application of ndt for defect detection rev28072007-dr. k

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Development of NDT Procedures Based on Codes& Standards

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Page 1: Application of Ndt for Defect Detection Rev28072007-Dr. k

Development of NDT Procedures Based on Codes& Standards

Page 2: Application of Ndt for Defect Detection Rev28072007-Dr. k

PART ONE

APPLICATION OF NDT FOR DEFECT DETECTION

Page 3: Application of Ndt for Defect Detection Rev28072007-Dr. k

PART TWO

DEVELOPING AN NDT PROCEDURE

Page 4: Application of Ndt for Defect Detection Rev28072007-Dr. k

Part 1:Part 1:APPLICATION OF NDT FOR DEFECT DETECTION

CONTENTCONTENT INTRODUCTIONINTRODUCTION NDT TECHNOLOGYNDT TECHNOLOGY CLASSIFICATION OF DEFECTSCLASSIFICATION OF DEFECTS DEFECT DETECTIONDEFECT DETECTION NDT PROCEDURE FOR DETECTION NDT PROCEDURE FOR DETECTION

Page 5: Application of Ndt for Defect Detection Rev28072007-Dr. k

NATIONAL FORUM ON THE QUALIFICATION AND CERTIFICATION OF NDT PERSONNEL IN MALAYSIA,RENAISSANCE PALM GARDEN HOTEL, PUTRAJAYA, 21 JANUARY 2002.

NDT

DETECTING DEFECTSDIMENSION MEASUREMENTMATERIAL PROPERTIES

WH

Y

TESTING MATERIALWITHOUT DAMAGING

RADIOGRAPHYULTRASONICMAGNETIC PARTICLELIQUID PENETRANTEDDY CURRENTVISUAL INSPECTIONINFRARED THERMOGRAPHYACOUSTIC EMISSIONADVANCED NDT:NON-CONTACT, EMAT, DIGI TALRADIOGRAPHY, REMOTE FIELDEDDY CURRENT, IRI S,TOFD,

RAW MATERIALDESIGNFABRICATIONINSTALLATIONIN-SERVICEMAINTENANCEPRODUCTIONMANUFACTURING

QUALIFIED&CERTIFIEDNDT PERSONNELS

WHO

OIL&GASPETROCHEMICALPOWER GENERATIONTRANSPORTATIONMILITARYSEMICONDUCTOR/ELECTRONICBUILDINGFOODSFOUNDRY

Page 6: Application of Ndt for Defect Detection Rev28072007-Dr. k

INTRODUCTIONINTRODUCTION

The ndt inspection objective is to identify and assess methods/techniques and associated procedures that are capable of detecting and sizing defects taking into account the following :

· Type of defect· Type of material system· Structural feature/ geometry

Page 7: Application of Ndt for Defect Detection Rev28072007-Dr. k

The inspection regime for materials systems needs to take account of a number of factors, including:

· How critical the component is to the performance of the overall system;· The nature of the defects that can occur;· How the defects may develop under the operating conditions of the system;· What is currently known about the condition of the component.

Page 8: Application of Ndt for Defect Detection Rev28072007-Dr. k

There are several factors that need to be considered to choose the optimum inspection technique,including:· Relevant defect types· Location and likely size of the defects· Suitability of material· Geometry and thickness of component· NDE performance required (sensitivity, speed, reliability, etc).· Prior inspection history· Accessibility· Manufacturing versus In-service inspection· Availability of procedures & standards· Cost benefit· Time available for inspection· Prescriptive requirements· Defect characterisation required· Defect assessment and requirements

Page 9: Application of Ndt for Defect Detection Rev28072007-Dr. k

SELECTION OF NDT METHOD AND TECHNIQUE

NDT provides information about the current condition of a component, that would otherwise be unknown. This may avoid unexpected failure, help plan future operation and inspection, and reduce the risk.

Often considered an additional cost, effective inspection can add considerable value over the lifetime of the component. For manufacturers, NDT will add value by increasing the quality of the component, and reducing the risk of subsequent failure in service.

