Fluor Corporation

Status Date: 22-MAY-2013

Contract: 00A6CV00
CV2 PRODUCTION UNIT EXPANSION
TAG COVER SHEET
_____________________________________________________________________________________________
Date Received: 22-MAY-2013
Supplier: INGENIERIO MANTENIMIENTO
Document Title: DYE PENETRATION TEST PROCEDURE, ACCORDING TO AWS D.1.1

Supplier Doc. No.: NDT-A6CV-4-0201-003 Sheet: Rev:

Projects OnLine Project 22-MAY-2013
Fluor Corporation Cont'l No.: 00A6CV00
4-0201-00007-1

Equip/Tag: Equip/Tag: Equip/Tag: Equip/Tag: Equip/Tag:

C2-3310-BX-107 C2-3310-BX-108 C2-3310-BX-207 C2-3310-BX-208 C2-3310-BX-307
C2-3310-BX-308 C2-3310-BX-407 C2-3310-BX-408 C2-3310-BX-507 C2-3310-BX-508
C2-3310-BX-607 C2-3310-BX-608 C2-3310-ST-107 C2-3310-ST-108 C2-3310-ST-207
C2-3310-ST-208 C2-3310-ST-307 C2-3310-ST-308 C2-3310-ST-407 C2-3310-ST-408
C2-3310-ST-507 C2-3310-ST-508 C2-3310-ST-607 C2-3310-ST-608 C2-3320-LA-101
C2-3320-LA-201 C2-3320-LA-301 C2-3320-LA-401 C2-3320-LA-501 C2-3320-LA-601
C2-3320-ST-109 C2-3320-ST-190 C2-3320-ST-209 C2-3320-ST-290 C2-3320-ST-309
C2-3320-ST-390 C2-3320-ST-409 C2-3320-ST-490 C2-3320-ST-509 C2-3320-ST-590
C2-3320-ST-609 C2-3320-ST-690 C2-3330-ST-130 C2-3330-ST-230 C2-3330-ST-330
C2-3330-ST-430 C2-3330-ST-530 C2-3330-ST-630 C2-3330-ST-701 C2-3330-ST-702
C2-3330-ST-703 C2-3330-ST-704 C2-3330-ST-705 C2-3330-ST-706 C2-3410-BX-051
C2-3410-BX-514 C2-3410-LA-103 C2-3410-LA-104 C2-3410-LA-203 C2-3410-LA-204
C2-3410-LA-303 C2-3410-LA-304 C2-3410-LA-403 C2-3410-LA-404 C2-3410-LA-503
C2-3410-LA-504 C2-3410-LA-506 C2-3410-LA-508 C2-3410-LA-511 C2-3410-LA-512
C2-3410-LA-513 C2-3410-LA-514 C2-3410-LA-515 C2-3410-LA-603 C2-3410-LA-604
C2-3420-BX-403 C2-3420-BX-502 C2-3420-BX-503 C2-3420-BX-504 C2-3420-BX-505
C2-3420-BX-506 C2-3420-BX-510 C2-3420-BX-513 C2-3420-DI-403 C2-3420-DI-501
C2-3420-DI-502 C2-3420-LA-051 C2-3420-LA-052 C2-3420-LA-053 C2-3420-LA-054
C2-3430-BX-511 C2-3430-BX-515 C2-3430-DI-520 C2-3510-BN-603 C2-3510-BX-600
C2-3510-BX-603 C2-3510-BX-604 C2-3510-BX-605 C2-3510-BX-606 C2-3510-BX-609
C2-3510-BX-610 C2-3510-BX-611 C2-3510-BX-612 C2-3510-BX-614 C2-3510-BX-615
C2-3510-BX-616 C2-3510-BX-617 C2-3510-LA-600

07-Jun-2013 GT623_SUP_TAG_COV_SHT.REP Page 6

 PROCEDURES MANUAL NDT-A6CV-4-0201-003

Revisión: 00
PROYECT : FABRICATED RUBBER LINED PLATEWORK Fecha: 29/04/2013
DYE PENETRATION TEST PROCEDURE ACCORDING AWS D1.1
Pág. 1 de 1

A – PROCEED ®

Authorization to proceed does not relieve Contractor/Supplier of its

responsibility or liability under the Contract and or Purchase Order.
By Lara Lambiotte on Jun 06, 2013

