Job Procedure for Liquid Penetrant Testing

As Per ASME Sec VIII

Document
Rev Issue Date Prepared by: Reviewed by: Approved by:
No:

Name & Signature: Name & Signature: Name & Signature:

Vipin Kumar Prakriti Samanta Ganesh Babu M

QHSE/
P 11/CNDT/JP39
/DPI-ASME Sec
11 14.01.2022
VIII

Date: 14.01.2022 Date: 14.01.2022 Date: 14.01.2022

 Job Procedure for Liquid Penetrant Testing

TABLE OF CONTENT

SECTION DESCRIPTION PAGE NO.

AMENDMENT RECORD
03

1 SCOPE
04

2 PERSONNEL
05

3 SURFACE CONDITIONING
05

4 EQUIPMENT AND SUPPLIES

06

5 EXAMINATION
09

6 CALIBRATION 10

7 INTERPRETATION OF INDICATORS 10

EVALUATION OF INDICATIONS
8 11

ACCEPTANCE STANDARD (AS PER ASME SEC I. ASME

9 11
SEC.VIII; DIV.1 & DIV.2,ASME B 31.1

10 REPAIR REQUIREMENTS 12

11 POST EXAMINTION CLEANING 12

12 REPORTING SYSTEM 13

13 SAFETY 13

14 RECORDING SYSYTEM 13

15 Attachment -1 14

16 Attachment -2 15

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 Job Procedure for Liquid Penetrant Testing

AMENDMENT RECORD

Section / Name
Revision Date of
Checklist Amendment Details
No. Amendment Reviewed Approved
Amended
Sec 1, 4, 5 Prakriti
11 14 Jan 2022 Revised Section: 1, 4, 5 & 8 Ganesh Babu
&8 Samanta
Sec 1.8 & Prakriti
10 15 Feb 2021 Revised Section: 1.8 & 2 Ganesh Babu
2 Samanta
Sec 1.8, 2, Revised Section: 1.8, 2, 6, 11 & Prakriti
09 30 Dec 2019 Ganesh Babu
6, 11 & 12 12 Samanta
Sec 1.8 & Aries written practice & safety Prakriti
08 30 Dec 2018 Ganesh Babu
13 added Samanta
Overall formatting & Sample Prakriti
07 28 Dec 2017 Ed-2017 Ganesh Babu
report Samanta
Prakriti
06 26 Dec 2016 All Section - 1.8,13 & annexure 2 Ganesh Babu
Samanta
Overall formatting and old
Procedure Reference No.
Aries/DPT/Sec VIII/01 changed Prakriti
05 03 Jan 2016 All to new number Ganesh Babu
Samanta
P 11/CNDT/JP39 DPI-ASME
Sec VIII
04 13 Mar 2014 All Revised Ganesh Babu Ramasamy
03 16.05.213 All Revised Ganesh Babu Ramasamy
02 16.11.2010 All Revised Jessen P. Ramasamy
01 10.08.2009 All Revised Jessen P. Ramasamy
00 10.08.2001 All Initial Issue Jessen P. Ramasamy

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 Job Procedure for Liquid Penetrant Testing

1.0 SCOPE

1.1 This work instruction provides the general requirements, methods, techniques and
acceptance standards for Solvent Removable, Visible Color Contrast Liquid Penetrant
Examination of weld, carbon & stain less steel material. Variables of T-621 applicable
to emulsifiers, water washable and florescent are not applicable.

1.2 This work instruction is used to determine the presence of discontinuities open to
examination surface only.

1.3 This work instruction is applicable when the material and penetrant is within the
temperature range of 50o F (10o C) to 125o F (52ºC).

1.4 This work instruction shall be used as specified in the shop ITP

1.5 ATTACHMENT- 1 to this procedure details the essential and non-essential

variables applicable for this work instruction and their qualified range, this 11
procedure is demonstrated to the satisfaction of client as per T-150(a) of
Section V & Certified by Manager QA/QC.
1.6 Any change in an essential variable shall require demonstration to AI and
applicable revisions to this procedure & thereby rectification of the same.
1.7 Any change in the non-essential variable does not require re-qualification but
may require revisions to this work instruction
1.8 Reference Documents
Latest edition of the following documents are referred:
11
· ASME–BPVC-Section V-2021 Edition
· ASME –BPVC-Section VIII Division 1 & 2-2021 Edition
· ASME-BPVC-Section I –Edition 2021
· ASME B 31.1 –Edition 2020
· NBIC NB-23 -2021 Edition
· ASNT SNT TC 1A- 2016 & 2020 Edition
· Aries Written Practice Document- QHSE/P11/CNDT/WP/P01

