Non Destructive Testing and Inspections Conventional NDT Special

RAVENNA E TARANTO
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Non Destructive Testing and Inspections
Conventional NDT
NDT includes those test methods used to examine an object, material or system without impairing its
future usefulness.
The followings are the most used testing methods:
Radiography
Ultrasounds
Dye Penetrants
Magnetic Particles
Special Applications
For Special Applications we intend inspection and testing methods not listed in traditional NDT, which
constitute a very effective support in plant maintenance, letting inspection to be carried out in service or
in turn-around, avoiding dismantling or damaging of parts to be controlled.
They are:
Heat Exchangers Tube Inspection.
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Eddy Currents
Infrared Termography.
Positive Material Identification.
Video boroscopes.
On site Metallographic preparation and examination.
Hardness Test
Advanced NDT
For Advanced NDT we intend the application of new technologies to traditional NDT, to be used both in
fabrication shop and on-field, which may be applied to very critical plants and items.
These NDT present an high added value for the customer due to:
Possibility of avoiding leakage of dangerous and polluting products.
Possibility of carrying out inspection without shutting plants down and avoiding undesired shut
down (Predictive Maintenance)
Possibility of reducing costs for scheduled Turn-around
Possibility of extending the life of items with very high replacement costs.
Possibility of reducing accessory costs for performing controls (insulation removal, scaffolding,
lifting,...)
Impossibility of performing any other inspection.
RAVENNA E TARANTO
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Acoustic Emissions Inspection of Flat Bottom
Storage Tank
Above Ground storage tanks floor may have so strong corrosion problems that undesired leakages of
materials may pollute the environment. The Acoustic Emission (AE) is a non-destructive testing and
monitoring method, which allows the user to detect and locate defects and leakage on tank's floors,
KEEPING TANKS ON LINE
The AE gives information about the physical integrity and the tightness of the tested structure, using a
classical principal for the detection and location of defects and leakage within the complete structure.
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Floormap
Floor Corrosion Survey with Magnetic Flux Leakage
Testing tank floors, even when opened for maintenance, represents a tough issue for inspectors because:
Visual Inspection does not allow to survey corrosion coming from the underside of the floor, which
is where corrosion more likely comes from.
Traditional Inspection (Ultrasonic Thickness neasurements) are too long to be carried out if a
significant area of the tank floor want to be covered.
Using the MFL Method, 100% of bottom plates can be quickly inspected, obtaining information about the
real loss of material and identification of flaws even if coming from the underside.
CUI with INCOTEST
RTD-INCOTEST is an acronym for INsulated COmponent TESTing and it was originally designed and
developed for corrosion detection under insulation on objects made of low alloyed carbon steel.
RTD-INCOTEST is a Pulsed Eddy Current inspection technology which is a cost-effective alternative to
traditional NDT inspection approach both above and below water: it is fast, it guarantees high production
rate, it is suitable for RBI and Integrity Inspection, it is not affected by fouling and marine growth, and
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therefore no expensive cleaning is needed. It does not need any contact with the object to be inspected,
it may inspect through paint, coating and concrete.
Incotest Application:
Spherical tank legs
Insulated tanks
Distillation columns
Insulated pipes and vessels
Piping in Nuclear Power Plants (FAC)
Port structures - Steel Sheet Piling
Risers
Marine ROV
Magnetic crawler remote operation
RTD-INCOTEST is a Applus RTD technology.
Tube Inspection
Multi technology system approach
Eddy current (EC) is commonly used to inspect nonferrous material, whereas remote field technology
(RFT) or magnetic flux leakage (MFL), is used to inspect carbon steel.
Ultrasonics (UT) may be used for accurate thickness measurement and crack detection in almost any type
of material. These limitations are nowhere as evident as in tube testing.
INSPECTION OF TUBES AND PLATES
APPLICATIONS
Eddy Current
Non magnetic heat exchanger tubes
✓
Steam generator tubes
✓
Remote Field
✓
✓
Air conditioner tubes
Boiler tubes
✓
Water pipes
✓
✓
✓
Carbon stell tubes, wear under support
Eddy Currents - Pipes
✓
✓
Aluminum-finned carbon stell tubes
Stell plate corrosion mapping
IRIS (Ultrasonics)
✓
✓
✓
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Eddy current testing is a nondestructive method based on inducing electrical currents, called eddy
current, in the material being inspected. Any defect in the material will disrupt the flow of eddy current
and will be sensed by the instrument (see illustration bellow).
Eddy current is a non-contact method and can be used for detection and sizing of metal discontinuity such
as cracks, pitting, and wall losses. In tube testing, multifrequency eddy current can locate and size defect
under support plate and at the tube sheet.
Remote Field Technique
Remote field is a variation of eddy current send-receive probe technique. The detector coils are separated
by a distance equivalent to two or three times the tube diameter. The receiving coils sense the flux lines
that cross the tube wall twice (see illustration below).
Remote field has an equal sensitivity to internal and external indications while the phase shift is directly
proportional to wall loss.
