Penetrant procedure

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PT Caterpillar Indonesia BatamLIQUID PENETRANT TESTING PROCEDURE

Document No : SOP-QCA-002-00

Revision No. : 00

Issued Date : 18/10/201

Pa!e : 1 o" 12

Desc#i$tion : ND% PROC&D'R&Re""e#ence : -Issue () : A(du* %#i +amdani

A$$#oved () : Anan! ,us anto

1. SCOPE

This procedure covers for penetrant examination of ferrous and non-ferrous weld, nonporous material

with the associated HAZ on the parent metal and components using solvent removable penetrant

technique (Method !" This procedure described non-destructive testing methods for detecting

discontinuities that are open to the surface such as crac#s, porosit$ and lac# of fusion b$ liquid penetrant

testing conducted in accordance with the requirements of %&' )*+- ( . */ - ! and acceptance criteria

. %&' + +// ( . +01!"

2. PURPOSE

The purpose of this procedure is to implement the liquid penetrant testing method in 2T AT 32%44A3

%.5'. &%A 6ATAM"

3. REFERENCES

" %&' )*+- ( . */ - ! .on-destructive testing-2enetrant testing-7eneral principles"+ 6& . %&' )*+-+ ( . */ -+ ! .on 8 5estructive Testing-2enetrant Testing - 2art +9 Testing of

penetrant materials" . %&' )*+- ( . */ - ! .on-destructive testing - 2enetrant testing - 2art 9 3eference test

bloc#s") . %&' + +// ( . +01! .on-destructive testing of welds - 2enetrant testing of welds -

Acceptance levels

"* . %&' 1/ +, .on-destructive testing : ;ualification and certification of personnel"< %&' =*1 .on-destructive testing : 2enetrant testing and magnetic particle testing >iewing

conditions"/ %&' *0 /9+= ) ?elding -- @usion-welded oints in steel, nic#el, titanium and their allo$s (beam

welding excluded! -- ;ualit$ levels for imperfections"0 A&.T &.T-T - A 3ecommended 2ractice - 2ersonnel ;ualification and ertification in

.ondestructive Testing

"1 AT 32%44A3 %.5'. &%A 6ATAM ?ritten 2ractice, 5' BM .T .o" &'2-; A-==)-==

%+& IN OR A%ION +&R&ON IS %+& PROP&R% O CA%&RPI AR INC. AND/OR I%S S' SIDIARI&S. 3I%+O'% 3RI%%&NP&R ISSION4 AN COP IN54 %RANS I%%A %O O%+&RS4 AND AN 'S& &6C&P% %+A% OR 3+IC+ I% IS OAN&D4 IS PRO+I I%&D.

PROC&SS / DOC' &N% %I% & R&7ISION DA%& DOC' &N% No.

LIQUID PENETRANT PROCEDURE 18-Oct-201 SOP-QCA-002-0023' && '?. 3 C A223'> 3 . DT 3 >% ? 5 5AT

> 3&%'.

Anan! ,us anto 12-Oct-201 00

Cate#$i**a#: Con"identia* 5#een - Re$#oduction Constitutes an 'ncont#o**ed Document -

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4. ABBREVIATION

2T 9 2enetrant Testing

HAZ 9 Heat Affected Zone

.5T 9 .on 5estructive Testing

5. PERSONNEL QUALIFICATION AND RESPONSIBILITY

The .5T %nspector shall be responsible for conducting and reporting the results of inspection"

*" 2ersonnel performing examinations to this procedure shall be qualified and certified in accordance

with the requirements of %&' 1/ + andCor A&.T &.T-T - A certified in accordance with

AT 32%44A3 %.5'. &%A 6ATAM written practice"

*"+ 'nl$ individuals qualified to .5T 4evel %% shall be perform the examinations in accordance with this

procedure"

*" valuation of test results shall be b$ .5T 4evel %% or level %%% onl$

*") ?hen the written practice is revised, the certification of .5T personnel remains valid to the

requirements of the previous revision until the expir$ date of the personnel qualification certificateE then,

recertification to the requirements of the new revision is required"

*"* The certification of personnel shall be chec#ed b$ the ;AC; Manager prior to wor# commencement"

"

6. EQUIPMENT AND CONSUMABLE%+& IN OR A%ION +&R&ON IS %+& PROP&R% O CA%&RPI AR INC. AND/OR I%S S' SIDIARI&S. 3I%+O'% 3RI%%&N

P&R ISSION4 AN COP IN54 %RANS I%%A %O O%+&RS4 AND AN 'S& &6C&P% %+A% OR 3+IC+ I% IS OAN&D4 IS PRO+I I%&D.



