BIT INSPECTION TECHNOLOGY

NDT,WELDING & THIRD PARTY INSPECTION

AN ISO 9001 2008 CERTIFIED ORGANISATION

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
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Inspector) AWS SCWI AWS CSWIP 3.1 (BRIDGING) NDT Level I & II API 570 Piping Inspector ISO Lead Audit

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(NDE)

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 wont get any damage

and use further.

DESTRUCTIVE TEST METHODS

Tensile

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

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

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

Power Plant Inspection

Periodically, power plants are shutdown for inspection. 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.

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.

Wire Rope Inspection

Storage Tank Inspection

Robotic crawlers use ultrasound to inspect the walls of large above ground tanks for signs of thinning due to corrosion. Cameras on long articulating arms are used to inspect underground storage tanks for damage.

 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

Jet Engine Inspection

Aircraft engines are overhauled after being in service for a period of time. They are completely disassembled, cleaned, inspected and then reassembled. Fluorescent penetrant inspection is used to check many of the parts for cracking.

A defect that went undetected in an engine disk was responsible for the crash of United Flight 232.

CrashSioux City, Iowa, July 19, 1989 232 of United Flight

Pressure Vessel Inspection

The failure of a pressure vessel can result in the rapid release of a large amount of energy. To protect against this dangerous event, 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.

Bridge Inspection The US has 578,000

highway bridges.

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.

For More Information on NDT

The Collaboration for NDT Education www.ndt-ed.org
The American Society for Nondestructive Testing

www.asnt.org

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

 DEFINITIONS Indication: A response or evidence of a response accruing

non-destructive tests.
Discontinuities: Any condition, which breaks the continuity

of the material/part, is called discontinuities.

While a discontinuity is an interruption in the normal

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.

ALL DISCONTINUITIES ARE NOT NECESSARILY DEFECTS.

 Interpretation:

The determination of indications are relevant or non-relevant.

whether

Evaluation: A determination of the significance of

relevant indication. (Accept or Reject as per specification)

Relevant Indication: Relevant indications are those

that are caused by discontinuities in part.

Non Relevant Indication: Non - relevant indications are caused by part configuration & they are not determine to the serviceability of the part.

 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.

Service Discontinuity: Resulting due to interaction

of stress temperature & environment.

Type of Flaw Vs Severity

Planar Flaws: Crack, LOF, LOP, Undercut &

Root

concavity
Volumetric Flaws: Burn through, Solid inclusion, Slag

inclusion & Porosity Weld Profile Defects

Undercut, Under fill, Overlap, Concavity, Convexity, 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. This is because of higher stress intensity factor associated with surface flaw.
Interaction of adjacent flaw: As per ASME boiler &

Pressure Vessel Code XI. When the spacing between two

 ASME - BOILER AND PRESSURE VESSEL CODE SECTIONS

I. II.

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

IV. Construction of Heating Boilers

V. Non-destructive Examination
VI. Recommended Rules for care & operation of heating boiler VII. Recommended Rules for care of Power Boilers

VIII.Pressure Vessels

Division 1 Division 2 Alternative Rules

IX. Welding & Brazing Qualification

X. Fibre glass Reinforced Plastic Pressure Vessels XI. Rules for in service Inspection of Nuclear Power Plant Components Division 1 XII. Rules for construction transport tankers

& continued service of

SOME IMPORTANT CODES

AWS D 1.1 code Steel
AWS D 1.5 ASME B 31.1 ASME B 31.3 API 1104

Structural Welding Bridge Welding code Power Piping Process Piping Cross Country

Pipeline

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

Nondestructive Examination (How to look)

AWS B1.11 Guide for the Visual Inspection of Welds AWS B1.10 Guide for the Nondestructive Inspection of Welds

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

ASNT The American Society for non destructive testing.

American National Standard/ASNT Standard for Qualification &

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

The SNT TC 1A Document

recommends that Level-I & Level-II NDT Technicians be examined in the following areas:
A. General Examination B. Specific Examination C. Practical Examination

The SNTTC1A document recommends

that NDT Level-III. Personnel shall be examined in the following areas:

A. Basic 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 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

Plate Sample - 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, arc strikes

require blending and crack detection

Six Most Common NDT Methods

Visual Liquid Penetrate Magnetic Particle Ultrasonic Eddy Current X-ray

Visual Inspection (VT)

Visual Inspection Tools

Visual Inspection Tools

Most basic and common inspection method. Tools include fiberscope, Bores copes, magnifying glasses and mirrors. Portable video inspection unit with zoom allows inspection of large tanks and vessels, railroad tank cars, sewer lines. Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipelines.

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

Magnifying glasses, Flashlights, 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

Visual Examination
Advantages Disadvantages
Easy Requires experience

Quick
Inexpensive Comprehensive Simple tool

Need clean, lighted

area Surface only Good Eye Vision Needs

Surface Inspection Dye Penetrate Inspection

.

Visual Inspection

Sub-surface Inspection

Magnetic Particle Inspection

.

Eddy Current Inspection

Internal Inspection

Ultrasonic Inspection
.

Radiographic Inspection

Dye Penetrant Inspection

Liquid Penetrant Inspection

Dye Penetrant Inspection (DPI) Penetrant Flaw Detection (PFD) Penetrant Testing (PT)

Liquid Penetrant Testing

Liquid Penetrant Inspection

Only for Surface breaking flaw inspection
Applicable to all Non-porous, 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, Plastic and Metal PT dose not require the part to be Magnetized.

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

Magnetic Particle Inspection

The part is magnetized. Finely milled iron particles coated with a dye pigment are then applied to the specimen. 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.

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

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 Principle Differential absorption

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

Radiation Penetrate the Sample

Exposure Recording Device

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

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

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

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

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

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