INSPECTION
& TESTING
Ultrasonic Thickness Measurements (UTM)
It is a technique for measuring the wall thickness reduction level due to corrosion and erosion on pipelines, vessels, storage tanks, and other assets.
It can be used to decide whether repairs or replacements are required, or if the item or structure should be retired and the metal thickness of tested equipment within acceptable range.
The ultrasonic thickness gauge measures the required time for a wave pulse generated by a probe known as an ultrasonic transducer to travel through a test material and reflect back from the inner surface or far wall, then the results displayed digitally.
Petromine’s inspectors are competent at performing UTM and corrosion analyses. We map our measurement locations for further inspections in order to calculate the metal reduction rate within a given period. As well as an extensive number of measurements around abnormal reduction locations to determine the shape of discontinuities.
We could serve all industrial sectors including oil and gas, power generation, structural contractors, fertilizers, cement, petrochemicals, pharmaceuticals, food, beverage, etc..
Advantages of UTM include the following:
Petromine has the capability to perform that technique in an efficient manner in accordance with international standards, codes, and other national legal requirements. We have the required tools to get a premium inspection and exceed our clients' expectations.
It can be used to decide whether repairs or replacements are required, or if the item or structure should be retired and the metal thickness of tested equipment within acceptable range.
The ultrasonic thickness gauge measures the required time for a wave pulse generated by a probe known as an ultrasonic transducer to travel through a test material and reflect back from the inner surface or far wall, then the results displayed digitally.
Petromine’s inspectors are competent at performing UTM and corrosion analyses. We map our measurement locations for further inspections in order to calculate the metal reduction rate within a given period. As well as an extensive number of measurements around abnormal reduction locations to determine the shape of discontinuities.
We could serve all industrial sectors including oil and gas, power generation, structural contractors, fertilizers, cement, petrochemicals, pharmaceuticals, food, beverage, etc..
Advantages of UTM include the following:
- Surface and subsurface fault detection.
- A pulse-echo approach requires only one-sided access.
- Highly precise at determining the magnitude and shape of discontinuities.
- Electronic equipment provides instantaneous results.
Petromine has the capability to perform that technique in an efficient manner in accordance with international standards, codes, and other national legal requirements. We have the required tools to get a premium inspection and exceed our clients' expectations.
Visual Inspection
It is a physical examination of an asset performed primarily with eye.
Petromine has competent inspectors who have the experience and certification to find discontinuities or any abnormalities that don’t meet the standards inspecting each component.
However, optical instruments such as magnifying glasses, mirrors, borescopes, charge-coupled devices (CCDs), and computer-assisted viewing systems can assist inspectors in detecting corrosion, part misalignment, physical damage, and cracks, to identify any discontinuities.
Advantages of visual inspection:
Petromine has competent inspectors who have the experience and certification to find discontinuities or any abnormalities that don’t meet the standards inspecting each component.
However, optical instruments such as magnifying glasses, mirrors, borescopes, charge-coupled devices (CCDs), and computer-assisted viewing systems can assist inspectors in detecting corrosion, part misalignment, physical damage, and cracks, to identify any discontinuities.
Advantages of visual inspection:
- It is a simple and cost-effective test that does not require expensive equipment.
- To identify any defects in the asset that may require maintenance.
- Highly sensitive visual inspection is made possible by experienced operators and advanced equipment.
- It enables the eye to detect discontinuities.
- It is entirely dependent on the human factor.
- Many organizations pay little attention to the proper training of operators.
- No subsurface discontinuities will be detectable.
Dye Penetrant Inspection (DPI)
It is widely used to detect surface-breaking flaws. It is a cost-effective method used to locate surface breaking flaws such as cracks, porosity, laps, seams, and other surface discontinuities. Dye penetrant inspection can be applied to both ferrous and non-ferrous materials and to all non-porous materials (metals, plastics, or ceramics).
Advantages:
Advantages:
- Remarkable sensitivity to minor surface imperfections.
- Rapid and cost-effective inspection of large areas of parts or materials.
- Metallic and non-metallic materials can all be inspected.
- Aerosol-based spray cans make the process more portable and convenient.
- Indications assist in determining the relative size and shape of the imperfection.
- It only detects flaws that are visible on the surface.
- This technique cannot be used to examine porous materials.
- Inspections are only possible on clean, smooth surfaces. (Dispose of any rusted items, dirt, paint, oil, or grease.)
- The examiner must have direct access to the investigation surface.
- The finish and roughness of the surface can affect the sensitivity of an examination.
- The pre-cleaning phase.
- Use a penetrant.
- Remove the penetrant.
- Use a developer.
- Evaluate indications, capture photos.
- Post-clean phase.
Magnetic Particle Testing (MPT or MPI)
It is used to detect surface and slightly subsurface flaws in ferromagnetic materials such as iron, nickel, and cobalt, as well as some of their alloys. It is also used to detect cracks, pores, cold lap, and a lack of sidewall fusion in welds. According to ASME Section V, "a MPI applied to materials that can be magnetized or strongly attracted by a magnetic field."
Advantages:
Advantages:
- It is a quick and inexpensive service.
- It gives immediate indications of defects.
- It reveals surface and near-surface flaws, which are the most serious because they concentrate stresses.
- It is only compatible with ferromagnetic materials, which are typically iron and steel, and cannot be used on austenitic stainless steel.
- Occasionally, it is unclear whether the magnetic field is strong enough to provide reliable indications.
- The method cannot be used in the presence of a thick paint coating.
- Due to the possibility of spurious or irrelevant indications, interpretation requires skilled inspector.
- When ferromagnetic material is defect-free (commonly iron or steel), magnetic flux (field) lines pass through it without interruption.
- When a crack or other discontinuity exists in a material, magnetic flux leaks out. As magnetic flux (magnetic field) leaks, it accumulates ferromagnetic particles (iron powder), indicating the size and structure of the discontinuity.
- By contrast, magnetic flux will leak out of a material only if the discontinuity is perpendicular to its direction of flow. If the discontinuity, such as a crack, is parallel to the magnetic flux lines, there will be no leakage and hence no signal. To resolve this issue, each area must be inspected twice. To discover discontinuities in any direction, the second examination must be perpendicular to the first. Throughout the testing procedure, the examiner must ensure that sufficient overlap of magnetic flux zones is maintained to avoid missing discontinuities.
Radiographic Testing (RT)
It uses either x-rays or gamma rays to examine the internal structure of manufactured components, identifying any flaws or defects.
A minimum surface preparation is required, and it detects both surface and subsurface defects. It detects and measures internal flaws and material density changes.
In industrial radiography, there are several imaging methods and techniques to display the final image, i.e., film radiography, digital radiography (DR), and computed radiography (CR).
Types of radioactive source:
There are two different radioactive sources available for industrial use; X-ray and Gamma-ray. These radiation sources use higher energy levels, i.e., shorter wavelength versions of the electromagnetic waves. Because of the radioactivity involved in radiography testing, it is of paramount importance to ensure that the local rules are strictly adhered to during operation.
