Liquid Penetrant Training Manual

Training Manual
For
Liquid Penetrant Testing

NDT Level - II
Job Number Document No Revision Number
3 Q A T R M 0 0 0 0 1 00
21/12/
RELIANCE ENGINEERING ASSOCIATES Date ? 99
PRIVATE LIMITED
Prepared By KMR
Department: Quality Management Checked By DR
Location: Jamnagar Approved By AJV

RELIANCE ENGINEERING
ASSOCIATES PRIVATE LIMITED
INDEX
Contents Page nos.
1. Introduction 3
2. Principles 3
2.1. Capillary Action 4
2.2. Surface Tension 4
3. Materials Used In Penetrant Inspection 4
3.1 Penetrants 5
3.1.1. Fluorescent, Type I 5
3.1.2. Visible, Type II 5
3.2 Emulsifiers 6
3.3 Developers 6
4. Selection of Penetrant Method 7
4.1. Sensitivity and Cost 7
4.2. Advantages and Limitations 7
5. Test Procedure to Qualify the DP materials 8
6. Description of Process 10
7. Pre-cleaning and Post-cleaning 13
8. Inspection and Evaluation 13
9. Special Requirements 16
10. Safety Aspects 17
11. Personnel Qualification and Certification 17
12. List of American Standards 18
ANNEXURE - I 19
ANNEXURE - II 20
Training Manual for PT level-II 2 of 20 Quality Management Dept.

Doc. No.: 3 QA TRM 00 001
1. Introduction
Liquid Penetrant Inspection is a non-destructive method of revealing the discontinuities

that are open to surfaces of solid and essentially nonporous materials. Indications of a
wide spectrum of flaw sizes can be found regardless of the configuration of the work
piece and regardless of flaw orientation. Liquid penetrants seep into various types of
minute surface openings by capillary action. Because of this, the process is well suited to
the detection of all types of surface cracks, laps, porosity, shrinkage areas, laminations
and similar discontinuities. It is extensively used for the inspection of wrought and cast
products of both ferrous and nonferrous metals, powder metallurgy parts, ceramics,
plastics and glass objects. The penetrant method is effective not only for detecting
surface flaws in non-magnetic metals but also for revealing surface flaws in a variety of
other non-magnetic materials.
1.1. Advantages of LPT method over other NDT methods
? ? Penetrant method can be used for detecting the surface openings in non-magnetic
metals also, where MPT can't be employed.
? ? Penetrant method is effective for detecting surface flaws, where other NDT methods
such as UT and RT are not effective.
? ? Liquid penetrant process is relatively simple.
? ? Low capital cost.
? ? Suitable for ferrous and non-ferrous metals.
? ? Shape of the work piece is not a limitation.
1.2. Limitations
? ? The major limitation of liquid penetrant inspection is that it can detect only
discontinuities/imperfections that are open to surface.
? ? Surface roughness is the another limitation of liquid penetrant inspection.
? ? Not effective on porous material.
2. Principles
Liquid penetrant inspection depends mainly on penetrant’s wetting property, i.e., the
ability to wet the surface of a solid work piece or specimen, flowing over that surface
to form a continuous and reasonably uniform coating, and then migrating into cavities
that are open to the surface. The cavities of interest are usually exceedingly small, often
invisible to the unaided eye. The ability of the given fluid to flow over a given surface
and enter surface cavities depends principally on the following:
? ? Cleanliness of the surface.

