Industrial Services

Non-Destructive Testing - Examination and Evaluation

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SGS Service Offer - Non Destructive Testing

NDT:

Also known as Non Destructive Examination or Evaluation (NDE), NDT refers to a method of examining materials, components and connections in order to identify and quantify internal defects and degradations.

The aim of NDT is to assess material properties before they result in failure - based on recognized acceptance criteria or degradation profiles defined along the years - to ensure product quality and performance upon production, as well as to ensure the safe utilization of engineering structures.

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SGS NDT – Service Offer and Client Benefits (I)

SGS service offer:

Not just a list of techniques but solutions using different techniques together.

Complete range of conventional and special NDT techniques

NDT operators certified to ASNT / EN 473

On-site NDT coordination

Project management (shut downs)

Interpretation of NDT results

SGS as main NDT contractor; one management and reporting structure; systems to ISO 9001:2000; one NDT contact person– safety systems

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SGS NDT – Service Offer and Client Benefits (II)

Client benefits: One contractor for inspection and evaluation of system-

integrity.

Know how on all NDT techniques, specialists all around the world.

Optimisation of complete chain –scaffolding, insulation, inspection; therefore downsizing total maintenance budget.

Reliable view on installation condition to ensure maximum production capacity.

Limited number of NDT contractors and inspectors

Direct and efficient contacts with one contractor

Efficient follow-up on NDT, less time spend on interpreting results

Fast construction is better supervised and controlled

Milestone dates met

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Non Destructive Testing and Examination

Conventional techniques::

Radiography [RT] (X-ray / Gamma –ray)

Ultrasonic testing [UT]

‘Eddy current’ [ET] Electromagnetic testing Tubing heat exchangers Surface testing

Magnetic Particle Inspection [MPI]

Dye/liquid penetrant exami-nation [DPE]

Visual examination

Positive Material Identification [PMI]

Specialised NDT techniques:

Time of Flight Diffraction [ToFD]

‘Guided Wave’ (UT) pipe examination

Magnetic Flux Leakage testing [MFL]

‘Floor mapping’

‘Corroscan’

Crawler automated UT [AUT]

Hot (temperature) Hydrogen Attack analysis [HHA/HTHA]

Conventional NDT techniques

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Conventional NDT – Radiographic Testing

Radiographic testing (RT): Gamma X-ray Crawler Low-radiation RT SCARS

X-ray on a jet engine

[CP unit (Constant potential)]

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Conventional NDT – Ultrasonic Testing

Ultrasonic testing (UT): Wall thickness Plate / Pipe Welds Hydrogen Induced Cracking (HIC) Corrosion Erosion

Ultrasonic probe for wall thickness

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Conventional NDT – Magnetic Particle and Penetrant Testing

Magnetic particle testing (MT): direct, indirect and colour and fluorescent

Penetrant testing (PT): rinseable with water, post-emulsifyable, solvent, colour, fluorescent and dual

Magnetic UV colour

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Visual inspection – Experience and Standards

External and internal inspection of vessels and storage tanks May lead to further examination using other

NDT techniques

Site inspections of piping and appendages

Welder certification and welding method qualification

Witnessing of hydrostatic testing

Rotating equipment inspection

Special examination NDT

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Examples of Special Examination techniques

Guided Wave

Floormap (MFL)

Corroscan

Time of Flight Diffraction (ToFD)

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Typically suitable for: Road crossings & buried pipelines Detection of corrosion/erosion under

insulation Offshore risers Applicable to 125 degrees C Refinery pipework, chemical plant &

power generation plants and utilities

Guided Wave

Guided Wave is a long range (10-40 mtr.) ultrasonic technique for screening of corrosion in pipework and pipelines

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Weld Metal loss Metal loss

FlangeConventional Transducer

Weld Metal loss Metal loss

FlangeTeletest® Tool Guided Wave

100% Inspection

Localised Inspection

Conventional UT vs Guided Wave

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Floormap (MFL)

Floormap Magnetic Flux Leakage (MFL) tank bottom inspection

Fast screening technique for detection of corrosion

Determination of wall thickness corrosion locations by UT

Applicable for bottom plates with thickness <12,5 mm

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Floormap (MFL)

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Corroscan

Corrosion mapping with the colour as function of wall thickness

100% reproducible

A camera determines probe location

Inspection possible till 160 degrees C

Visualising corrosion profiles

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Corroscan – cont.

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Time of Flight Diffraction (ToFD)

T R1

2

3

4

1

2

3

4

UT weld inspection

Wall thickness 6-400 mm

Diameter 6 “ till flat

C-st

Duplex sometimes possible

Temperatures -10 till 200 degrees C

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High accuracy sizing

Directly result

No radiation

Fast

Data digitally monitored

Time of Flight Diffraction (ToFD) – cont.

