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PROVISION OF ENGINEERING, PROCUREMENT, CONSTRUCTION AND COMMISSIONING

(EPCC) FOR OIL TRAIN 3, 4 AND 5 FOR PETRONAS CARIGALI IRAQ HOLDING B.V

CONTRACT NO. PCIHBV/2016/PD&T/1570

Document Title PENETRANT TESTING

Project Document No. GF-GCOT-PE17505404-Q-VD-9752
Location GCOT
Discipline PIPING
Tag Number (if applicable)

CONTRACTOR
CHINA PETROLEUM ENGINEERING CONSTRUCTION CORP. (CPECC)
&
PEG ENGINEERING & CONSTRUCTION DMCC (PEG)

The signing, countersigning or other endorsements of any drawings and documentation by PCIHBV’s Representatives, agents or employees shall neither be
construed as implying the responsibility for the correctness and accuracy of such documents nor relieving the CONTRACTOR of its obligations to review all
information, data, drawings, and specifications provided by PCIHBV.

Class 2
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REVISION HISTORY

Rev. Date Description of Change

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SR. # DESCRIPTION

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCE AND/OR RELEVANT DOCUMENTS

4.0 GENERAL

5.0 RESPONSIBILITIES

6.1 ACTIVITIES

6.2 PERSONAL COMPETENCE

6.3 EQUIPMENT

6.4 Working Method

6.5 Penetrant Removal

6.6 Developer Application

6.7 Examination

6.8 Fluorescent Light Examination

6.9 Visible Light Examination

6.10 Post Cleaning

6.11 Evaluation / Documentation

6.12 Acceptance Criteria

6.13 Test Report

7.1 ANNEXURES
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1. PURPOSE
This procedure defines the criteria and general requirements to carry out Dye Penetrant
examination.
2. SCOPE
2.1 This procedure covers the general requirements to carry-out Visible Liquid Penetrant
Examination using water washable and solvent removable color contrast penetrants.
2.2 This procedure defines the Liquid Penetrant Examination of non-porous, metallic
Materials, ferrous and non-ferrous metals and of non-metallic materials such as glazed or
fully densified ceramics, as well as certain nonporous plastics and glass.
2.3 The surface temperature of the parts being examined remains in the range of 5ºC to 52ºC
during the examination Process.
2.4 For examining Nickel base alloys, all the penetrant materials shall be analyzed for sulfur
content, which will not exceed 0.1% by weight.
2.5 For examining Austenitic or Duplex stainless steel and titanium ,all the penetrant
materials shall be analyzed chlorine and fluorine content, which shall not be exceed
0.1% by weight.
3. REFERENCE AND/OR RELEVANT DOCUMENTS
ASME Section V Article – VI - 2017
ASTM E-165 - 2009
SNT-TC-IA 2014 edition (Personnel Qualification and Certification in Non-Destructive
Testing). ANSI/ASNT Standard CP-189
4. GENERAL
Definitions
The following definitions/abbreviations apply to the application of this procedure
 INDIV - Industrial Services
 NDE Non-Destructive Examination
 SHALL Mandatory
 ASNT: American Society of Non-destructive Testing
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5. RESPONSIBILITIES

PERSONNEL RESPONSIBILITY
Director Operation Approves the Quality Manual

Operation Manager/Quality Manager Issues and review the QMS and General procedures

Issues and review specific procedures and

Operation Manager/Technical Manager
Reporting template working instructions

Draft and/or review general

Designated people
procedures, specific procedures
and working instructions

6. ACTIVITIES
6.1 Personal Competence

6.1.1 Personal performing examination shall be qualified in accordance to ARCO Written

Practice IND- QMS-GP-18 conforming the requirements of SNT-TC-IA 2014 edition.
6.1.2 NDT Personal Should be DPT Level II or Level I Certified working under the
supervision / with instruction of ASNT Level II person conforming to Requirements of
SNT-TC-IA 2014 edition and ARCO Written Practice no IND-QMS-GP-18 or
National & International Third Party Certification scheme e.g. ISO 9712, ANSI/ASNT
Standard CP-189, PCN etc.
6.2 Equipment
 One of the following commercial grade solvent removable or equivalent penetrants
shall be used along with non-aqueous wet developer for the liquid penetrant
examination described by this procedure. Any change in material from the
below list shall require procedure demonstration
6.2.1 Liquid Penetrant Solvent Removable

