| WORK INSTRUCTION HIN8241-QC103 ALSTOM rewsion: | PA Hydro India LIQUID PENETRANT TEST | : 1/10 | PREPARED BY ¢ ‘APPROVED BY Z ~ DATE Ral Pandya \WA,. Rv Bains, MST | so 0207 NATURE OF MODIFIOATIONS New Release Inpex L ORECTNE. . ‘Washing technique by Water. I. BASIC DOCUMENTS I, QUALIFICATION OF OPERATORS IV, MATERIAL TO BE INSPECTED \V. MATERIAL USED FOR INSPECTION 4. Andlyse of pollutants... 2. Sensibility test. Vi_ CONDITION REQUIRED FOR THE SURFACE TO BE INSPECTED AND METHOD OPF PREPARATION 3 1. Products of Cleaning a Vil. MODE AND TIME OF DRYING OF PRODUCTS UTILIZED IN PREVIOUS CLEANING OF THE SURFACE ... 4 Vill MODE OF AP'PLICATION OF THE LIQUID PENETRANT ‘AND TIME OF PENETRATION 4.Way of application ofthe Penetrating Liquid... 2.Time of penetration .. se IX._STRIP OF TEMPERATURE OF THE SURFACE AND OF THE PENETRATING LIQUID. X._WAY OF REMOVAL OF THE EXCESS PENETRATING QUID... of a 2 2 2 i OBJECTIVE 2. Technique of Removal by Solvent. XL, MODE AND TIME OF DRYING BEFORE OF APPLICATION OF REVEALER, 4.Washing technique by Water. 2.Technique of Removal by Solvent. 3. Drying time . Xil_ MODE AND MAXIMUM TIME FOR APPLICATION OF THE REVEALOR: vn Xill DESCRIPTION OF EXECUTION OF THE INSPECTION XIVEEINAL CLEANING joc snnnne XV. CRITERION OF ACEPTANCE 4A. doints Welded «nnn 1.1. Interpretation ofthe results 1.2, Acceptable standards. 2.Casting , Forged and Laminated... XVLREMOVAL OF DEFECTS AND REPAIR XVII, REPORT To standardize the routine of execution of the inspection, through liquid penetrant test, to be accomplished in chamfers and welded joints, forged, cast and laminated Il, BASIC DOCUMENTS * ASME, section V, article 6 © ASME, section VIII, div. 1, Apéndix 8 © ASTM E 165 © CCH70 TH PROCEDURE A PROPERTY OF ALSTOM. TS REPRODUCTION OR COMMUNICATION WITHOUT PREVIOUS AUTHORGATON 5 NOT ALLOWED.WORK INSTRUCTION HING241-aCI03 ALSTOM REMION | Hyena LIQUID PENETRANT TEST PAGE = 2/10 Ill. QUALIFICATION OF OPERATORS "NDT". The operators are trained and qualified as level Il, in agreement with the requirements of SNT-TC-1A, MATERIAL TO BE INSPECTED. Steel carbon, austenitic stainless steel, ferritic stainless steel, martensitic stainless steel, nickel connected (Welded joints, castings, forged, laminated). IV. MATERIAL UTILIZED FOR INSPECTION . The suitable products to be used are indicated in the table below Fabricator | Ponctrant | Type | Condition —_| yDe*2108" | Condition SKLWP [I-A Magnafux | SKL-sP_[II-¢ sk0-s2 SKLIP_|li=c | PP-19_ [I-A fee t02 PMET pPas | ic PD-31 ver-210 [il-c 2= Aerosol |= A= Washable by visible Water with normal light A= Washable by fluorescent water Il- C =Removable by visible solvent and visible with 1-C = Removable by fluorescent solvent rrormal light Notes: 8) Each manufacturers disoloser should be used on the area Inspected with the same manufacturer's penetrating liquid. 'b) Should be used only materials that contain in packing with the production date, the period of validity and the number ofthe production lot ¢) The used products must have certificate of chemical analysis with relation to the tenor Of pollutants. Chlorinate and Fluor for stainless steel austenitic and Sulfur for nickel connected, as well as to assist to the sensibilty test, 1. Analysis of pollutants In the Inspection of austenitic stainless steels and titanium, penetrating materials will only be used with certificate of chemical analysis with relation to the tenor of pollutants ( chlorinate and fldor), that should not exceed to the stipulated as follows “THiS PROCEDURES A PROPERTY OF ALSTOM. TS REPRODUCTION OR COMMIUNCATION WITHOUT PREVIOUS AUTHORATION1S NOT ALLOWED.WORK INSTRUCTION HIN8241-QCI03, ALSTOM REVSION : ] PAGE Hysro Inds LIQUID PENETRANT TEST ai40 a) The residue of