36983655 Pt 001 Rev 0 Liquid Penetrant Testing Procedure (1)

7/27/2019 36983655 Pt 001 Rev 0 Liquid Penetrant Testing Procedure (1)

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INDEX PAGE

PURPOSE 3

SCOPE 3

DEFINITIONS AND ABBREVIATIONS 3

REFERENCES 3

REQUIREMENTS 3


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PURPOSE:

This Procedure details the method for performing Liquid Penetrant Testing by Authorised Personnel on behalf of

XXXX (Pty) Ltd.

SCOPE:

Applicable to all castings, forgings, and butt welds in plate, piping and vessels when the Reference Code is:

API 1104

ASME B31.1

ASME B31.3

ASME III

ASME IX

ASME V

ASME VIII

ASME XI

AWS D1.1

EN 6443:1984

EN 5817:2005

PD 5500

DEFINITIONS AND ABBREVIATIONS:

NDT Non-Destructive Testing

PT Liquid Penetrant Testing

Technique Sheet A document compiled, when required, in accordance with the Reference Codedetailing special instructions on equipment use and other information that willassist the Technician during the use of a Specialised Technique.

Technician An authorized Level I, II or III RT Technician authorised by the Company in(Operator) accordance with XXXX-WP-001 Rev 0

The Company XXXX (Pty) Ltd

Specialized Technique Any PT Technique not covered in this Procedure

REFERENCES:

XXXX-WP-001 REV 0 Written Practice for Authorization of NDT Personnel.

XXXX-WP-003 REV 0 Written Practice for the Performance of NDT Equipment.

REQUIREMENTS:

Safety

Extreme caution shall be exercised as Penetrant materials can be flammable and/or emit hazardous and toxicvapour. Any additional manufacturers safety precautions must be observed.

Prerequisites

y All Liquid Penetrant Inspections shall be performed in accordance with the relevant Reference Code.

y Technique parameters shall be recorded on the Liquid Penetrant Testing Report.


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y Additional techniques (as required) shall be compiled by an authorised PT Level II Operator, Evaluator or

Reviewer. Technique sheets shall be reviewed by the authorised Level II or Level III Reviewer before Liquid

Penetrant Inspection.

Precautions and Limitations

y The Liquid Penetrant Testing method is an effective means for detecting discontinuities which are open tothe surface of clean, nonporous metals and other materials.

y Fluorescent Penetrant examination shall not follow a colour contrast Penetrant examination.

y Intermixing of Penetrant materials from different families or different manufacturers is not permitted.

y A retest with water washable Penetrants may cause loss of marginal indications due to contamination.

Personnel Requirements

y Liquid Penetrant Testing Operators, Evaluators and Reviewers shall be authorised in accordance with the

requirements of XXXX-WP-001 REV 0.

y Interpretation, Evaluation and Reviewing of test results shall only be done by Authorised Level II or Level III

Technicians.

Equipment and Consumable Requirements

y All equipment used for Liquid Penetrant Testing shall be in a good working order and calibrated as laid down

in XXXX-WP-003 Rev 0.

y Consumables used for Liquid Penetrant Testing shall be of a reputable Manufacturer as required by the

Client and within shelf life.

y Different Families of consumables shall not be mixed.

Location and Component Identification

y Each weld shall be identified on a work request together with an inspection package. At each weld location a

physical identification should be present, i.e. Plant Location Code (PLC).

y In cases where the inspection package and physical identification nomenclature cannot be reconciled, NO

inspection shall be performed until resolution is provided by the Client.

y Where temporary identification is allowed, the operator shall ensure that the type of marking will remain

present for any period of re-work, should repairs be necessary. The operator shall establish a zero referencedatum related to some prominent feature of the item (e.g. Top Dead Centre), which shall be detailed in the

inspection report.

Control of Contaminants

The Company shall obtain certification of contaminant content for all liquid Penetrant materials used on nickel

base alloys, austenitic stainless steels, and titanium. These certifications (MSDS) shall include the Penetrant

Manufacturers batch numbers and the test results obtained. These records shall be maintained as required by

the Referencing Code Section

TechniquesEither a colour contrast (visible) Penetrant or a fluorescent Penetrant shall be used with one of the following

three Penetrant processes:

y water washable

y post-emulsifying

y solvent removable

The visible and fluorescent Penetrant used in combination with these three Penetrant processes result in

six liquid Penetrant techniques.


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Surface Preparation

y In general, satisfactory results may be obtained when the surface of the part is in the as-welded, as-rolled,

as-cast, or as-forged condition. Surface preparation by grinding, machining, or other methods maybe

necessary where surface irregularities could mask indications, but after such operations the surface shall be

chemically etched to ensure that these operations did not peen over or closed any surface openings.

y Prior to each Liquid Penetrant examination, the surface to be examined and all adjacent areas within at least25 mm shall be dry and free of all dirt, grease, lint, scale, welding flux, weld spatter, paint, oil, and otherextraneous matter that could obscure surface openings or otherwise interfere with the examination.

y The part shall then be flushed with solvent remover and wiped clean with a clean, lint free cloth and left todry via evaporation for a minimum of 5 minutes.

Penetrant Application

y Penetrant Testing may only be performed on welds where the temperature is not less than 10 C but not

greater than 52 C or in accordance with Manufacturer recommendations. The component temperature shall

be noted at the commencement, during and at the completion of inspection. Welds outside this temperature

range (or where the temperature fluctuates outside this range) shall not be inspected without re-qualification.

y Penetrant shall be applied to the entire inspection area by either brushing, dipping, flowing or aerosol spray.

y The Penetrant dwell time shall be in accordance with the Reference Code Section.

y The Penetrant must remain wet throughout the dwell time and repeated applications of Penetrant may be

necessary. Should the Penetrant be allowed to dry or separate (bead) on any part of the surface theinspection must be repeated commencing with surface preparation.

