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Procedure
This article provides you with a example dye penetrant
inspection procedure. This procedure contains water washable
process with both visible and fluorescent systems.
1.0
SCOPE
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
3.2
REFERENCES:
ANSI/ASME
B31.1
ANSI/ASME
B31.3
Power Piping
Chemical Plant and Petroleum Refinery Piping
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
3.1
0
ASTM E-1209
3.1
1
ASTM E-1418
3.1
2
ANSI/ASNT-CP189
3.1
3
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
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 different families
(manufacturers) is not permitted by this procedure.
6.0
PARTS TO BE EXAMINED:
This procedure shall be used for parts or welds in ferrous and nonferrous 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,
EXAMINATION:
8.1
Form
Type of Discontinuity
Water-Washable
Penetration Time*
Aluminium
Castings
5 to 15 min
Aluminium
Extrusions,
Forgings
Laps
NR**
Aluminium
Welds
Lack of Fusion,
Porosity
30
Aluminium
All
Cracks, Fatigue
Cracks
Magnesium
Castings
15
Magnesium
Extrusions,
Forgings
Laps
not recommended
Magnesium
Welds
Lack of Fusion,
Porosity
30
Magnesium
All
Cracks, Fatigue
Cracks
Steel
Castings
30
Steel
Extrusions,
Forgings
Laps
not recommended
Steel
Welds
Lack of Fusion,
Porosity
60
Steel
All
Cracks, Fatigue
Cracks
Castings
10
Extrusions,
Forgings
Laps
not recommended
Brazed Parts
Lack of Fusion,
Porosity
15
All
Cracks
30
Plastics
All
Cracks
5 to 30
Glass
All
Cracks
5 to 30
Carbide-tipped Tools
All
Lack of Fusion
Porosity, Craks
30
All
not recommended
Temp Alloys
All Metals
8.4
All
not recommended
The test surface must be dry prior to the application of nonaqueous or dry developers. If water-based wet developer is
used, it is applied to still damp specimen immediately after the
penetrant removal wash. Excessive heat or too long a drying
time tends to bake the penetrant out of discontinuities.
8.6
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:
a) Visible penetrant indications can be examined in either
natural or artificial light. Adequate illumination is required to
ensure no loss in the sensitivity of the examination. A
minimum light intensity at the examination site of 100 fc (1000
Lx) is recommended.
b) Examine fluorescent penetrant indications under black light
in a darkened area. Visible ambient light should not exceed 2
ft candles (20 Lx). The measurement should be made with a
suitable photographic-type visible light meter on the surface
being examined.
Black Light Level Control - Black light intensity, minimum of
1000 W/cm2, should be measured on the surface being
examined, with a suitable black light meter. The black light
wavelength shall be in the range of 320 to 380 nm.
The intensity shall be checked at least once every 8 hours, or
whenever the work station is changed. Cracked or broken
ultraviolet (UV) filters should be replaced immediately.
Defective bulbs, which radiate UV energy, must be replaced
before further use. Since a drop in line voltage can cause
decreased black light output with consequent inconsistent
AND
EVALUATIONS
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-TC-IA (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
1.4 Record the meter reading without the UPV Filter # 50107
attached to the J-221.
1.5 Attach the UPV Filter # 50107 over the sensing element
of the J-221 and record the meter reading.
1.6 Subtract the reading recorded in 1.5 from the reading
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 012 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.