user's manual for electro magnetic crack detection machine having out put 6000 amp. ac

7/16/2019 USER's Manual for Electro Magnetic Crack Detection Machine Having Out Put 6000 Amp. AC

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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 : [email protected] ; [email protected] Web : www.ferrochemndtsystems.com

USER’S MANUAL

MPI BENCH

.

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

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mailto:[email protected]




http://www.ferrochemndtsystems.com/










CONTENTS

Sr. No.Contents

Page No.

1 Preface 12 Introduction about MPI 2

3 Description of MPI Bench 44 Installation of the MPI Bench 85 Trouble Shooting 96 Circuit Diagram 107 Warranty Certificate 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 applicationkeeping in mind the most desirable features to achieve the best performancefor years together without any failure. We are sure you will appreciate thequality 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 achievingtrouble 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 inferromagnetic 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 surfacethrough the leakage field.

Magnetic materials are held over discontinuities and form an outline of thediscontinuity indicating its location, size, shape and the extent.

Uses:-

The common defects such as cracks, laps, seams, inclusions, etc. aredetected by MPI

Material like bars, billets rods, forgings, castings, finished and semi-finishedmaterials, welds, and in-service parts are tested for defect detection byMagnetic particle Inspection.

MPI cannot be applied to Non-magnetic materials metals and alloys such asCopper, 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, oilor grease and any non-conducting coating.. Surface Preparation can be donewith 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 thecomponent for detection of defects in longitudinal direction.

Longitudinal Magnetization involves holding the component in MagnetizingCoil for detection of defects in transverse direction.

Combined Magnetization involves magnetizing both circular and longitudinalway to detect cracks in both longitudinal and transverse directionsimultaneously.

3. Application of Magnetic Particles

‘Bath’ i.e. Magnetic Particles suspended in Test Oil, is applied by spraying onto thesurface. A circulation tank and spraying arrangement is provided on theequipment.

4. Inspection

Inspection of the surface for locating accumulation of particles followsimmediately. When using Fluorescent Particles provision of a Dark Room andUV/Black light source becomes essential. Cracks appear as brilliant yellow-

green lines when viewed under UV/Black light.

5. Demagnetization and Cleaning

Inspected components are demagnetized by passing through a de-magnetizing 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 magnetizationavailable

Circular : Circular Magnetization being providedthorough a Central Conductor, i.e. a solidcopper rod of 25 mm square and length 1100mm. Central Conductor should be threadedthorough the component, which will be restingon a fixture being provided along with theequipment.Longitudinal: Longitudinal Magnetization beingprovided though two, three turn copper coilsprovided on both the ends of the equipment.

The coils are mounted on moving platforms,with locking facility, which will enablemovement of the coils on the bed, in such away that the coils can be fixed at a desirabledistance between each other. The coils areenergized though a separately provided currentgenerator to generate a combined field of 6000KA (6 KAT) maximum.Combined: Combined Magnetization will beprovided through simultaneous operation of both the circular and the longitudinalmagnetization. This can be achieved thorougha selector switch. The magnetic field beinginduced will be a resultant of both the Circularand the Longitudinal Magnetizations.

Current wave formsavailable

AC

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Method of current controland effect on waveform Current Control for Circular Magnetization( Central Conductor) can be achieved by usingtwo Six Step Control Switches. One of theswitches will be to control current in lowerrange ( Approximately 3000 Amp.) and other tocontrol current in higher range(3000 Amp. to 6000 Amp.). Thus the currentcontrol will be manual through 12 Step ControlSwitch.

The current control will have no effect onwaveform.

Current Control for Longitudinal Magnetization:Current Control for Longitudinal Magnetizationcan be achieved through a Six Step ControlSwitch. All switches are provided on the ControlBoard on right hand top side of the body of theequipment.

The current control will have no effect onwaveform.

Current Control for Combined Magnetization: Itis recommended to adjust magnetization levels

for Circular and Longitudinal Magnetizationindividually through controls as describedabove. While operating the equipment on“combined magnetization” the individualadjustments are not disturbed, but the selectorswitch is moved to the position marked as“Combined” magnetization.

Working range andincremental setting steps

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

Monitoring of magnetizingcurrent(s)

Through Six Steps Switch Controls

Magnetizing duration range Adjustable between 0.5 to 5 SecondsDuty cycle at maximumoutput

2 Seconds “ON” and 6 Seconds “OFF”, 25%

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Maximum current ‘ON’ time 2 SecondsOpen circuit voltage Uo

(RMS)22 Volts (Approx.)

Short circuit current I k

(RMS)6000 Amp. (Max.) for Circular Magnetization

Rated current I r (RMS) 130 Amp.

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Cross sectional dimensionsof poles

Components are not being clamped betweenpoles. Central Conductor is clamped betweenpoles. Pole dimensions are 25 mm x 75 mm.Pneumatic Cylinders are employed to establisha firm contact between Central Conductor andPole.

Maximum clamping length 1000 mmMethod of clamping Pneumatic Cylinders are employed to establish

a firm contact between Central Conductor andPole.

