Sample Penetrant Testing Procedure
Content
LESER WORKS STANDARD Procedure for penetrant testing
LWN331-04-EN page 1
Table of Contents
SUMMARY ........................................................................................................................................................ 2 1. 2. 3. 4. 5. GENERAL ................................................................................................................................................. 2 APPLICATION .......................................................................................................................................... 2 PURPOSE, DEFINITION........................................................................................................................... 2 TEST REFERENCES ................................................................................................................................ 2 TEST PROCEDURES AT LESER ............................................................................................................ 3 5.1 TEST INSTRUCTIONS................................................................................................................................ 3 5.2 TEST DEPTH ........................................................................................................................................... 3 5.3 TEST PROCEDURE ................................................................................................................................... 3 5.4 TESTING FACILITY ................................................................................................................................... 3 5.5 TEST MEDIA ............................................................................................................................................ 3 5.5.1 Penetrant systems, description.................................................................................................... 3 5.5.2 Test media ................................................................................................................................... 4 5.5.3 Sensitivity ..................................................................................................................................... 4 5.5.4 Compatibility of the test media, compatibility with the test object................................................ 4 5.6 TEST PROCEDURE ................................................................................................................................... 4 5.6.1 Preparation and pre-treatment..................................................................................................... 4 5.6.2 Application of the penetrant agent ............................................................................................... 5 5.6.3 Interim cleaning............................................................................................................................ 5 5.6.4 Development process .................................................................................................................. 5 5.6.5 Inspection, viewing conditions in accordance with DIN EN ISO 3059......................................... 6 5.6.6 Final cleaning and protective measures ...................................................................................... 6 6. 7. 8. 9. ACCEPTANCE CRITERIA (EVALUATION OF THE INDICATIONS) ...................................................... 6 QUALIFICATION OF THE TEST PERSONNEL....................................................................................... 6 DOCUMENTATION, OPTION CODE ....................................................................................................... 7 STANDARD REFERENCES ..................................................................................................................... 7
continues on page 2
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing Summary
LWN331-04-EN page 2
Purpose of the penetrant testing is to detect the presence of fissures/cracks in the surface (surface test) and in the surfaces of adjacent areas. The penetrant testing will not be applied in case of: − Ferromagnetic iron and steel castings The issue of a certificate that the test has been carried out can be ordered with: Option code H03 M03 M21 Certificate LESER CGA (Certificate for Global Application) – Inspection certificate 3.1 according to DIN EN 10204 Inspection certificate 3.1 acc. to DIN EN 10204: Dye penetrant testing Inspection certificate 3.1 acc. to DIN EN 10204: Fluorescent penetrant testing Remarks
optionally optionally
1. General
This LWN will list the standard requirements and describe the procedure during the penetrant testing at LESER and its documentation.
2. Application
At LESER the penetrant examination will be applied in case of metal and non-metal materials like castings, forgings, welding seams, and ceramics.
3. Purpose, definition
The penetrant testing belongs to the non-destructive tests and is a procedure to detect surface flaws like cracks, overlappings, laps, pores and binding flaws that are open in direction of the testing surface. The principle of the penetrant testing procedure is that a penetrant agent, due to its specific characteristics tends to spread optimally on a surface and will simultaneously penetrate into any existing surface flaws. The superfluous penetrant agent is removed from the surface and the developer is applied. The developer takes up the penetrant, in the flaws remaining penetrant agent and this will result in a clearly visible and amplified indication of flaws up to the μm measuring area.
4. Test references
The following standards were included at LESER for the penetrant testing: AD 2000-Merkblatt A4, chapter 6, Tests before operation, Section.6.1 The following tests are required for the bodies of component parts: 6.1 (5) non-destructive test of products for bodies of component parts and of welding seams at pressure bearing walls and ... ASME Code, Section VIII UG -136 Minimum Requirements for Pressure Relief Valves UG-136 (f) Welding and other requirements. All welding, brazing, heat treatment, and non-destructive testing used in the construction of bodies, bonnets and yokes shall be performed in accordance with the applicable requirements of this division.
continues on page 3
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing
EN 571-1 DIN EN ISO 3452 EN 1371 DIN 1690
LWN331-04-EN page 3
Non-destructive testing – penetrant testing - Part 1- General foundations Non-destructive testing - penetrant testing Founding - penetrant testing Technical delivery conditions for castings made of metal materials
ASME Code Section V, Non-destructive Examination Article 6 Liquid Penetrant Examination ASME B 16.34 Valves-Flanged, Threaded, and Welding End Mandatory Appendices III - Liquid Penetrant Examination: Procedure and Acceptance Standards LWN 221-04 Penetrant testing, testing at LESER
5. Test procedures at LESER 5.1 Test instructions
The penetrant testing has to be carried out in accordance with DIN EN ISO 571-1 according to a written test instruction. This specification will determine the test parameters in such a way that the test can be repeated in same manner.
5.2 Test depth
The penetrant testing is carried out at LESER in accordance with testing schedule.
