PETROL & PETROCHEMICAL COMPANY
FOR INDUSTRIAL SUPPORT SERVICES
(PETROCHEM)
C.R.2060033647
P.O.Box 31365-Aqrabia 31952
Al Khobar-Kingdom of Saudi Arabia
Tel: +966 13 8140566- Fax: +966 13 898 4211
‫شركة البترول والبتروكيماويات‬
‫للخدمات الصناعية المساندة‬
)‫(بتروكـــيــــم‬
2060033647 ‫ت‬.‫س‬
31952 ‫ــ العقربية‬31365 ‫ب‬.‫ص‬
‫الخبرــ المملكة العربية السعودية‬
966138140566 :‫تيلفون‬
LIQUID PENETRANT TEST PROCEDURE COLOR CONTRAST, VISIBLE (SOLVENT
REMOVABLE)
DOC. NO. PETROCHEM/PT/01.Rev.8.6, Dated: 15-Jan-2024
APPROVED BY
Name
: Mr.Mathew. K. Alexander
Designation
: ASNT NDT Level III (RT,UT,PT,MT,VT)
( Cert.No.73369 )
Signature
:
COMPANY AUTHORIZATION
Name
: Srihari Sivadas
Designation
: Quality Manager
Signature
:
Issued to : Gulf Asia Contracting Co. LLC, Ma’aden Phosphate Shutdown Project
Issue Date: 25-Mar-2024
PETROL AND PETROCHEMICAL COMPANY FOR
INDUSTRIAL SUPPORT SERVICES
LIQUID PENETRANT TEST PROCEDURE
Color contrast, visible (solvent removable)
DOC. NO.
PETROCHEM/PT/01
REV.
8.6
DATE
15-Jan-2024
TABLE OF CONTENTS
1.0
Scope
2.0
References
3.0
Procedure Variables
4.0
Qualification of Personnel
5.0
Specified Duties of Personnel
6.0
Extent of Examination
7.0
Surface Preparation
8.0
Equipment and Materials
9.0
Examination
10.0
Interpretation
11.0
Evaluation of Indications and Acceptance Standards
12.0
Post Cleaning
13.0
Repairs
14.0
Safety Precautions
15.0
Documentation
APPENDIX A - ACCEPTANCE CRITERIA
APPENDIX B - LIQUID PENETRANT EXAMINATION REPORT
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1.0 SCOPE
1.1 This procedure shall govern the methods and requirements for liquid penetrant examination
using color contrast, visible (solvent removable) penetrant for detecting open surface
discontinuities on ferrous, nonferrous and nonporous materials whose shapes and sizes are
suitable for liquid penetrant examination.When required by the referencing Code Section, all
non-destructive examinations performed shall be done to a written procedure and this
procedure shall be demonstrated to the satisfaction of the Authorized Inspector and shall be
verified and approved by ASNT NDT Level III.
2.0 REFERENCES
The current edition of the following documents have been referenced in the preparation of this
procedure and shall be considered a part of this procedure as applicable.
