Visual Inspection
Visual Inspection
The method of Non-Destructive testing, where the object is inspected through the naked eye or
magnifying glass, is known as visual testing NDT.
It is the first NDT method, that is used on any object to inspect. It gives a visual clarification about
the object and gives a quick observation result.
Visual Testing (VT) is widely used of all NDT techniques and it is the oldest of them. Visual
testing is the first test, which is performed when an object arrives.
Introduction
• Visual inspection is a normal Quality Control requirement in
components.
personnel moving with flash light, checking the wings and other
rolls into a station its wheels and axles are checked, you could see
• These are simple cost effective checks that can prevent failure.
Fundamentals of Visual Testing
Definition
• Visual inspection is the process of examination and evaluation of systems and
components by use of human sensory systems aided only by mechanical
enhancements to sensory input.
• The inspection process may be done using such behaviors as looking, listening,
feeling, smelling, shaking, and twisting. It is included with a cognitive component
wherein observations are correlated with knowledge of structure and with
descriptions and diagrams from service literature
Classification
Visual acuity is the ability to distinguish very small details. For example, as the distance from the eye to
the object increases, two lines that are close together appear as one heavy, dark line. The normal eye
can distinguish a sharp image when the object being viewed subtends an arc of one-twelfth of a degree
(five minutes), irrespective of distance from the eye to the object. Practically speaking, a person with
“normal” vision would have to be within eight feet of a 20-inch TV monitor to resolve the smallest detail
displayed.
• White light contains all colours.
• The colour of an object is various wavelengths of light that are
perceived as different colours by the eye.
• Colour can be described as having three measurable properties:
brightness, hue, and saturation.
• The colour of an object, ranging from light to dark, emitting more
or less light, is known as brightness.
• Different wavelengths give us different perspectives of colours;
this is known as hue. How red something is as opposed to white,
is how saturated it is with red.
• Visual acuity examinations are a requirement for certification. The
visual inspector’s natural visual acquity must be examined.
• The Jaeger (J) test is used in the United States for near-distance
visual acuity.
• It consists of an English language text printed on an off-white card.
• The parameters for near-distance visual acuity are described in
personnel certification and qualifications programs. Visual acuity
requirements will vary depending upon the needs of specific
industries
• The Jaeger chart is an eye chart used in testing near vision acuity. It
is a card on which paragraphs of text are printed, with the text sizes
increasing from 0.37 mm to 2.5 mm
• Brightness of light is an important factor in test environments.
• The apparent brightness of a test surface is dependent on the intensity of the light and the reflectivity of the
surface reflecting the light to the eye. Excessive brightness will interfere with the ability to see and will “white
out” the object. Inadequate light can cause excessive shadows and result in insufficient light being reflected
from the surface, preventing observation of the surface attributes.
• Some codes require a minimum intensity of 15 foot candles (fc) for general visual testing and a minimal 50 fc
for critical and fine detail viewing.
• The Illumination Engineering Society requires 100–300 fc for critical work. The inverse square law governs
the intensity of light noted or measured. It states that illuminance (E) at a point on a surface varies directly
with the luminous intensity of the source (I) and inversely as the square of the distance (d) between the
surface and the source
𝐼
𝐸=
𝑑2
Excessive brightness within the field of view can cause an unpleasant sensation called glare.
Glare interferes with the ability to see clearly and make critical observations and judgments.
Lighting requirements
• For general examination a minimum of 50 foot candles of light. A standard two (2) cell flashlight fully charged will
produce 50 foot candles at approximately 18mm distance for the point of observation.
• For the detection or study of small anomalies a minimum of 100 foot candles of light . For comparison, a 100
W incandescent bulb produces about 1750 lumens or 137 foot-candles, a 23 watt fluorescent light produces
about 1600 lumens or 125 foot-candles
• For direct general visual examinations, resolution and lighting shall be considered sufficient when a black line
1/32 Inch wide on a 18% neutral gray card can be resolved under the worst conditions of lighting, angles or
positions of the inspection to be encountered.
• A gray card is a flat object of a neutral gray color that derives from a flat reflectance spectrum. A typical example
is the Kodak R-27 set, which contains two 8x10" cards and one 4x5" card which have 18% reflectance across
the visible spectrum, and a white reverse side which has 90% reflectance. Note that flat spectral reflectance is a
stronger condition than simply appearing neutral; this flatness ensures that the card appears neutral under any
illuminant.
• Mirrors and magnifiers may be used to assist in the examination when necessary. Visual examination may
begin immediately after completed welds have cooled
Cleanliness
• The amount of light that reaches the eye from an object is dependent on the cleanliness of the
reflecting surface. In visual testing, the amount of light may be affected by distance, reflectance,
brightness, contrast or the cleanliness, texture, size, and shape of the test object.
