NDT Level-Il Training and Examination NDT Level-ll/2 Visual and Optical Testing Document No: VT/Level-II/2 Rev:00 Date:30 October 2022 Iris r Eyeli Urner Eyelid Pupil Caruncle Gavade Institute of Nondestructive Testing & Training (GINDT) 710/34 Ground Floor, Swami Vivekananda Road, Angol, Belgaum - 590 006, Karnataka State, INDIA > Walk-able Distance from 34 No. Marathi Government School Bus Stop:2 minutes Phone No.:+091-831-2484060, Fax No.:+091-831-2469074, Mobile No.:+091-9632916690 Email: [email protected]., Website: www.gindt.in Page 1 of 11VT- Visual and Optical Testing + Fundamentals + Vision and light + Ambient conditions + Test object characteristics ‘+ Equipment Accessories ‘+ Magnifiers/microscopes © Mirrors + Dimensional + Borescopes + Video systems + Machine vision © Replication + Temperature indicating devices and materials, © Chemical aids ‘+ Surface comparators and Surface Plates or Tables. + CMMarm type and Bench type © Lasers + Applications and Requirements + Raw materials + Primary process materials + Joining processes + Fabricated components + In-service materials + Coatings, Metallic Coating, Corrosion + Other applications + Requirements + Variables Affecting Results of interpretation/ Evaluations + Equipment including type and intensity of light ‘+ Material including the variations of surface finish + Discontinuity + Determination of dimensions (ie: depth, width, length and bore, etc.) + Sampling/scanning ‘+ Process for reporting visual discontinuities + Personnel (human factors) such as work fatigue etc. * Documentation + Safety Gavade Institute of Nondestructive Testing & Training (GINDT) Page 2 of 11eee eee eee eee VT - Visual and Optical Testing 1al Testing Level I/1 Topical Outline Note: The guidelines listed below should be implemented using equipment and procedures relevant to theemployer's industry. No times are given for a specific subject; this should be specified in the employer's written practice. Based upon the employer's product, not all of the referenced subcategories need apply. 1.0 Introduction 1.1 Definition of visual testing (VT) 1.2 History of VT visual testing 1.3. Overview of VT visual testing applications 2.0 Definitions Standard terms and their meanings in the employer's industry 3.0 Fundamentals, 3.1 Vision 3.2 Lighting 3.3 Material attributes 3.4 Environmental factors 3.5 Visual perception 3.6 Direct and indirect methods 4.0 Equipment (as applicable) 41 Micrors 4.2 Magnifiers 43 Borescopes 4.4 Fiber borescopes scopes 45 Video borescopes probes 4.6 Remote visual inspection systems 4.7 ight sources and special lighting 48 Gauges (welding, go/no-~go, etc.) templates, scales, micrometers, calipers, special tools, etc. 49 Automated systems 4.10 Computer~-enhanced systems 5.0 Employer-~Defined Applications (Includes a description of inherent, processing, and service—induced discontinuities) 5.1 Mineral-~based material 5.2 Metallic materials, including welds 53 Organic—based materials 5.4 Other materials (employer defined) 6.0 VT Visual Testing to Specific Procedures (based on industry specific) 6.1 Selection of parameters 6.1.1 Inspection objectives 6.1.2 Inspection checkpoints 6.1.3 Sampling plans 6.1.4 Inspection patterns Gavade Institute of Nondestructive Testing & Training (GINDT) Page 30f 11VT- Visual and Optical Testing 6.15 Documented procedures 6.2 Test standards/standardization calibration 6.3 Classification of indications per acceptance criteria, 6.4 Reports and documentation Testing Level il/2 T ! The guidelines listed below should be implemented using equipment and procedures relevant to the employer's industry. The employer should tailor the program to the company’s particular application area. Discontinuity cause, appearance, and how to best visually detect and identify these discontinuities should be emphasized, No times are given for a specific subject; this should be specified in the employer's written practice. Depending upon the employer's product, not all the referenced subcategories need apply 1.0 Purpose and Scope of VT 11 Scope 1.11 Internal quality control 1.1.2 Quality control by the customer 1.13 Quality control by authorities 1.2 VTlooks for 1.21 _Discontinuities 1.2.2 Shape and geometry deviations 1.2.3. Surface finish 1.3 Time of application 1.3.1 During manufacture 132 Inservice 2.0 Elements of Vision 2.1 Mechanics of vision 2.2 Adaptation and accommodation 2.3 Vision limitations 2.3.1 Perception and environmental conditions 2.3.2 Orientation, visual angle, and distance 2.3.3 Ophthalmic disorders 2.3.4 Mental attitude and fatigue 2.3.5 Physiology and health 2.4 Vision acuity examination and charts, 24.4 Vision acuity tests 24.2 Color and grey shade differentiation 3.0 Elements of Lighting 3.1 Fundamentals of light 3.2 Light sources 3.2.1 Incandescent radiators 3.22 Luminescent radiators (fluorescent light, high-~intensity discharge light, light-emitting