1. NON DESTRUCTIVE TESTING (MEMB453) Mini Project – NDT Visit To Nuclear Malaysia Group 1

2. Company Overview  From idea of the the Malaysia’s Deputy Prime Minister, Tun Dr. Ismail Dato’ Abdul Rahman  Play a role in the development of nuclear science and technology for peaceful purposes  Focusing on manpower development for a nuclear power programmed to provide an option for energy source

3. Objective 1. Creating a new product and technology based on research and innovation through the national development agenda 2. To achieve a minimum income from 30% of annual operating budget through technology transfer and commercialization 3. Improving organizational excellence through quality planning and management Vision Nuclear science and technology for generation of knowledge, prosperity and welfare society and country Mission Excellence research and nuclear technology for sustainable development

4. 2.0 PRODUCT MANUFACTURED Sterilization of Medical Products Non-Destructive Evaluation Plant Assessment Technology Compaction Control For Civil Work Radiation Vulcanization of Natural Rubber Latex Research & Lab Accessories Scientific Apparatus Glass-Blowing Training Center Nuclear Health & Safety Analytical Chemistry Laboratory Agro technology & Biosciences Waste Technology Development Center(WasTeC) Radiochemistry and Environment Lab Polymer Lab Isotope Ratio Mass Spectrometer (IRMS) Laboratory

5. NON DESTRUCTIVE TESTING DIGITAL INDUSTRIAL RADIOGRAPHY - dedicated electronic system that enables X-ray images of products under examination to be generated and displayed on a Radiography Image display monitor ULTRASONIC SENSOR - transmits ultrasonic waves into the matter under investigation and it also receives the reflected waves.

6. LOW COST EDDY CURRRENT SENSOR - circular electric current induced within conductors by a changing magnetic field in the conductor, due to Faraday's law of induction. GAMMA IRRADIATION - Physical means of sterilisation or decontamination where products are exposed to gamma rays.

7. 3.0 NDT METHOD USED IN NUCLEAR MALAYSIA The methods being used are: Liquid penetrant inspection Magnetic particle inspection Ultrasonic testing Radiographic testing Eddy current The methods being used are: Liquid penetrant inspection Magnetic particle inspection Ultrasonic testing Radiographic testing Eddy current

8. Liquid Penetrant Inspection Used to detect discontinuities (cracks, seams, laps, cold shuts, laminations, and porosity) that are open to the surface. Pre- CleaningDye PenetrantRemoving Excess DyeDeveloperPost- Cleaning

9. Magnetic Particle Inspection Process for detecting surface and slightly subsurface discontinuities in ferromagnetic materials Also can detect both production discontinuities (seams, laps, grinding cracks and quenching cracks) and in- service damage (fatigue and overload cracks). Ultrasonic Testing Ultrasonic inspection techniques utilise as the indicating parameter some particular characteristics of propagating stress wave in the range greater than 20kHz and usually in the form of pulses of energy.

10. Radiographic Testing Useful for the detection of internal flaws in many different materials and configurations especially used for quality assurance of castings, forgings and welds. Eddy Current Well suited for detecting surface cracks but can also be used to make electrical conductivity and coating thickness measurements

11. Nuclear Malaysia’s NDT Technology Center Nuclear Malaysia’s National NDT Technology Center holds 15 years of experience in identifying appropriate NDT methods and establishing procedures to solve inspection problems in industries. The center focuses on the following departments; i.Research & Development ii.Services and Consultancy iii.Specialized NDT Services.

12. 4.0 PROCEDURE USED IN NUCLEAR 1.Liquid penetrant testing 2.Magnetic particle testing 3.Ultrasonic testing 4.Radiographic testing 5.Eddy current testing

13. Liquid penetrant inspection a)Pre-cleaning b)Application of Penetrant c)Excess Penetrant Removal d)Application of Developer e)Inspection f)Post Cleaning

14. Magnetic particle inspection Basic steps involved: Component pre-cleaning. Introduction of magnetic field. The required magnetic field can be introduced into a component in a number of different ways: 1. Using a permanent magnet or an electromagnet that contacts the test piece 2.Flowing an electrical current through the specimen 3.Flowing an electrical current through a coil of wire around the part or through a central conductor running near the part. Application of magnetic media:  dry method (more portable).  wet method (more sensitive). Interpretation of magnetic particle indications.

