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Procedure No.

: OPS-PR-LPI-004-QP
Initial Issue Date : 20-Feb-2011
1 Revision No. : 00
Page 1 of 13
TITLE: LIQUID PENETRANT EXAMINATION

Company Name
GLOBAL INSPECTION SERVICES W.L.L.
Mailing Address P. O. Box 22410
DOHA QATAR

Telephone + (974) 4460 4550

Fax + (974) 4460 4054

Email technical.qa@gismea.com.

Document Title LIQUID PENETRANT EXAMINATION

Document Ref. # OPS-PR-LPI-004-QP Revision 00

Client

Contract #

Project Description

Revised to incorporate Anup Nair M.R. Sarath Babu


00 20-Feb-11 client comments Technical Support ASNT NDT Level III
(184206)

Revision Date Revision Details Prepared By Reviewed and Approved By

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Procedure No. : OPS-PR-LPI-004-QP
Initial Issue Date : 20-Feb-2011
1 Revision No. : 00
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TITLE: LIQUID PENETRANT EXAMINATION

TABLE OF CONTENTS
1. SCOPE

2. QUALIFICATION OF PERSONNEL

3. REFERENCED CODES AND/OR STANDARDS

4. DEFINITIONS

5. SUMMARY OF TEST METHOD

6. CLASSIFICATION OF METHODS

7. MATERIALS

8. PROCEDURE

9. ACCEPTANCE CRITERIA

10. SAFETY

11. RECORDS

12. REPORT FORM

APPENDIX

I. Ultraviolet (UV) Light Intensity Log

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Procedure No. : OPS-PR-LPI-004-QP
Initial Issue Date : 20-Feb-2011
1 Revision No. : 00
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TITLE: LIQUID PENETRANT EXAMINATION
1. SCOPE

1.1. This procedure establishes the minimum requirements for solvent removable liquid penetrant
examination of welds and components intended for Installation project of low pressure
associated gas compressor at Halul Island. The methods covered in this procedure can be
effectively used when performing specific tests on welds and components of non porous
materials and detect discontinuities that are open to surface.

1.2. Only Type I Method C (Solvent Removable Fluorescent Penetrant) and Type II Method C
(Solvent Removable Color Contrast Penetrant) Liquid Penetrant methods shall be applicable
to this procedure.

1.3. Final examination for acceptance of welds and components shall be performed after
completion of any heat treatment. On welds which are not subjected to PWHT, NDT for
acceptance purpose shall be performed no sooner than 48 hours after completion of welding.

1.4. If required by the client, the procedure shall be qualified on relevant test pieces.

2. QUALIFICATION OF PERSONNEL

2.1. All liquid penetrant examination personnel shall be qualified and certified to Level II in
accordance with GLOBAL INSPECTION SERVICES (hereinafter called GIS) Written Practice
OPR-PR-WP-014, prepared in accordance with SNT-TC-1A of ASNT and with a minimum two
years post certification experience.

2.2. The examination shall be performed, evaluated and interpreted by only a PT Level II qualified
personnel.

3. REFERENCED CODES AND/OR STANDARDS

3.1. ASME Boiler and Pressure Vessels Code Section V, Article 6 (2007 Ed.)
3.2. ASTM-Metal Test Methods and Analytical Procedures Vol: 03.03 Non-Destructive Testing
3.2.1. ASTM - E 165/02 Standard Test Method for Liquid Penetrant Examination
3.2.2. ASTM - E 1219/05 Standard Test Method for Fluorescent Liquid Penetrant
Examination using Solvent-Removable Process
3.2.3. ASTM - E 1220/05 Standard Test Method for Visible Penetrant Examination using
Solvent-Removable Process
3.3. ES-S-60 QP Specification for the Non Destructive Examination of Welds

3.4. ES-5.14.0020 Specification for the Fabrication, Inspection and Installation of process
pipe work in Austenitic Stainless Steel, Copper Base and Nickel Base
Alloys.

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Procedure No. : OPS-PR-LPI-004-QP
Initial Issue Date : 20-Feb-2011
1 Revision No. : 00
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TITLE: LIQUID PENETRANT EXAMINATION
4. DEFINITIONS

4.1. Penetrant
A solution of dye, either visible or fluorescent, capable of entering discontinuities open to
surface.

4.2. Developer Non-aqueous or Developer Solvent


A material that is suspended in a non-aqueous medium viz. a solvent that is applied to the test
surface to accelerate bleed-out and to enhance the contrast of indications.