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 Job Procedure for Liquid Penetrant Testing

2.0 PERSONNEL
2.1 Personnel performing examination to this work instruction shall be qualified
and certified according to Aries written practice, QHSE/P11/CNDT/WP/P01,
which meets the requirement of SNT-TC-1A, 2016 & 2020Edition.
2.2 Personnel performing Liquid Penetrant Examination - PT Level II
Personnel evaluating Liquid Penetrant Examination - PT Level II / III
2.3 Personnel performing Examination shall have vision, with correction if
necessary, to enable to read Jaeger Type No. 1 Standard Chart at a distance of
not less than 12 in., and differentiate the contrast between the colors or
shades of gray, and records of such vision test shall be maintained by ARIES.
Vision tests shall be conducted annually and shall be valid during examination.

3.0 EQUIPMENT AND SUPPLIES

3.1 Temple stick / Surface thermometer to check the examination surface temperature.

3.2 Penetrant material used shall be Solvent Removable Visible Color Contrast of
the approved Suppliers as follows

SUPPLIER MATERIAL PRODUCT

Cleaner (in aerosol can) SKC-S

MAGNAFLUX
Penetrant (in aerosol can) SKL-SP2

Developer (in aerosol can) SKD-S2

Cleaner (in aerosol can) Chekmor-222

Chemtell
Penetrant (in aerosol can) S-71A

Developer (in aerosol can) LD-3

Any change in material from the above list shall require procedure
demonstration.
3.3 Intermixing of chemicals of different manufacturers is not permitted.

3.4 NICKEL BASE ALLOYS: When examining nickel base alloys, all penetrant materials
shall be analyzed individually for sulfur content in accordance with SE-165,

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 Job Procedure for Liquid Penetrant Testing

Annex 4. Alternatively, the material may be decomposed in accordance with SD-

129 and analyzed in accordance with SD-516. The sulfur content shall not exceed
0.1% by weight. Alternatively manufacturer’s certified MDS can be considered
acceptable provided the sulfur content not exceed 0.1% by weight.

3.5 AUSTENITIC OR DUPLEX STAINLESS STEEL AND TITANIUM: When examining

austenitic or duplex stainless steel and titanium, all penetrant materials shall be
analyzed individually for chlorine and fluorine content in accordance with SE-
165, Annex 4. Alternatively, the material may be decomposed and analyzed in
accordance with SD-808 or SE-165, Annex 2 for chlorine and SE-165, Annex 3 for
fluorine. The total chlorine and fluorine content shall not exceed 0.1% by weight.

3.6 Certifications obtained on penetrant materials shall include the penetrant

manufacturers’ batch numbers and the test results obtained in accordance with
ASME Sec V Article 6, Mandatory appendix II, for Para 3.4 and 3.5 of this procedure.
These records shall be maintained as required by the referencing Code Section...

4.0 EXAMINATION
4.1 Surface Preparation 11
Surfaces to be examined may be in the as welded, as rolled, as cast or as
forged condition. Grinding may be necessary in certain cases where surface
irregularities could mask unacceptable discontinuities.
The temperature of the penetrant materials and the surface of the part to be
inspected and temperature shall not exceed 52°C (125°F). When it is not
Possible to comply with these temperature limits, the procedure must be
Qualified using the temperature to be used.

4.2 Pre-Examination Cleaning

4.2.1 Prior to penetrant application, the surface to be examined and all the
adjacent areas within at least 1 in. (25 mm) shall be cleaned by
mechanical means and organic solvent to remove any dart, grease,
lint, scale, welding flux or spatter, oil or other matter which could
interfere with the examination.

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 Job Procedure for Liquid Penetrant Testing

4.2.2 Operations that may peen / close the discontinuity openings and compromise
the integrity of the examination such as shot, sand, grit blasting are not
recommended. When these operations are performed, precautions such as
alkaline or acid etching shall be performed to ensure reopening of those
discontinuities.
4.2.3 Maximum of 2 minutes may be allowed for drying the surface to be examined
accomplished by normal evaporation or with forced hot or cold air before
applying penetrant.

