The post Guide for Industrial Radiography Artifacts appeared first on Trinity NDT WeldSolutions Private Limited.

Guide for Industrial Radiography Artifacts

All indications appearing in a radiograph are to be interpreted. Interpretation requires analysing the indication as to whether it is a true indication due to discontinuities or a false indication due to problems with film manufacturing, mishandling of film or poor storage. The interpreter should be able to distinguish a relevant discontinuity from a false indication.

No image in the area of interest must obscure the true indication. All false indications appearing in the area must be re-radiographed for interpretation. All true indications are interpreted and characterized.

In Industrial radiography, false indications are also called artifacts, which may form due to improper handling of film, lead screens or cassettes during any stage of the radiographic process. Common artifacts include: 

Static marks

Branchlike, jagged dark lines or irregular dark spots originating from rapid loading or unloading of film.

Pressure marks

produced by extreme pressure on an area of film.• Chemical stain – streaks on the film caused by inadequate removal of chemicals between processing stages or insufficient agitation of the film hanger.

Crimp marks

Caused by abrupt bending of film; typically crescent shaped. • Water mark – circular pattern caused by water droplets drying on the film surface. 

Reticulation

Formation of a network of wrinkles or cracks in a photographic emulsion. 

Dichoric fog

A stain visible under reflected or transmitted light due to improper development. 

Frilling of emulsion

Loosening of the emulsion from the film base due to warm or exhausted fixer solution, high temperature of processing solutions or prolonged washing in warm water. 

Scratches

Caused by abrasive materials or rough handling, including fingernails.

Damaged lead screens – Includes scratches on lead foil screens

Damaged or reused cassette – may cause a false indication to reappear after processing if the same cassette is used. However, the indication will probably move slightly because cassette placement is usually not exact.

Conclusion

The above guide may not be complete and exhaustive. Radiography Film Artifacts are common while processing the films. As long as they do not interfere with interpretation they can be ignored. If the artifacts are masking the relevant flaw indications it is better to re-shoot the same spot radiography.

Artifacts are not only appear in manual processing. There are artifacts in automatic processing such as PI Lines due to scratched on the rollers.

Proper precautions can minimize the artifacts in Industrial Radiography service and may not be completely avoidable. Visit us to know more about NDT testing services.

The post Guide for Industrial Radiography Artifacts appeared first on Trinity NDT WeldSolutions Private Limited.

Types of Weld Repairs

Weld repairs can be divided into two specific areas:
1 Production
2 In-service

Reasons For Weld Repair

The reasons for making a repair are many and varied, from the removal of weld defects induced during manufacture to a quick and temporary running repair to an item of production plant. In these terms, the subject of welding repairs is also wide and varied and often confused with maintenance and refurbishment where the work can be scheduled.

Repair Welding is Unplanned

With planned maintenance and refurbishment, sufficient time can be allowed to enable the tasks to be completed without production pressures being applied. In contrast, repairs are usually unplanned and may result in shortcuts being taken to allow the production programme to continue. It is, therefore, advisable for a fabricator to have an established policy on repairs and to have repair methods and procedures in place.

Welding Processes for Repairs

The manually controlled welding processes are the easiest to use, particularly if it is a local repair or one to be carried out on site. Probably the most frequently used of these processes is MMA as this is versatile,
portable and readily applicable to many alloys because of the wide range of off-the-shelf consumables. Repairs almost always result in higher residual stresses and increased distortion compared with first time welds. With C-Mn and low/medium alloy steels, the application of pre and post weld heat treatments may be required.

Key Factors to be Considered Before Weld Repairs

There are a number of key factors that need to be considered before undertaking any repair. The most important being a judgement as to whether it is financially worthwhile. Before this judgement can be made, the
fabricator needs to answer the following questions:
• Can structural integrity be achieved if the item is repaired?
• Are there any alternatives to welding?
• What caused the defect and is it likely to happen again?
• How is the defect to be removed and what welding process is to be used?
• Which NDT method is required to ensure complete removal of the defect?
• Will the welding procedures require approval/re-approval?
• What will be the effect of welding distortion and residual stress?
• Will heat treatment be required?
• What NDT is required and how can acceptability of the repair be demonstrated?
• Will approval of the repair be required – if yes, how and by whom?

