documentpt

Technical Guideline No: Page:

TGI-NDE06.00 1 of 28 Expiration Technical Guideline None

Supersedes Technical Guideline Revision Nondestructive Examination

Visible Liquid Penetrant Examination TGI-NDE06.00 Rev. 0 1

Issuing Department: Approval: Previous Rev. Date Current Revision Date

QA/QC - Houston Gene Nikstad 5-Mar-04 5-Mar-05

TABLE OF CONTENTS

1.0 PURPOSE OF TECHNICAL GUIDELINE .............................................................3 2.0 TECHNICAL GUIDELINE OBJECTIVE .................................................................3 3.0 SCOPE OF APPLICATION....................................................................................3 4.0 DEFINITIONS ........................................................................................................3 5.0 METHOD (PROCESS) ..........................................................................................3

5.1 PROCESS OVERVIEW............................................................................3 5.2 ROLES & RESPONSIBILITIES ................................................................4 5.3 PROCESS DETAIL...................................................................................5

5.3.1 PERSONNEL QUALIFICATIONS................................................5 5.3.2 PENETRANT EXAMINATION MATERIALS AND EQUIPMENT.5 5.3.3 SURFACE PREPARATION.........................................................6 5.3.4 EXAMINATION APPLICATION ...................................................6 5.3.5 INTERPRETATION / EVALUATION............................................8 5.3.6 ACCEPTANCE CRITERIA.........................................................10 5.3.7 POST EXAMINATION CLEANING............................................10 5.3.8 DOCUMENTATION ...................................................................10

6.0 REFERENCES.....................................................................................................11 7.0 REPORTS............................................................................................................11

(Table of Contents - Continued on Next Page)

Technical Guideline TGI-NDE06.00 Page 2 of 28 Nondestructive Examination Visible Liquid Penetrant Rev. 1, 5-Mar-05

Note: It is the user's responsibility to verify with their supervisor that they are using the correct and/or most current revision of this document.

8.0 ATTACHMENTS ..................................................................................................11

Attachment 1 - Liquid Penetrant Examination Report Form...................12

Attachment 2 - Color Contrast/Solvent Removable Method Technique Standard Temperature Examinations ...........................14

Attachment 3 - Color Contrast/Water-Washable Method Technique Standard Temperature Examinations ...........................16

Attachment 4 - Recommended Non-Standard Temperature Technique Guide ............................................................................18

Attachment 5 - Sequence and Time of Examination ..............................20

Attachment A - AWS D1.1 - Acceptance Criteria....................................27

Attachment B - ASME Section VIII Division 1 - Acceptance Criteria ......28

Attachment C - ASME B31.1 - Acceptance Criteria ...............................28

Attachment D - ASME B31.3 - Acceptance Criteria ...............................28



1.0 PURPOSE OF TECHNICAL GUIDELINE

1.2 The purpose of this technical guideline is to provide the specific requirements, methods, and techniques to be used when performing, evaluating, and documenting Liquid Penetrant Examinations.

2.0 TECHNICAL GUIDELINE OBJECTIVE

2.2 The objective if this technical guideline is to satisfy all applicable requirements pertaining to ASME Section V, Article 6, for Liquid Penetrant Examinations.

3.0 SCOPE OF APPLICATION

3.2 This technical guideline is applicable to the performance, evaluation, and documentation of all Visible, Color Contrast Liquid Penetrant examinations performed by employees of Jacobs.

3.3 This technical guideline applies to the detection of surface discontinuities in both ferrous and non-ferrous, welds and materials (plates and forgings) that are essentially non-porous. Liquid Penetrant examinations shall be performed while utilizing one of the following techniques:

3.3.1 Solvent-Removable

3.3.2 Water-Washable

3.4 The shape and size of objects to be examined are not limiting factors, provided the area under examination can be properly examined within the specified time intervals.

3.5 This technical guideline has been written to address the specific requirements of the ASME Boiler and Pressure Vessel Code, Section V, Article 6 in addition to the Standard Practice for Liquid Penetrant Inspection, SE-165.

3.6 This technical guideline is intended to allow the examiner the flexibility of applying whichever method or technique will provide the best examination results, based on the particular examination conditions encountered at the time of the examination. Once a method or technique is selected, compliance with the requirements of that method or technique is mandatory.

3.7 The sequence and time of examination is defined, in Attachment 5 to meet specific requirements of ASME Section VIII (Division 1), B31.1, B31.3, and AWS D1.1 for examinations of welds and base material.

4.0 DEFINITIONS

4.2 Liquid Penetrant terminology shall be in accordance with ASME Code Section V, Article 6, Appendix I, and Article 30 or SE-1316.

5.0 METHOD (PROCESS)

5.1 PROCESS OVERVIEW

5.1.1 This nondestructive examination technical guideline provides for both solvent removable and water washable visible liquid penetrant examination of nonporous materials for the purpose of detecting discontinuities that are open to the surface of the part being examined.

5.1.2 This examination method involves the pre-cleaning of the examination surface; the evaporation of the cleaner materials; the application of the a visible dye penetrant to the surface to be examined; the entering of the dye penetrant by capillary action into open-to the surface discontinuities for a specified dwell time; the removal of the excess penetrant from the part; the evaporation of the cleaner after excess penetrant removal and the application of a developer.