Page 10: Application of Ndt for Defect Detection Rev28072007-Dr. k

In many materials systems, the choice may be quite limited, because of the nature of the system and the type of defects that occur. If the nature of the damage that may occur is well known, then a very precise inspection could be specified.

If the condition of the component is not well known and the defects varied, then an alternative approach using a variety of methods or techniques which are sensitive to a number of defect types.

Page 11: Application of Ndt for Defect Detection Rev28072007-Dr. k

CONTENTCONTENT

INTRODUCTIONINTRODUCTION NDT TECHNOLOGYNDT TECHNOLOGY CLASSIFICATION OF DEFECTSCLASSIFICATION OF DEFECTS DEFECT DETECTIONDEFECT DETECTION NDT PROCEDURE FOR DETECTION NDT PROCEDURE FOR DETECTION

Page 12: Application of Ndt for Defect Detection Rev28072007-Dr. k

NDT TECHNOLOGY

• RADIOGRAPHY• ULTRASONIC• MAGNETIC PARTICLES• LIQUID PENETRANT• EDDY CURRENT• ADVANCED NDT

Conventional

Page 13: Application of Ndt for Defect Detection Rev28072007-Dr. k

ADVANCED NDT RT - COMPUTERISED RADIOGRAPHY - X-RAY SCANNING FOR DANGEROUS ITEMS UT - TIME OF FLIGHT DIFFRACTION (TOFD) - UT FOR PIPE SCANNING - PHASE ARRAY - LONG RANGE INSPECTION - NON-CONTACT ULTRASOUND - IRIS ET - REMOTE FIELD ET (RFET) - PULSE ET OTHERS - ACOUSTIC EMISSION - INFRARED THERMOGRAPHY

RT - COMPUTERISED RADIOGRAPHY - X-RAY SCANNING FOR DANGEROUS ITEMS UT - TIME OF FLIGHT DIFFRACTION (TOFD) - UT FOR PIPE SCANNING - PHASE ARRAY - LONG RANGE INSPECTION - NON-CONTACT ULTRASOUND - IRIS ET - REMOTE FIELD ET (RFET) - PULSE ET OTHERS - ACOUSTIC EMISSION - INFRARED THERMOGRAPHY

Page 14: Application of Ndt for Defect Detection Rev28072007-Dr. k

Comparison of NDT methods in Materials

X-rayIr-192Co-60

NormalAngle

AC YokePmnt magnet

ECTRFET

MPI DPTUTRT ET20

0m

mTh

ickn

ess

1m

2-3 mm

Skin depth•Frequency•Permeability•Conductivity

0 mm

Page 15: Application of Ndt for Defect Detection Rev28072007-Dr. k

PRINCIPLE OF RADIOGRAPHYPRINCIPLE OF RADIOGRAPHY

Page 16: Application of Ndt for Defect Detection Rev28072007-Dr. k

STEPS FOR MAKING RADIOGRAPH

• 1. SAFETY PROCEDURES1. SAFETY PROCEDURES2. TECHNICAL CONSIDERATION2. TECHNICAL CONSIDERATION3. SAMPLE PREPARATION3. SAMPLE PREPARATION4. VISUAL INSPECTION OF THE SPECIMEN4. VISUAL INSPECTION OF THE SPECIMEN5. MARKING THE SPECIMEN5. MARKING THE SPECIMEN6. MASKING6. MASKING7. IQI PLACEMENT7. IQI PLACEMENT8. FILM PROCESSING8. FILM PROCESSING9. FILM EVALUATION AND 9. FILM EVALUATION AND INTERPRETATIONINTERPRETATION10.DOCUMENTATION10.DOCUMENTATION

1. SAFETY PROCEDURES1. SAFETY PROCEDURES2. TECHNICAL CONSIDERATION2. TECHNICAL CONSIDERATION3. SAMPLE PREPARATION3. SAMPLE PREPARATION4. VISUAL INSPECTION OF THE SPECIMEN4. VISUAL INSPECTION OF THE SPECIMEN5. MARKING THE SPECIMEN5. MARKING THE SPECIMEN6. MASKING6. MASKING7. IQI PLACEMENT7. IQI PLACEMENT8. FILM PROCESSING8. FILM PROCESSING9. FILM EVALUATION AND 9. FILM EVALUATION AND INTERPRETATIONINTERPRETATION10.DOCUMENTATION10.DOCUMENTATION

Page 17: Application of Ndt for Defect Detection Rev28072007-Dr. k

RADIOGRAPHIC IMAGE QUALITYRADIOGRAPHIC IMAGE QUALITY

DEPEND ON:1. SENSITIVITY- A MEASURE OF THE SMALLEST DISCONTINUITY DETECTABLE IN A RADIOGRAPH.

