Api570 Chapter7 Nde Rev 005 141013224037 Conversion Gate02

7/24/2019 Api570 Chapter7 Nde Rev 005 141013224037 Conversion Gate02

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Chapter Seven

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NDE (Non Destructive Evaluation)

Do Not Duplicate

NDE

These course notes have been prepared by TWI, strictly for the use of attendees to this TWIAPI-570

Examination Preparation Course. This manual is to be used as an aid to assist those persons wishing to take

the API-570 Piping Inspector Certification Examination. This manual is not all-inclusive and may not beused in place of any recognized Code or Standard. This manual may not be reproduced by any means

without the express written consent of TWI.


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THE WELDING INSTITUTE

REV.005 NDE (570 ED) 2Copyright TWI Ltd 2008

ASME SECTION V, ARTICLE 1

T-110 Scope

General requirements for NDE when referenced by other Codes

Appendix A contains a list of common flaws and methods of detection

General NDE terms are defined in the Mandatory Appendix 1

T 120 General

Subsection A describes methods of NDE to be used.

Subsection B lists NDE Standards.

Reference to a paragraph in Subsection A or referencing Code includes all applicable

rules in the paragraph Standards in Subsection B are mandatory only to the extent specified when referenced

When this Article is referenced NDE Personnel shall be qualified per the employerswritten practice which must comply with: the User of this Article is responsible for personnel certification.

- the Users quality program shall specify the method.-certifications to previous versions of standards are good until recertification.

When no personnel qualification standard is referenced qualification may be bydemonstration in routine operations of competency in accordance with Manufacturers

procedures

Limited certification of NDE personnel who perform only one operation of an NDE

method or perform within scope may be based on less hours than specified in SNT-TC-1A, CP-189 or ACCP

-Such conditions shall be described in the Written Practice and noted on anycertifications

T-130 Equipment

The Code User is responsible for equipment compliance

T-150 Procedure

Special conditions such as part geometry or materials may require special procedures. If

required they shall:- Be equivalent or superior to the methods and techniques described in Section V.- Produce interpretable examination results- Be capable of detecting discontinuities- Be submitted to the Inspector for approval

The manufacturer, fabricator or installer is responsible for establishing:

- examination procedures-personnel certification procedures


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When required by referencing code sections all NDE performed shall be done in accordance with

a written procedure:- demonstrated to the satisfaction of the Inspector- in compliance with the applicable Article of Section V- Made available to the Inspector on request- Available to the NDE personnel performing the examinations for reference and use

T-160 Calibration

The manufacturer, installer or fabricator shall assure that all required calibrations areperformed.

The Code User shall specify what calibrations are needed when using special procedures; ifrequired

T- 170 Examinations and Inspections

The inspector is responsible for:- verifying that all examinations meet all of requirements Section V and referencing

Code

- witness any examinations to the extent stated in the referencing Code- Inspector means the Authorized Inspector as defined in the referencing Code

Inspection:

- Refers to the functions of the Authorized Inspector

Examination:

- Refers to the functions of the NDE PERSONNEL- There are some minor conflicts in these definitions in the ASTM documents.

However; the ASTM documents are excluded by the Body of Knowledge

T- 180 Evaluation

Acceptance standards are as stated in the Referencing Code

T- 190 Records/Documentation

Records shall be in compliance with:

The referencing Code and

Section V

The Code User shall be responsible for all records and documentation.


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MAGNETIC TESTING (MT)

ASME Section V, Article 7

T-710 Scope

- When specified by referencing Code Section, the MT techniques of this Article shall be used

- This Article generally in conformance with ASTM SE-709, Standard Recommended Practice

for Magnetic Particle Examination. (ASTM Standard are excluded in the 653 Body ofKnowledge.)

- SE-709 provides additional details to be considered in the procedures used

- Article 7 shall be used together with Article 1, General Requirements- Definition of term used found in Mandatory Appendix II which will send you to SE-1316.

T-720 General

The magnetic particle method is applied to detect cracks and other discontinuities on or near the

surfaces of ferromagnetic materials.

- Sensitivity greatest for surfaces discontinuities- Sensitivity decreases rapidly with increasing depth of discontinuity.

Principle

- Magnetizing an area to be examined

- Applying ferromagnetic particles to the surface- Particles form patterns on surface / discontinuities cause distortions in nominal

magnetic field.

- Patterns are usually characteristics of type of discontinuity detected- Maximum sensitivity is to linear discontinuities oriented perpendicular to the lines of

flux.

- Examine each area twice for optimum effectiveness in detecting all types offdiscontinuities.

- Lines of flux during one examination to be perpendicular to lines of flux during theother.


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T-721 Written Procedure Requirements

MT Shall be performed to a written procedure the procedure shall contain the requirements listed

in Table 721 as a minimum the procedure shall set a single value or range of values for each

requirement.

T-730 Equipment

- Suitable and appropriate means used to produce the necessary magnetic flux- Use techniques listed in T-752 and described in T-770

T-731 Examination Medium

Ferromagnetic particles shall meet the following requirements:

- Particles:

Adequate contrast with surface

Specific requirements given in SE-709- Temperature Limits given in manufacturers literature, or as qualified in the procedure in

accordance with Article 1, T-150.

T-741 Surface Preparation & Enhancement

Results usually satisfactory when surfaces are in the as-welded, as-rolled, as-cast, or as-forged condition

- Grinding or machining may be necessary where surface irregularities could maskindications due to discontinuities

Prior to examination: examine surface and all adjacent areas within 1 inch shall be dry, freeof dirt, grease, lint, scale, welding flux, weld spatter, paint, oil, and other extraneous matter

that could interfere with the examination

Typical cleaning agents: detergents, organic solvents, descaling operations, and paintremovers, degreasing, sand or grit blasting, or ultrasonic cleaning methods also may used

If coatings left on part, it must be demonstrated that indications can be detected through theexisting maximum coating thickness. When an AC yoke is used the demonstration must be

in accordance with Mandatory Appendix I or of this Article.-When temporary coatings are used to enhance particle contrast it must be demonstratedthat indications can be detected through the enhancement coating


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T-750 Techniques

One or more of five magnetization techniques shall be used:

- prod technique

- longitudinal magnetization technique- circular magnetization technique

- yoke technique

- multidirectional magnetization technique

T-752 Prod Technique

T-752.1 Magnetizing Procedure

- magnetization is accomplished by portable prod type contact pressed against the surface to

be examined- to avoid arcing, a remote control switch shall be provided to permit the current to be

applied after the prods have been properly positioned.

T-752.2 Magnetizing Current

- direct or rectified magnetizing current shall be used

- current shall be 100 (minimum) amp/in. (3.9 amp/mm) to 125 (maximum) amp/in. (4.9amp/mm) of prod spacing for sections 3/4 in. (19 mm) thick or greater.

- for sections less than 3/4 in. (19 mm) thick, the current shall be 90 amp/in. (3.5 amp/mm)to 110 amp/in. (4.3 amp/mm) of prod spacing.

T-752.3 Prod Spacing

- prod spacing shall not exceed 8 in. (203 mm)-shorter spacing may be used to accommodate the geometric limitations or to increase the

sensitivity

- prod spacings of less than 3 in. (76 mm) are usually not practical due to banding of theparticles around the prods.

- the prod tips shall be kept clean and dressed

- if the open circuit voltage of the magnetizing current source is greater than 25 V, lead,steel, or aluminium tipped prods are recommended to avoid copper deposits on the part

being examined

T-755 Yoke Technique

T-755.1 Application

- only be applied to detect discontinuities that are open to the surface of the part


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T-755.2 Magnetizing Procedure

- alternating or direct current electromagnetic yokes

- or permanent magnet yokes

- NOTE: For materials 1/4 in. (6 mm) or less in thickness, alternating current yokes aresuperior to direct or permanent magnet yokes of equal lifting power for the detection of

surface discontinuities.

