I-2.54-e Penetrant Procedure Revize

Inspection and Testing Department

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Liquid Penetrant Inspection Procedure

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CONTENTS

ESSENTIAL AND NON ESSETIAL VARIABELES

2

1.

AIM

3

2.

SCOPE

3

3.

REFERENCES

3

4.

PERSONNEL QUALIFICATION

6

5.

DEFINITIONS AND ABBREVIATIONS

6

6.

RESPONSIBILITIES

6

7.

GENERAL AND TECHNIQUE

7

8.

CALIBRATION

10

9.

TECHNIQUE

10

10. EXAMINATION COVERAGE

10

11. SAFETY AND ENVIRONMENT

11

12. DOCUMENTATION

11

13. ACCEPTANCE CRITERIA

11

14. REPAIR

13

15. DEMONSTRATION

13

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Liquid Penetrant Inspection Procedure

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Requirements

Essential Variable

Non-essential Variable

Applicable/ Not Applicable

Paragraph

ESSENTIAL AND NONESSENTIAL VARIABLES

Identification of and any change in type or family group of penetrant materials including developers, emulsifiers, etc.

X

-

A

7.3.1

Surface preparation (finishing and cleaning, including type of cleaning solvent)

X

-

A

7.1

Method of applying penetrant

X

-

A

7.5

Method of removing excess surface penetrant

X

-

A

7.7

Hydrophilic or lipophilic emulsifier concentration and dwell time in dip tanks and agitation time for hydrophilic emulsifiers

X

-

NA

-

Hydrophilic emulsifier concentration in spray applications

X

-

NA

-

Method of applying developer

X

-

A

7.9

Minimum and maximum time period between steps and drying aids

X

-

A

7.2-7.67.8 7.9-7.10

Decrease in penetrant dwell time

X

-

A

7.6

Increase in developer dwell time (Interpretation time)

X

-

A

7.9 7.10

Minimum light intensity

X

-

A

7.11.3

Surface temperature outside 40 to 125 ºF (5 to 52 ºC) or as previously qualified

X

-

A

7.3

Performance demonstration, when required

X

-

A

15

Personnel qualification requirements

-

X

A

5-6

Materials, shapes, or sizes to be examined and the extent of examination

-

X

A

7.1.1

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Liquid Penetrant Inspection Procedure

Post-examination cleaning technique

1

-

Document Page Date Revision

X

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A

AIM The aim of this procedure is to describe the requirements for implementation of Visible Liquid Penetrant Examination of welds for cracks or other surface braking discontinuities, which are being performed by S&Q Mart in compliance with the ASME Codes.

2

SCOPE This procedure defines the techniques to be used in order to carry out Visible Liquid Penetrant examination of welds and parent metals of all shapes and sizes in scope of ASME Code Work.

3

DEFINITIONS AND ABREVIATIONS

3.1 ASME American Society of Mechanical Engineers

3.2 ASME Code The ASME Boiler and Pressure Vessel Code, Section I & II Part A, B, C, D; SectionV; Section VIII Division 1, Section IX, ASME B 31.1.

3.3 A Linear Indication Indication, which is having a length greater than three times its width

3.4 A rounded indication Indication, which has a circular or elliptical shape that with length equal to or less than three times the width

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7.12

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3.5 Relevant indications Those, which are result due to unacceptable discontinuities

3.6 False indications Those are not result of magnetic forces. Examples are particles held mechanically or by gravity in shallow depressions or particles held by rust or scale on the surface.

3.7 Activity One of the organizational elements of agency of the S&Q MART.

3.8 Approval Requires dated signature by the approving person.

3.9 ASNT American Society of Nondestructive Inspection Testing

3.10 Authorized Inspection Agency An inspection organization which provides code inspections. Such Authorized Inspection Agency shall have a valid service agreement for code inspection with Stamp Holder and shall be accredited by ASME.

3.11 Authorized Inspector The Authorized Inspector is employed by the Authorized Inspection Agency and is the independent third-party inspector required by the ASME Code. The Authorized Inspector shall hold a valid National Board Commission, issued by the National Board of Boiler and Pressure Vessel Inspectors, with an A endorsement.

3.12 Certification Written testimony of qualification

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3.13 Certifying Authority The person or persons properly designated in the written practice to sign certification on behalf of the employer.

