100-pt-001 liquid penetrant examination in accordance with asme section v, article 6

100PT001

Liquid Penetrant Examination in Accordance with ASME Section V, Article 6

Revision Date Approved By QA Approval

Original 12/21/2007 Jon Ward, PT Level III Donald Smith, QA Manager

1 01/02/2008 Jon Ward, PT Level III Donald Smith, QA Manager

2 06/03/2008 Jon Ward, PT Level III Donald Smith, QA Manager

3 10/02/2009 Paul Haack, PT Level III Donald Smith Quality Assurance Director

4* 01/11/2010

Jon Ward, PT Level III Donald Smith, Quality Assurance Director

* Completely Revised

Document ID: 100‐PT‐001 Original Issue: 12/21/2007

Revision: 4 Revised: 01/11/2010


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Table of Contents

1.0 Scope ................................................................................................................................................................................................ 3

2.0 Reference Documents ............................................................................................................................................................. 3

3.0 Equipment, Materials and Personnel Requirements ................................................................................................. 3

4.0 Techniques for Standard Temperatures .......................................................................................................................... 4

5.0 Procedure for Nonstandard Temperatures .................................................................................................................... 4

6.0 Manufacturing Stage of Inspection..................................................................................................................................... 5

7.0 Cleaning and Surface Condition ........................................................................................................................................... 5

8.0 Drying .............................................................................................................................................................................................. 5

9.0 Penetrant Application .............................................................................................................................................................. 5

10.0 Excess Penetrant Removal ..................................................................................................................................................... 5

11.0 Drying after Excess Penetrant Removal .......................................................................................................................... 6

12.0 Developing .................................................................................................................................................................................... 6

13.0 Examination ................................................................................................................................................................................. 6

14.0 Post Examination Cleaning .................................................................................................................................................... 6

15.0 Evaluation of Indications per ASME Section III, 2007 Edition, Latest Addenda ............................................ 7

16.0 Evaluation of Indications per ASME Section VIII division I Appendix 8, 2007 Edition, Latest Addenda and API Standard 650 11th Edition ............................................................................................................... 8

17.0 Acceptance/Rejection Criteria for Casting in Accordance with ASME Section I, 2007 Edition, Latest Addenda .......................................................................................................................................................... 9

18.0 Acceptance/Rejection Criteria for Welds in Accordance with ASME B31.1, 2007 edition, Latest Addenda ........................................................................................................................................................................... 9

19.0 Acceptance/Rejection Criteria for Welds in Accordance with ASME B31.3, 2008 edition, Latest Addenda ........................................................................................................................................................................... 9

20.0 Marking .......................................................................................................................................................................................... 9

21.0 Reports ........................................................................................................................................................................................... 10

Table 1: Minimum Dwell Times ........................................................................................................................................................ 11

Table 2: Penetrant Materials .............................................................................................................................................................. 11




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1.0 Scope

1.1 This procedure provides methods for detecting discontinuities that are open to the surface such as cracks, seams, laps, cold shuts, laminations, through leaks or lack of fusion and are applicable to in process, final and maintenance examination of nonporous, metallic materials both ferrous and nonferrous, and of nonmetallic materials such as glazed or fully densified ceramics, certain nonporous plastics, and glass.

1.2 personnel performing liquid penetrant examination shall follow all manufactures recommended safety guidelines as well as all of the applicable Mistras Services and Client Safety procedures.

1.3 This procedure will address the use of Type I (Fluorescent Penetrants) and Type II (Color Contrast) Penetrants using Methods A (Water Washable), and Method C (Solvent removable). The Post‐emulsifiable, Lipophilic and Hydrophilic, Methods B & D, will be addressed as an addenda to this procedure.

