Enhanced Safety, Cost-Effective, Regulatory Compliance, Sustainability.
Advanced Non-Destructive Testing (ANDT) encompasses a variety of innovative techniques designed to inspect and analyze materials, components, and systems without causing any damage.
These methods leverage cutting-edge technology to provide quicker results, improve accuracy, and enhance cost-effectiveness compared to traditional NDT methods.
Automated Ultrasonic Testing (AUT)
Importance of Pipeline Girth Weld Inspection
Pipeline girth welds are essential connections in pipeline systems where even minor defects can lead to significant failures. The integrity of these welds is crucial for ensuring the safety and reliability of the entire pipeline infrastructure. Therefore, effective inspection methods are necessary to identify and address potential issues before they escalate, automated ultrasonic testing (AUT) is the replacement of choice for traditional radiography.
Advantages of AUT over radiography
• No radiation risks for personnel, no chemicals, or environmental concerns
• Comparatively short inspection cycle time enabling high productivity
• Better detection and sizing accuracy, leading to lower rejection rates
• Satisfies Engineering Critical Assessment (ECA) acceptance criteria with measurement of vertical height and depth
of indications
• Real-time analysis from smart output display
• Data and inspection reports
• No licensing required
Multitechnology Inspection Capabilities
each zone, approximately equal to a welding pass, is inspected individually with a PA pulse-echo or pitch-catch technique, enabling full coverage of the bevel area and the volume of the weld with accurate flaw sizing.
used to confirm indications seen on the strip chart or to improve detection and sizing on small or misoriented indications.
conventional PA techniques, such as sectorial, linear, or compound scans, can be used as complementary methods or to inspect weld configurations where zone discrimination is not optimal.
for detecting transverse flaws in a pitch-catch configuration, measuring wall thickness, inspecting the upper area of the weld with creeping waves, etc.
the powerful QuickScan iX PA data acquisition instrument is capable of supporting the complex firing patterns required for advanced techniques such as TFM
These technologies work together within platforms like PipeWIZARD iX girth weld inspection system is built for demanding and extreme conditions, from cold subarctic regions to hot deserts. Detecting defects including lack of fusion, incomplete penetration, porosity, burn through, undercut, hi-low, crack, cold lap, inclusion, etc. the PipeWIZARD iX system adapts to all circumferential weld configurations:
Any weld profile type
including J-bevel, V-bevel, double V, X, etc.
Pipe wall thicknesses
typically from 6 mm (0.25 in.) to more than 35 mm (1.4 in.); options are available for thicker pipes.
Pipe diameters
from 168 mm (6.625 in.) to 1524 mm (60 in.).
Pipe materials
from standard carbon-steel to more complex configurations, including Inconel, and cladded pipe.
Code Compliance for Girth Weld AUT Inspections
Confidently validate girth welds according to international standards and regulations governing both the offshore and onshore pipeline industry. The PipeWIZARD iX system enables you to perform AUT inspections that comply with the following codes:
- ASTM E-1961 code (covering key elements of AUT of girth welds, including zone discrimination, rapid data interpretation, specialized calibration blocks, and configuration procedures)
- API 1104 standard (by inference)
- DNV-OS-F101 standard (the offshore AUT code)
When your company’s specifications demand it, you can increase the accuracy of your flaw sizing and achieve a level of resolution that exceeds these code requirements.
Advantages of AUT
Speed and Efficiency: AUT allows for rapid inspections, significantly reducing the time required compared to manual ultrasonic testing or radiographic methods. For instance, systems like the Rotoscan can complete inspections in approximately 5 minutes depending on various factors such as pipe circumference and scanning speed.
Enhanced Detection Capabilities: AUT can detect a wide range of defects including lack of fusion, incomplete penetration, porosity, and cracks with high accuracy2. The use of advanced techniques such as Phased Array Ultrasonic Testing (PAUT) and Time-of-Flight Diffraction (TOFD) enhances defect sizing and characterization capabilities.
