WEST QURNA I

SECTION 1

WQI PRODUCED WATER TREATMENT PROJECT (AWQ0109-1)

P.O. Number: IQWQ-CE1091-XXUPO-00-0681-22A

Vendor: WIKA Middle East Fze. Reviewed with

comments.
Package: Pressure & Temperature Gauges 5th April, 2017
Bello F. Jackson
Equipment/Tag No.: All Tags as per PO

LIQUID DYE PENETRANT TEST PROCEDURE FOR THERMOWELL

IQWQ-CE1091-VPNDT-00-2566

Vendor Doc. No. : SO041829.17

A 28/03/17 Issued for Review Keny John Waseem

Rev Date Description Prepared By Checked By Approved By

Signed By
CPE CPECC
(Name & Date)

Review Category: III

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REVISION CONTROL

Revision Number &

Changes Remarks
Date

00
-- FIRST ISSUE
09th July 2015

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INDEX

Clause
Description of Content Page Ref.
Ref...
1 Scope 4
2 Reference Documents 4
3 Procedure Qualification & Revision 5
4 Performance Demonstration 6
5 Personnel Qualification 6
6 NDE Method Technique 7
7 Test Materials` 7
8 QC of Test Materials 8
9 Test Component Condition 8
10 Initial Solvent Cleaning 8
11 Test Temperature 9
12 Application of Penetrant 9
13 Dwell Time 9
14 Removal of Excess Penetrant 10
15 Drying of Test Surface 10
16 Application of Developer 10
17 Forming of Indications 11
18 Viewing Conditions 11
19 Interpretation of Indications 12
20 Post Examination Cleaning 13
21 Evaluation for Acceptance Status 13
22 Documentation and Reporting of Results 13
23 Safety 14
ANNEXURE
Annexure I - Acceptance Standards 15
Annexure II - Sample Report Format 22

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1. General

1.1. This procedure is in accordance with ASME Sec V, Article 6 and ASTM E-165, Standard Test
Method for Liquid Penetrant Examination.

1.2. Liquid Penetrant Examination is an effective means for detecting discontinuities, which are open to
the surface of nonporous metals and other materials (including but not limited to wrought/cast
products and welds).

1.3. The extent of examination shall be as per applicable construction-Code requirements / project
specifications and client directives.

1.4. Typical discontinuities detectable by this method are cracks, seams, laps, cold shuts, laminations and
porosity.

1.5. This procedure may be applicable to other Penetrant methods and product forms provided that the
procedure is qualified by demonstration and revised to incorporate the new variables.

2. Reference Documents

2.1 Current Editions of the following documents shall be referred:

2.1.1 ASME Section V, Article 6

2.1.2 ASTM E-165
2.1.2 ASME Section VIII Division 1& 2
2.1.3 ASME Section I Add Edition of the
2.1.4 ASME B31.1 code.
2.1.5 ASME B 31.3
2.1.6 AWS D1.1
2.1.7 API 1104
2.1.6 ASNT SNT TC 1A

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3 Procedure qualification & revision

3.1 This Procedure contains variables, which may need qualification by way of demonstration required
by the referencing Code. Under such situations, any change or deviation to essential variables will
require revision and re-qualification of this Procedure. Such demonstrations shall be on a case-to-
case basis and shall be demonstrated to the Inspector / Client Representative prior to
implementation of this procedure on Test Component and shall be incorporated in the
demonstration record. A change of a requirement identified as a nonessential variable does not
warrant re-qualification of the procedure. However, any change in either essential or non-essential
variables shall require revision or at least an addendum/ supplement to this procedure. Refer to
Table – 3.1 for the list of variables.
TABLE – 3.1
Requirements Essential Non-essential Clause ref.
variable variable
Identification of any change in type or family group of X 7.0
Penetrant materials including developers, emulsifiers etc.
Surface preparation (Finishing and cleaning, including type of X 7.0; 9.0
cleaning solvent)
Method of applying Penetrant X 12.0
Method of removing excess surface Penetrant X 14.0
Hydrophilic or Lipophilic emulsifier concentration and dwell X Nil
time in dip tanks and agitation time for Lipophilic emulsifiers
Hydrophilic emulsifier concentration in spray application X Nil
Method of applying developer X 16.0
Minimum and maximum time periods between steps and X 10.3
drying aids 16.1
Decrease in Penetrant dwell time X 13.0
Increase in developer dwell time (interpretation time) X 16.6
Minimum light intensity X 18.2
Surface temperature outside of 100C to 520C or as previously X 11.0
qualified
Performance demonstration, when required X 4.0
Personnel qualification requirements x 5.0
Materials, shapes or sizes to be examined and the extent of 1.1; 1.3
x
examination
Post examination cleaning technique x 20.0