Iris (Internal Rotating Inspection System)
IRIS is an ultrasonic technique well suited for petrochemical and BOP tube inspections (see illustration
bellow). The technique uses an ultrasonic beam to scan the tube internal surface in a helicoidal pattern
ensuring that the tube full length is tested.
The unit monitors the front wall and the back wall echoes in order to measure the tube wall thickness.
RAVENNA E TARANTO
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TOFD Combined With Pulse-Echo
Controllo TOFD combinato con Pulse-Echo
TOFD is an excellent method for detection and sizing of defects, but cannot be used as a stand alone
technique or as a single pass if 100% coverage of the weld volume is required. The best way is to
determine and employ an adequate number of TOFD configurations (according to weld thickness and
geometry) combined with at least two creeping wave probes in order to guarantee the coverage of the
TOFD "dead zone" from 0 to 5-6 mm depth.
An appropriate multichannel system allows the 100% weld volume coverage combining TOFD with PulseEcho technique with a single linear scan along the weld according to the ASME CODE CASE 2235-9.
Very much important are the AUT Scan Plans, that our operator study according to their long experience
and with the help of dedicated software.
Pulse-echo with scan recording
When TOFDT+P/E technique is not applicable due to weld geometry (limited access like nozzle to shell
welds) the inspection is performed using the ISONIC 2001 system which employs an airborne transducers
mechanics free scanner capable to monitor the X,Y and angular position of the probe in use. The system
record all information in digital forms and displays the scanned area in "top view", "side view" and "end
view" C-SCAN.
Automatic UT Inspection of tube to plate welds in Heat exchangers and
Urea Strippers
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This is a specific control for flaw detection in critical areas of the coupling tube-tube plate, both realized
by welding (fillet weld or IBW) and expanding. In the first case defects such as lack of fusion, inadequate
penetration, solid or gas inclusions are searched. In the second case defects such as over expanding,
etching, notch, blowing are searched. The inspection is carried out from plate side by mean of a borosonic
scanner, while B_SCAN and C_SCAN are recorded for Reportin
AUT Phased Array (AUT-PA)
Ultrasonic Phased Arrays have been widely employed in the medical field since decades. Since few years
the technology is suitable for industrial applications too.
The main advantages of Phased Array AUT (PA-AUT) systems are:
Wave front (beams) forming, modeling and simultaneous use of high number of focal laws
Echographic image evaluation of cross-sectional views
Simplify mechanical scanning (linear Vs. bidirectional)
A very interesting and complete approach is the combination of Phased Array AUT and TOFD
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Some typical AUT applications we perform:
Butt-weld testing with PA-TOFD combined technique in off-shore structures (more than 6000 weld
meters tested)
AUT-PA of complex weld geometries with limited access from one side (nozzle to shell set in
welds)
AUT-PA of austenitic welds
AUT-PA of piping butt joints (down to 2” diameter)
Specific PA-AUT inspection in petrochemical plants
Corrosion monitoring of flange face and inner bore in highly corrosive environment
Hydrogen Induced Damage detection and monitoring (HIC, SOHIC, SWC�..etc.)
PRESSURE VESSELS
Acoustic Emissions for structural Integrity Monitoring
Acoustic Emissions are high frequent, transient sound waves emitted when rapid local stress
redistributions occur in a material. The stress redistributions are normally caused by the generation of
structural changes in material under a general loading condition.
By analysing the quantity and the properties of the acoustic emission signals, information can be obtained
about the processes that are active in the material under loading. This technique has major advantages
such as:
possibility to perform a continous investigation of the material
RAVENNA E TARANTO
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processes can be monitored at the time and place of occurrence
a large structure can be monitored by a limited number of sensors
the spatial location of the signal origin can be calculated by using the signal arrival time times at
a number of sensors
That is the reason why AE is an ideal integral testing method for big pressure equipment. The results
received, allow that follow up NDT's can be reduced to definite and evaluated areas.
Moreover, Pressure equipment or piping systems do not have to be taken out of the production cycle; the
reliability is often higher than conventional methods, like for example visual examination of the interior.
Acoustic Emissions may be performed according to the following modalities:
AE Monitoring during a shop pressure test.
AE Monitoring during a repetition test with gaseous stok product or water.
AE leak detection during pressure test.
leak detection under normal service conditions.
In the field of global integrity tests the following is only a short list of items that can be inspected with
Acoustic Emissions:
Natural-gas storage spheres and cylinders
Reactors for the chemical and petrochemical industry
Steam drums within paper mills
Reactors, filters and storage vessels within air splitting systems
LPG storage devices
Temper furnaces High pressure operations theaters.
Heat Treatments
Control may execute any kind of Heat Treatment on weldings and pipes in fabrication shop and on-site,
both in pre-heating and post-welding.
Anneal
Hardening and Tempering
Stress Relieving
Drawing
Solution Heat Treatment
Heat Treatments are performed with up to date low tension equipment according to existing law and
customers requirements.
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