2.0 Reference Documents

2.1 ASME Section V, Article 6, 2007 Edition, Latest Addenda

2.2 ASME Section V, Article 24, SE1220, 2007 Edition, Latest Addenda

2.3 ASME Section V, Article 1, 2007 Edition, Latest Addenda

2.4 ASME Section VIII, Division 1, 2007 Edition, Latest Addenda

2.5 ASME Section III, Subsections – NB, NC, ND, AND NF, 2007 Edition, Latest Addenda

2.6 ASME Section I, 2007 Edition, Latest Addenda

2.7 ASME B31.1, 2007 Edition, Latest Addenda

2.8 ASME B31.3, 2008 Edition, Latest Addenda

2.9 API Standard 650, 11th Edition, Latest Addenda

2.10 ASNT Recommended Practice SNT‐TC‐1A, Qualification and Certification of Nondestructive Testing Personnel

2.11 99‐CNTP‐005, Procedure for the Certification of Non Destructive Test Personnel

3.0 Equipment, Materials and Personnel Requirements

3.1 Penetrant materials may consist of Type I (Fluorescent Penetrants) or Type II (Visible Dye Penetrants), Developers and Cleaners (See Table 2 for Manufacture and Designations of Each). Equivalent Penetrants, Developers and Cleaners may be used provided they meet the sensitivity requirements of the client and the requirements of Para. 3.2.

3.2 All materials used during the test (cleaners, penetrant and developers) shall be certified not to exceed 1% by weight in sulfur, for Nickel base alloys and the total Halogens content not to exceed 1% by weight for Austenitic or Duplex Stainless Steel and Titanium content, in accordance with the requirements of Article 6, Mandatory Appendix II. Records of certification shall include the penetrant materials manufacture’s batch numbers and test results. These records shall be maintained as required by the referencing Code section.

3.3 Penetrant materials from different manufactures, or a different type or family group, shall not be intermixed.

3.4 Whenever a spray application is specified herein, the propellant used shall always be an oil‐free compressed air or inert gas.




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3.5 Light meters, both visible and fluorescent light meters, shall be calibrated at least once a year or whenever the meter has been repaired. If meters have not been used for one year or more, calibration shall be done before being used.

3.5.1 With color contrast penetrants, a minimum light intensity of 100 fc (1000 Lux), as measure with a calibrated light meter, is required on the surface to be examined. The light source, technique used, and light level verification is required to be demonstrated one time, documented, and maintained on file.

3.5.2 With Fluorescent penetrants the black light intensity shall be measured with a black light meter (at not less than 15 inches) prior to use, whenever the light’s power source is interrupted or changed, and at the completion of the examination.

3.6 Personnel performing examinations shall be qualified and certified in accordance with Mistras Services’ written practice 99‐CNTP‐005. Only level II and Level III personnel shall review, interpret and evaluate results with respect to applicable codes, standards, and specifications.

3.7 Performance demonstration, when required by the referenced Code section or customer, shall be documented and maintained on file.

4.0 Techniques for Standard Temperatures

4.1 The temperature of the penetrant and the surface of the part to be processed shall not be below 40°F (5°C) or above 125°F (52°C) throughout the examination period. Local heating or cooling is permitted provided the part temperature remains in the range of 40°F (5°C) to 125°F (52°C) during the examination.

5.0 Procedure for Nonstandard Temperatures

5.1 When a liquid penetrant examination cannot be conducted within the temperature range of 40°F to 125°F, the examination procedure requires qualification at the proposed higher or lower temperature range. This qualification shall require the use of a quench cracked aluminum block designated as a liquid penetrant comparator block.

5.2 The liquid penetrant comparator block shall be made of aluminum, ASTM B209. Type 2024, ⅜‐in thick and should have approximate face dimensions of 2‐in x 3‐in. An area in the center approximately 1‐in diameter shall be marked with a 950°F temperature indicating crayon. This area shall be heated with a blowtorch or similar device to a temperature between 950°F and 975°F. The specimen shall be quenched in cold water producing a network of fine cracks on each face. The block shall be dried by heating, (300°F approximately) after cooling, the block shall be cut in half and one half shall be designated as “A” and the other as “B”.

