Appendix A APPENDIX A. COURSE OUTLINE FOR NDT METHODS
The entire body of knowledge contained in these training outlines for the applicable method shall be covered in the training course. Each method taught shall consist of basic classroom instruction and appropriate practical demonstrations and/or on-the-job training to ensure complete understanding.
1. RADIOGRAPHIC EQUIPMENT OPERATING & EMERGENCY INSTRUCTIONS TRAINING COURSE.
NOTE 1: It is recommended that the trai nee receive instruction in this course prior to performing work in radiography. This part of the training is not regulated by th e Fed eral A viation A dministration (FA A). It mu st comply with the requirements of the Agreement State or NRC License.
NOTE 2: Topics so i ndicated ( *) m ay be del eted i f t he radiography is limited to X-ray exposure devices (non-isotope inspection).
NOTE 3: The t raining hours f or radi ography can be reduced t o 40 hours total, providing the trainee is seeking qualification in non-isotope methods. If the trainee is to be qualified for isotope radiography, the additional 40 hours in isotope theory and practices is recommended.
a. PERSONNEL MONITORING
(1) Wearing of personnel monitoring badges
(2) Reading of pocket dosimeters
(3) Recording of daily dosimeter readings
(4) “Offscale” dosimeter – action required
(5) Permissible personnel exposure limits
b. SURVEY INSTRUMENTS
(1) Types of radiation survey instruments
(2) Reading and interpreting survey instrument meter indications
(3) Calibration frequency
(4) Calibration expiration – action
(5) Battery check – importance
c. LEAK TEST OF SEALED RADIOACTIVE SOURCES * (1) Requirements for leak test * (2) Purpose of leak test * (3) Performance of leak test
d. RADIOGRAPHICAL SURVEY REPORTS
(1) Requirements for completing
(2) Description of report format
e. RADIOGRAPHY WORK PRACTICES
(1) Establishment of restricted areas
(2) Radiation exposure Page 1
Appendix A
(3) Use of time, distance, and shielding to reduce personnel radiation exposure
(4) Applicable regulatory requirements for surveys, posting, and control of radiation and high radiation areas
f. EXPOSURE DEVICES
(1) Daily inspection and maintenance for exposure devices * (2) Radiation exposure limits for gamma ray exposure devices
(3) Labeling of exposure devices
(4) Use of exposure devices
(5) Use of collimators to reduce personnel exposure * (6) Use of “Source Changer” from gamma ray sources
g. STORAGE AND SHIPMENT OF EXPOSURE DEVICES AND SOURCES * (1) Vehicle accidents with radioactive sealed sources * (2) Fire involving sealed sources * (3) “Source Out” – failure to return to safe shielded conditions * (4) Emergency call list
h. STATE AND FEDERAL REGULATIONS
(1) The NRC and agreement states – authority
(2) License reciprocity * (3) Radioactive materials license requirements for industrial radiography
(4) Qualification requirements for radiography personnel
(5) Regulations for control of radiation (State/NRC as applicable) * (6) Department of Transportation regulations for radiography source shipment
(7) Regulatory requirements for X-ray machines (state/federal as applicable)
2. BASIC RADIOGRAPHY PHYSICS TRAINING COURSE
a. INSTRUCTION
(1) History and discovery of radioactive materials
(2) Definition of industrial radiography
(3) Radiation protection – why it is needed
(4) Basic math review, exponents, square roots, etc.
