ndt-nondestructive examination
TRANSCRIPT
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MATERIAL CLASSIFICATION
Metal
MATERIAL
Nonmetal
Ferrous
Nonferrous
Raw
Product
Raw
Product
Organic
Anorganic
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THE IMPORTANCE OF TESTING
Simple & low risk
Complicated & high risk
QUALITY ASSURANCE !!!
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NONDESTRUCTIVE
DESTRUCTIVE
TYPES OF TESTING
No/minor change to the material being examined
Early warning, no need to shutdown the operation, qualitative &
quantitative information may be obtained
Potentially causes significant change to the material being
examined
Used as statistical sampling basis only, not suited to huge and
expensive structures
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Visual, with or without aidLiquid Penetrant Testing (PT)
Magnetic Particle Testing (MT)
Propagation of Elastic Waves/VibrationUltrasonic Testing (UT)
Acoustic Emission (AE)
RadiationRadiography Techniques (X-Ray, Gamma-Ray)
Electromagnetic FieldEddy Current Testing (ET)
Alternating Current Potential Drop (ACPD)
Alternating Current Field Measurement (ACFM)
TYPES OF NONDESTRUCTIVE TESTING
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TYPES OF DESTRUCTIVE TESTING
Mechanical TestTensile test: weld metal, weld joint, nick break
Bend test: face bend, root bend, side bend
Charpy impact test: V-notch, U-notch, keyhole
Hardness test: Brinell, Vickers, RockwellFracture test: fillet weld
Fatigue Test
Chemical Composition Test
Metallurgical TestFractography
Macrography
Micrography
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TENSILE TEST
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BEND TEST
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CHARPY IMPACT TEST
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Fatigue Test
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Chemical Composition Test
ARL Spectrometer
Niton
X-Ray Fluorescence (XRF)
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Metallurgical Test
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What are Some Usesof NDE 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
Fluorescent penetrant indication
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When are NDE Methods Used?
To assist in product development
To screen or sort incoming materials
To monitor, improve or control manufacturing
processes
To verify proper processing such as heattreating
To verify proper assembly
To inspect for in-service damage
There are NDE application at almost any stage
in the production or life cycle of a component.
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Six Most Common NDTMethods Visual Liquid Penetrant
Magnetic
Ultrasonic
Radiography Eddy Current
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Most basic and common
inspection method.
Tools include
fiberscopes,
borescopes, magnifying
glasses and mirrors.
Robotic crawlers permit
observation in hazardous or
tight areas, such as air
ducts, reactors, pipelines.
Portable video inspection
unit with zoom allows
inspection of large tanks
and vessels, railroad tank
cars, sewer lines.
Visual Inspection
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DIRECT VISUAL INSPECTION
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INDIRECT VISUAL INSPECTION
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INDIRECT VISUAL INSPECTION
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However, reliability of visual inspection is
highly affected by human factor since evenan experienced personnel can be fooled by
the presence of scratches or machining
marks into seeing defects which are not
present.
Due to the reasons, there are some aids to
visual inspection which help to revealdefects more readily and consistently.
Li id P t t I ti
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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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HISTORY
The oil and whiting method was the
forerunner of modern liquid penetrant testing.The oil and whiting (chalk) method was used
in the early 1900s by the railroads in testing
locomotive parts such as axles, crank pins,and couplers.
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TYPE OF PENETRANT MATERIALS
Water-washable Post-emulsifiable
Solvent Removable
Either a color contrast (visible) penetrant or afluorescent penetrant shall be used with one of the
following three penetrant processes:
P t l ifi bl
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Post-emulsifiable
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Water-washable and Solvent-removable
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LIQUID PENETRANT INSPECTION
(Solvent-removable)
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Indication of Discontinuity
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Kelebihan: Sederhana & relatip murah.
Untuk semua material asalkan permukaannya, tidak berpori dan tidak
menyerap cairan.
Untuk komponen-komponen dengan semua bentuk dan ukuran.
Dipakai untuk quality control dan inline inspectionrutin.
Kelemahan:
Hanya untuk mendeteksi cacat permukaan.
Diperlukan akses untuk pembersihan permukaan.
Dapat mengecoh akibat adanya false indicationsdan nonrelevant
indications.
Tidak menunjukkan kedalaman cacat.
Pembersihan permukaan adalah critical.
