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Introduction Scope Objectives Brief description of NDT Application of NDT methods Selection of NDT methods Visual testing Magnetic particle testing. Liquid penetrant testing Ultrasonic testing. Radiography testing Leak testing Eddy current testing. Cont,d2

Welcome to the session of nondestructive testing . NDT methods are used to examine the materials or components without destroying it, This has played a very important role in the industry. Nowadays almost all industries are using various NDT methods to control the quality of their products. In RIL we are using various NDT methods to control the quality of our project components like- pressure vessel, piping, welding, casting etc . Most common methods used are RT,MT,UT,PT and VT.

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NDT methods are used to detect surface ,subsurface and internal discontinuities in the materials and give quality control checks in the various stages of manufacturing . ASME sec V is the relevant code for the various NDT methods used in the industries.

3.1. To bring awareness of various NDT methods, their applications, advantages and limitations. 3.2. To share our field experience and discuss case studies to high light the importance of NDT.

RELIANCE ENGINEERING ASSOCIATES (P) LIMITED

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Various NDT methods are used in the industries for the various purpose at different stages. The mechanism of each method varies and is based on the scientific principles. They are based on the application of sound energy , electrical energy, mechanical energy , magnetic energy, etc. Photo graphic principle of light energy also used. Each method has its own advantage and limitations . They are used in various fields like medical field ,Engg. industries and also in day to day life. Sonography is used to check the sex of unborn child . X-ray are used in the air port to check the luggage of the passengers. MT ,UT and PT are used in the industries.
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NDT methods are used for different applications. Some of them are listed below: 5.1. Defect detection- type, size & location of defects. 5.2. Checking of various properties Density , chemical composition , electrical and thermal conductivity. 5.3. Sorting out mix up of material composition , grain size, chemical composition & heat treatment conditions. 5.4. Dimensional gauging material thickness & coating /plating thickness check . In RIL We are using NDT methods mostly for defect detection and thickness checking of the pipes, plates,forgings castings and welding.
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Selection of NDT method to check the quality of product is based on the following information. 6.1. 6.2. 6.3. 6.4. 6.5. 6.6. Type & location of the defect. Nature of the defect. Expected orientation of the defect. Surface condition. Applicable code & standards, (ASME,BS,IS,DIN etc,). Quantity of material and facilities of NDT method .

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6.7. Inspection at site or at workshop. 6.8. Accessibility for the site inspections. 6.9. Environmental condition (temperature, wind, height, radiation hazard). 6.10. NDT instrument availability. 6.11. Cost &Time required

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Visual testing is the oldest and simple NDT method and most commonly used everywhere. It is used to detect surface defects likes laps, cracks, blow holes and many other defects which are visible to naked eyes. Nowadays sophisticated instruments like boroscope, fibroscope, magnifying lenses etc, are also used.

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The magnetism is induced in the part by electricity or by using permanent magnet resulting the flow of lines of magnetic flux in the part. The magnetic lines of force which pass through the component are breaking due to discontinuity in the material . This broken lines are checked by using iron powder forming the defect indications on the surface at the area where discontinuities are present . MT is applicable to ferromagnetic material only . It is applicable for the detection of surface and sub surface discontinuities only .

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MPT kits
Magnetic field indicator

Magnetic gauss meter

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Magnetic particle testing

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Lifting Power of Yoke

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This testing is applicable for detecting defects open to surface.

20 micron nickel chromium test plate

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Procedure Clean the surface area to be tested Apply penetrant by brushing or spraying, wait for 7 to 15 min, (dwell time). Remove excess penetrant by wiping with lint free cloth. Apply developer and wait for 15 minute. Inspection and evaluation of the defects . Cleaning to be done with lint free cloth only.

Limitation for testing Surface temperature with in 10 to 52 c. Smooth surface is required . Porous material can not be tested.

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Cleaner

Penetrant Developer

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Ultrasonic sound waves are generated by using electrical transducer . These waves are transmitted in the material by using couplant. The sound waves are flowing inside the material and are disturbed by the presence of discontinuities in the material. The path of sound wave and its disturbance is monitored on the CRT screen. The loss of sound energy ( amount & location ) is indicated on the screen. which gives the idea about the defects , its size & location.

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Ultrasonic testing.

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Probe Flaw Test job

Indication

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ltrasonic Flaw Detector
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Ultrasonic testing transducer

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Inspection

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Phase array ltrasonic testing

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Thickness reading

Ultrasonic thickness testing

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Transmitter LATERAL WAVE Sound beam

Receiver

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Radiography testing depends upon the ability of x-rays or gamma rays to penetrate the test material .During penetration the rays are partially absorbed by the material . The amount of absorption depends upon the density and the thickness of material. Defective areas do not absorbs the radiation energy. Difference in radiation energy due to presence of discontinuity is recorded on a photographic film.

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Information required for testing Thickness and diameter Material

Limitation for testing Radiation hazard Surface temperature with in 0 to 45 c for contact technique . Surface roughness

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11. Radiography testing

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The ability to find out the leakages using air / gas medium at pressure or at vacuum. The air or gas is filled in the vessel/ tank at the required pressure and temperature. The leakage is detected by the loss of pressure checked by pressure gauge. Some times soaps solution is also used which forms air bubbles at the area of leakage.
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method is used for various applications such as mix metal sorting , dimension gauging, detection of defect ,measuring electrical conductivity etc. Principle of eddy current is based on the generation of induced current in the material and monitoring on the screen.

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Non-contact probe 1.5 mm

Magnetic saturation coil Lift-off adjustment

Multielement probe

Magnetic saturation head

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