? ? Configuration of the cavity
? ? Cleanliness of the cavity
? ? Surface tension of the liquid
? ? Ability of the liquid to wet the surface.
? ? Contact angle of the liquid.
The cohesive forces between molecules of a liquid cause surface tension. The tendency
of free liquid to form a water droplet into a sphere shows the influence of surface
tension. Here, the internal hydrostatic pressure of the liquid counterbalances surface
tension. These two forces determine the contact angle. If the contact angle is less than
90deg. the liquid is said to have good wetting ability. If the angle is equal to or greater
than 90 deg. , then the wetting ability is considered low.
The phenomenon of capillary rise or depression can closely be related to contact angle.
If the contact angle, between the liquid and the wall of capillary tube is less than 90 deg,
then liquid will rise. If the contact angle is equal to 90 deg, then there is no capillary rise
or depression. If the contact angle is greater than 90 deg, the liquid is depressed in the
tube.
The height to which liquid rises is directly proportional to surface tension of the liquid
and to the cosine of the angle of contact and inversely proportional to density of the
liquid and to the radius of the tube. The surface wetting and capillary rise properties of
the liquid illustrate the basic principles by which a penetrant enters a fine surface
discontinuity. The practical circumstances may be more complex than the examples but
it simulates the basic interaction between a liquid and solid surface.
The viscosity of the liquid is not a factor in capillary rise.However, in general high
viscous fluids are not suitable as penetrants because they don’t flow rapidly enough over
the surface of the work piece, thus require excessively long periods of time to migrate
into fine flaws.
Chemical Activity: Penetrant should be non-corrosive towards the material being tested
and the containers in which they are stored. The use of penetrants with chlorine, fluorine
or sulfur is usually restricted to austenitic steel, Titanium and high nickel alloys,
respectively.
3. Materials Used In Penetrant Inspection
For conducting liquid penetrant inspection, the materials required are penetrants,
emulsifiers, solvent/cleaners and removers and developers.

3.1. Penetrants: There are two basic types of penetrants.
3.1.1. Fluorescent :Type I
Fluorescent penetrant utilizes penetrants that are usually green in colour and fluoresce
brilliantly under ultra violet light. The sensitivity of a fluorescent penetrant depends on
its ability to form indications that appear as small sources of light in an otherwise dark
area. These penetrants are available in different sensitivity levels classified as follows
? ? Level ½ : Ultralow
? ? Level 1: Low
? ? Level 2: Medium
? ? Level 3: High
? ? Level 4:Ultahigh
3.1.2. Visible: Type II
Visible penetrant employs a penetrant that is usually red in colour and produces vivid red
indications in contrast to the light background of the applied developer under visible
light. The visible penetrant indications must be viewed under adequate white light.
The penetrant selection and use depend upon the criticality of inspection, condition of
the work surface, type of processing and sensitivity. This topic is discussed in detail in
section-4.0. The above mentioned penetrants can be applied in four methods. They are
Method A: Water washable penetrants are designed for the removal of excess
penetrant by water rinsing directly after a suitable dwell time. The emulsifier is
incorporated into the water washable penetrant. When this type of penetrant is used, care
must be taken to prevent over washing, which can cause the penetrant to be washed out
of the flaws.
Methods B and D, lipophilic and hydro philic post emulsifiable penetrants are
insoluble in water and hence cannot be removed by water rinsing alone. They are
designed to be selectively removed from the surface of the work piece by the use of
separate emulsifier. The emulsifier, properly applied and left for sufficient emulsification
time, combines with the excess surface penetrant to form water washable surface mixture
that can be rinsed from the surface of the work piece. The penetrant that remains within
the flaw is not subjected to over washing.
Method C, Solvent-removable penetrants are removed by wiping with clean, lint free
material until most traces of the penetrant have been removed. The remaining traces are
removed by wiping with clean, lint-free material slightly moistened with solvent. To
minimize the possibility of removing penetrant from the flaw, use of excessive amount
of solvent must be avoided. This method is having the advantage of portability and can
be used in outdoors without any complex machinery.

3.2 Emulsifiers:
Emulsifiers are liquids used to render excess penetrant on the surface of a work piece
water washable. There are two methods in the postemulsifiable method.
3.2.1 Method B:
Lipophilic emulsifiers are oil based, are used as supplied and function by diffusion. The
emulsifier diffuses into the penetrant film and renders it spontaneously emulsifiable in
water. The rate at which it diffuses into penetrant establishes the Dwell time. The dwell
time in the emulsifiers is in the range of one to four minutes in accordance with the
manufacturer’s recommendations. The emulsifier acts as long as it is in contact with the
work piece therefore rinse operation should take place quickly to avoid
overemulsification.
3.2.2 Method D:
Hydrophilic are water based and supplied as concentrates that are diluted in water in
concentrations of 5 to30 % for dip applications and 0.05 to 5% for spray applications.
Hydrophilic emulsifiers function by displacing excess of penetrant by detergent action.
The emulsifier can be applied by either dipping or spraying only. The force of the water
spray or the air agitation in dip tanks provides scrubbing action. Hydrophilic emulsifier
is slower action than the lipophilic emulsifier, and hence it is easy to control the
cleaning action. In addition to the emulsifier application, method requires prerinse.
Utilizing a coarse water spray, the prerinse helps remove the excess penetrant to
minimize the contamination of the emulsifier. This step is required because the
penetrant is not miscible with the hydrophilic emulsifier.
The penetrant manufacturer shall recommend nominal emulsification times for the
specific type of emulsifier in use. The manufacturer shall recommend the concentrations
for hydrophilic emulsifiers.
3.3 Developer :
The purpose of the developer is to increase the brightness of fluorescent indications and
contrast of visible penetrant indications. The developer also provides a blotting action,
which serves to draw penetrant from the flaw to the surface and spreading the penetrant.
The developer is a critical part of the inspection process, borderline indications that
otherwise be missed can be made visible by the developer. In all applications of liquid
penetrant inspection, use of developer is desirable because it decreases inspection time
by hastening the appearance of indications.
The appearance of the discontinuity in the developer will be larger than the actual size.
There are four forms of developers in use.
? ? Form A, dry powder
? ? Form B, Water soluble
? ? Form C, Water suspendible

