Section 15 — Inspection
NDE Training Course Outlines
IPE Engineering Practice IPE-EP-15-3-3
Document number: IPE-EP-15-3-3 · Section: 15 — Inspection
8.0 Magnetic Particle Test Equipment 21
9.0 Types of Discontinuities Located by Magnetic Particle Testing 21
10.0 Magnetic Particle Test Indications and Interpretation 22
SUBJECT: MAGNETIC PARTICLE TESTING COURSE OUTLINE FOR RESTRICTED CERTIFICATION FOR YOKE TESTING 23
1.0 Introduction 23
2.0 Yokes for Magnetic Particle Testing 23
3.0 Magnetic Particle Media 23
4.0 Lighting 24
5.0 Test Application. 24
SUBJECT: ULTRASONIC TESTING COURSE OUTLINE FOR UNRESTRICTED CERTIFICATION 25
1.0 Fundamental Properties of Sound 25
2.0 Principals of Wave Propagation 25
3.0 Generation of Ultrasonic Waves 25
4.0 Ultrasonic Testing Methods 26
5.0 Ultrasonic Testing Equipment 26
6.0 Operation of Specific Equipment 26
7.0 Specific Testing 27
8.0 Variables Affecting Test Results 27
SUBJECT: ULTRASONIC TESTING COURSE OUTLINE FOR RESTRICTED CERTIFICATION FOR DIGITAL THICKNESS TESTING 29
1.0 Introduction 29
2.0 Digital Ultrasonic Thickness Measurement 29
SUBJECT: ULTRASONIC TESTING COURSE OUTLINE FOR RESTRICTED CERTIFICATION FOR LONGITUDINAL WAVE TESTING 30
1.0 Fundamental Properties of Sound 30
2.0 Principals of Wave Propagation 30
3.0 Generation of Ultrasonic Waves 30
4.0 Ultrasonic Testing Methods 31
5.0 Ultrasonic Testing Equipment 31
6.0 Operation of Specific Equipment 31
- Specific Testing Procedures 31
SUBJECT: RADIOGRAPHIC TESTING COURSE OUTLINE FOR UNRESTRICTED CERTIFICATION 33SUBJECT: RADIOGRAPHIC TESTING COURSE OUTLINE FOR UNRESTRICTED CERTIFICATION 33
1.0 Introduction 33
2.0 Physical Principals 33
3.0 Radiation Sources 34
4.0 Radiation Detection 35
5.0 Personnel Safety and Radiation Protection 35
6.0 The Radiographic Process 36
7.0 Test Result Interpretation 37
SUBJECT: RADIOGRAPHIC TESTING COURSE OUTLINE FOR RESTRICTED CERTIFICATION FOR FILM INTERPRETATION 38
1.0 Introduction 38
2.0 Source of Radiation 38
3.0 Specimen Considerations 38
4.0 Radiographic Film 38
5.0 Radiographic Imaging 39
6.0 Exposure Arrangements 39
7.0 Film Interpretation 39
8.0 Codes, Standards, and Specifications 39
SUBJECT: VISUAL TESTING 41
1.0 Introduction 41
2.0 Equipment 41
3.0 Visual Codes and Standards 43
SUBJECT: LEAK TESTING COURSE OUTLINE FOR RESTRICTED CERTIFICATION FOR BUBBLE TESTING 44
1.0 Introduction 44
SUBJECT: LEAK TESTING COURSE OUTLINE FOR RESTRICTED CERTIFICATION FOR PRESSURE CHANGE/MEASUREMENT 45
1.0 Introduction 45
2.0 Fundamentals of Testing 45
3.0 Testing Standards 45
4.0 Choice Of Procedure For Leak Testing 45
SUBJECT: LEAK TESTING COURSE OUTLINE FOR RESTRICTED CERTIFICATION FOR HALOGEN DIODE LEAK DETECTION. 48
1.0 Introduction: 48
2.0 Fundamentals of Testing 48
3.0 Testing Standards 48
4.0 Choice of Procedure for Leak Testing 48
5.0 Introduction 49
Subject: Basic Materials Course
Total Course Hours: 16
BASIC FERROUS METALLURGY
- Crystalline Nature of Metals
- Simple Cubic Lattice Structure
- and Lattice Network Formation
- Grain Development
- Anisotropic (Columnar) Grains
- Epitaxial (Round) Grains
- Alloys
- Substitutional
- Interstitial
- Allotropic properties of Iron
- Alpha Iron (Ferrite)
- Gamma Iron (Austenite)
- Metallurgy of Carbon Steel
- Iron Carbon Diagram
- Continuous Cooling Diagram
- Pearlite
- Martensite
- Metallurgy of Alloy Steel
- Effect of Alloy On Hardenability
- Carbon Equivalents
- Metallurgy of Stainless Steel
- Austenitic Stainless
- Ferritic Stainless
- Martensitic Stainless
BASIC NONFERROUS METALLURGY
- Monel
- Inconel
- Titanium
WELDING
- Welding Terminology
- Joint types and Nomenclature
- Weld Root, Root Gap, Root Land, and Root/Hot Pass
- Weld Bevel, Bevel Face, and Filler Passes
- Weld Cap, Weld Face, Weld Toes
- Welding Processes
- OxyFuel Gas Welding and Cutting
- Shielded metal Arc Welding (SMAW)
- Gas Tungsten Arc Welding (GTAW)
- Gas Metal Arc Welding (FCAW)
- Flux Cored Arc Welding (FCAW)
- Submerged Arc Welding (SAW)
- Plasma Arc Welding (PAW)
- Weld Solidification
- Dendritic Structure
- Weld Heat Affected Zone
- Weld Preheat
- Weld Interpass Temperature
