Here is the complete blog post — written in the authentic voice of a 30-year welding engineering veteran:

When Is PWHT Mandatory for Carbon Steel Welds? A Welding Engineer’s Practical Guide

By Ravi Kumar Thammana | IWE | ASNT Level III | CEO, Trinity NDT WeldSolutions Pvt. Ltd., Bangalore Published: March 2026 | Reading Time: 8 minutes

I want to start with a story.

A few years ago, a fabrication shop in Pune called us in a panic. They had completed a pressure vessel for a petrochemical client — P265GH carbon steel, 38mm wall thickness, fully welded, hydrotest passed, NDT cleared. The vessel was sitting in their yard, ready for dispatch.

Their client’s inspector arrived and asked one question:

“Where is your PWHT record?”

The fabricator had not performed PWHT. Nobody had told them it was required. The WPS didn’t mention it. The shop supervisor assumed that because the material was ordinary carbon steel — not chrome-moly, not stainless — PWHT wasn’t needed.

That vessel had to be stress-relieved before dispatch. Two weeks of delay. ₹4 lakh in additional cost. A near-miss on a critical delivery.

In 25 years of welding engineering, I have seen this mistake more times than I can count. And it almost always comes from the same assumption:

“It’s just carbon steel. PWHT is for exotic materials.”

That assumption is wrong. Dangerously wrong in some applications.

Let me explain exactly when PWHT is mandatory — and why — in plain engineering language.

What Is PWHT and What Does It Actually Do?

Post Weld Heat Treatment (PWHT) is a controlled thermal process in which a completed weld joint is heated to a specified temperature, held at that temperature for a specified time, and then cooled at a controlled rate.

For carbon steel, the typical PWHT temperature range is 595°C to 650°C (1100°F to 1200°F) — well below the lower critical transformation temperature (Ac1), so no metallurgical phase transformation occurs. This is purely a stress-relief operation.

What it achieves:

1. Residual Stress Relief Welding generates intense, localised heat followed by rapid cooling. The surrounding cold metal restrains the contracting weld metal, creating residual tensile stresses — often approaching the yield strength of the material. These stresses are invisible, unmeasurable by conventional NDT, and do not cause immediate failure. But combined with service loads and certain environments (especially hydrogen and wet H2S), they become a primary driver of cracking. PWHT reduces these residual stresses by 85–90%.

2. Hydrogen Diffusion Welding processes — particularly SMAW (stick welding) and FCAW — introduce atomic hydrogen into the weld metal and HAZ. Hydrogen causes delayed cracking (also called cold cracking or hydrogen-induced cracking), which can occur hours or even days after welding is complete. Elevated temperature accelerates hydrogen diffusion out of the joint. PWHT at 200–250°C (dehydrogenation heat treatment) or full PWHT at 595°C+ removes this risk.

3. HAZ Softening and Tempering The heat-affected zone of carbon steel welds, particularly in thicker sections or higher-carbon materials, can contain hard martensitic and bainitic microstructures. These are brittle and susceptible to stress corrosion cracking. PWHT tempers these hard zones, improving toughness and ductility.

4. Dimensional Stability For components that will be machined after welding, PWHT reduces distortion and improves dimensional accuracy.

When Does the Code Say PWHT Is Mandatory?

This is where most fabricators get confused — because the answer is not a single rule. It depends on which code governs your job, the material, the wall thickness, and the service conditions. Let me go through each major scenario.

1. Wall Thickness — The Universal Trigger

Regardless of service conditions, every major fabrication code mandates PWHT above a certain wall thickness. For carbon steel:

Let me emphasise B31.1 and B31.3 here — the threshold is 19mm, not 38mm. I have seen fabricators apply the Section VIII 38mm rule to their B31.1 piping jobs. That is incorrect and non-compliant. Always check the specific code governing your job.

2. Carbon Equivalent (CE) — The Often-Ignored Trigger

Carbon equivalent is a formula that combines the effect of carbon and other alloying elements on hardenability. High CE materials are more susceptible to hydrogen cracking, harder HAZ formation, and brittle fracture.

The most common formula (IIW):

CE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15

For carbon steel, when CE exceeds 0.45, both preheat and — in thicker sections — PWHT become critical. Many “standard” carbon steels like IS 2062 Grade B or ASTM A516 Grade 70 can have CE values of 0.42–0.48 depending on the heat. Always get the material test certificate (MTC) and calculate CE before writing your WPS.

3. Sour Service / Hydrogen-Containing Environments — Non-Negotiable

This is where PWHT transitions from a code requirement to a metallurgical necessity.

NACE MR0175 / ISO 15156 — the governing standard for equipment exposed to wet H2S (sour service in oil and gas) — mandates strict hardness limits: maximum 22 HRC (248 HBW) anywhere in the weld metal, HAZ, or base metal.

In practice, for carbon steel welds in sour service, achieving sub-22 HRC in the HAZ is extremely difficult without PWHT — especially in wall thicknesses above 12–15mm. The rapid cooling rates in the HAZ during welding promote hard microstructures, regardless of preheat.

For any carbon steel component that will be in contact with produced fluids, process streams containing H2S, or any wet sour environment — treat PWHT as mandatory, regardless of thickness. The consequence of getting this wrong is not a delayed delivery — it is catastrophic cracking, leaks, and potential fatality.

4. Impact Testing Requirements

When a design requires Charpy impact testing (toughness qualification) at low temperatures — such as for pressure vessels operating below 0°C, or LNG-related applications — PWHT is typically required as part of the WPS qualification to achieve the required toughness values in the HAZ.

If your WPS was qualified without PWHT and your job now requires impact testing, your WPS is not valid for that application. A new WPS with PWHT must be qualified.

5. Specific Materials — Even at Low Thickness

Certain carbon and low-alloy steels require PWHT at much lower thicknesses due to their chemistry:

• P-No.1 Group 2 (higher carbon content, e.g. A516 Gr.70 thick plates, A105 flanges) — some specifications require PWHT above 16mm
• Chrome-Moly steels (P-No.4, P-No.5) — PWHT is always mandatory regardless of thickness, though technically these are low-alloy steels, not plain carbon steels
• High-carbon content repair welds on castings or forgings — always require PWHT

Common Misconceptions I Encounter Every Week

“Our material is A36 structural steel — PWHT is not needed.” Correct for general structural work under AWS D1.1. Incorrect if the same structure carries cyclic loads, operates in a corrosive environment, or has specific code requirements imposed by the end-user.

“We did preheat — that means we don’t need PWHT.” Preheat and PWHT serve different purposes. Preheat controls cooling rate during welding and reduces hydrogen cracking risk. PWHT relieves residual stresses after welding is complete. In thick sections and sour service, you need both — they are not interchangeable.

“The weld passed UT and RT — there are no defects, so PWHT is unnecessary.” RT and UT detect existing defects. They cannot detect residual stress magnitude. A weld can be completely clean on RT and UT and still fail in service due to stress corrosion cracking if PWHT was not performed. These are different failure mechanisms.

“PWHT will distort our component.” Possible — but manageable with proper fixturing, controlled heating rates, and engineering. The distortion risk from PWHT is far smaller than the integrity risk from skipping it in a mandatory application.

Practical Checklist — Should Your Carbon Steel Weld Be PWHT’d?

Work through this list before finalising your WPS:

☑ Identify your governing code — ASME VIII, B31.1, B31.3, EN 13445, AWS D1.1, or client spec ☑ Check wall thickness against code mandatory threshold (19mm for B31.1/B31.3; 38mm for Section VIII Div.1) ☑ Calculate Carbon Equivalent (CE) from MTC — above 0.45 warrants serious PWHT consideration ☑ Confirm service environment — any H2S, wet sour, hydrogen-containing service = PWHT mandatory ☑ Check design temperature — sub-zero service requires impact testing, which typically requires PWHT qualification ☑ Review client specification — client specs often impose PWHT at lower thresholds than code minimum (always check) ☑ Review repair weld requirements — repair welds on existing equipment often have stricter PWHT requirements than original fabrication

If you answer YES to any of the above — PWHT is required. Do not proceed without it.

PWHT Parameters for Carbon Steel — Quick Reference

When PWHT is required for P-No.1 carbon steel per ASME BPVC:

Final Thought

PWHT is not a bureaucratic formality. It is not something you do to satisfy an inspector and forget about. It is a critical metallurgical process that directly determines whether your weld joint will survive its intended service life — or fail prematurely, sometimes catastrophically.

The 30-year-old pressure vessel still in service. The pipeline that has never leaked. The aircraft component that has never cracked. These outcomes are not accidents. They are the result of engineering decisions made correctly at the fabrication stage — including the decision to perform PWHT when the code, the material, and the service conditions demand it.

When in doubt — perform PWHT. The cost of a stress-relief cycle is a fraction of the cost of a failure investigation, a recall, or a tragedy.

