CERTIFICATION

ULTRASONIC LEVEL 1 & LEVEL II

AB RAZAK MAJID

CERTIFICATION

LIQUID PENETRANT TESTING LEVEL II

AB RAZAK MAJID

CERTIFICATION

INFRARED THERMOGRAPHY TESTING LEVEL I

AB RAZAK MAJID

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

Definition of NDT
The use of noninvasive techniques 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.

Difference betw. NDT & NDE

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 as fracture toughness, formability, and other physical characteristics.

MATERIAL DEFECTS

Definition

Definition of Discontinuities, Defects and Indications

Ingot Discontinuities

An ingot is a material, usually metal, that is cast into a shape suitable for further processing.

Inherent Discontinuities
*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 in the wrought are aligned when the casted isn't.

Classification of Discontinuities

Service Induce Discontinuities

Forging Discontinuities

Fig. The effect of defect shape on internal stress distribution

100%

90%

60%

30%

10%

Destructive Test

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.

Methods of NDT
Visual

What are Some Uses of NDE Methods?

Flaw Detection and Evaluation

Leak Detection
Location Determination Dimensional Measurements

Structure and Microstructure

Characterization
Fluorescent penetrant indication

Estimation of Mechanical and Physical Properties

Stress (Strain) and Dynamic Response Measurements

Material Sorting and Chemical Composition Determination

When are NDE Methods Used?

There are NDE application at almost any stage in the production or life cycle of a component. To assist in product development To screen or sort incoming materials To monitor, improve or control manufacturing processes To verify proper processing such as heat treating To verify proper assembly To inspect for in-service damage

When are NDE Methods Used?

Eg. NDT is used on weldments for the following reasons: 1. Improved product reliability 2. Accident prevention by eliminating faulty products 3. Determination of acceptability in accordance with a code or specification 4. Information for repair decisions 5. Reduction of costs by eliminating further processing of unacceptable components

Destructive test (or Proof test)

Frequently used to supplement, confirm, or establish the limits of NDT/NDE, and to provide supporting information. Some types of destructive testing: Stress tests Crash tests Hardness tests Metallographic tests

Why NDT?

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 HUMAN LIVES

Why NDT?

5. TO IMPROVE PRODUCT RELIABILITY

6. TO GIVE PROFIT TO THE USER BY: - HELPING IN BETTER PRODUCT DESIGN

- ENSURING CUSTOMER SATISFACTION

- CONTROLLING MANUFACTURING PROCESS - LOWERING MANUFACTURING COST - MAINTAINING A UNIFORM QUALITY LEVEL

Advantages of NDT
TESTED OBJECT CAN BE REUSED

TESTS CAN BE CONDUCTED TO ALL SAMPLES

MORE THAN ONE TECHNIQUES CAN BE APPLIED TO A SIMILAR OBJECT

REQUIRES MINIMUM (OR NO) SPECIMEN PREPARATION

EQUIPMENT ARE NORMALLY PORTABLE AND SUITABLE FOR FIELD INSPECTION INSPECTION MAY BE PERFORMED WHILE THE OBJECTS OR PART ARE IN SERVICE

Disadvantages of NDT

RESULTS ARE NORMALLY QUALITATIVE REQUIRE HIGHLY TRAINED AND EXPERIENCED PERSONNEL

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 SAY THAT ONE NDT METHOD IS BETTER THAN THE OTHER. EACH METHOD COMPLIMENTS EACH OTHER.

Other Facts of NDT

EXTREMELY USEFUL IN FAILURE INVESTIGATION

LIMITATION OF NDT

RESULTS ARE NORMALLY QUALITATIVE

REQUIRE HIGHLY TRAINED AND EXPERIENCED PERSONNEL

Service Induce Discontinuities Generated During Service Life

FATIGUE CRACK
EMBRITTLEMENT Material damage under thermal instability CREEP Material deformation for indifinite period of time under constant stress OCCUR DUE TO CYCLIC LOAD

WEAR Reducing of material size or deformation of shape under friction

STRESS CORROSION CRACKING Material crack under stress and corrosion

MT ON ROTOR BLADES

Six Most Common NDT Methods

Visual Liquid Penetrant Magnetic Ultrasonic Eddy Current X-ray

Visual Inspection
Most basic and common inspection method. Tools include fiberscopes, borescopes, magnifying glasses and mirrors AND EXPERIENCE!!!. 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.

Liquid Penetrant Inspection

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.

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.

Magnetic Particle Crack Indications

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 reaching the film through the test object.

