REVISIONS. App Thom. App PC. App Sud PB 2012/01/18 PB 2012/11/22 KLR 2015/06/17

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1 1/15 REVISIONS Rev Description 1 2 Document format and content changed. Previous number To comply with TSSA audit findings Updated Section 16.0 recording to comply with TSSA audit findings Rev n by JL 2011/12/29 AA 2012/11/16 KLR 2015/06/17 App Sud PB 2012/01/18 PB 2012/11/22 KLR 2015/06/17 App PC App Thom App VB App LH App Clyd Appr Act Issue Date YYYY/MM/DD Pending Pending Pending Pending Pending Pending 2012/06/06 Pending Pending Pending Pending Pending Pending 2012/11/22 Pending Pending Pending Pending Pending Pending 2015/06/17 Sud = Sudbury, Ontario, PC = Port Colborne, Thom = Thompson, Manitoba, VB = Voisey s Bay, LH = Long Harbour, Act = Acton, England, Clyd = Clydach, Wales, N/A = Not Applicable

2 2/ PURPOSE This procedure outlines the equipment and techniques to be employed for the Liquid Penetrant Inspection of nonporous, metallic materials, ferrous or nonferrous and nonmetallic materials. This is a non-destructive examination used for detecting discontinuities that are open to the surface such as cracks, seams, laps, cold shuts, laminations, through leaks or lack of fusion. This examination procedure is applicable to in-process, final and maintenance (in-service) inspections. Inspections may be carried out on forgings, castings, welds on vessels, piping, fittings and valves and related components. There are no restrictions to the size and shapes of the items to be examined 2.0 APPLICATION This specification, applies at any Vale locations indicated with approval on the cover page, with the following exceptions: 2.1 EXCEPTIONS None..0 REFERENCE DOCUMENTATION This procedure is in conjunction with the following standards and specifications. They shall be used in their most recent revision. ASME Section V, Article 24, SE 165 and SE 1209 ASME Section V, Article QUALIFICATION OF PERSONNEL All personnel performing Liquid Penetrant Inspection shall be qualified to C.G.S.B Level II or III or as required by code or specification. 5.0 PRE-CLEANING Prior to Liquid Penetrant Examination, the surface to be examined and all adjacent areas within at least 1" (25mm), shall be dry and free of any dirt, grease, lint, scale, welding flux,

3 /15 weld spatter, oil, or other extraneous matter, that could obscure surface openings or otherwise interfere with the examination. Typical cleaning agents which may be used, are detergents, organic solvents, descaling solutions, and paint removers. Degreasing and ultrasonic cleaning methods may also be used. Cleaning solvents shall meet the requirements of Section 14.0 of this procedure, as is applicable. The cleaning method employed is an important part of the examination procedure. Excess solution on the parts may be wiped with paper towels or a dry lint free cloth and then allowed to air dry. 6.0 DRYING AFTER CLEANING After cleaning, drying of the surface to be examined shall be accomplished by normal evaporation or with forced hot (drying oven) or cold air. A minimum period of time shall be established (ten minutes) to ensure solution as evaporated prior to the application of the penetrant. 7.0 METHODS AND MATERIAL 7.1 Techniques for Standard Temperatures As a standard technique, the temperature of the penetrant and the surface of the part to be processed shall not be below 40 F (5 C) nor above 125 F (52 C) throughout the examination period. Local heating or cooling is permitted provided the part temperature remains in the range of 40 F to 125 F (5 C to 52 C) during the examination. Where it is not practical to comply with these temperature limitations, other temperatures and times may be used, provided the procedures are qualified as specified in Section 7.2 of this procedure. 7.2 Techniques for Nonstandard Temperatures When it is not practical to conduct a liquid penetrant examination within the temperature range of 40 F to 125 F (5 C to 52 C), the examination procedure at the proposed lower or higher temperature range requires qualification of the penetrant materials and processing in accordance with Mandatory Appendix III of Article 6 of ASME V. 7. Technique Restrictions Fluorescent penetrant examination shall not follow a color contrast penetrant examination. Intermixing of penetrant materials from different families or different manufacturers is not