15. 1.An ultrasonic transducer is located in contact or in close proximity to the test object. 2.The transducer is energized in a pulsed mode. 3.Acoustic energy is transmitted, reflected and scattered within the test object. 4.Energy within the test object is transmitted or redirected by internal interfaces. 5.Transmitted or redirected energy from the test object is detected. 6.The transmitted or redirected energy is analyzed in the time and/or frequency domains, and interpretation of the internal condition of the test object is made by the pattern and amplitude features. Ultrasonic testing:

16. 5.0 REASONS FOR CHOOSING NDT METHODS Malaysian Nuclear Agency utilizes Penetrant Testing (PT) to locate cracks, porosity, and other defects. Liquid penetrant testing is used to inspect large areas very efficiently and will work on most nonporous materials Magnetic Particle Testing (MT) is also used to inspect ferromagnetic materials (that can be magnetized) for defects that result in a transition in the magnetic permeability of a material. To detect both surface and subsurface defect, Ultrasonic Testing (UT) utilizes sound waves that is more effective in detecting both defects in many materials including metals, plastics, and wood. Eddy Current Testing (ET) used to detect surface and near-surface flaws in conductive materials, such as the metals. Last but not least, Radiographic Testing (RT) used to inspect almost any material for surface and subsurface defects.

17. 6.0 NDT INTERNATIONAL STANDARDS ADOPTED Malaysia’s Nuclear Agency Inspection body currently operating a management system in compliance with the latest version of MS ISO 9001 and MS ISO/IEC 17025. There are several standards that are being taken as a requirement by the Malaysian Nuclear Agency. From our industrial visit, we understood that every testing/inspection have separate standards which being used by the company in order to ensure the quality of the product remains in excellent conditions.

18. 1)Liquid Penetrant Testing (PT) ASTM E165 This practice covers procedures for visible penetrant examination utilizing the solvent-removable process. It is a non-destructive testing method for detecting discontinuities that are open to the surface, and is applicable to in- process, final, and maintenance examination. 2) Magnetic Particle Testing (MT) BS EN ISO 9934-1:2001 This European Standard specifies the significant properties of magnetic particle testing products and the methods for checking their properties. ASTM E709-01 This guide describes techniques for both dry and wet magnetic particle examination, a non-destructive method for detecting cracks and other discontinuities at or near the surface in ferromagnetic materials.

19. 3) Ultrasonic Testing (UT) ISO 10543 Specifies requirements for full peripheral ultrasonic testing is intended to detect, over a zone at the ends of plain end and bevelled end tubes. It’s applicable to the inspection of tubes with an outside diameter greater than 30 mm. No lower limit of thickness is specified. ASTM E164 This practice covers techniques for the ultrasonic A-scan examination of specific weld configurations joining wrought ferrous or aluminium alloy materials to detect weld discontinuities. BSEN 10160 This standard describes a method for the ultrasonic testing of uncoated flat steel product for internal discontinuities. It is applicable to flat product in nominal thicknesses range of 6 mm to 200 mm.

20. 4) Radiographic Testing (RT) ASTM E1030 This test method provides a uniform procedure for radiographic examination of metallic castings using radiographic film as the recording medium. The radiographic method is highly sensitive to volumetric discontinuities that displace a detectable volume of cast material. 5) Eddy Current Testing (ET) ISO 17643 Defines eddy current testing techniques for detection of surface breaking and near surface planar discontinuities, mainly in ferrite materials (weld material, heat- affected zones, parent materials). ASTM E566 The procedure relates to instruments using absolute or comparator-type coils for distinguishing variations in mass, shape, conductivity, permeability, and other variables such as hardness that affect the electrical or magnetic properties of the material.

21. Radiographic testing 1.X-rays are produced by establishing a very high voltage between two electrodes, called the anode and cathode. 2.To prevent arcing, the anode and cathode are located inside a vacuum tube, which is protected by a metal housing. 3.The cathode contains a small filament much the same as in a light bulb. 4.Current is passed through the filament which heats it. The heat causes electrons to be stripped off. 5.The high voltage causes these “free” electrons to be pulled toward a target material located in the anode. 6.The electrons impact against the target. This impact causes an energy exchange which causes x-rays to be created.

