Liquid Penetrant Testing (PT) Level I & II

Liquid Penetrant Testing (PT) Level I & II Course

The Liquid Penetrant Testing (PT) Level I & II Course provides comprehensive training in one of the most widely used non-destructive testing (NDT) methods. Liquid Penetrant Testing is used to detect surface-breaking defects in non-porous materials such as metals, plastics, and ceramics. The course teaches participants how to apply the penetrant, develop the indications, and interpret the results for quality control, weld inspections, and other material evaluations.

Course Objectives:

Level I:

• Understand the basic principles of Liquid Penetrant Testing (PT).
• Learn to properly apply penetrant materials (dye or fluorescent) and develop indications.
• Gain the ability to perform PT inspections following standard procedures under supervision.
• Identify basic surface defects like cracks, porosity, laps, and seams in a variety of materials.

Level II:

• Gain a deeper understanding of penetrant testing techniques and process control.
• Learn advanced techniques for interpreting results and classifying defects.
• Perform independent PT inspections, interpret results, and prepare detailed inspection reports.
• Supervise Level I personnel and ensure compliance with relevant standards and codes.

Key Components of the Course:

1- Introduction to Liquid Penetrant Testing (PT)

• Overview of PT and its importance in detecting surface-breaking defects.
• How penetrants work by seeping into surface defects and becoming visible under proper lighting conditions.
• Advantages of PT over other NDT methods in detecting surface discontinuities.

2- Types of Penetrants and Testing Methods

• Types of penetrants:
  • Visible (dye) penetrants: Provide colored indications visible under white light.
  • Fluorescent penetrants: Provide high-contrast indications visible under UV (black) light.
• Testing methods:
  • Water-washable: Easy removal of excess penetrant with water.
  • Post-emulsifiable: Requires an emulsifier to remove excess penetrant, offering better sensitivity.
  • Solvent-removable: Ideal for field inspections where water is unavailable.

3- Step-by-Step PT Process

• Surface Preparation: Proper cleaning of the test surface to ensure accurate results.
• Penetrant Application: Applying the penetrant and allowing proper dwell time for the penetrant to seep into defects.
• Excess Penetrant Removal: Depending on the type of penetrant, using water, emulsifier, or solvent to remove excess penetrant from the surface.
• Developer Application: Applying a developer to draw penetrant from defects and enhance visibility.
• Inspection: Inspecting under proper lighting (white light for visible penetrants, UV light for fluorescent penetrants) to identify and interpret indications.

4- Types of Defects Detected by PT

• Surface-breaking defects such as:
  • Cracks: Caused by fatigue, overload, or welding.
  • Laps: Imperfections formed during metal forming processes.
  • Seams: Continuous defects running along the length of material.
  • Porosity: Small holes or voids in castings or welds.

5- Sensitivity and Penetrant Performance (Level II)

• Factors affecting sensitivity: How the choice of penetrant, dwell time, and developer affect defect detection.
• Penetrant performance: How to select the right penetrant for different materials and defect sizes.
• Controlling the process: Ensuring consistency in application, dwell times, and cleaning methods for accurate results.

6- Interpretation and Evaluation of Indications (Level II)

• Evaluating indications: Differentiating between relevant, non-relevant, and false indications.
  • Relevant indications: Defects such as cracks or porosity.
  • Non-relevant indications: Appear due to material characteristics or geometry but do not represent defects.
  • False indications: Arise from improper cleaning or excess penetrant left on the surface.
• How to assess the size, location, and nature of defects based on the appearance of the indication.

7- Standards and Codes for Liquid Penetrant Testing

• Key codes and standards used in PT, including:
  • ASME Section V: Nondestructive testing standards for penetrant testing.
  • ASTM E165: Standard practice for liquid penetrant inspection method.
  • AWS D1.1: Structural welding code for PT of welds.
  • ISO 3452: International standard for penetrant testing.
• Acceptance criteria: Understanding the permissible limits for defects in different applications and industries.

8- PT Equipment and Materials

• Penetrant systems: Equipment used for applying penetrants, removing excess penetrant, and applying developers.
• Types of developers:
  • Dry powder: Applied in powder form to absorb penetrant.
  • Solvent-based: Sprayed on the surface for fast results.
  • Aqueous developers: Water-based developers used in industrial applications.
• Proper use of UV lights and inspection tools for detecting and analyzing fluorescent penetrant indications.

9- Reporting and Documentation (Level II)

• How to document PT results in inspection reports.
• Recording information such as dwell times, developer type, lighting conditions, and the location, size, and type of detected defects.
• Preparing repair or rejection recommendations based on defect severity.

10- Practical Applications and Hands-On Training

• Hands-on training with actual PT inspections of various test specimens.
• Performing the full PT process: surface preparation, penetrant application, excess removal, developer application, and inspection.
• Practical exercises in interpreting indications and evaluating defects based on real-world scenarios.

Target Audience:

• NDT Technicians: Looking to specialize in penetrant testing for surface inspections.
• Weld Inspectors: Responsible for ensuring weld quality through surface defect detection.
• Quality Control Inspectors: Involved in detecting surface defects in materials and components.
• Engineers and Supervisors: Overseeing PT inspections and evaluating material integrity.

Certification:

• Level I Certification: Qualified to perform PT inspections under supervision after completing training and exams.
• Level II Certification: Qualified to independently conduct PT inspections, supervise Level I personnel, and prepare inspection reports after completing advanced training and practical exams.