diodes, lasers) 3.3 Adequate light levels 3.4 Glare and fatigue 3.5 General lighting requirements Gavade Institute of Nondestructive Testing & Training (GINDT) Page 4 of 11VT - Visual and Optical Testing 4.0 Contrast and Resolution 4.1 Reflection at smooth and rough/textured surfaces 4.2 Lawofillumination 4.3 Reflectivity and luminance 4.4 Luminous contrast 4.5 Influence of cleanliness on contrast 46 Dark field contrast 4.7 Colors and contribution of colors to contrast 4.8 Surface geometry and contrast 5.0 5.1 Transmission of light through solid and liquid media 5.2 Refraction of light 5.3 Refractive indexes of glasses 5.4 How prisms change the direction of light 5.5 How lenses focus and disperse light 5.6 Lens optics and lens trains 5.7 Fiber optics and fiber bundles 5.8 Digitization and digital technology 6.0 VT Equipment’s and Accessories 6.1 Generic tools such as magnifiers and mirrors 6.2 Rigid borescopes 6.3 Fiber borescopes 64 Video borescopes 6.5 Video borescopes measurement techniques 6.5.1 Comparison technique 6.5.2 Shadow technique 6.5.3 Stereo technique 6.5.4 Laser—-based measurements 6.6 Specialized inspection systems 6.6.1 Push~-tube cameras 6.6.2 Pipe crawler camera systems 6.6.3 Subsea remote camera systems 7.0 Visual Appearance of Discontinuities 7.1 Primary manufacturing discontinuities (e.g., Castings) 7.2 Secondary manufacturing discontinuities (e.g., Forgings) 7.3. Service-—induced discontinuities 7.3.1 Caused by mechanical loads (e.g., Fatigue) 7.3.2 Caused by thermal loads (e.g,, Thermal shock) 7.3.3 Caused by corrosion (e-g., Pitting) 7.3.4 Caused by abrasive wear (e.g, Erosion) 7.4 Inherent discontinuities Gavade Institute of Nondestructive Testing & Training (GINDT) Page 5 of 11,8.0 BL 82 B21 8.22 8.23 824 83 83.1 8.3.2 83.4 8a B41 B42 843 BS 9.0 a4 92 a3 34 35 100 10.1 10.2 103 104 105, 106 VT - Visual and Optical Testing Evaluation and Reporting General evaluation scheme (ASTM £1316) Evaluation criteria Verbal descriptions Comparison standards or catalogues (e.g., photos/replica) Size--based criteria (measures) Mixtures of the above Evaluation techniques Visual—tactile recognition Grading by comparison with a standard Measurement Reporting and documentation Technique reports Data reports Image reports (sketches, hard---copy photo, or digital photo) Completion of testing confirmed with a checklist, SOP-Standard Operating Procedure Codes, Standards, and Specifications \VTas an engineering task \VTasa technician task US standards (e.g., ASME BPVC Sections, AWS D1.1), US Specification (e.g., API Monogram and SCM-Supply Chain Management) European standards (based on PED EN 10204-3.1 and EN 10204-3.1) ISO standards Employer-~-specific Topics Applications and techniques Specifications Lighting Techniques Materials tested Special evaluation criteria Safety rules Gavade Institute of Nondestructive Testing & Training (GINDT) Page 6 of 11Vist tical Testin; Sector Specific and Use of other NDT Methods Sector Testing Methods eddy current, quid penetrant, magnetic particle, radiographic and ultrasonic Aerospace testing of aerorpace mater, components and stucures. Castings radiographic and ultrasonic testing of light and dense metal castings Wiens radiographic, ultrasonic (including time-of fight difraction techniques) and electromagnetic testing of ight and dense metal welds. Wrought Products eddy current and ultrasonic testing of wrought products. (forged, rolled, ring rolled, extruded,etc...) General Products ultrasonic thickness measurement, quid penetrant testing, magnetic particle testing and visual testing of general engineering products (multi-sector, including castings, welds and wrought products), and radiation safety certification. Railways Tiquid penetrant testing, magnetic particle testing and ultrasonic testing of rail and ultrasonic testing of railway axles; liquid penetrant and magnetic particle testing of general railway products (multi-sector, including castings and wrought products). Tubes & Pipes Tiquid penetrant testing, magnetic particle testing eddy current testing and ultrasonic testing of tubes and pipes [including fiat products for tube fabrication) for pressure purposes. Oil and Gas ultrasonic thickness measurement, liquid penetrant testing, magnetic particle testing and visual testing of general engineering products (multi-sector, including castings, welds and wrought products), and radiation safety certification. Energy-Thermal Power ultrasonic thickness measurement, liquid penetrant testing, magnetic particle testing and visual testing of general engineering products (multi-sector, including castings, welds and wrought products), and radiation safety certification. Energy-Nuclear Power ultrasonic thickness measurement, liquid penetrant testing, magnetic particle testing and visual testing of general engineering products (multi-sector, including castings, welds and