Non-Destructive Testing Services - LEIC Overseas and Oil Services

LEIC

Non-Destructive Testing Services

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NDE Methods 

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• Flaw Detection and Evaluation

• Leak Detection

• Location Determination

• Dimensional Measurements

• Structure and Microstructure Characterization

• Estimation of Mechanical and Physical Properties

• Stress (Strain) and Dynamic Response Measurements

• Material Sorting and Chemical Composition Determination.

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Most Common NDT Methods 

• Visual

• Liquid Penetrant

• Magnetic

• Ultrasonic

• Eddy Current

• X-ray

                                           

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Visual Inspection 

• Tools include fiberscopes, bores copes,magnifying glasses and mirrors.

• Portable video inspection unit with zoom allows inspection of large tanks and vessels, railroad tank cars,  sewer lines.

• Robotic crawlers permit observation in hazardous or tight areas, such as air ducts, reactors, pipeline.

Magnetic Particle Inspection

The part is magnetized. Finely milled iron particles coated with a dye pigment are then applied to the specimen. These particles are attracted to magnetic flux leakage fields and will cluster to form an indication directly over the discontinuity.

Radiography Testing

The radiation used in radiography testing is a higher energy (shorter wavelength) version of the electromagnetic waves that we see as visible light. The radiation can come from an X-ray generator or a radioactive source.

Film Radiography

• The part is placed between the radiation source and a piece of film.

• The part will stop some of the radiation.

• Thicker and more distance area will stop more of the radiation.

• The film darkness (density) will vary with the amount of radiation reaching the film through the test object.

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Pipeline Inspection Using Eddy Current Array

Service inspection of pipeline

is a challenging yet crucial operation, particularly for pipes buried under ground. After scanning the pipeline from the inside with the proper equipment, sections that present any anomalies are excavated. Once the specific section of the pipeline is accessible, the entire surface of the exposed pipe is sand-blasted until the coating is completely removed. Traditional surface inspections such as magnetic particle inspection (MPI) require this kind of intensive coating-removal preparation procedure.

Detecting surface breaking cracks, including stress corrosion cracking (SCC), even though the technique has been used for pipeline inspection for decades without any major advancement.

MPI method also presents some significant Disadvantages: the reliability of results is highly dependent on operator skill; when it's raining, outdoor inspection is problematic; and there is no result traceability or information on the depth of flaws that are detected.

However, these weaknesses can be resolved by using a different.

Eddy Current Array : Eddy Current Array Semi automated Solution for Pipeline Surface Cracking Inspection.

Gamma offers a variety of solutions solutions for surface crack detection on ferromagnetic material.

One of these solutions is based on existing equipment. Gamma customers already use for PA weld Inspection, The Omni Scan MX, the Hydro FORM scanner and the CHAIN scanner. Here is how it works: First, the Hydro FORM buggy, which is equipped with a specially designed ECA probe, is attached to the CHAIN scanner. Then, the scanner and probe assembly is connected to the Omni Scan MX with the ECA module. This equipment combination enables two-axis mapping of the inspected area of the pipeline. Unlike MPI, ECA inspection is able to record data for advanced reporting and result traceability. Detection sensitivity can be adjusted to show the severity of the indication or to set an inspection threshold that will reject a specific defect depth. According to the capacity of the CHAIN scanner,this solution is applicable to pipes ranging from 1.75 to 38 in. OD.

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 XY Mapping Principle On Pipes With The Hydro Form And CHAIN Scanner.


Scan For Stress Corrosion Cracking

Calibration over reference material and specific EDM notches.

Advantages of Eddy Current Array Over The Standard Surface Inspection Methods:

Using eddy current array (ECA) technology for stress corrosion cracking helps keep surface preparation to a minimum.

With acquisition speeds of up to two meters per second, performing an inspection with ECA is also extremely fast.

Instrument calibration is very simple; all that is required is a material sample with target defect to ensure that the sensitivity is adjusted properly.

Setup files can be saved and easily recalled for subsequent jobs. The data recording function permits post-process analysis as well as data archiving, and reports can be easily created directly on the instrument.

• Major time savings when compared with MPI.

• Intuitive imaging, very similar to MPI and PT displays.

• Solution uses existing standard phased array scanner.

• Result traceability and post-process analysis.

• High scan speed and instant results.

• Defect depth evaluation capability.

• Adjustable sensitivity.

• Environment-friendly method (no chemicals involved).

