Liquid Penetrant Testing LEVEL - II Training Course Prepared by Dr. Samir Saad General Manager Cutech Arabia LLCa About the Author Experience: 17 Years (Oil and Gas) Skills & Expertise + Welding and Welding Inspection Non-Destructive Testing Material Technology In Service & On-stream Inspection Corrosion and Management Asset Integrity Management DrSamir Saad Education Certification MSS. and Ph.D. dagrees in Welding Engineering Technology. Bachelor of Mechanical Engineering. Professional Certification ‘ASME Authorized Inspector (Al), Bol and Pressure, Vessel [ASNT NDT LEVEL Min 11 methods, ASNT 10: 190002 41. Visual and Optical Testing (VT), "7, Magnetic fx leskage Testing (ML), 2. Radiographic Testing. (EN, 8 inferred thermal testing (IR), 3. Utresonic Testing (UT). 8. Leak Testing (LD, 4. Liquid Ponotrant esting (PT), 10. Azouste Emission Testing (AE) 5. Magnetic Testing (MM), 11. Neutron Radiography (NA) 6. Electromagnetic Tesing (EM), AWIS-CWEng, -Cortiied Welding Engineer, ID NO. 17010086. AWS-CWE - Certied Welling Educator, ID NO, 1902001. ‘ANS-CWMI - Certied Welding Inspector, 1D NO. 19021321. ‘ANS-CWS ~ Certied Welding Superasor, ID NO. 20030008, [AS-CWSR - Cortiiod Welding Sales Representative, ID NO. 2003000R {CSWIP 3.22 - Senior Welting Inspector Personal, ID NO.74305, [BGAS-CEWIP-Painting Inspocior Grade 2-8GAS, 10:529730 ‘API 610- Pressure Vessel Inspector ID NO_ 38376, ‘APL 870- Process Piping Inspector ID NO. 38328 [API @83- aboveground storage tank inspector ID NO. 26171 [API RP 880 -Risk-Basod Inspection professional ID NO. 82784 ‘APLRP 6T1- Corrosion and Materials Profesional ID NO. 56350 ‘API 896 - Rofractory Personnel, ID NO. 9478 [API S77 = Welding Inspection and Metallurgy, 10 NO, 94785 [API SIFE-Source Inspector:Finad Equipment, ID.NO. 95780 Lead auditor according to 180 9001:2018 from IRCChapter-1 Qualification and Certification we Requirements = / Dr Samir Saad3XThe following documents outline personnel qualification and certification requirements: 1. ASNT Recommended Practice No. SNT-TC-1A. 2. ANSI/ASNT CP-189: Standard for Qualification and Certification of Nondestructive Personnel. 3. ACCP: ASNT Central Certification Program. 4. NAS 410, National Aerospace Standard Certification and Qualification of Nondestructive Testing Personnel.i Training and Qualification Process: Certification of NDT personnel is the responsibility of the employer ‘A person who is in the process of training and qualification is considered a trainee. Three Basic Levels of Qualification LEVEL | —is qualified to perform specific calibrations, specific tests, and specific evaluations. The NDT Level I should receive the necessary instruction and supervision from a certified NDT Level 1! or Ii individual. LEVEL I — is qualified to set up and calibrate equipment and to interpret and evaluate results with respect to codes, standards and specifications. LEVEL Ill — must be capable and responsible for establishing techniques, interpreting codes, and designating the test method and technique to be used. The NDT Level Ill, in the methods in which certified, should be capable of training and examining NDT Level | and Il personnel for certification in those methods.it Qualification Requirements: 1. Organized training (required class hours). |. Required testing (general, specific, practical). . Education (depends on written practice). . Experience (documented hours). . Physical attributes to perform examinations (vision acuity and color contrast test performed annually). Xf Certification “Certification is a written testimony that an individual has met all the qualifications of a company’s written practice.Chapter.2 Introduction to Liquid PenetrantTesting — — ? & Dr-Samir Saad1Nisual Testing(VT) 1.Radiography Testing(RT) 2.Magnetic Particle Testing (MT) 2.Ultrasonic Testing(UT) ( surface and near surface , applied on only ferromagnetic material) 3. Penetrant Testing (PT) (any defects open to surface) 4, Eddy Current (ET) ( surface and near surface)xt Nondestructive testing methods are used for the following reasons: . To ensure product integrity and reliability. . To avoid test object failure, prevent accidents and save lives. . To make user profits. To ensure customer satisfaction, . To aid in better product design. To lower manufacturers’ costs. . To maintain uniform quality levels. 1 2. 3, 4. 5. 6. 7. 8. . To ensure operations readiness.3 Liquid penetrant testing is one of the oldest methods of nondestructive testing. XE The origin of liquid penetrant testing is generally attributed to the inspection of wheel axles in the railroad industry inthe 1890s XE The oil-and-whiting test involves 1) immersing test objects in oil and then wiping with rags dampened with kerosene. 2) Powdered chalk was used to dust the surface to increase the visibility of any oil leaking back onto the test object surface.Xf Some advantages of liquid penetrant testing include the following: Liquid penetrant testing quickly examines all accessibleSurfaces. Liquid penetrant testing detects very small surfacediscontinuities. It can be used on a wide variety of materials including ferrous and nonferrous metals and alloys and fired ceramics. It uses relatively inexpensive and nonsophisticated equipment, Sensitivity magnifies size and location of discontinuities. Sensitivity can be adjusted by selection of penetrant, removal technique and type of developer. Technicians can visually detect indications, Liquid penetrant testing can be used for in-service checks to resolve production problems earlyXE Penetrant Testing (PT), is a nondestructive testing method that builds on the principle of Visual Inspection. XE PT increases the “seeability” of small discontinuities that the human eye might not be able to detect alone. 3X Penetrant examination is a sensitive method of detecting and locating discontinuities, provided the discontinuities are clear and open to the surface. XE Applicable to all non-porous, hon-absorbing materials. 4 However, liquid penetrant testing can only be used to inspect for flaws that break the surface of the sample (such as surface cracks, porosity, laps, seams, lack of fusion, etc.).X£Types of Discontinuities can be detected Via PT + All defects that are open to the surface. > Rolled products-- cracks, seams) laminations. > Castings--cold shuts, hot tears, porosity, blow holes, shrinkage. > Forgings— cracks, laps; external bursts. > Welds-— cracks, porosity, undercut, overlap, lack of fusion, lack of penetration.