TYPES OF TESTING

NONDESTRUCTIVE
No/minor change to the material being examined
Early warning, no need to shutdown the operation, qualitative &
quantitative information may be obtained

DESTRUCTIVE
Potentially causes significant change to the material being
examined
Used as statistical sampling basis only, not suited to huge and
expensive structures
TYPES OF NONDESTRUCTIVE TESTING

Visual, with or without aid

Liquid Penetrant Testing (PT)
Magnetic Particle Testing (MT)

Propagation of Elastic Waves/Vibration

Ultrasonic Testing (UT)
Acoustic Emission (AE)

Radiation
Radiography Techniques (X-Ray, Gamma-Ray)

Electromagnetic Field
Eddy Current Testing (ET)
Alternating Current Potential Drop (ACPD)
Alternating Current Field Measurement (ACFM)
What are Some Uses
of NDE Methods?
Flaw Detection and Evaluation

Leak Detection

Location Determination
Fluorescent penetrant indication
Dimensional Measurements

Structure and Microstructure Characterization

Estimation of Mechanical and Physical Properties

Stress (Strain) and Dynamic Response Measurements

Material Sorting and Chemical Composition Determination

When are NDE Methods Used?
There are NDE application 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
Radiography
Eddy Current
Visual Inspection
Most basic and common
inspection method.

Tools include
fiberscopes,
borescopes, magnifying
glasses and mirrors.

Portable video inspection

unit with zoom allows
inspection of large tanks
and vessels, railroad tank
cars, sewer lines.
Robotic crawlers permit
observation in hazardous or
tight areas, such as air
ducts, reactors, pipelines.
 VISUAL INSPECTION

AWS D1.1 (2010) par. 4.9.1.1 for Groove Welds

(1) Any cracks shall be unacceptable, regardless of size.
(2) All craters shall be filled to the full cross section of the
weld.
(3) Weld reinforcement shall not exceed 1/8 in. (3 mm).
(4) The weld shall have complete fusion.
(4) Undercut shall not exceed 1/32 in (1 mm)
(5) The weld root of CJP shall be inspected, and shall not
have any cracks, IF or IP.

7
Standard Acceptable Weld Profile
AWS D1.1 2008: Fig. 5.4

8
Standard Acceptable Weld Profile

9
DIRECT VISUAL INSPECTION
INDIRECT VISUAL INSPECTION
INDIRECT VISUAL INSPECTION
However, reliability of visual inspection is
highly affected by human factor since even
an 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 reveal
defects more readily and consistently.
 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.
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.
 TYPE OF PENETRANT MATERIALS
Either a color contrast (visible) penetrant or a
fluorescent penetrant shall be used with one of the
following three penetrant processes:
Water-washable
Post-emulsifiable
Solvent Removable
Post-emulsifiable
Water-washable and Solvent-removable
LIQUID PENETRANT INSPECTION
(Solvent-removable)
Indication of Discontinuity
 LIQUID PENETRANT INSPECTION
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 inspection rutin.

Kelemahan:
Hanya untuk mendeteksi cacat permukaan.
Diperlukan akses untuk pembersihan permukaan.
Dapat mengecoh akibat adanya false indications dan nonrelevant
indications.
Tidak menunjukkan kedalaman cacat.
Pembersihan permukaan adalah critical.
 Magnetic Particle Inspection
The part is magnetized. Finely milled iron particles coated with a dye
pigment 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.
Direction of Magnetization

Circular Magnetization
Direction of Magnetization

Longitudinal Magnetization
MAGNETIC PARTICLE INSPECTION
MAGNETIC PARTICLE INSPECTION
MAGNETIC PARTICLE INSPECTION
MAGNETIC PARTICLE INSPECTION
MAGNETIC PARTICLE INSPECTION
MAGNETIC PARTICLE INSPECTION

1. Material
2. Garis gaya magnet
3. Void/flaw
Magnetic Particle Crack
Indications
Sensitivity of Magnetic Particle
System
 MAGNETIC PARTICLE INSPECTION

Kelebihan:
Sangat sensitip terhadap cacat yang sangat halus.
Tidak diperlukan precleaning permukaan secara intensip.
Dapat mendeteksi cacat subsurface.
Mudah dan tidak mernerlukan keahlian khusus.
Cepat.

