‘Ratiary Ard Patrochamial ‘integrated Development, (RAPID) Package? OMACTOR Petes MERON Praceoune Coit; RAOIDETEE 20-03 act a PR PRC [Tar LIQUID PENETRANT EXAMINATION PROCEDURE o| mane TRF Ge wiv | Os Zane | You ot af oars8 Tn Fa Gu Biot | in oor | You Wobin ae Coron oeFate a aa ned Geto _fses, « INBAPD Pockage? oo TaD Pv SEIS [rae Table of Content 1. GENERAL PRINCIPLES... 2 ‘4. Purpose 3 12 Genera caus AND SCOPE OF APPLICATION 3 13 Nomarve Rerenence 3 2. PREPARATION FOR PENETRANT TESTING... 3 atovenven 3 22 Eau A 24. sunrace recrananon ‘ 2. Penson neoUmenT ‘ 3. LIQUID PENETRANT TESTING TECHNOLOGY AND TECHNICAL REQUIREMENTS. £11 LoUD PENeTRANT TESTING PROCEDURES ‘ 82. Penermat ‘ 3. Quai conto or ose onen $ 234 EouPuenT, MTRUMEN 3 35. OrenaroninsrnieTon 3 236. ecumy neounens 8 27, SeucononorpoxeTay Testo METIONS. 8 38 Derecnon ie 8 39 Openanon vero OPTRA TESTA ; 310 Recono or cerec es Tons 3 341.Revesr 8 312 Posr ein ‘a 3.19. PENETRANT TEST FOR PRESSURE EQUIPMENT IN USE 10 2.14, CLASSIFICATION ND RECORD OFTHE PENETRANT NDCATONS 0 215.cusssomnen or cua 0 ovens: Reronr ron 2 HSEle fo confivm on Level Ill approval foy this Procedureetary And Patrochanead Integrated Development [RAPID] Package 2 4. General principles 114. Purpose ‘The purpose ofthis univarsal process planning fs to guarantee the quality of pressure equipment non-destructive testing (NDT), specie work content of pressure equipment Inspection tecinology, working process and method, also, make sue the quay of detection technology measures. 1.2. General requirements and scope of application “This procedure is euitebe for the non-desiuctve testing of pressure equipment such as boler, pressure veste and process piping, non-pressue equipment can bo performed with the reerenceto the procedure. 4.24. The testing scope of tho cferent testing methods shouldbe cared out according fo their. applicable scope respectively. 4122, For some pencpls that universal process planning isnot stipulated, relevant national regulations and standards should be executed. For some Inconsistent situations, relevant halonal regulations, procedures and standards also can be used as reference. 4123, Aecorsing to national special equipment nondestructive ting personnel appraisal regulations, employees who engaged inthe work ofthe pressure equipment nondestructive testing must obtain coresponcing nondestructive testing personnel qualification. 4124, Detection place and envzonment should bo helpulto fective implementation ofthe NOT ‘and comply with the requirements of evant natioral and local envamental heath and labor protection laws and regulations. Trying to avid the envionment o place that have ‘area influence to the human body and may interfere wth the normal operation inspection ‘and judgrent of persone. When testing condtions do not conform to the technological requirements ofthe standard or operational condions, ts necessary to adopt fective ‘measurements; the testing procedure canbe cared out when the condkions can satshy the requirements. However, when environmental ccnditons endanger the est resus, sop testing 4.2.5. NOT records shall be tye, accurate and timely, complete snd effective with the acceptance of corresponding persennel by signature, NOT reper data should be consistent withthe record and the format ned to accord wit the requirements of standard and management system. 1.3, Normative Reference "ASME BPVC Section V- Nondestructive Examination [ASME BPVC Section Vl - Rule fr Construction of Pressure Vessels ‘ASTM E-185 Standard Practice fr Liguld Ponetrant Examination for General Industry 2. Proparation for penetrantteoting 24, Overview ‘The liquid ponetrant examination method is an effective means for detecting dscontinitios which are open to the surface of nonporous metals and other materials. Typical Giscontnuties detectatle by tis metiod are cracks, seams, laps, cold shuts, laminations, and porosity‘ating And Petrochem ‘Integrated Development 6 wall we {HEAP Package 2 commas ‘COMRACTOR raectnas weRHDD eee anente: RAROICTERSI01 73 osama API 9100 PNG TRE IOTOO [Pears In princi, a iquid pentrant is applied tothe surface to be examined and allowed to enter lscontinuties. Al excess penevants then removed, the aris cred, and @ developer is ‘2ppliod. The develope functions both as a biter to absorb penettant that has been trapped in dls-contnuifes, and 2s a contrasting background to enhance the vy of ‘enetrent indcaions. The dyes i penetrants are ether colour contrast (isle under white light or Muorescent (visble under utravolat ight. 22. Equipment ‘The term about penatant materials, as used in this Atle, ls intended to include a penetrants, emusifers, sohents of cleaning agents, developers, etc, used in the ‘examination process. The descripions ofthe liquid penetant classiicaons and material, ‘ypes are provided in SE-165 of Article 24 2.3. Surface preparation 2.3.1 In general, satisfactory results may be obtained when the surface ofthe part isin the welded, aolled, ascast, or asforged condition. Surface preparation by grinding, machining or other metiods may be necessary where suraceiegulates could mask ‘ncations 2.32 Porto each liquid pererant examination, the surface to be examined and all adjacent ‘162s within at east 1 ir (25 mm) shall be dy and fee of al dit, grease int, scale, welding ‘ux, weld spatter, pal, ol, and other extraneous matter that could obscure surfaca ‘openings or otneiiee intrare wih the examsnation, 2.33 Typlal cleaning agents which may be used are detergents, organic solvents, descaling solutions, and paint removers. Degreasing and ultrasonic cleaning methods may also be sed 2.34 Cleaning solvents shall meet the requtaments of 7-641, The cleaning method employed Is an important part ofthe examination process. 24. Personnel requirement PT personnel shal be qualifed for ASNT level Tor PCN Level lar equivalent. ‘The persoanel engaged in the penetrant examination shall be qualiied and certfid in accordance wih the requirement of te company's “Writen Practice for NDE Personnel Training, Qualification & Cetteation™ 3. Liquid Penvtrant testing technology and technical requirements 3.4. Lquid penetrant testing procedures Pre-teatment——» Penetrant Aplcaion ——» Remove excess penetrant — dying process —+ Developing ——+ Inspection and Evaluation + Post-Examinaton Cleaning 3.2. PenotrantRetinary And Patrochereal ‘SoNRAcTOR Peto: ean comme! Canine RAMDICTENE Dosen Tari Kom oop ROTO [Passer PPonetrant generally Ineude penetrans, emulsifes, soWents or cleaning agents, developers, ‘ote. Penetrant sheuc be selacted according to speci situation of pressure equipment, for ‘one workseca,cferer typeof penéant detection agent cannot be used. 3.21. Qualty contol of Penetant 41) Take out 500m from each batch of new-fermulatod penetrant and store into glass vessels as ‘samples for reference. Storage temperature must be 10~50°C and it must be kept away from ‘unlght Penetant mustbe stored in sealed vessels at low-temperature and dark paces. The relative deny ofall kinds of panerant must be verified with relative density meter according to spectfcations of manufacturers to keep te relative deny unchanged. 2) Fluorescence efficiency af pentrant of fuorescence must not be lower than 75% 3.3, Qualy conto of developer 1) ry developer must be hspected regulary, parce cohesion or obvious residual fuoresconce occurs or the perfrmange i low, irmust be rejected 2) Concentration of wet developer must be kept with the range of working concentration regulated by the manufacture, ancitsspectc gravy must be regulary verified by hydromater '3) When wet developer has 2eme turbid, colour changing characteristics or itis feu to form to balancing develop layor it must be rejected. 