• Cleanliness is a basic requirement for a successful visual test. Opaque dirt can mask or hide
attributes, and excessively bright surfaces cause glare and prevent observation of the visual
attributes.
Surface Condition
• Scale, rust, contaminants, and processes such as milling, grinding, and etching may affect the
ability to examine a surface.
Shape
The shape of an object can influence the amount of light reflected to the eye, due to various angles that
can determine the amount of light that will be reflected back to the eye.
Size
The size of an object will determine the type of scan pattern that may be used to view 100% of the
object or it may determine that some magnification is necessary to get a closer view of details otherwise
unobservable.
Temperature
Excessive temperature may cause distortion in viewing due to the heat wave effect. We are familiar with
the heat waves coming off a desert, resulting in a mirage; this is known as “heat wave distortion.” In a
nuclear reactor, underwater components are frequently distorted due to heat waves rising from the core
that can interfere with the view from an underwater camera as it scans a particular component during
visual examination.
Texture and Reflectance
One of the greatest variables in viewing an object is the amount of light that is reflected from it, and the
angle at which the light strikes the eye. Excessive rust or roughness can cause diffusion of the light and
limit the light returning to the eye. This can easily be corrected by increasing the amount of light or
improving the surface condition of the object under examination.
Visual Angle and Distance
• Visualize two pencils representing two parallel lines. If these are perpendicular to the incident angle of view,
two pencils can be clearly seen. As the two pencils rotate and become relatively parallel to the incident view
of the eye, the two pencils appear to become one, since one is now behind the other.
• The quantitative ability of a person to resolve objects is determined in a practical manner from the distance of
the object to the eye and the angle of separation of two points that can be resolved by the eye. This is known
as resolving power.
• For the average eye, the minimal resolvable angular separation of two points on an object is about one
minute of arc (1/60th of one degree). This means that at about 12 inches (300 mm) from the test surface, the
best resolution to be expected is 0.0035 inches (0.09 mm); at 24 inches (600 mm), the best anticipated
resolution is about 0.007 inches (0.18 mm).
• The best result from a visual test is obtained when the object is brought close to the eye and a large visual
angle is obtained.
• The eye cannot sharply focus if it is nearer to 10 inches
(250 mm) to an object.
• Therefore, direct visual tests are best performed at a
distance of 10–24 inches (250–600 mm).
• The viewing angle between the line of site that the eye
makes with the test site and the plane of the test surface.
As described above, two pencils can become one as the
viewing angle of the eye changes.
• For practical consideration, this angle should not be less
than 30° of view off the plane of the surface under
inspection.
Human Factors
Environmental
• The amount of light required for a visual test depends on several factors, such as speed or accuracy,
reflection from background, and other inspection variables. These inspection variables include
physiological processes, psychological states, and the inspector’s experience, health, and fatigue. All
of these factors contribute to the accuracy of a visual inspection.
• Surrounding colours and patterns can have an effect on the inspector’s attitude.
• Dark walls can absorb up to 50% of the light.
• A high contrast on the pattern being inspected can cause eye fatigue.
• It is recommended that blue colours be utilized and bright colours should be avoided.
Physiological
The act of seeing something is not a passive activity. The observer must be active in keeping track of what is going
on. Constant eye shifting back and forth from one location to another or scanning a large area at a rapid speed
causes the muscles in the eye to fatigue. If the eye isn’t focusing quickly when changing directions, the image can
be lost altogether. Any fatigue on the part of the observer can result in reduced efficiency and accuracy in
interpreting the visual data.
Psychological
Individuals can be in various psychological states. They can be suffering from tensions, emotions, and other
influences. These may influence the appraisal and ability to visualize an object and may also influence performance
of a visual task. The intention of a viewer may affect perception. A great deal of information is potentially available
immediately after viewing, but if one does not expect to find certain attributes, one may well overlook the physical
evidence that has been viewed and not perceive them. One of the ways to overcome this is to know ahead of time
what to expect, the attributes of what is to be seen, and what the greatest possibility is of these attributes existing.
Perception
The ability of the eye to sense a variety of views is not constant. If one is well rested in starting
out an inspection activity, perception can be greater than when one is fatigued. Grossly
changing light levels may cause painful glare. After a long period of relative darkness, normal
light may seem painful. Sudden exposure to full sunlight can cause discomfort. It may take up
to 30 minutes for the iris to adjust and regain normal vision. As the iris becomes tired and the
muscles that adjust the lens become fatigued due to age, overuse, drugs, disease, or
emotions, vision can be greatly affected. Vision examinations are usually administered
annually to provide assurance that the inspector meets the requirements for performing VT.
