Penetrant procedure

PT Caterpillar Indonesia Batam LIQUID PENETRANT TESTING PROCEDURE Description

: NDT PROCEDURE

Document No

: SOP-QCA-002-00

Refference Issue by Approved by

: : Abdul Tri Hamdani : Anang Kuswanto

Revision No.

: 00

Issued Date

: 18/10/2014

Page

: 1 of 12

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 C). This procedure described non-destructive testing methods for detecting discontinuities that are open to the surface such as cracks, porosity and lack of fusion by liquid penetrant testing conducted in accordance with the requirements of ISO 3452-1 (EN 571-1) and acceptance criteria EN ISO 23277 (EN 1289). 2. PURPOSE The purpose of this procedure is to implement the liquid penetrant testing method in PT CATERPILLAR INDONESIA BATAM. 3. REFERENCES 3.1 ISO 3452-1 (EN 571-1) Non-destructive testing-Penetrant testing-General principles 3.2 BS EN ISO 3452-2 (EN 571-2 ) Non – Destructive Testing-Penetrant Testing - Part 2: Testing of penetrant materials 3.3 EN ISO 3452-3 ( EN 571-3) Non-destructive testing - Penetrant testing - Part 3: Reference test blocks 3.4 EN ISO 23277 (EN 1289) Non-destructive testing of welds - Penetrant testing of welds Acceptance levels 3.5 EN ISO 9712, Non-destructive testing — Qualification and certification of personnel 3.6 ISO 3059 Non-destructive testing — Penetrant testing and magnetic particle testing Viewing conditions 3.7 ISO 5817:2014 Welding -- Fusion-welded joints in steel, nickel, titanium and their alloys (beam welding excluded) -- Quality levels for imperfections 3.8 ASNT SNT-TC-1A Recommended Practice - Personnel Qualification and Certification in Nondestructive Testing 3.9 CATERPILLAR INDONESIA BATAM Written Practice, DOCUMENT No. SOP-QCA-004-00

THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED. PROCESS / DOCUMENT TITLE

LIQUID PENETRANT PROCEDURE PROCESS OWNER / APPROVER

Anang Kuswanto

REVISION DATE

18-Oct-2014 NEXT REVIEWED DATE

12-Oct-2015

DOCUMENT No.

SOP-QCA-002-00 VERSION

00 Page 1 of 12

Caterpillar: Confidential Green

- Reproduction Constitutes an Uncontrolled Document -


: NDT PROCEDURE

Document No

: SOP-QCA-002-00



Revision No.

: 00

Issued Date

: 18/10/2014

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4. ABBREVIATION PT : Penetrant Testing HAZ : Heat Affected Zone NDT : Non Destructive Testing 5. PERSONNEL QUALIFICATION AND RESPONSIBILITY The NDT Inspector shall be responsible for conducting and reporting the results of inspection. 5.1 Personnel performing examinations to this procedure shall be qualified and certified in accordance with the requirements of ISO 9712 and/or ASNT SNT-TC-1A certified in accordance with CATERPILLAR INDONESIA BATAM written practice.

5.2 Only individuals qualified to NDT Level II shall be perform the examinations in accordance with this procedure.

5.3 Evaluation of test results shall be by NDT Level II or level III only 5.4 When the written practice is revised, the certification of NDT personnel remains valid to the requirements of the previous revision until the expiry date of the personnel qualification certificate; then, recertification to the requirements of the new revision is required. 5.5 The certification of personnel shall be checked by the QA/QC Manager prior to work commencement. .

6. EQUIPMENT AND CONSUMABLE THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED. PROCESS / DOCUMENT TITLE


Anang Kuswanto

REVISION DATE


12-Oct-2015

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: NDT PROCEDURE

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: SOP-QCA-002-00



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6.1 This procedure is intended for use with the following equipment and consumables or their equivalent. 

Liquid penetrant ; Type II- Color Contrast or Type I- Fluorescent Penetrant



Developer ; Form d- Solvent –based ( Non –Aqueous Wet for type I) or Form e solvent based (non-aqueous for type II or III)



Solvent Cleaner ; Method C – Solvent (Liquid)



Lint free cloth



Lux meter



UV- meter (if use fluorescent technique)



UV- lamp (if use fluorescent technique)

6.2 Penetrant families Liquid penetrant, solvent cleaner, and developer from one manufacturer shall be used and intermixing between family or manufacturer groups is prohibited based on EN 3452-2 (EN 5712). 7. EQUIPMENT AND CONSUMABLE CONTROL

Verification of equipment and chemicals components shall be carried out every day prior carried examination and recorded on examination report DOCUMENT No. CIB-QCA-004-00 to conform continuing satisfactory performance.

