Lecture-08

Inspection Methods

Practical Guide to Pressure Vessel Manufacturing

By Sunil Kumar Pullarcot

©2025 Chemical Equipment Design, CH3349 Ho Chi Minh University of Technology (HCMUT)
 Course Outcomes
Emphasis
Course Outcomes Total
Very high High Medium Low
Design pressure vessels using ASME
CLO1 standards and emphasis on safety and 66.0 66.0
resource sustainability.

Use readily available software (e.g.

CLO2 Excel) to carryout design calculations and 18.0 18.0
material selections

Practice leadership, cooperation, and 6.0

CLO3 6.0
accountability in a teamwork setting.

Produce a standard technical report for a 10.0

CLO4 10.0
chemical equipment design.
0.0
Total 66.0 18.0 10 6 100.0

©2025 Chemical Equipment Design, CH3349 Ho Chi Minh University of Technology (HCMUT)
 CONTENT
1. Introduction
✓ Summary of Lecture – 08
✓ Why inspection methods?
✓ Potential failures in pressure vessels
2. Relevant standards
➢ ASME Code for NDE
➢ API 510: Pressure Vessel Inspection
3. NDT Techniques
➢ VT, PT, RT, UT, ET, etc.
4. NDT Symbols

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 Learning Outcomes

At the end of this lecture, you should be able to

– discuss the various types of

➢failures in pressure vessels, and

➢NDT techniques applicable to pressure vessels.

– explain the symbols for NDT.

©2025 Chemical Equipment Design, CH3349 Ho Chi Minh University of Technology (HCMUT)
 Introduction:

©2025 Chemical Equipment Design, CH3349 Ho Chi Minh University of Technology (HCMUT)
 Summary of Lecture-07
➢ Definition of pressure vessel: according to ASME BPVC, pressure
vessel refers to "A container designed to withstand internal or external
pressure and intended to store or transport fluids, gases, or vapors."

➢ Classification: (i) unfired pressure vessels, (ii) fired pressure vessels,

and (iii) storage tanks.

➢ Melding methods: SMAW, FCAW, GMAW, GTAW, and SAW

➢ Types of Welded joints: butt , lap, corner, tee

➢ Relevant standard: ASME BPVC Sec. VIIII, Div.1 to Div.3 and ASME
BPVC Sec. IX

➢ Welding symbols: provide the standard information about the weld.

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 Why inspection methods?
• Chemical equipment, such as reactors, storage tanks, pipelines, heat exchangers, and pressure
vessels, is often exposed to extreme conditions, including high temperatures, corrosive chemicals,
and varying pressures. Therefore, ensuring their integrity, reliability, and safety is paramount.
Inspection methods are crucial to ensure:

➢ Strength and integrity: through inspection, we can ensure that the materials used are free of
defects (e.g. cracks, corrosion, etc.).

➢ Compliance with standards and codes: (i) Chemical equipment must comply with various
industry codes and safety standards, such as ASME, API, ISO, or ASTM standards, which
include requirements for inspections and maintenance. Regular inspection methods are used to
ensure that the equipment meets these standards, which helps prevent legal issues and
ensures that the equipment operates safely.

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 Common inspection methods:

Visual inspection • Simple yet effective for checking external damage,

wear, leaks, or improper installation.

Ultrasonic testing • Used to detect internal defects, corrosion, and erosion.

Hydrostatic
testing • Detects internal flaws such as voids, cracks, or inclusions.
Radiographic testing

Magnetic particle testing • Used for detecting surface and near-surface cracks in
ferromagnetic materials.
Pressure
testing Dye penetrant testing • Ideal for detecting surface cracks and leaks in non-ferrous
materials.

Eddy current testing • Used to detect surface and sub-surface defects,

particularly in conductive materials.

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 Potential Failures in Pressure Vessels:
Categories of Failures* Failure Types
(how the failure occurs)
• Material: inadequate • Elastic deformation
material selection; defect
• Excessive plastic deformation
• Design: incorrect/
inadequate design • Brittle fracture

• Fabrication: inadequate • Stress rapture

welding or post heat • Plastic instability
treatment; poor quality
control • High strain

• Service: breaching • Stress corrosion

design operating
• Corrosion fatigue
conditions
• Creep rapture
• External factors:
impact, dynamic loads • Dents or cracks
https://doi.org/10.1016/j.ultras.2022.106854
*Dennis R. Moss_2013_Pressure Vessel Design Manual, pp. 5

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 Mitigation strategy:
• Regular Inspections: Conduct thorough visual inspections, ultrasonic testing, radiography,
and other non-destructive tests to detect cracks, corrosion, or other signs of damage.
• Corrosion Protection: Use coatings, cathodic protection, and other corrosion prevention
techniques to protect pressure vessels from internal and external corrosion.
• Pressure Relief Systems: Ensure that pressure relief valves and other safety devices are
working correctly and maintained regularly to prevent overpressure situations.
• Fatigue Monitoring: Monitor operating cycles and pressure fluctuations to detect potential
fatigue damage over time.
• Proper Material Selection: Choose materials with the appropriate strength, corrosion
resistance, and fatigue properties for the operating environment.
• Adherence to Design Codes and Standards: Follow relevant codes and standards (e.g.,
ASME Boiler and Pressure Vessel Code) during the design and fabrication of pressure
vessels to ensure their safety and reliability.

