NON DESTRUCTIVE TEST

The frequency of test was following the BS 5400 part 6:1999 as state below:
All fillet weld, visual inspection and dye penetrate or magnetic particle test shall be carried out.
All transverse weld butt weld in tension weld
10% of the length of longitudinal butt welds in tension flanges
5% of the length of longitudinal butt weld in compression flanges

The non- destructive test is mainly divided to surface inspection and sub-surface
Inspection:
Surface inspection- Visual inspection, Dye penetration test and Magnetic Particle Test
Sub- surface inspection – Radiographic (X-ray or Gamma) and ultrasonic testing

ARHA SDN. BHD was carried out the NDT for this project and the codes of practice and
standards which cover various types of constructions fabricated by welding work is AWS D1.1
Structural welding code (American) was adopted.

The test has started on 1st April 2011 with the Ultrasonic testing and Magnetic Particle test. For
the Radiographic test had was have to test at night time to prevent the radioactive
For MAGNETIC PARTICLE TEST, the equipments used for testing are below:

Magnaflux Electro Magnetic

Model- Yoke Y-6
 White Contrast

To detect cracks by using ordinary magnetic particle, apply with magnetic particle paints evenly
on the surface of the inspection object. When the paint are dried, spray ordinary magnetic
particle to detected flaws, this paint makes contrast sharp in surface detection, making the
detection of fine cracks easily.

Black Magnetic
Ink/ ordinary
magnetic
particle fluid
This method is capable of detecting open surface and just below the surface flaws, the test
specimen was magnetized by the “Magnuaflux Electro Magnetic” The magnetic field thus
introduced into the specimen is composed of magnetic line of force.

Whenever there is a flaw which interrupts the flow of the magnetic line some of these lines must
exit and re-enter the specimen. These points of exit and re-entry from opposite magnetic poles.
Whenever minute magnetic particle are sprinkled onto the surface of such a specimen, these
particles are attracted by these magnetic poles to create a visual indication approximating the size
and shape of the flaw.
 Flux

Test specimen

Electro Magnet
ULTRASONIC INSPECTION

Equipment : Main unit comprising pulse generator, display oscilloscope, probe

Display
Oscilloscope

Probes
70 Deg. 4Mhz
Angle Probe
Mode of operation:

A pulse of electrical energy is fed to the probe in which a piezo-electric crystal converts it to
mechanical vibrations at an ultrasonic frequency. The vibrations are transmitted (via a layer of
grease to exclude the air) through the work. If they encounter a defect some are reflected back to
the probe, where they regenerate an electrical signal. A cathode ray tube trace, started when the
original signal is sent, displays the reflected defect signal and from it time - indicating distance
from probe, and amplitude - indicating defect size, can be calculated.

Operating parameters.
Probe frequency 1 - 5MHz
Portability Good
Access Good (can be battery operated)
Thickness range 5 - 500mm
Minimum defect size 5mm wide
 The weld for Joint at B-G 2 Butt weld for the web
plate was rejected after Ultrasonic Test carried out.
A defected found at depth 13-15mm with length of
50mm.

The weld had been repaired and retest at 8th April.

The Ultrasonic test was adopted to re-check on the
rejected portions.

Grease

Setting out for the

operating parameter
 The operating parameter adopted for 25mm flange plated are 60Deg. 5Mhz Angle Probe.
Full skip method

Pulse

100mm test
Daley = 0s range
Velocity = 3240m/s

Angle = 60⁰

Overall advantages. Overall limitations.

Immediate presentation of results. Trained and skilled operator needed.
Not necessary to evacuate personnel. No pictorial record.
Can be battery powered.

Safety.
Moderate care needed as for all electrical equipment.
WELD JOINTS

The most commonly occurring defects in welded joints are porosity, slag inclusions, lack of side-
wall fusion, lack of inter-run fusion, lack of root penetration, undercutting, and longitudinal or
transverse cracks.

With the exception of single gas pores all the defects listed are usually well detectable by
ultrasonic. Ultrasonic flaw detection has long been the preferred method for nondestructive
testing in welding applications. This safe, accurate, and simple technique has pushed ultrasonic‟s
to the forefront of inspection technology.