Ravi Kumar Thammana is the CEO and co-founder of Trinity NDT WeldSolutions Pvt. Ltd., Bangalore — India’s only NADCAP and NABL dual-accredited NDT and welding centre. He holds ASNT Level III certifications in UT, RT, MT, PT, VT, and ET; NAS 410 Level III for aerospace NDT; and is an International Welding Engineer (IWE) certified by the International Institute of Welding. With over 25 years in welding engineering, NDT, and quality assurance across aerospace, oil & gas, pressure vessels, and structural fabrication, he has qualified over 16,000 NDT and welding professionals across 45 countries.

📞 Training & Consulting: +91 98441 29439 | 🌐 www.trinityndt.com | ✉️ info@trinityndt.com

Free WPS, PQR, and NDT procedure templates available for download at www.trinityndt.com/ndt-procedures-and-report-formats

Tags: PWHT | Carbon Steel Welding | ASME B31.3 | Pressure Vessel Fabrication | Weld Procedure | Sour Service | Hydrogen Cracking | Residual Stress | ISO 3834 | Welding Quality | NDT India | Trinity NDT

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Basic Standard for QMS

   ISO 9001 -2000

Manufacturing

   ISO 3834, EN 1011, ISO 5817

Personnel

   ISO 9606, EN 287, ISO 14731, ISO 14732

Procedures

   ISO 15607 – 15614

Testing and Inspection Personnel

   ISO 9712, EN 1289

Basis for ISO 3834  series of welding standards

As is well known, weld quality is achieved by sound welding, not by inspection. Inspection, however, provides a check of the reliability of the product, but cannot improve poor quality. Therefore, welding requires continuous control and/or to follow documented procedures. Certifications such as ISO3834 can build a robust quality management systems thus attracting more customers.

Genesis of ISO-3834

A member of the International Union of Technical Associations and Organisations (UTAO), IIW is a part of the International Council for Engineering and Technology (ICET), one of the twelve key formal umbrella organisations associated with UNESCO.

The experts of International Institute of Welding (IIW) have supplied the technical basis of the great majority of welding standards issued by the International Standards Organisation – ISO.

Since 1989, IIW has been recognised by ISO as an International Standardisation Body to prepare the final texts of international welding standards.

Criteria of selection of part of  the standard

• Financial loss
• Loss to human life
• Repair cost
• Loads- static and dynamic

Application of ISO 3834

• Certification of companies in accordance with ISO – 3834 Parts 2, 3 or 4
• Certification of personnel in accordance with ISO 14731

What is ISO 3834?

ISO3834 is an international standard created by welding professionals. ISO 9001 provides the requirements for a quality management system; it does not establish requirements for products. The standard on the other hand, does provide the quality requirements for a welded product.

It specifies requirements relating only to the quality of the welded product. Encourages a proactive process orientated approach to managing and controlling welding   product quality in a workshop or on site. Also, gives a Factory Control System to control activities for the manufacture of the product.

Why adopt ISO 3834 when we have ISO 9001?

ISO 9001 is a comprehensive standard that lays down quality management system requirements for any organisation. However, the standard does not prescribe specific details for “special processes”. Welding is regarded as a ‘special process’. ISO 3834 was developed to identify all factors that could affect the quality of welded product and which need to be controlled at all stages, before, during and after welding.

What are the benefits of specifying the ISO 3834 Standard for the purchaser & supplier?

• More assurance of contract delivery dates
• Greater assurance of the quality of welded products
• Greater reliability and performance of plant
• Reduction in maintenance costs
• Reduction or elimination of third party inspection costs
• More competent suppliers of welded products

What are the benefits of using the ISO 3834 Standard for the manufacturer?

• Less rework
• Jobs completed on time
• Local and international recognition as a competent organisation
• Meet the welding-related requirements of ISO 9001
• More efficient coordination of welding activities
• More pro-active and responsible workforce
• Increased opportunities and capability to bid on jobs
• Cost savings – more efficient technology
• Reduced surveillance audits and inspections by purchasers with significant savings

What are the benefits of using the ISO 3834 Standard for the individual employees?

• Helps to do the job more satisfactorily
• Greater job security
• Higher regard by other people
• Professional recognition
• Satisfied employer and customer
• More rewarding job position
• Develops team spirit

How important are welding personnel?

A key feature of ISO 3834 is the requirement to ensure that people with welding responsibilities are competent to discharge those responsibilities. This is achieved by incorporation of another standard, namely, ISO 14731 “Welding coordination – Tasks and responsibilities”. The specifying of minimum requirements for personnel dealing with welding coordination and welding inspection personnel.

What is the definition of a manufacturer as per standard?

ISO 3834 defines a manufacturer as a ‘person or organization responsible for the welding production’.

The Standard uses this term to describe any such organisation, including manufacturing organisations supplying welding services, either for new products or for repair and maintenance, as well as others where the application of the requirements of ISO 3834 are relevant.

A manufacturer may be involved in manufacture, fabrication, construction, repair or maintenance.

What are the types of manufacturing organisation that ISO 3834 can be applied to?

Fabrication companies

• Construction companies – on-site work

• Repair and maintenance contractors

• Manufacturers of products

• Welding workshops on sites under the same technical and quality management

• Owners of plant with their own workshop(s)

What are the types of other organisation that ISO 3834 can be applied to?

Asset owners without own workshops, both private and government

• Project management companies

• Design companies

• Consultants

• Government agencies

Those which, though not creating welded product themselves, are specifying or requiring such work from others and are thus involved in weld design, contract development, and review of technical requirements and competencies of subcontractors

How many parts does ISO 3834 have?

• ISO 3834: 2005 “Quality requirements for fusion welding of metallic materials” consists of 6 parts:
• ISO 3834-1:2005, Criteria for the selection of the appropriate level of quality requirements
• ISO 3834-2:2005, Comprehensive quality requirements
• ISO 3834-3:2005, Standard quality requirements
• ISO 3834-4:2005, Elementary quality requirements
• ISO 3834-5:2005, Applicable documentation (not full title)
• ISO/TR 3834-6:2007, Guidelines on implementing ISO 3834

How does ISO 3834 link in with ISO 9001?

ISO 3834 does not replace ISO 9001 as a quality management system. However, it contains many attributes that will be important for a welding manufacturer, in both workshops and at field installation sites, seeking ISO 9001 certification. Elements of ISO 9001 should be considered when implementing ISO 3834 quality requirements and seeking ISO 3834 certification. The specific complementary elements of ISO 9001 are detailed in ISO 3834.

What are the main welding requirements covered in ISO 3834 ?

Review of requirements

• Technical review

• Subcontracting

• Welding personnel

– Welders and welding operators, Welding coordination personnel

• Inspection & testing personnel

– Welding Inspection personnel; Non-destructive testing personnel

• Equipment

– Production and testing equipment; Description of equipment; Suitability of equipment; New

equipment; Equipment maintenance

Welding and related activities

– Production planning; Welding procedure specifications (WPS); Qualification of the welding

procedures; Work instructions; Procedures for preparation and control of documents

• Welding Consumables

– Batch testing; Storage and handling

• Storage of parent materials

• Post-weld heat treatment

Inspection and testing

– Inspection & testing before welding; Inspection & testing during welding; Inspection & testing after

welding; Inspection & test status

• Non-conformance and corrective actions

• Calibration and validation of measuring, inspection and testing equipment

• Identification & traceability

• Quality records

Selection of Welding Quality Requirement as per ISO:3834

Comparison of Welding quality requirements with regard to ISO 3834-2, 3834-3  & 3834-4

How do Manufacturers select the Appropriate Part of ISO 3834?

A balanced decision needs to be taken based on the following, related to products & processes:

• The extent and significance of safety-critical products
• The complexity of manufacture
• The range of products manufactured
• The range of different materials used
• The extent to which metallurgical problems may occur
• The extent to which manufacturing imperfections e.g. misalignment, distortion or weld imperfection, affect product performance
• Service condition (Dynamic loading, fatigue, low/high Temperature, corrosion)
• The welding processes adopted, their level of sophistication and automation

Suggested Steps for Implementation of ISO 3834 by an Organisation

• Gap Analysis to identify action areas for  System, training and resources
• Upgradation of System based on above
• Personnel Training for competence
• Assessment of additional Resources if any
• Internal Audit to close NCR’s
• Management Review
• Trial operation to stabilise system
• Application for Certification to Certification Body

Gap Analysis internally by the Organisation against requirements of ISO 3834 & ISO 14731

• ISO 9001 systems if existing or desired and compare with the present system.
• System requirements for applicable part of 3834 (2, 3 or 4) as determined previously and detailed in next three slides.
• Identify each area as per check list for gaps between required/desired level and actual status recorded.
• May take assistance from Consultants or Certifying bodies for this step
• Management corrective action to close the non conformities

To check for Gaps –

Requirements in ISO 3834 & Essential Tasks of  Welding Coordination Personnel in ISO 14731

1.Review of requirements & Technical review to understand parent material specification and welded joint properties, quality and acceptance requirements, etc.

