PT Caterpillar Indonesia Batam: Liquid Penetrant Testing Procedure

PT Caterpillar Indonesia Batam
LIQUID PENETRANT TESTING PROCEDURE

Description : NDT PROCEDURE Document No : SOP-QCA-002-00
Refference : - Revision No. : 00
Issue by : Abdul Tri Hamdani Issued Date : 18/10/2014
Approved by : Anang Kuswanto 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 REVISION DATE DOCUMENT No.
LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

PROCESS OWNER / APPROVER NEXT REVIEWED DATE
VERSION
Anang Kuswanto 12-Oct-2015 00

Page 1 of 12
Caterpillar: Confidential Green - Reproduction Constitutes an Uncontrolled Document -
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


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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 571-
2).
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

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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.

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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

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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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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.

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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


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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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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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Table 1-Acceptance Level for Indication

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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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LIQUID PENETRANT TESTING PROCEDURE

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

5. PERSONNEL QUALIFICATION AND RESPONSIBILITY

6. EQUIPMENT AND CONSUMABLE

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

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

 Solvent Cleaner ; Method C – Solvent (Liquid)

 Lint free cloth

 UV- meter (if use fluorescent technique)

 UV- lamp (if use fluorescent technique)

7. EQUIPMENT AND CONSUMABLE CONTROL

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

8.1 Lightning Condition For Color Contrast Penetrant

8.2 lightning condition for fluorescent penetrant

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

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

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

10. SEQUENCE OF OPERATIONS

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

10.3 APPLY SOLVENT REMOVABLE PENETRANT

10.4 PENETRATION TIME

10.5 EXCESS PENETRANT REMOVAL

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

10.6 EXCESS PENETRANT REMOVAL CHECK

10.8 APPLYING DEVELOPER

10.9 DEVELOPING TIME

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

10.10 RECORDING INDICATION

10.11 POST CLEANING AND PROTECTION

11. EVALUATION OF INDICATIONS

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

11.3 Relevant and Non-relevant indication

12. ACCEPTANCE CRITERIA

12.1 Grouped Indication

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

12.1 False Indication

13.3. Any datum’s used shall be unambiguous.

13.4. A statement of acceptability against the acceptance standard should be made.

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

Table 1-Acceptance Level for Indication

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

14. NDT LEVEL III APPROVAL

NAME : RONNY ANDALAS

LIQUID PENETRANT PROCEDURE 18-Oct-2014 SOP-QCA-002-00

Anang Kuswanto 12-Oct-2015 00

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