4 4/15 permitted. A retest with water washable penetrants may cause loss of marginal indications due to contamination. Either a color contrast or fluorescent penetrant method may be used for an inspection. For each method, three types of penetrants are available: Classification of Penetrants - Type and Method Type I Fluorescent Penetrant Examination Method A Water-washable Method C Solvent removable Method D Post-emulsifiable, hydrophilic Type II Visible Penetrant Examination Method A Water-washable Method C Solvent removable Method D Post-emulsifiable, hydrophilic Examples of Water Washable and Solvent Removable Product Families Water Washable Manufacturer Penetrant Developer Cleaner Fluorescent Brent Ardrox P15 E Ardrox 9D1B Ardrox 9PR50 Visible Magnaflux Spotcheck SKL-4C Spotcheck SKD-S2 Spotcheck SKF-S Solvent Removable Manufacturer Penetrant Developer Cleaner Visible Cantesco P101S D101-A C101-A All chemicals used shall be of the same family, other equivalent manufacturers chemical may be used. Sensitivity Levels of Penetrant Level ½ - Very low Level 1 Low Level 2 Medium

5 5/15 Level High Level 4 Ultrahigh 7.4 Form or Type of Developers Utilized Form a - Dry Powder Nonaqueous Wet Developers are supplied as suspensions of developer particles in a nonaqueous solvent carrier ready for use as supplied. Nonaqueous, wet developers form a coating on the surface of the part when dried, which serves as the developing medium Form d Nonaqueous Dry Powder Developers are used as supplied. Care should be taken not to contaminate the developer with fluorescent penetrant, as the penetrant specks can appear as indications. 7.5 Post Emulsifiable Penetrants Post-Emulsifiable Penetrants are designed to be insoluble in water and cannot be removed with water rinsing alone. They are designed to be selectively removed from the surface using a separate emulsifier. The emulsifier, properly applied and given a proper emulsification time, combines with the excess surface penetrant to form a waterwashable mixture, which can be rinsed from the surface, leaving the surface free of fluorescent background. Proper emulsification time must be experimentally established and maintained to ensure that overemulsification does not occur, resulting in loss of indications. 7.6 Water Washable Penetrants Water-Washable Penetrants are designed to be directly water-washable from the surface of the test part, after a suitable penetrant dwell time. Because the emulsifier is built-in to the water-washable penetrant, it is extremely important to exercise proper process control in removal of excess surface penetrant to ensure against overwashing. Water-washable penetrants can be washed out of discontinuities if the rinsing step is too long or too vigorous. Some penetrants are less resistant to overwashing than others. 7.7 Solvent Removable Penetrants Solvent-Removable Penetrants are designed so that excess surface penetrant can be removed by wiping until most of the penetrant has been removed. The remaining traces should be removed with the solvent remover. To minimize removal of penetrant from discontinuities, care should be taken to avoid the use of excess solvent. Flushing the surface with solvent to remove the excess penetrant is prohibited.

6 6/ Hydrophilic Emulsifier Hydrophilic Emulsifiers are water-miscible liquids used to emulsify the excess oily fluorescent penetrant on the surface of the part, rendering it water-washable. These waterbase emulsifiers (detergent-type removers) are supplied as concentrates to be diluted with water and used as a dip or spray. The concentration, use and maintenance shall be in accordance with manufacturer s recommendations. 8.0 CALIBRATION Light meters, both visible and fluorescent (black) light meters, shall be calibrated at least once a year or whenever the meter has been repaired. If meters have not been in use for one year or more, calibration shall be done before being used. 9.0 PENETRANT APPLICATION The penetrant will be applied to the part by brushing, dipping, flooding or spraying. For A.S.M.E. code required inspections, the dwell times from table T-672 shall be used. See appendix for table. Otherwise, a dwell time of a minimum of 10 minutes to a maximum of 0 minutes will be employed before removing excess penetrant unless otherwise specified as per specific specifications. The temperature of the penetrant materials and the surface must be between 40 F and 125 F (5 C and 52 C). Fluorescent penetrants shall be applied under black light conditions to ensure full coverage of the inspection area EXCESS PENETRANT REMOVAL 10.1 Water-Washable Penetrants After the required dwell period has elapsed, any penetrant remaining on the surface of the part will be removed using a water spray under 50 psi and between 50 to 100 F. The parts may also be rinsed by immersion in the water bath, or by mechanical agitation rinse time should be a maximum of 2 minutes immersion. The surface may if required, then may be dried, by blotting with absorbent paper and the part allowed to air dry for a minimum of five minutes before applying the developer. When a fluorescent penetrant is used, the part shall