2.Subcontracting Supplier to be treated as extension of manufacturers facility

3.Welding personnel Welders and welding operators, Welding coordination personnel

4.Inspection & testing personnel Welding Inspection personnel; Non-destructive testing personnel

5.Equipment: Production and testing equipment; Description of equipment; Suitability of equipment; New equipment; Equipment maintenance

6.Welding and related activities: Production planning; Welding procedure specifications (WPS); Process Qualification of the welding (WPQR); Work instructions;

7.Welding Consumables: Batch testing; Storage and handling

8.Storage of parent materials

9.Post-weld heat treatment

10. Inspection and NDT testing: Inspection & testing before welding; Inspection & testing during welding; Inspection & testing after welding; Inspection & test status

11.Non-conformance and corrective actions ¬ Learning from experience

12.Calibration and validation of measuring, inspection and testing equipment

13.Identification & traceability

14.Quality records

How important are welding personnel?

A key feature of ISO 3834 is the requirement to ensure that people with welding responsibilities are competent to discharge those responsibilities.

This is achieved by incorporation of another standard, namely, ISO 14731 ‘Welding coordination – Tasks and responsibilities’

The specifying of minimum requirements for personnel dealing with welding coordination and welding inspection personnel

The Human Resource

­Without an appropriate specific technical competence (intended as a combination of knowledge, experience and attitude) no management system can be successful in the manufacturing of any product. ­

A great importance has been entrusted to the Welding Coordinator, who has become the real “key element” around whom all the welding production process works.

ISO 14731 Requirements for Welding Co-ordination Personnel

Welding Co-ordination :

   – Manufacturing operations for all welding and welding related activities

  – The sole responsibility of the manufacturer

  – May be sub-contracted

  – May be carried out by more than one person

Welding Co-ordinator

– Responsible and competent person

– Specified tasks and responsibilities

– Qualified for each task

Welding Inspection

– Is part of welding co-ordination

Role of the Responsible Welding Co-ordinator

The company shall nominate at least one Responsible Welding Co-ordinator ( RWC ). He must be competent to make decisions and sign on behalf of the manufacturer.

The RWC must be authorised with the overall responsibility for monitoring welding activities as well as taking action when welding has not been correctly performed. May also be responsible for the work of other welding co-ordinators in the in the same department / site.

RWC may be to an individuals normal job title eg, Technical Manager, QC Manager, Production Manager etc.

IIW International Diploma Qualifications for Welding Co-ordination Personnel

International Welding Engineer ( IWE )

International Welding Technologist ( IWT )

International Welding Specialist ( IWS )

International Welding Practitioner ( IWP )

International Welding Inspection Personnel (IWIP)

International Welded Structure Designer ( IWSD )

International Welder ( IW ) – Diploma awarded for Specific process and material & at 3 levels

In India, ANB-India of IIW India is authorised to award the above diplomas. Contact IIW India.

ISO 14731 Gradation of Responsible Welding Coordinators

Three different levels of RWC are given. The selection of RWC depends mainly on the variability and technical complexity of the welding procedures required.

How can Trinity NDT Can Help you in ISO3834 certifications?

Center of Welding – Trinity NDT provides comprehensive consulting services for ISO3834 certifications. Being an associate of The Indian Institute of Welding – IIW India, can hand hold organizations in the process of certification.

This includes, quality manual preparation, establishing wps, documentation, QMS implementation, Gap analysis from ISO9001 to ISO3834, NDT Level II personnel certification. Also provide welding coordinator services by our IWE experts. Also an IBR approved Welding & NDT Lab in Bangalore.

Let us know your requirement. Contact Trinity NDT today.

The post ISO3834 Quality Management in Welding Companies appeared first on Trinity NDT WeldSolutions Private Limited.

Basic Standard for QMS

   ISO 9001 -2000

Manufacturing

   ISO 3834, EN 1011, ISO 5817

Personnel

   ISO 9606, EN 287, ISO 14731, ISO 14732

Procedures

   ISO 15607 – 15614

Testing and Inspection Personnel

   ISO 9712, EN 1289

Basis for ISO 3834  series of welding standards

As is well known, weld quality is achieved by sound welding, not by inspection. Inspection, however, provides a check of the reliability of the product, but cannot improve poor quality. Therefore, welding requires continuous control and/or to follow documented procedures. Certifications such as ISO3834 can build a robust quality management systems thus attracting more customers.

Genesis of ISO-3834

A member of the International Union of Technical Associations and Organisations (UTAO), IIW is a part of the International Council for Engineering and Technology (ICET), one of the twelve key formal umbrella organisations associated with UNESCO.

The experts of International Institute of Welding (IIW) have supplied the technical basis of the great majority of welding standards issued by the International Standards Organisation – ISO.

Since 1989, IIW has been recognised by ISO as an International Standardisation Body to prepare the final texts of international welding standards.

Criteria of selection of part of  the standard

• Financial loss
• Loss to human life
• Repair cost
• Loads- static and dynamic

Application of ISO 3834

• Certification of companies in accordance with ISO – 3834 Parts 2, 3 or 4
• Certification of personnel in accordance with ISO 14731

What is ISO 3834?

ISO3834 is an international standard created by welding professionals. ISO 9001 provides the requirements for a quality management system; it does not establish requirements for products. The standard on the other hand, does provide the quality requirements for a welded product.

It specifies requirements relating only to the quality of the welded product. Encourages a proactive process orientated approach to managing and controlling welding   product quality in a workshop or on site. Also, gives a Factory Control System to control activities for the manufacture of the product.

Why adopt ISO 3834 when we have ISO 9001?

ISO 9001 is a comprehensive standard that lays down quality management system requirements for any organisation. However, the standard does not prescribe specific details for “special processes”. Welding is regarded as a ‘special process’. ISO 3834 was developed to identify all factors that could affect the quality of welded product and which need to be controlled at all stages, before, during and after welding.

What are the benefits of specifying the ISO 3834 Standard for the purchaser & supplier?

• More assurance of contract delivery dates
• Greater assurance of the quality of welded products
• Greater reliability and performance of plant
• Reduction in maintenance costs
• Reduction or elimination of third party inspection costs
• More competent suppliers of welded products

What are the benefits of using the ISO 3834 Standard for the manufacturer?

• Less rework
• Jobs completed on time
• Local and international recognition as a competent organisation
• Meet the welding-related requirements of ISO 9001
• More efficient coordination of welding activities
• More pro-active and responsible workforce
• Increased opportunities and capability to bid on jobs
• Cost savings – more efficient technology
• Reduced surveillance audits and inspections by purchasers with significant savings

What are the benefits of using the ISO 3834 Standard for the individual employees?

• Helps to do the job more satisfactorily
• Greater job security
• Higher regard by other people
• Professional recognition
• Satisfied employer and customer
• More rewarding job position
• Develops team spirit

How important are welding personnel?

A key feature of ISO 3834 is the requirement to ensure that people with welding responsibilities are competent to discharge those responsibilities. This is achieved by incorporation of another standard, namely, ISO 14731 “Welding coordination – Tasks and responsibilities”. The specifying of minimum requirements for personnel dealing with welding coordination and welding inspection personnel.

What is the definition of a manufacturer as per standard?

ISO 3834 defines a manufacturer as a ‘person or organization responsible for the welding production’.

The Standard uses this term to describe any such organisation, including manufacturing organisations supplying welding services, either for new products or for repair and maintenance, as well as others where the application of the requirements of ISO 3834 are relevant.

A manufacturer may be involved in manufacture, fabrication, construction, repair or maintenance.

What are the types of manufacturing organisation that ISO 3834 can be applied to?

Fabrication companies

• Construction companies – on-site work

• Repair and maintenance contractors

• Manufacturers of products

• Welding workshops on sites under the same technical and quality management

• Owners of plant with their own workshop(s)

What are the types of other organisation that ISO 3834 can be applied to?

Asset owners without own workshops, both private and government

• Project management companies

• Design companies

• Consultants

• Government agencies

Those which, though not creating welded product themselves, are specifying or requiring such work from others and are thus involved in weld design, contract development, and review of technical requirements and competencies of subcontractors

How many parts does ISO 3834 have?

• ISO 3834: 2005 “Quality requirements for fusion welding of metallic materials” consists of 6 parts:
• ISO 3834-1:2005, Criteria for the selection of the appropriate level of quality requirements
• ISO 3834-2:2005, Comprehensive quality requirements
• ISO 3834-3:2005, Standard quality requirements
• ISO 3834-4:2005, Elementary quality requirements
• ISO 3834-5:2005, Applicable documentation (not full title)
• ISO/TR 3834-6:2007, Guidelines on implementing ISO 3834

How does ISO 3834 link in with ISO 9001?

ISO 3834 does not replace ISO 9001 as a quality management system. However, it contains many attributes that will be important for a welding manufacturer, in both workshops and at field installation sites, seeking ISO 9001 certification. Elements of ISO 9001 should be considered when implementing ISO 3834 quality requirements and seeking ISO 3834 certification. The specific complementary elements of ISO 9001 are detailed in ISO 3834.

