Doc.

No:LTPQ-S-PROC-M-006
GUIDELINES FOR LIQUID PENETRANT EXAMINATION
Rev: 00 30-04-2010
L&T Power PROJECT : Standard PAGE : 3 OF 8

1.0 SCOPE
This procedure is applicable to the solvent removable Penetrant systems of non-fluorescent type. Liquid Penetrant
Examination is used to detect discontinuities that are opened to the surface of nonporous metals. Liquid Penetrant
Examination shall be performed at the various stages of production within the scope of ASME Sec I, ASME Sec VIII Div.1,
ASME B31.1, ASME B31.3 and AWS D1.1. This procedure is applicable for Liquid Penetrant Examination performed on
surfaces where the temperature shall not be below 50 C nor above 520 C throughout the examination period.

2.0 PURPOSE
This procedure provides guidance and acceptance standards for color contrast visible dye Penetrant examination of
Weldments, Stainless steel, Carbon and Low alloy steel materials.

3.0 REFERENCE
3.1 IBR - Indian Boiler Regulations-1950
3.2 ASME Sec-I, Power Boilers
3.3 ASME Sec-V Article -6, Liquid Penetrant Examination
3.4 ASME Sec VIII, Rules for Construction of Pressure Vessels
3.5 ASME B31.1 – Power Piping
3.6 ASME B31.3, Process Piping
3.7 AWS D1.1, Structural Welding Code - Steel
3.8 ASNT
Note: All codes referred shall be latest edition applicable at the time of award of contract/specified in technical
specification.
Note: This document is a general guideline for Penetrant Examination at shop and site apart from the Standards and
Suppliers instructions. If any conflict arises with respect to this specification, project specific requirements, Contractual
requirement, Codes, Standards and Engineering Approved Data sheets, the order of priority shall be Contract
requirements, Codes, Standards, Engineering Approved Data Sheets and this specification

4.0 RESPONSIBILITY
Construction Manager is overall responsible for ensuring the quality of works at site and QA/QC In charge will ensure the
implementation in line with procedure and controlling the current revision document.

5.0 GENERAL
5.1 Personnel Qualification:
5.1.1 Personnel performing examinations to the requirements of this specification shall be qualified and certified in
accordance with ASNT or any approved international standard for qualification and certification of Non
Destructive Testing Personnel. Personnel determining the acceptability to the requirements of this procedure
shall be Level II as minimum
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GUIDELINES FOR LIQUID PENETRANT EXAMINATION
Rev: 00 30-04-2010
L&T Power PROJECT : Standard PAGE : 4 OF 8

5.1.2 The inspector shall be familiar with the basic knowledge of Material processing, Forming, Machining, and
Joining processes and general understanding of Design features, Drawing, Material specifications, Codes &
Standards, Application, Service requirements, and Workmanship Standards.
5.1.3 Personnel shall have an annual vision test to assure natural or corrected near distance acuity such that they are
capable of reading J-1 letters on standard Jaeger test type charts for near vision .Equivalent near vision tests are
acceptable.
5.2 Surface Preparation
Prior to Liquid Penetrant Examination, the surface to be examined and all adjacent areas within at least 1” (25 mm)
shall be dried and free of all dirt, grease, lint, scale, welding flux, weld spatter, oil, and other extraneous material that
could obscure surface openings or otherwise interfere with the examination. Grit or shot blasting is prohibited as a
method of surface preparation. For cleaning the SS surfaces, SS wire brush only shall be used.
5.3 PT Consumables: Cleaner, Developer and Penetrant shall be of same brand all times. Different combinations shall not
be used. PT consumables used shall be of reputed brands.
6.0 EXAMINATION
6.1 Pre-Examination Cleaning
Precleaning the penetrant application, the surfaces to be examined and all adjacent areas within at least 1” (25 mm)
shall be cleaned with a cleaning agent. Typical cleaning agents which may be used are detergents, organic solvents,
descaling solutions, and paint removers. A minimum of five minutes shall be allowed for drying of the surfaces to be
examined. This shall be accomplished by normal evaporation, or forced warm air. The surface shall be cleaned with lint
free cloth or baniyan cloth. Cotton waste shouldn’t be used for cleaning the surface.
Note: PT shouldn’t be carried out immediately after completion of welding like root PT. The weldment shall be left to
cool in free air approximately 15 min. and shall be ensured that the metal temperature has come down below 520 C
maximum.
6.2 Penetrant Application
As a standard technique, the temperature of the penetrant and the surface of the part to be processed shall neither be
below 100 C nor be above 520 C throughout the examination period. Local heating or cooling is permitted provided the
part temperature remains in the range of 100 C to 520 C during the examination. Penetrant consumables shall be checked
lot wise for performance using fine and artificial cracks created in Nickel Chrome Plates.
6.2.1 Where it is not practical to comply with this temperature limitation, other temperatures and times may be used,
provided the qualification of the penetration time and temperature is in accordance with Mandatory Appendix III,
Article6, Section V, of the ASME Code.
6.2.2 The Penetrant expiry dates as per the manufacturer’s specification shall be checked before applying it. The
penetrant shall be thoroughly agitated prior to its application.
6.2.3 The penetrant may be applied by any suitable means, brushing and/or spraying so that the entire surface to be
examined is completely covered with penetrant. Over flooding is necessary while applying penetrant with brush.
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GUIDELINES FOR LIQUID PENETRANT EXAMINATION
Rev: 00 30-04-2010
L&T Power PROJECT : Standard PAGE : 5 OF 8

