Good Practices User Guide

PENETRANT TESTING

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TABLE OF CONTENTS
Topic Sheet P01
General points Main processes of penetrant testing

Topic Sheet P02

Products used for manual inspection Accessories and devices for quality control for manual inspection of penetrant testing

Topic Sheet P03

Constraints and environmental risks Risks for the operator associated with the implementation of penetrant inspection

Topic Sheet P04

Approach to reduce the environmental footprint of the penetrant testing Practices to minimize risks of accidents Improvements for a greener manual penetrant testing

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Penetrant Testing
Topic Sheet

P01 General points

Penetrant testing (PT) is a method of non-destructive testing developped at the beginning of the 20st century, which allows surface defects detection. With the magnetic particles testing, this technique represent 50% of the non-destructive field. This technique consists in applying on the surface to be inspected, a penetrant liquid which will seep into the surface defects. After impregnation, the penetrant excess is removed from the surface. Once dry, the surface is then covered with a thin layer of developer which will act as a blotter and suck the penetrant present in the defects. It gives colored or fluorescent indication, characteristic of the defect.

The penetrant testing can be perfom on any type of material (non porous) This technique can only allow the detection of through holes defects.

This technique can detect through the surface defects on nonporous materials such as: Cracks. Quenching cracks. Folds. Penetrant testing method requires the use of chemicals at each step of the inspection.

Step-by-step penetrant testing implementation:

Preliminary cleaning

Penetrant application and impregnation

Removal of penetrant excess

Developper application

Inspection

Last cleaning

The time required for the realization of a penetrant inspection exceeds one hour.

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Main processes of penetrant testing

They are different methods of penetrant testing:

Topic Sheet

P01

Pre-emusilfied penetrant testing method

Penetrant application

Post-emulsified penetrant testing method

Penetration time : 10 to 30 minutes

Penetrants used can be red or fluorescent, pre or post-emulsified Some penetrants can be removed with solventsoaked rags

Removal of penetrant excess by using water

Adding an emulsifier on the surface part

Chemical reaction between the penetrant and the emulsifier during a controlled time

Removal of water excess

The emulgation operation remains a delicate step of the implementation which may desorb the penetrant out of defects

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Penetrant Testing
Topic Factsheet Sheet

P02 02

Products used for manual inspection

Types of products:
Cleaning products: The use of cleaning products is a preliminary operation to the penetrant testing operation. The objective is to obtain a clean surface to allow the penetrant to seep into defects. Main cleaner products used: ethyl acetate, acetone, isopropyl alcohol, ... There are other types of cleaning processes: chemical, mechanical (blasting, sandblasting). They are generally not allowed or implemented with great caution (may occasionally recap defects). Penetrant products : Penetrants used :

- Colored, fluorescent, mixed, - Pre-emulsified, post-emulsified, - Thixotropic, Penetration time: 10 to 30 minutes.

Developpers : Developpers allow to view defects by capillary action. Developpers used: dry, wet organic or aqueous-based, peelable. Detection time: 10 to 30 minutes.

Product packaging:
Aerosol cans. Bulk.

Application methods of penetrating products:

Pulverization. Brush (well suited for localized examinations, for example for checking welds or repairs). Electrostatic spray (organic molecules are polarized at the exit of the electrostatic gun and subjected to an electric field associated with the difference of potential between parts connected to ground (- polarity) and gun (+ polarity). This method allow to have a high transfer efficiency, savings in product cost and time, a thin and uniform layer. Impregnation station (requires a small amount of penetrant thanks to the draining operation and allows a complete wetting of complex geometry parts).

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Accessories and devices for quality control for manual inspection of penetrant testing
Accessories :
Penetrant excess removal: Solutions to remove penetrant excess: air-water gun, water spray, paper towels, rags ...

Topic Sheet

P02

Drying before developper application: Drying means used: heat gun, drying oven, compressed air, dried and lint-free rags.

Display solution: White lighting. UV lighting (fluorescent penetrant testing).

Devices for quality control:

Lux meter and UV radiometer (allow to ensure that control is carried out
under standard lighting conditions ).

Plate panels for penetrants sensitivity characterization and cracked blocks (allow to check bathing and penetrant quality used over
time).

UV stereoscope (mainly used for counting indications revealed on

specimens).

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Penetrant Testing
Topic Sheet

P03 Constraints and environmental risks

Ecological impact of penetrant and magnetic particles testing in France per year: 100 000 tons of organic products. 200 000 tons of waste. MkWh 1000 is 200 million tons CO2 equivalent. In Europe : these figures are multiplied almost by 10. Products used for penetrant testing present significant risks to the operator and the environment. These products are: In general flammable (organic products) and explosives (spray cans). Toxic to the aquatic environment. Hazardous to health operators (must not be inhaled / ingested or in contact with eyes or skin). Usually contain volatile organic compounds (VOCs) with potentially greenhouse effect. In general, the penetrant testing operation produces a large quantity of waste (effluent, rags, empty cardboard packing).

VOCs are the cause of the ozone layer destruction. The ISO 14001 and the related European Directives, lead each firm to reduce its VOC emissions.

The implementation of penetrant inspection required large quantities of energy particularly for drying parts.

Environmental challenges and objectives of the Green Testing project: Reduce environmental pressures (energy consumption, greenhouse gases and VOCs emission, waste production by 20% to 30%), the potential risks to operators health and the tasks arduousness. Reduce drastically inspection costs (from 20% to 40%). Reduce environmental pollution (by 90%) through the provision of alternative technologies.