{what Can NOT be Inspected Via PT? * Components with rough surfaces, such as sand castings, that trap and hold penetrant. Porous ceramics Wood and other fibrous materials. Plastic parts that absorb.or react with the penetrant materials. Components with coatings that prevent penetrants from entering defects.xt Step 1: Pre-Cleaning > Surface is cleaned to remove all contaminants to the extent that the interior of the discontinuities are clean and dry. Surface to be cleaned using appropriate cleaning methods such that dirt, oil, grease, scale, rust, paint etc are completely removed. > The flaw openings mustbé clean to allow entry of penetrant. Part surface cleaned, > Following cleaning, the part shall be completely dried.St Step 2 : Apply penetrant > Penetrant maybe applied by, spraying, dipping, flooding, brushing. > For penetrant application the part temperature must be within 10 to 52°C. Penetrant must be applied to clean dry surface. The entire area to be tested must be covered with a thin layer of penetrant. Penetrant must not dry during the entire test cycle. the penetrant must left on the components surface for approximately 5 to 30 minutes (dwell time). The penetrant enters any defects that may be present by capillary action. Perevant apie on sutceit Step 3 : Remove Excess penetrant > To detect entrapped penetrant, excess penetrant on the surface is removed. Care must be taken not to remove entrapped penetrant from the discontinuities. Depending on the type of penetrant, excess surfate penetrant is removed by one of the following methods, a) Water washable: Rinsing with coarse water spray. b) Hydrophilic: Emulsifying the penetrant (prerinse ) and rinsing with water spray. Cc) _Lipophilic: Rinsing with emulsifier solution. d) Solvent removable: Manually wiping the surface with solvent dampened cloth. Solvent dempened cloth = a cess penetant removed Adeveloper, uniform coating of fine white powder, is used for blotting the penetrant out of the discontinuities. > Developer also provides a contrasting background for the indication. Penetrant bleeds and spreads into developer and the indication become easily detectable. > The indication may enlarge with time Lo] Dene pled, Iicatin apes<< Capillary Action > The rise of colored water along a capillary . Notice the concavity of the meniscus Liquid enters narrow openings due to capillary action. Liquid rises through the cavity of a fine bore tube against the gravity. This is known.as capillary action. The finer the bore, the more is the capillary force. Tye pers Liquid enters narrow discontinuities because of capillary forces. A plant takes in water through capillary action. Agood penetrant must easily spread on the test surface and enter tight discontinuity openings. > High surface tension and low contact angle allow liquids to spread on the surface easily (good wetting ability). > Liquids having a contact angle of 902 or less will act as penetrants. > Contact angle is strongly affected by surface cleanliness. > Liquid penetrants are formulated to have high surface tension, low contact angle and low viscosity. > Higher viscosity reduces the speed of penetration contact angle adhesiveness wettability solid surface free energyXt contact Angle | low Contact angle High Contact angle XLSurface Tension | | High Surface Tension Low Surface Tension*t Contact Angle > The height to which the liquid rises is directly proportional to the surface tension of liquid & to. the cosine of the angle contact and it is inversely proportional to density of the liquid & the radius of the capillary tube. the surface tension Strongly affected by conta! ion The viscosity of the liquid is not a factor in the basic equation of capillary rise. 9>90°,h <0 0<90°,h>0 2ycos@ hae 2h par In the formula shown at the left (which you need not memorize!) ‘h= elevation of the liquid (m) = surface tension (N/m) 6 = contact angle (radians) p= density of liquid (kg/m) g = acceleration of gravity (m/s) (r= radius of tube (m)Contact Angle > Fig. c: if the contact angle between the liquid & the wall of the capillary tube is less than 90° “the liquid is said to wet the surface, or to have good wetting ability”, the liquid meniscus in the tube is concave, and the liquid rises in the tub > Fig. b: If © = 90°, there is no capillary depression or rise. > Fig. a: If 0> 90°, the liquid depressed in the tube and doesn’t wet the tube wall and the meniscus is. Canvaan Capillary Tubes i r WMD My, © Greater than 90° Results In Depression (Very Poor Wetting), Rise nor Depression (Poor Wetting)<< Viscosity va > Viscosity is a measure of liquid's resistance to a charge in physical shape. Viscosity varies widely with temperature, decreasing when temperatures are raised & increase when temperatures are lowered. Viscosity has a strong effect on the time taken for capillary| action to work High viscosity penetrants cling to the part surface and require increased effort in removal, which increases dragout cases and dwell time. Viscometer tube, is used to measure viscosity Unit of viscosity, area / time, mm?/sec, m?/sec. (Or "centistokes", ¥- "9 centistokes = 5 mm/sec" Viscosity T + T dwell time. Viscosity of penetrant is ¥- Smm#/Sec at room temp. ¥_3mm*fsec at 38°C. Very thin (low viscosity) penetrants may drain from the part so quickly that insufficient penetrant remains on the part surface to fill any discontinuities. (202 Dr.Samir Saada Chapter 3» Penetrant Materials » a & Dr.Samir Saad<% Penetrants are formulated to possess a number of important characteristics. To perform well, a penetrant must:. . Spread easily over the surface being inspected. . Be drawn into surface breaking defects by capillary action or other mechanisms. . Remain in the defect but remove easily from the surface of the part. . Remain fluid through the drying and developing steps so it can be drawn back to the surface. 5. Be highly visible or fluoresce brightly to produce easy to see indications. 6. Not be harmful to the inspector or to the material being tested.Type Penetrant dye Type | Fluorescent penetrant ‘Type it Visible penetrant (color contrast). ‘Type ill Dual mode (visible/ fluorescent). Method Of removal Method A ‘Water- washable Method B postemulsifiable ipophilic” Method ¢ Sensitivity For type lonly ‘Level ¥/, ultra low ‘Level 1 Low ‘Level 2 “Medium ‘Level High Solventremovable Level 4 Method D postemulsifiable “Hydrophilic” Ultra high Developer, FormA: Dry powder. FormB: Water soluble, Form: Water suspendible. Form: NonaqueousType | (fluorescent). Form E: Nonaqueous Type tl (visible dye). Form F: ‘Special applications Solvent Removers ‘Class (1) Halogenated (nonflammable) Class (2) Nonhalogenated (flammable) ‘Class (3) Special ApplicationXtThere are three basic classification types by dye. a) Type I: Fluorescent penetrant. > Fluorescent penetrants provide a greenish yellow indication against a dark background when viewed in a darkened area under a black (ultraviolet) light source. > Fluorescent penetrant is more sensitive than Visible penetrant (color contrast) because the eye is more sensitive to a bright indication on a dark background. } Sensitivity For type! is Level 1/2: Ultra low , Level 1: Low, Level 2: Medium, Level 3: High and Level 4: Ultra high.Xithere are three basic classification types by dye. 2) Type II: Visible penetrant (color contrast). > Visible penetrant is usually red in color to provide a contrast against the white developer background. Normal white light is usually sufficient to view the discontinuiti > There is no sensitivity level classification for Type II penetrant systems. 