2.1 ASME Section V (2023) – Liquid Penetrant Examination
2.2 ASME Section VIII Div.1(2023) – Rules for construction of Pressure Vessels
2.3 ASME Section VIII Div.2 (2023) , Alternative Rules for construction of Pressure Vessels
2.4 ASME Sec.I (2023) - Rules for construction of Power Boilers
2.5 ASME Section IX (2023) – Qualification: Welding & Brazing
2.6 API5LD (4th Edition) - Specification for CRA Clad or Lined Steel Pipe
2.7 API 6A (21st Edition) - Specification for Weld head and Christmas Trees Equipment
2.8 ASTM E 165 (2009) - Standard Test Method for Liquid penetrant Examination
2.9 ASME B31.1 (2022) – Standards for Power Piping
2.10 ASME B31.3 (2022) – Standards for Chemical Plant and Petroleum Refinery piping
2.11 ASME B31.8 (2018) - Gas transmission & distribution piping system
2.12 API 1104 (22nd Edition) – Standard for Welding Pipeline and related facilities
2.13 AWS D1.1 (2020) – Structural Welding Code –Steel
2.14 ASNT CP-189 (2020) – ASNT Standard for Qualification and Certification of NDT Personnel.
2.15 PETROCHEM/WP/1 - PETROCHEM Written Practice for Qualification and Certification of
NDT Personnel
Note: Unless Otherwise specified all Codes/Standards are of latest edition
3.0 PROCEDURE VARIABLES
3.1 The following essential variables are applicable to this procedure.
Essential
Variable
X
Reference
X
6.0
X
8.2
Method of removing excess surface penetrant
X
8.3
Method of applying developer
X
8.4
Minimum and maximum time periods between steps and drying
aids
Decrease
in penetrant dwell time
X
3.2
X
3.2
Increase in developer dwell time (Interpretation Time)
X
3.2
Requirement
Identification of and any change in type or family group of
penetrant materials including developers
Surface preparation (finishing and cleaning, including type of
cleaning solvent)
Method of applying penetrant
7.3
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8.6
8.6
PETROL AND PETROCHEMICAL COMPANY FOR
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LIQUID PENETRANT TEST PROCEDURE
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Minimum light intensity
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X
7.4
Surface temperature outside 50 to 125 F (10 C to 52 C) or as
previously qualified
X
6.5
Performance demonstration, when required
X
3.3
o
o
o
o
3.2 Minimum and Maximum Time Limits for Steps in Penetrant Examination Procedures shall be
as follows:
ppppppreper previously qualified
Procedure Step
Minimum
Maximum
Drying after preparation (Para 8.1.4)
X
…
Penetrant Dwell time ( Para 8.2.2 & Table 1)
X
X
Drying after Penetrant Removal (Para 8.3.3)
…
X
Developer Application (Para 8.3.3 & 8.4.1)
…
X
Developing and Interpretation time (Para 9.1)
X
X
3.3 Demonstration: The procedure shall be certified by the manufacturer in accordance with T-150
of Article-1 of ASME Sec. V and Demonstrated to the satisfaction of the Inspector. Change in
essential variables and range qualified shall be re-qualified by the demonstration,when
qualification of procedure is required by the referencing construction Code Sections.
4.0 QUALIFICATION OF PERSONNEL
4.1 Personnel performing liquid penetrant examinations shall be qualified and certified in
accordance with Petrochem Procedure, PETROCHEM/WP/01- Procedure for Qualification and
Certification of NDT Personnel which is prepared in accordance with ASNT-CP-189.
4.2 The compliance of Certification of competency of Nondestructive Examination Personnwel is
as per 8-2 of Appendix 8. ASME Sec. VIII Div.1 shall be verified by the vessel manufacturer
and shall be certified by the responsible personnel.
4.3 Vision test of NDT personnel shall be carried out and certified on yearly basis.
SPECIFIED DUTIES OF PERSONNEL
Personnel performing liquid penetrant examination and recording the results shall have, as a
minimum, a Level II certification. Level I individuals shall perform the examination under the direct
supervision of a Level II or Level III individual.
5.0 EXTENT OF EXAMINATION
5.1 The extent of liquid penetrant examination shall be as specified in the applicable code and
contract documents.
5.2 Liquid penetrant examination shall cover the cap weld, HAZ, 25mm of base metal on each sides
of the weld.
5.3 All areas having discontinuities revealed by liquid penetrant examination that require repair
shall be re-examined by liquid penetrant examination after the repair has been made.
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6.0 SURFACE PREPARATION
6.1 The surfaces to be examined and all adjacent areas within at least 1 in. (25 mm) shall be dry and
free of all dirt, grease, lint, scale, welding flux and spatter, oil or other extraneous matter that
could obscure surface openings and interfere with the examination.
