Liquid Penetrant Procedures TABLE OF CONTENTS

Transcription

1 Page: 1 of 8 TABLE OF CONTENTS SECTION PAGE NO. 1.0 Introduction References Forms Personnel Qualifications Material Material Restrictions General Requirements Inspection Procedure Inspection Marking Reports & Documents Calibration and Material Certification 8

2 Page: 2 of INTRODUCTION 1.1 This procedure defines the requirements for color contrast, solvent removable and waterwashable visible dye liquid penetrant inspection of ferrous and nonferrous materials. This inspection is for detection of discontinuities that are open to the surface of the material only. 1.2 This procedure meets or exceeds the requirements of Section V of the ASME boiler and pressure vessel code When required by contract and a copy supplied, customer procedures or specifications may supersede this procedure provided the customer specification is more conservative than this document and the codes referenced within. 1.3 This procedure is intended for the use of portable liquid penetrant material and may be applied to in-process final or maintenance inspections. 2.0 DOCUMENTS A copy of reference documents shall be maintained. In case of conflict between these documents and customer drawings, the requirements of the customer drawings shall have precedence. All documents shall be in accordance with the latest accepted codes and addenda. For dated references, only the edition that is cited applies. 2.1 Easton Engineering & Inspection PLLC EEI-QA-10 EEI-QC-10 Quality Assurance Manual Quality Control Manual 2.2 American Society of Mechanical Engineers ASME BPV Sec. V Article 6, Examination ASME BPV Sec. V Article 24, SE-165 Standard Test Method for Examination ASME BPV Sec. VIII Boiler and Pressure Vessel Code, Division Military Standards / Specifications MIL-STD-45662A Calibration System Requirements (Replaced by ISO ) 2.4 American Welding Society AWS A2.4 Standard Symbols for Welding, Brazing, and Nondestructive Examination 2.5 American Society of Nondestructive Testing (ASNT) SNT-TC-1A, 2011 Personnel Qualification and Certification in Nondestructive Testing 3.0 FORMS EEI-F-PT-10A Inspection Report

3 Page: 3 of PERSONNEL QUALIFICATIONS 3.1 Personnel performing inspection shall be qualified and certified in accordance with EEI-QC-10 as specified by the requirements of ASNT SNT-TC-1A Records of Personnel Certifications shall be maintained on file by Easton Engineering & Inspection PLLC and be available at all times for review by the customer. 5.0 MATERIAL 5.1 Materials shall conform to the requirements of ASME Section V, Articles 6 and 24. Materials used for liquid penetrant examination shall be one of the following: Water Washable Visible Dye Sherwin Incorporated (DUBL-CHEK) TYPE BRAND Manufacturer Temperature Remover DUBL-CHEK DR-60/H 2 O F Penetrant DUBL-CHEK DP F Developer DUBL-CHEK D-100/D F Solvent Removable Visible Dye Magnaflux (SPOTCHECK) TYPE BRAND Manufacturer Temperature Cleaner/Remover SPOTCHECK SKC-S F Penetrant SPOTCHECK SKL-SP F Developer SPOTCHECK SKD-S F High Temperature Solvent Removable/Water Washable Visible Dye Sherwin Incorporated (DUBL-CHEK) TYPE BRAND Manufacturer Temperature Remover DUBL-CHEK KO F Penetrant DUBL-CHEK KO F Developer DUBL-CHEK D F Other Pre-Cleaning Materials: a) Acetone. b) Isopropyl alcohol.

