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Dye Penetrant Inspection Procedure

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This article provides you with a example dye penetrant inspection procedure.
This procedure contains water washable process with both visible and
fluorescent systems.

1.0 DYE PENETRANT INSPECTION - SCOPE

1.1 This procedure establishes the general requirements of Penetrant
Testing of ferrous and non-ferrous components (essentially non-porous) and
welds by Water Washable Process, Visible and Fluorescent Penetrant Systems
and are to be followed by NDT personnel Third Party.
Dye penetrant inspection procedure requirements are covered in several I4I
Academy courses, including API 510 pressure vessel inspector training
course for in-service pressure application, API 570 piping inspector for in-
service piping application, and API 653 Aboveground storage tank training
course for in-service storage tank application.

2.0 DYE PENETRANT INSPECTION - PURPOSE

2.1 The requirements are intended to detect discontinuities that are open
to test-surface and free from contaminants by interpreting the surface
indications and evaluating them in accordance with the applicable referenced
codes, standards or specifications by certified NDT personnel qualified in PT
to Level II.

2.2 Customer’s approved specific Inspection/Evaluation manuals have also

to be followed strictly, if available and applicable.

2.3 Any conflicts between any points of this procedure and the referenced
documents or job specifications of customer shall be resolved (if given in
writing) by the appointed ASNT NDT Level III or the Divisional Manager
(NDT) or his authorised representative.
2.4 Where special circumstances require unique techniques of Penetrant
Testing by Water Washable Process, specific technique sheets shall be
attached as Annex: IV etc., with the written approval of NDT Level III.

3.0 DYE PENETRANT INSPECTION -

REFERENCES
3.1 ANSI/ASME B31.1 Power Piping
3.2 ANSI/ASME B31.3 Chemical Plant and Petroleum Refinery Piping

3.3 ASME Sec.V Boiler and Pressure Vessel Code

3.4 ASME Sec.VIII Boiler and Pressure Vessel Code

3.5 ANSI/AWS DI.I Structural Welding Code - Steel

3.6 API 1104 Standard for Welding Pipelines and related facilities

3.7 API 620 Dsign and Construction of Large, Welded Low Pressure Storage Tanks

3.8 API 650 Welded Steel Tanks for Oil Storage

3.9 ASTM E-165 Standard Test method for liquid penetrant test

Standard Test Method for Fluorescent Penetrat Examination using Water

3.10 ASTM E-1209
Washable Process.

3.11 ASTM E-1418 Test Method for Visible PT using Water Washable

3.12 ANSI/ASNT-CP-189 Personnel Qualification and Certification Standard

SNT-TC-1A of
3.13 Personnel Qualification and Certification Guidelines
ASNT

4.0 SUMMARY OF TEST METHOD & WATER

WASHABLE PENETRANTS
4.1 A liquid penetrant which may be a visible or a fluorescent material is
applied evenly over the surface being examined and allowed to enter open
discontinuities. After a suitable dwell time, the excess surface penetrant is
removed. A developer is applied to draw the entrapped penetrant out of the
discontinuity and stain the developer. The test surface is then examined to
determine the presence or absence of indications.

Note: Caution - Fluorescent penetrant examination shall not follow a visible

penetrant examination because visible dyes may cause deterioration or
quenching of fluorescent dyes.
4.2 Processing parameters, such as surface precleaning, penetration time
and excess penetrant removal methods, are determined by the specific
materials used, the nature of the part under examination, (that is, size, shape,
surface condition, alloy) and type of discontinuities expected.

4.3 Liquid penetrant examination methods indicate the presence, location

and, to a limited extent, the nature and magnitude of the detected
discontinuities. Each of the various methods has been designed for specific
uses such as critical service items, volume of parts, portability or localised
areas of examination. The method selected will depend accordingly on the
service requirements.

4.4 Water-Washable Penetrants are designed to be directly water-washable

from the surface of the test part, after a suitable penetrant dwell time.
Because the emulsifier is “built-in” to the water-washable penetrant, it is
extremely important to exercise proper process control in removal of excess
surface penetrant to ensure against overwashing. Water-washable penetrants
can be washed out of discontinuities if the rinsing step is too long or too
vigorous. Some penetrants are less resistant to overwashing than others.

