SPEAKER INTRODUCTION

By R.RamakrishnanSCIENTIST

M.Sc ,AMIE MECH ENGG.ASNT NDT LEVEL III

ACCP LEVEL IIIRWTUV LEVEL III

RSO40 YEARS OF EXP.

Email :radiantndt@gmail.com

Honors And

AwardsFellow of

ISNTEXPERT NDTSPECIALIST

FROMGOVT. OF

INDIA

EXPERIENCEFROM

AIR-LINETO

PIPELINEPREPARINGBOOKS IN

NDT&COURSE

NOTESFOR

ASNT L III

Introduction to NDT

ENERGY ENERGY MODIFIED Input out putMATERIAL

ELECTROMAGNETIC RT MECHANICAL-UTELECTRICAL-ET

THERMAL-IROPTICAL-LASERMAGNETIC-MT

LIQUID -LPT

MATERIAL MODIFIES THE ENERGY

ABSORPTION,REFLECTION, REFRACTION

SCATTER,DIFFRACTIONPOLARISATION

INTERFERENCE

INDIRECT-INTERPRETATION

HUMAN ERRORPROCEDURES

CODESSTANDARDS

SPECIFICATION

RESULTSFORMS OF ENERGY

INTERACTION WITH JOBREPORT

THE PURPOSE OF NDT TO PROVIDE PRODUCT QUALITY TO PROVIDE SAFETY TO MEN AND

MATERIALS TO PROVIDE OVERALL SYSTEM RELIABILITYDEFECTS AND DISCONTINUITIES ARE ONE

AMONG THE SEVERAL FACTORS WHICH AFFECT THE QUALITY, SAFETY AND RELIABILITY AND LEADING TO PREMATURE FAILURE.

BASIC MATERIALS, fabrication and production technology Primary, secondary processes discontinuities

IngotBillets, blooms

CastingRollingForgingWelding

ExtrusionForming

Heat treatmentGrinding

MachiningGalvanizing

Painting

Primary process Secondary process

CorrosionErosion

CavitationWearCreep

VibrationFatigueabsuse

Service

Inherent defects

DEFECTS DEFECTS DEFECTS

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

WHAT IS A DEFECT ? A DEFECT IS NORMALLY DEFINIED AS LACK OR

OMISSION OF SOMETHEING ESSENTIAL FOR COMPLETELENESS

A DEFECT MAY RANGE FROM ATOM SIZED DISCOLLOCATION TO MAJOR METAL DISCONTINUITIES WHICH ARE VISIBLE TO NAKED EYE.

THE VARIOUS NDT METHODS SENSES THE MATERIALS DISCONTINUITY, AND REPORTS IN THE FORM OF IMAGE, SIGNAL, READOUT

UNACCETPABLE DISCONTINUITIES ARE DEFECTS, AND THEREFORE ALL DISCONITNUITIES ARE NOT DEFECTS

DEFECT CHARACERTIZATION

DEFECTSIZE

NATURESTRESS RISING, PASSIVE, ACTIVE

SPACING

LOCATION WITH REFERENCE TO PRINCIPAL STRESS DIRECTION

CASTING PROCESSES LIQUID TO SOLID STATE TO THE REQUIRED SHAPE DEFECTS- SHRINKAGE-MICRO, MACRO,FILAMENTRY HOT TEAR, BLOW HOLES INCLUSIONS MOTTLING, UNFUSED CHAPTLETS, COLD SHUTS MISRUN

