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NDT,WELDING & THIRD PARTY INSPECTION
AN ISO 9001 – 2008 CERTIFIED ORGANISATION
Mr. R. BASKAR A.M.I.E (Mech)
NDT & Welding Consultant ASNT Level – III CSWIP 3.2, AWS – SCWI Reach me @ email@example.com firstname.lastname@example.org
AWS – CWI ( Certified Welding
Inspector) AWS – SCWI AWS – CSWIP 3.1 (BRIDGING) NDT Level I & II API 570 Piping Inspector ISO Lead Audit
Elec. Prod) Diploma (Mech.Auto./M.Sc.Auto..Sc.Meta.INVITING ALL B.. Chemistry. Prod) ITI B.Elec..Meta. Material science) Welders Welding supervisors .E. ( Physics. (Mech.
Potential Opportunities in Oil & Gas Sectors in Gulf Canada India Australia And World wide .
Shastri Street B.O.OUR SERVICES AT H. Peyoli Road Diagonally Opp. 2nd Floor. Peelamedu Varadharaja mill Bus stop Coimbatore – 641 004 Tel: +91 – 422. Puram.600 097 Tel: + 91 .044 – 4272 0054 Mobile No: + 91 98408 00863 Email: Chennai@bitndtindia. 14. 38C/25. Sudheendra Hospital Kacherippady. CHENNAI No. +91 90375 23202 COIMBATORE BRANCH No.com Email: email@example.com COCHIN BRANCH Edatt Building.4371 614 Mobile No: +91 98408 00863 Email: Coimbatore@bitndtindia. 3rd Pillaiyar Kovil Street Ekkattuthangal. 4th Cross Street Behind Athiparasakthi Temple Thillai Nagar. Trichy – 620 018.431 4220 312 Mobile No: +91 98408 00863 Email: trichy@bitndtindia.R.com . 15. Tel: + 91 . Chennai . Eranakulam Kochi – 682 018 Tel: + 91 – 484 – 4050247 Mobile No: +91 98408 00863.com TRICHY BRANCH No.
c om .FOR MORE INFO @ www.bitndtindia.
TESTING DIRECT INDIRECT DESTRUCTIVE NON-DESTRUCTIVE .
. DESTRUCTIVE TESTING (DT) End of the Examination material will get damage and No further use. NON – DESTRUCTIVE TESTING (NDT) End of the Examination material won’t get any damage and use further.
Load resistance capability Toughness .Life calculation (cyclic loading ) Bend test .DESTRUCTIVE TEST METHODS Tensile - Strength Determination Hardness .Energy absorption Fatigue .Ductility (flexibility)determination .
TENSILE TEST .
HARDNESS TEST .
TOUGHNESS TEST .
FATIGUE TEST .
BEND TEST .
MACRO ETCHING .
Destructing Testing Methods Liquid Penetrant Testing Magnetic Particle Testing (PT) (MT) Ultrasonic Testing Radiography Testing Electromagnetic Testing Acoustic Emission Testing Leak Testing Neutron Radiographic Testing Visual Testing Vibration Analysis Testing Thermal/Infrared Testing Proof Testing (UT) (RT) (ET) (AET) (LT) (NRT) (VT) (VA) (TIR) PRT) .Non .
Is specialised technique of material inspection which provide information about the condition of material & component without destroying them.NDT INTRODUCTION What is NDT? NDT/NDE/NDI – Non-Destructive Testing/Evaluation/Inspection. .
NDT is one of the Quality control (QC) tool of various industries. such as. Aircraft Automotive Oil & Gas industry Construction (welding & fabrication) Casting & forging Manufacturing (Pressure vessel/Valve) Petrochemical Refinery Ship building Pipeline Power generation & Nuclear .
save human life & avoid failure To make a profit for user To ensure customer satisfaction & to maintain the manufactures good name To control manufacturing costs To lower manufacturing costs To maintain a uniform quality level Do not change any properties of material . Why NDT? To ensure product reliability To prevent accidents .
length & width) and Evaluation Leak Detection & Location Determination • Dimensional & Coating thickness Measurements Structure and Microstructure Characterization Estimation of Mechanical and Physical Properties Stress (Strain) and Dynamic Response Measurements Material Sorting (conductivity)and Chemical Composition Determination Thickness & Hardness Measurements Heat treatments condition & Corrosion thinning . Uses of NDT Flaw Detection (Depth.
