 13
REV. B Materials and Processes Engineering

6.7.4.2 If water is to be used as the vehicle, suitable conditioning agents should

be added such as wetting agents, corrosion and rust inhibitors, dispersing
agents, and anti-foaming agents. The agents should be added as per
manufacturer recommendations.

6.7.4.3 Before the use of a suspension, the concentration of particles and

contamination of the suspension must be checked. These checks shall be
made after initial mixing, daily and at any time the mixing motor is turned
off. The suspension shall be allowed to circulate for 15 minutes minimum,
then the concentration shall be checked using a centrifuge tube. A 100ml
sample shall be allowed to settle for 30 minutes and shall result in a
concentration of 1.2ml to 2.4ml for visible particles and 0.1ml to 0.5ml for
fluorescent unless otherwise specified by the specific instruction being
applied. Contamination shall not interfere with testing.

6.8 Lighting

6.8.1 A near ultraviolet (black) light, with a wavelength of 3200-4000 angstrom units,
shall be employed for fluorescent magnetic particle inspections. The black light
shall be maintained and calibrated annually to yield a minimum 1000 uw/cm2 of
near ultraviolet light at a distance of 15". A check of the blacklight intensity shall
be made at least weekly.

6.8.1.1 The background light intensity shall be no more than 20 lux (2 foot-
candles) at the part surface.

6.8.2 For visible magnetic particles, the visible light intensity shall be at least 1000
(100 foot-candles) lux at the part surface.
7. TEST AND INSPECTION REQUIREMENTS

7.1 All magnetic particle inspections shall be of the wet true continuous method with the
exception of weld inspection, which may be done using the dry true continuous
method. The residual method shall not be used when testing to this specification.

7.1.1 When using the wet method, the current shall not be turned off before the
magnetic particle solution stops flowing.

7.2 Each component shall be 100% inspected unless otherwise designated by a specific
process instruction. All areas of each component shall be inspected in two (2)
perpendicular directions unless otherwise designated by a specific process
instruction.

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 P3C-AL-0003 GE Energy Page 9 of 13
REV. B Materials and Processes Engineering

7.3 The magnetic field shall be verified each time current is applied. The magnetic field
shall be verified using the General Electric taper block (drawing# 173B5102) or a
Pie Gage. An equivalent quality indicator may be used if approved by Materials and
Processes Engineering - Low Temperature Materials Development Engineering
(LTMDE).

7.4 Direct Circular Magnetization

7.4.1 This technique passes current directly through the part using head and tail
stocks, prods, or clamping devices. Extreme care shall be taken to ensure
good contact with the test part to prevent localized heating and arcing.

7.4.2 For test specimens with multiple diameters, the smallest diameter shall be
tested first. Then the next smallest shall be tested until all of the surfaces have
been inspected.

7.4.3 A minimum magnetizing current of 100 amperes to 125 amperes per inch of
diameter or maximum cross section shall be used.
7.4.4 When using prods, the prod spacing shall be 3" to 8". The magnetizing current
shall be 100 amperes to 125 amperes per inch of prod spacing.
7.4.4.1 Prods shall never be used in contact with a finish machined surface.
7.4.4.2 Extreme care should be taken to ensure good prod contact and that the
prod points of contact are clean and in good condition.
7.4.4.3 The effective perpendicular test area using prods is % the pole spacing
from a line which connects the two prods.
7.4.4.4 Overlapping of pole spacing shall be at least 1 inch.
7.5 Indirect Circular Magnetization

7.5.1 This technique passes current through an electrical conductor which is placed
through the part being tested. If the part is not suspended on the central
conductor, an insulator shall be placed around the central conductor. Extreme
care shall be taken to ensure that the insulator is in good condition before each
use to reduce the risk of arcing between the central conductor and the part.

7.5.2 An attempt shall be made to position the central conductor in the center of the
part opening.

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7.5.3 For test specimens with multiple test diameters, the smallest diameter shall be
tested first. Then the next smallest shall be tested until all of the surfaces have
been inspected. For parts where the outer diameter is to be tested, the inner
and outer diameter shall be tested separately at each of their respective
current settings.