What are the main welding requirements covered in ISO 3834 ?

Review of requirements

• Technical review

• Subcontracting

• Welding personnel

– Welders and welding operators, Welding coordination personnel

• Inspection & testing personnel

– Welding Inspection personnel; Non-destructive testing personnel

• Equipment

– Production and testing equipment; Description of equipment; Suitability of equipment; New

equipment; Equipment maintenance

Welding and related activities

– Production planning; Welding procedure specifications (WPS); Qualification of the welding

procedures; Work instructions; Procedures for preparation and control of documents

• Welding Consumables

– Batch testing; Storage and handling

• Storage of parent materials

• Post-weld heat treatment

Inspection and testing

– Inspection & testing before welding; Inspection & testing during welding; Inspection & testing after

welding; Inspection & test status

• Non-conformance and corrective actions

• Calibration and validation of measuring, inspection and testing equipment

• Identification & traceability

• Quality records

Selection of Welding Quality Requirement as per ISO:3834

Comparison of Welding quality requirements with regard to ISO 3834-2, 3834-3  & 3834-4

How do Manufacturers select the Appropriate Part of ISO 3834?

A balanced decision needs to be taken based on the following, related to products & processes:

• The extent and significance of safety-critical products
• The complexity of manufacture
• The range of products manufactured
• The range of different materials used
• The extent to which metallurgical problems may occur
• The extent to which manufacturing imperfections e.g. misalignment, distortion or weld imperfection, affect product performance
• Service condition (Dynamic loading, fatigue, low/high Temperature, corrosion)
• The welding processes adopted, their level of sophistication and automation

Suggested Steps for Implementation of ISO 3834 by an Organisation

• Gap Analysis to identify action areas for  System, training and resources
• Upgradation of System based on above
• Personnel Training for competence
• Assessment of additional Resources if any
• Internal Audit to close NCR’s
• Management Review
• Trial operation to stabilise system
• Application for Certification to Certification Body

Gap Analysis internally by the Organisation against requirements of ISO 3834 & ISO 14731

• ISO 9001 systems if existing or desired and compare with the present system.
• System requirements for applicable part of 3834 (2, 3 or 4) as determined previously and detailed in next three slides.
• Identify each area as per check list for gaps between required/desired level and actual status recorded.
• May take assistance from Consultants or Certifying bodies for this step
• Management corrective action to close the non conformities

To check for Gaps –

Requirements in ISO 3834 & Essential Tasks of  Welding Coordination Personnel in ISO 14731

1.Review of requirements & Technical review to understand parent material specification and welded joint properties, quality and acceptance requirements, etc.

2.Subcontracting Supplier to be treated as extension of manufacturers facility

3.Welding personnel Welders and welding operators, Welding coordination personnel

4.Inspection & testing personnel Welding Inspection personnel; Non-destructive testing personnel

5.Equipment: Production and testing equipment; Description of equipment; Suitability of equipment; New equipment; Equipment maintenance

6.Welding and related activities: Production planning; Welding procedure specifications (WPS); Process Qualification of the welding (WPQR); Work instructions;

7.Welding Consumables: Batch testing; Storage and handling

8.Storage of parent materials

9.Post-weld heat treatment

10. Inspection and NDT testing: Inspection & testing before welding; Inspection & testing during welding; Inspection & testing after welding; Inspection & test status

11.Non-conformance and corrective actions ¬ Learning from experience

12.Calibration and validation of measuring, inspection and testing equipment

13.Identification & traceability

14.Quality records

How important are welding personnel?

A key feature of ISO 3834 is the requirement to ensure that people with welding responsibilities are competent to discharge those responsibilities.

This is achieved by incorporation of another standard, namely, ISO 14731 ‘Welding coordination – Tasks and responsibilities’

The specifying of minimum requirements for personnel dealing with welding coordination and welding inspection personnel

The Human Resource

­Without an appropriate specific technical competence (intended as a combination of knowledge, experience and attitude) no management system can be successful in the manufacturing of any product. ­

A great importance has been entrusted to the Welding Coordinator, who has become the real “key element” around whom all the welding production process works.

ISO 14731 Requirements for Welding Co-ordination Personnel

Welding Co-ordination :

   – Manufacturing operations for all welding and welding related activities

  – The sole responsibility of the manufacturer

  – May be sub-contracted

  – May be carried out by more than one person

Welding Co-ordinator

– Responsible and competent person

– Specified tasks and responsibilities

– Qualified for each task

Welding Inspection

– Is part of welding co-ordination

Role of the Responsible Welding Co-ordinator

The company shall nominate at least one Responsible Welding Co-ordinator ( RWC ). He must be competent to make decisions and sign on behalf of the manufacturer.

The RWC must be authorised with the overall responsibility for monitoring welding activities as well as taking action when welding has not been correctly performed. May also be responsible for the work of other welding co-ordinators in the in the same department / site.

RWC may be to an individuals normal job title eg, Technical Manager, QC Manager, Production Manager etc.

IIW International Diploma Qualifications for Welding Co-ordination Personnel

International Welding Engineer ( IWE )

International Welding Technologist ( IWT )

International Welding Specialist ( IWS )

International Welding Practitioner ( IWP )

International Welding Inspection Personnel (IWIP)

International Welded Structure Designer ( IWSD )

International Welder ( IW ) – Diploma awarded for Specific process and material & at 3 levels

In India, ANB-India of IIW India is authorised to award the above diplomas. Contact IIW India.

ISO 14731 Gradation of Responsible Welding Coordinators

Three different levels of RWC are given. The selection of RWC depends mainly on the variability and technical complexity of the welding procedures required.

How can Trinity NDT Can Help you in ISO3834 certifications?

Center of Welding – Trinity NDT provides comprehensive consulting services for ISO3834 certifications. Being an associate of The Indian Institute of Welding – IIW India, can hand hold organizations in the process of certification.

This includes, quality manual preparation, establishing wps, documentation, QMS implementation, Gap analysis from ISO9001 to ISO3834, NDT Level II personnel certification. Also provide welding coordinator services by our IWE experts. Also an IBR approved Welding & NDT Lab in Bangalore.

Let us know your requirement. Contact Trinity NDT today.

The post ISO3834 Quality Management in Welding Companies appeared first on Trinity NDT WeldSolutions Private Limited.

Penetrant Testing(PT) is also called as Dye Penetrant inspection(DPT) or Fluorescent Inspection FPI Testing in Aerospace is one of the most widely used Non-destructive Evaluation – NDE method. DPT testing is suitable for inspecting steels, aluminium, stainless steels and other materials for surface opened flaws. In brief, this NDT method is suitable for any non-porous material.

Also, a very reliable method for crack testing on Aerospace components and Aircraft structures. However, detectability depends on technique and penetrant sensitivity. For example: When compared to S2 penetrant, S3 will give better sensitivity. Similarly, fluorescent penetrants give better sensitivity when compared to visible penetrants.

Penetrant inspection method is one of the NDT methods for inspection of Welds, Castings, Forgings and Valves. Also, a very reliable method for in-service inspection to find fatigue cracks on automobile, aerospace, oil and gas pipe lines at economical cost.

Of the surface NDT methods, DPT testing is simple in principle and versatile method. To carry the test, the inspector should have proper level of training and certification in Penetrant testing.

Trinity NDT has compete testing labs for penetrant testing up to aerospace standards and procedures. The unique Aerospace NDT Labs at Bangalore India can perform Method A, C and D and sensitivities S2, S3 and S4. In addition, fluorescent and visible penetrant testing also available to offer. The penetrant testing FPI testing labs have accreditation as per ISO17025:2017 from NABL, Delhi, India.

Penetrant – Type, Methods & Sensitivity | Trinity NDT Labs

Even though it is treated as the simplest NDT method, the test results vary greatly in terms of techniques and sensitivity levels employed. Selection of PT technique normally depends on application of component and sensitivity desired. Penetrant inspection techniques are categorized broadly in to

• Type 1 – Fluorescent Penetrants
• Type 2- Visible Penetrants

And, based on method of removal classified as

• Method A – Water Washable
• Method B – Post Emulsifiable, Lipophilic
• Method C – Solvent Removable
• Method D – Post Emulsifiable, Hydrophilic

Also Penetrant Sensitivities are classified as

• ½
• 1
• 2
• 3
• 4

Developer Types

• Dry
• Wet – Aqueous
• Wet – Non Aqueous

Dry Developers are preferred for Aerospace NDT applications. Solvent removable, Wet Aqueous and Non Aqueous developers also available and used based on NDT procedure. That is to say, contact us with your test sensitivity, we have complete range of testing solutions.

As we are serving Aerospace NDT, our laboratory services have all the above types of penetrants and sensitivities to cater to need based inspections.

