SPEAKER INTRODUCTION

EXPERIENCE FROM AIR-LINE TO PIPELINE PREPARING BOOKS IN NDT &COURSE NOTES FOR ASNT L III

By R.Ramakrishnan SCIENTIST M.Sc ,AMIE MECH ENGG. ASNT NDT LEVEL III ACCP LEVEL III RWTUV LEVEL III RSO 40 YEARS OF EXP. Email :radiantndt@gmail.com

Honors And Awards Fellow of ISNT EXPERT NDT SPECIALIST FROM GOVT. OF INDIA

Introduction to NDT
ENERGY Input
FORMS OF ENERGY ELECTROMAGNETIC RT MECHANICAL-UT ELECTRICAL-ET THERMAL-IR OPTICAL-LASER MAGNETIC-MT LIQUID -LPT MATERIAL MODIFIES THE ENERGY ABSORPTION,REFLECTION, REFRACTION SCATTER,DIFFRACTION POLARISATION INTERFERENCE INTERACTION WITH JOB

MATERIAL

ENERGY MODIFIED out put

RESULTS INDIRECTINTERPRETATION HUMAN ERROR PROCEDURES CODES STANDARDS SPECIFICATION REPORT

THE PURPOSE OF NDT

TO PROVIDE PRODUCT QUALITY TO PROVIDE SAFETY TO MEN AND MATERIALS TO PROVIDE OVERALL SYSTEM RELIABILITY DEFECTS AND DISCONTINUITIES ARE ONE AMONG THE SEVERAL FACTORS WHICH AFFECT THE QUALITY, SAFETY AND RELIABILITY AND LEADING TO PREMATURE FAILURE.

BASIC MATERIALS, fabrication and production technology

Primary, secondary processes discontinuities
Primary process Secondary process Service Corrosion Erosion Cavitation Wear Creep Vibration Fatigue absuse

Ingot Billets, blooms

Casting Rolling Forging Welding Extrusion Forming

Heat treatment Grinding Machining Galvanizing Painting

Inherent defects

DEFECTS

DEFECTS

DEFECTS

F A I L U R E ,ACCIDENTS,PLANT SHUT DOWN

WHAT IS A DEFECT ?
A DEFECT IS NORMALLY DEFINIED AS LACK OR OMISSION OF SOMETHEING ESSENTIAL FOR COMPLETELENESS A DEFECT MAY RANGE FROM ATOM SIZED DISCOLLOCATION TO MAJOR METAL DISCONTINUITIES WHICH ARE VISIBLE TO NAKED EYE. THE VARIOUS NDT METHODS SENSES THE MATERIALS DISCONTINUITY, AND REPORTS IN THE FORM OF IMAGE, SIGNAL, READOUT UNACCETPABLE DISCONTINUITIES ARE DEFECTS, AND THEREFORE ALL DISCONITNUITIES ARE NOT DEFECTS

DEFECT CHARACERTIZATION
LOCATION WITH REFERENCE TO PRINCIPAL STRESS DIRECTION

S I Z E

DEFECT

SPACING

NATURE STRESS RISING, PASSIVE, ACTIVE

CASTING PROCESSES
LIQUID TO SOLID STATE TO THE REQUIRED SHAPE DEFECTS- SHRINKAGE-MICRO, BEST NDT MACRO,FILAMENTRY METHOD RT FOR HOT TEAR, BLOW HOLES ALL INTERNAL INCLUSIONS DISCONTINUITIES VT,MT,PT FOR MOTTLING, SURFACE BREAKING UNFUSED CHAPTLETS, DISCONTINUITIES UT LESS RELIABLE COLD SHUTS MISRUN

ROLLING PROCESS
TURNING THE INGOT INTO THE REQUIRED SHAPE BY SEQUECING THE METAL INBETWEEN THE ROLLERS PROCESS- HOT ROLLING, COLD ROLLING PRODUCTS- BARS, PLATES, DEFECTS BEST NDT STRINGERS & LAMINATIONS METHOD VT,PT,MT SEAMS ULTRASONIC CRACKS, FOLDS

FORGING
THE PROCESS: TURNING THE METAL INTO REQUIRED SHAPE BY APPLICATION OF EXTERNAL FORCE OPEN DIE,CLOSE DIE, PRODUCTS: BOLTS, NUTS, GEAR BLANKS, SHAFTS, TURBINE BLADES, PINS, DEFECTS BEST NDT LAP BURST PIPES METHOD VT, EXTERNAL INTERNAL & EXTERNAL INTERNAL
MT, PT, UT