- Control of Heat Input
- Weld Contaminants
- Hydrogen
- Cracking
- Weld Cracking
- Hot Short Cracking
- Cold Short Cracking
- Fatigue Cracking
- Thermal Stress Cracking
- Weld Residual Stress and Distortion
- Influence of Joint Design
- Influence of Welding Technique
- Post Weld Heat Treatment
- Sub–Critical Thermal Stress Relief
- Annealing
- Normalizing
- Quench and Temper
- Weld Discontinuities
- Porosity
- Slag
- Tungsten Inclusions
- Lack of Fusion
- Lack of Penetration
- Root Concavity
- Burn–Through
- Melt–Through
- Cracking
- Undercut
- Spatter
- Lamelar Tearing
CASTING
- Green Sand Casting
- Pattern making
- Drag
- Cope
- Mold Making
- Sprue
- Riser
- Gate
- Chill
- Chaplet
- Core
- Nails
- Casting Discontinuities
- Sand
- Porosity
- Shrinkage
- Hot–Tears
- Dross
- Misrun
- Investment Casting
- Die Casting
- Centrifugal Casting
5.0 FORGING
MANUFACTURE OF PIPE/TUBING
- Seamless
- Welded
- Electric Resistance Welded
- Fusion Welded
MANUFACTURE OF PIPE FITTINGS
- Elbows
- Forged
- Static Cast
- Fabricated
- Tees
- Hot Formed
- Cold Formed
- Fabricated
- Reducers
MECHANICAL PROPERTIES OF METAL
- Stress
- Tensile
- Shear
- Compressive
- Slip and Strain
- Tensile and Yield Strength
- Hardness
- Ductility and Impact Resistance
- Stress Concentrations
- Cyclic Fatigue
- High and Low Cycle Fatigue
- Endurance Limit
- Influence of Surface Geometry
- Brittle Fracture
CORROSION AND EROSION
- General Corrosive Attack
- Stress Corrosion
- Galvanic Corrosion
- Cavitation
- Crevice Corrosion
- Erosion
- Intergranular Stress Corrosion Cracking
- Hydrogen Blistering
- Hydrogen Induced Cracking
- Pitting
- Weld Heat Affected Zone Attack
- Environmentally Induced Cracking
- Fitness–For–Purpose Analysis
Subject: Overview of Nondestructive Test Methods
Total Course Hours: 12
INTRODUCTION
- Definition of Nondestructive Testing (NDT)
- Brief History of NDT
LIQUID DYE PENETRANT TESTING
- Introduction
- Theory of Test
- Visible vs. Fluorescent Systems
- Water Washable, Solvent Removed, and Post Emulsified Systems
- Aqueous, Nonaqueous, Dry Powder, and Plastic Developers
- Test Equipment
- Test Applications
MAGNETIC PARTICLE TESTING
- Introduction
- Theory of Test
- Methods of Magnetization
- Longitudinal Fields
- Circular Fields
- Prods vs. Yoke
- Visible vs. Fluorescent Particles
- Dry vs. Wet Particles
- Direct vs. Alternating Current Magnetization
- Test Equipment
- Test Applications
RADIOGRAPHIC TESTING
- Introduction
- Theory of Test
- X–Ray vs. Gamma Ray
- Equipment
- Radiographic Film
- Radiographic Image Quality
- Radiographic Test Techniques
- Film Interpretation
- Radiation Safety
ULTRASONIC TESTING
- Introduction
- Theory of Test
- Digital Thickness Testing
- Longitudinal Wave Tests Using Cathode Ray Tube (CRT_ A–Scan Displays/)
- Shear Wave Tests Using CRT A–Scan
- Ultrasonic Time–Of–Flight and Satellite Pulse Testing
- Test Applications
ELECTROMAGNETIC FLUX LEAKAGE TESTS
- Introduction
- Theory of Test
- Test Equipment and Systems
- Test Applications
EDDY CURRENT TESTING
- Introduction
- Theory of Test
- Test Equipment and Systems
- Ferrous vs. Nonferrous Test Specimens
- Examination of Exchanger Tubing
- Other Test Applications
ACOUSTIC EMISSION TESTING
- Introduction
- Test Theory
- Test Equipment
- Test Advantages and Limitations
- Test Techniques
- Test Applications
LEAK TESTING
- Introduction
- Leak Test Methods
- Equipment
- Applications
10.0 MISCELLANEOUS NONDESTRUCTIVE TESTS
Subject: Liquid Penetrant Testing Course Outline for Unrestricted Certification
Total Course Hours: Level 1: 4 Hrs. - Level 2: 8 Hrs.
INTRODUCTION
Level 1: 1/3 Hr. Level 2: 2/3 Hr.
- Brief History of Nondestructive Testing and Liquid Penetrant Testing
- Purpose of Liquid Penetrant Testing
- Types of Liquid Penetrates Commercially Available
LIQUID PENETRANT PROCESSING
Level 1: 1 Hr. Level 2: 2 Hr.
- Preparation of Parts Surface Temperature
- Application of Penetrants to Parts
- Removal of Surface Penetrant
- Developer Application and Drying
- Inspection and Evaluation
- Post–Cleaning
SELECTION OF PENETRANT TEST METHOD
Level 1: 1/3 Hr. Level 2: 2/3 Hr.