LIQUID PENETRANT INSPECTION
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Magnetic Particle Inspection
The part is magnetized. Finely milled iron particles coated with a dyepigment are then applied to the specimen. These particles are attracted
to magnetic flux leakage fields and will cluster to form an indication
directly over the discontinuity. This indication can be visually detected
under proper lighting conditions.
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Direction of Magnetization
Circular Magnetization
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Longitudinal Magnetization
Direction of Magnetization
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MAGNETIC PARTICLE INSPECTION
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MAGNETIC PARTICLE INSPECTION
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MAGNETIC PARTICLE INSPECTION
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MAGNETIC PARTICLE INSPECTION
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MAGNETIC PARTICLE INSPECTION
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MAGNETIC PARTICLE INSPECTION
1. Material
2. Garis gaya magnet
3. Void/flaw
M ti P ti l C k
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Magnetic Particle CrackIndications
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S iti it f M ti P ti l
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Sensitivity of Magnetic ParticleSystem
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ULTRASONIC INSPECTION
1. Transducer/probe
2. Couplant
3. Material
4. Void/flaw
5. Layar CRT
6. Indikasi permukaan depan
7. Indikasi void
8. Indikasi back wall.
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ULTRASONIC INSPECTION
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ULTRASONIC INSPECTION
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ULTRASONIC INSPECTION
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ULTRASONIC INSPECTION EQUIPMENT
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ULTRASONIC INSPECTION EQUIPMENT
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ULTRASONIC THICKNESS GAUGE
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Kelebihan: Tidak menimbulkan bahaya radiasi.
Peralatannyaportabledan mudah dibawa-bawa.
Dapat dipakai untuk mendeteksi dan sekaligus menentukan letak dan ukuran
internal discontinuitiespada material-material logam dan non logam.
Cacat planar dapat dideteksi dengan mudah.
Keterbatasan:
Diperlukan operator yang terlatih dan trampil.
Pemilihan frekuensi tergantung pada jenis material yang diperiksa.
Diperlukan couplant.
Nonrelevant indicationsdapat terjadi akibat bentuk komponen, cacat-cacat yang
membentuk sudut, dan adanya pantulan.
Tidak dapat dipakai untuk memeriksa material dengan tebal kurang dari 5 mm
(adanya dead zone).
ULTRASONIC INSPECTION
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RADIOGRAPHY TESTING
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RADIOGRAPHY TESTING
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Tabung Sinar X
RADIOGRAPHY TESTING
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RADIOGRAPHY TESTING
Isotop dan Kamera gamma ray
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Kelebihan: Mampu mendeteksi cacat-cacat internal.
Untuk memeriksa material-material logam dan non-logam.
Untuk memeriksa raw material dan hasil las.
Menghasilkan rekaman permanen dari komponen yang diperiksa.
Keterbatasan:
Harga peralatan dan beaya pengoperasian relatip mahal.
Bahaya radiasi.
Waktu set-up lama.
Cacat-cacat planar sulit terdeteksi.
Diperlukan akses dari kedua sisi komponen.
Perhitungan tegangan, exposure time, Source to Film Distanceadalah
critical.
RADIOGRAPHY TESTING
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EDDY CURRENT TESTING
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EDDY CURRENT TESTING
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EDDY CURRENT TESTING
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Applications
Surface crack detection
Non-ferrous metal sorting
Sub-surface crack/corrosion detection
Heat exchanger tube testing
In-line inspection of Steel tubing
Ferrous weld inspection
EDDY CURRENT TESTING
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EDDY CURRENT APPLICATION
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EDDY CURRENT APPLICATION
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EDDY CURRENT APPLICATION
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EDDY CURRENT EQUIPMENT
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EDDY CURRENT EQUIPMENT
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EDDY CURRENT TESTING
Kelebihan: Immediate assessment of crack depth and length.
Can be used to measure coating thickness.
Can be used to determine physical properties of materials.
Can be used for high-speed automatic inspection.
Keterbatasan:
Non-contacting, but close proximity of probe onto surface is required.
False indication as a result of local variation in permeability or physical
metallurgy, edge effect, and lift-off effects.
Calibration is critical prior to inspection. Low penetration power, limited to near surface flaws.
Applicable only to electrically conductive materials.