Tick the box

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4 Performance demonstration
under the supervision of level III
4.1 When required by referencing Code Section, performance demonstration shall be carried out to verify
the ability of the examiner to apply the examination procedure and shall be documented. All
personnel involved in performance demonstration shall be at least Level II in liquid penetrant test
method (refer Para 5.0).
4.2 In case the documentation requirements of personnel qualification and performance demonstration is
not specified by the referencing code sections, the following information shall be recorded as a
minimum:
4.2.1 Name of the organization i. e. WIKA
4.2.2 Examination method applied.
4.2.3 Procedure number or designation.
4.2.4 Number and date of most recent revision.
4.2.5 Date of the demonstration.
4.2.6 Name and/or identity and certification level of the personnel performing demonstration.

5. Personnel Qualification

5.1. All personnel conducting Liquid Penetrant Examination using this procedure shall be Level II
qualified and certified in accordance with the requirements of WIKA written practice as per the
guidelines of ASNT SNT TC-1A latest edition.

5.2. As defined in the Written Practice, a person certified in accordance with the older version of the
written practice shall remain certified until the next scheduled recertification. Recertification shall be
based on Written Practice which refers to current code approved edition of SNT-TC-1A.
Recertification may be based on evidence of continued satisfactory performance or reexamination in
full or part as per the Written Practice.

5.3. Personnel conducting Liquid Penetrant Examination shall have vision, with correction if necessary,
to enable to read Jaeger Type No. 2 Standard Chart at a distance of not less than 300mm, and is
capable of distinguishing and differentiating contrast between colors and shades of gray used. Vision
tests shall be conducted annually and be current during examination.

5.4. Where required by a specific Code, existing Personnel Qualification shall be verified for
applicability as to the Code conditions.
5.5. Personnel conducting Liquid Penetrant Examination should be aware of the safe-practice
requirements during examination. (Refer 23)

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6. NDE Method Technique

6.1. Color Contrast (Visible Dye)/Fluorescent, solvent removable/water washable penetrant System with
non-aqueous Developer.
(All essential variables relevant to this NDE method technique has been included)

7. Test Materials

Test materials as defined in below tables are used during examination:

Table-7.1
NON-FLUORESCENT

Material Brand Manufacturer Group

Penetrant Spot-check SKL-SP-2
Solvent Cleaner Spot-check SKC-S Magnaflux PT 1
Developer Spot-check SKD-S2
Penetrant Checkmor 240
Solvent Cleaner S72 Chemetall PT 2
Developer LD7
Penetrant MR 68 C
Solvent Cleaner MR 85 MRChemie PT 3
Developer MR 70

FLUORESCENT
Table-7.2

Material Brand Manufacturer

Penetrant Zyglo ZL-27A
Solvent Cleaner Spot-check SKC-S Magnaflux
Developer Zyglo ZP-9F

WATER-WASHABLE
Table-7.3
Material Brand Manufacturer Group
Penetrant Spot-check SKL-WP-2
Penetrant remover Water spray Magnaflux PT 1
Developer Spot-check SKD-S2
Penetrant CHEKMOR-200
Penetrant remover Water spray Chemetall PT 2
Developer LD-7
Penetrant MR 68 C
Penetrant remover Water spray MRchemie PT 3
Developer MR 70

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7.1. The Test materials used will be in ready-mix aerosol containers.

7.2. Intermixing of test materials from different Groups is not permitted.
8. QC of Test materials

8.1. Storage of test-materials shall be as per Manufacturer’s recommendation and shall be used within the
shelf life specified.

8.2 Control of Sulpher, Chlorine and Fluorine content: When potential use of materials involves
application on austenitic stainless steels & titanium, the total fluorine & chlorine content of each test-
material shall not exceed 1% by weight. When used on test material, which may also involve nickel-
based alloys, the total sulfur content of each test-material shall not exceed 1% by weight.