WELDING
JOINING THE PARTS, BY LOCALIZED CASTING VARIOUS PROCESSESSMAW,SAW,TIG,MIG,EB,.. SOLDERING, BRAZING ALL CRITICAL WELDS REQUIRE ONE OR MORE NDT METHODS TO FIND ALL DISCONTINUITIES FROM TOP TO BOTTOM OF THE JOINT ALL WELDERS AND WELDING PROCESSES SHALL BE QUALIFIED FOR PARTICULAR APPLICATIONS AS PER ASME SEC IX REQUIARES DT,NDT, CHEMICAL, METALLOGRAPHIC
NDT METHODS VT,PT,MT,UT,RT

SECONDARY PROCESSES
FINISHING STAGE MACHINING GRINDING HEAT TREATMENT ANODIZING GALVANIZING PAINTING

ALL DISCONTINUITIES ARE CONNECTED TO SURFACE SURFACE NDT PT,VT,MT

SERVICE INDUCED DISCONTINUITIES

CORROSION EROSION PLANT SHUT WEAR DOWN CAVITATION VT,PT,MT,UT + FATIGUE CREEP LOSS OF INTEGRITY OF STRUCTURES, EVIDANCE OF LEAK, MISSING PARTS, DENTS, ABUSE, THERMAL INSULATION,

EDDY CURRENT, REMOTE FIELD EC, MAGNETIC FLUX LEAKAGE, THERMOGRAPHY, FIBROSCOPE, HOLIDAY DETECTION, LEAK TESTING, IRIS, VIBRATION AND NOISE METALLOGRAPHY

TRAINING AND CERTIFICATION

ASNT SNT TC-1A ANSI/ASNT CP 189 ISO 9712 EN 473 RWTUV

THE NEED FOR TRAINING AND CERTIFICATION OF NDT PERSONNEL

NDT IS A BRANCH OF SCIENCE INVOLVING PHYSICS PRINCIPLES ON MATERIALS. NDT RESULTS ARE MOST OFTEN INDIRECT, AND READOUT IN THE FORM OF IMAGE, SIGNALS, SPECTRUM ANALYSIS. GENERALLY A LESS QUALIFIED PERSON HAS TO PERFORM THE JOB , CALLED TECHNICIAN, AND THE RELIABILITY OF THE TEST MAINLY DEPENDS ON HIS SKILL, TRAINING AND EXPERIENCE A TECHNICIAN HAS TO SUCCESSFULLY LOCATE THE DEFECTSINTERPRET,EVALUATE- FOLLOWING THE INSTRUCTIONS-THE PROCEDURE FOR ACCEPTANCE/REJECTION, DEPENDING UPON THE CRITICALLITY HE HAS TO MAKE REFERENCE TO THE CODE GENERAL KNOWLDEGE, SPECIFIC TO THE JOB, AND PRACTICAL DEMO ARE THE MUST FOR NDT PERSONNEL ANSI/ASNT IS A STD FOR QUALIFICATION OF NDT PERSONNEL ASNT SNT TC IA IS A RECOMMENDED PRACTICE ANSI/ASNT CP 189, ASNT SNT TC 1A HELP THE EMPLOYER TO DO THE JOB DONE RIGHT AT THE FIRST

ANSI/ASNT CP-189-2001
1.ESTABLISHES MIN. QUALIFICATION AND TRAINING FOR NDT PERSONNEL 2. MINI. TRAINING, EDUCATION, AND EXPERIENCE 3. EMPLOYER HAS TO ESTABLISH A PROCEDURE FOR CERTIFICATION OF NDT PERSONNEL EMPLOYER TO INTRODUCE ANY UNIQUE OR ADDITIONAL REQUIRMENTS IN CERTIFIATION PROCESS

CP 189 SOME DEFINITIONS

EDUCATION- SCHOOL, COLLEGE, UNIVERSITY PROVIDING ORDERLY INSTRUCTIONS, IN A SYSTEMATIC FASHION NDT LEVELS LEVEL I & II INDIVIDUAL CERTIFIED ACCORDING TO THIS PROCEDURE LEVEL III POSSING CURRENT VALID ASNT LEVEL III CERTIFICATE

LEVELS OF QUALIFICATION
NDT LEVEL III NDT LEVEL II NDT LEVEL I TRAINEE INSTRUCTOR

SNT-TC-1A 2001
IT IS A RECOMMENDED PRACTICE IT IS THE EMPLOYERS RESPONSIBILITY FOR CERTIFICATION AND TRAINING OF NDT PERSONNEL LEVELS OF QUALIFICATION I , II, III LEVEL I AND II VALID FOR 3 YEARS AND LEVEL III FOR 5 YEARS EMPLOYER ISSUED CERTIFICATE CEASES IF THE EMPLOYER LEAVES COMPANY OR TERMINATED

The need for NDT

To day every manufactured part shall have Quality- customer satisfaction Safety to men and materials Reliability a system has to do its intended function over a period of time without failure. Quality, safety, reliability start at the design, and the design engineer is responsible for quality, safety, and reliabiliaty The NDT specialist successfully locates the defects. Defects and discontinuities one among the several reasons for pre-mature failure.

