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DIRECTOR INFO
Mr. R. BASKAR A.M.I.E (Mech)
NDT & Welding Consultant ASNT Level III CSWIP 3.2, AWS SCWI Reach me @ rbaskar@bitndtindia.com bitndtchennai@gmail.com
US PROVIDING
AWS CWI ( Certified Welding
Inspector) AWS SCWI AWS CSWIP 3.1 (BRIDGING) NDT Level I & II API 570 Piping Inspector ISO Lead Audit
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Welders
Welding supervisors
Potential Opportunities in
Oil & Gas Sectors in
OUR SERVICES
AT
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No. 15, Shastri Street B.R. Puram, Peelamedu Varadharaja mill Bus stop Coimbatore 641 004 Tel: +91 422- 4371 614 Mobile No: +91 98408 00863 Email: Coimbatore@bitndtindia.com
Email: kochi@bitndtindia.com
www.bitndtindia.c om
(NDE)
TESTING
DIRECT
INDIRECT
DESTRUCTIVE
NON-DESTRUCTIVE
DESTRUCTIVE
TESTING (DT)
End of the Examination material will get damage and No further use.
Strength
Determination Hardness - Load resistance capability Toughness - Energy absorption Fatigue - Life calculation (cyclic loading ) Bend test - Ductility (flexibility)determination
TENSILE TEST
HARDNESS TEST
TOUGHNESS TEST
FATIGUE TEST
BEND TEST
MACRO ETCHING
Non - 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)
NDT INTRODUCTION
What is NDT?
NDT/NDE/NDI Non-Destructive Testing/Evaluation/Inspection. Is specialised technique of material inspection which
provide information about the condition of material & component without destroying them.
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
Why NDT?
To ensure product reliability
To prevent accidents , 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
Uses of NDT
Flaw Detection (Depth, length & width) and Evaluation
Leak Detection & Location Determination
Overhaul
Common Application of
NDT
Inspection of Raw Products Inspection Following Secondary
Processing
In-Services Damage Inspection
Electromagnetic devices and visual inspections are used to find broken wires and other damage to the wire rope that is used in chairlifts, cranes and other lifting devices.
Nondestructive testing is used extensively during the manufacturing of aircraft. NDT is also used to find cracks and corrosion damage during operation of the aircraft. A fatigue crack that started at the site of a lightning strike is shown below.
Aircraft Inspection
A defect that went undetected in an engine disk was responsible for the crash of United Flight 232.
Rail Inspection
Special cars are used to inspect thousands of miles of rail to find cracks that could lead to a derailment.
Corrosion, cracking and other damage can all affect a bridges performance.
The collapse of the Silver Bridge in 1967 resulted in loss of 47 lives. Bridges get a visual inspection about every 2 years. Some bridges are fitted with acoustic emission sensors that listen for sounds of cracks growing.
Pipeline Inspection
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.
Special Measurements
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.
www.asnt.org
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
non-destructive tests.
Discontinuities: Any condition, which breaks the continuity
structure of the part. 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, which interferes with the intended service of the material or part and is therefore objectionable, is called a defect.
Interpretation:
whether
Discontinuity are grouped into three categories Inherent Discontinuity: Typical of melting, casting
Processing Discontinuity: Typical of mechanical working (Hot/cold) welding & heat treatment.
Root
concavity
Volumetric Flaws: Burn through, Solid inclusion, Slag
severe than internal flaws. This is because of higher stress intensity factor associated with surface flaw.
Interaction of adjacent flaw: As per ASME boiler &
III.
Power Boilers Material specification Part A Ferrous Material Part B Non-ferrous Material Part C Welding rods, Electrodes & Filler Metals Part D - Properties Subsections NCA(Nuclear component) General requirements for Division 1 & 2
V. Non-destructive Examination
VI. Recommended Rules for care & operation of heating boiler VII. Recommended Rules for care of Power Boilers
VIII.Pressure Vessels
Structural Welding Bridge Welding code Power Piping Process Piping Cross Country
Pipeline
Article 5 UT Examination
Article 6 PT Examination Article 7 MT Examination
Article 9 VT Examination
Article 8 ET Examination Article 10 LT Examination
ARTICLES 1
1) PERSONNEL
2) EQUIPMENT
3) PROCEDURE
Personnel
Qualification
&
Certification
in Non-destructive
Testing.
