RSV Service Manual
Plant & Equipment Non-Destructive Testing (NDT), API Inspection, NDT Level III Services, Corrosion Control, Risk-Based Inspection and Training
Contents
Introduction Conventional NDT Testing Visual Inspection (VT) Ultrasonic Flaw Detection (UFD) Ultrasonic Thickness Measurement (UTM) Magnetic Particle Testing (MPT) Dye Penetrant Testing (DPT) Hardness Testing (HT) Vacuum Box Testing (VBT) Paint Dry Film Thickness (PDFT) Advance Inspection Techniques Time of Flight Diffraction (TOFD) Magnetic Flux Leakage (MFL) C-Scan Corrosion Mapping NDT Level-III Services API Services API 510 services API 653 Services API 570 Services Third Party QA/QC QA/QC Inspections Third Party Vendor Surveillance Risk Based Inspection (RBI) Failure Analysis Corrosion Control Consultancy Corrosion Inhibitor Injection Corrosion Monitoring Cathodic Protection Material Selection Painting & Coating Courses & Training Services Conventional NDT Advanced NDT Plant Inspection Welding Inspection Corrosion Control Risk-Based Inspection
Introduction: RSV offers Plant & Equipment Non-Destructive Testing (NDT), API Inspection, NDT Level III Services, Corrosion Control, Risk-Based Inspection and Training during routine-inspection, in-service inspection, shutdown & turnaround and new construction to Oil & Gas Exploration Industries, Petroleum Refineries, Fertilizer Industries, Oil & Gas Distribution Facilities, Power Generation Plants, Maritime Industries, Chemical Industries, Nuclear Plants, Automotive Manufacturing Industries, Cement Industries, Plant, Equipment, Ship and Pipeline Construction Companies and Mechanical Engineering Companies. Reliance Swift Veritas with its highly qualified/certified field team of Engineers, Technicians and equipment has significant experience in managing and performing conventional and advance NDT, equipment integrity and corrosion control works for operating and developing projects.
Conventional NDT Testing
Visual Inspection: Visual Inspection (VI) is one of the most widely used Non-Destructive Testing (NDT) methods for the detection of discontinuities before they cause major problems, e.g. poor welding, surface defects, corrosion pits, general condition, degradation, blockages and foreign materials. Visual Inspection means the inspection of equipment and structures using a combination of human senses such as vision, hearing, touch and smell. Visual Inspection is sometimes carried out in conjunction with devices such as a low power magnifying glass, boroscopes, fiberscope, digital video boroscopes, camera systems and robotic crawler systems.
Ultrasonic Flaw Detection: Ultrasonic Testing (UT) uses high frequency sound energy to conduct examinations and make measurements. Ultrasonic inspection can be used for flaw detection/evaluation, dimensional measurements, material characterization, and more. Of all the applications of industrial ultrasonic testing, flaw detection is the oldest and the most common. Since the 1940s, the laws of physics that govern the propagation
of sound waves through solid materials have been used to detect hidden cracks, voids, porosity, and other internal discontinuities in metals, composites, plastics, and ceramics. High frequency sound waves reflect from flaws in predictable ways, producing distinctive echo patterns that can be displayed and recorded by portable instruments. Ultrasonic testing is completely nondestructive and safe, and it is a well established test method in many basic manufacturing, process, and service industries, especially in applications involving welds and structural metals.
Ultrasonic Thickness Measurement: Ultrasonic NDT characterizing material thickness, integrity or other physical properties by means of high frequency sound waves. Accuracies as high as 1 micron or 0.0001 inch are available in some applications. Precision ultrasonic thickness gauge usually operate at frequencies between 500 KHz 100 MHz, using piezoelectric transducers to generate bursts of sound waves when excited by electrical pulses. Typically, lower frequencies will be used to optimize penetration when measuring thick, highly attenuating, or highly scattering materials, while higher frequencies will be recommended to optimize resolution in thinner, non-attenuating, non-scattering materials.