How difficult to carryout weld repairs?

Although a weld repair may be a relatively straightforward activity, in many instances it can be quite complex and various engineering disciplines may need to be involved to ensure a successful outcome.
It is recommended that ongoing analysis of the types of defect is carried out by the QC department to discover the likely reason for their occurrence (material/process or skill related).

Things to be considered before carrying out weld repairs

In general terms, a welding repair involves:
• A detailed assessment to find out the extremity of the defect. This may involve the use of a surface or sub-surface NDT methods.
• Cleaning the repair area, (removal of paint grease etc).
• Once established the excavation site must be clearly identified and marked out.
• An excavation procedure may be required (method used ie grinding, arc/air gouging, preheat requirements etc).
• NDT testing to locate the defect and confirm its removal.
• A welding repair procedure/method statement with the appropriate* welding process, consumable, technique, controlled heat input and interpass temperatures, etc will need to be approved.
• Use of approved welders.
• Dressing the weld and final visual inspection.
• NDT procedure/technique prepared and carried out to ensure that the defect has been successfully removed and repaired.
• Any post repair heat treatment requirements.
• Final NDT procedure/technique prepared and carried out after heat treatment requirements.
• Applying protective treatments (painting etc as required).
*Appropriate means suitable for the alloys being repaired and may not apply in specific situations.

Production Weld repairs

Repairs are usually identified during production inspection. Evaluation of the reports is carried out by the Welding Inspector, or NDT operator. Discontinuities in the welds are only classed as defects when they are
outside the range permitted by the applied code or standard. Before the repair can commence, a number of elements need to be fulfilled.

Analysis before commencement of Weld Repair

As this defect is surface-breaking and has occurred at the fusion face the problem could be cracking or lack of sidewall fusion. If the defect is found to be cracking the cause may be associated with the material or the welding procedure, however if the defect is lack of sidewall fusion this can be apportioned to the lack of skill of the welder.

Assessment

In this particular case as the defect is open to the surface, magnetic particle inspection (MPI) or dye penetrant inspection (DPI) may be used to gauge the length of the defect and ultrasonic testing (UT) used to gauge the depth. In addition for volumetric type flaws such as blow holes and slag it is good opt for X-ray radiography testing.

A typical defect is shown below:

Excavation – Removal of Defective area prior to weld repair

If a thermal method of excavation is being used ie arc/air gouging it may be a requirement to qualify a procedure as the heat generated may have an effect on the metallurgical structure, resulting in the risk of cracking in the weld or parent material.

Is Preheat Necessary?

To prevent cracking it may be necessary to apply a preheat based on carbon content of the base material and filler materials. High carbon and high alloy steels needs preheat to avoid cracking at later stages of repair.
The depth to width ratio shall not be less than 1 (depth) to 1 (width), ideally 1 (depth) to 1.5 (width) would be recommended (ratio: depth 1 to width 1.5).

Cleaning of the excavation

At this stage grinding of the repair area is important, due to the risk of carbon becoming impregnated into the weld metal/parent material. It should be ground back typically 3 to 4mm to bright metal.

Confirmation of Removal of Defective area

At this stage NDT should be used to confirm that the defect has been completely excavated from the area.

Re-welding of the excavation

Prior to re-welding of the excavation a detailed repair welding procedure/method statement shall be approved.

NDT confirmation of successful repair

After the excavation has been filled the weldment should then undergo a complete retest using the same NDT inspection techniques as previously used to establish the original repair.

This is carried out to ensure no further defects have been introduced by the repair welding process. NDT may also need to be further applied after any additional postweld heat treatment has been carried out.

In-service Weld Repairs

Most in-service repairs can be of a very complex nature as the component is very likely to be in a different welding position and condition than it was during production.

