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INDEX
PURPOSE SCOPE DEFINITIONS AND ABBREVIATIONS REFERENCES REQUIREMENTS

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PURPOSE:
This Procedure details the method for performing Liquid Penetrant Testing by Authorised Personnel on behalf of XXXX (Pty) Ltd.

SCOPE:
Applicable to all castings, forgings, and butt welds in plate, piping and vessels when the Reference Code is: API 1104 ASME B31.1 ASME B31.3 ASME III ASME IX ASME V ASME VIII ASME XI AWS D1.1 EN 6443:1984 EN 5817:2005 PD 5500

DEFINITIONS AND ABBREVIATIONS:

NDT PT Technique Sheet Non-Destructive Testing Liquid Penetrant Testing A document compiled, when required, in accordance with the Reference Code detailing special instructions on equipment use and other information that will assist the Technician during the use of a Specialised Technique. An authorized Level I, II or III RT Technician authorised by the Company in accordance with XXXX-WP-001 Rev 0 XXXX (Pty) Ltd Any PT Technique not covered in this Procedure

Technician (Operator) The Company Specialized Technique

REFERENCES:
XXXX-WP-001 REV 0 XXXX-WP-003 REV 0 Written Practice for Authorization of NDT Personnel. Written Practice for the Performance of NDT Equipment.

REQUIREMENTS:
Safety Extreme caution shall be exercised as Penetrant materials can be flammable and/or emit hazardous and toxic vapour. Any additional manufacturers safety precautions must be observed.

Prerequisites y All Liquid Penetrant Inspections shall be performed in accordance with the relevant Reference Code. y Technique parameters shall be recorded on the Liquid Penetrant Testing Report.

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y Additional techniques (as required) shall be compiled by an authorised PT Level II Operator, Evaluator or Reviewer. Technique sheets shall be reviewed by the authorised Level II or Level III Reviewer before Liquid Penetrant Inspection. Precautions and Limitations y The Liquid Penetrant Testing method is an effective means for detecting discontinuities which are open to the surface of clean, nonporous metals and other materials. y Fluorescent Penetrant examination shall not follow a colour contrast Penetrant examination. y Intermixing of Penetrant materials from different families or different manufacturers is not permitted. y A retest with water washable Penetrants may cause loss of marginal indications due to contamination. Personnel Requirements y Liquid Penetrant Testing Operators, Evaluators and Reviewers shall be authorised in accordance with the requirements of XXXX-WP-001 REV 0. y Interpretation, Evaluation and Reviewing of test results shall only be done by Authorised Level II or Level III Technicians.

Equipment and Consumable Requirements y All equipment used for Liquid Penetrant Testing shall be in a good working order and calibrated as laid down in XXXX-WP-003 Rev 0. y Consumables used for Liquid Penetrant Testing shall be of a reputable Manufacturer as required by the Client and within shelf life. y Different Families of consumables shall not be mixed.

Location and Component Identification y Each weld shall be identified on a work request together with an inspection package. At each weld location a physical identification should be present, i.e. Plant Location Code (PLC). y In cases where the inspection package and physical identification nomenclature cannot be reconciled, NO inspection shall be performed until resolution is provided by the Client. y Where temporary identification is allowed, the operator shall ensure that the type of marking will remain present for any period of re-work, should repairs be necessary. The operator shall establish a zero reference datum related to some prominent feature of the item (e.g. Top Dead Centre), which shall be detailed in the inspection report.

Control of Contaminants The Company shall obtain certification of contaminant content for all liquid Penetrant materials used on nickel base alloys, austenitic stainless steels, and titanium. These certifications (MSDS) shall include the Penetrant Manufacturers batch numbers and the test results obtained. These records shall be maintained as required by the Referencing Code Section

Techniques Either a colour contrast (visible) Penetrant or a fluorescent Penetrant shall be used with one of the following three Penetrant processes: y water washable y post-emulsifying y solvent removable The visible and fluorescent Penetrant used in combination with these three Penetrant processes result in six liquid Penetrant techniques.

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Surface Preparation y 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. Surface preparation by grinding, machining, or other methods maybe necessary where surface irregularities could mask indications, but after such operations the surface shall be chemically etched to ensure that these operations did not peen over or closed any surface openings. y Prior to each Liquid Penetrant examination, the surface to be examined and all adjacent areas within at least 25 mm shall be dry and free of all dirt, grease, lint, scale, welding flux, weld spatter, paint, oil, and other extraneous matter that could obscure surface openings or otherwise interfere with the examination. y The part shall then be flushed with solvent remover and wiped clean with a clean, lint free cloth and left to dry via evaporation for a minimum of 5 minutes.

Penetrant Application y Penetrant Testing may only be performed on welds where the temperature is not less than 10 C but not greater than 52 C or in accordance with Manufacturer recommendations. The component temperature shall be noted at the commencement, during and at the completion of inspection. Welds outside this temperature range (or where the temperature fluctuates outside this range) shall not be inspected without re-qualification. y Penetrant shall be applied to the entire inspection area by either brushing, dipping, flowing or aerosol spray. y The Penetrant dwell time shall be in accordance with the Reference Code Section. y The Penetrant must remain wet throughout the dwell time and repeated applications of Penetrant may be necessary. Should the Penetrant be allowed to dry or separate (bead) on any part of the surface the inspection must be repeated commencing with surface preparation.

