Liquid Penetrant Test Procedure

Date: 9/3/09
Revision: 2

PURPOSE:

This procedure will be used to perform color contrast Liquid Penetrant Testing when
required by contract or specification.

REFERENCE SPECIFICATIONS

ASME Section V, Latest Edition

ASME Section VIII, Divisions 1 and 2, Latest Edition

API 650, Latest Edition

API 620, Latest Edition

AWWA D-100, Latest Edition

PROCEDURE:

1.0 SCOPE

1.1 This procedure specifies the technique, acceptance standards and documentation
requirements which apply to liquid penetrant examination.

1.2 The liquid penetrant examination method is an effective means for detecting
discontinuities which are open to the surface of nonporous metals. Typical
discontinuities detectable by this method are cracks, seams, laps, cold shuts,
laminations, and porosity. A liquid penetrant is applied to the surface to be examined
and allowed to enter the discontinuities. All excess penetrant is then removed, the
part is dried, and the developer is applied. The developer functions as a blotter to
absorb penetrant that has been trapped in discontinuities and as a contrasting
background to enhance the visibility of penetrant indications. The test part is then
examined visually to determine the presents or absence of indications.

1.3 This procedure covers liquid penetrant examination by the Visible Penetrant
Examination (color contrast) type, using water washable or solvent removable
method. The material to be examined may be aluminum, steel, titanium and other
alloys.

2.0 PERSONNEL

2.1 Liquid penetrant examination personnel shall have vision, (with correction if
necessary), to enable them to read a Jaeger Type No 2 Standard Chart, at a distance
of not less than 12 inches (304mm), and shall be capable of distinguishing and
differentiating contrast between colors used. Inspection personnel shall be checked
annually to ensure that they meet this requirement.
 Liquid Penetrant Test Procedure
Date: 9/3/09
Revision: 2

2.2 Liquid penetrant examination personnel shall be proven competent in the technique of
Liquid Penetrant Examination, including performing the examination and interpreting
and evaluating the results; however, where the examination method consists of more
than one operation performing only a portion of the test needed to be qualified for that
portion of the operator performs.

3.0 SURFACE PREPARATION

3.1 In general, satisfactory results may be obtained when the surface of the part is in the
as-welded, as-rolled, as-cast, or as-forged condition. Surface preparation by grinding,
machining, or other means may be necessary where surface irregularities could mask
indications of unacceptable discontinuities.

3.2 All welds shall be visually examined and found to be visually acceptable prior to liquid
penetrant examination.

4.0 CLEANING

4.1 Prior to each liquid penetrant examination, the surface to be examined and all
adjacent areas within 1 inch (25mm) shall be dry and free of all dirt, grease, lint, scale,
welding flux, weld spatter, paint, oil and other extraneous matter that could obscure
surface openings or otherwise interfere with the examination.

5.0 MATERIALS

5.1 The following penetrant type or an approved equal shall be used:

5.1.1 Type II method A (water washable) or C (solvent removable) shall be used for all
inspection under this procedure.

5.2 Intermixing of penetrant material from different types or methods (families) is not
permitted with the exception of nonaqueous wet developers that qualify for more than
one method of penetrant examination as stated on the can by the manufacturer.

5.3 Intermixing of same family penetrant materials from different manufactures is allowed
but only if a satisfactory demonstration of technique is performed.

6.0 EXAMINATION

6.1 The temperature of the penetrant and the surface of the part to be examined shall not
be below 40F (4C), or above 125F (52C) throughout the examination period. Local
heating or cooling is permitted as long as the temperature range remains within the
acceptable limits mentioned herein.

6.2 The penetrant for this procedure may be applied by brushing or spraying.

6.3 The minimum penetration (dwell) time shall be 5 minuets when examining castings
and welds and 10 minuets when examining extrusions, forgings and plate material.
 Liquid Penetrant Test Procedure
Date: 9/3/09
Revision: 2

6.4 The maximum penetration (dwell) time shall be 30 minuets, but in no case shall the
penetrant material be allowed to dry. If penetrant material does dry, all dried material
shall be removed and the area shall be re-cleaned and re-examined.

6.5 After the specified dwell time has elapsed, any penetrant remaining on the surface
shall be removed by one of the following methods:

a For method A (water washable penetrant) excess water shall be removed with
a water spray. The water pressure shall not exceed 50 PSI, and the water
temperature will not exceed 110F.

b For method C (solvent removable penetrant) excess penetrant shall be

removed by wiping with a cloth or absorbent paper, repeating the operation until
most traces of penetrant have been removed. The remaining traces shall be
removed by lightly wiping the surface with a cloth or absorbent paper
moistened with solvent.

6.6 The non-aqueous wet developer shall be applied by spraying as soon as possible
after the surface of the part is dry but no longer than 15 minuets after the removal of
the excess penetrant. The developer should be agitated (Shake well before using) to
ensure that particles are in suspension and well dispersed. The part shall be sprayed
in a manor as to assure complete coverage of the part with a thin, even coat of
developer. Over or heavy application of developer can cause masking of indications.

