I

TABLE OF CONTENTS

LIQUID PENETRANT INSPECTION ................................................................................................. PTl

Introduction ..................................................................................................................................... PTl-1
The six basic steps to liquid penetrant testing ................................................................................. PTl - 1
Safety aspects involved when using penetrants .............................................................................. PT 1- I
Principles and stages of liquid penetrant inspection ....................................................................... PTl -2
Properties of penetrants ................................................................................................................... PTl-6
Properties of emulsifiers ................................................................................................................. PTl-6
Typical penetration times for various materials .............................................................................. PTl-6
Control checks on equipment performance ................................................................................... PTl-1 0
Techniques (including advantages/disadvantages of each system) .............................................. PTl-14
COSHH REGULATIONS ...................................................................................................................... PT2
Scope ............................................................................................................................................... PT2- 1
Responsibilities ............................................................................................................................... PT2-l
Occupational exposure limits (EH40) ............................................................................................. PT2-1
CONVERSION FACTORS & TERMINOLOGY ............................................................................... PT3
Old terminology vs new terminology ............................................................................................. PT3- I
Commonly referred to standards in liquid penetrant inspection ..................................................... PT3 -l
GLOSSARY ............................................................................................................................................. PT4
EXAMINATION SCHEMES ................................................................................................................. PTS
PCN examinations ........................................................................................................................... PTS-1
ASNT examinations ........................................................................................................................ PTS-2

Ruane & II
0 Ru& TP O'NUl
T P O'Neill
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 Ruane & II
TPO'Nei/1
'iOT ES
10
20
Viscosity is a property of a
penetrant and. whilst
important. does not affe ct
,.. the capillary action.
However. it does affect tire 30
speed of entry/exit of tire
penetrant material.
Viscosity: 77re resistance of
a fluid to flow.
Men iscus: By using a
siJ.!Idowgraplt, tire contact 40
angle may be determined
{or a penetrant on a specific
material. A good penetrant
is usually defined with a
contact angle in the order
of6- 10.
50
~ Where:
60
70
It is generally considered as
good working practice to
always 11se the same
1ami/y' Of COIISIItnables.
BS EN 571-1 quotes 'the
penetrant and developer 80
may be from mixed families
(if an approved source). bill
the penetrant and remover
MUST be of the same
family'
90
100
O Ru..,t& TPO' Ntlll
lssu 6 03104106
Ul~IT PTI LIQt;ID PE~ETRANT I~SPECTIO:\'
INTRODUCTION
Penetrant testing provides a means of detecting surface opening discontinuities, such as
cracks or porosity, in relatively non-absorbent materials. (Porous materials are
unsuitable for ~ral penetrant testing). It utilizes a penetrating liquid which is
applied to the surface to be tested and is drawn into any discontinuity present.
The excess penetrant is removed after a suitable period of time and a white finely
divided developer powder is applied to the surface under test. The developer assists in
drawing the residual penetrant from the discontinuities, thereby revealing their
location.
An early form of penetrant testing was the oil and chalk process. This method
consisted of coating the work piece with a heavy lubricating oil, usually thinned out
with paraffin or other light oils. After allowing penetrating time, the oil was removed
with dry rags and a mixture of chalk and alcohol was then applied to the surface.
Possible defects would be indicated where the chalk was stained with oil.
CAPILLARY ACTION
The concave meniscus
also referred to as a Capillary tube
+ve meniscus
The meniscus
Capillary pressure is determined by:
S = Surface tension
CosO = Cosine of the contact angle
d = Tube diameter/flaw width
THE SIX BASIC STEPS TO LIQUID PENETRANT TESTING
1. Pre-clean.
2. Penetration.
3. Wash.
4. Develop.
5. Inspect.
6. Final clean.
SAFETY ASPECTS INVOLVED WHEN USING DYE PENETRANTS
When the liquid penetration method for detecting flaws in materials is used, the
operator must always follow the recommended procedures and standards under the
Health & Safety at Work Act 1974. This act states that recommended procedures and
safety requirements are laid down in BS 6443 : 1984 and BS EN 571.
Within these standards are specific requirements with regard to safety.
PTl-1
 Ruane & II
TPO'Nei/1
NOT t::S
Guidance note used by the
Health & Safety Executive
EH40, referenced in Unit
PT2.
This is particrdarly relevam
with the use offluorescent
penetrants. One of the worst
contaminates will be the
colour contrast penetrant,
even minute quall(ities will
quench the fluorescent
abilities of the fluorescent
penetrant.
Sodium based glasses may
be used to improve visual
contrast and will also help
(rlter out the shorter UV
wme/engths.
90
100
U~IT PTI LIQUID PE~ETRANT INSPECTIO~
Fire hazards
The use of electrical equipment, when involved in the inspection of materials, shall
ensure that there is no risk of fire as a result of equipment sparking or overheating.
10 The use of inflammable vapours or solvents (aerosol cans, cleaning solutions, etc.)
should always be kept away from any possible source of ignition. Special care should
be taken not to use such equipment in confined spaces as this could provide a build up
of gas, unless adequate ventilation is provided.
Electrical safety
20
All equipment used with the Liquid penetrant method of inspection shall comply with
electrical safety regulations. This means that any mains equipment of IIOV or above
shall be fitted with an earth leakage current circuit breaker of rating 30 rnA. Where
portable equipment of 24V and above is used, the requirement for a circuit breaker
is 12 rnA.
30
Toxic materials
When in use, some aerosol sprays and solvent cleaners may emit a toxic vapour which
can cause a hazard to the health of the operator, therefore, precautions should be taken
to avoid these hazards in accordance with the suppliers' instructions.
Such precautions include the use of face masks to absorb any harmful mists or vapours
40
in the atmosphere, especially when in confmed spaces. For the acceptable level in a
confined space, see regulation in EH40* . Furthermore, there may remain a risk of
irritation to the skin due to the use of aerosol sprays or solvents. Under these
circumstances, the recommended safety garments should be worn and the extensive
use of protective clothing where necessary.
50
Permanent testing locations
Where it is necessary to carry out liquid penetrant testing on a continuous basis, a
suitable room or building should be available. This should contain adequate
ventilation, lighting for the inspection of materials, access to move equipment and
materials, both in and out, and sufficient space for cleaning.
60
The location of such a room or building should be well away from any manufacturing
processes which may cause airborne contamination*.
Safe use of ultraviolet light
Always ensure the safe use of ultraviolet light when inspecting a material with a
70 fluorescent penetrant. The source of ultraviolet light should always be directed
towards the work piece and away from the naked eye as exposure may cause damage.
The filters used on ultraviolet light equipment should be regularly checked for
cracking, as radiation waves below 315 nm can be very dangerous.
The use of photochromic spectacles should be avoided as these will darken under
80 ultraviolet light and increase the possibility of missing the smaller indications
fluorescing*.
PRINCIPLES AND STAGES OF LIQUID PENETRANT INSPECTION
Preparation
As penetrant inspection is totally dependent on the ability of a penetrant to enter a
surface discontinuity, contaminants such as oil, grease, paint, rust, scale, welding flux
etc., may restrict its entry. Moreover, such contaminants can absorb the penetrant,
masking fine defects or making them difficult or impossible to identify or interpret.
Methods of cleaning can be divided into two main groups; physical and chemical.
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 Ruane & II UNIT PTJ LIQUID PENETRANT INSPECTION
TPO'Nel/1

1\0TF.S
17ze use ofstrong alkaline lO
materials must also be
avoided wherever possible
due to the possible release of
chromate ions which are
opaque to ultraviolet light,
he11ce again increasing the
chance ofmissing 20
indications.
Physical
The physical methods, such as wire brushing or abrasive blasting (shot blasting, metal
scraping, sand blasting, etc.), essentially remove contaminants from the surface and are
generally incapable of removing any contamination which may exist within the
discontinuity, thereby stopping or reducing entry of the penetrant. If abrasive cleaning
is used, it should be followed by a light acid etching prior to penetrant application in
order to remove the peened surface, which is very likely to close up discontinuities so
making the penetrant test ineffective. Care should be exercised when using fluorescent
penetrants because the acid can kill the fluorescence and create poor or weak
indications. Depending on the test piece material and surface fmish, physical cleaning
may be unacceptable.