T-760 Calibration of Equipment

T-761 Frequency of Calibration (for equipment with ammeters)

Frequency:(for equipment with ammeters)

- Calibrate each piece of equipment at least once per year- Calibrate prior to first use after major electrical repair, periodic overhaul, or damage

Procedure:

- accuracy of meter verified annually by equipment traceable to a national standard- Take readings at 3 different current out put levels encompassing the usable range

Tolerance:- Units meter reading shall not deviate more than 10% full scale, relative to the actual

current value shown by the test meter.

T-762 Lifting Power of Yokes

Electromagnetic Check magnetizing force within the last year

Permanent magnet must be checked daily, prior to use

Whenever a yoke has been damaged or repaired

Alternating current yoke shall have a lifting power of at least 10 LB at the maximum polespacing to be used

Direct current yoke or permanent magnet yoke shall have a lifting power of at least 40 LB atthe maximum pole spacing to be used

Test weights to be weighed with a scale from a reputable manufacturer and stencilled withthe applicable nominal weight prior to its first use

verify weight only if damaged in a manner that could have caused potential weight loss


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T-764 Magnetic Field Adequacy and Direction

T-764.1 Magnetic Field Adequacy

- the magnetic field shall have sufficient strength to produce satisfactory indications- shall not be so strong that it causes masking of relevant indications by non-relevant

accumulations of magnetic particles

Factors that influence the required field strength include the:

- part size- part shape

- material permeability of the part

- technique of magnetization- coatings

- method of particle application

- type and location of discontinuities to be detected

When it is necessary to verify the adequacy of magnetic field strength, it shall be verified by

using one or more of the following three methods:

- 764.1.1 Pie-Shaped Magnetic Particle Field Indicator- 764.1.2 Artificial Flaw Shims- 764.1.3 Half-Effect Tangential Field Probe

T-770 Examination

T-771 Preliminary Examination

- check area for openings that may not hold particles due to width

T-772 Direction of Magnetization

- Perform 2 separate examinations on each area

- During 2nd

examination, lines of magnetic flux shall be approximately perpendicular tothose used during 1

stexamination

- A different technique may be used for 2nd

examination -For example: Yoke 1stand Prod 2

nd

T-773 Method of Examination

- particles may be either wet or dry- may be either fluorescent or non-fluorescent- examination(s) shall be done by the continuous method


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Dry Particles

- magnetizing current shall remain on while the examination medium is being applied- and while any excess of the examination medium is removed

Wet Particles- magnetizing current shall be turned on after the particles have been applied

- flow of particles shall stop with the application of current

- wet particles applied from aerosol spray cans may be applied before and/or after current is

applied- wet particles may be applied during the application of current if not applied directly to the

examination area and are allowed to flow over the examination area or area applied directly

to the examination area with low velocities insufficient to remove accumulated particles

T-774 Examination Coverage

Conduct with sufficient overlap to assure 100% coverage at required sensitivity

T-776 Excess Particle Removal

- excess dry particles in examinations shall be removed with a stream of low pressure dry air

- examination current or power shall be maintained while removing the excess particles

T-777 Interpretation

shall identify if an indication as false, non-relevant, or relevant

falseandnon-relevant indications shall be proven as false or non-relevant

identify the locations of indications

the character of the indication

T-777.1 Visible (Colour Contrast) Magnetic Particle

discontinuities are indicated by accumulations particles which contrast with the examinationsurface

colour of the particles shall be sufficiently different than the colour of the examinationsurface

a minimum light intensity of 100 fc (1000 Lx) is required on the surface to be examined

light source, technique used, and light level verification is required to be demonstrated onetime documented and maintained on life


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T-777.2 Fluorescent Magnetic Particles

same as 777.1 (above) with the exception that the examination is performed using an ultraviolet

light, called black light. The examination shall be performed as follows:

- shall be performed in a darkened area.- the examiner shall be in the darkened area for at least 5 min prior to performing the

examination

- if the examiner wears glasses or lenses, they shall not be photosensitive

- the black light shall be allowed to warm up for a minimum of 5 min prior to use ormeasurement of the intensity of the ultraviolet light emitted.

- reflectors and filters should be checked and cleaned daily in use

- Cracked or broken filters shall be replaced immediately- the black light intensity shall be measured with a black light meter

- a minimum of 1000 W/cm2on the surface to be examined is required

- the black light intensity shall be verified at least once every 8 hr, whenever the work stationis changed, or whenever the bulb is changed

T-778 Demagnetization

- do if residual magnetism in the part could interfere with subsequent processing.

T-780 Evaluation

- all indications shall be evaluated in terms of the acceptance standards of the referencingCode Section.

- discontinuities on or near the surface are indicated by retention of the examination medium

- localized surface irregularities due to machining marks or other surface conditions may

produce false indications

- broad areas of particle accumulation, which might mask indications from discontinuities,are prohibited, and such areas shall be cleaned and re-examined

T-791 Multidirectional Magnetization

A technique sketch shall be prepared for each different geometry examined, showing:

- the part geometry- cable arrangement and connections

- magnetizing current for each circuit

- and the areas of examination where adequate field strength are obtained

Parts with repetitive geometries, but different dimensions, may be examined using a single

sketch provided that the magnetic field strength is adequate when demonstrated in accordance

with T-755.2.


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T-792 Recording of Indications

T-792.1 Non-rejectable Indications

- Non-rejectable indications shall be recorded as specified by the referencing Code Section.

T-792 Rejectable Indications

Rejectable indications shall be recorded. As a minimum, the:- typeof indications (linear or rounded)

- location and extent (length or diameter or aligned) shall be recorded.

T-793 Examination Records

For each examination, the following information shall be recorded:(a) procedure identification and revision

(b) magnetic particle equipment and type of current

(c) magnetic particle (visible or fluorescent, wet or dry)

(d) examination personnel identity and if required by referencing Code Section,qualification level

(e) map or record of indications per T-792

(f) material and thickness(g) lighting equipment

(h) date and time examinations were performed

T-794 Performance Demonstration

Performance demonstration, when required by the referencing Code Section, shall be

documented

ASME Section VIII, Appendix 6, Paragraph 6-3

Definition of indication. Must be larger than 1/16.

ASME Section VIII, Appendix 6, Paragraph 6-4

Acceptance Standards - All surfaces to be examined shall be free of:

a) Relevant linear indicationsb) Relevant rounded indications greater than 3/16c) Four or more relevant rounded indications in line separated by 1/16 or less, edge to

edge.


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PENETRANT TESTING (PT)

ASME Section V, Article 6

T-610 Scope

Liquid penetrant examination techniques described in this Article shall be used:

- when specified by the reference Code Section

- techniques described in this Article shall be used- this Article is in conformance with SE-165, Standard Test Method for Liquid Penetrant

Examination

- this document provides details to be considered in the procedures used

When this Article is specified by a referencing Code Section:

- the liquid penetrant method described in this Article shall be used together with Article 1,General Requirements.

- Definitions of terms used in this Article appear in Mandatory Appendix 1 of this Article

and Article 1, Appendix 1

T-620 General

The liquid penetrant examination method is an effective means for detecting:

discontinuities which are open to the surface of nonporous metals and other materials

Typical discontinuities detectable by this method are:

cracks

seams

laps

cold shuts

laminations

porosity

In principle:

a liquid penetrant is applied to the surface to be examined allowed to enter (penetrate) open discontinuities

excess penetrant is removed

the part is dried

a developer functions both as:- a blotter to absorb penetrant that has been trapped in discontinuities- and as a contrasting background to enhance the visibility of penetrant indications


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The dyes in penetrants are either:- color contrast (visible under white light)- or fluorescent (visible under ultraviolet light)

T-621 Written Procedure Requirements

T-621.1 Requirements

Liquid penetrant examination shall be performed in accordance with a written procedure which

shall as a minimum, contain the requirements listed in Table T-621.The written procedure shall establish:

- a single value- or range of values- for each requirement

T-621.2 Procedure Qualification

When procedure qualification is specified:

A change of requirements in Table T-621 identified as an essential variable

- from the special value- or range of value

- shall require requalification of the written procedure.