2. FILM DENSITY- A MEASURE OF THE DEGREE OF BLACKENING OF FILM.

3. FILM ARTIFACT - ANY INDICATION OTHER THAN THOSE DUE TO THE CONDITION OF THE OBJECT SUCH AS IMPROPER PROCESSING,IMPROPER HANDLING.

DEPEND ON:1. SENSITIVITY- A MEASURE OF THE SMALLEST DISCONTINUITY DETECTABLE IN A RADIOGRAPH.

2. FILM DENSITY- A MEASURE OF THE DEGREE OF BLACKENING OF FILM.

3. FILM ARTIFACT - ANY INDICATION OTHER THAN THOSE DUE TO THE CONDITION OF THE OBJECT SUCH AS IMPROPER PROCESSING,IMPROPER HANDLING.

Page 18: Application of Ndt for Defect Detection Rev28072007-Dr. k

RADIOGRAPHIC SENSITIVITYRADIOGRAPHIC SENSITIVITY

S

t

Sensitivity (percentage) = s x 100 ts = the smallest detectable thickness differencet = total thickness of the specimen

Page 19: Application of Ndt for Defect Detection Rev28072007-Dr. k

MEASUREMENT OF SENSITIVITY

BY AN IMAGE QUALITY INDICATOR (I.Q.I)

WIRE TYPE

DIN 62 FE

1 ISO 7

HOLE TYPE

FE

100

PENETRAMETERMADE OF STEEL

4T

2T

1T

INDICATE THE THICKNESS OF THEPENETRAMETER(0.1”)

Page 20: Application of Ndt for Defect Detection Rev28072007-Dr. k

EXPOSURE CALCULATION

• 1. SLIDE RULE

2. REFERENCE TO PREVIOUS DATA

3. AUTOMATIC DEVICES

4. EXPOSURE CHARTS

Page 21: Application of Ndt for Defect Detection Rev28072007-Dr. k

X-RAY EXPOSURE CHART

1

100

10

1000100kV

120kV140kV

160kV

180kV

EX

PO

SU

RE

(m

A.m

in)

THICKNESS (mm)

0 5 10 15 20 25 30 35 40 45

Material: steelSFD : 70mmFilm : Agfa D7filter : noDensity : 2Machine: Andrex 257Screen: Lead front 0.125mm back 0.125mm

19.5

Page 22: Application of Ndt for Defect Detection Rev28072007-Dr. k

GAMMA-RAY EXPOSURE CHART

Source : Ir 192SFD : 60 mmMaterial : SteelScreen : Lead Front 0.1 mm Back 0.15 mmFilm : Agfa D7Developer : G121/g135

D=1.5

D=2.0

D=3.0

0 5 10 15 20 25 30 35

THICKNESS (mm)

1

10

100

1000

EX

PO

SU

RE (

Ci.

hr )

