c



÷




PROJECT: SUNPOWER MALAYSIA MANUFACTURING SDN BHD

PACKAGE : P6400 HVAC (FAB FOR DRY AND WET WORKS)
CONTRACTOR : MHPT ENGINEERING SDN BHD

METHOD STATEMENT FOR DYE PENETRANT TESTING

1.0 SCOPE

The following test procedure describes the minimum standard requirement for liquid penetrant testing on
welds, plates etc.; for both ferrous and non - ferrous materials using solvent removable dye in accordance
with ASME Section V Article 6 for weld joint fabricated to the requirement of ASME Section I

Penetrant testing is primarily used for the detection of discontinuities which are open to the surface
particularly cracks, seams, laps and porosity.

2.0 GENERAL REQUIREMENT

2.1 PRECLEANING OF PARTS AND MATERIALS

The success of any penetrant testing is greatly dependent upon the surface and the discontinuity being
free of any contaminant that might interfere with the penetrant process. All parts or areas of parts to
be tested must be cleaned and dried before the penetrant is applied. The surface must be free of any
rust, scale, welding flux, spatter, grease, paint, oil and dirt.

2.2 DRYING
All surfaces being tested should be subjected to a drying period of 1 to 5 minutes by normal
evaporation after precleaning.
Liquid residue that may hinder the entrance of the penetrant shall be wiped with a clean, dry cloth
prior to carrying out the testing. Surface temperature of parts or material shall not exceed 52 degree C
prior to application of penetrant.

2.3 POST EXAMINATION CLEANING

When post examination cleaning is required, it should be removed as soon as possible by means of
suitable solvents or water.

3.0 PENETRANT TECHNIQUE

3.1 A color contrast (visible) penetrant system with solvent remover consisting of the following shall
be used (Aerosol spray type) :
3.1.1 Cleaner ± as for Pre-Cleaning/Pretreatment and Cleaner
3.1.2 Penetrant
3.1.3 Developer

3.2 Penetrant material used shall be within the same family group of materials.

3.3 As a standard technique, the temperature of the penetrant and the surface of the part to be
processed shall not be below 10 degree C nor above 52 degree C throughout the examination period.
c


÷




4.0 TESTING PROCEDURE

4.1 Surface Preparation

4.1.1 In general satisfactory results may be obtained when the surface is in the as
welded, as rolled, as cast condition. In some cases, however, surface
preparation by grinding or machining may be necessary when surface
irregularities would otherwise mask the indications of unacceptable
discontinuities.
4.1.2 The surface to be tested and any adjacent area within at least one inch (25mm)
of the surface to be tested in each direction shall be dry and free of any dirt,
grease, lint, scale, welding flux, spatter, oil or any extraneous matter that would
obscure openings or otherwise interfere with the testing.
4.1.3 Typical cleaning agents which may be used are detergents, solvents remover
and paint removers.

4.2 Penetrant Application

4.2.1 Apply the penetrant by spraying to the entire surface to be tested, ensure that
the distribution is evenly applied.

4.3 Excess Penetrant Removal (Solvent wipe off)

4.3.1 Allowed Penetrant to settle for about (Dwell time) 10 to 30 minutes before
removing the excess penetrant. Excess Penetrant shall be removed by wiping
with a cloth, repeat it until most trace of penetrant has been removed. The
remaining traces shall be removed by lightly wiping the surface with cloth
moistened with solvent. Flashing the surface with solvent, following the
application of penetrant and prior to developing, is prohibited.
4.3.2 Allow the solvent drying time of 1 to 5 minutes before applying developer.

4.4 Developer Application

4.4.1 Apply developer by spraying at approximately 12 inches away from the surface
to be tested and apply only a
film. Drying shall be by normal evaporation.

5.0 INSPECTION

5.1 Inspection shall be done while applying the developer. Final interpretation shall be made after
allowing the penetrant to bleed out (developing time) for 10 to 30 minutes. A longer period is
acceptable if the surface to be tested is not altered by the bleed out. the surface to be tested is
too large as to preclude complete testing within the prescribed time, then only portions of the
surface shall be tested at one time.

6.0 EVALUATION OF INDICATIONS

6.1 Only indications which have any dimension greater than 1.5mm shall be considered relevant.
6.1.1 A linear indication one having a length greater than three times the width.
6.1.2 A rounded indication one of circular or elliptical shape with a length equal to
or less than three times its width.
6.1.3 Any questionable or doubtful indications shall be reexamined to determine
whether or not they are relevant.
c


÷




u.0 ACCEPTANCE/REJECTION CRITERIA

u.1 The acceptance/rejection criteria of the test component shall be determined as per ASME Section
I 200u Edition - A-2u0.4 as follows;
u.1.1 All surfaces to be examined shall be free of:
u.1.1.1 relevant linear indications;
u.1.1.2 relevant rounded indications greater than 5mm;
u.1.1.3 four or more relevant rounded indications in a line separated by 1.5mm
or less,edge to edge.