Chemical
Chemical cleaning can be carried out by using detergents. steam cleaning or vapour
degreasing but is ineffective for removing rust or scale.
30
Detergent cleaning
Detergents can be either acid or alkaline, therefore a detergent which is non-corrosive
to the material should be chosen. Detergents can be applied to small areas, or used in a
washing tank, therefore the size and shape of the component may have to be
considered.
40
Steam cleaning
This process is an excellent method of cleaning if the component cannot be
successfully cleaned by detergent or vapour degreasing. Steam cleaning is usually
used on large components.

so Vapour degreasing
By applying or immersing into the degreasing agent, the surface and also the
discontinuity are effectively cleaned. Trichlorethylene is usually used as the
degreasing agent, although this should not be used on titanium alloys as the
susceptibility of such alloys to stress corrosion may be enhanced by its use.
60 Sufficient time should be allowed after cleaning for drying out otherwise the efficiency
of the penetrant may be affected. The time interval allowed for the evaporation of
solvents can only be determined by the prevailing conditions of temperature, humidity
and the type of solvent used. Moisture from detergent cleaning can be removed by
oven drying the component:

10 Penetrants
Types
Penetrants are usually classified according to the type of dye; visible or fluorescent.

Colour contrast penetrants

80 The brightly coloured, usually red (as it provides a high contrast against the white
background), highly penetrating liquids are visually inspected under good daylight
conditions, or with the use of adequate artificial light.

Fluorescent penetrants
With these penetrants, the components are irradiated with an ultraviolet light (black
90 light) in a darkened area so that the yellow-green indications are readily visible.
The above classes of penetrant can be further sub-divided by the manner in which they
are removed from the material surface:
a. Solvent removable.
b. Water washable.
!00
c. Post emulsifiable.

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\ 0 '1 ES Alternative penetrant systems include dual sensitivity (reverse fluorescence) used in
poor lighting conditions, filtered particle used for porous materials, thixotropic used
for overhead work and LOX sensitive used on materials likely to come into contact
with liquid oxygen. These specialist systems are not covered in depth due to their
10
limited applications.

20
Precipitation : 111e change
from a solution to a
suspension, e.g. the base 30
pigments come our of
solution.
40
Application
After the surface has been prepared and completely dried, application of the penetrant
can be by spraying, pouring or dipping, using a swab or brush, or by immersing into a
tank. When using immersion, the test piece need only stay immersed until covered.
The penetrant does not seep into a discontinuity, it is pulled into it by capillary action.
The penetrant should be applied within the temperature range of 4C to 40C, unless
otherwise specified by the manufacturer. Higher temperatures will retard the
penetrating ability by evaporating the volatile constituents. Lower temperatures will
cause some precipitation of the dye and the penetrant to become more viscous.
Surface contact time of the p enetrant varies between 5 minutes and 60 minutes
depending upon the temperature, material, size and type of the defect being sought,
which is the primary factor. The contact time or dwell time is usually between 20 to
30 minutes for welds in low carbon materials.
The desirable features of a good penetrant are that it must possess the following
characteristics:
a. The ability to penetrate fine surface discontinuities.
b. Must not be easily removed from relatively coarse openings until required.
c. Be easily cleaned from the surface of the test piece.

50 d. Capable of being easily drawn from discontinuities by the developer.

60
70
Flash point: The minimum
tempera111re which the
vapour will ignite when
exposed ro a naked flame.
usually determined via a
closed cup method. 80
e. Have the ability to spread as a fine film.
f. In possession of intense colour or fluorescence, even as a thin film.
g. Have permanence in colour or fluorescence when exposed to heat, white light or
u ltraviolet light
h. Inert to the materials, including containers with which it comes in contact.
1. Be odourless, non-flammable, non-toxic and stable when stored and in use.
Two other properties of a penetrant are important and, whilst not affecting the
penetrating ability, they affect its use. These are:
Flash point
If a penetrant is to be used in bulk, it should have a flash point of 49C to 52C.
Below this, special installations may be necessary.
T oxicity
It is essential that the toxic effects of a penetrant, on inhalation of the vapour and on
contact with the skin, are known and guarded against.

Special purpose penetrants

These special inert penetrant materials are available for certain applications, in
particular, when testing nickel alloys, certain stainless steels and titanium where the
90 penetrants must be low in sulphur and chlorine because of their detrimental effects.

Effects of sulphur and chlorine

Halogen free: Contains no Certain alloy steels are susceptible to damage by sulphur or chlorine, especiaJly when
chlorine, fluorin e, bromide they are heated in processing or in service. The predominant mechanism of damage is
or iodine. intergranular corrosion and cracking. Because of this detrimental effect, it is of the
100 utmost importance to remove all traces of penetrant, emulsifier or developer from these

