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LWN331-04-EN page 1
Table of Contents
SUMMARY ........................................................................................................................................................ 2 1. 2. 3. 4. 5. GENERAL ................................................................................................................................................. 2 APPLICATION .......................................................................................................................................... 2 PURPOSE, DEFINITION........................................................................................................................... 2 TEST REFERENCES ................................................................................................................................ 2 TEST PROCEDURES AT LESER ............................................................................................................ 3 5.1 TEST INSTRUCTIONS................................................................................................................................ 3 5.2 TEST DEPTH ........................................................................................................................................... 3 5.3 TEST PROCEDURE ................................................................................................................................... 3 5.4 TESTING FACILITY ................................................................................................................................... 3 5.5 TEST MEDIA ............................................................................................................................................ 3 5.5.1 Penetrant systems, description.................................................................................................... 3 5.5.2 Test media ................................................................................................................................... 4 5.5.3 Sensitivity ..................................................................................................................................... 4 5.5.4 Compatibility of the test media, compatibility with the test object................................................ 4 5.6 TEST PROCEDURE ................................................................................................................................... 4 5.6.1 Preparation and pre-treatment..................................................................................................... 4 5.6.2 Application of the penetrant agent ............................................................................................... 5 5.6.3 Interim cleaning............................................................................................................................ 5 5.6.4 Development process .................................................................................................................. 5 5.6.5 Inspection, viewing conditions in accordance with DIN EN ISO 3059......................................... 6 5.6.6 Final cleaning and protective measures ...................................................................................... 6 6. 7. 8. 9. ACCEPTANCE CRITERIA (EVALUATION OF THE INDICATIONS) ...................................................... 6 QUALIFICATION OF THE TEST PERSONNEL....................................................................................... 6 DOCUMENTATION, OPTION CODE ....................................................................................................... 7 STANDARD REFERENCES ..................................................................................................................... 7
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LESER
GmbH & Co. KG
LWN331-04-EN page 2
Purpose of the penetrant testing is to detect the presence of fissures/cracks in the surface (surface test) and in the surfaces of adjacent areas. The penetrant testing will not be applied in case of: Ferromagnetic iron and steel castings The issue of a certificate that the test has been carried out can be ordered with: Option code H03 M03 M21 Certificate LESER CGA (Certificate for Global Application) Inspection certificate 3.1 according to DIN EN 10204 Inspection certificate 3.1 acc. to DIN EN 10204: Dye penetrant testing Inspection certificate 3.1 acc. to DIN EN 10204: Fluorescent penetrant testing Remarks
optionally optionally
1. General
This LWN will list the standard requirements and describe the procedure during the penetrant testing at LESER and its documentation.
2. Application
At LESER the penetrant examination will be applied in case of metal and non-metal materials like castings, forgings, welding seams, and ceramics.
3. Purpose, definition
The penetrant testing belongs to the non-destructive tests and is a procedure to detect surface flaws like cracks, overlappings, laps, pores and binding flaws that are open in direction of the testing surface. The principle of the penetrant testing procedure is that a penetrant agent, due to its specific characteristics tends to spread optimally on a surface and will simultaneously penetrate into any existing surface flaws. The superfluous penetrant agent is removed from the surface and the developer is applied. The developer takes up the penetrant, in the flaws remaining penetrant agent and this will result in a clearly visible and amplified indication of flaws up to the m measuring area.
4. Test references
The following standards were included at LESER for the penetrant testing: AD 2000-Merkblatt A4, chapter 6, Tests before operation, Section.6.1 The following tests are required for the bodies of component parts: 6.1 (5) non-destructive test of products for bodies of component parts and of welding seams at pressure bearing walls and ... ASME Code, Section VIII UG -136 Minimum Requirements for Pressure Relief Valves UG-136 (f) Welding and other requirements. All welding, brazing, heat treatment, and non-destructive testing used in the construction of bodies, bonnets and yokes shall be performed in accordance with the applicable requirements of this division.
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LWN331-04-EN page 3
Non-destructive testing penetrant testing - Part 1- General foundations Non-destructive testing - penetrant testing Founding - penetrant testing Technical delivery conditions for castings made of metal materials
ASME Code Section V, Non-destructive Examination Article 6 Liquid Penetrant Examination ASME B 16.34 Valves-Flanged, Threaded, and Welding End Mandatory Appendices III - Liquid Penetrant Examination: Procedure and Acceptance Standards LWN 221-04 Penetrant testing, testing at LESER
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LWN331-04-EN page 4
The test media shown in table 1 is used at LESER. Penetrant agent Penetrant testing
Type Description
Developer
Description
Water or solvent based cleaning agent: MET-L-Check special cleaning agent NPU Water or solvent based cleaning agent: MET-L-Check special cleaning agent NPU
Dry developer
II
The sensitivity class of the in chapter 5.5.1 stated penetrant system has been determined using the calibration block 1 in accordance with DIN EN ISO 3452-3. The determined class is only valid for the sample testing approved penetrant system. 5.5.4 Compatibility of the test media, compatibility with the test object
The test media has to be compatible with the materials of the parts to be tested and its final use. The test media of a system has to be compatible with each other. Penetrant agents of different manufacturers may not be mixed when filling the facility. Escaped penetrant agent may not be replaced by penetrant agents of different manufacturers.