Real-Time Analysis: Many AUT systems provide real-time data analysis, allowing operators to make immediate decisions based on inspection results.
User-Friendly Interfaces: Modern AUT systems are designed with intuitive user interfaces that streamline the inspection process from setup through data acquisition to reporting.
Automated Ultrasonic Testing (AUT) for Corrosion Mapping
Automated Ultrasonic Testing (AUT) is a sophisticated non-destructive testing technique used for corrosion mapping, which provides detailed insights into the integrity of materials, particularly in industrial applications. This method employs high-frequency sound waves to detect and assess corrosion and other forms of material degradation without causing any damage to the inspected components.
Key Features of AUT for Corrosion Mapping
High-Resolution Mapping: AUT delivers detailed and high-resolution maps that illustrate the extent and severity of corrosion on surfaces. This capability allows for precise assessment and monitoring, enabling maintenance teams to identify critical areas that require attention.
Large Area Coverage: The technology is capable of inspecting extensive surface areas efficiently, making it suitable for large infrastructures such as pipelines, storage tanks, and pressure vessels.
This efficiency reduces inspection time significantly compared to traditional methods.
Consistent Coupling: Automated systems ensure consistent coupling of ultrasonic transducers with the material being inspected. This consistency leads to accurate and reliable data collection, minimizing human error during inspections.
Non-Destructive Nature: One of the primary advantages of AUT is its non-destructive nature. It preserves the integrity of the materials being tested while providing valuable information about their condition.
Automated Data Collection: The use of automated systems enhances the speed and efficiency of inspections by reducing manual intervention. This automation allows for real-time data analysis, facilitating immediate decision-making regarding maintenance or repairs.
Benefits of Implementing AUT for Corrosion Mapping
Comprehensive Corrosion Assessment: By providing thorough assessments, AUT supports proactive maintenance strategies that can prevent costly failures down the line.
Increased Efficiency: The rapid inspection capabilities reduce downtime during maintenance activities, leading to significant operational cost savings.
Improved Safety Standards: Detailed corrosion maps help identify at-risk areas, enhancing overall safety protocols within industrial environments.
Real-Time Insights: The ability to analyze data on-the-fly allows organizations to respond quickly to potential issues before they escalate into serious problemst.
Applications of AUT in Industry
Regular inspections are crucial for maintaining pipeline integrity and preventing leaks.
Ensures that critical components like boilers and turbines remain safe from material degradation.
Used in quality control processes to ensure product reliability before deployment.
Phased Array Ultrasonic Testing (PAUT)
Phased Array Ultrasonic Testing (PAUT) is a technique that utilizes a specialized probe composed of multiple small ultrasonic elements. Each element can be pulsed independently, allowing for precise control over the emitted ultrasonic beams. This capability enables PAUT to effectively detect and characterize internal flaws in materials, making it a valuable tool across various industries.
Applications
Commonly employed for assessing weld integrity in pressure vessels and pipelines.
Effective in identifying stress corrosion cracking (SCC), hydrogen-induced cracking (HIC), and other types of flaws.
Utilized for monitoring corrosion levels in structures like storage tanks and pipelines.
Suitable for evaluating composite materials used in aerospace and automotive applications.
Advantages of PAUT
Time of Flight Diffraction (TOFD)
Time of Flight Diffraction (TOFD) is an advanced ultrasonic technique primarily used for the inspection of welds and other critical engineering structures. It was developed in the 1970s, initially as a research tool in the UK, and has since become one of the most reliable methods for detecting and sizing defects in welded components. Unlike traditional ultrasonic testing methods that rely on reflected signals, TOFD uses diffracted sound waves from defect tips to provide accurate information about flaw size and location.
Principle of Operation
TOFD operates on the principle of diffraction rather than reflection. A pair of ultrasonic probes is employed: one acts as a transmitter, emitting an ultrasonic pulse, while the other serves as a receiver. These probes are placed on opposite sides of the weld or test area.
