Job Procedure Liquid Penetrant Testing: Document No: Rev Issue Date Prepared By: Reviewed By: Approved By

Job Procedure for Liquid Penetrant Testing

Document No:

QHSE/P 11 CNDT JP48 LPIAPI 650

Rev

06

Issue Date

Prepared by:

Reviewed by:

Approved by:

Name & Signature: Vipin Kumar

Name & Signature: Prakriti Samanta

Name & Signature: Ganesh Babu

Date: 28.12.2017

Date: 28.12.2017

Date: 28.12.2017

28.12.2017

Job Procedure for Liquid Penetrant Testing Of welds

TABLE OF CONTENT SECTION

DESCRIPTION

PAGE NO.

AMENDMENT RECORD 1

SCOPE

2

PERSONNEL

3

SURFACE CONDITIONING

4

EQUIPMENT AND SUPPLIES

5

EXAMINATION

6

CALIBRATION

09

7

INTERPRETATION OF INDICATORS

09

8

EVALUATION OF INDICATIONS

04 05 05 06 09

10

9

ACCEPTANCE STANDARD (AS PER ASME SEC I. ASME SEC.VIII; DIV.1 & DIV.2,ASME B 31.1

10

10

REPAIR REQUIREMENTS

11

11

POST EXAMINTION CLEANING

12

12

REPORTING SYSTEM

13

13

RECORDING SYSYTEM

13

14

Attachment -1

14

15

Attachment -2

15

Doc. Ref.: P 11 CNDT JP48 LPI-API 650 Job Procedure for Liquid Penetrant Testing | Rev No: 06 | Date: 28.12. 2017

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Job Procedure for Liquid Penetrant Testing Of welds

AMENDMENT RECORD Revision No.

Date of Amendment

Section / Checklist Amended

06

28 Dec 2017

Sec

05

26 Dec 2016

1.8,13 & annexure 2

All

Name Amendment Details

Reviewed

Approved

Changes in Sec

Prakriti Samanta

Ganesh Babu

Section - 1.8,13 & annexure 2

Prakriti Samanta

Ganesh Babu

Overall formatting and old Procedure Reference No. Aries/DPT/API 650/03 changed to new number P 11/CNDT/JP48 DPI-API 650

Prakriti Samanta

Ganesh Babu

04

03 Jan 2016

03

27 July 2013

Revised

Ganesh Babu

Ramasamy

02

16.11.2010

Revised

Jessen P.

Ramasamy

01

10.08.2009

Revised

Jessen P.

Ramasamy

00

10.08.2001

Initial Issue

Jessen P.

Ramasamy

All

Doc. Ref.: P 11 CNDT JP48 LPI-API 650 Job Procedure for Liquid Penetrant Testing | Rev No: 06 | Date: 28.12. 2017

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Job Procedure for Liquid Penetrant Testing Of welds

1.0

SCOPE 1.1

This work instruction provides the general requirements, methods, techniques and acceptance standards for Solvent Removable, Visible Color Contrast Liquid Penetrant Examination of weld, carbon & stain less steel material.

1.2

This work instruction is used to determine the presence of

discontinuities open to

examination surface only. 1.3

This work instruction is applicable when the material and penetrant is within the temperature range of 50o F (10o C) to 125o F (52ºC).

1.4

This work instruction shall be used as specified in the shop ITP

1.5

ATTACHMENT- 1 to this procedure details the essential and non-essential variables applicable for this work instruction and their qualified range, this procedure is demonstrated to the satisfaction of AI as per T-150(a) of Section V & Certified by Manager QA/QC.

1.6

Any change in an essential variable shall require demonstration to AI and applicable revisions to this procedure & thereby rectification of the same.

1.7

Any change in the non-essential variable does not require re-qualification but may require revisions to this work instruction

1.8

Reference Documents Latest edition of the following documents are referred: ASME–BPVC-Section V-2017 Edition ASME –BPVC-Section VIII Division 1 & 2-2017 Edition ASME-BPVC-Section I –Edition 2015 API 653-5TH Edition 2014-Tank Inspection, Repair, Alteration ASNT SNT TC 1A-2011& 2016 Edition API 650 – 12 TH Edition 2013-Welded Tanks for Oil Storage Aries Written Practice-Aries-NDT-GQP-01-Rev 10

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Job Procedure for Liquid Penetrant Testing Of welds

2.0

PERSONNEL 2.1 Personnel performing examination to this work instruction shall be qualified and certified according to Aries written practice, which meets the requirement of SNT-TC-1A. 2.2 Personnel performing Liquid Penetrant Examination - PT Level II Personnel evaluating Liquid Penetrant Examination - PT Level II / III 2.3 Personnel As per API 650 8.4.3,Liquid penetrant Examiners shall pass an annual vision test using Jaeger 2 at a distance not less than 12 inches ,and shall also be subject to an annual color-contrast test.

3.0

EQUIPMENT AND SUPPLIES 3.1

Temple stick / Surface thermometer to check the examination surface temperature.

3.2

Penetrant material used shall be Solvent Removable Visible Color Contrast of the approved Suppliers as follows SUPPLIER

MAGNAFLUX

SUPPLIER

Chemetall

MATERIAL

PRODUCT

Cleaner (in aerosol can)

SKC-S

Penetrant (in aerosol can)

SKL-SP2

Developer (in aerosol can)

SKD-S2

MATERIAL

PRODUCT

Cleaner (in aerosol can)

S72

Penetrant (in aerosol can)

Checkmor 240

Developer (in aerosol can)

LD

Any change in material from the above list shall require procedure demonstration. 3.3

Intermixing of chemicals of different manufacturers is not permitted.

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Job Procedure for Liquid Penetrant Testing Of welds

3.4

When examining nickel base alloys, austenitic or duplex stainless steels and titanium materials in the absence of any specific requirements, the total halogen (in the form of ionic chloride) contents of the penetrant materials shall not exceed 1% of the residue by weight as certified by manufacturer.

3.5

When examining nickel base alloys, penetrant materials shall be analyzed for sulphur content in accordance with SE-165 Annex 4.The sulphur content shall not exceed 1% by weight.

3.6

Batch Test Certificates containing manufacturers’ batch numbers and the test result as per Mandatory appendix II of Article 6, ASME Sec V shall be obtained for Para 4.4 and 4.5.

4.0

EXAMINATION 4.1

Surface Preparation Surfaces to be examined may be in the as welded, as rolled, as cast or as forged condition. Grinding may be necessary in certain cases where surface irregularities could mask unacceptable discontinuities.

4.2

Pre-Examination Cleaning 4.2.1 Prior to penetrant application, the surface to be examined and all the adjacent areas within at least 1 in. (25 mm) shall be cleaned by mechanical means and organic solvent to remove any dart, grease, lint, scale, welding flux or spatter, oil or other matter which could interfere with the examination.

4.2.2 Operations that may peen / close the discontinuity openings and compromise the integrity of the examination such as shot, sand, grit blasting are not recommended. When these operations are performed, precautions such as alkaline or acid etching shall be performed to ensure reopening of those discontinuities. 4.2.3 Maximum of 2 minutes may be allowed for drying the surface to be examined accomplished by normal evaporation or with forced hot or cold air before applying penetrant. Doc. Ref.: P 11 CNDT JP48 LPI-API 650 Job Procedure for Liquid Penetrant Testing | Rev No: 06 | Date: 28.12. 2017

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Job Procedure for Liquid Penetrant Testing Of welds

4.3

Application of Penetrant 4.3.1. The temperature of the penetrant and the surface of the part to be examined shall not be below 40 0F (50C) nor above 1250F (520C). Local heating or cooling is permitted, provided the part temperature remains in the temperature range of 400F to 1250F (50C to 52 0C) during the examination. For use of temperature range other than that specified above the penetrant material will be re qualified per Appendix III of article 6 of Section V. 4.3.2 Penetrant application The penetrant shall be applied by spraying or brushing, so that all surface under examination shall be thoroughly and uniformly covered by penetrant. 4.3.3 Penetrant dwell time After application, excess penetrant is drained out from the part allowing suitable dwell time of minimum 10 minutes. The dwell time is typical for the material and product as shown in Table-1. The area to be examined shall remain covered by the penetrant throughout the entire dwell time. However the maximum dwell time shall not exceed 2 hrs. or as qualified by demonstration for specific applications

TABLE - 1 Product form Material

Types of Discontinuities open to surface

Penetrant Dwell Time* (Minutes)

Carbon or

Welds

Crack, porosity, lack of fusion

10

Stainless

Casting

Cracks, Porosity, cold shuts

10

Steel

Forgings, Extrusion

Laps, Seams, External bursts

20

* For the temperature range from 50º F (10º C) to 125º F (52º C). For temperature from 40º F (5º C) up to 50º F (10º C) minimum penetrant dwell time shall be 2 times the

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Job Procedure for Liquid Penetrant Testing Of welds

value listed. That means for welds from 40º F (5º C) to 50º F (10º C) the penetrant dwell time shall be 20 minutes minimum. Footnote: Interpretation shall start immediately after application of developer and the final inspection shall be made not less than 10 minutes nor more than 60 minutes. Table II - Minimum and Maximum Time Limits for Steps in Penetrant Examination* Procedure Step

Minimum

Maximum

Minutes

Minutes

Drying after preparation (T-643)

1

---

Penetrant dwell (T-672)

10

20

Drying after penetrant removal (T-674)

---

2

Developer application (T-675)

--

2

Developing and interpretation time (T-675.3 and T-676)

10

20

4.4

Penetrant Removal

4.1.1 After the minimum penetrant dwell time the excess penetrant on the surface shall be removed so far as possible by using clean lint free cloths & jute. This operation shall be repeated until most traces of penetrant on the surface have been removed. 4.1.2 The remaining traces of penetrant shall then be removed by lightly wiping the surface with a clean cloth moistened with solvent cleaner. To minimize removal of penetrant from discontinuities care shall be taken to avoid the use of excess solvent cleaner. If wiping is not effective the part shall be dried in ambient temperature and penetrant be reapplied for the prescribed dwell time range as per Table 1. 4.1.3 Flushing the surface with solvent cleaner following application of the penetrant and prior to developing is strictly prohibited. 4.5

Drying after Excess Penetrant Removal

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Job Procedure for Liquid Penetrant Testing Of welds

For this solvent removable technique, drying shall be accomplished by exposure to ambient temperature. Local heating / cooling is permitted but with proper care to the component provided the temperature of the part remains within the temperature range of 400F (5 0C ) to 1250F ( 520C). Minimum time of drying should be 1 minute and maximum time for drying shall be 2 minutes before application of developer. 4.6

Application of Developer 4.6.1 The developer is of solvent suspended non-aqueous wet type and shall be applied as soon as possible after the excess penetrant (shall not exceed 10 min.) has been removed and the part has been dried. Developer shall be applied by spraying from spray cans after good agitation in such a manner to assure complete part coverage with a thin uniform film. The spray nozzle tip of the spray should be held about

12

in.

from

the examination

surface

approximately

perpendicular. The second coat may be applied across the direction of first coat. Dipping, Flooding is prohibited. 4.6.2

Where safety or restricted access makes it impractical to apply developer by spraying; developer shall be applied by brushing. Drying shall be by normal evaporations.

4.7

Developing time Developing time being immediately as soon as the wet developer coating is dry. The length of time the developer is to remain on part being examined, prior to final interpretation shall be minimum 10 minutes maximum 20 minutes.

5.0

CALIBRATION Light meter shall be calibrated at least once in a year or whenever the meter has been repaired. If the meter has not been in use for one year or more, recalibration shall be done prior to use.

6.0

INTERPRETATION OF INDICATIONS

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Job Procedure for Liquid Penetrant Testing Of welds

6.1

Illumination (natural or supplemental white light) of the examination surface shall be required for the evaluation of indications. The minimum light intensity shall be 1000 lux (100 fc). The light intensity, natural or supplemental white light source, shall be measured with a white light meter prior to the evaluation of indications or a verified light source shall be used. Verification of light sources is required to be demonstrated one time, documented, and maintained in the file.

6.2

Observation of the formation of indications shall be performed during the application of developer. If defects are present, they will show up as red indications on white developer coating. Some may appear immediately while some may take a little longer to develop.

6.3

Final interpretation of indications shall be made within 10 - 20 minutes after the wet developer coating is dry. If the surface to be examined is so large that a complete examination cannot be completed within the prescribed time, then only portions shall be examined at time.

6.4

The rate of bleeding is an indication of the width & depth of defect while the extent and spread of bleeding is an indication of the volume of flaw. Relevant indications are those caused by discontinuities that are open to the examination surface.

6.5

Non-relevant indications are those caused by the conditions other than discontinuities such as surface irregularities due to machining, grinding, faying surfaces, press-fits, poorly removed paint etc. These indications, which may mask discontinuities, shall be removed, cleaned and re-examined

6.6

Linear indications are those having a length greater than 3 times the width

6.7

Rounded indications are those of circular or elliptical shape with a length equal to or less than 3 times the width

7.0

EVALUATION OF INDICATIONS 7.1

Indications whose major dimensions are greater than 1/16 in. (1.5mm) shall be considered relevant. All indications shall be evaluated in terms of acceptance standards as specified in this procedure.

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Job Procedure for Liquid Penetrant Testing Of welds

7.2

Discontinuities at the surface will be indicated by bleed back feature of the penetrant. Any indication, which is believed to be non-relevant, shall first be regarded as a defect and shall be re-examined to verify whether or not actual defects are present. Surface conditioning may precede the re-examination. No relevant indications and broad areas of pigmentation, which would mask indications of defects, are unacceptable and shall be eliminated from the surface and re-examined.

7.3

Indication of a discontinuity may be larger than the actual discontinuity that causes it; however, the size of the final indication and not the size of the discontinuity is the basis of acceptance or rejection it.

8.0

ACCEPTANCE STANDARD (AS PER ASME SEC. VIII; DIV. 1,). 8.1

All welds such as LS, CS, including pressure part fillets, such as welds joining nipple/ stub / branch to drum, header, pipelines shall be free of following relevant indications.