5.1.3 The developer provides a highly contrasting background as the dye bleeds through the developer hereby creating an indication of ether a linear or rounded nature. The indications are then evaluated and dispositioned, according to the acceptance criteria of the applicable code, standard, or specification.

5.2 ROLES & RESPONSIBILITIES

5.2.1 The Jacobs NDE level III Examiner/Corporate Level III has the overall responsibility for administrating the Jacobs NDE Program, including this Technical Guideline. The NDE Level III reports directly to the QA/QC Manager. Responsibilities shall include, but not be limited to:

5.2.1.1 Develop NDE techniques that are consistent with industry practices and safety recommendations.

5.2.1.2 Maintain the Jacobs NDE program and all Technical Guidelines for NDE methods and techniques, in compliance with all current requirements of the latest codes or standards, including applicable addenda.

5.2.1.3 Develop and administer written and practical examinations in accordance with Jacobs written practice (Technical Guidelines TGI-NDE-01) for all NDE methods and techniques that the Jacobs NDE program consists of.

5.2.1.4 Provide training and guidance to all Jacobs NDE personnel in the execution of their assigned duties.

5.2.1.5 Develop and administer training programs and classroom instruction, when application, for Jacobs NDE personnel, or others that may seek such training.

5.2.1.6 Administer the requirements for annual Visual Acuity Examinations for all Jacobs NDE personnel.

5.2.2 QA/QC Administrative Assistant - Responsibilities shall include, but not be limited to:

5.2.2.1 Maintaining the training, education, qualification and certification records of all Jacobs NDE personnel, in a current and validated manner.

5.2.2.2 Maintain the NDE Experience Logs and the Visual Acuity Examination records for all Jacobs NDE personnel in a current and valid manner.

5.2.3 The inspector reports to the QA/QC Supervisor and the Manager QA/QC. The Inspector is responsible for execution of the requirements of this Technical Guideline. Responsibilities shall include, but not be limited to:

5.2.3.1 Performing and evaluating NDE Examinations and/or reviewing documentation for compliance with the criteria of the referencing code or standard, and this Technical Guideline.

5.2.3.2 Verifying the qualifications and certifications of NDE personnel engaged in performing and evaluating the NDE examination.

5.2.3.3 Verifying the acceptability of the NDE method and technique and approval, when required by engineering and/or client specifications.

5.2.3.4 Auditing the performance of NDE examinations for compliance with the requirements of the referencing code or standard.



5.2.3.5 Maintaining the records required by this Technical Guideline.

5.2.3.6 Maintaining current and validated Qualification and Certification Records.

5.2.3.7 Maintaining current and validated NDE Experience Logs and Annual Visual Acuity Examination Records.

5.2.3.8 Reporting on the results of NDE Examinations.

5.2.4 The NDE Technician may be an employee, or under the direction of Jacobs as a subcontractor, or may be an employee, or under the direction of the Vendor/Supplier. When an employee of Jacobs, the NDE Technician will report directly to the QA/QC Supervisor and the Manager of QA/QC. Responsibilities shall include, but not be limited to:

5.2.4.1 Performing and evaluation the NDE Examination in accordance with the referencing code or standard, and the written practices governing the NDE examination technique.

5.1.-3.1 Performing the required calibration or technique verifications, to assure the acceptability and validity of the examination results.

5.1.-3.2 Maintaining current and validated Qualification and Certification Records.

5.1.-3.3 Maintaining current and validated NDE Experience Logs and Annual Visual Acuity Examination Records.

5.1.-3.4 Reporting on the results of NDE Examinations.

5.3 PROCESS DETAIL

5.3.1 PERSONNEL QUALIFICATIONS

5.3.1.1 Personnel performing, interpreting, and documenting examinations following this technical guideline shall be qualified and certified in accordance with Jacobs NDE Written Practice, Technical Guideline TGI-NDE01.00.

5.3.2 PENETRANT EXAMINATION MATERIALS AND EQUIPMENT

5.3.2.1 The term penetrant materials, as used in this technical guideline, are intended to include all penetrants, cleaners/removers, and developers used in the examination process. The list of approved materials for each technique is identified in the applicable Attachment.

5.3.2.2 Control of Contaminants

(a) The Manufacturers Certification of contaminant content shall be obtained for all liquid penetrant materials used on nickel based alloys, austenitic or duplex stainless steels, and titanium. These certificates shall include the penetrant manufacturers batch numbers and the test results obtained in accordance with ASME Section V, T-641.

(b) The total residual amount of sulfur and halogens shall not exceed one percent by weight.



5.3.2.3 Calibration of Light Meters

(a) A Model DSF-100X, 401027, light meter, or equivalent shall be used to measure the lighting conditions of the part under examination. The light meter 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.

5.3.3 SURFACE PREPARATION

5.3.3.1 In general, satisfactory results may be obtained when the surface of the part is in the as-rolled, as-welded or as-forged condition. However, surface preparation by grinding, machining or other methods may be necessary where surface irregularities could mask indications of discontinuities.

5.3.3.2 Cleaner/remover, or other commercial solvents may be used to remove traces of dirt, lint, oil, or other foreign matter. All cleaning solvents shall meet the requirements of T-641.

5.3.4 EXAMINATION APPLICATION

5.3.4.1 PENETRANT MATERIALS AND SPECIMEN TEMPERATURES

(a) Standard Temperatures. - The temperature of the penetrant materials and the surface of the part to be processed shall not be below 50F or above 125F, throughout the examination period. Local heating or cooling is permitted provided the part temperature remains within this range during the examination.

