Advanced NDT Archives | Apex

PEC

apex_dev — Sun, 25 Feb 2024 11:08:16 +0000

Pulsed Eddy Current Testing - PECT is a rapid screening corrosion assessment (remaining % thickness measurement) method utilized primarily on insulated ferrous pipelines, tanks & vessels eliminating the operating asset’s downtime.
Corrosion survey without removing up to 150mm thick insulation on the test surface having temperature up to 550 degree Celsius (hot or cold)
Measure wall thickness through any non-conductive insulation materials such as natural fibers, asbestos, fireproofing, coatings, ceramic, concrete, brick, foam, wool, thermocol, bitumen, etc
Measure thickness through galvanised, stainless, aluminium, cladding or weather jacket
Measure thickness through chicken or hog wire reinforced insulation, straps or protective and polymer coating
No need for surface preparation (scan over corrosion scab or blister) thus minimized risk and cost saving for the plant owner by avoiding grinding or removal.
Measure thickness from 4 to 65mm on pipes above 75mm diameter or vessels or spheres or support legs.
No need for scaffolding. Remote control inspection using extension arms up to 4.6m height.
Battery powered instrument. Perfect for remote locations.

Corrosion under insulation CUI is one of the most undetectable corrosion mechanisms that can affect the integrity of the plant or asset and may not be noticed until the degradation has occurred beyond risk mitigation. Corrosion under insulation CUI, as the name suggests occurs under the insulation layer which is not readily visible to the plant operators. Pulsed Eddy Current - PEC testing can provide wall thickness measurements through any non-ferrous insulation materials such as natural fibers insulations material, calcium silicate, titanium based coatings, ceramic paint, concrete, brick, foam, wool, thermocol, bitumen, dirt, sludge, etc. It can also measure through galvanised, aluminum and stainless weather sheeting.

Ideal Applications:

Detection of corrosion under insulation CUI degradation
Detection of internal flow induced erosion or corrosion
Wall thickness measurement of tanks or pipe-rack without additional cost of scaffolding work or use of elevated working platforms
Wall thickness measurement of excavated pipelines without coating removal and without sand blasting or surface grinding.
Most ideal on insulated, cladded, covered material surface. Subsea and splash zone inspection
Pulsed Eddy Current - PEC testing on high temperature surface without shutting down plant
Inaccessible test surface e.g. covered with asbestos or brick wall or sand covered
Hot or cold insulated pipelines, vessels, equipment, columns, storage tanks, concrete coated sphere legs
Insulated pipes above 100mm diameter or vessels or spheres
Pulsed Eddy Current - PEC testing can measure wall thickness from 4 to 65mm with repeatable results within the range of ±10%.

Advantages:

Absolutely safe. X-Ray or Gamma Ray radiation NOT involved.
No need to remove insulation, cladding, asbestos, fireproofing, concrete, coating from test materials
Pulsed Eddy Current - PEC testing can be performed on insulated materials thus eliminating the operating asset’s downtime
Cost saving for the asset owner by not removing or reinstating insulation
Pulsed Eddy Current - PEC testing can be performed on insulated materials having test surface temperature up to 550 degrees Celcius.
Measurement accuracy of ±10% of measured wall thickness
Pulsed Eddy Current - PEC testing can be performed on insulated layers up to 150mm thick
Test over corrosion scabs or blisters. No need of surface preparation thus cost saving for the plant owner.
Pulsed Eddy Current - PEC testing instrument is battery powered and hence perfect for remote locations.
PEC probes are water proof and hence they can be efficiently applied in marine environment.
PEC probes can be connected to 30m long telescopic extention arms for measuring under water. Perfect for piers at ports and bridges.

Limitations:

Thickness readings are average thickness under the sensor footprint measured in % remaining wall.
PECT measures average thickness at the test location (probe footprint) which varies between 35-200mm depending on insulation thickness, clad material and the wall thickness of the test material. Thickness readings are average thickness under the sensor footprint (1.8 times the footprint) measured in % remaining wall.
Pulsed Eddy Current - PEC testing cannot detect a small isolated pit
The edge effect impacts PEC measurements when a probe nears geometry variations such as nozzles, flanges, or the end of a structure. Measurements begin to vary from a distance of one Footprint from the center of a probe’s coils.
Difficult to use on elebows smaller than 200mm diameter
Current version of software is unable to discriminate near side and far side defects.
Flaws smaller than the averaging area of the probe will be undersized.

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SRUT

apex_dev — Sun, 25 Feb 2024 09:59:36 +0000

Short Range Ultrasonic Testing (SRUT) is a non-destructive testing technique that utilizes high frequency ultrasonic waves to inspect localized areas of a component or structure.
Short Range UT works based on the principle of sending high-frequency ultrasonic waves into the material and analyzing the reflected signals to detect defects. It involves using a small, handheld probe that emits and receives ultrasonic waves. The probe is placed directly on the surface of the component being inspected, allowing for localized and targeted inspection of specific areas. The received signals are analyzed to identify defects such as cracks, discontinuities, or wall thickness variations.

