part 1 ndt intro ilsas

7/30/2019 Part 1 Ndt Intro Ilsas

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CERTIFICATION

ULTRASONIC

LEVEL 1

&

LEVEL II

AB RAZAK MAJID


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CERTIFICATION

LIQUID PENETRANT

TESTING

LEVEL II

AB RAZAK MAJID


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CERTIFICATION

INFRARED

THERMOGRAPHY

TESTING

LEVEL I

AB RAZAK MAJID


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Topics

PART 1:Introduction to NDT

PART 2:Visual Inspection

PART 3: Penetrant Testing

PART 4: Magnetic Particle Testing

PART 5: Ultrasonic Inspection

PART 6:Radiographic Testing


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The use of noninvasivetechniques to determine

the integrity of a material,

component or structure

or

quantitatively measure

some characteristic of

an object.

i.e. Inspect or measure without doing harm.

Definition of NDT


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Nondestructive Evaluation (NDE) a term often used

interchangeably with NDT.

However, technically, NDE is used to describe

measurements that are more quantitative in nature.

For example, a NDE method would not only locate a defect,

but it would also be used to measure something about that

defect such as its size, shape, and orientation.

NDE may be used to determine material properties such asfracture toughness, formability, and other physical

characteristics.

Difference betw. NDT & NDE


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MATERIALDEFECTS


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Definition


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An ingot is a material,

usually metal, that is cast

into a shape suitable for

further processing.

Ingot Discontinuities
http://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Castinghttp://en.wikipedia.org/wiki/Castinghttp://en.wikipedia.org/wiki/Metal


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*inherent - belonging

by nature or habit :intrinsic

Question

Why are wrought

alloys stronger and

more ductile than

cast?

Answer

It all has to do with the grain

structure. Wrought alloys are

"hammered/pressed" with the

other is just casted. The grain inthe wrought are aligned when the

casted isn't.

Inherent Discontinuities


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Classification of Discontinuities


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Service Induce Discontinuities


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Forging Discontinuities


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100%

90%

60%

30%

10%

Fig. The effect of defect shape on internal stress

distribution


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Destructive Test


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In bloom and billet casting, the steel from the ladle is poured into a large "pot" called a

tundish from which it is fed into a water-cooled mold and extracted in a solidified

section as either a bloom or billet. Blooms are an intermediate product usually having

a much larger cross section than billets. These blooms are rolled into billets which are

subsequently rolled into bars or rods.


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Methods of NDT

Visual


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What are Some Usesof NDE Methods?

Flaw Detection and EvaluationLeak Detection

Location Determination

Dimensional Measurements

Structure and Microstructure

Characterization

Estimation of Mechanical and Physical Properties

Stress (Strain) and Dynamic Response Measurements

Material Sorting and Chemical Composition Determination

Fluorescent penetrant indication


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When are NDE Methods Used?

To assist in product development

To screen or sort incoming materialsTo monitor, improve or controlmanufacturing processes

To verify proper processing such as heat

treatingTo verify proper assembly

To inspect for in-service damage

There are NDE application at almost any stagein the production or life cycle of a component.


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Destructive test (or Proof test)

Frequently used to supplement, confirm, or establishthe limits of NDT/NDE, and to provide supporting

information.

Some types of destructive testing:

Stress tests

Crash tests

Hardness tests

Metallographic tests


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1. DOES NOT DAMAGE A JOB OR REDUCE THE

SERVICE LIFE OF A JOB.

2. TO LOCATE THE DEFECTS AND

DISCONTINUITIES IN A JOB.

3. TO OBTAIN HIGH LEVEL OF RELIABILITY AND

TO AVOID PREMATURE FAILURE.

4. TO PREVENT ACCIDENTS AND SAVE HUMANLIVES

Why NDT?


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Other Facts of NDT

EACH NDT IS DESIGNED TO PROVIDE VISUAL

EVIDENCE OF DISCONTINUITIES IN PARTS WHICH

ARE NOT NORMALLY VISIBLE TO THE UNAIDED

EYE. THE VISIBLE EVIDENCE LEFT BY EACH

METHOD IS CALLED AN INDICATION.

HOWEVER THERE ARE NO SINGLE NDT METHOD

CAPABLE OF DETECTING ALL TYPE OF

DISCONTINUITIES . THUS IT IS NOT RIGHT TO SAYTHAT ONE NDT METHOD IS BETTER THAN THE

OTHER. EACH METHOD COMPLIMENTS EACH

OTHER.