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LWN331-04-EN page 5
Chemical pre-treatment The chemical pre-treatment is carried out (spraying on a solvent) by using suitable chemical cleaning agents to remove residues like grease, oil, dye or corrosives. Residues of the chemical agent have to be removed from the testing surface. Drying In the last stage of the pre-treatment the test samples have to be completely dried with a cloth or by drying off so that neither water nor solvent will remain in the surface flaws. 5.6.2 Application of the penetrant agent
Methods of application The penetrant agent is applied by dipping (fluorescent penetrant testing), spraying or brushing (dye penetrant testing) it on the sample to be tested. The work piece temperature should be between +10C to +50C. Reaction time: The surface to be tested has to be completely covered during the entire reaction time. The reaction time is about 30 minutes for both suitable test procedures at LESER, i.e. dipping into the penetrant container and spraying. The penetrant agent may not start drying during the penetrant procedure. The reaction time of the penetrant agent is defined at LESERs as follows: - Cast iron/ Nodular cast iron 15 min - Carbon steel 30 min - Stainless steel 45 min - Weldings 60 min - Stellited parts applicable up to 300 bar 60 min - Stellited parts applicable above 300 bar 120 min 5.6.3 Interim cleaning
The interim cleaning helps to remove superfluous test media from the surface so that no penetrant agent will be removed out of the surface flaws: Fluorescent penetrant testing Interim cleaning will be done using water at normal tap pressure and at room temperature. During the interim cleaning the surface has to be examined for penetrant agent residues. When using fluorescent penetrant agent (penetrant facility) this will be done by using the exposure of a UV light with a minimum UV-A exposure intensity on the testing surface of 300 W / m. After that the surface should be cleaned with a clean, non-fuzz cloth moistened with solvent. Dye penetrant testing (red-white test) Interim cleaning is done by spraying water or cleaning with a non-fuzz cloth. Drying After removing the superfluous penetrant agent the testing surface has to be dried as quickly as possible: - in the oven at max. 50C for tested parts used with the fluorescent penetrant testing procedure (penetrant facility) - by flow of air (hairdryer), free of water and oil, with a pressure as low as possible for dye penetrant testing. The drying procedure of the testing surface has to be carried out in such a manner that the drying of the penetrant agent in the surface flaws is prevented 5.6.4 Development process
The developer is applied evenly on the surface. During the development a capillary active substance is applied, which can take up the penetrant agent from the flawed area. Due to this the flawed area appears to be larger and will be seen more easily.
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The application of the developers has to be done immediately after the interim cleaning. Dye penetrant testing (red-white test) Wet developers on a water-based suspension will be used for the red-white test. You should achieve an even and thin application by spraying the developer so that the underground is just covered. The developing period will start immediately after the drying and will take between 10 and 30 minutes. Fluorescent penetrant testing Dry developer will only be used in connection with a fluorescent penetrant agent. This has to be applied evenly by whirling on the testing surface immediately after the interim cleaning. The tested parts are left in the developer container for 5 to 10 minutes where the powder is whirled up for approx. 20 seconds using pressured air in order to completely cover the parts with powder. The development period starts immediately after application. The development time is equal to the reaction time of the penetrant agent, see chapter 5.6.2 5.6.5 Inspection, viewing conditions in accordance with DIN EN ISO 3059
The initial monitoring of the testing surface should be carried out immediately after the application of the developer and/or the drying of the developer. In this way indications can be interpreted in a better way. The final inspection has to be done after completion of the developing time. Fluorescent penetrant agent Photo chromatic glasses may not be worn. The test sample is exposed to UV-A light in a darkened room. The UV-A exposure intensity on the testing surface has to be greater than 1000 W / cm and the exposure intensity of the environment has to be smaller than 20 Lux. Before the test the eyes of the tester should adapt to the lower environmental light for some time. The UV-A light should be switched on a few minutes before the test (normally at least 5 minutes) to ascertain the required exposure intensity. The tester should avoid looking directly into the UV-A light or areas reflecting the light. Dye penetrant agent During dye penetrant testing, the testing surface should be examined under artificial light with an exposure intensity of at least 500 Lux on the testing surface. Reflections should be avoided. 5.6.6 Final cleaning and protective measures
A final cleaning will only be necessary in cases where residues of the penetrant test media could affect the further use of the tested part. A corrosion protection will only be applied if required.