It may also have been in contact with toxic or combustible fluids hence a permit to work will need to be sought prior to any work being carried out. The repair welding procedure may look very different to the original production procedure due to changes in these elements.

Other factors may also be taken into consideration, such as the effect of heat on any surrounding areas of the component, ie electrical components, or materials that may become damaged by the repair procedure. This may also include difficulty in carrying out any required pre- or post-welding heat treatments and a possible restriction of access to the area to be repaired.

For large fabrications it is likely that the repair must also take place on site without a shutdown of operations, which may bring other elements that need to be considered. Repair of in-service defects may require consideration of these and many other factors, and as such are generally considered more complicated than production repairs.

Joining technologies often play a vital role in the repair and maintenance of structures. Parts can be replaced, worn or corroded parts can be built up, and cracks can be repaired.

When a repair is required it is important to determine two things: Firstly, the reason for failure and, secondly, can the component be repaired? The latter point infers that the material type is known.

For metals, particularly those to be welded, the chemical composition is vitally important. Failure modes
often indicate the approach required to make a sound repair. When the cause-effect analysis, however simple, is not followed through it is often the case that the repair is unsafe –- sometimes disastrously so.

In many instances, the Standard or Code used to design the structure will define the type of repair that can be carried out and will also give guidance on the methods to be followed. Standards imply that when designing or
manufacturing a new product it is important to consider a maintenance regime and repair procedures. Repairs may be required during manufacture and this situation should also be considered.

Normally there is more than one way of making a repair. For example, cracks in cast iron might be held together or repaired by pinning, bolting, riveting, welding, or brazing. The method chosen will depend on factors such as the reason for failure, material composition and cleanliness, environment and the size and shape of the component.

It is very important that repair and maintenance welding are not regarded as activities, which are simple or straightforward. In many instances a repair may seem undemanding but the consequences of getting it wrong can be catastrophic failure with disastrous consequences.

Is welding the best method of repair?

If repair is called for because a component has a local irregularity or a shallow defect, grinding out any defects and blending to a smooth contour might be acceptable.

It will certainly be preferable if the steel has poor weldability or if fatigue loading is severe. It is often better to reduce the so called factor of safety slightly, than to risk putting defects, stress concentrations and residual stresses into a brittle material.

In fact brittle materials – which can include some steels (particularly in thick sections) as well as cast irons – may not be able to withstand the residual stresses imposed by heavy weld repairs, particularly if defects are not all
removed, leaving stress concentrations to initiate cracking.

Is the repair like earlier repairs?

Repairs of one sort may have been routine for years, but it is important to check that the next one is not subtly different.

For example, the section thickness may be greater; the steel to be repaired may be different and less weldable, or the restraint higher. If there is any doubt, answer the remaining questions.

What is the composition and weldability of the base metal?

The original drawings will usually give some idea of the steel involved, although the specification limits may then have been less stringent, and the specification may not give enough compositional details to be helpful.

If sulphur-bearing free-machining steel is involved, it could give hot cracking problems during welding.

If there is any doubt about the composition, a chemical analysis should be carried out. It is important to analyse for all elements, which may affect weldability (Ni, Cr, Mo, Cu, V, Nb and B) as well as those usually, specified
(C, S, P, Si and Mn).

A small cost spent on analysis could prevent a valuable component being ruined by ill-prepared repairs or, save money by reducing or avoiding the need for preheat if the composition were leaner than expected. Once the
composition is known, a welding procedure can be devised.

What strength is required from the repair?

The higher the yield strength of the repair weld metal, the greater the residual stress level on completion of welding, risk of cracking, clamping needed to avoid distortion and more difficulty in formulating the welding
procedure. In any case, the practical limit for the yield strength of conventional steel weld metals is about 1000N/mm2.

Can preheat be tolerated?

Not only does a high level of preheat make conditions more difficult for the welder; the parent steel can be damaged if it has been tempered at a low temperature. In other cases the steel being repaired may contain items which are damaged by excessive heating.