6.2.4 If re-examination is required on the same area after examination, the area shall be completely cleaned as
specified in clause 6.1 and re-examined in accordance with all of the requirements of this procedure.
6.2.5 Time: Penetrant time is critical and shall be minimum of 10 minutes. The area to be examined shall remain
wetted by the penetrant throughout the entire penetration time.
6.2.6 For special materials like SS, the penetrant material shall be free from harmful contents like chlorides. For
meeting this criteria, only reputed penetrants shall be used.
6.3 Removal of Excess Penetrant
6.3.1 After the minimum dwell time has elapsed, excess penetration remaining on the surface shall be removed, taking
care to minimize removal of penetration from discontinuities.
6.3.2 Excess solvent removable penetrants shall be removed by wiping with a lint free dry clean cloth or absorbent
paper repeating the operation until most traces of penetrant have been removed. Cotton waste shouldn’t be used
for cleaning the surface.
6.3.3 The remaining traces shall be removed by lightly wiping the surfaces with a clean cloth or absorbent paper
moistened with solvent.
6.3.4 To minimize removal of penetrant from discontinuities, care shall be taken to avoid the use of excess solvent.
Direct spray of solvent is prohibited. Flushing the surface with solvent, following the application of the penetrant
and prior to developing, is prohibited.
6.4 Application of Developer
6.4.1 The developer shall be applied by spraying as soon as possible after the penetrant removal, but no longer than 10
minutes after the excess penetrant has been removed.
6.4.2 Prior to applying the developer to the surface, the developer must be thoroughly agitated to ensure adequate
dispersion of suspended particles.
6.4.3 The developer shall be applied so that the coating thickness is uniform and sufficient enough to draw the
penetrant out of discontinuities, but not too excessive which could cause the masking of indications.
6.4.4 While applying the developer, the nozzle of the aerosol can shall be held at a distance of 12 to 16 inches (30 to
40 cm) from the examination surface.
6.4.5 The minimum developing times for final interpretation is 10 minutes but not longer than 30 minutes.
6.4.6 Precautions should be taken to prevent any object /dust from touching the dry developer film because it is very
brittle, loosely held and easily damaged.
6.5 Interpretation of Indication
6.5.1 Examination using color contrast visible dye penetrant shall be performed under visible light.
6.5.2 A minimum light intensity of 100 fc (1000 Lx) at the work surface is required to ensure adequate sensitivity
during the examination and evaluation of indications.
6.5.3 A hand lamp with 60 watt bulb at maximum 9 inch distance or 100 watt bulb at maximum 12 inch distance is
considered adequate to provide above level of illumination.
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GUIDELINES FOR LIQUID PENETRANT EXAMINATION
Rev: 00 30-04-2010
L&T Power PROJECT : Standard PAGE : 6 OF 8