Penetrant Dwell Time Penetrant dwell time will be as prescribed in the applicable Reference Code Section.

Penetrant Removal y Excess solvent removable Penetrant, after the prerequisite dwell time, shall be removed by wiping the inspection surface in a single direction with absorbent paper. When most traces of the Penetrant have been removed, the inspection surface shall be further wiped with absorbent paper lightly moistened with cleaner / remover. Flushing the inspection surface with cleaner / remover is expressly forbidden. y Excess water washable Penetrant, after the prerequisite dwell time, shall be removed with a coarse water spray at a pressure not exceeding 345 kPa and a temperature not exceeding 43C. Over-washing the test surface shall be avoided. y Postemulsification Penetrants y Lipophilic Emulsification . After the required Penetrant dwell time, the excess surface Penetrant shall be emulsified by immersing or flooding the part with the emulsifier. Emulsification time is dependent on the type of emulsifier and surface condition. The actual emulsification time shall be determined experimentally. After emulsification, the mixture shall be removed by immersing in or rinsing with water. The temperature and pressure of the water shall be as recommended by the manufacturer. y Hydrophilic Emulsification . After the required Penetrant dwell time and prior to emulsification, the parts shall be pre-rinsed with water spray using the same process as for water-washable Penetrant. Pre-rinsing time shall not exceed 1 min. After pre-rinsing, the excess surface Penetrant shall be emulsified by immersing in or spraying with hydrophilic emulsifier. Bath concentration shall be as recommended by the manufacturer. After emulsification, the mixture shall be removed by immersing in or rinsing with water. The temperature and pressure of the water shall be as recommended by the manufacturer. Note: Final Emulsification times shall be determined by experiment.

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Developer Application y Non-aqueous-wet developer shall be used for both solvent, water-based and post emulsification techniques. y Developer shall be immediately applied after the inspection surface has dried under natural evaporation for solvent-based Penetrant, or natural or forced evaporation for water-based Penetrant, providing the item temperature is not raised above 52C. y The developer shall be applied by spraying as a thin uniform coating over the entire inspection area, so that no metal surface or shine is visible.

Developer Dwell Time y Developing time for final interpretation begins as soon as the developer coating is dry. y Minimum developer dwell time shall be as required in the applicable Reference Code Section.

Interpretation y Final Interpretation. Final interpretation shall be made within the required time according to the applicable Reference Code Section. If the surface to be examined is large enough to preclude complete examination within the prescribed time, the examination shall be performed in increments. y Characterizing Indication(s). The type of discontinuities is difficult to evaluate if the Penetrant diffuses excessively into the developer. If this condition occurs, close observation of the formation of indication(s) during application of the developer may assist in characterizing and determining the extent of the indication(s). y Colour Contrast Penetrants. With a colour contrast Penetrant, the developer forms a reasonably uniform white coating. Surface discontinuities are indicated by bleed-out of the Penetrant which is normally a deep red colour that stains the developer. Indications with a light pink colour may indicate excessive cleaning. Inadequate cleaning may leave an excessive background making interpretation difficult. A minimum light intensity of 100 fc (1000 Lx) is required on the surface to be examined to ensure adequate sensitivity during the examination and evaluation of indications. The light source, technique used, and light level verification is required to be demonstrated one time, documented, and maintained on file. y Fluorescent Penetrants. With fluorescent Penetrant, the process is essentially the same as with colour contrast Penetrant, with the exception that the examination is performed using an ultraviolet light, called a black light. The examination shall be performed as follows: y It shall be performed in a darkened area. y The examiner shall be in the darkened area for at least 5 min prior to performing the examination to enable his eyes to adapt to dark viewing. If the examiner wears glasses or lenses, they shall not be photosensitive. y The black light shall be allowed to warm up for a minimum of 5 min prior to use or measurement of y The intensity of the ultraviolet light emitted. Reflectors and filters should be checked and cleaned daily when in use. Cracked or broken filters shall be replaced immediately. y The black light intensity shall be measured with a black light meter. A minimum of 1000 W/cm on the surface of the part being examined shall be required. The black light intensity shall be verified at least once every 8 hr, whenever the work station is changed, or whenever the bulb is changed.

Evaluation y All indications shall be evaluated in terms of the acceptance standards of the Referencing Code Section. y Discontinuities at the surface will be indicated by bleed-out of Penetrant; however, localized surface irregularities due to machining marks or other surface conditions may produce false indications. y Broad areas of fluorescence or pigmentation which could mask indications of discontinuities are unacceptable, and such areas shall be cleaned and re-examined.

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Documentation y Recording of Indications y Recordable Indications. Recordable indications shall be recorded as specified by the Referencing Code Section. y 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. y Examination Records. Reporting shall be done on a standard Report Sheet, unless otherwise required by the client. Post-examination Cleaning When post-examination cleaning is required by the Client, it should be conducted as soon as practical after Evaluation and Documentation using a process that does not adversely affect the part.

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