4.3 Application of Penetrant

4.3.1. The temperature of the penetrant and the surface of the part to be
examined shall not be below 400F (50C) nor above 1250F (520C). Local
heating or cooling is permitted, provided the part temperature
remains in the temperature range of 400F to 1250F (50C to 520C)
during the examination. For use of temperature range other than that
specified above the penetrant material will be re qualified per
Appendix III of article 6 of Section V.
4.3.2 Penetrant application
The penetrant shall be applied by spraying or brushing, so that all
surface under examination shall be thoroughly and uniformly covered
by penetrant.
4.3.3 Penetrant dwell time
After application, excess penetrant is drained out from the part
allowing suitable dwell time of minimum 10 minutes. The dwell time
is typical for the material and product as shown in Table-1. The area
to be examined shall remain covered by the penetrant throughout the
entire dwell time. However the maximum dwell time shall not exceed
2 hrs. or as qualified by demonstration for specific applications.

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 Job Procedure for Liquid Penetrant Testing

TABLE - 1

Product form Types of Discontinuities open to Penetrant

Material surface Dwell Time*
(Minutes)

Carbon or Welds Crack, porosity, lack of fusion 10

Stainless Casting Cracks, Porosity, cold shuts 10
Steel Forgings, Extrusion Laps, Seams, External bursts 20

* For the temperature range from 50º F (10º C) to 125º F (52º C). For temperature
from 40º F (5º C) up to 50º F (10º C) minimum penetrant dwell time shall be 2 times the
value listed. That means for welds from 40º F (5º C) to 50º F (10º C) the penetrant dwell
time shall be 20 minutes minimum.
Footnote:

Interpretation shall start immediately after application of developer and the final inspection
shall be made not less than 10 minutes nor more than 60 minutes.

Table II - Minimum and Maximum Time Limits for Steps in Penetrant Examination*
Procedure Step Minimum Maximum
Minutes Minutes

Drying after preparation (T-643) 1 ---

Penetrant dwell (T-672) 10 20
Drying after penetrant removal (T-674) --- 2
Developer application (T-675) -- 2
Developing and interpretation time (T-675.3 and T-676) 10 20

4.4 Penetrant Removal

4.1.1 After the minimum penetrant dwell time is elapsed, the excess solvent removable
penetrants shall be removed by wiping with a clean, dry, lint-free cloth or absorbent
paper, repeating the operation until most traces of penetrant have been removed.
The remaining traces shall be removed by wiping the surface with cloth or absorbent
paper, lightly moistened with solvent. To minimize removal of penetrant from
discontinuities, care shall be taken to avoid the use of excess solvent.

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 Job Procedure for Liquid Penetrant Testing

4.1.2 The remaining traces of penetrant shall then be removed by lightly wiping
the surface with a clean cloth moistened with solvent cleaner. To minimize
removal of penetrant from discontinuities care shall be taken to avoid the
use of excess solvent cleaner. If wiping is not effective the part shall be
dried in ambient temperature and penetrant be reapplied for the
prescribed dwell time range as per Table 1.
4.1.3 WARNING: Flushing the surface with solvent, following the application of the penetrant
and prior to developing, is prohibited.

4.5 Drying after Excess Penetrant Removal

For this solvent removable technique, drying shall be accomplished by
exposure to ambient temperature. Local heating / cooling is permitted but
with proper care to the component provided the temperature of the part
remains within the temperature range of 400F (50C) to 1250F (520C).
Minimum time of drying should be 1 minute and maximum time for drying
shall be 2 minutes before application of developer.
4.6 Application of Developer
4.6.1 The developer is of solvent suspended non-aqueous wet type and shall
be applied as soon as possible after the excess penetrant (shall not
exceed 10 min.) has been removed and the part has been dried.
Developer shall be applied by spraying from spray cans after good
agitation in such a manner to assure complete part coverage with a
thin uniform film. The spray nozzle tip of the spray should be held
about 12 in. from the examination surface approximately
perpendicular. The second coat may be applied across the direction of
first coat. Dipping, Flooding is prohibited.

