THE DOW CHEMICAL COMPANY ENGINEERING SPECIFICATION

MATERIALS G8S-5050-01
GLOBAL 03-DEC-2002
Page 1 of 12
Liquid Penetrant Examination

1 Overview

1.1 Scope

This standard applies to liquid penetrant examinations of nonporous

material which are performed for final acceptance at Dow Chemical
Company locations and which are required by Code, Engineering
Standards, and/or Site Standards. The requirements of this standard
may be applied to other liquid penetrant examinations (e.g., liquid
penetrant examinations performed at a vendor shop as part of a purchase
specification) when deemed appropriate. The basis for the mandatory
classification of this standard is safety, environmental protection,
and recognized industry standards (see Article 1.2).

1.2 Codes

This standard meets the liquid penetrant examination requirements of:

Section I, Section V, and Section VIII of the ASME Boiler and Pressure
Vessel Code; ASME B31.1 and B31.3 Piping Codes; and API 620 and 650
Storage Tank Codes.

1.3 Retrofit

Retrofit is not required.

1.4 References

Use the latest edition of the following codes, standards, guidelines

and references:

ASME Boiler and Pressure Vessel Code

• Section I, Power Boilers

• Section V, Nondestructive Examination

• Section VIII, Pressure Vessels

ASME Code for Pressure Piping

• B31.1, Power Piping

• B31.3, Process Piping

ASNT
• SNT-TC-1A, Personnel Qualification and Certification in
Nondestructive Testing

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1.5 Definitions

API: American Petroleum Institute.

ASME: American Society of Mechanical Engineers.

ASNT: American Society for Nondestructive Testing.

2 Personnel Qualification

2.1 Dow Personnel

Dow personnel who perform liquid penetrant examinations in accordance

with this standard shall be qualified and certified in accordance with
the requirements of G8s-5001-00.

2.2 Non-Dow Personnel

Non-Dow personnel who perform liquid penetrant examinations in

accordance with this standard shall be certified to NDT Level II or III
(PT) in accordance with their employer's written practice. The
employer's written practice shall comply with the requirements
published in ASNT Recommended Practice No. SNT-TC-1A.

2.3 Noncertified Helpers

Noncertified personnel may be utilized to assist with liquid penetrant

examinations provided the work is performed under the direct
supervision of a Level II or III (PT).

3 Penetrant Materials

3.1 Techniques

Either a color contrast (visible) penetrant or a fluorescent penetrant

shall be used with one of the following three penetrant processes:

1. Post-emulsifying.
2. Solvent removable.
3. Water washable.

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3.2 Control of Contaminants

All penetrant materials (penetrants, solvents or other cleaning agents,

emulsifiers, developers, etc.) used to examine austenitic stainless
steel, titanium, or nickel base alloys shall meet the requirements of
Section V of the ASME Boiler and Pressure Vessel Code for control of
contaminants (chlorine, fluorine, and sulphur). Evidence of compliance
with Section V requirements for control of contaminants shall be
available for each batch or lot number (does not apply for acetone,
alcohols, and naphtha).

4 Examination

4.1 Temperature

The temperature of the penetrant and the surface of the part to be

processed shall be within 50°F (10°C) to 125°F (52°C) throughout the
examination period. Local heating or cooling is permitted provided the
part temperature remains in the range of 50°F (10°C) to 125°F (52°C)
during the examination. A liquid penetrant examination may be
performed colder than 50°F (10°C) or warmer than 125°F (52°C) provided
the nonstandard technique is qualified in accordance with G8S-5050-02.

4.2 Precleaning

Prior to all liquid penetrant examinations, the surface to be examined

and, if applicable, all adjacent areas within at least 1 inch (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.

The surface(s) to be examined shall be precleaned with a solvent. The

surface(s) shall be allowed to dry until all visible traces of solvent
have evaporated or one minute, whichever is longer. Other cleaning
methods (e.g., ultrasonic cleaning) may be used provided no residues
are left on the surface(s) to be examined (see Article 3.2).