5.3 Test procedure
The testing system carried out at LESER is realised by using two methods: – Fluorescent penetrant testing (penetrating) – Dye penetrant testing (red and white test)
5.4 Testing facility
The specifications stipulated for LESER used penetrant test devices comply with DIN EN ISO 3452-4. The fluorescent penetrant testing (penetrating) is carried out in a HELLING penetrant facility. The dye penetrant testing (red and white test) is carried out on a special testing table.
5.5 Test media
5.5.1 Penetrant systems, description A penetrant system is understood to be a combination of the following test media: penetrant agent, interim cleaning agent and developer. There are different testing systems for penetrant testing. You may only use DIN EN ISO 3452-3 approved and sample tested penetrant systems. The approved penetrant system to be used for penetrant testing is assigned a description stating the type, the procedure and the kind of test media and a number for the sensitivity class. Two testing systems are carried out at LESER: - Brief description: EN 571/1 I A- a, for fluorescent penetrant testing (penetrant facility) - Brief description: EN 571/1 II A – d, for dye penetrant testing, so-called red and white test. This is shown in table 1.
continues on page 4
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing
5.5.2 Test media
LWN331-04-EN page 4
The test media shown in table 1 is used at LESER. Penetrant agent Penetrant testing
Type Description
Interim cleaning agent
Procedure Description Type
Developer
Description
Fluorescent penetrant testing (penetrating)
I
Fluorescent penetrant agent: MET- L - Check Penetrant HM 405
A
Water or solvent based cleaning agent: MET-L-Check special cleaning agent NPU Water or solvent based cleaning agent: MET-L-Check special cleaning agent NPU
a
Dry developer
Met-L-Check Developer D72/80
Dye penetrant testing
II
Dye penetrant agent
A
d
Wet developer on solvent basis MET-L-Check Developer D 70
MET- L –Check Penetrant Dye VP30
Table 1: Test media used at LESER 5.5.3 Sensitivity
The sensitivity class of the in chapter 5.5.1 stated penetrant system has been determined using the calibration block 1 in accordance with DIN EN ISO 3452-3. The determined class is only valid for the sample testing approved penetrant system. 5.5.4 Compatibility of the test media, compatibility with the test object
The test media has to be compatible with the materials of the parts to be tested and its final use. The test media of a system has to be compatible with each other. Penetrant agents of different manufacturers may not be mixed when filling the facility. Escaped penetrant agent may not be replaced by penetrant agents of different manufacturers.
5.6 Test procedure
5.6.1 Preparation and pre-treatment The surface to be tested has to be clean and free from oil, grease, moulding compound and finish residues or any other contaminations that may interfere with the test. The penetrant testing has to be carried out on castings in delivery condition. In as far as necessary the pre-treatment will be carried out using a mechanical, chemical procedure or using a combination of this procedure. This has to ascertain that the testing surface has to be free of residues and that the penetrant agent is able to penetrate any surface flaws. Mechanical pre-treatment When removing tinder, slag, and rust etc. by brushing, sanding, grinding, blasting it has to be ascertained that the surface flaws are not covered by a densification of the surface or are covered or sealed by abrasions.
continues on page 5
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing
LWN331-04-EN page 5
Chemical pre-treatment The chemical pre-treatment is carried out (spraying on a solvent) by using suitable chemical cleaning agents to remove residues like grease, oil, dye or corrosives. Residues of the chemical agent have to be removed from the testing surface. Drying In the last stage of the pre-treatment the test samples have to be completely dried with a cloth or by drying off so that neither water nor solvent will remain in the surface flaws. 5.6.2 Application of the penetrant agent
Methods of application The penetrant agent is applied by dipping (fluorescent penetrant testing), spraying or brushing (dye penetrant testing) it on the sample to be tested. The work piece temperature should be between +10°C to +50°C. Reaction time: The surface to be tested has to be completely covered during the entire reaction time. The reaction time is about 30 minutes for both suitable test procedures at LESER, i.e. dipping into the penetrant container and spraying. The penetrant agent may not start drying during the penetrant procedure. The reaction time of the penetrant agent is defined at LESERs as follows: - Cast iron/ Nodular cast iron 15 min - Carbon steel 30 min - Stainless steel 45 min - Weldings 60 min - Stellited parts applicable up to 300 bar 60 min - Stellited parts applicable above 300 bar 120 min 5.6.3 Interim cleaning
The interim cleaning helps to remove superfluous test media from the surface so that no penetrant agent will be removed out of the surface flaws: Fluorescent penetrant testing Interim cleaning will be done using water at normal tap pressure and at room temperature. During the interim cleaning the surface has to be examined for penetrant agent residues. When using fluorescent penetrant agent (penetrant facility) this will be done by using the exposure of a UV light with a minimum UV-A exposure intensity on the testing surface of 300 μW / m². After that the surface should be cleaned with a clean, non-fuzz cloth moistened with solvent. Dye penetrant testing (red-white test) Interim cleaning is done by spraying water or cleaning with a non-fuzz cloth. Drying After removing the superfluous penetrant agent the testing surface has to be dried as quickly as possible: - in the oven at max. 50°C for tested parts used with the fluorescent penetrant testing procedure (penetrant facility) - by flow of air (hairdryer), free of water and oil, with a pressure as low as possible for dye penetrant testing. The drying procedure of the testing surface has to be carried out in such a manner that the drying of the penetrant agent in the surface flaws is prevented 5.6.4 Development process
The developer is applied evenly on the surface. During the development a capillary active substance is applied, which can take up the penetrant agent from the flawed area. Due to this the flawed area appears to be larger and will be seen more easily.
