PENETRANT TESTING
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TABLE OF CONTENTS
Topic Sheet P01
General points Main processes of penetrant testing
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Penetrant Testing
Topic Sheet
The penetrant testing can be perfom on any type of material (non porous) This technique can only allow the detection of through holes defects.
This technique can detect through the surface defects on nonporous materials such as: Cracks. Quenching cracks. Folds. Penetrant testing method requires the use of chemicals at each step of the inspection.
Preliminary cleaning
Developper application
Inspection
Last cleaning
The time required for the realization of a penetrant inspection exceeds one hour.
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Topic Sheet
P01
Penetrants used can be red or fluorescent, pre or post-emulsified Some penetrants can be removed with solventsoaked rags
Chemical reaction between the penetrant and the emulsifier during a controlled time
The emulgation operation remains a delicate step of the implementation which may desorb the penetrant out of defects
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Penetrant Testing
Topic Factsheet Sheet
P02 02
Developpers : Developpers allow to view defects by capillary action. Developpers used: dry, wet organic or aqueous-based, peelable. Detection time: 10 to 30 minutes.
Product packaging:
Aerosol cans. Bulk.
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Accessories and devices for quality control for manual inspection of penetrant testing
Accessories :
Penetrant excess removal: Solutions to remove penetrant excess: air-water gun, water spray, paper towels, rags ...
Topic Sheet
P02
Drying before developper application: Drying means used: heat gun, drying oven, compressed air, dried and lint-free rags.
Plate panels for penetrants sensitivity characterization and cracked blocks (allow to check bathing and penetrant quality used over
time).
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Penetrant Testing
Topic Sheet
VOCs are the cause of the ozone layer destruction. The ISO 14001 and the related European Directives, lead each firm to reduce its VOC emissions.
The implementation of penetrant inspection required large quantities of energy particularly for drying parts.
Environmental challenges and objectives of the Green Testing project: Reduce environmental pressures (energy consumption, greenhouse gases and VOCs emission, waste production by 20% to 30%), the potential risks to operators health and the tasks arduousness. Reduce drastically inspection costs (from 20% to 40%). Reduce environmental pollution (by 90%) through the provision of alternative technologies.
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Risks for the operator associated with the Topic Sheet implementation of penetrant inspection
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Indirect risks: Risks associated with handling parts (parts dropping, fingers jamming). Burns risks (drying equipments and hot parts).
Electrical hazards : Electrocution hazards due to the use of both electrical sources (lights for example) and water simultaneously to achieve the penetrant inspection.
Risques of explosion due to spray cans: Care must be taken when using aerosols near direct heat sources (welding, hot parts, for example) because of the flammability of materials used and the risk of explosion of spray cans.
Risks related to vapors exposure of penetrant materials (solvents and organic products): Exposure to solvent and organic product vapors is deemed hazardous to health.
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Ressuage
Topic Factsheet Sheet
P04 04
Generally speaking, companies must invest in a policy of proactive protection, for example by setting up an environmental management system (EMS).
The eco approach within the company has been built according to a structured set of steps and controlled at every level of their implementation.
Making an environment diagnosis : Waste diagnosis: waste management by controlling the processing costs, waste reduction and establishment of a sorting and selective collection at the source ... Energy diagnosis: hunt wasting; energy saving solutions, energy recovery solutions (heat). Gaseous and liquid effluents diagnosis: optimized choice cost / performance of the treatment system ; reducing the amount of effluent at the source ; reusing treated wash water; recovering excess of used materials. Other possible diagnoses: dust and particles; odors; noises.
Monitoring: nuisance registry to record incidents occurred and responses relative to the environment feedback.
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Topic Sheet
P04
In every industrial process, all incoming and outgoing parts have a greater or lesser impact on the environment, that it is necessary to minimize as possible.
The incomings: Cleaning products. Products required for the implementation of the penetrant testing process (penetrant, developer). Electrical energy required mainly for drying operations. Water used for cleaning operations and for penetrant excess removing.
The outgoings: Wastes (cartons, empty spray cans, rags and papers, damaged control equipments : UV or white lightings ,). Sewages and residual cleaning products contaminated by organic or solid debris (penetrating and developer products, residual oil and grease).
Other possible nuisances: Odors caused by chemicals used or from effluents (air extractor) treatment plant. Noise due to control devices (ventilation noise of penetrant testing line and drying ovens or drying guns blowing hot air). Noise due to the handling parts in production control plant (falling of parts in the waste good containers at the end of the testing line of control for example).
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Topic Sheet
P04
Collective protective equipments: Ventilation and purifying atmosphere at the workplace. To delimit / or mark the access to dangerous areas. Protection by recording a dangerous function during interventions. Identification of dangerous products to prevent inadvertent use. Hazard signs To delimit work areas.
Personal protective equipments: Safety shoes and helmets. Goggles. Gloves, protective clothes. Masks and breathing equipments. Hearing protections (falling of parts in the scrap good containers at the
end of the testing line for example).
Give a sens of responsability at the operators : To take into consideration the user sheet of chemical products (by referencing to the company doctor who has at disposal the health and safety). To know the location of the fine extinguishers and their functionary use. Dont leave tools or parts on the ground in the workshop. To keep working equipments and accessories at their place and clean the working place.
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Topic Sheet
P04
Penetrating products:
Purchase products in bulk rather than spray cans: Diminution of the quantities of packaging and aerosol cans. Give priority to water-based products rather than organic-based products: Reduction of VOC emissions. Non-flammable products. Effluent treatment simplified and maintenance costs reduced (low fouling). Eliminating the inherent risk due to the use of organic solvents (harmful vapours, skin irritation, ...). Make easier removal of penetrant excess by water easier. To prefer electrostatic processes: although expensive, they allow the reduction of quantities of products required for the penetrant testing operation.
Spray systems:
Preferred rechargeable spray systems (with an adapted spray nozzle and mechanical pressure by pumping): Waste quantity reduced. Quantity of PT products reduced by 4 compared to the use of an aerosol. Does not require gas propulsive.
Lighting systems:
Preferred LED lamps (white light or UV) to conventional bulbs: Greater light intensity. Energy consumption 50 times smaller than for mercury vapor lamps (2.5 W instead of 100W). Longer life (over 10,000 hours). Less hazardous waste to the environment (especially mercury vapor lamps UV lamps).
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Topic Sheet
P04
Drying systems:
Preferred drying systems which consume less energy: Drying by infrared lamps for example, which can complement the usual drying systems (oven and air oven).
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