6.2 Surfaces may be in the as-welded or as rolled, as cast, or as forged condition..
6.3 Excessive weld ripples, unevenness, etc., which may interfere the evaluation of discontinuities
shall be ground smooth. Rust, scale, slag, etc., shall be removed by using a wire brush (handheld).
6.4 Surface preparation by grinding may be necessary where surface irregularities could mask
indication of unacceptable discontinuities.
6.5 The temperature of the test surface shall be in range of 50oF and 125o F (10oC and 52oC)
throughout the examination period. For temperatures from 40°F (5°C) up to 50°F (10°C),
minimum penetrant dwell time shall be 2 times the value listed in Table 1
7.0 EQUIPMENT AND MATERIALS
7.1 The test consumables shall be in accordance with the applicable client’s specification. This test
procedure calls for use of color contrast type solvent-removable dye in combination with a wet
solvent-suspended developer. Consumable control of contaminants shall be in accordance with
T-641, Artcle 6, ASME Sec. V (2021)
7.2 The total sulphur, chlorine and fluorine contents of the test consumables shall be controlled to the
requirements specified in ASME Section V. Batch Test certificates of conformity shall be kept
on file as part of the quality records in the company.
When examining nickel base alloyes, all penetrant materials shall be analysed individually for
sulphur content in accordance with SE-165, Annex 4. Alternatively, the material may be
decomposed in accordance with SD-129 and analysed in accordance with SD-516. The sulphur
content shall nto exceed 0.1% by weight.
When examining austenitic or duplux stainless steel and titanium, all penetrant materials shall be
analysed individually for chlorine and fluorine content in accordance with SE-165, Annex-4.
Alternatively, the material may be decomposed and analysed in accordance with SD-808 or SE165, Annex-2 for chlorine and SE-165, Annex-3 for fluorine. The total chlorine and fluorine
content shall not exceed 0.1% by weight.
7.3 Consumables shall be used in sets purchased from the same manufacturer. Brands of Dye,
Cleaner/Remover and Developer shall not be mixed.
The classification of chemicals shall be as follows:
Brand
Penetrant
Cleaner/Remover
Developer
Magnaflux
SKL-SP2
SKC-S
SKD-S2
Ardrox
996PB
9PR5
9D1B
ZCheck
ZCheck PT
ZCheck CR
ZCheck DL
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7.4 White Light Intensity: When performing penetrant examinations using visible dye, a minimum
light intensity of 100 fc (1076 Lux) is required to ensure adequate sensitivity during examination
and evaluation of indications. The light intensity, natural or supplemental white light source,
shall be measured with a white light meter prior to the evaluation of indications or a verified light
source shall be used. Verification of light sources is required to be demonstrated only one time,
documented, and maintained on file.
7.5 Calibration: Visible 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.
8.0 EXAMINATION
8.1 Pre-cleaning
8.1.1 Prior to liquid penetrant examination the surface to be examined and all adjacent areas
within at least one inch shall be dry and free of any dirt, grease, lint, scale, welding flux,
spatter, oil or other extraneous matter that would interfere with the examination
8.1.2 Cleaning may be accomplished by solvents.
8.1.3 Drying, after cleaning of the surfaces to be examined shall be accomplished by normal
evaporation or with circulating cold or hot air. The temperature of the test surface shall be
in range of 50oF (10oC) and 125o F (52oC) throughout the examination period.
8.1.4 After cleaning, drying of the surfaces to be examined shall be accomplished by normal
evaporations. Adequate time shall be provided for the solvent cleaner to evaporate
completely from the test surface. Minimum Peroid of time allowed for this shall be the
greater of 1 minute and shall ensure that the cleaning solution has evaporated prior to the
application of the penetrant. The maximum time between completion of pre-cleaning and
application of the penetrant shall not exceed 20 minutes
8.2 Penetrant Application
8.2.1 Care shall be exercised to ensure that the test surface is free of cleaner after completion of
the pre-cleaning operation before applying the penetrant dye. Application shall be done by
means of spraying-on or by brushing of the dye on the test surface and area of interest.