4.3. Bleed-out
Action of an entrapped liquid penetrant in surfacing from discontinuities to form indications.

4.4. Blotting
The action of the developer in soaking up the penetrant from the discontinuity to accelerate the
bleed-out.

4.5. Dwell Time or Penetration time


The total time that the penetrant is in contact with the test surface, including the time required
for application.

4.6. Penetrant Materials


The term "Penetrant Materials" is intended to include all penetrants, solvents or cleaning
agents, and developers used in the examination process.

4.7. Type I, Method C Materials


These materials consist of a solvent-removable fluorescent penetrant, a penetrant remover
(solvent), and a non-aqueous suspendible developer.

4.8. Type II, Method C Materials


These materials consist of a solvent-removable color contrast (visible dye) penetrant, a
penetrant remover (solvent), and a non-aqueous suspendible developer.

4.9. Linear Indication


An indication whose length is greater than three times its width.

4.10. Rounded Indication


An indication which is circular or elliptical and whose length is three times or less its width.

4.11. Relevant Indication


An indication resulting from a discontinuity requiring evaluation.

5. SUMMARY OF TEST METHOD

5.1. A liquid fluorescent or visible dye penetrant is applied evenly over the surface being tested and
allowed to enter discontinuities open to surface. After a suitable dwell time, the excess surface
penetrant is removed and the surface is dried prior to the application of a non-aqueous
developer. The developer causes the bleed-out of the entrapped penetrant out of the
discontinuity staining the developer. The surface is then examined visually or under black light
to determine presence or absence of indications.

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Procedure No. : OPS-PR-LPI-004-QP
Initial Issue Date : 20-Feb-2011
1 Revision No. : 00
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TITLE: LIQUID PENETRANT EXAMINATION
6. CLASSIFICATION OF METHODS

6.1. Detailed sequence of penetrant examination methods and types used by this procedure are
given in the following paragraphs. Paragraph 8.2 covers Type I Method C, Solvent-Removable
Fluorescent Penetrant Examination. Paragraph 8.3 covers Type II Method C, Solvent-
Removable Color Contrast (Visible Dye) Penetrant Examination.

7. MATERIALS

7.1. Fluorescent penetrant examination should not be applied to test objects which have been
tested prior with visible penetrant method.
7.2. Penetrant materials used shall belong to the same manufacturer and family of particular type
of penetrant used.
7.3. The following family of penetrant materials shall be used:

FAMILY OF PENETRANTS
METHOD MANUFACTURER PENETRANT CLEANER DEVELOPER
Type I Method C CHEMETALL ADROX 9VF2 ADROX 9PR5 ADROX 9D1B
Type II Method C CHEMETALL ADROX 996PA ADROX 9PR5 ADROX
9D1B/HFD

7.3.1. Documented test shall be performed to confirm if substitute penetrant matters are equal
to those listed in Table 7.3.
7.4. It shall be ensured that all penetrant materials used for liquid penetrant examination shall be
certified by the manufacturer to be in compliance with the residual sulfur and the halogen
requirements which may prove detrimental to certain materials like austenitic stainless steels,
titanium, nickel-base or other high-temperature alloys.
7.4.1. Batch certificates for penetrant materials shall be maintained for materials used to test
nickel based alloys, austenitic stainless steels and titanium.
7.4.2. For nickel based alloys, sulfur content shall be limited to 1% or less residue by weight.
For austenitic stainless steels and titanium, chlorine plus fluorine content shall be limited
to 1% or less". The halogen content of penetrant materials shall not exceed 1%.
8. PROCEDURE

8.1. The following general procedure shall apply to both Type I Method C and Type II Method C
methods of liquid penetrant examinations:
8.1.1. Temperature Limits: It shall be ensured that the temperature of penetrant materials and
the surface of the materials to be tested shall be between 15C and 52C for the
fluorescent liquid penetrant testing. For the visible color contrast dye penetrant testing,
the penetrant materials and the surface of the part examined shall be from 15C to
52C.In any case the manufacturer's recommendations while using these solvent based
penetrant materials shall be strictly complied with. Temperature of the surface being
tested shall be verified by a calibrated temperature gauge. Qualification tests results for
temperatures not in compliance with ranges in this procedure shall be submitted to the
client for review and approval.

