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EM&I

INSPECTION PROCEDURE

LIQUID PENETRANT INSPECTION

Prepared by D M Mortlock Date 01/05/2012

Reviewed by D A Constantinis Date 01/05/2012
Approved by I Judge Date 01/05/2012

Confidentiality Statement

This document is commercially confidential to the EM&I

organisation and its contents should not be distributed,
copied, or made known to parties other than the listed
recipients without written approval of a Director of EM&I.

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REVIEW / REVISION HISTORY

Review / Reviewed /
Rev Comments
Revision Date Revised By
01/10/99 A Draft – Issued for review and comment DMM
01/10/99 0 Approved for issue DMM
06/06/01 0 Format and contents reviewed, no changes DAC
26/08/04 0 Format and contents reviewed, no changes DMM
04/09/05 0 Format and contents reviewed, no changes DMM
14/09/06 0 Format and contents reviewed, no changes DMM
Section 3.0 amended to confirm manufacturer and continuity of
26/03/07 1 consumables. Section 3.7 amended to include minimum lighting DMM/IJ
requirements
Update ASME attachment. Add light level verification method.
Delete references to ES standards. Amend minimum allowable
26/04/07 2 DMM/IJ
temperature. Amend penetrant and developer time. Amend
interpretation time. Amend report format.
Addition of ASME Code issue status (2004 Edition, 2006
03/08/2007 3 Addenda) in Section 2.0 Scope and in Sections 5.0 and 6.0 DMM/IJ
Procedures (SLP.01 and SLP.02).

10/07/2008 3 Reviewed for content/format – no significant changes DMM

Reference to ASME V and ASME VIII 2007 Edition in Section 2.0
14/08/2008 4 DMM/IJ
Update Attachment III to include ASME 2007 Edition extract
Update ASME B31.3 – 2008 Standard Section 2.0
Addition of visual acuity requirements Section 4.0
29/03/2009 5 DMM
Reference to E165 Section 3.0
Addition of consumable compatibility with test item Section 3.0
15/05/2009 5 Reviewed + Approved by Level III IJ

28/09/2009 5 Reviewed for content and format – no significant changes made DMM

08/06/2010 5 Reviewed for content and format – no significant changes made DMM

14/09/2010 5 Reviewed for content and format – no significant changes made DMM

07/07/2011 5 Reviewed for content and format – no significant changes made DMM
Attachment III updated to include ASME 2010 / Addendum 2011
01/02/2012 6 DMM
extract
Section 2.0 Scope. Section 5.0 & 6.0 Procedures -
01/05/2012 7 DMM
Dates/Editions removed from Standards references
07/06/2012 7 Reviewed for content and format – no significant changes made DMM

19/06/2013 7 Reviewed for content and format – no significant changes made DMM

25/06/2014 7 Reviewed for content and format – no significant changes made DMM

25/06/2015 7 Reviewed for content and format – no significant changes made DMM

24/06/2016 7 Reviewed for content and format – no significant changes made DMM

15/06/2017 7 Reviewed for content and format – no significant changes made DMM

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REVISION STATUS

Issue Rev Date Comment Checked Authorised

Draft – Issued for
01 A 01/10/1999 DMM DAC
review & comment
02 0 01/10/1999 Approved for Issue DMM DAC

03 1 26/03/2007 Approved for Issue DMM DAC

04 2 26/04/2007 Approved for Issue DMM DAC

05 3 03/08/2007 Approved for Issue DMM DAC

06 4 14/08/2008 Approved for Issue DMM DAC

07 5 29/03/2009 Approved for Issue DMM DAC

08 6 01/02/2012 Approved for Issue DMM DAC

09 7 01/05/2012 Approved for Issue DMM DAC

AUTHOR

Author Name Title Date

David Mortlock Chief Technical Officer 01/05/2012

Signature

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CONTENTS
1.0 INTRODUCTION TO LIQUID PENETRANT EXAMINATIONS............................................................. 5

1.1 HEALTH & SAFETY ................................................................................................................. 5

1.2 QUALITY & COMPATIBILITY OF LIQUID PENETRANT CONSUMABLES.......................................... 5
1.3 CORROSIVE CONTAMINANTS................................................................................................... 5
2.0 SCOPE ................................................................................................................................................. 7

3.0 LIQUID PENENTRANT EXAMINATION .............................................................................................. 8

3.1 SURFACE PREPARATION – CLEANING ..................................................................................... 8

