INDEX

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 PERNAL QUALIFICATION

4.0 SAFETY

5.0 PROCEDURE QUALIFICATION

6.0 PERFORMANCE DEMONSTRATION

7.0 CONSUMABLE & ACCESSORIES

8.0 INSPECTION

9.0 EVALUATION

10.0 ACCEPTANCE CRITERIA

11.0 REPORTING

12.0 RECORDS

13.0 ANNEXURE-1

Project No.: P 90115

DOCUMENT TITLE:
ADCO Doc. No. 11.99.97.2665
LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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1. SCOPE

This procedure describes guide lines for the detection of open to surface
discontinuities of welds including band of 25mm width on each side of the weld and
the Ferrous and Non-ferrous materials such as CS and SS etc. in accordance with
the Boiler and Pressure Vessels Code ASME Section V. for the Project both
Pipeline per ASME B31.8 and Process Piping per ASME B31.3

This document shall cover the liquid penetrant examination using Visible Solvent
Removable Color Contrast Method. Typical discontinuities detectable by this
method are cracks, seams, laps, laminations and porosity. The extent of
examination shall be as per applicable construction-Code requirements / project
specifications and client directives.

2. REFERENCE DOCUMENTS( ALL LATEST EDITIONS)

Boiler and Pressure Vessel Code for Non Destructive

2.1 ASME Section V
Testing
Welding of Pipeline and Related Facilities
2.2 API -1104

Amendments/Supplements to
2.3 ADCO Doc. No. 30.99.00.0032
DEP 61.40.20.30-Gen

2.4 DEP 61.40.20.30-Gen Welding of Pipelines and Related Facilities

2.5 ADCO Doc. No. 11.99.12.1705 Specification for NDT

2.6 ADCO Doc No. 31-38-01-31-A Amendments/Supplements to DEP 31.38.01.31-GEN

Specification for Welding of Pipelines and

2.7 ADCO Doc. No. 11.99.12.1617
Related Facilities
Guidelines for Personnel Qualification &
2.8 ASNT SNT TC –1A
Certification
Gas Transmission and Distribution Piping
2.9 ANSI / ASME B31.8
Systems

2.10 ASME B31.3 Process Piping

Welding and Welding Inspection of Shop and

2.11 ADCO Spec. No. 30.99.0041-1
Field Carbon Steel Process and Utility Piping
Boiler and Pressure Vessel Code for Non Destructive
2.12 ASME Section V
Testing

Project No.: P 90115

DOCUMENT TITLE:
ADCO Doc. No. 11.99.97.2665
LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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3. PERSONNEL QUALIFICATION

The qualification of NDT Inspector to carry out this testing shall be minimum of
ASNT Level II in accordance with the company’s Written Practice NDT-SOP-001-
03, which is in accordance with documents ASNT SNT- TC -1A in Liquid Penetrant
Testing method.

4. SAFETY

All personnel shall be aware at all times of hazards both of site and method in order to
prevent accident or injury to self or others.
4.1 General
Care shall be taken when using the following,

 Avoid contact with eyes and skin.

 Electrical items such as lamps, ensuring undamaged wiring, correct plug for
socket, correct voltage, etc.

 Keep the aerosol cans away from any direct heat or flame.

 Check the surface temperature before applying.

 Scaffolding, safe and suitable for application with ladders lashed, etc.

 Lighting adequate for full illumination of the work area.

4.2 Specific

 As penetrant test materials are highly volatile, toxic, hydrocarbon based and
inflammable, care should be taken when working near naked flame.

 Being supplied in aerosol form, care to be taken when exposed to heat, and
cans must not be left in direct sunlight.

 When handling materials, wash hands immediately after use, flush eyes with
lukewarm water in event of contamination; avoid smoking, eating and drinking
whilst using products.

5. PROCEDURE QUALIFICATION

The procedure shall be demonstrated to the satisfaction of Client/company and shall

include all the variables as given in Table T621. Record of satisfactory demonstration
including the range of values qualified shall be attached to the procedure.

Project No.: P 90115

DOCUMENT TITLE:
ADCO Doc. No. 11.99.97.2665
LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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 Any change or deviation to essential variables will require revision and re-qualification
of this Procedure. A change of a requirement identified as a nonessential variable does
not need re-qualification of procedure.

The essential variables as detailed below shall remain constant for all the testing.
 Identification of and any change in type or family group of penetrant
 Materials including developers, emulsifiers, etc.
 Surface preparation (finishing and cleaning, including type of cleaning solvent
 Method of applying penetrant
 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 step and drying aids
 Decrease in penetrant dwell time
 Increase in developer dwell time (interpretation time)
 Minimum light intensity
 Surface temperature outside 40˚F to 125˚F (5˚C to 52˚C)
 or as previously qualified
 Performance demonstration, when required

6 PERFORMANCE DEMONSTRATION

When required by referencing Code Section or as per Client requirements,

performance demonstration shall be carried out and documented as report with the
variables used.