8.2.2 The dye penetrant shall be applied to the test surface to provide a thin uniform coating over
the entire area of interest. Penetration (dwell) time is critical. The minimum penetration
time shall be as required in Table-1 or as qualified by demonstration for specific
applications. The Minimum Dwell time shall not be less than 10 minutes and maximum
dwell time shall not exceed 30 min. Regardless of the length of the dwell time, the
penetrant shall not be allowed to dry. If for any reason the penetrant does dry, the
examination procedure shall be repeated, beginning with a cleaning of the examination
surface.
8.3 Excess Penetrant Removal:
8.3.1 Excess penetrant shall be removed by wiping with a lint-free cloth or absorbent paper,
repeating the operation until most traces of penetrant have been removed. The remaining
traces shall be removed by wiping the surface lightly with cloth or absorbent paper
moistened with solvent.
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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 penetrant
and prior to developing is prohibited.
8.3.2 After excess penetrant removal, the surfaces shall be dried by normal evaporation,
blotting, wiping or forced air.
8.3.3 When drying the surface after excess penetrant removal, ensure that the shortest amount of
time possible occurs between the penetration removal and developer application steps, but
not to exceed 30 minutes. The developer application time shall be of maximum 30 sec.
8.4 Developer Application
8.4.1 Application shall aim towards imparting a thin uniform film of developer on the area of
interest.Spraying of Developer shall be carried out at 25 cm to 30 cm (10” to 12”) from
the surface. Blotches and drips shall be avoided. Heavy coating of the developer shall be
avoided. The developer application time shall be of maximum 30 sec.
8.4.2 The developer shall be applied by means of spraying on after removal of excess dye and
the test surface is completely dry.
8.4.3 Drying of developer shall be by normal evaporation. Flooding of the surface being
examined with non-aqueous developers is prohibited as it can flush the penetrat form with
the discontinuities.
8.4.4 Developing Time: The length of developer is to remain on the part prior to examination
shall be more than 10 minutes. Developing time begins immediately after developer
coating is dry.
9.0 INTERPRETATION
9.1 Development of indications shall be actively observed from the time of complete drying of the
developer for a period of at least up to 10 minutes. Final interpretation and evaluation shall be
made within 10 to 30 minutes of complete drying of the developer. If bleed-out does not alter
the examination results, longer periods are permitted. If the surface to be examined is large
enough to preclude complete examination within the prescribed or established time, the
examination shall be performed in increments.
9.2 Discontinuities at 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.
9.3 Any Indication believed to be non-relevant shall be regarded as a defect unless it is shown by reexamination by the same method or by use of other nondestructive methods and/or surface reconditioning that no unacceptable discontinuity is present.
10.0
EVALUATION OF INDICATIONS AND ACCEPTANCE STANDARDS
The evaluation of indications and acceptance criteria shall be as per the relevant codes and
standards and is listed in Appendix A.
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POST CLEANING
Upon completion of the penetrant examination, the surface shall be thoroughly cleaned by
wiping with a clean cloth moistened with an approved acetone solvent or cleaner as required to
remove all traces of the examination materials.
13.0
REPAIRS
13.1
The examiner shall report all unsatisfactory discontinuities on a Liquid
Penetrant Examination Report (Exhibit-1).
13.2
14.0
15.0
When surface defects are identified, they may be removed by grinding or
machining and not repaired by welding, provided the following
requirements are met:
•
The remaining thickness is not below the minimum acceptable wall thickness.
•
The area, after defect removal, is blended uniformly into the surrounding surface.
•
The area is examined after blending by the Liquid Penetrant method to ensure that
the defect has been removed or reduced to an acceptable limit.
SAFETY PRECAUTIONS
14.1
Penetrant materials are highly volatile, relatively toxic and the liquid may
cause skin irritation. Use adequate ventilation at all times and avoid
prolonged skin contact.