b. FUNDAMENTAL PROPERTIES OF MATTER
(1) Elements and atoms
(2) Molecules and compounds
(3) Atomic particles, properties of protons, electrons, and neutrons
(4) Atomic structure
(5) Atomic number and weight
(6) Isotope versus radioisotope
c. RADIOACTIVE MATERIALS * (1) Production of radioactive materials
(a) Neutron activation
(b) Nuclear fission * (2) Stable v. unstable (radioactive) atoms * (3) Curie – the unit of activity Page 2
Appendix A * (4) Half-life of radioactive materials * (5) Plotting of radioactive decay * (6) Specific activity – curies/grams
d. TYPES OF RADIATION
(1) Particulate radiation properties: alpha, beta, neutron
(2) Electromagnetic radiation: X-ray, gamma ray
(3) X-ray production
(4) Gamma ray production
(5) Gamma ray energy
(6) Energy characteristics of common radioisotope sources
(7) Energy characteristics of X-ray machines
e. INTERACTION OF RADIATION WITH MATTER
(1) Ionization
(2) Radiation interaction with matter
(a) Photoelectric effect
(b) Compton scattering
(c) Pair production
(3) The unit of radiation exposure – the Roentgen
(4) Emissivity of commonly used radiography sources
(5) Emissivity of X-ray exposure devices
(6) Attenuation of electromagnetic radiation – shielding
(7) Half value layers/tenth value layers
(8) Inverse square law
f. BIOLOGICAL EFFECTS OF RADIATION
(1) “Natural” background radiation
(2) The unit of radiation dose – REM
(3) The difference between radiation and contamination
(4) Allowable personnel exposure limits and the banking concept
(5) Theory of allowable dose
(6) Radiation damage – repair concept
(7) Symptoms of radiation injury
(8) Acute radiation exposure and somatic injury
(9) Personnel monitoring for tracking exposure
(10) Organ radiosensitivity
g. RADIATION DETECTION
(1) The pocket dosimeter
(2) The difference between dose and dose rate
(3) Survey instruments
(a) Geiger muller tube
(b) Ionization chambers
(c) Scintillation chambers counters
(4) Film badge – radiation detector
(5) TLD (Thermoluminescent Dosimeters)
(6) Calibration of survey instruments
Appendix A
h. EXPOSURE DEVICES AND RADIATION SOURCES * (1) Radioisotope sources
(a) Sealed source design and fabrication
(b) Gamma ray sources
(c) Beta and bremsstrahlung sources
(d) Neutron sources * (2) Radioisotope exposure device characteristics
(3) Electronic radiation sources – 500 key & less – low energy
(a) Generator – high voltage rectifiers
(b) X-ray tube design and fabrication
(c) X-ray control circuits
(d) Accelerating potential
(e) Target material and configuration
(f) Heat dissipation
(g) Duty cycle
(h) Beam filtration
i. Final written/practical examination
TOTAL TIME (HOURS): 40
3. RADIOGRAPHY TECHNIQUE TRAINING COURSE
a. INTRODUCTION
(1) The process of radiography
(2) Types of electromagnetic radiation sources
(3) The electromagnetic spectrum
(4) Penetrating ability or quality of X-rays * (5) Penetrating ability or quality of gamma rays
(6) Spectrum of X-ray tube source * (7) Spectrum of gamma radioisotope source
(8) X-ray tube – change of ma or kvp effect on quality and intensity
b. BASIC PRINCIPLES OF RADIOGRAPHY
(1) Geometric exposure principles
(a) Shadow formation and distortion
(b) Shadow enlargement calculation
(c) Shadow sharpness
(d) Geometric unsharpness
(e) Finding depth of discontinuity
(2) Radiographic screens
(a) Lead intensifying screens
(b) Fluorescent intensifying screens
(c) Intensifying factors
(d) Importance of screen/film contact
(e) Importance of screen cleanliness and care
(f) Techniques for cleaning screens
(3) Radiographic cassettes
(4) Composition of industrial radiographic film
(5) The “heel effect” with X-ray tubes Page 4
Appendix A
c. THE RADIOGRAPH
(1) Formation of the latent image on film
(2) Inherent unsharpness
(3) Arithmetic of radiograph exposure
(a) Milliamperage-distance-time relationship
(b) The reciprocity law
(c) Photographic density
(d) X-ray exposure charts (material thickness, KV, and exposure) * (e) Gamma ray exposure chart
(f) Inverse square law considerations
(g) Calculation of exposure time for gamma and X-ray sources
(4) The characteristic (h and d) curve
(5) Film speed and class descriptions
(6) Selection of film for participation purpose
d. RADIOGRAPHIC IMAGE QUALITY
(1) Radiographic sensitivity
(2) Radiographic contrast
(3) Film contrast
(4) Subject contrast
(5) Definition
(6) Film graininess and screen mottle effect