8. VIEWING CONDITIONS THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED. PROCESS / DOCUMENT TITLE


Anang Kuswanto

REVISION DATE


12-Oct-2015

DOCUMENT No.


00 Page 3 of 12




: NDT PROCEDURE

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: SOP-QCA-002-00



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8.1 Lightning Condition For Color Contrast Penetrant

a. The working range of irradiation and illuminance meters shall be calibrated at the frequency recommended by the manufacturer using equipment and a system which is traceable to a national, European or International Standard. This period shall not exceed 12 months. The calibration of the UV-A irradiation meter shall be carried out with narrow band radiation at a wavelength of 365 nm. Maintenance of or damage to the meter shall necessitate calibration. When detachable sensors and readout units are used, calibration shall be carried out on the entire system (readout unit and sensors).

b. The test surface shall be inspected under daylight or under artificial white light with an illuminance not less than 500 lux on the surface of the tested part. The viewing condition shall be such that glare and reflections are avoided. The level of illuminance for removal of excess penetrant shall be at least 500 lx.

8.2 lightning condition for fluorescent penetrant

a.

The test surface shall be viewed under UV-A radiation source. The UV-A irradiance at the surface to be inspected shall not less than 1000 µW/cm2 and the visible light should not more than 20 Lux at 16 inch (400 mm) minimum distance between surface and end of light source.

b.

For the removal of excess penetrantcarried out under lighting condition as specified in section 8.2.sa above.



Anang Kuswanto

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c.

If the examiner wears glasses or lenses, they shall not be photosensitive.

d.

The inspector shall allow at least 5 minutes for dark adaptation before beginning the inspection.

e.

UV radiation shall not be directed in the operator`s eyes

f.

No paper or cloth which fluoresces under UV light shall be in sight of the operator

g.

A UV background lighting may be provided, if necessary, to allow the operator to move freely inside the booth

h.

The combination of high level and long duration of UV-A irradiance should be avoided, generally not more than 50 W/m2 (5000 μW/cm2).

9. TEMPERATURE

In order to minimize moisture entering discontinuities, the temperature of the test surface shall generally be within the range from 10o C to 50o C.

10. SEQUENCE OF OPERATIONS 10.1 PRE-CLEANING THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED. PROCESS / DOCUMENT TITLE


Anang Kuswanto

REVISION DATE


12-Oct-2015

DOCUMENT No.


00 Page 5 of 12




: NDT PROCEDURE

Document No

: SOP-QCA-002-00



Revision No.

: 00

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The surface of the test part shall be free form contaminant, e. g. scale, rust oil, grease or paint. If necessary using mechanical or chemical methods or combination of these methods. Pre cleaning shall ensure that test surface is free from residues and that it allows the penetrant to enter the discontinuity. The cleaned area shall be large enough to prevent interference from areas adjacent to the actual test surface. For welding shall be include the material minimum 25 mm (1 inch) each side of weld. 10.2 DRYING As the final stage of pre-cleaning the parts to be tested shall be thoroughly dried, so that neither water nor solvent remains in the discontinuities and drying method used is normal evaporation for minimum 5 minutes. 10.3 APPLY SOLVENT REMOVABLE PENETRANT The penetrant can be applied by spraying, brushing, flooding, dipping or immersion. Care should be taken to ensure that test surface remains completely wetted throughtout the entire penetration time. 10.4 PENETRATION TIME The appropriate penetration time depends on the properties of the penetrant, the application temperature, the material being inspected and the type of discontinuities to be detected. The penetration time can vary from 10 minutes to 30 minutes.

10.5 EXCESS PENETRANT REMOVAL



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: NDT PROCEDURE

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: SOP-QCA-002-00



Revision No.

: 00

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Generally, the excess penetrant shall be removed first using a clean lint free cloth. Subsequent cleaning with a clean lint free cloth moistened with solvent shall then be carried out. Applying solvent directly to the test surface is prohibited. 10.6 EXCESS PENETRANT REMOVAL CHECK During excess penetrant removal the test surface shall be visually checked for penetrant residues. For fluorescent penetrants, this shall be carried out under UV-A sources and lighting condition refer to section 8.2.a 10.7

DRYING

In order to facilitate rapid drying of excess water, any droplets and puddles of water shall be removed from the part by evaporation at ambient temperature and surface temperature shall not exceed 50oC during drying. 10.8 APPLYING DEVELOPER The solvent based (non-aqueous) developer shall be applied by spraying uniformly as soon as possible after dying. The spray shall be such that developer arrives slightly wet on the surface, giving a thin, uniform layer.