2) Type Ill: Dual mode (visible/ fluorescent). > Combination of fluorescent and color dye. > Examined under ultra violet as well as ordinary light. Used for special applications.( Availability of Liquid Penstrant._) Bleed out viewed under a UV-A light | Bleed out viewed “under white light ied Fluorescent penetrant. pi i a ‘olor contrast Penetrant<% Penetrants are also classified by the method of removing the excess penetrant. 1) Method A: Water- washable > Highly penetrating, oily liquids containing a built in emulsifying agent (as self-emulsifying systems) that renders the oily media washable with water. The simplest to use are visible penetrants or color contrast penetrants, because no fluorescent lighting is required, Greater visibility is obtained if fluorescent penetrants are used and viewed under ultraviolet radiation. penetrants are removed with a course spray of water. They are the easiest to employ and most cost effective when inspecting large areas.Penetrants are also classified by the method of removing the excess penetrant. 1) Method A: Water- washable > Advantages 1. Easily washed with water Good for quantities of small specimens (batch testing) Good on rough surfaces Good on keyways and threads Good on wide range of discontinuities Fast, single step process Relatively inexpensive Available in oxygen compatible form > Disadvantages os Not reliable for detecting scratches and similar shallow surface discontinuities Not reliable on reruns of specimens . Not reliable on anodized surfaces Acids and chromates affect sensitivity Easily over-washed . Penetrant subject to water contaminationxt Penetrants are also classified by the method of removing the excess penetrant. Q) Method B & D : Postemulsifiable > Postemulsification penetrants are available as either visible or fluorescent penetrants. When applied to a post-emulsification penetrant, emulsifiers combine with the penetrant to make the resultant mixture water washable. The emulsifier, usually dyed orange to contrast with the penetrant, may be either lipophilic (oil base) or hydrophilic (detergent water base). Typical Emulsifier Dip Tanktt Penetrants are also classified by the method of removing the excess penetrant. 2) Method B : Postemulsifiable "Lipophilic” Method B is lipophilic (oil loving). Used to emulsify the excess oily penetrant on the surface of the part, rendering it water washable. Application is done by dipping immersion . Agitation of the test object is prohibited. Brush-on or spray-on is not permitted. The mechanism of lipophilic is by diffusion. Emulsification time is critical and must be carefully controlled for reproducible results.tt Penetrants are also classified by the method of removing the excess penetrant. 2) Method B : Postemulsifiable "Lipophilic” Method B is lipophilic (oil loving). Used to emulsify the excess oily penetrant on the surface of the part, rendering it water washable. Application is done by dipping immersion . Agitation of the test object is prohibited. Brush-on or spray-on is not permitted. The mechanism of lipophilic is by diffusion. Emulsification time is critical and must be carefully controlled for reproducible results.4,¢ Penetrants are also classified by the method of removing the excess penetrant. 3) Method D : Postemulsifiable "Hydrophilic” Method D is hydrophilic (water loving). Works through detergent or surfactant reaction. Prewashing (prerinse) removes. 60 to 80% of the surface layer of penetrant. Following the prerinse, hydrophilic emulsifier or remover is applied by immersion or spray. Concentration by immersion is usually 5 to 30% by volume. Concentration of spray removers is usually 0.5 to 1% by volume; up to 5% may be used. The mechanism of spray hydrophilic emulsifier is a combination of chemical and mechanical action.{tPenetrants are also classified by the method of removing the excess penetrant. 3) Method D : Postemulsifiable "Hydrophilic” Slight agitation is necessary to remove the colloidal suspension of penetrant and emulsifier from the surface and to expose fresh penetrant. Agitation is done by gently moving the submerged test object in the remover, or by an air manifold in the bottom of the tank. Only enough air to cause slight bubbling is required. Immediately following the remover, a fresh water rinse of the entire test object is required. This stops the action of any remaining remover on the test object.‘Penetrants are also classified by the method of removing the excess penetrant. OU Method B & D : Postemulsifiable > Advantages > Disadvantages . High sensitivity for very fine 1. Two step process discontinuities 2. Equipment required for emulsifier . Good on wide shallow discontinuities application . Easily washed with water after 3. Difficult to remove penetrant from emulsification threads, keyways, blind holes and rough Short penetration time surfaces Cannot be easily over washedxt Penetrants are also classified by the method of removing the excess penetrant. 4) Method C: Solvent removable > solvent dampened cloth penetrants are removed by wiping with'a cloth ~~~ a a dampened with solvent. They are supplied in aerosol cans for portability and are primarily used for spot checks. Available in Type | and If materials. Aerosol cans do not require daily calibration or contamination checks. Weldment on a construction job site is usually inspected with a visible penetrants using a solvent removable method.XtPenetrants are also classified by the method of removing the excess penetrant. 4) Method C: Solvent removable > Advantages > Disadvantages 1. Portability 1. Flammable materials 2. No water required 2. Removal of excess surface penetrant 3. Good on anodized specimens is time consuming Materials cannot be used in open tanks 3. Difficult to use on rough surfaces such as cast magnesium 4. Good for spot checking 5. Specimens can be rerunxt Developer > Development of penetrant indications is the process of bringing the penetrant out of discontinuities open to the surface through blotting’action of the applied developer. > This increases the visibility of the indications under suitable visible white light or fluorescent light. 3 Developer materials are available in several different forms 1) Form A: Dry Powder Fluffy powder that is applied to dry test surfaces. Most adaptable to rough surfaces and automatic processing. i > > Easiest to remove. > Care should be taken not to contaminate developer with fluorescent penetrant. > Penetrant contamination may cause specks that appear as indications.X Advantages > Disadvantages 1. Easy to handle 1. Difficult to see if properly 2. No hazardous vapours applied 3. Easy to remove . Fine powders can be hazardous . Does not offer the best degree of colour contrastXfDeveloper materials are available in several different forms 2) Form D : Nonaqueous Wet Developer.