Magnetic Particle Inspection: Magnetic Particle testing is a surface and sub-surface testing method which uses electromagnetic energy for probing and ferromagnetic particles as indicators. This method is limited to test ferromagnetic materials. It is a simple method and more sensitive to linear defects. As the depth of defect increases, the sensitivity decreases rAPIdly. It is a cheap and fast testing method. A defect under the influence of magnetic field produces leakage field which attracts the magnetic particle sprayed on the specimen surface. Maximum response obtained from the defects that are perpendicular to the magnetic lines of force. Either dry or wet particles are used to detect indications. Fluorescent particles are used to increase sensitivity. MPI uses magnetic fields and small magnetic particles (i.e. iron filings) to detect flaws in components. The only requirement from an inspection standpoint is that the component being inspected must be made of a ferromagnetic material such as iron, nickel, cobalt, or some of their alloys. Ferromagnetic materials are materials that can be magnetized to a level that will allow the inspection to be effective.
Dye Penetrant Testing: Dye Penetrant Testing is a surface testing method. All non-porous materials can be inspected by this method. In order to be detected, the defect must be open to surface. This is an easy and cheap testing method most widely used in all industry. When a penetrant is applied on the suitably cleaned material surface, it is driven into the defect by capillary action. The capillary force depends on the physical properties such as surface tension, the contact angle, and the size of the defect opening. The developer applied on the surface after the excess Penetrant removal bleed out the penetrant trapped inside the defect and produce visible indication. The advantage that a liquid penetrant inspection (LPI) offers over an unaided visual inspection is that it makes defects easier to see for the inspector. There are basically two ways that a penetrant inspection process makes flaws more easily seen. First, DPT produces a flaw indication that is much larger and easier for the eye to detect than the flaw itself. Many flaws are so small or narrow that they are undetectable by the unaided eye. Due to the physical features of the eye, there is a threshold below which objects
cannot be resolved. This threshold of visual acuity is around 0.003 inch for a person with 20/20 vision.
Hardness Testing: Hardness is a characteristic of a material, not a fundamental physical property. It is defined as the resistance to indentation, and it is determined by measuring the permanent depth of the indentation. More simply put, when using a fixed force (load)* and a given indenter, the smaller the indentation, the harder the material. Indentation hardness value is obtained by measuring the depth or the area of the indentation.
Vacuum Box Testing: Vacuum Box is used to check for any leaks or faults in the welding of bottom and annular plates of the tank. It is a container with an acrylic sheet on top with an inlet valve connecting to the Vacuum Pump. Vacuum box bubble test is one of the safest and reliable nondestructive test method. The test is performed by applying a detergent solution on the test area and creating a vacuum around the test surface by external mechanism.
Paint Dry Film Thickness: paint dry film thickness or Coating thickness is an important variable that plays a role in product quality, process control, and cost control. Measurement of film thickness can be done with many different instruments. Understanding the equipment that is available for film thickness measurement and how to use it is useful to every coating operation. Dry Film Thickness is a critical measurement in the coating application process. It provides vital information as to the expected life of the substrate, the products fitness for purpose, its appearance and ensures compliance with a host of International Standards.
Advance Inspection Techniques:
Time of Flight Diffraction (TOFD): The TOFD technique is an ultrasonic image-generating technique, which offers the capabilities of detection, location and sizing. Permanent data recording with B-scan type imaging (side view) Accurate sizing capability (height)-through-wall height most critical for fracture mechanics Technique allows for rapid scanning Detection and sizing almost orientation independent Based on Time of Flight to avoid common amplitude technique sizing errors TOFD has a potential through-wall dimension accuracy of 1 mm and a crack growth monitoring capability of 0.3mm. Setup virtually independent of weld configuration Wide coverage area The depth sizing is not dependent on the amplitude of the signals and the corresponding errors Because no ionizing radiation is used, the inspection does not interfere with the production process.
TOFD inspections can therefore in general take place in parallel to production work during day shift.