DYE PENETRATION TEST PROCEDURE ACCORDING AWS D1.1

REV. 00

CODIGO: NDT-A6CV-4-0201-003

PROYECT: FABRICATED RUBBER LINED PLATEWORK

EMISSION CONTROL AND CHANGES

Rev.
Date Description Issued Translated Approved by:
Nº

00 29/04/13 Issued for Client Review E. Ramos T. Polleri R. Jara

Signatures of the current revision

All Tags
 PROCEDURES MANUAL NDT-A6CV-4-0201-003

Revisión: 00
PROYECT : FABRICATED RUBBER LINED PLATEWORK Fecha: 29/04/2013
DYE PENETRATION TEST PROCEDURE ACCORDING AWS D1.1
Pág. 2 de 2

INDEX

1. OBJETIVE
2. SCOPE
3. DEFINITIONS
4. APPLICABLE DOCUMENTATION
5. RESPONSIBILITIES
6. DEVELOPMENT
7. RESOURCES
8. ACCEPTANCE
9. PROGRESS REPORTING METHOD
10. APPENDIX
 PROCEDURES MANUAL NDT-A6CV-4-0201-003

Revisión: 00
PROYECT : FABRICATED RUBBER LINED PLATEWORK Fecha: 29/04/2013
DYE PENETRATION TEST PROCEDURE ACCORDING AWS D1.1
Pág. 3 de 3

1. OBJECTIVE

• To establish a method of execution that will guaranty to perform the weld dye penetration test
in a correct manner. The test will be performed on diverse structures produced in the plant.
• The objective of the basic nondestructive Dye Penetration Test is to reveal any discontinuities
on the welding stripe by coloring imperfection against a contrasting background.

2. SCOPE

The present procedure established the method and the acceptance criteria for the inspection by
dye penetration on structures and others. The test can detect defects that may cause problems
during commissioning of the fabrication. The test help ensure that the fabrications comply with
the technical specification and particular requirements.

3. DEFINITIONS

Client: Organization or person that receives a product and/or service provided by IMCO
Servicios S.A.C.

Procedures: Description of the activities, means and mechanisms that control the parameters
and standards of development in a unit.

Customer Satisfaction: Perception of the client about the level of fulfillment of his/her needs.

Surface Tension: Surface tension is a property of the surface of a liquid that allows it to resist an
external force.

Humidifying Power: The penetrating dye has to be capable of completely wetting the surface of
the material. This refers to the angle of contact between the liquid and the surface which has to
be as low as possible.

Viscosity: This property does not produce any effect on the ability of the liquid to penetrate the
surface but it affects the speed of penetration. High viscosity liquids penetrate very slowly and
vice versa. Low viscosity liquids may not be retained on surfaces with defects so a medium
viscosity is recommended.

Volatility: Penetrant liquids shall not be volatile. If there is an excessive amount of evaporation of
the penetrant products, the sensitivity of the whole process may be affected due to an unbalance
of the formula such as the loss of humidifying power.
 PROCEDURES MANUAL NDT-A6CV-4-0201-003

Revisión: 00
PROYECT : FABRICATED RUBBER LINED PLATEWORK Fecha: 29/04/2013
DYE PENETRATION TEST PROCEDURE ACCORDING AWS D1.1
Pág. 4 de 4

Specific Gravity: It does not play an important role on the behavior of the penetrant liquid. Never
the less small specific gravities facilitate the transportation of strain material that may set in the
bottom of open tanks. The majority of penetrant liquids have relative specific gravities that vary
between 0.86 and 1.06 at 16 degrees Celsius.

Combustion Point: As a practical safety measurement, penetrating dye shall have a high
combustion point in order to reduce chances of fire. As a general rule the combustion point shall
be higher than 95 °C in open containers and not less than de 65 °C.

Non reactivity: The products used as penetrating liquids shall be non-corrosive and non-reactive
with the materials to be tested and/or their containers.

Solubility: The liquid shall be capable of containing large concentrations of dissolved pigments
and fluorescents.

4. APPLICABLE DOCUMENTATION
The following documents apply to this procedure
• Quality Control Management Manual
• Quality Plan
• AWS D1.1 Structural Welding Code Steel
• Client specifications.