- Advantages of Various Methods
- Disadvantage of Various Methods
LIQUID PENETRANT TEST EQUIPMENT
Level 1: 2/3 Hr. Level 2: 1–1/3 Hr.
- Liquid Penetrant Test Units
- Lighting for Liquid Penetrant Inspection
- Materials for Liquid Penetrant
LIQUID PENETRANT TESTING COURSE OUTLINE FOR UNRESTRICTED CERTIFICATION
Level 1: 1 Hr. Level 2: Hr.
- General
- Reason for Indications
- Appearance of Indications
- Time for Indications to Appear
- Persistence of Indications
- Factors Affecting Indications
- Penetrant Used
- Prior Processing
- Technique Used
- Establishing Acceptance Standards
- Comparator Acceptance Standards
- Descriptive Acceptance Standards
- Indication From Cracks
- Cracks Occurring During Solidification
- Cracks Occurring During Processing
- Cracks Occurring During Service
- Indications from laminar Discontinuities
- Cold Shut or Fold
- Extrusion Defect
- Extrusion Defect
- Seams
- Indications from Porosity
- Nonrelevant Indications
INSPECTION
Level 1: 2/3 Hr. Level 2: 1–1/3 Hr.
- Inspection Procedures
- Standards
PRACTICE SESSION
- Examination of Typical Specimens
- Interpretation of Test Results
SAFETY AND PERSONNEL PROTECTION
- Flammable Material
- Skin Irritants
- Respiratory Protection
Subject: Liquid Penetrant Testing Course Outline for Restricted Certification for Solvent Removed Dye
Total Course Hours: Level 1: 2 Hr. - Level 2: 2 Hr.
INTRODUCTION
Level 1: 1/2 Hr. Level 2: 1/2 Hr.
- Overview of Test Method
- Principles of Capillarity
VISIBLE VS. FLUORESCENT DYE
Level 1: 1/2 Hr. Level 2: 1/2 Hr.
- Relative Sensitivity
- Advantages vs. Disadvantages
VISIBLE DYE TEST APPLICATION
Level 1: 1/2 Hr. Level 2: 1/2 Hr.
- Visible Dye Materials and Required Equipment
- Test Surface Preparation
- Cleaning
- Penetrant Application
- Dwell Time
- Excess Penetrant Removal
- Developer Application
- Examination of Test Area
- Removal of Dye Materials After Testing
FLUORESCENT DYE TEST APPLICATION
Level 1: 1/2 Hr. Level 2: 1/2 Hr.
- Fluorescent Dye Materials and Equipment
Black Lights
- Test Surface Preparation
- Cleaning
- Penetrant Application
- Removal of Excess Penetrant
- Developer Application
- Examination of Test Area
- Removal of Dye Materials After Testing
PRACTICE SESSION
- Examination of Typical Specimens
- Interpretation of Test Results
Subject: Magnetic Particle Testing Course Outline for Unrestricted Certification
Total Course Hours: Level 1: 12 Hr. - Level 2: 8 Hr.
PRINCIPALS OF MAGNETS AND MAGNETIC FIELDS
Level 1: 1 Hr. Level 2: N/A
- Theory of Magnetic Fields
- Earths’ Magnetic Field
- Magnetic Fields Around Magnetized Materials
- Theory of Magnetism
- Magnetic Poles
- Law of Magnetism
- Materials Influenced by Magnetic Fields
- Ferromagnetic
- Paramagnetic
- Diamagnetic
- Magnetic Characteristics of Nonferrous Materials
- Terminology Associated with Magnetic Particle Testing
CHARACTERISTICS OF MAGNETIC FIELDS
Level 1: 1 Hr. Level 2: N/A
- Bar Magnet
- Ring Magnet
EFFECT OF DISCONTINUITIES ON MATERIALS
Level 1: 1 Hr. Level 2: 1 Hr.
- Surface Cracks
- Scratches
- Subsurface Defects
MAGNETIZATION BY MEANS OF ELECTRIC CURRENT
Level 1: 2 Hr. Level 2: 1 Hr.
- Circular Field
- Field Around a Straight Conductor
- Right Hand Rule
- Fields in Parts Through Which Current Flows
- Long Solid Cylindrical Regular Parts
- Irregularly Shaped Parts
- Tubular Parts
- Methods of Inducing Current Flow in Parts
- Contact Plates
- Prods
- Discontinuities Commonly Discovered by Circular Fields
- Longitudinal Field
- Field Produced by Current Flow in a Coil
- Field Direction in a Current–Carrying Coil
- Field Strength in a Current–Carrying Coil
- Discontinuities Commonly Detected by Longitudinal Fields
- Advantages of Longitudinal Magnetization When Inspecting
- Disadvantages of Longitudinal Magnetization When Inspecting
SELECTING THE PROPER METHOD OF MAGNETIZATION
Level 1: 1 Hr. Level 2: 1–1/2 Hr.
- Alloy, Shape, and Condition of Part
- Type of Magnetizing Current
- Direction of Magnetic Field
- Sequence of Operations
- Value of Flux Density
INSPECTION MATERIALS
Level 1: 1 Hr. Level 2: 1/2 Hr.
- Wet Particles
- Dry Particles
PRINCIPLES OF DEMAGNETIZATION
Level 1: 1 Hr. Level 2: 1 Hr.