(Type | & Type Il) > Suspension of developer particles in a rapid drying solvent. > Used with solvent removable processing. > Applied only to dry surfaces. > This type of developer is intended for application by spray only. > It is too costly and difficult to apply to large areas.XfDeveloper materials are available in several different forms 2) Form D : Nonaqueous Wet Developer (Type | & Type I!) > Advantages > Disadvantages 1. Most sensitive 1. Hazardous solvents 2. Usable with fluorescent 2. Higher cost or colour contrast 3. Need to be correctly appliedX Applied before drying the test object. >The aqueous wet developer is suitable for high temperature examination A. Form C: Water suspendible developer: = Particles are held in suspension in water and require continuous agitation to keep the particles in suspension. B. Form B: Water soluble developer: Powder is dissolved in water, forming a solution; once mixed they remain mixed. Indications sometimes lack definition and look milky. Not recommended for use with water-washable penetrants.XfDeveloper materials are available in several different forms 3) Form C & B: Aqueous “Water-Based” Developers > Advantages > Disadvantages 1. No vapours or dust 1. Difficult to apply evenly 2. Cheaper than non- 2. Requires drying after application aqueousxt Developer materials are available in several different forms 1) Dry immersion (D.P). Least sensitive 2) Dry dust cloud (air agitation) 3) Dry fluidized bed. 1) Dry dust cloud (electrostatic) Increasing sensitive 2) Aqueous wet (immersion) 3) Water globule (immersion) 1) Aqueous wet (spray) 2) Water soluble (spray) 3) Plastic film (spray) 4) Non-Aqueous wet (solvent spray) Most sensitivex Developer materials are available in several different forms . The type of developer affects liquid penetrant system sensitivity. Nonaqueous wet developers are the most sensitive, followed by aqueous developer, dry developer and no developer, in that order. . Dry powder (solvent spry) sensitivity is slight lower than water soluble for smooth test object, but is it more sensitive for rough test (costing) objects or threads. . Dry developer and water soluble developers are not recommended for use with visible penetrant. . The use of Non-aqueous (solvent developer) is recommended with water-washable penetrant.Xt Special Purpose Penetrants 1. There are low sulfur and low chlorine materials for testing nickel alloys, certain stainless steels and titanium. High and low temperature penetrants are available for special applications. |. Low-energy emulsifiers and inhibited solvent removers are available to slow emulsification and the removal of excess penetrant. xt Precautions 1. Ensure that the test object is not damaged or overheated during the test. 2. The technician must ensure that solvent won’t harm the test object. 3. Review the MSDS frequently.aor Chapter 4 Liquid Penetrant Processing a & Dr-Samir Saad{Procedures and Techniques: 1. Procedures can be broad and cover several specific techniques. 2. Each procedure and technique should be approved and signed by a certified Level Ill.St Visible dye penetrant (color contrast) ™ usually requires 1000 lux (100 ftc) at the test surface. ™ These levels should always be verified against the governing procedure, standard or specification. 5o3 Fluorescent dye penetrant ™ Fluorescent evaluation station should be about 1000 pp W/cm2 of near ultraviolet radiation (UV-A) as measured at the test surface, and = the ambient (white) light should not be greater than 20 lux (2 ftc). Dr.Samir SaadAdequate Illumination Xt Adequate Illumination: Ambient Light Meters Illumination meters for the measurement of ambient (white) light in foot-candles or lux. Dr.Samir SaadTypical ultraviolet radiation meter used for fluorescent processes. measurement of (black /UV) light p , Dr.Samir SaadXtall cleaning methods must meet the following requirements: 1. Local environmental requirements. . Health and safety requirements. . Cause no harm to the test object. . Substrate should be wiped clean with an approved solvent cleaner. . Solvent cleaner should be allowed to dry completely before application of penetrantX<£Preparation of Test Objects: 1. The surface properties of the test object determine surface preparation. 2. High nickel alloys, titaniums and stainless steels require the use of low sulfur and chloride products. 3. Surfaces need to be free of foreign materials which block open discontinuities. 4. Cleaning operations such as power wire brushing, grit blasting, shot peening and other metal smearing operations should be avoided.XtPrecleaning and Postcleaning: 1. Liquid penetrant test will be ineffective if substrate is not physically and chemically cleaned and dried. . Liquid penetrant residue may have a harmful effect on test object if not properly removed before placing it in service. (Chlorine and sulfur may affect some alloys.) . The compatibility of cleaning agents and penetrant materials should be verified to ensure an acceptable penetrant testX£Cleaning processes include the following: A. Solvent. . Detergents. . Vapor degreasing. . Steam cleaning. . Ultrasonics. . Paint strippers . EtchingXt Cleaning processes include the following: Solvent Cleaning. . The application of solvent cleaning may be immersion, sprayed, brushed or wiped. . Solvent cleaning is commonly used for spot inspections. . Solvent cleaners must evaporate readily and completely from the substrate. . Solvent cleaners should be used to remove organic contaminants only. . Test object being cleaned with a solvent- damped, lint-free cloth prior to application of penetrant.Precleaning and Postcleaning of Test Objects } = xk Cleaning processes include the following: | A. Solvent Cleaning Light deposits of oil and grease on the part can be removed by solvent cleaner supplied with the spraying kit. damped, lint-free cloth prior to application of penetrant.{ Precleaning and Posteleaning of Test Objects J xk Cleaning processes include the following: A. Solvent Cl Solvent spray cleaning Solvent spray cleaning Solventdip cleaning: Remover cleans oily deposits( Precleaning and Posteleaning of Test Objects J tk Cleaning processes include the following: A. Solvent Cl Alarge number of small parts can be cleaned together for penetrant examiXt Cleaning processes include the following: B. Detergent Cleaning. > Cleaning is accomplished by the use of immersion tanks and or detergent solutions. > Immersion tanks and detergent solutions are common means of assuring that a specimen surface is both physically and chemically clean > Cleaning is accomplished as follows: 1. Detergents wet the substrate. . Penetrates various soils. Emulsification. Saponification (change to soap). Substrate is rinsed and driedX£Cleaning processes include the following: B. Detergent Cleaning. > Detergent Cleaning Equipment: Suitable rinsing stations. Suitable drying stations. Thorough rinsingand drying after detergent cleaning will leave the substrate physically and chémically clean for liquid penetranttesting.Xt Cleaning processes include the following: C. Vapor Degreasing. > Vapor degreasing is effective for the following procedures: 1 Removal of oils. Removal of greases. Removal of other similar organic contaminations. Vapor degreasing doés not-require a rinse or drying (oven) step. Vapor degreasing can be hazardous to the environment. Vapor degreasing safety is a large concern due to health hazards. Vapor degreasing is limited to cleaning of substrates that have been approved for this type of cleaning method.