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NEWSLETTER |
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A quarterly publication of |
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Scientific and Engineering Services Dte., Pakistan Atomic Energy Commission |
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Issue No 28 April-June,2002 |
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Right since inception of NDT Newsletter (1995) the work of hunting for news items, giving them shape, getting these typed, their reading, correcting errors, getting the text improved, composing on computer, putting up for approval, sending for printing, proof reading, distribution of copies, updating of the mailing lists and replying to the queries of the readers, etc. was all being done by the editor or, in other words, it was broadly speaking a one-man show. Detecting the drawbacks the General Manager, Scientific & Engineering Services Directorate (SES) suggested to constitute an editorial board. Director, National Centre for Non-destructive Testing (NCNDT) proposed this constitution from within NCNDT foreseeing communication difficulties between members of the editorial board if they are selected from different organizations of the national NDT community located at different cities.
Defect-free products just do not exist. In evaluating materials it is important to distinguish between a discontinuity and a defect. Some discontinuities are not serious because they mayor may not impair the material's function. On the other hand if the stress concentration is high, or the material's fracture toughness is poor, even a very small discontinuity can be serious. When a discontinuity is detrimental to a particular material, it is termed as defect. In fact a defect typically depends on the material and its properties, the loads placed on the structure, the distribution of stresses within the material and the size, location and type of discontinuity. Different types of discontinuities are generated in various manufacturing processes. For instance; cast parts might have inclusions, cracks, porosity, voids due to shrinkage as the metal cools and other types of casting discontinuities. Most welded parts can have many of the same types of discontinuities such as incomplete penetration, burn-throughs or melt-throughs and others common to welds. Discontinuities are usually not considered defects until they reach a certain size although some types, at any size, may not be permitted in a structure. A material containing a discontinuity that is not allowed by the applicable standard or code is said to be defective but in actual fact may or may not be defective. This is because all standards and codes include safety factors. A discontinuity barely exceeding the size that is allowed will probably not be immediately detrimental to the function of the structure unless for some reason another design consideration is compromised. However, such discontinuities often become worst. For example, a crack can grow through a process called fatigue and reach a critical size after which it will propagate very quickly. Or, other problems may be present such as corrosion or erosion. These conditions reduce the amount of material available to carry the forces and increase the stress concentration as well as continue to propagate discontinuities. Fracture mechanics is the field that evaluates whether a particular discontinuity may be detrimental to a structure based upon expected growth of the flaw, material properties and stresses in the material.
Contributed by: Mr. Abdul Hameed Akbar
On 6th Dec., 200 I NCNDT/SES entered into a contract for the In-Service Inspection (ISI) of Conventional Island of CHASHMA Nuclear Power Plant (CNPP).In order to familiarize the NCNDT experts about the various systems/ equipment of CNPP and ISI/QA personnel of CNPP on various NDT techniques available in NCNDT and to provide guidelines regarding preparation of QA/NDT documentation, etc. a workshop was organized at NCNDT, Islamabad from 0 I to 05 April, 1002. G. M. CHASNUPP inaugurated the workshop G. M. SES, Director NCNDT and representatives of the participants viz. Mr. A H Akbar and Mr. Zohair Haider Rizvi spoke on the occasion. The proceedings of the workshop included lectures, QA documentation and visit of NCNDT laboratories. Mr Javed Iqleem, Member Power; PAEC posing with the participants of workshop on preparation of QA/NDT documentation for ISI of Conventional Island of CHASNUPP on 5th April, 2002. As a result of the workshop various recommendations and suggestions were arrived at regarding establishment of separate Q.A. unit at NCNDT, establishment of comprehensive calibration programme and development of generalized administrative procedures, etc. including visits of both the parties to each other's sites. It was also suggested that SES library should strive to procure certain essential codes and standards recommended by CHASNUPP. The closing ceremony was held on 5th April, 2002 at NCNDT and Mr. Javed Iqleem, Member (Power), PAEC was the Chief Guest. He appreciated the effort of holding the workshop.
In the previous issue we announced that NCNDT intends to arrange regular seminars at its premises on topics related to NDT throughout the year 2002. In this context following three seminars were held:
The gist of the above seminars is reproduced below for the benefit of those readers who could not attend.