Wave Propagation: The transmitter emits longitudinal ultrasonic waves into the material.
Detection Mechanism: In defect-free materials, two primary signals are received:
- The lateral wave traveling along the surface.
- The back-wall echo reflecting off the far side of the material. When a defect such as a crack is present, part of the wave energy is diffracted at the tips of the crack.
Data Analysis: By measuring the time it takes for these diffracted waves to reach the receiver (time-of-flight), precise calculations can be made regarding:
- The depth and height of defects.
- Their spatial orientation within the material.
This method relies on trigonometry to determine defect dimensions with high accuracy.
Advantages of TOFD
It is highly sensitive to all types of weld flaws, including cracks, slag inclusions, and lack of fusion.
TOFD excels at accurately sizing vertical planar defects like cracks by analyzing diffracted signals from defect tips.
A single scan can cover large areas quickly due to its wide beam spread.
Inspection data can be recorded digitally for future reference or analysis.
Its high degree of repeatability makes it suitable for monitoring flaw growth over time during in-service inspections.
Unlike radiographic testing (RT), TOFD does not involve radiation hazards.
Equipment Used
- Ultrasonic probes designed specifically for diffraction-based detection.
- Wedges made from materials like Rexolite or stainless steel to direct sound waves effectively into test specimens.
- Scanners equipped with encoders for automated data acquisition along weld seams.
- Software tools for post-analysis and imaging (e.g., OmniPC).
Rapid Motion Scanner (RMS)
Rapid Motion Scanner (RMS) is a sophisticated piece of equipment developed by Silverwing UK, designed for advanced ultrasonic testing and corrosion mapping. This scanner is notable for its high-speed scanning capabilities and versatility in various industrial applications.
Key Features of the RMS
A crucial for assessing the integrity of various industrial assets such as storage tanks, pipelines, and pressure vessels. Below is a detailed exploration of how RMS operates, its benefits, and its applications.
The RMS can achieve scan speeds exceeding 700 mm per second. This impressive speed allows it to cover large areas efficiently, making it suitable for extensive inspections.
At a resolution of 2 mm x 2 mm, the RMS can scan an area of 2.5 m² (approximately 27 ft²) per hour. If the resolution is adjusted to 10 mm x 10 mm, the coverage increases significantly to 13 m² (about 140 ft²) per hour. This flexibility in resolution allows users to balance detail and speed based on their specific needs.
One of the standout features of the RMS is its ability to traverse obstacles such as weld caps that would typically hinder other scanning devices. This capability is facilitated by powerful drive motors and strong magnetic wheels, which enhance its mobility and adaptability in complex environments.
Integration with Ultrasonic Acquisition Systems
The RMS works in conjunction with a range of computerized ultrasonic acquisition systems produced by Technology Design Ltd., including:
- TD Focus-Scan
- TD Handy-scan
- TD-Scan
- TD Pocket-Scan
These systems utilize either pulse echo or phased array techniques to control data acquisition and analysis effectively. They are equipped with advanced electronics and software that provide fast data throughput, multiple display modes, offline re-gating, color palettes, and measurement tools for comprehensive analysis.
Tank Floor Scanning Magnetic Flux Leakage (MFL)
Magnetic Flux Leakage (MFL) is a widely used non-destructive testing (NDT) technique for inspecting ferromagnetic materials, particularly steel tank floors. It is designed to detect and map material loss caused by corrosion, pitting, or wall thinning. This method is especially critical in industries like petrochemicals, where storage tanks are used to hold hazardous substances. MFL technology provides rapid and reliable results over large areas, making it an essential tool for maintaining the structural integrity of storage tanks.
The principle of MFL involves magnetizing a ferromagnetic material and detecting distortions in the magnetic field caused by defects such as corrosion or pitting.
These distortions are referred to as “leakage fields,” which can be measured using sensors like Hall Effect sensors or coil sensors. The data collected is then analyzed to determine the location, size, and severity of the defects.