32:4 Penatrant should be used within its period of vay. tts found the performance cant sats the requirement in use, t should be disused and discarded, Fr spraying tank quid penetrant ‘agen, the spray tank suface canat have corresion, spray cans not leak. The testing agent ‘must possess excellent performance and does ct erade work pleoes and basicaly has no harm to human body 13.32 For nick! base allay materials, the content-wsight rato of sulphur element of botom of a ‘certain amount of tesing agent evaporated must not exceed 1%. If there are higher requirements, both parts can negotiate with each other. 9.33 For austente ste, titnium and titanium aloy matoras, the content-weght ratio of chlorine ‘and flor elements of batt ofa cartin amount of testing agent evaporated must not exceed '%. If thece are higher requirements, both partes can negotiate wih each other. 3.4. Equipment, instruments 341 Darkroom or test site should have enough space wiich can meet the requirements of esting, test site should Keep cean, When fuoreecence detection Is processing, visible ight a darkroom ‘or dark place should be not mere than 20 be 13.42 UV wavelength of blac ight lamp should be within the rango of 816nm-~400nm, wavelength of the peak value |s 365rm, power regulator shouldbe installed when the voltage fuctuaton of ‘ark black lamp is above 10%. 3.4.3 lradlanoy of black ight and its UV wavelength should be within the range of 818nm~400nm, ‘wavelength ofthe peak. vale I 365nm. Flerescent brightness and its wavelength should be ‘win the range of 420rm-~6OOnm, wavelength af tho peak value is 600 nm~620nm,ey Rie Peace ugratea Devetopront, Mees (RAPID) Package? ‘aRSNeD CONRACTOR Projo: Wn 10 Looe Covet: RaPCTEOE 01-08 DoT FAP an Ss PROB [pasar 2.44 Black Hight lamp, black light Huminaton meter, laht or Nuorescent ight meter and other Instruments shoul be calbated equiarly according to relevant provisions. 35. Operation instuction 3.51 Before testing, operation instruction should be made aocording to general procedure and the equirement of tested werkpiece, the content should meet requrement in ASEM V standard. 952 The manufacturer shall certy that each liquid penetant examiner meets the folowing requirements, (@) He has vision, with correction if necessary, to enable him to read a Jaeger Type No, 2 Standard Chart at a dstance of not less than 12 In. (200 mm), and is capablo of distinguishing and eterentting contrast between colours used. These requirements shal be ‘checked annually {(b) He is competent inthe techniques of the quid penetrant examination method for which he is certed,Incuding mabing the examination and interpreting and evaluating the resi, except that, where the examiraion method consists of mare tan one operation, he may ba ceifed as being quatfed oly for one or more ofthese 2.8. When detecting at an indoor fixed pace, environmental condons shouldbe tested periodical, 36. Security requirements During penetrant toting, the chemical products which used for penetrant materials, perhaps i harm inftammable and {rvoltla. Therefore, wo should pay stanton to protection measures ‘and comply with national er local regulations about environmental and heathy. Penatant testing ‘should be processed at opening fed if detection is processed at ited space, protective mack should be taten. Eyes sroulé be prevented when fuorescence detection which using a back Tights processing, 37. Selection of penetrant testing methods 3.71 Selection of penetrant testing methods should meet the requirement of esting defect types and sensitivly fisy. Based on this, testing method can be delermined according 10 surface roughness, inspection batch size and site conlon such as water, pow. 3:72 For workpiece which hes high requirement about smeath surface end detection sensi, ‘emulsion type calourng © ater emulseation fluorescence method can be adopted, also, the solvent to remove type fhoresoent method can be used ether 37.3 By contast, for workpiece which has low equrement about smooth surface and detection senstvty, washing colouing or fuorescence washing method Is appropiate. For tet without water ind power supply Ue volvent to remove colouring method is Bete, Yor large batch workplace inspection, wathing colouring or fluorescence washing method is beter, or partial inspection of tage wortgece, the solvent to remove ealoing method or solvent to remove ‘orescence can be adopted 38. Detection timeay TT eee “aang” | renew ‘SoMMAETOR Peto: ean atED oe ‘cenineio: RMMDIETERE aH 72 38:1 Penetrant esting of wad joints shouldbe processed ater welding procedure or woldng fish Unless special situation stipulated by regulations. For materials which has delayed cracking tendency, penetra testing should be processed at leas after 24 hours of welding. 