Preheat levels can be reduced by using consumables of ultra-low hydrogen content or by non-ferritic weld metals. Of these, austenitic electrodes may need some preheat, but the more expensive nickel alloys usually do not. However, the latter may be sensitive to high sulphur and phosphorus contents in the parent steel if diluted into the weld metal.

Can softening or hardening of the HAZ be tolerated?

Softening of the HAZ is likely in very high strength steels, particularly if they have been tempered at low temperatures. Such softening cannot be avoided, but its extent can be minimised. Hard HAZs are particularly
vulnerable where service conditions can lead to stress corrosion. Solutions containing H2S (hydrogen sulphide) may demand hardness below 248HV (22HRC) although fresh aerated seawater appears to tolerate up to about
450HV. Excessively hard HAZs may, therefore, require PWHT to soften them but provided cracking has been avoided.

Is Post Weld Heat Teatment (PWHT) practicable?

Although it may be desirable, PWHT may not be possible for the same reasons that preheating is not. For large structures, local PWHT may be possible, but care should be taken to abide by the relevant codes, because
it is too easy to introduce new residual stresses by improperly executed PWHT.

Is PWHT necessary?

PWHT may be needed for one of several reasons, and the reason must be known before considering whether it can be avoided.

Will the fatigue resistance of the repair be adequate?

If the repair is in an area which is highly stressed by fatigue and particularly if the attempted repair is of a fatigue crack, inferior fatigue life can be expected unless the weld surface is ground smooth and no surface defects are left.

Fillet welds, in which the root cannot be ground smooth, are not tolerable in areas of high fatigue stress.

Will the repair resist its environment?

Besides corrosion, it is important to consider the possibility of stress corrosion, corrosion fatigue, thermal fatigue and oxidation in-service.

Corrosion and oxidation resistance usually require the composition of the filler metal is at least as noble or oxidation resistant as the parent metal. For corrosion fatigue resistance, the repair weld profile may need to be
smoothed.To resist stress corrosion, PWHT may be necessary to restore the correct micro-structure, reduce hardness and the residual stress left by the repair.

Can the repair be inspected and tested?

For onerous service, radiography and/or ultrasonic examination are often desirable, but problems are likely if stainless steel or nickel alloy filler is used; moreover, such repairs cannot be assessed by Magnetic particle Inspection. In such cases, it is particularly important to carry out the procedural tests for repairs very critically, to ensure there are no risks of cracking and no likelihood of serious welder-induced defects.

Indeed, for all repair welds, it is vital to ensure that the welders are properly motivated and carefully supervised.

As-welded repairs

Repair without PWHT is, of course, normal where the original weld was not heat treated, but some alloy steels and many thick-sectioned components require PWHT to maintain a reasonable level of toughness, corrosion
resistance, etc. However, PWHT of components in-service is not always easy or even possible, and local PWHT may give rise to more problems than it solves except in simple structures.

The post Weld Repairs during Production and In-service Maintenance appeared first on Trinity NDT WeldSolutions Private Limited.

Types of Weld Repairs

Weld repairs can be divided into two specific areas:
1 Production
2 In-service

Reasons For Weld Repair

The reasons for making a repair are many and varied, from the removal of weld defects induced during manufacture to a quick and temporary running repair to an item of production plant. In these terms, the subject of welding repairs is also wide and varied and often confused with maintenance and refurbishment where the work can be scheduled.

Repair Welding is Unplanned

With planned maintenance and refurbishment, sufficient time can be allowed to enable the tasks to be completed without production pressures being applied. In contrast, repairs are usually unplanned and may result in shortcuts being taken to allow the production programme to continue. It is, therefore, advisable for a fabricator to have an established policy on repairs and to have repair methods and procedures in place.

Welding Processes for Repairs

The manually controlled welding processes are the easiest to use, particularly if it is a local repair or one to be carried out on site. Probably the most frequently used of these processes is MMA as this is versatile,
portable and readily applicable to many alloys because of the wide range of off-the-shelf consumables. Repairs almost always result in higher residual stresses and increased distortion compared with first time welds. With C-Mn and low/medium alloy steels, the application of pre and post weld heat treatments may be required.