the evaporation of 50g of the penetrating material (except solvents and removers) should be inferior to 0,0025g. In case the residue of the evaporation is same or superior to 0,0025g, the sum of the content of chlorine and for in the residue should not exceed to 1% of the residue in weight. The analysis procedure will be according determined in the norm ASME Section V, item T-641(b)(1), b) The residue of the evaporation of 100g of solvents and removers should be inferior to 0,0050g. In case the residue of the evaporation is same or superior to 0,0050g, the sum of the content of chlorine and flor in the residue should not exceed to 1% of, the residue in weight. The analysis procedure will be accordingly certain in the norm ASME Section \ item T-641(b)(3). ) In the Inspection of nickel connected , penetrating materials will only be used with certificate of chemical analysis with relation to the tenor of pollutants (sulfur), that should not exceed to the stipulated as follows d) The residue of the evaporation of 50g of the penetrating material (except solvents and removers) should be inferior to 0,0025g, In case the residue of the evaporation is same or superior to 0,0025g, the content of sulfur in the residue should not exceed to 1% of the residue in weight. The analysis procedure will be according to the norm ASME Section \, item T-641(a)(1). 8) The residue of the evaporation of 100g of solvents and removers should be inferior to 0,050. In case the residue of the evaporation is same or superior to 0 0050g, the content of sulfur in the residue should not exceed to 1% of the residue in weight. The analysis procedure will be as determined to the norm ASME Section V, item T- 641 (a3), 2. Sensibility test The sensibility test (if required) will be executed in the reception of the product (Penetrating Liquid, Discloser and Solvent) with the use of the sensibility pattern JIS 20 microns ". V. CONDITION REQUIRED FOR THE SURFACE TO BE INSPECTED AND METHOD OF PREPARATION. ‘The surface to be Inspected and all the adjacent areas, inside of at least 25 mm. should be dry , free from grease, oil, rust, dirt, bites, welding slag or other irregularities. For the preparation of the surfaces, tools should be used, such as: brushes manual or rotative, sandpaper, cut disks (sandpapers, nylon disks). Note: When the inspection is made in stainless steels, the tools should be made of stainless steel or covered withthe same, and the cut disks should have nylon soul or sim. These tols should be used exclusively in inoxideble steal, 41. Cleaning products For cleaning of the surfaces, solvent should be used like, thinner, SKC-1(Magnaflux), PC21 (P.met) ‘TH PROCEDURE A PROPERTY OF ALSTOM. TS REPRODUCTION OR COMMUNICATION WITHOUT PREVIOUS AUTHORZATION IS NOT ALLOWED.WORK INSTRUCTION HING2#7-QCi03_| ALSTOM rewsion:] pace: | Hydro India LIQUID PENETRANT TEST -__| ano | For the drying, should be used a cloth or paper towel clean and dry. VI. METHOD AND TIME OF DRYING OF THE PRODUCTS USED IN THE PRIOR CLEANING OF THE SURFACE ‘The surface to be inspected, after the cleaning and before the application of the penetrant, must be dry. The time of drying should not be inferior to 5 minutes. ‘The drying of the product used for cleaning should be for normal evaporation or using jet of air cold or hot (to observe @ maximum temperature of 52°C), In case air from the net of compressed air is used, a fiter should be used to avoid the contamination of the surface by cil. VII. MANNER OF APPLICATION OF THE PENETRATING LIQUID AND TIME OF PENETRATION. 