8.2 A certification statement from the manufacturer of Penetrant material stating the Penetrant material
batch nos. and test results obtained for the Sulpher and total Chlorine and Fluorine content in
accordance with mandatory appendix II of Article 6 of ASME Sec V 2013 edition shall be made
available whenever required for verification and the records shall be maintained.

9 Test Component Surface Preparation

9.1 In general, satisfactory results may be obtained when the surface of the component is as-rolled, as-
welded, as-cast or as-forged condition. Surface preparation may be necessary by grinding,
machining or other methods where surface irregularities could mask indications.
9.2 Prior to application of Penetrant all areas to be examined and all adjacent areas within in at least 25
mm shall be dry and free from any scale, grease, dirt, weld-flux or slag or spatter, paint, oil or other
foreign matter that might interfere with the penetration.

10 Initial Solvent Cleaning

10.1 When solvent cleaning is required Solvent Cleaner of the specific Group (Refer Section &) shall be
used. After cleaning, drying of the test surface shall be by normal evaporation or with forced hot air
as appropriate.
10.2 The drying time shall be sufficient to assure that the cleaning solution has evaporated prior to
application of Penetrant.
10.3 The Penetrant application shall not start prior to a minimum period of 1 minute elapsing after the
solvent cleaning process is completed. However, Penetrant application shall not be delayed by more
than 10 minutes after completion of the initial cleaning process. For procedure demonstration, a
minimum period of time is required to be satisfactorily demonstrated.

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11 Test temperature

11.1 The temperature of the Penetrant and the surface test component shall remain in the range 10º C –
52º C. Local heating or cooling is permitted provided the part temperature remains in the said
range.
Wherever the material-manufacturers’ recommendation of test temperature range is stringent than
the above, such recommendation shall be followed.
11.2 In case the temperature of the component is out side the range as specified above, the procedure
may be applicable but require re-qualification and revision as described in Para T-653 of Article 6
of ASME Sec V.

12 Application of Penetrant

The Penetrant shall be applied thoroughly and uniformly either by spraying or by brushing on the test
areas.

13 Dwell Time

13.1 The applied Penetrant shall be allowed to enter discontinuities. For the test temperature defined in
(11.1), the minimum penetration (dwell) time shall be as per Table-13.1 below.
Table-13.1
Dwell time
Material Form Type of Discontinuity (minutes)*
Penetrant**
Aluminium, magnesium, Castings and welds Cold shuts, porosity, lack of
5
steel, brass and bronze, fusion, cracks (all forms)
titanium and high- Wrought materials – Laps, cracks (all forms)
temperature alloys extrusions, forgings, 10
plate
Carbide-tipped tools Lack of fusion, porosity,
5
cracks
Ceramic All forms Cracks 5
Glass All forms Cracks 5
Plastic All forms Cracks 5

*: The minimum dwell times given are valid for the temperature range 100C to 520C. The minimum
Penetrant dwell time shall be 2 times of the value given if the test temperature ranges between 50C to
100C.
**: The maximum dwell time shall be limited to 30 minutes only.

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14 Removal of Excess Penetrant

14.1 After the completion of the minimum dwell time, the excess Penetrant on the test component
surface shall be removed by wiping with a clean and dry lint-free cloth or papers, repeating this
operation until most of the traces of Penetrant have been removed from the test surface.

14.2 Final stages of cleaning shall be done by wiping the surface with a clean cloth or paper moistened
with the solvent cleaner and care shall be taken to avoid use of excess solvent to avoid unwanted
removal of Penetrant from fine, shallow discontinuities.

14.3 Flushing the surface with solvent (following the application of Penetrant and prior to developing) is
prohibited.

14.4 For water washable penetrant system, after the completion of the minimum dwell time, the excess
penetrant on the test component surface shall be removed by a water spray. The water pressure shall
not be more than 50psi (350kPa) and the water temperature shall not exceed 430C. Measurement of
actual water pressure is not necessary; pressure range used in a normal tap water may satify the
pressure requirements. The water pipe hose shall not be held at 900 to the surface, which may wash
out the finer indications. It shall be held at 450 or lower angle to the test surface to avoid such wash
out

15 Drying of test Surface

The test surface shall be left drying by normal evaporation. Where normal evaporation will take
considerable time due to weather condition, blotting or forced air may be used.