7.5.4 A magnetizing current of 100 amperes to 125 amperes per inch of diameter
shall be used.

7.6 Longitudinal Magnetization

7.6.1 This technique passes current through a coil (usually multi-turn). This coil can
be rigid, a yoke, a solenoid, or can be created by wrapping a cable around the
part. Extreme care shall be taken to ensure that any cables used are in good
condition before each use to reduce the risk of arcing.

7.6.2 The magnetic field strength for longitudinal magnetization is expressed in

ampere-turns. This is the product of the current applied times the number of
turns in the coil.
7.6.3 Longitudinal magnetization is only valid for components which have an L/D
ratio (length divided by diameter or cross-section) of 2 or more.
7.6.4 Coil
7.6.4.1 For longitudinal magnetization using encircling coils, the minimum starting
amperage shall be calculated according to the L/D ratio. For parts with
L/D ratios greater than 5 and less than 15 use the following formula:

Ampere Turns = 45,000

L/D

Where L = Length of object being tested

D = Width of object being tested

When (L/D) ratios are greater than 15 use the number 15 in the
denominator.

7.6.4.2 For parts with L/D ratios between 2 and 5 use the following formula:

Ampere Turns = 30.000

L/D

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7.6.4.3 For longitudinal magnetization using induction coils, the minimum starting
amperage shall be calculated according to the L/D ratio according to the
following formulas:
Ampere Turns = 15,000
L/D

Machine Setting in Amps = Amp Turns

No. of turns in coil

7.6.4.4 For induction coils, use 10 turns for objects 10 inches (25 cm) or less in
length and for objects over 10 inches (25 cm) in length use 5 coil turns

7.6.4.5 The effective field is 12" on either side of the coil as verified by the quality
indicator.

7.6.4.6 Parts longer than 16" - 24", as determined by the quality indicator, will
require multiple coil inspections.

7.6.4.7 The wet continuous method must be used for inspections using a coil.

7.6.5 Yoke

7.6.5.1 The effective perpendicular test area using a probe is Vithe pole spacing
from a line which connects the two poles.

7.6.5.2 Overlapping of pole spacing shall be at least 1 inch.

7.6.6 Cable Wrap

7.6.6.1 A magnetizing current of 100 ampere-turns to 125 ampere-turns per inch

of diameter shall be used.

7.6.7 Solenoid

7.6.7.1 The magnetizing current shall be adjusted such that the quality indicator
verifies a sufficient field strength.

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8. DEMAGNETIZATION

8.1 An attempt shall be made to demagnetize all components subject to magnetic

particle testing. Demagnetization shall always be done when longitudinal
magnetization is employed.

* 8.2 A residual magnetic field of ±3 gauss is considered acceptable for all parts except
steam turbine shells unless otherwise stated in the component's specific process
instruction. Except on inner surface diameters, for steam turbine shells a residual
magnetic field of ±8 gauss is considered acceptable unless otherwise stated in the
component's specific process instruction. On inner surface diameters, a residual
magnetic field of ±3 gauss is considered acceptable unless otherwise stated in the
component's specific process instruction.

8.3 When demagnetization is required after employing a circular field, the

demagnetization shall be done using a longitudinal field.

8.3.1 Some examples of demagnetization techniques are:

8.3.1.1 Using a high intensity AC yoke, place the part in the center and slowly
withdraw.

8.3.1.2 Apply a full wave DC field at a higher intensity than the part was tested at.
Reduce current slightly and reverse cables. Apply field. Reduce current
slight and reverse cables again. Apply field. Keep repeating until the field
meets the criteria in Para. 8.2.

8.3.1.3 Use the automatic demagnetization cycle on a full wave DC unit.

9. ACCEPTANCE STANDARDS

9.1 The acceptance standards listed in a component's process instruction shall apply.

9.2 If no acceptance standard is listed:

9.2.1 For stationary components, the acceptance standards in P3C-AL-0012 shall

apply.
9.2.2 For rotating components, the acceptance standards found in P3C-AL-0032
shall apply.

"Changed
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 P3C-AL-0003 GE Energy Page 13 of 13
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9.2.3 Indications >1/32" are not allowed for Generator components. All indications
greater than or equal to 1/32" shall be reported to the purchaser by QCR/SDR.

/ct-01-20-06

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