Various NDT methods

Discontinuities may be located in any where in the object, and to successfully locate them, we need to use several NDT methods, depending upon the expected discontinuity, location, orientation, and size. All critical components have to be tested with more than one NDT method. A particular technique in each of the NDT method brings the expected discontinuity successfully.

The common most NDT methods

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

VISUAL AND OPTICAL TESTING PENETRANT TESTING MAGNETIC PARTICLE TESTING RADIOGRAPHY ULTRASONIC TESTING EDDY CURRENT TESTING THERMAL/ INFRA RED IMAGING ACOUSTIC EMISSION LEAK TESTING NEUTRON RADIOGRAPHY LASER BEAM TESING VIBRATION AND NOISE ANALYSIS

THE NDT SPECIALIST BE

FAMILIAR WITH THE MANUFACTURING PROCESS, AWARE OF THE SEQUENCE OF FORMING, SOLIDIFICATION AWARE OF VARIOUS DISCONTINUITIES, THEIR LOCATION,THEIR SEVERITY TO SERVICE,OR COMPONENTS LIFE ABLE TO SELECT THE MOST SUITABLE NDT METHOD, AND IN THAT METHOD THE MOST SUITABLE TECHNIQUE TO DETECT THEM

THE NDT SPECIALIST MUST BE ABLE TO

IDENTIFY EACH DISCONTINUITY DIFFERENTIATE DISCONTINUITY FROM ONE ANOTHER LIKE LOF, IP, CRACK, ETC CORRELATE THE POSSIBLE REASON FOR THE DISCONTINUITY CHARACTERIZE THE DISCONTINUITY AND TAKE DECISION FOR ACCEPTANCE/ REJECTION WITH REFERENCE TO APPLICABLE CODES AND STANDARDS

SELECTION OF NDT METHODS

EACH AND EVERY NDT METHOD HAS MERITS AND LIMITATIONS. SURFACE NDT METHODS LIKE VT,PT,MT, ET DETECTS SURFACE AND NEAR SURFACE DISCONTINUITIES AND HENCE NOT SUITABLE FOR INTERNAL DISCONTINUITIES RT,UT DETECTS DEFECTS THAT ARE SUBSTANTIALLY INSIDE. BUT RT IS BEST FOR VOULUME DEFECTS AND UT IS BEST FOR PLANNAR DISCONTINUITIES

VARIABLES WITH IN EACH METHODSPECIFY THE TECHNIQUE

FOR EXAMPLE IN ULTRASONIC METHOD THE VARIABLES ARE: 1. TYPE OF WAVE 2. FREQUENCY 3. SIZE 4. METHOD OF PRESENTATION- A SCAN, B SCAN, C SCAN, P SCAN, TOFD, GUIDED WAVE, SURFACE 5. PULSE ECHO, THROUGH TRANSMISSION, CONTACT, IMMERSION, 6. THE METALLURGY OF THE MATERIAL AND THE MANUFACTURING PROCESS.

VISUAL AND OPTICAL TESTING

IT IS THE BASIS OF ALL NDT INSPECTION IT AVOIDS COSTLY NDT INSPECTION OUR EYE IS THE DETECTOR RESULTS ARE SEEN AND INTERPRETATION IS STRAIGHT FORWARD LIMITED TO SURFACE,& REFLECTANCE ACCESS TO THE TEST SURFACE IS REQUIRED & POSSIBLE TO DAY WITH DIRECT AND REMOTE FIELD.

