part 1 ndt intro ilsas
TRANSCRIPT
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CERTIFICATION
ULTRASONIC
LEVEL 1
&
LEVEL II
AB RAZAK MAJID
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CERTIFICATION
LIQUID PENETRANT
TESTING
LEVEL II
AB RAZAK MAJID
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CERTIFICATION
INFRARED
THERMOGRAPHY
TESTING
LEVEL I
AB RAZAK MAJID
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Topics
PART 1:Introduction to NDT
PART 2:Visual Inspection
PART 3: Penetrant Testing
PART 4: Magnetic Particle Testing
PART 5: Ultrasonic Inspection
PART 6:Radiographic Testing
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The use of noninvasivetechniques to determine
the integrity of a material,
component or structure
or
quantitatively measure
some characteristic of
an object.
i.e. Inspect or measure without doing harm.
Definition of NDT
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Nondestructive Evaluation (NDE) a term often used
interchangeably with NDT.
However, technically, NDE is used to describe
measurements that are more quantitative in nature.
For example, a NDE method would not only locate a defect,
but it would also be used to measure something about that
defect such as its size, shape, and orientation.
NDE may be used to determine material properties such asfracture toughness, formability, and other physical
characteristics.
Difference betw. NDT & NDE
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MATERIALDEFECTS
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Definition
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An ingot is a material,
usually metal, that is cast
into a shape suitable for
further processing.
Ingot Discontinuities
http://en.wikipedia.org/wiki/Metalhttp://en.wikipedia.org/wiki/Castinghttp://en.wikipedia.org/wiki/Castinghttp://en.wikipedia.org/wiki/Metal -
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*inherent - belonging
by nature or habit :intrinsic
Question
Why are wrought
alloys stronger and
more ductile than
cast?
Answer
It all has to do with the grain
structure. Wrought alloys are
"hammered/pressed" with the
other is just casted. The grain inthe wrought are aligned when the
casted isn't.
Inherent Discontinuities
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Classification of Discontinuities
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Service Induce Discontinuities
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Forging Discontinuities
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100%
90%
60%
30%
10%
Fig. The effect of defect shape on internal stress
distribution
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Destructive Test
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In bloom and billet casting, the steel from the ladle is poured into a large "pot" called a
tundish from which it is fed into a water-cooled mold and extracted in a solidified
section as either a bloom or billet. Blooms are an intermediate product usually having
a much larger cross section than billets. These blooms are rolled into billets which are
subsequently rolled into bars or rods.
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Methods of NDT
Visual
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What are Some Usesof NDE Methods?
Flaw Detection and EvaluationLeak Detection
Location Determination
Dimensional Measurements
Structure and Microstructure
Characterization
Estimation of Mechanical and Physical Properties
Stress (Strain) and Dynamic Response Measurements
Material Sorting and Chemical Composition Determination
Fluorescent penetrant indication
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When are NDE Methods Used?
To assist in product development
To screen or sort incoming materialsTo monitor, improve or controlmanufacturing processes
To verify proper processing such as heat
treatingTo verify proper assembly
To inspect for in-service damage
There are NDE application at almost any stagein the production or life cycle of a component.
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Destructive test (or Proof test)
Frequently used to supplement, confirm, or establishthe limits of NDT/NDE, and to provide supporting
information.
Some types of destructive testing:
Stress tests
Crash tests
Hardness tests
Metallographic tests
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1. DOES NOT DAMAGE A JOB OR REDUCE THE
SERVICE LIFE OF A JOB.
2. TO LOCATE THE DEFECTS AND
DISCONTINUITIES IN A JOB.
3. TO OBTAIN HIGH LEVEL OF RELIABILITY AND
TO AVOID PREMATURE FAILURE.
4. TO PREVENT ACCIDENTS AND SAVE HUMANLIVES
Why NDT?
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Other Facts of NDT
EACH NDT IS DESIGNED TO PROVIDE VISUAL
EVIDENCE OF DISCONTINUITIES IN PARTS WHICH
ARE NOT NORMALLY VISIBLE TO THE UNAIDED
EYE. THE VISIBLE EVIDENCE LEFT BY EACH
METHOD IS CALLED AN INDICATION.
HOWEVER THERE ARE NO SINGLE NDT METHOD
CAPABLE OF DETECTING ALL TYPE OF
DISCONTINUITIES . THUS IT IS NOT RIGHT TO SAYTHAT ONE NDT METHOD IS BETTER THAN THE
OTHER. EACH METHOD COMPLIMENTS EACH
OTHER.
