Lecture # 4-5-6

MAINTENANCE ENGINEERING
&
INDUSTRIAL MANAGEMENT
CH-371
INSTRUCTOR: ENGR. RAMESHA TARIQ
2022 SPRING SEMESTER

DEPARTMENT OF CHEMICAL ENGINEERING

GHULAM ISHAQ KHAN INSTITUTE OF ENGINEERING SCIENCES AND TECHNOLOGY
NON DESTRUCTIVE
TESTING
 OUTLINE

 Introduction to Destructive and Nondestructive

testing
 Overview of most common NDT methods
 Selected Applications
 Nondestructive testing (NDT)
Non-destructive testing (NDT) is a testing and analysis technique used by
industry to evaluate the properties of a material, component, structure or
system for characteristic differences or welding defects and discontinuities
without causing damage to the original part.
Nondestructive testing (NDT)
Advantages
• Can test in-service structures
• Evaluate surface and internal conditions
• Cost efficient

Disadvantages
• Reliability (measurements are made
indirectly)
• Qualitative
• Requires a skilled professional for
interpretation of results
 Destructive testing (DT)
Destructive testing (DT) changes the dimensions or physical and structural
integrity of the specimen. (It is essentially destroyed during the test).
Ex:- Tensile, Compression, Shear and Rockwell Hardness.
Destructive testing (DT)
Advantages
• Reliable (direct measurements)
• Quantitative
• Directly relates to material properties

Disadvantages
• Cannot test in-service structures
• Requires a model
• Costly & Time Consuming
• Multiple tests are sometimes required
Difference between Destructive
& Nondestructive testing
NON DESTRUCTIVE TEST DESTRUCTIVE TEST
Used for finding out defects of Used for finding out the
materials properties of the material
Load is not applied on the Load is applied on the material
material
No load applications, so no Due to load application,
chance for material damage material gets damaged
No requirement of special Special equipment are required
equipment
Non expensive Expensive

Less Skill Skill is required

e.g.: dye penetrate test, e.g.: tensile test, compression
ultrasonic, radiography etc. test, hardness test etc.
 What are some uses of NDT Methods?
 Flaw Detection and Evaluation
 Leak 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
 When are NDT Methods used?
There are NDE application at almost any stage
in the production or life cycle of a component.
 To assist in product development
 To screen or sort incoming materials
 To monitor, improve or control manufacturing
processes
 To verify proper processing such as heat
treatment
 To verify proper assembly
 To inspect for in-service damage
Techniques of Non Destructive Testing
Vibration
Leak Monitoring Visual
Testing Method

Acoustic
Emission Liquid
Penetrant
Testing

Eddy
NDT
Ultrasonic
Current
Inspection
Testing
Magnetic
Radiography
particle
methods
testing Thermog
raphy
 Vibration Monitoring
 This technique uses the noise or vibration created by
mechanical equipment and in some cases by plant
systems to determine their actual condition.
 Vibration monitoring is the process of using sensors to
monitor small movements of various types of rotating
machinery.
 It identifies vibrations which may indicate a developing
failure, malfunction, or process restriction.
 What is Vibration?
 Vibration Analysis is defined as the measurement of
movement of a point on a machine.
 In order to measure the vibration (motion) of the point on
a machine, you would use a vibration sensor.
 This transforms mechanical motion into an electrical
voltage.
 This electrical signal is then sent to the vibration
analyzer connected to it.
 How Vibration Analysis
Work?
 After taking a measurement with a vibration analyzer
when the sensor is mounted to the machine, the analyzer
will read the incoming electrical voltage and generate a
Time Waveform (time domain).
 This plot compares the amplitude of vibration versus
time.
 How Vibration Analysis
Work?
 Most vibration analyzers will transform the Time Waveform
into a Frequency Spectrum (frequency domain).
 The Frequency Spectrum plots vibration amplitude versus
frequency.
 This allows the user to detect a much wider range of
machinery faults than the Time Waveform is capable of.
 Common Vibration Analysis
Detections:
Some of the common faults that you can detect when
analyzing vibration data are:
 Looseness
 Imbalance
 Misalignment
 Bearing faults
 Belt problems, and many more.
 VISUAL INSPECTION
Most basic and common inspection method.