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10
20
To emulsify is to render 30
water washable with the
application of a11 additional
chemical.
Note: Water contamination
ofwaier washable
penetrants will reduce the 40
penetrating quality and
adversely affect the
washabilitY.
BS 6443 : A maximum
pressure of 2 bar (29 p.s. i.)
and a temperature range o[.
15c- 3oc. 50
** BS EN 571 : A maximum
temperature of 50C and
if a fluoresce/It penetrant.
at/east 300 pWicm1 UV-A
irradiance and a maximum
ambient background 60
lighti11g of /50 lux as to
BS EN ISO 3059.
70
80
*/) American documentation
often referred to hydrophilic 90
removers as 'domestic
scrubbers'.
2) In dip tank systems.
the typical percentage is
in the range of
3% - 20%. whereas if
spray ecl. the percemage is I 00
more typically between
0.01%- 0.1%.
C Ruant & T P O' Neill
Issue 6 03/04106
UNIT PTI LIQUID PE~ETRANT I~SPECTION
alloy steels, or use the specially formulated so called sulphur/chlorine free penetrants,
emulsifiers and developers.
Removal of penetrants
The method of removal depends upon the type of penetrant used.
Solvent removable penetrants
The solvent can be applied by spray or by a cloth. During the initial inspection stage,
excess penetrant should be removed by applying the solvent to a cloth and then wiping
the surface clean. This method is used to limit the contact time of the solvent with the
penetrant to prevent it entering the discontinuity. If the solvent was allowed to flood
onto the surface from a high pressure spray, the penetrant could be washed out from
any wide, shallow discontinuities.
Water washable penetrants
Self-emulsified or water washable penetrants are removed from the surface or
components by direct water washing. The application of water is by using a spray or
by immersing into an agitated water wash. The surface of the component should be
washed to the point where the excess penetrant has only just been removed. If
fluorescent penetrants are being used, washing should take place under ultraviolet light
conditions.
The penetrant/emulsifier mixture in the discontinuity is just as susceptible to washing
as the material on the surface, so over-washing can be a very real risk.
The spray used to remove the penetrant should be of a coarse water droplet type, with a
pressure of *30-40 p.s.i.. Higher pressure would result in washing the penetrant out of
the discontinuity. In all water washable methods, the water temperature should be
between ** l5C and 40C.
Post emulsifiable penetrants
TI1e post emulsifying process has been the one traditionally used to give the highest
degree of sensitivity. Emulsifiers mix with the surface penetrant and render it water
washable, the success being dependent on the relative inability of the emulsifier to
combine with the penetrant in the discontinuity.
The emulsifier should never be applied using a brush as this causes uneven mixing.
The original conception of this process was for use with a lipophilic (oil loving)
emulsifier, this being a material with which the oily penetrant is mutually soluble.
When the emulsifier is applied, it dissolves the penetrant by a process of diffusion and
consequently, correct contact time is the essence of procedure. Otherwise, there is a
tendency for the emulsifier to dissolve the penetrant in shallow, relatively wide surface
discontinuities and so promote their loss on subsequent washing.
Since the short comings of lipophilic emulsifier systems are caused by the unlimited
mutual solubility of the penetrant and emulsifier over relatively short periods of time, a
different type of remover was introduced in which the mutual solubility was not the
prime factor.
To achieve this result, it is desirable to remove most of the excess penetrant by using a
preliminary water wash, leaving only a uniform and very thin film of penetrant. The
bulk of the excess penetrant is removed purely by the mechanical action of the water
jet.
To remove the thin film, a hydrophilic (water loving) remover* is used. This is similar
in action to a domestic detergent and is used in a low concentrated form. After
completion of the contact time, which is not too critical, subsequent washing by a
water spray cleans the surface effectively without an excessive tendency to wash
penetrant out of shallow discontinuities and so a better basic flaw sensitivity is
achieved.
Emulsification time is ideally established by experimentation and it will be different
for different parts or the same part with a different surface finish.
PTl-5
 Ruane & II UNIT PTI LIQt:ID PENETRA~T INSPECTION
T PO'Neill

'0TE S PROPERTIES OF PEI\~TRANTS

1. Surface tension.
2. Wetting ability.
10
3. Viscosity.
4. Density.
5. Toxicity.
6. Economy.
20 7. Volatility.
8. Flash point.
9. Chemical inertness.
10. Solubility.
Therefore:
30
A sensitive penetrant equals:
l. Measure of penetrability.
2. Ability to remain in flaw.
3. Ability to be developed.
40 4. Ability to be seen in small quantities.

PROPERTIES OF EMULSIFIERS
1. Must make the penetrant water washable.
50 2. Blending with the penetrant must be slow enough to vary contact time.
3. Blending must be fast enough not to delay processing unduly.
4. Suitable for use in open tanks.
5. Free from odour and non-toxic.
There are two main emulsifiers:
60
l. Lipophilic (oil based) - typical contact time = 30 - 45 seconds.
Contact time: 111e time
period where the material 2. Hydrophilic (water based) - typical contact time = 2 minutes.
is first put into comact
with the component until it
is finally removed.
TYPICAL PENETRATION TIMES FOR VARIOUS MATERIALS
Note: With reference to 70
emulsifiers. this time frame
varies enormously with the Penetrant time
Material Defect type
method of application, (typically)
i.e. if only a chemical Aluminium castings Porosity - cold shuts 5 - 15 minutes
reaction or whether a
mechanical action is also Welds Cracks 10 - 30 minutes
involved.
80 Magnesium forgings Laps 10- 30 minutes
Welds Porosity 10 - 30 minutes
Stainless steel forgings Laps 10 - 60 minutes
Welds Cracks 20 - 60 minutes
Glass Cracks 5 - 30 minutes
90 Carbon tipped tools Grinding cracks 10 - 30 minutes
Plastics Cracks 2 - 30 minutes

100

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10
BS 6443 : A maximum
drying time of 10 minutes
and the object should not
exceed 50C sUiface
temperature.
BS EN 571 : A maximum 20
of 50C surface
temperature.
BS EN ISO 3452-4 states
a maximum oven
temperature of80C.
30
40
50
Key points: Least sensitive
developer; mainly
restricted to fluorescent
penetrant systems; easily
applied to large or small 60
areas; ideal for rough
surface finishes and
complex shapes but gives
the best resolution of
indications as the
developer adheres only to
wet areas. which should 70
only be discontinuities.
Key points: Most sensitive
de veloper; may be used
with both fluorescent and
colour contrast penetrants;
ifsprayed too close to the
test surface, the solvent 80
carrier fluid may wash out
the penetrant from the
flaw; quick selfdrying
operation.
90
100
t.) Ruane &
ls.!ue 6 03/04/06
UNIT PTl LIQUID PENETRANT INSPECTION
Drying
When dry powder or solvent suspendible developers are to be used, the component
must be thoroughly dried. This is preferably carried out in a thermostatically
controlled air circulating oven. The temperature of the oven is usually in the range of
65 to 8Y'C* and the component should only remain in the oven until all surface
moisture is removed, otherwise penetrant evaporation may occur. Some specifications
may stipulate a low drying temperature in order to further control the penetrant
evaporation.
TI1e period of drying should be the minimum required to achieve the purpose and
should be established for each particular job, taking into consideration its size, shape
and also the nature of suspected discontinuities. It is also preferable to avoid mixing
components of thin cross sections and high thermal conductivity, with large heavy
components which dry at a slower rate. Excess drying may cause a reduction in
definition, i.e. the sharpness of the indication is reduced.
If it is intended to use water suspendible or water soluble developers, the developer is
applied immediately after the excess penetrant has been removed, whilst the surface is
still wet and before surface drying is carried out. Drying then assists in securing a
uniform developer coating.
Developers
The developer assists in the detection of penetrant retained in the discontinuities by
aiding in the bleed-out process by acting as a blotting agent and accentuating the
presence of a discontinuity by spreading out the penetrant over a greater area.
Developer is available in both dry and liquid forms and the selection of developer is in
accordance with the manufacturer's recommendation for the type of penetrant used.
Types of developer
There are three types of developer in use:
Dry powder
This is a dry, loose, fluffy white powder and can be applied to the specimen by dusting
(with an insuffulator or powder spray gun - electrostatic), blowing (in a dust storm
cabinet or using a flock gun) or by immersing into a container of developer powder,
preferably a fluidised bed. The main advantage of dry powder is its use to restrict
bleed-out, for it wiJI only stick to wet areas, which should only be areas containing
discontinuities. K _ .~
~__r-~
Solvent suspendible -.......; yr
Also known as non-aqueous wet developer. It consists of fine powder suspended in a
volatile solvent and is usually applied to the specimen by spraying from a pressurised
spray can or gun. The developer is applied to form a thin white coat of optimum
thickness for the type of discontinuity sought.
If the developer is prevented from coming in contact with the penetrant in the
discontinuity because the discontinuity may be very tight, the solvent will effectively
bridge the gap by bringing the penetrant to the developer.
The main problem with solvent suspendible developers is that operators tend to bury
the discontinuities under the developer.
T P O'Ntlll
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 Ruane& II U~JT PTl LIQUID PENETRANT INSPECTION
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:\OTF: S Water based