- Residual Magnetism
- Reasons for Requiring Demagnetization
- Longitudinal and Circular Residual Field
- Basic Principals of Demagnetization
- Retentivity and Coercive Force
- Methods of Demagnetization
MAGNETIC PARTICLE TEST EQUIPMENT
Level 1: 1 Hr. Level 2: 1/2 Hr.
- Equipment Selection Considerations
- Type of Magnetizing Current
- Location and Nature of Test
- Test Materials Used
- Purpose of Test
- Area Inspected
- Manual Inspection Equipment
- Medium and Heavy
- Stationary Equipment
- Mechanized Equipment Inspection
- Semi–Automatic Inspection Equipment
- Single–Purpose Semi–Automatic Equipment
- Multi–Purpose Semi–Automatic Equipment
- Fully Automatic Equipment
TYPES OF DISCONTINUITIES LOCATED BY MAGNETIC PARTICLE TESTING
Level 1: 1 Hr. Level 2: 1/2 Hr.
- Inclusions
- Blowholes
- Porosity
- Flakes
- Cracks
- Pipes
- Laminations
- Laps
- Forging Bursts
- Voids
MAGNETIC PARTICLE TEST INDICATIONS AND INTERPRETATION
Level 1: 2 Hr. Level 2: 2 Hr.
- Indications of Nonmetallic Inclusions
- Indications of Surface Seams
- Indications of Cracks
- Indications of Laminations
- Indications of Laps
- Indications of Bursts and Flakes
- Indications of Porosity
- Nonrelevant Indications
Subject: Magnetic Particle Testing Course Outline for Restricted Certification for Yoke Testing
Total Course Hours: Level 1: 4 Hr. Level 2: 4 Hr.
INTRODUCTION
Level 1: 1 Hr. Level 2: 1 Hr.
- Principles of Magnetism
- Bar Magnets
- Magnetic Poles
- Orientation and Behavior of Magnetic Flux Lines
- Magnetic Flux Leakage Fields
- Principles of Electromagnetism
- Magnetic Field Surrounding Current–Carrying Conductor
- Magnetic Field Within a Coil
- Construction of Electromagnetic Yoke
- Orientation of Electromagnetic Flux
- Influence of Electric Current Type
- Direct and Rectified Current
- Alternating Current
- Magnetic Properties of Materials
- Ferromagnetic Materials
- Magnetic Domains
- Paramagnetic Materials
- Diamagnetic Materials
YOKES FOR MAGNETIC PARTICLE TESTING
Level 1: 1 Hr. Level 2: 1 Hr.
- Yoke Construction and Operation
- Influence of Pole Spacing
- Plate Lift Test
- Orientation of Yoke for Effective Testing
MAGNETIC PARTICLE MEDIA
Level 1: 1/2 Hr. Level 2: 1/2 Hr.
- Visible Particles
- Dry Powder
- Wet Visible Particles
- Contrast Media
- Fluorescent Particles Wet Fluorescent Particles
- Oil or Kerosene Vehicle
- Water Vehicle
- Control of Wet Particle Concentration Settling Test
- Application of Magnetic Media
- Aerosol Spray Cans
- Pressure Spray Applicators
- Dry Powder Applicators
LIGHTING
Level 1: 1/2 Hr. Level 2: 1/2 Hr.
- White Light Requirements
- Black Light Requirements
- Nature of Ultraviolet Light
- Filters
- Bulb Warm–up
- Light Intensity Meters
TEST APPLICATION
Level 1: 1 Hr. Level 2: 1 Hr.
- Continuous Magnetization Method
- A.C. vs. D.C. Operation
- Application of Yoke Current
- Application of Magnetic Media
- Examination of Magnetized Test Area
- Re–Examination Using Different Flux Orientation
- Recording Examination Results
Subject: Ultrasonic Testing Course Outline for Unrestricted Certification
Total Course Hours: Level 1: 40 Hr. Level 2: 40 Hr.
FUNDAMENTAL PROPERTIES OF SOUND
Level 1: 1 Hr. Level 2: 4 Hr.
- Frequency, Velocity, and Wavelength
- Definition of Ultrasonic Vibrations
- General Application of Ultrasonic Vibrations
PRINCIPALS OF WAVE PROPAGATION
Level 1: 5 Hr. Level 2: 4 Hr.
- Modes of Vibration
- Acoustic Impedance
- Reflection
- Refraction and Mode Conversion
- Diffraction, Dispersion, and Attenuation
- Fresnel and Fraunhofer Effects
GENERATION OF ULTRASONIC WAVES
Level 1: 5 Hr. Level 2: 4 Hr.
- Piezoelectricity and Types of Crystals
- Construction of Ultrasonic Search Units
- Characteristics of search Units
- Frequency - Crystal Thickness Relationships
- Conversion Efficiency of Various Crystals
- Damping and Resolution
- Beam Intensity Characteristics
- Divergence
- Care of Search Units
ULTRASONIC TESTING METHODS
Level 1: 6 Hr. Level 2: 4 Hr.
- Contact Testing
- Straight Beam
- Angle Beam
- Surface Wave
- Lamb Wave
- Through Transmission
- Immersion Testing
- Straight Beam
- Angle Beam
- Through Transmission
- Modified Immersion Testing Tests Employing Special Devices
- Digital Thickness Testing
- Principles
- Equipment
- Procedure and Technique
ULTRASONIC TESTING EQUIPMENT
Level 1: 3 Hr. Level 2: N/A
- Description of Basic Pulse–Echo Instrument
- Time–Base (Synchronizer) Circuit
- Pulser Circuit
- Receiver or Echo–Amplifier Circuit
- A–Scan Display Circuit
- Special Instruments
- B–Scan Display
- C–Scan Display
- Scanning Equipment
- Manipulators
- Bridges
- Special Scanning Devices
OPERATION OF SPECIFIC EQUIPMENT
Level 1: 8 Hr. Level 2: 4 Hr.