A change of a requirement identified as a nonessential variable- from the specified value

- or range of values

- does not require requalification of the written procedure.All changes of essential or nonessential variables from the value or range of values specified by

the written procedure shall require:

- revision- or an addendum to, the written procedure.


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T-630 Equipment

The term penetrant materials, as used in this Article, is intended to include:

- all penetrants- emulsifiers- solvents- or cleaning agents- developers

used in the examination process.The descriptions of the material types are provided in SE 165 of Article 24

T-640 Miscellaneous Requirements

T-641 Control of Contaminants

The user of this Article shall obtain certification of contaminant content for all liquid penetrant

materials used on:

- nickel base alloys- austenitic stainless steels- and titanium

These certifications shall include:

- the penetrant manufacturers batch numbers- the test results obtained in accordance with Mandatory Appendix II of this Article

- these records shall be maintained as required by the referencing Code Section

T-642 Surface Preparation

In general, satisfactory results may be obtained when the surface of the part is in the:

- as-welded- as-rolled

- as-cast, or

- as-forged conditionSurface preparation by:

- grinding

- machining- or other methods

*may be necessary where surface irregularities could mask indications.*


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Prior to each liquid penetrant examination the surface to be examined and all adjacent areas

within at least 1 in. (25mm) shall be dry and free of all:- dirt- grease- lint- scale- welding flux- weld spatter-paint, oil,- and other matter that could obscure surface openings or interfere with the examination.

Typical cleaning agents which may be used are:- detergents, organic solvents, de-scaling solutions, and paint removers,- degreasing and ultrasonic cleaning methods may also be used.

Cleaning solvents shall meet the requirements of T-641. The cleaning method employed is an

importantpart of the examination process.

T-643 Drying After Preparation

After cleaning, drying of the surfaces to be examined shall be accomplished by:

- normal evaporation- or with forced hot or cold air.

A minimum period of time shall be established to ensure that the cleaning solution hasevaporated prior to application of the penetrant.

T-650 Technique

T-651 Techniques

Either a colour contrast (visible) penetrant or a fluorescent penetrant shall be used with one ofthe following three penetrant processes:

water washable

post-emulsifying

solvent removable

The visible and fluorescent penetrants used in combination with these three penetrant processes

result in six liquid penetrant techniques.


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T-652 Techniques for Standard Temperatures

As a standard technique, the temperature of the penetrant and the surface of the part to be

processed shall:

- not be below 50 F (10 C)- nor above 125 F (52 C)

- throughout the examination period.

Local heating or cooling is permitted provided the part temperature remains in the range of 50 Fto 125 F (10 C to 52 C) during the examination. Where it is not practical to comply with these

temperature limitations, other temperatures and times may be used, provided the procedures are

qualified as specified in T-653.

T-653 Techniques for Nonstandard Temperatures

When it is not practical to conduct a liquid penetrant examination within:

- 50 F to 1250 F (10 C to 52 C)

- the procedure at the proposed lower or higher temperature range

- requires qualification in accordance with Mandatory Appendix III of this Article.

T-654 Technique Restrictions

- fluorescent penetrant examination shall not follow a color contrast penetrant examination

- Intermixing of penetrant materials from different families or different manufacturers isnot permitted

- retest with water washable penetrants may cause loss of marginal indications

T-660 Calibration

Visible and fluorescent (black) light meters, shall be calibrated:

- at least once a year

- whenever the meter has been repaired- if meters have not been in use for one year or more, calibration shall be done before being

used

T-670 Examination

T-671 Penetrant Application

The penetrant may be applied by any suitable means, such as:

- dipping-brushing- spraying


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If the penetrant is applied by spraying using compressed-air-type apparatus:

- filters shall be placed on the upstream side near the air inlet to preclude contamination.

T-672 Penetration (Dwell) Time

Penetration (dwell) time is critical. The minimum penetration time shall be:

- as required in Table T-672- or as qualified by demonstration for specific applications

T-673 Excess Penetrant Removal

After the specified penetration (dwell) time has elapsed:- any penetrant remaining on the surface shall be removed

- take care to minimize removal of penetrant from discontinuities

T-673.1 Water-Washable Penetrants

Excess water-washable penetrant shall be removed:

- with a water spray- water pressure shall not exceed 50 psi (345 kPa),

- water temperature shall not exceed 110F (43C).

T-673.2 Postemulsification Penetrants

Lipophilic Emulsification.

Hydrophilic Emulsification

NOTE:Additional information may be obtained from SE-165

T-673.3 Solvent Removable Penetrants.

Excess solvent removable penetrants shall be removed by

- wiping with a cloth or absorbent paper,- repeating the operation until most traces of penetrant have been removed

- remaining traces shall be removed by lightly wiping with cloth paper moistened with

solvent- care shall be taken to avoid the use of excess solvent

NOTE: Flushing is Prohibited - flushing the surface with solvent, following the application of

the penetrant and prior to developing is prohibited


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T-674 Drying After Excess Penetrant Removal

For the water washable or post-emulsifying technique, the surfaces may be dried by:

- blotting with clean materials

- using circulating air- temperature of the surface may not be raised above 125 F (52 C)

For the solvent removable technique, the surfaces may be dried by:

- normal evaporation

- blotting- wiping

- forced air

T-675 Developing

The developer shall be applied as soon as possible after penetrant removal:- the time interval shall not exceed that established in the procedure

- insufficient coating thickness may not draw the penetrant out of discontinuities

- excessive coating thickness may mask indications

- with colour contrast penetrants, only a wet developer shall be used- with fluorescent penetrants, a wet or dry developer may be used

T-675.1 Dry Developer Application.

Dry developer shall be applied only to a dry surface by:- soft brush- hand power bulb

- powder gun

- or other means

- provided the powder is dusted evenly over the entire surface being examined

T-675.2 Wet Developer Application.

Wet developer must be thoroughly agitated to ensure adequate dispersion of suspended particles

(a) Aqueous Developer Application.Aqueous developer may be applied to either a wet or dry surface it shall be applied by:

- dipping- brushing- spraying- or other means provided a thin coating is obtained over the entire surface being

examined

- Drying time may be decreased by using warm air- Temperature of the part may not be raised above 125F (52 C).- Blotting is not permitted


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(b) Nonaqueous Developer Application.Nonaqueous developer shall be applied only to a dry surface. It shall be applied by:

- spraying- under such conditions, developer may be applied by brushing- drying shall be by normal evaporation.

T-675.3

- developing time for final interpretation begins immediately after application of a dry

developer

- or as soon as a wet developer coating is dry- minimum developing time shall be as required by Table T-672

T-675 Interpretation

T-676.1 Final Interpretation.

- shall be made within 10 to 60 min after the requirements of T-675.3 are satisfied- if bleed-out does not alter the examination results, longer periods are permitted

- if the surface to be examined is large enough to preclude complete examination within

the prescribed or established time, the examination shall be performed in increments

T-676.2 Characterizing Indication(s)

- type of discontinuities are difficult to evaluate if the penetrant diffuses excessively into

the developer

- if this condition occurs, close observation of the formation of indications(s) during

application of the developer may assist in characterizing and determining theindication(s).

T-676.3 Colour Contrast Penetrants

- developer forms a reasonably uniform white coating

- discontinuities are indicated by bleed-out of the penetrant (normally a deep red color)- indications with a light pink colour may indicate excessive cleaning

- inadequate cleaning may leave an excessive background making interpretation difficult

- minimum light intensity of 100 fc (1000 Lx) is required on the surface


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T- 676.4 Fluorescent Penetrants.

The examination shall be performed as follows:

- shall be performed in a darkened area.

- examiner shall be in the darkened area for at least 5 min prior to performing theexamination to enable his eyes to adapt to dark viewing

- if the examiner wears glasses or lenses, they shall not be photosensitive.