INDUSTRIAL APPLICATIONS NDT Can be applied to all levels of material usage Raw materials Fabrication Finishing In-Service Overhaul .
Common Application of NDT Inspection of Raw Products Inspection Following Secondary Processing In-Services Damage Inspection .
Inspection of Raw Products Forgings Castings Extrusions .
Inspection Following Secondary Processing Machining Welding Grinding Heat treating Plating .
Inspection of In-Service Damage Cracking Corrosion Erosion/Wear Heat Damage .
Inspectors feed eddy current probes into heat exchanger tubes to check for corrosion damage. . Pipe with damage Probe Signals produced by various amounts of corrosion thinning.Power Plant Inspection Periodically. power plants are shutdown for inspection.
cranes and other lifting devices.Electromagnetic devices and visual inspections are used to find broken wires and other damage to the wire rope that is used in chairlifts. Wire Rope Inspection .
Cameras on long articulating arms are used to inspect underground storage tanks for damage. .Storage Tank Inspection Robotic crawlers use ultrasound to inspect the walls of large above ground tanks for signs of thinning due to corrosion.
• Nondestructive testing is used extensively during the manufacturing of aircraft. • A fatigue crack that started at the site of a lightning strike is shown below. • NDT is also used to find cracks and corrosion damage during operation of the aircraft. Aircraft Inspection .
• They are completely disassembled. cleaned. • Fluorescent penetrant inspection is used to check many of the parts for cracking. inspected and then reassembled.Jet Engine Inspection • Aircraft engines are overhauled after being in service for a period of time. .
July 19.A defect that went undetected in an engine disk was responsible for the crash of United Flight 232. CrashSioux City. 1989 232 of United Flight . Iowa.
To protect against this dangerous event. .Pressure Vessel Inspection The failure of a pressure vessel can result in the rapid release of a large amount of energy. the tanks are inspected using radiography and ultrasonic testing.
.Rail Inspection Special cars are used to inspect thousands of miles of rail to find cracks that could lead to a derailment.
000 highway bridges.Bridge Inspection • The US has 578. . • The collapse of the Silver Bridge in 1967 resulted in loss of 47 lives. • Bridges get a visual inspection about every 2 years. • Corrosion. • Some bridges are fitted with acoustic emission sensors that “listen” for sounds of cracks growing. cracking and other damage can all affect a bridge’s performance.
NDT is used to inspect pipelines to prevent leaks that could damage the environment. Visual inspection, radiography and electromagnetic testing are some of the NDT methods used.
Boeing employees in Philadelphia were given the privilege of evaluating the Liberty Bell for damage using NDT techniques. Eddy current methods were used to measure the electrical conductivity of the Bell's bronze casing at a various points to evaluate its uniformity.
For More Information on NDT
The Collaboration for NDT Education www.ndt-ed.org
The American Society for Nondestructive Testing
Selection of the NDT methods In selecting the NDT method for the evaluation of specific discontinuities keep in mind that NDT method may supplement each other & that several NDT methods may be capable of performing the same task. The selection of one method over another is based upon such variables as: Type & origin of discontinuity Material manufacturing processes Accessibility of article Level of acceptability desired Equipment available Cost .
which interferes with the intended service of the material or part and is therefore objectionable. is called a defect. ALL DISCONTINUITIES ARE NOT NECESSARILY DEFECTS. It may not be defect if during the evaluation phase it is determined that the discontinuities interfere with the serviceability of the part or it does not meet the acceptance & rejection criteria. The discontinuity is then classified as a defect. Defect: Any discontinuity. While a discontinuity is an interruption in the normal structure of the part. Discontinuities: Any condition. . is called discontinuities. which breaks the continuity of the material/part. DEFINITIONS Indication: A response or evidence of a response accruing non-destructive tests.
Non Relevant Indication: Non . . (Accept or Reject as per specification) Relevant Indication: Relevant indications are those that are caused by discontinuities in part.relevant indications are caused by part configuration & they are not determine to the serviceability of the part. whether Evaluation: A determination of the significance of relevant indication. Interpretation: The determination of indications are relevant or non-relevant.