Key points: Suspension types
rarely used. now being 10
superseded by the solution
type; non-toxic; non-
flammable; no ljust nuisance
problems; either spray or dip
application; possible drying
problems; possibility of
.r- flocculation occurring
when used infrequently. 20
30
40
50
These are sometimes called aqueous developers and can either be a suspension of
absorptive white powder or a water-soluble absorptive white powder mixed with water.
The water-soluble powder, once mixed, remains in solution whereas the suspension
type requires mild agitation to keep the powder particles in suspension.
After the excess penetrant has been removed and the surface is still wet, the developer
is applied by either immersion or spray techniques to form a smooth even coating.
Care should be taken to avoid concentrations of developer in dished or hollow areas of
the specimen to avoid penetrant indications being masked.
Properties required of a developer
For a developer to carry out its function to the fullest extent, it must possess certain
properties or characteristics:
a. The developer material must have high absorptive qualities to secure a maximum
of blotting action.
b. It must have fine grained powder particles of a particular shape that will disperse
and expose the small amount of penetrant, at a discontinuity, over as large an area
as possible, whilst still retaining a strong and sharply defined indication.
c. It must be able to mask out, to a large degree, any interfering background colour
whilst providing a contrast background for indications, particularly with reference
to colour contrast penetrants.
d. The material must be easily applicable and able to form a thin or minimum coating
uniformly over the surface and be easily removed after inspection has been
completed.
e. The developer material must not contain any harmful or toxic ingredients that may
contaminate the parts being inspected or may be injurious to the operator.

Development times
This is the time allowed between the application of developer and the actual viewing of
indications. It is very important in the interpretation of indications because if too little
60 time is allowed, indications may not have had time to develop. Too much time will
cause the indications to become blurred or distorted.
The correct developing time depends on the developer used and should be determined
by experience only. Because a component may be rejected based on the intensity of
the indication, indicating a degree of severity, development time plays a significant
part in the intensity of a given indication. Therefore, under such circumstances,
70
inspection must be carried out at a stated time after a developer has been applied.

Viewing conditions
Whether or not an indication will be seen involves the relative amount of light
reflected and/or emitted as between an indication and its background.
80 This relationship is referred to as seeability and involves colour, ambient light level
and also contrast.

Colour contrast penetrants

Colour contrast indications must be viewed in bright white light in order to have
maximum use of the eye's ability to distinguish contrasts and colours. For optimum
90
results, the illumination level at the surface to be inspected should be no less than
500 lux.

Fluorescent penetrants
Inspection is carried out using dyes that have the property of absorbing short wave,
100 invisible ultraviolet light and re-emitting this energy in longer wavelengths in the
visible white light range

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:\OTES
500 lux, as defined by
BS EN ISO 3059 and
BS 6443. is equivalent to I0
either an 80 wall
fluorescent tube at a
distance of I metre or a
I 00 wall tungsten filament
bulb (pearl type) at a
distance of0.2 metres.
20
BS 6443 :Maximum of
10 lux ambient background.
BS EN 571 : Maximum of
20 lux ambient background.
30
BS 6443 : Minimum of
500 pW/cm1 at the work
surface, BS EN 571 and 40
BS EN ISO 3059 minimum
of 1000 pW/cm! at the work
surface and a maximum
value of 5000 p Wlcn/ .
50
60
70
80
90
100
(I) Run< &.
Issue 6 03/04/66
U~IT PTl LIQUID PE~ETRANT INSPECTION
The fluorescent penetrants give off light in the yellow-green or green-blue portion of
the visible spectrum (520- 580 nm).
Ultraviolet light is the term given to wavelengths that are shorter than the shortest
visible violet wavelengths (400 - 100 nm). The most harmful section of these
wavelengths is the range 315 - 200 nm, here ozone can be generated, bacteria can be
killed and will cause sunburn and injuries to the human eye.
By using a UV-A filter, the harmful short wavelengths are eliminated leaving the
ultraviolet range from 400 - 315 nm. The radiation passed by the fllter, peaks at
365 nm, thls being the optimum for energising most of the fluorescent dyes used for
penetrant inspection purposes.
When using fluorescent penetrants, the area where the inspection is to take place
should be darkened. Although, because of the super brilliance of the fluorescent
penetrant, inspection can take place in dim daylight using a strong ultraviolet light.
The darkened area may be illuminated with a dull amber light and the ultraviolet light
should be allowed to achieve a full brilliance before any inspection is allowed
(approximately 15 minutes). At least 5 minutes should be allowed for the operator's
eyes to adjust to the reduced ambient lighting.
The intensity of ultraviolet light illumination at the surface under examination should
be stipulated in the job specification. The intensity can be measured with a
radiometer. Dirt on the re.flector and also the filter will reduce the light intensity so
they must always be kept clean.
Interpretation
Since penetrant inspection can only indicate surface discontinuities, an indication can
be caused by a discontinuity on the surface or by penetrant remaining on the surface
from some non-relevant cause. Therefore, proper interpretation requires familiarity
with the manufacturing process, the types of indications likely to occur and their
appearance. We can break indications down into three categories; non-relevant, false
and true.
Non-relevant indications
Most of the non-relevant indications are easy to recognise since they are related
directly to some feature of the assembly that accounts for their presence. Indications,
such as items that are press-fitted, keyed, spliced, riveted or spot welded together, can
be easily recognised. Also, indications appearing on the surface of the fabrication or
casting such as scale or a rough surface, e.g. a genuine bleed-out of penetrant but not
from a discontinuity in the product.
All these non-relevant indications must be carefully examined since they may interfere
with the correct interpretation.
False indications
The most common source of false indications is poor washing of water-washable and
post-emulsified penetrants. The use of an ultraviolet light during the washing process,
when using fluorescent penetrants is essential. When using solvents, the removal
process is much more likely to be thorough, although there is a danger of over-washing
with solvents. Contamination can be caused by fluorescent or colour spots from
operator's hands or from the inspection table, e.g. an operator error allowing excess
penetrant to remain on the product surface during processing.
True indications
These are caused by discontinuities. The interpretation of an indication as true is a
matter of observing the indication eliminating the possibility of it being a false
indication and then further determining that it is not a non-relevant indication.
All true indications immediately become subject to evaluation as to their cause (type of
discontinuity) and their effect on the service life of the specimen.
T P O'Ntill
- PTl-9
 Ruane& II UNIT PTI LIQUID PENETRA~T INSPECTIO~
TPO'Neill

:\OlfS True indications logically fall into four categories: continuous line, intermittent line,
rounded and/or small dots and diffused or weak.
Continuous line indications are caused by cracks, cold shuts, forging laps, scratches or
10 die marks. Cracks usually appear jagged, whilst scratches and die marks can be seen,
once all surface penetrant is removed.
Intermittent line indications ore cou:.ed by the 5ome di5continuitie!; thot cou:;e
continuous lines but it may be that part of the discontinuity bas been closed by some
metal working process. The intermittent lines may also be caused by too liberal
application of developer.
20
Rounded indications are usually indicative of porosity. D eep cracks may also appear
as round indications since they trap a large amount of penetrant that spreads when the
developer is applied.
Small dots may be caused by pinholes or by the porous nature of the article.
30 Diffused or weak indications are the most difficult to interpret. They may be caused by
surface porosity but are usually the result of insufficient cleaning, incomplete penetrant
removal or excessive developer.