Page 23: Application of Ndt for Defect Detection Rev28072007-Dr. k

RADIOGRAPHIC EXPOSURE TECHNIQUES

• 1. SINGLE WALL RADIOGRAPHY

2. DOUBLE WALL RADIOGRAPHY

2.1 DOUBLE WALL SINGLE IMAGE

2.2 DOUBLE WALL DOUBLE IMAGE

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PRINCIPLE OF ULTRASONIC

• USE SOUND FREQUENCY > 20 khz• USE FOR DEFECT DETECTION/EVALUATION, DIMENSIONAL MEASUREMENT, MATERIAL CHARACTERISATION

TRANSDUCER

SPECIMEN

Page 32: Application of Ndt for Defect Detection Rev28072007-Dr. k

PRINCIPLE OF UT DEFECT DETECTION

DEFECT ECHOSIGNAL

Page 33: Application of Ndt for Defect Detection Rev28072007-Dr. k

TYPE OF TRANSDUCERTYPE OF TRANSDUCER

CONTACT TRANSDUCER

IMMERSION TRANSDUCER

TWIN CRYSTALTRANSDUCER

ANGLE BEAM TRANSDUCER

Page 34: Application of Ndt for Defect Detection Rev28072007-Dr. k

WELD INSPECTION

Page 35: Application of Ndt for Defect Detection Rev28072007-Dr. k

UT SCANNING

Page 36: Application of Ndt for Defect Detection Rev28072007-Dr. k

Double vee weld joint ut inspection

Inspection plan Reporting and recording of UTresults

Page 37: Application of Ndt for Defect Detection Rev28072007-Dr. k

CONTENTCONTENT

INTRODUCTIONINTRODUCTION NDT TECHNOLOGYNDT TECHNOLOGY CLASSIFICATION OF DEFECTSCLASSIFICATION OF DEFECTS DEFECT DETECTIONDEFECT DETECTION NDT PROCEDURE FOR DETECTION NDT PROCEDURE FOR DETECTION

Page 38: Application of Ndt for Defect Detection Rev28072007-Dr. k

WHAT IS THE DIFFERENCE BETWEEN DEFECTS AND DISCONTINUITIES ?

Discontinuity is defined as any imperfection or interruption in the normal physical structure or configuration of a product

Defect is defined as a discontinuity whose size, shape, orientation, location or properties makes it detrimental to the useful service of the product in which it occurs or exceeds the accept/reject criteria for the given design

Page 39: Application of Ndt for Defect Detection Rev28072007-Dr. k

THREE CLASSES OF DISCONTINUITIES

Inherent discontinuity Processing discontinuity In-service discontinuity

Page 40: Application of Ndt for Defect Detection Rev28072007-Dr. k

WHAT IS INHERENT DISCONTINUITIES ?

Those discontinuities that are related to the solidification of the metal in the ingot or in a casting

Example ; inclusion, porosity, pipe and segregation

Page 41: Application of Ndt for Defect Detection Rev28072007-Dr. k

WHAT IS PROCESSING DISCONTINUITIES ?

Those discontinuities that are related to various manufacturing processes such as machining, rolling, forging, welding, etc

Examples ; lamination, seams

Page 42: Application of Ndt for Defect Detection Rev28072007-Dr. k

WHAT IS IN-SERVICE DISCONTINUITIES ?

Those discontinuities related to various service conditions such as stress, corrosion, fatigue and erosion

Example ; fatigue crack

Page 43: Application of Ndt for Defect Detection Rev28072007-Dr. k

WHAT ARE THE FACTORS DETERMINING

THE SEVERITY OF DEFECTS ?

Type of defects Location of defects Distribution of defects Orientation of defects Size of defects

Page 44: Application of Ndt for Defect Detection Rev28072007-Dr. k

CONTENTCONTENT

INTRODUCTIONINTRODUCTION NDT TECHNOLOGYNDT TECHNOLOGY CLASSIFICATION OF DEFECTSCLASSIFICATION OF DEFECTS DEFECT DETECTIONDEFECT DETECTION NDT PROCEDURE FOR DETECTION NDT PROCEDURE FOR DETECTION

Page 45: Application of Ndt for Defect Detection Rev28072007-Dr. k

DEFECT DETECTION

STEPS FOR INSPECTION:STEPS FOR INSPECTION:DETECTING DEFECTS IN TERMS OFDETECTING DEFECTS IN TERMS OF - TYPES- TYPES - LOCATION- LOCATION - SIZE- SIZE

EVALUATION (ACCEPT/REJECT) BASED ON EVALUATION (ACCEPT/REJECT) BASED ON - CODES - CODES - STANDARDS - STANDARDS - SPECIFICATIONS- SPECIFICATIONS

Page 46: Application of Ndt for Defect Detection Rev28072007-Dr. k
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Page 48: Application of Ndt for Defect Detection Rev28072007-Dr. k

FUNCTIONS OF LEVEL 1 NDT PERSONNEL (ISO 9712)

FUNCTIONS OF LEVEL 1 NDT PERSONNEL (ISO 9712)

Prepare materials and accessories necessary for inspection

Set up equipment Perform specific test according to written instructions Maintain and carry out routine control of the

equipment Comply with safety instructions and procedures for

equipment and personnels Assist the trainee

LEVEL 1 PERSONNEL SHALL NOT BE RESPONSIBLE FOR THE CHOICE OF THE TEST METHOD OR TECHNIQUE TO BE USED.