5.- PERSONNEL REQUIREMENTS

The personnel that will perform these tests, is to be well capacitated, certified as an ASTN Level II
according to the recommended practice as sated on ASNT SNT-TC-1, 2006 edition.

6. DEVELOPMENT
A. PREVIOUS WORK
Before proceeding with the Dye Penetration Test a visual inspection is required to detect any
defects on the welds before they impede the correct execution of the test.
Give up recommendations before starting the task, i.e. communicate the procedure for dye
penetration test.
Coordinate with the Production department, Quality Control, Safety Department, Technical
Office and supervision about this procedure and the required action for the correct execution
of the task.
B. SURFACE PREPARATION
• Surface cleaning: All the surfaces to be examined and 25mm on each side shall be dry and
free of all contaminants that may interfere with the test (oxidation, grease, paint, oil, previous
tests residue, etc.)
 PROCEDURES MANUAL NDT-A6CV-4-0201-003

Revisión: 00
PROYECT : FABRICATED RUBBER LINED PLATEWORK Fecha: 29/04/2013
DYE PENETRATION TEST PROCEDURE ACCORDING AWS D1.1
Pág. 5 de 5

• Mechanical methods such as grinding, sanding or liquid methods such as solvents can be
used.
C. MATERIALS AND CLEANING PRODUCTS
For surface cleaning the removers listed on table 7.1 can be used. A clean and dry industrial
cloth can be used to clean the surface.
• Cleaner: Water, remover of the line of penetrant liquids.
• Penetrant Dye, Reveler and Remover: High prestige products shall be used.

MAKER DYE REMOVER REVELATOR TYPE APPLICATION

MAGNAFLUX
SPOTCHECK SKL - SP SKC – S SKD – S2 B-3 Aerosol
PENETRANT

CANTESCO P101S-A C101-A D101-A TP2 Aerosol

MET-L-CHECK VT 31 A E-59A D 70 TP1 Aerosol

Penetrant
CROWN Cleaner 1071 Revelador 1073 TP1 Aerosol
1072

ZYGLO
ZL 60D SKC S ZP 9F A-1 Aerosol
PENETRANT

SHERWIN
DP - 40 DR – 60 D - 100 B-3 Aerosol
INCORPORATED

D. DRYING TIMES FOR THE PRODUCTS USED ON SURFACE CLEANING

• It is necessary that the piece is completely dry after cleaning to avoid liquid residues affecting
the penetrating dye.
• The drying process can be performed with compressed air at room temperature or hot air with
a temperature lower than 52º C, for a minimum time of 5 to 10 minutes.

E. APPLICATION METHOD OF THE PENETRANT DYE AND PENETRATION TIME

• The penetrating dye can be applied by means of spray or brush, in way that the whole area to
be examined is completely covers in dye with a homogenous layer.
• The minimum penetration time is indicated by the maker of the dye but it shall be in no case
lower than 10 to 15 minutes.
 PROCEDURES MANUAL NDT-A6CV-4-0201-003

Revisión: 00
PROYECT : FABRICATED RUBBER LINED PLATEWORK Fecha: 29/04/2013
DYE PENETRATION TEST PROCEDURE ACCORDING AWS D1.1
Pág. 6 de 6

F. TEMPERATURE LIMIT FOR THE APPLICATION OF THE PENETRATING DYE

During the execution of the test, both the object surface and the penetrating dye shall be a
temperature of 16 to 52º C.

G. METHOD TO REMOVE THE EXCEEDING PENETRATING DYE

• Water removable dye (B1/A1)
Absorbent, dry, clean material shall be use humidified with water and it is to be scoured on the
surface. The use of pneumatic guns with a water pressure of 50 psi and a temperature range
between 16º y 43º C is also allowed.

• Solvent removable dye (B3/A3)

Absorbent, dry, clean material shall be use, Remove surplus materials with the cloth
humidified with solvent. Maximum care shall be taking in avoiding materials that may harm the
test results, such as cloth that may contain grease or oil, or cloth that leaves trail marks,
threads, or dust.

H. DRYING METHOD BEFORE APPLYING THE REVEALER

• Water removable dye

In this case the surface must be dry to apply the revealer in a non-watery suspension. In this
case the drying procedure can be performed with a clean absorbent material or by air
circulation as long as the surface temperature does not exceed 52º C.
• Solvent removable dye
In this case after the after removing the exceeding penetrating dye the surface shall be left to
dry by normal evaporation, compressed air may be used to speed up the process. For normal
evaporation the waiting time shall not be smaller than 5 minutes.