Magnetic Flux Leakage: MFL Tank Floor Scanning is a method that can detect underside corrosion from the top and can give a full coverage of the floor as corrosion may occur anywhere. Typically storage tanks suffer from corrosion at the underside of the floor bottom. Often this type of corrosion will be localized (pitting), sometimes larger areas may be corroded MFL tools are suited for inspection of exposed bare, painted or thinly coated carbon steel components. A strong magnet is used to establish a magnetic flux in the material to be inspected. When there is no defect the uniform flux remains in the metal. Near the defect, the flux "leaks" out of the metal. Sensors which can detect this flux leakage are placed between the poles of the magnet and generate an electric signal proportional to the magnetic leakage flux. Defects causing a leakage flux exceeding a predetermined threshold are detected. The amount of leakage flux is dependent on depth, orientation, type and position (topside/bottom-side) of the defect. Defects exhibiting various combinations of volume loss and depth can produce the same flux leakage level. Therefore truly quantitative depth information can not be obtained by this method. It is a qualitative not a quantitative inspection tool. For accurate sizing of the defects ultrasonic testing can be applied after detection.
C-Scan Corrosion Mapping: Large volumes of plant and equipment such as pipe work, pressure vessels, bends and elbows can be inspected using CScan that produces color graphic imaging of the area scanned. For nonintrusive work, scans typically cover 0.25sq meter per scan as a maximum, multi-scans are then are compiled into a composite to show the complete color graphic image of the inner surface. Recent developments include the capability to inspect plant on-line in temperatures of up to 250C. Corrosion mapping involves scanning by straight beam probes over a prescribed, dual axis scan pattern over a pipe or pressure vessel surface whilst taking thickness measurements. The measurements are converted into digital values which are color-coded to create topographic maps of the vessel or pipe wall thickness profile. Images (C-scans) from individual scan areas can be assembled together to create composite images covering large areas of material. This is a very powerful technique for management reporting or to observe widespread effects. The Micro Map system enables difficult access or awkward geometry components to be inspected by ultrasonic C-scan or corrosion mapping.
NDT UT Level III Services
Personnel qualification services, procedure development and review, third party overview, witness and problem resolution. Personnel qualification services include documentation review, training, and qualification examinations. Documentation review is performed to assure education, training, experience and qualification examinations meet your code, specification and client requirements. Written general and specific examinations meeting your code, specification or client requirements for each NDT method can be developed and administered in accordance with ASNT Recommended Practice SNT-TC-1A. Procedure development and review can be outsourced to relieve the burden of finding the dedicated time needed to accomplish such tasks. Industry experience combined with extensive involvement with ASNT and ASTM standards development ensures document(s) acceptable for use by your NDT personnel and to your clients. Third party overview, witness and problem resolution is a valuable resource to ensure expected results and reduce conflict. Outsourcing the overview or witnessing of quality activities is cost effective in assuring that specification requirements have been met. The services provide a qualified, objective evaluation for problem resolution that is usually acceptable to clients and reduces the potential conflicts of direct involvement with customers.
API Services
Inspection of Pressure Vessel, Boilers, Heat Exchangers, Storage Tank, Piping, Valve and any other pressurized equipments in Petroleum and Oil Refineries, Chemical Plants and Power Station Shutdown and Maintenance Inspection. API 510 services: RSV offers Professional Pressure Vessel Inspection services for Vessels, Boilers, Heat Exchangers and other pressurized equipments in petroleum and oil refineries. API 510 covers the in-service inspection, repair, alteration, and re-rating activities for pressure vessels and the pressure-relieving devices protecting these vessels. This inspection code applies to all refining and chemical process vessels that have been placed in service unless specifically excluded per 1.2.2. This includes: vessels constructed in accordance with an applicable construction code vessels constructed without a construction code (non-code)A vessel not fabricated to a recognized construction code and meeting no known recognized standard vessels constructed and approved as jurisdictional special based upon jurisdiction acceptance of particular design, fabrication, inspection, testing, and installation Non-standard vesselsA vessel fabricated to a recognized construction code but has lost its nameplate or stamping. RSV has a qualified team of inspectors having vast experience to carry out such inspections. API 653 Services: RSV offers Professional storage tank inspection and for all kinds of above ground tanks. API 653 covers Tank Inspection, Repair, Alteration, and Reconstruction. This inspection method promotes safe storage and material handling of petroleum products in a manner that protects employees, the public, and the environment. It was developed with the participation of storage tank owner/users, and establishes a uniform national program that will assist companies as well as state and local governments in above ground storage tank regulations. RSV has a qualified team of API 653 inspectors having vast experience to carry out such inspections.