16 Application of Developer

16.1 Developer shall be applied as soon as possible after the excess Penetrant removal. The maximum
time interval after removal of excess surface Penetrant and application of developer shall not
exceed 10 minutes to ensure that the entrapped Penetrants are not dried inside the flaws and also to
minimize the collection of dust particles on the test surface. The maximum time (10 minutes) has
to be demonstrated during procedure demonstration.

16.2 Before application, the developer shall be kept agitated to prevent settling and ensure uniform
dispersal of the particles in the carrier fluid.

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16.3 The developer shall then be uniformly applied by spraying to form a thin layer on the test surface,
just sufficient to draw the Penetrant retained in any discontinuity reservoir and also to provide a
contrasting background.

16.4 Under conditions when spraying is prohibited due to safety or restricted access, developer shall be
applied by brushing subject to qualification of the procedure by satisfactory demonstration in
presence of AI/ Client representative.

16.5 Drying of solvent suspended developers shall be by normal evaporation. Whenever it is realized
that an excess developer coat (which may mask indications) has been applied, the process of
examination shall be redone (re-examination) from the stages of initial solvent cleaning.

16.6 Developing time for final interpretation begins as soon as the wet developer coating is dry.

17 Forming of Indications

17.1 The developer forms a reasonably uniform white coating and surface discontinuities are indicated
by bleed-out of the Penetrant in deep red color staining the developer.
17.2 Indications with a light pink color may indicate excessive cleaning, while inadequate cleaning
may leave an excessive background making interpretation difficult.

18 Viewing conditions

18.1 The test area shall be adequately illuminated for proper evaluation of indications revealed on the
test surface.

18.2 A minimum light intensity of 100 fc (1000 lux) is required on the surface to be examined to ensure
adequate sensitivity during the examination and evaluation of indications.

18.3 The light-source (day light or artificial), technique used and light level verification shall be
documented one time and maintained on file.

18.4 A hand lamp without a focusing curvature hood, with a 100 watt/ 220 volt incandescent bulb
placed at a distance maximum 250 mm from the surface will fulfil the minimum light intensity
requirement (100 fc/ 1000Lx) on the test surface. For a 60 Watt/ 220volt incandescent bulb
without focusing hood the maximum distance will be 180mm.

18.5 Alternately, a rechargeable focused torch with quartz halogen bulb (Specification 6V 25W) of 25
watt/ 6 volts equipped with 6V 4AH sealed Lead acid battery placed at a distance of 1000mm from
test surface may fulfil the above requirements.

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18.6 The light level verification shall be done by a calibrated Light Meter. The light meter shall be
calibrated at least once in a year or whenever the meter has been repaired. If the light meter is not
in use for a year or more, it shall be recalibrated prior to first use.

18.7 For Fluoresent examination, the test area shall be as dark as possible for proper evaluation of
indications revealed on the test surface. The intensity of ambient visible light in the darkened area
where fluorescent magnetic particles examination is performed should not exceed 2-foot candles
(20 lux).

Black Light intensity at the test surface shall not be less than 1000µW / cm2 the black light must be
capable of developing the required wavelengths of 330 to 390 nm. Wavelengths at or near 365-nm
shall predominate; suitable filters should remove extraneous visible light emitted by the black
light. The backlight shall be allowed to warm-up for a minimum of 5min prior to its use

It is recommended that Inspector be in the darkened area for at least 3 min prior to examining the
part so that his eyes will adapt to dark viewing. Photo chromic or permanently tinted lenses shall
not be worn during examination.

19 Interpretation of indications

19.1 Final interpretation and evaluation of indications shall begin not less than 10 minutes after the
developer coating is dry, however the maximum time permitted for interpretation is limited to 60
minutes. For larger areas, the above functions shall be performed in increments.

19.2 Discontinuities are indicated by bleed-out of the Penetrant in deep red color staining the developer
(indications).

19.3 Relevant indications are those indications resulting from mechanical discontinuities on the surface.
Linear indication is one having a length having greater than three times the width.
Rounded indication is one of circular or elliptical shape with length equal to or less than three
times the width.