4 Page: 4 of MATERIAL RESTRICTIONS 6.1 Penetrant materials from one family group shall not be intermixed with those from another family group. 6.2 The temperature of the penetrant and the surface of the examination area shall not be below 40 F or above 125 F throughout the examination period. Local heating or cooling is permitted provided the temperature remains in the range of 40 F to 125 F during the examination. Where it is not practical to comply with these temperature limitations, other temperatures and times may be used, provided the non-standard temperature procedure is qualified as described in ASME Section V, Article 6, Paragraph T Aerosol cans are affected by temperature change; aerosol can pressure drops at lower temperatures and rises at higher temperatures. Temperatures below 60 F may result in insufficient pressure for adequate material performance, especially developers. 7.0 GENERAL REQUIREMENTS 7.1 Safety Protective garments gloves, respirators, and safety glasses shall be worn as applicable. Follow precautions listed below: a) Avoid prolonged or repeated contact with skin. b) Avoid prolonged or repeated breathing of vapors. c) Do not take internally. d) Wash thoroughly after handling and before eating or smoking Penetrant materials are highly volatile and flammable and shall be used in well ventilated areas away from ignition sources. Care should be taken to prevent vapors from building up Never puncture, heat, or burn spray cans; store at less than 120 F; keep out of direct sunlight. Spray cans are under pressure and an explosion hazard exists Magnaflux Spotcheck NFPA Rating: Health 1, Flammability 1 (Aerosol Flammability 4), Reactivity 0. Sherwin Dubl-Check HAZCOM Rating: F-3, H-1, R-0, S Visible Light Visible light shall be used when conducting examinations using color contrast penetrants The visible light intensity shall be measured at least one time prior to examination or whenever visible light conditions change, using a visible light meter. A minimum light intensity of 100 foot-candles (fc) or 1,000 Lux (Lx) is required to ensure adequate sensitivity during the examination and evaluation of indications The light source, technique used, and light level verification is required to be demonstrated, documented, and maintained on file.

5 Page: 5 of INSPECTION PROCEDURE 8.1 Inspection Areas & Locations Areas to be inspected shall be specified by the customer drawing or specifications. Drawings specifying liquid penetrant inspection shall be in accordance with nondestructive examination symbols as per AWS A Illuminated inspection areas shall provide suitable visual illumination in the area of inspection. Portable drop lights or heavy duty flashlights shall be used when necessary. 8.2 Surface Preparation Cleaning Prior to Examination Surfaces to be examined and the adjacent area (at least 1 ) on each side of the examination area, shall be free of oil, grease, lint, loose sand and rust, slag, paint, and other extraneous matter that would interfere with the examination Organic solvents, descaling solutions, detergents, paint removers, vapor degreasing, wire brushing, or ultrasonic cleaning shall be used to clean the areas of examination. Sand blasting is not an acceptable method of cleaning. Areas cleaned shall be allowed to dry completely prior to applying penetrant Contour With the exception of undercut that is within allowable tolerance, the surface may be in as welded, cast, rolled, or forged condition provided surface irregularities will not mask or hide defects. Irregular surface conditions shall be removed to the extent that they will not interfere with interpretation of test results. Unusual surface conditions shall be noted on the Inspection Report. 8.3 Penetrant Application Method After the part has been cleaned and dried, penetrant shall be applied evenly by suitable means such as spraying, dipping, or brushing Dwell Time Sufficient dwell time shall be allowed, as specified below and in Table 1 to allow maximum penetration. Manufacturer s recommendation for Sherwin Inc. Hi-Temp Penetrant System Allowances must be made for contamination and flaw sizes. Temp. ( F) Dwell time sec.- 1 min min min min min.