- light shall be allowed to warm up for a minimum of 5 min prior to use

- or measurements of the intensity of the ultraviolet light emitted- reflectors and filters should be checked and cleaned daily when in use

- cracked or broken filters shall be replaced immediately

Black light intensity shall be measured with a black light meter

- a minimum of 1000W/cm2 on the surface of the part being examined shall be required

- black light intensity shall be re-verified:

- at least once every 8 hr

- whenever the work station is changed- or whenever the bulb is changed.

T-677 Post-examination Cleaning

post-examination cleaning should be conducted as soon as practical after evaluation and

documentation using a process that does not adversely affect the part

T-680 Evaluation

- all indications shall be evaluated in terms of the acceptance standards of the referencingCode Section

- localized surface irregularities due to machining marks or other conditions may

procedure false indications- broad areas of fluorescence or pigmentation which could mask indications of

discontinuities are unacceptable, and such areas shall be cleaned and reexamined.

T-691 Recording of Indications

T-691.1 Non-rejectable Indications.

Non-rejectable indications shall be recorded as specified by the referencing Code Section

T-691.2 Rejectable Indications

rejectable indications shall be recorded. The following shall be recorded as a minimum:

- type of indications (linear or rounded)- location

- extent (length or diameter or aligned)


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T-692 Examination Records

For each examination, the following information shall be recorded:

(a) procedure identification and revision;

(b) liquid penetrant type (visible or fluorescent);(c) type (number or letter designation of each penetrant, penetrant remover, emulsifier, and

developer used;

(d) examination personnel identity and if required by referencing Code Section, qualification

level;(e) map or record of indications per T-691;

(f) material and thickness;

(g) lighting equipment; and(h) date and time examinations were performed.

T-693 Performance Demonstration

Performance demonstration, when required by the referencing Code Section, shall be

documented.

Appendix II Control of Contaminants for Liquid Penetrant Examination

U-610 Scope

this Appendix contains requirements for the control of contaminant content for all liquidpenetrant materials used on nickel base alloys, austenitic stainless steels, and titanium.

U-640 Requirements

U-641 Nickel Based Alloys

- when examining nickel based alloys, all materials shall be analysed individually for

sulphur content- the sulphur content shall not exceed 1% of the residue by weight.

U-642 Austenitic Stainless Steel and Titanium

when examining austenitic stainless steel or titanium, all materials shall be analysed individually

for chloride


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ASME Section VIII Division 1

Appendix 8 Paragraph 8-3 Evaluation of Indications

An indication is the evidence of a mechanical imperfection. Only indications with majordimensions greater than 1/16 shall be considered relevant.

a. A linear indications is one having a length greater than three (3) times thewidth.

b. A rounded indication is one of circular or elliptical shape with the lengthequal to or less then three times the width.

c. Any questionable or doubtful indications shall be re-examined to determinewhether or not they are relevant.

Appendix 8 Paragraph 8-4 Acceptance Standards

All surfaces shall be free of:

a. Relevant linear indicationsb. Relevant rounded indications greater than 3-16c. Four or more relevant rounded indications separated by 1/16

ULTRASONIC TESTING (UT)

ASME Section V, Article 23, SE-797

1. Scope

This practice provides guidelines for measuring the thickness of materials:

using the contact pulse-echo method

at temperatures not to exceed 200F (93C)

applicable to any material in which ultrasonic waves will propagate at a constantvelocity throughout the part

and from which back reflections can be obtained and resolved

The values stated in either inch-pound or S1 units are to be regarded as the standard

The values given in parentheses are for information only

This standard does not purport to address all of the safety concerns

4. Summary of Practice

Thickness M, when measured by the pulse-echo ultrasonic method, is a product of the velocity ofsound in the material and one half the transit time(round trip) through the material.


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Vt

T = ------

2

where:

T = thickness,

V = velocity

t= transit time.

NOTE: The pulse-echo ultrasonic instrument measures the transit time of the ultrasonic pulse

through the part

7. Procedure-Calibration and Adjustment of Apparatus

Case 1 Direct Contract, Single-Element Search Unit: Case II Delay Line Single-Element Search Unit: Case III Dual Search Units: Case IV Thick Sections:

8. Technical Hazards

1. Dual search units:

a.may be used effectively with rough surfaceconditions

b.only the first returned echo, such as from

the bottom of a pit, is used in the

measurement

c.generally, a localized scanning search ismade to detect the minimum remaining

wall.

2. Material Properties:a.the instrument should be calibrated on a material having the same acoustic velocity

and attenuation as the material to be measuredb.where possible, calibration should be confirmed by direct dimensional measurement

of the material to be examined.

3. Scanning:a.the maximum speed of scanning should be stated in the procedureb.the following may require slower scanning:

- material conditions- type of equipment- operator capabilities


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4. Geometry:a.Highest accuracy can be obtained from materials with parallel or concentric

surfaces

b.It is possible to obtain measurements from materials with nonparallel surfaces.

However: the accuracy of the reading may be limited as follows:- the reading obtained is generally that of the thinnest portion of the section being

interrogated by the sound beam at a given instant

- relatively small diameter curves often require special techniques and equipment- when small diameters are to be measured, special procedures including additional

specimens may be required to ensure accuracy of setup and readout.

5. High-Temperature materials:a.high-temperature materials, up to about 540oC (1000oF) can be measured with

specially designed instruments with high temperature compensation, search unit

assemblies, and couplantsb.normalization of apparent thickness reading for elevated temperatures is required

c.a rule of thumb often used is as follows:- the apparent thickness reading obtained from steel walls having elevated

temperatures is high (too thick) by a factor of about 1% per 55oC (100

oF)

- if the instrument was calibrated on a piece of similar material at 20oC (68oF). andif the reading was obtained with a surface temperature of 460

oC (860

oF), the

apparent reading should be reduced by 8%- this correction is an average one for many types of steel

- other corrections would have to be determined empirically for other materials.

6. Instrument:a.time base linearity is required so that a change in the thickness of material willproduce a corresponding change of indicated thickness

b.if a CRT is used as a readout, its horizontal linearity can be checked by usingPractice E 317.

7. Back Reflection Wave-train:a.direct-thickness readout instruments read the thickness at the first half cycle of the

wave-train that exceeds a set amplitude a fixed time.

b.If the amplitude of the back reflection from the measured material is different fromthe amplitude of the back reflection from the calibration blocks, the thickness

readout may read to a different half cycle in the wave-train, thereby producing an

errorc.this may be reduced by:

- using, calibration blocks having attenuation characteristics equal to those in themeasured material.

- Or adjusting back reflection amplitude to be equal for both the calibrating blocksand measured material.


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d.using an instrument with automatic gain control to produce a constant amplitude

back reflection.

8. Readouts:a.CRT displays are recommended where reflecting surfaces are rough, pitted, or

corroded

b.direct-thickness readout, without CRT, presents hazards of mis-adjustment and

misreading under certain test conditions such as:

- especially thin sections- rough corroded surfaces- and rapidly changing thickness ranges

9. Calibration Standards:a.Greater accuracy can be obtained when the equipment is calibrated on areas of

known thickness of the material to be measured

10.Variations in echo signal strengtha.may produce an error equivalent to one or more half-cycles of the RF frequency,

dependent on instrumentation characteristics.

9. Procedure Requirements

In developing the detailed procedure the following items should be considered:

Instrument manufacturers operating instructions

Scope of materials/objects to be measured

Applicability, accuracy requirements

Definitions

Requirements

Personnel

Equipment

Procedure qualification

Procedure

Measurement conditions

Surface preparation and couplant Calibration and allowable tolerances

Scanning parameters

Report

Procedure used

Standardization (calibration) record

Measurement record


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10. Report

Record the following information at the time of the measurements and include it in the report:

Examination procedure.

Type of instrument.

Standardization (calibration) blocks, size and material type

Size, frequency, and type of search unit

Scanning method

Results

Maximum and minimum thickness measurements

Location of measurements

Personnel data, certification level

SUPPLEMENTAL UT TECHNIQUES

This section of the course provides a brief introduction into some of the other UT techniques that

are mentioned in for example 571 and 577 recommended practices.

