Advanced NDT Techniques

Advanced NDT Techniques

Tube Inspection Techniques Advanced UT Techniques Electromagnetic Techniques

• IRIS – Internal Rotary Inspection System
• MFL – Magnetic Flux Leakage
• ECT – Eddy Current Testing
• RFT – Remote Field Testing
• NFT – Near Field Testing
• TECA – Tangential Eddy Current Array
• Phased Array Ultrasonic Testing (PAUT)
• Time of Flight Diffraction (TOFD)
• Ultrasonic Corrosion Mapping
• Long Range Ultrasonic Testing (LRUT)
• Electro-Magnetic Acoustic Transducer
(EMAT)
• Tank Floor Inspection - Magnetic Flux
Leakage (MFL)
• Pulsed Eddy Current (PEC)
• Eddy Current Array (ECA)
• Alternating Current Field Measurement
(ACFM)

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 Tube Inspection
Whether the tubing is in power generation, air conditioning, petrochemical,
food processing, or pharmaceutical manufacturing, the condition of tubes plays a vital
role in process efficiency and safety. Thus, a quality tube inspection program is necessary
to detect the damage before failure occurs.
The tubes are inspected periodically to detect and size discontinuities (e.g. pits, erosion, cracks, grooves and wear). Corre ct technique selection is critical
and depends on the tube material (ferromagnetic or non-ferromagnetic) and the type of discontinuities expected. No single inspec tion technique is adequate
for all tubing applications, all types of materials, and all defects. ECT is commonly used to inspect non-ferromagnetic tubes, RFT and MFL are used to
inspect carbon steel and other ferromagnetic tubes, while IRIS ultrasonic testing is perfect for metal loss measurements on both types of tubes.

Technologies Objectives
• Eddy Current Testing • Establish the overall condition of the heat exchanger.
• Eddy Current Array • Identify any trends.
• Identify potential leakers.
• Tangential Eddy Current Array
• Classify each tube in terms of defect type and severity.
• Remote-Field Testing
• Minimize or eliminate in-service tube failures.
• Near-Field Testing
• Reduce maintenance and re-tubing costs.
• Near-Field Array • Evaluate tube condition on a regular basis.
• Magnetic Flux Leakage • Analyze the effectiveness of preventative maintenance.
• Internal Rotating Inspection System ultrasonic testing • Provide invaluable data for strategic planning.

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 Phased Array Ultrasonic Testing (PAUT)
Developments in construction codes have allowed PAUT to be used as
a direct replacement to Radiography to meet the quality control requirements
of codes and standards.
Phased array is an advanced ultrasonic technique utilizing multiple miniaturized transducers and time-delays to shape the ultrasonic sound beam in a
desired angle and focus. PAUT enables reduced inspection time by simultaneously collecting multiple angle ultrasonic data in a one pass scan from either
side of the weld. By ensuring accurate scan plans and specifically designed techniques, the defects are easily detected, size d and characterized.

Advantages Applications
• Rapid inspections with digital recording of data • Weld inspection of vessels, pipelines and plates
• Radiation free. No safety hazards • Weld inspection of complex geometries, such as nozzle-welds
• Improved defect detection and sizing • Flange face corrosion inspection
• Highly sensitive to fusion face flaws • Fast corrosion scanning utilizing 0 degree angled wedges
• Great flexibility in parameter range • Code case inspection in combination with Time of Flight
• Many special techniques are possible. Diffraction (TOFD) and/or pulse-echo
• Visualization of indications in weld and/or • Turbine component inspection
base material, using B, C, D and S-scans • Shaft and axle inspections
• Facilitate inspections of complex geometries • Composite inspection
• Compliant with all known codes • Bolt testing

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 Time of Flight Diffraction (TOFD)
Time of Flight Diffraction (TOFD) technique is widely used in the oil and gas,
petrochemical and power generation industries and is even more reliable than
traditional radiographic, manual and automated UT weld testing methods.
TOFD is a fast fully computerized technique able to scan, store, and evaluate indications in terms of height, length, and pos ition with a grade of accuracy
never achieved by other ultrasonic techniques. TOFD is able to measure defect length and through thickness height, which are the key parameters in
mechanical strength. The accuracy of greater than ±1mm can be obtained in a wide range of material thickness from which pressurized components are
constructed. As a ”stand alone“ inspection, TOFD has the highest reliability with respect to defect detection and excluding fal se calls.

Advantages Applications
• Radiation free. No safety hazards • Pre-service inspections - Weld inspection of vessels, pipelines
• Sensitive to all kinds of defects and plates
• Higher Probability of Detection (POD) • In-service Weldments for preferential corrosion/erosion loss at the
• High degree of repeatability root and heat affected zone (HAZ).
• Defect detection does not depend on orientation. • In-service Weldments and material for fatigue or service related
• Very accurate determination of defect height and length. cracking problems
• Inspection results are immediately available and the interpretation is • New construction HDPE fusion weld inspection.
possible directly on-site • Defect monitoring
• High data collection speeds possible (250mm/ second). • Cladding thickness measurement
• Can be used between 6mm up to 300mm thick welds and even more.