4.6.2 Where safety or restricted access makes it impractical to apply

developer by spraying; developer shall be applied by brushing. Drying
shall be by normal evaporations.
4.7 Developing time
Developing time being immediately as soon as the wet developer coating is
dry. The length of time the developer is to remain on part being examined,

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 Job Procedure for Liquid Penetrant Testing

prior to final interpretation shall be minimum 10 minutes maximum 20

minutes.
5.0 CALIBRATION
· Light meter shall be calibrated at least once in a year or whenever the meter has
been repaired. 11
· If the meter has not been in use for one year or more, recalibration shall be done
prior to use.
6.0 INTERPRETATION OF INDICATIONS
6.1 Illumination (natural or supplemental white light) of the examination surface shall
be required for the evaluation of indications. The minimum light intensity shall be
1076 lux (100 fc). The light intensity, natural or supplemental white light source,
shall be measured with a white light meter prior to the evaluation of indications or a
verified light source shall be used. Verification of light sources is required to be
demonstrated one time, documented, and maintained in the file.

6.2 Observation of the formation of indications shall be performed during the

application of developer. If defects are present, they will show up as red indications
on white developer coating. Some may appear immediately while some may take a
little longer to develop.

6.3 Final interpretation of indications shall be made within 10 - 20 minutes after the wet
developer coating is dry. If the surface to be examined is so large that a complete
examination cannot be completed within the prescribed time, then only portions
shall be examined at time.

6.4 The rate of bleeding is an indication of the width & depth of defect while the extent
and spread of bleeding is an indication of the volume of flaw. Relevant indications
are those caused by discontinuities that are open to the examination surface.

6.5 Non-relevant indications are those caused by the conditions other than
discontinuities such as surface irregularities due to machining, grinding, faying
surfaces, press-fits, poorly removed paint etc. These indications, which may mask
discontinuities, shall be removed, cleaned and re-examined

6.6 Linear indications are those having a length greater than 3 times the width

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 Job Procedure for Liquid Penetrant Testing

6.7 Rounded indications are those of circular or elliptical shape with a length equal to or
less than 3 times the width

7.0 EVALUATION OF INDICATIONS

7.1 Indications whose major dimensions are greater than 1/16 in. (1.5mm) shall
be considered relevant. All indications shall be evaluated in terms of
acceptance standards as specified in this procedure.
7.2 Discontinuities at the surface will be indicated by bleed back feature of the
penetrant. Any indication, which is believed to be non-relevant, shall first be
regarded as a defect and shall be re-examined to verify whether or not actual
defects are present. Surface conditioning may precede the re-examination.
No relevant indications and broad areas of pigmentation, which would mask
indications of defects, are unacceptable and shall be eliminated from the
surface and re-examined.
7.3 Indication of a discontinuity may be larger than the actual discontinuity that
causes it; however, the size of the final indication and not the size of the
discontinuity is the basis of acceptance or rejection it.

8.0 ACCEPTANCE STANDARD (AS PER ASME SEC. I, ASME SEC. VIII; DIV. 1 & DIV. 2,
ASME SEC IX and ASME B 31.1).
11
8.1 All welds such as LS, CS, including pressure part fillets, such as welds joining
nipple/ stub / branch to drum, header, pipelines shall be free of following
relevant indications.
8.1.1 All relevant linear imperfections.
8.1.2 Relevant rounded indications with dimension greater than 3/16 in. (5.0 mm)
8.1.3 In-line porosity i.e. four (4) or more relevant porosity indications separated
by 1/16 in. (1.5 mm) or less edge to edge.

8.2 For non-load bearing attachment welds as determined by Design Engineering

shall be examined to an extent of 10% of total length and essentially free of
cracks. Here rounded indications are not a factor in acceptability of welds.

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 Job Procedure for Liquid Penetrant Testing