ACCOUSTIC EMISSION TECHNIQUE
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ACCOUSTIC EMISSION TECHNIQUE
Schematic diagram for an acoustic emission technique.
Test Component
PreamplifierBand pass
filter AmplifierMeasurement
circuits
Data buffers
Microcomputer Audio monitor
Visual monitor
X-Y recorder
Sensor
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ACCOUSTIC EMISSION SIGNALS
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ACCOUSTIC EMISSION SIGNALS
ACCOUSTIC EMISSION TECHNIQUE
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ACCOUSTIC EMISSION TECHNIQUE
Kelebihan:
Dapat memonitor daerah/area yang luas.
Continuous monitoring.
Teknik yang sensitif untuk memonitor timbulnya cacat pada struktur.
Keterbatasan:
Harga sistem peralatan yang sangat mahal.
Sensor/probe harus in contactdengan struktur.
Diperlukan accoustic couplingdan stressing source.
Interpretasi signal kadangkala rumit sehingga perlu operator yang terlatih.
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LEAK TESTING
LEAK TESTING
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LEAK TESTING
Water pressure test for water ballast pipes of 5 kg/cm2
LEAK TESTING
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LEAK TESTING
Water pressure test for water ballast pipes of 5 kg/cm2
LEAK TESTING
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LEAK TESTING
Hose test for hull butt joint of 300 bars
LEAK TESTING
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LEAK TESTING
Hose test for hull butt joint of 300 bars
LEAK TESTING
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LEAK TESTING
Air pressure test for double bottom of 0.25 kg/cm2
LEAK TESTING
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LEAK TESTING
Air pressure test for double bottom of 0.25 kg/cm2
LEAK TESTING
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LEAK TESTING
Air pressure test for double bottom of 0.25 kg/cm2
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POTENTIAL DROP TECHNIQUE
Probe
D
Contact pointContact point
Uniform potential currents
no crack between the two contact points.
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D
Contact pointContact point
h
Transversal crack
Probe
a crack between the two contact points.
2hD
V
D
V21
2
D
1V
V
h1
2
POTENTIAL DROP TECHNIQUE
POTENTIA DROP TECHNIQUE
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POTENTIAL DROP TECHNIQUE
Kelebihan:
Assessment of crack depth and length.
Can be used to monitor crack depth during service life of a component.
Accurate measurement is achieved on flat surface.
Keterbatasan:
Contacting technique requiring surface cleaning before testing.
False indication as a result of complex geometry, local variation in
permeability or physical metallurgy, edge effects, and lift-off effect.
Flaws should be oriented perpendicular to the current lines.
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ACFM Principle
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ACFM Principle
z
yx
Uniform current
Orientation of the magnetic fields on the surface of a component.
ACFM Principle
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Qualitative explanation of the nature of Bx and Bz above a defect.
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Noise in the ACFM signal.
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Scanning result of backwall defect in 6-Mo SS pipe.
ACFM Probe
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ACFM Probe
z x
Induction coil
Bz search coil Bx search coil
Pencil probe used with the ACFM technique.
ACFM Probes
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Standard Weld Probe Tight Access Probe Edge Effect Probe
Mini Pencil Probe Micro Pencil Probe Universal Thread Probe
Underwater Application
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Underwater ACFMCrack Microgauge Model U21
Underwater Application
Field Application
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ACFM/ACPD Crack Microgauge Model U9 (Field Use)
Field Application
Laboratory Application
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ACFM/ACPD Crack Microgauge Model U10
(Laboratory Use)
Laboratory Application
Array Probes
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ACFM Crack Microgauge Model U12
(Manual and Array ACFM Probes)
Array Probes
Advantages of ACFM Technique
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Advantages of ACFM Technique
Accurately measures depth and length of defect.
Ability to detect surface, subsurface or remote-surface defects in low
magnetic permeability materials.
Non-contacting technique.
Can inspect over rough surfaces and through coatings up to 5 mm
thick.
Rapid and cost effective inspection can be achieved. No need to calibrate the instrument prior to each use.
Provide data storage for off-line analysis.
Limitations of ACFM Technique
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q
Only applicable for inspecting electrically conductive materials.
Gives better results for flat or smooth surfaces.
Flaws should be oriented perpendicular to the electric field direction.
Materials to be inspected should be demagnetise.
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QUALIFICATION FOR NDT PERSONEL
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