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Equipment Required:

• Omni Scan ECA

• Omni Scan MX mainframe (which can also be

  Used for phased array inspection).

• C-scan view.

• Battery operated.

• Drives up to 32 channels and up to 64  

  Channels with an external multiplexer.

• Encoded or time-based scan.

• Data and setup recording.


NDT Methods, Facilitating The Interpretation Of ECA Signals.

Scan using a standard ECA probe that features the same color representation as the red dye PT (patent rights protected) .

The sensitivity can be adjusted to reveal more or fewer defects. A Variety of Familiar Color-Palette Choices Offering More Possibilities The MXE 3.0 ECA software features a range of patented intuitive color-palette representations that replicate the look of traditional NDT methods, facilitating the interpretation of ECA signals.

 

Part inspected with penetrant testing (visible red dye)

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Magnetic particle (black powder)  -    Penetrant testing(fluorescent) -      Magnetic particle(fluorescent)

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Storage Tank Inspection

In modern days, oil and gas storage tank's life cycle can be managed with the computing solution, which enables the construction and operational maintenance records to be archived permanently by electronic means. Electronic archiving is the alternative method to conventional data archiving which requires manual intervention and record keeping. These are now being replaced with NDE Life time records.

Major benefits associated with electronic archiving are:-

Information is preserved in its original quality i.e. does not degrade with time Computing solutions provide much more efficiency and cost savings Reduced physical storage space requirements Electronic retrieval and management

Gamma structured methodology OF permanent archiving holds digital radiography records as well as film digitization records along with critical construction information. This information is multiplied to meet the QA requirements of associated project.

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Gamma excelling in NDT

Radiographic testing systems and specialized services that is suitable for detection, identification of volume defects such as cavities and solid inclusions, and incomplete penetration where a gap exists. Gamma trained staff meets with the EN14015, EEMUA159, API653 and ISO 9002 standards to conduct the inspection of storage tanks directly or via your existing established NDT sub contractors.

X-ray radiography

is used as it can penetrate the double-walled structure of tanks that consists of an outer concrete layer. Storage tanks can be divided as Aboveground Storage Tanks (ASTs) and Underground Storage Tanks (USTs). While the ASTs have more capacity, they require frequent maintenance operations and inspection as compared to USTs that are of lower capacity.

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LEIC Welding Inspection Services

Welding Inspection :

• Ultrasonic Testing of weld metals & other components

• Ultrasonic Thickness gauging

• Radiography Testing (X-Ray/Gamma Ray)

• Radiography test with pipeline X-Ray Crawler

• Magnetic Particle Testing (Visible & Fluorescent)

• Dye penetrant Test


Inspection Services :

• 3rd Party Inspection

• Welding Inspection (AWS/CSWIP).

• Welder Qualification Test.

• Preparation of WPS&PQR.

• Visual Inspection.

• Hardness Test.

• Welding Wellhead.

• Welding all steel types.

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ADVANCED NDT SERVICES

Advanced NDT techniques are important . because they supply both increased productivity and the ability to reduce other ancillary costs. such as scaffolding, insulation removal, etc. Advanced NDT techniques help to solve industry problems cost effectively and efficiently. LSI ( large structure inspection ) survey used in lieu of scaffolding and Traditional NDT yielding equipment cost savings through less trade involvement and increased scan speeds.

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Oil & Gas industry

Advanced products, systems and services are used extensively in the Oil & Gas industry for a high degree of reliability, which supports improved safety, drives productivity, increases process availability and helps meet regulatory compliance standards. Our advanced technologies and techniques are utilized in Oil & Gas 

operations on the following critical assets to identify potential damage mechanisms :

• Tanks

• Vessels

• Heat Exchangers and Condensers

• Piping

• Rotating Equipment

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Petrochemical

Petrochemical and Power plants experience various flaws in their heat exchanges. As a result, Petrochemical and Power need to detect I.D and O.D. pitting, cracking and SCC, induced corrosion, erosion, support wear and cracking at or in the tube sheets, wear/wall loss.


Services

• Corrosion mapping

• Detection of HIC and SOHIC

• Weld Inspection of pressure vessels, piping and tubing

• Vessels and piping fabricated with composite materials

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Power Generation 

inspection of Assets such as Boilers, Piping, Tanks and Pressure Vessels. Problems identified from these inspections can help prevent unscheduled shutdowns and help trend problems so they can be safely monitored and tracked.