wrought products), and radiation safety certification. Energy-Hydrogen ultrasonic thickness measurement, liquid penetrant testing, magnetic particle | testing and visual testing of general engineering products (mult-sector, including castings, welds and wrought products), and radiation safety certification. Gavade Institute of Nondestructive Testing & Tr ing (GINDT) Page 7 of 11VT - Visual and Optical Testing ‘Stud, Nut, Bolts as per Metric Thread and other Thread Practice Internal Thread E Dyax D2 Durw Dmx D2 Draw AXIS OF SCREW THREAD ISO Metric Thread The ISO metric screw threads are the worldwide most commonly used type of general-purpose screw thread. They were one of the first international standards agreed upon when the International Organization for ‘Standardization (ISO) was set up in 1947. ‘The design principles of ISO general-purpose metric screw threads ("M'" series threads) are defined in international standard ISO 68-1. Each thread is characterized by its major diameter and its pitch. ISO metric threads consist of symmetric V-shaped thread. In the plane of the thread axis, the flanks of the V have an angle of 60° to each other. 180 Metric Thread Preferred Size Superfine pitch metric threads are occasionally used in automotive components, such as suspension struts, and are commonly used in the aviation manufacturing industry. This is because extra fine threads are more resistant to coming loose from vibrations. Thread Count (TP!) PI stands for Threads Per Inch, which means the total number of threads per inch measured along the length of a fastener. TPIis used only with American fasteners. Metric Fasteners use a thread Pitch. In general, smaller fasteners have finer threads, so the thread count is higher. Gavade Institute of Nondestructive Testing & Training (GINDT) Page 8 of 11VT - Visual and Optical Testing Thread Pitch Metric fasteners are specified with a thread pitch, instead of a thread count. The thread pitch is the distance between threads expressed in millimeters. In general, smaller fasteners have finer threads, so they have a lower thread pitch. SoMevic External Thread Thread Major Diameter Pitch Diameter Minor Diameter ‘Size xPitch | Maximum [Minimum [Maximum [Minimum [Maximum [Minimum Gavade Institute of Nondestructive Testing & Tr Page 9 of 11VT - Visual and Optical Testing Supply Chain Management (SCM) related products supporting and affecting the quality of Final products. ‘API 20 Series ~ Supply Chain Management (SCM) + Specification 20A: Castings for use in the Petroleum and Natural Gas Industry. + Specification 208: Open Die Forgings for use in the Petroleum and Natural Gas Industry. + Specification 20C: Closed Die Forgings for use in the Petroleum and Natural Gas Industry. + Specification 200: Qualification of Nondestructive Testing Operations for use in the Petroleum and Natural Gas Industry. + Specification 20€: Specification for Low Alloy Steel Bolting for Pressure Containing Gas Equipment. + Specification 20F: Specification for CRA Steel Bolting for Pressure Containing Gas Equipment. + Specification 206: Welding services used in the Petroleum and Natural Gas Industry. + Specification 20H: Hest treat services used in the Petroleum and Natural Gas Industry. + Specification 201: Quality requirements for Distributors of Raw materials for use in the Petroleum and Natural Gas Industry. Gavade Institute of Nondestructive Testing & Training (GINDT) Page 10 of 11,VT ual and Optical Testing API Specification 6D 25" Edition: 01-Novernber-2021 Annexure-| (Normative) Quality Specification Level (QSL) and Supplemental Testing Table-I.2—Extent, Method, and Acceptance ria of NDE/Item Examination Code NOTE See Table 1.1 for application of the examinations referred to in this table. Sam Bent iethod crear via | 1003 sessile as Cstsuraces ae a (Castings) van | 200K accessble as Forged sracee ae ae (Forgings) 005 acessie ae Welded vrs eae 153201780178 | 153.20r780r79 ma w0% acewile surface”) Petmanufactrer” | Permandactrer requirements requirements 100% acesibie machined vis Surfaces (Machining) aaa eae ~ASIIE, BPVCSeeton-V NDE Edon:202, Article 9 Visual Examination PguidPenetant Testing by Visual Examination Sam Beant Wiethod fecepance ASME BPVC, | ASME BPC Section ma Al ccessibe surfaces Seeéon, NDE | Vil, Division 3, Article 6 Appendix 8 TSMEBPVC, | ASME BPVC, Seton PT-2 All accessible surfaces Section V, NDE Vill, Division 1, Article 6 Appendix 7_ ‘No relevant rounded or asucsove, | ttt ines ms Al sealing surfaces secion, noe | indcations Article 7 a sealing surfaces shall be permitted * For PT-3 on machined surface: *A relevant indication is defined as a surface NDE indication with major dimensions greater than 1/16 in. (1.6 mm). An indication not associated with a surface rupture Is not considered to be a relevant indication Gavade Institute of Nondestructive Testing & Training (GINDT) Page 11 of 11