NABL ISO17025:2017 Accreditation for our FPI Testing Labs

Accreditation of NDT Labs gives additional confidence in test results to customers. Therefore, Our FPI labs are NABL ISO17025 accredited and meets international standards. In addition, the aerospace FPI testing equipment meets ASTM E 1417 and ASTM E 165. One major advantage with Trinity NDT is, all penetrant testing techniques including Fluorescent, Visible penetrants, Water washable, Post Emulsifiable, Solvent removable penetrants up to sensitivity Level 4 are available. So that we are the one stop solutions providing NDT agency trusted by over 500 customers across India.  

Quick Contact us for your requirements on NDT

Stationery FPI equipment | Aerospace NDT Lab in India

Aerospace sector uses altogether high standards of Penetrant materials. Starting from pre cleaning to final cleaning controlling the parameters in each step is vital. Therefore, PT equipment, procedures, training of personnel has clear impact on test results.

We have the best infrastructure to carry FPI testing of aerospace components. The state of art modern Aerospace FPI testing set up is catering to the needs of customers. Our aerospace penetrant testing lab is one of the best facility available in India.

Pre-cleaning procedures include Ultrasonic Cleaning, Alkaline cleaning and solvent cleaning solutions.

Our NDT facility undertakes Dye penetrant testing DPT testing both onsite and off-site. We have expertise in DP testing of Welds, Pressure vessels and boiler components, cross country pipe lines, Castings, Valves, gears, Turbine blades and critical aircraft engine components. Timely calibrations, Daily control checks using TAM/PSM panels ensures the process controls are intact.

Aerospace FPI Testing Agency In Bangalore India

Our Aerospace FPI testing labs are providing services to CEMILAC, Government of India, HAL, L & T Aerospace and many more. Contact us to outsource your NDT Testing to us. We assure to deliver the best to meet your expectations in terms of Timely delivery, professional services at affordable cost.

Know more about Aerospace NDT FPI testing facilities.

Codes, Standards On Liquid Penetrant Testing

Even though there are numerous standards on Penetrant testing such as ASTM E 165 and ASTM E 1417. Also ASME Section V – Non-destructive Examination, API Codes, AWS codes, BS Standards, EN standards provide acceptance criteria. Trinity NDT – Testing Labs uses procedures that meets international standards, codes and customer specifications.

NDT PT Level II Technicians | PT FPI Services

Trinity NDT maintains its Written practice that meets ASNT SNT TC 1A. We engage only Dye penetrant testing / FPI testing Level II technicians. All the DPT testing procedures are duly approved before starting testing by in house ASNT NDT level III. 

NAS410, ASNT NDT Level III Services | Penetrant Inspection

Trinity NDT have in-house Penetrant Testing ASNT Level III. Every NDT procedure is approved by the Level III to meet client needs. We also provide ASNT NDT Level III services such as preparing NDT procedures, Written Practice for personnel certification and layout setting up of penetrant testing facility.

Why do you need to choose Trinity NDT Labs in Bangalore India ?

• We are the best Liquid dye penetrant inspection services provider in Bangalore.
• Modern testing equipments with S2, S3 & S4 sensitivity penetrants. Water washable, post Emulsifiable penetrants for high sensitivity Aerospace NDT FPI testing. Also suitable for components upto 600mm in size.
• UV black light kits for fluorescent inspection
• Liquid penetrant testing technicians with PT Level I, II ASNT SNT-TC-1A and or IS:13805 certified by ISNT. Also have NAS410 Level 2 in Penetrant testing for Aerospace FPI inspections.
• In house NAS410 & ASNT NDT Level III consultants and experts for providing NDT procedure preparation, approval and consultancy services.
• NDT Level III trainers for conducting NDT Level 1, 2 training and certification courses on Liquid dye penetrant testing and other NDT inspection methods. Read more about Liquid Penetrant Testing Personnel Certifications.
• Strong team of NDT Level 2 certified Technicians and inspectors to provide PT and NDT services across India
• Sales and Supply of Dye penetrant inspection (DPT) chemicals kit, penetrants, cleaners, solvents, developers in Peenya Bangalore. If you want to buy DPT chemicals kit, we are the suppliers in Bangalore with ready stock today. Read more about sales of Liquid Penetrant inspection chemicals kit and consumables.

What is the principle of Dye Penetrant testing?

Dye penetrant testing works on principle of capillary action and blotting action (reverse of capillary action). While Capillary action allows penetrant to enter the surface opened flaws, blotting action brings back penetrant from inside of flaws. As capillary action can work in any direction irrespective of gravity forces, therefore cracks of any direction can be easily detected in DPT testing. Earlier the method is called as ‘Oil and whiting method’.

Dye Penetrant inspection | Applications

Penetrant inspection NDT method has many applications. Following a few of them.

• DPT of weld root run to find root flaws before proceeding for next welding layers
• Castings DP testing to find shrinkage at raisers and other areas
• Pipeline and pressure vessel weld joints after final welding
• Leak testing using penetrant testing for gross leaks
• In-service inspection of gears, shafts, valve castings, forging and plates
• Penetrant Inspection after bending to required angle to find cracks
• PT testing of Boiler tubes, pipes, headers and power plant machinery
• FPI testing of turbine blades for aerospace
• Aircraft Structural skin testing using FPI testing

Training Courses | Penetrant testing PT Level 2 and 3

Want To Learn And Get Certified To NDT Level / II after training course on Penetrant Inspection? You hear it right. We would like to share our experience through QA/QC courses organized at our Training Centre in Bangalore India. We offer these NDT courses since 2001 in Hosur and Mysore as well for the industries in these areas.

Trinity Institute of NDT Technology is a training division of Trinity NDT. The institute in India offers world class NDT courses on Penetrant inspection and other NDT testing methods. The training meets written practice and framed to the requirements of ASNT SNT TC 1A. For upcoming Training & certification schedule on PT inspection Level II course visit our Training Calendar page, fee structure, eligibility criteria for the training courses and register for the courses.

Participants from over 40 countries have benefited from our courses. The following are participants from countries whom the institute trained so far in India. Read reviews on Youtube channel

Sale And Supply Of Penetrant Testing Chemicals

Dye Penetrant and fluorescent penetrant chemicals – Solvent removable penetrants, solvent cleaners, developers, accessories and aluminium cracked samples are stocked and supplied for ready use. Items can be hand picked from our office or couriered with prepayment. Quick Contact us for your requirements on PT chemicals sales

Quick Contact us for your requirements on NDT

The post Penetrant Testing Principle, Types, Techniques and Services appeared first on Trinity NDT WeldSolutions Private Limited.

Penetrant Testing(PT) is also called as Dye Penetrant inspection(DPT) or Fluorescent Inspection FPI Testing in Aerospace is one of the most widely used Non-destructive Evaluation – NDE method. DPT testing is suitable for inspecting steels, aluminium, stainless steels and other materials for surface opened flaws. In brief, this NDT method is suitable for any non-porous material.

Also, a very reliable method for crack testing on Aerospace components and Aircraft structures. However, detectability depends on technique and penetrant sensitivity. For example: When compared to S2 penetrant, S3 will give better sensitivity. Similarly, fluorescent penetrants give better sensitivity when compared to visible penetrants.

Penetrant inspection method is one of the NDT methods for inspection of Welds, Castings, Forgings and Valves. Also, a very reliable method for in-service inspection to find fatigue cracks on automobile, aerospace, oil and gas pipe lines at economical cost.

Of the surface NDT methods, DPT testing is simple in principle and versatile method. To carry the test, the inspector should have proper level of training and certification in Penetrant testing.

Trinity NDT has compete testing labs for penetrant testing up to aerospace standards and procedures. The unique Aerospace NDT Labs at Bangalore India can perform Method A, C and D and sensitivities S2, S3 and S4. In addition, fluorescent and visible penetrant testing also available to offer. The penetrant testing FPI testing labs have accreditation as per ISO17025:2017 from NABL, Delhi, India.

Penetrant – Type, Methods & Sensitivity | Trinity NDT Labs

Even though it is treated as the simplest NDT method, the test results vary greatly in terms of techniques and sensitivity levels employed. Selection of PT technique normally depends on application of component and sensitivity desired. Penetrant inspection techniques are categorized broadly in to

• Type 1 – Fluorescent Penetrants
• Type 2- Visible Penetrants

And, based on method of removal classified as

• Method A – Water Washable
• Method B – Post Emulsifiable, Lipophilic
• Method C – Solvent Removable
• Method D – Post Emulsifiable, Hydrophilic

Also Penetrant Sensitivities are classified as

• ½
• 1
• 2
• 3
• 4

Developer Types

• Dry
• Wet – Aqueous
• Wet – Non Aqueous

Dry Developers are preferred for Aerospace NDT applications. Solvent removable, Wet Aqueous and Non Aqueous developers also available and used based on NDT procedure. That is to say, contact us with your test sensitivity, we have complete range of testing solutions.

As we are serving Aerospace NDT, our laboratory services have all the above types of penetrants and sensitivities to cater to need based inspections.

