NDE Laboratory: LABEND Introduction€¦ · • Small bore pipe radiography • Ultrasonic Thickness Measurement (TM) • Ultrasonic Flaw Detection (UFDT) • Remote Field Testing

Introduction

Non Destructive Evaluation Laboratory (LABEND) at ISQ is organized to provide our clients not only conventional NDE solutions but also Non Conventional advanced services and customized automated answers, developed in-house, to fulfill particular requirements of a job or client.

On the corporate Level, NDE LABORATORY is responsible not only for the provision of the services in ISQ headquarters, but also for providing technical assistance and technology transfer to ISQ Branches. NDE Laboratory serves its purpose as a knowledge and logistical centre with specialized teams that can be allocated on the different branches for limited time. LABEND is also responsible for the maintenance of accreditations, giving training, assistance to maintenance and regular technical audit to its branches.

This laboratory is accredited by IPAC – Instituto Português de Acreditação according to EN ISO 17025 standard to tests in the accreditation scope L0050 (www.ipac.pt) and certified by APCER according to EN ISO 9001 standard.

Besides its own activities ISQ LABEND holds considerable experience in supporting Maintenance and Structural Integrity and Mechanical Construction Activities inside ISQ. This valuable experience has brought changes to LABEND, bring it from an NDT provider of conventional solutions to an expert on condition monitoring working teaming within ISQ group and with clients to provide valuable data on life assessment and RBI studies on high temperature and pressure equipment, under insulation corrosion monitoring, HSOIC affected equipments or dimensioning of cracking for Fitness for Service Studies.

As warranty of its technical skills, besides a considerable number of state of the art equipment, this laboratory has highly skilled human resources composed by experienced technicians and Engineers that warrant the proficiency and exemption of the work done.

Services provided by this Laboratory includes:

• Magnetic Particle Testing

• Dye Penetrant Testing

• Radiography Testing (including RX)

• Ultrasonic Testing

• Eddy Current Testing*

• Vacuum Box Testing*

• Tank Floor Scan (MFL and LFET)*

• Internal Rotational Inspection System (IRIS)*

• Automated Thickness Mapping*

• EMAT tube boiler inspection*

• LFET tube boiler inspection*

• ToFD*

• Phased Array*

• Digital Radiography*

• ACFM*

• Long Range UT (Guided Waves)*

• Video Endoscopy*

(* Services provided out of EN ISO 17025 accreditation scope)

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IntroductionIntroductionIntroductionIntroduction

Conventional Solutions

ISQ offers the full range of conventional NDE Solutions as covered by ASME. ISQ has been extensively using these techniques on the control of new construction and as complement of more advanced technologies for in-service inspections. During turnarounds on Refinery and Petro-Chemical complexes, these are the core techniques still in use.

Services Offered

• Magnetic Particle Testing (MPT)

• Dye Penetrant Testing (DPT)

• Radiography and RX (RT and RX)

• Ultrasonic Thickness Measurement (TM)

• Ultrasonic Flaw Detection (UFDT)

• Eddy Current Testing (ECT)

• Positive Material Identification (PMI)

• Hardness Testing (HT)

• Visual Inspection (VI)

• Thermography Inspection

• Acoustic Emission Inspection

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Conventional SolutionsConventional SolutionsConventional SolutionsConventional Solutions

Tank Inspection

LABEND provides support to tank inspections, both on new construction (API 650) and in-service inspection (API 653). ISQ experience ranges from Atmospheric tanks to bullets, Gas Spheres or LNG Cryogenic Tanks. ISQ extensive experience in this domain brings our clients the added value of the proven procedures and capacity to optimize resources and increase productivity.

Despite the outstanding results of these inspections, ISQ is now moving forward and making use of alternative solutions as the Computed Radiography of Phased Array + ToFD to perform control of new constructions.

Standard Services Offered

• MFL / LFET

• UT (Thickness Gauging)

• UFDT

• Vacuum Testing of roof and bottom welds

• MPI ( Wet & Dry) for checking of welds (Fluorescent /Non-Fluorescent)

• Hardness check of welds

• Visual Inspection

• Chalk Kerosene Test

• PT (Fluorescent / Non-Fluorescent)

• RT (In compliance with API 653/510)

Alternative Services Offered

Computed Radiography

Under a contract with ENIP Petromar, Lyon and Bechtel Corp, ISQ has successfully used the Computed Radiography on the Angola LNG Project, for the control of all the 2 LNG, 1 Condensate and 6 API 650 Atmospheric Tanks. Advantages for the use of this technology include full compliance with construction code, time savings on exposure and development time, no need for use of double film on Austenic Cryogenic Tank control, no disposal of development liquids and thus no environmental issues, full automated report and 3rd party inspection viewer.