- General Operating Characteristics
- Functional Block Diagram of Circuits
- Purpose and Adjustment of External Controls
- Care of Equipment
SPECIFIC TESTING
Level 1: 8 Hr. Level 2: 12 Hr.
- Selection of Test Parameters
- Frequency
- Search Unit Size and Type
- Water Distance (For Immersed Tests)
- Scanning Speed and Index
- Test Standardization
- Ultrasonic Standard Reference Blocks
- Adjustment of Test Sensitivity
- Interpretation of Results
- Acceptance Standards
- Comparison Between Responses form Discontinuities to Those From Ultrasonic Reference Standards
- Estimated Length of Discontinuities
- Location of Discontinuities
- Zoning
- Test Records
- Data Sheets
- Maps
- Identification Stamps and Certification
- Equipment Performance Variations
VARIABLES AFFECTING TEST RESULTS
Level 1: 4 Hr. Level 2: 8 Hr.
- Instrument Performance Variations
- Search Unit Performance Variations
- Inspected Part Variations
- Entry Surface Condition
- Part Size and Geometry
- Metallurgical Structure
- Discontinuity Variations
- Size and geometry
- Distance Location from Entry Surface
- Orientation to Entry Surface
- Type of Discontinuity - Reflecting Characteristics
Subject: Ultrasonic Testing Course Outline for Restricted Certification for Digital Thickness Testing
Total Course Hours: Level 1: 4 Hr. Level 2: 4 Hr.
INTRODUCTION
Level 1: 2 Hr. Level 2: 1 Hr.
- Overview of Test Method
- Limitations of Thickness Tests Using Digital Equipment
- Limitations of Digital Equipment for Corrosion Detection
DIGITAL ULTRASONIC THICKNESS MEASUREMENT
Level 1: 2 Hr. Level 2: 3 Hr.
- Principle of Operation
- Piezoelectric Transducer Operation
- Transducer Selection
- Couplants
- Calibration of Test Instrument
- Compensation for Material Velocity
- Practice Session
Subject: Ultrasonic Testing Course Outline for Restricted Certification for Longitudinal Wave Testing
Total Course Hours: Level 1: 24 Hr. Level 2: 16 Hr.
FUNDAMENTAL PROPERTIES OF SOUND
Level 1: 4 Hr. Level 2: 2 Hr.
- Frequency, Velocity, and Wavelength
- Definition of Ultrasonic Vibrations
- General Application of Ultrasonic Vibrations
PRINCIPALS OF WAVE PROPAGATION
Level 1: 2 Hr. Level 2: 2 Hr.
- Modes of Vibration
- Acoustic Impedance
- Reflection
- Retraction and Mode Conversion
- Diffraction, Dispersion, and Attenuation
- Fresnel and Fraunhofer Effects
GENERATION OF ULTRASONIC WAVES
Level 1: 4 Hr. Level 2: 4 Hr.
- Piezoelectricity and Types of Crystals
- Construction of Ultrasonic Search Units
- Characteristics of Search Units
- Frequency - Crystal Thickness Relationships
- Conversion Efficiency of Various Crystals
- Damping and Resolution
- Beam Intensity Characteristics
- Divergence
- Care of Search Units
ULTRASONIC TESTING METHODS
Level 1: 4 Hr. Level 2: 2 Hr.
- Contact Testing
- Straight Beam
- Through Transmission
- Digital Thickness Testing
- Principles
- Equipment
- Procedure and Technique 4)
ULTRASONIC TESTING EQUIPMENT
Level 1: 2 Hr. Level 2: N/A
- Description of Basic Pulse–Echo Instrument
- Time–Base (Synchronizer) Circuit
- Pulser Circuit
- Receiver or Echo–Amplifier Circuit
- A–Scan Display Circuit
OPERATION OF SPECIFIC EQUIPMENT
Level 1: 4 Hr. Level 2: 2 Hr.
- General Operating Characteristics
- Functional Block Diagram of Circuits
- Purpose and Adjustment of External Controls
- Care of Equipment
SPECIFIC TESTING PROCEDURES
Level 1: 4 Hr. Level 2: 4 Hr.
- Selection of Test Parameters
- Frequency
- Search Unit Size and Type
- Scanning Speed and Index
- Test Standardization
- Ultrasonic Standard Reference Blocks
- Adjustment of Test Sensitivity
- Interpretation of Results
Subject: Radiographic Testing Course Outline for Unrestricted Certification
Total Course Hours: Level 1: 20 Hr. Level 2: 40 Hr.
INTRODUCTION
Level 1: 1.5 Hr. Level 2: 1 Hr.
- History of Industrial Radiography
- General Principals of Examination of Materials with Penetrating Radiation
- Relationship of Penetrating Radiation, Radiography, and Radiometry
- Comparison with other Methods
- General Areas of Application
- Imaging
- Metrological
- Product
PHYSICAL PRINCIPALS
Level 1: 2 Hr. Level 2: 5 Hr.