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. It is not intended to be used as a strict specification:
ANSI/ASNT CP 189 1995 ANSI American National Standard Institute
Certification
of NDT Personnel is the responsibility of the employer & is usually at three levels.
Trainee: A person who is not yet certified to any level shall be considered a trainee. 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. LevelI is qualified to perform specific calibration, specific tests & specific evaluation.
LevelII 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. LevelIII must be capable & responsible for establishing Techniques, Interpreting Codes & Designated the test method & technique to be used
recommends that Level-I & Level-II NDT Technicians be examined in the following areas:
A. General Examination B. Specific Examination C. Practical Examination
Slide 4 of 81
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
Porosity
SLAG INCLUSIONS
TUNGSTEN INCLUSION
Undercut
INTERNAL CONCAVITY
LACK OF PENETRATION
BURNING THROUGH
MIS-ALIGNMENT
Lamellar Tearing
Incomplete Fusion
SPATTERS
Arc Strikes
CRACKS
OVERLAP
Lack of penetration
MACRO
LACK OF SIDEWALL FUSION LACK OF INTER-RUN FUSION & SLAG
ROOT UNDERCUT
MACRO PHOTOGRAPH
LACK OF SIDEWALL FUSION
LACK OF SIDEWALL FUSION & SLAG
MACRO ETCHING
MACRO
SLAG INCLUSION
GAS PORE
Porosity
Arc Strike
Arc Strike
Visual Inspection
Visual Inspection is the most & least common
inspection method
VT reveals spatter, excessive buildup, incomplete
slag removal, cracks, Heat distortion, undercutting, Under fill, Dimensions& poor penetration ..
Typical tools for VT consist of Fillet gauges
Visual Examination
Advantages Disadvantages
Easy Requires experience
Quick
Inexpensive Comprehensive Simple tool
Visual Inspection
Sub-surface Inspection
Internal Inspection
Ultrasonic Inspection
.
Radiographic Inspection
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, Plastic and Metal PT dose not require the part to be Magnetized.
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
Colour Contrast
Fluorescent
Quick
Inexpensive Simple equipment
Easy interpretation
High Sensitivity
metal Applicable to complex Compatibility of Chemicals geometry Non need electric in put
indications Applicable only for FERRO Magnetic materials Magnetic field induced in component Maximum depth up to 6mm only Defects revealed by applying ferromagnetic particles
Defect Orientation
Defect Orientation
Defect Orientation
Un
Examination
Advantages Disadvantages
Easy to perform Ferromagnetic material only
Economical
Quick result Can go over thin coating
Handy
Radiographic Inspection
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, Ceasium-137 . 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
Radiation Source
Radiographic Inspection
Lower density Higher density
Radiographic Inspection
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. The radiation can come from an X-ray generator or a radioactive source.
High Electrical Potential
Electrons
+ X-ray Generator or Radioactive Source Creates Radiation
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. The film darkness (density) will vary with the amount of radiation X-ray film reaching the film through the test object. = less exposure = more exposure
Top view of developed film
Radiographic Films
Examination
Advantages Disadvantages
Detects surface and
Planar discontinuity
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
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. 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. A sound wave is directed through tested material Sound waves reflect at interface of different medium General depth detection 200 inch
Impedance
High frequency sound waves are introduced into a material and they are reflected back from surfaces or flaws.
f Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect initial sound. pulse
crack echo
crack
0 2 4 6 8 10
plate
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
Inspection
Inspection
UT Field Inspection
ULTRASONIC INDICATIONS
Examination
Advantages Disadvantages
Deep penetration Immediate result Detect depth, length, 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
orientation
Defect height can be exactly
detecting tool
Need experienced interpreter
Calibration required
determined
Permanent print is available