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optionally optionally
9. Standard references
AD 2000-Merkblatt A4 EN 571-1 DIN EN ISO 3452-3 DIN EN ISO 3452-4 DIN EN ISO 3059 EN 1371 DIN 1690 DIN EN 473 ASME Code, Section VIII ASME Code Section V ASME B 16.34 Bodies of component parts; Tests before operation Non-destructive test- penetrant testing Part 1- General foundations Non-destructive testing penetrant testing - Part 3 -calibration block Non-destructive testing penetrant testing - Part 4- devices Non-destructive testing - penetrant testing and magnetic particle examination, viewing conditions Founding - penetrant testing Technical delivery conditions for castings made of metal materials Non-destructive testing - Qualification and certification of personnel of non-destructive tests - General foundations Rules for Construction of Pressure Vessels, Division 1 Non-destructive Examination. Article 6 - Liquid Penetrant Examination SE-165 Standard Test Method for Liquid Penetrant Examination Valves-Flanged, Threaded, and Welding End Mandatory Appendices III - Liquid Penetrant Examination: Procedure and Acceptance Standards Personnel Qualification and Certification in Non-destructive Testing Regulative requirements regarding welding components at LESER safety valves
End of LWN
LESER
GmbH & Co. KG
T he S afety V alve
Inspection certificate 3.1 acc. to DIN EN 10204
. . .
Customer Order No.: LESER Job No.: LESER-Customers-No.: LESER-Contact: Fon: Fax: eMail:
This LESER inspection certificate confirms that the test object was tested according to the undermentioned test references.
1 Test object
xxx xxx xxx
Art.-No. xxxx.xxxx Cold differential test pressure x,xx barg LESER Job No. xxx xxx,xx psig Pos.No. xx Option Code: Further SV-Info: xxx xxx Nominal size Inlet xxx xxx xx Outlet xx Pressure rating Inlet xx Outlet xx
Serial No.
Body material
Tested component
Pos. xx Description xxx Material xxx Manufacturer xxx Heat No. / Batch xxx
2 Test reference
Dye penetrant testing acc. to: AD 2000-Merkblatt A4, chapter 6 ASME Code, Section VIII Div. 1, UG-136 LESER Works Standard LWN 331-04
5 Acceptance criteria
The castings will be evaluated in accordance with DIN EN 1371, DIN 1690 and ASME B16.34. The evaluation at the welding seams will be carried out in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99.
6 Test result
The test was realised without any objection. The requirements of the test references are fulfilled. Manfred Orlowski Inspection Representative
This certification is written digitally and requires no handwritten signature. (Acc. to EN 10204, chapter 5)
Hohenwestedt, xx.xx.200x
Fon +49 (40) 251 65-100 Fax +49 (40) 251 65-500 E-Mail sales@leser.com Internet www.leser.com
Bank HypoVereinsbank Hamburg BLZ 200 300 00, Konto Account 3203171 BIC: HYVEDEMM300 IBAN: DE64 2003 0000 0003 2031 71 USt-ID VAT-Reg DE 118840936
T he S afety V alve
Inspection certificate 3.1 acc. to EN 10204
. . .
Customer Order No.: LESER Job No.: LESER-Customers-No.: LESER-Contact: Fon: Fax: eMail:
This LESER inspection certificate confirms that the test object was tested according to the undermentioned test references.
1 Test object
xxx xxx xxx
Art.-No. xxxx.xxxx Cold differential test pressure x,xx barg LESER Job No. xxx xxx,xx psig Pos.No. xx Option Code: Further SV-Info: xxx xxx Nominal size Inlet xxx xxx xx Outlet xx Pressure rating Inlet xx Outlet xx
Serial No.
Body material
Tested component
Pos. xx Description xxx Material xxx Manufacturer xxx Heat No. / Batch xxx
2 Test reference
Flourescent penetrant testing acc. to: AD 2000-Merkblatt A4, chapter 6 ASME Code, Section VIII Div. 1, UG-136 LESER Works Standard LWN 331-04
5 Acceptance criteria
The castings will be evaluated in accordance with DIN EN 1371, DIN 1690 and ASME B16.34. The evaluation at the welding seams will be carried out in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99.
6 Test result
The test was realised without any objection. The requirements of the test references are fulfilled. Manfred Orlowski Inspection Representative
This certification is written digitally and requires no handwritten signature. (Acc. to EN 10204, chapter 5)
Hohenwestedt, xx.xx.200x
Fon +49 (40) 251 65-100 Fax +49 (40) 251 65-500 E-Mail sales@leser.com Internet www.leser.com
Bank HypoVereinsbank Hamburg BLZ 200 300 00, Konto Account 3203171 BIC: HYVEDEMM300 IBAN: DE64 2003 0000 0003 2031 71 USt-ID VAT-Reg DE 118840936