NDE in Manufacturing and Life Management

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

2. NDT&E Techniques • Physics of techniques • Types of materials • Accessibility • Types of defects and damage Inspect or measure without doing harm

3. Visual • Dye penetrant • Magnetic particle • Radiography (X,  and Neutron) • Ultrasonic • Eddy current • Acoustic emission • Infrared thermography Different NDT Techniques

4. 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)

5. Codes, Standards and Specifications Procedures for inspection Acceptance criteria Calibration of sensors and instrumentation Reference standards Artificial defects Natural defects Forward and inverse modeling

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. Robotics and Automation Reliability Radiation hazard Inaccessible areas Space constraint Speed Steam Generator

13. 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

14. Reprocessing plants Laser based profilometry and ultrasonic inspection of dissolver vessels EMAT based guided ultrasonic wave inspection Remote visual inspection of waste vault

15. SUMMARY OF APPLICABILITY AND CAPABILITY OF VARIOUS NDT TECHNIQUES USED FOR ASSESSMENT OF DEFECTS IN MATERIALS AND COMPONENTS Y – POSSIBLE N – NOT POSSIBLE * - FEASIBILITY EXISTS A – ALL MATERIALS E – ONLY ELECTRICALLYCONDUCTIVE 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