Application:

Short Range UT is commonly used for the inspection of welds, pipes, tanks, and other components in various industries, including manufacturing, construction, oil and gas, and aerospace. It is particularly effective for inspecting areas that are difficult to access with conventional UT techniques, such as complex geometries, narrow gaps, or curved surfaces. Short Range UT can detect defects in localized regions, making it suitable for focused inspections and rapid defect identification.

Advantages:

1. Targeted Inspection: Short Range UT allows for localized inspection of specific areas, enabling targeted defect detection and analysis.
2. Easy to Use: The handheld nature of the probe makes Short Range UT easy to use and maneuver, even in areas with limited accessibility.
3. Rapid Inspection: Short Range UT provides quick inspection results, making it efficient for spot inspections and assessments.
4. Real-Time Feedback: The immediate feedback from the probe allows for real-time analysis of the inspection results.
5. Portable and Versatile: The portable nature of Short Range UT equipment makes it adaptable to various inspection scenarios and field applications.

Limitations:

1. Limited Inspection Range: Short Range UT is not suitable for inspecting large areas or performing full coverage inspections. It is best suited for localized inspections.
2. Surface Condition Dependency: The effectiveness of Short Range UT is dependent on the surface condition and coupling between the probe and the material being inspected. Rough or contaminated surfaces can affect the accuracy of the inspection.
3. Limited Depth Penetration: Short Range UT is typically used for near-surface defect detection and may have limitations in detecting defects deeper within the material.
4. Operator Skill: Proper training and expertise are required to correctly position and interpret the signals obtained from Short Range UT inspections.

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ToFD

apex_dev — Sun, 25 Feb 2024 09:46:33 +0000

Time of Flight Diffraction (TOFD) is a reliable method of nondestructive ultrasonic testing (UT) used to look for flaws in welds. TOFD uses the time of flight of an ultrasonic pulse to find the location of a reflector. It can also be used for weld overlays and the heat affected zones of other components as well such as piping, pressure vessels, clad material, storage tanks, and structural steel.
Like most UT methods, TOFD works by emitting sound waves into a component and measuring the time from them to return. What makes TOFD different from other UT methods is that, rather than measuring only for the high amplitude sound waves that reflects off of the back of the component, it instead measures the response time of low amplitude waves that are diffracted by the tips of cracks.

To do this, TOFD uses a pair of ultrasonic transducers, one as a transmitter and the other as a receiver. The low frequency waves propagate at an angle and only diffract back to the receiver if they hit a defect. If this happens, the time it takes for both waves to make it to the receiver can be used to create a complete image of the weld and identify the size and location of the damage.
TOFD is one of the fastest methods of nondestructive testing because, unlike other types of UT methods, generally only one scan is required to find any defect information within the weld. It can locate and measure the size of many different types of defects with incredible precision. It also has a high degree of repeatability. Because of this, the growth of any flaws can be tracked over time. Finally, it is able to detect damage which would traditionally only be able to be detected through other techniques, such as pulse echo or radiography.

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PAUT

apex_dev — Sun, 18 Feb 2024 12:38:55 +0000

Phased Array is an ultrasonic testing technique that uses specialized multi-element “array” transducers and pulses those elements separately in a patterned sequence called “phasing”. This phasing sequence allows wave steering, focusing, and scanning. This is all performed electronically. The examination can be tailored for each application, increasing speed and reliability of the inspection.
With the ability to collect and encode full volumetric data, Phased Array brings code compliance and auditable results to the everyday Ultrasonic examination. This makes Phased Array an effective and efficient alternative to Radiographic inspection. And since there is no radiation or environmental hazards, Phased Array inspections can access radiation sensitive areas, increase project production by not displacing other crafts in the area, and maximizes on-site and personnel safety.

Advantages of Phased Array:

Excellent repeatability
Increased inspection speed
Accurate results
Ability to inspect complex geometries
Ability to inspect large areas
Permanent auditable results
No safety hazards

Phased Array Inspection Applications

Petrochemical
Corrosion mapping
Detection of hydrogen-induced cracking (HIC), stress corrosion cracking (SCC), and stress oriented hydrogen induced cracking (SOHIC)
Weld inspection of pressure vessels, piping, and tubing
Vessels and piping fabricated with composite materials
Accurate sizing data for fitness-for-service (FFS) calculations
Power Generation
Turbine blades and Christmas tree designs
Pressure vessel and piping welds
Erosion/corrosion mapping

Corrosion mapping

Phased array testing helps make corrosion inspection fast and efficient. Our solutions enable inspectors to be more productive and collect higher resolution data with fully encoded C-scan imaging.
The HydroFORM® scanner, FlexoFORM™ scanner, RexoFORM wedge, and Dual Linear Array™ probe offer efficient inspection options for detecting loss of wall thickness due to corrosion, abrasion, and erosion. Our solutions can also detect mid-wall damage, such as hydrogen-induced blistering or manufacturing-induced laminations, and easily differentiate these anomalies from loss of wall thickness.