BEST NDTMETHODRT FOR

ALL INTERNALDISCONTINUITIES

VT,MT,PT FOR SURFACE BREAKING

DISCONTINUITIESUT LESS RELIABLE

ROLLING PROCESS TURNING THE INGOT INTO THE REQUIRED

SHAPE BY SEQUECING THE METAL INBETWEEN THE ROLLERS

PROCESS- HOT ROLLING, COLD ROLLING PRODUCTS- BARS, PLATES, DEFECTS STRINGERS & LAMINATIONS SEAMS CRACKS, FOLDS

BEST NDTMETHODVT,PT,MT

ULTRASONIC

FORGING THE PROCESS: TURNING THE METAL INTO

REQUIRED SHAPE BY APPLICATION OF EXTERNAL FORCE – OPEN DIE,CLOSE DIE,

PRODUCTS: BOLTS, NUTS, GEAR BLANKS, SHAFTS, TURBINE BLADES, PINS,

DEFECTS LAP BURST PIPES

EXTERNAL INTERNAL INTERNAL & EXTERNAL

BEST NDT METHOD

VT,MT,PT,UT

WELDING JOINING THE PARTS, BY LOCALIZED CASTING VARIOUS PROCESSES- SMAW,SAW,TIG,MIG,EB,

…………………….. SOLDERING, BRAZING ALL CRITICAL WELDS REQUIRE ONE OR MORE

NDT METHODS TO FIND ALL DISCONTINUITIES FROM TOP TO BOTTOM OF THE JOINT

ALL WELDERS AND WELDING PROCESSES SHALL BE QUALIFIED FOR PARTICULAR APPLICATIONS AS PER ASME SEC IX –REQUIARES DT,NDT, CHEMICAL, METALLOGRAPHIC

NDT METHODSVT,PT,MT,UT,RT

SECONDARY PROCESSES FINISHING STAGE MACHINING GRINDING HEAT TREATMENT ANODIZING GALVANIZING PAINTING

ALL DISCONTINUITIES ARE CONNECTED

TO SURFACESURFACE NDT

PT,VT,MT

SERVICE INDUCED DISCONTINUITIES CORROSION EROSION WEAR CAVITATION FATIGUE + CREEP LOSS OF INTEGRITY OF STRUCTURES,

EVIDANCE OF LEAK, MISSING PARTS, DENTS, ABUSE, THERMAL INSULATION,

EDDY CURRENT,REMOTE FIELD EC,MAGNETIC FLUX

LEAKAGE,THERMOGRAPHY,

FIBROSCOPE,HOLIDAY DETECTION,

LEAK TESTING,IRIS,

VIBRATION AND NOISEMETALLOGRAPHY

PLANT SHUT DOWN

VT,PT,MT,UT

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

THE NEED FOR TRAINING AND CERTIFICATION OF NDT PERSONNEL

NDT IS A BRANCH OF SCIENCE INVOLVING PHYSICS PRINCIPLES ON MATERIALS.

NDT RESULTS ARE MOST OFTEN INDIRECT, AND READOUT IN THE FORM OF IMAGE, SIGNALS, SPECTRUM ANALYSIS.

GENERALLY A LESS QUALIFIED PERSON HAS TO PERFORM THE JOB , CALLED TECHNICIAN, AND THE RELIABILITY OF THE TEST MAINLY DEPENDS ON HIS SKILL, TRAINING AND EXPERIENCE

A TECHNICIAN HAS TO SUCCESSFULLY LOCATE THE DEFECTS- INTERPRET,EVALUATE- FOLLOWING THE INSTRUCTIONS-THE PROCEDURE

FOR ACCEPTANCE/REJECTION, DEPENDING UPON THE CRITICALLITY HE HAS TO MAKE REFERENCE TO THE CODE

GENERAL KNOWLDEGE, SPECIFIC TO THE JOB, AND PRACTICAL DEMO ARE THE MUST FOR NDT PERSONNEL

ANSI/ASNT IS A STD FOR QUALIFICATION OF NDT PERSONNEL ASNT SNT TC IA IS A RECOMMENDED PRACTICE ANSI/ASNT CP 189, ASNT SNT TC 1A HELP THE EMPLOYER TO DO

