introduction to ndt
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SPEAKER INTRODUCTION
By R.RamakrishnanSCIENTIST
M.Sc ,AMIE MECH ENGG.ASNT NDT LEVEL III
ACCP LEVEL IIIRWTUV LEVEL III
RSO40 YEARS OF EXP.
Email :radiantndt@gmail.com
Honors And
AwardsFellow of
ISNTEXPERT NDTSPECIALIST
FROMGOVT. OF
INDIA
EXPERIENCEFROM
AIR-LINETO
PIPELINEPREPARINGBOOKS IN
NDT&COURSE
NOTESFOR
ASNT L III
Introduction to NDT
ENERGY ENERGY MODIFIED Input out putMATERIAL
ELECTROMAGNETIC RT MECHANICAL-UTELECTRICAL-ET
THERMAL-IROPTICAL-LASERMAGNETIC-MT
LIQUID -LPT
MATERIAL MODIFIES THE ENERGY
ABSORPTION,REFLECTION, REFRACTION
SCATTER,DIFFRACTIONPOLARISATION
INTERFERENCE
INDIRECT-INTERPRETATION
HUMAN ERRORPROCEDURES
CODESSTANDARDS
SPECIFICATION
RESULTSFORMS OF ENERGY
INTERACTION WITH JOBREPORT
THE PURPOSE OF NDT TO PROVIDE PRODUCT QUALITY TO PROVIDE SAFETY TO MEN AND
MATERIALS TO PROVIDE OVERALL SYSTEM RELIABILITYDEFECTS 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
IngotBillets, blooms
CastingRollingForgingWelding
ExtrusionForming
Heat treatmentGrinding
MachiningGalvanizing
Painting
Primary process Secondary process
CorrosionErosion
CavitationWearCreep
VibrationFatigueabsuse
Service
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
DEFECTSIZE
NATURESTRESS RISING, PASSIVE, ACTIVE
SPACING
LOCATION WITH REFERENCE TO PRINCIPAL STRESS DIRECTION
CASTING PROCESSES LIQUID TO SOLID STATE TO THE REQUIRED SHAPE DEFECTS- SHRINKAGE-MICRO, MACRO,FILAMENTRY HOT TEAR, BLOW HOLES INCLUSIONS MOTTLING, UNFUSED CHAPTLETS, COLD SHUTS MISRUN
BEST NDTMETHODRT FOR
ALL INTERNALDISCONTINUITIES
VT,MT,PT FOR SURFACE BREAKING
DISCONTINUITIESUT LESS RELIABLE
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 STRINGERS & LAMINATIONS SEAMS CRACKS, FOLDS
BEST NDTMETHODVT,PT,MT
ULTRASONIC
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 LAP BURST PIPES
EXTERNAL INTERNAL INTERNAL & EXTERNAL
BEST NDT METHOD
VT,MT,PT,UT
WELDING JOINING THE PARTS, BY LOCALIZED CASTING VARIOUS PROCESSES- SMAW,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 METHODSVT,PT,MT,UT,RT
SECONDARY PROCESSES FINISHING STAGE MACHINING GRINDING HEAT TREATMENT ANODIZING GALVANIZING PAINTING
ALL DISCONTINUITIES ARE CONNECTED
TO SURFACESURFACE NDT
PT,VT,MT
SERVICE INDUCED DISCONTINUITIES CORROSION EROSION WEAR CAVITATION 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 NOISEMETALLOGRAPHY
PLANT SHUT DOWN
VT,PT,MT,UT
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 DEFECTS- INTERPRET,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-189-20011.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 EMPLOYER’S 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 methods1. VISUAL AND OPTICAL TESTING2. PENETRANT TESTING3. MAGNETIC PARTICLE TESTING4. RADIOGRAPHY5. ULTRASONIC TESTING6. EDDY CURRENT TESTING7. THERMAL/ INFRA RED IMAGING8. ACOUSTIC EMISSION 9. LEAK TESTING10. NEUTRON RADIOGRAPHY11. LASER BEAM TESING12. 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 COMPONENT’S 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 METHOD- SPECIFY 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 OPERATOR’S BACKGROUND
QUALIFICATION PROCEDURE, CODE,
AIDS FOR VT DIMENSIONAL METROLOGY- RULE TO
INTERFEROMETERS MIRROR, COMPARATORS, BORESCOPE,
FIBROSCOPE, PERISCOPE, TELESCOPES FILMS, REPLICATION MACHINE VISION TECHNOLOGY- VIDICON,
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 = 2TCOS Wg
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 ½ , 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. ROUNDEDMETHOD 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. OPERATOR’S QUALIFICATION
MAGNETIC PARTICLE TESTING PRINCIPLE: “ LEAKAGE FIELD”
N S NORTH SOUTH POLE 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
N S
N S N S
MAGNETIC PARTICLE TESTING -STEPS 1. MAGNETIZE THE JOB 2. APPLY POWDER 3. SEE FOR INDICATIONS
WHY WE HAVE TO MAGNETIZE THE JOB? BEFORE AFTER LINES OF FORCE
NO YES
NO LEAKAGE LEAKAGE FIELD NO POLES POLES ARE FORMED NO INDICATION INDICATION
MAGNETIC PARTICLE TESTING 2 MATERIALS 2 DIA MAG , PARA MAG MAGNETS 2 PERMANENT, ELECTRO FIELDS 2 CIRCULAR, LONGI…. CURRENTS 2 AC AND DC METHODS 2 CONTINUOUS,RESIDUAL MEDIUM 2 WET, DRY WET 2 FLUORESCENT, NON-FLU INDICATIONS 2 TRUE , FALSE TRUE INDI 2 RELEVANT, NON RELEVANT RELEVANT IND 2 LINEAR, ROUNDED CRACKS 2 OPEN LIP, CLOSED LIP OPERATIONS 2 MAGNETIZE, DEMAG OPERATORS 2 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
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