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BHARAT HEAVY ELECTRICALS LIMITED BHE:NDT:RP:PT:Ol
RANIPET - 632406 REVISION 03
NON - DESTRUCTIVE TESTING PAGE 1 of 10

PROCEDURE FOR LIQUID PENETRANT EXAMINATION

(Visible Method)

Prepared by Reviewed by Approved by

Kaushal Kumar M S Ravikumar

Engineer Sr. Manager Level III
Level IT Level IT

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Effective Date 30 08 2016

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BHARAT HEAVY ELECTRICALS LIMITED BHE:NDT:RP:PT:Ol

Ijl RANIPET - 632406

NON - DESTRUCTIVE TESTING
REVISION 03
PAGE 2 of 10

1. RECORD OF REVISION

Revision Date of Revision Reason for Revision

No.
01 2807 1999 Revision in entirety
02 14082003 Clause
2.1,2.2,2.3,12.1.2.2,12.1.3.1,12.13.2
and 13.1."2.1 modified
Clause 8.2 added
03 30082016 Revised in entirety based on latest
standards.

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BHARAT HEAVY ELECTRICALS LIMITED BHE:NDT:RP:PT:Ol
RANIPET - 632406 REVISION 03
NON - DESTRUCTIVE TESTING PAGE 3 of 10

1.0 SCOPE
1.1 This procedure defines the method, techniques and acceptance standards for liquid
penetrant Examination of all shapes of ferrous and Non-ferrous product forms in
Boilers, Boiler Auxiliaries, pressure vessels, Heat Exchangers and structural.

1.2 In pressure vessels the Examination shall include all welds around openings;
attachment welds with a throat thickness over 6mm and on finished surfaces of welds
as required by referencing code. The examination includes base material 13mm on
each side of the weld.

2.0 REFERENCE

2.1 ASME Section VI Article 6, I & VIII (Division 1 &2) -2015

2.2 ASME B 31.1 /2015

2.3 AWS D 1.1 IDI.lM: 2015

3.0 EQUIPMENT

3.1 The term 'penetrant materials' as used in the procedure is intended to include all liquid
penetrants, solvents (penetrant removers) or cleaning agents, developers etc used for
'Liquid penetrant Examination'.
3.2 Penetrant used shall be of solvent removable type and have a color contrast, which can
be seen, readily in daylight or under normal interior illumination.
3.3 The cleaner used for the surface cleaning shall be an organic chemical such as
Acetone or Trichloro Ethylene.
3.4 Developer shall be of non-aqueous suspendible type. When the developer dries, it shall
form a white coating of fine powder on the part.
o 3.5 The Chemicals used for the examination of austenitic stainless steel or nickel base
alloys shall be analysed for sulphur and total halogens. The residual amount of total
sulphur and chlorine content shall not exceed 1 % by weight.

4.0 SURFACEPREPARATION

4.1 In general satisfactory results may be obtained when the surface is as welded, as rolled,
as forged or as cast condition. When the surface irregularities might mask the
indications of unacceptable discontinuities, the surface shall be prepared by grinding or
machining or any other suitable method.
4.2 The surface to be examined and all adjacent areas within at least 25mm shall be dry
and free of any dirt, grease, lint, scale, welding flux, weld spatter, rust, paint, oil or any
other extraneous matter that could obscure surface openings or otherwise interfere with
the examination by preventing the penetration.
 BHARAT HEAVY ELECTRICALS LIMITED BHE:NDT:RP:PT:Ol
RANIPET - 632406 REVISION 03
NON - DESTRUCTIVE TESTING PAGE40fl0

4.3 Shot blasting may close discontinuities at the surface and should not be used before
conducting penetrant examination. lfthe component is shot blasted, the surface is to be
etched before conducting penetrant examination.
4.4 Prior to the application of the penetrant, the surface is recleaned with typical industrial
cleaning agents such as Acetone.