Key Factors to be Considered Before Weld Repairs

There are a number of key factors that need to be considered before undertaking any repair. The most important being a judgement as to whether it is financially worthwhile. Before this judgement can be made, the
fabricator needs to answer the following questions:
• Can structural integrity be achieved if the item is repaired?
• Are there any alternatives to welding?
• What caused the defect and is it likely to happen again?
• How is the defect to be removed and what welding process is to be used?
• Which NDT method is required to ensure complete removal of the defect?
• Will the welding procedures require approval/re-approval?
• What will be the effect of welding distortion and residual stress?
• Will heat treatment be required?
• What NDT is required and how can acceptability of the repair be demonstrated?
• Will approval of the repair be required – if yes, how and by whom?

How difficult to carryout weld repairs?

Although a weld repair may be a relatively straightforward activity, in many instances it can be quite complex and various engineering disciplines may need to be involved to ensure a successful outcome.
It is recommended that ongoing analysis of the types of defect is carried out by the QC department to discover the likely reason for their occurrence (material/process or skill related).

Things to be considered before carrying out weld repairs

In general terms, a welding repair involves:
• A detailed assessment to find out the extremity of the defect. This may involve the use of a surface or sub-surface NDT methods.
• Cleaning the repair area, (removal of paint grease etc).
• Once established the excavation site must be clearly identified and marked out.
• An excavation procedure may be required (method used ie grinding, arc/air gouging, preheat requirements etc).
• NDT testing to locate the defect and confirm its removal.
• A welding repair procedure/method statement with the appropriate* welding process, consumable, technique, controlled heat input and interpass temperatures, etc will need to be approved.
• Use of approved welders.
• Dressing the weld and final visual inspection.
• NDT procedure/technique prepared and carried out to ensure that the defect has been successfully removed and repaired.
• Any post repair heat treatment requirements.
• Final NDT procedure/technique prepared and carried out after heat treatment requirements.
• Applying protective treatments (painting etc as required).
*Appropriate means suitable for the alloys being repaired and may not apply in specific situations.

Production Weld repairs

Repairs are usually identified during production inspection. Evaluation of the reports is carried out by the Welding Inspector, or NDT operator. Discontinuities in the welds are only classed as defects when they are
outside the range permitted by the applied code or standard. Before the repair can commence, a number of elements need to be fulfilled.

Analysis before commencement of Weld Repair

As this defect is surface-breaking and has occurred at the fusion face the problem could be cracking or lack of sidewall fusion. If the defect is found to be cracking the cause may be associated with the material or the welding procedure, however if the defect is lack of sidewall fusion this can be apportioned to the lack of skill of the welder.

Assessment

In this particular case as the defect is open to the surface, magnetic particle inspection (MPI) or dye penetrant inspection (DPI) may be used to gauge the length of the defect and ultrasonic testing (UT) used to gauge the depth. In addition for volumetric type flaws such as blow holes and slag it is good opt for X-ray radiography testing.

A typical defect is shown below:

Excavation – Removal of Defective area prior to weld repair

If a thermal method of excavation is being used ie arc/air gouging it may be a requirement to qualify a procedure as the heat generated may have an effect on the metallurgical structure, resulting in the risk of cracking in the weld or parent material.

Is Preheat Necessary?

To prevent cracking it may be necessary to apply a preheat based on carbon content of the base material and filler materials. High carbon and high alloy steels needs preheat to avoid cracking at later stages of repair.
The depth to width ratio shall not be less than 1 (depth) to 1 (width), ideally 1 (depth) to 1.5 (width) would be recommended (ratio: depth 1 to width 1.5).

Cleaning of the excavation

At this stage grinding of the repair area is important, due to the risk of carbon becoming impregnated into the weld metal/parent material. It should be ground back typically 3 to 4mm to bright metal.

Confirmation of Removal of Defective area

At this stage NDT should be used to confirm that the defect has been completely excavated from the area.

Re-welding of the excavation

Prior to re-welding of the excavation a detailed repair welding procedure/method statement shall be approved.