NABL ISO17025:2017 Accreditation for our FPI Testing Labs

Accreditation of NDT Labs gives additional confidence in test results to customers. Therefore, Our FPI labs are NABL ISO17025 accredited and meets international standards. In addition, the aerospace FPI testing equipment meets ASTM E 1417 and ASTM E 165. One major advantage with Trinity NDT is, all penetrant testing techniques including Fluorescent, Visible penetrants, Water washable, Post Emulsifiable, Solvent removable penetrants up to sensitivity Level 4 are available. So that we are the one stop solutions providing NDT agency trusted by over 500 customers across India.  

Quick Contact us for your requirements on NDT

Stationery FPI equipment | Aerospace NDT Lab in India

Aerospace sector uses altogether high standards of Penetrant materials. Starting from pre cleaning to final cleaning controlling the parameters in each step is vital. Therefore, PT equipment, procedures, training of personnel has clear impact on test results.

We have the best infrastructure to carry FPI testing of aerospace components. The state of art modern Aerospace FPI testing set up is catering to the needs of customers. Our aerospace penetrant testing lab is one of the best facility available in India.

Pre-cleaning procedures include Ultrasonic Cleaning, Alkaline cleaning and solvent cleaning solutions.

Our NDT facility undertakes Dye penetrant testing DPT testing both onsite and off-site. We have expertise in DP testing of Welds, Pressure vessels and boiler components, cross country pipe lines, Castings, Valves, gears, Turbine blades and critical aircraft engine components. Timely calibrations, Daily control checks using TAM/PSM panels ensures the process controls are intact.

Aerospace FPI Testing Agency In Bangalore India

Our Aerospace FPI testing labs are providing services to CEMILAC, Government of India, HAL, L & T Aerospace and many more. Contact us to outsource your NDT Testing to us. We assure to deliver the best to meet your expectations in terms of Timely delivery, professional services at affordable cost.

Know more about Aerospace NDT FPI testing facilities.

Codes, Standards On Liquid Penetrant Testing

Even though there are numerous standards on Penetrant testing such as ASTM E 165 and ASTM E 1417. Also ASME Section V – Non-destructive Examination, API Codes, AWS codes, BS Standards, EN standards provide acceptance criteria. Trinity NDT – Testing Labs uses procedures that meets international standards, codes and customer specifications.

NDT PT Level II Technicians | PT FPI Services

Trinity NDT maintains its Written practice that meets ASNT SNT TC 1A. We engage only Dye penetrant testing / FPI testing Level II technicians. All the DPT testing procedures are duly approved before starting testing by in house ASNT NDT level III. 

NAS410, ASNT NDT Level III Services | Penetrant Inspection

Trinity NDT have in-house Penetrant Testing ASNT Level III. Every NDT procedure is approved by the Level III to meet client needs. We also provide ASNT NDT Level III services such as preparing NDT procedures, Written Practice for personnel certification and layout setting up of penetrant testing facility.

Why do you need to choose Trinity NDT Labs in Bangalore India ?

• We are the best Liquid dye penetrant inspection services provider in Bangalore.
• Modern testing equipments with S2, S3 & S4 sensitivity penetrants. Water washable, post Emulsifiable penetrants for high sensitivity Aerospace NDT FPI testing. Also suitable for components upto 600mm in size.
• UV black light kits for fluorescent inspection
• Liquid penetrant testing technicians with PT Level I, II ASNT SNT-TC-1A and or IS:13805 certified by ISNT. Also have NAS410 Level 2 in Penetrant testing for Aerospace FPI inspections.
• In house NAS410 & ASNT NDT Level III consultants and experts for providing NDT procedure preparation, approval and consultancy services.
• NDT Level III trainers for conducting NDT Level 1, 2 training and certification courses on Liquid dye penetrant testing and other NDT inspection methods. Read more about Liquid Penetrant Testing Personnel Certifications.
• Strong team of NDT Level 2 certified Technicians and inspectors to provide PT and NDT services across India
• Sales and Supply of Dye penetrant inspection (DPT) chemicals kit, penetrants, cleaners, solvents, developers in Peenya Bangalore. If you want to buy DPT chemicals kit, we are the suppliers in Bangalore with ready stock today. Read more about sales of Liquid Penetrant inspection chemicals kit and consumables.

What is the principle of Dye Penetrant testing?

Dye penetrant testing works on principle of capillary action and blotting action (reverse of capillary action). While Capillary action allows penetrant to enter the surface opened flaws, blotting action brings back penetrant from inside of flaws. As capillary action can work in any direction irrespective of gravity forces, therefore cracks of any direction can be easily detected in DPT testing. Earlier the method is called as ‘Oil and whiting method’.

Dye Penetrant inspection | Applications

Penetrant inspection NDT method has many applications. Following a few of them.

• DPT of weld root run to find root flaws before proceeding for next welding layers
• Castings DP testing to find shrinkage at raisers and other areas
• Pipeline and pressure vessel weld joints after final welding
• Leak testing using penetrant testing for gross leaks
• In-service inspection of gears, shafts, valve castings, forging and plates
• Penetrant Inspection after bending to required angle to find cracks
• PT testing of Boiler tubes, pipes, headers and power plant machinery
• FPI testing of turbine blades for aerospace
• Aircraft Structural skin testing using FPI testing

Training Courses | Penetrant testing PT Level 2 and 3

Want To Learn And Get Certified To NDT Level / II after training course on Penetrant Inspection? You hear it right. We would like to share our experience through QA/QC courses organized at our Training Centre in Bangalore India. We offer these NDT courses since 2001 in Hosur and Mysore as well for the industries in these areas.

Trinity Institute of NDT Technology is a training division of Trinity NDT. The institute in India offers world class NDT courses on Penetrant inspection and other NDT testing methods. The training meets written practice and framed to the requirements of ASNT SNT TC 1A. For upcoming Training & certification schedule on PT inspection Level II course visit our Training Calendar page, fee structure, eligibility criteria for the training courses and register for the courses.

Participants from over 40 countries have benefited from our courses. The following are participants from countries whom the institute trained so far in India. Read reviews on Youtube channel

Sale And Supply Of Penetrant Testing Chemicals

Dye Penetrant and fluorescent penetrant chemicals – Solvent removable penetrants, solvent cleaners, developers, accessories and aluminium cracked samples are stocked and supplied for ready use. Items can be hand picked from our office or couriered with prepayment. Quick Contact us for your requirements on PT chemicals sales

Quick Contact us for your requirements on NDT

The post Penetrant Testing Principle, Types, Techniques and Services appeared first on Trinity NDT WeldSolutions Private Limited.

Magnetic Particle testing is also known as MPI or MPT is a well accepted NDT method to reveal surface and below surface flaws. Applied for ferro-magnetic metals such as Iron, Nickel and Cobalt alloys. Due to its effectiveness in detecting flaws, industries such as Automobile, Oil and Gas, Processing and Aerospace accepted as a means of verifying quality of components and structures.

How to Start Magnetic particle testing?

Before start of any NDT method a detailed procedure shall be prepared. MPI testing also needs a procedure that outlines, essential and non essential parameters. The MPI procedure shall address all key elements of testing. For instance, MPI techniques, powders, light requirements, medium, current calculations, sequence of testing, equipment to be used, personnel qualification etc.,

Therefore, an MPI testing procedure shall be prepared considering the parameters on site. Procedure shall be prepared by a certified NDT Level II and shall be approved by a NDT Level III in Magnetic Particle testing.

Here are key elements and procedure for MPI testing as per ASTM E709/ASTM E1444

What is the difference between ASTM E709 and ASTM E1444

Both the international standards are issued by The American Society for Testing Materials (ASTM). Both the standards are widely used in every industry involving MPI. ASTM E 709 is a mother standards for many of the worlds country specific standards being used today.

ASTM E709 – A Standard Guide for Magnetic Particle testing, covers in detail about every requirement, recommendation pertaining magnetic particle testing.

ASTM E1444 – A standard practice for Magnetic Particle Testing is specifically applicable for Aerospace NDT applications. This is a replacement for US military standard – MIL-STD-1949. Covers minimum requirements for performing MPI testing. Also recommended to use in conjunction with ASTM E709.

Though both the standards are widely accepted in industry, where stringent requirements are to be followed ASTM E1444 is a better choice. Because it has close acceptance limits, this standard is especially used in Aerospace sector for MPI testing. More specifically this standard covers requirement for aerospace industry.

Scope

It covers the techniques for both dry and wet magnetic particle inspection. Applicable for raw materials and semi-processed materials such as blooms, billets, castings, rolled products, forgings and weld joints. It is also can be used in in-service maintenance inspection of plants and structures.

ASTM E709 is a guide that helps you in preparing MPI procedures, establishing techniques. This can also be used for evaluating and reviewing customer specifications. This standard can be applied for parts of any size, material(ferro) and any shape for any application. Therefore, users of this standard are required to exercise to evaluate specific requirements pertaining to their job and conditions.

Does This Standard Specify Acceptance Criteria?