continues on page 6
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing
LWN331-04-EN page 6
The application of the developers has to be done immediately after the interim cleaning. Dye penetrant testing (red-white test) Wet developers on a water-based suspension will be used for the red-white test. You should achieve an even and thin application by spraying the developer so that the underground is just covered. The developing period will start immediately after the drying and will take between 10 and 30 minutes. Fluorescent penetrant testing Dry developer will only be used in connection with a fluorescent penetrant agent. This has to be applied evenly by whirling on the testing surface immediately after the interim cleaning. The tested parts are left in the developer container for 5 to 10 minutes where the powder is whirled up for approx. 20 seconds using pressured air in order to completely cover the parts with powder. The development period starts immediately after application. The development time is equal to the reaction time of the penetrant agent, see chapter 5.6.2 5.6.5 Inspection, viewing conditions in accordance with DIN EN ISO 3059
The initial monitoring of the testing surface should be carried out immediately after the application of the developer and/or the drying of the developer. In this way indications can be interpreted in a better way. The final inspection has to be done after completion of the developing time. Fluorescent penetrant agent Photo chromatic glasses may not be worn. The test sample is exposed to UV-A light in a darkened room. The UV-A exposure intensity on the testing surface has to be greater than 1000 μW / cm² and the exposure intensity of the environment has to be smaller than 20 Lux. Before the test the eyes of the tester should adapt to the lower environmental light for some time. The UV-A light should be switched on a few minutes before the test (normally at least 5 minutes) to ascertain the required exposure intensity. The tester should avoid looking directly into the UV-A light or areas reflecting the light. Dye penetrant agent During dye penetrant testing, the testing surface should be examined under artificial light with an exposure intensity of at least 500 Lux on the testing surface. Reflections should be avoided. 5.6.6 Final cleaning and protective measures
A final cleaning will only be necessary in cases where residues of the penetrant test media could affect the further use of the tested part. A corrosion protection will only be applied if required.
6. Acceptance criteria (evaluation of the indications)
The indication of flaws will be evaluated in accordance with standard specifications. The castings will be evaluated in accordance with DIN EN 1371, DIN 1690 and ASME B16.34. The evaluation of the penetrant testing at the welding seams will be carried out in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99. The tested parts are marked with the marking OFR. (OFR = surface test)
7. Qualification of the test personnel
The personnel for the penetrant testing will be qualified and certified in accordance with EN 473 and SNT-TC 1A. The level of qualification of personnel involved in penetrant testing is equal to the LESER nondestructive testing training: PT Level 1 and 2.
continues on page 7
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing
LWN331-04-EN page 7
8. Documentation, Option Code
The issue of a certificate that the test has been carried out can be ordered with: Option code H03 M03 M21 Certificate LESER CGA (Certificate for Global Application) – Inspection certificate 3.1 according to DIN EN 10204 Inspection certificate 3.1 acc. to DIN EN 10204: Dye penetrant testing Inspection certificate 3.1 acc. to DIN EN 10204: Fluorescent penetrant testing Remarks
optionally optionally
9. Standard references
AD 2000-Merkblatt A4 EN 571-1 DIN EN ISO 3452-3 DIN EN ISO 3452-4 DIN EN ISO 3059 EN 1371 DIN 1690 DIN EN 473 ASME Code, Section VIII ASME Code Section V ASME B 16.34 Bodies of component parts; Tests before operation Non-destructive test- penetrant testing Part 1- General foundations Non-destructive testing – penetrant testing - Part 3 -calibration block Non-destructive testing – penetrant testing - Part 4- devices Non-destructive testing - penetrant testing and magnetic particle examination, viewing conditions Founding - penetrant testing Technical delivery conditions for castings made of metal materials Non-destructive testing - Qualification and certification of personnel of non-destructive tests - General foundations Rules for Construction of Pressure Vessels, Division 1 Non-destructive Examination. Article 6 - Liquid Penetrant Examination SE-165 Standard Test Method for Liquid Penetrant Examination Valves-Flanged, Threaded, and Welding End Mandatory Appendices III - Liquid Penetrant Examination: Procedure and Acceptance Standards Personnel Qualification and Certification in Non-destructive Testing Regulative requirements regarding welding components at LESER safety valves
SNT-TC 1A LWN 287-99
End of LWN
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
T he S afety V alve
Inspection certificate 3.1 acc. to DIN EN 10204
DYE PENETRANT TESTING [Option code M03]
LESER GmbH & Co. KG Postfach 26 16 51 20506 Hamburg, Germany
. . .
