52 Training G Training uidelines in N on-destructive Testing Techniques: Leak Testing at Level 2 Level at Testing Leak Techniques: Testing on-destructive Training Guidelines in Non-destructive Testing Techniques: Leak Testing at Level 2 TRAINING COURSE TRAINING S ERIES ISSN 1018–5518 VIENNA, 2012 TRAINING COURSE S ERIES 52 Training Guidelines in Non-destructive Testing Techniques: Leak Testing at Level 2 The following States are Members of the International Atomic Energy Agency: AFGHANISTAN GHANA NIGERIA ALBANIA GREECE NORWAY ALGERIA GUATEMALA OMAN ANGOLA HAITI PAKISTAN ARGENTINA HOLY SEE PALAU ARMENIA HONDURAS PANAMA AUSTRALIA HUNGARY PARAGUAY ICELAND AUSTRIA PERU AZERBAIJAN INDIA PHILIPPINES BAHRAIN INDONESIA POLAND BANGLADESH IRAN, ISLAMIC REPUBLIC OF PORTUGAL BELARUS IRAQ QATAR BELGIUM IRELAND REPUBLIC OF MOLDOVA BELIZE ISRAEL BENIN ITALY ROMANIA BOLIVIA JAMAICA RUSSIAN FEDERATION BOSNIA AND HERZEGOVINA JAPAN SAUDI ARABIA BOTSWANA JORDAN SENEGAL BRAZIL KAZAKHSTAN SERBIA BULGARIA KENYA SEYCHELLES BURKINA FASO KOREA, REPUBLIC OF SIERRA LEONE BURUNDI KUWAIT SINGAPORE CAMBODIA KYRGYZSTAN SLOVAKIA CAMEROON LAO PEOPLES DEMOCRATIC SLOVENIA REPUBLIC CANADA SOUTH AFRICA LATVIA CENTRAL AFRICAN SPAIN REPUBLIC LEBANON SRI LANKA CHAD LESOTHO SUDAN CHILE LIBERIA SWEDEN CHINA LIBYA SWITZERLAND COLOMBIA LIECHTENSTEIN SYRIAN ARAB REPUBLIC CONGO LITHUANIA COSTA RICA LUXEMBOURG TAJIKISTAN CÔTE DIVOIRE MADAGASCAR THAILAND CROATIA MALAWI THE FORMER YUGOSLAV REPUBLIC OF MACEDONIA CUBA MALAYSIA CYPRUS MALI TUNISIA CZECH REPUBLIC MALTA TURKEY DEMOCRATIC REPUBLIC MARSHALL ISLANDS UGANDA OF THE CONGO MAURITANIA UKRAINE DENMARK MAURITIUS UNITED ARAB EMIRATES DOMINICA MEXICO UNITED KINGDOM OF DOMINICAN REPUBLIC MONACO GREAT BRITAIN AND ECUADOR MONGOLIA NORTHERN IRELAND EGYPT MONTENEGRO UNITED REPUBLIC OF TANZANIA EL SALVADOR MOROCCO ERITREA MOZAMBIQUE UNITED STATES OF AMERICA ESTONIA MYANMAR URUGUAY ETHIOPIA NAMIBIA UZBEKISTAN FINLAND NEPAL VENEZUELA FRANCE NETHERLANDS VIETNAM GABON NEW ZEALAND YEMEN GEORGIA NICARAGUA ZAMBIA GERMANY NIGER ZIMBABWE The Agency’s Statute was approved on 23 October 1956 by the Conference on the Statute of the IAEA held at United Nations Headquarters, New York; it entered into force on 29 July 1957. The Headquarters of the Agency are situated in Vienna. Its principal objective is “to accelerate and enlarge the contribution of atomic energy to peace, health and prosperity throughout the world’’. IAEA TRAINING COURSE SERIES NO. 52 TRAINING GUIDELINES IN NON-DESTRUCTIVE TESTING TECHNIQUES: LEAK TESTING AT LEVEL 2 INTERNATIONAL ATOMIC ENERGY AGENCY VIENNA, 2012 COPYRIGHT NOTICE All IAEA scientifi c and technical publications are protected by the terms of the Universal Copyright Convention as adopted in 1952 (Berne) and as revised in 1972 (Paris). Th e copyright has since been extended by the World Intellectual Property Organization (Geneva) to include electronic and virtual intellectual property. Permission to use whole or parts of texts contained in IAEA publications in printed or electronic form must be obtained and is usually subject to royalty agreements. Proposals for non-commercial reproductions and translations are welcomed and considered on a case-by-case basis. Enquiries should be addressed to the IAEA Publishing Section at: Marketing and Sales Unit, Publications Section International Atomic Energy Agency Vienna International Centre PO Box 100 1400 Vienna, Austria fax: +43 1 2600 29302 tel.: +43 1 2600 22417 email: [email protected] http://www.iaea.org/books For further information on this publication, please contact: Industrial Applications and Chemistry Section International Atomic Energy Agency Vienna International Centre 1400 Wien Austria TRAINING GUIDELINES IN NON-DESTRUCTIVE TESTING TECHNIQUES: LEAK TESTING AT LEVEL 2 IAEA, VIENNA, 2012 IAEA/TCS/52 ISSN 1018–5518 © IAEA, 2012 Printed by the IAEA in Austria March 2012 FOREWORD The International Atomic Energy Agency (IAEA) has been active in the promotion of non- destructive testing (NDT) technology for many decades. The prime reason for this interest has been the need for stringent standards for quality assurance for safe operation of nuclear and other industrial installations. The IAEA successfully executed a number of programmes, including technical cooperation projects (national and regional) and coordinated research projects (CRPs), in which NDT was an important part. Through these programmes, a large number of personnel have been trained in Member States, leading to the establishment of national certifying bodies responsible for the training and certification of NDT personnel. Consequently, a state of self-sufficiency in this area of technology has been achieved in many Member States. All along there has been a realization of the need