- Nature of Penetrating Radiation (All types briefly, X–ray and Gamma Detailed)
- Particles
- Wave Properties
- Electromagnetic Waves
- Electrical Theory of Matter
- Fundamentals of Radiation Physics
- Sources of Radiation
- Electronic
- Isotopic
- Interaction Between Penetrating Radiation and Matter
- Absorption
- Scatter
- Pair Production
- Photoelectric Effect
- Other Secondary Emission
- Radiography
- Imaging By Film
- Imaging By Fluorescent Materials
- Imaging By Electronic Devices
- Radiometry
Physics of Detection Devices
- Glossary of Terms and Units of Measure
RADIATION SOURCES
Level 1: 3 Hr. Level 2: 3 Hr.
- Electronic Sources X–ray Sources
- Generators and Tubes as an Integrated System
- Electron Sources
- Cold Cathode
- Hot Cathode
- Beam Focusing
- Field Emission
- Other
- Accelerating Potential
- General
- Tesla Coils
- Mechanical Rectifiers
- Resonant Coil Transformers
- Metal Core Transformers
- Electrostatic
- Targets
- Material
- Configuration
- Heat Dissipation
- Equipment Design Considerations
- Generating Wave Shape
- Window Design
- Duty Cycle
- Roentgen Output
- Tube Shielding
- Installation - Fixed, Mobile, Etc.
- Particulate Radiation Sources
- Electrons
- Neutrons
- Other (Alpha, Etc.)
- Isotopic Sources
- 1. Gamma
- Types
- Spectra
- Activity Including Self Absorption
- Handling
- 2. Beta
- 3. Neutron
RADIATION DETECTION
Level 1: 3Hr. Level 2: 3 Hr.
- Imaging
- Film - Principals - Properties
- Material Examination
- Monitoring
- Fluoroscopy
- Fluorescent Screen
- Image Amplification
- Cine Techniques
- Direct TV Viewing
- Solid State Devices
- Xeroradiography
- lonography
- Solid State Viewer
- Other
- Special Instrumentation Associated with Solid State Devices
- Nonimaging Devices
- 1. Solid State
- Scintillometers
- Photresistive
- Other
- 2. Gaseous
- Proportional Counters
- Geiger Counters
- Ionization Chambers
- Ohmart Cells
- Other
- Instrumentation
- Rate Meters
- Counters
- Amplifiers and Pre–Amplifiers
- Recording Readouts
- Other
PERSONNEL SAFETY AND RADIATION PROTECTION
Level 1: 2.5 Hr. Level 2: 3 Hr.
- Hazard of Excessive Exposure
- Methods of Controlling Radiation Dose
- Time
- Distance
- Shielding
- Specific Equipment Requirements
- X–ray
- Gamma Handling
- Survey
- Recording
- Exposure Shields and/or Rooms
- Operation
- Alarms
- Operation and Emergency Procedures
- Federal, State, and Local Operations
THE RADIOGRAPHIC PROCESS
Level 1: 5 Hr. Level 2: 12 Hr.
- Basic Imaging Considerations
- Definition of Sensitivity (Including Penetrameters)
- Contrast and Definition
- Relation of Kilovoltage or Wavelength to Contrast and Definition
- Geometric Principles
- Intensifying Screens
- Fluorescent
- Metallic
- Generation and Control of Scatter
- Choice of Source
- Choice of Film
- Use of Exposure Curves and How to Make Them
- Fluoroscopic Inspection
- Theory of Operation
- Applications
- Limitations
- Film Processing
- Darkroom Procedures
- Darkroom Equipment and Chemicals
- Film Processing Do’s and Don’ts
- Viewing of Radiographs
- Illuminator Requirements
- Background Lighting
- Judging Quality of Radiograph
- Causes and Correction of Unsatisfactory Radiographs
- High Film Density
- Insufficient Film Density
- High Contrast
- Low Contrast
- Poor Definition
- Fog
- Light Leaks
- Artifacts
- Arithmetic of Exposure and Other Factors Affecting Test
- Miscellaneous Applications
- Blocking and Filtering
- Multifilm Techniques
- Enlargement and Projection
- Stereoradiography
- Autoradiography
- Triangulation Methods
- Neutron Radiography
- “In Motion” Radiography and Fluoroscopy
- Flash Radiography
- Backscatter Radiography
- Microradiography
- Cause of “Diffraction” Effects and Minimization of Interference With Test
- Determination of Focal Spot Size
- Panoramic Techniques
- Altering Film For Contrast and For Density
- Gaging and Process Control
TEST RESULT INTERPRETATION
Level 1: 3 Hr. Level 2: 13 Hr.
- Basic Factors
- General Aspects
- Effects on Measurement and Interpretation of Test
- Administrative Control of Quality by Interpreter
- Familiarization with Image
- Material Considerations
- Metallurgy or Other Material Discipline as it Affects Use of Item and Test Results
- Materials Process Effects on Use of Item and Test Results
- Discontinuities, Their Cause and Effects
- Codes, Standards, Specifications, and Procedures
Subject: Radiographic Testing Course Outline for Restricted Certification for Film Interpretation
Total Course Hours: Level 1: 12 Hr. Level 2: 12 Hr.
INTRODUCTION
Level 1: 1/2 Hr. Level 2: 1/2 Hr.
- Overview of the Radiographic Process
- Electromagnetic Radiation (EMR)
- Interaction of EMR and Test Object
- Interaction of EMR with Film
- Significance of Discontinuity Orientation
SOURCE OF RADIATION
Level 1: 1–1/2 Hr. Level 2: 1–1/2 Hr.