Keterbatasan:
Kekuatan dan orientasi medan magnet sangat menentukan.
Diperlukan proses demagnetisasi.
Pembersihan partikel dari permukaan komponen.
Hanya untuk bahan ferromagnetik.
Tidak memberikan gambaran kedalaman cacat.
Adanya false indications dan nonrelevant indications.
 ULTRASONIC INSPECTION

1. Transducer/probe 5. Layar CRT

2. Couplant 6. Indikasi permukaan depan
3. Material 7. Indikasi void
4. Void/flaw 8. Indikasi back wall.
ULTRASONIC INSPECTION
ULTRASONIC INSPECTION
ULTRASONIC INSPECTION
ULTRASONIC INSPECTION EQUIPMENT
ULTRASONIC INSPECTION EQUIPMENT
ULTRASONIC THICKNESS GAUGE
 ULTRASONIC INSPECTION

Kelebihan:
Tidak menimbulkan bahaya radiasi.
Peralatannya portable dan mudah dibawa-bawa.
Dapat dipakai untuk mendeteksi dan sekaligus menentukan letak dan ukuran
internal discontinuities pada 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 indications dapat 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).
RADIOGRAPHY TESTING
RADIOGRAPHY TESTING
RADIOGRAPHY TESTING

1. Source
2. Material
3. Film
4. Weld metal
5. Flaw
RADIOGRAPHY TESTING

Tabung Sinar X
RADIOGRAPHY TESTING

Isotop dan Kamera gamma ray

 RADIOGRAPHY TESTING

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 Distance adalah
critical.
EDDY CURRENT TESTING
EDDY CURRENT TESTING
EDDY CURRENT TESTING
 EDDY CURRENT TESTING

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 APPLICATION
EDDY CURRENT APPLICATION
EDDY CURRENT APPLICATION
EDDY CURRENT APPLICATION
EDDY CURRENT EQUIPMENT
EDDY CURRENT EQUIPMENT
EDDY CURRENT EQUIPMENT
 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 METHOD

Band pass Measurement

Preamplifier Amplifier
filter circuits

Data buffers

Visual monitor

Microcomputer Audio monitor

X-Y recorder

Sensor

Test Component

Schematic diagram for an acoustic emission technique.

ACCOUSTIC EMISSION SIGNALS
 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 contact dengan struktur.
Diperlukan accoustic coupling dan stressing source.
Interpretasi signal kadangkala rumit sehingga perlu operator yang terlatih.
LEAK TESTING
 LEAK TESTING

Water pressure test for water ballast pipes of 5 kg/cm2

 LEAK TESTING

Water pressure test for water ballast pipes of 5 kg/cm2

 LEAK TESTING

Hose test for hull butt joint of 300 bars

 LEAK TESTING

Hose test for hull butt joint of 300 bars

 LEAK TESTING

Air pressure test for double bottom of 0.25 kg/cm2

 LEAK TESTING

Air pressure test for double bottom of 0.25 kg/cm2

 LEAK TESTING

Air pressure test for double bottom of 0.25 kg/cm2

POTENTIAL DROP TECHNIQUE

Uniform potential currents

Contact point Contact point

Probe

no crack between the two contact points.

 POTENTIAL DROP TECHNIQUE

Transversal crack

Contact point Contact point

D
h
V1 V2

Probe D D 2h
V2 D
h 1
V1 2
a crack between the two contact points.
 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.
 ACFM TECHNIQUE

What is ACFM?
Relatively new NDT technique that works based on:

The flow of a uniform high frequency alternating

current within the material.

The measurement of associated electromagnetic

fields close to the surface.
 ACFM Principle

Uniform current

x y

Orientation of the magnetic fields on the surface of a component.

 ACFM Principle

Qualitative explanation of the nature of Bx and Bz above a defect.

Noise in the ACFM signal.
Scanning result of backwall defect in 6-Mo SS pipe.
 ACFM Probe

Induction coil

Bz search coil Bx search coil

z x

Pencil probe used with the ACFM technique.

 ACFM Probes

Standard Weld Probe Tight Access Probe Edge Effect Probe

Mini Pencil Probe Micro Pencil Probe Universal Thread Probe

Underwater Application

Underwater ACFM
Crack Microgauge Model U21
 Field Application

ACFM/ACPD Crack Microgauge Model U9 (Field Use)

 Laboratory Application

ACFM/ACPD Crack Microgauge Model U10

(Laboratory Use)
 Array Probes

ACFM Crack Microgauge Model U12

(Manual and Array ACFM Probes)
 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

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.
 Conclusions

Low operational cost

Low risk of error
Easily operated
Rapid & accurate Non-destructive Inspection

ACFM has a good prospect to be applied in Indonesian

offshore/marine industry
QUALIFICATION FOR NDT PERSONEL