3.82 Penelrant testing fr fastener and forging piece shouldbe arranged to process after fal heat treatment 38. Operation method of panetrant testing 3.9.1 Surface preparation 1) The tested workpiece surfaco should be fre of rust, scale, weld spatter, chip, bur and diferent kids of protective coatings which affect the penetant 2) For the sectional inspection, the reparation scope should be widened outward al around {fr 25mm from te lation beng tested, 3:92 Pre-lesning ‘Surface conditions oftatd parts infuence the flocs of panetating testing to grost extent “Therefore, after the surfse cleaning, pre-leanng is necessary to remove dis on the surface, ‘which ean be done with slvent and detergent tc. The cleaning range must accord with 3.81, ‘Aluminum, magnesium end itanium aloy austenitic steel parts and the machining surface, i indeed need, can be lo 4 or akaline to deaning fst, then processing penetra tests. Solvent ‘and detergent remaining on the tasted surface must be ied and it must not be poled prior to ‘aplication of penetant 39:3 Penetrant 1) Methods for penetrantappicaton ‘Application methods can be selected according to size, shape, quantity and tested part of components, which must ensue thatthe tested partis completely covered by penetant snd is Inwet conditions during the course of penetrating and they ae as flows: 2) Spraying: Spraying canbe carried out wth static spraying devices, spraying bottle and low pressure pump, et ards applicsbeto paral or entire testing of large work pices, 'b) Brushing: It canbe dane by using brush, eoton yan and cloth, et: and is appicable to paral ‘or wel testing of large work pioces.. ©) Pouring: Pour the partrant on the surface ofthe tested piece rectly andi is appicable to pata esting of large work pleves «) Dipping: Dip the workpiece completly into penerant andi s applicable to complete testing of small components. 2) Immersion tine an temperature ‘Ding the whole process, temperature of penetrant and workpiece should be within the range of S'C~50°C, The penstant time should not be less than 10 min in general under the temperate condtion af 10.50 °C. 3.94 Emulsticaton treement 4) Before emulsifcationreatment, residual pentrant onthe surface ofthe work pice must be removed as thoroughy as possible, When water base emulsifying agent is employed, waterTatinory And Petrochemical Integrated Development (RAPID) Package? PeTmowas be Bas ao PR PR [Papas ‘spraying method must be used to get rid of excess penetant. The water pressure must be ‘normaly 014MPa without special requirements. 2) For emulsification, methods of immersing, pouring and spraying ete can be used for the ‘pplication tothe surface of ested werk paces, and brushing method isnot allowed. 38) Emulsication time depands en performance of emulsifying agent and penetant as well 2s roughness of surtace tested pieces. Generally, the emulsifcaton time i ess than 2min for oillbase emulsifying agent and win Smin fr water base emulsiying agent, 4) transiton background can be removed by adding emulsifcaon, fa satisfactory background stil have not reached ster adding emusioation, wich should be re-processed according to the tecinotogieal requirments. 