14.2
Penetrant materials shall not be exposed above 122oF (50oC) or exposed to open flames
and it shall be followed manufacturer recommendations.
14.3
The liquid penetrant examiner shall be responsible for compliance with
applicable safety rules in the use of liquid penetrant materials.
14.4
Keep aerosol cans containing penetrant materials out of direct sunlight as excessive
heat may cause aerosol cans to explode. And storage areas not in excess of 122oF
(50oC) or as recommended by manufacturer.
DOCUMENTATION
15.1
15.2
The results of liquid penetrant examination shall be recorded on Liquid Penetrant
Examination Report (Appendix-B).
penetrant material manufacturer’s name, product designation, and batch number of each
penetrant, penetrant remover, and developer used shall also be included in the report.
The original reports shall be submitted to the client and copy shall be stored in a file.
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8.6
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Penetrant
(Note 1)
Developer
10
10
10
10
10
10
TABLE 1
Minimum Dwell Time (Minutes)
Material
Form
Type of Discontinuity
Aluminum, magnesium,
steel, brass and
bronze, titanium and hightemperature
alloys
Welds, heat-affected
zones, and castings
Porosity, lack of fusion,
cracks (all
forms), cold shuts
Laps, cracks
Carbide-tipped tools
Wrought materials extrusions, forgings,
plate
Brazed or welded
Lack of fusion, porosity,
cracks
Notes
1. Select dwell time carefully. Although Table 1 lists various recommended dwell times, some
circumstances may exist where the required. Where dwell times exceeds 20 min., additional penetrant
must be applied at least 20 minutes or as needed to keep the surface wet. If the penetrant is allowed to
dry during the examination the part must be re-cleaned and the entire examination repeated.
2. For temperature range from 50oF to 125oF (10oC to 52oC). For temperatures from 40°F (5°C) up to
50°F (10°C), minimum penetrant dwell time shall be 2 times the value listed in Table 1
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APPENDIX- A – Acceptance Criteria
1. ASME B31.1 -Power Piping
1.1. Evaluation of Indications
a) Mechanical discontinuities at the surface will be indicated by bleeding out of the penetrant;
however, localized surface imperfections, such as may occur from machining marks or surface
conditions, may produce similar indications that are nonrelevant to the detection of unacceptable
discontinuities.
b) Any indication that is believed to be nonrelevant shall be regarded as a defect and shall be
reexamined to verify whether or not actual defects are present.
Surface conditioning may precede the reexamination.
Nonrelevant indications and broad areas of pigmentation that would mask indications of defects
are unacceptable.
c)
Relevant indications are those that result from mechanical discontinuities. Linear indications are
those indications in which the length is more than three times the width. Rounded indications are
indications that are circular or elliptical with the length less than three times the width.
d)
An indication of a discontinuity may be larger than the discontinuity that causes it; however, the
size of the indication and not the size of the discontinuity is the basis of acceptance or rejection.
1.2.
Acceptance Standards.
a) Indications whose major dimensions are greater than 1⁄16 in. (2.0 mm) shall be considered
relevant. The following relevant indications are unacceptable:
b) any cracks or linear indications
2. ASME B31.3– Process Piping
Acceptance Criteria. Liquid penetrant indications are caused by the bleed-out of dye from a surface
discontinuity in the area under test. However, all such indications are not necessarily imperfections,
since excessive roughness, poor surface preparation, etc., may produce nonrelevant indications.
Inadvertent evidence of penetrant not related to actual bleed-out is classified as a false indication.
Indications shall be verified as being relevant, nonrelevant, or false. Additional surface preparation
and/or other test methods may be used as needed to verify the relevance of an indication.
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.
Only indications that have any dimension greater than 1.5 mm (1⁄16in.) shall be considered relevant.
(a) Indications
(1) A linear indication is one having a length greater than three times its width.
(2) A rounded indication is one of circular or elliptical shape with a length equal to or less than
three times its width.
