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Transcript of NDT Lecture01 2015
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NON-DESTRUCTIVE TESTING IN
THE OFFSHORE INDUSTRY
Lecture 01
28 February 2015
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1.Introduction in Nondestructive testing.
2.Discontinuities , origin and classification3.Visual testing.4.Liquid penetrant inspection method.5.Process control and interpretation of liquid penetrant inspection6.Magnetic particle testing theory.
7.Magnetic particle inspection applications and interpretations8.Ultrasonic inspection method.9.Ultrasonic inspection equipments and materials.10.Ultrasonic inspections process control and safety.
11.Eddy current inspection method.12.Application on eddy current inspection13.Acoustic emission testing.14.Thermal infrared testing.
Topic
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ReferencesCharles J. Hellier, Handbook of Nondestructive Evaluation, McGrawHill, ISBN 0-07-139947-X, 2003;NDT Training program, American Society for Nondestructive Testing;Subrata K. Chakrabarti, Handbook of offshore engineering, Elsevier, ISBN-13: 978-0-08-044568-7 (vol 1), 2005;Subrata K. Chakrabarti, Handbook of offshore engineering, Elsevier, ISBN-13: 978-0-08-044569-4 (vol 2), 2006;William C. Lyons, Standard Handbook of petroleum & natural gas engineering, GulfPublishing company, Houston Texas, ISBN 0-88415-642-7 (vol.1), 1996;
William C. Lyons, Standard Handbook of petroleum & natural gas engineering, GulfPublishing company, Houston Texas, ISBN 0-88415-643-5, (vol.2), 1996;Mocanu D. Remus, Safta Voicu, ncercarea materialelor. Controlul nedistructiv almetalelor, Editura Tehnic,1986;Amza Gheorghe, Ultrasunete. Aplicaii active, Academia de tiine Tehnice dinRomnia, Editura Agir, 2006;
* * * - BS EN ISO, 19902:2007, Petroleum and natural gas industries Fixed steeloffshore structures* * * BS EN 10225:2009, Weldable structural steels for fixed offshore structures Technical delivery conditions* * * - ISO / TC67 Material equipment and offshore structures for petroleum,petrochemical and natural gas industries;
* * * - API Specification 5L, forty-second edition, January, 2000, American PetroleumInstitute Publishing Service, 1999;
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Definition of NDT
The use of noninvasive
techniques to determine
the integrity of a material,component or structure
or
quantitatively measuresome characteristic of
an object.
Introduction to Nondestructive Testing
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Ultrasonic NDT in various industries
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What are some uses
of NDE Methods?
Flaw Detection and EvaluationLeak Detection
Location DeterminationDimensional MeasurementsStructure and Microstructure CharacterizationEstimation of Mechanical and Physical Properties
Stress (Strain) and Dynamic Response MeasurementsMaterial Sorting and Chemical Composition Determination
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Six Most Common NDT Methods
Visual
Liquid Penetrant
Magnetic Ultrasonic
Eddy Current
X-ray
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Visual Inspection
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.
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Liquid Penetrant Inspection
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.
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Magnetic Particle
InspectionThe part is magnetized. Finely milled iron particles coated with adye pigment are then applied to the specimen. These particles are
attracted to magnetic flux leakage fields and will cluster to form anindication directly over the discontinuity. This indication can bevisually detected under proper lighting conditions.
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Magnetic Particle Crack Indications
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Radiography
The radiation used in radiographytesting is a higher energy (shorterwavelength) version of theelectromagnetic waves that wesee as visible light. The radiation cancome from an X-ray generator or aradioactive source.
High Electrical Potential
Electrons
-+
X-ray Generator
or Radioactive
Source Creates
Radiation
Exposure Recording DeviceRadiation
Penetrate
the Sample
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Film Radiography
The part is placed between theradiation 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.
= more exposure
= less exposure
The film darkness
(density) will vary with
the amount of radiation
reaching the filmthrough the test object.
Top view of developed film
X-ray film
The part is placed between theradiation 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.
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Radiographic Images
l ( l h )
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Ultrasonic Inspection (Pulse-Echo)
High frequency sound waves are introduced into
a material and they are reflected back fromsurfaces or flaws.
Reflected sound energy is displayed versus time,and inspector can visualize a cross section of the
specimen showing the depth of features thatreflect sound.
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Ultrasonic Imaging
High resolution images can be produced by
plotting signal strength or time-of-flight using a
computer-controlled scanning system.
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Eddy Current Testing
Eddy current testing isparticularly well suited fordetecting surface cracks butcan also be used to makeelectrical conductivity andcoating thicknessmeasurements.
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Inspection of Raw Products
Forgings;
Castings;
Extrusions;
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Inspection Following
Secondary Processing
Machining
Welding
Grinding
Heat treating Plating
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Inspection For
In-Service Damage
Cracking
Corrosion
Erosion/Wear Heat Damage
Pi li I ti
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Pipeline Inspection
NDT is used to inspect pipelinesto prevent leaks that could
damage the environment. Visualinspection, radiography andelectromagnetic testing are someof the NDT methods used.
Remote visual inspection usinga robotic crawler.
Radiography of weld joints.
Magnetic flux leakage inspection.This device, known as a pig, isplaced in the pipeline and collectsdata on the condition of the pipe as itis pushed along by whatever is beingtransported.
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Power Plant Inspection
Periodically, power
plants are shutdown
for inspection.
Inspectors feed eddy
current probes into
heat exchanger tubes
to check for corrosiondamage.
Probe
Signals produced
by variousamounts of
corrosion
thinning.
Pipe with damage
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Storage Tank Inspection
Robotic crawlers
use ultrasound toinspect the walls oflarge above groundtanks for signs ofthinning due tocorrosion.
Ai f I i
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Aircraft Inspection
Nondestructive testing is usedextensively during the
manufacturing of aircraft. NDT is also used to find cracks
and corrosion damage duringoperation of the aircraft.
A fatigue crack that started atthe site of a lightning strike isshown below.
Pressure Vessel Inspection
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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.
B id I ti
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Bridge Inspection Corrosion, cracking and
other damage can allaffect a bridges
performance.
Bridges get a visualinspection about every 2years.
Some bridges are fitted
with acoustic emissionsensors that listen forsounds of cracks growing.
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Rail Inspection
Special cars are used to inspect thousands of miles ofrail to find cracks that could lead to a derailment.
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