5.0 DRYING AFTER PREPARATION

After cleaning, drying of the surface shall be accomplished by normal evaporation

and ensure that the cleaning solution has evaporated. The minimum time required for
the cleaner to dry from the surface 60 seconds and maximum time shall be 10 minutes
depending on the position.

6.0 TECHNIQUES

6.1 Color contrast (visible) penetrant shall be used with solvent removable penetrant
process.
6.2 The temperature of the penetrant and the surface of the part shall not be below SOC
and not above S2°C throughout the examination period. Local heating or cooling is
permitted provided the part temperature remains in the range of 5°C to 52°C during
the examination.

7.0 TECHNIQUE RESTRICTIONS

7.1 Intermixing of penetrant materials from different families or different manufacturers

is not permitted.
7.2 Fluorescent penetrant examination shall not follow a color contrast penetrant
examination.

8.0 EXAMINATION
o 8.1 Penetrant Application

8.1.1 The penetrant shall be applied by brushing, spraying or dipping after the surface is
dried. For spraying a handpump or an aerosol spray cans will be used.

8.2 Penetration time

The penetrant shall be remaining wet on the minimum and maximum period (dwell
time) as given in Table 2 or as qualified by demonstration for specific application.

Table 2
I MATERIAL I FORM MINIMUM DWELL I ivIAxIMUMTIME·
DWELL I
I TIME _ .
 BHARAT HEAVY ELECTRICALS L1MITEO BHE:NDT:RP:PT:Ol
RANIPET - 632406 REVISION 03
NON - DESTRUCTIVE TESTING PAGE 5 of 10

Alumimium, TEMPERATURE TEMPERATURE

Magnesium, steel, RANGE RANGE
Brass, Bronze,
Titanium Casting and 10 Minutes 20 Minutes
Welds
Wrought 10 Minutes 20 Minutes
materials-
Extrusions,
Forging and
Plates.

8.2.1 If the penetrant has completely dried up during the dwell time, then the surface shall
be recleaned and reexamined.

8.3 REMOVALOF EXCESSPENETRANT

8.3.1 After the required dwell time has elapsed, the excess penetrant remaining on the
surface shall be removed by wiping with a lint free cloth, repeating the operation until
most traces of penetrant have been removed. Final left out penetrant shall be remove
by wiping with a clean cloth moistened with the solvent. Excessive application of the
cleaner shall be avoided to prevent the possibility of removing the penetrant from
discontinuities causing a decrease in the sensitivity of the test. FLUSHING THE
MATERIAL SURFACE WITH THE SOLVENT FOLLOWING THE
APPLICATION OF PENETRANT AND PRIOR TO DEVELOPING IS
PROHIDITED.

8.3.2 Drying after excess penetrant removal.

8.3.2.1 After the removal of excess penetrant the surface shall be dried by normal
evaporation. The minimum time required for the surface to get dried by normal
a evaporation is 60 seconds and maximum shall be 10 minutes.Drying of developer
shall be by normal evaporation.

8.4 DEVELOPING

8.4.1 The developer shall be applied by spraying to provide uniform coating as soon as
possible to the dry surface after the removal of excess penetrant. Insufficient coating
thickness may not draw penetrant out of discontinuities. Excessive coating thickness
may mask indications.

8.5 WET DEVELOPER APPLICATION

8.5.1 Prior to applying suspension type wet developer to the surface the developer must be
thoroughly agitated too ensure adequate dispersion of suspended particles. The
developer shall be applied by spraying using spray pump or aerosol spray can. The
developer shall be applied. over the surface in such a manner to assure complete
 BHARAT HEAVY ELECTRICALS LIMITED BHE:NDT:RP:PT:Ol
RANIPET - 632406 REVISION 03
NON - DESTRUCTIVE TESTING PAGE 6 of 10

coverage of the part with a thin, uniform film of developer. Drying of developer shall
be by normal evaporation.

8.6 DEVELOPMENT TIME

8.6.1 The surface shall be closely observed during the application of the developer to
monitor the behavior of the indication, which tends to bleed-out. Developing time for
final interpretation begins as soon as a wet developer coating is dry. The minimum
developing time shall be 10 minutes and maximum shall be 60 minutes.