- Atomic Structure
- Radioisotopes
- Gamma Radiography Equipment
- X–ray Production
- X–ray Equipment
SPECIMEN CONSIDERATIONS
Level 1: 1 Hr. Level 2: 1 Hr.
- Absorption
- Scatter
- Unsharpness
- Subject Contrast
RADIOGRAPHIC FILM
Level 1: 1 Hr. Level 2: 1 Hr.
- Film Construction
- Grain Size
- Film Characteristics
- Cassettes
- Intensifying Screens
- Film Processing
RADIOGRAPHIC IMAGING
Level 1: 2 Hr. Level 2: 2 Hr.
- Enlargement
- Distortion
- Unsharpness
- Penetrameters (Image Quality Indicators)
EXPOSURE ARRANGEMENTS
Level 1: 1 Hr. Level 2: 1 Hr.
- Location Markers
- Single Wall Techniques
- Double Wall Techniques
- Multiple (Composite) Film Techniques
FILM INTERPRETATION
Level 1: 3 Hr. Level 2: 3 Hr.
- Orthographic Projection Analogy
- Evaluating Erosion/Corrosion
- Evaluating Welds
- Evaluating Castings
CODES, STANDARDS, AND SPECIFICATIONS
Level 1: 2 Hr. Level 2: 2 Hr.
- National Codes and Standards
- IPE Engineering Practices
Subject: Visual Testing
| 1.0 | Total Course Hours: Level 1: 24 Hr INTRODUCTION |
Level 2: 16 Hr. |
|---|---|---|
| Level 1: 1 Hr. Level 2: 1 Hr. | Level 2: 16 Hr. | |
| 2.0 | EQUIPMENT | Level 2: 16 Hr. |
| Level 1: 16 Hr. Level 2: 1 Hr. | Level 2: 16 Hr. | |
| 2.1 | Optical Aids and Techniques Magnifiers and Mirrors Borescopes Pyrometers and Temperature Indicating Crayons Infrared Devices Photographic and Video Equipment Surface Roughness Measurement Practice Session |
Level 2: 16 Hr. |
| 2.2 | Mechanical Measuring Devices and Techniques Direct Measurement Indirect Measurement Practice Session |
Level 2: 16 Hr. |
| 2.3 | Hardness Testing Devices Hardness Testing Theory Stationary Equipment |
Level 2: 16 Hr. |
| a. Rockwell Tester | Level 2: 16 Hr. | |
| b. Brinnell Tester 3) Portable Equipment |
Level 2: 16 Hr. | |
| a. Telebrinneller | Level 2: 16 Hr. |
- Ames Hardness Tester
- Reihle Hardness Tester
- Schore Schleroscope
- Equotip Hardness Tester
- New Age Hardness Tester
4) 4. Practice Session
- Welding Inspection
- Welder and Welding Procedure Qualification
- Welding Procedure Specification
- Welding Procedure Qualification Record
- Welder Performance Qualification Testing
- Welding Symbols and Joint Design
- Weld Joint Nomenclature
- Typical Weld Joint Configurations
- Welding Techniques
- Typical Pipe Welding Techniques
- Typical Pressure Vessel Welding Techniques
- Typical Structural Welding Techniques
- Weld Repair Methods and Techniques
- Fabrication Sequence and Control of Residual Stress
- Pre–Inspection
- Joint Preparation
- Welding Parameters
- Fit–Up
- Preheat
- In–Process Inspection
- Control of Welding Consumables
- Tack Weld Inspection
- Control of Interpass Temperature
- Weld Root Inspection
- Interpass Cleaning
- Backgouging
- Hot Pass Inspection
- Inspection of Filler Passes
- Final Weld Inspection
- Weld Cap Profile and Appearance
- Welder Stencils
- Equipment for Welding Inspection
- Welding Gauges
- Workmanship Standards
- Practice Session
- Coating Inspection Devices and Techniques
- Surface Preparation
- Wet Coating Thickness
- Holiday Detectors
- Practice Session
- Positive Material Identification Equipment and Techniques
- Review of Alloy Designations
- Wet Chemistry
- Chemical Spot Testing
- Eddy Current Testing
- Emission Spectroscopy
- Texas Nuclear Analyzer
- Principles of X–ray Florescence
- Filtering and Counting
- Standardization and Calibration
- Test Application
- Practice Session
- Refractory Inspection
- Refractory Types
- Refractory Application
- Inspection of Mix
- Inspection of Anchors and Mesh
- Inspection of Applied Refractory
- Inspection of Cured Refractory
- Inspection of Existing Refractory
VISUAL CODES AND STANDARDS
Level 1: 3 Hr. Level 2: 3 Hr.
- ASME Section VIII
ASME B31.1
ASME B31.3
- National Board Inspection Code
AWS D1.1
- APl Std 510
- APl Std 620
- APl Std 650
- TEMA Standard
- State and Local Regulations
Subject: Leak Testing Course Outline for Restricted Certification for Bubble Testing
Total Course Hours: Level 1: 2 Hr. Level 2: 2 Hr.
INTRODUCTION
Level 1: 1 Hr. Level 2: 2 Hr.
- Bubble Testing Materials and Equipment
- Solutions
- Solution Applicators
- Vacuum Boxes
- Bubble Testing Practices and Techniques Level 1: 1 Hr. Level 2: 2 Hr.