1. Mode of application of the Penetrating Liauid 1a) The penetrating liquid should be applied with * spray ", brush or immersion after the surface is totally clean and dry ; b) The layer of penetrating liquid applied in the surface, should be homogeneous and to cover the whole Inspection area foreseen (area of interest for welded joint is the welding more 25 mm of the adjacent areas). 2. Time of penetration ¢) The time of penetration of the penetrating liquid, should not be inferior to 10 minutes, however it should not surpass 30 minutes. vill. ‘TEMPERATURE OF THE SURFACE AND OF THE PENETRATING Liquip For execution of the Inspection, the temperature should be in the limits as shown below; Hi Maximum Minimum Norms, jennie Temperature Surface to be _ Inspected 10"C sarc ASME | Penetrating Liquid 40°C ‘cCHTO 10" ‘TH PROCEDURE Is A PROPERTY OF ALSTOM. FS REPRODUCTION OR COMMUNICATION WITHOUT PREVIOUS AUTHORZATION I NOT ALLOWED.WORK INSTRUCTION HINS247-AG103, ALSTOM ension = | PAGE Hyon LIQUID PENETRANT TEST 510 IX. MANNER OF REMOVAL OF THE EXCESS PENETRATING LIQUID. After the time of penetration mentioned in the iter Vill, the excess of penetrating liquid should be removed, taking care to minimize the removal of the penetrating liquid from within of discontinuities .The following stages should be followed: 4. Technique of washing by water. a) To remove the excess of Penetrating Liquid from the Inspected surface, by using clean and dry cloth or paper towel, 'b) With the use of cloth or paper towel humidified with water, to remove the remaining lines from the Inspected surface. c) The stages mentioned in X (1a) and (1b) can be substituted , in the cases of wrinkled surfaces, making the removal of the excess with the use of a jet of water, since the pressure doesn't exceed 2,8 Kgficm* (40 Psi) and its r temperature is in the strip from 10°C to 38°C (50 to 100° F}. d) To remove, quickly, any excess of water from the Inspected surface, with the use of clean and dry cloth or paper towel. 2. Technique of Removal by Solvent 1a) To remove the excess of penetrating liquid from the Inspected surface, by using a clean and dry cloth or paper towel b) Its prohibited the application of the remover directly on the piece or part ) With the use of cloth or paper towel, humidified smoothly with solvent, to remove the lines remaining from the Inspected surface. d) The use of excess solvent should be avoided to minimize the removal of Penetrating Liquid from within of the discontinuity X. MANNER AND TIME OF DRYING BEFORE THE APPLICATION OF THE DISCLOSER 4. Technique of washing by water . ‘The drying of the surface should be made with the use of a clean and dry cloth or paper or with the use of a fan, since the temperature doesn't exceed to 62°C (125 °F) for colour enetrants and 38°C for penetrating fluorescent 2. Téchnique of removal by solvent ‘The drying of the surface should be made by normal evaporation. ‘HS PROCEDURE Is A PROPERTY OF ALSTOM. FS REPROOUCTIONOR COMMUNICATION WTHOUT PREVIOUS AUTHORZATION SHOT ALLOWED.WORK INSTRUCTION HIN8241-QC103 revision - | pace : 6/10 ALSTO} Hydro india LIQUID PENETRANT TEST 3. Time for drying Before applying the revealer and after the execution of the stages mentioned in XI (1) or (2), £n interval of time of at least § minutes should pass for the surface to be completely dry, however this time should not exceed to 30 minutes. XI, METHOD AND MAXIMUM TIME FOR APPLICATION OF THE DEVELOPER : After having elapsed the time for drying mentioned in the item XI(3), the wet developer, non @queous can be applied through packing type " spray and the recipient should be shaken ,S0 as fo assure the homogeneity of the product and the maintenance of the solid particles in Suspension. For bigger areas the developer can be applied in bulk through a pistol through the system of ar filtration. The pressure of the net should be at the most 