4.5 Post-Emulsifiable penetrants with lipophilic and hydrophilic

emulsifiers are not included in this procedure.

5.0 EQUIPMENT AND MATERIALS

5.0 EQUIPMENT AND MATERIALS:

5.1 This procedure is intended for use with the following consumables or their
equivalent. It has to be ensured that the consumables are selected in such a
way that they are compatible to the test surface and object and as per test
requirements.

Dye Penetrant Inspection - Water Washable, Fluorescent Penetrant System

Manufacturer PENETRANT REMOVER DEVELOPER

Sherwin HM-440, HM-430 Water D-100, D-100NF

Ardrox P133D, P134D, P135D Water 9D1B

Magnaflux ZL-60C Water SKD-LT or ZP-9F

 Dye Penetrant Inspection - Water Washable, Visible Penetrant
System

Manufacturer PENETRANT REMOVER DEVELOPER

Sherwin DP-51 Water D-100, D-100NF

Ardrox 906/303A Water 9D1B

Magnaflux SKL-WP Water SKD-NF,SKD-S, ZP-9B

5.2 Intermixing of penetrant materials from different families

(manufacturers) is not permitted by this procedure.

Manufacturer’s recommendation for compatible penetrant systems must be

adhered with.

5.3 Dye Penetrant Inspection - Control of Contaminants

When testing nickel based alloys, austenitic stainless steels and titanium,
contaminant content of penetrant materials shall be controlled. Control shall
be based on the manufacturers batch certification which shall include, as a
minimum, the manufacturer’s name, batch number and chemical contaminant
content as determined in accordance with ASME Section V, paragraph T-625.

Only dye penetrant inspection materials having a batch number printed on the
container and traceable to a valid manufacturer’s batch certification on file
shall be used.

6.0 PARTS TO BE EXAMINED

This procedure shall be used for parts or welds in ferrous and non-ferrous
materials in accordance with applicable code or specifications for parts or
welds.

When welds are tested, at least one inch of the base material on both sides of
the weld is to be covered.

7.0 SURFACE PREPARATION

7.1 Prior to the test, the area to be inspected and at least one inch on either
side shall be free from all contaminants (dirt, grease, lint, slag, spatter, oil,
scale, water and protective coatings).

7.2 In general for welds, satisfactory results may be obtained when the
surface to be inspected is in as welded condition.

If mechanical methods of cleaning like grinding, machining or sanding is

necessary, the surface area shall be etched to remove smeared metal. (For full
details, ASME Sec. V, article 24 and SE-165 shall be referred).

After etching, suitable neutralising solutions shall be used and test surface be
washed with water.

7.3 Unless otherwise recommended by the manufacturer, welded

components or parts cleaned by Vapour degreasing, organic solvents or
detergents, and properly protected from contamination, need not be re-
cleaned with penetrant cleaner (remover) prior to application of the penetrant.

On occasion, a wire brush may be helpful in removing rust, surface scale, but it
is used only when no other means of removal will surface. It shall be followed
by cleaning with penetrant cleaner if compatible.

7.4 Dye Penetrant Inspection - Drying:

Evaporation time, following precleaning, shall be 5 minutes minimum. Where

indications of retained moisture exist, the evaporation time shall be increased
till no evidence of moisture in the area of test can be detected.

8.0 EXAMINATION
8.1 Dye Penetrant Inspection - Temperature Limitations:

The temperature of the penetrant materials and the surface of the part should
be between 50°F and 100°F for fluorescent water washable penetrants and
between 60°F and 125°F for visible penetrants.

8.2 Dye Penetrant Inspection - Penetrant Application:

a) Either immersion (dipping), flow-on, spray, or brushing technique is used
to apply the penetrant to the precleaned dry specimen.

b) The penetrant is applied evenly over the entire area.

c) Fillers shall be used on the upstream side of the air inlet when using
compressed air to apply penetrant.

8.3 Dye Penetrant Inspection - Dwell times:

a) Penetrant dwell times are critical and should be adjusted depending on

temperature and other conditions and may require qualification by
demonstration for specific applications.

b) Typical minimum penetration times are given in the Table-1.

c) Penetrant shall remain on the test surface for the entire dwell time period.

d) Care shall be taken to prevent drying out of the applied penetrant and
additional penetrant must be applied to re-wet the surface.