SHEAR WAVE ULTRASONIC TESTING (SWUT)

SWUT is used for the inspection of welds as the angle of the beam is selected to intersect defects

perpendicular to the beam path.


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TIME OF FLIGHT DIFFRACTION (TOFD)

ToFD is an automated ultrasonic inspection technique that produces a high-resolution image of

an item

ToFD Inspection Methodology The item to be tested is straddled by a scanner assembly that contains ultrasonic

transducers and an encoder to measure the distance that the transducers travel.

One transducer floods the test area with pulses of ultrasonic energy. The other transduceris used to detect diffraction from geometric features and any flaws that may occur.

Signal processing is used to convert this information into an image, which can beinterpreted by skilled operators to define item condition.

The signals, processed image, calibration parameters and other relevant information arestored electronically and can be recalled whenever required

GUIDED WAVE ULTRASONIC TESTING (GWUT)

GWUT or more commonly called LRUT (Long Range Ultrasonic Testing) concept was

developed at Imperial college with TWI (The Welding Institute) with the major aim of

developing a method of inspection for insulated pipe-work for detecting external CorrosionUnder Insulation (CUI). Detailed experimental studies and site trials, backed up by numerical

modeling using finite elements, showed that guided waves propagating in the pipe wall can be

used to detect both internal and external corrosion in pipe-work systems. The Teletest

LRUTsystem for monitoring pipes and pipelines in service was introduced commercially by Plant

Integrity Ltd (Pi) in early 1998. It was found that this new technology has far wider applications

than just CUI and has since been found a useful tool for screening remote and inaccessible pipingsuch as risers, road crossings, furnaces and boilers.


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Equipment

LRUT equipment consists of a bracelet transducer array, a purpose built 24 channel low

frequency flaw detector and a ruggerdised laptop computer (Figure 1). The bracelet transducer

array which consists of an inflatable collar (Figure 2) and separate multi-mode modules (Figure3) fitted with transducers (Figure 5) is placed around the pipe and inflated. The bracelet

transducer array is modular in design allowing easy interchanges of separate transducers,

modules and or leads if the need arises.

Figure 1. Bracelet Transducer Array Figure 2. Inflatable Collar

Figure 1. Teletest System Figure 3. Multimode Module

Figure 4. Mini-Test Figure 5.Individual Transducers

The computer and specifically produced software package, which controls the test,

communicates via an umbilical cable which can extend up to 100m with the low frequency flaw

detector which energises the transducers and receives the returning signal responses.


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LRUT Inspection Methodology

LRUT ultrasonic methods use so called guided ultrasonic waves and these wave have the

property that their velocity is independent of frequency over a wide range of frequencies (Figure

6). Guided waves, similar in form to Lamb waves, have the characteristic that any change infrequency may change their velocity. Normally this form of wave propagation would spread in

every direction similar to the waves formed by a stone tossed in a pond which expand radially

outward and dissipate. Given that on pipe the entire volume of the cross sectional area is filled

with the wave motion because of the encircling bracelet of transducers the guided waves canpropagate up to hundred metres in plain pipe. In contrast with conventional ultrasonic testing,

where generally only a single mode such as either compression or shear exists, a large number of

guided wave modes are possible during a single test with LRUT. In order for the responses fromdiscontinuities in pipes to be interpretable it is necessary to use selected wave modes that allow

the signals to be simplified.

Fig 6. Dispersion curves for guided waves in pipes, showing the fast moving non-dispersive L(0,2) mode

To generate the appropriate wave modes in common pipe thicknesses, frequencies in the range20 - 120 kHz are utilised, compared with around 5MHz for conventional thickness testing.

These waves can travel many metres with minimal attenuation and therefore offer the potential

of testing large distances from a single point using a pulse-echo transducer collar wrappedaround the pipe. Where changes in the thickness of the pipe, either on the inside or the outside,

cause reflections they are detected by the transducer (Figure 9). Hence metal loss defects from

corrosion/erosion inside the pipe or corrosion on the outside of the pipe can be detected.


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Figure 9. Principle of operation of long range ultrasonic testing of pipes

Anomalies are located by distance from the transducer and approximate circumferential location.By separating the transducer modules into quadrant sets allows for the approximate

circumferential location to be determined. These quadrant sets of transducers independently

receive returning signals, allowing for any flexural changes in the returning signal to be detected,thereby providing quadrant location.

Data is presented in a A scan fashion with black lines indicating symmetrical results, redlines

are horizontal flexural and blue is used to indicate vertical flexural responses (Figure 10). Thispipe length is free from any corrosion and the trace shows a clean baseline with sharp peaks from

the butt welds in the line. The Teletest

system applies a phased input to the different parts of

the transducer which makes it possible to send the ultrasound in one direction only along thepipe. By sending the ultrasound in one direction only avoids any confusion in interpretation. By

switching the input the test may be performed in the opposite direction.


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Figure 10. Inspection data results.

Numerous factors affect the sound wave propagation and subsequent system performance.

Surface condition Geometry Contents

Bare metal

Smooth well bonded

paint

Fusion bonded epoxy

Light pitting

Heavy pitting

Bitumastic coated

Concrete coated

Straight lengths

Attachments/brackets

Branches

Multiple bends

Gas

Liquid

High viscosityDifficult

Ease of Test


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RADIOGRAPHIC TESTING (RT)

ASME Section V, Article 2 Radiographic Examination

T-210 Scope

When this Article is specified by the referencing Code Section, the radiographic method

described in this Article shall be used together with Article 1, General Requirements.

T- 220 General Requirements

T- 221 Procedure Requirements

T- 221.2 Radiographic examination shall be performed to a written procedure.

Requirements and Compliance for a Written Radiographic Procedure Minimum Contents of aWritten Procedure:

- material & thickness range

- isotope used or maximum X-ray voltage- minimum source-to-object distance

- Maximum distance from source side of object to the film

- Maximum source size- film brand and designation

- screens used

Demonstration of the density and IQI image requirements of the written procedure on productionor technique radiographs shall be considered satisfactory evidence of compliance with that

procedure


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T- 222 Surface Preparation

T-222.1 Materials

Surfaces shall satisfy the requirements of the applicable materials specification. Additional

conditioning may be required (grinding, etc.), if necessary, by any suitable process to a degreethat surface irregularities cannot mask or be confused with surface discontinuities.

T-222.2 Welds

Weld ripples or weld surface irregularities on both the inside and outside shall be removed byany suitable process to such a degree that the resulting radiographic image due to any

irregularities cannot mask or be confused with the image of any discontinuity.

The finished surface of all butt-welded joints may be flush with the base in the referenced CodeSection. (API 650 and/or API 653 in the case of Atmospheric Aboveground Storage Tanks)

T-223 Backscatter Radiation

A lead symbol B with minimum dimensions of in height and 1/16 in thickness, shall be

attached to the back of each film holder during each exposure to determine if backscatter

radiation is exposing the film.

T-224 System of Identification

Permanent identification system shall be establish to trace radiograph to the contract, component,

weld or weld seam, or part numbers, as appropriate. In addition:- Manufacturers symbol or name and the date of the radiograph shall be plainly

and permanently included on the radiograph.

- I.D. system does not require that the information appear as radiographic image- the information shall not obscure the area of interest.

T-225 Monitoring Density Limitations of Radiographs

Either a densitometer or step wedge comparison film shall be used for judging film density.

T-226 Extent of Examination

The extent of examination shall be as specified by the referencing code.

T-230 Equipment and Materials


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T-231 Film

T-231.1 Radiographs shall be made using industrial radiographic film.

T-231.2 Processing The following shall be used as a guide for processing film:- SE -999

- SE-94, Part III

T-232 Intensifying Screens

May be used except when restricted by the referencing Code Section.