REMOVER DEVELOPER
SUPPLIER CLEANER PENETRANT

MAGNAFLUX SKC-S SKL-SP1 SKC-S SKD-S2

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6.2.2 Water washable Method

DEVELOPER
SUPPLIER CLEANER PENETRANT REMOVER
(*)
MAGNAFLUX SKC-S SKL-WP H20 SKD-S2

 Lighting Equipment/ Light Meter

 A light meter should be available to measure the light intensity at the inspection area.
6.3 Working Method
6.3.1 Removal of Surface Contaminants:
 Pre-cleaning – The success of any penetrant examination procedure is greatly dependent
upon the surrounding surface and discontinuity being free of any contaminant (solid or
liquid) that might interfere with the penetrant process.
 In general, satisfactory results may be obtained when the surface of the part is in the as-
welded, as-rolled, as-cast, or as-forged condition. Surface preparation by grinding,
machining, or other methods may be necessary where surface irregularities could mask
indications.

 (b) Prior to each liquid penetrant examination, the surface 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, weld spatter, paint, oil, and other extraneous matter that could
obscure surface openings or otherwise interfere with the examination.
 (c) Typical cleaning agents which may be used are detergents, organic solvents, descaling
solutions, and paint removers. Degreasing and ultrasonic cleaning methods may also be used.
 Drying, after cleaning of the surface to be examined, shall be accomplished by normal
evaporation or with forced hot air, as appropriate
 For water used in precleaning or as part of processes that involve water, if potable
water (e.g., drinking, bottled, distilled, or deionized water) is used, it is not required to be
analyzed for chlorine and sulfur.
 Any other type of water used that does not meet the requirements of (a) above shall be
analyzed for chlorine in accordance with ASTM D1253 and for sulphur in accordance
with SD-516. The chlorine content shall not exceed 0.1% by weight and the sulphur
content shall not exceed 0.1% by weight.
Caution — Sand or shot blasting may possibly close discontinuities and extreme care should be used with grinding and
machining operations to avoid masking discontinuities.
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6.3.2 Drying after Cleaning

 It is essential that the surface of parts be thoroughly dry after cleaning, since any liquid
residue will hinder the entrance of the penetrant. Drying may be accomplished by
warming the parts in drying ovens, with infrared lamps, forced hot air, or exposure to
ambient temperature.
6.3.3 Penetrant Application
 After the part has been cleaned, dried, and is within the specified temperature
range, the penetrant is applied to the surface to be examined so that the entire
part or area under examinations completely covered with penetrant.
 The Penetrant may be applied to the part being examined by dipping, brushing,
flooding, or spraying as suitable, small parts are quite often placed in suitable baskets
and dipped into a tank of penetrant. On larger parts, and those with complex
geometries, penetrant can be applied effectively by brushing or spraying.
 Both conventional and electrostatic spray guns are effective means of applying liquid
penetrants to the part surfaces. Electrostatic spray application can eliminate excess
liquid build- up of penetrant on the part, minimize overspray, and minimize the
amount of penetrant entering hollowcored passages which might serve as penetrant
reservoirs, causing severe bleedout problems during examination. Aerosol sprays are
conveniently portable and suitable for local application.

Warning — With spray applications, it is important that there be proper ventilation. This is
generally accomplished through the use of a properly designed spray booth and exhaust
system.