6.7 The minimum developing time for non-aqueous wet developer shall be 10 minutes.

7.0 INTERPRETATION

7.1 Final interpretation shall be made within 10 to 60 minuets after the developer coating
is dry. If bleed-out does not alter the examination results, longer periods are
permitted. If the surface to be examined is large enough to preclude complete
examination within this prescribed time, the examination shall be performed in
increments.

7.2 With color contrast penetrant, the developer forms a reasonably uniform white
coating. Surface discontinuities are indicated by bleed-out of the penetrant which is
normally a deep red color that stains the developer. Indications with a light pink color
may indicate excessive cleaning. Inadequate cleaning may leave an excessive
background making interpretation difficult. A minimum light intensity of 100 fc
(1000Lx) is required to ensure adequate sensitivity during the examination and
evaluation of indications. (This light intensity can be achieved by use of an LED head
lamp at 2' or a 1000 watt halogen light at 6').

8.0 EVALUATION OF INDICATIONS

8.1 Discontinuities at the surface will be indicated by bleed-out of penetrant; however,

localized surface irregularities due to machining marks or other surface conditions
may produce false indications.
 Liquid Penetrant Test Procedure
Date: 9/3/09
Revision: 2

8.2 Broad areas of pigmentation which could mask indications of discontinuities are
unacceptable, and such areas shall be cleaned and reexamined.

8.3 An indication is the evidence of a mechanical imperfection. The following applies:

8.3.1 Only indications with major dimensions greater than a 1/16 inch (1.6
mm) shall be considered relevant.

8.3.2 A liner indication is one having a length greater than three times the
width.

8.3.3 A rounded indication is one of circular or elliptical shape with the

length equal or less than three times the width.

8.3.4 Any questionable or doubtful indications shall be reexamined to

determine whether or not they are relevant.

8.3.5 An indication of an imperfection may be larger than the imperfection

that causes it; however, the size of the indication is the basis for
acceptance evaluation.

8.3.6 Any indication of an imperfection which is believed to be non-

relevant shall be regarded as a defect 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.

9.0 ACCEPTANCE STANDARDS

9.1 All surfaces to be examined shall be free of:

9.1.1 Relevant liner indications.

9.1.2 Relevant rounded indications greater than 3/16 inch (4.8 mm).

9.1.3 Four or more relevant rounded indications in a line separated by

1/16 inch (1.6 mm) or less, edge-to-edge.

9.1.4 No crack or linear indication is acceptable.

10.0 REPAIR REQUIREMENTS

10.1 Sections of welds that do not meet the acceptance standards in Section 9.0 shall be
repaired and reexamined in accordance with the requirements specified herein.
Unacceptable imperfections shall be repaired and reexamined made to assure
removal or reduction to an acceptable size. Whenever an imperfection is removed
by chipping or grinding and subsequent repair is by welding is not required, the
excavated are shall be blended into the surrounding surface so as to avoid sharp
notches, crevices, or corners and welding performed by a qualified welder or welding
operator in accordance with a qualified welding procedure.
 Liquid Penetrant Test Procedure
Date: 9/3/09
Revision: 2

10.2 After an imperfection is thought to have been removed and prior to, making weld
repairs, the area shall be examined by suitable methods to assure the imperfection
has been removed or reduced to an acceptable size.

10.3 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 that were
originally required for the affected area.

10.4 Surfaces shall be cleaned to remove residual penetrant and developer using the
solvent cleaner described in Paragraph 5.1.1.

11.0 RECORDS AND REPORTS

11.1 The examining operator shall report the results on the inspection form and complete
it in its entirety (attached).
 Liquid Penetrant Test Procedure
Date: 9/3/09
Revision: 2

LIQUID PENETRANT EXAMINATION

RECORD

CONTRACT/JOB No.: DRAWING No.:

ASSEMBLY: PIECE MARK:
TYPE OF MATERIAL: MATERIAL THICKNESS:
DYE PENETRANT TYPE: DYE PENETRANT METHOD:
DEVELOPER TYPE: DEVELOPER METHOD:
PENETRANT BATCH No.: EXPIRATION DATE:
DEVELOPER BATCH No.: EXPERATION DATE:
PENETRANT DWELL TIME: DEVELOPER DWELL TIME:
LIGHT @ POINT OF INSPECTION: LIGHT GAGE:
TEMPERATURE: BEFORE / AFTER PWHT:

WELD NUMBER WELD LOCATION ACCEPT REJECT REMARKS

COMMENTS:

INSPECTION OPERATOR DATE:

THIRD PARTY INSPECTOR DATE:

OWNERS DATE:
REPRESENTATIVE

CODE INSPECTOR DATE: