039-procedure liquid penetrant testing.pdf

Pearl GTL Project

LINDE ENGINEERING

Contractor Project No : 5887 Shell Project No: HP-3000-QAT

Project Document Number: T- 4.250.909 Project Rev.: A Page 2 of 12

Purchase Order Number: 2MH127

N/A Tag/Item Number(s):

ASU Unit(s):

Z PCWBS:

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

D A 24.04.2008 Ready For Construction BR UA ZG RFC

C O 11.12.2007 Issued for Company comments BR AU/MC ZG ICC

B 05.12.2007 Issued for Review BR AU/MC ZG IFR

A 26.11.2007 Issued for Internal Review BR AU/MC ZG IIR

Approved By

GAMA Project Rev Rev. Date Description

Prepared By

Checked By Status

No. No. ORIGINATOR

Document Title:

LINDE ENGINEERING AG PROCEDURE FOR LIQUID PENETRANT TESTING

Document No.

GAM PRO QAC GTL 039 D LOC470

Contractor

Gama Qatar Co. W. L. L. Org.

Code Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T-4.250.909 Rev No: A

Doc. Title : PROCEDURE FOR LIQUID PENETRANT TESTING

Doc. No. : GAM-PRO-QAC-GTL-039 Rev. D Date: 24.04.2008

T-4.251.909 Rev. A Page 4 of 12

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TABLE OF CONTENTS

1. SCOPE ________________________________________________________________________5 2. REFERENCES _________________________________________________________________5 3. PERSONNEL___________________________________________________________________5

3.1. Qualification _____________________________________________________________________5 3.2. Personnel _________________________________________________________________________5

4. MATERIALS ___________________________________________________________________6 4.1. Materials_________________________________________________________________________6 4.2. Quality___________________________________________________________________________6

5. SURFACE CONDITION _________________________________________________________6 6. METHOD______________________________________________________________________6

6.1. Techniques ______________________________________________________________________6 6.2. Inspection _______________________________________________________________________7

6.1.1 Surface Preparation_______________________________________________________________________ 7 6.1.2 Cleaning Process_________________________________________________________________________ 7 6.1.3 Drying Process __________________________________________________________________________ 7 6.1.4 Application of the Penetrant ________________________________________________________________ 8 6.1.5 Application for the developer _______________________________________________________________ 8

7. INTERPRETATION _____________________________________________________________9 8. DOCUMENTATION ____________________________________________________________10

8.1. Reports _________________________________________________________________________10 8.2. Attachments ____________________________________________________________________10



T-4.251.909 Rev. A Page 5 of 12

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1. SCOPE This procedure specifies the minimum requirements for liquid penetrant inspection of materials and weldments, not applicable for fluorescent penetrant methods.

2. REFERENCES The following documents shall be referred to in conjunction with this procedure:

a) ASME Boiler and Pressure Vessel Code, Section V b) ASME Section VIII Div1. c) ASME B 31.3 Process Piping d) ASME B 31.1 Power Piping e) Linde/Shell HSSE Policy. f) ASNT document SNT-TC-1A g) DEP-31.38.01.31 GEN (Shop & Field Fabrication of Steel Piping)

3. PERSONNEL

3.1. QUALIFICATION

Personnel undertaking liquid penetrant inspection shall be qualified to minimum of ASNT Level II based on ASNT document SNT-TC-1A.

3.2. PERSONNEL Personnel employed in liquid penetrant inspection for Linde shall be aware of the substances used with regard to flammability and possible breathing and/or skin irritation and shall familiarize themselves with manufacture's instructions before use of same in inspection.

All personnel shall have responsibility to themselves and other persons concerning safety and

shall ensure that site facilities are adequate concerning ventilation, lighting, scaffolding and the like before commencement of operations.



T-4.251.909 Rev. A Page 6 of 12

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4. MATERIALS Storage of Penetrant materials shall be as per manufactures recommendations. The room temperature shall be between 18 to 26 deg C unless no manufactures specifications available.

4.1. MATERIALS a) Solvent cleaner b) Penetrant/remover c) Developer d) Lint free cloth or equivalent

4.2. QUALITY

Only materials of a recognized commercial quality shall be used. Same shall be identified by the manufacturer e.g. Ardrox, Magnaflux or similar, to a known, related specification. For the purpose of this procedure consumables in aerosol can form shall be used. LPI Kit shall be from same manufacturer. Mixing is not allowed. The penetrant shall be of low sulphur contents.