Daily influences external to the inspector, such as emotions, drugs, excessive light,
inadequate sleep, etc., can cause temporary loss of visual acuity. Another influence on
perception is appearance.
The two lines represented in Figure appear to have different lengths due the perceptions
created by the “Vee” extensions on each end. In fact, the two lines are identical in length; the
brain perceives the lengths differently.
Defects that can be detected by unaided Visual Inspection
➢ Surface porosity, unfilled crates, contour of the weld beads, and the probable orientation
of the interface between the fused weld bead and the adjoining parent metal
Magnifier
The magnifier can increase the image size of the viewed object.
Magnifying power = 10 ÷ focal length (in inches)
• Whenever the eye cannot obtain a direct, unobstructed view of the specimen test surface
without use of another tool, instrument, or device, a “remote visual” examination is
performed.
• that uses visual aids such as mirrors, telescopes, borescopes, fiber optics, cameras, or
other suitable instruments.
Borescope
One of the oldest applications of remote visual examination is the inspection of gun barrels. The failure of a gun
barrel, be it the earliest mortar siege gun of medieval times or the precision machined barrel of a modern rifle, is
catastrophic to the gunner at the very least. Two obstacles had to be overcome in the inspection of gun barrels:
access to the area to be inspected, and a provision of a light source to provide adequate illumination in order to
see the conditions of interest on the inside surface. Small rigid borescopes containing a series of lenses was
fabricated for this purpose.
Rigid Borescope
Small lamps were used at the far end to provide sufficient light.
Since the original applications utilized a lens train to access the bore of a rifle, the name “borescope”
The object image to the eye is obtained using an objective lens, sometimes a prism, a relay lens, and
an eyepiece lens.
The eyepiece lens allows each inspector to adjust the focus as needed with the use of a “focus ring.”
Rigid Borescope
A more practical means of transferring light to the examination surface is with the use of a
light source transmitted through a fiber bundle.
The reflective image from the object is returned to the eye via a second “image” bundle. Both
bundles are made up of individual fibers
Borescope
• As technology evolved, the glass fiber bundle
called fiberoptic borescope came into use.
• This device transmits both the light to illuminate
the inspection surface as well as the light
reflected off the object back to the viewing end
Fiber optic borescopes use optical glass fibers to relay the image. Resolution depends on the number of fibers
and their diameter. Each fiber forms a pixel in the final image. If your entry path is not straight, fiber optic
borescopes have the advantages of flexibility and articulation
Video borescope
Fiber Cameras Like the fiber optic borescope, the fiber camera uses light from an external source brought to the test
site via the fiber optic bundle (light guide). This fiber bundle that delivers the external light to the object site is limited in
its length. An articulated (four-directional tip) bundle can be manufactured up to 40 feet long. Fiberglass bundles up to
45 feet can be made without articulating tips. Unlike the fiber optic borescope, the light waves from the object pass
through the objective lens and strike a charged coupled device (CCD). The light waves are then converted to
electronic signals and are transmitted to the processor in the central control unit (CCU). The signals are processed
before being viewed on the monitor. Another name for this equipment is “video borescope”
Visual Inspection of Weld Joints
• Protective lenses with pocket viewer and shade lens for use when observing the welding process
• A magnifying glass
• Flashlight
• Chisel and/or welding hammer for spatter and slag removal before the weld is inspected
• Temperature device (Tempelstick, Pyrometer) to determine the preheating, interpass and post-heating
temperatures.
• Magnet to indicate the type of material being welded
• Tape measure
• Callipers
Visual Inspection Before Welding
• Check drawings
• Look at the weld position and how ti corresponds to the specification. Watch the vertical
direction of travel
• Does the procedure align with local codes and the weld specification
Disadvantages
Advantages Explanation
Detailed Inspection The multispectral sensors aid in focusing on the important
aspects and searching for errors, faults, or flaws. With the use
of drones for industrial inspection, multiple checks for full
examination of the same asset can be reduced.
Accurate Results The onset of aerial and drone inspection has allowed accurate
results to be effectively delivered.
Time-Critical Inspection Operations Aerial inspection services have modernized and enhanced the
prevalent and traditional visual inspection practices. As a
result, UAV inspection has resulted in significant progressive
developments in the inspection industries.
Reduced Cost of Aerial Inspection Services Drones are cost-effective in the sense that they save time and
resources. The cost of resources has been reduced because
UAVs perform the majority of inspection tasks.