No. ASTM E709 does not specify any acceptance or rejection criteria. This only covers the procedure for magnetic particle inspection. As this standard is used for variety of applications such as automotive, structural, oil and gas and even for aerospace, it is left to the user to specify the criteria for acceptance or rejection.

Therefore, the contracting parties shall specify acceptance or rejection criteria in the MPI procedure. It may also be cross referenced in place of specifying in procedure. An ASNT Level III or an expert in design shall be consulted for deciding on the criteria. This shall be based on criticality of application, risk associated with failure of the part.

What MPI techniques are used?

1. Dry Powder Technique
2. Wet powder technique

and other techniques which are not much use in industries.

What is the personnel qualification requirement to do MPT testing?

MPI testing inspector should be performed by qualified and certified as per ASNT recommended practice SNT TC 1A or ANSI, CP189 or NAS410(aerospace). The document also gives freedom to specify certification scheme based on agreement between contacting parties such as ISO9712 certifications.

Reference Documents

A number of specifications and standards are listed for the benefit of users. It is good if you can buy there standards from ASTM website for additional knowledge. Also, a standard ASTM E1316 gives definitions related to terminology applicable for Nondestructive testing.

Summary of Magnetic particle Testing

In MPT testing, initially magnetic flux is introduced by a suitable means. This could be using directly passing current techniques such as Head Shot, Prod or Indirect techniques that passes only magnetic field, such as Yoke, Central conductor etc.,

By applying Fleming’s right hand rule we can find the direction of magnetic field if we know the direction of electric current. Once magnetic field is introduced into any ferro magnetic metals, flux lines will be travelling through the materials. If there are any flaws, flux will be distorted and leakage field is created. As we cannot sense leakage flux, a finely powdered ferro-magnetic powder is uniformly sprinkled on the surfaces.

Leakage flux attracts the ferro-magnetic powder thereby bridging the space between the crack/flaw faces. The powder is added with a pigment for suitable viewing. Fluorescent powders are to be used only in darkened room. These powders emits yellowish green light when impinged by Ultraviolet (UV) light in the wavelength range of 320-365nm.

Fluorescent powder absorbs UV light and emit visible light at around 555nm. As Yellowish green light is highly sensitive to human eye, the MPI inspector will be able to locate the indication easily. Non-fluorescent powders are colored with black, red, grey to give contrast with respect to surface.

How to select fluorescent or Non-fluorescent techniques in Magnetic particle testing?

Fluorescent powder technique is suitable for high speed sensitive applications. Non-fluorescent techniques are good for field/site testing conditions where components cannot be moved to a darked area to maintain darkness. Later technique is economical and a cost effective solution at the cost of less sensitivity.

Magnetization Techniques

• Permanent Magnet
• Electromagnetic Yoke
• Head Shot
• Central Conductor
• Cable wrap
• Solenoid
• Coil Shot
• Prod Technique
• What kind flaws can MPI testing detect?

Magnetic particle testing detect flaws located perpendicular to magnetic flux. Flaws located up to 45 degree may also be detected.

How many directions do we need to magnetize?

For effective testing, magnetic field shall be introduced in two mutually perpendicular directions. Inspector shall ensure this while establishing the technique for all surfaces, wherever practicable. The procedure must address techniques to generate the field in various directions.

What is multi-directional magnetization?

Equipment with multi directional magnetization are available. These equipment generate vector field so that the magnetic field rotates almost 360 degree in each shot. Therefore, whatever may be the flaw orientation at one point of time the vector will be perpendicular to the flaw. However, equipment that generate multi directional fields are expensive thus can be used only in critical applications such as aerospace.

Magnetic Field Strength

Magnetic field strength should be sufficient enough to generate leakage flux to detect flaws. Under magnetized components cannot generate the flux enough to detect the defects. Over magnetization causes the field to cause excess in whole of the materials leading to excessive field leakage and heavy accumulation of particles. This leads to shadowing of relevant indications. Because, the contrast is lost flaw identification becomes a challenge.

Therefore, while establishing magnetic field strength it is required to generate just sufficient to detect minimum size of flaw and should not over magnetize to mask indications.

Check how to use ASTM field indicator (Pie Gauge)

Types of Magnetic Particles

Magnetic particles both Dry or Wet based can be used. Fluorescent and non-fluorescent dry or wet particles to be selected based on end user need. Powder concentrates also are specified. Wet particles can be dispersed in water(water based) or carrier oil based (petroleum distillate) that confirms to ASTM E709.

What is meant by indication?

Clustering of powder at a specific area under MPI testing is called Indication. Each indication shall be evaluated for relevance, acceptance or rejection.

How does surface indications looks like?

MPI Indications from surface flaws will be sharp, distinct pattern and tightly held to the surface.

How does subsurface indications looks like?

In MPI testing, subsurface(near surface) indications produce less distinct, fuzzy patterns and powder is loosely held. Indications will be broader than sharp. Just with a small puff of air from mouth can fully or partially eliminate from the surface.

Magnetic Particle testing Equipment Selection

A big challenge for inspectors in MPI testing is selecting right equipment. Numerous equipment and types are available today to choose for testing components and structures.

With the exception of permanent magnetic yoke, all other equipment needs electricity to generate magnetic field.

When do you choose permanent magnetic yoke?

If you want to perform the testing at fire hazard area or where spark can ignite the surrounding or getting electricity at a high altitude is a challenge, such as chimney, permanent magnet is preferred. This equipment does not need electricity. In almost all petroleum refineries, for testing weld joints and parts, permanent magnet is the best option. When all other equipment are prohibited to use, this equipment is the last option.

Before using permanent magnetic yoke, check for calibration and evaluate the strength. It is covered in this post else where.

The post How to Do Magnetic Particle Testing as per ASTM E709 & E1444 appeared first on Trinity NDT WeldSolutions Private Limited.

Magnetic Particle testing is also known as MPI or MPT is a well accepted NDT method to reveal surface and below surface flaws. Applied for ferro-magnetic metals such as Iron, Nickel and Cobalt alloys. Due to its effectiveness in detecting flaws, industries such as Automobile, Oil and Gas, Processing and Aerospace accepted as a means of verifying quality of components and structures.

How to Start Magnetic particle testing?

Before start of any NDT method a detailed procedure shall be prepared. MPI testing also needs a procedure that outlines, essential and non essential parameters. The MPI procedure shall address all key elements of testing. For instance, MPI techniques, powders, light requirements, medium, current calculations, sequence of testing, equipment to be used, personnel qualification etc.,

Therefore, an MPI testing procedure shall be prepared considering the parameters on site. Procedure shall be prepared by a certified NDT Level II and shall be approved by a NDT Level III in Magnetic Particle testing.

Here are key elements and procedure for MPI testing as per ASTM E709/ASTM E1444

What is the difference between ASTM E709 and ASTM E1444

Both the international standards are issued by The American Society for Testing Materials (ASTM). Both the standards are widely used in every industry involving MPI. ASTM E 709 is a mother standards for many of the worlds country specific standards being used today.

ASTM E709 – A Standard Guide for Magnetic Particle testing, covers in detail about every requirement, recommendation pertaining magnetic particle testing.

ASTM E1444 – A standard practice for Magnetic Particle Testing is specifically applicable for Aerospace NDT applications. This is a replacement for US military standard – MIL-STD-1949. Covers minimum requirements for performing MPI testing. Also recommended to use in conjunction with ASTM E709.

Though both the standards are widely accepted in industry, where stringent requirements are to be followed ASTM E1444 is a better choice. Because it has close acceptance limits, this standard is especially used in Aerospace sector for MPI testing. More specifically this standard covers requirement for aerospace industry.

Scope

It covers the techniques for both dry and wet magnetic particle inspection. Applicable for raw materials and semi-processed materials such as blooms, billets, castings, rolled products, forgings and weld joints. It is also can be used in in-service maintenance inspection of plants and structures.

ASTM E709 is a guide that helps you in preparing MPI procedures, establishing techniques. This can also be used for evaluating and reviewing customer specifications. This standard can be applied for parts of any size, material(ferro) and any shape for any application. Therefore, users of this standard are required to exercise to evaluate specific requirements pertaining to their job and conditions.

Does This Standard Specify Acceptance Criteria?

No. ASTM E709 does not specify any acceptance or rejection criteria. This only covers the procedure for magnetic particle inspection. As this standard is used for variety of applications such as automotive, structural, oil and gas and even for aerospace, it is left to the user to specify the criteria for acceptance or rejection.

Therefore, the contracting parties shall specify acceptance or rejection criteria in the MPI procedure. It may also be cross referenced in place of specifying in procedure. An ASNT Level III or an expert in design shall be consulted for deciding on the criteria. This shall be based on criticality of application, risk associated with failure of the part.

What MPI techniques are used?

1. Dry Powder Technique
2. Wet powder technique

and other techniques which are not much use in industries.

What is the personnel qualification requirement to do MPT testing?