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Risk Based Inspection and Specialised NDT

Risk Based Inspection (RBI) is regarded as a cost effective alternative to traditional planning and implementation of inspection and maintenance programs. All pressure equipment contain flaws Most flaws are innocuous - Don’t cause problems Few flaws cause catastrophic failure Must find (inspect) those critical flaws in high risk service - Cost

effectively Typically 80% of the risk is associated with < 20% of the pressure

equipment

Optimising inspection expenses also involves using specialised NDT techniques, such as ToFD and Guided Wave

RBI describes the inspection plan based on risk ranking; special NDT provides both input for the RBI analysis as well as execution of the actual risk-based inspection plan.

Traditional ApproachTraditional Approach

RBI ApproachRBI Approach

Digital Radiography forNDT Applications

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Exposure time: 10% of D7

Dynamic Range: Factor 1.000 compared with Film

Film quality comparable to D7/D8, in some instances even D5

Scanning time: 10 to 120 sec

Storage cassettes allow for unlimited exposure cycles

No chemicals required like for film processing

Easy data storage

Storage cassettes are flexible and (medium) protected against mechanical damage

Storage Phosphor Computed Radiography

Digital radiography

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RADView CR Tower

Automatic cassette handling

Increased lifetime of Ph Plates

Designed for convenience

Standard sizes of phosphor plates and cassettes: 8” x 10” and 14” x 17”

Fuji: ‘flexible’ sheets that can be bend around a pipe

Phosphor Scanner Systems

Digital radiography – cont.

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Casting

Original

Contrast Enhanced

Digital Radiography - RADView

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Casting

Region of interest

Digital Radiography - RADView

Zoomed

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Original Contrast Enhanced

Digital Radiography - RADView

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Digital Radiography – Implementation

Cost Savings: Lower archival costs Removal of film storage monitoring costs (Thosulphate testing etc) Remote Contractor approval Reduced number of site buildings Less site personnel Removal of liquid waste disposal costs

Successful implementation of a Digital Radiographic System involves a number of considerations. These involve exposure conditions, image quality requirements and productivity and acceptability to International Codes of Practice within our industry.

Similar to conventional radiographic film, digital radiography exhibits a wide range of resolutions, speeds and throughput capabilities. Not one solution can meet all radiographic needs The right choice depends upon the application.

NDT related services

Destructive materials testing laboratories

Training services

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SGS Service Offer – Training Services

Client benefits:

Improvement of knowledge/skill level of clients staff

Updated expertise through experienced trainers

Benefit of SGS’ extensive experience and knowledge base

SGS service offer:

OHS training courses, e.g. Basic safety generic training Specialised safety training courses

NDT training courses, Level I, II, III MT, UT, RT, etc Specialised NDT techniques Interpretation of NDT results

Technical inspection courses

Quality assurance and Environmental courses

NDT references

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Reference: Nigeria LNG Plant - Bonny Island

The NLNG in Nigeria will be one of the world’s largest natural gas liquefaction plants.

SGS provided NDT services on Trains 1& 2, from Dec 96 to Nov 99.

SGS has completed the NDT program for Train 3 and is presently undertaking the NDT program for Trains 4 & 5.

SGS successfully developed innovative high volume radiography techniques for field application in a hostile, wet tropicalenvironment.

As many as 1500-1800 welds examined per week

SGS achieved weld verifications rates of 1800 per week, within a fully compliant ISO 9001 Quality Management System.

SGS realised an exemplary safety and

training record and added value to the

local communities.

Fully compliant ISO 14000 system in

place

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Owned by Union Fenosa - Spain / ENI Italy

EPC contractor Halliburton KBR. Managedby affiliate M.W.Kellogg UK

Single train complex with capacity of 5million t.p.a. for first train

SGS Egypt awarded contract for NDTincluding PMI

Imported expertise from Nigeria to Egyptfor high volume radiography techniques and data storage & retrieval

SGS Egypt have successfully achieved weld verification rates of 1500 per week within a fully compliant ISO 9001 system

Appointed for inspection and verification of on site plant and equipment including periodic inspection of cranes & lifting tackle.

Reference: Damietta LNG Plant - Egypt

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Reference: Taipei Financial Centre - Taiwan

July 99, SGS awarded contract as OwnersRepresentative Third Party Inspection Co.for World’s Tallest (101 floors) super highrise building in Taipei.

Project has 357,721 sqm floor area, on a30,278 m2 footprint ; steel structure withglass cladding.

Follows previous contract for NDT & QAServices on 85 storey building in Kaohsiungduring 1993-1996

SGS services on-site include overall project QA materials controls and inspection Welder qualification control NDT Inspections Non-Conformance Control

SGS laboratory services off-site include material and engineering compliance tests to approved codes materials testing of steel plate, welding rods and tension bolts to contractual specifications.