9.0 INTERPRETATION

9.1 Final interpretation shall be made with in 10 to 60 minutes after the wet developer
coating is dry. If the bleed - out does not alter the examination results longer periods
are permitted.

9.2 The surface shall be examined in increments if the surface to be examined is large
enough to complete the inspection within the prescribed time.

A minimum light intensity of 100 foot candle (1000 lux) is required to ensure
adequate sensitivity during the examination and evaluation of indications, which can
be achieved by a hand lamp or torch light positioning at a distance of 300mm. The
light intensity shall be measured with white light meter prior to evaluation of
indications or verified light source shall be used. Verification of light sources is
required to be demonstrated only one time, documented, and maintained.

10.0 EVALUATION

10.1 Flaws at the surface will be indicated by bleed out of the penetrant. However localize
surface irregularities such as machining marks or other surface conditions may
produce false indications. Broad areas of pigmentation which would mask indications
0 are not acceptable and such areas shall be cleaned and reexamined.

10.2 The surface shall be examined in increments if the surface to be examined is large
enough to complete the inspection within prescribed time.

10.3 An indication of an imperfection may be large than the imperfection that causes it
however, the size of the indication is the basis for acceptance evaluation.

10.4 Relevant indications area are those which result from mechanical discontinuities
(imperfection).

10.5 Only indications with major dimension greater than 1.5mm shall be considered
relevant.
 SHARAT HEAVY ELECTRICALS LIMITED BHE:NDT:RP:PT:Ol
RANIPET - 632406 REVISION 03
NON - DESTRUCTIVE TESTING PAGE 7 of 10

10.6' Any indication which is believed to be non-relevant shall be regarded as a defect until
the indication is either eliminated by surface conditioning or it is evaluated by other
non- destructive testing and proved to be non - relevant.

10.7 Linear indications are those indications in which the length is more than three times
the width.

10.8 Rounded indications are those which are circular or elliptical with the length equal to
or less than three times the width.

10.9 Any questionable or doubtful indications shall be reexamined to determine whether

they are relevant, or not.

11.0 ACCEPTANCE STANDARD

11.1 Welds and Materials (as per ASME Sec 1 and VIII Div 1&2)
11.1.1 All surface to be examined shall be free of
11.1.2 A)Relevant linear indications.
B) Relevant rounded indications greater than 5mm.
C) All relevant indications shall be investigated to assure that no leak-path exists in
welds joining nipples to drums, dished - ends and headers.
11.1.3 Four or more relevant rounded indications in a line separated by 1.5mm or less edge
to edge.
11.1.4 In attachment welds of non-load carrying class, indications from crack or due to
material separation are unacceptable

C 11.2 For Power Piping( as per ASME B31.1)

11.2.1 Indications whose major dimensions greater than 2.0mm shall be considered relevant.
11.2.2 The following relevant indication are unacceptable:
a. Any crack or linear indications.
b. Rounded indication whose dimensions greater than 5.0mm.
c. Four or more rounded indication in a line separated by 2.0mm or less edge to
edge.
d. Ten or more rounded indication in any 3870mm2 of surface with the major
dimensions of this area not to exceed 150mm with the area taken in the most
unfavorable location relative to the indications being evaluated.
·, BHARAT HEAVY ELECTRICALS LIMITED BHE:NDT:RP:PT:Ol
RANIPET - 632406 REVISION 03
NON - DESTRUCTIVE TESTING PAGE 8 of 10

12.0 WELDS MADE TO STRUCTURAL WELDING CODE AWS D 1.1

12.1 For statically and cyclically loaded non-tubular connections made to AWS code the
acceptance of any discontinuity shall be based upon a visual examination of the
discontinuity after the removal of developer medium and evaluated for its nature and
size. Where the discontinuity cannot be seen after removal of the developer medium
either directly or using magnifying glass evaluation shall be based on the size and
nature of liquid penetrant indication.

