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 safety for vapour degreasing
Personnel using vapour degreasing systems
should be aware of health hazards, including
the possibility of excessive inhalation of
chlorinated hydrocarbon vapours. These
vapours adversely affect the mucous
membranes of the respiratory system.
Symptoms of excessive inhalation or
absorption include headaches and fatigue.
Long-term exposure may result in kidney and
liver damage. High temperatures and high
intensity ultraviolet light, such as produced
by arc welding, can oxidize or decompose
chlorinated hydrocarbon vapours to produce
the highly toxic and dangerous gas phosgene
(a poison gas once used in warfare).

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 safety for vapour degreasing
Other products of such decomposition include hydrochloric acid,
carbon dioxide, and dichloroacetyl chloride, which aid corrosion and
are strong irritants as well. Like other fluids used in penetrant
testing, prolonged exposure of the skin to vapour degreasing
solvents can extract oils from the skin, resulting in cracking of the
skin and dermatitis.

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 Personnel safety for solvent cleaning
Personnel using solvent cleaning methods should be aware of
the hazards of fire (with flammable solvents) and toxicity
(with chlorinated hydrocarbon solvents, ketones, and
alcohols), the flash points and permissible toxicity
concentrations and should ensure operation in a well
ventilated atmosphere.

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 Applicable safety standards
The organic base solvents used as cleaning of test parts and
removal of excess penetrant are hazardous for their
flammability and toxic effects. The organizations such as US
Department of Health Education and Welfare, National
Institute for Occupational Safety and Health (NIOSH) have
laid down the flash points and toxicity values as standards of
common cleaning solvents for safe use during inspection by
liquid penetrant testing method.

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 safety precautions for acid cleaning
Personnel using acid cleaning techniques
should be aware of the hazards associated
with use of acids, particularly during hand
wiping operations. Operators should be
protected with face shields and rubber gloves,
aprons, and boots. Nonslip floor coverings are
recommended in areas used for hand wipe or
acid spray cleaning. The work areas should be
adequately ventilated to remove acid fumes
and mists. Operators handling chemicals
should wash their hands and faces before
eating and before leaving the work areas at
the end of a shift. If chemicals come into
contact with the hands or body, immediate
and thorough washing with cold water is
required.

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 safety precautions for acid cleaning
If significant exposure has occurred,
emergency treatment may be necessary. Eye
fountains and showers are usually located
adjacent to acid cleaning work areas for
immediate use in case of accidents. Even
dilute acids are dangerous and cause serious
injuries if they contact the human eye.
Immediate and thorough washing of the eyes
at an eye fountain is vital in minimizing such
injury. Mist from spray systems can contain all
of the ingredients of the acid cleaners, and
gassing can be a health hazard. Electrolytic
acid cleaning systems can contribute to mist
formation and are especially dangerous.
Rubber shoes and gloves are recommended
for operators working with electrolytic
cleaning systems.

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 Acids and alkaline for descaling purpose
When making use of acids and alkaline for descaling purposes, the
operator should follow the normal precautions as are recommended.
Few of the precautions are outlined as under:
1. Always add acid to water, never add water to concentrated acid.
2. When preparing new solutions, add acid to cold water and do not
heat the solution until all the acid has been added.
3. Test objects should be immersed or withdrawn slowly from acid
cleaning solutions to avoid splashing acid.
4. After acid cleaning, all test objects should be rinsed in water to
remove all traces of residual acid.
5. Before discarding used or spent acid cleaning solutions, the solutions
should be neutralized or pumped into safe receptacles to be
processed for later disposal. Federal, state, and local regulations
should be observed when disposing of acid chemicals, even after
neutralization for alkaline solutions.
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 Acids and alkaline for descaling purpose
6. Alkaline should be added to water slowly using a hopper or a shovel,
to obtain an even distribution of the chemicals in the solution.
7. Adequate agitation should be provided after an alkali has been added
to ensure that the chemicals dissolve.
8. Temperature of the solution should not exceed 65°C (150°F) when
alkaline chemicals are added. This precaution is to prevent eruption of
the solution.
9. When making use of black light sources, the operator should follow
the safety precautions as already discussed above.

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 safety precautions for salt bath descaling
Personnel hazards and safety precautions with salt
bath descaling Salt bath descaling equipment should
be operated only by trained personnel fully aware of
the hazards involved. Flushed salts at 370 to 540°C
(700 to 1000°F) are dangerous and produce severe
burns and attack if splashed onto the human body.
Eyes must be fully protected from the caustic. Test
objects must be totally free of water when immersed
in a salt bath, since the molten caustic will react
violently and spatter when contacted with water. The
highly reactive metal sodium is used in the sodium
hydride cleaning process. Extreme caution is required
to prevent water from coming into contact with
sodium. Sodium fires are very intense and the
operator should never use water, acid soda pyrene or
carbon dioxide fire extinguishers on sodium fires. only
should be used to extinguish sodium fires.

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 safety instructions for DPT personnel
The operators involved in the inspection work by
penetrant method should be aware of necessary
safety aspects of the chemicals and penetrant
materials. The brief instructions worth bearing in
mind are outlined as under:
1. Operators should not expose hands or skin to
solvents since they dissolve skin oils and can
lead to dermatitis or cracking of skin.
Protective gloves and ointments to restore
skin oil should be used, when operators must
be in contact with solvents.
2. Areas used for solvent cleaning should have
adequate ventilation to remove fumes and
prevent accumulation of vapours in explosive
or toxic concentrations. This is very important
as vapours of chlorinated hydrocarbons can
have potentially lethal anesthetic actions
when they are inhaled.