(b) When doubt exists as to the actual temperature meeting these requirements, the temperature shall be verified by use of a contact pyrometer or thermometer.

(c) Nonstandard Temperatures - Where it is not practical to comply with the standard temperatures, an examination technique at the proposed lower or higher temperature range requires qualification in accordance with ASME Section V Article 6, Paragraph T-653. This qualification shall be documented and permanently maintained on file.

(d) Attachment 4 provides recommended penetrant materials, and examination processing times to be used during the qualification demonstration.

(e) Variations outside the standard temperature ranges are permitted only by approved technique sheets, which are attachments to this technical guideline. These technique sheets shall be approved by the Jacobs NDE Level III, and incorporated into this technical guideline.

(f) Lighting Requirements - A minimum light intensity of 100 fc (1000 Lx) is required to ensure adequate sensitivity during the examination and evaluation of indications.



5.3.4.2 PRE-CLEANING

(a) The surface to be examined and the adjacent areas within at least one-inch shall be cleaned with absorbent paper towels or cloths and the approved cleaner/remover as referenced for the selected technique. The cleaner may be applied directly to the area being cleaned.

(b) Prior to liquid penetrant application, the cleaned surfaces shall be allowed to dry by normal evaporation or with forced hot or cold air. Drying time shall be as specified by the applicable techniques sheet.

5.3.4.3 TECHNIQUE

(a) The color contrast liquid penetrant examination techniques listed in Section 3.0 shall be performed in accordance with the general requirements of this technical guideline, as well as the specific requirements for the selected technique. (See Attachments 2 or 3)

5.3.4.4 PENETRANT APPLICATION

(a) Dipping, brushing or spraying may be used to apply the penetrant. If the penetrant is applied by spraying using compressed air-type apparatus, filters shall be placed on the up-stream side near the air inlet to preclude contamination of the penetrant by oil, water, dirt, or sediment that may have collected in the lines.

(b) Area of Interest - Unless otherwise specified, the examination area for welds shall be the weld surface plus inch of base material on each side of the weld, except where physical configuration prohibits such examination. The examination area for raw materials (plates and forgings) shall be as defined on the applicable drawing, specification, or work order.

(c) If the surface to be examined is large enough to preclude complete examination within the prescribed time, the surface shall be examined in increments.

5.3.4.5 PENETRANT DWELL TIME

(a) The penetrant dwell time is critical. The minimum dwell time shall be five (5) minutes for castings and welds. The minimum dwell time shall be ten (10) minutes for wrought materials (extrusions, forgings, and plate). The maximum time shall be sixty (60) minutes.

(b) Variations in dwell times are permitted provided they are qualified by demonstration for specific applications.

(c) The examination surface shall be kept wetted with penetrant throughout the specified dwell time. Additional applications of penetrant may be required if the penetrant appears to be drying or draining away from the surface.



5.3.4.6 EXCESS PENETRANT REMOVAL

(a) After the specified penetrant dwell time has elapsed, any excess penetrant remaining on the surface shall be removed, taking care to minimize removal of penetrant from discontinuities.

(b) Excess penetrants shall be removed in accordance with the applicable technique sheet. (See Attachment 2 or 3)

5.3.4.7 DRYING AFTER EXCESS PENETRANT REMOVAL

(a) Normal evaporation, blotting, wiping, or forced air may be used to dry the part surfaces. Drying times and methods shall be as specified in the applicable technique sheet.

5.3.4.8 DEVELOPER APPLICATION

(a) Prior to application, the developer shall be thoroughly agitated to assure that the particles are in suspension. The developer shall be applied by spraying to form a thin uniform white coating. Insufficient coating thickness may not draw the penetrant out of discontinuities; conversely, excessive coating thickness may mask indications.

(b) The developer shall be applied as soon as possible after excess penetrant removal and drying time; the time interval shall not exceed that established in the applicable techniques sheet.

Note: Only non-aqueous developers are approved for use with this technical guideline.

5.3.4.9 DEVELOPER DWELL TIME

(a) Developing time for final interpretation begins immediately after the application of non-aqueous developer coating is dry. The minimum developing time shall be per paragraph 5.3.5.6.

5.3.5 INTERPRETATION / EVALUATION

5.3.5.1 With a color contrast penetrant, the developer forms a reasonably uniform white coating. Surface discontinuities are indicated by bleed-out of the penetrant, which is normally a deep red color that stains the developer. Indications with a light pink color may indicate excessive cleaning. Inadequate cleaning may leave an excessive background making interpretation difficult.

5.3.5.2 Discontinuities at the surface will be indicated by bleed-out of penetrant; however, localized surface irregularities due to machining marks or other surface conditions may produce false indications.

5.3.5.3 Characterizing Indication(s)

(a) The type of discontinuities is difficult to evaluate if the penetrant diffuses excessively into the developer. If this condition occurs, close observation of the formation of indication(s) during application of the developer may assist in characterizing and determining the extent of the indication(s).

(b) Classification of indications with regards to being linear, rounded, relevant or non-relevant shall be determined in accordance with the applicable governing Code or Standard.



5.3.5.4 Non-Relevant indications and broad areas of pigmentation, which could mask indications of discontinuities, are unacceptable, and such areas shall be cleaned and reexamined.