Dye Penetrant Inspection - Typical Minimum Penetration Times

8.4 Dye Penetrant Inspection - Excess Penetrant Removal:

After the elapse of penetrant dwell time, the excess penetrant is removed by
water spray. Water at 60°F to 110°F and a pressure not exceeding 30 psi (210
KPa) is applied with droplet type sprayer specifically designed for penetrant
removal. The nozzle of sprayer is held so that water strikes the surface of the
specimen at an angle of approximately 45 degrees. Care is to be taken to avoid
over-washing, which causes washout of penetrant from discontinuities. Other
methods of referenced codes or specifications could also be used if applicable
for the test surface conditions.

8.5 Dye Penetrant Inspection - Drying:

The test surface must be dry prior to the application of non-aqueous or dry
developers. If water-based wet developer is used, it is applied to still damp
specimen immediately after the penetrant removal wash. Excessive heat or
too long a drying time tends to bake the penetrant out of discontinuities.
8.6 Dye Penetrant Inspection - Developer Application:

When the drying process is complete, the specimen is ready for the application
of either dry or non-aqueous wet developer. When water-based wet developer
is used, it is applied by flooding the surface to the wet specimen immediately
after excess penetrant is removed.

It is recommended to use aerosol cans, after agitation, typically for weld

inspection at various project-site works. Spray distance shall be 10” to 12”
from test surface. The test-areas must be cool enough to prevent too repaid
evaporation of the developer vehicle.

Dry developer is applied to the specimen by brushing with soft brush, by use
of a powder gun, or by dipping the specimen in a tank of the developer and
removing excess powder with a low pressure air flow.

An even thin coat/film of developer is preferred.

Applied developer shall not be removed from test surface.

8.7 Dye Penetrant Inspection:

8.7.1 The area under inspection shall be observed during application of

developer and at intervals during development time.

8.7.2 The recommended development time is between 7 and 30 minutes.

Development time begins directly after application of dry developer and as

soon as wet developer coating has dried on parts-surface.

8.7.3 Indications getting formed and formed at the test surface (by the
blotting action of developer) be noticed, analysed (relevant indications be
noted) under adequate lighting conditions.

8.7.4 Lighting Conditions:

a) Visible penetrant indications can be examined in either natural or artificial

light. Adequate illumination is required to ensure no loss in the sensitivity of
the examination. A minimum light intensity at the examination site of 100 fc
(1000 Lx) is recommended.
b) Examine fluorescent penetrant indications under black light in a darkened
area. Visible ambient light should not exceed 2 ft candles (20 Lx). The
measurement should be made with a suitable photographic-type visible light
meter on the surface being examined.

Black Light Level Control - Black light intensity, minimum of 1000 µW/cm2,
should be measured on the surface being examined, with a suitable black light
meter. The black light wavelength shall be in the range of 320 to 380 nm.

The intensity shall be checked at least once every 8 hours, or whenever the
work station is changed. Cracked or broken ultraviolet (UV) filters should be
replaced immediately. Defective bulbs, which radiate UV energy, must be
replaced before further use. Since a drop in line voltage can cause decreased
black light output with consequent inconsistent performance, a constant-
voltage transformer should be used when there is evidence of voltage
fluctuation.

Caution: Certain high-intensity black light may emit unacceptable amounts of

visible light, which will cause fluorescent indications to disappear.
Care should be taken to use only bulbs certified by the supplier to be suitable
for such examination purposes.

Note: The recommended minimum light intensity is intended for general

usage. For critical examination, higher intensity levels may be required.

Black Light Warm Up - Allow the black light to warm up for a minimum of 10
min prior to its use or measurement of the intensity of the ultraviolet light
emitted.

Visual Adaptation - The examiner should be in the darkened area for at least 5
min before examining parts to allow the eyes to adapt to the dark viewing.

Caution - Photochromic lenses shall not be worn during examination.

9.0 INTERPRETATIONS AND EVALUATIONS

OF INDICATIONS:
9.1 All indications shall be evaluated in accordance of the referencing Code or
Specification.
9.2 Acceptance Criteria are listed for specific codes in Annex-1 of this
document. Any conflicts between these documents and applicable Code
section shall be resolved by the NDT Level III or Divisional Manager (NDT) .

