.P.M.'s Polytechnic, Information Technology Centre, Thane Course/¥r/Master —1T1G. Subject — Safety In Engineering Industrie, Chapter 6 N.D, Test: ‘The Need For NDT:AW ‘Visual observation, even with magnification, cannot locate all small, below the surface dete; forged metals or in weld-metals such as found in pressure vessels, boilers and nuclear com, Proper NDT will, however reveal, all suc! indications, without damage to the components The Types Of NDTs ;Av The types of most commonly used NDTs are as follows: UX Magnetic particle Test: MP inspection test is the most commonly used test method for forgings. It utilizes magnetism » and hold very fine magnetic particles right on the part itself. If a defect present, it inter magnetic field and is clearly shown by the pattern made by the particles. The part is magnetized in suitable direction by DC line voltages transformed to low voltage + | volts), high amperage AC, half wave current, or three phase full wave current. Safety Precaution: * Allelectric circuits should be installed and grounded according to National Electrical Code other appropriate code. © Local exhaust should be provided to control the dust particles used for testing. © If local exhaust is not feasible, operator should wear respirator protective equipment. © Eye protection should be worn by the operator to guard against the irritating effects particles and arcing, © Personal protective equipment should be worn to protect against the possible skin iritao> the powder. 2. Penetrant Inspection (DP): DP tests are used for detecting cracks, pores and similar indication which are open to the sur ‘metals or other solid material. First the part to be inspected is cleaned. A penetrant is the applic! surface and within a few minutes is drawn into defects by capillary action. The penetrant is °° + from the surface but will remain in the surface opening until removed by the developer 198-P.M.'s Polytechnic, Information Technology Centre, Thane ; rse/Vr/Master — IT1G. Subject — Safety In Engineering Industries (23109) Precaution: (Most penetrant are organic compounds that may cause dermatitis, kin contact should be avoided with good personal hygiene practices strictly followed. smoking, Smoking materials, Food or Drinks should not be stored or use in the test area. JExposed skin should be washed before smoking, eating or drinking. aSonic Tests(Ut):- 4 sonic waves (above the audible range of 20,000Hz) are created by an electronic generator with plies high frequency voltage to a piezoelectric crystal, Thréé basic ultrasonic metals have been eloped. The reflection method, the true transmission method and the resonant-frequency method. ety Precaution: +, Equipment should be disconnected from power supply and \The condensers discharged whenever a cathode ray tube must be adjusted or removed ctromagnetic Method: Ay 4o1ypes of electromagnetic test are currently used: magneto inductive and eddy current. magneto inductive method uses variation in the permeability of magnetic materials to create ation in a pickup coil or probe. fe eddy current utilizes alternating current in a coil or a probe to induce eddy current in the part pe tested. Defects in variations in properties or geometry causes changes in the strength and @ribution in the eddy current. Readout is presented on a cathode ray tube, on a meter, by a suitable ddby visible alarm, or by a combination of these methods ety Precaution: wIn some reader-frequency testing installation, operators have been burnt internally, when they pass between object and the testing device Special regulation should be formulated and enforced. ¢ Barriers should be setup to prevent operators and others from entering such areas. « Recommendations of the manufacturer of the equipment should be followed explicitly. 199)V.P.M.’s Polytechnic, Information Technology Centre, Thane Course/¥r/Master = 1T1G Subject - Safety In Engineering Indust Radiography Tests: i Radiography uses X-rays and Gamma Rays, X-rays are unidirectional and their wave lengy, varied within certain limits, to suit the con¢ ions. Gamma Radiography differs from radiography, in that the gamma rays are multidirectional and their wave lengths being ct of the source cannot be regulated, Safety Precautio ¢ All sources of ionizing radiations are potentially dangerous. They should be stored and accordance with the instruction of the supplier of the source. ‘The exposure to the radiation by the operator should be regularly monitored, in the supplier's instructions Only trained and certified operator should be allowed to do the work. ‘The surrounding area should be effectively cordoned off and ensured that no one enters thi Where ever possible, the work should be done in a suitable enclosed room, built in with the supplier of the source. * All operators should be medically examined at frequency suggested by the supplier of the sa © After the work is over the source should be stored in accordance with the instruction supplier of the source. Nondestructive testing Nondestructive testing or Non-destructive testing (NDT) is a wide group of analysis techniques in science and industry to evaluate the properties of a material, component or system without ex damage. The terms Nondestructive examination (NDE), Nondestructive inspection and Nondestructive evaluation (NDE) are also commonly used to describe this technology. NDT does not permanently alter the article being inspected, it is a highly valuable technique thai save both money and time in product evaluation, troubleshooting, and research. Common methods include ultrasonic, magnetic-particle, liquid penetrant, radiographic, remote visual inst (RVD, eddy-current testing, and low coherence interferometry. NDT is commonly use! forensic, mechanical engineering, petroleum —_ engineering, electrical __ engineering, engine systems. aeronautical engineering, medicine, and art. 200VM? . 