3.14 Code Work All activities necessary to construct Code products, including design, procurement, material control, fabrication, site construction, examination, test, inspection, certification and Code stamping.

3.15 Documented The condition of being in written form.

3.16 Evaluation The determination of the significance of relevant indications.

3.17 Interpretation The determination of whether indications are relevant or not relevant.

3.18 Method One of the disciplines of Nondestructive Inspection or testing (e.g. radiography) within which different techniques exist.

3.19

Procedure

A detailed, written instruction for conducting NDI or NDT or certifying personnel.

3.20 isible Penetrant A liquid penetrant that is characterized by intense color, usually red.

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3.21 Abreviations AI : Authorized Inspector AIA : Authorized Inspector Agency AIS : Authorized Inspector Supervisor TIM : Testing and Inspection Department Manager

4

REFERENCES

4.1 ASME Section V, Article 6 (2007 Edition, 2008 Addenda) Liquid Penetrant Examination ASME Section I (2007 Edition, 2008 Addenda) ASME Section VIII Div. 1(2007 Edition, 2008 Addenda) ASME B31.1 (2007 Edition, 2008 Addenda)

5

Power Boilers Pressure Vessel Power Piping

PERSONNEL QUALIFICATION All personnel to carry out penetrant testing shall be qualified and certified according to S&Q MART Written Practice for NDT Personnel Certification based on SNT-TC-1A and alternatively; personnel may be qualified and certified based on company procedures and related article of Construction Code. For acceptance evaluation, Level II shall be the minimum requirement. If PED 97/23/EC is applicable than supplemental qualifications shall required to comply with PED.

6

RESPONSIBILITIES and PERSONNEL

6.1 Inspection and Testing Department Manager shall be responsible for the execution of this procedure.NDT Level III shall be responsible for preparation and revision of this procedure.

6.2 NDT personnel who will be apply Liquid Penetrant Examination shall be qualified as described in section 6.3 below 6.3

Liquid Penetrant Examination shall only be performed by qualified personnel who is level I, Level II or Level III.

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6.4

Liquid Penetrant examination shall be carried out by at least Liquid Penetrant examination Level I persons.

6.5

Evaluation of the indications shall be carried out by at least Liquid Penetrant examination Level II persons.

7

GENERAL AND TECHNIQUE

7.1 SURFACE PREPARATION 7.1.1 As-welded, grinded or machined surfaces are acceptable for the penetrant examination. The material, shape and size of the examination object are as given on the manufacturing drawing. Blasting with shot or dull sand may close discontinuities at the surface and should not be used.

7.1.2 Prior to each liquid penetrant examination, the surface to be examined and all adjacent areas within at least 25 mm shall be dry and free of all dirt, grease, lint, scale, welding flux, weld spatter, paint, oil, and other extraneous matter that could obscure surface openings or otherwise interfere with the examination . 7.1.3 Cleaning agents used is BETA BT 69. 7.1.4 Cleaning solvents shall meet the requirements of 7.1.5. The cleaning method employed is an important part of the examination process. 7.1.5 The user of this procedure shall obtain certification of contaminant content for all liquid penetrant materials used on nickel base alloys, austenitic or duplex stainless steels, and titanium. These certifications shall include the penetrant manufacturers’ batch numbers and the test results obtained in accordance with ASME Section V Article 6 Mandatory Appendix II.

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7.2 DRYING AFTER PREPARATION 7.2.1 After cleaning, drying of the surfaces to be examined shall be accomplished by normal evaporation or with forced hot or cold air. Minimum 2 minutes shall pass to ensure that the cleaning solution has evaporated prior to application of the penetrant.

7.3

PENETRANT MATERIAL AND SURFACE TEMPARATURES

7.3.1 The temperature of the penetrant and the surface of the part to be processed shall not be below 5°C or above 52°C throughout the examination period. Local heating or cooling is permitted provided the part temperature remains in the range of 5°C to 52°C during the examination. 7.3.2 Nonstandard temperatures outside of Paragraph 7.3.1 may be used if qualified according to Sec. V Article 6 Mandatory Appendix III.

7.4

PENETRANT MATERIALS

7.4.1

Cleaner used before and/or after penetrant application shall be BETA BT 69.