<£Cleaning processes include the following: D. Steam Cleaning. > Precleaning with steam and alkaline detergents provide ideal cleaning. . Alkaline detergent emulsifies, softens or dissolves organic contamination. . Steam provides mechanical action for removal of detergents/contaminations from the surface of the substrate. . Steam cleaning is suitable for cleaning large, unwieldy components which are not easily submerged.X<£cleaning processes include the following: E. Ultrasonic Cleaning. > Ultrasonic cleaning is often combined with detergent or alkaline cleaning. > Combined ultrasonic cleaning improves efficiency and reduces cleaning time. > Ultrasonic cleaning is useful for cleaning large quantities of small test objects. > Ultrasonic agitation requires special approval on some substrates.( Precleaning and Postcleaning of Test Objects ) 5o% Cleaning processes include the following: E. Ultrasonic Cleaning. Ultrasonic agitation produces microscopie bubbles which explodes Parts cleaned by and displaces surrounding material. It ultrasonic method may take 30 to 60 minutes for complete An Ultrasonic cleaning unit with power supply.X Approved commercial scale, rust, oxides and corrosion removers include the following. 1. Acid rust removers. 2. Alkaline rust removers. > These require special equipment, and specific procedures should be followed.X Paint removal methods include the following. 1. solvent type paint removers 2. alkaline type paint removers > These require special equipment, and specific procedures should be followed.Removing paint with solvent wipe. Removing paint with solvent.<£Cleaning processes include the following: H. Etching. 1. Some machining, surface finishing and cleaning operations can cause a thin layer of metal to smear on the surface’and prevent penetrant from entering any flaws that may be present 2. Acid or alkaline solutions are used to remove smeared metal from operations, including the following: a. Power wire brushing. b. Sand blasting. 3. Solutions open'up grinding burrs and remove smeared metals. 4. Etching and neutralization processes use either tanks/immersion or manual equipment.H. Etching. OTE) ease)<£Precleaning Processes to be Avoided: > The following methods should not.be used before liquid penetrant tests. . Blasting (shot, sand, grit, pressure, etc.). . Liquid honing. . Emery cloth. . Power wire brushes. > These processes tend to close discontinuities by smearing metal, peening or cold working the surface.Application of Penstrant ] = +X Penetrant applications include the following: 1, . Usually using a low pressure circulation pump or from pressurized spray cans "Usually applied with rags, cotton waste, or brushes. = The penetrant is simply poured over the surface i = The entire part is dipped into a tank of penetrant.XY Before penetrant application part surface must be thoroughly cleaned and dried. XE The penetrant must cover the examination area in a thin consistent layer. XE Penetrant may be applied by dipping, spraying, flooding or brushing. eO2 Application by rubbing with apenetrant soaked cloth is not permitted. xt Test surfaces should remain wetted the entire penetrant dwell time. xt Ultraviolet radiation sources may assist when using fluorescents.Application of Penstrant Color Contrast =. Application of penetrant also * technicians should review procedures t= Test object held in suspension while required dwell time elapses for fluorescent process.<{Penetrant dwell time > Penetrant dwell time is a period of time to.allow penetrant to enter and fill any discontinuities open to the surface through capillary action. Tight crack line discontinuities may require in excess of 30 minutes for penetration that will give an adequate indication. However, gross discontinuities may be suitably penetrated in 3 to 5 minutes. The temperature of the specimen and temperature of the penetrant can affect the required dwell time. care should be taken not to overheat the specimen since too much heat may cause evaporation of the penetrant from the discontinuity.3% Penetrant dwell time Dwell times are based on the assumption that the penetrant will remain wet on the part surface. Additional penetrant may be applied during dwell time. The penetrant manufacturer will provide suggested dwell times for the various penetrants that it produces. xt Development time or Developer dwell time. Liquid penetrant is drawn out of discontinuity entrapments to the test object surface during the so-called development time or developer dwell time. Liquid penetrant may spread into the developer coating to form enhanced indications. This is sometimes referred to as reverse capillary action.Xf itis important for the test to use sufficient penetration and developing time. 34£ Recommended penetration and developing times Aluminium Steel Magnesium Brass and bronze Titanium and high-temperature,X 1. Dipping/ immersing a test object in the solution. 2. Spraying the solution onto the test Object. This/iiy. type of aqueous developer forms a translucent film. 3. The part is then dried in a hot air circulating oven. 4. Water soluble developer can be used for fluorescent dyes. 5. Not recommended for use with visible dye.

Prior to spraying of developer, the following procedures should be followed: & 2; Aerosol can requires agitation before spraying. The test object must be thoroughly dry. Several thin, uniform coats are preferred over one heavy coat. Acheck spray should be performed before spraying the test surface to prevent spattering of the developer.Xf Development/Dwell Time . The development of indications does not begin until the moisture is completely evaporated from the developer. . The test object must be monitored very closely during the developer dwell time to properly evaluate the indications as they form. . Typically, the developer dwell time is a minimum of 10 min. Always reference the specifications. .. The point at which the developer dwell time begins depends on the type of developer being used. Wet developer dwell time begins as soon as the developer is dry. Dry and nonaqueous developer dwell times begin at application.xt Interpretation: = The determination of whether indications are relevant or nonrelevant. xt Evaluation: = Areview, following interpretation of the indications noted, to determine whether they meet specified acceptance criteria. Xt Types of Indications = Indications form on the surface of test objects during examinations because of discontinuities located on the surfaces. They may be classified as the following: 1, False indications, 2. Nonrelevant indications 3. Relevant indications.xt False indications 1. A nondestructive testing indication that is interpreted to be caused by a discontinuity at a location where no discontinuity exists. 