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Risks for the operator associated with the Topic Sheet implementation of penetrant inspection

03

Indirect risks: Risks associated with handling parts (parts dropping, fingers jamming). Burns risks (drying equipments and hot parts).

Electrical hazards : Electrocution hazards due to the use of both electrical sources (lights for example) and water simultaneously to achieve the penetrant inspection.

Risques of explosion due to spray cans: Care must be taken when using aerosols near direct heat sources (welding, hot parts, for example) because of the flammability of materials used and the risk of explosion of spray cans.

Risks related to vapors exposure of penetrant materials (solvents and organic products): Exposure to solvent and organic product vapors is deemed hazardous to health.

Risks related to UV radiation: Aging and skin cancer. Eyes problems(cataract).

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Ressuage
Topic Factsheet Sheet

P04 04

Approach to reduce the environmental footprint of the penetrant testing

To manage the environment in everyday life:

Generally speaking, companies must invest in a policy of proactive protection, for example by setting up an environmental management system (EMS).

The eco approach within the company has been built according to a structured set of steps and controlled at every level of their implementation.

Making an environment diagnosis : Waste diagnosis: waste management by controlling the processing costs, waste reduction and establishment of a sorting and selective collection at the source ... Energy diagnosis: hunt wasting; energy saving solutions, energy recovery solutions (heat). Gaseous and liquid effluents diagnosis: optimized choice cost / performance of the treatment system ; reducing the amount of effluent at the source ; reusing treated wash water; recovering excess of used materials. Other possible diagnoses: dust and particles; odors; noises.

To inform and educate the different agents or stakeholders

Monitoring: nuisance registry to record incidents occurred and responses relative to the environment feedback.

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Approach to reduce the environmental footprint of the penetrant testing

To reduce incomings and outgoings:

Topic Sheet

P04

In every industrial process, all incoming and outgoing parts have a greater or lesser impact on the environment, that it is necessary to minimize as possible.

The incomings: Cleaning products. Products required for the implementation of the penetrant testing process (penetrant, developer). Electrical energy required mainly for drying operations. Water used for cleaning operations and for penetrant excess removing.

The outgoings: Wastes (cartons, empty spray cans, rags and papers, damaged control equipments : UV or white lightings ,). Sewages and residual cleaning products contaminated by organic or solid debris (penetrating and developer products, residual oil and grease).

Other possible nuisances: Odors caused by chemicals used or from effluents (air extractor) treatment plant. Noise due to control devices (ventilation noise of penetrant testing line and drying ovens or drying guns blowing hot air). Noise due to the handling parts in production control plant (falling of parts in the waste good containers at the end of the testing line of control for example).

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Practices to minimize risk of accidents and impact on operators health

Solutions to reduce risks of accident:

Topic Sheet

P04

Collective protective equipments: Ventilation and purifying atmosphere at the workplace. To delimit / or mark the access to dangerous areas. Protection by recording a dangerous function during interventions. Identification of dangerous products to prevent inadvertent use. Hazard signs To delimit work areas.

Personal protective equipments: Safety shoes and helmets. Goggles. Gloves, protective clothes. Masks and breathing equipments. Hearing protections (falling of parts in the scrap good containers at the
end of the testing line for example).

Give a sens of responsability at the operators : To take into consideration the user sheet of chemical products (by referencing to the company doctor who has at disposal the health and safety). To know the location of the fine extinguishers and their functionary use. Dont leave tools or parts on the ground in the workshop. To keep working equipments and accessories at their place and clean the working place.

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Improvements for a greener manual penetrant testing

Topic Sheet

P04

Penetrating products:
Purchase products in bulk rather than spray cans: Diminution of the quantities of packaging and aerosol cans. Give priority to water-based products rather than organic-based products: Reduction of VOC emissions. Non-flammable products. Effluent treatment simplified and maintenance costs reduced (low fouling). Eliminating the inherent risk due to the use of organic solvents (harmful vapours, skin irritation, ...). Make easier removal of penetrant excess by water easier. To prefer electrostatic processes: although expensive, they allow the reduction of quantities of products required for the penetrant testing operation.

Ecologic inspection products

Spray systems:
Preferred rechargeable spray systems (with an adapted spray nozzle and mechanical pressure by pumping): Waste quantity reduced. Quantity of PT products reduced by 4 compared to the use of an aerosol. Does not require gas propulsive.

Lighting systems:
Preferred LED lamps (white light or UV) to conventional bulbs: Greater light intensity. Energy consumption 50 times smaller than for mercury vapor lamps (2.5 W instead of 100W). Longer life (over 10,000 hours). Less hazardous waste to the environment (especially mercury vapor lamps UV lamps).

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Improvements for a greener manual penetrant testing

Effluent recovery systems :
Using cleaning fountains with recycling of cleaning products by debris filtration: Reduces the amount of solvent required for cleaning. Use of recovery equipment and wastewater filtration (activated carbon): Prevents the spread of effluents into the environment and allows their treatment. Use extractor hood and filtering systems of organic vapors: Prevents the spread of toxic vapours into the atmosphere. Protects the operator against toxic vapours inhalation.

Topic Sheet

P04

Ecologic inspection products

Work stations are generally autonomous and equiped with a hood.

Drying systems:
Preferred drying systems which consume less energy: Drying by infrared lamps for example, which can complement the usual drying systems (oven and air oven).

Penetrant testing stations:

To prefer penetrant stations use, promoting the implementation of the process and reducing risks significantly: Recovery by draining parts. Parts handling easier. Opportunity to recover heat from drying ovens.

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