Customer Order No.: LESER – Job – No.: LESER-Customers-No.: LESER-Contact: Fon: Fax: eMail:
xxx xxx xxx xxx + 49 (40) 25 165+ 49 (40) 25 165-500 [email protected]
This LESER inspection certificate confirms that the test object was tested according to the undermentioned test references.
1 Test object
xxx xxx xxx
Art.-No. xxxx.xxxx Cold differential test pressure x,xx barg LESER – Job – No. xxx xxx,xx psig Pos.No. xx Option Code: Further SV-Info: xxx xxx Nominal size Inlet xxx xxx xx Outlet xx Pressure rating Inlet xx Outlet xx
Tag – No. xxx
Serial – No.
Body material
Tested component
Pos. xx Description xxx Material xxx Manufacturer xxx Heat No. / Batch xxx
2 Test reference
Dye penetrant testing acc. to: AD 2000-Merkblatt A4, chapter 6 ASME Code, Section VIII Div. 1, UG-136 LESER Works Standard LWN 331-04
3 Procedure 4 Test specifiation
Test equipment: Test system: Test media: Qualification of the test personnel: Dye penetrant testing table (red and white test) acc. to EN 571/1 II A – d Penetrant agent MET-L-Check Penetrant Dye VP30 PT Level I, PT Level II (DIN EN 473 and SNT-TC 1A)
5 Acceptance criteria
The castings will be evaluated in accordance with DIN EN 1371, DIN 1690 and ASME B16.34. The evaluation at the welding seams will be carried out in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99.
6 Test result
The test was realised without any objection. The requirements of the test references are fulfilled. Manfred Orlowski Inspection Representative
This certification is written digitally and requires no handwritten signature. (Acc. to EN 10204, chapter 5)
Hohenwestedt, xx.xx.200x
LESER GmbH & Co. KG Hamburg HRA 82424
GF · BoD Joachim Klaus, Martin Leser 20537 Hamburg, Wendenstr. 133 – 135 20506 Hamburg, P.O. Box 26 16 51 ( )
Fon +49 (40) 251 65-100 Fax +49 (40) 251 65-500 E-Mail [email protected] Internet www.leser.com
Bank HypoVereinsbank Hamburg BLZ 200 300 00, Konto · Account 3203171 BIC: HYVEDEMM300 IBAN: DE64 2003 0000 0003 2031 71 USt-ID · VAT-Reg DE 118840936
LESER – The Safety Valve
T he S afety V alve
Inspection certificate 3.1 acc. to EN 10204
FLUORESCENT PENETRANT TESTING [Option code M21]
LESER GmbH & Co. KG Postfach 26 16 51 20506 Hamburg, Germany
. . .
Customer Order No.: LESER – Job – No.: LESER-Customers-No.: LESER-Contact: Fon: Fax: eMail:
xxx xxx xxx xxx + 49 (40) 25 165+ 49 (40) 25 165-500 [email protected]
This LESER inspection certificate confirms that the test object was tested according to the undermentioned test references.
1 Test object
xxx xxx xxx
Art.-No. xxxx.xxxx Cold differential test pressure x,xx barg LESER – Job – No. xxx xxx,xx psig Pos.No. xx Option Code: Further SV-Info: xxx xxx Nominal size Inlet xxx xxx xx Outlet xx Pressure rating Inlet xx Outlet xx
Tag – No. xxx
Serial – No.
Body material
Tested component
Pos. xx Description xxx Material xxx Manufacturer xxx Heat No. / Batch xxx
2 Test reference
Flourescent penetrant testing acc. to: AD 2000-Merkblatt A4, chapter 6 ASME Code, Section VIII Div. 1, UG-136 LESER Works Standard LWN 331-04
3 Procedure 4 Test specifiation
Test equipment: Test system: Test media: Qualification of the test personnel: HELLING penetrant facility acc. to EN 571/1 I A – a Penetrant agent MET-L-Check Penetrant HM 405 PT Level I, PT Level II (DIN EN 473 and SNT-TC 1A)
5 Acceptance criteria
The castings will be evaluated in accordance with DIN EN 1371, DIN 1690 and ASME B16.34. The evaluation at the welding seams will be carried out in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99.