BASIC ELEMENTS FOR VT

EYE & OUR VISION, NEAR, FAR, COLOR, VISION ACUITY LIGHT ILLUMINANCE, UNIT TEXTURE AND REFLECTACNE CLEANLINESS VISION ANGLE OPERATORS BACKGROUND QUALIFICATION PROCEDURE, CODE,

AIDS FOR VT
DIMENSIONAL METROLOGY- RULE TO INTERFEROMETERS MIRROR, COMPARATORS, BORESCOPE, FIBROSCOPE, PERISCOPE, TELESCOPES FILMS, REPLICATION MACHINE VISION TECHNOLOGYVIDICON, CID, CCD, PHOTOVOLTALIC CELL, PHOTOCONDUCTIVE CELL,

VT ON WELDS
BEFORE WELDING DURING WELDING AFTER WELDING NDTS AND DTS REQUIREMENTS AS PER PROCEDURE REPAIRS AND VT + NDTS PROCEDURES AS PER ASME, API, AWS FOR VT WELD GAUGES

PENETRANT TESTING
BEST OF ALL NDT METHODS CAN BE USED ON ALL MATERIALS, OF ANY SHAPE, SIZE, AND GEOMETRY INSPECTION IS STRAIGHT FORWARD, AND IS SEEN AS FORMED SIMPLE IN PRACTICE, AND EASY TO TRAIN AN OPERATOR LIMITATIONS: DEFECTS SHALL BE OPEN TO SURFACE NOT FIT ON POROUS MAT.

PENETRANT PROCESS;
STEPS IN PT 1. PRE CLEANING 2. APPLY PENETRANT 3. REMOVE THE EXCESS PENETRANT 4. APPLY DEVELOPER 5. INSPECT 6 POST CLEAN

THE PHYSICAL PRINCIPAL

CAPILLARY PRESSURE h = 2TCOSU WVg
h

PENETRANT MATERIALS
TYPES OF PENETRANT- I , II, III METHODS OF REMOVAL OF EXCESS PENETRANT - A , B, C, D FORMS OF DEVELOPERS a , b, c, d, spl LEVELS OF SENSITIVITY , 1.2.3.4 ALL OF THE ABOVE WITH REFERENCE TO ASTM STANDARD # ASTM E 165

PT- METHOD OF REPORTING

INTERPRET ALL THE INDICATIONS CLASSIFY THEM AS TRUE OR FALSE ALL TRUE INDICATIONS SHALL BE EVALUATED AS RELEVANT OR NON RELEVANT ALL RELEVANT INDICATIONS ARE FURTHER EVALUATED AS 1. LINEAR 2. ROUNDED METHOD OF RECORDING

PT TEST REPORT
1. JOB DETAILS 2. PENETRANT MATERIALS USED 3. THE PENETRANT PROCESS- TYPES, METHODS, FORMS, LEVELS OF SENSITIVITY 4. RECORDING METHOD 5. POST CLEANING 6. INTERPRETATION, EVALUATION, AS PER APPLICABLE CODE 7. OPERATORS QUALIFICATION

MAGNETIC PARTICLE TESTING

PRINCIPLE: LEAKAGE FIELD

N
NORTH POLE

S
SOUTH POLE

AT POLES LINES OF FORCE LEAVE OR ENTER AT POLES ONLY POWDER ATTACT WHENEVER THERE IS A BREAK, THERE IS A LEAK, WHEREVER THERE IS LEAK THERE ARE POLES NORTH AND SOUTH WHEREVER THERE ARE POLES POWDER ATTRACTS. MAGNETIC LINES OF FORCE LEAVE AT ONE END AND ENTER THE OTHER END. THIS IS CALLED LEAKAGE FIELD.

SHAFT WITH AND WITH OUT CRACK

S N

MAGNETIC PARTICLE TESTING STEPS

1. 2. 3. MAGNETIZE THE JOB APPLY POWDER SEE FOR INDICATIONS

WHY WE HAVE TO MAGNETIZE THE JOB?

BEFORE AFTER LINES OF FORCE

NO

YES

NO LEAKAGE NO POLES NO INDICATION

LEAKAGE FIELD POLES ARE FORMED INDICATION

MAGNETIC PARTICLE TESTING 2

MATERIALS 2 MAGNETS 2 FIELDS 2 CURRENTS 2 METHODS 2 MEDIUM 2 WET 2 INDICATIONS 2 TRUE INDI 2 RELEVANT IND 2 CRACKS 2 OPERATIONS 2 OPERATORS 2 DIA MAG , PARA MAG PERMANENT, ELECTRO CIRCULAR, LONGI. AC AND DC CONTINUOUS,RESIDUAL WET, DRY FLUORESCENT, NON-FLU TRUE , FALSE RELEVANT, NON RELEVANT LINEAR, ROUNDED OPEN LIP, CLOSED LIP MAGNETIZE, DEMAG ONE TO MAG ONE TO PUT MED

For further NDT

Contact me at the following address: Radiant NDT Services 00914422461285, Email radiantndt@gmail.com radiant_ndt@hotmail.com Thanks R.Ramakrishnan