5. SURFACE CONDITION Satisfactory results can usually be obtained on surfaces in the as welded, as cast, as rolled, or as forged conditions, however surface preparation by grinding or machining is necessary when surface irregularities might mask the indications of unacceptable discontinuities or otherwise interfere with the effectiveness of the examination.

6. METHOD This procedure is intended to cover methods to be employed for liquid penetrant inspection subject to the limitations of access.

6.1. TECHNIQUES

The area or weld under examination shall be cleaned. A liquid penetrant is applied to the surface to be examined and allowed to penetrate discontinuities, all excess penetrant is then removed. The area is dried and a developer applied. The developer functions both as a blotter to penetrant that has been trapped in discontinuities and as a contrasting background to enhance the visibility of penetrant.



T-4.251.909 Rev. A Page 7 of 12

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6.2. INSPECTION

6.1.1 Surface Preparation

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

b) Typical cleaning agents that may be used are detergents, organic solvents, and de-

scaling solutions and paint removers. Degreasing and ultrasonic cleaning methods may also be used.

c) After cleaning, drying of the surfaces to be inspected shall be accomplished by normal evaporation or with forced hot air, as appropriate. A minimum of 3 minutes drying time shall be given to ensure that the cleaning solution has evaporated before application of the penetrant.

d) A minimum of 1000 lux* is required to ensure adequate sensitivity during the examination & evaluation of indications. (*Note. 1000 lux can be achieved with a 100 W lamp, in a distance of less than 600mm from the testing area/surface.)

6.1.2 Cleaning Process Solvent cleaner method: On removal of any rust, scale, welding flux, and spatter and in general, inorganic soils. The surfaces to be inspected shall be cleaned firstly with a dry, lint-free cloth. Subsequently with a cloth lightly moistened with solvent cleaner and finally cleaned with a dry lint-free cloth.

6.1.3 Drying Process

The drying process shall be accomplished by normal evaporation. Minimum time allowed drying 1 minute.



T-4.251.909 Rev. A Page 8 of 12

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6.1.4 Application of the Penetrant

a) After the area has been cleaned, dried and the temperature of the surface and penetrant are within the range of 50 to 125F (10 to 52C)

b) The penetrant shall be sprayed directly to the surface to be inspected by the means of an aerosol container, such that the entire part of area under inspection is completely covered with penetrant.

c) After application, excess penetrant shall be allowed to drain from part (care being taken to prevent pools of penetrant forming on the part), while allowing for proper penetrant dwell time.

d) Dwell time shall be in accordance with ASME Section V, SE-165, Table 2, Dwell Times, and Penetrant.

e) All dwell times given are those recommended as minimum. f) Maximum penetrant dwell time shall be 60 minutes. g) After the specified penetrant dwell time has elapsed, any penetrant remaining on the

surface shall be removed with a dry or slightly moistened cloth of solvent cleaner, taking care to minimize removal of penetrant from any possible discontinuity.

h) Flushing the surface with solvent cleaner, following the application of the penetrant and prior to developing is prohibited.

i) Drying process (on removal of all excess penetrant and prior to application of the developer).

The drying process shall be accomplished by normal evaporation minimum time allowed for drying 1 minute.

6.1.5 Application for the developer

a) The non-aqueous wet developer is applied directly to the part by spraying from an aerosol container. A maximum of 3 minutes can be taken after removing of excess Penetrant.

i. The non-aqueous developer evaporates very rapidly at normal room

temperature and does not require the use of a dryer. It should be used, however, with proper ventilation.

ii. Parts shall be sprayed in such a manner as to assure complete part coverage with a thin, even film of developer.

b) Dipping or flooding parts with non-aqueous developer is prohibited. c) Developer dwell time shall not be less than 7 minutes. Dwell times shall be in accordance

with ASME Section V, SE-165, Table 2, Dwell Times, and Developer.



T-4.251.909 Rev. A Page 9 of 12

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7. INTERPRETATION All indications shall be considered as discontinuities until investigated, upon investigation such indications shall be recognized as weld or material related and relevant, therefore subject to interpretation in accordance with the clients governing specification with regard to accept/reject criteria. For piping the acceptance criteria shall be ASME B 31.1 or ASME B 31.3 whichever is applicable.