Compressed air pressure 5 Kg/cm2 ( Minimum)Maximum dimensionbetween headstocks and

bed

100 mm

Maximum test piecediameter

180 mm

Maximum mass of testpiece (supported andunsupported)

70 Kgs. Supported

Type of usable detectionmedia (water -/ oil-based)

Water based florescent powder i.e. FerroChemMake Product 134C/P-7 or 135C.1/L-2.

Schematic layout of theequipment (currentgenerator, control panel,location of the detection

medium reservoir)

The Equipment has a main frame of size : 1600x 600 x 800 mm (LxBxH). On top of the mainframe is “Bed”, which supports stocks at twoends and coils, which move on the same. Below

the bed is a “Tray” which collects excesscirculation fluid and sends it back to a reservoirof 20 ltr capacity.

Current generator, two numbers, Control Panel, Timers, Switches are placed below the tray. Foreasy access, doors are provided on all sides.

The back doors have louvers for ventilation.On the left side of the equipment conicalreservoir 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 overhead crane. When un-folded inspection can becarried out after drawing curtains of the frontside.

Mains Switch is located on the right side.Control panel is on the right top portion at thefront of the equipment. Current control and

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type of magnetization can be achieved throughuse of switches provided there.

Type of meter (digital,analog)

Analog Meter.

Accuracy and resolution of meter

Accuracy +/- 10%, Resolution: 150 Amp.(Approx)

Electrical supplyrequirements at maximumcurrent output (voltage,phases, frequency andcurrent)

415 V, 3 Phase, + N, 50 Hz, 150 Amp.

Overall dimensions of equipment

1900 mm x 1300 mm x 2100 mm (LxBxH)

Equipment mass, in

kilograms.

1000 Kgs. (Approx.)

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Characteristics of Coils :

Number of turns Number of Turns 3 x 2Maximum achievable ampereturns

6000 AT

Length of the coil 1.6 meters (Approx.)Internal diameter of the coil orlength of sides if the coil isrectangular

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 yourpremises.

We will need the following from you.

Clear space for keeping the Bench. 2750 x 1550 x 2300 mm.Electrical Power Supply 3-phase +1N 415 Volts, 125 Amps.Compressed Air 5 Kg./cm2 MinimumMain Cable Not provided

Installation: Our team of experts will visit your premises for installation andcommissioning of the MPI Bench as and when it reaches the premises. Theteam will spend enough time to ensure that the MPI Bench runs to yoursatisfaction 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 therequirements of relevant ASTM Standard.

Guarantee and Warranty: In addition to aforesaid precautions for goodrunning of the MPI Bench, we also provide guarantee and warranty againstworkmanship for the MPI Bench.

After Sales Service: Kindly note that we provide all After Sales Services suchas 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 trainingprogram at site for your personnel, at the time of installation, for those whowill be responsible for maintenance and calibration of your MPI Bench.

Installation: Our team of experts will visit your premises for installation andcommissioning of the MPI Bench as and when it reaches the premises. Theteam will spend enough time to ensure that the MPI Bench runs to the

satisfaction of the user for initial run and will train the operators andMaintenance Staff for smooth running of the MPI Bench in future.

Guarantee and Warranty: In addition to aforesaid precautions for goodrunning of the equipment, we also provide guarantee and warranty againstworkmanship for the MPI Bench.

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After Sales Service: Kindly note that we provide all After Sales Services suchas 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 trainingprogram at site for your personnel, at the time of installation, for those whowill be responsible for maintenance and calibration of your MPI Bench.

TROUBLE SHOOTING

You are advised to contact FerroChem immediately, in case of any troubleeither 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: [email protected]; [email protected]

Working Hours: 9.00 AM to 5.30 PM Monday to FridayWeekly 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 notethat our Warrantee and Guarantee stands canceled if either of

MPI Bench is opened and an attempt is made to correct the defect withoutour 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 periodof 12 months from the date of dispatch against all manufacturing defects,faulty material and bad workmanship. This warrantee will not cover anyfragile electrical items like Chokes, and Mains Indicator Lamp, polycarbonatecover, etc; and bought out items such as Contactors, Fuses, Diodes, Timers,Meters, etc. Most of the electrical are “bought out” items. They arepurchased from reputed makes, which are manufactured as per IS and otherInternational Standards. Please note that we do not manufacture these items,hence they are not covered under manufacture’s warranty. It is ourobservation of many years that if properly used; the components do not giveproblem in the normal running. Moving contacts have a life of one millionoperations and are required to be replaced after that period. Workingconditions govern the life of the components. Warranty can be given frommanufacturing view point.

If any defective material is noticed during the above period, the defectivematerial shall be replaced or rectified free of cost within a reasonable time.

Model 6000 Amp. Bench Type Machine

Equipment Sr. No 11331122256120510

Month of Manufacture May - 2012Delivery Challan No & Date 83143 Date : 08/06/2012Invoice No & Date C0150 Date : 08/06/2012Customer Usai Forge (P) Ltd.

“Kamineni”, 4th Floor, King Koti,Hyderabad – 500 001. A.P. India.

P.O. No & Date 40110089 Date : 07/03/2012

For FerroChem NDT Systems Pvt. Ltd.

Authorized Signatory

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user's manual for electro magnetic crack detection machine having out put 6000 amp. ac

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