TUV SUD - PT Procedure Rev.05

TÜV SÜD MIDDLE EAST LLC
Subsidiary of TÜV SÜD Industry Service GmbH, Munich Germany
Procedure For Liquid Penetrant Examination

PROCEDURE NO.: TUV-SUD/NDT/PT/001 Rev. No.: 05 Date: 10-12-2019 PAGE No. Page 1 of 13
TITLE LIQUID PENETRANT EXAMINATION PROCEDURE
Copy No.
Issued
to:
Prepared by: Reviewed & Issue for Implementation Approved and accepted to use in TÜV SÜD ME by:
Mr. Farag Abdalla – Level III Mr. Yasser Hassan –Industry Mr. Salah Safah – Managing Director
238808 Manager
Middle East
Liquid Penetrant Examination Procedure
__________________________________________________________________________________________________________________
This is an official document of TUV SUD Middle East. Printed copies without the original seal of the company is “Uncontrolled Copy”.

Table of Contents
Section Description
1 Scope
2 Reference Documents
3 Definitions
4 Personnel Qualifications
5 Equipment
6 Materials
7 Surface Preparation
8 Method of Examination
9 Viewing
10 Evaluation of Indications
11 Acceptance Standards
12 Post Examination Cleaning
13 Documentation
14 Records
15 Attachments
__________________________________________________________________________________________________________________

1. SCOPE
1.1. This procedure defines the criteria and general requirements to carry out liquid penetrant examination on
welded joints and weld bevels of materials of boilers, and pressure vessels.
1.2. This procedure specifies the minimum requirements for liquid penetrant examination of welds and areas in
nonporous materials, to detect discontinuities open to the surface, employing solvent removable visible liquid
penetrant system.
1.3. This procedure covers liquid penetrant examination using solvent removable visible method, in the
temperature range of 40 °F (5 °C) to 125 °F (52 °C).
1.4. A change of a requirement in Table T-621 identified as an essential variable from the specified value or range
of values shall require requalification of this written procedure. A change of a requirement identified as
nonessential variable from the specified value, or range of values, does not require requalification of this
procedure. All changes of essential or nonessential variables from the value or range of values, specified by
this procedure shall require revision.
2. REFERENCE DOCUMENTS
2.1. This Procedure refers to the following:
2.1.1. ASME Section V, 2019 Edition, Nondestructive Testing.

2.1.2. API 650 13th Ed , Welded Steel Tanks for Oil Storage.
2.1.3. API 653 5th Ed , Tank Inspection, Repair, Alteration, and Reconstruction.
2.1.4. ASTM E 165/E165M-12 , Standard test method for Liquid penetrant examination.
2.1.5. ASTM E 1220-16, Standard Test Method for Visible Penetrant Examination Using the Solvent Removable
process.
2.1.6. ASTM SE 1209-10, Standard Test Method for Fluorescent Penetrant Examination using the water
washable process.
2.1.7. ASTM SE 1219, Standard Test Method for Fluorescent Penetrant Examination Using the Solvent
Removable process.
2.1.8. ASME Section VIII, 2017 Edition Rules for Construction of Pressure Vessels
2.1.9. ASME B31.1, 2019 Edition, Power Piping.
2.1.10. ASME B31.3, 2019 Edition, Process Piping
2.1.11. ASME B31.4, 2019 Edition, Pipeline transportation system for liquids and slurries
2.1.12. ASME B31.8, 2019 Edition Gas transmission and distribution piping systems.
2.1.13. API 1104 – 22st Edition, 2018 Welding of Pipelines and Related Facilities
2.1.14. AWS D 1.1, 2017 Edition Structural Welding Code – Steel.
2.1.15. AWS D 1.6,2017 Edition Structural Welding Code – Stainless Steel.
2.1.16. SAEP-1142, Qualification of Non-Saudi Aramco NDT personnel.
2.1.17. SAEP-1145, Liquid Penetrant Examination
2.1.18. Client’s specification requirements for acceptance criteria.
__________________________________________________________________________________________________________________