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 Relevant
Standards:
©2025 Chemical Equipment Design, CH3349 Ho Chi Minh University of Technology (HCMUT)
 List of standards:

• ASME BPVC: most widely recognized code for the design, construction, and
inspection of pressure vessels.

• API 510 Pressure Vessel Inspection Code: outlines the requirements for the
inspection, repair, alteration, and rerating of in-service pressure vessels. It is specific to
the oil, gas, and petrochemical industries but is widely used across various sectors.

• BS EN 13445-5:2014 Unfired pressure vessels, Part 5: Inspection and testing

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Sections of ASME BPVC Codes
• Section I: Rules for Construction of Power Boilers
• Section II: Materials
• Section III: Rules for Construction of Nuclear Facility Components
• Section IV: Rules for Construction of Heating Boilers
✓ • Section V: Non-destructive Examination
• Section VI: Recommended Rules for the Care and Operation of Heating Boilers
• Section VII: Recommendation Guidelines for the Care of Power Boilers
• Section VIII: Rules for Construction of Pressure Vessels
• Section IX: Welding, Brazing and Fusing Qualifications
• Section X: Fiber-Reinforced Plastic Pressure Vessels
• Section XI: Rules for Inservice Inspection of Nuclear Power Plant Components
• Section XII: Rules for Construction and Continued Service of Transport Tanks
Source: https://www.asme.org/codes-standards/bpvc-standards

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 Section V
• Article 1: General Requirements • Scope and Use of Section V
• Responsibilities of the owner/user,
• Article 2: Radiographic Testing & of subcontractors.
• Calibration
• Inspection and Examination
• Article 4: Ultrasonic Testing for Welds
• Record keeping requirements
• Article 5: Ultrasonic Testing for Materials

• Article 6: Liquid or Dye Penetrant Testing

• Article 7: Magnetic Particle Testing

• Article 8: Eddy Current Testing

• Article 9: Visual Inspection

• Article 10: Leak Testing

Source: https://nexnor.com/wp-content/uploads/2020/01/ASME-V-2019.pdf

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 Fatigue Analysis:

• After the design life of the vessel is reached, the owner or

Fit for
user must determine whether to retire the vessel or apply Service
some periodic inspections and NDE to determine if the (FFS)

vessel can continue in service.

• If the screening method determines that a fatigue

analysis is required, ASME Sec. VIII, Div. 2, Part-5 gives
detailed methods for performing this analysis.

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 Radiographic
Testing
(X-Ray):
ASME BPVC, Sec. V, Article -2

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 Type of NDT Commonly used for PV
• Out of the various conventional and advanced nondestructive examination (NDE)
methods, five are widely used for the examination of pressure vessels and tanks by
certified pressure vessel inspectors.
• The names and acronyms of these common five methods are:
➢ VT: Visual Examination,
➢ PT: Liquid Penetrant Test,
➢ MT: Magnetic Particle Test,
➢ RT: Gamma and X-ray Radiography, and
➢ UT: Ultrasonic Test.
• VT, PT and MT can detect only those discontinuities and defects that are open to the
surface or are very near the surface.
• In contrast, RT and UT can detect conditions that are located within the part. For these
reasons, the first three are often referred to as surface examination methods and the
last two as volumetric methods.
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 1. Article 2 covers radiographic examination of welds in various materials.
➢ Including ferrous and non-ferrous metals, and in various forms such as castings, forgings, and
welded joints.
2. Personnel must be qualified and certified to perform radiographic testing.
➢ Test must be performed by personnel who are qualified and certified in accordance with ASME
Section V, Article 1
3. Radiographic examination requires specialized equipment, including X-ray machines or gamma
ray sources, film or digital imaging systems, and radiation detection devices.
➢ Specialized equipment must be properly calibrated and maintained.
4. Procedures must be developed and documented with specific details.
➢ Procedures, techniques, acceptance criteria, and the reporting requirements.
5. Radiographs must be evaluated by a qualified interpreter.
6. Acceptance criteria specify the maximum size and number of flaws or defects allowed.
7. Records of examination must be maintained with details on results and any corrective actions
taken.