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EXTREMELY USEFUL IN

FAILURE INVESTIGATION

Other Facts of NDT


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Service Induce Discontinuities

Generated During Service Life

MT ON ROTOR BLADES

FATIGUE CRACK

OCCUR DUE TO CYCLIC LOAD

CREEP

Material deformationfor indifinite period

of time under

constant stress

STRESS CORROSIONCRACKING

Material crack under

stress and corrosion

EMBRITTLEMENT

Material damage under

thermal instability

WEAR

Reducing of material size or

deformation of shape under

friction


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Six Most Common NDT Methods

Visual Liquid Penetrant

Magnetic

Ultrasonic

Eddy Current

X-ray


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A liquid with high surface wetting characteristics is

applied to the surface of the part and allowed time to

seep into surface breaking defects.

The excess liquid is removed from the surface of the

part.

A developer (powder) is applied to pull the trapped

penetrant out the defect and spread it on the

surface where it can be seen.

Visual inspection is the final step in the process.

The penetrant used is often loaded with a

fluorescent dye and the inspection is done under

UV light to increase test sensitivity.

Liquid Penetrant Inspection


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Magnetic Particle Inspection

The part is magnetized. Finely milled iron particlescoated with a dye pigment are then applied to thespecimen. These particles are attracted to magnetic fluxleakage fields and will cluster to form an indicationdirectly over the discontinuity. This indication can be

visually detected under proper lighting conditions.


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Magnetic Particle Crack Indications


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Radiography

The radiation used in radiographytesting is a higher energy (shorter

wavelength) version of theelectromagnetic waves that wesee as visible light. The radiation cancome from an X-ray generator or aradioactive source.

High Electrical Potential

Electrons

-+

X-ray Generatoror Radioactive

Source Creates

Radiation

Exposure Recording Device

RadiationPenetrate

the Sample


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Radiographic Images


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Conductivematerial

CoilCoil'smagnetic field

Eddycurrents

Eddy current'smagnetic field

Eddy Current Testing


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Eddy Current TestingEddy current testing is particularly well suited for detecting

surface cracks but can also be used to make electrical

conductivity and coating thickness measurements. Here a smallsurface probe is scanned over the part surface in an attempt to

detect a crack.


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Eddy Current Testing

Fig. Electronic magnetic induction thickness

gauges

Models now come with

Bluetooth wireless

technology. Instanttransmission to your

PC or hand held data

device is now possible -

no more cables

required.

Coating thickness measurements

Ul i I i


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High frequency sound waves are introduced into a material andthey are reflected back from surfaces or flaws.

Reflected sound energy is displayed versus time, and inspectorcan visualize a cross section of the specimen showing the depthof features that reflect sound.

plate

crack

0 2 4 6 8 10

initial

pulse

crack

echo

back surface

echo

Oscilloscope, or flaw

detector screen

Ultrasonic Inspection

(Pulse-Echo)

Ult i I i


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Ultrasonic Imaging

Gray scale image produced using

the sound reflected from the front

surface of the coin

Gray scale image produced using the

sound reflected from the back surface

of the coin (inspected from heads side)

High resolution images can be produced by plotting signal

strength or time-of-flight using a computer-controlled

scanning system.


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Common Application of NDT

Inspection of Raw Products

Inspection Following Secondary

ProcessingIn-Services Damage Inspection


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Inspection of Raw Products

Forgings,Castings,Extrusions,

etc.


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MachiningWeldingGrinding

Heat treatingPlatingetc.

Inspection Following

Secondary Processing


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Cracking

Corrosion

Erosion/Wear

Heat Damage

etc.

Inspection For

In-Service Damage


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Power Plant Inspection

Probe

Signals produced

by various

amounts of

corrosion

thinning.

Periodically, power plants are

shutdown for inspection.Inspectors feed eddy current

probes into heat exchanger

tubes to check for corrosion

damage.

Pipe with damage

Wi R I i


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Wire Rope Inspection

Electromagnetic devices andvisual inspections are used tofind broken wires and otherdamage to the wire rope that isused in chairlifts, cranes andother lifting devices.

St T k I ti


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Storage Tank Inspection

Robotic crawlers useultrasound to inspect the

walls of large aboveground tanks for signs ofthinning due to corrosion.

Cameras on longarticulating armsare used toinspectunderground

storage tanks fordamage.