X-ray film

= less exposure

= more exposure
Top view of developed film

Radiographic Images

Eddy Current Testing

Coil's magnetic field

Coil

Eddy current's magnetic field

Eddy currents Conductive material

Eddy Current Testing

Eddy 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 small surface probe is scanned over the part surface in an attempt to detect a crack.

Eddy Current Testing

Coating thickness measurements

Models now come with Bluetooth wireless technology. Instant transmission to your PC or hand held data device is now possible no more cables required.

Fig. Electronic magnetic induction thickness gauges

Ultrasonic Inspection (Pulse-Echo)

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

Reflected sound energy is displayed versus time, and inspector can visualize a cross section of the specimen showing the depth of features that reflect sound.
initial pulse back surface echo

crack echo

crack
0 2 4 6 8 10

plate

Oscilloscope, or flaw detector screen

Ultrasonic Imaging
High resolution images can be produced by plotting signal strength or time-of-flight using a computer-controlled scanning system.

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)

Common Application of NDT

Inspection of Raw Products Inspection Following Secondary Processing In-Services Damage Inspection

Inspection of Raw Products

Forgings, Castings, Extrusions, etc.

Inspection Following Secondary Processing Machining Welding Grinding Heat treating Plating etc.

Inspection For In-Service Damage Cracking Corrosion Erosion/Wear Heat Damage etc.

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.

Wire Rope 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.

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.

Aircraft Inspection
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.

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.

Crash of United Flight 232

Sioux City, Iowa, July 19, 1989
A defect that went undetected in an engine disk was responsible for the crash of United Flight 232.

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.

Remote visual inspection using a robotic crawler.

Magnetic flux leakage inspection. This device, known as a pig, is placed in the pipeline and collects data on the condition of the pipe as it is pushed along by whatever is being transported.

Radiography of weld joints.

Power Plant Inspection

IN-SITU METALLOGRAPHY FOR THE PLANT HEALTH ASSESSMENT STUDY AND FAILURE INVESTIGATION

Schematic representation of replication process.

Photo: indicates graphite formation in plain carbon steel after a prolong exposure to high temperature.

Sketch:3 Different stage of creep along with microstructure degradation stages

Thermographic Inspection

eg. STEAM LEAKAGE UNDER INSULATION of CROSS OVER PIPE AT KAPAR POWER STATION

Infra-red Camera

TNB Chenderoh Hydro Rehabilitation Project (1996 1999)

INTAKE
CONTROL ROOM POWERHOUSE CRANE

NORMAL WATER LEVEL 60.45 m

GENERATOR
ELIN

HEAD GATE

GOVERNOR

FRANCIS RUNNER

TURBINE

SPIRAL CASE

DRAFT TUBE GATE

NORMAL TAIL WATER LEVEL 40.54 m

TAILRACE

DRAFT TUBE

Fig. Power House Cross Section

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 various points to evaluate its uniformity.

INTRODUCTION TO INFRARED THERMOGRAPHY

THERMOGRAPHY VS PHOTOGRAPHY

THERMOGRAPHY ;
MEAN WRITING WITH HEAT

PHOTOGRAPHY ; MEANS WRITING WITH LIGHT

We use Long wave camera

PHOTOGRAPHY - LIGHT IS IMPORTANT

NOT ENOUGH LIGHT

CUKUP CAHAYA

0.4 m (violet) to 0.7 m (red)

Wavelength bands

Wavelength bands are approximates

Wavelength bands are not sharply defined,they change gradually

The Electromagnetic Spectrum

INFRARED TEMPERATURE TESTING THERMOGRAPHY

The Electromagnetic Spectrum

The Infrared region is part of the Electromagnetic Spectrum that is dividing up all types of electromagnetic radiation. This radiation is divided up rather arbitrarily (rambang) into a number of regions based on their wavelengths: Gamma < 10 nanometers, Ultraviolet radiation, Visible light 0.4 to 0.7 micrometers, Infrared Radiation, Microwaves, Radio waves

CAMERA PRINCIPLE
INFRARED RADIATION

Passive camera receive (emit) infrared radiation. Not like x-ray RADIATE RAY

A PICTURE OF RADIATION INTENSITY, NOT TEMPERATURE

HOW DO THE CAMERAS WORK?

THE IR CAMERA SENSES AND MEASURES THE IR ENERGY IN THE BAND IT OPERATE IN. SO AN IR CAMERA IS ALSO RADIOMETER. A RADIOMETER MEASURE RADIATION.
InfraRed Camera tak boleh scan Matahari, ia akan rosak dan tidak boleh pulih, Tapi mata kita jika terpandang cahaya yang terlalu terang akan menjadi gelap, tetapi ia akan pulih beberapa ketika kemudian.