Cleaning after inspection

After inspection, subsequent processes may require that parts are cleaned necessitating
40 removal of all developer and penetrant.
If parts are to be cleaned after inspection, it should be done without long delay since
fresh penetrant and developer are easier to remove then than later.
As stated earlier, some nickel alloys are susceptible to damage by sulphur and chlorine
when heated in processing or in service, therefore, they should be thoroughly cleaned
50 after inspection. Similarly, some alloys can be damaged by residues of penetrant or
developer remaining on the surface, i.e. corrosion caused by residues trapped under
splines, fasteners or rivets. Wet developers and most emulsifiers are alkaline, and if
left on surfaces (like aluminium) will be attacked by the alkalis which can cause
surface pitting. This is especially true in moist atmospheres.

60
CONTROL CHECKS ON EQUIPMENT PERFORMANCE
Where bulk penetrant processes are employed, periodic checks ensure that the test
BS EN ISO 3452-2 : 2000 sensitivity is maintained. Typical checks are given below.
contains full equipment
check details for bulk Specific gravity
COIIS/IIIIab/es.
70 This is carried out using an accurately calibrated hydrometer. The specific gravity will
rise as the more volatile constituents in the penetrant evaporate. The manufacturer will
supply information about the permissible specific gravity range.
Colour intensity
The penetrant should be compared with a standard of new unused penetrant.
80 Red dye penetrant- 5 ml of the test penetrant is made up to a solution of 100 ml with
dicbloromethane. A similar solution is made up with the standard penetrant. The
colour intensities are compared in Nessler tubes.
Fluorescent penetrant - two filter papers are soaked, one in the test penetrant, the other
in the standard penetrant. The papers are dried in an oven, then viewed under
90 ultraviolet light for comparison. If there is a noticeable difference in
colour/fluorescence intensity, further tests are used to quantify the difference. In the
case of red dyes, this can be done by diluting the darker penetrant with
dichloromethane to obtain a colour match and using the dilution as a measure of
intensity. In the case of fluorescent dyes, the fluorescence can be measured by placing
the filter paper onto a radiometer and irradiating with ultraviolet light.
100

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'\OTES
10
20
30
40
Used to determine 50
the sensitivity levels
for both colour
contrast and
fluorescent
p~l!f#ranJs
BS EN 3452-3 refers to
a similar comparator, 60
Type I, although this is a
series of 35 x 100 :c 2 mm
panels with a nickel-
chromium plated swface
which is covered in
transverse cracks. The
only difference between 70
the 4 pmtels is the plated
coating thickness (10 pm.
20 pm. 30 pm and 50 pm
respectively).
80
BS EN 3452-3 refers to a
similar comparator.
Type 2. although, in
addition to the 5
indentations, this has a 90
section with 4 differing
swface profiles (2.5 pmRa,
5 pmRa, 10 pmRa and
15 pmRa). Which is used
for rollline checks of
penetrant performance.
1oo
Ruane & T P O'Ntlll
WU< 6 03/04/06
UNIT PTl LIQUID PENETRANT INSPECTION
Emulsifier/remover control
There are three main checks which can be carried out:
1. Comparison of performance using old and new mixtures on a known rough
surface such as that found on the sherwin/tam panel.
2. For hydrophilic removers view the chemical bath. It should be a clear orange/red
liquid, if it starts to turn opaque, it should be replaced.
3. Use of a refractometer which was previously calibrated on a range of known
percentage strength mixtures. This is widely accepted as the most accurate
method and allows the strength of the bath to be adjusted accurately in service.
Water wash
Water temperature must be kept below the specified maximum. Water spray pressure
must be within specified limits. Oil contamination can be detected by directing the
sprays onto a filter paper.
Developer
Developers must be checked for penetrant contamination. Dry powders must be light
and fluffy .
Ultraviolet light efficiency
This is conducted using the radiometer. The method is explained in the glossary of
these notes.
Plant performance checks
A few simple test blocks are recommended to make comparisons of penetrant
processes and to keep a check on process performance.
a. The ARB block.
b. Chromium plated steel.
c. Demountable test block.
ARB Block* (Aeronautical Registration Board)
The ARB block is made from aluminium alloy (type 2024-T-3). It is heated to 525C
(checked with a tempi! stick) in approximately 4 minutes, then quenched in cold water.
This will produce thermal cracks.
A cross groove is cut down the centre of the block for each half to be used for
comparisons of different penetrant processes:
Chromium plated steel strips*
5 indentations
ultra small cracking -coarse cracking
Cracks are made in the brittle chrome coating with an indentor. The size of the cracks
can be controlled by the thickness of the coating and the pressure of the indentor.
PTl-11
 Ruane & II Ui':IT PTJ LIQUID PEr\ETRA~T INSPECTION
TPO'Nei/1

:'IOTF.S TI1is is similar to one half of a Tam/Sherwin panel. The roughened surface half, as
used for emulsifier/remover performance checks is not shown here.
Demountable block
10
Sleeves

fl /"'
~..----\::(_ ___J(t-
20
"
Position of shim
NB. Slightly smaller ethan the sleeves

The demountable block consists of two sleeves bolted together to simulate a test crack.
A soft antimony-lead shim separates the carefully lapped sleeves. At a specific torque,
the test crack has four segments of width: 0.001 ", 0.002", 0.003" and 0.004".
30 alternative width shims are available.
The whole assembly is demountable for cleaning and re-use.

Fluorescence
Fluorescence is a property of certain materials which are able to absorb ultraviolet light
40 which is not visible and emit a greenish yellow light which is visible. The effect is
illustrated on the electromagnetic spectrum.
Electromagnetic Spectrum

50

100 400 500 600 700

NANOMETERS
(10'' m )
ABSORBED E.MIITEO
60 365nm 520-580 nm
n, w~rklng' W<J\'t!{errgt!J
of tlrt UV-A light source

The background to fluorescent indications is black in ultraviolet light viewing

conditions. Their contrast is therefore very high. To attain an adequate level of test
sensitivity for NDT, the concentrations of ink or dye need not be as high as when using
10 visible detecting media. Their performance is subsequently improved.
Ultraviolet light is generated by mercury vapour lamps.
A High Pressure Mercury Vapour Discharge Lamp
Low pressure mercury
vapour discharge lamps
are also available but the
ou!put is rarely sufficient 80
(or irradiating the
fluorescent dyes so these
are predominately used for
ambient background
lighting.