4.3 Technique Restriction

4.3.1 Fluorescent Penetrant

When reexamining a component that has previously been examined by

liquid penetrant examination, fluorescent penetrant examination
shall not follow color contrast penetrant examination (excludes
routine maintenance examinations where the component has been in
service for at least one year since the previous liquid penetrant
examination).

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4.3.2 Water Washable Penetrant

When reexamining a component that has previously been examined by

liquid penetrant examination, water washable penetrant
examination shall not be performed (excludes routine maintenance
examinations where the component has been in service for at least
one year since the previous liquid penetrant examination).

4.3.3 Different Penetrant Families

Penetrant materials from different families shall not be

intermixed (e.g., solvent-removable color contrast vs. water
washable fluorescent). Penetrant materials from the same family
but from different manufacturers shall not be intermixed.

4.4 Penetrant Application

4.4.1 Coverage

Penetrant shall be applied to the surface to be examined plus 1/4

inch (6.4 mm) of all adjacent areas, if applicable [e.g., a weld
plus 1/4 inch (6.4 mm) of adjacent base material], by dipping,
brushing, pouring, or spraying . If the penetrant is applied by
spraying using compressed-air-type apparatus, air filters shall
be placed on the upstream side near the air inlet to prevent
contamination of the penetrant by oil, water, dirt, or sediment
that may have collected in the air lines. If application is by
dipping, the component(s) shall be positioned to allow excess
penetrant to drain without forming pools on the surface.

4.4.2 Surface Wetting

If the applied penetrant does not uniformly wet the surface, the
entire examination process shall be repeated.

4.5 Penetration Time

4.5.1 Routine Maintenance Examinations

For maintenance examinations for the purpose of detecting

service-related imperfections (e.g., stress-corrosion cracking
and fatigue cracks), the minimum penetration (dwell) time for
shall be 20 minutes for post-emulsified and solvent removable
penetrants and 30 minutes for water washable penetrants.

4.5.2 Other Examinations

For examinations not covered by Article 4.5.1 (e.g., new

fabrication and repairs), the minimum penetration (dwell) time
for shall be 10 minutes for post-emulsified and solvent removable
penetrants and 15 minutes for water washable penetrants.

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4.5.3 Shorter Penetration Times

If shorter penetration times than those specified in Article

4.5.1 or 4.5.2 are required, the nonstandard technique shall be
qualified as specified in G8S-5050-02.

4.5.4 Dried Penetrant

Penetrant must be kept wet for the entire dwell time. If

penetrant begins to dry on the surface of the component during
the penetration time, the penetrant shall be reapplied for the
minimum penetration time (i.e., the dwell time is restarted). If
penetrant completely dries on the surface of the component, the
entire examination process shall be repeated.

4.6 Emulsification

4.6.1 Lipophilic Emulsifiers

After the required penetration time for post-emulsified

penetrants, the excess penetrant on the component shall be
emulsified by spraying, dipping in a tank, or flowing emulsifier
over the test surfaces. If application is by dipping, the
component(s) shall be positioned to allow excess emulsifier to
drain without forming pools on the surface.

Brushing shall not be used to apply emulsifier.

Emulsification time shall be determined by actual tests (the

required emulsification time depends upon surface roughness and
type of emulsifier).

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4.6.2 Hydrophilic Emulsifiers

After the required penetration time for post-emulsified

penetrants, prerinse the component by water washing. The
prerinse water spray shall comply with the requirements in
Article 4.7.3.

The excess penetrant remaining on the component after prerinsing

shall be emulsified by spraying or immersion.

If immersion is used:

• The bath shall be agitated.

• The emulsifier concentration shall be in accordance with
manufacturer's recommendations, but shall not exceed 33%.
• The bath temperature shall be maintained between 50°F (10°C)
and 100°F (38°C).

If spray application is used:

• The emulsifier concentration shall be in accordance with

manufacturer's recommendations, but shall not exceed 5%.
• The spray temperature shall be maintained between 50°F (10°C)
and 100°F (38°C).
• The spray pressure shall not exceed 25 psig (175 kPa) for air
and 40 psig (280 kPa) for water.