3.2 DRYING .................................................................................................................................. 8
3.3 PENETRANT APPLICATION ...................................................................................................... 8
3.4 PENETRANT REMOVAL ........................................................................................................... 9
3.5 DRYING .................................................................................................................................. 9
3.6 DEVELOPING .......................................................................................................................... 9
3.7 INSPECTION ......................................................................................................................... 10
3.8 INTERPRETATION .................................................................................................................. 10
3.9 REPORTING.......................................................................................................................... 10
4.0 PERSONNEL...................................................................................................................................... 12

5.0 LIQUID PENENTRANT EXAMINATION PROCEDURE - SLP.01 ...................................................... 13

6.0 LIQUID PENENTRANT EXAMINATION PROCEDURE - SLP.02 ...................................................... 14

ATTACHMENT I - LIQUID PENETRANT TERMINOLOGY ........................................................................... 15

ATTACHMENT II - EXAMPLE OF LIQUID PENETRANT EXAMINATION REPORT FORM......................... 17

ATTACHMENT III - ACCEPTANCE CRITERIA ASME VIII, DIVISION 1, APPENDIX 8 ................................ 19

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1.0 INTRODUCTION TO LIQUID PENETRANT EXAMINATIONS

1.1 Health & Safety

Penetrant flaw detection techniques require the use of toxic, flammable and volatile
materials and safety precautions must be considered.

Well ventilated conditions should always be used, situated well away from heat, open
fires etc.

Penetrant flaw detection materials and ancillary equipment should be used with
caution, and always in accordance with the manufacturer’s instructions.

When used in confined areas a standby person must be in attendance and when
used at heights a safety harness must be worn.

Ventilation time for fumes to disperse must be considered before allowing personnel
back into areas where inspection has previously been carried out.

Empty aerosol cans must be collected and correctly disposed of and must not be left
lying around the examination areas.

1.2 Quality & Compatibility of Liquid Penetrant Consumables

There may be a vast difference in the penetrant quality, corrosive content and
compatibility of liquid penetrant consumables as supplied by different manufacturers.
Therefore, it is necessary to control and check batches of supplied consumables on
a comparator test block, at the same surface temperature as the examination
material, before issue and commencement of examination exercises.

Continuity of one consumable manufacturer shall be maintained throughout the

examination of discrete items.

1.3 Corrosive Contaminants

Each issue of liquid consumables will have the minimum of:

a) Sulphur content – not to exceed .005 gs per 100 gs

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b) Chlorine content – not to exceed .005 gs per 100 gs

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2.0 SCOPE

This document is to be used whenever a requirement for liquid penetrant inspection is

required to be carried out in compliance with the requirements of ASME Section VIII and
ASME Section V.

Where the Client has additional requirements to those included in this procedure then the
additional requirements shall be noted in the report.

It may be used when no other code or specification is called for as a general procedure for
liquid penetrant inspection for the purpose of crack or leak detection.

It may not be used when fluorescent penetrant inspection methods are specified.

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3.0 LIQUID PENENTRANT EXAMINATION

All consumables used during liquid penetrant examination may be solvent or water-
washable. They shall be manufactured by a recognised manufacturer, typically Johnson &
Allen or Magnaflux or equivalent. However, continuity of one consumable manufacturer shall
be maintained throughout the examination of discrete items.

Consumable shall meet the requirements of ASTM E165 “Standard Test Method for Liquid
Penetrant Examination”.

Penetrant consumables shall be compatible with and shall not be detrimental to the material
being examined.

3.1 Surface Preparation – Cleaning

Prior to the application of penetrant, it is of the utmost importance that the surface
are to be examined shall be cleaned of scale, rust, paint etc., and any surface
irregularities that could mask indication are dressed by light grinding.

Note: Coarse dressing methods and shot blasting are to be avoided, as fine
flaws can become masked by peening over the surface opening.

Finally, the surface area must be thoroughly degreased.

For components which have been in service, the cleaning method shall be adequate
to remove any contamination from the surface and from the inside of any possible
flaws. When suitable surface cleaning cannot be achieved, then alternative methods
of inspection should be considered.

3.2 Drying

After cleaning, the surface area will be dried; this by allowing sufficient time or the
use of drying methods to ensure the evaporation of any cleaning fluids from the
surface, or from the inside of any possible flaws.

3.3 Penetrant Application

The penetrant will be applied in sufficient amount so as to soak the area.

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On vertical surfaces, further applications of penetrant liquids will be made, so as to

replace penetrant which may flow off the examination area.

Penetrant contact time will be a minimum of 10 minutes. Refer to specific procedures

SLP.01 and SLP.02 in this document.