ISQ as a partnership with software company Seringsoft, and is co-proprietary of specially developed application for CRT on tank construction projects.

ToFD + Phased Array Automated Solution

Sines LNG terminal contract (Portugal) with SMM/Enterpose is a reference on this domain with successful implementation of ToFD+Phased Array automated solutions to perform the control of Cryogenic Tanks.

While demanding a larger qualification phase on preparation phases, this solution allows much shorter production cycle avoiding the need for Radiography windows in job schedule. The non use of radiation and the much larger productivity both on welding and control cycles are invaluable advantages on construction works.

Automated Thickness Mapping

ISQ solutions for tank shell monitoring include a wide range of automated vehicles and remote controlled devices to perform encoded thickness mapping, on one and two axes, with wet and dry methods.


Tank InspectionTank InspectionTank InspectionTank Inspection

Boilers Inspection

As one of the world reputed companies in Remnant Life Assessment studies, ISQ Engineering and Structural Integrity group relies on it Materials and NDE Laboratories to supply the needed data for complete Remnant life Assessment Studies.

ISQ LABEND technology has grown by facing each problem and by investing on R&D programs to solve problems such as the detection of Hydrogen Embrittlement on boiler tubes or an accurate way of determining Oxid-layer – which allowed a change on ISQ assessment method that now encompasses the thermal analysis of tubes and its oxid layer.

As a specialist on supporting Remnant Life Assessment and Structural Condition on Boilers, ISQ provides full range of services. In Situ Metallographic Replica, Mechanical Testing (creep) and Deposit Analysis (using Energy Dispersive X-ray Spectroscopy, WDS & X-ray Diffraction) are made teaming up with Materials Laboratory.

Services Offered

• Magnetic Particle Testing / Wet Fluorescent Magnetic Particle Testing

• Dye Penetrant Testing

• Small bore pipe radiography



• Remote Field Testing

• Video Endoscopy

• Furnace Hydrogen Damage Assessment

• Steam oxide thickness measurement

• Dimensional Checks


• Hardness Checking


In addition to the above mentioned services, ISQ offers added valued advance alternatives to the assessment of water wall condition:

• EMAT

• IRIS

• Remote Field Testing

• LFET


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Pressure and Temperature: Process Vessels / Columns Assessment

The inspection of Pressure Vessels or columns is a delicate study that demands the knowledge of the process in the vessel and the means to detect the damage expected by each mechanism present on that process.

LABEND may provide these special services either by direct request of the final client or integrated on ISQ Maintenance and Structural Integrity teams. As for the boilers, ISQ LABEND teams up with the Materials Laboratory to perform In Situ Metallographic Replica, Mechanical Testing (creep) and Deposit Analysis (using Energy Dispersive X-ray Spectroscopy, WDS & X-ray Diffraction).

LABEND provides services not only on the corrosion mapping and weld checking, but also on the detection of SOHIC problems, accurate crack dimensioning for Fitness for Service Studies, etc,,,

LABEND provides non intrusive solutions as well as expert testing on shutdowns and turnarounds.

We monitor the condition of your assets,

Services Offered






• ToFD + Phased Array on welds for detection of HSOIC

• Automated Thickness mapping of shell or shell elements

• Positive Material Identification

• Acoustic Emission Testing

• ACFM

• Thermography

• X-ray diffraction


Vessels & Columns AssessmentVessels & Columns AssessmentVessels & Columns AssessmentVessels & Columns Assessment

Tube Inspection

ISQ provides a comprehensive inspection program consisting of multiple tube inspection techniques, to determine the integrity of heat exchanger tube bundles. Our extensive experience in heat exchanger inspection provides the assurance that components are properly evaluated to detect damage or defects thereby ensuring that tube bundles are safe to remain in operation. Failures can result in unplanned shutdowns, dangerous catastrophic failures or severe costly damage.