? ? Form D, nonaqueous solvent suspendible.
The characteristics of each form are discussed below.
Form A, Dry powder developers are widely used with fluorescent penetrants, but
shouldn’t be used with visible-dye penetrants because they don’t produce satisfactory
contrast. Dry powder developers should be light and fluffy to allow for ease of
application. For the purpose of storage and handling as well as applications, powders
shouldn’t be hygroscopic, and remain dry.
Form B; Water soluble developers can be used for both penetrants. Water-soluble
developers are not recommended for use with water washable penetrants, because the
potential to wash the penetrant from within the flaw if developer is not carefully
controlled.
Form C; Water suspendible developer can be used with both the penetrants. Water
suspendible developers are supplied as a dry powder concentrate, which is then dispersed
in water in recommended proportions, usually 0.04 to 0.12 kg/L. Too much or too little
developer on a surface of a work piece can affect the sensitivity.
Form D; Non-aqueous suspendible developers can be used for both the penetrants. This
type of developers is most sensitive form of developers used with type-I, fluorescent
penetrants because the solvent action contributes to absorption and adsorption
mechanism. The flaws, which are small and tight can effectively, be identified with this
type of developer where all other types of developers are found to be ineffective.
4 Selection of Penetrant Method
The size, shape as well as the number of similar work pieces to be inspected often
influence the selection of a penetrant method.
4.1 Sensitivity and Cost
The desired degree of sensitivity and cost are usually most important factors in selecting
the proper penetrant method for a given application. The methods capable of the greatest
sensitivity are also the most costly. On practical basis, the fluorescent methods are
employed in a wider variety of production operations than the visible penetrant methods,
which are utilized primarily for localized application. Penetrants are also classified in
terms of sensitivity levels, as specified in 3.1.1.
4.2 Advantages and Limitations
The advantages and limitations of each method are tabulated below.

Water washable penetrant method
Advantages Disadvantages
? ? Fast process. ? ? Not reliable for detecting shallow and

relatively wide flaws.
? ? Simplest of all techniques.
? ? Less sensitive for locating tight
? ? Relatively inexpensive. cracks.
? ? Good on threads, keyways. ? ? Easily over-washed.
? ? Good on rough surfaces. ? ? Not reliable on anodised specimen.
? ? Good for quantities of small

specimen.
Solvent Removable penetrant
? ? Portability. ? ? Flammable material
? ? More sensitive than water ? ? Removal of excess penetrant is time

washable. consuming.
? ? No water requirement. ? ? Difficult to use on rough surfaces

such as cast magnesium.
? ? Good for spot-checking.
? ? Good on anodized specimen.
Post-emulsifiable penetrant
? ? Most reliable method ? ? Two step process.
? ? High sensitivity for very fine ? ? Difficult to remove penetrant from

discontinuities. threads, blind holes and rough
surfaces.
? ? Good on wide shallow
discontinuities. ? ? Equipment required for emulsifier.

