Doc.No.

WKI-QC-02-03

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FUNCTIONAL PROCEDURE Rev.00

Date: 24/07/2011

DYE PENETRATION TEST

TABLE OF CONTENTS

O SCOPE

O REFERRENCE DOCUMENTS

O PERSONNEL QUALIFICATION

O EQUIPMENT AND MATERIAL

O EVALUATION OF INDICATION

O ACCEPTANCE CRITERIA

O EXAMINATION OF REPAIRS

O REPORTS
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DYE PENETRATION TEST

1. SCOPE
This procedure is based on ASME B 31.3 and for performance of liquid penetrant
examination of welds and Carbon and Stainless Steel Materials by solvent removal
method. The materials, shapes, size and extent of examination is indicated on
production drawings and travelers as per ASME Code, Current applicable Edition and
Addenda.

2. REFERENCE DOCUMENTS

1. ASME B31.3, Process Piping, 2004 Edition.

2. ASME Section V, Article -6; 2004 Edition.

3. American Society for Nondestructive Testing Recommended Practice SNT-TC-1A

4. Welding and NDE of Piping System as per project specifications.

3. PERSONNEL QUALIFICATION
The personnel performing shall have been qualified in accordance with written procedure
which meets the requirements of the ASNT Recommended Practice SNT-TC-1A (Current Code
Accepted Edition) and certified as an NDE Level II in the Liquid Penetrant Examination
method. The Interpretation of results shall be performed by personnel certified Level II or III

The examiner shall have an annual vision test, with correction if necessary and be able to read
a minimum of Jaeger Type No. 1 or equivalent type and size letter at a distance of not less
than 12 inches (30.5 cms) on a Standard Jaeger Test Chart. He should be capable of
distinguishing and differentiating contracts between color used.

4. EQUIPMENT AND MATERIAL

4.1 One of the following solvent removable may be used for the Liquid
penetrant Examination described as per the Table -1

4.2 When Nickel base alloys are to be examined, materials to be

certified as containing less than 1% Sulphur by weight.

4.3 When Stainless Steels are to be examined. Materials are to be

certified as containing less than 1% Chlorine by weight
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Table -1

MANUFACTURERS DESIGNATION
Cleaning Solvent Penetrant Developer

Magnaflux Corp SKC-NF SKL-HF/S SKD-NF

Magnaflux Corp SKC S SKL SP SKD S2

Magnaflux Corp SKC-S SKL-SP1 SKD- S2

5. PROCEDURE
Surface preparation by grinding, machining or other methods may be necessary where
surface irregularities could mask unacceptable discontinuities. The area to be examined
shall be cleaned, dry and free of contamination and irregularities which could mask or be
confused with a defect. In general, as welded, as cast, as forged, as rolled surfaces are
satisfactory. Welds shall include a band of base metal at least 25 mm on each side of the weld.

Drying of the pre-cleaned surfaces may be accomplished by forced hot air, or exposure to
ambient temperature.

The temperature of the penatrant material and surface being tested shall be within the
following range 50o F to 125o F through out the examination period other temperatures and
time may be used provided the procedure are qualified in accordance with T-653 of Article 6 of
the ASME Code Sec. V.

The Dye-penetrant shall be applied to the surface being examined the entire surface
being examined shall be maintained wet with the dye-penetrant a minimum dwell time as
recommended as per Manufacturer Recommendation or in table 1 shall be used. The
Penetrant shall not be allowed to dry during this period. The penetrant may be applied by
brushing, dipping or spraying.

After the required Dwell time, remove the excess Penetrant, taking care to minimize
removal of penetrant from discontinuities.

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 surface with cloth or absorbent paper
moistened with solvent.
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For the solvent removable technique, the surfaces may be dried by normal evaporation,
blotting, wiping, or forced air.

Apply developer as soon as the part is dry to all surface being inspected by spraying.

Examination shall begin not sooner than 10 minutes after the developer appears dry
(i.e Solvent carries have evaporated to dryness). If bleed out does not alter the inspection
results, the maximum developing times of 2 hours for aqueous and 1 hour for non aqueous,
developer are permitted.

Examination of parts after the applicable developments time to assure proper bleed out of
penetrant from discontinuities on to the developer coating. It is good practice to observe the
surface while applying the developer as an aid in evaluating. Indications.

Keep the inspection area free of interfering debris.

Post cleaning is necessary 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.

Post cleaning shall be performed with the materials listed in Table-1. Wiping until all signs of
Penetrant and developer have been removed shall be adequate.

The examiner shall demonstrate his ability to perform Liquid Penetrant Examination prior to
being allowed to examine production pieces.

6. EVALUATION OF INDICATIONS
The specific part, component, vessel, or section thereof under examination shall be
illuminated to attain a minimum of 100 foot-candles at the surface. A standard industrial
flashlight placed within 28 inches of the surface being examined may provide this lighting
intensity.

Defects on the surface to be examined will be revealed as red stains in the white
developer background. An indication of a discontinuity may be larger than the discontinuity that
caused it; however, the size of the indication and not the size of the discontinuity is the basic
for acceptance or rejection.

Mechanical discontinuities at the surface are revealed by bleeding out of the penetrant;
however, localized surface discontinuities, such as machining marks, surface conditions, or an
incomplete bond between base metal and cladding, may produce similar indications which are
not relevant. Mechanical discontinuities are actual or real openings in the surfaces of the
material such as cracks, laps, slag, porosity, incomplete fusion, etc., or any interruption in the
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normal physical structure of the material (weld or base metal) which will cause detectable
penetrant indications.

Any indication in excess of the acceptance standards, which is believed to be

nonrelevant, shall be reexamined to verify whether or not actual defects are present. Surface
conditioning may precede the reexamination. Nonrelevant indications or broad areas of
pigmentation, which would mask defects, are unacceptable.

Relevant indications are indications from imperfections. Linear indications are

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 than three times the
width.

7. ACCEPTANCE CRITERIA
Acceptance will as per ASME B31.3

For weld made to the requirement of ASME B31.3 the only criterion is
that no cracks are allowed. If indications other than the cracks are found,
they shall evaluated in accordance with ASME B31.3 Visual Examination
acceptance criteria.

8. EXAMINATION OF REPAIRS
Repairs shall be re-examined by the same method used for the original examination.

9. REPORTS
The NDT examiner shall prepare a DYE PENETRANT EXAMINATION Report in the
form as attached, given by the Contractor and when the material or weld is not
acceptable to the requirements, the item(s) shall be marked for Repair.

TABLE-2

RECOMMENDED MINIMUM DWELL TIMES

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Material Form Type of Discontinuity Dwell time (min)

Penetrant Developer
Aluminum, magnesium Casting and Cold Shuts, Porosity 5 10
Steel, Brass & Bronze welds Lack of fusion, Cracks
Titanium and high (all forms)
temperature alloys.
Wrought Laps, 10 10
materials Cracks (All forms)
extrusions,
Forging,
Plate
Carbide tipped tools Lack of fusion, porosity, 5 10
cracks
Plastic All Forms Cracks 5 10
Glass All Forms Cracks 5 10
Ceramic All Forms Cracks, porosity 5 10