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• This technique involves the use of penetrating gamma or X-radiation to
examine parts and products for imperfections.
• An X-ray machine or radioactive isotope is used as a source of radiation.
• Radiation is directed through a part and onto film or other media.
• The resulting shadowgraph shows the internal soundness of the part.
• Possible imperfections are indicated as density changes in the film in the
same manner as an X-ray shows broken bones.
• Radiographic applications fall into two distinct categories evaluation of
material properties and evaluation of manufacturing and assembly properties.
• Material property evaluation includes the determination of composition,
density, uniformity, and cell or particle size.
• Manufacturing and assembly property evaluation is normally concerned with
dimensions, flaws (voids, inclusions, and cracks), bond integrity (welds,
brazes, etc.), and verification of proper assembly of component pieces.

Source: https://www.youtube.com/watch?v=7oR_l8nXdmo

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 Ultrasonic
Testing:
ASME BPVC, Sec. V, Article - 4&5

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 ULTRASONIC TESTING

Ultrasonic testing
uses high frequency
sound energy to
conduct
examinations and
make
measurements.
Ultrasonic

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• Ultrasonic inspection is a nondestructive method in
which beams of high-frequency sound waves are
introduced into materials for the detection of
subsurface flaws in the material.
• The sound waves travel through the material with
some attendant loss of energy (attenuation) and
are reflected at interfaces (cracks or flaws).
• The reflected beam is displayed and then analyzed
to define the presence and location of flaws or
discontinuities.
• The most commonly used ultrasonic testing
technique is pulse echo, wherein sound is
introduced into a test object and reflections
(echoes) are returned to a receiver from internal
imperfections or from the part's geometrical
surfaces.
• Applications include inspections for voids, cracks,
and laminations, inspections of welds and
thickness measurements.

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https://youtu.be/UM6XKvXWVFA

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 Dye Penetration
Test:
ASME BPVC, Sec. V, Article -6

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• Apart from visual inspection this is probably the oldest and most widely
used of all the NDT methods.
• It can be used on any non-porous material. Its use is confined to the
detection of surface breaking defects.
• Liquid penetration inspection is used to reveal surface breaking flaws by
bleed out of a colored or fluorescent dye from the flaw. Test objects are
coated with visible or fluorescent dye solution. Excess dye is then
removed from the surface, and a developer is applied.
• The developer acts as blotter, drawing trapped penetrant out of
imperfections open to the surface.
• With visible dyes, vivid color contrasts between the penetrant and
developer make "bleed out" easy to see.
• With fluorescent dyes, ultraviolet light is used to make the bleed out
fluoresce brightly, thus allowing imperfections to be readily seen.
• Penetrant inspection can be used on any material and is most often used
on materials clad in stainless steel, and stainless welded items which
cannot be inspected by other methods.

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©2025 Chemical Equipment Design, CH3349 Ho Chi Minh University of Technology (HCMUT)
 Magnetic Particle
Inspection
(MPI):
ASME BPVC, Sec. V, Article -7

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 • Magnetic particle inspection (MPI) is used for the detection of
surface and near-surface flaws in ferromagnetic materials.
• A magnetic field is applied to the specimen, either locally or
overall, using a permanent magnet, electromagnet, flexible
cables or hand-held prods.
• If the material is sound, most of the magnetic flux is
concentrated below the material's surface.
• However, if a flaw is present, such that it interacts with the
magnetic field, the flux is distorted locally and 'leaks' from the
surface of the specimen in the region of the flaw.
• Fine magnetic particles, applied to the surface of the specimen,
are attracted to the area of flux leakage, creating a visible
indication of the flaw.

• The materials commonly used for this purpose are black iron particles and red or yellow iron oxides.
• In some cases, the iron particles are coated with a fluorescent material enabling them to be viewed
under a UV lamp in darkened conditions.

©2025 Chemical Equipment Design, CH3349 Ho Chi Minh University of Technology (HCMUT)
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 Eddy Current
Testing:
ASME BPVC, Sec. V, Article -8

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 • Eddy current is the most widely applied electromagnetic NDT technique.
• Eddy current testing uses an electromagnet to induce an eddy current in a conductive sample.
• The response of the material to the induced current is sensed. Since the probe does not have to contact the
work surface, eddy current testing is useful on rough surfaces or surfaces with wet films or coatings.
• In standard eddy current testing, a circular coil carrying an AC current is placed in close proximity to an
electrically conductive specimen.
• The alternating current in the coil generates a changing magnetic field, which interacts with the test object and
induces eddy currents. Variations in the phase and magnitude of these eddy currents can be monitored using a
second 'search' coil, or by measuring changes to the current flowing in the primary 'excitation' coil.
• Variations in the electrical conductivity or magnetic permeability of the test object, or the presence of any flaws,
will cause a change in eddy current flow and a corresponding change in the phase and amplitude of the
measured current.