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- meter (if use fluorescent technique!

B>- lamp (if use fluorescent technique!

erification of equipment and chemicals components shall be carried out ever$ da$ prior carriedexamination and recorded on examination report 5' BM .T .o" %6-; A-==)-== to conform

continuing satisfactor$ performance"

8. VIEWING CONDITIONS




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0" 4ightning ondition @or olor ontrast 2enetrant

a" The wor#ing range of irradiation and illuminance meters shall be calibrated at the frequenc$

recommended b$ the manufacturer using equipment and a s$stem which is traceable to a national,

uropean or %nternational &tandard" This period shall not exceed + months" The calibration of the

B>-A irradiation meter shall be carried out with narrow band radiation at a wavelength of -A irradiance at the surface to

be inspected shall not less than === F?Ccm + and the visible light should not more than += 4ux at

< inch ()== mm! minimum distance between surface and end of light source"

b" @or the removal of excess penetrantcarried out under lighting condition as specified in section 0"+"sa

above"




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c" %f the examiner wears glasses or lenses, the$ shall not be photosensitive"

d" The inspector shall allow at least * minutes for dar# adaptation before beginning the inspection"

e" B> radiation shall not be directed in the operatorGs e$es

f" .o paper or cloth which fluoresces under B> light shall be in sight of the operator

g" A B> bac#ground lighting ma$ be provided, if necessar$, to allow the operator to move freel$

inside the booth

h" The combination of high level and long duration of B>-A irradiance should be avoided, generall$

not more than *= ?Cm+

(*=== ?Ccm+

!"

. TEMPERATURE

%n order to minimiIe moisture entering discontinuities, the temperature of the test surface shall generall$

be within the range from = o to *= o "

1!. SEQUENCE OF OPERATIONS

=" 23 - 4 A.%.7




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The surface of the test part shall be free form contaminant, e" g" scale, rust oil, grease or paint" %f

necessar$ using mechanical or chemical methods or combination of these methods" 2re cleaning shall

ensure that test surface is free from residues and that it allows the penetrant to enter the discontinuit$" The

cleaned area shall be large enough to prevent interference from areas ad acent to the actual test surface"

@or welding shall be include the material minimum +* mm ( inch! each side of weld"

="+ 53J%.7

As the final stage of pre-cleaning the parts to be tested shall be thoroughl$ dried, so that neither water nor

solvent remains in the discontinuities and dr$ing method used is normal evaporation for minimum *

minutes"

=" A224J &'4> .T 3 M'>A64 2 . T3A.T

The penetrant can be applied b$ spra$ing, brushing, flooding, dipping or immersion" are should be ta#en

to ensure that test surface remains completel$ wetted throughtout the entire penetration time"

=") 2 . T3AT%'. T%M

The appropriate penetration time depends on the properties of the penetrant, the application temperature,

the material being inspected and the t$pe of discontinuities to be detected"

The penetration time can var$ from = minutes to = minutes"

="* D && 2 . T3A.T 3 M'>A4




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7enerall$, the excess penetrant shall be removed first using a clean lint free cloth" &ubsequent cleaning

with a clean lint free cloth moistened with solvent shall then be carried out" Appl$ing solvent directl$ to

the test surface is prohibited"

="< D && 2 . T3A.T 3 M'>A4 H K

5uring excess penetrant removal the test surface shall be visuall$ chec#ed for penetrant residues" @or

fluorescent penetrants, this shall be carried out under B>-A sources and lighting condition refer to section

0"+"a

="/ 53J%.7

%n order to facilitate rapid dr$ing of excess water, an$ droplets and puddles of water shall be removed

from the part b$ evaporation at ambient temperature and surface temperature shall not exceed *= o during

dr$ing"

="0 A224J%.7 5 > 4'2 3

The solvent based (non-aqueous! developer shall be applied b$ spra$ing uniforml$ as soon as possible

after d$ing" The spra$ shall be such that developer arrives slightl$ wet on the surface, giving a thin,

uniform la$er"

="1 5 > 4'2%.7 T%MThe development time should be between = and = minutes, longer times ma$ be agreed between the

contracting parties"

The development time begin %mmediatel$ after dr$ing when non-aqueous wet developer is applied"




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=" = %.&2 T%'.

