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1.1
This procedure establishes the general requirements of Penetrant
Testing of ferrous and non-ferrous components (essentially non-porous) and
welds by Water Washable Process, Visible and Fluorescent Penetrant
Systems and are to be followed by NDT personnel Third Party.
2.0
PURPOSE:
2.1
The requirements are intended to detect discontinuities that are open
to test-surface and free from contaminants by interpreting the surface
indications and evaluating them in accordance with the applicable referenced
codes, standards or specifications by certified NDT personnel qualified in PT
to Level II.
2.2
Customers approved specific Inspection/Evaluation manuals have
also to be followed strictly, if available and applicable.
2.3
Any conflicts between any points of this procedure and the referenced
documents or job specifications of customer shall be resolved (if given in
writing) by the appointed ASNT NDT Level III or the Divisional Manager (NDT)
or his authorised representative.
2.4
Where special circumstances require unique techniques of Penetrant
Testing by Water Washable Process, specific technique sheets shall be
attached as Annex: IV etc., with the written approval of NDT Level III.
3.0
3.1
REFERENCES:
ANSI/ASME B31.1
Power Piping
3.2
ANSI/ASME B31.3
3.3
ASME Sec.V
3.4
ASME Sec.VIII
3.5
ANSI/AWS DI.I
3.6
API 1104
3.7
API 620
3.8
API 650
3.9
ASTM E-165
3.10
ASTM E-1209
3.11
ASTM E-1418
3.12
ANSI/ASNT-CP189
3.13
SNT-TC-1A of
ASNT
4.0
SUMMARY OF TEST METHOD & WATER WASHABLE
PENETRANTS
4.1
A liquid penetrant which may be a visible or a fluorescent material is
applied evenly over the surface being examined and allowed to enter open
discontinuities. After a suitable dwell time, the excess surface penetrant is
removed. A developer is applied to draw the entrapped penetrant out of the
discontinuity and stain the developer. The test surface is then examined to
determine the presence or absence of indications.
Note: Caution - Fluorescent penetrant examination shall not follow a visible
penetrant examination because visible dyes may cause deterioration or
quenching of fluorescent dyes.
4.2
Processing parameters, such as surface precleaning, penetration time
and excess penetrant removal methods, are determined by the specific
materials used, the nature of the part under examination, (that is, size, shape,
surface condition, alloy) and type of discontinuities expected.
4.3
Liquid penetrant examination methods indicate the presence, location
and, to a limited extent, the nature and magnitude of the detected
discontinuities. Each of the various methods has been designed for specific
uses such as critical service items, volume of parts, portability or localised
areas of examination. The method selected will depend accordingly on the
service requirements.
4.4
Water-Washable Penetrants are designed to be directly waterwashable from the surface of the test part, after a suitable penetrant dwell
time. Because the emulsifier is built-in to the water-washable penetrant, it is
extremely important to exercise proper process control in removal of excess
surface penetrant to ensure against overwashing. Water-washable penetrants
can be washed out of discontinuities if the rinsing step is too long or too
vigorous. Some penetrants are less resistant to overwashing than others.
4.5
Post-Emulsifiable penetrants with lipophilic and hydrophilic emulsifiers
are not included in this procedure.
5.0
5.1 This procedure is intended for use with the following consumables or their
equivalent. It has to be ensured that the consumables are selected in such a
way that they are compatible to the test surface and object and as per test
requirements.
Dye Penetrant Inspection - Water Washable, Fluorescent Penetrant System
Manufacturer
PENETRANT
REMOVER
DEVELOPER
Sherwin
HM-440, HM-430
Water
D-100, D-100NF
Ardrox
Water
9D1B
Magnaflux
ZL-60C
Water
SKD-LT or ZP-9F
PENETRANT
REMOVER
DEVELOPER
Sherwin
DP-51
Water
D-100, D-100NF
Ardrox
906/303A
Water
9D1B
Magnaflux
SKL-WP
Water
SKD-NF,SKD-S, ZP-9B
5.2
Intermixing of penetrant materials from
(manufacturers) is not permitted by this procedure.
different
families
When testing nickel based alloys, austenitic stainless steels and titanium,
contaminant content of penetrant materials shall be controlled. Control
shall be based on the manufacturers batch certification which shall
include, as a minimum, the manufacturers name, batch number and
chemical contaminant content as determined in accordance with ASME
Section V, paragraph T-625.