19.4 Discontinuities due to localized surface imperfections (such as machining marks, rough weld
profile) or attributable directly to some feature of the assembly or component examined may
produce non-relevant indications.

19.5 Contamination due to improper handling of various test materials or improper cleaning during
testing may produce false indications.
19.6 Any questionable or doubtful indications shall be explored by visual or other means, and if

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necessary, evaluated by a re-examination.

20 Post-examination cleaning

20.1 The post-examination residues of Penetrant or developer will not normally have any deleterious
effect on the test component since the test materials are selected to avoid any such effects
significantly. However, post-examination cleaning may be required when such residues may have
adverse chemical reactions with the test component. Under such conditions, the residues may be
cleaned to the desired extent by solvent cleaning or a coarse water spray.

21 Evaluation for Acceptance Status

21.1 Refer Annexure-1 for acceptance standards.

21.2 Indications those have their major dimension greater than 1/16th inch (1.5mm) shall be considered
as relevant.
21.3 An indication from a discontinuity may show size, which is larger than its actual dimension as seen
on the surface; however the size of the indication shall be the basis for evaluation.
21.4 All relevant (including non-relevant, if necessitated by any referencing document or client
requirement) indications (type of indication – linear or rounded, location, length or diameter or
aligned) shall be recorded as a minimum and interpreted against the relevant acceptance criteria.
Where none specified, all the relevant indications shall be recorded.
21.5 Acceptance criteria used shall be documented in the NDE Report (22.1).
21.6 Broad areas of pigmentation, which could mask indications, are not acceptable and shall be cleaned
and retested in accordance with the method stated in this procedure.

22 Documentation & reporting of results

22.1 For each Liquid Penetrant Examination as per this Procedure, the following information shall be
recorded and suitably addressed in the relevant WIKA Report (Refer Annexure II):

22.1.1 Job Add:

22.1.2 Customer 1.Procedure Identification and revision
22.1.3 Code/Specification 2.liquid penetrant type(visible or
22.1.4 Test Equipments fluorescent)
22.1.5 Item Number 3.type (number or letter designation of
22.1.6 Part/Tag or weld
each penetrant, penetrant remover,
22.1.7 Area tested
emulsifier and developer
22.1.8 Result of Test
4. Map of indication
22.1.9 Comments
5.material and thickness
6.light equipment
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22.1.10 Name & Signature of Level II Inspector

*: These are optional information and may be included in the report or attached in a separate sheet.

23. Safety

23.1. All inspection personnel shall be responsible for compliance with applicable safety rules in the use
of liquid Penetrant materials.

23.2. Penetrant materials are highly volatile, relatively toxic and the liquids may cause skin irritation.
Use adequate ventilation at all times and avoids prolonged skin contact.

23.3. Penetrant materials shall never be heated above the recommended temperature limits prescribed by
the manufacturer.
23.4. Penetrant materials shall never be exposed to open flames.

23.5. Keep aerosol cans containing Penetrant materials out of direct sunlight and storage areas in excess
of the recommended temperature limits specified by manufacturer; an excessive heat may cause
aerosol cans to explode

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ANNEXURE I
Acceptance Criteria

ASME Section IX (QW-195)

Acceptance Criteria (corrosion resistant overlay welds – performance & procedure qualification)
Terminology:

a. Relevant Indications – indications with major dimensions greater than 1.6 mm (1/16 in)
b. Linear Indication – an indication having a length greater than three times the width
c. Rounded Indication – an indication or circular or elliptical shape with the length equal to less than three
times the width
Acceptance Standard:
Indications in excess of the limits specified below are unacceptable:
a. Relevant linear indications
b. Relevant rounded indications greater than 4.8 mm (3/16 in.)
c. Four or more relevant rounded indications in a line separated by 1.6 mm (1/16 in.) or less edge-to-edge.

ASME Section VIII Div 1 Appendix 8 & ASME Section VIII Div 2 Para 7.5.7.2 & ASME Sec XII :
Mandatory Appendix VI:

Terminology:
a. Relevant Indications – indications with major dimensions greater than 1.5 mm (1/16 in)
b. Linear Indication – an indication having a length greater than three times the width
c. Rounded Indication – an indication or circular or elliptical shape with the length equal to less than three
times the width.
Any indication, which is believed to be non-relevant, shall be regarded as an imperfection 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.