5 Test Procedure to Qualify the DP materials :
There are approved procedure for testing the DP material namely penetrant, Developer
and emulsifier.
5.1 Test for Penetrants
5.1.1 Sensitivity Test:
There have been no simple quantitative tests developed for measuring the penetrant
sensitivity. A simple comparative test is usually adequate. A small sample of the
penetrant from the test area is placed on one side of an aluminum test block and a small
sample of penetrant on the other side. By visual observation it is determined that whether
the old penetrant is contaminated to the point where it must be discarded.
5.1.2. Meniscus Test:
This test is used for evaluating the dye concentration in thin liquid films. A drop of a
solution is placed on the flat glass platen and a convex lens is placed on it. A colourless
or non-fluorescent spot is formed around the point of contact. The resultant contact angle
simply indicates the ability of a liquid to wet a surface.
The diameter of the remaining spot of colourless penetrant provides a measure of film
thickness, which can be used to compare the dye concentrations of different penetrants.
The spot diameter depends on exposure time of film to ultraviolet rays and the
contamination by acids.
Spo
Penetran Lens Plate
5.1.3 Some of the other tests are Ceramic block test, Viscosity test, Water content test, and
Fluorescent penetrant fade test.
5.2. Test for Emulsifier:
5.2.1. Water washability test is carried out, where applicable.
5.3. Test for Developers
5.3.1. Dry developers are to be visually inspected to see that they are not lumpy or caked
instead of fluffy and light.
5.3.2. Wet developers are to be checked with hydrometer to ensure that the density of the
powder is within the range specified /recommended range.
6 Description of Process: Penetrant inspection consists of following essential steps.
6.1 Surface Preparation: All the surfaces to be inspected, whether localized or entire surface,
must be thoroughly cleaned and completely dried before the application of penetrant.
6.2 Application of Penetrant: After the work piece has been cleaned, penetrant is applied in a
suitable manner so as to form a film of penetrant over the surface. The penetrant shall remain
on the surface for sufficient time i.e., dwell time, as recommended, in the table below.
6.3 Removal of excess penetrant: Excess penetrant shall be removed from the surface. The type
of penetrant used determines the removal method. Uniform removal of excess surface
penetrant is necessary for effective inspection, but over removal must be avoided.
6.4 Application of Developer: Developer functions as a blotter to assist the natural seepage of
penetrant out of surface opening and to spread it so as to enhance the penetrant indication.
6.5 Inspection: After it is sufficiently developed, the surface is visually examined for the
indications of penetrant bleed back from the surface openings. This examination must be
performed in a suitable inspection environment. Visible penetrant inspection is performed in
a good white light. When fluorescent penetrant is used, inspection is performed in a suitably
darkened area using black (Ultraviolet) light, which causes penetrant to fluoresce brilliantly.
Table shows the recommended dwell times as per ASME Sec-V, SE-165.
Material Form Type of discontinuity Dwell time (in

Minutes)
Penetrant Developer
Aluminum, Cast-- Casting Cold shuts, porosity, 5 7

magnesium, Steel, and welding lack of fusion
brass and bronze, cracks(all forms)
titanium and high-
temperature alloys.
Carbide-tipped tools Laps, cracks (all 10 7

Wrought— forms)
extrusion,
forging, and Lack of fusion,
plate. porosity, cracks 5 7
Plastics all forms Cracks 5 7
Glass all forms Cracks 5 7
Ceramics all forms cracks 5 7

Notes:
? ? Dwell time given is recommended minimum.
? ? Maximum penetrant dwell times 60 min.
? ? Development time begins directly after application of dry developer and as soon as
developer coating has dried on surface of parts (recommended minimum).
The flow charts, explain the sequence of operations.The diagrams in Annexure-I give the
pictorial view of the same.
Vapor
Solvent Acid
Alkaline Steam Degreas
Wash Etch
e
Paint
Mechanical
Stripper Ultrasonic Detergent
DRY
Apply Solvent
Apply Post
Apply Water Removable emulsifiable
washable Penetrant
Penetrant
Penetrant
Apply Emulsifier Apply Remover

Solvent Wipe
Water Wash off
Water Wash
Dry Developer Developer

(Aqueous) Dry Developer
Developer Dry (Aqueous)
Developer
Dry
Inspect
Mechanical
Water Rinse Detergent
Wash
Dry
Vapor Ultrasonic
Solvent Soak
Degrease Clean
Outgoing Parts
Fluorescent and Visible Penetrant Inspection General Processing Procedures Flowsheet

Preclean
Penetrant
Application
Solvent Wipe off
Dry Parts
Apply Developer
Inspection
Post Cleaing
Solvent Removable Penetrant Inspection Processing Procedure

(for both Fluorescent and Visible)

