PENETRANT TESTING (PT) – Level 1- MC-112-1

[block border=”5px solid #aacb24″ padding=”10px 15px”]

[/block]

PENETRANT TESTING  PT)

Liquid penetrant inspection is a nondestructive testing method that reveals surface breaking flaws by bleedout of a penetrating liquid colored with a visible or fluorescent dye from the flaw. The technique is based on the ability of a liquid to be drawn into a “clean” (in other words, unobstructed) surface breaking flaw by capillary action. After an appropriate period of time for penetration has papsed, called the “dwell time,” excess penetrant on the surface is removed and a developer applied. The developer acts as a blotter and draws the penetrant from the flaw to reveal its presence. Penetrants with a visible dyed added (color contrast) require sufficient white light to insure proper inspection, while penetrants with a fluorescent dye added need to be used in darkened conditions with an ultraviolet or “black light”. This method is used to inspect a variety of product forms including castings, forgings, and weldments. The structural steel, automotive, petrochemical, power generation, and aerospace industries are a few examples that utilize liquid penetrant inspection.

COURSE DESCRIPTION

The course provides a full appreciation in the techniques and methods of penetrant testing. A high theory and practical content is offered by the course. The course will suit a wide variety of NDT personnel including QC inspectors and technicians and relates to the inspection of forging, casting and welded structures.

WHO SHOULD ATTEND
This course is opened to all participants, in participant NDT personnel, supervisors, NDT trainers, contractors and researchers and those who are interested in Liquid Penetrant Testing technique.

COURSE CONTENTS :

SCOPE
This course covers the principles of Liquid Penetrant Testing and prepares a candidate to
• Select equipment to conduct test
• Setup test equipment
• Steps to conduct test
• Familiarize with codes and standards
• Interpret results with respect to applicable written instruction
• Understand limitation of the test method
• Write test reports.

TRAINING
Training material is presented in modules that are followed by quizzes

PERSONNEL CERTIFICATION SCHEME
Sijil Kemahiran Malaysia (SKM)
Training, experience and examination requirements
Training Requirements
• Recommended Course Outline
• Training Hours
• Practical
• Quizzes and examinations

MODULE 1: MANUFACTURING DISCONTINUITIES
• Types of Discontinuities: Inherent, Processing and Service
• Casting Discontinuities: Hot Tear, Cold Shut, Porosity, Shrinkage
• Primary Processing Discontinuities including discontinuities in Rolling,
Forging, Drawing, Extruding
• Secondary Processing Discontinuities including discontinuities in Grinding,
Heat Treating, Machining, Welding, Plating
• Service Discontinuities:- Erosion, Wear, Fatigue, Corrosion, Creep

MODULE 2: PRINCIPLES
• Purpose of Liquid Penetrant Testing
• Physical Principles
• Wetting Characteristics and Contact Angle
• Wetting Ability
• Force of Cohesion and Surface Tension
• Capillary Action
• Viscosity
• Reversed Capillary Action
• Visibility of Indication
• Categories of Test Processes
• Types of Dye: Type I (Fluorescent) and Type II (Visible)
• Methods of Removal of excess Penetrant including Water Washable, Emulsifiers and Solvent Removable
• Sensitivity Levels – ½, 1, 2, 3, 4
• Selection of Process
• Limitations of Penetrant Testing

MODULE 3: BASIC STEPS
This module covers the basic steps involved in the following processes
• Method A – Water Washable
• Method B – Lipophilic Emulsifier
• Method C – Solvent Removable
• Method D – Hydrophilic Emulsifier

MODULE 4: PRE AND POST CLEANING
• Choice of Cleaning Method
• Different Cleaning Methods including Detergent, Solvent, Alkaline, Steam, Ultrasonic cleaning, Vapor Degreasing

MODULE 5: APPLICATION OF PENETRANTS AND DEVELOPERS
• Selection of Penetrant Materials

• Cleaners
• Penetrant
• Developer
• Selection based on family

• Application of Penetrant
• Standard Temperature Limits
• Dwell time
• Drying
• Drying Parameters
• Drying Time Limits
• Application of Developers

• Types of Developers

• Aqueous
• Non-Aqueous

• Developing Time

• Fluorescent Inspection

• Black Light Warm Up Time
• Minimum intensity and light meter
• Visual Adaptation

• Visible Inspection

• Minimum light intensity and light meter

• Post Cleaning

• Limitation of Penetrant Testing

MODULE 6: INTERPRETATION
• Interpretation of Test Results as per written instruction
• Flow Chart for Interpretation
• True, False, Relevant and Non Relevant indications
• Categories of Indications: – Rounded and Linear
• Evaluation of Indications (follow written instruction)

MODULE 7: WRITTEN INSTRUCTION (Specific Training)

PRACTICAL TRAINING
Test on component and weld samples

Visible
• Solvent Removable

Fluorescent
• Water Washable
• Solvent Removable
• Emulsifier both Hydrophilic and Lipophilic
• Tests on component and weld samples

EXAMINATIONS
• General
• Specific
• Practical Tests

Candidates must score a minimum of 70 % in each test