6.3.4 Penetrant Dwell Time

 After application, allow excess penetrant to drain from the part (care should be taken to
prevent pools of penetrant from forming on the part), while allowing for proper
penetrant dwell time is given in table below.
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FIG. 1 FLUORESCENT AND VISIBLE PENETRANT INSPECTION GENERAL PROCESSING

PROCEDURES FLOWSHEET
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6.4 Penetrant Removal

6.4.1 Water Washable:

 Removal of Excess Penetrants — After the required penetration time, the excess
penetrant on the surface being examined must be removed with water, usually a washing
operation. It can be washed off manually, by the use of automatic or semi-automatic
water-spray equipment or by immersion. For immersion rinsing, parts are completely
immersed in the water bath with air or mechanical agitation.
 Accumulation of water in pockets or recesses of the surface must be avoided.
 If the final rinse step is not effective, as evidenced by excessive residual surface
penetrant after rinsing, dry and re-clean the part, then re-apply the penetrant for the
prescribed dwell time.
 The temperature of the water should be relatively constant and should be maintained
within the range of 50 to 100°F (10 to 38°C).
 Spray-rinse water pressure should not be greater than 40 psi (280 kPa).
 Rinse time should not exceed 120 s unless otherwise specified by part of material specification.
 Removal by Wiping — water-washable penetrants may be removed by wiping with a
clean, dry, 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 with a cloth or absorbent paper, lightly moistened with water. To
minimize removal of penetrant from discontinuities, care shall be taken to avoid the
use of excess water
Caution — Avoid over washing. Excessive washing can cause penetrant to be washed out of discontinuities. With fluorescent
penetrant methods perform the rinsing operation under black light so that it can be determined when the surface penetrant has
been adequately removed.

6.4.2 Lipophilic Emulsification:

 Application of Emulsifier — After the required penetration time, the excess penetrant on
the part must be emulsified by immersing or flooding the parts with the required
emulsifier (the emulsifier combines with the excess surface penetrant and makes the
mixture removable with water rinsing). After application of the emulsifier, the parts
are drained in a manner that prevents the emulsifier from pooling on the part(s).
 Emulsification Dwell Time begins as soon as the emulsifier has been applied. The length
of time that the emulsifier is allowed to remain on a part and in contact with the
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penetrant is dependent on the type of emulsifier employed and the surface condition
(smooth or rough).
 Post Rinsing — Effective post rinsing of the emulsified penetrant from the surface
can be accomplished using either manual, semi-automated, or automated water
immersion or spray equipment or combinations thereof.
 Immersion — For immersion post rinsing, parts are completely immersed in the water
bath with air or mechanical agitation. The time and temperature should be kept
constant. The maximum dip-rinse time should not exceed 120 s unless otherwise
specified by part or material specification.

 The temperature of the water should be relatively constant and should be maintained
within the range of 50 to 100°F (10 to 38°C).
Caution: A touch-up rinse may be necessary after immersion.
 Spray Post Rinsing — Effective post rinsing following emulsification can also be
accomplished by either manual or automatic water spray rinsing of the parts as follows:
 Control rinse water temperature within the range of 50 to 100°F (10 to 38°C).
 Spray rinse water pressure should be in accordance with manufacturers’ recommendations.
 The maximum spray rinse time should not exceed 120 s unless otherwise specified by
part or materials specification.
 Rinse Effectiveness — If the emulsification and final rinse step is not effective, as
evidenced by excessive residual surface penetrant after emulsification and rinsing, dry
and reclean the part and reapply the penetrant for the prescribed dwell time.
6.4.3 Hydrophilic Emulsification:
 Pre-rinsing — Directly after the required penetration time, it is recommended that the
parts be pre-rinsed with water prior to emulsification. This step allows for the removal
of excess surface penetrant from the parts prior to emulsification so as to minimize
the degree of penetrant contamination in the hydrophilic emulsifier bath, thereby
extending its life. In addition, pre- rinsing of penetrated parts minimizes possible oily
penetrant pollution in the final rinse step of this process. This is accomplished by
collecting the pre-rinsings in a holding tank, separating the penetrant from water.
 Pre-rinsing Controls — Effective pre-rinsing is accomplished by either manual or
automated water spray rinsing of the parts as follows:
(a) Water should be free of contaminants that could clog spray nozzles or leave a residue on parts.
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(b) Control water temperature within the range of 50 to 100°F (10 to 38°C).
(c) Spray rinse at a water pressure of 25 to 40 psi (175 to 275 kPa).
(d) Pre-rinse time should be the least possible time (nominally 60 s maximum) to provide a
consistent residue of penetrant on parts. Wash time is to be as specified by the part or
material specification.
(e) Remove water trapped in cavities using filtered shop air at a nominal pressure 25 psi
(175 kPa) or a suction device to remove water from pooled areas.
 Application of Emulsifier — After the required penetration time and following the pre-
rinse, the residual surface penetrant on part(s) must be emulsified by immersing the
part(s) in a hydrophilic emulsifier bath or by spraying the part(s) with the emulsifier
rendering the remaining residual surface penetrant water-washable in the final rinse
station.
 Immersion — For immersion application, parts are completely immersed in the
emulsifier bath. The hydrophilic emulsifier should be gently agitated throughout the
contact cycle.

