SCANTECH INSPECTION SERVICES

Non Destructive Testing, Positive Material Identification, QA/QC Consultancy

Unit 13 Wallows Industrial Estate, Fenspool Avenue, Brierley Hill, West Midlands. DY5 1QA

Telephone

:01384 79924 Fax

:01384 79925

DYE PENETRANT INSPECTION PROCEDURE NUMBER D010 REVISION 0 BASED ON THE REQUIREMENTS OF ASME VIII DIVISION 1 APPENDIX 8

DYE PENETRANT INSPECTION PROCEDURE NUMBER D010.

CONTENTS
1. SCOPE. 2. REFERENCE DOCUMENTS. 3. DEFINITIONS. 4. PERSONNEL. 5. EQUIPMENT (CONSUMABLES). 6. GENERAL REQUIREMENTS. 7. FUNCTION TESTS AND METHOD. 8. PRE-CLEANING. 9. PENETRANT APPLICATION. 10. PENETRANT REMOVAL. 11. SURFACE DRYING. 12. APPLICATION OF DEVELOPER. 13. EXAMINATION. 14. VIEWING CONDITIONS. 15. CLASSIFICATION OF INDICATIONS. 16. POST CLEANING. 17. INDICATION SIZING. 18. REPORTING. 19. ACCEPTANCE STANDARDS. 20. SAFETY PRECAUTIONS. APPENDIX 1. TYPICAL REPORT FORMAT.

DYE PENETRANT INSPECTION PROCEDURE NUMBER D010.

1. SCOPE This procedure is applicable to the Penetrant flaw detection system for metallic materials and is limited to the following. The detection of surface breaking discontinuities.

2. REFERENCE DOCUMENTS. This procedure conforms to the requirements of the following documents. ASME VIII DIVISION 1 pr EN 1330-6. BS EN ISO 10228-2 Pr EN ISO 3452-2, 3 & 4. ASTM E165.

3. DEFINITIONS. The terms and definitions given in pr EN 1330-6 shall apply.

4. PERSONNEL. Operators performing examination to this procedure shall be qualified to PCN/ASNT LEVEL II.

5. EQUIPMENT (CONSUMABLES). The following consumables shall be used unless otherwise specified by the client. Penetrant Developer Cleaner :Johnson and Allen W/W. Visible water washable Johnson and Allen Neon w/w Fluorescent water washable :Johnson and Allen JAD Non aqueos Johnson and Allen PD3 Dry powder :Johnson and Allen JAC Cleaner (Pre and Post).

They are manufactured to conform to the following standards as applicable. MIL-1-25135. DTD 929. DIN 54 152 T2.

DYE PENETRANT INSPECTION PROCEDURE NUMBER D010. 6. GENERAL REQUIREMENTS. The areas to be tested shall be free from any extraneous matter and surface coating that may impair the results of the examination. The temperature of the surface of the item under test shall be between 10 o C and 40 o C as recommended by the manufacturer. 7. FUNCTION TESTS AND METHOD. 7.1. The penetrant system and the equipment used must be capable of providing consistent and repeatable results. Prior to any work commencing, checks shall be made on the equipment and the consumable materials by running standard test pieces through the complete system. If the results are shown to be unsatisfactory the relevant component of the system shall be replaced and the function test repeated in full. FUNCTION AND TEST METHOD (continued) 7.2. The testing shall be carried out in the following order. 1. 2. 3. 4. 5. 6. 7. Pre-clean. Apply penetrant. Remove excess penetrant. Dry surface. Apply developer. Inspect and record results. Post-clean.

8. PRE-CLEANING. Chemical pre-cleaning shall be carried out using a suitable agent in order to remove residues such as grease oil paint etc. As a final pre-cleaning operation each surface is to be dipped, sprayed, wiped or brushed with the systems approved cleaner and dried with forced air, lint free cloths and allowed to stand for a minimum of 5 minutes prior to penetrant application to allow for evaporation.

DYE PENETRANT INSPECTION PROCEDURE NUMBER D010.