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EXTREMELY USEFUL IN
FAILURE INVESTIGATION
Other Facts of NDT
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Service Induce Discontinuities
Generated During Service Life
MT ON ROTOR BLADES
FATIGUE CRACK
OCCUR DUE TO CYCLIC LOAD
CREEP
Material deformationfor indifinite period
of time under
constant stress
STRESS CORROSIONCRACKING
Material crack under
stress and corrosion
EMBRITTLEMENT
Material damage under
thermal instability
WEAR
Reducing of material size or
deformation of shape under
friction
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Six Most Common NDT Methods
Visual Liquid Penetrant
Magnetic
Ultrasonic
Eddy Current
X-ray
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A liquid with high surface wetting characteristics is
applied to the surface of the part and allowed time to
seep into surface breaking defects.
The excess liquid is removed from the surface of the
part.
A developer (powder) is applied to pull the trapped
penetrant out the defect and spread it on the
surface where it can be seen.
Visual inspection is the final step in the process.
The penetrant used is often loaded with a
fluorescent dye and the inspection is done under
UV light to increase test sensitivity.
Liquid Penetrant Inspection
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Magnetic Particle Inspection
The part is magnetized. Finely milled iron particlescoated with a dye pigment are then applied to thespecimen. These particles are attracted to magnetic fluxleakage fields and will cluster to form an indicationdirectly over the discontinuity. This indication can be
visually detected under proper lighting conditions.
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Magnetic Particle Crack Indications
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Radiography
The radiation used in radiographytesting is a higher energy (shorter
wavelength) version of theelectromagnetic waves that wesee as visible light. The radiation cancome from an X-ray generator or aradioactive source.
High Electrical Potential
Electrons
-+
X-ray Generatoror Radioactive
Source Creates
Radiation
Exposure Recording Device
RadiationPenetrate
the Sample
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Radiographic Images
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Conductivematerial
CoilCoil'smagnetic field
Eddycurrents
Eddy current'smagnetic field
Eddy Current Testing
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Eddy Current TestingEddy current testing is particularly well suited for detecting
surface cracks but can also be used to make electrical
conductivity and coating thickness measurements. Here a smallsurface probe is scanned over the part surface in an attempt to
detect a crack.
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Eddy Current Testing
Fig. Electronic magnetic induction thickness
gauges
Models now come with
Bluetooth wireless
technology. Instanttransmission to your
PC or hand held data
device is now possible -
no more cables
required.
Coating thickness measurements
Ul i I i
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High frequency sound waves are introduced into a material andthey are reflected back from surfaces or flaws.
Reflected sound energy is displayed versus time, and inspectorcan visualize a cross section of the specimen showing the depthof features that reflect sound.
plate
crack
0 2 4 6 8 10
initial
pulse
crack
echo
back surface
echo
Oscilloscope, or flaw
detector screen
Ultrasonic Inspection
(Pulse-Echo)
Ult i I i
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Ultrasonic Imaging
Gray scale image produced using
the sound reflected from the front
surface of the coin
Gray scale image produced using the
sound reflected from the back surface
of the coin (inspected from heads side)
High resolution images can be produced by plotting signal
strength or time-of-flight using a computer-controlled
scanning system.
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Common Application of NDT
Inspection of Raw Products
Inspection Following Secondary
ProcessingIn-Services Damage Inspection
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Inspection of Raw Products
Forgings,Castings,Extrusions,
etc.
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MachiningWeldingGrinding
Heat treatingPlatingetc.
Inspection Following
Secondary Processing
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Cracking
Corrosion
Erosion/Wear
Heat Damage
etc.
Inspection For
In-Service Damage
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Power Plant Inspection
Probe
Signals produced
by various
amounts of
corrosion
thinning.
Periodically, power plants are
shutdown for inspection.Inspectors feed eddy current
probes into heat exchanger
tubes to check for corrosion
damage.
Pipe with damage
Wi R I i
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Wire Rope Inspection
Electromagnetic devices andvisual inspections are used tofind broken wires and otherdamage to the wire rope that isused in chairlifts, cranes andother lifting devices.
St T k I ti
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Storage Tank Inspection
Robotic crawlers useultrasound to inspect the
walls of large aboveground tanks for signs ofthinning due to corrosion.
Cameras on longarticulating armsare used toinspectunderground
storage tanks fordamage.
Ai ft I ti
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Aircraft Inspection
Nondestructive testing is usedextensively during the
manufacturing of aircraft. NDT is also used to find cracks
and corrosion damage duringoperation of the aircraft.