6.5.4 Observation of the formation of indications begin immediately after the application of a dry developer or as soon
as wet developer coating is dry.
6.5.5 Final interpretation of indications shall be made after allowing the penetrant to bleed-out for at least 10 minutes,
but not longer than 30 minutes.
6.5.6 Relevant indications are those indications caused by discontinuities that are opened to the examination surface
and with major dimension greater than 1/16 in. (1.5 mm).
6.5.7 Non-relevant indications are indications caused by conditions other than discontinuities. Surface irregularities
due to machining, grinding, or welding are conditions that may cause non-relevant indications.
6.5.8 Non-relevant indications that could mask indications caused by discontinuities are unacceptable and shall be re-
examined after Surface conditioning, if necessary with acid etching.
6.5.9 Broad areas of pigmentation which could mask relevant indications are unacceptable and shall be cleaned and
reexamined.
6.5.10 Linear indications are indications having a length greater than three times the width.
6.5.11 A rounded indication is one of circular or elliptical shape with a length equal to or less than three times its width.
6.6 Post Cleaning
Post the completion of the examination, the surface shall be thoroughly cleaned by wiping with a clean cloth moistened
with an approved acetone, solvent or cleaner as required to remove all traces of test material.
6.7 Repair/Removal of Indications: Indications found any after testing shall be removed by grinding and shall be
rechecked again with the same NDE. If found any discontinuities needs to be repaired with welding shall be done by
using qualified WPS and Qualified welder and the required NDE as original shall be repeated.
7.0 ACCEPTANCE STANDARDS
7.1 These standards shall apply unless other standards are specified for specific materials or application within ASME Sec I,
ASME B31.1 and ASME Sec VIII Div.1.
All surfaces examined shall be free of:
(1) Relevant linear indications
(2) Relevant rounded indications greater than 3/16 in. (5 mm)
(3) Four or more relevant rounded indications in a line separated by 1/16 in. (1.5 mm) or less (edge to edge).
(4) 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.
(5) Ten or more rounded indications in any 6 sq in. (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 (only ASME B31.1).
7.2 Acceptance standards for ASME B31.3:
ACCEPTANCE CRITERIA FOR WELDS (ASME B 31.3)
Criteria for (A to M) for Types of Welds and Service Conditions (Note-1)
Weld Imperfection Normal and Category M Fluid Service Severe Cyclic Conditions Category D Fluid Service
 Doc.No:LTPQ-S-PROC-M-006
GUIDELINES FOR LIQUID PENETRANT EXAMINATION
Rev: 00 30-04-2010
L&T Power PROJECT : Standard PAGE : 7 OF 8

Longitudinal

Longitudinal
Girth, Miter

Girth, Miter
Connection

Connection

Connection

Connection
Longitudinal
Girth, Miter
groove, &

groove, &

groove, &
(Note-4)

(Note-4)

(Note-4)
(Note 2)

(Note 3)

(Note 2)

(Note 3)

(Note 2)

(Note 3)

(Note 4)
Groove

Groove

Groove
Branch

Branch

Branch

Branch
Fillet

Fillet
Fillet
Crack A A A A A A A A A A

CRITERIAL VALUE NOTES FOR ABOVE TABLE

Criteria
Acceptable Value Limits (Note 6)
Symbol Measure
A Extent of Imperfection Zero (No evident imperfection)
Note:
(1) Criteria given are for required examination.
(2) Longitudinal groove weld includes straight and spiral seam
(3) Fillet welds include socket and seal welds, attachment welds for slip on flanges, branch reinforcement, and supports.
(4) Branch connection welds include pressure retaining welds in branches and fabricated laps.
(5) These imperfections are evaluated only for welds ≤ 5 mm in nominal thickness
(6) Where two limiting values are separated by “and”, the lesser of the values determines acceptance. Where two sets of values are separated by “or”, the
larger value is acceptable. T w is the nominal wall thickness of the thinner of two components joined by a butt weld.

7.3 Acceptance Standard for Structural Components as per AWS D1.1

The Penetrant Testing acceptance criteria are based on the size of the actual discontinuity and not the size of the
discontinuity as indicated by the Penetrant Testing inspection medium. Where discontinuity cannot be visually seen
(with magnification if required), after removal of the indicating medium, evaluation shall be based on size and nature of
the Penetrant Testing indication. Observation of the penetrant as it bleeds out will provide useful information
concerning the nature of the discontinuity. The acceptance/rejectance will be evaluated based on the applicable
requirements for visual inspection.
8.0 Documents
8.1 Suggestible Liquid Penetrant Examination Report Format is attached in Annexure – 1.