A variety of state of the art inspection methods such as: Eddy Current Testing (ET) of non-ferrous tubing and Remote Field Inspection (RFT) of ferrous tubing are supplied. ISQ state of the art equipment and automated reporting software allow for optimal performance on shutdown jobs and work where scheduling must be rigorous.

Applications:

• Condensers

• Feedwater heaters

• Heat exchangers

• Air conditioners

Services Offered

• Eddy Current

• Magnetic Flux Leakage

• Remote Field

• IRIS Ultrasound

• Video Endoscopy

Equipment

Olympus MS5800

ZETEC MIZ35 and 55

IRIS Ultima

IRIS 9000

Multiview Inspection Software

ZETEC Acquisition Software

CARTO Tube design


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Pipeline Inspection

LABEND provides sevices in the frame of of pipeline inspection, for in-service condition and during construction phases.

ISQ has been involved on much of the new projects for gas distribution on its home country, with valuable experiences in difficult environments as Angola.

ISQ provides pipeline condition assessment trough standard spot thickness measurements, profile radiography, etc…

Services Offered

New Projects:



• Radiography and RX (RT and RX) – tie ins

• Crawler equipment


In service Inspection:

• Radiography - RT

• Ultrasonics – UT (area scaning and spot checking)

• Visual - VT

• Magnetic Particle MT

• Vibration Measurement VB


New Projects

ToFD + Phased Array Solution brings to pipeline construction all the advantages of the automated UT systems, allowing for:

• Full code covered: API 1104:2005, ASTM E1961-06

• Traceable and electronic data storage. Digital reporting,

• Speed of inspection

• No use of radiation source, allowing close follow up of the production and avoiding long displacement of construction teams for repair

• Immediate and on spot assessment of results

• Very high POD – Probability of Detection

• Industrial radiography poses many difficulties to the application of ECA - Engineering Critical Assessment – based codes, once it does not provide information on the depth of indications. This new new approach allows to minimize the repair frequency to levels under 1% avoiding unnecessary repairs

Assessment Phase ISQ solutions for monitoring your pipeline include:

• ACFM

• AUT Corrosion Mapping

• LRUT / Guided Waves

• Phased Array

• Computed Radiography


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Computed Radiography

The digital radiography uses phosporous image plates (IPs) that can be re-used. These IPs do not need a dark chamber, nor chemicals for their development. The radiographies are developped by a laser scanner and can be saved directly in a computer as a digital file.The image can then be treated in order to improve its evaluation conditions, allowing a clear observation of defects. Thanks to its algorithms, this technique can be used to determine rates of corrosion.

The radioactive sources are the same as for the conventional radiography, i. e., Selenium 75, Iridium 192, low energy X-Ray (<75kV) and average energy X-Ray (>75 kV and <300 kV). The advantages of digital radiography in comparison with conventional radiography are:

• The traditional film doesn’t exist, thus archive and degradation problems don’t exist;

• The image plates can be moderately exposed to direct light;

• The image plates, as the traditional films, are flexible enabling the adjustment to the piece geometry;

• The dark chamber and revelation lab are not needed;

• The stocking units associated with the chemicals are not needed;

• The exposure time are smaller, approximately 20 to 70% comparing to the traditional films;

• The evaluation and interpretation cycles can be reduced to 90%;

• The operational procedures for preparation and use are similar;

• Due to a greater latitude of this technique there is no need for double film or double exposition for pieces with different thicknesses;

• Because the images are computer files, they can be analyzed by several persons;

• The comparison with previous images is possible

Applications

• in-service: Corrosion under insulation on elbows and curves (low radiation application)

• In-service: Pitting detection

• In-service: Thickness measurement on small bore pipes

• In-service: Valve control

• New construction: Piping weld control (limitations on the thickness can exist, depending on used code)

• New construction: Tanks and other vessels, structures (like conventional RT)

• New

• Art Work analysis

Equipment

Computed Radiography Scanners at ISQ are the HD-CR 35 NDT

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EMAT

EMAT technology is an Ultrasonic Non Destructive Testing method that differs from traditional ultrasonics in the way the sound is generated. In conventional ultrasound technology a piezoelectric crystal is used to convert electrical energy into mechanical vibration. The vibration makes its way into the test piece via the couplant. EMAT consists of a magnet and a coil of wire and relies on electro-magnetic acoustic interaction for elastic wave generation.

