NDT in Process Equipment Industries

Liquid Penetrant Testing

Liquid penetrant testing is one of the oldest and simplists NDT methods where its earliest versions (using kerosene and oil mixture) dates back to the 19th century. This method is used to reveal surface discontinuities by bleedout of a colored or fluorescent dye from the flaw. The technique is based on the ability of a liquid to be drawn into a "clean" surface discontinuity by capillary action. After a period of time called the "dwell time", excess surface penetrant is removed and a developer applied. This acts as a blotter that draws the penetrant from the discontinuity to reveal its presence.
The advantage that a liquid penetrant inspection offers over an unaided visual inspection is that it makes defects easier to see for the inspector where that is done in two ways:
 It produces a flaw indication that is much larger and easier fo

the eye to detect than the flaw itself. Many flaws are so smal             l
or narrow that they are undetectable by the unaided eye (a
person with a perfect vision can not resolve features smaller
than 0.08 mm).

 It improves the detectability of a flaw due to the high level of
contrast between the indication and the background which helps
to make the indication more easily seen (such as a red indication
on a white background for visable penetrant or a penetrant that
glows under ultraviolate light for flourecent penetrant).
Liquid penetrant testing is one of the most widely used NDT methods. Its popularity can be attributed to two main factors: its relative ease of use and its flexibility. It can be used to inspect almost any material provided that its surface is not extremely rough or porous. Materials that are commonly inspected using this method include; metals, glass, many ceramic materials, rubber and plastics.
However, liquid penetrant testing can only be used to inspect for flaws that break the surface of the sample (such as surface cracks, porosity, laps, seams, lack of fusion, etc.).

Advantages and Disadvantages

The primary advantages and disadvantages when compared to other NDT methods are:
Advantages
 High sensitivity (small discontinuities can be detected).
 Few material limitations (metallic and nonmetallic, magnetic and nonmagnetic, and conductive and nonconductive materials may be inspected).

 Rapid inspection of large areas and volumes.
 Suitable for parts with complex shapes.
 Indications are produced directly on the surface of the part and constitute a visual representation of the flaw.
 Portable (materials are available in aerosol spray cans)
 Low cost (materials and associated equipment are relatively inexpensive)

Disadvantages

 Only surface breaking defects can be detected.
 Only materials with a relatively nonporous surface can be inspected.
 Pre-cleaning is critical since contaminants can mask defects.
 Metal smearing from machining, grinding, and grit or vapor blasting must be removed.
 The inspector must have direct access to the surface being inspected.
 Surface finish and roughness can affect inspection sensitivity.
 Multiple process operations must be performed and controlled.
 Post cleaning of acceptable parts or materials is required.
 Chemical handling and proper disposal is required.

NDT in Process equipment industries

Radiographic Testing

Radiography is used in a very wide range of aplications including medicine, engineering, forensics, security, etc. In NDT, radiography is one of the most important and widely used methods. Radiographic testing (RT) offers a number of advantages over other NDT methods, however, one of its major disadvantages is the health risk associated with the radiation.
In general, RT is method of inspecting materials for hidden flaws by using the ability of short wavelength electromagnetic radiation (high energy photons) to penetrate various materials. The intensity of the radiation that penetrates and passes through the material is either captured by a radiation sensitive film (Film Radiography) or by a planer array of radiation sensitive sensors (Real-time Radiography). Film radiography is the oldest approach, yet it is still the most widely used in NDT.

Basic Principles

In radiographic testing, the part to be inspected is placed between the radiation source and a piece of radiation sensitive film. The radiation source can either be an X-ray machine or a radioactive source (Ir-192, Co-60, or in rare cases Cs-137). The part will stop some of the radiation where thicker and more dense areas will stop more of the radiation. The radiation that passes through the part will expose the film and forms a shadowgraph of the part. The film darkness (density) will vary with the amount of radiation reaching the film through the test object where darker areas indicate more exposure (higher radiation intensity) and liter areas indicate less exposure (higher radiation intensity).
This variation in the image darkness can be used to determine thickness or composition of material and would also reveal the presence of any flaws or discontinuities inside the material.

Advantages and Disadvantages

The primary advantages and disadvantages in comparison to other NDT methods are:

Advantages

 Both surface and internal discontinuities can be detected.
 Significant variations in composition can be detected.
 It has a very few material limitations.
 Can be used for inspecting hidden areas (direct access to surface is not required)
 Very minimal or no part preparation is required.
 Permanent test record is obtained.
 Good portability especially for gamma-ray sources.

Disadvantages

 Hazardous to operators and other nearby personnel.
 High degree of skill and experience is required for exposure and interpretation.
 The equipment is relatively expensive (especially for x-ray sources).
 The process is generally slow.
 Highly directional (sensitive to flaw orientation).
 Depth of discontinuity is not indicated.
 It requires a two-sided access to the component.