(a) Bath concentration should be as recommended by the manufacturer. Most hydrophilic

emulsifiers are used within the range of 20 to 33% in water. Nominal use
concentration for immersion applications is 20%.
(b) Bath temperatures should be maintained between 50 and 100°F (10 to 38°C).
(c) Immersion contact time should be kept to the minimum time consistent with an
acceptable background and should not exceed 120 s or the maximum time stipulated by
the part or material specification.
(d) Emulsifier drain time begins immediately after parts have been withdrawn from the
emulsifier tank and continues until the parts are washed in the final rinse station
(8.6.3.6). This drain time should be kept to a minimum to avoid over emulsification and
should not exceed 90 s.
 Spray Application — For spray application following the prerinse step, parts are
emulsified by the spray application of an emulsifier. All part surfaces should be evenly
and uniformly sprayed to effectively emulsify the residual penetrant on part surfaces to
render it water-washable.
(a) The concentration of the emulsifier for spray application should be in accordance
with the manufacturer’s recommendations, but should not exceed 5%.
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(b) Temperature to be maintained at 50 to 100°F (10 to 38°C).

(c) The spray pressure should be 25 psi (175 kPa) max for air and 40 psi (280 kPa) max for water.
(d) Contact time should be kept to the minimum consistent with an acceptable
background and should not exceed 120 s or the maximum time stipulated by the part or
material specification.
 Post-Rinsing of Hydrophilic Emulsified Parts — Effective post-rinsing of emulsified
penetrant from the surface can be accomplished using either manual, semi-
automated, or automated water immersion or spray equipment or combinations thereof.
 Immersion Post-Rinsing — Parts are to be completely immersed in the water bath
with air or mechanical agitation & The temperature of the water should be relatively
constant and should be maintained within the range of 50 to 100°F (10 to 38°C).
 The maximum dip rinse time should not exceed 120 s unless otherwise specified by
part or material specification.
Caution: A touch-up rinse may be necessary after immersion.
 Spray Post-Rinsing — Following emulsification parts can be post-rinsed by water
spray rinsing as follows:
(a) Control rinse water temperature within the range of 50 to 100°F (10 to 38°C).
(b) Spray rinse water pressure should be in accordance with manufacturer’s instructions.
(c) The maximum spray rinse time should not exceed 120 s unless otherwise specified by
part or materials specification.
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 If the emulsification and final rinse steps are not effective, as evidenced by
excessive residual surface penetrant after emulsification and rinsing, dry and re-
clean the part and reapply the penetrant for the prescribed dwell time.
6.4.4 Solvent-Removable:
 Removal of Excess Penetrant — After the required penetration time, Excess solvent
removable penetrants shall be removed by wiping with a clean, dry, lint-free
cloth or absorbent paper, repeating the operation until most traces of penetrant have
been removed.
 Then using a lint-free material lightly moistened with solvent remover the
remaining traces are gently wiped to avoid removing penetrant from discontinuities.
Avoid the use of excess solvent.
 If the wiping step is not effective, as evidenced by difficulty in removing the excess
penetrant, dry the part, and reapply the penetrant for the prescribed dwell time.
Flushing the surface with solvent following the application of the penetrant and prior
to developing is prohibited.
 Drying — Drying the surface of the part(s) is necessary prior to applying dry or
non-aqueous developers or following the application of the aqueous developer.
Drying time will vary with the size, nature, and number of parts under examination.
 Drying Modes — Parts can be dried by using a hot-air re-circulating oven, a hot or
cold air blast, or by exposure to ambient temperature, particularly when the
excess surface penetrant was removed with a solvent. Drying is best done in a
thermostatically controlled re-circulating hot-air dryer.
 Local heating or cooling is permitted provided the temperature of the part remains
in the range of 50 to 100°F (10 to 38°C) for fluorescent methods and in the range of
50 to 125°F (10 to 52°C) for visible methods.
Caution — Drying oven temperature should not exceed 160°F (71° C).