7 CONSUMABLE & ACCESSORIES

All penetrant materials used in a particular application shall be of a same family.
Intermixing of materials from different families is not permitted. Readily aerosol cans of
cleaner/remover, penetrant and developer of the following manufacturer shall be used.

Table 1
SI No. Consumable Manufacturer Trade Name Group

1 Remover Chematall Remover S72

2 Penetrant Chematall Checkmore 222 PT 1
3 Developer Chematall LD3/LD7 Liquid Developer
1 Penetrant Spot-check SKL-SP-1
2 Cleaner Spot-check SKC-S Magnaflux PT 2
3 Developer Spot-check SKD-S2

Project No.: P 90115

DOCUMENT TITLE:
ADCO Doc. No. 11.99.97.2665
LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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 A manufacturer batch certificate shall indicate levels of chlorine and sulfur are as per
recommendations of ASME V and is safe for use on austenitic and high nickel steels.

8 INSPECTION

8.1 Surface Preparation

 Test surface to be examined include the weld and adjacent areas within at least
25 mm on either side of the weld edge shall be dry and free from any dust, oil,
grease, water, loose scale, paint or any other extraneous matter that could
obscure surface openings or otherwise interfere with the examination.
 Surface preparation by grinding, machining or other methods may be necessary
where surface irregularities could mask indications of unacceptable
discontinuities.
 Grit sand blasting is not recommended prior to liquid penetrant inspection

8.2 Pre-cleaning

 The Testing area shall be cleaned thoroughly with solvent cleaner by flushing
and wipe with the clean dry lint free cloth.
 Typical cleaning agents which may be used are detergents, organic solvents,
de-scaling solutions, and paint removers. Degreasing and Ultrasonic cleaning
methods may also be used.
 After cleaning with solvent / remover, drying of the surfaces shall be
accomplished by normal evaporation or with forced hot air, or as appropriate. It
shall be ensured that the cleaning solution has evaporated prior to the
application of the penetrant. The minimum and maximum drying time shall be
1 minute and 3 minutes respectively.
 The temperature of the test surface and the penetrant shall be within range of
5° to 52°C (40° to 125°F).
 In case the temperature of the component is outside the range as specified
above, the procedure may be applicable but require re-qualification and revision
as described in Para T-653 of Article 6 of ASME Sec V.

8.3 Application of penetrant

 The penetrant shall be applied by spraying, brushing or swabbing to the surface

being inspected, such that the entire part of the area under inspection is
completely covered with the penetrant.
 When longer penetration times are observed intermittent application of
penetrants shall be carried out in order to avoid drying.

Project No.: P 90115

DOCUMENT TITLE:
ADCO Doc. No. 11.99.97.2665
LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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 8.4 Penetration time (Dwell time)

 The applied penetrant shall be allowed to enter discontinuities. For the test
temperature defined (in Table-2), the minimum penetration (dwell) time shall be
as per Table-13.1 below.
Table-2
Dwell time (minutes)*
Material Form Type of Discontinuity
Penetrant Developer
Aluminium, Castings and welds Cold shuts, porosity, lack
5 10
magnesium, steel, of fusion, cracks (all forms)
brass and bronze, Wrought materials – Laps, cracks (all forms)
titanium and high- extrusions, forgings, 10 10
temperature alloys plate
Carbide-tipped tools Lack of fusion, porosity,
5 10
cracks
Ceramic All forms Cracks 5 10
Glass All forms Cracks 5 10
Plastic All forms Cracks 5 10
*: The minimum dwell times given are valid for the temperature range 100C to 520C. The
minimum Penetrant dwell time shall be 2 times of the value given if the test temperature
0 0
ranges between 5 C to 10 C.

8.5 Removal of excess penetrant

 On completion of the Dwell time solvent based penetrants shall be removed by

lightly wiping with a lint-free cloth, repeating the operation until most traces of
penetrant have been removed. The remaining traces shall be removed by lightly
wiping the surface with a lint free cloth moistened with solvent.
 To minimize removal of penetrant from discontinuities, care shall be taken to
avoid the use of excess solvent.
 Flushing or spraying directly onto the test surface is prohibited as this action
may draw residual penetrant from indication thus negating the examination.
 Drying process shall be accomplished by normal evaporation. The minimum
and maximum drying time shall be 1 minute and 3 minutes respectively.
8.6 Application of developer

 The Non-aqueous wet developer (agitate well before use) is applied directly to
the part by spraying after the removal of excess penetrant. It shall be sprayed in
such a manner as to assure complete part coverage with a thin, even film of
developer.
 The developer evaporates rapidly at normal room temperature and does not
require the use of dryer. However, it should be used with proper ventilation.
 Dipping or Brushing of developer is prohibited.