5.3.5.5 Sufficient illumination is required to ensure adequate sensitivity during the examination and evaluation of indications.

5.3.5.6 Final interpretation shall be made within 10 to 60 minutes after the general and specific technique sheet requirements are satisfied. If bleed-out does not alter the examination results, longer periods are permitted.

5.3.5.7 AWS D1.1 Liquid Penetrant Indication Evaluations

(a) The liquid penetrant acceptance criteria in Attachment A are based on the size of the actual discontinuity and not the size of the discontinuity as indicated by the bleed-out. When surface discontinuities are revealed by liquid penetrant means, acceptance shall be based on a direct visual measurement of the actual discontinuity.

(1) Where the discontinuity cannot be visually seen (with magnification if required) after removal of the bleed-out, evaluation shall be based on the size and nature of the bleed-out.

5.3.5.8 ASME Section VIII, Div. 1 Liquid Penetrant Indication Evaluations

(a) Except as otherwise stated for Appendix 26 in paragraph 5.3.5.8 (b) below, liquid penetrant indications shall be evaluated per the following criteria:

(1) An indication is the evidence of a mechanical imperfection. Only indications, which have any dimension greater that 1/16-inch, shall be considered relevant.

(2) A linear indication is one having a length greater than three times the width.

(3) A rounded indication is one of circular or elliptical shape with a length equal to or less than three times its width.

(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.

(5) Any questionable or doubtful indications shall be reexamined to determine whether or not they are relevant.

(b) Appendix 26 - Pressure Vessel and Heat Exchanger Expansion Joints, paragraph 26-5 (Base Metal and Welds)

(1) Indications shall be evaluated, based on the preceding paragraphs except, any linear indication found by examination shall be considered relevant if the dimension exceeds tm/4, but not less than 0.010-inch, where tm is the minimum bellows wall thickness before forming in inches.

5.3.5.9 ASME B31.1 and B31.3 - Liquid Penetrant Indication Evaluations

(a) An indication is the evidence of a mechanical imperfection



(b) A linear indication is one having a length equal to or greater than three times the width.

(c) A rounded indication is one of circular or elliptical shape with a length less than three times its width.

(d) 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.

5.3.5.10 ASME B31.1 Only Indications, which have any dimensions greater than 1/16-inch, shall be considered relevant.

(a) ASME B31.3 indications are not limited on size.

5.3.6 ACCEPTANCE CRITERIA

5.3.6.1 Unless otherwise stated in the governing work instructions, acceptance criteria shall be per the applicable code or standard as follows:

(a) AWS D1.1 - Attachment A

(b) ASME Section VIII, Division 1 - Attachment B

(c) ASME B31.1 - Attachment C

(d) ASME B31.3 - Attachment D

5.3.7 POST EXAMINATION CLEANING

5.3.7.1 After final evaluation, the test surface shall be cleaned with the approved cleaner to remove all traces of penetrant and developer.

5.3.8 DOCUMENTATION

5.3.8.1 Recording of Indications

(a) Nonrejectable Indications. Nonrejectable indications shall be recorded as specified by the referencing Code Section.

(b) 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.

5.3.8.2 Examination Records

(a) For each examination, the following information shall be recorded:

(1) procedure identification and revision; (2) liquid penetrant type (visible or fluorescent); (3) type (number or letter designation of each penetrant,

penetrant remover, and developer used; (4) examination personnel identify and qualification level; (5) map or record of indications per the above Recording of

Indication Criteria; (6) material and thickness; (7) lighting equipment; and (8) date and time examinations were performed.



6.0 REFERENCES

6.1 Jacobs NDE Written Practice, Technical Guideline TGI-NDE01.00

6.2 ASME Section V, Latest Edition and Addenda

6.3 ASME Section VIII, Division 1, Latest Edition and Addenda

6.4 AWS D1.1 Structural Welding Code, Latest Edition and Addenda

6.5 ASME B31.1 and B31.3 Piping Codes, Latest Edition and Addenda

7.0 REPORTS

7.1 The Site QA/QC Supervision or the Project QA/QC Coordinator shall be responsible for maintaining the NDE records, if required, in accordance with the specific site or project requirements.

8.0 ATTACHMENTS

8.1 Attachment 1 - Liquid Penetrant Examination Report Form

8.2 Attachment 2 - Color Contrast/Solvent Removable Standard Temperature Method Technique

8.3 Attachment 3 - Color Contrast/Water Washable Standard Temperature Method Technique

8.4 Attachment 4 - Recommended Non-Standard Temperature Technique Guide

8.5 Attachment 5 - Sequence and Time of Examination

8.6 Attachment A - AWS D1.1 - Acceptance Criteria

8.7 Attachment B - ASME Section VIII Division 1 - Acceptance Criteria

8.8 Attachment C - ASME B31.1 - Acceptance Criteria

8.9 Attachment D - ASME B31.3 - Acceptance Criteria



ATTACHMENT 1 - LIQUID PENETRANT EXAMINATION REPORT FORM

Report No.: Client:Job Location: Project No.:Procedure No.: Rev. No.: Drawing No.: Rev. No.:Part Status:

Base Material Weld Prep. Weld Root Partial Weld Final Weld Repair Surface Preparation: Application:

Ground As-Welded Fluorescent Solvent Removable Machined Color Contrast Water Washable

Material Type: Material Thickness: Pre-Cleaner Type Batch No. Evaporation/Drying TimePenetrant Type: Batch No. Dwell Time Excess Removal Agent Batch No. Evaporation/Dying Time:Developer Type Batch No. Developing Time: Post Cleaning Agent Batch No.