THE JOB DONE RIGHT AT THE FIRST

ANSI/ASNT CP-189-20011.ESTABLISHES MIN. QUALIFICATION AND

TRAINING FOR NDT PERSONNEL 2. MINI. TRAINING, EDUCATION, AND

EXPERIENCE 3. EMPLOYER HAS TO ESTABLISH A

PROCEDURE FOR CERTIFICATION OF NDT PERSONNEL

EMPLOYER TO INTRODUCE ANY UNIQUE OR ADDITIONAL REQUIRMENTS IN CERTIFIATION PROCESS

CP 189 SOME DEFINITIONS EDUCATION- SCHOOL, COLLEGE,

UNIVERSITY PROVIDING ORDERLY INSTRUCTIONS, IN A SYSTEMATIC FASHION

NDT LEVELS LEVEL I & II INDIVIDUAL CERTIFIED

ACCORDING TO THIS PROCEDURE LEVEL III –POSSING CURRENT VALID ASNT

LEVEL III CERTIFICATE

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

SNT-TC-1A 2001 IT IS A RECOMMENDED PRACTICE IT IS THE EMPLOYER’S RESPONSIBILITY

FOR CERTIFICATION AND TRAINING OF NDT PERSONNEL

LEVELS OF QUALIFICATION I , II, III LEVEL I AND II VALID FOR 3 YEARS AND

LEVEL III FOR 5 YEARS EMPLOYER ISSUED CERTIFICATE CEASES IF

THE EMPLOYER LEAVES COMPANY OR TERMINATED

The need for NDT To day every manufactured part shall have Quality- customer satisfaction Safety – to men and materials Reliability – a system has to do its intended

function over a period of time without failure. Quality, safety, reliability start at the design, and

the design engineer is responsible for “quality, safety, and reliabiliaty”

The NDT specialist successfully locates the defects.

Defects and discontinuities one among the several reasons for pre-mature failure.

Various NDT methods Discontinuities may be located in any

where in the object, and to successfully locate them, we need to use several NDT methods, depending upon the expected discontinuity, location, orientation, and size.

All critical components have to be tested with more than one NDT method. A particular technique in each of the NDT method brings the expected discontinuity successfully.

The common most NDT methods1. VISUAL AND OPTICAL TESTING2. PENETRANT TESTING3. MAGNETIC PARTICLE TESTING4. RADIOGRAPHY5. ULTRASONIC TESTING6. EDDY CURRENT TESTING7. THERMAL/ INFRA RED IMAGING8. ACOUSTIC EMISSION 9. LEAK TESTING10. NEUTRON RADIOGRAPHY11. LASER BEAM TESING12. VIBRATION AND NOISE ANALYSIS

THE NDT SPECIALIST BE FAMILIAR WITH THE MANUFACTURING PROCESS, AWARE OF THE SEQUENCE OF FORMING,

SOLIDIFICATION AWARE OF VARIOUS DISCONTINUITIES, THEIR

LOCATION,THEIR SEVERITY TO SERVICE,OR COMPONENT’S LIFE

ABLE TO SELECT THE MOST SUITABLE NDT METHOD, AND IN THAT METHOD THE MOST SUITABLE TECHNIQUE TO DETECT THEM

THE NDT SPECIALIST MUST BE ABLE TO IDENTIFY EACH DISCONTINUITY DIFFERENTIATE DISCONTINUITY FROM ONE

ANOTHER LIKE LOF, IP, CRACK, ETC CORRELATE THE POSSIBLE REASON FOR

THE DISCONTINUITY CHARACTERIZE THE DISCONTINUITY AND

TAKE DECISION FOR ACCEPTANCE/ REJECTION WITH REFERENCE TO APPLICABLE CODES AND STANDARDS

SELECTION OF NDT METHODS EACH AND EVERY NDT METHOD HAS MERITS AND

LIMITATIONS. SURFACE NDT METHODS LIKE VT,PT,MT, ET

DETECTS SURFACE AND NEAR SURFACE DISCONTINUITIES AND HENCE NOT SUITABLE FOR INTERNAL DISCONTINUITIES

RT,UT DETECTS DEFECTS THAT ARE SUBSTANTIALLY INSIDE.