2. False indications are nonrelevant. 3. In some reference documents, false indications and nonrelevant indications are considered to be the same thing, 4. False indications are caused by the following reasons: A. Lack of cleanliness by poor processing conditions. B. Lack of cleanliness in the testing booth or other aspects of the penetrant process. C. Penetrant on the hands of technicians. D. Contamination of wet or dry developer.itFalse indications 4. False indications are caused by the following reasons: E. Penetrant from other test objects. F. Penetrant on examination table. G. Fluorescent specks or particles. 5. Cleaning and reprocessing atest object is required when false indications are noted. 6. A typical false indication is a piece of lint on a part that resembles a crack during ultraviolet radiation testing.itFalse indications 4. False indications are caused by the following reasons: E. Penetrant from other test objects. F. Penetrant on examination table. G. Fluorescent specks or particles. 5. Cleaning and reprocessing atest object is required when false indications are noted. 6. The most serious problem with false indications is determining whether the indication is masking a relevant indication.XtFalse indications 7. Sources of False indications : A B. fe D. E “ram Tool marks. Finger prints. Penetrant patches at the table or at the fingers of the operator. Lint or dirt particles on surface. Scales on surface. . Oily residue on surface when fluorescent is performed. All surfaces to be examined shall be free of: a) relevant linear indications; Only indications which have any dimension greater than 1/16 in. (1.5 mm) shall be considered relevant. 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.xt Postcleaning can involve the following: 1. Vapor degreasing. 2.Solvent soak. 3.Ultrasonic cleaning. 4. Other postcleaning operations may be required by specifications and procedures.ASME:V ARTICLE 1 GENERAL;REQUIREMENTS. yw & Dr-Samir SaadXf T-110 Scope ‘This Section of the Code contains requirements and methods for nondestructive examination (NDE), which are Code requirements to the extent they are specifically referenced and required by other Code Sections or referencing document. ‘These NDE methods are intended to detect surface and internal imperfections in materials, welds, fabricated parts, and components. 2 7-120 General qualification of NDE personnel, the qualification shall be in accordance with their employer's written practice which shall be in accordance with one of the following document (1) SNT-T-1A,3 Personnel Qualification and Certification in Nondestructive Testing; or (2) ANSI/ASNT cP-189,3 ASNT Standard for Qualification Xf T-130 Equipment “It isthe responsibility of the Code User (Manufacturer, fabricator, or installer) to ensure that the examination a@auipment being used conforms to the requirementsafithis Code Section. 1Xf T- 150 Procedure When required by the referencing Code Section, all nondestiuctive examinations performed under this Code Section shall be done to a writtenprocedure. This procedure shall be demonstrated to the satisfaction of the Inspector. The procedure or method shall comply with the applicable requirements of this Section for the particular examination method. Where so required, written procedures shall be made available to the Inspector on request. At least one copy of each procedure shall be readily available to the Manufacturer’s Nondestructive Examination Personnel for their reference and use. XE T-160 Calibration (a) The Manufacturer, fabricator, or installer shall assure that all equipment calibrations required are performed.Xf T-160 Calibration {b) When special procedures are developed [seeT-150(a}], the Code User shall specify what calibration is necessary, when calibrationis required. Xf 1-170 Examinations and inspections 4 the word Inspector means the Authorized Inspector who has been qualified as required in the various referencing Code Sections. 4 The term inspection applies to the functions performed by the Authorized Inspector, but the term examination applies to those quality control functions performed by personnel employed by the Manufacturer. 3X T-180 Evaluation ‘% The acceptance standards for these methods shall be as stated in the referencing Code Section. Xf T-190 Records/Documentation ‘% Records/Documentation shall be in accordance with the referencing Code Section and the applicable <“* Fequirements of this Section. ‘Desamir SaadQ-01: Scope [T-110] What is the intent of the NDE methods specified in ASME V? a) intended to detect surface and internal defects in materials, welds, fabricated parts, and components b) intended to detect surface and internal imperfections in materials, welds, fabricated parts, and components c) intended to examine all flaws and defects in materials, welds, fabricated parts, and components d) intended to examine surface and internal bodies in materials, welds, fabricated parts, and componentsQ-01: Scope [T-110] What is the intent of the NDE methods specified in ASME V? a) intended to detect surface and internal defects in materials, welds, fabricated parts, and components b) intended to detect surface and internal imperfections in materials, welds, fabricated parts, and components c) intended to examine all flaws and defects in materials, welds, fabricated parts, and components d) intended to examine surface and internal bodies in materials, welds, fabricated parts, and componentsQ-02: Procedure [T-150] When NDE requirements of ASME Section V are required, who shall be responsible to establish nondestructive examination procedures? a) manufacturer b) fabricator c) installer d) all of the aboveQ-02: Procedure [T-150] When NDE requirements of ASME Section V are required, who shall be responsible to establish nondestructive examination procedures? a) manufacturer b) fabricator c) installer d) all of the aboveQ-03: Procedure [T-150] When required by the referencing ASME Code Section, how shall all nondestructive examinations performed under ASME Section V be done? a) to a verbal procedure b) to a demonstrated procedure c) to a written procedure d) to a qualified procedureQ-03: Procedure [T-150] When required by the referencing ASME Code Section, how shall all nondestructive examinations performed under ASME Section V be done? a) to a verbal procedure b) to a demonstrated procedure c) to a written procedure d) to a qualified procedureQ-04: Calibration [T-160] Who shall assure that all NDE equipment calibrations required by ASME V are performed? a) inspector b) manufacturer, fabricator, or installer c) owner user d) owner user or designeeQ-04: Calibration [T-160] Who shall assure that all NDE equipment calibrations required by ASME V are performed? a) inspector b) manufacturer, fabricator, or installer c) owner user d) owner user or designeeQ-05: Examinations and inspections [T-170] What does the term “inspection” apply to in ASME V? a) the functions performed by the