NOTE: THIS PROCEDURE SHALL BE USED ONLY FOR EXAMINATION PURPOSE ONLY

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 Table of Contents

1.0 SCOPE
2.0 REFERENCE
3.0 PERSONNEL QUALIFICATION
4.0 PENETRANT EXAMINATION TYPES & METHODS
5.0 TYPE OF MATERIALS
6.0 PROCEDURE REQUIREMENTS
7.0 ESSENTIAL AND NON ESSENTIAL VARIABLES
8.0 SURFARE PREPARATION
9.0 CONDITION OF EXAMINATIONS
10.0 GROUP OF PENETRANTS
11.0 TEST PROCEDURE
12.0 EVALUATION AND ACCEPTANCE CRITERIA
13.0 DOCUMENTATION OF REJECTABLE INDICATIONS
14.0 EXAMINATION RECORDS
15.0 POST CLEANING
16.0 SAFETY

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 1.0 SCOPE

1.1 This procedure describes the requirements of Liquid Penetrant Examination by Solvent
Removable technique using type-1 (Color contrast/Visible) and Type-2 (Fluorescent)
penetrants for the purpose of detecting the discontinuities which are open to the surface in
welds, prepared bevel surface and parent metal for construction of vessels, power boiler,
power piping and related attachments of carbon steel, stainless steel, duplex stainless steel or
other alloy steels and casting.

2.0 REFERENCES

a) SE-165 ASME Sec V Art 24 Ed.2015 : Standard Test method for Liquid Penetrant
Examination

b) ASME Sec I Ed.2015 : Rules for construction of Power Boilers

c) ASME Sec VIII Div. 1 Ed.2015 : Rules for construction of Pressure vessels

d) ASME Sec VIII Div. 2 Ed.2015 : Alternative Rules for construction of Pressure Vessels

e) ASME Sec V Article 6 Ed.2015 : Boiler and Pressure Vessel Code Non-Destructive
Testing- Liquid Penetrant Examination.

f) HITIS/WP/01 (Latest Revision) : Written practice for control and administration of

non-destructive testing personnel, training,
examination and certification.

g) NBIC ANSI/NB 23 Ed.2015 : Requirements for the repair and/or alternation of

boilers, pressure vessels and other pressure-
retaining items.

h) ASME B 31.1 Ed.2014/2012 : Specification for Power Piping

3.0 PERSONNEL QUALIFICATION

3.1 Personnel performing Penetrant examination shall be qualified and certified as per the written
Practice of Enagol In compliance with SNT SNT-TC-1A (2006 & 2011). Personnel qualified to
ASNT NDT Level-I or equivalent shall be used as an assistant. Interpretation and reporting of
results shall be done by a certified NDT Level II/III.

3.2 NDT Level-II/III shall have vision, with correction if necessary, to enable him to read a Jaeger
Type No. 2 Standard Chart at a distance of not less than 12 in. (300 mm), and is capable of
distinguishing and differentiating contrast between colors used. These requirements shall be
checked annually.

3.3 NDT Level-II shall be competent in the techniques of the liquid penetrant examination method
for which he is certified, including making the examination and interpreting and evaluating the
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 results, except that, where the examination method consists of more than one operation, he
may be certified as being qualified only for one or more of these operations.

4.0 PENETRANT EXAMINATION TYPES AND METHODS

The following type of penetrant and method of removal shall be applied in this procedure.

Type I- Fluorescent Penetrant Examination with method C- Solvent Removable

Type II- Visible Penetrant Examination with method C- Solvent Removable.

5.0 TYPES OF MATERIALS

The following types of penetrant examination materials are to be used.

Penetrant - Solvent Removable Penetrants (Type-I & Type-II)

Remover – Solvent Remover.
Developer – Non-Aqueous Wet Developer (NAWD).

6.0 PROCEDURE REQUIREMENTS

6.1 When required by the construction code procedure qualification test shall be performed to
meet the requirements of this procedure, before starting of the work. Any change in essential
variables in this procedure from specified value or range of values shall require the re-
qualification of this procedure. Any change other than to the essential variables does not need
re-qualification of this procedure.

6.2 All changes of essential and non-essential variables from the value, or range of values in this
procedure shall need a revision of this procedure.

