Reliance

Procedure For
Liquid Penetrant Testing

EPCMD-2-QM00-JEP-ME-023

00

17.12.2011

Issued for
Implementation

PPP / PKD

PKS / EMK / KSS

SNS

Rev

Date

Revision

Prepared
By

Checked By

Approved
By

Reliance
Contents
1.

Purpose .........3

2.

Scope ...3

3.

References

4.

Abbreviations and Terms ..3

5.

Responsibilities ...3

6.

Methodology .4
Appendix I

..9

Appendix I I .10

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Reliance
1.

Purpose
The purpose of this procedure to give the step by step instructions to carryout
PT, on Weldment, weld bevels, bends, knuckle areas and /or as specified by
referencing code of construction and applicable specification.

2.

Scope
This procedure is applicable for solvent removable type penetrant examination
of ferrous and non-ferrous materials only.

3.

References
ASME Sec VIII Div. I

Boiler and Pressure Vessel Code Rules for

construction of Pressure Vessels

ASME Sec. V

Boiler and Pressure Vessel

Destructive Examination

ASME B 31.3

Process Piping

ASME B 31.1

Power piping

AWS D 1.1

5.

Non

Structural Steel Code

EPCMD 2 QM00 JEP ME 041

4.

Code

Procedure for selection test of PT/MT Technician

Abbreviation and Terms

ASME

American Society for Mechanical Engineers

HOD

Head of the Department

NDT

Non Destructive Testing

PT

Penetrant Testing

QMD

Quality Management Department

DCC

Document Control Center

Responsibilities
Construction

Managers

Engineer

in

Charge

are

responsible

implementing this procedure in their area.

HOD, QMD is responsible for maintaining this procedure.
DCC is the custodian of this document.

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for

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6.

Methodology

6.1

Procedure Requirements

6.1.1

Personnel Qualification
The personnel, who perform and interpret, shall be qualified in compliance with
SNT-TC-1A. There are three basic levels of qualification as mentioned below:
NDT Level I: An NDT Level I personnel is qualified to perform specific
calibrations, specific tests and specific evaluations according to the written
instructions and record the results.
NDT Level II: An NDT Level II personnel is qualified to set up procedure and
to interpret and evaluate the results with respect to applicable codes, standards
and specifications. An NDT Level II personnel should be able to train and give
the guidance to NDT Level I personnel and should be able to organize and
report the results.
NDT Level III: An NDT Level III personnel should be capable of establishing
techniques and procedures, interpreting codes, standards, specifications and
procedures and designating the test method and techniques to be used. The
NDT Level III must have practical background in applicable materials,
fabrication, and product technology to assist in establishing the acceptance
criteria and be familiar with other commonly used NDT methods.

6.1.2

Penetrant Material Requirement

It is recommended to use all the components of PT materials like penetrant,
cleaner and developer manufactured by one manufacturer. The material
manufacturer selected shall be as per the approved list of Reliance.

6.1.3

Special Requirements
Sulfur and Chlorine/fluorine Content: When penetrant inspection is to be carried
out on austenitic stainless steel, titanium or nickel base alloys, total
chlorine/fluorine content and sulfur content shall be restricted. In the absence
of specific requirement, the chlorine content shall be limited to 1%, where
potential use includes application to austenitic stainless steel or titanium.
Similarly, in the absence of specific requirement, the sulfur content shall be
limited to 1%, where potential use includes application to nickel-base alloys at
elevated temperatures. All these contamination tests shall be carried out in
compliance with the requirement of SE-165 of ASME Sec. V.

