SOUTHERN AFRICAN INSTITUTE OF WELDING. Non Destructive Testing (NDT) Course Syllabus & Programme

Transcription

1 SOUTHERN AFRICAN INSTITUTE OF WELDING Non Destructive Testing (NDT) Course Syllabus & Programme Certification Body Please refer to our Website ( for any information relating to the Training, Qualification and Certification of SAQCC-NDT personnel Certification Scheme NDT Method : Eddy Current Testing Qualification Level : Level 1 Reference Standards : ISO 9712 Industrial Sector : ECT 1.0 Pre and In - Service ECT 1.1 Wrought Products / Forgings Product Sector : ECT 1.2 ECT 1.3 Castings Welds Surface ECT 1.4 Tube and Pipes (Optional : Digital storage & reporting) Surface Tubes & Pipe Electrical conductive material - Non-magnetic & magnetic materials Thickness measurement, material properties, Defect detection: flat and hollow surfaces Electrical conductive material - Non-magnetic & magnetic materials Non-finned straight tubes Defect detection: internal, external and tube ends SAIW - CERTIFICATION: DOC/CS : ECT/G 1.0 : General Applicable documents (Contained within this document) : SAIW - CERTIFICATION: DOC/CS : ECT/S 1.1 : Specific - Forgings SAIW - CERTIFICATION: DOC/CS : ECT/S 1.2 : Specific - Castings SAIW - CERTIFICATION: DOC/CS : ECT/S 1.3 : Specific - Welds SAIW - CERTIFICATION: DOC/CS : ECT/S 1.4 : Specific - Tubes Compliant with ISO 25107, IAEA Tecdoc 628, ASNT CP 105 Compilation / Revision date : Date to be revised : 52 Western Boulevard, off Main Reef Road, City West, Johannesburg P.O. Box 527, Crown Mines, 2025, Telephone (011) , Fax (011) , info@saiw.co.za

2 INFORMATION Objective To provide the Level 1 candidate with adequate knowledge and skill to be able to inspect and report sector specific components in accordance with written instructions which are based on international codes and procedures. Target Group NDT Operators or Practitioners wanting to perform surface as well as subsurface inspections on castings, forgings, welds and tubes manufactured from conductive material. COURSE: 1. Grade 12 with Maths and Science Or Eligibility 2. Pass ( 70%) in applicable Proficiency test (No charge, available of contact jansenh@saiw.co.za for booking). EXAMINATION: 1. Training : 80 hrs (100% Attendance) 2. Vision Acuity Qualification Examination General : 40 Multiple Choice Questions : Pass 70% Specific : 40 Multiple Choice Questions : Pass 70% Practical : Weld, Casting, Forging samples 5 x Tube samples : Manual No data storage Or 20 x Tube samples : with Digital storage INITIAL : INDUSTRIAL EXPERIENCE 1. 3 months / 528 hrs RENEWAL : After 5 years Certification 1. Full practical examination 2. Annual NDT activity report & Vision Acuity 3. Valid Certification RECERTIFICATION : After 10 years 1. Full examination : General, Specific & Practical 2. Annual NDT activity report & Vision Acuity 3. Valid Certification DOC / CS / ECT 1.0 Page 2 of 14 TRAINING EXAMINATION CERTIFICATION

3 DOC. REF : SAIW - CERTIFICATION: DOC/CS : ECT/G 1.0 Description 1. Foreword : Non Destructive Testing 1.1. What is testing? Destructive vs. Non Destructive What is the purpose of NDT? 1.3. When and why is NDT performed? 1.4. Main NDT Methods (Surface : PT, MT, ET; Volumetric : UT, RT) 1.5. Material Properties & parameters influence 1.6. General NDT terms / definitions viz. discontinuities, indication, defect, etc Defects Surface Inherent (Primary) : Melting, Pouring, Cooling Processing : Welding, forging, rolling, heat treatment, machining, plating, other process Service : Overload, fatigue, corrosion, brittle fracture, others 1.8. Defects Tube and pipes Manufacturing Fabrication Service 1.9. Who may perform NDT? Personnel qualification & certification General Theory Duration 1 hr 2. INTRODUCTION TO EDDY CURRENT TESTING 2.1. Electromagnetic testing : Remote field, flux leakage, ACMF, ET, Saturation ET, EMAT Basic application of each 2.2. Testing fundamentals, process for Eddy current testing (ET) 2.3. Applications : Material properties : Conductivity, material sorting, heat treatment Material geometry : Coating thickness, thickness variation Defect detection a Surface : Flat, profiled, hollow designs b Tubes : Internal, external, tube ends 2.4. Advantages, Limitations, Disadvantages 2.5. General considerations 2.6. Terminology 3 hrs DOC / CS / ECT 1.0 Page 3 of 14 TRAINING EXAMINATION CERTIFICATION