(About the speaker: Mr. M. Arif Iftikhar Senior Engineer; NCNDT did his Bachelor of Engineering from the University of the Punjab, Lahore in 1984. After his graduation he joined Pakistan Steel Mills, Karachi and served there.for 4 years. Then he joined Faculty of Engineering and Technology, University of the Punjab, Lahore as Research Scholar: While there he also completed his Masters in Metallurgical Engineering and Materials Science. In 1990 MJ: M Arif Iftikhar joined Pakistan Atomic Energy Commission where he actively particlipate ! in the development/ implementation of Q.A.system .for nuclear power plants. He was involved during the development of overall Quality Assurance Programme for the design and construction of Chasma Nuclear Power Plant (CHASNUPP). He also participated in the development of Quality Assurance Programme .for the operation of Nuclear Power Plant in China and at CHASNUPP Site. After the successful start-up of CHASNUPP; Mr. M. Arif Iftikhar was transferred to NCNDT in January 2000. Based Upon his experience Mr. Arif Iftikhar is now assigned to assist in writing Q. A. Manual of the NCNDT.f'or the first ISI of Conventional Island of CHASNUPP) Purpose This lecture intends to provide the guidelines on the development i.e. preparation, review and approval of Q.A. Manual for In-Service Inspection (ISI) activities to be conducted by NCNDT for Conventional Island of CHASNUPP unit-I. The contents of this are also, in principle, applicable to all other units or technical departments of any organization having specific responsibility for performing Q.A. tasks. Scope To outline the steps to be taken for the development of Q.A. manual for In-service Inspection (ISI) of Conventional Island (CI) CHASNUPP unit-I. General The quality assurance manual describes an overview of the quality management system operated in an organization to assure that the quality of the products and equipment of that organization are in accordance with the customer's requirements. Q.A. Manual should be prepared to meet the contractual requirements and/or the requirements of Q..A. Standards on which this system is based. It provides guidance for documenting the plans and actions that intend to ensure achievement of the appropriate quality through each task i.e. design, fabrication, etc. The description of the QA Manual is applied to all activities affecting quality during manufacturing right from acceptance of order upto delivery of the final tested product including preparation of pertinent quality documentation. The Q.A. Manual provides the framework for detailed operating procedures applicable to main functional areas. For this purpose the Quality System established in any organization provides a disciplined approach to all activities affecting quality. A series of quality related documents are prepared to ensure that final product conforms to the customer's need and expectations. His remaining lecture was spread over the following main headings:
(About the speaker: ,Sqn. Ld,: Kamran Ahmad, Deputy Chief Engineer (QAC),Pakistan Aeronatical Complex, (PAG) graduated in the year 1990 from College qf Aeronautical Engineering, Risalpurspecializing in Aerospace. Since then he has been handling first, second and fourth line maintenance on different aircrafts.He has been associated with NDT applications on a variety of aircra,fts and engines for the past 11 years. He is also incharge of NDT Cell.) Scope of NDT is expanding in all industries at a rapid pace. Technological developments in all NDT techniques are making coverage of all ranges of materials, shapes and configurations. Aviation industry utilizes almost all industrial technologies during manufacturing of the aircraft for which effective NDT coverage is essential. Introduction of pro-active maintenance concept on aircraft has enhanced the application of NDT techniques manifold. Ensuring safety for the traveling public is an increasingly difficult task in an atmosphere of deregulation, budget cuts, and cost competitiveness. Few new aircrafts are being bought and therefore those already in service are expected to be used as long as possible. Because of this emphasis on increased service life, testing and inspection of aircraft components and structures has become increasingly critical to ensure flight safety and retain the confidence of passengers and aviation operators. In this scenario NDT is the most effective and economical tool. Rapid and accurate repair of material flaws due to stress, fatigue and corrosion is a key to aircraft component maintenance. Aircraft systems represent the potential for enormous economic loss due to structural failures as well as possible impacts to the public safety. Similarly, structural integrity of airframes is a critical safety factor within military and civilian aviation communities especially with the increasing age of the airframes in use. This is especially important when airframes have already been repaired because of structural cracking. To address this problem a number of non-destructive techniques are in use to detect the existence of defects in the aircraft. Expensive non-destructive testing equipment is useless without proper training. Yet training requirements are nebulous at best. Trained and competent NOT personnel are in demand today more than ever before. Increasingly aerospace manufactures and suppliers realize the need for high-quality products and improved personnel proficiency. The need for highly qualified personnel with appropriate certifications will continue as long as new materials are being developed and the quest to achieve higher quality standards exists. Part of training technicians is making sure that they actually understand how the equipment works so that they know its strengths and weaknesses. In USA questions have been raised by federal aviation administration (FAA) inspectors as to how to determine whether qualified personnel are performing non-destructive testing. Currently, there is no national policy to determine if personnel performing NDT are qualified. There are several current national and international standards acceptable to the FAA that may be used to assure that only qualified personnel perform. ISO 9712 is one of them. In Pakistan thanks to NCNDT who through its untiring and remarkable efforts provides us an institution whose qualifying standards are beyond doubt and are accepted in all industries with full confidence. Persons qualified from this institution handle all NDT in industry. All PAC facilities are ISO 9002 certified. NDT facilities of PAC are also in a process of civil aviation authority certification. Most of us must be knowing that PAC has become an autonomous body with the creation of PAC Board through a presidential order in year 2001. This was intended to let the civil sector come and explore the tremendous capabilities and facilities and state-of-art equipment available at PAC so that maximum benefit can be taken of this industry.