Lighting Light Meter Visible Light Light Intensity at the Examination Surface (fc) Manufacturer Ultraviolet Light Intensity at the Examination Surface W/cm

2 Model

Lighting Equipment Used: Calibration Date:

9.0 Acceptance Criteria ASME B31.1 Normal Fluid Service AWS Statically Loaded Non-Tubular Connections ASME Section I, Appendix A-260.4

ASME B31.1 Severe Cyclic Conditions AWS Cyclically Loaded Non-Tubular Connections ASME Section VIII, Art. 8 & App. 9-2

ASME B31.1 Category D Fluid Service AWS Tubular Connections ASME Section IX, QW-195.2

ASME B31.1 High Pressure ASME B31.3 Par. 136.4,4,B Other:

Examination Results Part/Weld

Identification Accept Reject Linear Length Aligned Rounded Dia. Comments

Sketch

(See continuation page for additional information, if required)

I II III Examiner/Technician (Print Name) & (Signature) (Level) (Date) (Time)

Client Representative (Print Name) & (Signature)

Page 1 of __



Report No.: Client:

Examination Results Continued Part/Weld

Identification Accept Reject Linear Length Aligned Rounded Dia. Comments

Sketch

Page 2 of __



ATTACHMENT 2

COLOR CONTRAST/SOLVENT REMOVABLE METHOD TECHNIQUE

STANDARD TEMPERATURE EXAMINATIONS

1.0 PENETRANT MATERIALS

1.1 Liquid Penetrant examinations shall be performed using color-contrast, solvent-removable penetrant and non-aqueous developer. The brand names and specific types acceptable for use are listed below:

Manufacturer Cleaner/Remover Penetrant Developer

Magnaflux SKC-S SKL-SP SKD-S2

Sherwin Double-Check DR-60 DP-40 D-100

Dynaflux Crack-Check CNF PHF DNF

Met-L-Check E-59A VP-31A D-70

Crown Fault Finder 1071 1075 1079

Note: (1) Intermixing of penetrant materials from different families or different manufacturers is not permitted.

2.0 PRE-CLEANING

2.1 The area to be examined shall be pre-cleaned with appropriate cleaner/removers listed above and in accordance with the general requirements.

2.2 The examination surface shall be allowed to dry 3 minutes after pre-cleaning is completed.

3.0 PENETRANT APPLICATION

3.1 Using the appropriate penetrant material listed above, the penetrant shall be applied directly to the surface by brushing, spraying or dipping in accordance with paragraph 5.3.4.4.

4.0 PENETRANT DWELL TIME

4.1 The penetrant shall remain on the surface as specified in paragraph 5.3.4.5 (a).

4.2 The penetrant shall not be allowed to dry on the examination surface. When necessary, the penetrant materials shall be re-applied in accordance with the general requirements.



5.0 EXCESS PENETRANT REMOVAL

5.1 Step 1 - 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.

5.2 Step 2 - Using the appropriate cleaner/removers listed above, 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.

5.3 Steps 1 and 2 - Shall be repeated until the excess penetrant has been removed from the examination surface.

5.4 Flushing or spraying the surface with solvent, for the purpose of removing excess penetrant is prohibited.

5.5 After all traces of the excess penetrant have been removed, allow the examination surface to dry by normal evaporation, 3 to 20 minutes prior to application of the developer.

6.0 DEVELOPER APPLICATION

6.1 Using the appropriate developers listed above and after the prescribed drying time has elapsed, apply the developer by spraying with a light, even spray. The developer shall be applied in accordance with paragraph 5.3.4.8.

6.2 Examine the surface as the developer is applied for indications that may bleed profusely.

7.0 INTERPRETATION AND EVALUATION

7.1 Developing time for final interpretation begins immediately after the non-aqueous developer coating is dry.

7.2 Final interpretation shall be made within the time interval established.

7.3 Indications shall be classified in accordance with the applicable criteria and the Accept/Reject determinations shall be in accordance with the applicable Attachment listed in paragraph 8.0.

8.0 POST-EXAMINATION CLEANING

8.1 At the conclusion of the examination, all remaining penetrant and developer shall be removed from the examination surface with the appropriate cleaning material listed above.



ATTACHMENT 3

COLOR CONTRAST/WATER-WASHABLE METHOD TECHNIQUE

STANDARD TEMPERATURE EXAMINATIONS

1.0 PENETRANT MATERIALS

1.1 Liquid Penetrant examinations shall be performed using color-contrast, water-washable penetrant and non-aqueous developer. The brand names and specific types acceptable for use are listed below:

Manufacturer Cleaner/Remover Penetrant Developer

Magnaflux SKC-S SKL-WP SKD-S2

Sherwin Double-Check DR-60 DP-51 D-100

Dynaflux Crack-Check CNF PWW-PHF DNF

Met-L-Check E-59A VP-30 D-70

Note: (1) Intermixing of penetrant materials from different families or different manufacturers is not permitted

(2) A retest with water washable penetrants may cause loss of marginal indications due to contamination.