Only dye penetrant inspection materials having a batch number printed
on the container and traceable to a valid manufacturers batch
certification on file shall be used.
6.0
PARTS TO BE EXAMINED:
This procedure shall be used for parts or welds in ferrous and non-ferrous
materials in accordance with applicable code or specifications for parts or
welds.
When welds are tested, at least one inch of the base material on both
sides of the weld is to be covered.
7.0
SURFACE PREPARATION:
7.1
Prior to the test, the area to be inspected and at least one inch on
either side shall be free from all contaminants (dirt, grease, lint, slag,
spatter, oil, scale, water and protective coatings).
7.2
In general for welds, satisfactory results may be obtained when the
surface to be inspected is in as welded condition.
If mechanical methods of cleaning like grinding, machining or sanding is
necessary, the surface area shall be etched to remove smeared metal.
(For full details, ASME Sec. V, article 24 and SE-165 shall be referred).
After etching, suitable neutralising solutions shall be used and test surface
be washed with water.
7.3
Unless otherwise recommended by the manufacturer, welded
components or parts cleaned by Vapour degreasing, organic solvents or
detergents, and properly protected from contamination, need not be recleaned with penetrant cleaner (remover) prior to application of the
penetrant.
On occasion, a wire brush may be helpful in removing rust, surface scale,
but it is used only when no other means of removal will surface. It shall
be followed by cleaning with penetrant cleaner if compatible.
7.4
EXAMINATION:
8.1
The temperature of the penetrant materials and the surface of the part
should be between 50F and 100F for fluorescent water washable
penetrants and between 60F and 125F for visible penetrants.
8.2
c) Fillers shall be used on the upstream side of the air inlet when using
compressed air to apply penetrant.
8.3
Form
Type of Discontinuity
Water-Washable Penetration
Time*
Aluminium
Castings
5 to 15 min
Aluminium
Extrusions,
Forgings
Laps
NR**
Aluminium
Welds
30
Aluminium
All
Magnesium
Castings
15
Magnesium
Extrusions,
Forgings
Laps
not recommended
Magnesium
Welds
30
Magnesium
All
Steel
Castings
30
Steel
Extrusions,
Forgings
Laps
not recommended
Steel
Welds
60
Steel
All
Castings
10
Extrusions,
Forgings
Laps
not recommended
Brazed Parts
15
All
Cracks
30
Plastics
All
Cracks
5 to 30
Glass
All
Cracks
5 to 30
Carbide-tipped Tools
All
30
All
All Metals
All
8.4
not recommended
Stress or Inter-Granular
Corrosion
not recommended
When the drying process is complete, the specimen is ready for the
application of either dry or non-aqueous wet developer. When
water-based wet developer is used, it is applied by flooding the
surface to the wet specimen immediately after excess penetrant is
removed.
It is recommended to use aerosol cans, after agitation, typically for
weld inspection at various project-site works. Spray distance shall
be 10 to 12 from test surface. The test-areas must be cool
enough to prevent too repaid evaporation of the developer vehicle.
8.7.1
The area under inspection shall be observed during
application of developer and at intervals during development time.
8.7.2
The recommended development time is between 7 and 30
minutes.
Development time begins directly after application of dry developer
and as soon as wet developer coating has dried on parts-surface.
8.7.3
Indications getting formed and formed at the test surface
(by the blotting action of developer) be noticed, analysed (relevant
indications be noted) under adequate lighting conditions.
8.7.4
Lighting Conditions:
output with consequent inconsistent performance, a constantvoltage transformer should be used when there is evidence of
voltage fluctuation.
Caution: Certain high-intensity black light may emit unacceptable
amounts of visible light, which will cause fluorescent indications to
disappear. Care should be taken to use only bulbs certified by the
supplier to be suitable for such examination purposes.