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 safety instructions for DPT the personnel
3. Smoking should be prohibited in all
areas used for pre-cleaning by vapor
degreasing or solvents.
4. Disposal of sludge residues from
cleaning operations must follow
federal, state and local regulations.
The sludge residue is toxic and may
be flammable since it contains oil and
grease collected during the
degreasing operations. Direct contact
with hot residue is dangerous. Sludge
residues should be disposed of in
covered containers which should not
be airtight.

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 Personal Protective Equipment(PPE)
Safety clothing Safety clothing must be worn in
the work area where penetrant testing is being
conducted, just as they are anywhere products
are being sprayed or chemicals handled. This
avoids the penetrant material coming into
contact with any part of the body. Most of the
chemical testing materials remove the natural
oils from the skin or have other negative
medical effects, such as anesthetic vapors.
1. Face protection: Safety goggles or face
shield.
2. Hand protection: Gloves, skin-protection
cream.
3. Body protection: Work over-all and /or
apron.
4. Foot protection: Safety shoes

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 Potential health effects
Skin Contact : Can irritate by removing natural skin oils on
long or repeated exposures
Eyes : May Irritate
Inhalation : Not significant at room temperatures. When
heated or sprayed, vapors may cause dizziness or nausea
Ingestion : Not significant in small(mouthful)quantities

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 First aid
If chemical contact occurs with eyes or skin, the instructions of the
manufacturer must be followed. If no such instructions are
available, the follow procedure should be followed:
Chemical contact with the skin:
1. Remove the clothes.
2. Wash with soap and plenty of water.
3. Dry the skin.
4. Rub in skin protection cream.
5. Get medical attention if there is a problem.
Contact with the eyes:
1. Wash off with soap and plenty of water.
2. Get medical attention immediately
Note : if any serious problem occurred for inhalation and ingestion
should to take help of physician.
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 Storage of the DPT testing materials
The testing materials must be stored according to the newest
transport and storage orders. In addition to the storage conditions
and the storage duration on the label or the package, the date of
expiration is also given. Some manufacturers also give information
about the range of the storage temperature and advise that testing
materials must not be kept near acids and alkalis, the storage
places must be kept specifically for PT and MT materials and must
adhere to local regulations.

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 Safety for confined spaces
Closed rooms or areas could be tanks,
pressure vessels, small rooms, pipes, etc.
Because of the number of sources of
danger in such areas, several safety
orders must be followed closely. The
person in charge is also obligated to take
the following measures.
1. Appointing a supervisor.
2. Choosing and training co-workers.
3. Ascertaining the given hazards.
4. Choosing working procedures,
working tools and working areas.
5. Following the safety measures
required by special personnel. Issuing
working instructions.

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 Fired hazard of magnaflux cleaner
1. Conditions of flammability : Flammable
2. Flash point : Min 12 deg C (PMCC)
3. Flammable limits in air : 2 to 12.7%
4. Extinguishing media : Apply alcohol type or all purpose type foam for
larger fires. Carbon dioxide or dry chemical media for small fires.
5. Special fire fighting procedures : Keep containers cool with water
spray. Use water spray to disperse vapors or it might reignite. Use self-
contained breathing apparatus and protective clothing.
6. Hazardous combustion products : Oxides or carbon
7. Unusual fire hazards : Vapors form may travel or be removed by air
currents and ignite by pilot fire, other flames at distant Locations
.Vapors from this material may settle in low or confined areas .This
material may produce a floating fire hazard.

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 Fired hazard of magnaflux penetrant
1. Conditions of flammability :
Aerosol : Spraying near an ignition source will ignite spray mist
Bulk : None unless heated over 93 deg C near ignition source
2. Flash point : Min 93 deg C (PMCC)
3. Flammable limits in air : 1 to 6%
4. Extinguishing media : Carbon dioxide , Foam
5. Special fire fighting procedures : Keep containers cool with water
spray .Do not spray water directly on burning SKL-SP1.It may float
and spread the fire
6. Hazardous combustion products : Smoke, soot, oxides or carbon
and nitrogen
7. Unusual fire hazards : Aerosol containers may burst at
temperatures over 54 deg C and spray contents into a fire
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 Safety required for the use of UV light
When an operator is making use of
black light source for inspection
purposes, he should be sure of the
following.
(a) The filter glass is in place and is not
cracked or damaged such that white
light is emitted.
(b) Gloves and the otherwise necessary
safety clothing may be worn.
(c) After prolonged running of the
lamp, housing gets very hot and can
cause burning. Do not touch this
lamp housing with unprotected
flesh.

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 Safety required for the use of UV light
d) Do not, under any circumstances,
shine the ultraviolet light onto the
eyes.
e) Direct viewing of the lamp may, with
certain people, cause an irritation of
the eyes known as fluorescence of
the retina. This is a temporary
condition and can be overcome by
wearing sodium glasses.
f) When using kerosene based inks
with the hood in place, always have
the ventilation fan operating

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 Contamination control for dye penetrant test
The control of contaminant for all liquid penetrant materials used on
nickel base alloys, austenitic stainless steels, and titanium
nickel Base Alloys: When examining nickel base alloys, all penetrant
materials shall be analyzed individually for sulfur content in accordance
with SE-165, Annex 4.The sulfur content shall not exceed 1% by weight.
Austenitic or Duplex Stainless Steel and Titanium: When
examining austenitic or duplex stainless steel and titanium, all penetrant
materials shall be analyzed individually for halogens content in
accordance with SE-165, Annex 4. The total halogens content shall not
exceed 1% by weight

Reference: ASME section-V, article-6

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