T-233 Image Quality Indicator (IQI) Design

- IQIs shall be either hole type or wire type- Manufactured and identified in accordance with:

- SE-1025 (for hole type)- SE-747 (for wire type)

- ASME standard IQIs shall consist of those in:Table T-223.1 for hole type (See table in Section V)

Table T-233.2 for wire type (See table in Section V)

T-270 Examination

T-271 Radiographic Technique

T-271.1 Single-Wall Technique

- Use whenever practical

- Radiation passes through only one wall of the weld (material)- Adequate number of exposures shall be made to determine required coverage

T-271.2 Double-Wall Technique- Use when a single-wall technique is not practical

- Radiation passes through two walls of the weld (material) for a double wall exposure. For

single wall views, only one wall is viewed. For double wall views (3.5 in. nominal O.D. orless) both walls may be viewed.

- Adequate number of exposures shall be made to demonstrate required coverage

A) Single-Wall Viewing via Double-Wall Technique- for materials and for welds in components- weld (material) on the film side is viewed for acceptance on the radiograph.- When complete coverage is required for circumferential welds, a minimum of 3

exposures taken 120 degrees to each other shall be made.


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b) Double-Wall Viewing via Double-Wall TechniqueFor materials and for welds in components 3.5-inches or less in nominal OD the radiationpasses through two walls/weld in both walls is viewed for acceptance only a source side

IQI shall be used

- If the geometric un-sharpness requirement cannot be met use single-wall viewing

T-274 Geometric Un-sharpness

Geometric un-sharpness of the radiograph shall be determined in accordance with:

Ug = Fd/D

Where:Ug = geometric unsharpness.

F = source size; the maximum projected

dimension of the radiating source (or

effective focal spot) in the planeperpendicular to the distance D from the

weld or object being radiographed, inches.

D = distance from source of radiation to weld orobject being radiographed, inches.

d = distance from source side of welded or object

being radiographed, inches.

T-275 Location Markers (See Fig. T-275)

- to appear as radiographic images on the film

- shall be placed on the part, not on the exposure holder/cassette.- their locations are to be permanently marked on surface of part being radiographed

- or on a map in a manner permitting the area of interest to be accurately traceable

- Locations shall be available for the required retention period of the radiograph- Evidence provided on the radiograph that the required coverage has been obtained

T-280 Evaluation

T-281 Quality of Radiographs

All radiographs must be free from mechanical, chemical, or other blemishes to the extent that

they do not mask and are not confused with the image of any discontinuity in the area of interest

of the object being radiographed. Such blemishes include, but are not limited to:- fogging-processing defects such as streaks, watermarks, or chemical stains- scratches, finger marks, crimps, dirtiness, static marks, smudges, or tears- false indications due to defective screens


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T-282 Radiographic Density

The transmitted film density through the radiographic image of the body of the appropriate hole

IQI or adjacent to the designated wire of a wire IQI and the area of interest shall be:

- 1.8 minimum for single film viewing for radiographs made with an X-ray source- 2.0 minimum for radiographs made with a gamma ray source- For composite viewing of multiple film exposures, each film of the composite set shall

have a minimum density of 1.3

- The maximum density shall be 4.0 for either single or composite viewing- A tolerance of 0.05 in density is allowed for variations between densitometer readings

T-283 IQI Sensitivity

Radiography shall be performed with a technique of sufficient sensitivity to display

- the hole IQI image and the 2T- or the designated wire of a wire IQI- the radiographs shall display the ID numbers and letters.- If the required hole IQI image and specified hole, or designated wire, do not show

on any film in multiple film technique, but do show in composite film viewing,interpretation shall be permitted only by composite film viewing

- If a thinner or thicker IQI is substituted for those shown in Table T-276 therequirements of Table T-283 must be met (i.e., if Table T-276 calls for a 35 IQIand the required hole is 2T, then a 50 IQI showing a 1T hole or a 25 IQI showing

a 4T hole may be used as alternatives).

T-284 Excessive Backscatter

- If a light image of the B appears on a darker background of the radiograph,protection from backscatter is insufficient and the radiograph shall be consideredunacceptable

- A dark image of the B on a lighter background is not cause for rejection.

T-285 Geometric Unsharpness Limitations

Shall not exceed:

Material Ug

Thickness in inches Maximum in inches

Under 2 0.020

2 through 3 0.030

Over 3 through 4 0.040

Greater than 4 0.070

NOTE: Material thickness is the thickness on which the IQI is based.


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T-290 DOCUMENTATION

T-291 Radiographic Technique Documentation Details

Details of the radiographic examination technique used shall accompany each group ofradiographs. As a minimum the information shall include:

- identification, e.g., job or heat number

- data specified in T-275.3 when applicable (dimensioned ID marker map)- number of exposures

- isotope or maximum X-ray voltage used

- effective focal spot sizes- material type and thickness range

- minimum source-to-object distance

- maximum distance from source side of object to the film- film brand and designation

- number of films per cassette

- single-or double-wall exposure

- single-or double-wall viewing

SUPPLEMENTAL RT TECHNIQUES

This section of the course provides a brief introduction into some of the other RT techniques thatare mentioned in for example 571 and 577 recommended practices.

NEUTRON BACKSCATTER

Operation Theory

The device contains a small quantity of sealed radioactive material that emits fast neutrons butalso gamma radiation. This is provided by an Americium 241 Beryllium neutron emitting

compound of low activity; approximately 1.85GBq (50 milli Curies) with a 458 year half-life.

These fast neutrons travel outward in all directions from the base of the hand held instrumentpenetrating the material under test. Some of these neutrons are reflected back towards the

detectors mounted in the base of the Hydrotector head producing a pulse. These backscattered

neutrons are called thermal neutrons. The number of pulses is proportional to the amount ofHydrogen atoms contained in the test material and therefore by inference, the likelyconcentration of water moisture.


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SUPPLEMENTAL NDT TECHNIQUES

This section of the course provides a brief introduction into some of the other NDT techniques

that are mentioned in for example 571 and 577 recommended practices.

ALTERNATING CURRENT FIELD MEASUREMENT (ACFM)

The ACFM technique is an electromagnetic non-contacting technique that is able to detect andsize surface breaking defects in a range of different materials and through coatings of varying

thickness.

Requires minimal surface preparation.

Can be used at elevated temperatures up to 9000F (482

0C).

Uses a probe similar to an eddy current probe and introduces an alternatingcurrent in a thin skin near to the surface of any conductor.

When a uniform current is introduced into the area that is defect free, the current flows

undisturbed. If the areas have a crack, the current flows around the ends and the faces of the

crack. A magnetic field is present above the surface associated with this uniform alternatingcurrent and will be disturbed if a surface-breaking crack is present.


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Two components of the magnetic field are measured:

Bx along the length of the defect, whichresponds to changes in surface current

density and gives an indication of depth

when the reduction is the greatest; and

Bz which gives a negative and positive

response at either end of the defect.

During the application of the ACFM technique actual values of the magnetic field are beingmeasured in real time. These are used with mathematical model look-up tables to eliminate theneed for calibration of the ACFM instrument using a calibration piece with artificial defects such

as slots.