2.1.19. TUV SUD ME written Practice for the Qualification and Certification of NDT Personnel complying with
CP-189, 2011 requirements
3. DEFINITIONS
3.1. Liquid penetrant examination is a method of NDE, which provides for the detection of discontinuities that are
open to the surface of nonporous ferrous and nonferrous materials. Typical surface discontinuities detectable
by this method are: cracks, seams, laps, laminations, through leaks or lacks of fusion. In principle, a liquid
penetrant is applied to the surface to be examined and allowed to enter discontinuities. All excess penetrant is
then removed, the part is dried, and the developer applied.
3.2. NDE : Non Destructive Examination.
4. PERSONNEL QUALIFICATIONS
4.1. All personnel involved in Liquid Penetrant Examinations shall be qualified in accordance with the requirements
of TUVSUD ME written practice (Written Practice for NDE Personnel Qualification).
4.2. When the written practice is revised, the certification of NDE personnel remains valid to the requirements of
the previous revision until the expiry date of the personnel qualification certificate; then, recertification to the
requirements of the new revision is required.
4.3. Subcontractor’s personnel involved in Liquid Penetrant Examinations shall be qualified in accordance with the
requirements of subcontractor’s written practice, which shall be reviewed and accepted by TUV SUD ME level
III.
4.4. The certification of personnel shall be checked by the TUV SUD level III prior to work commencement.
5. EQUIPMENT
5.1. Solvent Removable Visible / fluorescent Dye Penetrant materials consists of:
5.1.1. Penetrant.
5.1.2. Penetrant remover/cleaner.
5.1.3. Developer.
5.1.4. Lint free cloth.
5.1.5. Light meter capable of measuring visible light intensity in lux / foot candles (f.c.). The light meter shall
meet the calibration requirement of T-660 of ASME Code Section V.
5.2. The black lights used include the Spectronics B-100, Labino 135, and Magnaflux ZB-100F,
Magnaflux ZB-100 LED UV or equivalent.
6. MATERIALS
6.1. Only materials of a recognized commercial quality shall be used as identified by the manufacturer’s name i.e.
Ardrox, Ely Chemicals, Bycosin or Magnaflux or as specified by the client.
6.2. Penetrant materials of the same family group shall be used; mix between family groups is prohibited.
6.3. Certification of contaminant content shall be provided by manufacturers for all liquid penetrant materials used
on nickel base alloys, austenitic or duplex stainless steels, and titanium. These certifications shall include the
penetrant manufacturers' batch numbers and the test results obtained in accordance with Mandatory Appendix
__________________________________________________________________________________________________________________

II of Article 6, ASME Code Sec. V. These records shall be maintained as required by the referencing Code
Section.
6.4. Penetrant as well as solvent and developer shall be supplied in spray bottles or closed containers clearly
identified with lot / batch numbers.
7. SURFACE PREPARATION
7.1. Generally satisfactory results may be obtained when the surface of the part is in the as-welded, as-rolled, as-
cast, or as forged condition. Surface preparation by grinding, machining, or other methods may be necessary
where surface irregularities could mask indications of unacceptable discontinuities. Precautions shall be made
with the mechanical cleaning not to close the discontinuities open to the surface. Etching of the cleaned
surfaces may be necessary to open the discontinuities.
7.2. Prior to all liquid penetrant inspections, the surface to be examined and all adjacent areas within at least
25mm (1”) shall be dry and free of dirt, grease, lint, scale, welding flux, weld spatter, oil and other extraneous
matters that could obscure surface openings or otherwise interfere with the examination.
7.3. Typical cleaning agents that may be used are detergents, organic solvents, descaling solutions and paint
removers. Degreasing and ultrasonic cleaning methods may also be used.
8. METHOD OF EXAMINATION
8.1. Surface Cleaning Process:
8.1.1. Solvent cleaning method:
8.1.1.1. On removal of any rust, scale, welding flux, spatter, and in general, inorganic soils, the surfaces to
be inspected shall be cleaned, with solvent cleaner and then finally with a dry lint free cloth.
8.1.2. Drying Process:
8.1.2.1. The drying process shall be accomplished by normal evaporation. Minimum time allowed for drying
is 3 minutes to ensure that the cleaning solution has been evaporated prior to application of the
penetrant.
8.2. Application of penetrant:
8.2.1. After the area has been cleaned, dried and the temperature of the surface and penetrant are within the
range of 40 F (5 C) to 125 F (52 C), the penetrant shall be sprayed directly to the surface to be
inspected by means of aerosol container, so that the entire area under inspection is completely covered.
8.2.2. After application, excess penetrant shall be allowed to drain (care being taken to prevent pools of
penetrant forming on the test area) while allowing for minimum penetration (dwell) time stated in Table T-
672 (in accordance with ASME Section V) unless otherwise specified by the client in a more restrictive
manner.
8.2.3. Maximum penetrant dwell time shall be 30 minutes. In case, for any reason, a longer time than 30
minutes should elapse, penetrant application shall be repeated.
8.3. Excess Penetrant removal:
8.3.1. After the specified dwell time has been elapsed, any penetrant remaining on the surface shall be
removed with a dry or slightly moistened lint free cloth of solvent cleaner, taking care to minimize removal
of penetrant from possible discontinuity.
__________________________________________________________________________________________________________________