6 Test result
The test was realised without any objection. The requirements of the test references are fulfilled. Manfred Orlowski Inspection Representative
This certification is written digitally and requires no handwritten signature. (Acc. to EN 10204, chapter 5)
Hohenwestedt, xx.xx.200x
LESER GmbH & Co. KG Hamburg HRA 82424
GF · BoD Joachim Klaus, Martin Leser 20537 Hamburg, Wendenstr. 133 – 135 20506 Hamburg, P.O. Box 26 16 51 ( )
Fon +49 (40) 251 65-100 Fax +49 (40) 251 65-500 E-Mail [email protected] Internet www.leser.com
Bank HypoVereinsbank Hamburg BLZ 200 300 00, Konto · Account 3203171 BIC: HYVEDEMM300 IBAN: DE64 2003 0000 0003 2031 71 USt-ID · VAT-Reg DE 118840936
LESER – The Safety Valve
LWN331-04-EN page 1
Table of Contents
SUMMARY ........................................................................................................................................................ 2 1. 2. 3. 4. 5. GENERAL ................................................................................................................................................. 2 APPLICATION .......................................................................................................................................... 2 PURPOSE, DEFINITION........................................................................................................................... 2 TEST REFERENCES ................................................................................................................................ 2 TEST PROCEDURES AT LESER ............................................................................................................ 3 5.1 TEST INSTRUCTIONS................................................................................................................................ 3 5.2 TEST DEPTH ........................................................................................................................................... 3 5.3 TEST PROCEDURE ................................................................................................................................... 3 5.4 TESTING FACILITY ................................................................................................................................... 3 5.5 TEST MEDIA ............................................................................................................................................ 3 5.5.1 Penetrant systems, description.................................................................................................... 3 5.5.2 Test media ................................................................................................................................... 4 5.5.3 Sensitivity ..................................................................................................................................... 4 5.5.4 Compatibility of the test media, compatibility with the test object................................................ 4 5.6 TEST PROCEDURE ................................................................................................................................... 4 5.6.1 Preparation and pre-treatment..................................................................................................... 4 5.6.2 Application of the penetrant agent ............................................................................................... 5 5.6.3 Interim cleaning............................................................................................................................ 5 5.6.4 Development process .................................................................................................................. 5 5.6.5 Inspection, viewing conditions in accordance with DIN EN ISO 3059......................................... 6 5.6.6 Final cleaning and protective measures ...................................................................................... 6 6. 7. 8. 9. ACCEPTANCE CRITERIA (EVALUATION OF THE INDICATIONS) ...................................................... 6 QUALIFICATION OF THE TEST PERSONNEL....................................................................................... 6 DOCUMENTATION, OPTION CODE ....................................................................................................... 7 STANDARD REFERENCES ..................................................................................................................... 7
continues on page 2
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing Summary
LWN331-04-EN page 2
Purpose of the penetrant testing is to detect the presence of fissures/cracks in the surface (surface test) and in the surfaces of adjacent areas. The penetrant testing will not be applied in case of: − Ferromagnetic iron and steel castings The issue of a certificate that the test has been carried out can be ordered with: Option code H03 M03 M21 Certificate LESER CGA (Certificate for Global Application) – Inspection certificate 3.1 according to DIN EN 10204 Inspection certificate 3.1 acc. to DIN EN 10204: Dye penetrant testing Inspection certificate 3.1 acc. to DIN EN 10204: Fluorescent penetrant testing Remarks
optionally optionally
1. General
This LWN will list the standard requirements and describe the procedure during the penetrant testing at LESER and its documentation.
2. Application
At LESER the penetrant examination will be applied in case of metal and non-metal materials like castings, forgings, welding seams, and ceramics.
3. Purpose, definition
The penetrant testing belongs to the non-destructive tests and is a procedure to detect surface flaws like cracks, overlappings, laps, pores and binding flaws that are open in direction of the testing surface. The principle of the penetrant testing procedure is that a penetrant agent, due to its specific characteristics tends to spread optimally on a surface and will simultaneously penetrate into any existing surface flaws. The superfluous penetrant agent is removed from the surface and the developer is applied. The developer takes up the penetrant, in the flaws remaining penetrant agent and this will result in a clearly visible and amplified indication of flaws up to the μm measuring area.
4. Test references
The following standards were included at LESER for the penetrant testing: AD 2000-Merkblatt A4, chapter 6, Tests before operation, Section.6.1 The following tests are required for the bodies of component parts: 6.1 (5) non-destructive test of products for bodies of component parts and of welding seams at pressure bearing walls and ... ASME Code, Section VIII UG -136 Minimum Requirements for Pressure Relief Valves UG-136 (f) Welding and other requirements. All welding, brazing, heat treatment, and non-destructive testing used in the construction of bodies, bonnets and yokes shall be performed in accordance with the applicable requirements of this division.
continues on page 3
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing
EN 571-1 DIN EN ISO 3452 EN 1371 DIN 1690
LWN331-04-EN page 3
Non-destructive testing – penetrant testing - Part 1- General foundations Non-destructive testing - penetrant testing Founding - penetrant testing Technical delivery conditions for castings made of metal materials
ASME Code Section V, Non-destructive Examination Article 6 Liquid Penetrant Examination ASME B 16.34 Valves-Flanged, Threaded, and Welding End Mandatory Appendices III - Liquid Penetrant Examination: Procedure and Acceptance Standards LWN 221-04 Penetrant testing, testing at LESER
5. Test procedures at LESER 5.1 Test instructions
The penetrant testing has to be carried out in accordance with DIN EN ISO 571-1 according to a written test instruction. This specification will determine the test parameters in such a way that the test can be repeated in same manner.
5.2 Test depth
The penetrant testing is carried out at LESER in accordance with testing schedule.
5.3 Test procedure
The testing system carried out at LESER is realised by using two methods: – Fluorescent penetrant testing (penetrating) – Dye penetrant testing (red and white test)
5.4 Testing facility
The specifications stipulated for LESER used penetrant test devices comply with DIN EN ISO 3452-4. The fluorescent penetrant testing (penetrating) is carried out in a HELLING penetrant facility. The dye penetrant testing (red and white test) is carried out on a special testing table.