6.3 Minimum and Maximum Step Times

The minimum and maximum times for the applicable examination steps listed in below table;

Minimum and Maximum Time Limits for Steps in Penetrant Examination Procedures

Procedure Step Minimum Maximum

Drying After Preparation 2 Min --
Penetrant Dwell 5 Min 10 Min
Penetrant Removal Solvent Removable -- --
Drying After Penetrant Removal - Solvent Removal
-- 10 Min
Penetrants
Developer Application -- 10 Min
Developing And Interpretation Time 10 Min 30 Min

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7.0 ESSENTIAL AND NONESSENTIAL VARIABLES

Type of Variable
Sl.
Requirement Clause
No. EV NEV
Reference
Identification of and Any Change in Type or Family Group of
1  -- 10.1
Penetrant Materials Including Developers, Emulsifiers, etc.
Surface Preparation (Finishing and Cleaning, Including Type of
2  -- 8.0
Cleaning Solvent)
3 Method of Applying Penetrant  -- 11.4
4 Method of Removing Excess Surface Penetrant  -- 11.5
Hydrophilic or Lipophilic Emulsifier Concentration and Dwell Time
5  -- N/A
in Dip Tanks And Agitation Time For Hydrophilic Emulsifiers
6 Hydrophilic Emulsifier Concentration in Spray Applications  -- N/A
7 Method of Applying Developer  -- 11.7
Minimum and Maximum Time Periods Between Steps and Drying
8  -- 11.3/11.6
Aids
Decrease in Penetrant Dwell Time 11.5
9  --
.0
10 Increase in Developer Dwell Time (Interpretation Time)  -- 11.8,11.9
11 Minimum Light Intensity  -- 11.9.1
Surface Temperature Outside 400F To 1250F (50C To 520C) Or as
12  -- 9.1
Previously Qualified
13 Performance Demonstration, When Required  -- 6.1
14 Personnel Qualification Requirements --  3.1
Material, Shapes, or Sizes To Be Examined and The Extent of
15 --  1.1
Examination
16 Post Examination Cleaning Technique --  15.0

8.0 SURFACE PREPARATION

8.1 In general, satisfactory results may be obtained when the surface of the part is in the
as-welded, As-rolled, as-cast, or as-forged condition.

8.2 Surface Preparation by grinding, machining or other methods may be necessary where
surface irregularities could mask indications of unacceptable discontinuities.
8.3 The use of grit blast cleaning or acid treatments on the surface before liquid penetrant
examination is prohibited.

8.4 Prior to liquid penetrant examination, the surface to be examined and all adjacent areas
within at least 1 inch (25 mm) shall be dry and free of all dirt, grease, lint, welding flux, weld
spatter, paint, oil, irregularities and other extraneous matter which could mask or be confused
with a defect.

8.5 In order to have a proper clean surface any one or a combination of the following cleaning
agents shall be used as feel appropriate. The typical cleaning agents are detergents, organic
solvents, descaling solution and paint remover.
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 8.6 After cleaning, the part shall be dried up properly by normal evaporation prior to application
of penetrant.

9.0 CONDITIONS FOR EXAMINATIONS

9.1 As a standard technique, the temperature of the penetrant and the surface of the part to be
processed shall not be below 40o F (5o C) nor above 125o F (52o C) throughout the
examination period. Temperature shall be measured with digital thermometer or tempilstik
temperature indicator. Calibration frequency shall be one year for digital thermometer.

9.2 Local heating or cooling is permitted provided the part temperature remains in the range of
40o F (50 C) to 125o F (52o C) during the examination.

10.0 GROUP OF PENETRANTS

10.1 The following solvent removable materials shall be used for the Liquid Penetrant Examination
described by this procedure. Inter mixing of penetrant, remover or developer materials from
different families / different manufacturers shall not be permitted. The penetrant, remover or
developer materials to be used under this procedure shall be limited to the list of penetrant
testing material list as given below.

List of families or group of Penetrant Materials;

Description MAGNAFLUX

Penetrant SKL – SP2 (Type-1) & ZL-27A (Type-II)

Remover (Solvent) SKC – S

Developer SKD – S2 (Non Aqueous Wet Developer)

10.2 When examining nickel based alloys, the sulfur content in all penetrant materials shall not
exceed 1% by weight. (Refer T-641 and Mandatory appendix II of ASME Section V, Article 6)

10.3 When examining Austenitic stainless steel/Duplex Stainless Steel or titanium, the total chlorine
plus fluorine content in all penetrant testing materials shall not exceed 1% by weight. (Refer
T-641 and Mandatory appendix II of ASME Section V, Article 6)

10.4 The certificate of contaminants content for all penetrant materials including developer,
remover or other cleaning agents shall be made available. These certificates shall include the
test results and manufacturer’s batch number. These contaminant content certificates shall be
maintained in file.