A fatigue crack that started atthe site of a lightning strike is
shown below.
Jet Engine Inspection
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Jet Engine Inspection
Aircraft engines are overhauledafter being in service for a period
of time.
They are completelydisassembled, cleaned, inspectedand then reassembled.
Fluorescent penetrant inspection
is used to check many of the partsfor cracking.
C h f U it d Fli ht 232
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Sioux City, Iowa, July 19, 1989
A defect that went
undetected in an
engine disk was
responsible for the
crash of United
Flight 232.
Crash of United Flight 232
P V l I ti
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Pressure Vessel Inspection
The failure of a pressure vessel can
result in the rapid release of a large
amount of energy. To protect
against this dangerous event, the
tanks are inspected using
radiography and ultrasonic testing.
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Rail Inspection
Special cars are used to inspect
thousands of miles of rail to findcracks that could lead to aderailment.
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Bridge Inspection
The US has 578,000 highway
bridges.
Corrosion, cracking andother damage can all affect abridges performance.
The collapse of the Silver
Bridge in 1967 resulted inloss of 47 lives.
Bridges get a visualinspection about every 2years.
Some bridges are fitted withacoustic emission sensorsthat listen for sounds ofcracks growing.
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Pipeline InspectionNDT is used to inspect pipelinesto prevent leaks that could
damage the environment. Visualinspection, radiography andelectromagnetic testing are someof the NDT methods used.
Remote visual inspection usinga robotic crawler.
Radiography of weld joints.
Magnetic flux leakage inspection.This device, known as a pig, isplaced in the pipeline and collectsdata on the condition of the pipe as itis pushed along by whatever is beingtransported.
P Pl t I ti
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Power Plant InspectionIN-SITU METALLOGRAPHY FOR THE PLANT HEALTH ASSESSMENT
STUDY AND FAILURE INVESTIGATION
Photo: indicates graphite formation in plain
carbon steel after a prolong
exposure to high temperature.
Schematic
representation of
replication process.
Sketch:3 Different stage of creep along with
microstructure degradation stages
Th hi I ti
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Thermographic Inspection
eg. STEAM LEAKAGE UNDER INSULATION of
CROSS OVER PIPE AT KAPAR POWER STATION
Infra-red Camera
TNB Chenderoh Hydro
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y
Rehabilitation Project (1996 1999)
NORMAL
WATER LEVEL
60.45 m
INTAKE
HEAD GATE
GENERATOR
POWERHOUSE CRANE
DRAFT TUBE
TAILRACE
DRAFT
TUBE
GATE
TURBINE
GOVERNOR
SPIRAL
CASE
FRANCIS
RUNNER
NORMAL
TAIL WATER
LEVEL
40.54 m
CONTROL
ROOM
ELIN
Fig. Power House Cross Section
Special Measurements
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Special Measurements
Boeing employees in Philadelphia were given theprivilege of evaluating the Liberty Bell for damage using
NDT techniques. Eddy current methods were used tomeasure the electrical conductivity of the Bell's bronzecasing at various points to evaluate its uniformity.
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INTRODUCTION TO
INFRAREDTHERMOGRAPHY
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THERMOGRAPHY ;
MEAN WRITING WITH HEAT
PHOTOGRAPHY ;
MEANS WRITING WITH LIGHTWe use Long wave camera
THERMOGRAPHY VS PHOTOGRAPHY
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PHOTOGRAPHY - LIGHT IS IMPORTANT
NOT ENOUGH LIGHT CUKUP CAHAYA
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0.4 m
(violet) to
0.7 m
(red)
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Wavelength bands
Wavelength bands are approximates
Wavelength bands are not sharply defined,they change gradually
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The Electromagnetic Spectrum
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INFRARED TEMPERATURE TESTING -
THERMOGRAPHY
The Electromagnetic Spectrum
The Infrared region is part of the Electromagnetic
Spectrum that is dividing up all types ofelectromagnetic radiation. This radiation is dividedup rather arbitrarily (rambang) into a number ofregions based on their wavelengths: Gamma < 10nanometers, Ultraviolet radiation, Visible light 0.4 to0.7 micrometers, Infrared Radiation, Microwaves,Radio waves
CA A C
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CAMERA PRINCIPLE
A PICTURE OF RADIATION INTENSITY, NOT TEMPERATURE
INFRARED RADIATION
Passivecamera receive (emit)
infrared radiation.
Not like x-rayRADIATE RAY
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