ASME Sec.VIII Div.1 App.8*

[*This shall apply unless more restrictive standards are specified for specific materials or applications within ASME Sec VIII Div.1

All surfaces to be examined shall be free of;

Relevant linear indications Relevant rounded indications greater than 3/16 inch(4.8mm) Four or more relevant rounded indications in a line separated by 1/16 inch

(1.6mm) or less edge to edge.

An indication of an imperfection may be larger than the imperfection that causes it; however, the size of the indication is the basis for the evaluation.] Indications considered non-relevant can be caused by change in section, property of material, inadequate preparation (eg. slag, scale etc.) and therefore deemed not detrimental to the weld or area examined.

Should any indication not be identified then item shall be rejected and reported as same for supplementary inspection method to be utilized.

Post-Examination Cleaning: When post-examination cleaning is needed, it shall be conducted as soon as practical using a process that does not adversely affect the part.



T-4.251.909 Rev. A Page 10 of 12

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8. DOCUMENTATION

8.1. REPORTS

Each examination shall be reported together with interpretation of flaws/defects encountered; where necessary a diagrammatic sketch shall be made to show locations of defects.

The reports shall give the following information as a minimum:

a) Client identity b) Contractor identity c) Drawing/line number d) Date of Test e) Welders mark, number of identity f) Specification

g) Consumable used & Manufacturer for each item h) Dwell time i) Light source j) Technique Used k) Location of test l) Test Procedure used. m) Acceptance Standard or Specification & Accept or reject n) Technician Name & Signature

Records shall be maintained.

8.2. ATTACHMENTS TABLE-1 TABLE-2 GAM-QCR-QAC-GTL-043: Liquid Penetrant Report



T-4.251.909 Rev. A Page 11 of 12

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TABLE 1 Recommended Dwell Times (ASTM E-165)

Material Form Type of Discontinuity Dwell Times (in

minutes) for Methods Penetrant Developer

Aluminum, magnesium, steel, brass and bronze, titanium and high-temperature

alloys

Cast - castings and welds

Cold shuts, porosity, lack of fusion, cracks (all forms) 5 5

Carbide-tipped tools Wrought -

extrusions, forgings, plate

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

cracks 10 10

Plastic Glass

Ceramic

All forms All forms All forms

Cracks Cracks Cracks

5 10

a) For temperature range from 50 to 125F (10 to 52C) b) All dwell times given are recommended minimums c) Development time begins directly after application of dry developer and as soon as wet

developer coating has dried on surface of parts (recommended minimum). TABLE 2 Classification of Liquid Penetrant Inspection Methods and Types

Type 1 - Fluorescent, Liquid Penetrant Inspection Method A - water-washable (E-1209) Method B - post-emulsifiable (E-1209) Method C - solvent-removable (E-1219) Method D Post emulsifiable Hydrophilic (E-1210)

Type 2 - Visible, Liquid Penetrant Inspection Method A - water-washable (E-1418) Method C - solvent-removable (E-1220)

Test Report Liquid Penetrant Examination (PT)

C2 ASU Pearl GTL PROJECT -Qatar Testing Contractor Testing Consumables Doc No: Testing Code, Standard Ilumination [lx] System Trade Name Batch Data Penetrant General Evaluation Standard Surface Temperature [C] Cleaner Developer

Object Data Testing Data Testing Results (a = accepted / na = not accepted) Test Defect No. Line No. Area NPS Welder 1 Piping Testing Penetr. Develop. Test no no Type. Length Location Pos. Comments a/na

1) Sheet No. Weld No. Thick-ness Welder 2 Contractor

before/ after PWHT

Time [min]

Time [min] Date Defects

Defects after grinding 2) [mm] 3) 4)

Abbreviations GAMA REP Third Party

1)

R1 Repair N new after Rep. G non pressure tested weld

2)Type. Of Defect G = globular L = in Line

3)

Location of Defect B = Base Material T = Transition Area W = Weld Metal

4)Position of Defect Distance to Reference Point in [mm]

Date Name Signature

Date Name Signature

LINDE REP _______________________________________ Date Name Signature

QSGTL OR its PMC REP _______________________________________ Date Name Signature

GAM-QCR-QAC-GTL-043

PT PROCEDURE NEW.pdf TABLE 2 Classification of Liquid Penetrant Inspection Methods and Types

GAM-PRO-QAC-GTL-039-REV-C.pdfPT PROCEDURE NEW.doc TABLE 2 Classification of Liquid Penetrant Inspection Methods and Types

QCR-043-PT REPORT.doc

039-procedure liquid penetrant testing.pdf

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