 Drying Time Limits — Do not allow parts to remain in the drying oven any longer
than is necessary to dry the surface. Times over 30 min in the dryer may impair the
sensitivity of the examination.
6.5 Developer Application:
 Modes of Application — There are various modes of effective application of the
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various types of developers such as dusting, immersing, flooding or spraying. The

size, configuration, surface condition, number of parts to be processed, and so
forth, will influence the choice of developer application.
 Dry Powder Developer — Dry powder developers should be applied immediately
after drying in such a manner as to ensure complete part coverage. Parts can be
immersed in a container of dry developer or in a fluid bed of dry developer.
They can also be dusted with the powder developer through a hand powder
bulb or a conventional or electrostatic powder gun. It is common and effective
to apply dry powder in an enclosed dust chamber, which creates an effective and
controlled dust cloud. Other means suited to the size and geometry of the

specimen may be used, provided the powder is dusted evenly over the entire
surface being examined. Excess powder may be removed by shaking or tapping
the part, or by blowing with low-pressure (5 to 10 psi) (34 to 70 kPa) dry, clean,
compressed air.
NOTE 17: Caution — The air stream intensity should be established experimentally for each application.

 Aqueous Developers — Aqueous developers should be applied to the part

immediately after the excess penetrant has been removed and prior to drying.
Aqueous developers should be prepared and maintained in accordance with the
manufacturer’s instructions and applied in such a manner as to ensure complete,
even, part coverage. Caution should be exercised when using an aqueous developer
with water-washable penetrants to avoid possible stripping of indications.
Aqueous developers may be applied by spraying, flowing, or immersing the part.
 Nonaqueous Wet Developers — After the excess penetrant has been removed and
the surface has been dried, apply developer by spraying in such a manner as to
ensure complete part coverage with a thin, even film of developer. These types of
developer carrier evaporate very rapidly at normal room temperature and do not,
therefore, require the use of a dryer.
 Dipping or flooding parts with non-aqueous developers is prohibited, since they
may flush or dissolve the penetrant from within the discontinuities because of the
solvent action of these types of developers.
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Warning — The vapors from the evaporating, volatile solvent developer carrier may be hazardous. Proper ventilation should
be provided in all cases, but especially when the surface to be examined is inside a closed volume, such as a process drum or
a small storage tank.

 Liquid Film Developers — Apply by spraying as recommended by the manufacturer.

