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NON-DESTRUCTIVE TESTING IN

THE OFFSHORE INDUSTRY

Lecture 01

28 February 2015

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1.Introduction in Nondestructive testing.

2.Discontinuities , origin and classification3.Visual testing.4.Liquid penetrant inspection method.5.Process control and interpretation of liquid penetrant inspection6.Magnetic particle testing theory.

7.Magnetic particle inspection applications and interpretations8.Ultrasonic inspection method.9.Ultrasonic inspection equipments and materials.10.Ultrasonic inspections process control and safety.

11.Eddy current inspection method.12.Application on eddy current inspection13.Acoustic emission testing.14.Thermal infrared testing.

Topic

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ReferencesCharles J. Hellier, Handbook of Nondestructive Evaluation, McGrawHill, ISBN 0-07-139947-X, 2003;NDT Training program, American Society for Nondestructive Testing;Subrata K. Chakrabarti, Handbook of offshore engineering, Elsevier, ISBN-13: 978-0-08-044568-7 (vol 1), 2005;Subrata K. Chakrabarti, Handbook of offshore engineering, Elsevier, ISBN-13: 978-0-08-044569-4 (vol 2), 2006;William C. Lyons, Standard Handbook of petroleum & natural gas engineering, GulfPublishing company, Houston Texas, ISBN 0-88415-642-7 (vol.1), 1996;

William C. Lyons, Standard Handbook of petroleum & natural gas engineering, GulfPublishing company, Houston Texas, ISBN 0-88415-643-5, (vol.2), 1996;Mocanu D. Remus, Safta Voicu, ncercarea materialelor. Controlul nedistructiv almetalelor, Editura Tehnic,1986;Amza Gheorghe, Ultrasunete. Aplicaii active, Academia de tiine Tehnice dinRomnia, Editura Agir, 2006;

* * * - BS EN ISO, 19902:2007, Petroleum and natural gas industries Fixed steeloffshore structures* * * BS EN 10225:2009, Weldable structural steels for fixed offshore structures Technical delivery conditions* * * - ISO / TC67 Material equipment and offshore structures for petroleum,petrochemical and natural gas industries;

* * * - API Specification 5L, forty-second edition, January, 2000, American PetroleumInstitute Publishing Service, 1999;

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Definition of NDT

The use of noninvasive

techniques to determine

the integrity of a material,component or structure

or

quantitatively measuresome characteristic of

an object.

Introduction to Nondestructive Testing

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Ultrasonic NDT in various industries

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What are some uses

of NDE Methods?

Flaw Detection and EvaluationLeak Detection

Location DeterminationDimensional MeasurementsStructure and Microstructure CharacterizationEstimation of Mechanical and Physical Properties

Stress (Strain) and Dynamic Response MeasurementsMaterial Sorting and Chemical Composition Determination

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Six Most Common NDT Methods

Visual

Liquid Penetrant

Magnetic Ultrasonic

Eddy Current

X-ray

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Visual Inspection

Most basic and common

inspection method.

Tools include

fiberscopes,

borescopes, magnifying

glasses and mirrors.

Robotic crawlers permit

observation in hazardous or tight

areas, such as air ducts, reactors,

pipelines.

Portable video inspection

unit with zoom allows

inspection of large tanks

and vessels, railroad tank

cars, sewer lines.

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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.

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Magnetic Particle

InspectionThe part is magnetized. Finely milled iron particles coated with adye pigment are then applied to the specimen. These particles are

attracted to magnetic flux leakage fields and will cluster to form anindication directly over the discontinuity. This indication can bevisually detected under proper lighting conditions.

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Magnetic Particle Crack Indications

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Radiography

The radiation used in radiographytesting is a higher energy (shorterwavelength) version of theelectromagnetic waves that wesee as visible light. The radiation cancome from an X-ray generator or aradioactive source.

High Electrical Potential

Electrons

-+

X-ray Generator

or Radioactive

Source Creates

Radiation

Exposure Recording DeviceRadiation

Penetrate

the Sample

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Film Radiography

The part is placed between theradiation 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.

= more exposure

= less exposure

The film darkness

(density) will vary with

the amount of radiation

reaching the filmthrough the test object.

Top view of developed film

X-ray film

The part is placed between theradiation 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.

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Radiographic Images

l ( l h )

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Ultrasonic Inspection (Pulse-Echo)

High frequency sound waves are introduced into

a material and they are reflected back fromsurfaces or flaws.

Reflected sound energy is displayed versus time,and inspector can visualize a cross section of the

specimen showing the depth of features thatreflect sound.

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Ultrasonic Imaging

High resolution images can be produced by

plotting signal strength or time-of-flight using a

computer-controlled scanning system.

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Eddy Current Testing

Eddy current testing isparticularly well suited fordetecting surface cracks butcan also be used to makeelectrical conductivity andcoating thicknessmeasurements.

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Inspection of Raw Products

Forgings;

Castings;

Extrusions;

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Inspection Following

Secondary Processing

Machining

Welding

Grinding

Heat treating Plating

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Inspection For

In-Service Damage

Cracking

Corrosion

Erosion/Wear Heat Damage

Pi li I ti

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Pipeline Inspection

NDT is used to inspect pipelinesto prevent leaks that could

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

Remote visual inspection usinga robotic crawler.

Radiography of weld joints.

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

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Power Plant Inspection

Periodically, power

plants are shutdown

for inspection.

Inspectors feed eddy

current probes into

heat exchanger tubes

to check for corrosiondamage.

Probe

Signals produced

by variousamounts of

corrosion

thinning.

Pipe with damage

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Storage Tank Inspection

Robotic crawlers

use ultrasound toinspect the walls oflarge above groundtanks for signs ofthinning due tocorrosion.

Ai f I i

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Aircraft Inspection

Nondestructive testing is usedextensively during the

manufacturing of aircraft. NDT is also used to find cracks

and corrosion damage duringoperation of the aircraft.

A fatigue crack that started atthe site of a lightning strike isshown below.

Pressure Vessel Inspection

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Pressure Vessel Inspection

The failure of a pressure vessel can result in the rapid release of a

large amount of energy. To protect against this dangerous event,

the tanks are inspected using radiography and ultrasonic testing.

B id I ti

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Bridge Inspection Corrosion, cracking and

other damage can allaffect a bridges

performance.

Bridges get a visualinspection about every 2years.

Some bridges are fitted

with acoustic emissionsensors that listen forsounds of cracks growing.

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Rail Inspection

Special cars are used to inspect thousands of miles ofrail to find cracks that could lead to a derailment.

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Q i ?