5.2.1 An alternative to using a two piece black is single block with a straight groove machined/cut into the center. The surface of the block on either side of this groove are designated “A” and “B”. Each side of the groove are then processed separately and compared in accordance with section 5.3.

5.3 Application of Liquid Penetrant Comparator Block

5.3.1 To qualify a liquid penetrant examination procedure at a temperature of less than 40°F, the proposed procedures shall be applied to block “B” after the block and all penetrant materials have been cooled and held at the proposed examination temperature until the comparison if completed. A standard procedure that has been previously demonstrated shall be applied to block “A” in the 40°F to 125°F range. The indications revealed on blocks “A” and “B” shall be compared and if the indications are essentially the same on both blocks the proposed procedure shall be qualified for use.




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5.3.2 To qualify an examination above 125°F, block “B” shall be held at this temperature throughout the examination. Block “A” shall be subjected to a previously demonstrated procedure in the 40°F to 125°F temperature range. The indications revealed on Blocks “A” and “B” shall be compared and if the indications are essentially the same on both blocks, the proposed procedure shall be qualified to use.

5.3.3 A procedure qualified at a temperature lower than 40°F shall be qualified from that temperature to 40°F. To qualify a procedure for temperatures above 125°F, the upper and lower temperature limits shall be established and the procedure qualified at these temperatures.

6.0 Manufacturing Stage of Inspection

6.1 It is the manufacture’s responsibility to ascertain the stage of manufacture its particular components or parts are to be inspected as the inspection agency has no control over its manufacturer or ultimate application. Therefore, materials submitted for inspection shall be considered as having met the applicable code requirements for processing prior to nondestructive examination. The manufacture must also designate the Penetrant Type and, if applicable, sensitivity level to be used.

7.0 Cleaning and Surface Condition

7.1 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 methods may be necessary where surface irregularities could mask indications.

7.2 Surfaces to be examined and all adjacent areas within one inch shall be free of grease, dirt, scale, rust, paint, oil, weld flux, or any contaminant that may obscure opening or interface with the examination.

7.3 Surface may be cleaned with organic solvents, de‐scaling solutions, paint removers, detergents, or other solutions that will not interfere with the test. Cleaning solvents shall meet the requirements of Paragraph 3.2.

8.0 Drying

8.1 Parts may be air‐dried after cleaning. Forced air (hot or cold) may be employed to hasten the drying process. A minimum of five (5) minutes drying time shall be employed to ensure the cleaning solution has evaporated prior to the application of the penetrant.

9.0 Penetrant Application

9.1 The penetrant shall be applied by brushing, dipping or spraying. Whenever a spray application is specified herein, the propellant used shall always be an oil‐free compressed air or inert gas.

9.2 The minimum penetration time shall be in accordance with Table 1.0, but shall not exceed 30 minutes or that recommended by the penetrant manufacturer, and in no case shall the penetrant be allowed to dry during the dwell period.

10.0 Excess Penetrant Removal

10.1 After the specified penetration (dwell) time has elapsed, any penetrant remaining on the surface shall be removed, taking care to minimize removal of penetrant from discontinuities.

10.2 Remove excess solvent removable penetrant (Method C), with clean, dry, lint free cloth or absorbent paper. If all the penetrant cannot be removed with the dry cloth or paper, the cloth or paper may be slightly dampened with solvent and surfaces lightly wiped to remove the remaining traces. Flushing the surface with solvent following the application of penetrant and prior to developing is prohibited.




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10.3 Excess water washable penetrant (Method A) shall be removed with a water spray. The water pressure shall not exceed 40psi (280kPa), and the water temperature shall not exceed 110°F (43°C). Rinse time should not exceed 120 seconds unless otherwise specified by part of material specification.