Project No.: P 90115

DOCUMENT TITLE:
ADCO Doc. No. 11.99.97.2665
LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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8.7 Developing time

 Developer Dwell time shall not be less than 10 minute. The surface shall be
closely examined during application of developer to monitor the behavior of
indications.

 Final evaluation shall be made within 10 to 60 minutes after the application

of the developer.
8.8 Interpretation & Evaluation

 The testing area shall have adequate light to insure no loss of sensitivity in
the examination. A minimum light intensity of 100-foot candle (1000 lux) is
required during the evaluation of indications.
 Indications which have any dimension greater than 1.6 mm shall be
considered as relevant.
 A linear indication is one having a length greater than 3 times its width.
 A rounded indication is one of circular or elliptical shape with a length equal
to or less than 3 times its width.
 Any questionable or doubtful indication shall be retested to verify.
 Careful evaluation is required to discriminate the surface defects due to
machining and grinding.
8.9 Post-Examination Cleaning

Cleaning after testing shall only be undertaken using a process that does not
adversely affect the part and if specified in the purchase order.

9.0 EVALUATION
Only certified Level II Liquid Penetrant Testing personnel shall interpret and
evaluate the testing result.

10.0 ACCEPTANCE CRITERIA

10.1 Pressure containing piping

Indications observed and identified as a crack during testing shall
be evaluated as unacceptable in accordance with the ANSI
B31.3.Table 341.3.2A.

Project No.: P 90115

DOCUMENT TITLE:
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 Table 341.3.2 Acceptance Criteria for Welds and Examination Methods for
Evaluating Weld Imperfections

Criteria (A to M) for Types of Welds and for Service Conditions Examination

(Note (1) ) Method
Normal and Category Service Cyclic Category D Fluid
M Fluid Service Conditions Service
Type of Weld Type of Weld Type of Weld
Longitudinal Groove (Note (2) )

Branch Connection (Note (4) )

Longitudinal Groove (Note (2)
Girth, Miter Groove & Branch

Girth, Miter Groove & Branch

Connection (Note (4) )

Connection (Note (4) )

Girth, Miter Groove

Penetrant Testing
Fillet (Note (3) )

Fillet (Note (3) )

Fillet (Note (3) )

Weld Imperfection
A A A A √ A A A A A Crack √
A A A A √ A C A N/A A Lack of fusion -
B A N/A A √ N/A C A N/A B Incomplete penetration -
N
E E N/A D √ N/A N/A N/A N/A / Internal porosity -
A
N
Internal slag inclusion, tungsten
G G N/A F √ N/A N/A N/A N/A / -
inclusion, or elongated indication
A
H A H A √ A I A H H Undercutting -
Surface porosity or exposed slag
A A A A - A A A A A -
inclusion (Note (5) )
N
N/A N/A N/A J - J N/A N/A N/A / Surface finish -
A
Concave root surface
K K N/A K √ N/A K K N/A K -
(suck up)
Weld reinforcement or internal
L L L L - L M M M M -
protrusion

GENERAL NOTES:
(a) Weld imperfections are evaluated by one or more of the types of examination methods
given, as specified in paras. 341.4.1, 341.4.2, 341.4.3 and M341.4, or by the engineering
design.
(b) “N/A” indicates the Code does not establish acceptance criteria or does not require
evaluation of this kind of imperfection for this type of weld.
(c) Check (√) indicates examination method generally used for evaluating this kind of weld
imperfection.
(d) Ellipsis (-) indicates examination method not generally used for evaluating this kind of weld
imperfection.