Using Lorentz forces and magnetostriction, the EMAT and metal test surface interact and generate an acoustic wave within the material. The material being inspected is its own transducer, eliminating the need for liquid couplant. As no couplant is required it is much easier to do continuous scanning rather than spot checks as it normally the case with ultrasonics.

The EMAT system is relatively insensitive to surface roughness due to the principle of operation. With ultrasonics it is normally not possible to test through scale due to absorption and scattering of the beam. In the case of EMAT it is possible to test through moderate scale deposits, although very thick scale deposits can still prove troublesome.

Advantages of EMAT as against thickness testing:

• B- Scan register;

• High precision and continuous scan using transveral waves;

• No need of any type of coupling fluid;

• No probe contact with the material;

• No need to performe surface cleanning;

• High veleocity on testing and data acquisition

• Results easily viewed on a 3D model.

• Data trending can be carried out from follow up inspections

Limitations: EMAT can only be used on piping presenting a magneto-stictive layer that is usually formed only on components working over 500ºC.

Applications

• Boiler tube Inspection

• EMAT is a valuable tool on RLA as it allows direct comparison between data acquired at different stages

Equipment

ISQ uses, under license, Babcok equipment.

ISQ also has a in-hose developed system with enhanced automation capacity


EMATEMATEMATEMAT

ToFD + Phased Array

Time of Flight Diffraction (ToFD) : This technique is a variation of the ultrasonic test that uses diffraction for the detection and measurement of discontinuities. The ToFD technique is characterized by its sensibility, precision of measurement and speed of inspection. ToFD can be used for weld inspection during construction as well as during maintenance inspections.

This technique is very sensible to small discontinuities what enables a complete and precise inspection. Once ToFD is normally connected to a computer the register and data treatment makes ToFD a very reliable technique.

Phased Array (PA) : PA assumes uses an array of individually controlled transducers, in the same probe to generate a controlled wave front. Each of the individual crystals can be considered as a linear source of cylindrical waves. The wave fronts of the acoustic block will interfere in such a way that they created a general wave front that can be delayed and synchronised in phase and in amplitude creating an ultrasonic concentrated beam.

The main characteristic of Phased Array technology is the automatic controlled excitation, through computer aid (wave amplitude and delay), of the individual elements in a multielement probe. Generally speaking, the beam can be made to vary between 30º and 75º, approximately, what allows the detection of discontinuities with almost any direction.

Superficial defects are detected with the aid of creeping waves to scan the surface and the opposite face.

The phased array inspection results may be presented on a A, B or C-scan.

Advantages of this technique include: speed of inspection, possibility of automation, digital data and report and the inspection of complex geometry pieces. Another advantage is its sensibility to defects comparing to conventional or digital radiography (specially on planar defects on welds).

Integrated Automated Solutions : Through its development division, ISQ performs integration of ToFD+Phased Array Systems for various applications. The obvious advantages of this integrated solutions are the speed, data processing facility, encoding.

ISQ has successfully used integrated solutions for weld control during construction phases (LNG tanks, pipelines, nuclear facilities components, wind generator columns, gas spheres, etc..) as well for in-service control (HSOIC detection, corrosion assessment,..)

Applications

• High thickness components weld control (example LNG tanks, submarine shells, wind generator towers, )

• Excellent results replacing crawlers on pipe line control

• Excellent results replacing RT on tank inspection

• Dimensioning of cracking for support of Fitness For Service Studies

• Detection of Hydrogen Induced Cracking and Stress Oriented Hydrogen Induced Cracking on welds and shell (ToFD)

Equipment

Multix 128 full parallel channels and Olympus Omnyscan


ToFD + Phased ArrayToFD + Phased ArrayToFD + Phased ArrayToFD + Phased Array

Long Range UT / Guided Waves (LRUT)

The Guided Waves inspection technique is a long range scan technique for pipeline and insulated or protected equipment inspection with very big advantages above any other spot measurement. The Guided Wave technology screens 100% of the volume of the piping inspected for metal loss features such as corrosion and erosion. The piping can be in operation, insulated and even be buried

The Guided Wave technology uses low frequency guided ultrasound waves traveling along the pipe, providing 100% coverage of the pipe length. Affected areas are precisely located in terms of distance from the transducer ring and highlighted for further local examination by visual or other conventional NDT methods. This non-destructive screening technique can be used without extensive scaffolding and minimizes the requirement of removing insulation along the piping.