API 570 Services: RSV offers Professional pressure piping inspection. API 570 covers inspection, rating, repair, and alteration procedures for metallic and fiber glass reinforced plastic (FRP) piping systems and their associated pressure relieving devices that have been placed in service. The intent of this code is to specify the in-service inspection and conditionmonitoring program that is needed to determine the integrity of piping. This program provides a reasonably accurate and timely assessment to determine if any changes in the condition of piping could possibly compromise continued safe operation. It is also the intent of this code that owner-users shall respond to any inspection results that require corrective actions to assure the continued safe operation of piping.
Third Party QA/QC
To provide Third Party Inspection services Implementation, monitoring, auditing and Review of procedures, certification, reporting etc. QA/QC Inspections of New Construction and Repairs or Alterations to Existing Equipment: RSV can serve as Quality Assurance/Quality Control (QA/QC) representative at the manufacturer, repair facility, or onsite to assure quality and compliance of your specific standards. BAY Technical maintains working relationships with several Non-Destructive Examination (NDE) organizations. This allows us to offer NDE services such as Infra-red, Airborne Ultrasonic, Radiography, Ultrasonic, Liquid Penetrant, and Magnetic Particle, to name just a few. Third Party Vendor Surveillance for Owner/Users, Contractors and Subcontractors: RSV can represent the owner/user, contractors and subcontractors during fabrication and erection of specific projects. We can provide inspection to ensure contractual and codes/standards compliance during equipment fabrication or installation. We can also provide representation during repairs, alterations or maintenance activities.
Risk Based Inspection (RBI)
Risk Based Inspection is a methodology that enables the assessment of the likelihood and potential consequences of equipment vulnerable to different forms of corrosion to fail prematurely. RBI quantifies the risk posed by corrosion with a systematic approach. RSV team of consultants work with potential clients to prioritize the clients equipment for inspection, optimized inspection methods, frequencies and resources and to develop specific equipment inspection plans, enabling the implementation of the Reliability Centered Maintenance (RCM) The Key Benefits: Improved Safety Lower Failure Risk Fewer Forced Shut-downs Reduced Operational Costs
Failure Analysis
Failure analysis is the process of studying and understanding a particular incident where a material or a system has experienced failure, to determine the cause of the failure and most importantly to prevent it from happening again. The significance of failure analysis is the latter half of the definition impeding a recurrence of the failure. In the world of designing critical products used on a daily basis by millions of people, the integrity of materials is a number one priority. Businesses hire experts to perform failure analysis to ensure the product's quality.
Corrosion Control Consultancy
Corrosion Monitoring Consultancy: RSV provides Corrosion Monitoring and Consultancy Services for asset integrity assessments on plant, piping and structural elements, including Developing the Monitoring Program Baseline surveys Cathodic Protection surveys Key point thickness measurements Corrosion mapping.
Cathodic Protection Consultancy: Cathodic protection is commonly applied to a coated structure to provide corrosion control to areas where the coating may be damaged. It may also be applied to existing structures to prolong their life. Structures that are commonly protected by cathodic protection are the exterior surfaces of: Pipelines Ships hulls Storage tank bases Jetties and harbor structures Steel sheet, tubular and foundation pilings
Cathodic protection is also used to protect the internal surfaces of: Large diameter pipelines Ships tanks (product and ballast) Storage tanks (oil and water) Water-circulating systems
Material Selection Consultancy: The selection and formulation of new materials, whether for cost, supplier, performance, processing, quality or environmental reasons, has become increasingly important across all industries. Raw material analysis fit for purpose & legal compliance testing Materials formulation and application advice on how properties can affect and enhance performance Materials selection advice on sourcing cost-effective alternatives without compromising quality or performance Failure analysis identifying material failures and contamination Environmental analysis consultancy regarding the sustainability of the product and process.
Painting & Coating Consultancy:
Courses & Training
Conventional NDT Advanced NDT Plant Inspection Welding Inspection Corrosion Control Risk-Based Inspection