2.0 PRE-CLEANING

2.1 The area to be examined shall be pre-cleaned with appropriate cleaner/removers listed above and in accordance with the general requirements.

2.2 The examination surface shall be allowed to dry at least 3 minutes after pre-cleaning is completed.

3.0 PENETRANT APPLICATION

3.1 Using the appropriate penetrant material listed above, the penetrant shall be applied directly to the surface by brushing, spraying or dipping in accordance with paragraph 5.3.4.4.

4.0 PENETRANT DWELL TIME

4.1 The penetrant shall remain on the surface as specified in paragraph 5.3.4.5 (a).

4.2 The penetrant shall not be allowed to dry on the examination surface. When necessary, the penetrant materials shall be re-applied in accordance with the general requirements.



5.0 EXCESS PENETRANT REMOVAL

5.1 Excess water washable penetrants shall be removed with a water spray.

5.2 The water pressure shall not exceed 50 psi and the water temperature shall not exceed 1100F.

5.3 After all traces of the excess penetrant have been removed, the surface may be dried by blotting with clean cloth or absorbent paper materials, by circulating air, or a combination of both. If circulating air is used the temperature of the examination surface shall not exceed 1250F.

5.4 Allow the examination surface to dry by normal evaporation, an additional 3 to 20 minutes after the drying operation is completed and prior to application of the developer.

6.0 DEVELOPER APPLICATION

6.1 Using the appropriate developers listed above and after the prescribed drying time has elapsed, apply the developer by spraying with a light, even spray. The developer shall be applied in accordance with paragraph 5.3.4.8.

6.2 Examine the surface as the developer is applied for indications that may bleed profusely.

7.0 INTERPRETATION AND EVALUATION

7.1 Developing time for final interpretation begins immediately after the non-aqueous developer coating is dry.

7.2 Final interpretation shall be made within the time interval established.

7.3 Indications shall be classified in accordance with the applicable criteria and the Accept/Reject determinations shall be in accordance with the applicable Attachment listed in paragraph 8.0.

8.0 POST-EXAMINATION CLEANING

8.1 At the conclusion of the examination, all remaining penetrant and developer shall be removed from the examination surface with the appropriate cleaning material listed above.



ATTACHMENT 4

RECOMMENDED NON-STANDARD TEMPERATURE TECHNIQUE GUIDE

Color-Contrast/Solvent-Removable Method Technique Non-Standard

Temperatures Examination Guidelines

1.0 Penetrant Materials

1.1 Recommended types of penetrant materials for specific temperature ranges are listed below:

Temperature Range Manufacturer

Cleaner/ Remover Penetrant Developer

Magnaflux SKC-S SKL-PS SKD-S2

Dynaflux CNF PHF DNF

Met-L-Check E-59A VP-31A D-70 330F to 400F Crown 1071 1075 1079

Magnaflux SKC-S SKL-PS SKD-S2

Sherwin DR-60 DP-40 D-100

Dynaflux CNF PHF DNF

Met-L-Check E-59A VP-31A D-70 410F to 490F Crown 1071 1075 1079

Sherwin K-019 K-017 D-350

Dynaflux CNF PHF DNF 1260F to 1500F Met-L-Check R-502 VP-302 D-702

Sherwin K-019 K-017 D-350 1510F to 3500F Met-L-Check R-502 VP-302 D-702

2.0 Pre-Cleaning and Excess Penetrant Removal Evaporation Times

2.1 Recommended evaporations times for the different types of cleaners/removers for specific temperature ranges are listed below:

Temperature Range Minimum Evaporation Time

330F to 400F 12 Minutes






3.0 Penetrant Dwell Time

3.1 Recommended dwell times for different types of penetrant materials for specific temperature ranges are listed below:

Temperature Range Minimum Dwell Time





4.0 Final Evaluation time

4.1 Recommended Indication Evaluation times for different types of Developer materials for specific temperature ranges are listed below:

Temperature Range Minimum Evaluation Time







ATTACHMENT 5

SEQUENCE AND TIME OF EXAMINATION

1.0 In addition to the requirements of paragraph 8.4.2, the following specific criteria shall be considered when performing examinations to the various referencing codes covered by this technical guideline.

1.1 Unless otherwise specifically addressed, herein, liquid penetrant examinations should be performed at the last feasible stage of the manufacturing process.

2.0 AWS D1.1 - Structural Welding Code

2.1 When welds are subject to Liquid Penetrant Examination in accordance with AWS D1.1, the testing may begin immediately after the welds have cooled to ambient temperature, however, acceptance criteria for ASTM A514 and A517 Steels shall be based on examinations performed not less than 48 hours after completion of welds.

3.0 ASME Section VIII, Divisions 1

3.1 Part UG - Inspection of Materials, paragraph UG-93 (d)(3) (Base Material)

3.1.1. When specified by engineering specification(s) or drawing(s), pressure parts welded to a flat plate thicker than inch to form a corner joint under the provision of UW-13 (e), the weld joint preparation in the flat plate shall be examined before welding as specified in 3.1.3 below by the appropriate liquid penetrant examination method.

3.1.2. After welding, both the peripheral edge of the flat plate and any remaining exposed surface of the weld joint preparation shall be reexamined by the appropriate liquid penetrant examination method as specified in 3.1.3 below.

