Advanced Non-Destructive Testing

IRC Engineering is the only company in the Northern part of the Country to be carrying out Advanced NDT inspection Services. Though it is a feeling in the industry that these inspections are costlier , but in the long run they have proven to be cheaper than the conventional methods. The following are the reasons for their Cost Affectiveness:

  • In case of Conventional Methods of Inspection we are unable to carry out welding at a nearby location at the same time when we are carrying out Radiography Test but by Means of Techniques such as Phased Array we are able to carry out Welding and Inspection Round the clock.
  • In case of Conventional Methods NDT Vendor is using consumables for every joint but in case of the newer techniques the amount of usage of consumables is reduced to once in around 800th joint, which in long term reduces the cost of services.
  • The need to used Scaffolding is reduced due to techniques such as LRUT. Hence the cost of Scaffolding or making of Underground pits is reduced.
  • Inspections can be carried out very fast and accurately , hence project can be completed quickly.

Advanced Inspections Details

IRC is carrying out at present the below mentioned Advanced Inspections:

  1. Long Range Ultrasound Testing
  2. Pulsed Eddy-Current Testing
  3. Phased Array Ultrasound Testing
  4. Time OF Flight Diffraction
  5. Eddy-Current Testing
  6. Helium Leak Detection
  7. Computed Radiography
  8. Corrosion Mapping

It will be our pleasure to create value for our clients by usage of any of the above techniques.

Services Quick-Links

LONG RANGE ULTRASOUND TESTING

Long range ultrasonic testing is a rapid way of screening for corrosion in pipelines. The method enables screening of up to 120 meters of pipeline in one test, i.e. 60 meters in both directions. By fitting a ring of transducers around the pipeline, a wave maker device directs low frequency (20-100 kHz) ultrasonic waves via the transducers, longitudinally into the pipeline wall. The method effectively detects changes in the pipeline’s cross-section, enabling it to indentify corrosion and other abnormalities. At the same time this provides the possibility of using welds and flanges as distance references. IRC has qualified experts in using this method to help you get a cost-effective report on the condition of your pipelines. The test results are displayed in an easy-to-interpret visual interface on a laptop computer – enabling us to draw conclusions quickly and correctly. Upon identifying a defect we carry out follow-up detailed testing of the affected area, using complementary ultrasonic or x-ray methods. With this highly advanced testing method you will get an accurate status report of your pipelines in the most effective way. Benefits of long range ultrasonic testing

  • More than 100 times faster than traditional ultrasonic methods
  • Up to 100 meters screening distance on pipelines above ground
  • Up to 10 meters screening distance on pipelines buried in the ground
  • Possibility to do sub-sea scanning
  • Saves time since there is no need to remove insulation, apart from 1 meter for the transducer ring.
  • Easy to screen wall penetrating pipelines (both built-in and sleeved penetrations)

Pulsed Eddy-Current Testing

IRC offers Pulsed Eddy Current (PEC) inspection technology for the detection of corrosion areas in carbon and low alloy steels. Measurements are taken through any non-conductive material e.g. insulation, protective coatings, concrete and marine growth.

Technique

It is an electromagnetic inspection technique used for measuring the thickness of steel objects, such as pipes and vessels, without the need for contact with the steel surface. This makes PEC very suitable for inspections where the surface of an object is not accessible. Readings are generated when a transmitter coil within a protective housing produces a magnetic pulse which induces eddy currents within the component wall. The eddy currents in turn produce a second magnetic pulse, which is detected by the receiving coil. The system monitors the rate of decay of the eddy current pulse within the steel wall and produces an average thickness value from the comparison of a calibrated signal.

Capability

  • Provides the average remaining wall thickness measurement within the interrogated area (footprint).
  • Direct contact is not required and wall thickness can be measured through any non-conductive material up to 150mm thick, e.g. insulation material, paint, bitumen, dirt, ice or sludge
  • Works through Stainless Steel and Aluminum sheeting less than or equal to 1mm
  • Surface preparation is not required enabling measurements to be taken through corrosion products
  • Wide temperature range -100°C to 550°C
  • Good reproducibility of PEC readings at the same locations makes it ideal for corrosion monitoring
  • Rope Access deployable
  • Subsea and splash zone deployable
  • Battery operated and robust design
  • Fast and reliable data collection typically 700 to 1000 readings per day

Applications

  • Vessel and pipe work inspection
  • In-service corrosion/erosion monitoring
  • Wall loss measurement through corrosion product
  • Riser inspection above and below splash zones
  • Ship hull surveys
  • Refractory lined vessels
  • Subsea Inspections

PEC Limitations

  • Applicable to carbon steel and low alloy steels
  • PEC is suitable for general wall loss. Isolated pitting defects cannot be detected.
  • PEC wall thickness readings are relative values, showing variations in wall thickness on the object being inspected.
  • Geometry of the test object should be simple.
  • Wall thickness readings are affected by nearby nozzles, welds, internals, near supports and on sharp bends not possible.
  • Requirements to test through Galvanised Steel sheeting is not possible

TIME OF FLIGHT DIFFRACTION

TOFD is another advancement in Ultrasonics and IRC Engineering is the only company presently in the Northern Part of India to have procured it. In a TOFD system, a pair of ultrasonic probes sits on opposite sides of a weld. One of the probes, the transmitter, emits an ultrasonic pulse that is picked up by the probe on the other side, the receiver. In undamaged pipes, the signals picked up by the receiver probe are from two waves: one that travels along the surface and one that reflects off the far wall. When a crack is present, there is a diffraction of the ultrasonic wave from the tip(s) of the crack. Using the measured time of flight of the pulse, the depth of a crack tip can be calculated automatically by simple trigonometry. This method is even more reliable than traditional radiographic, pulse echo manual and automated weld testing methods. IRC Engineering has PCN and ASNT NDT LEVEL-II experts who can perform these specialised tests. TOFD has been widely used due to its capability of getting accurate results of defect size.