22. 7.0 SERVICE OR MAINTENANCE IMPROVEMENT BY THE APPLICATIONS NDT NDT has been used widely in industrial sectors such as petroleum, petrochemical, ship construction, aircraft, railway, power station, gas pipeline etc. Materials used in these industries are mostly made from steel and aluminum which involved processes such as welding, casting, forging or machining during construction. The quality of the product was checked and evaluated by NDT methods.

23. Nuclear Malaysia’s national NDT technology center has a very good experience in identifying appropriate NDT methods and establishing procedures to solve inspection problems in the industries. The center offers possible solutions to a range of NDT needs, including: 1. Research and Development 2. Services and Consultancy 3. Specialized NDT Services

24. 8.0 Alternative NDT Methods

25. Electromagnetic acoustic transducers (EMATs) EMAT is generally used to assess the condition of manufactured objects and the technology is particularly effective for detection of stress corrosion cracking and disbanded coating. The EMAT generates an ultrasonic pulse within a metallic and/or ferromagnetic test object. The sound waves are generated in the material and thus no couplant is needed. Consisting of a magnet and an electrical coil, the EMAT uses electro- magnetic forces to introduce sound energy into the test object through a combination of Lorentz Force and Magnetostriction.

26. Computerized radiography Computed radiography (CR) uses very similar equipment to conventional radiography except that in place of a film to create the image, an imaging plate (IP) made of photo stimulable phosphor is used. The imaging plate is housed in a special cassette and placed under the body part or object to be examined and the x-ray exposure is made. Hence, instead of taking an exposed film into a darkroom for developing in chemical tanks or an automatic film processor, the imaging plate is run through a special laser scanner, or CR reader, that reads and digitizes the image. The digital image can then be viewed and enhanced using software that has functions very similar to other conventional digital image-processing software, such as contrast, brightness, filtration and zoom.

27. 9.0 EFFECT OF NDT PROCESS AND MATERIALS USED ON ENVIRONMENT – Magnetic particle inspection – Liquid penetrant inspection – Radiographic testing

28. Radiographic testing First of all, the health risks associated with the radiation is considered to be one the major disadvantages of radiography. The amount of risk depends on the body parts exposed, the amount of radiation dose received, and the time over which the dose is received. The fact that X-ray and gamma-ray radiation are not detectable by the human senses complicates matters further. However, the risks can be minimised and controlled when the radiation is handled and managed properly in accordance to the radiation safety rules.

29. Magnetic particle inspection Environment must be protected just as care must be taken to ensure that operators and other people working nearby are not exposed to hazards in the application of magnetic particle inspection. During the formulation of materials for magnetic particle inspection care is taken to use as raw materials chemicals which can be managed in manufacture, use and disposal in such a way as to cause minimal impact on the environment.

30. Liquid penetrant inspection Liquid Penetrant Testing, the application of a colored detects surface breaking defects on nonporous materials. Liquid penetrant testing is a low-cost, easy-to-use technique that can be conducted on all non-porous materials, including glass, ceramics, and non-magnetic materials. It cannot be used on hot assemblies. Besides that, penetrants are classified by sensitivity levels. Visible penetrants are typically red in color, and represent the lowest sensitivity.

31. 10.0 MATERIALS RELATED TO THE NDT RECYCLEABLE Nuclear Malaysia is a government organization with an R&D function, established with the onus of introducing and promoting the use of nuclear science and technology in national development. NDT plays a vital role in manufacturing, quality control and plant life management. It is used in a wide range of industries including manufacturing, petrochemical, power generation, transport and civil engineering. Nuclear Malaysia’s research and technology development activities cover 6 main areas, namely industrial technology, radiation processing technology, medical technology, agro technology and biosciences. One of the services provided is radioactive waste management, which started its operation since 1984. The Waste Technology Development Centre (WasTeC- Nuclear Malaysia) is the only Center in Malaysia currently given the responsibility to manage radioactive waste throughout the nation. WasTeC-Nuclear Malaysia is equipped with professional and skilled manpower as well as necessary facilities to perform tasks as mandated to it

32. 11.0 CONCLUSION As conclusion, we found that the visit to Malaysian Nuclear Agency have stimulated and reinforced a positive attitude towards the theory of non-destructive testing which have been learnt during lecture. Besides that, we are exposed to non-destructive testing procedure and also observe how the testing is carried out during the visit. As a result, these provide great opportunities to extend our learning and to enrich our understanding about the equipment used in testing.