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 https://youtu.be/oriFJByl6Hs

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 Visual
Inspection:
ASME BPVC, Sec. V, Article -9

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 • Visual Inspection is the most basic and widely used method of non-destructive testing.

• It involves visually examining the surface of the material or weld for any defects, such as cracks,
porosity, incomplete penetration, etc.

• Personnel performing visual inspection must be trained and certified to the appropriate level of
proficiency.

• Visual Inspection must be performed under appropriate lighting and magnification conditions to
ensure that all relevant details are visible.

• The acceptance criteria for visual inspection are based on the size, shape, and location of the
defects and are defined in the relevant codes and standards.

• The inspection results should be documented in a report, including details of the defects found,
their size and location, and the acceptance or rejection criteria.

• Visual inspection can be supplemented with other non-destructive testing methods to provide
additional information about the internal structure of the material.

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 https://www.youtube.com/watch?v=Jztag-LVCdQ&t=642s

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 Leak
Testing:
ASME BPVC, Sec. V, Article -10

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 1. Article 10 of Session V of the Pressure Equipment Directive (PED) requires that all pressure
equipment items subject to the PED must undergo leak testing before they can be put into
service.

2. The appropriate leak testing method chosen must be appropriate for the specific application,
taking into account the size, geometry, and operating conditions of the equipment.

3. The leak testing must be carried out by competent personnel using calibrated equipment.

4. Results must be recorded and kept for a period of at least five years.

5. The equipment must be marked to indicate that it has undergone leak testing, along with the
date and results of the testing.

6. Appropriate leak testing methods include pressure testing, vacuum testing, bubble testing,
and tracer gas testing.

7. The purpose of leak testing is to determine whether a pressure equipment item or system is
capable of retaining a gas or liquid under pressure without leakage.

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 Source: https://www.youtube.com/watch?v=UJNrLoZsMX0

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 NDT
Symbols:
Source:
• Nondestructive Testing Methods - Training Workbook

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 • Non-destructive testing symbols are standardized much
like the symbols used for welding. A reference line is
used in the same manner as welding symbols and is as
long as necessary for adding information.

• An arrow is used to direct the information to the desired

location. It can be placed at either end of the reference
line, pointing up or down, on either side where welds are
to be placed.

• The side of the joint the arrow points to is referred to as

the “arrow side”. The opposite side is called the “other
side”. It is important because it specifies which side of
the welded joint is to be inspected.

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 • The symbols use initials to indicate the test
method to be used. They are:
➢ VT = visual testing
➢ PT = penetrant testing
➢ MT = magnetic particle testing
➢ UT = ultrasonic testing
➢ RT = radiographic testing

• When the test symbol is located below the

reference line, it signifies that inspection is to be
performed on the arrow side of the joint. When placed
above the line, it indicates the inspection is to be
performed on the other side.

• The test symbol can be placed on both sides of the

reference line to indicate that each side of the weld is
to be inspected.

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 • The symbol is centered between a break in the
reference line when it doesn’t matter on which
side the inspection is to be performed. In all
cases, the inspection is for 100% of the
weld unless otherwise noted.

• Details, such as testing procedures,

specification, processes, or other pertinent
information are sometimes placed at the end of
the reference line inside a “tail bracket”.

• When less that 100% of the length is to be

inspected, it can be specified by a section length
or percentage located to the right of the symbol.
The required sections or areas are usually
specified in the written procedures. When no
percentages are noted, 100% of the weld is to be
checked.

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 • The all-around test symbol is used when the inspection
is to be performed completely around a welded joint.

• The number of tests to be performed is indicted in

parenthesis. The symbol shown here specifies four
applications of magnetic particle inspection.

• Multiple reference lines are nondestructive test

symbols combined with other nondestructive or
welding symbols. The order in which operations and
tests are performed is indicted by the order of the lines.
The first operation is the closest to the arrow.

• This multiple reference line shows a single V- groove

weld with melt through to be inspected on the arrow
side with a combination of visual and radiographic
testing methods. Visual inspection is performed on the
other side. Inspection details are located in procedure
T-28.

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©2025 Chemical Equipment Design, CH3349 Ho Chi Minh University of Technology (HCMUT)
 Thank You!

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 References

1. Chuck Hellier, “Handbook of Nondestructive

Evaluation,” 2020

2. Sunil Kumar Pullarcot, “Practical Guide to Pressure

Vessel Manufacturing”

3. Nondestructive Testing Methods - Training Workbook

4. Nathan Ida, Norbert Meyendorf, “Handbook of

Advanced Nondestructive Evaluation,” Springer
Reference, 2019

5. Peter J. Shull, “Nondestructive evaluation: theory,

techniques, and applications,” M. Dekker, Year: 2002

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