Materials with a maximum thickness of 50 millimeters can be tested with X-rays, while materials with a thickness of 10 to 120 millimeters can be tested with gamma rays. An X-ray tube or a gamma-radiating pellet is used as the source of radiation.
The electrical voltage across the X-ray tube is usually used to describe X-ray equipment: 300 kV X-rays, for example. The higher the voltage, the more penetrating power of the radiation; industrial X-ray equipment ranges from about 20 kV to 20 MV, with the most powerful machines capable of radiographing steel up to 500 mm (20").
Almost all gamma-radiography is performed with cobalt-60 or iridium-192 sources. However, there are a few other radioactive isotopes suitable for gamma-radiography that are used for special applications.
Advantages:
A minimum surface preparation is required, and it detects both surface and subsurface defects. It detects and measures internal flaws and material density changes.
In industrial radiography, there are several imaging methods and techniques to display the final image, i.e., film radiography, digital radiography (DR), and computed radiography (CR).
Types of radioactive source:
There are two different radioactive sources available for industrial use; X-ray and Gamma-ray. These radiation sources use higher energy levels, i.e., shorter wavelength versions of the electromagnetic waves. Because of the radioactivity involved in radiography testing, it is of paramount importance to ensure that the local rules are strictly adhered to during operation.
Materials with a maximum thickness of 50 millimeters can be tested with X-rays, while materials with a thickness of 10 to 120 millimeters can be tested with gamma rays. An X-ray tube or a gamma-radiating pellet is used as the source of radiation.
The electrical voltage across the X-ray tube is usually used to describe X-ray equipment: 300 kV X-rays, for example. The higher the voltage, the more penetrating power of the radiation; industrial X-ray equipment ranges from about 20 kV to 20 MV, with the most powerful machines capable of radiographing steel up to 500 mm (20").
Almost all gamma-radiography is performed with cobalt-60 or iridium-192 sources. However, there are a few other radioactive isotopes suitable for gamma-radiography that are used for special applications.
Advantages:
- No surface preparation is necessary.
- On both surface and subsurface defects, indications of volumetric changes can be discovered.
- Appropriate for inspecting assembled components.
- This tool enables both on-site and in-stream inspections.
- There is a permanent record of deliverables (film or digital file)
- The presence of hazardous ionising radiation necessitates the establishment of a safety perimeter.
- The inspection process is relatively slow.
- Sensitive to flaw orientation.
- It is not always possible to determine the depth of indications.
- The test object must be accessed from both sides.
Pulsed Eddy Current (PEC)
In-service inspection of ferromagnetic materials such as carbon steel or low alloy steel using PEC is an electromagnetic technology that can detect flaws, corrosion, and average remaining wall thickness under insulation (CUI), under fireproofing (CUF), or under layers of coating without the need to remove any insulation or coating, and without the need for direct contact or any special preparation of the surface. Measure through claddings constructed of aluminum, stainless steel, or galvanized steel. Furthermore, it is useful when the surface of an object is insulated, unclean, rough, hot, wire mesh, or inaccessible. Aside from that, it is a simple and cost-effective option. It can be used in subsea environments.
Advantages:
Corrosion Under Insulation (CUI)
It persists to be one of the most significant threats to the integrity of insulated piping and vessels. When Petromine gains access to a plant or asset, it utilizes PECT to gain a comprehensive understanding of CUI.
Susceptible areas of CUI that need to be assessed to ensure asset integrity include:
FAC causes gradual wall thinning and is frequently associated with elbow bends. PECT is ideal for detecting FAC because it quickly identifies areas of wall loss and is applicable to pipelines with or without insulation.
Corrosion on Jetty Legs and Marine Structures Caused by Marine Growth
Although PECT is frequently associated with the detection of CUI on pipelines and vessels, it was developed for the purpose of detecting corrosion underneath marine growth at the splash zone on marine structures such as oil rigs and jetties.
PECT is ideal for this application because it can transmit a signal through marine growth and any neoprene coatings without the need to remove them. In this case, marinized (waterproof) probes are used, and the inspection is frequently completed by rope access teams or divers, as needed. Rope access personnel or divers can position the probe in the inspection area, while the technician analyses the data in a separate location.
Advantages:
- Detection of internal flow-induced erosion or corrosion.
- measurement of the thickness of excavated pipeline walls without the need for coating removal, sandblasting, or surface grinding.
- Subsea and splash zone inspection.
- Pipelines, vessels, equipment, columns, tanks, and concrete-coated sphere legs that are heated or cooled are some of the things that are in the pipes.
- Insulated pipes, vessels, or spheres with a diameter greater than 100mm
- It is capable of measuring wall thicknesses ranging from 4 to 65 mm.
- It's completely safe.
- Insulation, cladding, asbestos, fireproofing, concrete, and coatings do not need to be removed from test materials, reducing shutdown and cost-saving.
- PEC testing can be carried out on insulating materials with a test surface temperature of up to 550 degrees Celsius.
- PEC testing can be done on insulating layers that are up to 150 mm thick.
- Perform a test.
- There is no need for surface preparation, which saves money for the plant owner.
- Because the Pulsed Eddy Current instrument is battery-powered, it is ideal for use in remote areas.
- Assess the equipment before the shutdown for maintenance planning purposes.
- PEC probes are water-resistant, allowing them to be used in a marine environment.
- For underwater measurements, PEC probes can be connected to 30m long telescopic extension arms. perfect for piers and bridges at ports.
Corrosion Under Insulation (CUI)
It persists to be one of the most significant threats to the integrity of insulated piping and vessels. When Petromine gains access to a plant or asset, it utilizes PECT to gain a comprehensive understanding of CUI.
Susceptible areas of CUI that need to be assessed to ensure asset integrity include:
- Areas exposed to mist overspray from cooling towers.
- Piping close to steam vents.
- Insulated piping close to deluge systems.
- Carbon steel piping capable of operating at temperatures ranging from -5°C to 120°C.
- Through-insulation dead legs and piping attachments
- Steam tracing lines may contain leaks from the team.
- damaged insulation.
- Fireproofing cracks.
- Evidence of brown staining on insulation.
FAC causes gradual wall thinning and is frequently associated with elbow bends. PECT is ideal for detecting FAC because it quickly identifies areas of wall loss and is applicable to pipelines with or without insulation.
Corrosion on Jetty Legs and Marine Structures Caused by Marine Growth
Although PECT is frequently associated with the detection of CUI on pipelines and vessels, it was developed for the purpose of detecting corrosion underneath marine growth at the splash zone on marine structures such as oil rigs and jetties.
PECT is ideal for this application because it can transmit a signal through marine growth and any neoprene coatings without the need to remove them. In this case, marinized (waterproof) probes are used, and the inspection is frequently completed by rope access teams or divers, as needed. Rope access personnel or divers can position the probe in the inspection area, while the technician analyses the data in a separate location.
