LIQUID PENETRANT TEST Doc No: STS/QAC/SOP/09

Rev No: 00
PROCEDURE Date Rev: 17 Dec 2008
Page No: 1 of 6

REVISION HISTORY

Rev Originator Description Of Amendments Date

00 Farid New Document 17.12.2008

Designation Name Signature

Originator Mechanical Eng Mohd Farid Abu Bakar

Reviewed

Approved

Controlled document: No part of this document may be printed or reproduced for external purposes
without the written permission of the management appointee of Science-Tech Solutions Sdn Bhd.

SCIENCE-TECH SOLUTIONS SDN BHD

 LIQUID PENETRANT TEST Doc No: STS/QAC/SOP/09
Rev No: 00
PROCEDURE Date Rev: 17 Dec 2008
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1. PURPOSE

This procedure will be used to perform color contrast Liquid Penetrant Testing when
required by contract or specification.

2. SCOPE

This procedure specifies the minimum requirements for liquid penetrant inspection of materials and
weldments.

The liquid penetrant examination method is an effective means for detecting discontinuities which are
open to the surface of nonporous metals. Typical discontinuities detectable by this method are cracks,
seams, laps, cold shuts, laminations, and porosity.

A liquid penetrant is applied to the surface to be examined and allowed to enter the discontinuities. All
excess penetrant is then removed, the part is dried, and the developer is applied. The developer functions
as a blotter to absorb penetrant that has been trapped in discontinuities and as a contrasting background to
enhance the visibility of penetrant indications. The test part is then examined visually to determine the
presents or absence of indications.

This procedure covers liquid penetrant examination by the Visible Penetrant Examination (color contrast)
type, using water washable or solvent removable method. The The material to be examined may be
aluminum, steel, and other alloys.

3. CODE AND STANDARD REFERENCE

3.1. ASME Section VIII Div1.

3.2. ASME Boiler and Pressure Vessel Code, Section V
3.3. ASME B 31.3 Process Piping
3.4. ASME B 31.3 Process Piping
3.5. API 650
3.6. API 620

4. PROCEDURE

4.1. PERSONNEL

4.1.1. Liquid penetrant examination personnel shall have vision, (with correction if necessary),
to enable them to read a Jaeger Type No 2 Standard Chart, at a distance of not less than
12 inches (304mm), and shall be capable of distinguishing and differentiating contrast
between colors used. Inspection personnel shall be checked annually to ensure that they
meet this requirement.
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4.1.2. Liquid penetrant examination personnel shall be proven competent in the technique of
Liquid Penetrant Examination, including performing the examination and interpreting
and evaluating the results; however, where the examination method consists of more than
one operation performing only a portion of the test needed to be qualified for that portion
of the operator performs.

4.2. SURFACE PREPARATION

4.2.1. 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. Surface preparation by grinding,
machining, or other means may be necessary where surface irregularities could mask
indications of unacceptable discontinuities.
4.2.2. All welds shall be visually examined and found to be visually acceptable prior to liquid
penetrant examination.

4.3. CLEANING

4.3.1. Prior to each liquid penetrant examination, the surface to be examined and all adjacent
areas within 1 inch (25mm) shall be dry and free of all dirt, grease, lint, scale, welding
flux, weld spatter, paint, oil and other extraneous matter that could obscure surface
openings or otherwise interfere with the examination

4.4. MATERIALS

4.4.1. The following penetrant type or an approved equal shall be used:

4.4.1.1. Type II method A (water washable) or C (solvent removable) shall be used for all
inspection under this procedure.
4.4.2. Intermixing of penetrant material from different types or methods (families) is not
permitted with the exception of nonaqueous wet developers that qualify for more than
one method of penetrant examination as stated on the can by the manufacturer.
4.4.3. Intermixing of same family penetrant materials from different manufactures is allowed
but only if a satisfactory demonstration of technique is performed.