3.95 Cleaning axcose penetrant 41) When the excess penotant is romovod trom tasted surface of the work plese, excess cleaning must be prevented from causing testing offects to loner. At the seme time, Insuffcent ceaning must be also avoided from leading to acu recognition oF defect indication, When fuorsscence penetrant is used, clearing can be done by using ultraviolet lamp, 2) Both water washing and post emulsification penetrant can be rinsed with water. In rinsing, the incluted angle between water spraying beam and tested surface must be 200. Without ‘rinsing devices, clean and tnt fee wing Goth can be used for ordinal sxubbing by apping Water. When the rising method is empoyed, water pressure at nazzle ofthe rinsing device ‘must not exceed 0 Sala witout spacial regulations. '3) Solvent removal type penetrant must be cleaned wih detergent. Except the places very fc to clean, general, clean and in-free wiping dth must be used for ordinal subbing ntl most excess penatant Ie removed, then clean and nt-ee wing clth or paper dpped with detergent can be utlized to clean til excess penotrant on the tasted surface are removed completly. However, repested cleaning must be avoided, and detrgert cannot be used fr direct cleaning of surface, 3.96 Dryng treatment 1 Before appicaton of quick-drying developer or after that of wet developer, the tested surfaces must be ckied. When adding the water wet imaging agent water dssoWved, suspended imaging agent), the test surface shouldbe died ater application, 2) When using seltimage method, crying process shouldbe dane after water cleaning, 3) Normally ican be dd with hot wind or naturally. In drying the temperate of tested ‘surface mast not be more than 60°C When using solvents to remove excess penerat, ‘alural dying t oom emparsture shouldbe adopted 4) Normally, te drying tine is 510 min, 3.87 Application of developer 1D) Dy daveloper must cid before used, and then sprayed onthe whole tested surface evenly wth appropiato methods ad kept on the surface for some time, Redundant developer should be removed by tapping or light aetiary And Petrochameal grated Development ot SEG. _“[RAPIO) Package? | PETROMAS CONMAGTOR Pista: MOEOHED oe ovate: RAMBCTOOS 200.72 aso Tari Ro oP ORE TOR [Pavone 2) fit is wet doveloper, ater cleaning of tho tested surface spray or brush it onthe feted surface or immerse the work place info the davalaper and then remave excess developer raplly before ayn resent. 2) Iftie quick dying developer, ser dying treatment spray or brush it on the tested surface ‘and then let tary natural a low t ry with low temperature ait. 4) When adopting sotimage, the minimum stopping time is 10mins and the maximum is 2 hours. '5) Developer must be mixed sufsonty before used and must be appled evenly and thinly, and repeated application at the same place must be avoted, 6) During the course of spraying of developer, the nazzle must be $00~400mm away from the tested surface, andthe incided angle between spraying direction and the tested surface ‘must be 30°~40" 7D) Pouring quick-dyng developer onto the tested surface must be prevented fom rinsing out the panetrant inside defects 8) The time of developing is based on the type of the developing agent, detect size and the temperature of wopie, and wil be 1060 min 3.88 Inspection 1) Inapeaion of ineested traces must be performed within 7~30min after application of eveloper. If the sizeof indicted traces does not change, the time regulation here can be loosened. When indistd traces occur, t must be determined whether they are tue or false ‘fect, 50 fold magnifier can be uiized for inspection or retest necessary. 2) Assessment of the cefect should be done undet white ght. The intensy of Huminaion of ‘the te light on the surface ofthe workpiece being tested should be greater than or equal 4 1000Lx, i the condition cant satisfy the requrement, the intensity of urination ofthe vile light coud be reduced properly but should not be less than SODLx, {) For fuorescenca panatating testing, the utravolet intensity on the surface of workpieces of ‘ravolt lamp must nat be less than 1000 W/ em2, and ultraviolet wavelength must bo ‘thin the range of 032 ~ 0.40m. Before inspection, a least § minutes must be lft for eyes to adaptto the