Note: These standard procedures are for examination of welds and materials
between the temperature ranges of 50oF (10oC) to 125oF (52oC). Any
temperatures either side of this range will not comply, and the practicality of
the examination, and penetrant time required, will have to be proved by using
the liquid penetrant comparator test block adjusted to the same appertaining
examination environmental conditions.

3.4 Penetrant Removal

After the specified penetrant contact time, the penetrant remaining on the surface will
be removed TAKING CARE NOT TO REMOVE PENETRANT FROM
DISCONTINUITIES.

First, remove all possible traces by wiping off with cloths or absorbent paper.

Secondly, remove final remaining traces by lightly wiping with a lint-free cloth, which
has been moistened with removal solvent. It must not be washed off with aerosol
sprays.

3.5 Drying

The surface will be allowed to dry by normal evaporation of removal solvent. This
time should be kept to the minimum between the cleaning and applying the
developing media.

3.6 Developing

The developer shall be applied as soon as possible after the excess surface
penetrant removal.

The developer will be applied over the surface in a fine, even coat.

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Note: Where aerosol containers are used, they must be adequately agitated to
ensure even dispersion of developer powder throughout the carrier fluid,
before application.

3.7 Inspection

White light viewing conditions shall be greater than 1000 LUX at the examination
surface (refer ASME V Article 6). Where natural light is insufficient, artificial lighting
shall be used to meet this requirement. The light level at the examination surface
shall be verified with a light meter prior to commencement of the examination.

The interpretation of a defect size and type is difficult to determine if the penetrant
drawn out by the developer diffuses excessively on the surface.

It is therefore important that the surface is initially observed during the application of
the developer, to monitor the appearance of penetrant from large defects, with a
further final inspection being carried out 10-60 minutes after application of developer
for penetration drawn out from fine, tight cracks.

Note: Broad areas of penetrant liquid on the examination surface, either from
localised surface irregularities or insufficient cleaning will render the
examination unacceptable. Such areas will be re-cleaned and re-examined.

3.8 Interpretation

Any surface linear indications will be considered as representing defects, and will
remain so until proved to be non-relevant.

Normally, surface pores and cracks are easy to define. In areas of faint indications,
or suspect cold lapping, the surface will be lightly dressed and re-examined, taking
care to thoroughly re-clean prior to applying penetrant oils.

3.9 Reporting

All results of examinations and of defects detected shall be reported on the standard
report sheet (refer Attachment II) and shall include the following minimum
information:

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a) Client
b) Contract/Work Order No
c) Report Number
d) Work location
e) Job / Weld identification reference
f) Date of examination
g) Testing media used, supplier’s name and batch number
h) Written Examination Procedure followed
i) Description and location of all relevant indications (with sketches)
j) Identity, signature and qualification of testing technician
k) Lighting method
l) Standard
m) Acceptance Criteria
n) Limitations

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4.0 PERSONNEL

Personnel performing work in accordance with this procedure shall be qualified to a

minimum of CSWIP / PCN Grade II or SNT level II, or equivalent, in liquid penetrant
inspection and shall be confirmed acceptable to the Client prior to commencement of work.

Personnel carrying out ultrasonic inspections shall have normal colour vision evidenced by
passing an Ishihara (or equivalent) test and shall be able to demonstrate unaided or
corrected vision in at least one eye and shall be capable of reading a Jaeger type standard
chart type No. 1 (N4 Times Roman), or equivalent, at a distance of not less than 300 mm.

Eyesight tests shall be carried out at least annually and the results shall be kept on file.

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5.0 LIQUID PENENTRANT EXAMINATION PROCEDURE - SLP.01

LIQUID PENENTRANT EXAMINATION PROCEDURE

SLP.01
PROCEDURE TYPE Normal

SURFACE PREPARATION The surface to be examined and all adjacent areas within
at least 25mm shall be dry and free of all dirt, grease,
lint, scale, welding flux, weld spatter, oil and other
extraneous matter that could obscure surface openings
otherwise interfere with the examination.

MATERIAL TEMPERATURE RANGE 10 to 52 degrees Centigrade

LIGHTING Minimum 1000 Lux at examination surface

PENTRANT Red dye applied by spraying from aerosol

PENETRANT TIME Minimum 10 minutes

REMOVAL OF EXCESS PENETRANT i) Clean with cloths or absorbent paper

ii) Wipe with lint free cloth moistened with solvent
remover taking care to minimise removal of penetrant
from discontinuities

DEVELOPER White powdered developer from aerosol applied in a thin

even coat

DEVELOPER TIME Minimum 10 minutes

EVALUATION OF RESULTS All relevant discontinuities to be reported in compliance

with ASME VIII
The surface shall be closely observed during the
application of the developer to monitor the behaviour of
indications which tend to bleed out profusely.
Final interpretation shall be made after allowing the
penetrant to bleed out for 10-60 minutes.