8.3.2. Flushing the surface with solvent cleaner, following the application of the penetrant and prior to
developing is prohibited.
8.3.3. Drying after removal of excess penetrant:
8.3.4. The drying process shall be accomplished by normal evaporation. Minimum time for drying is 3 minutes;
maximum time allowed for drying is 5 minutes.
8.4. Application of the developer:
8.4.1. Apply the non-aqueous wet developer directly to the area being inspected, by spraying from the aerosol
container.
8.4.2. The non-aqueous developer evaporates rapidly at room temperature and therefore does not require the
use of a dryer.
8.4.3. Areas being inspected shall be sprayed in such a manner so as to assure complete coverage with a thin,
even film of developer.
8.4.4. Dipping or flooding parts with non-aqueous developer is prohibited.
8.4.5. Developing time for final interpretation begins immediately after the application of a dry developer or as
soon as a wet developer coating is dry.
9. VIEWING
9.1. While the developer is being applied to the part, the surface shall be observed as an aid evaluating indications.
9.2. Final interpretation shall be made not less than 10 min. nor more than 60 min. after the requirements of 8.4 are
satisfied.
9.3. Visible penetrant indications can be inspected in natural or artificial white light. A minimum intensity at the
inspection surface of 100 foot candles (1000 Lx) is required.
9.4. The light source, technique used, and light level verification is required to be demonstrated one time,
documented, and maintained on file.
10. EVALUATION OF INDICATIONS
10.1. All personnel performing liquid penetrant examination according to this procedure shall be qualified and
certified as per TUV SUD ME written practice. Evaluation of test results shall be employed by personnel
certified to a minimum level II.
10.2. Relevant indications are those that result from mechanical discontinuities:
10.2.1. Linear indications are those indications in which the length is more than three times the width. Only
indications with major dimensions greater than 1.5mm (1/16) shall be considered relevant.
10.2.2. Rounded indication or indications which are circular or elliptical with lengths less than three times
the width.
10.2.3. Any questionable or doubtful indications shall be re-tested to verify whether or not actual defects
are present.
10.2.4. Localized surface imperfections may occur, such as machine marks, surface conditions, or
incomplete bond between base metal and cladding, may produce similar indications which are not
relevant.
__________________________________________________________________________________________________________________

11. Extend of inspection
- The following welds shall be examined by the liquid penetrant method before the hydrostatic test of the tank:
a) shell opening reinforcement and structural attachment plates, excluding lightly loaded attachments, that
intersect a shell weld shall be examined for a distance of 150 mm (6 in.) on each side of the intersection and
the butt weld for a distance of 50 mm (2 in.) beyond the pad weld.
b) all welds of openings in the shell that are not completely radiographed, including nozzle and manhole neck
welds and neck-to-flange welds;
c) all butt-welded joints in tank shell and annular plate on which backing strip remins
12. ACCEPTANCE STANDARDS

12.1. Refer to the applicable ASME referencing Code Section:
12.2. ASME Section VIII-Div.1/ Appendix 8./API 650
12.3. ASME Section VIII Div 2 / Part 7 /paragraph 7.5.7.
12.4. ASME Section I / paragraph A-270
12.5. ASME B31.1 / paragraph 136.4.4.
12.6. ASME B31.3 / table 341.3.2.
12.7. ASME Section IX / QW 195.
12.8. NBIC / the acceptance standard shall be as specified in the original code of construction.
12.9. AWS D1.1 Table.6.1 .
12.10. AWS D1.6 6.28.1
13. POST EXAMINATION CLEANING

13.1. Upon completion of the test, in cases where residual penetrant or developer could interfere with subsequent
processing or with service requirements, a suitable technique, such as a water rinse or solvent soak for
cleaning may be employed.
14. DOCUMENTATION
14.1. Non-rejectable indications shall be recorded as specified by the referencing Code Section.
14.2. Rejectable indications shall be recorded. As a minimum, the type of indications (linear or rounded), location
and extent (length or diameter or aligned) shall be recorded.
14.3. A report shall be issued containing the following information as a minimum:
14.3.1. Procedure identification and revision;
14.3.2. Liquid penetrant type (visible or fluorescent);
14.3.3. Type (number or letter designation) of each penetrant, penetrant remover, emulsifier, and
developer used;
__________________________________________________________________________________________________________________