9.3 Mechanical discontinuities at the surface can result in false or irrelevant

indications. Any indications which is believed to be non relevant shall be
regarded as a discontinuity and shall be re-examined to verify whether or not
actual defects are present.

9.4 Non relevant indications and broad areas of pigmentation which would
mask indications of defects are unacceptable and require corrective action by
cleaning or other suitable means of surface preparation as described herein
and retest.

9.5 Make sure that surface indications are not false indications i.e. machining
marks, mechanical conditions or other surface conditions which cause or
produce false indications.

9.6 Interpretation of indications found and determined to be rejectable shall

be based on the size of the indication. Linear indications are those having a
length greater than three times the width. Rounded indications are those that
are circular or elliptical shape with the length equal to or less than three time
the width.

9.7 All examination shall be reported on the penetrant testing report form.

10. SAFETY:
10.1 The certified Inspector shall be responsible for compliance with
applicable safety rules in the use of liquid penetrant materials.

10.2 Liquid penetrant should not be heated or exposed to open flames.

10.3 Penetrant materials may be highly volatile, relatively toxic and the liquid
may cause skin irritation. Adequate ventilation at all times shall be used.

10.4 Aerosol cans of penetrant materials should be kept out of direct sunlight
or areas in excess of 130 °F. Excessive heat may cause aerosol cans to explode.
10.5 Avoid looking directly into black light source, since the eyeball contains
a fluid that fluoresces if black light shines directly into the eye.

11. POST CLEANING:

11.1 Post cleaning is required (unless otherwise specified in contract) to
remove any excess residues from the penetrant process.

11.2 A suitable cleaning technique such as water wash, vapours degreasing,

solvent soak may be employed.

11.3 Caution should be exercised to remove all developer prior to vapour

degreasing as vapour degreasing can bake the developer on parts.

11.4 Post cleaning of water washable fluorescent penetrant tests could be

done by flushing surface with forced water spray or by flushing the surface
with an approved solvent cleaner depending on the actual job requirements.
Clean cloth and or absorbent paper towel and or dry air jet could also be used.

11.5 Points mentioned in 11.4 is applicable for water washable - visible dye
also.

12. PERSONNEL QUALIFICATION AND

CERTIFICATION
12.1 Personnel performing examinations in accordance with this procedure
shall be qualified and certified in accordance with SNT-TC-IA (1992 edition)
or CP-189 (1995 edition) of ASNT.

12.2 Only individuals qualified to NDT Level I and working under the
supervision of an NDT Level II or III or individuals qualified to NDT Level II
shall perform the examinations in accordance with this procedure.

13. PREFERENCE FOR WATER WASHABLE

PROCESS
Water washable process shall be used for testing the following:
13.1 Articles having a rough surface.

13.2 Articles having threads and keyways.

13.3 High production of many small articles.

13.4 Weld inspection in closed vessels or tanks.

13.5 Weld or other component inspection when solvent process is found not
suitable or preferable.

13.6 Articles having medium rough surfaces (if medium sensitivity is

acceptable).

13.7 Leak detection system.

13.8 Welds, articles when cost control is a prime point.

14.0 CHARACTERISTICS OF WATER-

WASHABLE FLUORESCENT PENETRANT
TESTS:
Dye Penetrant Inspection - Advantages

 Fluorescence Ensures Visibility

 Easily Washed with Water
 Good for Volume Testing of
 Small Specimens
 Good on Rough Surfaces
 Good on Keyways and Threads
 Good on Wide Range of Discontinuities
 Fast, Single Step Process
 Relatively Inexpensive
 Available in Lox Compatible Form

Dye Penetrant Inspection - Disadvantages

 Requires Darkened Area For Inspection

 Not Reliable for Detecting Scratches and
  Similar Shallow Surface Discontinuities
 Not reliable on Reruns of Specimens
 Not Reliable on Anodised Surfaces
 Acids and Chromate’s Affect Sensitivity
 Easily Over-washed
 Penetrant Subject to Water Contamination

DYE PENETRANT INSPECTION - ANNEX - I

PENETRANT TESTING ACCEPTANCE CRITERIA

The acceptance criteria given hereunder for relevant indications for various
codes shall be used in general throughout of Third Party. The inspector using
this is cautioned that Code requirements do change, and that in the case of
conflict it shall be referred (in writing) to the appointed NDT Level III or
the Divisional Manager (NDT) .