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 Ultrasonic Corrosion Mapping
Ultrasonic corrosion mapping is a key method in non-intrusive inspection
strategies and an effective way of finding, revealing and measuring corrosion,
erosion and other service induced defects.
The main advantage of corrosion mapping is that it guarantees 100 percent scan coverage of the area under examination. This gives a much improved
effectiveness over standard ‘random’ UT wall thickness scans. Another practical advantage is that corrosion mapping produces a permanent record of
corrosion measurements with a high degree of reproducibility which makes it an interesting tool for corrosion monitoring all owing the corrosion rate of the
material to be calculated efficiently. Furthermore, due to the speed of modern systems, considerable coverage can be complete d on a daily basis.

Benefits Applications
• Permanent record of inspection results. • Improvements in accuracy result in more reliable estimates and
• High degree of repeatability. more cost effective integrity management.
• A greatly improved probability of detection. • Accurate wall thickness measurements permit more reliable
• Guaranteed 100% coverage of the inspection area. identification of the corrosion mechanism and can assist in
• Improved sizing and characterization comparing to decisions on operation and corrosion control.
conventional techniques • Determination of degradation characteristics and dimensions for
• Improved speed versus manual UT. fitness for service assessment.
• Thickness measurements in an easily • Estimation of corrosion growth rates for remaining life
Understandable topographical color map. assessment.
• Inspection can be performed on in-service equipment

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 Long Range Ultrasonic Testing (LRUT)
Guided wave ultrasonic testing is one of the latest methods in the field
of non-destructive evaluation that provides a rapid and reliable new
solution for pipe inspection.
Also known as long range ultrasonic testing (LRUT), the technique is a fast and cost -effective method for inspecting long lengths of pipe for corrosion and
other defects from one single location allowing screening hundreds of meters of pipe in one day. The technique is used to det ect internal and external
volumetric change allowing the inspection of 100% of the pipe wall for internal or external metal loss features such as corro sion and erosion. The piping can
be in operation, insulated, with protective coating and even be buried.

Capabilities Applications
• Sleeved road crossings
• Can be performed at elevated temperatures up to 125°C without taking the
• Buried pipe
pipe out of service (300°C using special high temperature transducer ring).
• Wall penetrations
• Minimal insulation removal for corrosion under insulation (CUI) inspections
• Pipe racks
• Inspection of pipe from 2 to 72 inch diameter is possible
• Corrosion under supports
• Fluid and gas does not affect test
• Subsea lines
• Ability to detect (internal/external) metal loss and planar defects
• Offshore risers and caissons
• Up to ½ km per day can be inspected in ideal conditions
• Corrosion under insulation (CUI)
• Sensitivity can be as good as 1% loss of cross-section in ideal conditions
• Offshore topsides pipework
• Minimal cleaning at the test location
• Jetty lines
• Portable and battery powered equipment

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 EMAT – Medium Range Ultrasonic Testing
Corrosion under pipe supports is regarded as a worldwide integrity threat within
the oil and gas industry and has long been a problem for integrity departments,
due to the lack of reliable technology to detect and quantify it.

MRUT (Medium Range Ultrasonic Testing) is one of the latest technique which uses Guided Waves technology to detect corrosion using EMAT
transducers. MRUT (Medium Range Ultrasound Testing) uses high frequency guided waves with a typical inspection range between 0.1m and 5m to detect
corrosion, cracks, and discontinuities on both pipes and plate, and is suitable for inaccessible geometries such as clamps, s addles and pipe supports. The
inspection can be performed on rough and corroded surfaces, when covered with thin wraps or coatings (<3mm).

Benefits
• Permit coverage up to 5m in front of the sensors (typical distance 0-1m)
using reflection technique (circumferential scanning)
• Ideal for inspection of corrosion under supports and air-to-soil interfaces on
exposed or thinly coated parts (<3mm).
• Sensitive to both internal and external surface degradation
• Works on any conductive material (ferrous and non-ferrous).
• Dry inspection where no couplant is needed.
• Insensitive to surface conditions where it is capable of inspecting rough,
dirty, oxidized or uneven surfaces
Applications
• Inspection under supports: It works for either pipelines that
are welded or those resting on supports.
• Air-to-soil interfaces: the technique can be used for
inspection of the first 1-2m of an inaccessible structure
(buried or hidden).
• Free-standing pipeline: Detects smooth corrosion, pitting,
and cracks on free-standing pipelines with minimum
insulation (less than 3mm).

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 MFL Tank Floor Inspection
Storage tanks require inspection at regular intervals to ensure deterioration is detected
at an early stage. Effective inspection identifies the repairs required before the point where
leakage or other failure occurs, avoiding environmental contamination and product loss.