13.0 ACCEPTANCE STANDARD(AS PER AWS)

13.1 Statically loaded non-tubular connections.

13.1.1 Indications from cracks, lack of penetration and lack of fusion are not acceptable.

13.2 Porosity.

13.2.1 Complete joint penetration groove welds in butt joints transverse to the computed
tensile stress shall have no visible piping porosity.
13.2.2 For all other groove welds and for fillet welds, the sum of the visible piping porosity
of 1.0 mm or greater in diameter shall not exceed 10 mm in any linear 25 mm of weld
and shall not exceed 20 mm in any 300 mm length of weld.

13.3 Undercut

13.3.1 For material less than 25 mm thick, undercut shall not exceed 1.0 mm except that a
maximum 2.0 rnm is permitted for an accumulated length of 50 mm in any 300 mm

13.2 For material equal to or greater than 25 mm thick undercut shall not exceed 2.0 mm
for any length of weld.

C 14.0 Cyclically loaded non-tubular connections.

14.1 Indications from Cracks, Lack of penetration and lack of fusion are not acceptable in
any welds.

14.2 Porosity
14.2.1 Complete joint penetration groove welds in butt joints transverse to the direction of
computed tensile stress shall have no piping porosity. For all other groove welds, the
frequency of piping porosity shall not exceed one in 100mm of length and the
maximum diameter shall not exceed 2.5 mm.

14.2.2 The Frequency of piping porosity in fillet welds shall not exceed one in each 100mm
of weld length and the maximum diameter shall not exceed 2.5mm. EXCEPTION for
fillet welds connecting stiffeners to web, the sum of the diameter of piping porosity
 BHARAT HEAVY ELECTRICALS L1MITEO BHE:NDT:RP:PT:Ol
RANIPET - 632406 REVISION 03
NON - DESTRUCTIVE TESTING PAGE 9 ofl0

shall not exceed lomm in any linear 25mm of weld and shall not exceed 20mm in any
300mm length of weld.

14.3 Undercut.

14.3.1 In primary members, undercut shall not be more than 0.25mm deep when the weld is
transverse to tensile stress under any design loading condition. Undercut shall not be
more than lmm deep for all other cases.

15.0 REPAIR AND RE-EXAMINATION

15.1 Whenever an imperfection is repaired by chipping or grinding the excavated area shall
be blended into the' surrounding surface so as to avoid sharp notches, crevices or
corners.

15.2 After a defect is thought to have been removed and where welding is required after
repair, the area shall be examined for removal of defects, area cleaned and repair
carried out. The repaired area shall be blended into the surrounding surface as in 14.1
and re-examined by the liquid penetrant or any other NDT methods originally
required for the affected area.

16.0 PERSONNEL 'QUALIFICATION

16.1 Wherever penetrant examination is required by the referencing code, the same shall be
conducted by Level I and evaluated by a personnel qualified to minimum Level II as
per ASNT SNT-TC-IA Edition 2006.

17.0 POST CLEANING

17.1 After the examination and evaluation is completed all penetrant testing material shall
be removed from the surface, so that it will not interfere with the subsequent
processing or service requirements.

18.0 REPORTING
18.1 Where penetrant test is mandatory, a copy of the report signed by personnel certified to
minimum Level-Il will be issued in format R49-720B or equivalent, after completion
the examination.
 BHARAT HEAVY ELECTRICALS LIMITED BHE:NDT:RP:PT:Ol
RANIPET - 632406 REVISION 03
NON - DESTRUCTIVE TESTING PAGE 10 of 10

BHARAT HEAVY ELECTRICALS LIMITED

BAP I RANIPET 632 406
R49-720/B NON-DESTRUCTIVE TESTING
LIQUID PENETRATION TEST
REPORT NO
REQ DT

REF NO
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WORK ORDER
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PART NAME

QTY
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STAGE OF TEST

MATERIAL SPECIFICATION
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QP REFERENCE

REMARKS

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