3.1.3. For Figure UW-13.2 the weld joint preparation and the peripheral edges of flat plate forming a corner joint shall be examined as follows:

3.1.3.1. The weld edge preparation of typical weld joint preparations in the flat plate as shown in sketches (b), (c), (d), (f), and (n);

3.1.3.2. The outside peripheral edge of the flat plate after welding as shown in sketches (a), (b), (c), and (d);

3.1.3.3. The outside peripheral edge of the flat plate after welding, as shown in sketches (e), (f), and (g) if the distance from the edge of the completed weld to the peripheral edge of the flat plate is less than the thickness of the flat plate such as defined in UG-34 (b);

3.1.3.4. The inside peripheral surface of the flat plate after welding as shown in sketches (m) and (n);

3.1.3.5. No examination is required on the flat plate as shown in sketches (h), (i), (j), (k), and (l).

3.2 Part UNF - Nonferrous Vessels, paragraph UNF-58 (Welds)

3.2.1 All welds, both groove and fillet, in vessels constructed of materials covered by UNS N06625 (for Grade 2 only in SB-443, SB-444, and SB-446), UNS N10001, and UNS N10665 shall be examined for the detection of cracks by the appropriate liquid penetrant method.

3.2.1.1 This examination shall be made following heat treatment if heat



treatment is performed. All cracks shall be removed by grinding, or grinding and filing. Where a defect is removed and welding repair is not necessary, care shall be taken to contour notches or corners. The contoured surface shall then be re-inspected by the same means originally used for locating the defect to be sure it has been completely removed.

3.2.2 All joints in vessels constructed of titanium or zirconium and their alloys shall be examined by the appropriate liquid penetrant method.

3.2.3 Welded joints in vessels or parts of vessels, constructed of materials listed in Table UNF-23.3, with the exception of alloys 200 (UNS No. N02200), 201 (UNS No. N02201), 400 (UNS No. N04400), 405 (UNS No. N04405), and 600 (UNS No. N06600), shall be examined by the appropriate liquid penetrant method when they are not required to be fully radiographed.

3.2.4 Laser welded lap joints are exempt from liquid penetrant examination requirements of 3.2.1, 3.2.2, and 3.2.3 above.

3.3 Part UHA - High Alloy Steel Vessels, paragraph UHA-34 (Welds)

3.3.1 All austenitic chromium-nickel alloy steel and austenitic/ferritic duplex steel welds, both groove and fillet, which exceed a nominal size of in., shall be examined for the detection of cracks by the liquid penetrant method. This examination shall be conducted after heat treatment if heat treatment is performed.

3.4 Part UHT - Ferritic Steel Vessels, paragraph UHT-57 (Nozzle Attachment Welds, Overlay Welds, and all other Welds including welds for attaching non-pressure parts to heat treated steels)

3.4.1 When specified by engineering specification(s) or drawing(s), welds shall be examined by the appropriate liquid penetrant method, as follows:

3.4.1.1 Nozzle Attachment Welds. Figure UHT-18.2 type nozzles having an inside diameter of 2 in. or less shall be examined. For nozzle attachments illustrated as sketches (a), (b), and (f) of Figure UHT-18.2, the exposed cross section of the vessel wall at the opening shall be included in the examination.

3.4.1.2 All corrosion resistant overlay weld deposits shall be examined by the liquid penetrant method.

3.4.1.3 All welds, including welds for attaching non-pressure parts to heat treated steels covered by Part UHT, shall be examined after the hydrostatic test, except that those surfaces not accessible after the hydrostatic test shall be examined at the last feasible stage of vessel fabrication. Cracks shall be repaired or removed.

Note: As an acceptable alternative to magnetic particle examination or when magnetic particle methods are not feasible because of the nonmagnetic character of the weld deposits, a liquid penetrant method shall be performed.

3.4.1.4 For vessels constructed of SA-333 Grade 8, SA-334 Grade 8, SA-353, SA-522, SA-553 Grades A and B, and SA-645 materials, welds not examined radiographically shall be examined by the liquid penetrant method either before or after the hydro test.

3.5 Part UHT - Ferritic Steel Vessels, paragraph UHT-85 (Structural and Temporary



Weld)

3.5.1 When specified in the engineering specification(s) or drawing(s), temporary welds and weld repairs shall be inspected as follows:

3.5.1.1 Temporary welds shall be removed and the metal surface shall be restored to a smooth contour. The area shall be examined by the appropriate liquid penetrant method for the detection and elimination of cracks.

3.5.1.2 If repair welding is required, the finished weld surface shall be examined by the appropriate liquid penetrant method for the detection and elimination of cracks.

3.6 Part ULT - Low Temperature Vessels, paragraph ULT-57 (Welds)

3.6.1 All attachment welds, and all welded joints subject to pressure not examined by radiography or ultrasonic testing, shall be given a liquid penetrant examination either before or after hydro test.

3.6.2 Liquid penetrant examinations shall be performed prior to any required pneumatic test.

3.7 Appendix 26 - Pressure Vessel and Heat Exchanger Expansion Joints, paragraph 26-5 (Base Metal and Welds)

3.7.1 When specified in the engineering specification(s) or drawing(s), all expansion joint flexible elements and welds shall be examined, as follows:

3.7.1.1 All expansion joint flexible elements shall be visually examined for and shall be free of injurious defects, such as notches, crevices, material buildup or upsetting, weld spatter, etc., which may serve as points of local stress concentrations. Suspect surface areas shall be further examined by the appropriate liquid penetrant examination method.