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(b) Examination. All surfaces to be examined shall be free of
(1) relevant linear indications
(2) relevant rounded indications >5.0 mm (3⁄16 in.)
(3) four or more relevant rounded indications in a line separated by 1.5 mm (1⁄16 in.) or less,
edge to edge
3. ASME Section I
3.1. Evaluation of Indications.
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.
Only indications that have any dimension greater than 1/16 in. (1.5 mm) shall be considered
relevant.
(a) A linear indication is one having a length greater than three times the width.
(b) A rounded indication is one of circular or elliptical shape with a length equal to or less
than three times its width.
(c) Any questionable or doubtful indications shall be reexamined to determine whether or
not they are relevant.
3.2 Acceptance Standards.
All surfaces to be examined shall be free of
(a) relevant linear indications
(b) relevant rounded indications greater than 3/16 in.(5 mm)
(c) four or more relevant rounded indications in a line separated by 1/16 in. (1.5 mm) or less, edge to
edge
4. ASME Section VIII, Division 1
4.1. Evaluation of Indications
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. Only indications with major
dimensions greater than 1/16 in (1.5 mm) shall be considered relevant.
(a) A linear indication is one having a length greater than three times the width.
(b) A rounded indication is one of circular or elliptical shape with the length equal to or less than
three times the width.
(c) Any questionable or doubtful indications shall be reexamined to determine whether or not
they are relevant.
4.2. Acceptance Standard
All surfaces to be examined shall be free of:
(a) relevant linear indications;
(b) relevant rounded indications greater than 3/16 in.(5 mm);
(c) four or more relevant rounded indications in a line separated by 1/16 in. (1.5 mm) or less
(edge to edge).
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5. ASME Section VIII, Division 2
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. Only indications with major dimensions
greater than 1.5 mm (1/16 in.) shall be considered relevant.
(1) A linear indication is one having a length greater than three times the width.
(2) A rounded indication is one of circular or elliptical shape with a length equal to or less than three
times its width.
(3) Any questionable or doubtful indications shall be reexamined to determine whether or not they
are relevant.
Acceptance Criteria.
(a) All surfaces to be examined shall be free of:
(1) Relevant linear indications
(2) Relevant rounded indications greater than 5 mm (3/16 in.)
(3) Four or more relevant rounded indications in a line separated by 1.5 mm (1/16 in.) or less,
edge-to-edge
(b) Crack like indications detected, irrespective of surface conditions, are unacceptable
6. ASME Section IX (2019)
a) relevant indications: indications with major dimensions greater than 1/16 in. (1.5 mm)
b) linear indications: an indication having a length greater than three times the width.
c) rounded indications: an indication of circular or elliptical shape with the length equal to or less
than three times the width.
Acceptance Standards.
Procedure and performance tests examined by liquid penetrant techniques shall be judged
unacceptable when the examination exhibits any indication in excess of the limits specified in the
following:
(a) relevant linear indications
(b) relevant rounded indications greater than 3/16 in.(5 mm)
(c) four or more relevant rounded indications in a line separated by 1/16 in. (1.5 mm) or less
edge‐to‐edge)
7. API 1104 – Welding of Pipelines and Related Facilities
Any indication with a dimension greater than 1/16” (1.6 mm) shall be considered relevant.
Relevant indications shall be unacceptable when any of the following conditions exist:
7.1 Linear indications evaluated as crater cracks or star cracks which exceed 5/32” (3.96
mm) in length.
7.2 Linear indications evaluated as cracks other than crater cracks or star cracks.
7.3 Linear indications evaluated as incomplete fusion (IF) and exceed 1 inch (25 mm)
in total length in a continuous 12 inch (300 mm) length of weld or 8% of the weld
length.