NDT confirmation of successful repair

After the excavation has been filled the weldment should then undergo a complete retest using the same NDT inspection techniques as previously used to establish the original repair.

This is carried out to ensure no further defects have been introduced by the repair welding process. NDT may also need to be further applied after any additional postweld heat treatment has been carried out.

In-service Weld Repairs

Most in-service repairs can be of a very complex nature as the component is very likely to be in a different welding position and condition than it was during production.

It may also have been in contact with toxic or combustible fluids hence a permit to work will need to be sought prior to any work being carried out. The repair welding procedure may look very different to the original production procedure due to changes in these elements.

Other factors may also be taken into consideration, such as the effect of heat on any surrounding areas of the component, ie electrical components, or materials that may become damaged by the repair procedure. This may also include difficulty in carrying out any required pre- or post-welding heat treatments and a possible restriction of access to the area to be repaired.

For large fabrications it is likely that the repair must also take place on site without a shutdown of operations, which may bring other elements that need to be considered. Repair of in-service defects may require consideration of these and many other factors, and as such are generally considered more complicated than production repairs.

Joining technologies often play a vital role in the repair and maintenance of structures. Parts can be replaced, worn or corroded parts can be built up, and cracks can be repaired.

When a repair is required it is important to determine two things: Firstly, the reason for failure and, secondly, can the component be repaired? The latter point infers that the material type is known.

For metals, particularly those to be welded, the chemical composition is vitally important. Failure modes
often indicate the approach required to make a sound repair. When the cause-effect analysis, however simple, is not followed through it is often the case that the repair is unsafe –- sometimes disastrously so.

In many instances, the Standard or Code used to design the structure will define the type of repair that can be carried out and will also give guidance on the methods to be followed. Standards imply that when designing or
manufacturing a new product it is important to consider a maintenance regime and repair procedures. Repairs may be required during manufacture and this situation should also be considered.

Normally there is more than one way of making a repair. For example, cracks in cast iron might be held together or repaired by pinning, bolting, riveting, welding, or brazing. The method chosen will depend on factors such as the reason for failure, material composition and cleanliness, environment and the size and shape of the component.

It is very important that repair and maintenance welding are not regarded as activities, which are simple or straightforward. In many instances a repair may seem undemanding but the consequences of getting it wrong can be catastrophic failure with disastrous consequences.

Is welding the best method of repair?

If repair is called for because a component has a local irregularity or a shallow defect, grinding out any defects and blending to a smooth contour might be acceptable.

It will certainly be preferable if the steel has poor weldability or if fatigue loading is severe. It is often better to reduce the so called factor of safety slightly, than to risk putting defects, stress concentrations and residual stresses into a brittle material.

In fact brittle materials – which can include some steels (particularly in thick sections) as well as cast irons – may not be able to withstand the residual stresses imposed by heavy weld repairs, particularly if defects are not all
removed, leaving stress concentrations to initiate cracking.

Is the repair like earlier repairs?

Repairs of one sort may have been routine for years, but it is important to check that the next one is not subtly different.

For example, the section thickness may be greater; the steel to be repaired may be different and less weldable, or the restraint higher. If there is any doubt, answer the remaining questions.

What is the composition and weldability of the base metal?

The original drawings will usually give some idea of the steel involved, although the specification limits may then have been less stringent, and the specification may not give enough compositional details to be helpful.

If sulphur-bearing free-machining steel is involved, it could give hot cracking problems during welding.

If there is any doubt about the composition, a chemical analysis should be carried out. It is important to analyse for all elements, which may affect weldability (Ni, Cr, Mo, Cu, V, Nb and B) as well as those usually, specified
(C, S, P, Si and Mn).

A small cost spent on analysis could prevent a valuable component being ruined by ill-prepared repairs or, save money by reducing or avoiding the need for preheat if the composition were leaner than expected. Once the
composition is known, a welding procedure can be devised.

What strength is required from the repair?