7 7/15 be examined while washing with a black light to determine that the surface penetrant has been adequately removed. (Note: Do not over wash parts) Hydrophilic Post Emulsified Penetrant After the required penetrant dwell time and prior to emulsification, the parts shall be prerinsed with water spray using the same process as for water-washable penetrants. Prerinsing time shall not exceed 1 min. After pre-rinsing, the excess surface penetrant shall be emulsified by immersing in or spraying with hydrophilic emulsifier. Bath concentration shall be as recommended by the manufacturer. After emulsification, the mixture shall be removed by immersing in or rinsing with water. The temperature of the water shall be between 50 to 100 F. The pressure of the spray water shall be under 50 psi. 10. Solvent Removable Penetrant 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. To minimize removal of penetrant from discontinuities, care shall be taken to avoid the use of excess solvent. Flushing the surface with solvent, following the application of the penetrant and prior to developing, is prohibited DEVELOPER APPLICATION Non-Aqueous Developer Developers shall be applied to a dry surface using a pressure sprayer containing clean, filtered compressed air or an aerosol freon free propellant. The developer shall be thoroughly agitated before application to ensure adequate dispersion of suspended particles. Dipping or flooding parts with nonaqueous developers is prohibited, since they may flush or dissolve the penetrant from within the discontinuities because of the solvent action of these types of developers. The length of time the developer is to remain on the part prior to examination should be not less than 10 minutes. Developing time begins as soon as the wet nonaqueous developer coating is dry. The maximum permitted developing time is 1 hour for nonaqueous developers. Dry Developer Apply dry developer (by dusting), immediately after drying to the dry surfaces to be inspected. Develop for 10 minutes minimum to 0 maximum for penetrant to bleed before inspecting. Developing time begins immediately after the application of dry powder

8 8/15 developer. Excess powder may be removed by gently shaking or tapping the part, or by blowing with low pressure (5 to 10 psi, 4 to 70 kpa) dry, clean compressed air. On parts that are too large for dry developer application or whenever an alternate is required, a non-aqueous wet developer shall be used EXAMINATION OF INDICATIONS The surface of the part will be observed during application of the developer; however, final interpretation will be made between 7 minutes minimum and a maximum of 0 minutes after the developer has dried. Adequate illumination is required to ensure no loss of sensitivity in the examination Visible White Light Inspection Visible penetrant indications can be examined in either natural or artificial light. Adequate illumination is required to ensure no loss in the sensitivity of the examination. A minimum light intensity at the examination site of 100 fc (1000 Lx) is required. The light source, and light level verification is required to be demonstrated one time, documented and maintained on file. The white light source, shall be verified with a calibrated white light meter. See appendix for qualification of a white light source form. Unless otherwise agreed, it is normal practice to interpret and evaluate the discontinuity based on the size of the indication Fluorescent Penetrant Inspection Visible Ambient Light Level Examine fluorescent penetrant indications under black light in a darkened area. Visible ambient light should not exceed 2 ft candles (20 Lx). The measurement should be made with a suitable photographic-type visible light meter on the surface being examined. Black Light Level Control Black light intensity, minimum of 1000 uw/cm², should be measured on the surface being examined, with a suitable black light meter. The black light wavelength shall be in the range of 20 to 80 nm. Reflectors and filters should be checked daily for cleanliness and integrity. Cracked or broken ultraviolet (UV) filters should be replaced immediately. Defective bulbs, which radiate UV energy, must be replaced before further use. Since a drop in line voltage

9 9/15 can cause decreased black light output with consequent inconsistent performance, a constant-voltage transformer should be used when there is evidence of voltage fluctuation. The black light intensity at the surface under examination shall be measured at least once every 8 hours, whenever the work location is changed, whenever the light s power source is interrupted or changed, and at the completion of the examination or series of examinations. Black Light Warm-Up 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. Visual Adaptation The examiner should be in the darkened area for at least 5 minutes before examining parts. Longer times may be necessary under some circumstances. Photochromic Lenses All inspectors using photochromic, light sensitive lenses are restricted from performing inspection (using sunlight, white light, or ultraviolet light) while wearing these corrective lenses. This restriction does not apply to yellow lenses used to filter out ultraviolet radiation when performing fluorescent liquid penetrant inspection (Reference contrast control spectacles UVP # or equivalent). 1.0 POST CLEANING Subsequent to final interpretation, all defective areas will be marked and reported. The entire part will then be cleaned with water or solvent, whichever is applicable, and dried with a clean lint free cloth CONTROL OF CONTAMINANTS The user of the article shall obtain certification of contaminant content for all liquid penetrant materials used on nickel-based alloys, austenitic stainless steels, and titanium. These certifications shall include the penetrant manufacturer's batch number and the test results as follows: When examining nickel base alloys, all materials shall be analyzed individually for sulphur content. The sulphur content must not exceed 1% by weight.