With Long Range Ultrasonic Technology is possible to detect thickness loss due to corrosion on insulated pipelines, reducing access and access costs problems. This kind of inspection enables the coverage of 100% of the material volume, with a fast scan. The LRUT technique is possible in a temperature range between -20ºC and 80ºC.

The test is applied installing a probe ring on the pipe, sending, then, the waves on both direction of the pipeline. The result is a fast inspection covering, until, 30m on each side of the ring.

Applications

• Pipe screening on pipe-rack

• Insulated pipe screening

• Buried pipe screening

• ISQ methodology is recognized by TUV SUD as RBI data provider

Equipment

GUL G3 equipments. GUL G4 equipments and sets of rings covering 2” to 36”.

DAC

LABEND Advanced LABEND Advanced LABEND Advanced LABEND Advanced SolutionsSolutionsSolutionsSolutions

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Automated Thickness Mapping

ISQ offers specialist corrosion mapping services, including non accessible locations. These services designed for originally for atmospheric tanks shell assessment and for follow ups on corrosion of process vessels with non-intrusive methodologies, are also being used successfully on pipe line follow up, giving a better insight on the data supplied by pigging inspection.

ISQ is also adapting the same vehicles used for corrosion mapping to the use of ToFD allowing a 100% screening on vessels suspected of HSOIC.

Advantages of automate thickness mapping are:

• Testing on location with no accessibility with no need for scaffolding or rope access.

• Full automated process, through the use of encoders, produces a map of thickness on the examined area.

• Fast and reliable.

• Digital data and better integration with RBI systems

Applications

• Corrosion on Pipeline follow up

• Pressure vessels assessment inspection

• API650 Atmospheric Tanks shell inspection

• Ultrasonic Thickness Measurement (TM) on non accessible locations

Equipment

ISQ equipment includes:

• Magnetic crawler vehicles, dry uni-dimensional measurements (tank inspection)

• Magnetic crawler vehicle, wet bi-dimensional measurements


Automated Thickness MappingAutomated Thickness MappingAutomated Thickness MappingAutomated Thickness Mapping

ACFM

Alternating Current Field Measurement (ACFM) is an electromagnetic technique used for the detection and sizing of surface breaking cracks in metallic components, that does not require any electrical contact with the surface being inspected.

The technique measures absolute values of the magnetic field in real time and these are used together with mathematical model lookup tables to avoid the need for calibration of the ACFM instrument using a sample piece with artificial defects such as slots.

The ACFM technique is generally insensitive to permeability changes and lift off and as it does not rely on probe contact it can be used to inspect through coatings of various thickness and material.

Advantages compared to other Inspection Techniques:

• Provides data storage for improved auditability, and allowing off-line reanalysis or year-on-year comparison of crack size.

• Allows a high degree of automation, making the system very user- independent.

• Simple scanning to allow 1 or 2 man operation including deployment by abseiler.

Other advantages compared to Magnetic Particle and Dye Penetrant Inspection

• Works through coatings up to 10mm thick, so there is no need to remove and then reapply paint, or to clean off rust.

• Provides information on depth as well as length, saving time on removing defects of insignificant depth.

Other advantages compared to Eddy Current Inspection

• Relatively insensitive to material property changes, so ideal for inspecting at welds.

• Relatively insensitive to probe lift-off, allowing deployment through coatings and on rough surfaces.

• Allows depth sizing of defects up to about 25mm (depending on probe type).

Originally introduced to the offshore industry for subsea weld inspection, the use of ACFM has now broadened to include inspection of pressure vessels, process piping, drill pipe threads and risers.

Applications

• Good alternative for Dye Penetrant Testing – Crack detecting

• Pressure Vessels internal weld inspection

• Bridges and Cargo Cranes

• Threads on drilling pipe

• Process Piping

Equipment

ISQ uses the ACFM Amigo by TSC.


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Documents

NDE Laboratory: LABEND Introduction€¦ · • Small bore pipe radiography • Ultrasonic Thickness Measurement (TM) • Ultrasonic Flaw Detection (UFDT) • Remote Field Testing