dark om of wbich vse lurinance cannot be greater than 20, 4) When identiying tne defects a 5 - 10 time magnifer can be used. Treatment and penetrant tests shoud be card out ini necessary 3.10, Record of defect indications “The defect inaloation canbe recorded with photographie method or graphic method and should be lndestes ot drat. 3.11, Retest 11.4 Retesting fs necessary under any condtion as follows: +) When the testing is or, sensitty cannot meet the requirement 2) Operation methods ae found inappropriate during the couse of estingTatiary And Petrochenical Integrated Development permowa. (RAPID) Package" Sosa RAD oo SP PRT A [tam oorns 3) Supplier and purchaser ae in cispute with each other, or for other reasons. 4) There has doubt on esting resus, 8.11.2 For reesing, the test surface must be cleaned completly to remove the marks lt by the ‘previous tes, and organi solvent can be used fr immersing i necessary. 3.12, Post cleaning Post clering should be preceded after the inspection has been finished fo remove any residues being harmiul-» Iter use orto workpiece material 8.13. Penetrant test for pressure equipment in use \When processing penetra testing for pressure equipment in use, ifthe high strength stee nd materials which f eenstve to cracking lke cold racks, hot rack and rehoat cracks used for pressure equipment or the equipment Is wotking at cowosion and strength crack ‘environment for long time, It should be tested according to ASME Vil. Mandstory Appendi°8-3. Moreover, ts inner wall should be tested by fhiorescent penetrant testing metros 3.14, Classification and record ofthe penetrant indications 3.14.1 The indications are died into contested indications, non-cortelated incicaions and false Indlations. Record ant assessment are not neaded for nen-crrelated indications and false indications. {3.14.2 The indcation being las than 0.5mm wil be Ignored, Al other indcatlons wil be treated a8 elects excepting those indications are confrmed being caused by extemal factors of ‘proper operations. 8.143 If the included angle between the major dlameter of the defect indication and the longitudinal ‘2 oF main line ofthe aockpiace being tested >= 30%, wil be tested as ranaveree direction ofoc; otherwise it wil be treated asthe ongtudnal detect 3.144 Detect indication with lengthwicth rato >3 wil treted as linear defect and the defect Inccation wth length vat ratio <= 3 wil be Weated as round detect 53.145 If two tines of, or more, defecs are on the same Ine and spaces between them ares2mm, they wil be treated as one tne defect, the length wil be the sum af lengths of these two \efecs plus space between them 3.15. Classification of qualty ‘According to ASME VEMandatory Appendi®§.4, these acceptance standard ehsll appl Unless othor more restive standards are specied for specific materials or epplcatons within the Division, ‘All surfaces tobe examired shal be fee of {@) Relevant linear incicatons; (@) Relevant rounded indeations greater than 16in, (Sm)Fatinary And Petrochem Integrated Development ios (RAPID) Peckage Pernowas, Basan Rap ra 0 ua PROT [Par rors (© Four or mora relevant rounded ination in a line separated by 1/16 In. (1.5 mm) oF ess (edge to edge)‘atiory And Peirochonical Integrated Development (RAPID) Packago 2 ‘SoMRACTOR rojas Hea > Corint Nes MMMBCTENS 043.02 Sa SST rae ears spp amanans TERETEERERS a 4 Bennie panes nati bes Shes eae § aaa See a fe aay ee Hi eo at anes 2 aa ay ae antl 7 a an a og naw onus eae Rasa ane ‘ean Bee a | eae tela = Ei mg Eo scone es = oe aa amma | jee |i us| mimes | Be | ze | ae worsen” | [|| cect ik | S| haa aaa ae a a ar ai SHANE WPLEERELR. tomnonsocanaeesatecrey WR RoweRatiary And Petrochemical ces Bes SUES | nem CONRACTOR Project No.- MéBe2-#100 ronnie ‘Comiract No: RAPIDICTCHOE2013.62 ——— are FuRETHRMARA A 4 eaew eS Peas Fert ar Ct LEE a EEE eee anne) ae SES) omnaany | ee] seme | ea [eee |e ie eer Ba a 7 SECT RON RRA, Mien emai ER Aa OTF AGAR, WOAITAIIER tanesinisteage tome Bm He ine