PROCEDURE FOR PIPING LIQUID

PENETRANT TEST
NOCPL DOC NO.: W488-C-E-MS-004 REV: 00
WORLEY DOC NO.: 15963-2171-NOCPL-GE010-0010 REV: 00

Project Details

PROJECT MECHANICAL AND PIPING COMPOSITE WORKS AT

MANGALORE, HPCL PROJECT.

CLIENT HINDUSTAN PETROLEUM CORPORATION LIMITED

PMC WORLEY SERVICES INDIA PRIVATE LTD.

CONTRACTOR NARMADA OFFSHORE CONSTRUCTIONS PVT. LTD.

APPROVED FOR
00 27/10/2021 Prakash Jha Khirod Kumar Giri
CONSTRUCTION

REV DATE DESCRIPTION PREPARED BY CHECKED BY APPROVED BY

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WORLEY DOC NO.: 15963-2171-NOCPL-GE010-0010 REV: 00

Table of Contents

SL nos. Descriptions Page nos.

1.0 PROJECT.......................................................................................3

2.0 PURPOSE………………………………………………………………3

3.0 SCOPE……………………………………………………...................3

4.0 REFERENCES……………………………………………..................3

5.0 QUALIFICATION OF PERSONNEL AND PROCEDURE.………..3

6.0 HSE……………………………………………………………………...3

7.0 METHODOLOGY….…………........................................................4

8.0 PERSONNEL QUALIFICATION……………………………………..6

9.0 APPENDICES/FORMATS……………………………………..….…..6

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WORLEY DOC NO.: 15963-2171-NOCPL-GE010-0010 REV: 00

1.0 PROJECT
Mechanical and Piping composite works at Mangalore, HPCL Project.
2.0 PURPOSE
The Purpose of this work instruction is to lay guidelines and requirements and to be
established a method or a system to control the liquid penetrant test as specified by
referencing code of construction applicable specification.

3.0 SCOPE
This specification provides for the method and acceptance for liquid penetrant examination for
Bevel Edges, Root welds, Final welds etc. whenever required. The Penetrant method is used
for detecting discontinuities, which are open to surface typical discontinuities
deflectable by the method are cracks, laminations, porosity and scans.

4.0 REFERENCE
HPCL Specification
API 1104 (Latest Edition)
ASME Sec V
5.0 QUALIFICATION OF PERSONNEL AND PROCEDURE

All LPT personnel shall hold certification issued by American Society for Nondestructive Testing
(ASNT). LPT personnel validation test shall be carried out by Reliance to verify their capabilities
to perform to the requirements of the qualified procedure and then approved by HPCL. NDT LPT
level II or level II certified personnel in ultrasonic shall calibrate equipment, perform the test
interpret the test results and evaluate the result per the acceptance / rejection criteria.

6.0 HEALTH, SAFETY, ENVIRONMENT

Job Safety Analysis needs to be strictly followed during Liquid Penetrant Test at site. Tool Box
shall be conducted prior to start the activity for all persons. Safety requirements will be fulfilled.
PT will be performed by only authorized personnel as per manufacture safety instruction. The

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surface preparation, light source, technique used & light level verification is required to be
demonstrated one time.
7.0 METHODOLOGY
7.1 Material
Penetrant, cleaner & developer used shall be checked before use. Materials used for PT
examination are magna flux or equivalent which are to be spray can type. The chemicals used
for the above shall not contain harmful halogen & Sulphur. The content of each of the above
limited to 25 ppm. Visible solvent removable penetrates shall be used. The penetrant contains a
dye having a contrast colours, which can be seen reading on day light or under normal interior
illumination.
7.2 Surface Preparation
It is essential that the part of surface to be examined shall be cleaned at least 25mm on both
side. All rust, scale, welding flux, spatter etc. Shall be removed by suitable method such as
grinding and wire brushing etc. Excessive weld ripples unevenness which may interfere the
evaluation discontinues shall be grounded suitably.
7.3 Pre Cleaning
It is essential that the part of surface to be examined shall be cleared. All rust ,scale welding flux,
spatter paints oil shall be removed by suitable method such as grinding and wire brushing etc.
followed by cleaning with cleaner using lint free dry cloth. Ensure 100% evaporation of the
cleaner before applying penetrant.
7.4 Drying
It is essential that the part of surface to be examined be sufficiently dried prior to application of
penetrant.

7.5 Penetrant Application

The surface to be tested shall be thoroughly coated with penetrant by spraying and/or by brush
application. The Dwell time for the penetrant shall 10-15 minutes or as recommended by
manufacturer. The temperature of the area to be inspected shall be between 15 0C & 500C for
spray method, the spray nozzles should be kept at a distance of 15 to 30 cm from the job. The

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penetration time shall be 15 to 20 minutes and/ or as recommended by manufacturer. In case of

an investigation, necessitating a great sensitivity, it can extend up to minutes.

7.6 Surface Cleaning

After suitable penetration time has elapsed, excess penetrant remaining on the surface shall be
removed by wiping with clean fiber free cloth dampened with cleaner.
Excess penetrant shall be very carefully removed from the examined surface; otherwise it could
produce a background blushing, capable of masking defects or interfering with their accurate
identification.
After removing the excess penetrant, the examined surface shall be dried by normal evaporation
or forced air.
7.7 Developer Application
The developer shall be uniformly applied over the surface by spraying. The spray nozzles should
be kept at a distance of 15 to 30 cm from the job. Aerosol type of spray cans shall be
continuously agitated in order to prevent setting of solid particles dissolved in the liquid.
Inspection shall be made after a minimum of 7 minutes and not later than 30 minutes after the
developer is applied so as to prevent the dye from diffusing in the developer coating.
If a discontinuity is on the surface, the dye penetrant will draw a color pattern on the white
background.
Any doubtful indications shall be ground out to evaluate their characteristics. Then a second PT
of the area shall follow according to the same procedure as the first one of show if the false
indications were eliminated.

7.8 Evaluation of Indications

Bleeding out of the penetrant will indicate defects that occur as Mechanical discontinuities on the
surface. The discontinuity normally appears in the following shapes. Usually a crack or similar
opening will show a red line. Light cracks, porosity or welded lap will show a broken line. Gross
porosity may produce large indication covering an entire area of weld. Fine porosity is indicated
by random red dots.

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7.9 Final Cleaning

When the inspection is conducted the penetrant and developing material shall be removed as
soon as possible by means of wiping with a cloth and/ or by spraying cleaner on the surface.
7.10 Acceptance Standard
Acceptance standard and removal & repair of defects shall be as per HPCL Specifications / API
1104 & ASME SEC V.
7.11 Repairs
Unacceptable defects shall be rectified by grinding/ machining or chipping. Visual examination
shall be conducted to check that the defect has completely removed prior to repair.

8.0 Personnel Qualification

The operator performing this examination shall be certified at site in accordance with the
requirements of ASME Section V, SNT TC-1A, Level II or equivalent.

9.0 APPENDICES/FORMATS:

• Inspection Test Plan for Piping Liquid Penetrant Test

• IR Liquid Penetrant Test of Piping

Note: In case of any conflict between the requirements of this procedure and HPCL
Specification the later shall govern.

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