11.0 Drying after Excess Penetrant Removal

11.1 For Solvent removable method, drying shall be accomplished by normal evaporation, blotting, wiping or forced air.

11.2 For water washable technique, the surface may be dried by blotting with clean materials or by using circulating air, provided the temperature of the surface is not raised above 125°F (52°C).

12.0 Developing

12.1 A liquid non‐aqueous developer shall be used and applied by spraying only. For solvent removable penetrants the developer (form e) shall be applied as soon as possible after excess penetrant removal. Care shall be taken to ensure complete coverage of the part or examination area with an even, thin film of developer. Refer to Paragraph 3.4 with regard to propellant for spray method.

12.2 For Water washable penetrants the developer (form d) will be applied to a dry surface. Developer solutions shall be frequently agitated. Care shall be taken to ensure complete coverage of the part or examination area with an even, thin film of developer. Refer to Paragraph 3.4 with regard to propellant for spray method.

12.3 The minimum final interpretation developing time begins as soon as the wet developer coating is dry. The minimum developing time shall be specified in Table 1.

12.4 Dry developer, wet developer and aqueous developers shall be address in addenda to this procedure.

13.0 Examination

13.1 For Color Contrast penetrant examination shall begin immediately after application of the Non‐aqueous developer and as the indications are forming. Final interpretation shall not be made prior to ten (10) minutes or later than a maximum of 60 minutes after the developer is dry. 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 increments.

13.2 For Fluorescent Penetrant the examination shall be in a darkened area. The examiners shall be in a darken area for a minimum of 5 minutes prior to performing the examination to enable their eyes to adapt to dark viewing. Photosensitive glasses or lenses shall not be worn. Black light Reflectors and filters should be checked and if necessary, cleaned prior to use. Cracked or broken filters shall be replaced immediately. Allow black light to warm up for a minimum of 10 minutes prior to examining parts or measuring the intensities. Black light intensities shall achieve a minimum of 1000µW/cm² at the surface of the part being examined throughout the examination. Black light intensity shall be measured as described in 3.5.2

14.0 Post Examination Cleaning

14.1 Post examination shall be performed as soon as possible upon completion of all inspection activities. Any cleaning shall be conducted using a process that does not adversely affect the part.




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15.0 Evaluation of Indications per ASME Section III, 2007 Edition, Latest Addenda

15.1 Mechanical discontinuities at the surface will be indicated by bleeding out of the penetrant; however, localized surface imperfections may occur from machining marks or surface conditions may produce indications which are non‐relevant to the detection of unacceptable discontinuities.

15.2 Any indication, which is believed to be non‐relevant, shall be regarded as a defect and shall be re‐examined to verify whether or not actual defects are present. Surface conditioning may precede the re‐examination. Non‐relevant indications and broad areas of pigmentation, which would mask indications of defects, are unacceptable.

15.3 Relevant indications are those which result from mechanical discontinuities. Linear indications are those indications in which the length is more than three times the width. Rounded indications are indications which are circular or elliptical with the length equal to or less times the width.

15.4 An indication of a discontinuity may be larger than the discontinuity that causes it; however, the size of the indication and not the size of the discontinuity is the basis of acceptance or rejection.

15.5 Acceptance/Rejection Criteria for Welds in Accordance with ASME Section III, Subsection NB, NC, ND, NE, and NF, 2007 Edition, Latest Addenda

15.5.1 Only indications with major dimensions greater than 3∕16‐in shall be considered relevant.

15.5.2 Unless otherwise specified in the Subsection, the following relevant indications are unacceptable:

Any cracks or linear indications; Rounded indications with dimensions great than 3∕16‐in;

Four or more rounded indications in a line separated by 1∕16‐in or less edge to edge;

Ten or more rounded indications in any 6‐in² of surface with the major dimension of this area not to exceed 6‐in with the area taken in the most unfavorable location relative to the indications being evaluated.