4 DOC. REF : SAIW - CERTIFICATION: DOC/CS : ET/G 1.0 Description 3. THEORY : ELECTRICITY 3.1. DC theory: Voltage / Potential, EMF, Current flow (I), Resistance (R), Conductance (C), Ohm s law, Conductivity (Units), Resistivity (Units), Conductivity values for some metals (S/m or %IACS), Unit conversion, Joules law, I & R in resistive circuits General Theory Duration 3 hrs 3.2. AC theory:: Sinusoidal current and voltage, amplitude, frequency, phase, period 4. THEORY : MAGNETISM 4.1. What is magnetism? Natural magnet, electro magnet 4.2. Types of magnetic material : Paramagnetism, diamagnetism, ferromagnetism 4.3. Magnetic saturation 4.4. Hysteresis curve : Field strength, magnetic flux, flux density, retentivity, coercive force, residual magnetism, reluctance, units 4.5. Permeability 4.6. Magnetic fields: primary, secondary (transformer) 4.7. Penetration of magnetic flux 4.8. Magnetic field caused by current flow, right hand rule, Magnetic Field, lines of force, magnetic field strength 3 hrs 5. THEORY : ELECTROMAGNETISM / PRODUCTION OF ET 5.1. Magnetic Field created by current flow : straight conductor (R only), coil( R & XL) 5.2. Arago, Oersted 5.3. Electromagnetic Induction Faradays Law, Inductance (L), self-inductance, inductive reactance, I & XL in inductive circuit, impedance, impedance plane (introduction only) 5.4. Primary magnetic field (coil), Influencing factors 5.5. Electromagnetic Coupling, Mutual inductance, Influencing factors, Induced currents (ET), Lenz s Law 5.6. Secondary Magnetic field, Influencing factors 3 hrs DOC / CS / ECT 1.0 Page 4 of 14 TRAINING EXAMINATION CERTIFICATION

5 DOC. REF : SAIW - CERTIFICATION: DOC/CS : ET/G 1.0 Description 6. EDDY CURRENT CHARACTERISTICS (non-magnetic materials) 6.1. Distribution : Flat conducting material, depth of penetration, skin effect, standard depth of penetration, influencing factors (Frequency, conductivity), amplitude, phase angle, 6.2. Distribution : Tubes (thin wall only), signal shape, geometrical effect 6.3. Phase lag :Amplitude, phase angle, depth correlation 6.4. Influencing factors : Frequency, conductivity (hardness), permeability, temperature, geometry, edge effect, lift-off 7. PROPERTIES OF MATERIAL 7.1. Physical properties Conductivity, effect of chemical analysis, Temperature, gain size, texture, cold work, structure Magnetic permeability, effect of chemical analysis, Temperature, gain size, texture, cold work, structure, curie point Anomalies related to manufacture and service 7.2. Influence of various parameters on eddy current measurement Defect position and orientation EC path, penetration depth, zone of probe action Material temperature, `Heating, deviations, compensation Structure and geometry of test part Choices of frequency, phase discrimination, noise filtering, magnetic saturation Coupling influence Vibrations, centring, fill factor, sensitivity, compensation, Relative speed a testing frequency according to speed General Theory Duration 3 hrs 3 hrs DOC / CS / ECT 1.0 Page 5 of 14 TRAINING EXAMINATION CERTIFICATION

6 SAIW - CERTIFICATION: DOC/CS : ET/G 1.0 Description 8. EDDY CURRENT EQUIPMENT 8.1. Probe arrangements: differential, absolute, reflection probes, bridge probes, magnetic saturation, shielding, focussing 8.2. Instrument : Simple circuits, Bridge circuits, Oscillator, Balance unit, Tuned HF amplifier, Filters, Signal display devices, e.g., CRT and meter reading instruments, Signal presentation; Demodulation and detection; 8.3. Signal display : Types, Absolute, differential, Operating point, signal amplitude, phase angle 8.4. Defect signal response : Point defects, Large defects, Multiple defects, depth 8.5. Probe cables 8.6. Calibration samples: design, manufacture, identification, maintenance, monitor, & storage (Level 2 : reference samples) General Theory Duration 4 hrs 9. PRODUCT KNOWLEDGE, CAPABILITIES AND DERIVED TECHNIQUES 9.1. Eddy current applications : Material sorting, thickness measurements, ferrite content detection, conductivity measurement, weld detection, localised hardness or heat treatment variation 9.2. Defect detection : Surface, rotating, tubes 9.3. Capabilities : Depth of penetration, conductive material, non-contact, high speed, high temperature, may be mechanised 9.4. Techniques : Single frequency, dual frequency, multi-frequency, multi-parameter, mixing 2 hrs 10. INSPECTION : PRE-TEST PREPARATION Product information : Material, grade, metallurgical condition, shape, operating environment, inspection history Discontinuity information : type of discontinuities anticipated, location, orientation Test conditions : temperature, humidity, access, availability, unwanted interfering signals, electric and magnetic disturbances, surface condition 2 hrs DOC / CS / ECT 1.0 Page 6 of 14 TRAINING EXAMINATION CERTIFICATION

