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Element 5 – Work Equipment 2. Any defects are shown up by the differences in the intensity of the radiation striking the film.
3. The benefits of this technique are that it detects internal defects and produces a permanent
record of the test.
1. Jul 08-E4-Q9-20
Disadvantages
Question 9 Corrosion is a major problem in many industrial processes.
• However, the operation is time-consuming, expensive and requires bulky equipment and
(a) Outline the characteristics and causal factors of electrolytic corrosion. (8)
skilled radiographers.
(b) Outline the strategies AND methods for identifying potential corrosion failures. (12)
• Additionally, there is the danger of radiation exposure.
Part (a)
1. Electrolytic corrosion is an electrochemical process in which one metal corrodes preferentially Finally, using an ultrasonic technique, advantages
when in electrical contact with a different type of metal and both metals are immersed in an 1. Short pulses of high frequency ultrasound are used on welded joints, with the reflected waves
electrolyte. being detected and shown on an oscilloscope or digital display.
2. The metals have different electrode potentials and the electrolyte provides a means for ion 2. This technique detects both surface and sub-surface defects, requires access to one side of the
migration whereby metallic ions can move from the anode to the cathode. joint.
3. This leads to the anodic metal corroding more quickly than it otherwise would whereas the 3. Only and takes little time with portable equipment that can be used in most environments.
Disadvantages
corrosion of the cathodic metal is retarded.
The limitations of the technique are that it requires a high level of expertise and coupling the
equipment probe onto rough surfaces can be difficult.
Characteristics of corrosion include pitting and erosion and its products may affect quality of
product and may lead to a reduction in flow in pipe work.
2. Jan08-E5-Q11-20
Question 11 (a) Organisations may use a range of reactive and proactive strategies for plant
Part (b)
maintenance. Identify FOUR possible plant maintenance strategies AND outline the principles of
1. A strategy to prevent corrosion would aim to interrupt the formation of a corrosion cell by the
removal of electrical contact or the removal of the electrolyte. EACH strategy. (10)
2. Removal of electrical contact can be achieved by insulation using plastic or a similar
insulating material, or by the use of protective coatings such as galvanising or painting.
3. Additional methods of preventing corrosion include – Page 1 of 9
o use of a sacrificial anode made of a metal which is more active than the protected metal
o connection of an electrical power supply to oppose the corrosive current
o use of water treatment and/or purification techniques.
4. The use of visual inspections and NDT are a means of identifying the effects of corrosion as
is also checking for the presence of contaminant in the product and the use of corrosion
measure currents.
1. Jul 07-E5-Q7-20, Jul 09-E5-Q3-10 & Jul 11-E5-Q4-10
Question 7 Outline the principles, advantages and disadvantages of:
(a) Dye penetrant;
(b) Magnetic particle inspection;
(c) Radiography;
(d) Ultrasonics as methods of non-destructive testing on the welded joints of a safety critical vessel.
(20)
This question was generally approached logically by taking each technique in turn and outlining its
particular advantages and limitations.
In answering part (a) Examiners were looking for answers that gave an outline of the principles of use
of dye penetrant advantages
1. A liquid penetrant is sprayed onto the test piece, the excess is wiped off and
2. An absorbent powder is then sprayed on which draws to the surface
3. Any penetrant that has seeped in to any cracks which will then highlight any defects.
The advantages are that the use of a
• Dye penetrant method is relatively cheap and is a simple operation.
The disadvantages are that
• It does not detect sub-surface faults,
• is not totally reliable and
• Interpretation of the indications may be difficult (although enhancement can sometimes be
achieved by using a fluorescent penetrant with a UV source).
• Additionally, the penetrant used may have toxic properties.
In part (b) magnetic particle inspection advantages
1. Involves coating the joint to be tested with magnetic particles that may be in powder form or within
a liquid.
2. It is a simple and quick operation
3. Very sensitive to surface cracks and,
4. In certain circumstances, can detect sub-surface defects.
Disadvantages
• Is that the interpretation of results may be difficult, particularly on the inside surface of a
pressure vessel.
In part (c) with radiography, advantages