7.4.2 The type of the penetrant material used shall be Type II – Visible Penetrant Examination, Method C – Solvent Removable. 7.4.3 Penetrant material shall be visible BETA BT 68. 7.4.4 Developer materials shall be BETA BT 70.

7.5 METHOD OF APPLICATION 7.5.1 The penetrant shall be applied by spraying.

7.6

DWELL TIMES

7.6.1 Minimum dwell times for penetrants and developers shall be as recorded in Table-1. Materials

Forms

Ferritic materials, Austenitic stainless steel

Welds and Casting

Type of Discontinuities Cold shuts, porosity, lack of fusion, cracks (all forms)

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Dwell Times Penetrant Developer 10 minutes

10 minutes

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materials and nickel base alloys Ferritic steel, austenitic stainless steel and nickel base alloys

Liquid Penetrant Inspection Procedure

Wrought materials (Extrusions, forging, plate)

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Laps, cracks (all forms) 10 minutes

10 minutes

NOTE: (1) For temperature range from 50°F to 125°F (10°C to 52°C). For temperatures from 40°F (5°C) up to 50°F (10°C), minimum penetrant dwell time shall be 2 times the value listed.

TABLE-1 Dwell Times 7.6.2 Maximum penetrant dwell time shall not exceed 30 minutes provided that penetrant on the surface do not dry during this period.

7.7 EXCESS PENETRANT REMOVAL 7.7.1 After the specified penetration time has elapsed, any penetrant remaining on the surface shall be removed, taking care to minimize removal of penetrant from discontinuities. 7.7.2 Excess solvent removable penetrants shall be removed by wiping with a cloth or absorbent paper, repeating the operation until most traces of penetrant have been removed. The remaining traces shall be removed by lightly wiping the surface with cloth or absorbent paper moistened with solvent. To minimize removal of penetrant from discontinuities, care shall be taken to avoid the use of excess solvent. Flushing the surface with solvent, following the application of the penetrant and prior to developing, is prohibited.

7.8 DRYING AFTER EXCESS PENETRANT REMOVAL 7.8.1 For the solvent removable technique, the surfaces may be dried by normal evaporation, blotting, wiping or forced air and this drying process shall not exceed 5 minutes and developer shall be applied not later than 5 minutes after excess penetrant removal.

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7.9 DEVELOPING 7.9.1 Non-aqueous developer shall be applied only to a dry surface. It shall be applied by spraying, except where safety or restricted access precludes it. Under such conditions, developer may be applied by brushing. Drying shall be by normal evaporation. 7.9.2 Developing time for final interpretation begins as soon as a wet developer coating is dry. The minimum developing time shall be as required by Table 1.

7.10 FINAL INTERPRETATION 7.10.1 Final interpretation shall be made within 10 to 30 min. after the requirements of 7.8.2 are satisfied. If bleed-out does not alter the examination results, longer periods are permitted. If the surface to be examined is large enough to preclude complete examination within the prescribed or established time, the examination shall be performed in increments.

7.11 CHARACTERIZING THE INDICATIONS 7.11.1 The types of discontinuities are 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). 7.11.2 With a color 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 color that stains the developer. Indications with a light pink color may indicate excessive cleaning. Inadequate cleaning may leave an excessive background making interpretation difficult. 7.11.3 Minimum 250 W Arcstream HALOLINE Bulb is required at a distance of maximum 2000 mm to provide a light intensity of 1015 Lux minimum to ensure adequate sensitivity during the examination and evaluation of indications.

7.12 POST INSPECTION CLEANING 7.12.1 Post inspection cleaning should be conducted by brushing or wiping with a cloth. However, if it is required for special circumstances, it shall be conducted as soon as practical after Evaluation and Documentation, using the same cleaning agent used for pre-cleaning.

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8

8.1

9

9.1

Liquid Penetrant Inspection Procedure

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CALIBRATION

Visible light meter shall be calibrated at least once a year, or whenever the meter has been repaired. If meters have not been used for more than one year or more, calibration shall be done before being used.

TECHNIQUE

Steps as described in paragraph 7.0 shall be applied.

10 EXAMINATION COVERAGE 10.1 The extent of penetrant testing coverage shall be 100% of the surface of the weld plus 25 mm each side unless otherwise stated by the client.