Page 49: Application of Ndt for Defect Detection Rev28072007-Dr. k

FUNCTIONS OF LEVEL 2 NDT PERSONNEL (ISO 9712)

FUNCTIONS OF LEVEL 2 NDT PERSONNEL (ISO 9712)

Select equipment and technique for the test Supervise and/or perform test according to

written procedures Interpretes and evaluates results according to

codes, standards and specifications mention in written procedures

Issues and signs corresponding technical reports Prepare written instruction for Level 1 personnel Undertakes the responsibility for training and

guidance of trainee and Level 1 personnel Instructs personnel of lower level in the correct

and safe use of equipment Suggests additional tests whenever neccessary

Page 50: Application of Ndt for Defect Detection Rev28072007-Dr. k

FUNCTIONS OF LEVEL 3 NDT PERSONNEL (ISO 9712)

FUNCTIONS OF LEVEL 3 NDT PERSONNEL (ISO 9712)

Determines the adequate technique and procedure for each test

Supervises the steps necessary for carrying out the test with required level of quality

Ensures that codes, standards and specifications and written procedures are complied

Trains, instructs and controls the performance of personnel of lower level

Initiates, assigns and controls NDT and follow up test procedures

Establish criterions for acceptance or rejection based on standards and/or specifications and applicable technical procedures ……………..

Page 51: Application of Ndt for Defect Detection Rev28072007-Dr. k

FUNCTIONS OF LEVEL 3 NDT PERSONNEL (ISO 9712)

FUNCTIONS OF LEVEL 3 NDT PERSONNEL (ISO 9712)

Decides the validity of results with respect to the method and technique utilised and objectives of test

Controls the quality and performance of testing equipment and materials

Establish and maintains filing system for NDT documents and records

Responds and ensure that the tests are conducted according to safety requirements

Suggests any other NDT methods suitable for specific requirements

Assists the design engineer in establishing acceptance criteria where non are otherwise available

Page 52: Application of Ndt for Defect Detection Rev28072007-Dr. k

PART TWO

DEVELOPING AN NDT PROCEDURE

Page 53: Application of Ndt for Defect Detection Rev28072007-Dr. k

SIRIM Berhad… YOUR PARTNER TO GLOBAL TRADE

An orderly sequence set of rules An orderly sequence set of rules which describe in detailed terms which describe in detailed terms where, how and when method(s) where, how and when method(s) should be applied to a product.should be applied to a product.

WHAT IS AN NDT PROCEDURE?

Page 54: Application of Ndt for Defect Detection Rev28072007-Dr. k

REQUIREMENT FOR USING REQUIREMENT FOR USING NDT PROCEDURESNDT PROCEDURES

e.g. BY ASME V, General Requirementse.g. BY ASME V, General Requirements

T-150 ProceduresT-150 Procedures

When required by the reference Code Section, all non-destructive When required by the reference Code Section, all non-destructive

examinations performed under this code section shall be done toexaminations performed under this code section shall be done to

a written procedure. This procedure shall be demonstrated to thea written procedure. This procedure shall be demonstrated to the

satisfaction of inspector. The procedure or method shall comply with satisfaction of inspector. The procedure or method shall comply with

the applicable requirements of this section for the particular examination the applicable requirements of this section for the particular examination method. Where so required, written procedures shall be made available method. Where so required, written procedures shall be made available to the inspector on request. At least one copy of each procedure shall be to the inspector on request. At least one copy of each procedure shall be readily available to the manufacturer’s non destructive examination readily available to the manufacturer’s non destructive examination personnel for their reference and use.personnel for their reference and use.