90

1oo The mercury vaporised inside the quartz capsule by a small low current arc from the
auxiliary electrode. After about 5 minutes there is sufficient mercury vapour in the

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 Ruane & II U~IT PTI LIQUID PE~ETRANT INSPECTIO~
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~OTES capsule to start the arc between the main electrodes. The lamp should be left a further
10 minutes for it to attain full working intensity*.
BS EN ISO 3059: A The spectrum of electromagnetic radiation produced extends into the ultraviolet range.
minimum warm up period
of 10 minutes. I0 The hazardous short wavelength ultraviolet rays must be filtered out because they are
harmful. The filters on the front of the lamps must be checked regularly.
Do not look into the ultraviolet light lamps as they will cause the eyeballs to fluoresce,
an unpleasant, if harmless effect. Prolonged exposure may lead to cataracts or scarring
of the retina.
20
The efficiency of the high pressure mercury vapour discharge lamp can deteriorate
quickly without any obvious effect. Their intensity should be checked regularly with a
radiometer, such as the one specified by BS EN ISO 3059.

Typically commercially available light meters

30
Analogue Style Radiometer

Fluorescent screen with a

black 5 mm framework
40
~

50

Black box

60 The flap at the rear of the unit falls down to a 45 angle exposing a fluorescent plate
(this is retained by a black 5 mm width frame). Removal of the fluorescent plate and
exposure to ultraviolet light should indicate a uniform light emission from the plate. If
the outer border is noticeably brighter, the plate must be replaced.
When the fluorescent plate is in position, the central point will be exactly 70 mm from
70 the sensor of the meter. This central point of the plate is also used for the vertical
positioning of the UV-A light source*.

Digital Radiometer/Photometer
BS EN ISO 3059 :
Lighting conditions are
quoted on the test surface
whereas BS 4489 quoted SO
the lighting intensities at o
400 mm distance from tire
test surface.

90

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Ruane & II UNIT PTl LIQUID PENETRANT INSPECTION
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\OTF:S TECHNIQUES {INCLUDING ADV ANTAGES/DISADVANTAGES OF

EACH SYSTEM
10 Solvent removable penetrants and a liquid spray developer
Stages
l. Pre-cleaning of the surface.
2. Application of penetrant.
20 3. Removal of excess penetrant.
4. Application of developer.
5. Inspection.

Characteristics of solvent removable dye penetrants

30
Advantages
I. Portability.
2. No water required.
3. Good on anodized specimens.
40
4. Good for spot checking.
5. Specimens can be re-run easily.

Disadvantages
1. Flammable materials.
50
2. Removal of excess surface penetrant is time consuming.
3. Materials not recommended to be used in open tanks.
4. Difficult to use on rough surfaces such as cast components.
5. Toxic in enclosed spaces.
60

70

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'0TES
Water washable penetrants with a liquid spray or dry powder
developer
10 Stages
1. Pre-cleaning of the surface.
2. Application of penetrant.
3. Water rinsing (removal) of excess penetrant.

20
4. Drying of surface.
5. Application of developer.
6. Inspection.

Characteristics of water washable penetrants

30
Advantages
1. Easily washed with water.
2. Good for quantities of small specimens.
3. Good on rough surfaces.
40 4. Good on keyways and threads.
5. Good on a wide range of discontinuities.
6. Fast single step process.
7. Relatively inexpensive.
50
Disadvantages
1. Not reliable for detecting scratches and similar shallow surface discontinuities.
2. Not reliable on re-runs of specimens.
3. Easily over washed.
60 4. Penetrant subject to water contamination.

70

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90

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Ruane & II t:;\'IT PTI LIQUID I'F.~ETRANT INSPECTIO~
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:'iOTES
Post-emulsifiable penetrants used with a lipophilic emulsifier and a
liquid spray or dry powder developer
10 Stages
1. Pre-cleaning of the surface.
2. Application of penetrant.
3. Application of emulsifier.

20 4. Water rinsing (removal) of excess penetrant and emulsifier.

5. Drying of surface.
6. Application of developer.
7. Inspection.

30
Post-emulsifiable penetrants used with a hydrophilic remover and a
liquid spray or dry powder developer
Stages
1. Pre-cleaning of the surface.
40 2. Application of penetrant.
3. 1$1 stage water rinsing.
4. Application of remover.
5. 2"d stage water rinsing.
50 6. Drying of surface.
7. Application of developer.
8. Inspection.

Characteristics of post-emulsifiable penetrants

60
Advantages
I. High sensitivity for very thin discontinuities.
2. Easily washed with water after emulsification.
3. Good on wide shallow discontinuities.
70
4. Short penetration time.
5. Cannot be easily over-washed.

Disadvantages
I. Two step process.
80
2. Equipment required for emulsifier application.
3. Difficult to remove penetrant from threads, keyways, blind holes, rough surfaces,
etc ..

90

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Ruane & II UNIT J>TJ LIQUID J>Ei'lETRA~T INSPECTION
TPO'Neill

\OTtS Since all of these penetrant systems may be colour contrast or fluorescent, we must be
aware of the considerations to make the correct choices:

Visible dyes
10
1. No special lighting conditions are required.
2. No power supplies are required.
3. Lower eye strain when viewing, therefore longer inspection periods permissible.
4. Ideal for polished surfaces since a developer is almost always used to cover the
20 work surface, hence eliminating the possibility of glare from the light source used.

Fluorescent dyes
1. Special purpose light sources are required - may be expensive.
2. Higher contrast between background to indication, therefore increasing the overall
30
sensitivity of the test.
3. No requirement of a white background, hence use of dry powder developers are
more common place, which reduces amounts of consumables used and reduces
post cleaning requirements. Ideal for production line runs.
4. Higher care of contamination is required, i.e. handling/cross-contamination of
40
baths.
5. Regular breaks required for operators to reduce eyestrain. This requirement
increases with the reduction in ambient lighting conditions.
6. Fluorescent dyes can be quenched by high temperatures (in excess of 50C).
7. Strong acids/alkaline agents may release chromate ions which are opaque to UV-A
so light, therefore increasing the probability of missing small indications fluorescing.

60

70

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 I

Ruane& II t:l\IT PT2 COSHII REGULATIONS

TPO'Neill

'\OTE S

SCOPE
10 The Control of Substances Hazardous to Health Regulations, referred to as The
COSHH Regulations, define a substance hazardous to health as:
a. a substance listed in part I A of the approved list as dangerous for supply, see
Hazard Information & Packaging for Supply Regulations 1994 (CHIP2) - nature
of risk classified as very toxic, toxic, harmfuJ, corrosive or irritant.
b. one which has an MEL in Schedule I of COSHH or if the H & S Commission has
20 approved an OES.
c. a micro-organism which creates a hazard to health.
d. dust in air (when substantial).
e. a substance comparable with the above.

30
The COSHH regulations are not applicable to the control of lead, radioactivity,
explosive or flammable properties of materials, high or low temperatures, high
pressures, medical treatment or below ground work (mining).

RESPONSmiLITIES
40
The exposure of an employee to substances hazardous to health is under the control of
the employer. A training organisation is responsible for exposure by trainees.
Employers must prevent exposure to substances hazardous to health, or control
exposure when total prevention is not reasonably practicable. Personal protective
equipment, e.g. masks, are a second choice for control.
50 Employees have a duty to report any problems in exposure control procedures or any
defects found in protective equipment.
Employers must keep records of examinations/monitoring tests carried out. These are
kept for 5 years; 30 years for identifiable employees.