Services

• Pressure vessel and piping welds

• Turbine blades and Christmas tree designs

• Erosion/corrosion mapping

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Phased Array Ultrasonic Technology

Phased Array Ultrasonic Testing 

Phased Array is the latest advanced Ultrasonic technology that operates by a computer controlled excitation of individual elements in a multi-element transducer. In short, Phased Array generates multiple ultrasonic signals, in nanoseconds, that produce controllable angles, focus depths and/or wide coverage from one inspection point.

It has many advantages including

excellent repeatability, increased inspection speeds, more accurate results and the ability inspection speeds, more accurate results and the ability to inspect complex geometries.

interactive analysis of A-scans, B-scans,S-scans, and C-scans for multigroup and multiprobe inspections.

The technology also produces multiple measurements that are synchronized and cursor/ gate associated, making the detection, location and characterization of defects much more reliable and exact than the results obtained with conventional shear wave inspection.

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This technology has many applications 

Applications across a variety of industries including:

• Weld Inspection of pressure vessels, piping and tubing.

• Vessels and piping fabricated with composite materials.

• Pressure vessel and piping welds.

• Erosion/corrosion mapping.

• Corrosion mapping.

• Turbine blades and Christmas tree designs.

Phased arrays offer significant advantages over traditional radiography of welds as well:

• No safety hazards

• Inspection as soon as weld is cool

• Better defect detection and sizing

• Able to penetrate thick sections

• Compliant with all known codes

Time of Flight Diffraction (TOFD)

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Phased Array engineers/technicians. 

Our highly qualified automated ultrasonic engineers/technicians operate the system in both manual and automated scanning modes. automated pipe and vessel weld inspection or erosion corrosion surveys.

 Phased Array generates an ultrasonic beam with the capability of setting beam parameters such as angle, focal distance, and focal point size through computer controlled excitation of the beam. it can be multiplexed covering large areas and the operator can vary the angle of the beam without moving the probe. Applications include weld inspection, complex geometries, defect detection and location, and sizing. the ability to record weld scans and to visualize the reflectors and their position within the weld makes it a qualified technology and an excellent choice for projects constructed to All ASME phased array code cases , ASTM E2700-09 ASTM E2491-06, AWS, API 1104 and API RP2X,CEN EN 583-6 , BSI BS7706 And more.

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Eddy Current Technology

Eddy Current

Eddy current inspection is leading the industry for in-service inspections on coated components. Eddy current has the ability to detect surface breaking defects such as in-service cracking under non metallic surface finishes.Services Division offers a complete range of inspection, training and QA/QC services. We integrate innovative technologies with conventional testing methods to ensure the integrity of industrial materials and components as cost effectively as possible. Eddy Current testing is based on measuring the impedance of a coil or inducing electrical currents (Eddy Currents) in a conductive material. Any changes in the coils impedance due to geometry, material changes, or discontinuities- such as pitting, erosion, corrosion, baffle fretting, cracking, and/or other anomalies will disrupt the flow of Eddy Current and produce a representative signal on the Eddy Current Testing instrument.

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Eddy Current Applications: 

Application Solutions provides highly qualified Eddy Current technicians . The equipment allows the technician to accurately and confidently inspect any tubing in Real-time, by allowing full length recording capabilities. This allows Data Analysis to be performed offline in order to assess damage with the customer.

Applications:

•    Heat Exchangers

•    Condensers

•    Feedwater Heaters

•    AC Chillers (Air Conditioners)

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Applications Advantages: 

• Sensitivity to gradual wall loss, corrosion, pitting, erosion,

   baffle fretting, cracking and etc.

• Inspection of nonferromagnetic tubing.

• High rate of inspection (80 to 100 tubes per/hr).

• Can distinguish between I.D. and O.D. defect orientation.

Eddy Current has several basic advantages over PT including:

•  More sensitive for detection of tight cracks

•  Can inspect through paint coatings

•  Much faster for small areas

•  Detects SCC in stainless steel pipes

•  Locates cracks in stainless steel vessels/tanks, turbine blades

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Pulsed Eddy Current technology

Pulsed Eddy Current

FAILURES DUE TO CORROSION

Failure of steel support structures, piping systems or vessels can be caused by corrosion of the steel under passive fire protection or insulation and visual signs of degradation may not be evident.

Pulsed Eddy Current technology can help detect such hidden corrosion before it becomes a potentially expensive and hazardous problem.

Pulsed Eddy Current inspection approach based on this technology checking for corrosion under passive fire protection or insulation. A detailed visual inspection is carried out to look for signs of degradation and Pulsed Eddy Current technology is used to measure the wall thickness of the metal behind the fire proofing or insulation.