Authorized Inspector b) the functions performed by the Authorized Examiner c) the functions performed by the NDE Inspector d) the functions performed by the NDE ExaminerQ-05: Examinations and inspections [T-170] What does the term “inspection” apply to in ASME V? a) the functions performed by the Authorized Inspector b) the functions performed by the Authorized Examiner c) the functions performed by the NDE Inspector d) the functions performed by the NDE ExaminerQ-06: Examinations and inspections [T-170] What does the term “examination” apply to in ASME V? a) those quality control functions performed by personnel employed by the Manufacturer b) those quality control functions performed by personnel employed by the owner/user c) those examination functions performed by personnel employed by the Manufacturer d) those examination functions performed by personnel employed by the owner/userQ-06: Examinations and inspections [T-170] What does the term “examination” apply to in ASME V? a) those quality control functions performed by personnel employed by the Manufacturer b) those quality control functions performed by personnel employed by the owner/user c) those examination functions performed by personnel employed by the Manufacturer d) those examination functions performed by personnel employed by the owner/userQ-07: General [T-120] ASNT recommended Practice SNT-TC-1A is a; A) Manual covering nondestructive examination (NDE) safety procedures B) Procedure for the visual examination of piping systems C) Document covering NDE personnel qualifications D) Document covering NDE proceduresQ-07: General [T-120] ASNT recommended Practice SNT-TC-1A is a; A) Manual covering nondestructive examination (NDE) safety procedures B) Procedure for the visual examination of piping systems C) Document covering NDE personnel qualifications D) Document covering NDE proceduresASME.V ARTICLE 6 Liquid Penetrant Examination 7 & Dr-Samir Saad Liquid penetrant examination shall be performed in accordance with a written procedure which shall as a minimum, contain the requirements listed in Table T-621. } The written procedure shall establish a single value, or range of values, for each requirement. “ 7-621.2 Procedure Qualification. > When procedure qualification is specified by the referencing Code Section, a change ofa requirement n Table 7621 identified as an essential variable shall require requaification ofthe “2°%@ritten procedure by demonstration.it T- 621 Written Procedure Requirements T-621.2 Procedure Qualification. > Achange of a requirementidentified as a nonessential variable does not requi n procedure. Table T-621, Requirements of a Liquid Penetrant Examination Procedure ‘Noneasential Requirement Essential Variable ‘Varia ‘surface preparation (finishing and cleaning Including eyps lenin solvent) etd of removing excess surface penetrant Tor hydrops emulsiirs Imcrense bn developerdwel tine (nterpetion Tine) Minune intensy ‘outside 40°F to 125°F (5°C to S2°C) or as previously qusiedE-01:- Procedure Qualification [T-621.2] Which of the following requirements need re-qualification of if they liquid penetrant examination procedure if they changed? a) method of applying developer b) personnel qualification requirements c) materials, shapes, or sizes to be examined and the extent of examination d) post-examination cleaning techniqueE-01:- Procedure Qualification [T-621.2) REQUIREMENTS OF Requirement doniicaton of ane any enange In type or fariy group oF peretrant ‘atid oF applying penetrant ‘Mathod of removing excess surTace panetrant rmulefer concentration and well an ma for hyarephie cratirs Hyaropilic emulzier concentration spray applicators ‘Minimum and maximn Une periods betwen seps ane Oran) aids Decremae in penetrant dll time Increase in dovelopar dell ime (nterprepstS te) ‘Minimum light Intensity Surface tomperature outside 40F 0 125P\(5G/t0 920) Performance demonstration, wen required Porsonnel quainicaion roqurerants ‘Materials. shapes oF sizes to be examined and the extent of examination Post examination cleaning technique PROCEDUREE-01:- Procedure Qualification [T-621.2] Which of the following requirements need re-qualification of if they liquid penetrant examination procedure if they changed? a) method of applying developer b) personnel qualification requirements c) materials, shapes, or sizes to be examined and the extent of examination d) post-examination cleaning techniqueE-02:- Procedure Qualification [T-621.2] Which of the following requirements do not need re-qualification of if they liquid penetrant examination procedure if they changed? a) method of applying penetrant b) method of applying developer c) decrease in penetrant dwell time d) post-examination cleaning techniqueE-02:- Procedure Qualification [T-621.2] TABLE 7-621 REQUIREMENTS OF A\LIQUID PENETRANT/EXAMINATION PROCEDURE Erential Requirement Variable ‘dentification of and any change in type oF family group of penetrane x ators including developers. emulsifiers. ete Surface preparation (finiining aed cleaning, inekading type x ‘of cleaning solvent) ‘Method of appiying penetrant ‘Method of removing excess surface ponctrant Hyarophiie 0 lipophilic emututier concentration ane dw te, “ip tanks and agitation time for hydrophilic emulsfler= Hycrophilc erullfer concentration in sprey appli ‘Method of applying sovcioper Minimum and maximum time periods between saps of Bring aia Decrease in ponetrant cell time Increase in developar dwell timo (Inter peailn Fyre) Minirnar ligne intonsity Surface temperature ouside 40F to 128% (96 to 520) ‘or as previously qualified Performance demonstration. when required Materiats, shapes, or sizes to be examined and the extent of examinationE-02:- Procedure Qualification [T-621.2] Which of the following requirements do not need re-qualification of if they liquid penetrant examination procedure if they changed? a) method of applying penetrant b) method of applying developer c) decrease in penetrant dwell time d) post-examination cleaning technique3 T-642 Surface Preparation a) 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. Y Surface preparation by grinding, machining, or other methods may be necessary where surface irregularities could mask indications of unacceptable discontinuities. b) Priorto each liquid penetrant examination, the surface to be examined and all adjacent areas within at least 1 in. shall be dry and free ofall dirt, grease, lint, scale, welding flux, weld spatter, paint, oil, and other. RE T-650 Technique * T-651 Techniques > Penetrants are colour (visible) type and fluorescent type. Each of these have: a) water washable b) post emulsifying ¢) solvent removable “39°Thus, total six liquid penetrant techitiqués‘are available.St T-652 techniques for standard temperatures Asa standard technique, the temperature of the penetrant and the surface of the part to be processed shall not be below 40°F (5°C) nor above 125°F (52°C) throughout the examination period. 