60
70
Tire occupational exposure
limit for xylene is an
occupational exposure 80
standard (OES). therefore
the short term OEL is
100 ppm over a 15 minute
reference period. The long
term OEL is 50 ppm over
an 8 hour time weighted
average refe rence period.
90
100
0CCUPATIONAL EXPOSURE LIMITS (EH40 - JANUARY 2002)
The Guidance Note EH40, entitled Occupational Exposure Limits, is a document
published by the Health and Safety Executive which gives occupational exposure
limits for substances hazardous to health.
A solvent, which is a substance hazardous to health, has its own occupational exposure
limit as given in EH40.
The toxicity value of a solvent is expressed in parts per million (ppm), e.g. the short
term occupational exposure limit for xylene is 100 ppm, this means to say that if the air
contained xylene exceeding 100 ppm, the air would be considered to be a significant
hazard to health.
There are two types of occupational exposure limit:
1. Maximum exposure limit (MEL): "is the maximum concentration of an airborne
substance, averaged over a reference period, to which employees may be exposed
by inhalation under any circumstances and is specified, together with the
appropriate reference period, in Schedule 1 of COSHH".
2. Occupational exposure standard (OES): "is the concentration of an airborne
substance, averaged over a reference period, at which, according to current
knowledge, there is no evidence that it is likely to be injurious to employees if
they are exposed to inhalation, day after day to that concentration, and which is
specified in a list approved by HSE".

O Ruont& T PO'Ntlll
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Ruane & II UNIT PT2 COSHH REGULATIOl\S
TP O'Neill

'OIES When a MEL is specified, exposures must be kept as low as is reasonably practicable,
but always below the specified value.
As OES should not be exceeded, but, an exposure over the limit is acceptable,
10 providing the reason for exceeding the OES has been identified and measures are taken
to reduce the exposure below the OES as soon as is reasonably practicable.

20

30

40

50

60

70

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Ruane & II UNIT PT3 CONVERSION FACTORS & TERMINOLOGY
TPO'Nel/1

\ OTES OLD TERMINOLOGY VS NEW TERMINOLOGY

Old Terminology New Terminology

10
3200 - 4000 A 320 - 400 nm (UV-A)
3650A 365 nm
Black light Ultraviolet light
Black light monitor Radiometer
20 Woods!Klopps filter UV-A filter
UN UV-A

2 2 2
I W/m 0.1 mW/cm = 100 ~W/cm

1 Ft/Cd 10.76Lux
30
2
I Lux 7.444 ~W/cm
-10
IA 10 m
-9
1 nm 10 m
40 5
oc 9 X (?F - 32)

COMMONLY REFERRED TO STANDARDS IN LIQUID

PENETRANT INSPECTION
50 BS 6443 : 1984 Penetrant flaw detection [SUPERSEDED)
BS 4489 : 1984 Measurement ofUV-A radiation (black light) used in
non-destructive testing [SUPERSEDED]
BS EN ISO 3059 : 200 I Non-Destructive Testing
Penetrant and Magnetic Particle Testing Viewing
60 Conditions
BS EN 571-1 Non-Destructive Testing - Penetrant Testing
Part 1: General Principles
BS EN ISO 3452-2 : 2000 Non-Destructive Testing - Penetrant Testing
Part 2: Testing of Penetrant Materials
70 BS EN ISO 3452-3 : 1999 Non-Destructive Testing - Penetrant Testing
Part 3: Reference Test Blocks
BS EN ISO 3452-4: 1999 Non-Destructive Testing - Penetrant Testing
Part 4: Equipment
CP 3012: 1972 Cleaning and Preparation of Metal Surfaces
80
[SUPERSEDED]
BS 7773 : 1995 Cleaning and Preparation of Metal Surfaces
RPS 702 Non-Destructive Testing - Fluorescent Penetrant
Inspection (Rolls Royce)
BSM39 Method for Penetrant Inspection of Aerospace Materials
and Components
90
BS 3683 : Part 1 : 1985 Terms used in Non-Destructive Testing
Part 1: Penetrant Flaw Detection
[SUPERSEDED by BS EN !SO 12706}
BS EN ISO 12706: 2001 Non-Destructive Testing Terminology
Terms used in Penetrant Testing
100
BS EN 1330-6 Non-Destructive Testing Terminology - Part 6 - Terms
used in Penetrant Systems

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Ruane & II
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'\OTF:S Term
Air-agitated wash
Air/water spray gun
lO
Anti-coagulants
Aqueous liquid developer
20
Background
30
Background coloration
Carrier fluid
Carry over of penetrant
40
Colour contrast penetrant
Combined colour contrast
50
Comparator test block
60
Contact time
Corrosion inhibitor
70 Degreasing plant
Development time
Drag-out of penetrant
80
Dry developing cabinet
Electrostatic spraying
90
Emulsifiable penetrants
Emulsification time
lOO Emulsifiers
0 Ruane & T P O'Neill
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UNIT PT4 GLOSSARY
Deji1tition
Washing in liquid agitated by air pressure
A spray gun of the venturi type, using compressed
air to deliver the water as a pressurised spray.
Agents which prevent the separation and
agglomeration of the dispersed phase from an
emulsion, dispersion or colloidal solution.
A suspension of inert white powders in a water-
based carrier medium, usually incorporating
corrosion inhibitors.
Note: Such developers are suitable for application
by dipping or spraying.
The general appearance of the surface on which
defect indications are sought.
The unwanted coloration remaining after incomplete
removal of a fluorescent penetrant from the surface.
A fluid that acts as a carrier for the active materials.
The transfer into the rinse tank of the penetrant
remaining on the parts.
A solution of dyes, typically red, in an organic
carrier system.
A solution of dyestuffs in an organic carrier
and fluorescent penetrant medium that is capable of
reflecting visible light and of absorbing radiation in
the ultraviolet region with consequent emission of
radiation in the visible region.
An intentionally cracked metal block having two
separate areas for the application of different
penetrants so that a direct comparison can be
obtained.
The time during which the penetrant is in contact
with the component under test.
A substance that minimises corrosive attack.
Equipment comprising tanks for use with de greasing
fluids.
The time between the application of the developer
and subsequent viewing.
The loss of penetrant from the tank as a result of
carry over.
An enclosed cabinet in which a dust storm of fine
developer particles is created by recirculating air.
Application of penetrant and developer by
electrostatic methods.
Penetrants which can be converted to a water
washable condition by the addition of emulsifiers.
The time in which the component treated with
penetrant is in contact with the emulsifier.
Liquids used to facilitate removal of excess
penetrant by forming an emulsion during the rinsing
operation.
PT4-1
Ruane & II UNIT PT4 GLOSSARY
TPO'Nel/1

i'iOTES Term Definition

Flash point The temperature at which a liquid, heated in a
Cleveland cup (open test) or in a Pensky-Martens
10 apparatus (closed test), gives off sufficient vapour to
flash momentarily on the application of a small
flame.
Hydrophilic remover A water-based penetrant remover that is miscible in
all proportions with water.

20 lnunersion time The time during wruch components are submerged.