5.5 Test media
5.5.1 Penetrant systems, description A penetrant system is understood to be a combination of the following test media: penetrant agent, interim cleaning agent and developer. There are different testing systems for penetrant testing. You may only use DIN EN ISO 3452-3 approved and sample tested penetrant systems. The approved penetrant system to be used for penetrant testing is assigned a description stating the type, the procedure and the kind of test media and a number for the sensitivity class. Two testing systems are carried out at LESER: - Brief description: EN 571/1 I A- a, for fluorescent penetrant testing (penetrant facility) - Brief description: EN 571/1 II A – d, for dye penetrant testing, so-called red and white test. This is shown in table 1.
continues on page 4
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing
5.5.2 Test media
LWN331-04-EN page 4
The test media shown in table 1 is used at LESER. Penetrant agent Penetrant testing
Type Description
Interim cleaning agent
Procedure Description Type
Developer
Description
Fluorescent penetrant testing (penetrating)
I
Fluorescent penetrant agent: MET- L - Check Penetrant HM 405
A
Water or solvent based cleaning agent: MET-L-Check special cleaning agent NPU Water or solvent based cleaning agent: MET-L-Check special cleaning agent NPU
a
Dry developer
Met-L-Check Developer D72/80
Dye penetrant testing
II
Dye penetrant agent
A
d
Wet developer on solvent basis MET-L-Check Developer D 70
MET- L –Check Penetrant Dye VP30
Table 1: Test media used at LESER 5.5.3 Sensitivity
The sensitivity class of the in chapter 5.5.1 stated penetrant system has been determined using the calibration block 1 in accordance with DIN EN ISO 3452-3. The determined class is only valid for the sample testing approved penetrant system. 5.5.4 Compatibility of the test media, compatibility with the test object
The test media has to be compatible with the materials of the parts to be tested and its final use. The test media of a system has to be compatible with each other. Penetrant agents of different manufacturers may not be mixed when filling the facility. Escaped penetrant agent may not be replaced by penetrant agents of different manufacturers.
5.6 Test procedure
5.6.1 Preparation and pre-treatment The surface to be tested has to be clean and free from oil, grease, moulding compound and finish residues or any other contaminations that may interfere with the test. The penetrant testing has to be carried out on castings in delivery condition. In as far as necessary the pre-treatment will be carried out using a mechanical, chemical procedure or using a combination of this procedure. This has to ascertain that the testing surface has to be free of residues and that the penetrant agent is able to penetrate any surface flaws. Mechanical pre-treatment When removing tinder, slag, and rust etc. by brushing, sanding, grinding, blasting it has to be ascertained that the surface flaws are not covered by a densification of the surface or are covered or sealed by abrasions.
continues on page 5
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing
LWN331-04-EN page 5
Chemical pre-treatment The chemical pre-treatment is carried out (spraying on a solvent) by using suitable chemical cleaning agents to remove residues like grease, oil, dye or corrosives. Residues of the chemical agent have to be removed from the testing surface. Drying In the last stage of the pre-treatment the test samples have to be completely dried with a cloth or by drying off so that neither water nor solvent will remain in the surface flaws. 5.6.2 Application of the penetrant agent
Methods of application The penetrant agent is applied by dipping (fluorescent penetrant testing), spraying or brushing (dye penetrant testing) it on the sample to be tested. The work piece temperature should be between +10°C to +50°C. Reaction time: The surface to be tested has to be completely covered during the entire reaction time. The reaction time is about 30 minutes for both suitable test procedures at LESER, i.e. dipping into the penetrant container and spraying. The penetrant agent may not start drying during the penetrant procedure. The reaction time of the penetrant agent is defined at LESERs as follows: - Cast iron/ Nodular cast iron 15 min - Carbon steel 30 min - Stainless steel 45 min - Weldings 60 min - Stellited parts applicable up to 300 bar 60 min - Stellited parts applicable above 300 bar 120 min 5.6.3 Interim cleaning
The interim cleaning helps to remove superfluous test media from the surface so that no penetrant agent will be removed out of the surface flaws: Fluorescent penetrant testing Interim cleaning will be done using water at normal tap pressure and at room temperature. During the interim cleaning the surface has to be examined for penetrant agent residues. When using fluorescent penetrant agent (penetrant facility) this will be done by using the exposure of a UV light with a minimum UV-A exposure intensity on the testing surface of 300 μW / m². After that the surface should be cleaned with a clean, non-fuzz cloth moistened with solvent. Dye penetrant testing (red-white test) Interim cleaning is done by spraying water or cleaning with a non-fuzz cloth. Drying After removing the superfluous penetrant agent the testing surface has to be dried as quickly as possible: - in the oven at max. 50°C for tested parts used with the fluorescent penetrant testing procedure (penetrant facility) - by flow of air (hairdryer), free of water and oil, with a pressure as low as possible for dye penetrant testing. The drying procedure of the testing surface has to be carried out in such a manner that the drying of the penetrant agent in the surface flaws is prevented 5.6.4 Development process
The developer is applied evenly on the surface. During the development a capillary active substance is applied, which can take up the penetrant agent from the flawed area. Due to this the flawed area appears to be larger and will be seen more easily.