Thermography camera (infrared camera)
It provides information on the distribution of heat across a surface. The influence of flaws on the thermal conductivity and emissivity of test materials can be determined by identifying hot hotspots caused by wall loss, flaws in a vessel/pipe containing hot products, and thermal insulation breakdown.
The advantage of infrared thermography over destructive testing methods is the ability to scan large areas quickly and without destroying anything. This results in significant cost savings in terms of time, labor, and machinery. The infrared thermographic device is completely risk-free, as it emits no radiation and records only the infrared radiation emitted by the material being evaluated.
All bodies emit electromagnetic radiation at temperatures greater than absolute zero because of temperature differences observed on the investigated surface during infrared camera monitoring. Thermal imaging, or infrared thermography, is a technique for detecting radiation in the infrared spectrum (typically between the wavelengths of 2–5.6 mm and 8–14 mm). These two spectral bands are frequently used due to their low absorption by the atmosphere.
Advantages:
Petromine inspectors are ASNT level I, II, or III certified. We employ advanced thermography equipment to detect deterioration and potential problems.
The advantage of infrared thermography over destructive testing methods is the ability to scan large areas quickly and without destroying anything. This results in significant cost savings in terms of time, labor, and machinery. The infrared thermographic device is completely risk-free, as it emits no radiation and records only the infrared radiation emitted by the material being evaluated.
All bodies emit electromagnetic radiation at temperatures greater than absolute zero because of temperature differences observed on the investigated surface during infrared camera monitoring. Thermal imaging, or infrared thermography, is a technique for detecting radiation in the infrared spectrum (typically between the wavelengths of 2–5.6 mm and 8–14 mm). These two spectral bands are frequently used due to their low absorption by the atmosphere.
Advantages:
- Detecting defects in pipes, metals, and plastic components because of temperature variations.
- Early detection of hidden defects and material wear.
- Measuring and observing areas that are inaccessible or hazardous for other non-destructive testing methods.
- Capable of inspecting large areas.
- Does not affect the production process.
- Real-time detection of problems.
Petromine inspectors are ASNT level I, II, or III certified. We employ advanced thermography equipment to detect deterioration and potential problems.
Tube Inspection
In the power, petrochemical, and oil and gas industries, a variety of heat exchangers are used. It used to heat, cool, evaporate, or condense process flows. Depending on the application, heat exchangers come in a variety of shapes, sizes, and materials. The most frequently used construction models are tube/shell exchangers and fin/fan coolers.
Maintaining a plant's heat exchangers in good condition is critical for cost-effective operation. Failure or leakage of heat exchangers can result in decreased efficiency, unplanned shutdowns, or even accidents, resulting in damage to the equipment, the environment, or people.
Heat exchangers are subject to a variety of degradation mechanisms that can result in leaks while in use. Construction materials can deteriorate due to corrosion, erosion, cracking, or impingement, material, and operation conditions.
The Best Protection Is Prevention
Due to the constant heating and cooling cycles, these tubes operate in harsh conditions and can sustain significant wear over time. Typical issues to look for include the following:
- Internal and external corrosion.
- Erosion on inlet ends, tube to tube erosion, condensate grooving and baffle wear.
- Fretting.
- Fatigue cracks.
- Pitting caused by process liquids and gases.
- Physical damage caused by handling on turnarounds.
Whether the defects you're looking for are inside or outside tubes has a significant impact on the type of technology you'll use. What are your imperfections:
Petromine ensures that our reports are understood by our customers by:
- Explanation of initial inspection reports on the day of the inspection.
- Providing a timeline for the completion of the final report.
- Conducting an exit interview to ensure that all questions are answered.
The objective is to provide exceptional service and to outperform the industry standard.
Tube inspection: The internal rotatory inspection system (IRIS)
It is based on ultrasonic Time of Flight (ToF) technology and is used to determine the remaining wall thickness in tubes such as heat exchangers, boilers, and fin fan cooler tubes. It is applicable to both ferromagnetic and nonmagnetic materials. This method is extremely effective at detecting and quantifying corrosion, erosion, and baffle wear. Take measurements throughout the whole length of the tubes. For better and more accurate results, stored data is displayed using C-scan and B-scan pictures. Tube cleaning is critical for obtaining high-quality data and conducting an accurate inspection.
Operation principle
IRIS inspection utilizes a probe that consists of a centering device, an ultrasound transducer, and a rotating mirror. A transducer mounted axially will generate an ultrasound pulse. The probe's 45-degree rotating mirror will direct the pulse bundle toward the tube wall. At both the inner and outer walls of the tube, an ultrasound reflection (echo) will occur. The equipment then reflects and processes these echoes. The time interval between these two echoes represents the tube's wall thickness. Calculating the accompanying wall thickness requires knowledge of the material's sound velocity. Water rotates the probe mirror and serves as a couplant between the transducer and the tube wall.
To verify the IRIS system's response, a calibration standard made of the same material and dimensions as the tubes to be examined is used. Following the inspection, the client will receive an "on-site" report detailing the condition of each tube.
Advantages:
Operation principle
IRIS inspection utilizes a probe that consists of a centering device, an ultrasound transducer, and a rotating mirror. A transducer mounted axially will generate an ultrasound pulse. The probe's 45-degree rotating mirror will direct the pulse bundle toward the tube wall. At both the inner and outer walls of the tube, an ultrasound reflection (echo) will occur. The equipment then reflects and processes these echoes. The time interval between these two echoes represents the tube's wall thickness. Calculating the accompanying wall thickness requires knowledge of the material's sound velocity. Water rotates the probe mirror and serves as a couplant between the transducer and the tube wall.
To verify the IRIS system's response, a calibration standard made of the same material and dimensions as the tubes to be examined is used. Following the inspection, the client will receive an "on-site" report detailing the condition of each tube.
Advantages:
- Actual wall thickness can be accurately measured.
- Internal and external defects can both be quantified.
- It could differentiate between internal and external defects.
- It is possible to detect and size defects under support plates.
- It is not affected by changes in permeability or conductivity, which can result in false indications when electromagnetic methods are used.
- It could be used on a wide variety of materials (ferrous, non-ferrous, plastics).
- It provides details about the geometry of defects.
Tube inspection: Eddy current testing (ECT)
It utilizes electromagnetic induction to detect tubing defects. It is used to detect corrosion, pitting, erosion, and other surface changes on the interior and exterior of tubes. It is a high-speed inspection method that can be performed through paint and coatings. Non-ferrous materials such as stainless steel, copper, and titanium are excellent with this method. This is an effective approach for testing the performance and durability of tubes.
Operation principle
Current examination contains a coil which generates a changing magnetic field. When the probe is inserted into a tube made of a conductive material, the magnetic field induces the flow of eddy currents in the tube material. The amount of eddy currents that can flow through a tube is dependent on the tube's condition at the coil location. Eddy currents generate a magnetic field that is in opposition to the coil's original magnetic field. The resultant of the two opposing magnetic fields influences the probe's coil's impedance. This means that the impedance of the test coil is condition dependent. On a computer screen, signals representing the impedance of the test coil and thus the condition of the tube are displayed.