However, in case of appreciable number & size of rounded indications

rectifications and re-examinations required.
9.0 REPAIR REQUIREMENTS
Unacceptable imperfections shall be repaired and reexamination made to assure
removal or reduction to an acceptable size. Whenever an imperfection is repaired by
chipping or grinding and subsequent repair by welding is not required, the excavated
area shall be blended into the surrounding surface so as to avoid sharp notches,
crevices, or corners. Where welding is required after repair of an imperfection, the
area shall be cleaned and welding performed in accordance with a qualified welding
procedure.
Treatment of indications believed no relevant: Any indication which is believed to
be no relevant shall be regarded as an imperfection unless it is shown by
reexamination by the same method or by the use of other nondestructive methods
and/or by surface conditioning that no unacceptable imperfection is present.
Examination of areas from which defects have been removed: After a defect is
thought to have been removed and prior to making weld repairs, the area shall be
examined by suitable methods to ensure it has been removed or reduced to an
acceptably sized imperfection.
Reexamination of Repair areas. After repairs have been made, the repaired area
shall be blended into the surrounding surface so as to avoid sharp notches, crevices,
or corners and reexamined by the liquid penetrant method and by all other methods
of examination that were originally required for the affected area, except that, when
the depth of repair is less than the radiographic sensitivity required, re radiography
may be omitted.
10.0 POST EXAMINATION CLEANING
Post examination cleaning is necessary only in those cases where residual penetrant
materials could interfere with subsequent processing or with service requirements. It
is specially required in case of stainless steel components where residual penetrant
materials smite interact with other factors leading to corrosion. If post cleaning is
deemed necessary it shall be done promptly after evaluation by coarse water rinsing
or water spray or solvent wiping, which does not adversely affect the part.

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 Job Procedure for Liquid Penetrant Testing

11.0 LIGHT METER

11.1 Calibrated white light meter shall be used to establish the light intensity
required for examination. A 60W/220V bulb gives sufficient light intensity
(1076 Lux) at a distance of 250 mm (10”).
11.2 The white light meter shall be calibrated at least once in a year or whenever
the meter has been damaged or repaired or there is a doubt on the accuracy
of the meter. If the meter has not been in use for one year or more,
recalibration shall be done before being used.

11.3 Calibrated white light meter shall be used when it is required to establish the
required light intensity for any other light source and distance.

12.0 REPORTING SYSTEM

Examination results shall be reported in Form (ATTACHMENT 2). This shall include
as a minimum:
a) Procedure No. And revision
b) Liquid penetrate type (visible or fluorescent)
c) Type (Number or letter designation) of each penetrant, penetrant remover
and developer used
d) Identification of weld/part no
e) Examination personnel identity / qualification level
f) Map or record of indication
g) Material and thickness
h) Lighting equipment
i) Date and time examinations were performed

13.0 SAFETY

a. All inspection personnel shall be responsible for compliance with applicable

safety rules in the use of liquid Penetrant materials.

b. Penetrant materials are highly volatile, relatively toxic and the liquids may cause
skin irritation. Use adequate ventilation at all times and avoid prolonged skin
contact.

c. Penetrant materials shall never be heated above the recommended temperature

limits prescribed by the manufacturer.
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 Job Procedure for Liquid Penetrant Testing

d. Penetrant materials shall never be exposed to open flames

e. Keep aerosol cans containing Penetrant materials out of direct sunlight and
storage areas in excess of the recommended temperature limits specified by
manufacturer; an excessive heat may cause aerosol cans to explode.

14.0 RECORDING SYSTEM

All reports shall be retained for a minimum period of three (3) years unless otherwise
specified in the Code Contract or Bid requirement and will be a part of
documentation.
Attachment-1 Requirements of Liquid Penetrant Examination Procedure (Table-T-621)

No. Requirement Essential Variable Non-essential

variable
1 Identification of any change in the family group of X ----
chemical. (Penetrant Examination Chemicals)
2 Surface preparation (finishing and cleaning, X ----
including type of cleaning solvent)

3 Method of applying penetrant X ----

4 Method of removing excess surface penetrant X ----

5 Hydrophilic or lipophilic emulsifier concentration X ----
and dwell time in dip tanks and agitation time for
hydrophilic emulsifiers
6 Hydrophilic emulsifier concentration in spray X ----
applications
7 Method of applying developer X ----
8 Minimum & Maximum Time Periods between X ----
steps and drying aids.
9 Decrease in penetrant Dwell time. X ----
10 Increase in Developer Dwell time(Interpretation X ----
Time)
11 Minimum Light Intensity X ----

12 Surface temperature outside 40°F to 125°F (5°C to X ----

52°C) or as previously qualified.
13 Performance demonstration, when required X ----

14 Personnel qualification requirements ---- X

15 Materials, shapes, or sizes to be examined and the ---- X
extent of examination
16 Post examination cleaning technique ---- X

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 Job Procedure for Liquid Penetrant Testing

Attachment- 02 Reporting Format

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