7 SAIW - CERTIFICATION: DOC/CS : ET/G 1.0 Description 11. PERFORMANCE TEST / CALIBRATION Frequency selection : Basic and auxiliary, harmonisation Probe & calibration samples selection Settings : Data acquisition procedure and instructions Calibration, reference indications Calibration curves : only relating to quality, not evaluation (Level 2) Operating modes, signal display Data recording criteria Probe speed, probe clearance (Lift-off / fill factor), probe vibration and centralisation Indication orientation Quality checks / verification General Theory Duration 5 hrs 12. APPLICATIONS Material properties Conductivity, Heat treatment, Permeability Material sorting (ferrous and nonferrous) Thickness variation Non Conductive & Conductive coating thickness Non-magnetic & magnetic substrate Material thickness measurement Erosion / Corrosion detection, single layer, multilayer Defect detection Surface inspection (Non-magnetic, weak magnetic & magnetic material) Flat / slightly curved surfaces Coated / non coated surfaces Welds & HAZ area 2 hrs Defect detection Tube inspection (Non-magnetic & weak magnetic material thus only ET using internal bobbin probe) Internal & external indications Tube-ends External support structures DOC / CS / ECT 1.0 Page 7 of 14 TRAINING EXAMINATION CERTIFICATION

8 SAIW - CERTIFICATION: DOC/CS : ET/G 1.0 Description 13. INTERPRETATION Characteristics of indications Basic metallurgical factors that can affect eddy current readings Types of discontinuity and their identification Relevant, non-relevant and false indications and their cause Equipment faults, causes and corrective actions Off scale readings on instrument, reasons and corrective actions. General Theory Duration 2 hrs 14. REPORTING Relevant / non relevant indications Report format / required parameters Indication parameters Digital storage of data, settings & applicable calibration criteria 2 hrs 15. QUALITY ASPECTS Personnel qualification, Code of ethics, responsibilities, equipment verification, quality documentation 1 hr Level 1 certified personnel shall neither be responsible for the choice of test method or technique to be used, nor for the evaluation of test results. Total Training : General 40 Hrs DOC / CS / ECT 1.0 Page 8 of 14 TRAINING EXAMINATION CERTIFICATION

9 DOC. REF. SAIW - CERTIFICATION: DOC/CS : ET/G 1.1 : Castings Specific Theory Section Description Page 1 Product Knowledge 30 mins 2 Typical Discontinuities 30 mins 3 Signal response & Detectability 1 hr 4 Written Instruction & Report Sheets (Based on Codes, Standards or Specifications) OUTCOME : Perform the tests (Setup, Calibration, Inspection, Verification) 1) Conductivity measurement 2) Coating thickness 3) Defect detection PRACTICAL OUTCOME : Record and classify the results of the tests according to written criteria Interpretation & measurement 6 hrs OUTCOME : Reporting Report results Assignment / Homework Evaluation Outcome Training Aids Ref Docs DOC / CS / ECT 1.0 Page 9 of 14 TRAINING EXAMINATION CERTIFICATION

10 DOC. REF. SAIW - CERTIFICATION: DOC/CS : ET/G 1.2 : Forgings / Wrought Products Specific Theory Section Description Page 1 Product Knowledge 30 mins 2 Typical Discontinuities 30 mins 3 Signal response & Detectability 1 hr 4 Written Instruction & Report Sheets (Based on Codes, Standards or Specifications) OUTCOME : Perform the tests (Setup, Calibration, Inspection, Verification) 1) Conductivity measurement 2) Coating thickness 3) Defect detection PRACTICAL OUTCOME : Record and classify the results of the tests according to written criteria Interpretation & measurement 6 hrs OUTCOME : Reporting Report results Assignment / Homework Evaluation Outcome Training Aids Ref Docs DOC / CS / ECT 1.0 Page 10 of 14 TRAINING EXAMINATION CERTIFICATION