Advantages:
Operation principle
Current examination contains a coil which generates a changing magnetic field. When the probe is inserted into a tube made of a conductive material, the magnetic field induces the flow of eddy currents in the tube material. The amount of eddy currents that can flow through a tube is dependent on the tube's condition at the coil location. Eddy currents generate a magnetic field that is in opposition to the coil's original magnetic field. The resultant of the two opposing magnetic fields influences the probe's coil's impedance. This means that the impedance of the test coil is condition dependent. On a computer screen, signals representing the impedance of the test coil and thus the condition of the tube are displayed.
Advantages:
- Rapid (450-700 tubes per day).
- Detection of overall wall loss and local defects.
- Possible to distinguish between in-and external defects.
- Possible to detect and quantify defects under support plates.
Tube inspection: Remote-field testing (RFT)
It is an electromagnetic testing technique mainly used to find defects in small-diameter ferromagnetic carbon steel, ferritic SS (SS439), nickel, and other ferromagnetic alloy tubes. sensitive to inner and outer defects but it is not possible to distinguish between them and highly sensitive to wall thickness variations and accurately quantified.
Operation principle
The RFT examination probe is comprised of a sender and a receiver coil. The larger send coil generates an alternating magnetic field. This field is indirectly coupled to the receiver coil as a direct coupling between the two coils is shielded by the strong magnetic fields originating from the eddy currents that are being generated in the tube. At a sufficiently low frequency, the shielding weakens, allowing the exciter field to penetrate the tube wall axially. Once the magnetic field reaches the tube's exterior, it spreads rapidly and with little further attenuation along the tube. According to research, a portion of the magnetic field re-diffuses back through the pipe wall and into the tube's interior at a specific location.
At this position, the smaller receiver coil is placed to detect the remaining field. The path for indirect coupling between the sender and receiver coils is now complete. The magnitude and phase of the magnetic field received are dependent on the amount of material crossed along the indirect coupling path. If a tube has wall loss, the exciter field is attenuated and delayed less before it reaches the receiver coil. On a computer screen, signals representing the change in the received magnetic field and thus the condition of the tube are displayed.
Advantages:
Operation principle
The RFT examination probe is comprised of a sender and a receiver coil. The larger send coil generates an alternating magnetic field. This field is indirectly coupled to the receiver coil as a direct coupling between the two coils is shielded by the strong magnetic fields originating from the eddy currents that are being generated in the tube. At a sufficiently low frequency, the shielding weakens, allowing the exciter field to penetrate the tube wall axially. Once the magnetic field reaches the tube's exterior, it spreads rapidly and with little further attenuation along the tube. According to research, a portion of the magnetic field re-diffuses back through the pipe wall and into the tube's interior at a specific location.
At this position, the smaller receiver coil is placed to detect the remaining field. The path for indirect coupling between the sender and receiver coils is now complete. The magnitude and phase of the magnetic field received are dependent on the amount of material crossed along the indirect coupling path. If a tube has wall loss, the exciter field is attenuated and delayed less before it reaches the receiver coil. On a computer screen, signals representing the change in the received magnetic field and thus the condition of the tube are displayed.
Advantages:
- Carbon steel tubes can be examined.
- It is possible to detect and quantify both overall wall loss and local defects.
- Accurate defect sizing is possible.
- Volumetric defects can be detected beneath support plates.
- Because of the fill factor is less critical, the cleanliness is less critical.
- Tubes with extremely large diameters can be examined.
Tube inspection: Magnetic flux leakage (MFL)
It uses a powerful magnet to detect pitting, circumferential cracks, and wall losses in all ferromagnetic tubes, such as carbon steel and ferrous stainless steel. It is used to inspect finned tubes and normal tubes with high-speed inspection and is applied as a fast-screening technique, but the sizing defect is limited. Additionally, MFL can be used on air-fin cooler tubes.
MFL is particularly sensitive to angular defects such as pits and grooving. Pits can be detected both internally and externally. MFL can distinguish between internal and external defects and detect gradual wall loss depending on the probe configuration. A second coil is required for ID/OD discrimination, and a Hall-effect sensor is required for gradual defect detection.
Operation principle
Permanent magnets are used in the MFL probe to create a magnetic flux field in the tube wall. Defects alter the path of the magnetic field and allow some flux to escape through the tube wall. The coils and Hall-effect sensors in the probe will detect this leakage field. The size of the leakage field is determined by the probe's pull speed as well as the shape, dimensions, and location of defects. On a computer screen, signals representing the size of the leakage field and thus the tube's condition are displayed.
Advantages:
MFL is particularly sensitive to angular defects such as pits and grooving. Pits can be detected both internally and externally. MFL can distinguish between internal and external defects and detect gradual wall loss depending on the probe configuration. A second coil is required for ID/OD discrimination, and a Hall-effect sensor is required for gradual defect detection.
Operation principle
Permanent magnets are used in the MFL probe to create a magnetic flux field in the tube wall. Defects alter the path of the magnetic field and allow some flux to escape through the tube wall. The coils and Hall-effect sensors in the probe will detect this leakage field. The size of the leakage field is determined by the probe's pull speed as well as the shape, dimensions, and location of defects. On a computer screen, signals representing the size of the leakage field and thus the tube's condition are displayed.
Advantages:
- It is a rapid screening technique.
- Carbon steel (finned) tubes can be examined.
- It is possible to detect both pits and overall wall loss (diam. pits 〉 2 mm).
- It is possible to differentiate between internal and external flaws.
- Cracks and other non-volumetric defects can be detected based on their size, shape, and orientation.
- Defects beneath support plates can be deected and quantified to a certain extent.
Remote Visual Inspection (RVI)
This is the evolution of traditional visual testing and is based on the use of flexible borescopes, videoscopes, or similar equipment.
Remote visual inspections make it possible to conduct visual observations remotely using external camera-based equipment. While videoscopes are used to gain access to the target area, video technology enables an inspector to analyze the area remotely via a monitor. On the screen, image data can be viewed in real time and recorded for subsequent assessment, analysis, and reporting.
It assesses the integrity of components and infrastructure in areas that are too dangerous or remote for direct human intervention. Examine components for corrosion and damage. It is used to examine equipment as diverse as boilers, steam and gas turbines, generators, heat exchangers and condensers, tanks and vessels, rotating equipment, welds, and piping systems for flaws and corrosion.
What advantages does remote visual inspection provide?
The primary advantage of remote visual inspection is that it enables examination of critical infrastructure and components in inaccessible or confined spaces, making it more cost effective and efficient than inspection methods that require asset disassembly or service interruption. Additionally, it reduces safety risks by allowing operators to observe dangerous areas from a distance.