DYE PENETRANT INSPECTION - API 1104

Rejection Criteria

1. Liner Indications

Indications > 1/16” (1.59mm) shall be considered as Relevant

Indication, Relevant indications are rejectable if:

a. Evaluated as crater cracks or star cracks and > 5/32” (3.96mm) in length.

b. Evaluated as cracks other than crater cracks or star cracks.

c. Evaluated as IF and >1” (25.4mm) in total length in a continuous 12” (304.8

mm) weld or >8% of the weld length.

2. Rounded Indications.

For evaluation, the maximum dimension of rounded indications shall

be considered as it size. Indications are rejectable as defects if:

a. Individual indication > 1/8” (3.17mm)

b. Distribution of scattered rounded indications exceed concentration
API 1104 fig. 18 or 19.

c. Clustered rounded indications > 1/2” (12.7mm)

d. Combined length of clustered indications > 1/2” in any 12”

(304.8mm) weld.

e. Any individual indication in a cluster > 1/16” (1.59mm).

DYE PENETRANT INSPECTION - ANSI/ASME B31.1

1. Liner indication: Any crack or liner indication.

2. Rounded indications

a. Indications is dimensions > 3/16” (5.0mm).

b. Four or more rounded indication in a line separated by 1/16” (2.0mm) or

less edge to edge.

c. Ten or more rounded indication in any 6 sq. in. (3870mm2) of surface with
the major dimension of this area not to exceed 6 in. (150mm).

DYE PENETRANT INSPECTION - ANSI/ASME B31.3

1. Liner indications: Any cracks or linear indications.

2. Rounded indications

Pending verification from ANSI. Until otherwise stipulated by ANSI

B31 Committee, apply B31.1 criteria for rounded indications.

DYE PENETRANT INSPECTION - ASME Section VIII Div. 1

The following indications shall be rejectable as defects:

1. Relevant linear indication >1/16” (1.59mm)

2. Relevant rounded indications >3/16: (4.77mm)

3. Four or more rounded indications in a line separated by 1/16” (1.59mm) or

less (edge to edge).

DYE PENETRANT INSPECTION - AWS D1.1

Acceptance criteria is dependent on service condition. Refer to the relevant

project NDT Supervisor or Area NDT Manager.

DYE PENETRANT INSPECTION - ANNEX - II

ULTRAVIOLET LIGHT INTENSITY

VERIFICATION
1. The ultraviolet light intensity shall be determined using a UV Products
Mode J-221 Long Wave UV Meter or equivalent. The procedure for using the
J-221 meter is as follows:

1.1 Secure the black light fixture in a stable position at a distance greater
than 6 inches.

1.2 Check to see that the black light bulb is on and has been allowed to warm
up for at least 5 minutes.

1.3 Ensure that the J-221 meter face is vertical and the meter has been
zeroed. (The zero should be checked with the sensor cell unplugged). Correct
the zero when necessary by turning the screw located directly below the meter
pointer.

1.4 Record the meter reading without the UPV Filter # 50107 attached to the
J-221.

1.5 Attach the UPV Filter # 50107 over the sensing element of the J-221 and
record the meter reading.
1.6 Subtract the reading recorded in 1.5 from the reading recorded in 1.4 and
document the results.

1.7 Ensure that the value obtained in step 1.6 is a minimum of 3000
microwatt/cm2 for work in areas other than booths specifically designed for
ultraviolet light work. For work in a darkened booth, a minimum value of
1000 microwatt/cm2 is required.

1.8 The black light intensity shall be measured at least once every 8 hours, or
whenever the work station is changed.

Note: The J-221 meter has 2 scales. The A scale reads from 0-12 and the B
scale reads from 10-60. To convert the meter reading to microwatts per
square cm., multiply the meter reading by 100. For example, a meter reading
of 30 would be 30 x 100 = 3000 microwatts/cm2.

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