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NDE PRACTICE QUESTIONS

1. The __________________ is responsible for examination equipment calibration records.a) Code User

b) NDE technician calibrates his own equipment andc) company that manufactures the NDE equipmentd) Authorized Inspector

2. At least __________________ copy/copies of an NDE procedure must be available to the ManufacturersNondestructive Examination Personnel at the work site.

a) twob) onec) noned) there is no requirement

3. The difference between as inspection and an examination per Section V of the ASME Code is:a) Inspections are NDE functions performed by contractors

b) examinations are QC functions performed by the manufacturers employeesc) inspections are performed by the Authorized Inspectord) 2 & 3 above

4. How must all Nondestructive Examination Personnel be qualified when Article 1 is referenced?a) per the manufacturers PQRs

b) per the requirements of their employers written practicec) The AI will specify the requirements for each jobd) they are always qualified per ASNT SNT-TC-1A

5. Which of the following is not part of the minimum content of a written radiographic procedure?a) type of screens used if any

b) type of emulsion usedc) film brand & designationd) maximum X-ray voltage or isotope used

6. How can compliance with a written radiographic procedure be demonstrated?a) by showing the film to the Authorised Inspector

b) by confirming the accuracy of the radiographs with a welder or welding foremanc) by verifying the proper density and demonstrating the IQI image requirementsd) by demonstrating the required sensitivity by showing the 3T hole in a hole type IQI

7. What finished surface is required of butt welds?

a) all surface cracks must run vertically in the centerb) all surface cracks must run horizontally in the centerc) they must not have any irregularities or contours that will mask defects or interfere with

interpretation

d) they must not have any undercut or pinholes that will mask defects or interfere with interpretation

8. One reason for a system of radiographic film identification is:a) to identify the film manufacturer

b) so the location of detects will be traceable to the weldmentc) to keep track of how much film is used for billing purposesd) so the welders will know where to have the film placed by the radiographer


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9. Intensifying screens may be used ________________

a) only when radiographing at nightb) only for Polaroid SE-1968 instant radiographsc) when performing radiography in accordance with ASME Section V, Article 2d) for color radiographs only

10. IQIs may be what types?a) wire

b) holec) crackd) 1 & 2 above

11. Viewing facilities for radiographs shall ____________________a) be small, warm and comfortable enough for afternoon naps

b) have adjustable lighting with lots of ferns and plansc) be bright and airy with lots of ferns and plantsd) have subdued background lighting that will not cause glare on the film

12. The direction of the central beam of radiation should be _________________ the area of interest wheneverpractical.

a) as close as possible tob) centered onc) no more than 18 fromd) at least 36 from

13. Where are hole type IQIs placed when radiographing welds?a) always in the center of the weldment

b) adjacent to or on the weld but not in the area of interestc) on the film sided) none of the above

14. Where are location markers placed if they are to appear as a radiographic image?a) on the part to be radiographed

b) on the film in the dark roomc) on the IQI top side over the 2T holed) 1 & 3 above

15. The IQIs is normally placed on which side of a part?a) the IQI is optional so it doesnt matter

b) the film side; the same side of the part to be inspected as the comparatorc) the source side except when inaccessibility prevents hand placement on that sided) the film side; the same side of the part to be inspected as the film

16. What designation is used to indicate the IQIs is on the film side?a) it is only noted on the radiographic report there is no other designation used

b) the welder noted it on the weld mapc) the IQI may not be placed on the film sided) a lead letter F placed next to or on the IQI


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17. How many IQIs should appear on each radiograph?

a) there must always be one on every radiograph and it must appear as a radiographic imageb) there must always be one on every radiograph but it need not appear as a radiographic imagec) there must always be two on every radiograph and it must appear as a radiographic imaged) it depends on the configuration used to set up the shot (panoramic multifilm, single shots, etc)

18. Shims may be placed under IQIs to simulate weld reinforcement to assure the density in the area of interest isno more than __________________ lighter than the density through the IQI.

a) 10%b) 25%c) 15%d) 5%

19. Which of the following blemishes is permitted on film as long as they do not interfere with interpretation and

do not mask or become confused with discontinuities in the area of interest?a) fogging & false indications from defective screens

b) scratches, crimps, static marks & dirtinessc) processing defects such as streaks & water marksd) all of the above

20. The minimum density requirements for single film viewing are:a) 1.8 for film made gamma ray and 2.0 for film made with an X-ray machine

b) 4.0 for film made gamma ray and 4.0 for film made with an X-ray machinec) 2.0 for film made gamma ray and 1.8 for film made with an X-ray machined) no more than 25% lighter in any area than the density in the darkest area

21. When using only one IQI per film density measurements may vary through the area of interest by no more

than ________________ or additional IQIs will be required.a) minus 15% or plus 30%b) plus 15% or minus 30%c) plus 1.5 X ratio of average densitiesd) no more than 15% from the density of the step wedge

22. Which of the below is an essential indication of sensitivity for image quality of a radiograph?a) display of the welders stampings

b) clearly visible location markersc) display of the designated hole or essential wire of the IQI usedd) proper density variations within 50% of the IQI thickness

23. Excessive backscatter in indicated by:a) a lead letter F being visible on the radiograph

b) a dark image of the letter B on a lighter backgroundc) any image of the lead letter B in the background of the filmd) a light image of the lead letter B on a dark background

24. A tank is built with plate under 2 inches thick. The geometric un-sharpness of the radiographs shall notexceed:

a) 0.010b) 0.020c) 0.030d) 0.040


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25. The following information may not be included in the documentation accompanying the radiographs:

a) minimum source to object distance and film brand & designationb) number of exposures & film identificationc) Isotope & effective focal spot sizesd) development time & exact shim material specifications

26. When the radiographs are presented to the Authorized Inspector ______________a) he will interpret them and indicate the disposition of each film on the report

b) he will view them only after a good lunch paid for by the NDE technician.c) the manufacturer will have interpreted all the film and will have indicated the disposition of each

on the report and will have also included all the other information required to on the report.

d) the radiographs will be marked with a permanent marker or by other means to indicate whichtechnician processed them

27. Which of the following is not a type of discontinuity liquid penetrant examination is effective in detecting.a) cold shuts & laminations

b) subsurface cracksc) pinholesd) seams

28. Which of the following is an essential variable for a Liquid Penetrant procedure?a)post examination cleaning details

b)materials, shapes & sizes to be examinedc)decrease in penetrant dwell timed)processing details for removal of excess penetrant

29. Revisions to PT procedures may be required if there is

a)a change in surface preparationb)a change or substitution in type or family of penetrant materialsc)a change in the method of applying developerd)All of the above

30. Which of the following penetrant techniques may not be used?a) solvent removable

b) hard drying fluorescentc) water washabled) post emulsifying

31. What materials require the use of tested and certified liquid penetrants as to the contaminants in thepenetrant?

a) carbon steels with > 3% chromeb) aluminumc) nickel base alloys & titaniumd) copper

32. What condition must the surface to be examined be in prior to conducting the examination?a) dry & free of all remedial demagnetization materials & effects

b) dry & free of any oil, grease, lint, scale or other extraneous matter for 1 on all sides of the area tobe examined

c) free of all subsurface defects previously detected by other methodsd) dry & free of extraneous matter for 2 on all sides of the area to be examined


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33. How shall PT indications be evaluated per ASME Article 6?

a) per universal acceptance standards in ASNT SNT-TC-1Ab) in terms of the acceptance standards of the referencing code sectionc) per the specific requirements in appendix N.5.3 of API-789d) per the Owner/User procedures for NDE

34. The minimum period of drying time after initial cleaning is _________________.a) at least 5 minutes to assure that all the cleaning solution has evaporated prior to applying the

penetrant

b) a minimum time established to assure that all the cleaning solution has evaporated prior toapplying the penetrant

c) at least 15 minutes to assure that all the cleaning solution has evaporated prior to applying thepenetrant

d) at least 10 minutes to assure that all the cleaning solution has evaporated prior to applying the

penetrant

35. Which of the following is not a suitable means of removing penetrant.a) flushing water washable penetrant with water spray of less than 50 PSI & 110 F

b) steaming water washable penetrant at 300 PSI to remove itc) wiping solvent removable penetrant with a lint free clothd) rinsing post emulsifying penetrant at a temperature & pressure as recommended by the

manufacturer

36. Without special qualification penetrant testing can be performed between _______________ degrees.1. 50 degrees F to 135 Degrees F2. 50 degrees F to 125 degrees F3. 72 degrees F to 130 Degrees F

4. 50 degrees F to 130 Degrees F

37. When PT examination is to be performed above or below _________________ the procedure is qualified forthe temperature range intended using a ____________.

a) 50 degrees F to 125 degrees F --- Image Quality Indicatorb) 50 degrees F to 125 degrees F --- field indicatorc) 50 degrees F to 125 degrees F --- comparatord) 50 degrees F to 125 degrees F --- and DAC curve