10.9 DEVELOPING TIME The development time should be between 10 and 30 minutes, longer times may be agreed between the contracting parties. The development time begin Immediately after drying when non-aqueous wet developer is applied.



Anang Kuswanto

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: NDT PROCEDURE

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: SOP-QCA-002-00



Revision No.

: 00

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: 18/10/2014

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10.10 INSPECTION Generally it is advisable to carry out the first examination just after the application of the developer or as soon as the developer dry. This facilitates a better interpretation of indication. The final inspection shall be carried out when the development time has elapsed. 10.10 RECORDING INDICATION Recording may be done by any of the methods below and use LPT report form CIB-QCA-004-00 : a. Written description b. Sketch c. Photography 10.11 POST CLEANING AND PROTECTION After final inspection, post cleaning shall be carried out . If required a suitable corrosion protection shall be applied. 10.12 RETESTING If retesting is necessary, e.g. because no unambiguous evaluation of indications is possible, the entire test procedure, starting with the pre-cleaning. The use of a different type of penetrant or a penetrant of the same type from different manufacturer is not allowed unless a thoroughly cleaning has been carried out to remove penetrant residues remaining in the discontinuities.

11. EVALUATION OF INDICATIONS THE INFORMATION HEREON IS THE PROPERTY OF CATERPILLAR INC. AND/OR ITS SUBSIDIARIES. WITHOUT WRITTEN PERMISSION, ANY COPYING, TRANSMITTAL TO OTHERS, AND ANY USE EXCEPT THAT FOR WHICH IT IS LOANED, IS PROHIBITED. PROCESS / DOCUMENT TITLE


Anang Kuswanto

REVISION DATE


12-Oct-2015

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: NDT PROCEDURE

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: SOP-QCA-002-00



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11.1 Any indication which is believed to be non relevant shall be re-examined again as per section 10.12 to conform relevant or non- relevant indication. 11.2 A liner indication is one having a length greater than three time its width. A non-linear indication having length equal to or less than three times its width. 11.3 Relevant and Non-relevant indication

An Indication shall be consider relevant if the length is more than 1.5 mm and indication with length equal or less than 1.5 mm shall be considered non-relevant indication.

11.4 Unacceptable indications shall be removed or repaired according to qualified repair welding procedure. 11.5 The repaired area has to be re-examined by PT and UT (UT only for “deeper” imperfections). Result to be mentioned in related protocol: Rework successfully done. 12. ACCEPTANCE CRITERIA

The acceptance criteria for discontinuities shall be meet the requirements of EN ISO 23277 (EN 1289) acceptance level 2X accordance to table 1 .The width of the test shall be include in the weld metal and adjacent parent metal up to a distance of 25 mm of each side. Other acceptance criteria such as EN ISO 5817 may applied for quality level B or Table 1 for acceptance Level 1which ever is stringent.

12.1 Grouped Indication



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: NDT PROCEDURE

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Revision No.

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Any adjacent indication separated by less than the major dimension of the smaller shall be assessed as a single, continuous indication. Grouped indication shall be evaluated in accordance with application standards such as EN ISO 5817 may applied for quality Level B or table 1 for acceptance level 1 whichever is stringent.

12.1 False Indication

False indication arise for many reasons, e.g. surface not properly clean, finger mark of technician, and porous material could built an false indication.

13. REPORTING 13.1. A report shall be prepared detailing the results of the examination and recorded on penetrant testing report form DOCUMENT No. CIB-QCA-004-00 13.2. The report shall contain sufficient information to enable a full assessment of quality and to ensure that any non-acceptable areas can be accurately located should repair be necessary. 13.3. Any datum’s used shall be unambiguous. 13.4. A statement of acceptability against the acceptance standard should be made.



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: NDT PROCEDURE

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Table 1-Acceptance Level for Indication



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: NDT PROCEDURE

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13. SAFETY The materials and equipment required by this procedure may be harmful, flammable and/or volatile. All personnel whose doing examination shall be wearing PPE including mask, eyeglass, and other safety equipment that need for protection from incident and shall follow MSDS.

14. NDT LEVEL III APPROVAL NAME

: RONNY ANDALAS

TITLE

: ASNT NDT Level III Certificate No. 168822 (MT, PT, UT, RT) EN 473/ISO 9712 NDT Level 3 Certificate No. 07644-2012-02 (MT, PT, UT)

SIGNATURE :



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Penetrant procedure

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