The higher the yield strength of the repair weld metal, the greater the residual stress level on completion of welding, risk of cracking, clamping needed to avoid distortion and more difficulty in formulating the welding
procedure. In any case, the practical limit for the yield strength of conventional steel weld metals is about 1000N/mm2.

Can preheat be tolerated?

Not only does a high level of preheat make conditions more difficult for the welder; the parent steel can be damaged if it has been tempered at a low temperature. In other cases the steel being repaired may contain items which are damaged by excessive heating.

Preheat levels can be reduced by using consumables of ultra-low hydrogen content or by non-ferritic weld metals. Of these, austenitic electrodes may need some preheat, but the more expensive nickel alloys usually do not. However, the latter may be sensitive to high sulphur and phosphorus contents in the parent steel if diluted into the weld metal.

Can softening or hardening of the HAZ be tolerated?

Softening of the HAZ is likely in very high strength steels, particularly if they have been tempered at low temperatures. Such softening cannot be avoided, but its extent can be minimised. Hard HAZs are particularly
vulnerable where service conditions can lead to stress corrosion. Solutions containing H2S (hydrogen sulphide) may demand hardness below 248HV (22HRC) although fresh aerated seawater appears to tolerate up to about
450HV. Excessively hard HAZs may, therefore, require PWHT to soften them but provided cracking has been avoided.

Is Post Weld Heat Teatment (PWHT) practicable?

Although it may be desirable, PWHT may not be possible for the same reasons that preheating is not. For large structures, local PWHT may be possible, but care should be taken to abide by the relevant codes, because
it is too easy to introduce new residual stresses by improperly executed PWHT.

Is PWHT necessary?

PWHT may be needed for one of several reasons, and the reason must be known before considering whether it can be avoided.

Will the fatigue resistance of the repair be adequate?

If the repair is in an area which is highly stressed by fatigue and particularly if the attempted repair is of a fatigue crack, inferior fatigue life can be expected unless the weld surface is ground smooth and no surface defects are left.

Fillet welds, in which the root cannot be ground smooth, are not tolerable in areas of high fatigue stress.

Will the repair resist its environment?

Besides corrosion, it is important to consider the possibility of stress corrosion, corrosion fatigue, thermal fatigue and oxidation in-service.

Corrosion and oxidation resistance usually require the composition of the filler metal is at least as noble or oxidation resistant as the parent metal. For corrosion fatigue resistance, the repair weld profile may need to be
smoothed.To resist stress corrosion, PWHT may be necessary to restore the correct micro-structure, reduce hardness and the residual stress left by the repair.

Can the repair be inspected and tested?

For onerous service, radiography and/or ultrasonic examination are often desirable, but problems are likely if stainless steel or nickel alloy filler is used; moreover, such repairs cannot be assessed by Magnetic particle Inspection. In such cases, it is particularly important to carry out the procedural tests for repairs very critically, to ensure there are no risks of cracking and no likelihood of serious welder-induced defects.

Indeed, for all repair welds, it is vital to ensure that the welders are properly motivated and carefully supervised.

As-welded repairs

Repair without PWHT is, of course, normal where the original weld was not heat treated, but some alloy steels and many thick-sectioned components require PWHT to maintain a reasonable level of toughness, corrosion
resistance, etc. However, PWHT of components in-service is not always easy or even possible, and local PWHT may give rise to more problems than it solves except in simple structures.

The post Weld Repairs during Production and In-service Maintenance 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.

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.

Detailed Online NDT Level II Schedule for ‘April’ and ‘May’ is

Spell ‘1’

• 03 – 04 April 2023 Radiography Film Interpretation (RTFI Level II)
• 05 – 06 April 2023 Visual Testing
• 05 – 07 April 2023 Welding Inspector Course
• 07 – 10 April 2023 Eddy Current testing

Spell ‘2’

• 03 – 06 May 2023 Ultrasonic Testing
• 07 – 08 May 2023 Magnetic Particle testing
• 09 – 10 May 2023 Liquid Penetrant testing

Online NDT examinations dates will be announced for each method. Training Coordinator will inform the registered candidates.