. Service Discontinuity: Resulting due to interaction of stress temperature & environment. Discontinuity are grouped into three categories Inherent Discontinuity: Typical of melting. casting & solidification process. Processing Discontinuity: Typical of mechanical working (Hot/cold) welding & heat treatment.
Excess reinforcement Planar flaws are considered more severe than Volumetric flaws because of higher stress concentration associated with them Flaw location Vs severity: Surface flaw is much more severe than internal flaws. Interaction of adjacent flaw: As per ASME boiler & Pressure Vessel Code – XI.Type of Flaw Vs Severity Planar Flaws: Crack. Solid inclusion. Under fill. LOP. LOF. When the spacing between two . Concavity. This is because of higher stress intensity factor associated with surface flaw. Overlap. Undercut & Root concavity Volumetric Flaws: Burn through. Convexity. Slag inclusion & Porosity Weld Profile Defects Undercut.
Construction of Heating Boilers V. ASME . Non-destructive Examination VI. Power Boilers Material specification Part A – Ferrous Material Part B – Non-ferrous Material Part C – Welding rods. Recommended Rules for care & operation of heating boiler VII. III. Electrodes & Filler Metals Part D . Recommended Rules for care of Power Boilers . II.BOILER AND PRESSURE VESSEL CODE SECTIONS I.Properties Subsections NCA(Nuclear component) – General requirements for Division 1 & 2 IV.
Fibre glass – Reinforced Plastic Pressure Vessels XI. Rules for construction transport tankers & continued service of .VIII.Pressure Vessels Division 1 Division 2 – Alternative Rules IX. Welding & Brazing Qualification X. Rules for in service Inspection of Nuclear Power Plant Components – Division 1 XII.
5 ASME B 31.3 API 1104 Structural Welding Bridge Welding code Power Piping Process Piping Cross Country Pipeline .1 code – Steel AWS D 1.SOME IMPORTANT CODES AWS D 1.1 ASME B 31.
ASME SECTION – V FOR NDT TESTING Article 2 – RT Examination Article 5 – UT Examination Article 6 – PT Examination Article 7 – MT Examination Article 9 – VT Examination Article 8 – ET Examination Article 10 –LT Examination .
10 Guide for the Nondestructive Inspection of Welds .Nondestructive Examination (How to look) AWS B1.11 Guide for the Visual Inspection of Welds AWS B1.
ARTICLES – 1 1) PERSONNEL 2) EQUIPMENT 3) PROCEDURE .
Recommended Practice No: SNT – TC – 1A 2001 Society for Non-destructive Testing (SNT) Technical Council – TC First Document – 1A This document is intended as a guideline for employers establish their own written practice for the qualification of nondestructive testing personnel. Personnel Qualification & Certification in Non-destructive Testing. It is not intended to be used as a strict specification: ANSI/ASNT CP – 189 – 1995 ANSI – American National Standard Institute ASNT – The American Society for non destructive testing. American National Standard/ASNT Standard for Qualification & .
specific tests & specific evaluation. Level–I is qualified to perform specific calibration. Trainees shall work with a certified person under the direction on NDT Level II or Level III & shall not independently conduct any tests for or write a report of test results. Interpreting Codes & Designated the test method & technique to be used . Level–III must be capable & responsible for establishing Techniques.Certification of NDT Personnel is the responsibility of the employer & is usually at three levels. Level–II is qualified to set up & calibrate equipment & to interpret & evaluate results with respect to codes standards & specifications must be able to prepare written instructions & report test results. Trainee: A person who is not yet certified to any level shall be considered a trainee.
Personnel shall be examined in the following areas: A. Specific Examination C. General Examination B. Basic Examination .The SNT – TC – 1A Document recommends that Level-I & Level-II NDT Technicians be examined in the following areas: A. Practical Examination The SNT–TC–1A document recommends that NDT Level-III.
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WELDINING DISCONTINUITIES Porosity Undercutting Lack of penetration Slag inclusion Lack of root fusion Cracks Incomplete fusion Tungsten inclusion Internal concavity (suck back) Burning through Overlap .
CASTING DISCONTINUITIES Sand inclusions Gas inclusions Shrinkage Hot tear Crack Cold shut Un fused chaplets Chills .
SLAG INCLUSIONS .
TUNGSTEN INCLUSION .
INTERNAL CONCAVITY .
LACK OF PENETRATION .