I. TIME ALLOWANCES AND METHOD OF APPLICATION OF THE REVEALER

• The revealer shall be applied immediately after the excess dye has being removed and the
surface has being dried in a maximum interval of 20 minutes. The application method shall be
by spray or pneumatic gun, taking into account that the gun shall have filters to avoid
contamination of the dye.
• Brushes are not allowed to be used as application method of the revealer.
• For the application of the revealer, the container shall be shaking to achieve the homogeneity
of the product.
• The application of the revealer shall be perform in order to obtain a thin uniform layer over the
examined surface.
 PROCEDURES MANUAL NDT-A6CV-4-0201-003

Revisión: 00
PROYECT : FABRICATED RUBBER LINED PLATEWORK Fecha: 29/04/2013
DYE PENETRATION TEST PROCEDURE ACCORDING AWS D1.1
Pág. 7 de 7

J. DESCRIPTION OF THE EXECUTION OF THE TEST

• The penetrating dye shall be applied over the whole surface to penetrate all possible
discontinuities.
• All exceeding penetrating dye is to be removed and over the dry surface the revealer is
applied, the revealer fulfills the function of absorbing the imprisoned dye and provides a
contrasting background that improves the visibility of imperfections.
• The test shall be performed under good lighting conditions to ensure that the inspection is
performed correctly. The minimum luminosity is 1000 lux.
• If the surface is too large to be tested on the timeframe stated bellow, the test shall be
performed on stages by dividing the surface area in adequate parts which will be tested.
• The final interpretation of the test will be performed in a timeframe of 7 to 30 minutes after the
application of the revealer, allowing the penetrating dye to be absorbed by the revealer.

K. RESULT REGISTRY
The method used to identify the reference point for the mapping of the testing zones shall
maintain the same orientation as the drawing used to fabricate the pieces. The
reference/identification points shall obey the following criteria:
Sheet:
A zero (0) coordinate will be placed as indicated in the following graph. The region that contains
imperfections will be marked with a crayon on the sheet.
The registry shall contain the values of the coordinated to the center of the affected area as
shown in the (graph).
 PROCEDURES MANUAL NDT-A6CV-4-0201-003

Revisión: 00
PROYECT : FABRICATED RUBBER LINED PLATEWORK Fecha: 29/04/2013
DYE PENETRATION TEST PROCEDURE ACCORDING AWS D1.1
Pág. 8 de 8

Join Welds
The zero reference point shall be placed in the center of the intersection between the longitudinal
and the round welds. Usually from left to right on longitudinal welds and in a clockwise direction
on round welds.

The examined regions shall correlate to the test registries where the following shall be stated:
• Design Reference
• Sketch of the examined piece
• Identification of the examined areas
• Reference Points

7. RESOURCES
The necessary resources for this task are:
• Personnel:
- 01 Welding Supervisor
- 01 QC Supervisor Level II PT. SNT TC-1A.
- Welders assigned to the task
• Equipment
- Penetrating Dye Kit
- Industrial Cloth
- Hand Brush
- Circular Brush

8. ACCEPTANCE
Acceptance related to the size of the imperfection. Only imperfection with dimensions larger than
1/16’’ are considered relevant.
An imperfection is linear when its length is larger than three times its width.
An imperfection is round if its length is less than three times its width.
No imperfection is to be reexamined unless it is considered relevant
All examined surfaces shall be free of:
• Relevant linear imperfections
• Round imperfections larger than 3/16’’
 PROCEDURES MANUAL NDT-A6CV-4-0201-003

Revisión: 00
PROYECT : FABRICATED RUBBER LINED PLATEWORK Fecha: 29/04/2013
DYE PENETRATION TEST PROCEDURE ACCORDING AWS D1.1
Pág. 9 de 9

• Four or more imperfection in a line separated by 1/16’’ or less.

9. PROGRESS REPORTING METHOD

• Daily report of the Dye Penetration Test
• Spread this procedure with talks
• Constant verification of the tolerances stated in this procedure.

10. APPENDIX
• Dye Penetration test Registry QC-M-111