Remote visual inspections make it possible to conduct visual observations remotely using external camera-based equipment. While videoscopes are used to gain access to the target area, video technology enables an inspector to analyze the area remotely via a monitor. On the screen, image data can be viewed in real time and recorded for subsequent assessment, analysis, and reporting.
It assesses the integrity of components and infrastructure in areas that are too dangerous or remote for direct human intervention. Examine components for corrosion and damage. It is used to examine equipment as diverse as boilers, steam and gas turbines, generators, heat exchangers and condensers, tanks and vessels, rotating equipment, welds, and piping systems for flaws and corrosion.
What advantages does remote visual inspection provide?
The primary advantage of remote visual inspection is that it enables examination of critical infrastructure and components in inaccessible or confined spaces, making it more cost effective and efficient than inspection methods that require asset disassembly or service interruption. Additionally, it reduces safety risks by allowing operators to observe dangerous areas from a distance.
Long Range Ultrasonic Testing (LRUT)
It is a guided wave ultrasonic technique that is used for in-service inspection. It is a screening tool to test long lengths of pipe rapidly from a single test point with 100% coverage of the pipe wall and to identify areas of corrosion around the pipe circumference and average metal loss. used in inaccessible pipes or tubes, such as those buried in soil, encased in a sleeve, or located at a high elevation; pipes in areas such as road and river crossings; power plant tubing, risers, offshore topside pipework, and refinery pipes corrosion under insulation.
LRUT utilizes low-frequency ultrasonic modules to generate an ultrasonic waveform that travels longitudinally and circumferentially, allowing for the scanning of large lengths of piping. The method is used to detect and analyze ultrasonic signals produced by metal loss processes such as corrosion and erosion.
LRUT, also known as Guided Wave Ultrasonic Testing (GWUT), provides a comprehensive view of the condition of a pipeline. Petromine's experts can detect corrosion, erosion, and mechanical damage by scanning in both directions along the pipe or piping from a single inspection location.
The Advantages of LRUT:
LRUT is an excellent tool for inspecting long components, such as pipework, for signs of localized thickness loss, such as external and internal corrosion pits.
LRUT utilizes low-frequency ultrasonic modules to generate an ultrasonic waveform that travels longitudinally and circumferentially, allowing for the scanning of large lengths of piping. The method is used to detect and analyze ultrasonic signals produced by metal loss processes such as corrosion and erosion.
LRUT, also known as Guided Wave Ultrasonic Testing (GWUT), provides a comprehensive view of the condition of a pipeline. Petromine's experts can detect corrosion, erosion, and mechanical damage by scanning in both directions along the pipe or piping from a single inspection location.
The Advantages of LRUT:
LRUT is an excellent tool for inspecting long components, such as pipework, for signs of localized thickness loss, such as external and internal corrosion pits.
- The ability to determine the length of a significant pipe from a single point.
- Scaffolding, coating removal, or excavation are not required.
- The ability to inspect pipes up to 100 degrees Celsius in temperature.
- The inspection can be conducted while the asset is in operation, thereby avoiding production losses and downtime.
- Rapid inspection and timely results.
- May struggle to detect extremely small, isolated pits or pinholes.
- Incapable of quantifying minimum wall thickness loss in millimeters but provides loss as a percentage of nominal thickness.
- May be negatively affected by certain coatings, as well as certain soils and moisture.
Surface Inspection: Eddy current
It uses electromagnetism to find flaws in conductive materials, such as surface-breaking defects, linear defects, cracks, lack of fusion, general corrosion, and defects through several layers of non-conductive coatings eliminating the need to remove coatings such as paint. It can also inspect high-temperature surfaces and underwater surfaces. It demonstrates to be an extremely cost-effective, time-efficient, and reliable method of non-destructive testing.
Eddy Current Testing - What Is It?
Eddy current testing is one of several non-destructive methods for detecting flaws in conductive materials that utilize the electromagnetism principle. A specially designed coil powered by an alternating current is placed close to the test surface, generating a changing magnetic field that interacts with the test part and generates eddy currents in the area.
The changing phases and magnitudes of these eddy currents are then monitored using a receiver coil or by monitoring changes in the alternate current flowing through the primary excitation coil.
Variations in the electrical conductivity, magnetic permeability, or presence of discontinuities will result in a change in the eddy current and a corresponding change in the phase and amplitude of the measured current. The changes are displayed on a screen and interpreted to detect defects.
Permeability refers to how easily a material can be magnetized. The higher the permeability, the shallower the penetration depth. Nonmagnetic metals such as austenitic stainless steels, aluminum, and copper have a very low magnetic permeability, whereas ferritic steels have a magnetic permeability several hundred times that of austenitic stainless steels.
Advantages
The Advanced NDT Eddy Current Array Testing method allows the replacement of MPI and DPI, thus providing a traceable, computed 3D test area scanned image and an electronic image.
Eddy Current Testing - What Is It?
Eddy current testing is one of several non-destructive methods for detecting flaws in conductive materials that utilize the electromagnetism principle. A specially designed coil powered by an alternating current is placed close to the test surface, generating a changing magnetic field that interacts with the test part and generates eddy currents in the area.
The changing phases and magnitudes of these eddy currents are then monitored using a receiver coil or by monitoring changes in the alternate current flowing through the primary excitation coil.
Variations in the electrical conductivity, magnetic permeability, or presence of discontinuities will result in a change in the eddy current and a corresponding change in the phase and amplitude of the measured current. The changes are displayed on a screen and interpreted to detect defects.
Permeability refers to how easily a material can be magnetized. The higher the permeability, the shallower the penetration depth. Nonmagnetic metals such as austenitic stainless steels, aluminum, and copper have a very low magnetic permeability, whereas ferritic steels have a magnetic permeability several hundred times that of austenitic stainless steels.
Advantages
- It can detect cracks on the surface and near the surface as small as 0.5 mm.
- Capable of detecting defects without interference from planar defects through multiple layers, including non-conductive surface coatings.
- The non-contact method enables the inspection of high-temperature and underwater surfaces.
- Effective on test objects whose geometries are physically complex.
- It immediately provides feedback.
- Equipment that is portable and lightweight.
- Rapid preparation time – minimal surface preparation is required, and couplant is not required.
- Capable of determining the conductivity of test objects.
- Can be automated for the inspection of uniform components such as wheels, boiler tubes, or aero-engine discs.
- Only effective on conductive materials.
- Metallic coatings, such as galvanization, can severely restrict reliability.
- Defects parallel to the surface, such as laminations, will not be detected.
The Advanced NDT Eddy Current Array Testing method allows the replacement of MPI and DPI, thus providing a traceable, computed 3D test area scanned image and an electronic image.
Phased Array Ultrasonic Testing (PAUT)
It can perform inspections of material thickness, welds, corrosion, and adhesives by Petromine's competent inspectors.
It is an advanced non-destructive inspection technique that employs an array of ultrasonic testing (UT) probes composed of many small elements. Each of these is pulsed with computer-calculated timing to make the process phased, while the array refers to the many parts that make up a PAUT system.