11.0 TEST PROCEDURE

11.1 Pre-cleaning
Weld and the adjacent HAZ shall be cleaned such that the surface is free of rust, scales,
welding flux, weld spatter, grease, paint, oily films, dirt etc.

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 11.2 Cleaning

After pre-cleaning, the weld surface and adjacent surface area up to 25.0 mm (1.0”) of either
side of the weld shall be further cleaned thoroughly with the solvent by flushing and wipe
with the clean dry lint free cloth.

11.3 Drying after cleaning

After cleaning and prior to penetrant application the surface shall be accomplished dry by
normal evaporation and a minimum period of time shall be established to ensure that the
cleaning solution has evaporated prior to application of the penetrant. The drying time shall
be at least
2 minute minimum.

11.4 Penetrant Application

The penetrant shall be applied by brushing or spraying on the surface under examination. The
surface shall be kept fully wetted to allow adequate penetration. Dwell time shall be as given
in the table below. It shall be ensured that the penetrant applied remains wet all through the
dwell time. In case the penetrant dries up the entire cycle of precleaning and re-applying the
penetrant shall be repeated.

11.5 Penetration (Dwell) Time

Penetration (dwell) time is critical. The minimum penetration time shall be as required in
below table or as qualified by demonstration for specific applications. The maximum dwell
time shall not exceed 2 hr. or as qualified by demonstration for specific applications.
Regardless of the length of the dwell time, the penetrant shall not be allowed to dry. If for
any reason the penetrant does dry, the examination procedure shall be repeated, beginning
with a cleaning of the examination surface.

Dwell Time
Material Form Type of Discontinuity (As given in note1)
Penetrant
Aluminum, Cold shut, porosity, lack
Casting and welds 5 Minutes
magnesium, steel, of fusion, cracks (all form)
brass and bronze, Wrought materials-
titanium and high extrusions, forgings, Laps, cracks all forms 10 Minutes
temperature alloys plate
Note 1: For temperature range from 50 0F to 1250F (100C to 520C). For temperatures from 40 0F (50C)
up to below 500F (100C), minimum penetrant dwell time shall be twice the value listed in the above
table.

11.5 Excess Penetrant Removal

The area sprayed with penetrant shall be wiped with dry and clean lint free cloth until the
most traces of the penetrant are removed. Final cleaning shall be carried out with a clean
lint-free cloth dampened with the cleaner (solvent). Care shall be taken to avoid use of
excess cleaner. Flushing and spraying the surface with solvent is prohibited.

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 11.6 Drying After Excess Penetrant Removal
After removal of excess penetrant the surface shall dry by normal evaporation. The drying
time shall be maximum 10 min.
11.7 Application of Developer
Developer shall be applied as soon as possible after penetrant removal, the time interval shall
not exceed that established in the procedure by spraying through aerosol cans. The aerosol
can shall be shakened well prior to the application to ensure adequate dispersion of
suspended particles. Developer spraying shall be in such a manner as to ensure complete
coverage with adequately thick even film. The maximum time between penetrant removal and
developer application shall not exceed 10 min.
11.8 Developing Time

Developing time for final interpretation begins immediately after the application of a dry
developer or as soon as a wet developer coating is dry.
.

11.9 Interpretation
The surface shall be closely examined during application of developer to examine the behavior
of indications. Final interpretation shall be made not less than 10 min nor more than 30 min
after the requirements of 11.8 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.

11.9.1 Light Requirement

11.9.1.1 Visible/Color contrast penetrants (Type-II)

Indications can be examined in either natural or supplemental white light. The intensity of the
visible light at the surface of the part / work piece undergoing examination shall be a
minimum of 100 foot candles (1000 Lux) to ensure no loss of sensitivity in the examination.

11.9.1.2 Fluorescent Penetrants (Type-I)

With fluorescent penetrants the examination is performed using an ultraviolet light called
black light. The examination shall be performed as follows:

a) It shall be performed in a darkened area.

b) Examiners shall be in a darkened area for at least 5 min prior to performing examinations to
enable their eyes to adapt to dark viewing. Glasses or lenses worn by examiners shall not be
photochromic or exhibit any fluorescence.
c) Black lights shall achieve a minimum of 1000 µW/cm2 on the surface of the part being
examined throughout the examination.
d) Reflectors, filters, glasses, and lenses should be checked and, if necessary, cleaned prior to
use. Cracked or broken reflectors, filters, glasses, or lenses shall be replaced immediately.