7enerall$ it is advisable to carr$ out the first examination ust after the application of the developer or as

soon as the developer dr$" This facilitates a better interpretation of indication"

The final inspection shall be carried out when the development time has elapsed"

=" = 3 '35%.7 %.5% AT%'.

3ecording ma$ be done b$ an$ of the methods below and use 42T report form %6-; A-==)-== 9

a" ?ritten description

b" etch

c" 2hotograph$

=" 2'&T 4 A.%.7 A.5 23'T T%'.

After final inspection, post cleaning shall be carried out " %f required a suitable corrosion protection shall

be applied"

=" + 3 T &T%.7

%f retesting is necessar$, e"g" because no unambiguous evaluation of indications is possible, the entire test

procedure, starting with the pre-cleaning" The use of a different t$pe of penetrant or a penetrant of the

same t$pe from different manufacturer is not allowed unless a thoroughl$ cleaning has been carried out to

remove penetrant residues remaining in the discontinuities"

11. EVALUATION OF INDICATIONS%+& IN OR A%ION +&R&ON IS %+& PROP&R% O CA%&RPI AR INC. AND/OR I%S S' SIDIARI&S. 3I%+O'% 3RI%%&N

P&R ISSION4 AN COP IN54 %RANS I%%A %O O%+&RS4 AND AN 'S& &6C&P% %+A% OR 3+IC+ I% IS OAN&D4 IS PRO+I I%&D.



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" An$ indication which is believed to be non relevant shall be re-examined again as per section =" +to conform relevant or non- relevant indication"

"+ A liner indication is one having a length greater than three time its width" A non-linear indicationhaving length equal to or less than three times its width"

" 3elevant and .on-relevant indication

An %ndication shall be consider relevant if the length is more than "* mm and indication with length

equal or less than "* mm shall be considered non-relevant indication"

") Bnacceptable indications shall be removed or repaired according to qualified repair welding procedure"

"* The repaired area has to be re-examined b$ 2T and BT (BT onl$ for Ldeeper imperfections!"3esult to be mentioned in related protocol9 3ewor# successfull$ done"

12. ACCEPTANCE CRITERIA

The acceptance criteria for discontinuities shall be meet the requirements of . %&' + +// ( . +01!

acceptance level +D accordance to table "The width of the test shall be include in the weld metal and

ad acent parent metal up to a distance of +* mm of each side" 'ther acceptance criteria such as . %&'*0 / ma$ applied for qualit$ level 6 or Table for acceptance 4evel which ever is stringent"

+" 7rouped %ndication




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An$ ad acent indication separated b$ less than the ma or dimension of the smaller shall be assessed as a

single, continuous indication" 7rouped indication shall be evaluated in accordance with application

standards such as . %&' *0 / ma$ applied for qualit$ 4evel 6 or table for acceptance level

whichever is stringent"

+" @alse %ndication

@alse indication arise for man$ reasons, e"g" surface not properl$ clean, finger mar# of technician, and

porous material could built an false indication"

13. REPORTING

" " A report shall be prepared detailing the results of the examination and recorded on penetrant testingreport form 5' BM .T .o" %6-; A-==)-==

"+" The report shall contain sufficient information to enable a full assessment of qualit$ and to ensurethat an$ non-acceptable areas can be accuratel$ located should repair be necessar$"

" " An$ datumNs used shall be unambiguous"

")" A statement of acceptabilit$ against the acceptance standard should be made"




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Table -Acceptance 4evel for %ndication




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13. SAFETY

The materials and equipment required b$ this procedure ma$ be harmful, flammable andCor volatile" All

personnel whose doing examination shall be wearing 22 including mas#, e$eglass, and other safet$

equipment that need for protection from incident and shall follow M&5&"

14. NDT LEVEL III APPROVAL

.AM 9 3'..J A.5A4A&

T%T4 9 A&.T .5T 4evel %%% ertificate .o"

Penetrant procedure

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