8.1.2. Surface condition of the part under test prior to examination: The surface to be examined

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Procedure No. : OPS-PR-LPI-004-QP
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TITLE: LIQUID PENETRANT EXAMINATION
shall be free from rust, scale, paint, slag, sand, greases, oily films or other conditions
which could interfere with the examination. It shall be ensured that the surface of the part
under examination is not subjected to shot sand or grit blasted without the approval of
the client.

8.1.3. Removal of Surface Contaminants: Pre-cleaning of the surface to be tested is utmost


essential so that no contaminants interfere with the penetrant process. All surfaces to be
examined shall be thoroughly cleaned by spraying the part with the corresponding
penetrant materials cleaning as per the method required. Other cleaning processes like
use of detergents, vapor degreasing etc. shall also be permitted provided they are finally
given a solvent soak and proper drying is ensured prior to application of penetrant. Use
of dry lint-free cloths for removal of excess cleaner is permitted. When cleaners other
than the penetrant manufacturer's corresponding cleaner/remover, a final pre-cleaning
step shall be added whereby the manufacturer's corresponding cleaner shall be used.

8.2. Type I Method C Solvent Removable Fluorescent Penetrant Examination:

8.2.1. Penetrant Application: Pre-cleaning shall be as per Para 8.1.3. Use of only Ardrox
9PR5 as a cleaning medium is permitted. After ensuring the part has been thoroughly
dry after cleaning and is within the specified temperature range i.e. 15C - 25C. Local
heating or cooling is permitted provided that the part temperature remains in the range of
15C - 52C. The penetrant 9VF2 shall be applied to the surface being examined so that
the entire part or the area under examination is completely covered with penetrant.
Application of penetrant shall be effected by spraying with aerosol cans or by brushing
with cloth dipped in penetrant depending on the geometry and area to be covered.
Minimum wait time between pre-cleaning and penetrant application shall be five (5)
minutes to a maximum of one (1) hour. The area pre-cleaned shall include at least 1"
(25mm) past both (all) sides of the area of interest.

Inspection of all welds shall include a band of base metal at least one inch wide on each
side of the weld.

8.2.2. Dwell Time: After application, penetrant shall remain on the surface of the part being
tested for a dwell as specified below. Care shall be taken for the part to remain wet
throughout the penetration time. If the penetrant dries on the surface of the part, it shall
be subjected to complete reprocessing beginning with initial pre-cleaning.

Dwell Times
Penetrant Developer
Casting and welds 10 minutes 10 minutes

Wrought materials, 20 minutes 10 minutes


extrusions, forgings, plate, etc.

8.2.3. Penetrant Removal: The excess penetrant shall be removed after the required
penetration time by using clean dry cloth or other lint-free material. The process shall be
repeated until most traces of penetrant have been removed. The adhering penetrant
shall be removed with a clean cloth moistened with penetrant remover 9PR5. Flushing
the surface with the cleaner following the application of the penetrant prior to
developing is prohibited. Care shall be taken not to dampen the cloth during the
solvent-wipes. A black light shall be used to assure complete excess penetrant removal.

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Procedure No. : OPS-PR-LPI-004-QP
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TITLE: LIQUID PENETRANT EXAMINATION
8.2.4. Drying: The surface of the part being examined shall be dried before application of
developer through solvent-wipes. The part shall not be allowed to remain dry for very
long periods. The surface may be dried by normal evaporation, blotting, wiping, or forced
air.

8.2.5. Developer Application: Areas to be examined shall be sprayed with ADROX 9D1B
evenly so as to form a thin even film of developer layer. The spraying cans shall be
thoroughly agitated before spraying to thoroughly mix the ingredients. The developer
shall be applied as soon as possible after penetrant removal. The time interval between
penetrant removal and developer application shall not exceed ten (10) minutes.

8.2.6. Developing Time: Developing time for final interpretations begins immediately after
developer coating is dry. Final interpretation shall be performed between 10 to 30
minutes after the developer coating is dry. To aid in interpretation of the test results, the
surface of the part shall be continuously observed from the point developer is applied.

8.2.7. Examination and Evaluation of indications: All indications shall be considered as


relevant until the origin is determined. Relevant indications shall be evaluated on the
size of the penetrant "bleed out" (stain) created by the developer's absorption of the
penetrant. Examination of the surface shall be performed using a black light with a
measured intensity of 1000 W/cm as measured at the surface of the part being tested.
Testing shall be performed in a darkened area where measured ambient light levels do
not exceed 2fc (20 lux).

8.2.7.1. Allow the black light to warm up for a minimum of 10 minutes prior to its use or
measurement of the intensity of the ultraviolet light emitted.