7 Pre-cleaning and Post-cleaning
7.1 Pre-cleaning
Adequate pre-cleaning is absolutely necessary for accurate results. Without adequate

cleaning or removal of surface contamination,
? ? Penetrant doesn’t enter the flaw
? ? Penetrant may lose its ability to identify the flaw because it reacts with some existing
material
? ? False indications may be caused by residual material holding the penetrant.
Cleaning methods are classified as chemical, mechanical, solvent or combination of

these.
7.1.1. Chemical cleaning method includes alkaline or acid cleaning, pickling or chemical
etching and molten salt bath cleaning.
7.1.2. Mechanical cleaning method includes tumbling, wet blasting, dry adhesive blasting, wire
brushing and steam cleaning. This method should be used carefully because they mask
flaws by smearing adjacent metal over them or by filling them with adhesive material.
7.1.3. Solvent cleaning method includes vapor degreasing, solvent cleaning, Solvent wiping
and ultrasonic immersion using solvents. Most commonly used method among them is
vapour degreasing.
The factors to be considered in selecting the cleaning method, are type of contaminants
to be removed and composition of the work piece.
7.2. Post-Cleaning: Some residue will remain on work pieces after the penetrant inspection is
completed. In many cases it may not have deleterious effects, but in some cases post
cleaning is essential, where subsequent welding /brazing is to be carried out. Cleaning
methods such as Mechanical, chemical or solvents cleaning are seldom adopted.
8. Inspection and Evaluation:
8.1. Inspection: After the penetrant process is completed, the work piece is ready for
inspection. An inspector must have the tools that are capable of providing the required
accuracy. These tools usually include
? ? Flash light
? ? Magnifier ranging from 3 to 10X
? ? Suitable black light for fluorescent light, i.e., intensity of black light shall be
minimum of 1000 ? W/Sq.cm and wavelength in the range of 330 to 390 nm.
? ? A minimum light intensity at inspection site of 32.5 foot-candles (350lx) for visible
penetrant, is recommended as per SE-165.
? ? Sometimes, Photographic standards have specific known flaws as inspection aid.
A typical inspection begins with an overall examination to determine that the work
piece has been properly processed and is in satisfactory condition for inspection.
Inspection shouldn’t begin until the wet developers are completely dry. The work piece
should be cleaned and reprocessed if
? ? Developer film is too thick
? ? Penetrant bleed out is too excessive
? ? Penetrant background is excessive.
8.2. Evaluation:
The inspector determines the type, location and size of discontinuity and interprets it to
applicable acceptance standard. Each indication that is not acceptable should be
evaluated. All discontinuities are not necessarily defects. If any indication effects the
service of the part, it is called a discontinuity.
Here, some types of discontinuities are discussed, which are related to various
manufacturing processes, such as casting, forging, forming, welding and brazing, heat
treatment and machining as depicted in ANNEXURE-II.
Casting: When metals are cast into molds and solidify from the molten state into
substantially finished shape, they are subjected to a variety of discontinuities which are
in general peculiar to the casting process regardless of type of metal or size or shape of
the cast. The principal discontinuities, which may occur in almost any type of casting,
are:
? ? Shrinkage cracks
? ? Micro-shrinkage
? ? Porosity
? ? Cold shuts
? ? Surface sand inclusions
? ? Blow holes
? ? Cracks
In addition to the inspecting discontinuities, a most important use of penetrant in the

foundry is to test pilot runs to ensure that the sound casting can be produced from the
mold. If any evidence of porosity is established then relocation of gates and raisers
becomes essential and design of the casting may be altered if the pilot run indicates
proneness to shrinkage or cracking.

Forging: Numerous metals and alloys are forged into a wide variety of parts, many for
highly critical service in automotive, aircraft, jet engine, nuclear and space applications.
These metals include aluminum and magnesium alloys, stainless steel, heat resistance
alloys, alloys designated for high strength at high temperatures. The principal
discontinuities, which may occur in almost any type of forging, are:
? ? Cracks
? ? Laps
? ? Tears
? ? Bursts
? ? Flak
? ? Seams
? ? Laminations
? ? Cracking due to residual stresses.
The post-emulsification technique is quite commonly used in forging inspection because