Total contact time of emulsifier with excess surface penetrant

shall not exceed 2 minutes unless a longer emulsification time is
qualified per SU-30.

4.7 Excess Penetrant Removal

4.7.1 Water Washable

Excess water washable penetrant shall be removed by water washing

(see Article 4.7.3). Water washing shall begin immediately after
the conclusion of the emulsification time in Article 4.6. Water
washing shall be terminated immediately after excess surface
penetrant has been removed.

Note: Water washing shall be performed under black light when

fluorescent penetrants are used.

4.7.2 Post Emulsified

Excess post-emulsified penetrant shall be removed by water

washing (see Article 4.7.3). Water washing shall begin
immediately after the conclusion of the emulsification time in
Article 4.6.

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GLOBAL 03-DEC-2002
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4.7.3 Water Washing Requirements

For both the water washable and the post-emulsified penetrant

techniques, water washing shall meet the following requirements:

1. Water wash rinsing shall be accomplished by a coarse spray of

water.
2. The water pressure shall not exceed 50 psi (345 kPa).
3. The water temperature shall not exceed 110°F (43°C).

4.7.4 Solvent Removable

Excess solvent removable penetrant shall be removed from the

surface by wiping with a clean, dry, lint free cloth or absorbent
paper, repeating until most traces of penetrant have been
removed. Remaining traces of penetrant shall be removed by
lightly wiping the surface with lint free cloth or absorbent
paper moistened with solvent.

Cloth or absorbent paper soaked with solvent shall not be used to

remove excess surface penetrant. Flushing the test surface with
solvent prior to developing is prohibited.

Only the type of solvents recommended by the penetrant

manufacturer shall be used for excess penetrant removal.

4.8 Drying

4.8.1 Water Washable/Post Emulsified

For the water washable and post-emulsified penetrant techniques,

component surfaces may be dried by using circulating warm air
provided the component surface temperature does not exceed 125°F
(52°C) during the drying operation. Drying shall be performed
prior to developer application when using dry or nonaqueous
developers. Drying shall be performed after developer
application when using aqueous developers.

4.8.2 Solvent Removable

For solvent removable penetrant techniques, component surfaces

shall be dried by normal evaporation, blotting, wiping, or forced
air, until all traces of solvent are removed or one minute,
whichever is longer.

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4.9 Developer Application

4.9.1 All Developers

All developers shall be applied immediately after excess

penetrant removal and, except for aqueous developer, after
drying.

4.9.2 Wet Developers

Wet developers shall be agitated prior to application. Care

shall be exercised when applying wet developer to avoid excess
developer build-up.

4.9.2.1 Nonaqueous

Nonaqueous developer shall be applied only to a dry

surface. Nonaqueous developer shall be applied only by
spraying, except that brushing is permitted where safety
or restricted access precludes spraying. Drying shall be
by normal evaporation.

4.9.2.2 Aqueous

Aqueous developer shall be applied prior to the drying

operation by spraying, dipping, or brushing. After
aqueous developer application, the component surfaces may
be dried by using circulating warm air provided the
component surface temperature does not exceed 125°F (52°C)
during the drying operation. Blotting shall not be
permitted.

4.9.3 Dry Developer

Dry developer shall be applied only to a dry surface by a soft

brush, hand powder bulb, powder gun, or other means, such that
the powder is dusted evenly over the entire surface being
examined. Developer application shall immediately follow the
drying operation.

Dry developer shall not be used with visible penetrants.

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4.10 Interpretation

The surface shall be closely observed during developer application to

determine the true shape of imperfections during bleed-out (i.e.,
determine whether indications are rounded of linear).

Final interpretation shall be made after allowing the penetrant to

bleed-out for 7 to 60 minutes. Bleed out (developing) time shall begin
with the application of dry developer or as soon as wet developers dry
(carrier has evaporated).

Surfaces too large to permit complete examination within the 60 minute

time limit shall be examined in overlapping increments. The 60 minutes
maximum developing time may be exceeded provided the nonstandard
technique is qualified in accordance with G8S-5050-02.

4.10.1 Fluorescent Penetrant

When fluorescent penetrant is used, the following requirements

shall be met:

1. Interpretation shall be performed under black light in a

darkened area.

2. The examiner shall be in the darkened area for at least 1

minute prior to performing interpretation.

3. The examiner shall not wear tinted or photosensitive glasses

or lenses.

4. The black light shall be allowed to warm up for a minimum of

5 minutes prior to performing interpretation.

5. The black light intensity shall be a minimum of 1000 µW/cm2

on the surface of the part being examined. The black light
intensity shall be measured with a black light meter at 8
hour intervals or prior to next usage.

4.10.2 Visible Penetrant

Interpretation of visible penetrant indications shall be

performed with a minimum illumination at the surface of the part
being examined of 50 footcandles (500 lux). Illumination
measurements are not required for external liquid penetrant
examinations performed during daylight hours. Otherwise, the
light source, technique used, and light level verification shall
be demonstrated prior to the examination (once for each type of
artificial lighting) and documented. Note: Illumination can
only be verified by measurement with a light meter.

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4.11 Post Interpretation Cleaning

The component shall be cleaned after completion of the examination and

final interpretation such that all visible traces of penetrant
materials are removed.

5 Safety

5.1 Solvents

When liquid penetrant examinations are performed, all location and

Corporate safety requirements pertaining to the handling and use of
solves must be complied with.

5.2 Black Light

Black light units with mercury arc lamps shall not be operated unless
the proper, undamaged filter is in place.

5.3 Temporary Enclosures

When temporary enclosures are erected to provide a darkened area for

fluorescent penetrant techniques, all location and Corporate safety
requirements pertaining to confined spaces and use of enclosures must
be complied with.

6 Acceptance Standards

6.1 General

Broad areas of fluorescence or pigmentation which could mask

indications of imperfections shall be cleaned and reexamined.

Questionable or doubtful indications shall be reexamined to determine

whether they are relevant.

Although penetrant indications are usually larger than imperfections

that cause them, the indication size (not imperfection size) is the
basis for acceptance/rejection.

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6.2 Welds in Process Vessels and Tanks

Except for indications that are not indicative of imperfections (e.g.,

indications produced by machining marks), only indications with major
dimensions greater than 1/16 inch (1.6 mm) shall be considered
relevant.

All welds plus 1/4 inch (6.4 mm) of adjacent base material shall be
free of:

1. Relevant linear indications (indications having lengths greater than

three times the widths).

2. Rounded indications with a maximum dimension greater than 3/16 inch

(4.8 mm) (a rounded indication is one of circular or elliptical
shape with a length equal to or less than three times the width).

3. Four or more relevant rounded indications in a line separated by

1/16 inch (1.6 mm) or less (edge to edge).

6.3 Welds in Piping

6.3.1 Power Piping (B31.1)

Welds shall meet the acceptance criteria in Article 6.2. In

addition, welds shall be free of ten or more relevant rounded
indications in any 6 square inches (39 cm2) of surface. The
major dimension of this area shall not exceed 6 inches (150 mm)
and the area shall be taken in the least favorable location
relative to the indications being evaluated.

6.3.2 Process Piping (B31.3)

When liquid penetrant examination of plant piping is specified by

Engineering Standards and/or Site Standards and the standard does
not specify the acceptable criteria, the acceptance criteria of
Article 6.3.1 shall be used.

6.4 Other Components

For components not covered by either Article 6.2 or 6.3, acceptance

criteria shall be as specified on the referencing specification or
standard, or by the equipment owner.

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7 Reports

A report of the examination shall be made and shall, as a minimum, include

the following:

1. Date examinations were performed.

2. Names and certification levels of examination personnel.

3. Cleaning technique used (prior to inspection, removal of excess

penetrant and final)
4. Temperature (test item and ambient)

5. Dwell times (penetrant and developer)

6. Examination procedure number and revision.

7. Examination technique used.

8. Penetrant materials used including brand names, manufacturer, and, if

applicable, batch or lot numbers.

9. Identification of components and location of areas examined.

10. Examination results describing locations of rejectable indications or

areas free from indications.

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