15.6 Acceptance/Rejection Criteria for Repair for Castings Forgings and Bars Accordance with ASME Section III, Subsection NB, NC, ND, And ND, 2007 Edition, Latest Addenda

15.6.1 Acceptance Criteria

a. Only indications with major dimensions greater than 1∕16‐in shall be considered relevant.

b. The relevant indications of 1 through 4 below are unacceptable:

1. Any linear indication greater than 1∕16‐in long for material less than ⅝‐in thick, greater than 1∕8-in long for material from 5∕8-in thick to under 2‐in thick, and 3∕16‐in long for material 2‐in thick and greater;

2. Rounded indications with dimensions great than 1∕8-in for thickness less than 5∕8-in and greater than 3∕16‐in for thickness 5∕8-in and greater;

3. Four or more indications in a line separated by 1∕16‐in or less edge to edge;

4. Ten or more rounder indications in any 6‐in² of surface with the major dimension of this area not to exceed 6‐in with the area taken in the most unfavorable location relative to the indications being evaluated

15.7 Acceptance/Rejection Criteria for Weld Prep Edges in Accordance with ASME Section III, Subsection NB, and NC, 2007 Edition, Latest Addenda

15.7.1 Acceptance Criteria (Joint categories A, B, C, D 2‐in or more in thickness)




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a. Only indications with major dimensions great than 1∕16‐in shall be considered relevant.

b. Laminar‐type discontinuities are acceptable without repair if they do not exceed 1‐in length. The extent of all laminar type indications exceeding 1‐in length shall be determined by ultrasonic examination. Indication exceeding 1‐in length shall be repaired by welding to a depth of ³∕8‐in or the depth of indication, whichever is less, unless the ultrasonic examination reveals that additional depth of repaid is required to meet the ultrasonic examination requirements for the product form.

c. Other non‐laminar relevant indications which are unacceptable are:

any linear indications greater than 3∕16‐in long;

rounded indications with dimensions great than 3∕16‐in;

4 or more indications, in a line separated by 1∕16‐in or less, edge to edge

15.8 Acceptance/Rejection Criteria for Bolting Material in Accordance with ASME Section III, Subsection NF, Component Supports, 2007 Edition, Latest Addenda

15.8.1 All bolting material and rods greater than 2‐in normal size for Class 1 component supports shall be examined by magnetic particle method or liquid penetrant method. Such examinations shall be performed on the finished bolting material after threading or on the material stocks at approximately the finished diameter before threading and after heading (if involved). Linear non‐axial indications are unacceptable. Linear axial indications greater than 1” in length are unacceptable.

16.0 Evaluation of Indications per ASME Section VIII division I Appendix 8, 2007 Edition, Latest Addenda and API Standard 650 11th Edition

16.1 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. Only indications with major dimensions greater than 1∕16‐in shall be considered relevant.

a. A linear indication is one having a length greater than three times the width.

b. A rounded indication is one of the circular or elliptical shapes with the length equal to or less than three times the width.

c. Any questionable or doubtful indications shall be re‐examined to determine whether or not they are relevant.

16.2 Acceptance Criteria: These acceptance standards shall apply unless other more restrictive standards are specified for specific materials or applications within the division. All surfaces to be examined shall be free of:

Relevant linear indications;

Relevant rounded indications great than 3∕16‐in;

4 or more relevant rounded indications in a line separated by 1∕16‐in or less, edge to edge




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17.0 Acceptance/Rejection Criteria for Casting in Accordance with ASME Section I, 2007 Edition, Latest Addenda

17.1 Acceptance Criteria

a. All cracks and hot tears;

b. Any group of more than six linear imperfections other than those in (a) in any rectangular area of 1½‐in x 6‐in or less, or any circular area having diameter of 3½‐in or less, these areas being taken in the most unfavorable location relative to the imperfections being evaluated;

c. Other linear indications more than ¼‐in. long for thickness up to ¾‐in inclusive more than 1∕3 of the thickness in length for thickness from ¾‐in to 2¼‐in and more than ¾‐in long for thickness over 2¼‐in (Aligned acceptable indications separated from one another by a distance equal to length of the longer indications separated from one another by a distance equal to the length of the longer indication are separated).

d. All imperfections of nonlinear defects which have any dimension exceeding 3∕32‐in.

