DOCUMENT NO.
KIE - TP P232
REVISION NO.
LIQUID PENETRANT EXAMINATION PROCEDURE
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LIQUID PENETRANT
EXAMINATION
PROCEDURE for
A S M E CODE
(NAME)
(DATE)
(Dept)
Yang, Sam Wook
(PREPARED BY)
2008. 09. 08
Level
Song, Chang Ho
(REVIEWED BY)
2008. 09. 09
Level
Song, Byung Ho
(APPROVED BY)
2008. 09. 11
QAD MGR
KIE-QR-A03-2(03.02, Rev.0)
(SIGN)
TEL:(02)598-2525
DOCUMENT NO.
KIE - TP P232
REVISION NO.
LIQUID PENETRANT EXAMINATION PROCEDURE
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CONTENTS
1.
Purpose
2.
Reference
3.
Procedure Qualification
4.
Personnel Qualification
5.
General Requirements
6.
Examination
7.
Procedure for Nonstandard Temperature
8.
Evaluation of Indications
9.
Acceptance Standards
10.
Repair Requirements
11.
Post-Cleaning
12.
Examination Results
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1. Purpose
This procedure is to describe the minimum requirements for method, techniques and acceptance
standards to be used when performing liquid penetrant examination of carbon steel, stainless
steel and welding procedure or welder and welding operator qualification for corrosion
resistant overlay.
1.1 Scope
This procedure shall be applied to following object.
1) Material type : Carbon steel, Stainless Steel
2) Examination area : Weld metal and Material.(Pipe, Plate, etc)
2. Reference
2.1 ASME Sec. V
----- 2004 Ed., with 2006 Add.
2.2 ASME Sec. Div. 1
----- 2004 Ed., with 2006 Add.
3. Procedure Qualification
3.1 This procedure shall be demonstrated to the satisfaction of the A.I. and QA Dept
General Manager of Clients, before use.
3.2 When procedure qualification is specified, a change of a requirement in Table 1
identified as an essential shall require requalification of the written procedure by
demonstration. A change of a requirement identified as a nonessential does not require
requalification of the written procedure.
4. Personnel Qualification
Personnel performing nondestructive examination shall be qualified in accordance with the
KIE procedure "NDE PERSONNEL CERTIFICATION PROGRAM" which meets the requirements of ASNT
Recommended practice, SNT-TC-1A(2001Ed. and the more restrictive requirement of previous
editions) and other applicable codes.
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TABLE.1
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Requirements of a Liquid Penetrant Examination Procedure.
Requirement
Essential
Non-
Paragraph of this
Variable
essential
procedure
Variable
Identification of and change in type or
family
group
of
penetrant
materials
5.2
Surface Preparation
5.4
Method of applying penetrant
6.1
6.2
N/A
N/A
6.4.1
5.5 & 6.4
6.1
6.5.1
6.5.3
7.
3.0.
4.
1.1
11.
including developers, emulsifiers, etc.
Method
of
removing
excess
surface
penetrant
Hydrophilic
or
lipophilic
emulsifier
concentration and dwell time in dip
tanks
and
agitation
time
for
hydrophilic emulsifiers
Hydrophilic emulsifier concentration in
spray applications
Method of applying developer
Minimum
and
Maximum
time
periods
between steps and drying aids
Decrease in penetrant dwell time
Increase
in
developer
dwell
time
(interpretation time)
Minimum Light Intensity
Surface
temperature
125(10
to
52)
outside
or
as
50
to
previously
qualified
Performance
demonstration,
when
required
Personnel qualification requirements
Materials,
shapes,
or
sizes
to
be
examined and the extent of examination
Post examination cleaning technique
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5. General Requirements
5.1 Technique
Color contrast penetrant techniques with the solvent removable type shall be used.
5.2 Penetrant Materials
The following materials (Visible Penetrant) shall be used.
Material
Maker
Type
Penetrant
Nawoo
NPP2
Remover
Nawoo
NPR1-3
Developer
Nawoo
NPD4
* Restriction : Intermixing of penetrant materials from different type or
family group is not permitted.
5.3 Control of Contaminants
The penetrant materials employed shall meet the requirements of T-641, Art.6, ASME Sec.V.
5.3.1 Nickel base alloy
When examining nickel base alloy, the sulfur contents in certification shall not exceed 1%
of the residue by weight.
5.3.2 Austenite stainless steel or titanium
When examining austenitic stainless steel or titanium, the chlorine and fluorine contents in
certification shall not exceed 1 % of the residue by weight.
5.4 Surface Preparation
5.4.1 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.
5.4.2 Prior to each liquid penetrant examinations, the surface to be examined and all
adjacent areas within at least 1 in.(25mm) shall be dry and free of all dirt, grease, lint,
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scale, welding flux, weld spatter, paint, oil, and other extraneous matter that could
obscure surface openings or otherwise interfere with the examination.
5.4.3 Typical cleaning agents which may be used are detergents, organic solvents, descaling
solutions, and paint removers. Degreasing and ultrasonic cleaning methods may also be used.
