Driving industrial plant performance through Advanced Non-destructive Testing (ANDT) methods
WHAT IS ADVANCED NON-DESTRUCTIVE TESTING (ANDT)?
The ever-growing global demand for electricity and industrial production capability is putting significant pressure on our ageing industrial infrastructure. In an increasingly competitive marketplace, industrial plant owners and operators simply cannot afford plant downtime. Advanced Non-destructive Testing (ANDT) services utilize advance instrumentation based on latest software and hardware technology to perform NDT testing of critical components. Several Advanced NDT methods can be used to perform in-service inspection of plant assets. These critical plant assets are tested for fitness during shutdowns, with the use of Advanced NDT methods, testing can be performed in less time and quantitative data can be obtained to take the necessary course of corrective actions by plant operators to avoid in-service failures and to further enhance productivity.
IMPORTANCE OF ADVANCED NON-DESTRUCTIVE TESTING SERVICES
Mitigates the risk of emergency shutdown due to leakages/failure of plant assets
Cost effective and useful for condition monitoring
Helps perform time bound inspections
Less operational disturbances are involved
Quantitative data collection is expedited to take timely corrective action
Expertise and experience of interpreting data and plan are offered to avoid future failures
Various ANDT instruments use batteries to function and do not require power supply
Software based report preparation and permanent test parameters recorded in soft copies
Our fully equipped state-of-the-art Advanced non-destructive testing, non-destructive testing and destructive testing lab based at Noida, India, and highly experienced and certified on-site inspectors ensure that your assets, components, equipment and systems continue to operate effectively and efficiently for a long time.
Our Advanced NDT services include:
Long Range Ultrasonic Testing for Piping/Pipeline inspection (LRUT):
Tool for rapidly inspecting long lengths of pipelines from single location.
Unlike conventional ultrasonic inspection method, LRUT screens pipelines 360 degrees to locate discontinuities for further verification by saving time and money.
Combination of multiple wave modes assures operators about finding longitudinal as well as circumferential discontinuities.
When low frequency waves (15 kHz to 85 kHz) are propagated from a single location, it can reach up to several meters of distance and inspection data can be captured, interpreted, stored and reported in advanced software.
Features and Advantages
Possible to inspect diameters from 2” up to 48”. Possible to inspect wide temperature ranges: 0 to 1000 degree C.
Road crossing, river crossing, Dyke, culvert and in-cased pipelines
Off-shore and jetty pipelines
Tank farm and cross-country pipelines
Pulsed Eddy Current testing (PEC) for Thickness measurement of carbon steel under insulation/fireproofing:
Pulsed Eddy Current Testing is saving huge amount of money and time for operators while inspecting plant equipment's or components which are insulated. It is very difficult to perform inspections on coated, insulated surfaces; PECT makes it easy by measuring thicknesses through insulation. This electromagnetic principle based instrument works on battery and stores inspection data which can be easily converted into tabulated format for reporting purpose. In 1 working day, we can inspect up to 500-600 inspection points.
Features & Advantages
Possible to inspect diameters from 1” up to flat surfaces
Possible to inspect thickness up to 100 mm
Possible to inspect wide temperature ranges: -100 to 6500C
Possible to inspect insulation/fireproofing thicknesses from 0 to 203 mm
Concrete coated skirts and sphere legs
Piping, tank, vessel, columns
Inspections on Al, SS and Galvanized weather jacket/cladding
Magnetic Flux Leakage (MFL) for detection of corrosion in storage tank bottom plates, Scorpion2 and Vacuum box for complete out of service tank inspection
Storage tanks of petroleum, fire water or vegetable products are prone to soil side corrosion over long duration in operation. As a severe consequence; tank starts leaking from bottom or from shell, resulting in emergency turnarounds. Despite routine inspections, operators miss spots of corrosion due to conventional methods of inspection. Using MFL plate scanner, we can scan 100% of the bottom plate surface and detect soil side corrosion at an early stage before it leaks.
Features & Advantages
Variable speeds: 500 mm/s to 1 m/s (19.7 in/s to 3.3 ft/s)
Through-coating inspection up to 6 mm (0.24 in), including fibre-reinforced plastic (FRP), glass-reinforced plastic (GRP), and stainless steel
Advanced defect sizing and classification tools
Full tank floor mapping
High probability of detection
Dry-coupled, remote-access ultrasonic crawler brings major efficiency and data improvements to tank shell inspections and other structures such as vessels and offshore installations.
Battery operated system can inspect 4.7 to 100 mm of thickness.
Unique, dry-coupled ultrasonic wheel probe eliminates the need for couplant.
Vacuum box has been designed to API 650/653 recommendations.
Bubble leak (or vacuum box) testing is an integral part of tank inspections as required by the American Petroleum Institute (API) and other international standards.
System is more efficient, reduces operator fatigue, increases operator safety. System incorporates calibrated vacuum gauge with flat and corner weld inspection models.
Corrosion Mapping on carbon steel structures using Automated X-Y scanners
RMS2 is a high-speed, high-accuracy remote-access ultrasonic corrosion mapping system. RMS2 offers 100% coverage in a band up to 1 m wide, significantly increasing the probability of detection (PoD) of defects, enabling engineers to determine optimal repair strategies, and improve remaining life assessment (RLA) and risk-based inspection (RBI) maintenance programs.
Features & Advantages
High probability of corrosion detection with up to 0.5 mm
Helps reduce maintenance costs by minimizing use of scaffolding
No paint removal required
Wide range of applications up to 200˚C
Inspect materials as thick as 150 mm
3D data view
Can be used on any ferrous item from 152.4 mm (6in) NB to flat plates
Storage tank shells
Phased Array (PAUT) & TOFD
Phased Array Ultrasonic Testing (PAUT)
A power full ultrasonic testing tool which is replacing Radiography in many applications.