Spray parts in such a manner as to ensure complete part coverage of the area being
examined with a thin, even film of developer.
 Developing Time — The length of time the developer is to remain on the part prior to
examination should be not less than 10 min. Developing time begins immediately
after the application of dry powder developer and as soon as the wet (aqueous and
non-aqueous) developer coating is dry (that is, the solvent carrier has evaporated to
dryness). The maximum permitted developing times are 2 h for aqueous developers
and 1 h for non-aqueous developers.
6.6 Examination
 Perform examination of parts after the applicable development time as specified
above to allow for bleed out of penetrant from discontinuities into the developer
coating. It is good practice to observe the bleed out while applying the developer
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as an aid in interpreting and evaluating indications.
6.7 Fluorescent Light Examination:
 Visible Ambient Light Level — Examine fluorescent penetrant indications under
black light in a darkened area. Visible ambient light should not exceed 2 ft candles
(20 Lx). The measurement should be made with a suitable photographic-type
visible light meter on the surface being examined.

 Black Light Level Control — Black light intensity, minimum of 1000 mW/cm2,
should be measured on the surface being examined, with a suitable black light meter.
The black light wavelength shall be in the range of 320 to 380 nm. The intensity
should be checked weekly to ensure the required output. Reflectors and filters
should be checked daily for cleanliness and integrity. Cracked or broken ultraviolet
(UV) filters should be replaced immediately. Defective bulbs, which radiate UV
energy, must be replaced before further use. Since a drop in line voltage can cause
decreased black light output with consequent inconsistent performance, a
constant-voltage transformer should be used when there is evidence of voltage
fluctuation.
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Caution: Certain high-intensity black light may emit unacceptable amounts of visible light, which will cause fluorescent
indications to disappear. Care should be taken to use only bulbs certified by the supplier to be suitable for such examination
purposes.

 Black Light Warm-Up — Allow the black light to warm up for a minimum of 10
min prior to its use or measurement of the intensity of the ultraviolet light
emitted.
 Visual Adaptation — The examiner should be in the darkened area for at least 1
min before examining parts. Longer times may be necessary under some
circumstances.
Caution — Photochromic lenses shall not be worn during examination.

6.8 Visible Light Examination:

 Visible Light Level — Visible penetrant indications can be examined in either
natural or artificial light. Adequate illumination is required to ensure no loss in the
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sensitivity of the examination. A minimum light intensity at the examination site of
100 fc (1000 Lx) is recommended.
6.9 Post Cleaning
 Post cleaning is necessary in those cases where residual penetrant or
developer could interfere with subsequent processing or with service
requirements. It is particularly important where residual penetrant examination
materials might combine with other factors in service to produce corrosion. A
suitable technique, such as a simple water rinse, waterspray, machine wash,
vapor degreasing, solvent soak, or ultrasonic cleaning may be employed.
 It is recommended that if developer removal is necessary, it should be carried out
as promptly as possible after examination so that it does not ‘‘fix’’ on the part.
Caution — Developers should be removed prior to vapour degreasing. Vapor degreasing can bake the developer on parts.

6.10 Evaluation / Documentation

 Evaluation of the indication shell be carried out by a ASNT Level II or ASNT Level I
person under the Supervision/ with instruction of ASNT Level II or ASNT Level III
person.
 Mechanical discontinuities at the surface will be indicated by the retention of the
examination medium.
NOTE: Other NDE methods (i.e. Penetrant) may be used to verify these indications.
 Relevant Indications - Relevant indications are those which result from
mechanical discontinuities.
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 Linear indications are those indications in which the length is more than three times the width.
 Rounded indications are indications which are circular or elliptical with the
length less than three times the width

6.11 Acceptance Criteria

 For determination of the appropriate criteria, the inspector shall review the
required engineering documentation or applicable code/standard color
contrast technique (visible under natural or artificial white light) solvent
removable Penetrant system shall be used.
6.12 Test Report
The report shall include but not limited to the following details:
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 Client or Manufacturer
 Job or Project Number
 Report Number
 Seam, nozzle or part number.
 Type of Penetrant material
 Sketch showing location and type of defects (if necessary)
 Date of test

7. ANNEXES

 Annex I : DPT Report Template

 Annex II : DPT Work Instruction
 Annex III : DPT Raw Data Format
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