to have well established training guidelines, in order to orient the IAEA experts who were involved in training and certification programmes, and to achieve some level of international uniformity and harmonization of training materials and certification processes, and consequent competence of NDT personnel. The syllabi for training courses were published in the form of IAEA TECDOC publications. The first was IAEA-TECDOC-407 (1987), which contained the syllabi for liquid penetrant testing, magnetic particle testing, eddy current testing, radiographic testing and ultrasonic testing methods. To accommodate progress in NDT technology, revised versions of this TECDOC were published in 1991, 2002 and 2008. The current version (i.e. IAEA-TECDOC- 628/Rev.2 (2008)) includes additional and more advanced NDT methods. That TECDOC, as well as most of the international standards on the subject of training and certification of NDT personnel, including ISO 9712 (2005), defines three levels of competence. Among these, Level 1 is the lowest and Level 3 is the highest. The intermediate Level 2 is considered to be the most appropriate for personnel who, besides other duties, are expected to: independently undertake practical testing in the relevant method of NDT; develop NDT procedures to address various problems; prepare written instructions; make accept/reject decisions in accordance with relevant standards and specifications; organize and report NDT results; and train and supervise Level 1 personnel. The next logical step after finalizing the syllabi was to compile textbooks and training manuals in accordance with the syllabi. Manuals on liquid penetrant testing, magnetic particle testing, radiographic testing, ultrasonic testing and eddy current testing have already been published in the IAEA’s Training Course Series. These play a vital role for training and certification of NDT personnel throughout the world. Compilation of the present book is a continuation of that effort. The first draft was developed with the help of experts from the Canadian Institute for Non-Destructive Evaluation (CINDE). The introduction to basic NDT methods, materials, manufacturing processes and defects, and quality assurance common to all the NDT methods, has been adapted from previous publications in the Training Course Series. The IAEA wishes to express its appreciation to all those who contributed to the production of this publication. The IAEA officers responsible for this publication were Joon-Ha Jin, A.A. Khan and B.P.C. Rao of the Division of Physical and Chemical Sciences. EDITORIAL NOTE The use of particular designations of countries or territories does not imply any judgement by the publisher, the IAEA, as to the legal status of such countries or territories, of their authorities and institutions or of the delimitation of their boundaries. The mention of names of specific companies or products (whether or not indicated as registered) does not imply any intention to infringe proprietary rights, nor should it be construed as an endorsement or recommendation on the part of the IAEA. CONTENTS 1. INTRODUCTION ............................................................................................................ 1 1.1. Basic principles of non-destructive testing (NDT) ............................................. 1 1.1.1. Definition and importance of NDT ......................................................... 1 1.1.2. Types of NDT methods ........................................................................... 1 1.1.3. Comparison of different NDT methods ................................................ 12 1.1.4. New developments in NDT .................................................................. 13 1.1.5. Inspection methodology ........................................................................ 18 1.1.6. Responsibilities of levels of certification .............................................. 19 1.2. Materials and defects - Physical and mechanical properties of materials ........ 20 1.2.1. Metallic materials ................................................................................. 20 1.2.2. Non-metallic materials .......................................................................... 24 1.2.3. Structures of metals and alloys ............................................................. 25 1.2.4. Indications, discontinuities and defects in materials ............................ 31 1.3. Processing and defects ...................................................................................... 32 1.3.1. Casting .................................................................................................. 32 1.3.2. Powder metallurgy processes ...............................................................