38. Fluorescent penetrant examination shall not follow _________________.a) UT thickness measurement

b) radiography because the residual radiation will cause false indicationsc) Eddy current examinationd) color contrast PT examination

39. The emulsification time for lipophilic emulsification of a post emulsifying penetrant is:a) 90 seconds

b) 6 minutesc) 10 minutesd) as determined experimentally

40. When removing water washable penetrant the spray of water may not exceed?a) 100 degrees F & 50 psi

b) 90 degrees F & 60 psic) 110 degrees F & 50 psid) 110 degrees F & 55 psi


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41. Water washable and post emulsifying penetrants may be dried using circulated air as long as the surface of

the part does not exceed:a) 100 degrees F

b) 110 degrees Fc) 212 degrees Fd) 125 degrees F

42. Five typical of discontinuities detectable by the magnetic particle method are:a) seams, low carbon content, cold shuts, laminations, and bad developing

b) cracks, caustic embrittlement, seams, and silicon isotope matrix syndromec) excessive weld seam reinforcement, cracks, cold shuts, seams, and low viscosityd) cracks, laps, seams, cold shuts and laminations

43. What is the magnetic particle examination medium?

a) the surface of ferromagnetic work piecesb) dry, wet or fluorescent ferromagnetic particlesc) any type of small metal particlesd) high iron content enamel or latex coatings

44. If coatings are left in place during MT examination ______________a) the particles used must be the same color as the coating

b) coatings are not allowed to be left in place all coatings must be removedc) the procedure must be demonstrated as capable of detecting indications through the maximum

thickness of the coating applied

d) all indications must be verified with penetrant examination in addition to the magnetic particleexamination

45. What type of discontinuity is the magnetic particle method most sensitive to?a) subsurface discontinuitiesb) slag inclusions not open to the surfacec) linear discontinuities perpendicular to the lines of fluxd) high nickel alloy weld defects

46. When performing fluorescent MT examiners shall allow _________________ for their eyes to adjust to thedarkened conditions.

a) 5 minutesb) 90 secondsc) 3 minutesd) 10 minutes

47. The intensity of the black light used shall be a minimum of:a) 800 W / cm212 from the surface of the part being examined

b) 600 W / cm2on the surface of the part being examined

c) 1800 W / cm218 from the surface of the part being examined

d) 1000 W /cm2on the surface of the part being examined

48. Normally dry particles may not be used on surfaces above:a) 800 F and 135 F

b) ambient temperaturesc) 600 F and 135 Fd) the manufactures recommendations


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49. Magnetic field strength may be verified by using ______________

a) an amp meter to determine if the field is within 10% of full scaleb) the proper IQI manufactured using all magnetically identical materials

c) an ohm meter to determine if the field is within 5% of full scaled) pie shaped magnetic particle field indicator or artificial flaw shims

50. All examinations will be conducted with sufficient overlap to assure a minimum of __________________coverage?

a) 99%b) 100%c) 80%d) 90

51. When using the prod technique the maximum prod spacing allowed is _____________

a)1 footb)3 inchesc)1/2 footd)8 inches

52. Magnetic particle equipment with ammeters must be calibrated _________________a) always prior to each use

b) after every 10 examination sessionsc) before and after examinationd) prior to first use if it the equipment has not been used for a year or more

53. AC yokes must be able to lift ______________ pounds at a maximum spacing of ______________.a) 40 pounds at the maximum spacing to be used during examinations

b) 10 pounds at the maximum spacing of 18 inches or 1 1/2 feetc) 40 pounds at the maximum spacing of 1.5 times the length of the yoke legsd) 10 pounds at the maximum spacing to be used during examinations

54. MT equipment with ammeters must be calibrated to a standard ________________a) supplied by the MT equipment manufacturer

b) supplied by the ISO MT standards committeec) traceable to a National Standardd) welded by a qualified welder or welding operator qualified in accordance with ASME Section V

55. What is the maximum temperature of materials covered under SE 797?a) 350 F

b) 400 Fc) 150 Fd) 200 F

56. SE-797 provides guide lines for the ________________ method for measuring thickness.a) Z scan

b) contact pulse echoc) submerged radiant echod) real time 1/2 echo


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57. A pulse echo instrument measures the _____________ of the ultrasonic pulse though the part.

a) speedb) wavec) velocityd) transit time

58. Reference blocks used to calibrate equipment should have an ultrasonic velocity:a) of V= .4562X 3

b) of no less than 210,000 inchesc) the same as the piece to be testedd) based on sheer wave impact

59. Which is not a type of thickness measurement instrument?a) Flaw detectors with CRT readout

b) Flaw detectors with CRT floor scan pressure readoutc) Flaw detectors with CRT and direct thickness readoutd) Direct thickness readout.

60. For measuring thin section which type of search unit is generally used?a) Highly damped, high frequency

b) Highly attenuated, low frequencyc) Highly damped, low frequencyd) 5 MHz single element

61. When using a direct contact, single element search unit the display start is:a) based on the average value of the display

b) synchronized to the initial pulse

c) equal to e = m

2

d) always at the top

62. When performing a complete calibration of an instrument using a delay line single element search unitcalibration blocks should be:

a) At least two one near the maximum thickness of the range to be measured and one near the midrange

b) At least two a 1 inch block and a 6 inch block of the same velocityc) At least three blocks with a minimum difference in thickness between each of at least 1 inchd) At least two with a thickness near the maximum of the range to be measured and the other block

near the minimum thickness

63. When calibrating a UT instrument using Case II, what minimum number of test blocks should be used whenthe instrument must be completely calibrated with the delay line search unit?

a) 3b) 4c) 2d) 1

64. When using dual search units there is an inherent error due to the:a) distance between the units

b) velocity rate averagesc) Vee path that the sound beam travelsd) geometry of the special calibration blocks required


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65. When measuring materials at high temperatures the readings are high by a factor of:

a) 1% per 50 Fb) 1% per 10 Fc) 5% per 50 Fd) 1% per 100 F

66. When developing a detailed UT thickness measurement procedure which of the following does not need to beconsidered?

a) Equipmentb) lighting conditionsc) surface preparation and couplantd) allowable tolerances and calibration

67. Which of the following would not be included in a UT report:

a) examination procedureb) Calibration blocks, size and material typec) density readingsd) Size, frequency, and type of search unit


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NDE ANSWER KEY

1 A, T-130

2 B, T-150

3 D, T-170

4 B, T-120, (e)

5 B, T-221.1

5 B, T-221.1

6 C, T-221.2

7 C, T-222.2

8 B, T-224

9 C, T-23210 D, T-233

11 D, T-234

12 B, T-273

13 B, T-277

14 A, T-275

15 C, T-277.1, (a)

16 D, T-277.1, (b)

17 D, T-277.3

18 C, T-277.3

19 D, T-281

20 C, T-28221 A, T-282

22 C, T-283

23 D, T-284

24 B, T-285

25 D, T-291

26 C, T-292

27 B, T-620

28 C, T-621

29 D, T-621

30 B, T-651

31 C, T-641

32 B, T-642

33 B, T-680

34 B, T-643

35 B, T-673.1

36 B, T652

37 C, T-653

38 D, T-654

39 D, T-673.2

40 C, T-673.1

41 D, T-674

42 D, T-720

43 B, T-731

44 C, T-741

45 C, T-720

46 A, T-77747 D, T-777

48 D, T-731

49 D, T-764

50 B, T-774

51 D, T-752

52 D, T-761

53 D, T-762

54 C, T-761

55 D, T-797 1.1

56 B, T-797 1.1

57 D, T-797 4.258 C, T-797 4.4

59 B, T-797 6.1

60 A, T-797 6.2

61 B, T-797 -7.1.1

62 D, T-797 7.2.2.1

63 C, T-797 7.2.2.1

64 C, T-797 7.3.1

65 D, T-797 8.5

66 B, T-797 - 10

67 C, T-797 - 10

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