5.4.4 Cleaning solvents shall meet the requirements of Para. 5.3. the cleaning method
employed is an important part of the examination process.
5.5 Drying After Preparation
After cleaning, drying of the surfaces to be examined shall be accomplished by normal
evaporation or with forced hot or cold air.
The surfaces shall be dried for minimum 30 seconds prior to application of the penetrant.
6. Examination
6.1 Penetrant Application
Penetrant shall be applied by spraying.
The minimum penetration and developing time shall be as follows;
Table 2] Minimum Dwell Times
Materials
Steel, Hightemperature,
alloy
Form
Casting and weld
Type of
Dwell Time(min.)
Discontinuity
Penetrant / Developer
5
/
10
cold shuts, porosity,
Cracks, Lack of Fusion
Laps, Cracks(all
Wrought materialsExtrusions, forgings, forms)
plate
10
10
6.2 Excess Penetrant Removal
Excess solvent removable penetrants 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 surfaces with cloth or absorbent
paper moistened with solvent. To minimize removal of penetrant from discontinuities, care
shall be taken to avoid the use of excess solvent. Flushing the surface with solvent,
following the application of the penetrant and prior to developing, is prohibited.
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6.3 Drying After Excess Penetrant Removal
The surfaces may be dried by normal evaporation, blotting, wiping, or forced air.
6.4 Developing
The developer shall be applied as soon as possible after penetrant removal; the time
interval shall not exceed the maximum 10 minutes. Insufficient coating thickness may not
draw the penetrant out of discontinuities; conversely, excessive coating thickness may mask
indications. With color contrast penetrants, only a wet developer shall be used.
6.4.1 Prior to applying suspension type wet developer to the surface, the developer must be
thoroughly agitated to ensure adequate dispersion of suspended particles. The developer
shall be applied only to a dry surface by spraying.
Nonaqeous developer shall be applied
only to a dry surface. It shall be applied by spraying. Drying shall be by normal
evaporation.
6.4.2 Developing time for final interpretation begins immediately after the application of
as soon as a wet developer coating is dry. The minimum developing time shall be as required
by para.6.1.
6.5 Interpretation
6.5.1 Final Interpretation
Final interpretation shall be made within 10 to 60 min after the requirements of 6.4.2 are
satisfied. 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 the
prescribed or established time, examination shall be performed in increments.
6.5.2 Characterizing Indication(s)
The type of discontinuities are difficult to evaluate if the penetrant diffuses excessively
into the developer. If this condition occurs, close observation of the formation of
indication(s)
during
application
of
the
developer
may
assist
in
characterizing
and
determining the extent of the indication(s).
6.5.3 Color Contrast Penetrant
With a color contrast penetrant, the developer forms a reasonably uniform white coating.
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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 indicated
excessive
cleaning.
Inadequate
cleaning
may
leave
an
excessive
background
making
interpretation difficult. A minimum light intensity of 1000 Lux is required to ensure
adequate sensitivity during the examination and evaluation of indications.
7. Procedure for Nonstandard Temperatures
When it is not practical to conduct a liquid penetrant examination within the temperature
range of 50 to 125(10 to 52), the examination procedure at the proposed lower or
higher temperature range requires qualification of the penetrant materials and processing in
accordance with following paragraphs.
7.1 Materials
A liquid penetrant comparator block shall be made as follows. The liquid penetrant
comparator blocks shall be made of aluminum, ASTM B 209, type 2024, 3/8 in. (9.5mm) thick,
and should have approximate face dimensions of 2 in x 3in (50mm x 75mm). At the center of
each face, an area approximately 1in.(25mm) in diameter shall be marked with a 950(510)
temperature- indicating crayon or paint. The marked area
shall be heated with a blowtorch, a Bunsen burner, or similar device to a temperature
between 950(510) and 975(524). The specimen shall then be immediately quenched in
cold water, which produces a network of fine cracks on each face. The block shall then be
dried by heating to approximately 300(149). After cooling, the block shall be cut in
half. One-half of the specimen shall be designated block A and the other block B for
identification in subsequent processing. Fig.1 illustrate the comparator block "A" and "B".
As an alternate to cutting the block in half to make blocks A and B, separate blocks 2
in. x 3 in (50mm x 75mm) can be made using the heating and quenching technique as described
above. Two comparator blocks with closely matched crack patterns may be used. The blocks
shall be marked A and B.
7.2 Comparator application
a) Temperature Less Than 50(10)
If it is desired to qualify a liquid penetrant examination procedure at a temperature
of less than 50(10), the proposed procedure shall be applied to block "B" after
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the block and all materials have been cooled and held at the proposed examination
temperature until the comparison is completed. A standard procedure which has
previously been demonstrated
as suitable for use shall be applied to block "A" in the
50 to 125(10 to 52) temperature range. The indication of cracks shall be
compared between blocks "A" and "B".
If the indications obtained under the proposed conditions on block "B" are essentially
the same as obtained on block "A" during examination at 50 to 125(10 to 52),
the proposed procedure shall be considered qualified for use.