Phased array pulse-echo technique

the phased array technique uses a mosaic of transducer elements in which the timing of the
elements' excitation can be individually controlled to produce a certain desired effect, such as
steering the beam axis or focusing the beam.

Pulse-Echo technique
The pulse echo technique is an ultrasonic test in which discontinuities are detected by the
reflected echoes from defects.
Time-of-flight Diffraction (TOFD) technique
The time-of-flight diffraction technique is an ultrasonic test that relies on the diffraction of
ultrasonic beams from the "corners" and "ends" of internal structures (primarily defects) in a
component being tested.

Creeping wave technique

The creeping wave technique is an ultrasonic test in which discontinuities are detected by the
return of a creeping wave that tracks the surface of the component being tested.
 RADIOGRAPHY TEST

Type of operation.
Static - development may be mechanised.

Equipment.
Radioactive isotope in storage container. Remote handling gear. Lightproof cassette.
Photographic development facilities. Darkroom and illuminator for assessment.

Control
Amersham Gamma
housing -50ft
Ray Projector –
Model: Delta 880

Pistol Control

Survey Meter-ND 2000

Pocket dosimeters are used to provide the wearer with an

immediate reading of his or her exposure to x-rays and gamma
rays

Pocket dosimeter

Wire penetrameter are used as the Image Quality Indicator on

films

Wire Penetrameter
880 Delta Series Source Projectors

Model 880 series source projectors are used for industrial applications of gamma radiography to
inspect materials and structures in the density range of approximately 2.71 g/cm3 through 8.53
g/cm3.

SENTINELTM Model 880 Delta, 880 Elite and 880 Omega source projectors are portable,
lightweight and compact industrial radiographic exposure devices. The patented device body
consists of a titanium „S‟ tube and cast depleted uranium (DU) shield contained within a
300series stainless steel tube with stainless steel discs welded at each end forming a cylinder
shaped housing. The discs are recessed to provide protection for the rear mounted locking
mechanism and front mounted outlet port.

The horizontally oriented design allows the locking mechanism, source assembly connector and
outlet port to be easily operated, simplifying connection of source guide tubes and remote
controls.

EXPOSURE DEVICE

The exposure device body, containing the DU shield, locking mechanism, outlet port, protective
covers and required labels*, comprises the radioactive material transport Type B(U) package.

REMOVABLE JACKET

An impact resistant plastic jacket surrounds the exposure device to protect labels and provide the
means for carrying andplacement during radiographic operations. The three models are identified
by jacket color; yellow for the 880 Delta, blue for the 880 Elite and orange for the 880 Omega

*Multilingual labeling is available upon request.

For Batukawa
Sources
Bridge Project
Isotope Selenium-75 Iridium-192 Cobalt-60 Ytterbium-
169
Assembly Model Number A424-25W A424-9 A424-19 91810
Gamma Energy Range 66-401 keV 206-612 keV 1.17-1.33 8-308 keV
MeV
Half-Life 120 Days 74 Days 5.27 Years 32 Days
Aproximate Steel Working 3-29 mm 12-63 mm 50-150 mm 2-20 mm
Thickness
Maximum Source Capacity 150Ci 150Ci 65mCi 20Ci 0.74
5.55TBq 5.55TBq 2.40GBq TBq
Setting up for Radiographic Test

Films

Source
positioning rod

Source guide tube

Front Side Back Side

The Ray Projector was connect with the control housing tube and the control pistol, another side
of the projector then connected to the source guide tube at the Front side of the welding.

This method of weld testing makes use gamma rays, produced by a radioactive isotope. The
basic principle of radiographic inspection of welds is the same as that for medical
radiography. Penetrating radiation is passed through a solid object, a weld onto a photographic
film, resulting in an image of the object's internal structure being deposited on the film.

The amount of energy absorbed by the object depends on characteristic, its thickness and
density. Energy not absorbed by the object will cause exposure of the radiographic film. These
areas will be dark when the film is developed. Areas of the film exposed to less energy remain
lighter.