Without moving the probe, itself, the beam from a phased array probe can be focused and electronically swept across an inspection piece.
Advantages
Compared to conventional ultrasonic probes, phased arrays offer increased portability, convenience, inspection speed, and safety. A phased array is more robust and convenient to use than conventional single-element probes, increasing efficiency by simultaneously capturing hundreds of signals and reducing false alarms. When combined with simulation, PAUT inspection strategies can be optimized to improve flaw detection, while data recording and traceability are also significantly improved.
Phased array ultrasonic testing leaves a permanent record, emits no radiation, and is applicable to a variety of applications. Due to the fact that PAUT can detect defects both on the surface and within the volume of a weld (without a dead zone), it also provides information about the lateral position of a defect (depth and height).
- Simplified Inspection and Interpretation without safety hazards.
- Improved Detection of Flaws.
- Faster Inspection Speeds.
- More Consistent Results.
- PAUT is adaptable when evaluating unusual geometries.
- Inspection is performed in-situ, avoiding disassembly and transportation costs as well as unneeded downtime.
- Detects and sizes many subsurface defects accurately, with a high probability of detecting developing cracks.
- Able to work with a wide range of materials.
- A permanent record of the inspection is maintained.
As an advanced NDT method, it is used to look for flaws in components to see how well they work. This makes it great for things like:
- Weld Inspections.
- Thickness Measurements.
- Corrosion Inspection.
- PAUT Validation/Demonstration Blocks.
- Inspection of Rolling Stock Wheels and Axles.
- PAUT and TOFD Standard Calibration Blocks.
- Pressure Vessel.
Saturated Low Frequency Eddy Current (SLOFEC)
The Advantages of SLOFEC
SLOFEC techniques enable rapid screening of large areas of magnetic materials and the detection of very small and isolated corrosion. The following are the primary technical advantages of the SLOFEC technique:
- Capable of inspecting materials that are both ferromagnetic and non-ferromagnetic.
- Efficient inspection time and minimal surface preparation required.
- A high inspection temperature of up to 150 degrees Celsius capable of detecting corrosion across a wide range of wall thicknesses.
- It is unique in that it distinguishes between defects on the top, bottom, and through holes.
- Real-time scanning capability.
- It has a very high probability of detection (POD) and is therefore particularly useful for detecting MICs (Microbial Induced Corrosion).
- Fast screening method for local metal loss.
- Inspection of thick wall components up to 35 mm.
- Inspection through thick coating up to 10 mm.
- Inspection speeds up to 25 m/min.
- Higher defect detection sensitivity than MFL.
- Storage tank floor, annular, roof and wall plates.
- Pipelines from 4” diameter upwards.
- Plant process piping.
- Pressure vessels.
Short-Range Ultrasonic Testing (SRUT)
In-service inspection to annular plate of above-ground storage tanks (AST’s) while the tank remains in service. The guided waves propagate up to one meter into the annular plate. When corrosion, pitting, and thickness reduction are present, the ultrasonic waves detect the same transducer. The technique is used to test for corrosion under pipe supports, at soil-air interfaces, and at similar difficult-to-access locations. Short Range Guided Wave Testing has become a proven and reliable technique as one method for determining the integrity of tank annular plates where the highest probability of corrosion exists to help prioritize out of service tank maintenance requirements.
- In-Service Inspection of annular plate corrosion.
- In-Service Inspection of corrosion under pipe support.
- Because SRUT probes use multiple frequencies, they can detect all indications.
- Rapid scanning of annular rings, under support structures, and against cement walls.
- Scan the entire surface area (up to 1m in length) in a single inspection.
Rapid Motion Scanner RMS 2 technique
In-service inspection is a high-speed, high-accuracy, automated or remote-access ultrasonic corrosion mapping system. Typically designed to perform cost-effective thickness measurements on aboveground ferromagnetic structures without the use of scaffolding or rope access, RMS2 can give 100% coverage in a band up to 1000 mm wide, significantly increasing Probability of Detection (PoD) of defects and corrosion, enabling engineers to determine the optimum repair strategy and improve remaining life assessment (RLA) & risk-based inspection (RBI) maintenance programs. It supports integrity management processes, ensuring effective and safe operation.
Applications
Applications
- Storage tank shells and roofs.
- Horizontal storage tanks.
- Pipelines.
- Pressure vessels.
- Spheres.
- Ship hulls
- High temperatures assets up to 200°c
- Localized pitting.
- General corrosion and erosion.
- Laminations.
- Internal coating failures or dis-bonding.
- Hydrogen blistering (HB).
- Hydrogen induced cracking (HIC).
- Extremely fast for rapid coverage.
- A-scan and C-scan displays in real time.
- Mechanical defects on the top, bottom, and far surface should be detected.
- A joystick or on-screen controls are used to operate the scanner.
- With a detection probability of up to 0.5 mm and a scan grid of up to 0.5 mm, this sensor is suitable for a wide range of applications up to 200 degrees Celsius.
- Inspect material thicknesses ranging from 1 to 280 mm.
- Camera mounted on the scanner to assist in visualizing 3D data for internal/external profiles.
- It can be used on any ferrous item with a diameter of 6" or less up to a flat plate.
- Longitudinal scanning head for increased productivity in applications such as crude oil transfer lines, slug catchers, and other similar applications.
- In the field, durability, dependability, and accuracy have been demonstrated.
- Reduce maintenance costs by limiting scaffolding use.
- There is no need to remove any paint.
- It is capable of riding over weld caps and lap joints up to a height of 8 mm.
- operates effectively with ferromagnetic materials.
On-line Robotic Tank Inspection technique
Internal tank inspections are performed using a remotely operated vehicle (ROV) and do not require vessel entrance. These robotic crawler devices have proved successful in delivering ultrasonic thickness and visual information on tank bottoms containing clear finished products such as gasoline, naphtha, jet fuel, fuel oils, water, condensate, and certain crude oil. It collects quantitative and statistical information about the tank floor according to the API 653 standards.
Petromine Integrity's tank inspection methodology is widely recognized and trusted in the industry today. By avoiding the need to remove tanks from service and scheduling out-of-service periods, tank owners can significantly reduce the cost of performing API 653 inspections.
Petromine Integrity is a highly efficient and cost-effective robotic system that:
Our high-quality robotic equipment ensures that tank bottom inspections are conducted in a consistent, controlled, and proven manner. Robotic inspection is a safer alternative to manual inspection because it is not affected by working conditions. Its advanced, computer-based ultrasonic technique increases the accuracy of data collection.
PETROMINE will ensure the safety, reliability and integrity of your storage tank, while providing more efficient operations.
We offer skilled personnel, a global reach and the best available equipment to ensure a high-quality inspection solution you can trust.
Petromine Integrity's tank inspection methodology is widely recognized and trusted in the industry today. By avoiding the need to remove tanks from service and scheduling out-of-service periods, tank owners can significantly reduce the cost of performing API 653 inspections.