8.2.7.2. Light meters, both visible and fluorescent (black) light meters, shall be calibrated
at least every six months or whenever the meter has been repaired.

8.2.7.3. The black light intensity shall be measured with a calibrated black light meter
prior to use, whenever the lights power source is interrupted or changed, and at
the completion of the examination or series of examinations and recorded on a
log sheet and shall be kept with the black light unit at all times and monitored for
intensity fading before each usage.

8.2.7.4. The examiner shall be in the darkened area for at least five (5) minute prior to
performing the examination to enable his eyes to adapt to dark viewing. Glass or
lenses worn by examiners shall not be photosensitive.

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Procedure No. : OPS-PR-LPI-004-QP
Initial Issue Date : 20-Feb-2011
1 Revision No. : 00
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TITLE: LIQUID PENETRANT EXAMINATION
8.3. Type II Method C Solvent Removable Color Contrast (Visible) Penetrant Examination

8.3.1. Penetrant Application: Pre-cleaning shall be as per Para 8.1.3. Use of only Ardrox
9PR5 as a cleaning medium is permitted. After ensuring the part has been thoroughly
dry after cleaning and is within the specified temperature range i.e. 15C - 52C. Local
heating or cooling is permitted provided that the part temperature remains in the range of
15C - 52C .The penetrant ADROX 996PA shall be applied to the surface being
examined so that the entire part or the area under examination is completely covered
with penetrant. Application of penetrant shall be effected by spraying with aerosol cans
or by brushing with cloth dipped in penetrant depending on the geometry and area to be
covered. Minimum wait time between pre-cleaning and penetrant application shall be
five (5) minutes to a maximum of one (1) hour.
Inspection of all welds shall include a band of base metal at least one inch wide on each
side of the weld.

8.3.2. Dwell Time: After application, penetrant shall remain on the surface of the part being
tested for a dwell as specified below. Care shall be taken for the part to remain wet
throughout the penetration time. If the penetrant dries on the surface of the part, it shall
be subjected to complete reprocessing beginning with initial pre-cleaning.

Dwell Times
Penetrant Developer
Casting and welds 10 minutes 10 minutes

Wrought materials 20 minutes 10 minutes


extrusions, forgings, plate, etc.

8.3.3. Penetrant Removal: The excess penetrant shall be removed after the required
penetration time by using clean dry cloth or other lint-free material. The process shall be
repeated until most traces of penetrant have been removed. The adhering penetrant
shall be removed with a clean cloth moistened with penetrant remover ADROX 9PR5.
Flushing the surface with the cleaner following the application of the penetrant prior to
developing is prohibited. Care shall be taken not to dampen the cloth during the solvent-
wipes.

8.3.4. Drying: The surface of the part being examined shall be dried for at least 5 minutes
before application of developer through solvent-wipes. The part shall not be allowed to
remain dry for very long periods as it may reduce the sensitivity of operation. The
surface may be dried by normal evaporation, blotting, wiping, or forced air.

8.3.5. Developer Application: Areas to be examined shall be sprayed with 9D1B/HFD evenly
so as to form a thin even film of developer layer. The spraying cans shall be thoroughly
agitated before spraying to thoroughly mix the ingredients. The developer shall be
applied as soon as possible after Penetrant removal. The time interval between
penetrant removal and developer application shall not exceed ten (10) minutes.

8.3.6. Developing Time: Developing time for final interpretations begins immediately after
developer coating is dry. Final interpretation shall be performed between 10 to 30
minutes after the developer coating is dry. To aid in interpretation of the test results, the
surface of the part shall be continuously observed from the point developer is applied.

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TITLE: LIQUID PENETRANT EXAMINATION
8.3.7. Examination and Evaluation of indications: All indications shall be considered as
relevant until the origin is determined. Relevant indications shall be evaluated on the
size of the penetrant "bleed-out" (stain) created by the developers absorption of the
penetrant. The examination area shall be observed under either natural or artificial white
light. The light intensity at the examination surface shall be a minimum of 100fc (1000
lux) measured by a calibrated white light meter.

8.4. Post Cleaning: The penetrant materials shall be removed as soon as possible after evaluation
and documentation by flushing the part with the cleaner and wiping with clean cloths.

9. ACCEPTANCE CRITERIA

9.1. The indication of a discontinuity may be larger than the actual discontinuity that causes it,
however, the size of the indication and not the size of the discontinuity is the basis for
acceptance or rejection.