Applications of MFL Technology
MFL technology has diverse applications across various industries due to its efficiency in detecting defects in ferromagnetic materials:
- MFL is extensively used for inspecting storage tank floors in petrochemical facilities.
- It helps identify general corrosion, localized pitting, and wall thinning that could lead to leaks or structural failures.
Inline inspections of pipelines ensure their reliability by detecting cracks, wall thinning, and other flaws.
Detects pitting and wall loss in boiler tubes and heat exchangers.
Ensures safety by identifying cracks and wear on rail tracks.
Used for inspecting curved surfaces where manual inspection may be challenging.
Monitors corrosion and damage in offshore structures exposed to harsh environments.
Advantages of MFL for Tank Floor Scanning
Rapid Inspection Over Large Areas: MFL scanners can cover hundreds of square meters quickly without requiring direct contact with both sides of the tank floor
High Sensitivity: Modern MFL systems achieve near-saturation magnetization levels, allowing them to detect even small defects with high accuracy.
Real-Time Feedback: Advanced scanners provide immediate visual feedback through mapping software like C-Scan displays.
Cost-Effectiveness: By identifying defects early, MFL reduces repair costs and prevents catastrophic failures that could result in environmental damage or product loss.
Electromagnetic Inspection (EMI)
Electromagnetic Inspection (EMI) is a critical nondestructive testing method used to detect various types of defects in materials, particularly in metallic structures such as drill pipes. This technique utilizes electromagnetic fields to identify flaws that could compromise the integrity and longevity of the material being tested.
Applications of EMI
EMI is particularly effective for detecting:
Small cracks that develop due to repeated stress cycles.
Degradation caused by chemical reactions with environmental elements.
Surface imperfections that can lead to structural weaknesses.
Reduction in wall thickness due to wear or corrosion.
Importance of EMI in Industry
The use of EMI in industries such as oil and gas is crucial because it helps ensure safety and reliability. Regular inspections can prevent catastrophic failures that not only incur financial losses but also pose risks to personnel and the environment. By identifying issues early through EMI testing, companies can implement timely repairs or replacements before more serious problems arise.
By employing an effective inspection and maintenance program utilizing EMI, companies can significantly reduce the risk of failure in their drill strings, which could lead to costly downtime or even loss of well integrity
Advanced Digital Radiography (ART)
Key Features of ART
ART employs advanced digital detectors, such as flat panel detectors or phosphor-coated imaging plates, which capture images electronically rather than using traditional film. This transition allows for immediate viewing and analysis of the captured data.
The digital nature of ART enables superior image resolution compared to conventional radiography. Images can be magnified or enhanced for more accurate defect assessment, making it easier to identify issues like cracks, corrosion, and other structural anomalies.
One of the significant advantages of ART is the ability to generate instant reports. Digital images can be easily stored, shared, and accessed remotely, allowing inspectors to evaluate findings on-site or off-site without delay.
By eliminating the need for film and chemical processing associated with traditional radiography, ART reduces operational costs significantly. This cost-effectiveness extends to both equipment maintenance and storage requirements.
The use of digital technology minimizes radiation exposure risks for technicians since there are no chemicals involved in developing films. Additionally, smaller exclusion zones are required during inspections, enhancing overall safety.
ART is applicable across various sectors including aerospace, oil and gas, construction, and manufacturing. It is particularly effective in inspecting pipes, valves, welds, castings, and detecting corrosion under insulation (CUI).
ANDT ensures that its ART services adhere to strict legal requirements and industry standards related to nondestructive testing (NDT). This compliance guarantees that inspections meet quality assurance protocols.
ANDT employs highly trained inspectors who are certified at Level 2 or 3 according to ASNT SNT-TC-1A standards. Their expertise ensures accurate assessments using advanced digital radiographic techniques.
Digital radiography (CR & DR)
Digital radiography (CR & DR) has transformed imaging by providing faster, more efficient, and higher-quality images compared to traditional film-based methods. The two primary types of digital radiography systems are Computed Radiography (CR) and Digital Radiography (DR). Each system has its unique characteristics, advantages, and disadvantages.