Ai ft I ti


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Aircraft Inspection

Nondestructive testing is usedextensively during the

manufacturing of aircraft. NDT is also used to find cracks

and corrosion damage duringoperation of the aircraft.

A fatigue crack that started atthe site of a lightning strike is

shown below.

Jet Engine Inspection


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Jet Engine Inspection

Aircraft engines are overhauledafter being in service for a period

of time.

They are completelydisassembled, cleaned, inspectedand then reassembled.

Fluorescent penetrant inspection

is used to check many of the partsfor cracking.

C h f U it d Fli ht 232


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Sioux City, Iowa, July 19, 1989

A defect that went

undetected in an

engine disk was

responsible for the

crash of United

Flight 232.

Crash of United Flight 232

P V l I ti


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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.

R il I ti


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Rail Inspection

Special cars are used to inspect

thousands of miles of rail to findcracks that could lead to aderailment.


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Bridge Inspection

The US has 578,000 highway

bridges.

Corrosion, cracking andother damage can all affect abridges performance.

The collapse of the Silver

Bridge in 1967 resulted inloss of 47 lives.

Bridges get a visualinspection about every 2years.

Some bridges are fitted withacoustic emission sensorsthat listen for sounds ofcracks growing.

Pi li I ti


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Pipeline InspectionNDT is used to inspect pipelinesto prevent leaks that could

damage the environment. Visualinspection, radiography andelectromagnetic testing are someof the NDT methods used.

Remote visual inspection usinga robotic crawler.

Radiography of weld joints.

Magnetic flux leakage inspection.This device, known as a pig, isplaced in the pipeline and collectsdata on the condition of the pipe as itis pushed along by whatever is beingtransported.

P Pl t I ti


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Power Plant InspectionIN-SITU METALLOGRAPHY FOR THE PLANT HEALTH ASSESSMENT

STUDY AND FAILURE INVESTIGATION

Photo: indicates graphite formation in plain

carbon steel after a prolong

exposure to high temperature.

Schematic

representation of

replication process.

Sketch:3 Different stage of creep along with

microstructure degradation stages

Th hi I ti


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Thermographic Inspection

eg. STEAM LEAKAGE UNDER INSULATION of

CROSS OVER PIPE AT KAPAR POWER STATION

Infra-red Camera

TNB Chenderoh Hydro


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y

Rehabilitation Project (1996 1999)

NORMAL

WATER LEVEL

60.45 m

INTAKE

HEAD GATE

GENERATOR

POWERHOUSE CRANE

DRAFT TUBE

TAILRACE

DRAFT

TUBE

GATE

TURBINE

GOVERNOR

SPIRAL

CASE

FRANCIS

RUNNER

NORMAL

TAIL WATER

LEVEL

40.54 m

CONTROL

ROOM

ELIN

Fig. Power House Cross Section

Special Measurements


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Special Measurements

Boeing employees in Philadelphia were given theprivilege of evaluating the Liberty Bell for damage using

NDT techniques. Eddy current methods were used tomeasure the electrical conductivity of the Bell's bronzecasing at various points to evaluate its uniformity.


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INTRODUCTION TO

INFRAREDTHERMOGRAPHY


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THERMOGRAPHY ;

MEAN WRITING WITH HEAT

PHOTOGRAPHY ;

MEANS WRITING WITH LIGHTWe use Long wave camera

THERMOGRAPHY VS PHOTOGRAPHY


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PHOTOGRAPHY - LIGHT IS IMPORTANT

NOT ENOUGH LIGHT CUKUP CAHAYA


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0.4 m

(violet) to

0.7 m

(red)


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Wavelength bands

Wavelength bands are approximates

Wavelength bands are not sharply defined,they change gradually


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The Electromagnetic Spectrum


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INFRARED TEMPERATURE TESTING -

THERMOGRAPHY

The Electromagnetic Spectrum

The Infrared region is part of the Electromagnetic

Spectrum that is dividing up all types ofelectromagnetic radiation. This radiation is dividedup rather arbitrarily (rambang) into a number ofregions based on their wavelengths: Gamma < 10nanometers, Ultraviolet radiation, Visible light 0.4 to0.7 micrometers, Infrared Radiation, Microwaves,Radio waves

CA A C


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CAMERA PRINCIPLE

A PICTURE OF RADIATION INTENSITY, NOT TEMPERATURE

INFRARED RADIATION

Passivecamera receive (emit)

infrared radiation.

Not like x-rayRADIATE RAY


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