(7) Penetrameters or image quality indicators
e. FILM HANDLING, LOADING, AND PROCESSING
(1) Safelight and darkroom practices
(2) Loading bench and cleanliness
(3) Opening of film boxes and packets
(4) Loading of film and sealing cassettes
(5) Handling techniques for “green film”
(6) Elements of manual film processing
f. EXPOSURE TECHNIQUES – RADIOGRAPHY
(1) Single-wall radiography
(2) Double-wall radiography
(a) Viewing two walls simultaneously
(b) Offset double-wall exposure single-wall viewing
(c) Elliptical techniques
(3) Panoramic radiography
(4) Use of multiple film loading
(5) Specimen configuration
4. FILM QUALITY & MANUFACTURING PROCESS TRAINING COURSE
a. REVIEW OF BASIC RADIOGRAPHIC PRINCIPLES
(1) Interaction of radiation with matter
(2) Math review
(3) Exposure calculations Page 5
Appendix A
(4) Geometric exposure principles
(5) Radiographic image quality parameters
b. DARK ROOM FACILITIES, TECHNIQUES, AND PROCESSING
(1) Facilities and equipment
(a) Automatic film processor versus manual processing
(b) Safe lights
(c) View lights
(d) Loading bench
(e) Miscellaneous equipment
(2) Film loading
(a) General rules for handling unprocessed film
(b) Type of film packing
(c) Cassette loading techniques for sheet and roll
(3) Protection of radiographic film in storage
(4) Processing of film – manual
(a) Developer and replenishment
(b) Stop bath
(c) Fixer and replenishment
(d) Washing
(e) Prevention of water spots
(f) Drying
(5) Automatic filming processing
(6) Film filing and storage
(a) Retention life measurements
(b) Long-term storage
(c) Filing and separation techniques
(7) Unsatisfactory radiographs, causes, and cures
(a) High film density
(b) Insufficient film density
(c) High contrast
(d) Low contrast
(e) Poor definition
(f) Fog
(g) Light leaks
(h) Artifacts
(8) Film density
(a) Step wedge comparison film
(b) Densitometers
c. INDICATIONS, DISCONTINUITIES, AND DEFECTS
(1) Indications
(2) Discontinuities
(a) Inherent
(b) Processing
(c) Service
(3) Defects Page 6
Appendix A
d. RADIOLOGICAL SAFETY PRINCIPLE REVIEW
(1) Controlling personnel exposure
(2) Time, distance, shielding concepts
(3) ALARA concept
(4) Radiation-detection equipment
(5) Exposure device operating characteristics
5. RADIOGRAPHIC EVALUATION & INTERPRETATION TRAINING COURSE
a. RADIOGRAPHIC VIEWING
(1) Film illuminator requirements
(2) Background lighting
(3) Multiple-composite viewing
(4) Penetrameter placement
(5) Personnel dark adaptation and visual acuity
(6) Film identification
(7) Location markers
(8) Film density measurement
(9) Film artifacts
b. APPLICATION TECHNIQUES
(1) Multiple film techniques
(a) Thickness variation – parameters
(b) Film speed
(c) Film latitude
(2) Enlargement and projection
(3) Geometrical relationships
(a) Geometrical unsharpness
(b) Penetrameter sensitivity
(c) Source film distance
(d) Focal spot size
(4) Triangulation methods for discontinuity location
(5) Magnification localized
(6) Film handling techniques
c. EVALUATION OF WELDMENTS
(1) Welding method review
(2) Welding discontinuities
(3) Origin and typical orientation of discontinuities
(4) Radiographic appearance
(5) Welding codes and standards – applicable acceptance criteria
(6) Reference radiographs or pictograms
d. STANDARDS, CODES, AND PROCEDURES FOR RADIOGRAPHY\
(1) ASTM E94/E142
(2) Acceptable radiographic techniques and setups
(3) Applicable employer procedures Page 7
Appendix A
(4) Procedure/radiograph parameter verification
(5) Radiographic reports
e. FINAL WRITTEN/PRACTICAL EXAMINATION
TOTAL TIME (HOURS): 40
6. MAGNETIC PARTICLE TESTING TRAINING COURSE
a. PRINCIPLES OF MAGNETS AND MAGNETIC FIELDS
(1) Theory of magnetic fields
(a) Earth’s magnetic field
(b) Magnetic fields around magnetized materials
(2) Theory of magnetism
(a) Magnetic poles
(b) Law of magnetism
(c) Materials influenced by magnetic fields:
(i) Ferrom agnetic
(ii) Paramagnetic
(d) Magnetic characteristics of nonferrous materials
(3) Terminology associated with magnetic particle testing
b. CHARACTERISTIC OF MAGNETIC FIELDS
(1) Bar magnet
(2) Ring magnet
c. EFFECT OF DISCONTINUITIES ON MATERIALS
(1) Surface cracks
(2) Scratches
(3) Subsurface defects
d. MAGNETIZATION BY MEANS OF ELECTRIC CURRENT
(1) Circular field
(a) Field around a straight conductor
(b) Right-hand rule
(c) Field in parts through which current flows:
(i) Long solid cylindrical regular parts
(ii) Irregularly shaped parts