Lipophilic remover An oil based penetrant remover that is miscible in all
proportions with post-emulsifiable penetrants.
Oil and chalk A process (out-moded) in which oil is used as a
penetrant and chalk as a developer.
30 Penetrant A liquid which, when applied to a component, is
designed to find its way into surface fissures and to
remain there in detectable amounts during the
subsequent removal of excess penetrant from the
surface.

40 Penetration time The time allowed for penetration of discontinuities

by the penetrant.
Post-emulsifier An emulsifying agent which is applied to a non-
washable penetrant in the post-emulsifiable
penetrant process.

50 Quenching of fluorescence The extinction of fluorescence by causes other than

the removal of the exciting radiation, e.g. by the
action of strong oxidising agents and/or acids or
changes in temperature or concentration.
Radiometer See UV-A monitor.
Replenishes Materials added to compensate for the loss of
60
particular constituents of a penetrant during use.
Solvent cleaners Agents employed to clean oil and grease from the
surface of components prior to application of
penetrant process materials. Note: A synonymous
term is degreasingjluids.
70
Test piece A device specially prepared for checking the
efficiency of penetrant flaw detection processes. It
may be a: an electroplated artificially cracked block.
b. aluminium block quench cracks. c. cracked
component obtained from production.
80 Thixotropic penetrant A gelatinous penetrant in which the viscosity is
reduced with the duration of an applied shear stress.
Through penetrant technique A process in which a suitable penetrant is applied to
one side of a component and a developing agent to
the other with the object of revealing discontinuities
giving a continuous leak path through the
90
component.
Ultrasonic cleaning A method using a combination of a solvent or a
detergent and high frequency sound to remove
organic soil.

100

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Ruane & II U~IT I,T4 GLOSSARY
TPO'Nel/1

:\01 ES Term Definition

Ultraviolet radiation Radiation for which the wavelengths of the
monochromatic components are smaller than those
10 for visible radiation and more than about 1 nm.
Note: The limits of the spectral range of ultraviolet
radiation are not well defmed and may vary
according to the user. The International
Commission of Illumination (CIE) distinguishes the
following spectral range:
20 UV-A: 315 nm to 400 nm.
UV-B: 280 nm to 315 nm.
UV-C: 100 nm to 280 nm.
UV-A filter A filter that suppresses visible light and ultraviolet
radiation other than UV-A.
30 UV-A monitor Apparatus used for the measurement ofUV-A
radiation (see BS EN ISO 3059: 2001).
Vapour degreasing The removal of oils, greases and organic solids by
the use of a suitable vapour.
Wetting agents Substances added to liquid to decrease their surface
40 tension.

50

60

70

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\OTF.S PCN EXAMINATIONS

General
10 PCN (Personnel Certification in Non-Destructive Testing) is an international scheme
for the certification of NDT technicians and supervisors and meets EN 473 and
ISO 9712 requirements.

Levels of qualification
See EN 473 for a full description for levels of competence.
20
Levell
This level qualifies personnel to carry out NDT operations according to written
instructions under the supervision of a Level 2 or Level 3 person. A Level 1 person
has demonstrated competence to:
30 set up equipment and carry out tests;
record and classify the results in terms of written criteria.

Level2
This level qualifies personnel to perform and direct NDT according to established or
recognised procedures and has demonstrated competence to:
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choose the technique for the test method used;
perform and supervise the test;
interpret, evaluate and report results according to applicable standards, codes or
specifications;
defme the limitations of the testing method for which the qualification covers;
50 understand and transform NDT standards and specifications into practical testing
instructions adapted to the actual working conditions.

Level3
This level qualifies personnel to direct any NDT operation for which they are
certificated and:
60
assume full responsibility for a test facility and staff;
establish and/or validate NDT instructions or procedures;
interpret codes, standards, specifications and procedures;
designate the particular test methods, techniques and procedures to be used.

70 Pre-examination requirements
Level I and Level 2: There are mandatory minimum pre-approval training
requirements which are given in the PCN requirements documents.
Pre-examination training courses must be validated by The British Institute of Non-
Destructive Testing and need to cover the syllabus over a designated minimum number
so ofhours.
Documented in-house training may account for up to one third of the required training
hours. The candidate also has to demonstrate practical experience in line with the
requirements ofPCN.
Level 3: The candidates have two access routes available which are shown in the PCN
90 requirements documents. Both training and experience requirements depend upon
academic background. Note: A mature candidate route is available.

Examinations
The examinations consist of general theory, specific theory and practical parts
dependant on level and type of examination.
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By holding other PCN qualifications, candidates may be eligible for exemptions.

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:\OTF:S Following an examination, a results notice will be issued; this counts as evidence of
PCN certification for a period of 42 days. The certificate will follow the results notice
within 21 days.
1o Where the candidate is unsuccessful, one retest may be allowed providing the
percentage grades are not lower than the grades required by PCN.

ASNT EXAMINATIONS
20
General
ASNT (American Society for Non-Destructive Testing) examinations are held at the
Rotherham training centre.
Examination content is determined by an employer's Written Practice, i.e. employers
who do not have a Written Practice cannot have their NDT personnel certificated under
30 the ASNT scheme.
All companies who wish their NOT operators to be qualified to ASNT requirements
must hold a Written Practice in accordance with the ASNT document SNT-TC- 1A -
Recommended Practice; this document is intended as a guideline for employers to
establish their own Written Practice for the qualification and certification of their non-
destructive testing personnel.
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Written Practices are available via Ruane & T P O'Neill.
A self-employed individual may hold his own Written Practice but it should be
appreciated that he may be re-examined in accordance with a different Written Practice
when employed by another organisation.
50
Written Practice
A Written Practice is not a set ofNDT procedures.
A Written Practice is for the control and administration of NDT personnel and is
written specifically for a company's needs, e.g. related to welds only, for welds and
castings, for forgings only, etc.. The document may also relate to specific British
60
Standards, American Standards, in-house procedures etc., and may cover one NDT
method or several.
A Written Practice typically consists of 10 - 25 pages and includes the following:
Minimum training and experience requirements for personnel wishing to be
certificated.
70
The methods which may be relevant, e.g. UT, MT, PT, RT, ET.
The syllabus for the training related to each method.
The number of examination questions and number of practical test points.
(Theoretical questions are usually of the multi-choice type).
Minimum examination pass marks.
80 Although it is common practice for ASNT examined Level Til personnel to produce
Written Practices, it should be noted that it is the employer who is responsible for the
document, i.e. it is the employer who is responsible for his own qualification system
for NDT personnel under the ASNT scheme.

Examinations
90
Examination duration is typically less than a day and is divided into three parts:
( I) General - Typically 30-40 multi-choice questions related to the relevant NOT
method.
(2) Specific - Typically 15-20 questions re lated to the test equipment used,
product/process and specifications/procedures used by the employer.
100
(3) Practical - Typically 10 check points which may relate to one or more test sample.

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\OT[S All candidates would also have to undertake physical tests applicable to the test
method, e.g. eyesight and, in some cases, colour differentiation.

10 Examination results
Examination results are normally available within 2 working days of the examination;
the employer receives details of the examination results and certificates of achievement
for successful candidates, normally within 7 working days.
ASNT certificates are normally valid for 3 years.
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