6.1.4

Temperature Requirements:
During the period of examination, the surface temperature of the job to be

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examined shall be in the range of 5C to 52C.
However, if the job
temperature is beyond the above mentioned range, a sensitivity test and
procedure qualification shall be demonstrated using the comparator block as
per ASME Sec V, Article-6, T-653.
6.1.5

Surface Preparation
In general, the satisfactory results may be obtained in as welded surface
condition of the part. Surface preparation by grinding, machining or other
suitable methods may be necessary, when there is possibility of masking
unacceptable indication because of surface irregularities.
The surface area to be inspected as well as adjacent area of not less than 25
mm wide must be dry and free from dirt, grease, lint, scale, flux, powder, slag,
spatter, or any other material which may obscure surface opening or otherwise
interfere with the examination.
Cleaning methods are classified as chemical, mechanical, solvent or
combination of these. Chemical cleaning method includes alkaline or acid
cleaning, pickling or chemical etching and molten salt bath cleaning.
Mechanical cleaning method includes tumbling, wet blasting, dry adhesive
blasting, wire brushing and steam cleaning. This method should be used
carefully because they mask flaws by smearing adjacent metal over them or by
filling them with adhesive material.
Solvent cleaning method includes vapor degreasing, solvent cleaning, Solvent
wiping and ultrasonic immersion using solvents. Most commonly used method
among them is vapor degreasing.

6.1.6

Drying After Surface Preparation

After the surface cleaning/preparation, the drying of surface to be examined
shall be accomplished by the normal evaporation or with forced hot or cold air.

6.1.7

Inspection Requirements
An inspector must have the tools that are capable of providing the required
accuracy. These tools usually include Flash light Magnifier ranging from 3 to
10X.
The inspector shall, with correction if necessary, be able to read a Jaeger Type
No. 2 Standard Chart at a distance of not less than 12 in. (300 mm), and shall
distinguish and differentiate contrast between colors used. These requirements
shall be checked annually.

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Reliance
For visible penetrant, a minimum light intensity of 100 foot-candles (1000 lx)
required on the surface to be examined. In-order to ensure the adequate
illumination after day light, the experiments are conducted and results are as
follows,

6.1.8

1.

The illumination of > 1000 lux is obtained with 100-Watts (240 volts) bulb
was held at a distance of 350 - 500 mm (max) from test object.

2.

The illumination of > 1000 lux is obtained with 100-Watts (24 volts) bulb
was held at a distance of 300 - 450 mm (max) from test object.

Process Restriction
The intermixing of the Penetrant material from different family or different
manufacturer is not permitted. The materials whose expiry period is over shall
be duly revalidated by the manufacturer.

6.2

Application and Processing

6.2.1

Application of Penetrant
The penetrant shall be applied by spraying. After the work piece has been
cleaned, penetrant is applied in a suitable manner so as to form a film of
penetrant over the surface. The penetrant shall remain on the surface for
sufficient time i.e., dwell time, as recommended, in the TABLE-I or as per
manufacturers recommendations.

6.2.2

Removal of Excess Penetrant

After allowing sufficient dwell time, excess penetrant shall be removed from the
surface. Uniform removal of excess surface penetrant is necessary for effective
inspection, but over removal must be avoided. The type of penetrant used
determines the removal method. The removal of excess penetrant shall be
carried out by solvent and lint-free cloth.
Solvent removal penetrant may be removed by wiping with a cloth or absorbent
paper, until the traces of penetrant have been removed. The remaining traces
may be removed by a cloth moistened with solvent. Flushing the surface with
solvent, following the application of the penetrant and prior to developing, is
not permitted.

6.2.3

Drying After Excess Penetrant Removal

For solvent removable penetrant, the surface may be dried by normal
vaporation, wiping or forced air.

6.2.4

Application of Developer
The developer (wet or dry) shall be applied as soon as possible after penetrant

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removal. Care shall be taken to avoid over spraying, which may mask the
indication, and insufficient thickness of developer, which may not draw the
penetrant out of discontinuities. A minimum distance of 10 from work piece
shall be maintained, during the application of developer. The developer can
need to be shaken well before spraying.
The minimum developing time shall be 10 minutes, after the application of dry
developer or as soon as developer coating drying starts in case of wet
developer.

Table-1 Minimum Dwell Times

Type of
discontinuity

Material

Form

Aluminum,
magnesium,
Steel, brass and
bronze, titanium
and hightemperature
alloys,
Carbide-tipped
tools.

Cast-Casting
and welding

Cold shuts, porosity,

lack of fusion cracks
(all forms)

Wroughtextrusion,
forging, and
plate.