(iii) T ubular parts
(iv) Parts containing critical holes
(d) Methods of inducing current flow in parts
(i) C ontact plates
(ii) Prods
(e) Discontinuities commonly discovered by circular fields
(2) Longitudinal field
(a) Field produced by current flow in a coil
(b) Field direction in a current-carrying coil
(c) Field strength in a current-carrying coil
(d) Discontinuities commonly discovered by longitudinal fields Page 8
Appendix A
(e) Advantages of longitudinal magnetization
(f) Disadvantages of longitudinal magnetization
e. SELECTING THE PROPER METHOD OF MAGNETIZATION
(1) Alloy, shape, and condition of part
(2) Type of magnetizing current
(3) Direction of magnetic field
(4) Sequence of operations
(5) Value of flux density
f. INSPECTION MATERIALS
(1) Wet particles
(2) Dry particles
g. PRINCIPLES OF DEMAGNETIZATION
(1) Residual magnetism
(2) Reasons for requiring demagnetization
(3) Longitudinal and circular residual field
(4) Basic principles of demagnetization
(5) Retentivity and coercive force
(6) Methods of demagnetization
h. MAGNETIC PARTICLE TEST EQUIPMENT
(1) Equipment selection considerations
(a) Type of magnetizing current
(b) Location and nature of test
(c) Test materials used
(d) Purpose of test
(e) Area inspected
(2) Manual inspection equipment
(3) Medium and heavy duty equipment
(4) Stationary equipment
(5) Mechanized inspection equipment
(a) Semi-automatic inspection equipment
(b) Single-purpose semi-automatic equipment
(c) Multi-purpose semi-automatic equipment
(d) Fully automatic equipment
i. TYPES OF DISCONTINUITIES LOCATED BY MAGNETIC PARTICLE TESTING
(1) Inclusions
(2) Blowholes
(3) Porosity
(4) Flakes
(5) Cracks
(6) Pipes
(7) Laminations
(8) Laps
(9) Forging bursts
(10) Voids Page 9
Appendix A
j. MAGNETIC PARTICLE TEST INDICATIONS AND INTERPRETATION
(1) Indications of nonmetallic inclusions
(2) Indications of surface seams
(3) Indications of cracks
(4) Indications of laminations
(5) Indications of laps
(6) Indications of bursts and flakes
(7) Indications of porosity
(8) Nonrelevant indications
k. FINAL WRITTEN/PRACTICAL EXAMINATION
TOTAL TIME (HOURS): 16
7. ULTRASONIC TESTING TRAINING COURSE
a. FUNDAMENTAL PROPERTIES OF SOUND
(1) Frequency, velocity, and wavelength
(2) Definition of ultrasonic vibrations
(3) General application of ultrasonic vibrations
b. PRINCIPLES OF WAVE PROPAGATION
(1) Modes of vibration
(2) Acoustic impedance
(3) Reflection
(4) Refraction and mode conversion
(5) Diffraction and mode conversion
(6) Fresnel and Fraunhofer effects
c. GENERATION OF ULTRASONIC WAVES
(1) Piezoelectricity and types of crystals
(2) Construction of ultrasonic search units
(3) Characteristics of search units
(a) Frequency-crystal thickness relationships
(b) Conversion efficiencies of various crystals
(c) Damping and resolution
(d) Beam intensity characteristics
(4) Care of search units
d. ULTRASONIC TESTING METHODS
(1) Contact testing
(a) Straight beam
(b) Angle beam
(c) Surface wave
(d) Lamb wave
(e) Through transmission
(2) Immersion testing
(a) Straight beam Page 10
Appendix A
(b) Angle beam
(c) Through transmission
(3) Modified immersion testing
(a) Tests employing special devices
(4) Resonance testing
(a) Contact technique
(b) Immersion technique
e. ULTRASONIC TESTING EQUIPMENT
(1) Description of basic pulse-echo instrument
(a) Time-base (synchronizer) circuit
(b) Pulser circuit
(c) Receiver or echo-amplifier circuit
(d) A-Scan display unit
(2) Special Instructions
(a) B-Scan display
(b) C-Scan display
(c) Monitors and recording devices
(3) Scanning equipment
(a) Manipulators
(b) Bridges
(c) Special scanning devices
(4) Ultrasonic bond test equipment
f. OPERATION OF SPECIFIC EQUIPMENT
(1) General operating characteristics
(2) Functional block diagram of ciruits
(3) Purpose and adjustment of external controls
(4) Care of equipment
g. SPECIFIC TESTING PROCEDURES
(1) Selection of test parameters
(a) Frequency
(b) Search unit size and type
(c) Water distance (for immersed tests)
(d) Scanning speed and index
(2) Test standardization
(a) Ultrasonic standard reference blocks
(b) Adjustment of test sensitivity
(3) Interpretation of results
(a) Acceptance standards
(b) Comparison between responses from discontinuities to those from ultrasonic reference standards
(c) Estimated length of discontinuities
(d) Location of discontinuities
(e) Zoning
(4) Equipment performance variations