3.7.1.2 All full penetration butt-type welds shall be examined 100% on the inside and outside surfaces by the appropriate liquid penetrant methods before forming. This examination shall be repeated after forming to the maximum extent possible considering the physical and visual access to the weld surfaces after forming.

3.7.1.3 The circumferential attachment welds between the bellows and the weld ends shall be examined 100% by the appropriate liquid penetrant examination method.

4.0 ASME Standard B31.1 (Code Cases No. 25 to B31.1 Power Piping

4.1 When specified in the engineering specification(s) or drawing(s), alloy S32550 (P-No. 10H) piping material in exceeds of -inch thickness, shall be examined as follows:

4.1.1 The welds shall be examined by the appropriate liquid penetrant method

5.0 ASME Standard B31.3

5.1 Chapter VI Inspection, Examination, and Testing, paragraph 341.4.3 (Socket and Branch Connection Welds in Sever Cyclic Service)

5.1.1 When specified in the engineering specification(s) or drawing(s), socket welds and branch connection welds, which are not radiographed, shall be examined by the appropriate liquid penetrant method.

5.2 Chapter VI Inspection, Examination, and Testing, paragraph 345.9.1 (Examination



of Welds in lieu of Hydrostatic or Pneumatic Leak Testing)

5.2.1 When engineering determined the hydrostatic, pneumatic or a combination hydrostatic-pneumatic leak test to be impracticable, piping welds shall be examined as follows:

5.2.1.1 All welds, including structural attachment welds, not covered by 100% radiography, shall be examined by the appropriate liquid penetrant method.



(Continued on next Page)



ATTACHMENT A

AWS D1.1 - ACCEPTANCE CRITERIA

ACCEPTANCE CRITERIA FOR STATICALLY LOADED NON-TUBULAR CONNECTIONS

Welds that are subject to Liquid Penetrant Examination shall have no cracks and shall be acceptable if:

(a) Thorough fusion exists between adjacent layers of weld metal and between weld metal and base metal.

(b) Complete joint penetration groove welds in butt joints transverse to the direction of computed tensile stress shall have no visible piping porosity. For all other groove welds and for fillet welds, the sum of the visible piping porosity 1/32 inch or greater shall not exceed 3/8 inch in any linear inch of weld and shall not exceed inch in any 12-inch length of weld.

ACCEPTANCE CRITERIA FOR CYCLICALLY LOADED NONTUBULAR CONNECTIONS



(b) The frequency of piping porosity in fillet welds shall not exceed one in each 4 inches of weld length and the maximum diameter shall not exceed 3/32 inch. Exception: for fillet welds connecting stiffeners to web, the sum of the diameters of piping porosity shall not exceed 3/8 inch in any linear inch of weld and shall not exceed inch in any 12-inch length of weld.

(c) 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 4-inch of length and the maximum diameter shall not exceed 3/32 inch.

ACCEPTANCE CRITERIA FOR TUBULAR CONNECTIONS (ALL LOADS)



(b) The sum of diameters of piping porosity in fillet welds does not exceed 3/8 inch in any linear inch of weld and does not exceed inch in any 12-inch length of weld.

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, piping porosity shall not exceed 3/8 inch in any linear inch of weld and shall not exceed inch in any 12-inch length of weld.



ATTACHMENT B

ASME SECTION VIII DIVISION 1 - ACCEPTANCE CRITERIA

1.0 All surfaces to be examined shall be free of:

(a) relevant linear indication;

(b) relevant rounded indication greater than 3/16 inch;

(c) four or more rounded indications in a line separated by 1/16 inch or less (edge to edge).

2.0 Part UNF,- Nonferrous Vessels, paragraph UNF-58. In additions to the requirements of paragraph 1.0, liquid penetrant indications detected and evaluated as cracks, are unacceptable regardless of length, if detected on groove or fillet welds, constructed of materials covered by UNS NO6625 (for Grade 2 only in SB-443, SB-444, and SB-446), UNS N10001, and UNS N10665.

3.0 Part UHA - High Alloy Steel Vessels, paragraph UHA-34 (Welds) In additions to the requirements of paragraph 1.0, liquid penetrant indications detected and evaluated as cracks, are unacceptable regardless of length, if detected on austenitic chromium-nickel alloy steel and austenitic/ferritic duplex steel welds, both groove and fillet, which exceed a nominal size of -inch.

4.0 Part UHT - Ferritic Steel Vessels, paragraph UHT-57 and UHT-85 (Welds) In additions to the requirements of paragraph 1.0, liquid penetrant indications detected and evaluated as cracks, are unacceptable regardless of length, if detected on Ferritic Steel Vessel welds.

ATTACHMENT C ASME B31.1 - ACCEPTANCE CRITERIA

The following relevant indications are unacceptable:

(a) Any crack or linear indication;

(b) Rounded indication with dimensions greater than 3/16 inch;

(c) Four or more rounded indications in a line separated by 1/16 inch or less (edge to edge);

(d) Ten or more rounded indications in any 6 square inches of surface with the major dimension of this area not to exceed 6 inches. This measurement is to be taken in the most unfavorable location relative to the indications being evaluated.

ATTACHMENT D ASME B31.3 - ACCEPTANCE CRITERIA

The following relevant indications are unacceptable:

Cracks are not acceptable in welds or base materials.

documentpt

Documents