Advantages

  1. Results obtained are digital and can be stored for life time period.
  2. Defect Sizing is highly accurate and thus the system can be used to carry out Fitness For Service and Residual Life Assessment.
  3. Due to exact defect sizing, Acceptance and Rejection of flaw is possible during erection activities.
  4. No Radiation Hazard.
  5. Erection activities can be performed in parallel with inspection activities.

Eddy Current Testing (ET)

Eddy Currents are closed loops of induced current circulating in planes perpendicular to the magnetic flux. They normally travel parallel to the coils winding and the flow is limited to the area of the inducing magnetic field. Eddy Currents concentrate near to the surface adjacent to an excitation coil and their strength decreases with distance from the coil i.e. Eddy Current density decreases exponentially with depth. Eddycurrent testing is a rapid and accurate technique used to detect discontinuities in tubing, heat exchangers, condensers. IRC has defecto-meters working on the principle of eddy current testing, i.e., it has a probe coil which can also detect surface and near surface discontinuities in the turbine blades. Eddy current testing is also performed for alloy separation i.e, sorting and for the determination of treatment conditions. The location of repair welds, girth welds and seam welds may also be detected on ground machined surfaces. IRC is having OLYMPUS MS-5800 and TECHNOFOUR Machine using which we are performing Eddy-current and Remote Field Eddy-Current Services. IRC has even carried out successfully these services in Saudi Arabia for SAFCO Plant. IRC can take such kind of jobs for overseas shutdown jobs.

Applications

  1. This Technique is usually used for Inspection Heat Exchanger Tubes.
  2. Sorting of Components.
  3. Detection of Defects in Turbine Blades.

Helium Leak Detection

The Helium Leak test method is totally dry. There is no soap bubble residue or water droplets to clean and dry after testing. The costs associated with cleaning supplies and drying equipment can be eliminated, along with the mess and unpleasantness of running a bubble test operation. The Atomic Weight of Helium Gas is very less that it can penetrate easily through a smaller leak faster than a water or air molecule can. Being an inert gas, it doesn’t react with anything. IRC’s specialised technicians carries out Helium Leak Detection using both Pressurized Method as well as Vacuum Method. Helium Leak Detection is also used these days for Online Detection Of Leakages in Piping from Turbine to Heat Exchanger. IRC presently has Alcatel Equipment and has been carrying out services during both Manufacturing and In- Service inspection. IRC Engineering Services provides services for Helium Leak Detection in Refineries, Fertilizer plants, Power plants and other process industries . The ASNT NDT Level-II and ASNT NDT Level-III experts are committed to render quick response and efficient service to its esteemed clients . IRC has carried out jobs even in Saudi Arabia, Kuwait and Oman for Helium Leak Detection and is exploring more opportunities to carry out these services.

Computed Radiography (CR)

Computed radiography (CR) is used to assess internal or external corrosion/erosion losses in process piping, pressure vessels and valves. Based on it one can estimate remaining thickness and wall losses. The computerized images allow easy data sharing and result in significant improvements in radiographic inspection productivity as well as faster identification of defects. Computed Radiography system can be used for following below mentioned applications.

  1. Piping for internal corrosion or for corrosion under insulation (CUI).
  2. Valves and their internals for internal or external corrosion/erosion
  3. Piping and valves for build-up of products and for blocks.
  4. Newly fabricated welds according to:
    • ASME Section V for pressure vessels
    • ASME B31.1 and B31.3 for piping
    • API 1104 for pipelines
  5. For losses in boiler tubes at temperatures of the order of 350 ⁰C.
  6. Asbestos insulated equipment and assess losses around the circumference (not only those perpendicular to the radiation source)
  7. In-service welds

ADVANTAGES

  1. The images can be readily shared, e-mailed and stored electronically by anyone needing reliability information for the equipment.
  2. The imaging plates practically eliminate re-shots by providing a greater range over which exposures can be useful.
  3. Significant exposure reductions
    • Reduction of exposure times from 40-60% when using IR 192
    • Similar or better results are obtained when utilizing Se 75, Co60 and X-rays
    • Highly reproducible
  4. Images on film or digitized
  5. Data is stored for future comparison or audit

LIMITATIONS

  1. Radiation safety considerations are the same for CR as standard radiography
  2. An equipment reading station is required to scan the imaging plates
  3. Physical space and on-site electrical power are required to set up the equipment
  4. Requires access to both sides of the part
ircenggAdvanced Non-Destructive Testing