2.0 Kaflem? (30 psi) to shake the product to guarantee its homogeneity A Uniform & fine developer film shall be the final result of this application. XIL DESCRIPTION ON_THE EXECUTION OF THE INSPECTION, 4) To execute a verification, i the state of the surface is as foreseen in the item VI 1b) To execute the cleaning of the surface with the products of cleaning mentioned in the item vi(1) ¢) Afier the execution of the prior cleaning, to await the time of drying, as described in the item Vil. 4d) The application of the penetrating liquid and the time of penetration should be as described in the item VIL. ) When the temperature is out of the specified range (item IX), heating or cooling is allowed, in order to obtain the temperature in the strip from 10 to 52°C. f) The removal of the excess of penetrating liquid should be made in accordance with the item x. 9) After the end of drying, according to item XI, to apply the discloser or revealer as described in the item Xi fh) The interpretation / evaluation should be executed with appropriate illumination, to assure that there is no loss of sensibility. (The light intensity should not be inferior to 1000 lux). |) For the use, of issuing a lamp of -utra-violet radiation, this should be heated up for at least 10 minutes, before the beginning of the Inspections when fluorescent penetrating liquid is used. The maximum intensity of visible light in the atmosphere, should not surpass 20 Lux (ASTM E 165) J) The Examiner should stay in the darkened area for at least 5 minutes to familiarize with the ‘atmosphere before the beginning of the exam (ASTM E 165) 'K) The black light should have fiter for utraviolet radiation, to allow the passage of light with wavelength in the strip from 320 to 380nm nm TH PROCEDURE A PROPERTY OF ALSTOM. TS REPRODUCTION OR COMMUNICATION WITHOUT PREVIOUS AUTHOREATONIS NOT ALLOWEDWORK INSTRUCTION HIN8241-QC103 ALSTOM Rewsion: | PAGE fy nda LIQUID PENETRANT TEST Fito |) The intensity of black light in the Inspection surface should be proven through a sensitive eter to the light ultra-violet (radiometer) the same should be equal or superior to 1000 uWiem?, m) A proof should be made at least once in 8 (eight) hours, and whenever the work place is changed. n) In a way to avoid that the excessive diffusion of the penetrating liquid in the developer hinders the interpretation of the type and real size of the discontinuities, an initial interpretation should be made, immediately after the application of the developer. 0) The final evaluation of the Inspection should be made between 10 and 60 minutes after the application of the developer. P) When the surface to be inspected is very big, the Inspection should be made subdividing in appropriate parts, which should be inspected separately, in order to assist to the item Xill (0). 4) Areas containing pigmentation, that can mask discontinuities, should not be accepted and consequently, they should be clean and inspected. *) The radiation meters of light ultra-violet and also of normal light should be gauged annually or every time that the equipment is repaired. XIll. FINAL CLEANING It should be executed when it is requested by the project norm or of construction and assembly of the equipment, or whenever it affects the following operation of the production of the equipment ‘The materials and products mentioned in the item VI (1). should be used In the case of machined finished surface, where painting is not requested, it should be protected with anti-corrosive oil, XIV. ACCEPTABLE CRITERIONS . 