7 Tri Polytechnic, Information Technology Centre, Thane Subject ~ Safety In Engineering Indus' tries (23109) guts tahodls at methods may r 'y Tely upon use of electromagnetic radiation, sound, and inherent properties of rials to examine samy i ples. This includes some kinds of microscopy to examine external surfaces in ee bail, althe wil although sample preparation techniques for metallography, optical microscopy and electron Xcoscopy are generally destructive as the surfaces must be made smooth through polishing or the ed with ple mus Jnple must be electron transparent in thickness. The inside of a sample can be examin trating iat in Frsating radiation, such as X-rays, neutrons or terahertz radiation. Sound waves are utilized in the bse of ultrasonic testing. Contrast between a defect and the bulk of the sample may be enhanced for method (liquid egiitlg a al we ferrous materials involves fsual examination by the unaided eye by using liquids to penetrate fatigue cracks. One rade \ vie fib ow gay piterials, usually ‘metals Another commidily used’ NDT ttiethod used on ‘application of fine iron particles (ether liquid or dry dust) that are applied toa part while it is in an remally magnetized state (magnetic-partile testing). The particles will be attracted to leakage fields {niin the test object, and form on the objects surface. Magnetic particle testing can r (or use of the See beck effect) uses reveal surface & {ome sub-surface defects within the part. Thermoelectric effect ( Jtsrmal properties of an alloy to quickly and easily characterize many alloys. The chemical test, or cmical spot test method, utilizes application of sensitive chemicals that can indicate the presence of aiividual alloying elements. Electrochemical methods, such as electrochemical fatigue crack sensors, size the tendency of metal structural material to oxidize readily in order to detect progressive Jamage. Weld verification 1 2 L. Section of material with a surface-breaking crack that is not visible to the naked eye. 2 Penetrant is applied to the surface. 5. Excess penetrant is removed, 4. Developer is applied, rendering the crack visible. 201Course/Yr/Master -IT1G V.P.M.’s Polytechnic, Information Technology Centre, Thane Subject — Safety In Engineering Industries @31af In manufacturing, welds are commonly used to join two or more metal parts. Because 4 y ‘connections may encounter loads and fatigue during product lifetime, there is a chance that they fail if not created to proper specification. For example, the base metal must reach a certain temper; during the welding process, must cool at a specific rate, and must be welded with compatible materi or the joint may not be strong enough to hold the parts together, or cracks may form in the wel si causing it to fail. The typical welding defects (lack of fusion of the weld to the base metal, cracks of! porosity inside the weld, and variations in weld density) could cause a structure to break or a pipeling» 410 Mut. pixie bigs ang aathione rae Welds may be tested using NDT techniques such as industrial radiography or industrial scanning using X-rays or rays, ultrasonic, liquid penetrant testing, magnetic particle inspection via eddy current. In a proper weld, these tests would indicate a lack of cracks in the radiograph, show" clear passage of sound through the weld and back, or indicate a clear surface without pene captured in cracks. Welding techniques may also be actively monitored with acoustic emission techniques production to design the best set of parameters to use to properly join two materials, In the case of high stress or safety critical welds, weld monitoring will be employed to conficm the specified welding * Parameters (are current, ore voltage, tel speed, heat input etc.) are being adhered io those statedig nsleibae oih Dale ewe Bsa 1 lie sibeipionlat nate alyimiatpcee 8 dynnalancs Caliente tobe! nN oc Applications NDT is used in a variety of settings that covers a wide range of industrial activity, with new NDI methods and applications, being continuously developed. NTD services are not only integrated wi ‘Asset Integrity Management (AIM) solutions, but also with Material Testing laboratories and seamlessly fit into chain services. Automotive, engine parts, aviation & aerospace parts Gas turbine engines, rocketry, construction, structure, bridges, cover meter maintenance, reps and operations Bridges Manufacturing Machine parts 202' V.P.M.’s Polytechnic, Information Technology Centre, Thane gourse/Vr/Master —IT1G Subject — Safety In Engineering Industries (23109) |, Castings and forgings + Fabrication inspection inustrial plants such as nuclear, petrochemical, power, refineries, pulp and paper, fabrication shops, sine processing and their risk based inspection programmes. + Pressure vessels + Storage tanks + Welds + Boilers + Heat exchangers + Turbine bores + Incplant piping + Full storage tank assessment + Shutdown inspections + In-service equipment inspections + Miscellaneous + Pipelines + Incline inspection using “pigs” + Pipeline integrity management + Leak detection * Pipeline open data standard + ASME pressure vessel and piping as-built inspections + Piping and pressure vessel corrosion monitoring + Railways Rail inspection Wheel inspection * Tubular NDT. for tubing material 203* Corrosion under insulation (CUN) Amusement park rides © Submarines and other naval warships V.P.M.s Polytechnic, Information Technology Centre, Thane Subject — Safety In Engineering Industries (239 # Wire rope testing for, crane wires, mooring, wires, rope-way wires Introduction to Nondestructive Testing Outline © Introduction to NDT © Overview of Most Common NDT Methods ‘© Selected Applications Definition of NDT The use of noninvasive techniques to determine the integrity of a material, component or structure quantitatively measure some characteristic of an object. i.e. Inspect or measure without doing harm. Methods of NDT Visual © Microwave © Thermography © Tap Testing 204V.P.M.'s Polytechnic, Information Technology Centre, Thane yso/Ve/Master = TG ‘Subject ~ Safety In Engineering Industries (23109) ~\tagnetic Particle Syray Acoustic Microscopy | acoustic Emission Magnetic Measurements. Liquid Penetrant Ultrasonic Replication = | Laser Interferometry | Eddy Current 4 Fux Leakage ‘fbat are Some Uses of NDE Methods? ‘ Flaw Detection and Evaluation Leak Detection « Location Determination f) Pimensional Measurements |) Structure and Microstructure Characterization ) Estimation of Mechanical and Physical Properties ) Stress (Strain) and Dynamic Response Measurements » Material Sorting and Chemical Composition Determination 205Thane V.P.M.’s Polytechnic, Information Technology Centre, Course/Vr/Master — 1T1G Subject - Safety In Engineering Industries (2315 When are NDE Methods Used? ‘There are NDE applications 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 treating, To verify proper assembly To inspect for in-service damage Six Most Common NDT Methods Visual Liquid Penetrant Magnetic Ultrasonic Eddy Current X-ray 206