A phased array system is normally based around a specialized ultrasonic transducer that contains many individual elements (typically from 16 to 256).
Test frequencies are most commonly in the range from 1 to 10 MHz.
Features & Advantages
The benefits of phased array technology over conventional UT is that it can steer, focus and scan multiple element beams with a single transducer assembly.
Battery operated – Battery lasts 6-7 hours.
Simplicity in inspecting components with complex geometry.
Increased probability of detection of anomalies.
Possible to inspect ¾ diameter to flat surfaces.
Possible to inspect minimum 5 mm thickness.
Ability to focus at multiple depths improving the ability for sizing critical defects for volumetric inspections.
Time of Flight Diffraction (TOFD)
Primary use is rapid weld testing of circumferential and axial weld seams.
In many applications PAUT and TOFD is carried out in combination.
Ultrasonic sensors are placed on each side of the weld. One sensor sends the ultrasonic beam into the material and the other sensor receives reflected and diffracted ultrasound from anomalies and geometric reflectors.
Excellent and highly sensitive tool for detecting welding flaws/cracks.
Features & Advantages
Uses time of arrival of signals received from crack tips for accurate defect positioning and sizing.
Precise sizing capability
Quick to set up and perform an inspection, as a single beam offers a large area of coverage
Rapid scanning with imaging and full data recording.
Can also be used for corrosion inspections
Pipeline weld inspection
Complex geometry welds
Heat Exchanger Tube Testing (ECT/RFT/IRIS)
ECT is used with non‐ferromagnetic metal such as copper, brass, and copper‐nickel alloys.
RFT can detect ID and OD defects but cannot distinguish between ID and OD.
Outer Diameter Range: 0.5” (12.7mm) to 3.5” (88.9mm)
Wall Thickness Range: 0.049” (1.2mm) to 0.250” (6.35mm)
Production: 350-400 tubes / 8-hour shift
IRIS can be used on ferrous or non-ferrous tubes material.
Detects: accurate wall thickness, pitting, corrosion
IRIS can distinguish between ID and OD.
Outer Diameter Range: 0.5” (12.7 mm) to 3” (76.2mm) (OD less than 0.75” (19.05mm) requires special equipment)
Wall Thickness Range: 0.049” (1.2mm) to 0.500” (12.7mm)
Feed water heaters
Heat exchanger tubes (Ferromagnetic)
Heat exchanger tubes (Non-Ferromagnetic)
API Compliant Inspections
Non-destructive Testing (NDT) provide critical information on condition of assets. TÜV SÜD’s engineering experts and on-site inspectors have the technical expertise and experience to support plant operators in challenging tasks across all relevant applications. Our specialists are certified in accordance with ISO 9712, SNT-TC-1A, and API. Our comprehensive services enable you to maintain highest standards of quality throughout the lifecycle. Accurate and reliable testing data from our experts can be utilized to prevent and repair equipment, component, infrastructure failures and correct & improve processes.
API compliant inspections as per API 653 for Above Ground & Under Ground Storage Tanks
API compliant inspections as per API 570 for Piping & Pipelines
API compliant inspections as per API 510 for Pressure Vessels
Risk Based Inspections (RBI) – API 581
Remaining life calculations / Condition Assessment – as per IBR
Fit for Service assessment – API 579
Asset Integrity Management
Root Cause Failure Analysis
TÜV SÜD uses high end instrumentation operated by skilled manpower to aid API compliant studies.
Thickness gauging at normal and high temperature.
Dye Penetrant Inspection (DP)
Magnetic Particle Testing (MPT)
Oxide layer measurement
In-situ Metallography (Replica)
Corrosion mapping using Advanced crawler based X-Y scanners
Welding inspection for surface and internal defects (PAUT/TOFD, MPI, DP, ECT)
Long Range Ultrasonic Testing for Piping/Pipeline inspection
Pulsed Eddy Current Testing (PEC) for Thickness measurement of carbon steel under insulation/fireproofing.
Bottom plate inspection by Magnetic Flux Leakage Technology
Bottom plate weld inspection using Silver Wing Vacuum box system
Storage Tank Shell Plate inspection Scorpion2 – dry coupled UT (Without scaffolding)
Tank settlement and verticality
TÜV SÜD HELPS TO TEST YOUR PLANT’S COMPONENTS AND SYSTEMS FOR SAFETY AND COMPLIANCE WITH OUR ANDT SERVICES
Following are few business benefits of our ANDT services:
Testing can be performed without time consuming operational arrangements.
Faster data interpretation and report generation results can be achieved through quicker decision making for plant operators.
We utilise advanced battery-operated instrumentation requiring no power supply on site.
Availability of our trained and highly skilled manpower to perform tests.
Availability of our ANDT experts to assist in interpretation and consulting for taking corrective actions by the plant operators.
We have excellent knowledge and expertise in dealing with various international codes used in construction as well as in-service applications.
As we are present over 1000 locations globally, we have ANDT experts world-wide.
DRIVING INDUSTRIAL PLANT PERFORMANCE THROUGH ADVANCED NON-DESTRUCTIVE TESTING (ANDT) METHODS
We have world-class state-of-the-art ANDT equipment from Manufacturers like Olympus, Eddyfi and Silverwing
We utilize latest software and hardware technology for accurate results
Highly trained and qualified manpower
Global expertise in the field of ANDT, NDT & DT
Availability of multiple resources.
Capacity to manage long term and large quantum jobs due to presence in more than 30 location in India with adequate manpower.