4.5. EXAMINATION

4.5.1. The temperature of the penetrant and the surface of the part to be examined shall not be
below 40°F (4°C), or above 125°F (52°C) throughout the examination period. Local
heating or cooling is permitted as long as the temperature range remains within the
acceptable limits mentioned herein.
4.5.2. The penetrant for this procedure may be applied by brushing or spraying.
4.5.3. The minimum penetration (dwell) time shall be 5 minutes when examining castings and
welds and 10 minutes when examining extrusions, forgings and plate material.
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4.5.4. The maximum penetration (dwell) time shall be 30 minutes, but in no case shall the
penetrant material be allowed to dry. If penetrant material does dry, all dried material
shall be removed and the area shall be re-cleaned and re-examined.
4.5.5. After the specified dwell time has elapsed, any penetrant remaining on the surface shall
be removed by one of the following methods:
4.5.5.1. For method A (water washable penetrant) excess water shall be removed with a
water spray. The water pressure shall not exceed 50 PSI, and the water
temperature will not exceed 110°F.
4.5.5.2. For method C (solvent removable penetrant) excess penetrant shall be removed
by wiping with a cloth or absorbent paper, repeating the operation until most
traces of penetrant have been removed. The remaining traces shall be removed by
lightly wiping the surface with a cloth or absorbent paper moistened with solvent.
4.5.6. The non-aqueous wet developer shall be applied by spraying as soon as possible after the
surface of the part is dry but no longer than 15 minutes after the removal of the excess
penetrant. The developer should be agitated (Shake well before using) to ensure that
particles are in suspension and well dispersed. The part shall be sprayed in a manner as to
assure complete coverage of the part with a thin, even coat of developer. Over or heavy
application of developer can cause masking of indications.
4.5.7. The minimum developing time for non-aqueous wet developer shall be 10 minutes.

4.6. INTERPRETATION

4.6.1. Final interpretation shall be made within 10 to 60 minutes after the developer coating is
dry. If bleed-out does not alter the examination results, longer periods are permitted. If
the surface to be examined is large enough to preclude complete examination within this
prescribed time, the examination shall be performed in increments.
4.6.2. With color contrast penetrant, the developer forms a reasonably uniform white coating.
Surface discontinuities are indicated by bleed-out of the penetrant which is normally a
deep red color that stains the developer. Indications with a light pink color may indicate
excessive cleaning. Inadequate cleaning may leave an excessive background making
interpretation difficult. A minimum light intensity of 100 fc (1000Lx) is required to
ensure adequate sensitivity during the examination and evaluation of indications. (This
light intensity can be achieved by use of an LED head lamp at 2' or a 1000 watt halogen
light at 6').

4.7. EVALUATIONS OF INDICATIONS

4.7.1. Discontinuities at the surface will be indicated by bleed-out of penetrant; however,

localized surface irregularities due to machining marks or other surface conditions may
produce false indications.
4.7.2. Broad areas of pigmentation which could mask indications of discontinuities are
unacceptable, and such areas shall be cleaned and reexamined.
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4.7.3. An indication is the evidence of a mechanical imperfection. The following applies:

4.7.3.1. Only indications with major dimensions greater than a 1/16” inch (1.6mm) shall
be considered relevant.
4.7.3.2. A liner indication is one having a length greater than three times the width.
4.7.3.3. A rounded indication is one of circular or elliptical shape with the length equal or
less than three times the width.
4.7.3.4. Any questionable or doubtful indications shall be reexamined to determine
whether or not they are relevant.
4.7.3.5. An indication of an imperfection may be larger than the imperfection that causes
it; however, the size of the indication is the basis for acceptance evaluation.
4.7.3.6. Any indication of an imperfection which is believed to be non relevant shall be
regarded as a defect unless it is shown by reexamination by the same method or
by the use of other nondestructive methods and/or by surface conditioning that no
unacceptable imperfection is present.

4.8. ACCEPTANCE STANDARD

4.8.1.All surfaces to be examined shall be free of:

4.8.1.1. Relevant liner indications.
4.8.1.2. Relevant rounded indications greater than 3/16” inch (4.8 mm).
4.8.1.3. Four or more relevant rounded indications in a line separated by 1/16” inch (1.6
mm) or less, edge-to-edge.
4.8.1.4. No crack or linear indication is acceptable.

4.9. REPAIR REQUIREMENTS

4.9.1. Sections of welds that do not meet the acceptance standards in Section 9.0 shall be
repaired and reexamined in accordance with the requirements specified herein.
Unacceptable imperfections shall be repaired and reexamined made to assure removal or
reduction to an acceptable size. Whenever an imperfection is removed by chipping or
grinding and subsequent repair is by welding is not required, the excavated are shall be
blended into the surrounding surface so as to avoid sharp notches, crevices, or corners
and welding performed by a qualified welder or welding operator in accordance with a
qualified welding procedure.
4.9.2. After an imperfection is thought to have been removed and prior to, making weld repairs,
the area shall be examined by suitable methods to assure the imperfection has been
removed or reduced to an acceptable size.
4.9.3. After repairs have been made, the repaired area shall be blended into the surrounding
surface so as to avoid sharp notches, crevices, or corners and reexamined by the liquid
penetrant method and by all other methods that were originally required for the affected
area.
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Rev No: 00
PROCEDURE Date Rev: 17 Dec 2008
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4.9.4. Surfaces shall be cleaned to remove residual penetrant and developer using the solvent
cleaner described in Paragraph 4.4.1.1.

4.10. RECORDS AND REPORTS

4.10.1. The examining operator shall report the results on the inspection form and complete it in
its entirety.