3 T-653 Techniques for Nonstandard ‘tin. (76mm) 7B mit be tin Temperatures fhemm| When it is not practical to conduct a liquid penetrant ‘examination within the temperature range of 40°F to 125°F (5°C to 52°C), the examination procedure at the proposed lower or higher temperature range 4 requires qualification of the penetrant materials and processing in accordance with Mandatory Appendix Il of this Article. » This shall require the use of a quench cracked ‘aluminum block, which in this Article is FIG. 111-630 LIQUID PENETRANT COMPARATOR (NOTE: Dimenstons given are for guidance only and are svodesignated as a liquid penetrant comparator block... OS onaXf T-654Technique Restrictions Fluorescent penetrant examination shall not follow a color contrast penetrant examination. ~ Intermixing of penetrant materials from different families or different manufacturers is not permitted. A retest with water washable penetrants may cause loss of marginal indications due to contamination. X£T-671 Penetrant Application The penetrant may be applied by any suitable means, such as dipping, brushing, or spraying. X£T-672 Penetration (DWELL)Time ‘~ Penetration time Is critical. The minimum penetration time shall be as required in Table T-672 or as qualified by demonstration for specific applications.X£T-672 Penetration (DWELL)Time Table T-672 Minimum Dwell Times Material Form Type of Discontinuity ‘Aluminum, magnesium, steel, brass and bronze, Castings and welds (Gold shuts, porosity, ack of fasion, ‘tanium and high-temperature alloys cracks (al forms) ‘Wrought inaterals — Laps, cracks exrusions forgings, plate Carbide-ipped tools Brmed oc welded Lack of fasion, porosity, cracks Mastic Al forms Cracks. Gass All forms Cracks. Ceramic All forme Cracks, NOTE: (1) Fortemperature range from 50°F to 125°F (10°Cto 52°C). For temperatures from 40°F (5°) up to 50°F (10°C), minimum penetrant dwell time shall be 2 times the value listed. ZT COSET TEST =E-01:- Penetration (DWELL)Time [T-672] What is the minimum penetration dwell time for a titanium weld that may contain a small surface crack at 40° F test temperature? a) penetrant 2 minutes b) penetrant 5 minutes Cc) penetrant 20 minutes d) penetrant 10 minutesMaterial ‘Aluminum, magnesium, see, brass and bronz 1nd high temperature alloys Carbide tipped tools Prastlc Glass TABLE 1.672 Min WELT) ‘Dwell Times (Note (1)] (minutes) Form Type of Discontinuity _Penetrant Castings and welds (Cold shuts, porosity, lack of fusion Ea forms) Wrought mater ls. darisions, Laps, cracks (al forms) forgings pate Lack of fusion, porosity. cracks All forms Cracks ‘Al forms Cracks Al Forms Cracks ‘5125 (0c «52S eR ONSET S10 REE-01:- Penetration (DWELL)Time [T-672] What is the minimum penetration dwell time for a titanium weld that may contain a small surface crack at 40° F test temperature? a) penetrant 2 minutes b) penetrant 5 minutes Cc) penetrant 20 minutes d) penetrant 10 minutes3 T-673 Excess Penetrant Removal After the specified penetration(dwell) time has elapsed, any penetrant remaining on the surface ‘shall be removed, taking care to minimize removal of penetrant from discontinuities. + T-673.1 Water Washable Penetrants > Excess water washable penetrant shall be removed with a water spray. » The water pressure shall not exceed 50 psi, and the water temperature shall not exceed 110°F (43°C). % -673.2 Post-Emulsification Penetrants. a) Lipophilic Emutsification. > After the required penetrant dwell time, the excess surface penetrant shall be emulsified by immersing or flooding the part with the emulsifier. » The actual emulsification time shall be determined experimentally. > After emulsification, the mixture shall be removed by immersing in or rinsing with water. ondenThe temperature and pressure of the water shall be as recommended by the manufactureri{T-673 Excess Penetrant Removal % T-673.2 Post-Emulsification Penetrants. b) Hydrophilic Emulsification. > After the required penetrant dwell time and prior to emulsification, the parts shall be pre- rinsed with water spray using the same process as for water-washable penetrants. » Pre-rinsing time shall not exceed 1 min. > After pre-rinsing, the excess surface penetrant shall be emulsified by immersing in or ‘spraying with hydrophilic emulsifier: » After emulsification, the mixture shall’be removed by immersing in or rinsing with water. » The temperature and pressure ofthe water shall be as recommended by the manufacturer. + T-673.3 Solvent Removable Penetrants > Excess solvent removable penetrant shall be removed by wiping with a cloth or absorbent paper, repeating the operation until most traces of penetrant have been removed. > Flushing the surface with solvent, following the application of the penetrant and prior to cnanoeveloping, is prohibited.if T-674 Drying After Excess Penetrant Removal a) For the water washable or post-emulsifying technique, the'surfaces may be dried by blotting with clean materials or by using circulating alr, provided the temperature of the surface is not raised above 125°F (52°C). b) For the solvent removable technique, the surfaces may be dried by normal evaporation, blotting, wiping, or forced air. X£ T-675 Developing ‘The developer shall be applied as soon as possible after penetrant removal; the time interval shall not exceed that established in the procedure Insufficient coating thickness may not draw the penetrant out of discontinuities; conversely, excessive coating thickness may mask indications. With color contrast penetrants, only a wet developer shall be used. With fluorescent penetrants, a wet or dry developer may be used. 1-675.3 > Developing time for final interpretation begins immediately after the application of a dry seontdeveloper or as soon as a wet developer. coating is dry.Xt T-676 Interpretation + T-676.1 Final Interpretation > Final interpretation shall be made within 10 to 60 min. > Ifthe surface to be examined is large enough to preclude complete examination within the prescribed or established time, the examination shall be performed in increments. ‘ T-676.3 Color Contrast Penetrants. > minimum light intensity of 100 fe (1000 Ix) is required on the surface to be examined to ensure adequate sensitivity during the examination and evaluation of indications. + T-676.4 Fluorescent Penetrants. > The examination shall be performéd as follows: a) It shall be performed in a darkened’area. b) Examiners shall be in a-darkened area for at least 5 min prior to performing examinations to enable their eyes to adapt to dark viewing. Glasses or lonses worn by examiners shall not be photosensitive. ¢) Black lights shall achieve.¢ minimum of 1000 uWicm2 on the surface of the part being examined throughout the examination. d) Reflectors and filters should be checked and, if necessary, cleaned prior to use. Cracked or broken filters shall be replaced immediately.XI-640 Requirements % 11-641 Nickel base alloys > sulfur content shall not exceed 1% by weight. *~ Il-642 Austenitic or duplex stainless steel and titanium > The total halogens (chlorine plus fluorine) content shall not exceed 1% by weight.