17.2 Acceptance/Rejection Criteria in Accordance with ASME Section I, 2007 Edition, Latest Addenda

17.2.1 Indications whose major dimensions are greater than 1∕16‐in shall be considered relevant. All surfaces examined shall be:

a. Free of all relevant linear indications;

b. Relevant rounded indications greater than 3∕16‐in (5mm);

c. Four or more relevant rounded indications in line separated by 1∕16‐in (1.5mm) or less, edge to edge.

18.0 Acceptance/Rejection Criteria for Welds in Accordance with ASME B31.1, 2007 edition, Latest Addenda

18.1 Acceptance Criteria: Indications whose major dimensions are greater than 1∕16‐in shall be considered relevant. The following relevant indications are unacceptable:

any cracks or linear indications:

rounded indication with dimensions greater than 3∕16‐in;

4 or more rounded indications in a line separated by 3∕16‐in or less edge to edge;

10 or more rounded indications in any 6 in² of surface with the major dimension of this area not to exceed 6‐in. with the area taken in the most unfavorable location relative to the indications being evaluated.

19.0 Acceptance/Rejection Criteria for Welds in Accordance with ASME B31.3, 2008 edition, Latest Addenda

19.1 Indications that are interpreted as cracks are unacceptable unless otherwise required by the code or stated in engineering design.

20.0 Marking

20.1 All relevant indications will be marked in a manner to easily identify the indication’s exact location to expedite repair. A sulfur and halogen‐free marker will be used.




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21.0 Reports

21.1 A report of the NDE results shall be completed for each required examination. Content of the report shall include date closely related to:

a. Procedure identification and revision number

b. Acceptance Criteria

c. Type (number or letter designation) of each penetrant, penetrant remover, and developer used including batch numbers

d. Equipment Utilized

e. Examination personnel identity and certification levels

f. Non‐rejectable indications shall be recorded as specified by the referencing Code sections

g. Rejectable indications shall be recorded as follows

1. Type (Rounded or Linear)

2. Location and extent (Length or Diameter or aligned)

3. Cycles of repair by welding

h. Materials and thickness

i. Lighting Equipment

j. Date and time examinations were performed




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Table 1: Minimum Dwell Times

Material Form Type of

Discontinuity

Dwell Times (minutes) NOTES (1, 2)

Penetrant Developer Aluminum,

Magnesium, Steel, Brass and Bronze,

Titanium, High Temp Alloys

Castings and Welds Cold Shuts, Porosity, Lack of Fusion, cracks

(all forms) 5 10

Wrought materials‐extrusions, forgings,

plate

Laps, Cracks (all forms) 10 10

Carbide‐tipped tools Lack of fusion, porosity, cracks 5 10

Plastic All forms Cracks 5 10Glass All Forms Cracks 5 10

Ceramic All forms Cracks, porosity 5 10

Notes:

1. for temperature ranges from 50°F to 125°F (10°C to 52°C)

2. for temperature range from 40°F to 50°F (5°C to 10°C) minimum dwell times shall be 2 times the value listed

Table 2: Penetrant Materials

Type I Fluorescent Dye

Level of Sensitivity

Type II Visible Dye

Cleaners

Nonaqueous Developers

ZL‐60D Level 2 SKL‐SP1 SKC‐S SKD‐S2 ZL‐67 Level 3 SKL‐WP SKC‐HF ZL‐9F ZL‐56 Level 4

Notes:

1. Equivalent Penetrants, Developers and Cleaners may be used provided they meet the sensitivity requirements of the client and the requirements of Para. 3.2