About the speaker: Mr. Kwang -Sic roan is working as ISI Manager at Korean # Advanced Inspection Technology (KAITECH) Company in Korea. He has " 19 years experience of PSI/ISI as Project Engineer and a Manager: He is aso an Expert and Instructor in Ultrasonic Testing and a Specialist in Ultrasonic Transducers Design and Manufacuring.) Mr. Kwang -Sic Yoon in his lecture touched the following topics:
Those of our readers who wish to participate in this series of Seminars are requested to send their resume and outline of lectures to Mr. Zaheer Ahmed, Principal Engineer, Convenor Seminar Organizing Committee, NCNDT; P.O. Box 1781, Islamabad
During the reported period following three training courses were conducted by NCNDT: I. Level-I Radiographic Testing Course (NDT-129),3-25 April. 2002 There were 14 participants out of which 5 were nominees of different PAEC Establishments. Ten participants were declared successful. Mr. Shahbaz Waris Bhatti of PFL stood First by obtaining 94% marks in the aggregate. Certificate distribution function was held over lunch on 25th April and Major (Retired) Masood K. Ahmad, Senior Principal Administrator, SES Directorate was the Chief Guest. Major (Retired) Masood K. Ahmad, Senior Principal Administrator; SES awarding certificates to the participants of RT-1 (NDT-129) course on 25'" April, 2002. 2. Level-l Eddy Current Testin&Course (NDT-131), 6-23rd May. 2002 The number of course participants were 9. Four were from different PAEC Establishments. Out of these participants, 7 were declared successful. Mr. Yasir Qadeer from NCNDT stood First by securing 90% marks in the aggregate. Mr. Munim Awais, Director International Affairs & Training, PAEC presided over the certificate distribution ceremony. 3. Level-l Radiographic Testing Course(NDT-133), 7-30th May. 2002 It was a repeat course arranged specially to accommodate additional nominations received against the previous RT-l (NDT -129) course offered in April. Out of l8 participants, 13 belonged to outside industries while 5 were from different PAEC Establishments. A total of 10 participants were declared successful. Mr. Anees-ur-Rehman. from an outside industry stood First by obtaining 91 % marks in the aggregate. Mr. Saeed Ahmed, G.M. (SES) was the Chief Guest on the concluding ceremony of the course on 30110 May. 2002 and awarded the certificates.
During the remaining part of the year, NCNDT plans to conduct the following activities related to its training and certification programme:
TRAINING AND CERTIFICATES SCHEDULE
Re-certification & Re-examination was conducted for II participants belonging to organizations such as Mis. CIA, JIACCO& NESPAK, etc. Six candidates appeared for re-certification, while five appeared for re-examination purpose in the NDT methods like Radiographic Testing and Surface Methods (Liquid penetrant) and magnetic particle testing.
During the reported quarter NCNDT provided the following services to the national industry in addition to carrying out its internal programme:
Repair of Gamma Ray Projector
The source was shifted to NCNDT for its repair. A proper procedure for the transportation of such types of sources was followed. The source had to be first transferred on temporary basis to a well shielded col1tailler. The wall thickness of this container of lead was calculated and designing & fabrication of the contail1er was done. The source was then transferred to its original shielded contail1er and successful demonstration of the proper functionil1g of the Gamma ray source was given. NCNDT can undertake repair & maintenance of some of the NDT equipment. The NDT Community may therefore refer their prblems to NCNDT for advice.
Following international events in the shape of Conference/Symposium/Exhibition, etc. related to NDT are falling in near future:
Dr. M. AsifKhan, Senior Principal Engineer (Mechanical) paid an official two-week visit to Malaysian Institute for NuclearTechnology Research (MINT). It was arranged under IAEA technical co- operation programme (2002). The topic of studies for his visit was "In-service Inspection (ISI) of industrial plants."
Dr. M. Asif Khan
During the period April to June 2002 following personnel visited NCNDT:
A six members team of PAEC officers (NCNDT / CHASNUPP) visited Wapda Central Gas Turbine Maintenance Workshop, Faisalabad in April 2002. The objective of this visit was to acquire know-how about turbine repair & maintenance. This is a part of planning for ISI activity of CHASNUPP be performed by NCNDT in future. A three members team comprising of Mr. Jamaluddin, Head UTD; Mr. Shabbir Ahmed, Head SMD and Mr. Mukhtar Ali, PT -I visited PIA, Karachi from 17-20 June to finalize details for organizing the special Level-2 Course on Surface Methods for PIA personnel at their premises in Karachi.
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