The Need for Ndt, Rca & Rbi

8/8/2019 The Need for Ndt, Rca & Rbi

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The need for NDT

During their service lives, many industrial componentsneed regular non-destructive tests to detect damage thatmay be difficult or expensive to find by everydaymethods. For example:

o Aircraft skins need regular checking to detect cracks;

o Underground pipelines are subject to corrosion andstress corrosion cracking;

o Pipes in industrial plants may be subject to erosion and

corrosion from the products they carry;

o Reinforced concrete structures may be weakened if the

inner reinforcing steel is corroded;o Pressure vessels may develop cracks in welds;

o The wire ropes in suspension bridges are subject to

weather, vibration, and high loads, so testing for broken

wires and other damage is important.


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Applications

Automotive

Engine parts

Frame

Aviation / Aerospace

Airframes

Spaceframes

Powerplants

Propellers Reciprocating Engines

Gas Turbine Engines

Rocketry Construction

Structures

Bridges

Maintenance

Bridges

Manufacturing Machine parts

Castings and Forgings

Industrial plants such as Nuclear, Petrochemical,Power, Refineries, Pulp and Paper, Fabricationshops, Mine processing and their Risk BasedInspection programmes.

NDT is used in a variety of settings that covers

a wide range of industrial activity.

Pressure vessels

Storage tanks

Welds

Boilers

Heat exchangers

Turbine bores In-plant Piping

Miscellaneous

Pipelines

In-line Inspection using "pigs"

Pipeline integrity

Leak Detection

Railways

Rail Inspection

Wheel Inspection

Tubular NDT, for Tubing material

Corrosion Under Insulation (CUI)

Amusement park rides

Submarines and other Naval warships

Medical imaging applications


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Methods and techniques

Liquid penetrant testing (PT or LPI)

Radiographic testing (RT)

Digital radiography (real-time)

Computed radiography

SCAR (Small Confined Area Radiography)

Neutron radiographic testing (NR)

Computed tomography (CT)

Impulse excitation technique (IET)

Ultrasonic testing (UT)

Phased array ultrasonics

Time of flight diffraction ultrasonics (TOFD)

Time of Flight Ultrasonic Determination of 3D Elastic Constants (TOF)

Internal Rotary Inspection System (IRIS) ultrasonics for tubes

EMAT Electromagnetic Acoustic Transducer (non-contact)

laser ultrasonics (LUT) Electromagnetic testing (ET)

Alternating Current Field Measurement (ACFM)

Alternating Current potential drop measurement (ACPD)

Direct Current potential drop measurement (DCPD)

Eddy-Current Testing (ECT)

Remote field testing (RFT)

Magnetic-particle inspection (MT or MPI)

Magnetic flux leakage testing (MFL) for pipelines, tank floors, and wire rope

NDT is divided into various methods of nondestructive testing,

each based on a particular scientific principle.

These methods may be further subdivided into various techniques.


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Methods and techniques (cont.)

Acoustic emission testing (AE)

Positive Material Identification (PMI) Hardness testing (Brinell) (HT)

Infrared and thermal testing (IR) Thermographic inspection

Laser testing Profilometry

Holographic interferometry

Electronic Speckle Pattern Interferometry

Shearography

Leak testing or Leak detection (LT) Tracer-gas method testing Helium, Hydrogen and refrigerant gases

Bubble testing

Absolute pressure leak testing (pressure change)

Halogen diode leak testing

Mass spectrometer leak testing

Magnetic resonance imaging and NMR spectroscopy Visual inspection (VT)

Pipeline video inspection


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Root Cause Analysis

Root cause analysis (RCA) is a class of problem solving methodsaimed at identifying the root causes of problems or events.

The practice ofRCA is predicated on the belief that problems are bestsolved by attempting to correct or eliminate root causes, as opposed

to merely addressing the immediately obvious symptoms.

By directing corrective measures at root causes, it is hoped that thelikelihood of problem recurrence will be minimized.

However, it is recognized that complete prevention of recurrence by a

single intervention is not always possible. Thus, RCA is oftenconsidered to be an iterative process, and is frequently viewed as atool of continuous improvement.


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General principles of root cause analysis

Aiming performance improvement measures atroot causes is more effective than merelytreating the symptoms of a problem.

To be effective, RCA must be performedsystematically, with conclusions and causesbacked up by documented evidence.

There is usually more than one root cause forany given problem.

To be effective the analysis must establish allknown causal relationships between the rootcause(s) and the defined problem.


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General process for performing and

documenting an RCA-based Corrective Action

Define the problem.

Gather data/evidence.

Ask why and identify the causal relationships

associated with the defined problem. Identify which causes if removed or changed will

prevent recurrence.

Identify effective solutions that prevent recurrence, arewithin your control, meet your goals and objectives and

do not cause other problems. Implement the recommendations.

Observe the recommended solutions to ensureeffectiveness.


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Basic elements of root cause

Materials Defective raw material

Wrong type for job

Lack of raw material

Machine/Equipment Incorrect tool selection

Poor maintenance or design

Poor equipment or tool placement

Defective equipment or tool

Environment Orderly workplace

Job design or layout of work

Surfaces poorly maintained

Physical demands of the task

Forces of nature

Management No or poor management involvement

Inattention to task

Task hazards not guarded properly

Other(horseplay, inattention....)

Stress demands

Lack ofProcess

Methods

No or poor procedures

Practices are not the same as written

procedures

Poor communication

Management system

Training or education lacking

Poor employee involvement

Poor recognition of hazard

Previously identified hazards were not

eliminated


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Risk based inspection

Risk based Inspection (orRBI) is a risk-

based approach to inspection in the Oil

and Gas industries. This type of inspection

analyzes the likelihood of failure and the

consequences of the same, often in

industrial pipework. It is also called Risk

Based Asset Management (RBAM), RiskBased Integrity Management (RBIM) or

simply Risk Based Management (RBM).


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RBI objectives

RBI will assist a company to select cost

effective and appropriate maintenance and

inspection tasks and techniques, to

optimize such efforts and cost, to shift

from a reactive to a proactive maintenance

regime, to produce an auditable system, to

give an agreed Operating window, topromotes Team work and to create a Risk

Management Tool.


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RBI purposes

To move away from time based inspectiongoverned by minimum compliance with rules,regulations and standards for inspection.

To apply a strategy of doing what is needed forsafeguarding integrity and improving reliability

and availability of the unit by planning andexecuting those inspections that are needed.

To provide economic benefits such as fewerinspections, shorter shutdowns, longer runlength, and less frequent shutdowns.

To safeguard integrity.


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Sample ofRBI process

The Need for Ndt, Rca & Rbi

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