6 Page: 6 of 8 TABLE 1 Types of Discontinuities Minimum Dwell Time (mins.) Material Forms Penetrant Developer Aluminum, Casting and welds Cold shuts, porosity, lack of magnesium, steel, fusion, cracks (all forms) 5 10 brass, bronze, Wrought materials, titanium, and high extrusions, forgings, plates Laps, cracks (all forms) temp. alloys Carbide tipped tools Same as above Lack of fusion, cracks, 5 10 porosity Plastic All forms Cracks 5 10 Glass All forms Cracks 5 10 Ceramic All forms Cracks, porosity 5 10 NOTE: This table is for dwell times when the surface or ambient temperature range is 50 F F. For temperatures from 40 F - 50 F, the minimum penetrant dwell time shall be twice the value listed. 8.4 Excess Penetrant Removal 8.5 Drying After the specified penetrant dwell time has elapsed, any penetrant remaining on the surface shall be removed, taking care to minimize removal of the penetrant from discontinuities Excess penetrants shall be removed by wiping the areas with lint-free cloths or absorbent paper until most traces of the penetrant have been removed. The remaining traces shall be removed by lightly wiping the surface with lint-free cloths or absorbent paper moistened with water or cleaner/remover solvent. Flushing the surface with water or cleaner solvent prior to developing is prohibited. Care shall be taken to avoid the use of excess water or cleaner solvent to minimize the removal of penetrant from discontinuities. Drying of the part after removal of the penetrant by the use of the cleaner solvent for solvent removable methods or H2O for water washable method is necessary prior to applying the developer. Drying time will vary with size, nature, and number of parts under examination. 8.6 Developer The developer shall be a wet developer powder suspended in a volatile solvent. Solvent suspensions shall be applied by spraying The developer shall be applied, after the minimum drying time has elapsed, by spraying evenly at 8 15 inches. 8.7 Interpretation of Results The true size of discontinuities is difficult to evaluate if the penetrant diffuses excessively into the developer. In essence, the surface shall be closely observed during the application of the developer to monitor the behavior of indications, which tend to bleed-out profusely With visible dye penetrants, the developer forms a uniform white coating. Surface discontinuities are indicated by a bleed-out process of the penetrant which is a deep red

7 Page: 7 of 8 color which stains the developer. Indications with a light pink color may indicate inadequate cleaning process Final interpretation shall be within minutes after the developer is dried on the surface. If bleed-out does not alter the examination results, longer periods are permitted. When the surface or area to be examined is large enough to preclude, complete the examination within the prescribed time. The surface shall be examined in increments. 8.8 Evaluation Indications shall be evaluated in terms of the referencing code. Discontinuities at the surface will be indicated by bleed-out penetrant. Localized surface irregularities due to machining marks or other surface conditions may produce false indications. Broad areas of pigmentation which could mask indications of discontinuities are unacceptable, and such areas shall be cleaned and reexamined. 8.9 Post Cleaning 9.0 INSPECTION Developers shall be removed as soon as possible using a lint-free cloth or absorbent paper moistened with cleaner/remover solvent after the interpretation and results are recorded so that it does not fix on the part. 9.1 Inspection personnel who interpret examination results for liquid penetrant inspections shall be certified Level II or III. 9.2 The standards for acceptance / rejection shall be specified on the customer drawing, specification, purchase order, or construction code. 9.3 All results shall be recorded as per Paragraph MARKING 10.1 Defective areas unless otherwise specified, shall be marked with a contrasting color type permanent marker If specified, discontinuities shall be preserved by utilization of one of the following methods: a) Photography. b) Sketch REPORTS & DOCUMENTS 11.1 A penetrant inspection report (EEI-F-PT-10A) shall be completed for each inspection or groups of inspections, if they are identical. It shall be signed by a Level II or III and a copy of the report forwarded to the customer Records shall be retained for a minimum of three years.

8 Page: 8 of CALIBRATION AND MATERIAL CERTIFICATION 12.1 All calibrated equipment shall be provided with a calibration certification label. All calibrations are recorded and maintained in the Easton Engineering & Inspection Maintenance and Calibration Database. Easton Engineering & Inspection form EEI-F-QA-10E, Equipment Calibration Log is available upon customer request Visible light meters shall be calibrated at least once a year or whenever the meter has been repaired. Calibration will be performed using standards that are traceable to the National Institute of Standards and Technology (NIST) Each batch of liquid penetrant material shall be certified by the manufacturer. The certification shall include the batch number, statement of specification compliance and analytical results and will be kept on file by EEI and made available upon request. Note: Where penetrant materials are supplied by the client, it is the responsibility of the client to acquire and retain material certifications.