Project No.: P 90115

DOCUMENT TITLE:
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LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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 Criterion Value Notes for Table 341.3.2
Criterion
Symbol Measure Acceptable Value Limits ( Note (6) )
A Extent of imperfection Zero (no evident imperfection)
≤ 1 mm (1/32 in.) and ≤ 0.2 Tw
Depth of incomplete penetration
B ≤ 38 mm (1.5 in.) In any 150 mm (6 in.)
Cumulative length of incomplete penetration
weld length
Depth of lack of fusion and incomplete ≤ 0.2 Tw
C penetration cumulative length of lack of fusion ≤ 38 mm (1.5 in.) in any 150 mm (6 in.)
and incomplete penetration ( Note (7) ) weld length
See BPV Code, Section VIII, Division 1,
D Size and distribution of internal porosity
Appendix 4
For Tw ≤ 6 mm (1/4 in.) limit is same as
D
E Size and distribution of internal porosity
For Tw ≤ 6 mm (1/4 in.) limit is same as
D
Slag inclusion, tungsten inclusion, or elongated
indication
F Individual length ≤ 2Tw /3
Individual width ≤ 2.5 mm (3/32 in.) and ≤ Tw /3
Cumulative length ≤ Tw in any 12 Tw weld length
Slag inclusion, tungsten inclusion, or elongated
indication
G Individual length ≤ 2Tw
Individual width ≤ 3 mm (1/8 in.) and ≤ Tw /2
Cumulative length ≤ 4 Tw in any 150 mm (6 in.) weld length
H Depth of undercut ≤ 1 mm (1/32 in.) and ≤Tw/4
≤ 1.5 mm (1/16 in.) and ≤ [Tw/4 or 1mm
I Depth of undercut
(1/32 in.)]
J Surface roughness ≤ 500 min. Ra per ASME B46.1
Total joint thickness, incl. weld reinf., ≥
K Depth of root surface concavity
Tw
Height of reinforcement or internal protrusion ( Height mm
Note (8) ) in any plane through the weld shall be For Tw mm (in.) (in.)
within limits of the applicable height value in the ≤ 6 (1/4) ≤ 1.5 (1/16)
L
tabulation at right, except as provided in Note > 6 (1/4), ≤ 13 (1/2) ≤ 3 (1/8
(9). Weld metal shall merge smoothly into the > 13 (1/4), ≤ 25 (1) ≤ 4 (5/32
component surfaces. > 25 (1) ≤ 5 (3/16)
Height of reinforcement or internal protrusion ( Limit is twice the value applicable for L
M Note (8) ) as described in L. Note (9) does not above
apply.

10.2 Pipelines API – 1104

Indications observed during pipeline inspection shall be evaluated

in accordance with API-1104 and DEP 61.40.20.30-Gen.

10.2.1 Linear Indications

Relevant indications shall be unacceptable when any of
the following conditions exist.
a. Linear indications are evaluated as cracks,
including crater cracks or star cracks.

Project No.: P 90115

DOCUMENT TITLE:
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LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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 b. Linear indications are evaluated as incomplete
fusion (IF).

10.2.2 Rounded indications

Individual or scattered porosity (P) shall be considered a
defect should any of the following conditions exist:

a. The size of an individual pore exceeds 1/8 inch

(3mm).
b. The size of an individual pore exceeds 25% of the
thinner of the nominal wall thickness joined.
c. The distribution of scattered porosity exceeds the
concentration permitted by Figures 7 or 8.

Cluster porosity (CP) that occurs in any pass except the

finish pass shall comply with the criteria of 10.2.2. CP that
occurs in the finish pass shall be considered a defect
should any of the following conditions exist:

a. The diameter of the cluster exceeds ½ inch (13mm)

b. The aggregate length of CP in any continuous 12
inches (300mm) length of weld exceeds ½ inch
(13mm).

11.0 REPORTING
Reports shall have clear and detailed information about the component tested
and test results. After evaluation in comparison with the relevant acceptance
criteria, results shall be reported on prescribed form (Annexure – 1).

The qualified and certified PT level II technicians shall sign all reports.

The report shall contain the following information, as a minimum.

Report number

Date

Client’s name

Project

Work order

Job / Part number

Joint number
Project No.: P 90115
DOCUMENT TITLE:
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LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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 PT procedure number and revision

Weld number

Welder number

Welding procedure

Acceptance criteria

Results: accept / reject status

Name and signature of technician

Liquid penetrant type (visible / fluorescent) number or designation of penetrant /

developer / cleaner

Material and thickness

Lighting equipment

Date of examination

Record of indications

12.0 RECORDS
Following acceptance of report by Client, copy shall be filed together with copies
of sketch (es), specific procedures, technique sheets, photographs or other
relevant material, in such manner to allow easy retrieval if and when required.

Project No.: P 90115

DOCUMENT TITLE:
ADCO Doc. No. 11.99.97.2665
LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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 13.0 ANNEXURE 1 Report Form

LIQUID PENETRANT TESTING REPORT

Date Job # Report # /
Client PT
Project
Job Location
Job Description
Date of Examination
Material & Thickness Heat Treatment Status
Surface Condition Test Temperature
Weld ID Welder ID
Weld Type Weld Process
PT Procedure No. Rev. Acceptance criteria
Lighting Equipment Light Intensity
Dwell Time (Penetrant) Dwell Time (Developer)

Cleaner Penetrant Developer

Type: Type: Type:
Designation: Designation: Designation:
Batch No. Batch No. Batch No.

OBSERVATIONS:

Technician Client’s Representative AI

Level

Signature Signature Signature

File Ref: NDT-FRM-037-00-Liquid Penetrant Testing Report

Distribution:
White: Client, Pink: Client, Blue: Job File, Green: Records (Do not tear)

Project No.: P 90115

DOCUMENT TITLE:
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LIQUID PENETRANT TESTING PROCEDURE Rev. 1 Date :14/04/2010
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