Acceptance Standard:
All surfaces to be examined shall be free of:
a. Relevant linear indications
b. Relevant rounded indications greater than 5 mm (3/16 in.)
c. Four or more relevant rounded indications in a line separated by 1.5 mm (1/16 in.) or less edge-to-edge.

Any crack like indication is unacceptable irrespective of surface conditions.

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ASME B 31.1: POWER PIPING

Terminology:

Relevant Indications – Those indications which result from mechanical discontinuities with major
dimensions greater than 2 mm (1/16 in)
Linear Indication – an indication having a length greater than three times the width
Rounded Indication – an indication or circular or elliptical shape with the length equal to less than three
times the width.

Acceptance Standard:

All surfaces to be examined shall be free of:

Any Cracks or linear indications.

Rounded indications with dimensions greater than 5 mm (3/16 in.).
Four or more rounded indications in a line separated by 2 mm (1/16 in.) or less edge-to-edge.
Ten or more rounded indications in any 3870 mm2 (6 sq. in.) of surface with the major dimension of this
area not to exceed 150mm (6 in.) with the area taken in the most unfavorable location relative to the
indications being evaluated.

ASME SECTION I: POWER BOILERS

A-270.3 Evaluation of Indications:

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. Only indications, that have any dimension greater than 1⁄16 in. (1.5
mm), shall be considered relevant.
(a) A linear indication is one having a length greater than three times the width.
(b) A rounded indication is one of circular or elliptical shape with a length equal to or less than three times its width.
(c) Any questionable or doubtful indications shall be reexamined to determine whether or not they are relevant.

A-270.4 Acceptance Standards:

All surfaces to be examined shall be free of:

(a) Relevant linear indications
(b) Relevant rounded indications greater than 3⁄16 in. (5 mm)
(c) Four or more relevant rounded indications in a line separated by 1⁄16 in. (1.5 mm) or less, edge to edge

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ASME B 31.3: PROCESS PIPING

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AWS D1.1: STEEL STRUCTURAL WELDING CODE

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API 1104: WELDING PIPELINES & RELATED FACILITIES

Any relevant indication shall be considered as defect if any of the following conditions exists:-

a) Linear indications are interpreted as star or crater cracks and having length greater 4 mm.
b) Linear indications are evaluated as cracks other crater or star cracks.
c) Linear indications are evaluated as IF and having length that exceeds 25 mm in total length in a continuous
300 mm length of weld or 8% of the weld length.
d) Rounded indications & inclusions open to surface shall be evaluated as per the following criteria ( for pipes
with OD greater than or equal to 60 mm) :-
1. Length of any elongated slag inclusion or group of inclusions shall not exceed 50 mm in any
continuous 300 mm length of weld.
2. The width of any elongated slag inclusion exceeds 1.6 mm.
3. The aggregate length of isolated slag inclusions in any 300 mm length of weld exceeds 13 mm.
4. The width of any isolated slag inclusion exceeds 3 mm.
5. More than four isolated slag inclusions with the maximum width of 3 mm are present in any
continuous 300 mm length of weld.
6. The aggregate length of elongated and isolated inclusions exceeds 8% of the weld length.
7. The size of an individual pore exceeds 3 mm.
8. The size of an individual pore exceeds 25% of the thickness of the thinner of the nominal wall
thickness joined.
9. The diameter of cluster porosity exceeds 13 mm.
10. The aggregate length of cluster porosity in any 300 mm length exceeds 13 mm.
11. An individual pore in a cluster exceeds 2 mm in size.
12. The length of an elongated inclusion exceeds three times the thickness of thinner of the nominal wall
thickness joined. (for pipes with OD less than 60 mm)
13. The width of an elongated inclusion exceeds 1.6 mm (for pipes with OD less than 60 mm).
14. The aggregate length of isolated inclusions exceeds two times the thickness of the thinner the metal
joined and width exceeds one half of the thickness of the thinner of the nominal wall thickness
joined.The aggregate length elongated and isolated inclusions exceed 8% of the weld length

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ANNEXURE II – SAMPLE REPORT FORMAT

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