Magnetic Flux Leakage (MFL) is a method of non-destructive testing that is used to detect corrosion and pitting in steel structures, most commonly pipelines
and storage tanks, using powerful magnets to magnetize the steel. Development of the technique has vastly reduced the time taken to inspect a tank floor
whilst producing detailed and accurate reports allowing engineers to determine optimum maintenance strategies.

Advantages Objectives
• Most reliable inspection method available • Identify areas of degradation before failure occurs
• Repeatable results • Provide trend information on deterioration so that life time and
repair predictions can be made
• 100% coverage of the tank floor
• Minimize the out-of-service time to ensure maximum productivity
• Able to scan the annular plates
of the tank
• Exceeds API 653 Inspection Requirements • Provide records of assessment that can be used to demonstrate
• Improves overall integrity management programs compliance with operation standards and guidelines such as API
• Used to create tank repair scopes of work 653 requirements
• Documentation of inspection performed is provided • Secure statutory operating license and negotiate lower TP
insurance based validation that plant is in good condition

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 Pulsed Eddy Current (PEC)
Corrosion under insulation, fireproofing and coatings are possibly the greatest unresolved asset
integrity problems in the industry. Pulsed eddy current (PEC) is an advanced electromagnetic
inspection technology used in detecting flaws and corrosion in ferrous materials typically hidden
under layers of coating, fireproofing or insulation.
The technique measures the thickness of a conductive component through insulation and hence presents major upsides for the inspection of CUI. New
equipment are suitable for use on a number of materials including metal, aluminium, stainless steel and galvanized steel weather jackets. The equipment
can scan through thick metal (up to 100 mm) and insulation (up to 300 mm) providing real-time C-scan imaging, wall thickness measurements (ID and OD
corrosion), grid and dynamic scanning modes with fast data acquisitions.

Benefits Applications
• Inspect through thick metal and insulation • Corrosion Under Insulation (CUI)

• Save on insulation removal costs • Corrosion Under Fireproofing (CUF)

• Real-time imaging for instant results • Insulated pipes and vessels

• One-touch automated reporting • Through aluminum, stainless steel, and galvanized steel weather

• Range of application-specific probes jackets

• Fast data acquisition • In-service scab corrosion assessment, no need to remove the scale

• Easy setup with automatic optimization of pulser and receiver parameters • In-service inspection of storage tank annular plates
• Underwater and splash zone structures

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 Eddy Current Array (ECA)
Aging infrastructure found in the power generation, petrochemical and industrial sectors are subject
to cyclic loading and fatigue stress, resulting in a physical response of cracking in materials or fixed
equipment being exposed to damaging conditions.
Eddy current array (ECA) offer fast inspection of surface-breaking cracks, often with only minimal surface preparation. Users can collect a digital record of
their assessment and measure the depth of surface breaking cracks which is a direct advantage over PT and MT. Surface applications of ECA technology
are numerous, ranging from weld inspection on pressure vessels and pipes to corrosion mapping. The technology is now widely for the detection of surface
or near-surface defects in materials such as aluminum, stainless steel, copper, titanium, brass, Inconel, and even carbon steel.

Benefits Applications
• Faster inspections • Detecting and Sizing Cracks in Carbon Steel Welds
• Wider coverage • Detecting and Sizing Cracks in Stainless Steel Welds
• Less operator dependent • Assessing Corrosion on Aluminum and Stainless Steel Tank Floors
• Better detection capabilities • Detecting and Assessing Stress Corrosion Cracking in Base Metal
• Easier analysis because of simpler scan patterns • Assessing Circumferential Cracking in
• Improved positioning and sizing because of encoded data Non-Ferromagnetic Heat Exchanger Tubes
• Eddy current array probes can easily be designed to be flexible or
shaped to specifications, making hard-to-reach areas easier to inspect

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 Alternating Current Field Measurement (ACFM)
Over its 30-year history, ACFM® technology has developed a solid reputation for accurately
detecting and sizing surface-breaking cracks through paint and coatings.

ACFM® is an electromagnetic inspection technique that has been developed by TSC and is widely used across high integrity industries such as oil and gas,
defense, nuclear, transport and mining. ACFM® was developed to reliably detect and size in-service defects with a low number of false calls. It is designed
to work on rough, corroded surfaces, or through protective coatings. ACFM® technology is widely recognized and accepted as one of the most reliable
methods of detecting surface-breaking cracks in steel structures and metallic components, being able to measure both crack lengt h and depth.

Benefits Applications
• Applicable for base material or welds, ferritic or non-ferritic conductive • Weld inspection: w/ standard probes and single-pass array probes
metals • One or two-person operation (e.g., confined spaces)
• Can be used on hot surfaces, underwater, or in irradiated environments • High-temperature applications
• Provides both depth and length information • Inspection through thick coatings
• Accurate sizing of defects up to 25mm in depth • Thread inspection
• Requires minimal surface preparation and can be applied over paint and • Splash zone inspection
other coatings
• Applicable for under water inspection as well as normal inspection
• Inspection data can be stored and analyzed offline
• Inspection can be encoded
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