Transcript Slide 1

NDE in Manufacturing and Life Management
Raw Materials
Fabrication
Pre-service inspection
In-service inspection
Condition monitoring
Fracture mechanics
Intelligent processing
Damage assessment
Repair technology
Life extension
Sensitivity
Reliability
Safety
Quantification
Characterisation
Defects
Microstructure
Stresses
Properties
Sensors
Instrumentation
Signal & image processing
Artificial intelligence – KBS
Automation & Robotics
New techniques & procedures
NDT&E Techniques
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Physics of techniques
Types of materials
Accessibility
Types of defects and
damage
Inspect or measure without doing harm
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Visual
Dye penetrant
Magnetic particle
Radiography
(X,  and Neutron)
Ultrasonic
Eddy current
Acoustic emission
Infrared thermography
Different NDT Techniques
Sensors
Heart of the NDE techniques
Physical principles
Sensitivity
Calibration
Ruggedness (operating conditions)
Selection (for example, variety of ultrasonic
sensors)
Problem specific design (for example, eddy current
sensors)
Instrumentation and signal and image processing
Miniaturisation (for example, MEMS/ NEMS)
Codes, Standards and Specifications
Procedures for inspection
Acceptance criteria
Calibration of sensors and instrumentation
Reference standards
Artificial defects
Natural defects
Forward and inverse modeling
Human Resource Development
Training and certification of personnel
Various Techniques
Different Levels (I, II, III)
National Certification Board of Indian Society for NDT
Accreditation
Standard procedures
Bureau of Indian Standards (IS-13805)
International Standards Organisation (ISO-9712)
Quality manual
Nuclear reactors and other installations
Reactor vessels
Feed water nozzles in BWR
Core shrouds in BWR
Inspection of coolant channels (BARCIS) & end shields
Steam generators and heat exchangers
Piping joints
Concrete structures and containment buildings
Pumps
Turbine components
Heavy water plant components
Reprocessing plants
Research Reactors (CIRUS, DHRUVA and FBTR)
NDE for life extension of CIRUS
Reactor vessel, piping and valves
In service inspection of FBTR
Highly stresses joints in high temperature sodium
circuits (similar and dissimilar weld joints) using ultrasonic
testing
Inspection of sodium valves (consequent to sodium
leakage) using ultrasonic wall thickness gauging
Boiling water reactors (Tarapur)
Inspection of reactor vessel feed water nozzles using
ultrasonic testing
Inspection of core shrouds for detection of SCC using
underwater visual inspection and underwater ultrasonic
testing
Inspection of pump castings using In-situ metallography
Infrared thermography for inspection of electrical installations
Pressurised Heavy Water Reactors
Inspection of end shields using ultrasonic testing and acoustic emission testing
for cracks and leaks
BARCIS for comprehensive inspection of coolant channels (ultrasonic and eddy
current testing)
Detection of fine scratches in calandria tubes (en-mass coolant channel
replacement programme) – Special focussed eddy current probe designed,
developed and patented
Detection of leaking coolant channel using acoustic emission testing and
advanced signal analysis methodologies
Eddy current testing of tubes of moderator heat exchangers, steam generators etc.
Development of acoustic resonance technique for detection of leaks with
high sensitivity and speed (patented)
Structural integrity assessment of ring beam of containment structure of KAIGA
plant using impact echo testing
Inspection of steam turbine blades with high sensitivity fluorescent magnetic
particle testing for defects and XRD based fatigue damage assessment
Inspection of 17-4 PH steel ram heads of fueling machines using precision
radiography
Prototype Fast Breeder Reactor
Design for inspection (fabrication and in service)
Enhanced detection sensitivity for defects in austenitic stainless steel
welds using advanced ultrasonic inspection methodologies
Reliable inspection of fuel cladding tubes
Ultrasonic and eddy current testing (Complementary)
Inspection of ferromagnetic tubes and tube to tube sheet weld joints of
steam generators
Saturation magnetisation eddy current testing
Microfocal radiography, videoimagescopy and replication
Ultrasonic Internal rotary inspection system
Remote field eddy current testing with wavelet transform based
analysis)
Real time radiography of thermocouples
Robot based inspection system for main vessel and safety vessel
(visual, Eddy current for weld centre line, ultrasonic for welds)
Data management software
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Reliability
Radiation hazard
Inaccessible areas
Space constraint
Speed
25000
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Robotics and Automation
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Steam Generator
Heavy water plants
Integrity assessment and life extension of conical inlet of a
heavy water plant using ultrasonic, in-situ metallography and
hardness methods
Acoustic emission monitoring during hydro testing of waste
stripper for structural integrity assessment
Inspection of ammonia cracker tubes made of Inconel 625
Development of ultrasonic velocity based method for
monitoring microstructural degradation in service and also to
qualify rejuvenation process
Inspection of steam generators and heat exchangers
Inspection of piping
Reprocessing plants
Laser based profilometry and ultrasonic inspection of
dissolver vessels
EMAT based guided ultrasonic wave inspection
Remote visual inspection of waste vault
SUMMARY OF APPLICABILITY AND CAPABILITY OF
VARIOUS NDT TECHNIQUES USED FOR ASSESSMENT OF
DEFECTS IN MATERIALS AND COMPONENTS
METHOD
MATERIALS
APPLICABLE
APPLICABLE
COMPONENT
GEOMETRIES
DETECTION CAPABILITY
Linear
Nonlinear
Surface
Subsurface
Internal
DYNAMIC
DETECTION @
DEFECT SIZING
Length
Orientation
DEFECT
CHARACTERIZATION
NUMERICAL
MODELLING
VI
A
Y
Y
Y
N
N
N
Y
N
Y
N
LPI
A
Y
Y
Y
N
N
N
Y
N
Y
N
MPI
M
Y
*
Y
Y
N
N
Y
N
Y
*
ACPD
E
Y
Y
Y
N
N
N
Y
N
*
Y
DCPD
E
Y
Y
Y
Y
N
N
Y
*
*
Y
UT
A
Y
Y
Y
Y
Y
N
Y
Y
Y
Y
ECT
E
Y
Y
Y
Y
Y1
N
Y
Y1
Y
Y
RT
A
Y
Y
Y
Y
Y
N
Y
Y
Y
Y
AET
A
Y
Y
Y
Y
Y
Y
Y
N
*2
N
IRT
A
Y
Y
Y
Y
Y
Y
*
Y
*
*
MFLT
M
Y
Y
Y
Y
Y
N
Y
N
N
Y
Y – POSSIBLE
N – NOT POSSIBLE
* - FEASIBILITY EXISTS
A – ALL MATERIALS
E – ONLY ELECTRICALLY CONDUCTIVE
MATERIALS
M – ONLY MAGNETIC MATERIALS
1 – LESS THAN 6 mm
2 – ONLY HARMFUL (GROWING DEFECTS)
@ - DETECTED AS AND WHEN DEFECT
INITIATES AND GROWS
VI – VISUAL INSPECTION
LPI – LIQUID PENETRANT INSPECTION
MPI – MAGNETIC PARTICLE
INSPECTION
PD – POTENTIAL DROP TECHNIQUE
(AC AND DC)
UT – ULTRASONIC TESTING
ECT – EDDY CURRENT TESTING
RT – RADIOGRAPHY
AET – ACOUSTIC EMISSION
TESTING
IRT – INFRARED
THERMOGRAPHY
MFLT – MAGNETIC FLUX
LEAKAGE TECHNIQUE