BURNING THROUGH .
Lamellar Tearing .
Incomplete Fusion .
Arc Strikes .
Lack of side-wall fusion Lack of root fusion Lack of inter-run fusion Lack of penetration .
MACRO LACK OF SIDEWALL FUSION LACK OF INTER-RUN FUSION & SLAG CLUSTER / WORMHOLE POROSITY LAMINATIONS LACK OF SIDEWALL FUSION & SLAG GAS PORES LACK OF INTER-RUN FUSION ROOT UNDERCUT .
MACRO PHOTOGRAPH LACK OF SIDEWALL FUSION LACK OF SIDEWALL FUSION & SLAG LACK OF SIDEWALL FUSION LACK OF ROOT PENETRATION LACK OF SIDEWALL FUSION .
MACRO ETCHING .
MACRO SLAG INCLUSION INCOMPETELY FILLED GOOVE GAS PORE LACK OF ROOT FUSION .
Plate Sample – Weld Root Welding Process MMA (SMAW) Slag Inclusion Crater Pipe Lack of Root Fusion Lack of Root Penetration Lack of Root Fusion .
arc strikes require blending and crack detection .Weld Cap Welding Process MMA (SMAW) Porosity Incomplete Filled Groove Lack of fusion Cap Undercut Intermittent Slag Inclusion Cap Undercut Intermittent Cap Undercut Intermittent Arc Strike Arc Strike Note: spatter and surface slag requires removal.Plate Sample .
Six Most Common NDT Methods • • • • • • Visual Liquid Penetrate Magnetic Particle Ultrasonic Eddy Current X-ray .
Visual Inspection (VT) .
Visual Inspection Tools .
pipelines. such as air ducts. Bores copes. reactors. Portable video inspection unit with zoom allows inspection of large tanks and vessels.Visual Inspection Tools Most basic and common inspection method. railroad tank cars. sewer lines. Tools include fiberscope. magnifying glasses and mirrors. . Robotic crawlers permit observation in hazardous or tight areas.
cracks. Dimensions& poor penetration . Heat distortion. Under fill. . Flashlights..Visual Inspection Visual Inspection is the most & least common inspection method VT reveals spatter. undercutting. incomplete slag removal. Typical tools for VT consist of Fillet gauges Magnifying glasses. excessive buildup. Bores copes & Tape measures or calipers.
Visual Inspection Gauges Fillet gauges measure The “Legs "of the weld Convexity (weld rounded outward) Concavity (weld rounded inward) Flatness .
GAUGE FOR BUILD UP METAL & UNDERCUT .
lighted area Surface only Good Eye Vision Needs .Visual Examination Advantages Disadvantages Easy • Requires experience Quick Inexpensive Comprehensive Simple tool Need clean.
Visual Inspection .Surface Inspection Dye Penetrate Inspection .
Eddy Current Inspection .Sub-surface Inspection Magnetic Particle Inspection .
Radiographic Inspection .Internal Inspection Ultrasonic Inspection .
Dye Penetrant Inspection .
Liquid Penetrant Inspection Dye Penetrant Inspection (DPI) Penetrant Flaw Detection (PFD) Penetrant Testing (PT) Liquid Penetrant Testing .
. Plastic and Metal PT dose not require the part to be Magnetized. Non-absorbing materials Liquid penetrant inspection uses colored or fluorescent dye to check for surface flaws PT will not show sub-surface flaws PT can be used on Both metallic and Non metallic surfaces such as Ceramic. Glass.Liquid Penetrant Inspection Only for Surface breaking flaw inspection Applicable to all Non-porous.
DYE PENETRANT CONSUMABLES .
PROCESS FLOW CHAT Surface preparation Penetrant application Dwell Time Removal of excess penetrant Drying (Not universally required) Application of developer Inspection Post cleaning and protection .
Penetrant Examination BASIC PRINCIPLE – CAPILLARY ACTION .
Penetrant Inspection Penetrant Application .
Penetrant Inspection Dwell Time .
Penetrant Inspection Excess penetrant removal .
Penetrant Inspection Developer application .
Penetrant Inspection Indication showing .
True Indication – Visible Dye Penetrant Method .
True Indication – Fluorescent Dye Penetrant Method .
Colour Contrast Fluorescent .