10 10/15 When examining austenitic stainless steels and titanium, all materials shall be analyzed individually for chlorine and fluorine content. The chlorine and fluorine content must not exceed 1% by weight EVALUATION OF INDICATIONS All indications shall be evaluated in terms of the acceptance standards of the referencing Code Section. Mechanical discontinuities at the surface will be indicated by bleeding out of the penetrant, however, localized surface imperfections such as machining marks or surface conditions may produce similar indications which are non-relevant to the detection of unacceptable discontinuities. Any indication, which is believed to be non-relevant shall be regarded as a defect and shall be re-examined to verify whether or not actual defects are present. Surface conditioning may precede the re-examination. Non-relevant indications, and broad areas of pigmentation, which would mask indications of defects are unacceptable. Relevant indications are those which result from mechanical discontinuities. Linear indications are those indications in which the length is more than three times the width. Rounded indications, are indications which are circular or elliptical with the length less than three times the width REPORTING Reports shall include at least the following: a. Procedure identification and revision number b. Contract Reference (Customer PO #, etc.) c. Date of examination d. Code class of items examined e. Identification of items examined e.g. Part #, Heat #. f. Liquid penetrant type (visible or fluorescent) with batch numbers g. type (number or letter designation) of each penetrant, penetrant remover, a. emulsifier, and developer used along with batch numbers h. Dwell time(s) i. Name, signature and qualification of the inspector. j. Equipment used with serial numbers including lighting equipment k. Material Certificates of Compliance.

11 11/15 l. Quantity of items examined. m. Results of examination with reference to the Acceptance Standard. n. Material and thickness (Only required for A.S.M.E. code required inspections) o. Map or record of indications. Must indicate if nonrejectable or rejectable. Nonrejectable Indications- Nonrejectable indications shall be recorded as specified by the referencing Code Section. Rejectable Indications- Rejectable indications shall be recorded. As a minimum, the type of indications (linear or rounded), location and extent (length or diameter or aligned) shall be recorded ACCEPTANCE STANDARDS Acceptance standards shall be as per referencing code or customer purchase order QUALIFICATION When procedure qualification is specified by the referencing Code Section, a change of a requirement in Table T-621 of ASME V, Article 6 (see page 12 of this procedure), identified as an essential variable shall require requalification of the written procedure by demonstration. A change of a requirement identified as a nonessential variable does not require requalification of the written procedure. All changes of essential or nonessential variables from those specified within the written procedure shall require revision of, or an addendum to, the written procedure.

12 12/15 TABLE T-621 FROM ASME V, ARTICLE 6 TABLE T-672 FROM ASME V, ARTICLE 6

13 1/ QUALIFICATION OF WHITE LIGHT SOURCE Inspection of visible (colour contrast) indications must be carried out where light at the inspection surface is at a minimum intensity of 1000 lux. The light may be measured with a white light meter at the time of inspection. Alternatively, a source may be qualified as per the following method: Equipment White light: Light source (describe) Light meter: Serial Number: Calibration due date: 1.) Set the meter in a stationary location 2.) Place the light in front of the meter sensor and retract while observing the light output on the meter..) Stop retraction when the meter reads 1000 lux. Record the distance. The light is qualified inspection use at a maximum distance as noted. White light source is qualified for use at a maximum distance of cm. Technician (Signature) Technician (Print name) Date

14 14/ APPENDICES Appendix A: Revision and Transition Notes Appendix B: Keywords Appendix A: Revision and Transition Notes (Revisions are listed in reverse chronological order with most recent revision at the top. Revision notes describe: what was changed, why it was changed, and the plan to implement the change, including whether changes are retroactive) Revision Revised document to comply with TSSA lead auditor s requirements: Section 16.0: Added requirement for procedure and revision number identification Revision 2 Revised document to comply with TSSA lead auditor s requirements: Section 1.0: Listed restrictions. Section 9.0: Added reference to ASME section V for dwell time. Section 12.1: Added white light source qualification requirements. Section 16.0: Added lighting equipment, material and thickness and map or records of indications. Added Section 19.0: Qualification of white light source Revision 1 Document format and number changed due to Vale Engineering Document Program changes in Previous Standard number was Rev 0.

15 15/15 Appendix B: Keywords Issued By: Jerry Lech Date: Dec. 29, 2011 Approved By Philippe Belzile Date: January 18 th 2012 Certification: CGSB , LPI Level Signature: Certification: P. Eng. (On, Mb, Qc. NF) Signature:

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