Note: The recommended minimum light intensity is intended for
general usage. For critical examination, higher intensity levels may
be required.
Black Light Warm Up - Allow the black light to warm up for a
minimum of 10 min prior to its use or measurement of the intensity
of the ultraviolet light emitted.
Visual Adaptation - The examiner should be in the darkened area for
at least 5 min before examining parts to allow the eyes to adapt to
the dark viewing.
Caution - Photochromic
examination.
lenses
9.0
INTERPRETATIONS
INDICATIONS:
shall
AND
not
be
worn
EVALUATIONS
during
OF
9.5 Make sure that surface indications are not false indications i.e.
machining marks, mechanical conditions or other surface conditions
which cause or produce false indications.
9.6
Interpretation of indications found and determined to be
rejectable shall be based on the size of the indication. Linear
indications are those having a length greater than three times the
width. Rounded indications are those that are circular or elliptical
shape with the length equal to or less than three time the width.
9.7 All examination shall be reported on the penetrant testing
report form.
10.
SAFETY:
10.1
The certified Inspector shall be responsible for compliance
with applicable safety rules in the use of liquid penetrant materials.
10.2 Liquid penetrant should not be heated or exposed to open
flames.
10.3
Penetrant materials may be highly volatile, relatively toxic
and the liquid may cause skin irritation. Adequate ventilation at all
times shall be used.
10.4 Aerosol cans of penetrant materials should be kept out of
direct sunlight or areas in excess of 130 F. Excessive heat may
cause aerosol cans to explode.
10.5 Avoid looking directly into black light source, since the eyeball
contains a fluid that fluoresces if black light shines directly into the
eye.
11.
POST CLEANING:
11.1
Post cleaning is required (unless otherwise specified in
contract) to remove any excess residues from the penetrant
process.
11.2
A suitable cleaning technique such as water wash, vapours
degreasing, solvent soak may be employed.
11.3
Caution should be exercised to remove all developer prior to
vapour degreasing as vapour degreasing can bake the developer on
parts.
11.4
Post cleaning of water washable fluorescent penetrant tests
could be done by flushing surface with forced water spray or by
flushing the surface with an approved solvent cleaner depending on
the actual job requirements. Clean cloth and or absorbent paper
towel and or dry air jet could also be used.
11.5
Points mentioned in 11.4 is applicable for water washable visible dye also.
12.
12.1
Personnel performing examinations in accordance with this
procedure shall be qualified and certified in accordance with SNT-TCIA (1992 edition) or CP-189 (1995 edition) of ASNT.
12.2
Only individuals qualified to NDT Level I and working under
the supervision of an NDT Level II or III or individuals qualified to
NDT Level II shall perform the examinations in accordance with this
procedure.
13.
13.2
13.3
13.4
13.5
Weld or other component inspection when solvent process is
found not suitable or preferable.
13.6 Articles having medium rough surfaces (if medium sensitivity
is acceptable).
13.7
13.8
14.0 CHARACTERISTICS
OF
FLUORESCENT PENETRANT TESTS:
Dye Penetrant Inspection - Advantages
WATER-WASHABLE
Small Specimens
Relatively Inexpensive
Easily Over-washed
1.
Liner Indications
Rounded Indications.
indications
exceed
1.
2.
Rounded indications
1.
2.
Rounded indications
2.
1.6
Subtract the reading recorded in 1.5
recorded in 1.4 and document the results.
1.7
Ensure that the value obtained in step 1.6 is a minimum of
3000 microwatt/cm2 for work in areas other than booths specifically
designed for ultraviolet light work. For work in a darkened booth, a
minimum value of 1000 microwatt/cm2 is required.
1.8 The black light intensity shall be measured at least once every
8 hours, or whenever the work station is changed.
Note: The J-221 meter has 2 scales. The A scale reads from 0-12
and the B scale reads from 10-60. To convert the meter reading to
microwatts per square cm., multiply the meter reading by 100. For
example, a meter reading of 30 would be 30 x 100 = 3000
microwatts/cm2.
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