11 DOC. REF. SAIW - CERTIFICATION: DOC/CS : ET/G 1.3 : Welds Specific Theory Section Description Page 1 Product Knowledge 30 mins 2 Typical Discontinuities 30 mins 3 Signal response & Detectability 1 hr 4 Written Instruction & Report Sheets (Based on Codes, Standards or Specifications) OUTCOME : Perform the tests (Setup, Calibration, Inspection, Verification) 1) Conductivity measurement 2) Coating thickness 3) Defect detection PRACTICAL OUTCOME : Record and classify the results of the tests according to written criteria Interpretation & measurement 6 hrs OUTCOME : Reporting Report results Assignment / Homework Evaluation Outcome Training Aids Ref Docs DOC / CS / ECT 1.0 Page 11 of 14 TRAINING EXAMINATION CERTIFICATION

12 DOC. REF. SAIW - CERTIFICATION: DOC/CS : ET/G 1.4 : Tubes and Pipes Specific Theory Section Description Page 1 Product Knowledge 1 hr 2 Typical Discontinuities 1 hr 3 Signal response & Detectability 2 hrs 4 Written Instruction & Report Sheets (Based on Codes, Standards or Specifications) OUTCOME : Perform the tests (Setup, Calibration, Inspection, Verification) 1) Tube inspection (Optional : Digital storage require computer literacy) PRACTICAL OUTCOME : Record and classify the results of the tests according to written criteria Interpretation & measurement 12 hrs OUTCOME : Reporting Report results Assignment / Homework Evaluation Outcome Training Aids Ref Docs DOC / CS / ECT 1.0 Page 12 of 14 TRAINING EXAMINATION CERTIFICATION

13 SAQCC-NDT : Eddy Current (ET) : ET 1.0 SAQCC Syllabus : Training and examinations EDDY CURRENT LEVEL 1 - COURSE PROGRAM: DURATION 80 hrs TIME DAY 1 DAY 2 DAY 3 DAY 4 DAY 5 8:00 9:00 ADMIN REVISION & HOMEWORK REVISION & HOMEWORK REVISION & HOMEWORK REVISION & HOMEWORK 9:00 10:00 Background Theory fundamentals ET characteristics ET Equipment Pre-test preparation 10:00 10:15 TEA / COFFEE BREAK WEEK 1 Defects : Surface 10:15 12:15 Theory fundamentals ET characteristics Introduction 12:15 13:00 LUNCH PRACTICAL 4 Application : Casting / forging Surface defect detection PRACTICAL 6 Application : Welds Surface defect detection 13:00 14:00 Theory fundamentals Theory fundamentals ET Capabilities ET Equipment Calibration & inspect 14:00 14:15 TEA / COFFEE BREAK PRACTICAL 1 PRACTICAL 2 PRACTICAL 3 PRACTICAL 5 PRACTICAL 7 14:15 16:30 Getting to know the instruments : settings, probes Eddy Equipment : Frequency, display, calibration, lift off, thickness Operating point ET Characteristics : Calibration,distribution, phase lag, Material Properties Application : Rotating inspection Application : Welds Surface defect detection 13

14 SAQCC-NDT : Eddy Current (ET) : ET 1.0 SAQCC Syllabus : Training and examinations EDDY CURRENT LEVEL 1 - COURSE PROGRAM: DURATION 80 hrs TIME DAY 6 DAY 7 DAY 8 DAY 9 DAY 10 8:00 9:00 REVISION & HOMEWORK REVISION & HOMEWORK REVISION & HOMEWORK REVISION & HOMEWORK REVISION & HOMEWORK 9:00 10:00 Defects : Tubes ET Capabilities (Tubes) Calibration & Inspect Reporting : Tubes Revision 10:00 10:15 TEA / COFFEE BREAK PRACTICAL 9 PRACTICAL 11 PRACTICAL 13 PRACTICAL 15 WEEK 2 10:15 12:15 ET Characteristics (Tubes) Getting to know the instruments : software External Indications & support structures 12:15 13:00 LUNCH Finned tubes, bent tubes Surface 13:00 14:00 ET Capabilities (Tubes) Calibration & Inspect Reporting : Surface Revision Revision 14:00 14:15 TEA / COFFEE BREAK PRACTICAL 8 PRACTICAL 10 PRACTICAL 12 PRACTICAL 14 PRACTICAL 16 14:15 16:30 Getting to know the instruments : settings, probes Getting to know the instruments : software Internal indications Tubes : Tube ends Tubes TOTAL TRAINING DURATION : 80hrs Educational Training : 40 hrs Practical Training Surface : 20 hrs Tubes : 20 hrs 14