Therefore, areas of the object where the thickness has been changed by discontinuities, such as
porosity or cracks, will appear as dark outlines on the film. Inclusions of low density, such as
slag, will appear as dark areas on the film while inclusions of high density, such as tungsten, will
appear as light areas. All discontinuities are detected by viewing shape and variation in density
of the processed film.
 Defects appears dark
outline due to films
exposed more energy

Radiographic testing can provide a permanent film record of weld quality that is relatively easy
to interpret by trained personnel. This testing method is usually suited to having access to both
sides of the welded joint. Although this is a slow and expensive method of nondestructive testing,
it is a positive method for detecting porosity, inclusions, cracks, and voids in the interior of
welds. It is essential that qualified personnel conduct radiographic interpretation since false
interpretation of radiographs can be expensive and interfere seriously with productivity.

There are obvious safety considerations when conducting radiographic testing. X-ray and
gamma radiation is invisible to the naked eye and can have serious heath and safety
implications. Only suitably trained and qualified personnel should practice this type of testing.
 Image Quality
Indicator

Project Name

Girder Thickness
No: B-G Flange 25mm
37

Cluster porosity / Slag Inclusion

Cluster porosity is caused when flux coated electrodes are contaminated with moisture. The
moisture turns into a gas when heated and becomes trapped in the weld during the welding
process. Cluster porosity appear just like regular porosity in the radiograph but the indications
will be grouped close together.

Slag inclusions are nonmetallic solid material entrapped in weld metal or between weld and base
metal. In a radiograph, dark, jagged asymmetrical shapes within the weld or along the weld joint
areas are indicative of slag inclusions.

Lack of fusion / penetration

Lack of fusion is a condition where the weld filler metal does not properly fuse with the base
metal. Appearance on radiograph: usually appears as a dark line or lines oriented in the direction
of the weld seam along the weld preparation or joining area

Incomplete penetration (IP) or lack of penetration (LOP) occurs when the weld metal fails to
penetrate the joint. It is one of the most objectionable weld discontinuities. Lack of penetration
allows a natural stress riser from which a crack may propagate. The appearance on a radiograph
is a dark area with well-defined, straight edges that follows the land or root face down the center
of the weldment.
Interpretation of radiographs takes place in three basic steps: (1) detection, (2) interpretation, and
(3) evaluation. All of these steps make use of the radiographer's visual acuity.
ACCEPTANCE CRITERIA

The acceptance criteria for the Non- Destructive Test was followed the AWS (American
Welding Society) D1.1 Section 6.

The visual inspection was carried out by the KKB Engineering QA/QC Team, Mr. Hashim,
QA/QC Manager and his crew once the welding completed.
Automated Ultrasonic Testing Versus Radiography Testing

Ultrasonic technology has been proven very effective for pressure vessel weld inspections and it
is easily adapted to common codes such as API and ASME Sec III, V, VIII, CC2235, CC2599,
and CC2600.

Comparing the Indications

Analysis of the weld inspection results given by UT and radiography shows that UT provides
both depth and height information, and is more sensitive to planar-type defects while eliminating
radiation hazards.
 Measurements Performed by
ID Type of Defect UT Radiography
1 Toe crack Position X, Y, and Z Position X and Y
Length sizing Length sizing
Height sizing
2 Centerline crack Position X, Y, and Z No detection
Length sizing
Height sizing
3 Porosity Position X, Y, and Z Position X and Y
Length sizing Length sizing
4 Incomplete root penetration Position X, Y, and Z Position X and Y
Length sizing Length sizing
Height sizing

Ultrasonic Weld Inspection Solutions

Olympus has created the UT solutions (automated ultrasonic testing) to provide you with an
affordable means to inspect welds according to code. These solutions are portable and can be put
to work virtually anywhere. The perfect combination of acquisition unit, scanner, encoder, and
software makes the inspection of pressure vessel welds and other welds an easy task.

 Fast inspection of small- and large-diameter welds

 100 % volumetric weld coverage
 Adaptable to butt welds, circumferential welds, long seams, one-sided access
configuration, and most common weld profiles
 Inspection of wall thicknesses from 8 mm to 300 mm and part diameters from 100 m to
flat
 Digital archiving of inspection data
 Elimination of film archiving
 Portable for in-house and field inspections
 Improved productivity compared to radiography
 Improved probability of detection (POD) compared to radiography
 Combining Different Techniques for Full-Weld Coverage and Improved Efficiency