of the tendency of surface flaws to be filled with oxide or other foreign matter. Such
conditions as flakes, laminations and pipe are not found with penetrants unless or until
they have been made into surface discontinuities as by cutting billets into blanks or by
machining. Billets intended for rolling, extruding for forging into quality products are
profitably examined with penetrants to locate surface defect so that such defects can be
removed before further processing. Elimination of seams in the billet stage assures clean
strip for making of welded aluminum tubing. When billets are cut up into forging blanks
or extruding blanks the cropped or cut ends are inspected for pipe or other internal
discontinuities by applying penetrant to the cut surfaces.
Forming: Various process are used to form and shape metals into the usable parts.
These include extruding, explosive forming, spinning, stamping, drawing and others.
Metals include are stainless steel, aluminum, brass, beryllium, copper etc. The principal
discontinuities, which may occur during forming, are:
? ? Seams
? ? Silvers
? ? Tears
? ? Laminations
? ? Cracks.
Depending upon the sensitivity required, kind of surface condition of the metal / part,
type of penetrant to be used will be decided. For example color contrast penetrants are
frequently used, water washable or post-emulsifiable will be adopted as per requirement

and conditions.
Welded and brazed joints: Surface cracks or other surface discontinuities in welded
joints in magnetic/non-magnetic metals are located very accurately. All variety metals
are included; for example aluminum, stainless steel and corrosion resistant alloys are
welded. The discontinuities, which may occur, are cracks, surface porosity, lack of
bonding etc. The same is true for brazed joints also.
Machining and Grinding: Machined and ground parts may contain discontinuities,
which occur from improper control of process. Poor machining practice i.e., use of dull
tools or improper speeds may produce crack like indications, tears and chatter marks.
Overheating during grinding may cause cracks, which are minute and often invisible to
the unaided eye.
Heat Treatment: When metals are heat treated , there are instances of cracking. This is
particularly true during quenching of parts having sharp radius areas between the light
and heavy sections.
Fatigue cracking: Machine members or components, which are subjected to many

cycles of reversing and fluctuating stresses, under certain circumstances, are prone to
failure, because of fatigue cracking. Fatigue cracking is initiated at some locations in
stressed parts where for some reasons the stress is raised locally above the average
stress. Once crack is initiated, it will propagate and result in failure.
When a very small grinding crack or even a small accidental nick in the surface of the
part is repeatedly stressed can develop into a fatigue crack. The very purpose of
performing non-destructive testing is to detect and eliminate the stress raising flaws of
this kind.
8.3. False and Non-relevant Indication:

? ? An undesirable flaw, such as crack causes a real indication.
? ? A False indication is due to the poor washing or streaking caused by continued

bleedout.
? ? Non-relevant indications are caused by entrapment of penetrant, caused by the

feature of assembly such as Press-fitted, Keyed, Splined or riveted.
9. Special Requirement:
Sulfur, and Chlorine fluorine Content : When penetrant inspection is to be carried out
on austenitic stainless steel, titanium or nickel base alloys, then need to restrict
chloride/fluoride ion content, total chlorine/fluorine content and sulfur content should be
considered. In the absence of specific requirement, the chlorine content should be limited
to 1%, where potential use includes application to austenitic stainless steel or titanium
Similarly, in the absence of specific requirement, the sulfur content should be limited to
1%, where potential use includes application to nickel-base alloys at elevated
temperatures.
10.Safety Aspects:
10.1 The materials used in penetrant inspection can be flammable and can cause skin irritation.
? ? Fire: Many penetrant materials are flammable. And hence, material with low flash
point will be less hazardous. Safe practice requires that penetrant material used in
open tanks have a flash point of greater than 52 deg C.
? ? Skin Irritation: The oil base of the liquid penetrant material has a drying action on
the skin. Skin irritation can be avoided by preventing the surface contact by the use
of gloves, aprons and protective hand creams.
10.2 Ultraviolet Rays:
? ? The ultraviolet spectrum of light rays can cause sunburn and may be injurious to the
eyes. However, the proper filter used with fluorescent dye inspection, will filter
harmful rays. Missing Cracked or broken filters are to be replaced.
10.3 Air pollution:
? ? The developing powders are considered nontoxic, but excessive inhalation must be
avoided. When performing the test in confined area, care should be taken to install
exhaust fans.
11. Personnel Qualification and Certification:
The American Society of Nondestructive Testing gives Recommended Practice No.