9. PENETRANT APPLICATION. Penetrant shall be applied by spraying, brushing or immersion and shall remain in contact with the surface under test for a minimum of 20 minutes. If the penetrant dwell time shall not exceed thirty minutes without a further application of penetrant to prevent drying / thickening. In all cases penetrant dwell time shall not exceed 60 minutes. 10. PENETRANT REMOVAL. The surface may be washed with a low-pressure water jet or wiped with a dampened lint free cloth. Water pressure shall not exceed 2 bar (mains pressure) and the temperature shall not exceed 50 o C. Care shall be taken to avoid over washing and penetrant removal confirmed with a UV-A light placed at the wash station. 11. SURFACE DRYING. The excess water can be removed with forced air or with absorbent paper. Final drying shall take place by applying a low temperature warm airflow for a few minutes to aid natural evaporation with the temperature not exceeding 50 o C as supplied by a heater cabinet.

12. APPLICATION OF DEVELOPER. 12.1 Fluorescent technique Dry powder developer shall be applied by the use of a powder cabinet. The test surface shall be thinly covered. Collections of powder are not permitted and shall result in the complete process being repeated. 12.2 Visible technique The developer shall be applied by the use of an aerosol spray. The test surface shall be thinly covered. Collections of developer per are not permitted and shall result in the complete process being repeated.

13. EXAMINATION. Examination shall take place no sooner than 7 minutes after developer application and no longer than 15 minutes after developer application.

DYE PENETRANT INSPECTION PROCEDURE NUMBER D010. 14. VIEWING CONDITIONS. 14.1 Fluorescent technique

The area under test shall be illuminated with a UV-A light fitted with the appropriate filter and shall be in accordance with EN ISO 3059. The output of the light shall be checked weekly and the results recorded. The background white light level at the area of interest shall not exceed 20 lux. The UV-A level at the level of interest shall be not less than 1000 uW/cm2. A period not less than 15 minutes shall be allowed for the operator to become accustomed to the reduced lighting levels and for the UV-A light to reach full intensity. The wearing of light sensitive spectacles is not permitted. 14.2 Visible technique The test area shall be illuminated by daylight or artificial light to a level of not less than 500 lux for the proper evaluation of the indications revealed on the test surface. Viewing conditions are to be such that glare is avoided. 15. CLASSIFICATION OF INDICATION. Penetrant flaw detection is capable of revealing surface breaking flaws in the following categories. Linear indications whose length is more than 3 times its width. Rounded indications whose length is less than 3 times its width and a predominantly circular or elliptical. Intermittent and aligned indications shall be treated as linear.

16. POST CLEANING. On completion of the examination all test materials shall be removed as soon as possible using water or the systems approved cleaner.

DYE PENETRANT INSPECTION PROCEDURE NUMBER D010. 17. INDICATION SIZING. The assessment of flaws by size is to be based on the bleed out not the defect causing the bleed. The brightness of the indication is determined by many variables and shall not be used to make an assessment of flaw depth. 18. REPORTING. The following information will be added as a minimum to the standard Scantech Inspection report format. (See appendix 1.). 1. Procedure number. 2. Equipment type. 3. Surface condition. 4. Penetrant dwell time. 5. Development time. 6. Acceptance level. 7. Item size and cast / batch numbers. 8. Results of inspection. 9. Operators name (printed and signed). 10. Operators qualification status. 19. ACCEPTANCE STANDARD. The results of the test shall be interpreted against the acceptance criteria specified by the client which for the purpose of this procedure shall be ASME VIII DIVISION 1 APPENDIX 8

20. SAFETY PRECAUTIONS. It is necessary for all personnel engaged in penetrant flaw detection to be aware of and to observe the requirements of the Health and safety at work act 1974 and the Control of substances hazardous to health regulations. Suitable precautions to avoid hazards shall be taken and all materials shall be used in accordance with the manufacturers instructions and the company Health and safety manual.

DYE PENETRANT INSPECTION PROCEDURE NUMBER D010.

APPENDIX 1.

DYE PENETRANT INSPECTION REPORT NUMBER

Customer Item Order number Drawing number Weld process Surface condition Procedure number Equipment Soak time Acceptance criteria VIEWING CONDITIONS U.V Output Background level Date Job reference Material Thickness Stress relief Dye type Developer Remover Dev time

RESULTS

Client / Inspection authority Name Date Signature

Scantech Inspection Services Operators Name Qualification Signature