- Vacuum Box Testing
- Pipe, Nozzle, and Pad Plate Testing
- Vessel Testing
- Liner Testing
- Weather Effects and Lighting
Subject: Leak Testing Course Outline for Restricted Certification for Pressure Change/Measurement
Total Course Hours: Level 1: 24 hr. Level 2: 16 Hr.
INTRODUCTION
Level 1: 1/2 Hr. Level 2: N/A
- Brief History of Leak Testing
- Reasons for Leak Testing
- To Prevent Loss of Contents
- To Prevent Contamination
- To Detect Unreliable Components
- To Assure Maintenance of a Pressure Differential
FUNDAMENTALS OF TESTING
Level 1: 1/2 Hr. Level 2: 1/3 Hr.
- Leak Testing Units
- Leak Conductance
- Detector Sensitivity
- Leakage Measurement
TESTING STANDARDS
Level 1: 1/2 Hr. Level 2: 1/3 Hr.
- Calibration vs. Qualification
- Common Types of Calibrated Leaks
- Calibration Techniques
CHOICE OF PROCEDURE FOR LEAK TESTING
Level 1: 1/2 Hr. Level 2: 1/3 Hr.
- Discussion
- Type of Leak Testing
- Leakage Measurement
- Units Accessible on Both Sides - Single Sealed Units
- Units Which May Be Evacuated
- Systems Leaking at Atmospheric Pressure
- Evacuated Unit Testing
- Units Sealed With Ambient Gas
- Units Sealed With Tracer Gas
- Leak Location
- Pressure Change/Measurement Test
- Principles of Absolute
- Principles of Absolute Pressure Testing i.) General Gas Law Equation
ii.) Effects of Water Vapor Pressure Change iii.) Effects of Barometric Pressure Change
- Terminology Related to Absolute Pressure Testing Level 1: 1–1/2 Hr. Level 2: 1 Hr.
i.) Pressure Measuring Instruments
ii.) Temperature Measuring Instruments iii.) Dewpoint Measuring Instruments iv.) Calibration of Equipment
- Pressurizing Gases
Level 1: 1/2 Hr. Level 2: N/A
- Analysis of Data for Determination of Accurate Results Level 1: 2 Hr. Level 2: 3 Hr.
Effects of Temperature Change
- Reference System Testing
- Principles of Reference System Testing Level 1: 2 Hr. Level 2: 1 Hr.
- General Gas Law Equation
- Effects of Temperature Change
- Effects of Water Vapor Pressure
- Effects of Barometric Pressure Change
- Terminology Related to Reference System Testing Level 1: 1 Hr. Level 2: 1 Hr.
- Reference System Testing Equipment Level 1: 3 Hr. Level 2: 1 Hr.
- Pressure Measuring Instruments
- Temperature Measuring Instruments
- Dewpoint Measuring Instruments
- Reference System Installation and Testing
- Reference System Installation and Testing
- Accuracy of Equipment
- Calibration of Equipment
- Pressurizing Gases
Level 1: 1/2 Hr. Level 2: N/A
- Analysis of Data for Determination of Accurate Results Level 1: 2 Hr. Level 2: 2 Hr.
Subject: Leak Testing Course Outline for Restricted Certification for Halogen Diode Leak Detection
Total Course Hours Level 1: 12 Hrs. Level 2: 8 Hrs.
INTRODUCTION:
Level 1: 1/2 Hr. Level 2: N/A
- Brief History of Leak Testing
- Reasons for Leak Testing
- To Prevent Loss of Contents
- To Prevent Contamination
- To Detect Unreliable Components
- To Assure Maintenance of a Pressure Differential
FUNDAMENTALS OF TESTING
Level 1: 1/2 Hr. Level 2: 1/3 Hr.
- Leak Testing Units
- Leak Conductance
- Detector Sensitivity
- Leakage Measurement
TESTING STANDARDS
Level 1: 1/2 Hr. Level 2: 1/3 Hr.
- Calibration vs. Qualification
- Common Types of Calibrated Leaks
- Calibration Techniques
CHOICE OF PROCEDURE FOR LEAK TESTING
Level 1: 1/2 Hr. Level 2: 1/3 Hr.
- Discussion
- Type of Leak Testing
4.3 Leakage Measurement
- Units Accessible on Both Sides - Single Sealed Units
- Units Which May Be Evacuated
- Systems Leaking at Atmospheric Pressure
- Evacuated Unit Testing
- Units Sealed with Ambient Gas
- Units Sealed with Tracer Gas
- Leak Location
INTRODUCTION
- Principles of Halogen Diode Detector Testing Level 1: 1 Hr. Level 2: 1 Hr.
- Terminology Related to Halogen Diode Detector Testing Level 1: 1 Hr. Level 2: 1 Hr.
- Halogen Testing Equipment Level 1: 1 Hr. Level 2: 1 Hr.
- Leak Detector Control Unit
- Gun Detectors
- Standard Leaks
- Refrigerant Tracer Gases
- Calibration of Halogen Leak Detectors for Testing Level 1: 1 Hr. Level 2: 1 Hr.
- Standard Leak Settings
- Halogen Mixture Percentages
- Test Sensitivity
- Halogen “Sniffer” Testing Techniques and Practices Level 1: 3 Hr. Level 2: 2 Hr.
- “Sniffer” Speed
- Halogen Background
- Effects of Heat on Refrigerant R–12
- Halogen Leak Detector Operation and Servicing Level 1: 2 Hr. Level 2: 1 Hr.
- Operation of Gun
- Replacing the Sensing Element
- Cleaning of Sensing Elements
- Standard Leak Operation and Refilling
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