Tools include fiberscopes,

borescopes, magnifying glasses
and mirrors.

Portable video inspection

unit with zoom allows
inspection of large tanks and
vessels, railroad tank cars,
sewer lines.
Robotic crawlers permit
observation in hazardous or tight
areas, such as air ducts, reactors,
pipelines.
 Liquid Penetrant Method
Principle
A liquid penetrant is applied at the surface of the specimen. The penetrant
is drawn by the surface flaws due to capillary action and this is
subsequently revealed by a developer, in addition with visual inspection.

Procedure

Cleaning the surface

Application of the penetrant

Removal of excess penetrant

Developing

Inspection
 Magnetic Particle Inspection
The process begins by running a magnetic current through the component.
Any crack or defect in the material will interrupt the flow of current and will
cause magnetism to spread out from them. This will create a “flux leakage
field” at the site of the damage.
The second step involves spreading metal particles over the component. If
there are any flaws on or near the surface, the flux leakage field will draw the
particles to the damage site. This provides a visible indication of the
approximate size and shape of the flaw.

It is highly portable

Inexpensive

No stringent pre-cleaning required

Magnetic Particle Crack Indications
Magnetic Particle Crack Indications
 Radiography
Radiographic Testing (RT) involves the use of either x-rays or gamma
rays to view the internal structure of a component.

High Electrical Potential

In the petrochemical industry, RT is often used to
inspect machinery, such as pressure vessels and Electrons
valves, to detect for flaws. RT is also used to + -
inspect weld repairs.
X-ray Generator
Creates Radiation
 Can be used on variety of materials
 Highly reproducible
 Requires very little surface preparation. Radiation
Penetrate
the Sample

Exposure Recording Device

 Radiography
Conventional Radiography Digital Radiography

 Image on a film  Digital detector to display images

 Long process time required.  Instant results
 Films can only be used once  Higher quality images, can be
 Image cannot be magnified. magnified.
 Radiographic Testing

The latent image is the invisible product of x-ray or photographic film

emulsions, build after radiation or light exposure. The visible image is developed
and fixed chemically from the latent image.
 Film Radiography
The part is placed between the radiation 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.

The film darkness (density) will

vary with the amount of
radiation reaching the film
through the test object.
X-ray film

= less exposure
(lower radiation intensity)
= more exposure
Top view of developed film (higher radiation intensity)
Radiographic Images
Ultrasonic Inspection (Pulse-echo)
High frequency sound waves are introduced into a material and they
are reflected back from surfaces or flaws.
Reflected sound energy is displayed versus time, and inspector can f
visualize a cross section of the specimen showing the depth of features
that reflect sound.
initial
pulse

back surface
echo
crack
echo

crack

0 2 4 6 8 10 plate

Oscilloscope, or flaw detector screen

 It can scan for flaws both on and underneath the surface.
 High accuracy.

 Not all materials are receptive to ultrasonic testing.

 It requires a good deal of skill and training to perform.

ULTRASONIC IMAGING

Ultrasonic probe using the sound reflected from the surface of the
object
 Eddy Current Testing
Coil's
Coil magnetic field

Eddy current's
magnetic field
Eddy
currents

Conductive
material
 Eddy Current Testing
• Based on electromagnetic induction.
• It is particularly used for detecting surface cracks but can also be used
to make electrical conductivity and coating thickness measurements.
• Here a small surface probe is scanned over the part surface in an
attempt to detect a crack.
 Infrared Thermography (IR)
IR Thermography is a technique that uses an infrared imaging and
measurement camera to "see" and "measure" invisible infrared energy
being emitted from an object.
f