8.1.1

All cracks lack of fusion and relevant linear imperfections.

8.1.2 Relevant rounded indications with dimension greater than 3/16 in. (5.0 mm) 8.1.3 In-line porosity i.e. four (4) or more relevant porosity indications separated by 1/16 in. (1.5 mm) or less edge to edge. 8.2

For non-load bearing attachment welds as determined by Design Engineering shall be examined to an extent of 10% of total length and essentially free of cracks. Here rounded indications are not a factor in acceptability of welds. However, in case of appreciable number & size of rounded indications rectifications and re-examinations required.

9.0

REPAIR REQUIREMENTS Unacceptable imperfections shall be repaired and reexamination made to assure removal or reduction to an acceptable size. Whenever an imperfection is repaired by chipping or grinding and subsequent repair by welding is not required, the excavated area shall be blended into the surrounding surface so as to avoid sharp notches,

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Job Procedure for Liquid Penetrant Testing Of welds

crevices, or corners. Where welding is required after repair of an imperfection, the area shall be cleaned and welding performed in accordance with a qualified welding procedure. Treatment of indications believed no relevant: Any indication which is believed to be no relevant shall be regarded as an imperfection unless it is shown by reexamination by the same method or by the use of other nondestructive methods and/or by surface conditioning that no unacceptable imperfection is present. Examination of areas from which defects have been removed: After a defect is thought to have been removed and prior to making weld repairs, the area shall be examined by suitable methods to ensure it has been removed or reduced to an acceptably sized imperfection. Reexamination of Repair areas. After repairs have been made, the repaired area shall be blended into the surrounding surface so as to avoid sharp notches, crevices, or corners and reexamined by the liquid penetrant method and by all other methods of examination that were originally required for the affected area, except that, when the depth of repair is less than the radiographic sensitivity required, reradiography may be omitted. 10.0

POST EXAMINATION CLEANING Post examination cleaning is necessary only in those cases where residual penetrant materials could interfere with subsequent processing or with service requirements. It is specially required in case of stainless steel components where residual penetrant materials smite interact with other factors leading to corrosion. If post cleaning is deemed necessary it shall be done promptly after evaluation by coarse water rinsing or water spray or solvent wiping, which does not adversely affect the part.

11.0

LIGHT METER 11.1 Calibrated white light meter shall be used to establish the light intensity required for examination. A 60W/220V bulb gives sufficient light intensity (1000 Lux) at a distance of 250 mm (10”). 11.2 The white light meter shall be calibrated at least once in a year or whenever the meter has been damaged or repaired or there is a doubt on the accuracy

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Job Procedure for Liquid Penetrant Testing Of welds

of the meter. If the meter has not been in use for one year or more, recalibration shall be done before being used. 11.3 Calibrated white light meter shall be used when it is required to establish the required light intensity for any other light source and distance. 12.0

REPORTING SYSTEM ( Ref: Aries/PT/01 Rev 03) Examination results shall be reported in Form (ATTACHMENT 2). This shall include as a minimum: a)

Procedure No. And revision

b)

Liquid penetrate type (visible or fluorescent)

c)

Type (Number or letter designation) of each penetrant, penetrant remover and developer used

13.0

d)

Examination personnel identity / qualification level

e)

Map or record of indication

f)

Material and thickness

g)

Lighting equipment

h)

Date and time examinations were performed

RECORDING SYSTEM All reports shall be retained for a minimum period of three (3) years unless otherwise specified in the Code Contract or Bid requirement and will be a part of documentation.

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Job Procedure for Liquid Penetrant Testing Of welds

Attachment-1 Requirements of Liquid Penetrant Examination Procedure (Table-T-621) No.

Requirement

Essential Variable

1

Identification of any change in the family group of chemical. (Penetrant Examination Chemicals) Surface preparation (finishing and cleaning, including type of cleaning solvent) Method of applying penetrant

X

Non-essential variable ----

X

----

X

----

Method of removing excess surface penetrant Hydrophilic or lipophilic emulsifier concentration and dwell time in dip tanks and agitation time for hydrophilic emulsifiers Hydrophilic emulsifier concentration in spray applications Method of applying developer Minimum & Maximum Time Periods between steps and drying aids. Decrease in penetrant Dwell time. Increase in Developer Dwell time(Interpretation Time) Minimum Light Intensity

X X

-------

X

----

X X

-------

X X

-------

X

----

Surface temperature outside 40°F to 125°F (5°C to 52°C) or as previously qualified. Performance demonstration, when required

X

----

X

----

Personnel qualification requirements Materials, shapes, or sizes to be examined and the extent of examination Post examination cleaning technique

-------

X X

----

X

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

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Job Procedure for Liquid Penetrant Testing Of welds

Attachment- 02 Reporting Format

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