Petromine Integrity is a highly efficient and cost-effective robotic system that:
- It eliminates the high cost associated with tank downtime.
- It saves you the cost of cleaning.
- It is critical to keep the costs of waste disposal to a bare minimum.
- It reduces inspection time from weeks to a few days.
- Additionally, it maintains revenue consistency by avoiding disruptions in plant operations.
- It mitigates environmental risks associated with spills and VOC emissions.
- It enhances safety by removing the need for personnel to enter confined spaces and be exposed to hazardous chemicals.
Our high-quality robotic equipment ensures that tank bottom inspections are conducted in a consistent, controlled, and proven manner. Robotic inspection is a safer alternative to manual inspection because it is not affected by working conditions. Its advanced, computer-based ultrasonic technique increases the accuracy of data collection.
Expertise:
PETROMINE provide tank inspections for:- Petrochemical industries.
- Oil & Gas.
- Water industries.
PETROMINE will ensure the safety, reliability and integrity of your storage tank, while providing more efficient operations.
We offer skilled personnel, a global reach and the best available equipment to ensure a high-quality inspection solution you can trust.
Acoustic Emission Testing (AET) technique
It is an in-service inspection method to detect the location of active corrosion and leaks and flaws, assessing the structural integrity of the bottom of aboveground storage tanks, detecting creep damage in high energy piping (HEP) systems, and pressure vessel inspection. It is based on the generation of waves produced by the redistribution of stress in a material. When a piece of equipment is subjected to an external stimulus, such as a change in pressure, load, or temperature, this triggers the release of energy in the form of stress waves, which propagate to the surface and are recorded by sensors.
Advantages:
Expertise:
PETROMINE's capabilities go well beyond the ability to conduct AET; we leverage our vast capabilities and experience to thoroughly analyze AET results to determine their impact on fitness for service.
We can then analyze the data to determine the condition of the material and identify any defects. The recorded data may contain potentially useful information regarding the origin and significance of a structural defect.
Advantages:
- The capability to detect a variety of damage mechanisms in their earliest stages, including but not limited to fiber breakages, friction, impacts, cracking, delamination and corrosion.
- It can locate and classify damage sources based on their acoustic signatures.
- Assesses the structure or machine under real operational conditions.
- A non-invasive method that can be used in hazardous environments such as those with high temperatures, high pressures, corrosive materials, and nuclear materials.
- It can be performed remotely.
- It can detect damage to defects that are inaccessible using conventional non-destructive testing techniques.
Expertise:
PETROMINE's capabilities go well beyond the ability to conduct AET; we leverage our vast capabilities and experience to thoroughly analyze AET results to determine their impact on fitness for service.
We can then analyze the data to determine the condition of the material and identify any defects. The recorded data may contain potentially useful information regarding the origin and significance of a structural defect.
Acoustic Emission Testing (AET) technique
Tank Floor Inspection
A common mechanism of failure is leakage through the floor, which damages the tank's foundation and can result in instability and catastrophic failure. Due to its sensitivity to volumetric variations, the most frequently used technology for inspecting bottom plates for corrosion is magnetic flux leakage. MFL creates a magnetic field in the bottom plate by using a powerful magnet. The magnetic field "leaks" when it comes into contact with corrosion of a certain size. Leakage increases in direct proportion to the proportional volumetric rate. While multiple types of sensors are used to detect leakage. As a result, we incorporate MFL into our formulations. This enables the complete mapping of storage tank floors and the differentiation of top- and bottom-level defects. It significantly reduces the time required to inspect tank floors while still producing detailed and accurate reports, allowing engineers to focus on other tasks.
Benefits of Floormap®X
- Maximum coverage, including critical zone.
- High-resolution for increased Probability of Detection.
- Multi-technology for top and bottom defect discrimination.
- Flexible scanning, one scanner with three scan modes.
- Inspect thicker plates up to 20 mm (3/4 in) thick.
- Unmatched reporting, comprehensive and on-the-spot.
- 10% reporting thresholds, increase inspection intervals.
- EEMUA 159 and API 653 compliance.
Multi-technology Array Solution
MFL Array: 64 channel, 128 multi-orientated MFL sensors, configuration. It produces a highest resolution imaging and market leading Probability of Detection (PoD). On its own, MFL cannot differentiate if the corrosion is top side or bottom side of the tank bottom.
STARS: The patented technology enabling the FloormapX to differentiate between the top side and bottom side corrosion and report them separately. STARS also generates detailed top surface image profiles, even in the presence of coating, thus contribute to vital tank integrity information.
Computed radiography (CR)
Computed radiography (CR) is the digital replacement of conventional film radiography with a reduction in exposure and processing time, and it doesn’t require darkroom conditions or chemistry.
It is used to assess internal or external corrosion/erosion losses in process piping for internal corrosion, for corrosion under insulation (CUI), and for localized losses in pressure vessels, valves, and in-service welds. Based on that, we can measure wall thickness automatically.
Reported Computerized images facilitate data sharing and result in significant increases in radiographic inspection productivity and defect detection. Simple digital data exchange and archiving
Advantages:
It is used to assess internal or external corrosion/erosion losses in process piping for internal corrosion, for corrosion under insulation (CUI), and for localized losses in pressure vessels, valves, and in-service welds. Based on that, we can measure wall thickness automatically.
Reported Computerized images facilitate data sharing and result in significant increases in radiographic inspection productivity and defect detection. Simple digital data exchange and archiving
Advantages:
- The plate's phosphors have an extremely wide dynamic range, allowing for a high degree of tolerance for varying exposure conditions and doses. This minimizes the need for retakes.
- The increased sensitivity of the plate enables shorter exposure times or the use of a weaker radiation source, resulting in a dose reduction compared to film radiography.
Gamma Scanning for Refinery Towers (In-Service Inspection)
It is one of the most effective non-invasive methods for diagnosing and resolving production issues inside trayed and packed towers that are already in operation. It gives important data for optimizing column performance. Identify mechanical damage or missing trays which represent process flow characteristics within distillation columns; Flooding, entrainment, foaming, weeping, and down-comer liquid levels, base liquid levels, foamed packing, liquid misdistribution, crushed or shifted packing, and internal damage: location and extent.
Theory:
The radioactive material remains encapsulated within a special source housing and no contact with the column. A source holder with an appropriate collimator is used to direct the radiation beam to the column.
A dense material (liquid) blocks more radiation from reaching the detector than does a light material (vapor). Then to a powerful portable computer to facilitate data storage and analysis. Performance is evaluated by analyzing the liquid holdup and liquid/vapor disengagement at each tray level.
Specification:
Throughout the period of investigation, the radioactive material remains permanently encapsulated within a special source housing and no contact with the column, safety features to comply with national and international legislative requirements.
A source holder with an appropriate collimator is used to direct the radiation beam to the column.