Computed Radiography (CR)
Computed Radiography (CR) utilizes photostimulable phosphor (PSP) plates to capture X-ray images. When exposed to X-rays, these plates store energy which is later released as visible light when scanned by a dedicated CR reader. This light is then converted into a digital image. The process involves several steps:
Image Acquisition: The PSP plate captures the X-ray image.
Processing: The plate is scanned in a CR reader, converting the stored energy into a digital format.
Storage and Retrieval: The digital images can be easily stored and retrieved for analysis.
While CR offers a cost-effective solution for facilities transitioning from film-based systems, it does have some limitations:
Slower Workflow: The need to process the cassette after exposure results in longer wait times for images.
Lower Image Quality: Generally, CR produces lower resolution images compared to DR systems.
Digital Radiography (DR)
Digital Radiography (DR) employs advanced flat-panel detectors that convert X-ray energy directly into digital signals without the intermediate step of scanning a phosphor plate. This allows for immediate image availability. Key features include:
Direct Image Capture: Images are captured directly onto digital detectors.
Instantaneous Processing: Images can be viewed within seconds of exposure.
Higher Image Quality: DR typically provides superior spatial resolution and dynamic range compared to CR.
The advantages of DR systems include:
Images are ready for review almost instantly, significantly improving patient throughput.
DR systems often require less radiation to produce high-quality images due to their increased sensitivity
DR systems often integrate better with electronic health record systems, enhancing workflow efficiency
Eddy Current (ECT)
Applications of Eddy Current
In petrochemical facilities, ECT has reduced unnecessary grinding during internal inspections following magnetic particle tests. It allows operators to set acceptable thresholds for defects while keeping equipment operational during inspections.
Within the power industry, ECT is employed extensively for inspecting piping systems, valve bodies, and welds in hydro stations. This method helps determine fitness for service by identifying potential failure points before they lead to significant issues
The pharmaceutical sector benefits from ECT’s clean application process compared to dye-penetrant tests. Its effectiveness in inspecting thin-walled non-ferrous components aligns well with the industry’s high hygiene standards
In aerospace applications, ECT plays a crucial role in ensuring safety by detecting cracks and corrosion in aircraft components. Regular inspections help maintain airworthiness and comply with stringent safety regulations. The ability to identify defects early allows for timely repairs or replacements, thereby extending the lifespan of critical components.
Principles of Eddy Current
Key Features of Eddy Current
Advantages Over Traditional Methods
Internal Rotary Inspection System (IRIS)
Internal Rotary Inspection System (IRIS) is a sophisticated technique primarily used for inspecting the integrity of pipes and tubes in various industrial applications. This method employs ultrasonic technology to assess wall thickness and detect defects such as corrosion, pitting, and wall loss.
Applications of IRIS
IRIS is widely utilized across several industries due to its versatility and accuracy:
Oil & Gas: For inspecting pipelines and storage tanks.
Power Generation: Commonly used in boilers, heat exchangers, and steam generators.
Chemical Processing: To ensure safety in processing equipment.
Aerospace: For inspecting hydraulic tubes and other critical components.
Marine & Shipbuilding: Used in evaluating piping systems on ships.
The method’s ability to work with both ferrous and non-ferrous materials makes it particularly valuable in environments where different types of metals are used
Advantages of Using IRIS
A technique primarily used for inspecting small diameter pipes and tubes. This method employs ultrasonic technology to assess the integrity of materials without causing any damage, making it essential in various industries, particularly those involving heat exchangers, boilers, and other critical components.
High Accuracy: Wall thickness measurements can be accurate within ±0.005 inches (±0.13 mm).
Comprehensive Coverage: The helical scanning technique ensures 100% coverage of the tube’s circumference.
Real-Time Data Analysis: Data can be analyzed live during inspection or stored for later review.