Page 55: Application of Ndt for Defect Detection Rev28072007-Dr. k

USE OF CODES, STANDARDS AND USE OF CODES, STANDARDS AND SPECIFICATIONS SPECIFICATIONS

USE OF CODES, STANDARDS AND USE OF CODES, STANDARDS AND SPECIFICATIONS SPECIFICATIONS

CODESCODES - A conventionalised set of rules of good practice - A conventionalised set of rules of good practice e.g. ASME,e.g. ASME, For UT (Article 4 and 5, Section V)For UT (Article 4 and 5, Section V)

STANDARDS - A level of excellence or quality of product and/or Service. STANDARDS - A level of excellence or quality of product and/or Service. e.g. Japanese Industrial Std.JIS) For UT (JIS Z 3060)e.g. Japanese Industrial Std.JIS) For UT (JIS Z 3060)

SPECIFICATIONS- A detailed description of criteria for the constituents,SPECIFICATIONS- A detailed description of criteria for the constituents, constructions, appearance etc., of a material and/orconstructions, appearance etc., of a material and/or service.service.

Purpose of Function of Codes, Standards and SpecificationPurpose of Function of Codes, Standards and Specification

To prescribe a test method or procedure which could give correct, reliable and To prescribe a test method or procedure which could give correct, reliable and uniform assessment of the quality of the product, and will ensure that the uniform assessment of the quality of the product, and will ensure that the method is reproducible.method is reproducible.

Page 56: Application of Ndt for Defect Detection Rev28072007-Dr. k

CONTENT OF AN NDT PROCEDURE

1. SCOPE 2. RELATED DOCUMENTS 3. DEFINITIONS 4. DESCRIPTIONS: 4.1 EQUIPMENT REQUIREMENTS 4.2 PERSONNELS REQUIREMENTS 4.3 MATERIAL SPECIFICATION 4.4 MECHANICAL ARRANGEMENT 4.5 CALIBRATION 4.6 IDENTIFICATION SYSTEM 4.7 SURFACE PREPARATION 4.8 EXECUTION OF INSPECTION 4.9 RESULTS EVALUATION 4.10 REPORTING

Page 57: Application of Ndt for Defect Detection Rev28072007-Dr. k

CONTENT OF AN NDT PROCEDURE

1. SCOPE Provide objective and coverage of inspection

2. RELATED DOCUMENTS Lists all documents such as codes, standards, specifications pertaining to this inspection

3. DEFINITIONS Define any parameters or subjects related to the scope of work

4. DESCRIPTIONS:

4.1 EQUIPMENT REQUIREMENTS List all equipment used to execute the work

Page 58: Application of Ndt for Defect Detection Rev28072007-Dr. k

CONTENT OF AN NDT PROCEDURE

4.2 PERSONNELS REQUIREMENTS Describe the level of NDT personnel and qualification, their duty and task to perform the work

4.3 MATERIAL SPECIFICATION Give details of material specification of the object/specimen to be inspected

4.4 MECHANICAL ARRANGEMENT Outline in details with diagram of how, where to carry out your equipment to the specimen.

Page 59: Application of Ndt for Defect Detection Rev28072007-Dr. k

CONTENT OF AN NDT PROCEDURE

4.5 CALIBRATION Describe how the equipment will be calibrated before the work start,eg, ut time base, sensitivity, etc.

4.6 IDENTIFICATION SYSTEM Explain and state clearly inspection identification to be used to differentiate one to another

4.7 SURFACE PREPARATION Give details of how sample surface preparation will be conducted

Page 60: Application of Ndt for Defect Detection Rev28072007-Dr. k

CONTENT OF AN NDT PROCEDURE

4.8 EXECUTION OF INSPECTION Describe how data of inspection to be collected so that defects can be detected, identified and sized

4.9 RESULTS EVALUATION Describe how data will be evaluated based on agreed acceptance and rejection criteria.

4.10 REPORTING Outline how data will be recorded and reported for inspection documentation.

Page 61: Application of Ndt for Defect Detection Rev28072007-Dr. k

ACCEPTANCE AND REJECTION

CRITERIA - RADIOGRAPHYINDICATIONS SHOWN ON RADIOGRAPH ARE UNACCEPTABLE UNDER THE FOLLOWING CONDITIONS:

(1) ANY INDICATION CHARACTERISED AS A CRACK, OR ZONE OF INCOMPLETE PENETRATION OR FUSION;(2) ANY OTHER ELONGATED INDICATION ON THE RADIOGRAPHY WHICH ;HAS LENGTH GREATER THAN:

(a) 1/4 in. (6mm) for t up to 3/4 in(19mm)(b) (1/3) t for t from 3/4 in (19mm) to 2 1/4 in.

(57mm)(c) 3/4 in. (19mm)for t over 2 1/4 in. (57mm)

wheret = the thickness of the weld excluding any allowablereinforcement. For a butt weld joining two membershaving different thicknesses at the weld, t is the thinnerof these two thicknesses.

Page 62: Application of Ndt for Defect Detection Rev28072007-Dr. k

ACCEPTANCE AND REJECTION

CRITERIA - ULTRASONIC

APPENDIX 12IMPERFECTIONS WHICH PRODUCE A RESPONSE GREATHER THAN20% OF THE REFERENCE LEVEL SHALL BE INVESTIGATED TO THE EXTENT THAT THE OPERATOR CAN DETERMINE THE SHAPE,IDENTITY AND LOCATION OF ALL SUCH IMPERFECTIONS ANDEVALUATETHEM IN TERMS OF (a) and (b) BELOW:

(a) INDICATIONS CHARACTERISED AS CRACKS, LACK OF FUSION ORINCOMPLETE PENETRATIONARE UNACCEPTABLE REGARDLESS OFLENGTH.(b) OTHER IMPERFECTIONS ARE UNACCEPTABLE IF THE INDICATIONS EXCEED THE REFERENCE LEVEL AMPLITUDE AND HAVELENGTHS WHICH EXCEED:

(1) 1 1/4 in. fo t up to 3/4 in.(2) (1/3) t for t from 3/4 in. to 2 1/4 in.(3) 3/4 in. for t over 2 1/4 in. where

t = the thickness of the weld excluding any allowable reinforcement.For a butt weld joining two members having different thicknesses at the weld, t is the thinner of these two thicknesses.

Page 63: Application of Ndt for Defect Detection Rev28072007-Dr. k

RT WRITTEN PROCEDURE

TASK: GIVEN A DOUBLE V CARBON STEEL PLATE OF 24 mm THICKNESS,EXPOSURE CHARTS FOR X-RAY AND Ir- 192, ASME CODE v ARTICLE 2.

Page 64: Application of Ndt for Defect Detection Rev28072007-Dr. k

POINTS FOR CONSIDERATION (RT)

SAFETY=?IQI =?SENSITIVITY=?DENSITY=?EXPOSURE TIME=?IDENTIFICATION MARKING=?RADIOGRAPHIC TECHNIQUE=?

Page 65: Application of Ndt for Defect Detection Rev28072007-Dr. k

REPORT NO : JOB NO. : DATE :

SIRIM BERHAD 1, Persiaran Dato Menteri P.O. Box 7035, Section 2 40911 Shah Alam, Selangor Tel: 60-3-55446068 Fax: 60-3-55446057

RADIOGRAPHIC INSPECTION

REPORT PAGE : OF :

LOCATION :

SPECIFICATION : -

PROJECT : -

PROCEDURE :

CLIENT : .

DRAWING NO : -

ACCEPTANCE : -

TECHNICAL INSPECTION DATA

OBJECT :

EXPOSURE TECHNIQUE :

FILM TO SOURCE :

MATERIAL :

SOURCE TYPE :

FILM TYPE :

PROCESS :

SOURCE SIZE : -

SCREEN TYPE :

AREA OF INSPECTION :

SOURCE STRENGTH : -

FRONT :

IQI : -

FOCAL SPOT SIZE :

SCREEN THICKNESS

BACK : POSITION : -

K.V.P/M.A :

TOTAL NO. OF FILMS :

SENSITIVITY : -

MANUFACTURER :