1. Welded Joints . When requested by the plan of quality, the use of the code ASME, Section Vill, division 1. ‘appendix 8 or ASME Section | A 270, this criterion shown below should be used: 1.4. Interpretation of the Results AAn indication originating from discontinuity is the evidence of a mechanical imperfection, and they are considered important only those that have larger dimension than 1,6 mm, 4) lineal Indication is that whose length is longer by three times the width; ve jae THSPROGEOUREIS APROPERTYOFALSTOW.TS|__ = ff _MWUNGATION WITHOUT PREVOUS AUTHORZATONIS WOT ALLOWED.WORK INSTRUCTION HINB241-QC103 ALSTOM Rewsion: | PACE Hye nda LIQUID PENETRANT TEST ato 'b) Round Indication is that which has a circular or elliptic form, with the length same or smaller to three times the width ‘@ alb<=3 ©) Any questionable or doubtful indication should be re-Inspected to determine if it is or not an important indication, 1.2, Acceptable Standards . ‘The Inspected surface should be free from: a) Relevant Linear indication, b) Relevant and rounded indication larger than 4,7 mm. ¢) Four or more round important indications, aligned separated by 1.6 mm or less (mm or less). Corner to comer. 1 d<=1,6mm d) the originating indication of an imperfection, can be larger than the imperfection that caused her; however, the size to be taken as base for the evaluation of the acceptance is the size of the indication ( stains) and not the size of the imperfection. 2. Castings , Forged and Laminated The criterion for acceptance, should be that as documents or drawing XV. REMOVAL OF DEFECTS AND REPAIRS All the defects out of the limits of the acceptance criterion should be removed and re- Inspected to assure the removal of the defects. icated in the plan of quality, technical In the case of making the repair by welding, the same should be re-Inspected by penetrating liquid, one more area of 25 mm, adjacent to the repair, in agreement with the same Inspection procedure used intially. |n case of no welding repair, areas should be rounded by grinding to eliminate notches. TH PROCEDURE A PROPERTY OF ALSTON. TS REPRODUCTION OR CORMUNICATION WITHOUT PREVIOUS AUTHOREATONIS NOT ALLOWED.WORK INSTRUCTION HIN8241-QC103 ALSTOM rewsion: ] pxoe tyra LIQUID PENETRANT TEST -_| 90 XVI. REPORT All the relevant indications should be registered, as well as all the referring essential information to the Inspection in the report, enclosure 01. |n case there are indications to repair the conclusion of the report it should be rejected. In the reevaluation of the indications after repair a new report should be emitted with the same number of the accompanied original report with the letter" R" plus the number " 1" and thus successively , that many times the repair persist. Former: R1, R2, R3,. TH PROCEDURE A PROPERTY OF ALSTOM. TS REFROOUCTION OR COMMUNICATION WITHOUT PREVOUS AUTHORZATON I NOT ALLOWED,| WORK INSTRUCTION HIN8241-QCI03 ALSTOM REVISION; | PAGE Hyde nda LIQUID PENETRANT TEST -__ | 40/10 ANNEX 04 ALSTOM TEST REPORT PAGE 10F Hydfo India LIQUID PENETRANT TESTING ‘Customer Insp./Test No. Dis Tem: | — TP/QAP Ne. Drawing NG Rov | P.O.Nos Tien/Operation No F Quen WAS Now Material Test Site Fea Teainjens]Yer)No LNA] Bye ten Materiel ~ Surface Condiion __| Welding Process Walder No. Procedure ref. ~ Material Thickness rom) Acceptance Slondard TEST DATA Remover Penetrant Manufacturer fen Temperaas Ponetani- WT Colour o Fluorescence Developer Manufacturer Penetrating Time: llumination: 2 Dey light Light Type of Black Light Light Point) Black Developing Time: ‘Measured Black Light TEST RESULT No Remarks Remarks (see below) Sign. Remarks according to additional sketch Date ‘AETER REPAIR TaN 4 — Approved __) Not Approved eee = a Sawn SIGNATURE Format Na HINGEATGCIS-OT Rev, BF OFORTO THs PROCEDURE ISA PROPERTY OF ALSTOM. TS REPRODUCTION OR COMMUNICATION WTHOUT PREVIOUS AUTHORZATION SHOT ALLOWED.