9.2. Arc strikes outside of the weld preparations shall not be acceptable. The arc strike found
during examination shall be ground out to smooth profile and subjected to LPI.

9.3. Acceptance criteria for examinations performed shall be based on either ES.5.14.0020 Table-
6 or ASME Sec VIII, Division 1, Appendix-8 as stipulated by specification.

Acceptance criteria ES.5.14.0010 table-6

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TITLE: LIQUID PENETRANT EXAMINATION
Acceptance criteria ASME Sec VIII, Division 1, Appendix-8

1. Evaluation of Indications
An indication is the evidence of a mechanical imperfection. Only indications with major dimensions
greater than 1/16 in. shall be considered relevant.
1.1. A linear indication is one having a length greater than three times the width.
1.2. A rounded indication is one of circular or elliptical shape with the length equal to or less than
three times the width.
1.3. Any questionable or doubtful indications shall be reexamined to determine whether or not they
are relevant.

2. Acceptance Standards
These acceptance standards shall apply unless other standards are specified for specific
applications within this Division. All surfaces to be examined shall free of:
2.1. relevant linear indications;
2.2. relevant rounded indications greater than 3/16 in. (4.8 mm);
2.3. four or more rounded indications in a line separated by 1/16 inch (1.6mm) or less (edge to
edge);
2.4. 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.

3. Treatment of imperfections believed non-relevant


Any indication which is believed to be non-relevant shall be regarded as a imperfection unless it is
shown by reexamination by the same method or by the use of other nondestructive methods and/or
by surface conditioning that no unacceptable defect is present.

4. 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 the defect has been removed or reduced to an acceptably
sized imperfection.

5. Report
5.1. Identify all examination reports to permit positive correlation with the material or part
examined.
5.2. Identify the equipment and examination medium in sufficient detail to permit duplication of the
examination at a later date.
5.3. Provide a sketch, chart, or marked-up drawing to show coverage and orientation if necessary
for clarity and/or to permit duplication of the examination.

10. SAFETY

10.1. The minimum safety requirements when performing liquid penetrant testing shall be:

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Procedure No. : OPS-PR-LPI-004-QP
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TITLE: LIQUID PENETRANT EXAMINATION
10.1.1. Penetrant materials are highly volatile, relatively toxic and may cause skin irritation. Use
adequate ventilation at all times and avoid prolonged skin contact.

10.1.2. Penetrant material aerosol cans should be kept out of direct sunlight or areas in excess
of 130 F.

10.1.3. Adequate and correct PPE to be used at all times, i.e. gloves, respirator (face mask).

10.1.4. Ensure MSDS is available and it is read and understood by all.

11. RECORDS

11.1. Nonrejectable Indications shall be recorded as specified by the referencing Code Section.

11.2. Rejectable Indications shall be recorded. As a minimum, the type of indications (rounded or
linear), location and extent (length or diameter or aligned) shall be recorded.

11.3. The following information shall be recorded for each examination:

11.3.1. procedure identification and revision


11.3.2. Stage of inspection
11.3.3. Surface Condition.
11.3.4. liquid penetrant type (visible or fluorescent)
11.3.5. type (number or letter designation) of each penetrant, remover and developer used
11.3.6. material and thickness
11.3.7. Technique Number and essential parameters.
11.3.8. lighting equipment
11.3.9. record of examination
11.3.10. examination personnel identity, qualification level
11.3.11. date and time examinations were performed

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Procedure No. : OPS-PR-LPI-004-QP
Initial Issue Date : 20-Feb-2011
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TITLE: LIQUID PENETRANT EXAMINATION
12. REPORT FORM

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Procedure No. : OPS-PR-LPI-004-QP
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TITLE: LIQUID PENETRANT EXAMINATION
Appendix - I

Ultraviolet (UV) Light Intensity Log

UV Light Manufacturer: UV Light Model:


UV Light Sr. No.: Calibration dated:

Date Intensity @ 15 inches Technician Date Intensity @ 15 inches Technician

Notes:
1. The ultraviolet light intensity at the examination surface shall be measured:
a. At least every 4 hours
b. Whenever the work location is changed
c. After changing a filter or bulb
d. After a UV light unit failure

2. If UV meter reads lower than 1000W/cm, clean the filter as required and re-measure. If still
below 1000W/cm, replace the bulb.

3. UV light intensity shall be minimum 1000W/cm at 15 inches in a darkened area and 3000W/cm
at 15 inches in other areas of ambient white light which exceed 2 ft candles.

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