Examination Advantages Disadvantages Easy application Cleaning before and after Open Surface flaw only Requires smooth surface Temperature dependent Not applicable to Porous Quick Inexpensive Simple equipment Easy interpretation High Sensitivity metal Applicable to complex Compatibility of Chemicals geometry Non need electric in put .
Magnetic Particle Inspection .
Magnetic Particle Inspection • Method detect surface and sub-surface • • • • indications Applicable only for FERRO Magnetic materials Magnetic field induced in component Maximum depth up to 6mm only Defects revealed by applying ferromagnetic particles .
Basic Principle : Flux Leakage Defect No Defect N S N S .
These particles are attracted to magnetic flux leakage fields and will cluster to form an indication directly over the discontinuity. . This indication can be visually detected under proper lighting conditions. Finely milled iron particles coated with a dye pigment are then applied to the specimen.Magnetic Particle Inspection The part is magnetized.
Defect Orientation Defect at 90 degrees to flux : maximum indication .
Defect Orientation >45 Degrees to Flux Acceptable indication : .
Defect Orientation <45 Degrees to Flux acceptable indication : Un .
Magnetic Particle Visible Indications .
Magnetic Particle Fluorescent Indications .
Examination Advantages Disadvantages Easy to perform Ferromagnetic material only Economical Quick result Can go over thin coating Electricity usually required Arc strikes reduce sensitivity No substantial internal flaw Near surface flaws detectable Reliable Difficult on rough surfaces Requires skill interpreter No permanent record Handy Part should be Clean .
Radiographic Inspection .
Radiation is absorbed by the test piece Thick or dense areas absorb more Thin or open areas absorb less Film measures passed radiation providing indication Light areas represent areas hard to penetrate . Ceasium-137 .Radiographic Examination Radiation is passed through the test piece Test by X –ray or Gamma ray & General depth up to 200mm General gamma ray source – Iridium-192. Cobalt60.
Radiographic Principle – Differential absorption
Lower density Higher density
Radiograph of weld showing: Crack Slag Lack of fusion Porosity Undercut
Radiography The radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. High Electrical Potential Electrons + X-ray Generator or Radioactive Source Creates Radiation Radiation Penetrate the Sample Exposure Recording Device . The radiation can come from an X-ray generator or a radioactive source.
= less exposure = more exposure Top view of developed film . The film darkness (density) will vary with the amount of radiation X-ray film reaching the film through the test object.Film Radiography The part is placed between the radiation source and a piece of film. The part will stop some of the radiation. Thicker and more dense area will stop more of the radiation.
Radiographic Films .
Examination Advantages Disadvantages Detects surface and Planar discontinuity • • internal Provides permanent record (to scale!) Accurate • Direct image of flaws • Real .time imaging Can be used on most materials orientation Radiation hazard Initial cost Requires skilled operators/ interpreters Must access both sides Sensitive to defect orientation Limited ability to detect fine cracks Limited by material .
Ultrasonic Inspection .
A sound wave is directed through tested material Sound waves reflect at interface of different medium General depth detection 200 inch . Sound waves are sent through a transducer into the material and the shift in time require for their return or echo is plotted. Ultrasonic waves will not travel through air therefore flaws will alter the echo pattern.Ultrasonic testing (UT) Ultrasonic testing (UT) is a method of determining the size and location of discontinuities within a component using High frequency sound waves.
and inspector can visualize a cross section of the specimen showing the depth of features that reflect initial sound. f Reflected sound energy is displayed versus time.Impedance High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws. pulse crack echo back surface echo crack 0 2 4 6 8 10 plate Flaw detector screen (CRT screen) .
Sound Spectrum Audible Range 200 kHz 70 kHz 1-5 MHz Usual steel testing range Ultrasonic testing range 16Hz 256 Hz 20 kHz 15 MHz .
UT Field Inspection .
ULTRASONIC INDICATIONS .
size Smooth surface Required Skilled operator required Difficult for Fillet welds • The weld must be reasonably also Versatile & low cost High sensitivity than any other NDT • Does not depend on defect accessible from both sides • There is a dead zone for defect detection close to the surfaces • Is more a sizing tool than a orientation • Defect height can be exactly detecting tool • Need experienced interpreter • Calibration required determined • Permanent print is available . length.Examination Advantages Disadvantages Deep penetration Immediate result Detect depth.
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