Penetrant Dwell Time

Penetrant dwell time will be as prescribed in the applicable Reference Code Section.

Penetrant Removal

y Excess solvent removable Penetrant, after the prerequisite dwell time, shall be removed by wiping the

inspection surface in a single direction with absorbent paper. When most traces of the Penetrant have been

removed, the inspection surface shall be further wiped with absorbent paper lightly moistened with cleaner /remover. Flushing the inspection surface with cleaner / remover is expressly forbidden.

y Excess water washable Penetrant, after the prerequisite dwell time, shall be removed with a coarse water

spray at a pressure not exceeding 345 kPa and a temperature not exceeding 43C. Over-washing the test

surface shall be avoided.

y Postemulsification Penetrants

y Lipophilic Emulsification .After the required Penetrant dwell time, the excess surface Penetrant shall

be emulsified by immersing or flooding the part with the emulsifier. Emulsification time is dependent on

the type of emulsifier and surface condition. The actual emulsification time shall be determined

experimentally. After emulsification, the mixture shall be removed by immersing in or rinsing with

water. The temperature and pressure of the water shall be as recommended by the manufacturer.

yHydrophilic Emulsification .After the required Penetrant dwell time and prior to emulsification, the

parts shall be pre-rinsed with water spray using the same process as for water-washable Penetrant.

Pre-rinsing time shall not exceed 1 min. After pre-rinsing, the excess surface Penetrant shall be

emulsified by immersing in or spraying with hydrophilic emulsifier. Bath concentration shall be as

recommended by the manufacturer. After emulsification, the mixture shall be removed by immersing in

or rinsing with water. The temperature and pressure of the water shall be as recommended by the

manufacturer.

Note: Final Emulsification times shall be determined by experiment.


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Developer Application

y Non-aqueous-wet developer shall be used for both solvent, water-based and post emulsification techniques.

y Developer shall be immediately applied after the inspection surface has dried under natural evaporation for

solvent-based Penetrant, or natural or forced evaporation for water-based Penetrant, providing the item

temperature is not raised above 52C.

y The developer shall be applied by spraying as a thin uniform coating over the entire inspection area, so that

no metal surface or shine is visible.

Developer Dwell Time

y Developing time for final interpretation begins as soon as the developer coating is dry.

y Minimum developer dwell time shall be as required in the applicable Reference Code Section.

Interpretation

y Final Interpretation. Final interpretation shall be made within the required time according to the applicable

Reference Code Section. If the surface to be examined is large enough to preclude complete examination

within the prescribed time, the examination shall be performed in increments.

y Characterizing Indication(s). The type of discontinuities is difficult to evaluate if the Penetrant diffuses

excessively into the developer. If this condition occurs, close observation of the formation of indication(s)

during application of the developer may assist in characterizing and determining the extent of the

indication(s).

y Colour Contrast Penetrants. With a colour contrast Penetrant, the developer forms a reasonably uniform

white coating. Surface discontinuities are indicated by bleed-out of the Penetrant which is normally a deep

red colour that stains the developer. Indications with a light pink colour may indicate excessive cleaning.

Inadequate cleaning may leave an excessive background making interpretation difficult. A minimum light

intensity of 100 fc (1000 Lx) is required on the surface to be examined to ensure adequate sensitivity during

the examination and evaluation of indications. The light source, technique used, and light level verification is

required to be demonstrated one time, documented, and maintained on file.

y Fluorescent Penetrants. With fluorescent Penetrant, the process is essentially the same as with colour

contrast Penetrant, with the exception that the examination is performed using an ultraviolet light, called a

black light.The examination shall be performed as follows:

y It shall be performed in a darkened area.

y The examiner shall be in the darkened area for at least 5 min prior to performing the examination to

enable his eyes to adapt to dark viewing. If the examiner wears glasses or lenses, they shall not be

photosensitive.

y The black light shall be allowed to warm up for a minimum of 5 min prior to use or measurement of

y The intensity of the ultraviolet light emitted. Reflectors and filters should be checked and cleaned daily

when in use. Cracked or broken filters shall be replaced immediately.

y The black light intensity shall be measured with a black light meter. A minimum of 1000

W/cm on the

surface of the part being examined shall be required. The black light intensity shall be verified at least

once every 8 hr, whenever the work station is changed, or whenever the bulb is changed.

Evaluation

y All indications shall be evaluated in terms of the acceptance standards of the Referencing Code Section.

y Discontinuities at the surface will be indicated by bleed-out of Penetrant; however, localized surface

irregularities due to machining marks or other surface conditions may produce false indications.

y Broad areas of fluorescence or pigmentation which could mask indications of discontinuities are

unacceptable, and such areas shall be cleaned and re-examined.


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Documentation

y Recording of Indications

y Recordable Indications. Recordable indications shall be recorded as specified by the Referencing

Code Section.

y Rejectable Indications. Rejectable indications shall be recorded. As a minimum, the type of indications

(linear or rounded), location and extent (length or diameter or aligned) shall be recorded.

y Examination Records. Reporting shall be done on a standard Report Sheet, unless otherwise required by

the client.

Post-examination Cleaning

When post-examination cleaning is required by the Client, it should be conducted as soon as practical after

Evaluation and Documentation using a process that does not adversely affect the part.

Documents

36983655 Pt 001 Rev 0 Liquid Penetrant Testing Procedure (1)