ACCELERATED CORROSION

Degradation of steel can start when water penetrates the interface between the metal and the fireproofing because of faulty seals or inadequate construction. The corrosion products that are created may exert pressure on the passive fire protection and cause it to crack. This can allow more water to reach the steel, which accelerates corrosion.

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BENEFITS OF PEC TECHNOLOGY 

• PEC technology can be applied in-service, so there is no need to empty the storage spheres.

• No need to remove the passive fire protection. PEC technology can measure through up to 250 mm of material including the reinforcement mesh.

• Performed in service during plant operation

• Monitor to assess CUI or FAC damage

• Accessibility issues minimized by using rope access Operators


PEC TECHNOLOGY APPLICATIONS

• For in-service wall thickness monitoring – monitor

  the corrosion rates of critical equipment to facilitate 

  the safe extension of run times and the reduction 

  of shutdown frequency and duration

• To  annular  rings:  detect  corrosion  while atmospheric 

  storage tanks are in service by measuring the wall loss of 

  annular rings.

• In the splash  zone: improve  safety  cost effectively when 

  measuring caisson and riser wall thickness. 

  Readings can be made through marine growth and up 

  to 20 mm of coatings and corrosion products. 

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Corrosion Under Insulation (CUI) 

Without an effective CUI protection program, the damage can be difficult to detect, harder to mitigate, and comes with even greater cost. As the industry's truest one-source provider of asset protection solutions, We Have the resources, knowledge, and subject to implement and manage all phases of CUI program.


Visual & Qualitative Inspection

Our API-certified inspectors then conduct visual inspections to get a first look at the potential problem areas, after which they'll determine and perform the appropriate qualitative inspection technique.

Inspection Preparation

Our expert mechanical service technicians prepare areas for quantitative inspection,through combinations of insulation removal, corrosion mitigation, and surface preparation.

Quantitative Inspection

We can deploy a variety of quantitative inspections to determine corrosion severity,including ultrasonic thickness, phased array, and radiography. Localized vs General corrosion, radiation concerns, and access to the asset guide the decision process.

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Tube Inspection Services

Tube Inspection 

Many problems can arise from the failure of alloy tubing in heat exchangers and boilers. Eliminating problems with leaking feed water heater and condenser tubing can improve heat transfer performance and provide safe, reliable plant operation. Ferrous tubing is inspected using Remote Field Testing. The inspection of boiler tubes and other ferrous tubing can assist with the reliability and integrity of components and systems. Prevention of the release of oils and hazardous materials to the environment meets the strict government guidelines that are currently in place.

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EDDY CURRENT & REMOTE FIELD INSPECTION 

Eddy Current Testing (ET) is the fastest way to assess the condition of non-ferrous tubing in chillers, condensers, feed water heaters and evaporators. The inspection is performed swiftly and efficiently, with data collection speeds faster than any other inspection method. Analysis is performed on site to provide immediate results. On larger projects, analysis can be performed at a remote location,saving mobilization costs to the customer.


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BASELINE INSPECTIONS

Performing baseline inspections on new heat exchangers can ensure the integrity of the new equipment prior to being installed.

IRIS Inspection

utilizes the Internal Rotating Inspection System (IRIS) to perform examinations. This inspection system is used at the request of the customer or when inspection results warrant the need for additional prove-up type information.

NEAR FIELD TESTING (NFT)

NFT is an emerging technology, specifically design to inspect air cooler (Fin Fans) tubes found in the Oil & Gas Industries. The NFT probes are designed to detected internal corrosion, inlet erosion, and I.D. pitting commonly found in air coolers. This application has proven itself in the industry as cost saving alternative. Determining the condition of the component and proper reporting of damaged areas is the ultimate goal of any inspection.

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Tube Inspection Services for

 

•  Condensers

•  Boiler Tubes

•  Feed Water Heaters

•  Oil Coolers

•  Hydrogen Coolers

•  A/C Chillers

•  Air Coolers 

•  Type Of Heat Exchanger

Testing, Remote Field Testing, Near Field Testing and Internal Rotating Inspection System inspections. Using Tube Inspection Services our certified technicians within our Tubing Inspection Center of Excellence, we bring a wealth of knowledge and technical expertise to various industries. Choosing the proper tubing inspection technique depends on many factors. Tubing characteristics and expected damage impact the type of inspection you need to perform.

Let the professionals at LEIC assist you in choosing the proper inspection program.






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