11 SAFETY AND ENVIRONMENT

11.1 The control of any waste associated with the use of this procedure or any hazards to the environment shall be the responsibility of the approved NDT subcontractor. 11.2 All penetrant materials used by this procedure are flammable liquids and aerosols. Vapor may cause flash fire. Harmful or fatal if swallowed. Mist or vapor may irritate the respiratory tract. Liquid contact may cause eye and skin irritation. Overexposure may cause central nervous system (CNS) depression and target organ effects. Spills may create a slipping hazard. 11.3 For detailed information on hazards, Material Safety Data Sheets (MSDS) of related penetrant material shall be consulted.

12 DOCUMENTATION

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12.1 Rejectable indications shall be recorded as a minimum, the type of indications (linear or rounded), location and extent (length or diameter or aligned). 12.2 Each examination, the following shall be recorded on the PT Report attached: Procedure identification and revision, Liquid penetrant type (visible), Type (number or letter designation) of each penetrant, penetrant remover and developer used, Examination personnel identity, qualification level, and referencing Code Section, Map or record the indications as per 12.1, Material and thickness Lighting equipment Date of examinations 12.3 Performance demonstration shall be documented when required by referencing Code Section.

13 ACCEPTANCE CRITERIA The acceptance criteria shall be as per ASME B31.1 chapter 6 paragraph 136.4.4 & ASME SECTION VIII DIV.-1 APPENDIX 8.4 & ASME SECTION I Applications -Nonmandatory Appendix A.

13.1 EVALUATION OF INDICATIONS

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13.1.1 Mechanical discontinuities at the surface will be indicated by bleeding out of the penetrant; however, localized surface indications, such as may occur from machining marks or surface conditions, may produce similar indications which are non-relevant to the detection of unacceptable discontinuities. 13.1.2 Any indication which is believed to be non-relevant shall be regarded as a defect and shall be reexamined to verify whether or not actual defects are present. Surface conditioning may precede the reexamination. Non-relevant indications and broad areas of pigmentation, which would mask indications of defects, are unacceptable. 13.1.3 Relevant indications are those, which result from mechanical discontinuities. A linear indication is one having a length greater than three times the width. A rounded indication is one of circular or elliptical shape with length equal to or less than three times the width. 13.1.4 An indication of a discontinuity may be larger than the discontinuity that causes it; however, the size of the indication not the size of the discontinuity is the base of acceptance or rejection.

13.2 ACCEPTANCE CRITERIAASME SECTION VIII, DIVISION 1 Applications  : Only indications with major dimensions greater than 1/16” (1.5 mm) shall be considered relevant indications. The following relevant indications are unacceptable: a) b) c)

Any cracks or linear indications. Relevant rounded indications greater than 5 mm. Four (4) or more relevant rounded indications in a line separated by 1.5 mm or less edge to edge.

ASME B31.1 CHAPTER 6 applications: Only indications with major dimensions greater than 1/16” (2.0 mm) shall be considered relevant indications. The following relevant indications are unacceptable: a) b) c) d)

Any cracks or linear indications. Relevant rounded indications greater than 5 mm. Four (4) or more relevant rounded indications in a line separated by 2 mm or less edge to edge. Ten (10) or more rounded indication in any 3870 mm 2 of surface with the major dimension of this are not exceed 150 mm with the area taken in the most unfavorable location relative to the indications being evaluated.

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ASME SECTION I Applications (Nonmandatory Appendix A)   All surfaces to be examined shall be free of (a) relevant linear indications (b) relevant rounded indications greater than 3.16 in. (5 mm) (c) four or more relevant rounded indications in a line separated by 1.16 in. (1.5 mm) or less, edge to edge

13.2.1 Any questionable or doubtful indications shall be reexamined to determine whether they are relevant or not.

14 REPAIR

14.1 Penetrant inspection of repairs shall be performed by same technique used during the original examination.

15 DEMONSTRATION Hereby we certify that this procedure has been demonstrated to the satisfaction of the AI, and it is capable of detecting discontinuities under the conditions defined in the procedure.

_________________________ TIM

___________________________ Date

Annex 1: Liquid Penetrant Examination Report Annex 2: Light Source Verification Report

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