• Thermography helps in easily determining hot-spots (overheating)

especially on electrical systems without contact.
• Qualified team of inspectors to carry out thermography service
NDT Techniques
 ACOUSTIC EMISSION
TESTING (AE)
 It is used to detect damages, cracks and
leaks caused due to pressure, load or
temperature, in different structures
such as metals, composites, wood,
fiberglass, ceramics, plastics, concrete,
polymer, etc.
 It uses elastic waves generated by a
material subjected to an external
stimulus like pressure, load or
temperature which propagate to the
surface and are recorded by sensors.
 How to Conduct Acoustic
Emission Testing?
Inspectors conducting Acoustic Emission Tests are examining materials
for bursts of acoustic energy, also called acoustic emissions, which are
caused by defects in the material.
Intensity, location, and arrival time can be examined to reveal
information about possible defects within the material.
 LEAK TESTING (LT)
Leak Testing refers to the process
of studying leaks in a vessel or
structure in order to identify defects
in it.
Leak testing can be achieved using
various leak detection methods and
is employed to test for defects in
products and to ensure the proper
function and maintenance of
industrial systems and pipelines..
 How to Conduct Leak
Testing?
Inspectors can detect leaks within a vessel using measurements taken
with a pressure gauge, soap-bubble tests, or electronic listening
devices, among others.
Vacuum Chamber Leak Testing
Common Application of NDT

 Inspection of Raw Products

 Inspection following Secondary Processing
 In-Service Damage Inspection
 Inspection of Raw Products
 Forgings
 Castings
 Extrusions
Inspection following Secondary Processing
 Machining
 Welding
 Grinding
 Heat treating
 Plating
Inspection for In-Service Damage

 Cracking
 Corrosion
 Heat Damage
 Erosion/Wear
 Wire Rope Inspection
Electromagnetic devices and visual
inspections are used to find broken wires
and other damage to the wire rope that is
used in chairlifts, cranes and other lifting
devices.
 Storage Tank Inspection
Robotic crawlers use
ultrasound to inspect the
walls of large above
ground tanks for signs
of thinning due to
corrosion.

Cameras on long
articulating arms
are used to inspect
underground
storage tanks for
damage.
 AIRCRAFT INSPECTION
• Nondestructive testing is used
extensively during the
manufacturing of aircraft.
• NDT is also used to find cracks
and corrosion damage during
operation of the aircraft.
• A fatigue crack that started at
the site of a lightning strike is
shown below.
JET ENGINE INSPECTION
• Aircraft engines are overhauled after
being in service for a period of time.
• They are completely disassembled,
cleaned, inspected and then
reassembled.
• Fluorescent penetrant inspection is
used to check many of the parts for
cracking.
 CRASH OF UNITED FLIGHT 232
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

The fracture in the recovered fan disk. Engine fan disk

 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.
 Rail Inspection
Special cars equipped with NDT
Equipment are used to inspect
thousands of miles of rail to find
cracks that could lead to
derailment.
 Bridge Inspection
• Corrosion, cracking and other
damage can all affect a bridge’s
performance and load carrying
capacity.
• The collapse of the Silver
Bridge, Ohio in 1967 resulted in
loss of 47 lives.
• Bridges get a visual inspection
about every 2 years.
• Some bridges are fitted with
acoustic emission sensors that
“listen” for sounds of cracks
growing.
Collapse of the Silver Bridge
 PIPELINE INSPECTION
NDT is used to inspect pipelines
to prevent leaks that could
damage the environment.
Visual inspection, radiography
and electromagnetic testing are
some of the NDT methods used.
 Assignment No. 1
Explain the Principle, Advantages, Disadvantages / Limitations
and Applications of different Non-Destructive Techniques in the
form of a table as shown below:

Technique Principle Advantages Disadvantages Applications

Deadline: 28-02-2022