continues on page 6
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing
LWN331-04-EN page 6
The application of the developers has to be done immediately after the interim cleaning. Dye penetrant testing (red-white test) Wet developers on a water-based suspension will be used for the red-white test. You should achieve an even and thin application by spraying the developer so that the underground is just covered. The developing period will start immediately after the drying and will take between 10 and 30 minutes. Fluorescent penetrant testing Dry developer will only be used in connection with a fluorescent penetrant agent. This has to be applied evenly by whirling on the testing surface immediately after the interim cleaning. The tested parts are left in the developer container for 5 to 10 minutes where the powder is whirled up for approx. 20 seconds using pressured air in order to completely cover the parts with powder. The development period starts immediately after application. The development time is equal to the reaction time of the penetrant agent, see chapter 5.6.2 5.6.5 Inspection, viewing conditions in accordance with DIN EN ISO 3059
The initial monitoring of the testing surface should be carried out immediately after the application of the developer and/or the drying of the developer. In this way indications can be interpreted in a better way. The final inspection has to be done after completion of the developing time. Fluorescent penetrant agent Photo chromatic glasses may not be worn. The test sample is exposed to UV-A light in a darkened room. The UV-A exposure intensity on the testing surface has to be greater than 1000 μW / cm² and the exposure intensity of the environment has to be smaller than 20 Lux. Before the test the eyes of the tester should adapt to the lower environmental light for some time. The UV-A light should be switched on a few minutes before the test (normally at least 5 minutes) to ascertain the required exposure intensity. The tester should avoid looking directly into the UV-A light or areas reflecting the light. Dye penetrant agent During dye penetrant testing, the testing surface should be examined under artificial light with an exposure intensity of at least 500 Lux on the testing surface. Reflections should be avoided. 5.6.6 Final cleaning and protective measures
A final cleaning will only be necessary in cases where residues of the penetrant test media could affect the further use of the tested part. A corrosion protection will only be applied if required.
6. Acceptance criteria (evaluation of the indications)
The indication of flaws will be evaluated in accordance with standard specifications. The castings will be evaluated in accordance with DIN EN 1371, DIN 1690 and ASME B16.34. The evaluation of the penetrant testing at the welding seams will be carried out in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99. The tested parts are marked with the marking OFR. (OFR = surface test)
7. Qualification of the test personnel
The personnel for the penetrant testing will be qualified and certified in accordance with EN 473 and SNT-TC 1A. The level of qualification of personnel involved in penetrant testing is equal to the LESER nondestructive testing training: PT Level 1 and 2.
continues on page 7
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
LESER WORKS STANDARD Procedure for penetrant testing
LWN331-04-EN page 7
8. Documentation, Option Code
The issue of a certificate that the test has been carried out can be ordered with: Option code H03 M03 M21 Certificate LESER CGA (Certificate for Global Application) – Inspection certificate 3.1 according to DIN EN 10204 Inspection certificate 3.1 acc. to DIN EN 10204: Dye penetrant testing Inspection certificate 3.1 acc. to DIN EN 10204: Fluorescent penetrant testing Remarks
optionally optionally
9. Standard references
AD 2000-Merkblatt A4 EN 571-1 DIN EN ISO 3452-3 DIN EN ISO 3452-4 DIN EN ISO 3059 EN 1371 DIN 1690 DIN EN 473 ASME Code, Section VIII ASME Code Section V ASME B 16.34 Bodies of component parts; Tests before operation Non-destructive test- penetrant testing Part 1- General foundations Non-destructive testing – penetrant testing - Part 3 -calibration block Non-destructive testing – penetrant testing - Part 4- devices Non-destructive testing - penetrant testing and magnetic particle examination, viewing conditions Founding - penetrant testing Technical delivery conditions for castings made of metal materials Non-destructive testing - Qualification and certification of personnel of non-destructive tests - General foundations Rules for Construction of Pressure Vessels, Division 1 Non-destructive Examination. Article 6 - Liquid Penetrant Examination SE-165 Standard Test Method for Liquid Penetrant Examination Valves-Flanged, Threaded, and Welding End Mandatory Appendices III - Liquid Penetrant Examination: Procedure and Acceptance Standards Personnel Qualification and Certification in Non-destructive Testing Regulative requirements regarding welding components at LESER safety valves
SNT-TC 1A LWN 287-99
End of LWN
LESER
GmbH & Co. KG
processed: Sa approved: refer to ÄM 103600
edition: 14.08.07 replaces edition: 00.00.00
T he S afety V alve
Inspection certificate 3.1 acc. to DIN EN 10204
DYE PENETRANT TESTING [Option code M03]
LESER GmbH & Co. KG Postfach 26 16 51 20506 Hamburg, Germany
. . .