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LIQUID PENETRANT TEST PROCEDURE
Color contrast, visible (solvent removable)
7.4
Individual or scattered porosity (P) shall be unacceptable when any of the following
conditions exists:
a)
The size of an individual pore exceeds 1/8 inch. (3.0 mm) or 25% of the
specified wall thickness,which ever is less.
b)
The size of an individual pore exceeds 25% of the thinner of the nominal
wall thicknesses joined, but no more than 1/8 inch (3.0mm) in diameter.
c)
The distribution of scattered porosity exceeds the concentration permitted
by Figure 19 or 20 of API 1104.
7.5 Cluster Porosity (CP) that occurs on any pass except the finish pass shall comply with the
criteria of 7.4 above. CP that occurs in the finish pass shall be unacceptable when any
of the following conditions exists:
a)
The diameter of the cluster exceeds ½ inch (12.7 mm)
b)
The aggregate length of CP in any continues 12 inch (300 mm) length of
weld exceeds ½ inch (12.7 mm).
c)
Any individual pore within a cluster exceeds 1/6 inch (1.6 mm) in size.
8. API Specification -6A (PSL 3)
a. No relevant linear indications allowed.
b. No more than ten relevant rounded indications in any continuous 40 cm2 (6 inch2) area.
c. No rounded indications greater than 3mm (1/8 inch) for welds whose depth is 16mm (5/8 inch).
Or less, or 5mm (3/16 inch.) for welds whose depth is greater than 16mm (5/8inch).
d. No Four (or more) relevant rounded indications in a line separated by less than 1.6 mm (1/16
inch) edge to edge.
e. No Relevant indications in pressure contact sealing surface
9. API 16 A - Specification for Drill Through Equipment,
a. No relevant Indication with a Major dimension equal to or greater than 0.2 inch(5mm)
b. No more than ten relevant indications in any continuous 2.5 inch square (10cm square) area.
c. Four or more relevant rounded indications in a line separated by less than 0.06inch (1.5mm) edge
to edge are unacceptable.
d. No relevant indications in pressure contact sealing surfaces.
The following acceptance criteria in addition to the criteria defined by Appendix-A, 9.0 of this procedure
apply to the acceptance of examinations on welds;
a. No relevant linear indication
b. No rounded indication greater than 3mm (0.125 in) for welds whose depth is 16mm(0.63 in) or
less; or 5mm (0.2 in) for welds whose depth is greater than 16mm (0.63 in)
Page 13 of 16
PETROL AND PETROCHEMICAL COMPANY FOR
INDUSTRIAL SUPPORT SERVICES
DOC. NO.
PETROCHEM/PT/01
REV.
8.6
DATE
15-Jan-2024
LIQUID PENETRANT TEST PROCEDURE
Color contrast, visible (solvent removable)
10. AWS D1.1 Structural Welding Code – Steel
Welds subject to magnetic particle testing, in addition to visual inspection, shall be evaluated on the
basis of the requirements for visual inspection. Refer to Visual Inspection Acceptance Criteria, Table
6.1of AWS D1.1
Visual Inspection Acceptance Criteria (AWS D1.1)
Discontinuity Category and Inspection Criteria
(1) Crack Prohibition
Any crack shall be unacceptable, regardless of size or
location
(2) Weld/Base-Metal Fusion
Thorough fusion shall exist between adjacent layers of
weld metal and between weld metal and base metal.
(3) Crater Cross Section
All craters shall be filled to provide the specified weld
size, except for the ends of intermittent fillet welds
outside of their effective length.
(4) Weld Profiles
Weld profiles shall be in conformance with 5.24.
(5) Time of Inspection
Visual Inspection of welds in all steels may begin
immediately after the completed welds have cooled to
ambient temperature. Acceptance criteria for ASTM
A514, A517 and A709 Grade 100 and 100W steels shall
be based on visual inspection performed not less than 48
hours after completion of weld.
(6) Undersized Welds
The size of a fillet weld in any continuous weld may be
less than the specified nominal size (L) without
correction by the following amounts (U):
L
U
Specified
Nominal Allowable Decrease from L, in.