Laps, cracks
(all forms)
Lack of fusion,
porosity, cracks

Dwell time
(in Minutes)
PenetrantNote-1
5

10
5

Note 1:
Penetrant dwell time given is recommended minimum for temperature range
10C to 52C. For temperatures from 5C to 10C, minimum penetrant dwell time
shall be 2 times.
Maximum penetrant dwell shall be as per the manufacturer recommendations.
Note 2: Developing time for final interpretation begins immediately after the
application of a dry developer or as soon as wet developer coating is dry.
6.3

Inspection
Final inspection shall be made after 10 minutes and before 60 minutes. If the
surface to be examined is large enough to preclude complete examination
within the prescribed or established time, the examination shall be performed in
increment. The surface is visually examined for the indications of penetrant
bleed out from the surface openings. This examination must be performed in a
suitable inspection environment.

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6.3.1

Evaluation
All surface discontinuities shall be indicated by bleed-out of penetrant; however
localized surface imperfections, occurring from the machining marks may
produce similar indications which are treated as non-relevant indications.
Non-relevant indications and broad areas of pigmentation that would mask
indications of defects are not acceptable.
An indication may be larger than the actual size of imperfection / discontinuity;
however the size of the indication is the basis for the acceptance evaluation.
The indication with major dimension greater than 1/16 in. (1.6mm) shall be
considered as relevant.
Linear indications are indications, which are circular or elliptical with the length
more than three times the width.
Rounded indications are indications, which are circular or elliptical with the
length equal to or less than three times the width.
Any questionable/doubtful indications shall be re-examined.

6.3.2

Acceptance Criteria
Acceptance criteria of weld defects shall be as per applicable codes and
specifications.

6.4

Repairs
The defects, the non-acceptable indications, shall be repaired by grinding or
welding, and re-examined to assure the removal of it.

6.5

Post Cleaning
Some residue will remain on work pieces after the penetrant inspection is
completed. In many cases it may not have deleterious effects, but in some cases
post cleaning is essential, where subsequent welding /brazing is to be carried
out. Cleaning methods such as Mechanical, chemical or solvents cleaning shall
be adopted.

6.6

Record
All the observation and results shall be recorded in the Dye Penetrant Inspection
Report format no.: EPCMD-2-QM00-FMT-ME-024 and shall be retained for the
period as specified in the contract.

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Reliance

Appendix-I
Approved PT material for Reliance- site
1.

2.

P-MET, Baroda
a. Penetrant

LPM-PP 15B-280ml.

b. Developer

LPM-PD 31B-280ml

c. Cleaner

LPM-PC 21B-280ml

Ferro Chem, Pune

a. Penetrant Solvent Base

FC-911

b. Developer non-aqueous

FC-811

c. Cleaner Solvent Type

FC-711

All the above materials are in Aerosol can.

Other Penetrant materials, solvent type, may also be used subject to successful
procedure qualification.

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Reliance
Appendix-II
Consumption norm for PT material
1 (one) set of PT material is defined as 1 bottle of penetrant, 3 bottles of developer and
5 bottles of cleaner. Each aerosol can contain 280 ml of material. Lint free clothes
required per set of penetrant material is 1 Kg.
The consumption norms are given in the following table for estimation/material
reconciliation purpose. One set of PT material can be used for considering 20% wastage
Sl No

Thickness of the base material

Length covered for groove weld

Tankage/Pressure
vessel/Structures

Piping

Up to 10 mm

44 Meter

370 Inch Dia

Above 10 mm and up to 20 mm

30 Meter

250 Inch Dia

Above 20 mm and up to 30 mm

21 Meter

175 Inch Dia

Above 30 mm and up to 40 mm

16 Meter

130 Inch Dia

For fillet welds, considering 20% wastage one set of PT material can be used for
Sl No

Fillet size

Length covered

Up to 25 mm

40 meter

For removal of temporary attachment, cleats on piping joints, considering 20%

wastage one set of PT material can be used for
Sl No
1
2
3

Pipe size
Up to 4 NB
6 NB to 12 NB
Above 12

Length covered
60% of Inch Dia
40% OF Inch Dia
30% of Inch Dia

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