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LRUT

apex_dev — Sun, 18 Feb 2024 12:01:27 +0000

Long range ultrasonic testing (LRUT), also known as guided wave ultrasonic testing, is a fast and cost-effective method for inspecting long lengths of pipe.
Hundreds of metres of pipe can be screened in one day from one single location and the technique can inspect 100% of the pipe wall. LRUT can be performed on piping that is in operation, insulated and buried, and in areas that are difficult to access such as those at high elevations. The method can therefore save time and money that would otherwise be spent on excavation, insulation removal and scaffolding.
A ring of transducers is fitted around the pipeline and the transducers generate and receive low frequency ultrasonic guided waves along the pipe. The returning echoes indicate defects such as corrosion and other abnormalities.

The benefits of long range ultrasonic testing include:

Screening long lengths of pipe at one time
Inspection of 100% of the pipe
Detection of corrosion and erosion under insulation of pipes
Analysis of pipes at difficult-access locations, such as wall penetrations, road crossings and buried sites
Screening of on and offshore pipework, even in tightly packed racks
Riser inspection

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Thermography

apex_dev — Sun, 18 Feb 2024 11:58:48 +0000

In engineering, thermography is used as a non-destructive testing (NDT) method in aerospace, defence and many other industries to detect flaws in structures. Able to inspect large areas, this NDT technique doesn’t require contact with the object being tested and can highlight defects including corrosion; cracking; delamination; disbonds; diffusivity; impact damage; moisture ingress; porosity; systemic wall thinning and voids. It can also be used to inspect electrical and mechanical equipment based on the fact that most malfunctioning components will show an increase in temperature, which can be read by the camera.
Thermography involves the use of thermal imagers, which are sophisticated devices that measure the natural emission of infrared radiation from a heated object to produce a thermal picture or video. Modern infrared cameras are portable and easy to operate, meaning that they can be used for many different applications.

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MFL

apex_dev — Sun, 18 Feb 2024 11:55:10 +0000

Magnetic Flux Leakage (MFL) is an advanced nondestructive testing (NDT) technique commonly used in the oil & gas and chemical processing industries to inspect for wall loss and sharp defects such as pitting, grooving, and circumferential cracks in ferromagnetic materials (most commonly pipelines and storage tanks).
Magnetic flux leakage is commonly used for inspecting pipelines and storage tanks in the oil & gas industry; however, the technique can be applied to assets in other industrial sectors. In fact, MFL is the oldest and most commonly used ILI technique for pipelines due to its ability for reliably detecting—while the pipelines are in service—internal and external metal loss due to corrosion. MFL is also widely used for detecting flaws and corrosion in above ground storage tank floors.

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Tube Testing

apex_dev — Sun, 18 Feb 2024 11:48:22 +0000

Eddy current testing of tubes is an effective way of assessing the condition and lifespan of tubes, particularly in the power generation, petrochemical, chemical, fertilizer and air conditioning industries. The technique is applied to detect corrosion, pitting, cracks, erosion and other changes to both the tube’s interior and exterior surfaces.
It is a high-speed inspection method and one of the major advantages is that it can be performed through paint and coatings. The technique is only suitable for non-ferrous material such as stainless steel, copper and titanium. We also perform remote field and magnetic biased eddy current testing on carbon tubing.
Eddy current testing uses electromagnetic induction to identify defects in tubing. A probe is inserted into the tube and pushed through the entire length of the tube. Eddy currents are generated by the electromagnetic coils in the probe and monitored simultaneously by measuring probe electrical impedance. The information revealed by the probe will detail the tube defects. The scanning data will be recorded by the software and kept us as a backup for future reference.

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ECA

apex_dev — Sun, 18 Feb 2024 11:43:50 +0000

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ACFM Array

apex_dev — Sun, 18 Feb 2024 11:40:35 +0000

Alternating Current Field Measurement (ACFM) technique uses electromagnetic inspection with an alternating current to find indications within metals. The ACFM probe measures the electromagnetic field by inducing electric currents on the surface. An indication or crack is detected when these electric currents are disturbed.
ACFM can locate surface-breaking cracks and give information about the length and depth of the indication. With ACFM, the interpretation of the results can be done directly and the testing can be done through coating, paint and rust without calibration.
ACFM has multiple benefits compared to Magnetic Particle Testing (MPI) and Eddy Current Testing (ET). ACFM is seen as an advanced inspection technique similar to Eddy Current Testing, but with significantly lower amount of spurious signals. Just like MPI, ACFM can test welds in underwater conditions, but ACFM has a higher probability of detection (PoD).

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