SNT-TC-1A. This practice is intended as a guideline for the employers to establish their own
written practice for a qualification and certification of nondestructive testing personnel. There
are three basic levels of qualification as mentioned below:
NDT Level I : An NDT Level I personnel is qualified to perform specific calibrations,

specific tests and specific evaluations according to the written instructions and record the
results.
NDT Level II : An NDT Level II personnel is qualified to set up and calibrate

equipment and to interpret and evaluate the results with respect to applicable codes,
standards and specifications. An NDT Level II personnel should be able to train and give
the guidance to NDT Level I personnel and should be able to organize and report the
results.
NDT Level III : An NDT Level III personnel should be capable of establishing
techniques and procedures, interpreting codes, standards, specifications and procedures
and designating the test method and techniques to be used. The NDT Level III must have
practical background in applicable materials, fabrication, and product technology to
assist in establishing the acceptance criteria and be familiar with other commonly used
NDT methods.

12. List of American Standards
Spec no. Title of spec/standard
ASTM Standards
ASTM-E-165-------------------Standard practice for Liquid –penetrant Inspection Method
ASTM-E-270-------------------Standard Definitions of terms relating to for Liquid–penetrant
Inspection Method
ASTM-E-1208-----------------Standard Method for fluorescent Liquid-Penetrant Examination
Using the Lipophilic Post-Emulsification Process
ASTM-E-1209-----------------Standard Method for fluorescent -Penetrant Examination
Using the Water-Washable Process
Using the Hydrophilic Post-Emulsification Process.
Using the Solvent-Removable Process.
ASTM-E-1220-----------------Standard Method for Visible-Penetrant Examination
Using the Solvent-Removable Process.
ASTM-E-1135-----------------Standard Test method for Comparing the Brightness of Fluorescent
Penetrants
ASME specification
ASME-SEC V-----------------ASME Boiler and Pressure Vessel Code Section V, article 6.

ANNEXURE - I

ANNEXURE - II


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Liquid Penetrant Testing

Job Number Document No Revision Number

Department: Quality Management Checked By DR

Location: Jamnagar Approved By AJV

Contents Page nos.

2.1. Capillary Action 4

2.2. Surface Tension 4

3. Materials Used In Penetrant Inspection 4

3.1.1. Fluorescent, Type I 5

3.1.2. Visible, Type II 5

4. Selection of Penetrant Method 7

4.1. Sensitivity and Cost 7

4.2. Advantages and Limitations 7

5. Test Procedure to Qualify the DP materials 8

7. Pre-cleaning and Post-cleaning 13

8. Inspection and Evaluation 13

10. Safety Aspects 17

11. Personnel Qualification and Certification 17

12. List of American Standards 18

Training Manual for PT level-II 2 of 20 Quality Management Dept.

Liquid Penetrant Inspection is a non-destructive method of revealing the discontinuities

1.1. Advantages of LPT method over other NDT methods

? ? Liquid penetrant process is relatively simple.

? ? Low capital cost.

? ? Suitable for ferrous and non-ferrous metals.

? ? Shape of the work piece is not a limitation.

? ? Surface roughness is the another limitation of liquid penetrant inspection.

? ? Not effective on porous material.

? ? Cleanliness of the surface.

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? ? Configuration of the cavity

? ? Cleanliness of the cavity

? ? Surface tension of the liquid

? ? Ability of the liquid to wet the surface.

? ? Contact angle of the liquid.

3. Materials Used In Penetrant Inspection

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3.1. Penetrants: There are two basic types of penetrants.

3.1.1. Fluorescent :Type I

3.1.2. Visible: Type II

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? ? Form A, dry powder

? ? Form B, Water soluble

? ? Form C, Water suspendible

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? ? Form D, nonaqueous solvent suspendible.

The characteristics of each form are discussed below.

4 Selection of Penetrant Method

4.1 Sensitivity and Cost

4.2 Advantages and Limitations

The advantages and limitations of each method are tabulated below.

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Water washable penetrant method

? ? Fast process. ? ? Not reliable for detecting shallow and

? ? Good on threads, keyways. ? ? Easily over-washed.

? ? Good on rough surfaces. ? ? Not reliable on anodised specimen.

? ? Good for quantities of small

Solvent Removable penetrant

? ? Portability. ? ? Flammable material

? ? More sensitive than water ? ? Removal of excess penetrant is time

? ? No water requirement. ? ? Difficult to use on rough surfaces