NO. APPROVED :

QUALITY LEVEL : -

EXPOSURE TIME :

NO. OF REPAIR : -

RESULTS

FILM DENSITY

EVALUATION

JOINT/PART IDENTIFICATION

POSITION

DIAMETER/ THICKNESS

WELDER

REF. MIN

MAX

TYPE OF DEFECT*

ACCEPT

REJECT

REMARKS

*LEGENDS :

A : Gas cavity

F : Undercut

Aa : Gas pore

G : Flux inclusion

RADIOGRAPH TAKEN BY :

Ab : Worm hole

H : Metallic inclusion

Ba : Slag inclusion

J : Oxide inclusion

FILM INTERPRETED BY :

C : Lack of fusion

K : Shrinkage cavity

D : Lack of penetration

NAD : No apparent defect

Ea : Longitudinal crack

Eb : Transverse crack

EC : Crater crack

Verified By: DATE :

Page 66: Application of Ndt for Defect Detection Rev28072007-Dr. k

UT WRITTEN PROCEDURE

TASK: GIVEN A DOUBLE V CARBON STEEL PLATE OF 24 mm THICKNESS,ASME CODE V ARTICLE 5.

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POINTS FOR CONSIDERATION (UT)

CALIBRATION OF PROBE=? UT TEST RANGE=?DAC CURVE CALIBRATION=?INITIAL SCANNING SENSITIVITY =? PARENT METAL INSPECTION=?WELD BODY INSPECTION=?EVALUATION SCANNING SENSITIVITY =?DEFECT SIZING TECHNIQUE=?IDENTIFICATION MARKING=?RECORDING AND REPORTING=?

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SIRIM BERHAD Company No. 367474-V 1, Persiaran Dato Menteri Section 2, P.O. Box 7035 40911 Shah Alam, Selangor. Tel: 60-3-5567079 Fax: 60-3-5567092

ULTRASONIC INSPECTION REPORT

REPORT NO. : MTL/98/0133 SPECIFICATION : AWS D1-1 86

CLIENT :.

ACCEPTANCE CRITERIA : ASW D1-1 86

PROJECT :

PROCEDURE NO. : SIRIM-UT-2

CONTRACT/JOB NO. : MTL/98/0133

TEST DATE : 3/9/98

SPECIMEN DATA: MATERIAL : CAST IRON

TESTING TEMPERATURE : 27oC

SURFACE CONDITION : ROUGH

ITEM/OBJECT INSPECTION : FINE ROLL SUPPORTER

OBJECT/WELDING PROCESS :

JOINTS DETAILS : -BUTT JOINT

MATERIAL THICKNESS : 16 mm

COUPLANT : MOTOR OIL/GREASE

PROBES :

ANGLE

SIZE (mm)

MHz

SC/TC

S/NO.

0O

Ø 10

4

SC

07023

45O

8 X 9

2

SC

30218

60O

-

-

-

-

70O

8 X 9

4

SC

07607

EQUIPMENT ULTRASONIC UNIT : USK 7

SERIAL NO. : 31281-6633

CALIBRATION BLOCK : V1 & V2

REFERENCE BLOCK : V1 & V2

UT DATA CALIBRATION : 50 mm & 100 mm SCANNING TECHNIQUE : AS PER SIRIM PROCEDURE

SENSITIVITY : 1st BWE from Parent Metal to 100% FSH TRANSFER LOSS : -

SIZING TECHNIQUE : - LENGTH : - HEIGHT (WIDTH) : - NOTCH : -

RESULTS PARENT METAL : WELD METAL : NO REJECTABLE INDICATION APPEAR BOTH ON PARENT AND WELD METAL. ACCEPTABLE TO SPECIFICATION.

REMARKS :

UT TECHNICIAN : MOHD. ARIS FATHILLAH SALEH/ SURI TAIB UT QUALIFICATION : PCN (3.1, 3.2) /MLVK LEVEL 2

Q.C. INSPECTOR : DATE :

CLIENT ACCEPTANCE : DATE :

Page 69: Application of Ndt for Defect Detection Rev28072007-Dr. k

THANK YOU

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