BUT RT IS BEST FOR VOULUME DEFECTS AND UT IS BEST FOR PLANNAR DISCONTINUITIES

VARIABLES WITH IN EACH METHOD- SPECIFY THE TECHNIQUE FOR EXAMPLE IN ULTRASONIC METHOD THE

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

VISUAL AND OPTICAL TESTING IT IS THE BASIS OF ALL NDT INSPECTION IT AVOIDS COSTLY NDT INSPECTION OUR EYE IS THE DETECTOR RESULTS ARE SEEN AND INTERPRETATION

IS STRAIGHT FORWARD LIMITED TO SURFACE,& REFLECTANCE ACCESS TO THE TEST SURFACE IS

REQUIRED & POSSIBLE TO DAY WITH DIRECT AND REMOTE FIELD.

BASIC ELEMENTS FOR VT EYE & OUR VISION, NEAR, FAR, COLOR,

VISION ACUITY LIGHT – ILLUMINANCE, UNIT TEXTURE AND REFLECTACNE CLEANLINESS VISION ANGLE OPERATOR’S BACKGROUND

QUALIFICATION PROCEDURE, CODE,

AIDS FOR VT DIMENSIONAL METROLOGY- RULE TO

INTERFEROMETERS MIRROR, COMPARATORS, BORESCOPE,

FIBROSCOPE, PERISCOPE, TELESCOPES FILMS, REPLICATION MACHINE VISION TECHNOLOGY- VIDICON,

CID, CCD, PHOTOVOLTALIC CELL, PHOTOCONDUCTIVE CELL,

VT ON WELDS BEFORE WELDING DURING WELDING AFTER WELDING NDTS AND DTS REQUIREMENTS AS PER

PROCEDURE REPAIRS AND VT + NDTS PROCEDURES AS PER ASME, API, AWS FOR

VT WELD GAUGES

PENETRANT TESTING BEST OF ALL NDT METHODS CAN BE USED ON ALL MATERIALS, OF ANY SHAPE,

SIZE, AND GEOMETRY INSPECTION IS STRAIGHT FORWARD, AND IS SEEN

AS FORMED SIMPLE IN PRACTICE, AND EASY TO TRAIN AN

OPERATOR LIMITATIONS: DEFECTS SHALL BE OPEN TO SURFACE NOT FIT ON POROUS MAT.

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

THE PHYSICAL PRINCIPAL CAPILLARY PRESSURE

h = 2TCOS Wg

h

PENETRANT MATERIALS TYPES OF PENETRANT- I , II, III METHODS OF REMOVAL OF EXCESS

PENETRANT - A , B, C, D FORMS OF DEVELOPERS a , b, c, d, spl LEVELS OF SENSITIVITY ½ , 1.2.3.4 ALL OF THE ABOVE WITH REFERENCE TO

ASTM STANDARD # ASTM E 165

PT- METHOD OF REPORTING INTERPRET ALL THE INDICATIONS

CLASSIFY THEM AS TRUE OR FALSE ALL TRUE INDICATIONS SHALL BE

EVALUATED AS RELEVANT OR NON RELEVANT

ALL RELEVANT INDICATIONS ARE FURTHER EVALUATED AS

1. LINEAR 2. ROUNDEDMETHOD OF RECORDING

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

MAGNETIC PARTICLE TESTING PRINCIPLE: “ LEAKAGE FIELD”

N S NORTH SOUTH POLE POLE AT POLES LINES OF FORCE LEAVE OR ENTER AT POLES ONLY POWDER ATTACT WHENEVER THERE IS A BREAK, THERE IS A LEAK, WHEREVER

THERE IS LEAK THERE ARE POLES NORTH AND SOUTH WHEREVER THERE ARE POLES POWDER ATTRACTS. MAGNETIC

LINES OF FORCE LEAVE AT ONE END AND ENTER THE OTHER END. THIS IS CALLED LEAKAGE FIELD.

SHAFT WITH AND WITH OUT CRACK

N S

N S N S

MAGNETIC PARTICLE TESTING -STEPS 1. MAGNETIZE THE JOB 2. APPLY POWDER 3. SEE FOR INDICATIONS

WHY WE HAVE TO MAGNETIZE THE JOB? BEFORE AFTER LINES OF FORCE

NO YES

NO LEAKAGE LEAKAGE FIELD NO POLES POLES ARE FORMED NO INDICATION INDICATION

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

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