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 e) The black light intensity shall be measured with a black light/UV meter prior to use, whenever
the light’s power source is interrupted or changed, and at the completion of the examination.

11.9.1.3 Verification of light intensity and calibration of light intensity measuring instruments

11.9.1.4 For visible/color contrast penetrants, the light intensity shall be verified by a lux meter prior
to the evaluation of indications or a verified light source shall be used. The verification of
light
sources is required to be demonstrated only one time, documented and maintained in a file

11.9.1.5 Light meters, Black light/UV meters shall be calibrated at least once a year or whenever the
meter has been repaired. If the meter has not been used for one year or more, calibration
shall be done before being use. The calibration results shall be documented.

12.0 EVALUATION and ACCEPTANCE CRITERIA

An indication of an imperfection may be larger than the imperfection that causes it; however,
the size of the indication is the basis for acceptance Evaluation. Only indications with major
dimensions greater than 1.5 mm shall be considered relevant.

Linear Indication- A linear indication is one having a length greater than three times the
width.

Rounded Indication- A rounded indication is one of circular or elliptical shape with the length
equal to or less than three times the width.

Any questionable or doubtful indications shall be reexamined to determine whether or not

they
are relevant.

12.1 ASME Sec I Para 270 and ASME Sec VIII Div. 1 Mandatory Appendix 8

All surfaces to be examined shall be free of:

12.1.1 Relevant linear indications

12.1.2 Relevant rounded indications greater than 5 mm

12.1.3 Four or more relevant rounded indications in a line separated by 1.5 mm or less
(edge to edge).

12.2 ASME B 31.1

Indications whose major dimensions are greater than 1⁄16 in. (2.0 mm) shall be considered
relevant.

The following relevant indications are unacceptable:

1. Any cracks or linear indications
2. Rounded indications with dimensions greater than 3⁄16 in. (5.0 mm)
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 3. Four or more rounded indications in a line separated by 1⁄16 in. (2.0 mm) or less, edge to edge

4. Ten or more rounded indications in any 6 in. square (3870 mm2) of surface with the major
dimension
of this area not to exceed 6 in. (150 mm) with the area taken in the most unfavorable location
relative to the indications being evaluated

12.3 ASME Sec VIII Div. 2

All surfaces to be examined shall be free of:

1. Relevant linear indications
2. Relevant rounded indications greater than 5 mm
3. Four or more relevant rounded indications in a line separated by 1.5 mm or less (edge to edge).
4. Crack like indications detected, irrespective of surface conditions, are unacceptable.

12.4 ASME Sec IX Clause No. QW 195.2 (Same As ASME Section VIII Division-1 Appemdix-8)

13.0 DOCUMENTATION OF REJECTABLE INDICATIONS

13.1 Non-rejectable Indications- Non-rejectable indications shall be recorded as specified by the

referencing Code Section.

13.2 Rejectable Indications- Rejectable indications shall be recorded. As a minimum, the type of
indications (linear or rounded), location and extent (length or diameter or aligned) shall be
recorded.

14.0 EXAMINATION RECORDS

All the Dye Penetrant Inspection reports shall contain as a minimum the following information

Procedure Number and Revision

Material and Thickness
Liquid Penetrant Type (Visible)
Type of Penetrant, Remover and Developer
Batch Number and Expiry Date of Penetrant, Remover and Developer
Surface Preparation
Lighting Equipment and Light Intensity
Part Temperature
Acceptance Criteria / Standard
Map or Record of Indication
Acceptable or Reject With Respect To Acceptance Standard
Examination Personnel Identity, Level and Signature
Date and Time of Examination

15.0 POST CLEANING

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 On completion of testing and interpretation, the part shall be cleaned with lint free cloth piece
to remove all the trace of non-aqueous developer. Further it shall be ensured that no trace of
penetrant is remained on the test surface. In case the test part contains entrapped penetrant
which is bleeded out after the application of developer, shall be flashed with solvent and
wiped out with clean lint free cloth piece. Proper post cleaning shall be ensured before leaving
site.

16.0 SAFETY

a) Personnel involved in the Liquid Penetrant Inspection should take following

precautions because of the toxic and inflammable nature of chemicals used.
b) Do not expose the pressurized containers to direct sunlight and in excess of 50 0 C
c) Do not pierce or burn the cans even when empty
d) Do not spray onto naked flames or incandescent material
e) Keep away the cans from the source of ignition – No Smoking
f) Avoid contact with Skin and Eye

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