Weld Size, in. (mm)
(mm)
≤ 3.6 (5)
≤ 1/16 (2)
¼ (6)
≤ 3/32 (2.5)
≤ 5/16 (8)
≤ 1/8 (3)
In all cases, the undersize portion of the weld shall not
exceed 10% of the weld length. On web-to-flange welds
on girders, under-run shall be prohibited at the ends for a
length equal to twice the width of the flange.
(7) Undercut
(a) For material less than 1 in. (25 mm) thick, undercut
shall not exceed 1/32 in. (1 mm), with the following
exception: undercut shall not exceed 1/16 in. (2 mm) for
any accumulated length up to 2 in. (50 mm) in any 12 in.
(300 mm). For material equal to or greater than 1 in.
thick, undercut shall not exceed 1/16 in. (2 mm) for any
length of weld.
Statically
Located Non
tubular
Connections
X
Cyclically
Loaded Non
tubular
Connections
X
Tubular
Connections
(All Loads)
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Page 14 of 16
PETROL AND PETROCHEMICAL COMPANY FOR
INDUSTRIAL SUPPORT SERVICES
LIQUID PENETRANT TEST PROCEDURE
Color contrast, visible (solvent removable)
DOC. NO.
PETROCHEM/PT/01
REV.
8.6
DATE
15-Jan-2024
Cyclically
Loaded
Nontubular
Connections
Tubular
Connections
(All Loads)
X
X
X
X
(b) In primary members, undercut shall be no more than
0.01 in. (0.25 mm) deep when the weld is transverse to
tensile stress under any design loading condition.
Undercut shall be no more than 1/32 in. (1 mm) deep for
all other cases.
Discontinuity Category and Inspection Criteria
Statically
Located
Nontubular
Connections
(8) Porosity
(a) CJP 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 in.
(1 mm) or greater in diameter shall not exceed 3/8 in.
(10 mm) in any linear inch of weld and shall not exceed
¾ in. (20 mm) in any 12 in. (300 mm) length of weld.
(b) The frequency of piping porosity in fillet welds shall
not exceed one in each 4 in. (100 mm) of weld length
and the maximum diameter shall not exceed 3/32 in. (2.5
mm). Exception: for fillet welds connecting stiffeners to
web, the sum of the diameters of piping porosity shall
not exceed 3/8 in. (10 mm) in any linear inch of weld
and shall not exceed ¾ in. (20 mm) in any 12 in. (300
mm) length of weld.
(c) CJP 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 in. (100 mm)
of length and the maximum diameter shall not exceed
3/32 in. (2.5 mm).
X
APPENDIX B
LIQUID PENETRANT EXAMINATION REPORT
Page 15 of 16
PETROL AND PETROCHEMICAL COMPANY FOR
INDUSTRIAL SUPPORT SERVICES
LIQUID PENETRANT TEST PROCEDURE
Color contrast, visible (solvent removable)
Customer:
Date:
Report No.:
Project;
Procedure Ref. No.:
PT Chemicals(Brand):
Penetrant:
Cleaner/Remover:
Developer:
DOC. NO.
PETROCHEM/PT/01
REV.
8.6
DATE
15-Jan-2024
Page No.
of
Date of Test:
Location:
Project Ref.
Procedure Rev. No.:
Batch No.:
Batch No.:
Batch No.:
Penetrant Test Technique: Visible - Colour Contrast
Code/Standard Ref:
Acceptance Criteria:
Time between pre cleaning and application of Penetrant:
Penetrant Application by:
Penetrant Dwell Time :
Time between excess penetrant removal & application of developer:
Developer Application by: Spraying
Development Time:
Lighting equipment :
Light Intensity:
Surface Temperature :
Surface Condition:
Component Description:
Sl #
Component
Material
Weld#
Thickness
Ref.
No.
Result
Location
Type
Size
Remarks
Sketch of the component
Examined by:
Approved by:
NDT Level :
Signature:
Designation:
Signature:
Page 16 of 16