MPI testing inspector should be performed by qualified and certified as per ASNT recommended practice SNT TC 1A or ANSI, CP189 or NAS410(aerospace). The document also gives freedom to specify certification scheme based on agreement between contacting parties such as ISO9712 certifications.

Reference Documents

A number of specifications and standards are listed for the benefit of users. It is good if you can buy there standards from ASTM website for additional knowledge. Also, a standard ASTM E1316 gives definitions related to terminology applicable for Nondestructive testing.

Summary of Magnetic particle Testing

In MPT testing, initially magnetic flux is introduced by a suitable means. This could be using directly passing current techniques such as Head Shot, Prod or Indirect techniques that passes only magnetic field, such as Yoke, Central conductor etc.,

By applying Fleming’s right hand rule we can find the direction of magnetic field if we know the direction of electric current. Once magnetic field is introduced into any ferro magnetic metals, flux lines will be travelling through the materials. If there are any flaws, flux will be distorted and leakage field is created. As we cannot sense leakage flux, a finely powdered ferro-magnetic powder is uniformly sprinkled on the surfaces.

Leakage flux attracts the ferro-magnetic powder thereby bridging the space between the crack/flaw faces. The powder is added with a pigment for suitable viewing. Fluorescent powders are to be used only in darkened room. These powders emits yellowish green light when impinged by Ultraviolet (UV) light in the wavelength range of 320-365nm.

Fluorescent powder absorbs UV light and emit visible light at around 555nm. As Yellowish green light is highly sensitive to human eye, the MPI inspector will be able to locate the indication easily. Non-fluorescent powders are colored with black, red, grey to give contrast with respect to surface.

How to select fluorescent or Non-fluorescent techniques in Magnetic particle testing?

Fluorescent powder technique is suitable for high speed sensitive applications. Non-fluorescent techniques are good for field/site testing conditions where components cannot be moved to a darked area to maintain darkness. Later technique is economical and a cost effective solution at the cost of less sensitivity.

Magnetization Techniques

• Permanent Magnet
• Electromagnetic Yoke
• Head Shot
• Central Conductor
• Cable wrap
• Solenoid
• Coil Shot
• Prod Technique
• What kind flaws can MPI testing detect?

Magnetic particle testing detect flaws located perpendicular to magnetic flux. Flaws located up to 45 degree may also be detected.

How many directions do we need to magnetize?

For effective testing, magnetic field shall be introduced in two mutually perpendicular directions. Inspector shall ensure this while establishing the technique for all surfaces, wherever practicable. The procedure must address techniques to generate the field in various directions.

What is multi-directional magnetization?

Equipment with multi directional magnetization are available. These equipment generate vector field so that the magnetic field rotates almost 360 degree in each shot. Therefore, whatever may be the flaw orientation at one point of time the vector will be perpendicular to the flaw. However, equipment that generate multi directional fields are expensive thus can be used only in critical applications such as aerospace.

Magnetic Field Strength

Magnetic field strength should be sufficient enough to generate leakage flux to detect flaws. Under magnetized components cannot generate the flux enough to detect the defects. Over magnetization causes the field to cause excess in whole of the materials leading to excessive field leakage and heavy accumulation of particles. This leads to shadowing of relevant indications. Because, the contrast is lost flaw identification becomes a challenge.

Therefore, while establishing magnetic field strength it is required to generate just sufficient to detect minimum size of flaw and should not over magnetize to mask indications.

Check how to use ASTM field indicator (Pie Gauge)

Types of Magnetic Particles

Magnetic particles both Dry or Wet based can be used. Fluorescent and non-fluorescent dry or wet particles to be selected based on end user need. Powder concentrates also are specified. Wet particles can be dispersed in water(water based) or carrier oil based (petroleum distillate) that confirms to ASTM E709.

What is meant by indication?

Clustering of powder at a specific area under MPI testing is called Indication. Each indication shall be evaluated for relevance, acceptance or rejection.

How does surface indications looks like?

MPI Indications from surface flaws will be sharp, distinct pattern and tightly held to the surface.

How does subsurface indications looks like?

In MPI testing, subsurface(near surface) indications produce less distinct, fuzzy patterns and powder is loosely held. Indications will be broader than sharp. Just with a small puff of air from mouth can fully or partially eliminate from the surface.

Magnetic Particle testing Equipment Selection

A big challenge for inspectors in MPI testing is selecting right equipment. Numerous equipment and types are available today to choose for testing components and structures.

With the exception of permanent magnetic yoke, all other equipment needs electricity to generate magnetic field.

When do you choose permanent magnetic yoke?

If you want to perform the testing at fire hazard area or where spark can ignite the surrounding or getting electricity at a high altitude is a challenge, such as chimney, permanent magnet is preferred. This equipment does not need electricity. In almost all petroleum refineries, for testing weld joints and parts, permanent magnet is the best option. When all other equipment are prohibited to use, this equipment is the last option.

Before using permanent magnetic yoke, check for calibration and evaluate the strength. It is covered in this post else where.

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Introduction to NDT

NDT, or Non-Destructive Testing, is a unique technology that involves the use of various techniques to inspect and evaluate the properties of a material, component, or system without causing damage. There are a wide variety of NDT methods, each of which has its own unique set of principles and applications. Some common NDT methods include eddy current testing, acoustic emission testing, ultrasonic testing, magnetic particle inspection, radiographic testing, and visual inspection.

Technicians for NDT Inspection

NDT technicians are trained to use these methods to detect and evaluate defects in materials and structures, ensuring that they meet required specifications and standards. These technicians are often employed in industries such as aerospace, manufacturing, oil and gas, and power generation, as well as in the public sector for infrastructure maintenance.

Tests are performing during various stages of manufacturing such as raw materials, in process and final stages. This will ensure the quality of products is not deviating out of the standard. Besides, NDT is also routinely used for periodic in-services inspection of plants and structures to maintain safety and reliability.

Unlike Destructive testing where certification is not essentials, NDT needs a certified technician either to Level I or Level II. Standards mandates certification of individuals. Level I technicians can do specific testing, calibration and set up of instruments. Level II technicians in addition to Level I duties, can select a technique, do interpretation and evaluation of indications.

How to become NDT Technician?

To become certified as an NDT technician, individuals must complete a certain amount of training and pass exams that demonstrate their proficiency in a specific NDT method or methods. The certifying organizations for NDT technicians are typically professional societies or government agencies that have established standards and guidelines for the training and certification of NDT personnel.

Certifying Institutions, Certification Bodies

One of the most well-known certifying organizations for NDT technicians is the American Society for Nondestructive Testing (ASNT). The ASNT offers a variety of NDT certification programs, including levels I, II, and III. To become certified at Level I, individuals must complete a specific amount of classroom training and pass a written exam. To become certified at Level II, individuals must have practical experience in the specific NDT method they are seeking certification in, as well as pass a written exam. Level III certification is the highest level of NDT certification, and it requires a combination of practical experience and management skills, as well as the successful completion of written (General and Specific) and practical exams.

Other certifying organizations for NDT technicians include the Canadian Society for Nondestructive Testing (CSNDT), the British Institute of Nondestructive Testing (BINDT), and the European Federation for Nondestructive Testing (EFNDT). These organizations offer their own certification programs and exams, which may have slightly different requirements and standards. These organizations are chosen based on end customer needs.

Employer certifications such as ASNT SNT TC 1A are issued by employers based on written practice. Companies can use outside agencies such as Trinity Institute of NDT Technology for training.

Regulatory and Industry Specific Requirements

In addition to professional certification, NDT technicians may also be required to meet certain regulatory or industry-specific requirements. For example, technicians who work in the aviation industry may be required to hold an Airworthiness Certificate, which demonstrates their competency in the use of NDT methods for the inspection and maintenance of aircraft. NAS410 certification falls under this category. It is a mandatory certification if a technician chooses to work on aerospace NDT.

Technicians to work in Boiler pressure vessel code ASME shall meet the provisions in ASME Section V- nondestructive evaluation. Similarly, Radiography technicians (RT) shall take radiation safety course as per the country norms. For example, In India, technicians performing RT shall be certified in Radiation safety from Atomic Energy Regulatory Board (AERB), Mumbai.

Each institution doing radiography shall have a Radiological Safety Officer (RSO) from BARC, Mumbai to ensure safety of operations. This is also known as BARC Level II certification in Radiography testing. Technicians interested in taking RT Level I or Level II can contact AERB/BARC for details.

Conclusion

Overall, NDT certification is an important way for technicians to demonstrate their knowledge and skills in the use of NDT methods, and it is often a requirement for employment in certain industries. By becoming certified, NDT technicians can be confident that they have the knowledge and skills necessary to perform their job duties safely and effectively. Being a technician gives job satisfaction and gives lucrative packages for happy living.

Suggested Further Reading

How to Choose online NDT Courses | Best Mode of NDT learning ? Find more

6 Best NDT courses for Mechanical Engineers

How Long Does NDT Certification last?

How Do You Become NDT Certified?

Which courses are Suitable for Mechanical Engineers? Short term courses

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