14.3.4. Examination personnel identity and if required by referencing Code Section, qualification level;
14.3.5. Map or record of indications per T-691;
14.3.6. Material and thickness;
14.3.7. Lighting equipment;
14.3.8. Date examinations were performed.
14.3.9. The technique used.
14.3.10. The part number / weld number and specific area examined.
15. RECORDS:
15.1. Liquid Penetrant Examination shall be documented on Liquid Penetrant Examination Report form.
16. ATTACHMENTS:
16.1. Liquid Penetrant Examination Report form.
16.2. Procedure qualification record and demonstration report
DYE PENETRANT INSPECTION REPORT

REPORT NO.-TUV-XXXXX-PT-XX
CLIENT: LOCATION:
PROJECT: TYPE:
ITEM: Procedure no.:
MATERIAL: SURFACE CONDITION:
TEST TEMP.: DWEL TIME :
VIEWING CONDITION: DEVLEPOING TIME:
CONSUMABLE: BRAND NAME:
Acc. Criteria: light intensity:
CLEANER/REMOVER: PENETRANT: DEVLEPER:
__________________________________________________________________________________________________________________

Observation &Evaluations:
Dye Penetrant test has been conducted randomly on some dents for the following Lines
S.N Line number Result Remarks

1
2
3
4
INSPECTED BY: Approved BY:
LEVEL: LEVEL:
SIGNATURE: SIGNATURE:
DATE: DATE:
Attachment # 2 Acceptance Criteria

Code Acceptance Criteria
Only indications which have any dimension greater than 1/16”
(1.5 mm) shall be considered relevant
ASME , Section VIII, Div. 1 All surfaces to be examined shall be free of
Mandatory Appendix 6 and a. Relevant linear indications
API 650 b. Relevant rounded indications greater than 3/16” (5 mm)
c. Four or more relevant rounded indications in a line
separated by 1/16” (1.5 mm) or less edge to edge.
Only indications which have any dimension greater than 1/16”
(1.5 mm) shall be considered relevant
All surfaces to be examined shall be free of
ASME B 31.3 a. Relevant linear indications
b. Relevant rounded indications greater than 3/16” (5 mm)
c. Four or more relevant rounded indications in a line
separated by 1/16” (1.5 mm) or less edge to edge.
__________________________________________________________________________________________________________________

Any indication with a maximum dimension of 1/16 inch (1.6

mm) or less shall be classified as non-relevant
Relevant Indications shall be considered defects should any of
the following conditions exist:
a. Linear indications evaluated as crater cracks or star
cracks exceed 5/32 inch (4 mm ) in length
API 1104 b. Linear indications are evaluated as cracks other than
crater cracks or star cracks
c. Linear indications evaluated as IF and exceed 1 inch in
total length in a continuous 12 in (300 mm)length of weld
or 8% of the weld length
For evaluation of rounded indications, the maximum dimension
shall be considered its size.
- Welds that are subject to PT shall be evaluated on the basis of the applicable requirements for visual
inspection criteria as detailed in Table 6.1 of AWS D1.1
__________________________________________________________________________________________________________________

- For Welds that are subject to PT in accordance to AWS D1.6 , it shall be evaluated on the basis of the
applicable requirements for visual inspection criteria as detailed in article 6.28.1
__________________________________________________________________________________________________________________

__________________________________________________________________________________________________________________

Attachment 3, UV Intensity Log.
__________________________________________________________________________________________________________________

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TÜV SÜD MIDDLE EAST LLC

Subsidiary of TÜV SÜD Industry Service GmbH, Munich Germany

Procedure For Liquid Penetrant Examination

Liquid Penetrant Examination Procedure

Procedure For Liquid Penetrant Examination

12 Post Examination Cleaning

Procedure For Liquid Penetrant Examination

2.1.1. ASME Section V, 2019 Edition, Nondestructive Testing.

Procedure For Liquid Penetrant Examination

Procedure For Liquid Penetrant Examination

Procedure For Liquid Penetrant Examination

10. EVALUATION OF INDICATIONS

Procedure For Liquid Penetrant Examination

11. Extend of inspection

12. ACCEPTANCE STANDARDS

13. POST EXAMINATION CLEANING

Procedure For Liquid Penetrant Examination

DYE PENETRANT INSPECTION REPORT

Procedure For Liquid Penetrant Examination

S.N Line number Result Remarks

INSPECTED BY: Approved BY:

Attachment # 2 Acceptance Criteria

Procedure For Liquid Penetrant Examination

Any indication with a maximum dimension of 1/16 inch (1.6

Procedure For Liquid Penetrant Examination

Procedure For Liquid Penetrant Examination

Procedure For Liquid Penetrant Examination

Attachment 3, UV Intensity Log.

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