Customer Order No.: LESER – Job – No.: LESER-Customers-No.: LESER-Contact: Fon: Fax: eMail:
xxx xxx xxx xxx + 49 (40) 25 165+ 49 (40) 25 165-500 [email protected]
This LESER inspection certificate confirms that the test object was tested according to the undermentioned test references.
1 Test object
xxx xxx xxx
Art.-No. xxxx.xxxx Cold differential test pressure x,xx barg LESER – Job – No. xxx xxx,xx psig Pos.No. xx Option Code: Further SV-Info: xxx xxx Nominal size Inlet xxx xxx xx Outlet xx Pressure rating Inlet xx Outlet xx
Tag – No. xxx
Serial – No.
Body material
Tested component
Pos. xx Description xxx Material xxx Manufacturer xxx Heat No. / Batch xxx
2 Test reference
Dye penetrant testing acc. to: AD 2000-Merkblatt A4, chapter 6 ASME Code, Section VIII Div. 1, UG-136 LESER Works Standard LWN 331-04
3 Procedure 4 Test specifiation
Test equipment: Test system: Test media: Qualification of the test personnel: Dye penetrant testing table (red and white test) acc. to EN 571/1 II A – d Penetrant agent MET-L-Check Penetrant Dye VP30 PT Level I, PT Level II (DIN EN 473 and SNT-TC 1A)
5 Acceptance criteria
The castings will be evaluated in accordance with DIN EN 1371, DIN 1690 and ASME B16.34. The evaluation at the welding seams will be carried out in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99.
6 Test result
The test was realised without any objection. The requirements of the test references are fulfilled. Manfred Orlowski Inspection Representative
This certification is written digitally and requires no handwritten signature. (Acc. to EN 10204, chapter 5)
Hohenwestedt, xx.xx.200x
LESER GmbH & Co. KG Hamburg HRA 82424
GF · BoD Joachim Klaus, Martin Leser 20537 Hamburg, Wendenstr. 133 – 135 20506 Hamburg, P.O. Box 26 16 51 ( )
Fon +49 (40) 251 65-100 Fax +49 (40) 251 65-500 E-Mail [email protected] Internet www.leser.com
Bank HypoVereinsbank Hamburg BLZ 200 300 00, Konto · Account 3203171 BIC: HYVEDEMM300 IBAN: DE64 2003 0000 0003 2031 71 USt-ID · VAT-Reg DE 118840936
LESER – The Safety Valve
T he S afety V alve
Inspection certificate 3.1 acc. to EN 10204
FLUORESCENT PENETRANT TESTING [Option code M21]
LESER GmbH & Co. KG Postfach 26 16 51 20506 Hamburg, Germany
. . .
Customer Order No.: LESER – Job – No.: LESER-Customers-No.: LESER-Contact: Fon: Fax: eMail:
xxx xxx xxx xxx + 49 (40) 25 165+ 49 (40) 25 165-500 [email protected]
This LESER inspection certificate confirms that the test object was tested according to the undermentioned test references.
1 Test object
xxx xxx xxx
Art.-No. xxxx.xxxx Cold differential test pressure x,xx barg LESER – Job – No. xxx xxx,xx psig Pos.No. xx Option Code: Further SV-Info: xxx xxx Nominal size Inlet xxx xxx xx Outlet xx Pressure rating Inlet xx Outlet xx
Tag – No. xxx
Serial – No.
Body material
Tested component
Pos. xx Description xxx Material xxx Manufacturer xxx Heat No. / Batch xxx
2 Test reference
Flourescent penetrant testing acc. to: AD 2000-Merkblatt A4, chapter 6 ASME Code, Section VIII Div. 1, UG-136 LESER Works Standard LWN 331-04
3 Procedure 4 Test specifiation
Test equipment: Test system: Test media: Qualification of the test personnel: HELLING penetrant facility acc. to EN 571/1 I A – a Penetrant agent MET-L-Check Penetrant HM 405 PT Level I, PT Level II (DIN EN 473 and SNT-TC 1A)
5 Acceptance criteria
The castings will be evaluated in accordance with DIN EN 1371, DIN 1690 and ASME B16.34. The evaluation at the welding seams will be carried out in accordance with regulations and standards for welding seams stipulated in table 19 of LWN 287-99.
6 Test result
The test was realised without any objection. The requirements of the test references are fulfilled. Manfred Orlowski Inspection Representative
This certification is written digitally and requires no handwritten signature. (Acc. to EN 10204, chapter 5)
Hohenwestedt, xx.xx.200x
LESER GmbH & Co. KG Hamburg HRA 82424
GF · BoD Joachim Klaus, Martin Leser 20537 Hamburg, Wendenstr. 133 – 135 20506 Hamburg, P.O. Box 26 16 51 ( )
Fon +49 (40) 251 65-100 Fax +49 (40) 251 65-500 E-Mail [email protected] Internet www.leser.com
Bank HypoVereinsbank Hamburg BLZ 200 300 00, Konto · Account 3203171 BIC: HYVEDEMM300 IBAN: DE64 2003 0000 0003 2031 71 USt-ID · VAT-Reg DE 118840936
LESER – The Safety Valve