REPORTING i) To include defect length, position on weld /

material and distance from recorded datum.
ii) Any non-conformance to the procedure

EXAMINING TECHNICIAL APPROVAL CSWIP / PCN Level II or SNT Level II or equivalent

ACCEPTANCE CRITERIA As stated in ASME VIII, Division 1, Appendix 8, Section

8.4, or ASME B31.3 (Acceptance Standards)

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6.0 LIQUID PENENTRANT EXAMINATION PROCEDURE - SLP.02

LIQUID PENENTRANT EXAMINATION PROCEDURE

SLP.02

PROCEDURE TYPE Intensive

SURFACE PREPARATION The surface to be examined and all adjacent areas within
at least 25mm shall be dry and free of all dirt, grease,
lint, scale, welding flux, weld spatter, oil and other
extraneous matter that could obscure surface openings
or otherwise interfere with the examination.

MATERIAL TEMPERATURE RANGE 10 to 52 degrees centigrade

LIGHTING 1000 Lux at examination surface

PENTRANT Red dye oil applied by spraying from aerosol

PENETRANT TIME 45 minutes

REMOVAL OF EXCESS PENETRANT i) Clean with cloths or absorbent paper

ii) Wipe with lint free cloth moistened with solvent
remover taking care to minimise removal of penetrant
from discontinuities

DEVELOPER White powdered developer from aerosol applied in a thin

even coat

DEVELOPER TIME Minimum 60 minutes

EVALUATION OF RESULTS All relevant discontinuities to be reported in compliance

with ASME VIII
The surface shall be closely observed during the
application of the developer to monitor the behaviour of
indications which tend to bleed out profusely.
Final interpretation shall be made after allowing the
penetrant to bleed out for 60 minutes.

REPORTING i) To include defect length, position on weld /

material and distance from recorded datum.
ii) Any non-conformance to the procedure

EXAMINING TECHNICIAL APPROVAL CSWIP / PCN Level II or SNT Level II or equivalent

ACCEPTANCE CRITERIA As stated in ASME VIII, Division 1, Appendix 8, Section

8.4, or ASME B31.3 (Acceptance Standards)

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ATTACHMENT I - LIQUID PENETRANT TERMINOLOGY

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Comparator Test Block : Specimen containing artificial defects used for checking the
efficiency of penetrant flaw detection process

Developer : A substance which has the property of withdrawing a penetrant

retained by defects and intensifying the indications by
providing a contrast background

Development Time : The time between the application of the developer and
subsequent viewing.

Dye Penetrant : A penetrant liquid used for flaw detection, containing dyes.
Intended for viewing in normal light.

Indication : That which marks the presence of a discontinuity.

Inspection : Visual examination of the test piece after completion of the

penetrant processing cycle.

Interpretation : The determination of the significance of the indications or

whether they are relevant or not.

Non-relevant Indication : Any indication which cannot be associated with a discontinuity.

Penetrant Remover : Any means employed to remove excess penetrant from the
surface.

Penetrant Contact Time : The time allowed for penetration of flaws by the penetrant.

Pre-Cleaning : The preparation of a surface prior to penetrant inspection.

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ATTACHMENT II - EXAMPLE OF LIQUID PENETRANT EXAMINATION REPORT FORM

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LIQUID PENETRANT INSPECTION FORM

REPORT NO. INSPECTOR (Name) REGULATOR REP. (Name)

CONTRACT NO. CLIENT REP. (Name) PAGE

CLIENT LOCATION TEST SITE

ITEM IDENTIFICATION DRAWING No.

MATERIAL DIMENSIONS SURFACE CONDITION

WELD PROC CONFIGURATION LIGHTING CHECK LUX

LIGHTING TYPE (TICK) Natural: Artificial:
PROCEDURE ACCEPTANCE DATE: PENETRANT TYPE:
REVISION STANDARD
VISIBLE (TICK) FLUORESCENT (TICK) PENETRANT TIME:

WATER WASHABLE WATER WASHABLE REMOVER TYPE:

POST EMULSIFIER POST EMULSIFIER DEVELOPER TYPE:

SOLVENT REMOVABLE SOLVENT REMOVABLE DEVELOPER TIME:

RESULTS

DEFECT AREAS MARKED ON

OBJECT SKETCH

Inspector (Signature) Client Rep. (Signature) Regulator Rep. (Signature)

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ATTACHMENT III - ACCEPTANCE CRITERIA

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