Online Course Timings: 06am to 08am & 06:30pm to 08:30pm every day.

Mode of sessions: Through Microsoft Teams

Prerequisites: A lap top or computer with internet connection. We recommend to have a standby system or a mobile phone for any exigencies.

Eligibility for Level II online NDT

• 10+2 with maths or science
• B.E or B.Tech in Engineering
• B.Sc with Science or Maths

Check more details and requirements about Eligibility for NDT Level II certifications.

Fee Structure* for Online NDT Courses and Duration. Check more details about each course at below links.

• Ultrasonic testing Course (5Days) – Rs. 7399/-
• Magnetic particle testing Course (3Days) – Rs.6399/-
• Liquid penetrant testing (3Days) Rs.6399/-
• Radiography Film Interpretation Course (3Days) – Rs.6999/-
• Visual Testing Course (3 Days)- Rs.6999/-
• Welding Inspector Course (3days) – Rs.9500/-
• Eddy Current Testing Course (5days) – Rs 12499/-

gst will be charged extra as per Government of India policy. Training cost specified is for Indian Nationals. Other nationals can contact ‘Training Coordinator’ for Foreigner Fee Details in USD. Duration is inclusive of practical duration to be held at NDT Service Labs.

For information contact:

Training Coordinator,

Trinity Institute of NDT Technology ( A Unit of Trinity NDT),

#491, Site No.12, 14th Cross, 4th Phase, Peenya Industrial Area, Bengaluru 560 058, India

Phone: +91 9844129439, 9141339994 | E-mail: training@trinityndt.com | Website: www.trinityndt.com

The post Online NDT Training Schedule April & May 2023 appeared first on Trinity NDT WeldSolutions Private Limited.

Detailed Online NDT Level II Schedule for ‘April’ and ‘May’ is

Spell ‘1’

• 03 – 04 April 2023 Radiography Film Interpretation (RTFI Level II)
• 05 – 06 April 2023 Visual Testing
• 05 – 07 April 2023 Welding Inspector Course
• 07 – 10 April 2023 Eddy Current testing

Spell ‘2’

• 03 – 06 May 2023 Ultrasonic Testing
• 07 – 08 May 2023 Magnetic Particle testing
• 09 – 10 May 2023 Liquid Penetrant testing

Online NDT examinations dates will be announced for each method. Training Coordinator will inform the registered candidates.

Online Course Timings: 06am to 08am & 06:30pm to 08:30pm every day.

Mode of sessions: Through Microsoft Teams

Prerequisites: A lap top or computer with internet connection. We recommend to have a standby system or a mobile phone for any exigencies.

Eligibility for Level II online NDT

• 10+2 with maths or science
• B.E or B.Tech in Engineering
• B.Sc with Science or Maths

Check more details and requirements about Eligibility for NDT Level II certifications.

Fee Structure* for Online NDT Courses and Duration. Check more details about each course at below links.

• Ultrasonic testing Course (5Days) – Rs. 7399/-
• Magnetic particle testing Course (3Days) – Rs.6399/-
• Liquid penetrant testing (3Days) Rs.6399/-
• Radiography Film Interpretation Course (3Days) – Rs.6999/-
• Visual Testing Course (3 Days)- Rs.6999/-
• Welding Inspector Course (3days) – Rs.9500/-
• Eddy Current Testing Course (5days) – Rs 12499/-

gst will be charged extra as per Government of India policy. Training cost specified is for Indian Nationals. Other nationals can contact ‘Training Coordinator’ for Foreigner Fee Details in USD. Duration is inclusive of practical duration to be held at NDT Service Labs.

For information contact:

Training Coordinator,

Trinity Institute of NDT Technology ( A Unit of Trinity NDT),

#491, Site No.12, 14th Cross, 4th Phase, Peenya Industrial Area, Bengaluru 560 058, India

Phone: +91 9844129439, 9141339994 | E-mail: training@trinityndt.com | Website: www.trinityndt.com

The post Online NDT Training Schedule April & May 2023 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.

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