A procedure qualified at a temperature lower than 50 (10) shall be qualified from
that temperature to 50(10).
Fig.1 LIQUID PENETRANT COMPARATOR
(NOTE: Dimensions given are for guidance only and are not critical.)
b) Temperature Greater Than 125(52),
If the proposed temperature for the examination is above 125(52), block "B" shall
be held at this temperature throughout the examination. The indications of cracks
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shall be compared as described in 7.2. a) while block "B" is at the proposed
temperature and block
"A" is at the 50 to 125 (10 to 52) temperature range.
To qualify a procedure for temperatures above 125(52), the upper and lower
temperature limits shall be established and the procedure qualified at these
temperature.
c) Alternate Techniques for Color Contrast Penetrants.
As an alternate to the requirements of 7.2 a) and 7.2 b) When using the color
contrast penetrant, it is permissible to use a single comparator block for the
standard and non-standard temperatures and to make the comparison by photography.
1) When the single comparator block and photographic technique is used, the
processing details (as applicable) described in 7.2 a) 7.2.b) apply. The block
shall be thoroughly cleaned between the two processing steps. Photographs shall be
taken after processing at the non-standard temperature and than after processing
at the standard temperature.
The indication of cracks shall be compared between the two photographs. The same
criteria for qualification as 7.2 a) shall apply.
2) Identical photographic techniques shall be used to make the comparison
photographs.
7.3 When liquid penetrant examination shall be performed on non-standard condition, The
minimum penetrant time at that temperature is limited as follows;
Temperature Range
Recommended dwell time
Penetrant/Developer
less than 5
Must be local heating
5 and over, less than 10
15 min. / 15 min.
10 to 52
Para. 6.1 Table.2
NOTE : Recommended dwell time is based on the procedure qualification
demonstration.
8. Evaluation of Indications
1) Only indications with major dimensions greater than 1/16 in. shall be considered
relevant.
(1) A linear indication is one having a length greater than three times the
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width.
(2) A rounded indication is one of circular of elliptical shape with a length
equal to or less than three times width.
(3)
Any
questionable
is
or
doubtful
indications
shall
be
reexamined
to
determined whether or not they are relevant.
2) Mechanical discontinuities at the surface will be indicated by bleeding out of the
penetrant; however, localized surface imperfections, such as may occur from machining
marks or surface conditions, may produce similar indications which are not relevant to
the detection of unacceptable discontinuities.
3) Any indication which is believed to be nonrelevant regarded as a defect and shall be
reexamined to verify whether or not actual defects are present.
Surface conditioning may precede the reexamination.
Nonrelevant indications and broad areas of pigmentation which would mask indications of
defects are unacceptable.
4) Relevant indications are those which result from mechanical discontinuities.
Linear indication 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 less than three times the width.
5) 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.
9. Acceptance Standards
9.1 ASME Sec. Div. 1.
All surfaces to be examined shall be free of :
1) Relevant linear indications ;
2) Relevant rounded indications greater than 3/16 in.(5.0mm) ;
3) Four or more relevant rounded indications in a line separated by 1/16in.(1.5mm) or
less (edge to edge).
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10. Repair Requirements
Unacceptable imperfections shall be repaired and reexamination made to assure removal or
reduction to an acceptable size.
Whenever an imperfection is repaired by chipping or grinding and subsequent repair by
welding is not required, the excavated area shall be blended into the surrounding surface so
as to avoid sharp notches, crevices, or corners.
Where welding is required after repair of an imperfection, the area shall be cleaned and
welding performed in accordance with a qualified welding procedure.
1) Treatment of Indications Believed Nonrelevant.
Any indication which is believed to be nonrelevant shall be regarded as an imperfection
unless it is shown by reexamination by the same method or by the use of other
nondestructive method or by the use of other nondestructive methods and/or by surface
condition that no unacceptable imperfection is present.
2) Examination of Areas From Which Defects Have Been Removed.
After a defect is thought to have been removed and prior to making weld repairs, the area
shall be examined by suitable methods to ensure it has been removed or reduced to an
acceptably sized imperfection.
3) Reexamination of Repair Areas.
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 of examination that were originally required
for the affected area, except that, when the depth of repair is less than the
radiographic sensitivity required, reradiography may be omitted.
11. Post-Cleaning
Post cleaning is nesessary in those cases where residual penetrant or developer could
interfere with subsequent processing or with service requirements. It is particularly
important where residual penetrant inspection materials might combine with other factors in
service to produce corrosion.
A suitable technique, such as a simple water rinse, machine wash, vapor degreasing, solvent
soak, or ultrasonic cleaning may be employed.
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12. Examination Results
The examination results must be reported on the attached form by the certified Level II or
III certifying the examination results.
-
procedure identification and revision
liquid penetrant type (visible or fluorescent)
type (number or letter designation) of each penetrant, penetrant remover, emulsifier
developer used;
examination
personnel
identity
and
if
required
by
referencing
Code
Section,
qualification level
-
map or record of indications
material and thickness
lighting equipment
date examinations
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