Radioactive sources used for distillation column investigations should be capable of penetrating the wall thickness of the column and the medium of interest. For this reason, gamma-ray from Cobalt-60 or Caesium-137 is usually employed.
The strength of the sources used for this activity is extremely small such that the scan poses insignificant radiation hazard to plant personnel. For the sake of comparison, the level of radiation intensity for column scanning activity is approximately between 1/ 10000th to 1/1000th of the gamma rays' intensities used in examining welds.
Inspection Requirements :
Theory:
The radioactive material remains encapsulated within a special source housing and no contact with the column. A source holder with an appropriate collimator is used to direct the radiation beam to the column.
A dense material (liquid) blocks more radiation from reaching the detector than does a light material (vapor). Then to a powerful portable computer to facilitate data storage and analysis. Performance is evaluated by analyzing the liquid holdup and liquid/vapor disengagement at each tray level.
Specification:
- No pre-preparation of the column, no remove of the insulation.
- Non-contact measurement.
- Full length scanning capabilities and Applicable to all column sizes.
- High temperature, high pressure, corrosiveness etc.
Throughout the period of investigation, the radioactive material remains permanently encapsulated within a special source housing and no contact with the column, safety features to comply with national and international legislative requirements.
A source holder with an appropriate collimator is used to direct the radiation beam to the column.
Radioactive sources used for distillation column investigations should be capable of penetrating the wall thickness of the column and the medium of interest. For this reason, gamma-ray from Cobalt-60 or Caesium-137 is usually employed.
The strength of the sources used for this activity is extremely small such that the scan poses insignificant radiation hazard to plant personnel. For the sake of comparison, the level of radiation intensity for column scanning activity is approximately between 1/ 10000th to 1/1000th of the gamma rays' intensities used in examining welds.
Inspection Requirements :
- We need Only access to the uppermost platform.
- An overall mechanical drawing of the tower or process equipment.
- Tower height and diameter.
- The elevation and orientation of trays.
- Packed beds and nozzles.
Packed beds and nozzles
EX Certified It has an ATEX license to work in dangerous conditions and is also recommended by API in some situations. Old way of safety valve testing:
- The plant went down.
- Valves were disassembled.
- The valves were transported offsite for testing.
- Time-Consuming. Costly. High risk.
Under operation pressure safety valves in real process pressure which are safety valves exposed:
- Process system temperature.
- Accumulation and flow capacity.
- Compliance of the back pressure.
- Time Saver. Cheaper. Lower risk.
- The Accuracy and Credibility of the results in an Unfavorable, industrial Environment.
Advantages:
- Less shutdowns – less production loss!
- No system discharges – No fuel costs!
- No raising the system pressure
- No Dismantling the safety valves from the system – We Save Time and Money
- Welded S. Valves – the cost for cutting and subsequent welding and weld inspections are avoided.
- Inspection at any time, under any conditions, winter, or summer.
Positive material identification (PMI) NDT
It is an in-situ technique for analysing and identifying material grade and alloy chemical composition in order to ensure quality, safety, and compliance with standards and specifications. As a result, assurance that the metallic parts' composition contains the precise percentage of key elements before and during service, PMI inspection of critical components and welds can help prevent breakdown and its costly consequences. The device uses an emitted electromagnetic wave, X-ray fluorescence (XRF), to scan the metallic material and receive a response.
Hardness testing NDT
It is an in-situ technique to determine material characteristics. It is used to assess welds and weld overlays, weld heat affected zones (HAZ's), castings and forgings, piping, stress relieved material, machined parts, pressure vessels, and structural steel as well as damaged materials as part of a failure analysis. Verify material compliance with ASME and NACE / ISO requirements.
Ferrite testing NDT
It measures delta ferrite content in austenitic and duplex stainless steels quickly and accurately. Proper ferrite content provides a balance between ductility, toughness, corrosion resistance, and crack prevention. A correct ferrite measurement can help to avoid both solidification cracking and corrosion in stainless steel. A ferrite content that is too high or too low can be detrimental to stainless steel. When ferrite content is too high, stainless steel can lose ductility, toughness, and corrosion resistance—especially at high temperatures. If ferrite content is too low, stainless-steel welds become susceptible to hot cracking or solidification cracks. In duplex stainless-steel welds, a deficit of ferrite content can also reduce weld strength and contribute to the development of stress corrosion cracks.
The Metallography Replica test NDT
It is to view the microstructure of a component. It provides in-depth information such as creep damage, cracking, and grain size. It is used to inspect high-temperature piping, tubing (boiler tubes and furnaces), and pressure vessels as well as assess surface flaws (cracks, laminations). It gives information about the thermal history of the component and its approximate high temperature range and cooling rates, as well as possible mechanical properties for all shapes and sizes.
In-situ metallographic replication involves removal of the surface material by grinding, followed by polishing. The surface is then etched with various acids to reveal the metallographic features. Acetate tape is then placed on the material surface, prepared, and placed on a metallograph for viewing.
In-situ metallographic replication involves removal of the surface material by grinding, followed by polishing. The surface is then etched with various acids to reveal the metallographic features. Acetate tape is then placed on the material surface, prepared, and placed on a metallograph for viewing.
- On-Site Evaluation: – Replication testing enables replication in the field – without removing the specimen from service.
- Abnormal Dimensions or Size: – Large or irregularly shaped specimens are relatively easy to replicate.
- Lower Cost: If a project requires the sectioning and mounting of numerous specimens, the process can become quite costly. Additionally, each component is destroyed and rendered useless. Both are not required for replication.
- On-Site Evaluation: Replication metallography enables replication in the field – without removing the specimen from service.
- Abnormal Dimensions or Size: Large or irregularly shaped specimens are relatively easy to replicate.
Alternating Current Field Measurement (ACFM)
Surface-breaking cracks in components and welds are detected and sized using an electromagnetic approach while the components and welds are in service.
Applicable to base material or welds, ferritic or non-ferritic conductive metals, used on hot surfaces, underwater, or in irradiated environments, it provides depth and length information. It requires minimal surface preparation and can be applied directly to rough or corroded surfaces or through protective coatings.
Detection and sizing of fatigue and hydrogen cracks; inspection of fillet welds in mobile offshore drilling units; highway bridges and rail components; and other crack and corrosion detection in vessels, storage tanks, and piping in the oil and gas and power generation industries.
Applicable to base material or welds, ferritic or non-ferritic conductive metals, used on hot surfaces, underwater, or in irradiated environments, it provides depth and length information. It requires minimal surface preparation and can be applied directly to rough or corroded surfaces or through protective coatings.
Detection and sizing of fatigue and hydrogen cracks; inspection of fillet welds in mobile offshore drilling units; highway bridges and rail components; and other crack and corrosion detection in vessels, storage tanks, and piping in the oil and gas and power generation industries.
Valve Leak Detection
The methods of inspection vary according to the type of valve. As a result, the first rule is to understand your system in detail, including how a particular valve may operate under specific conditions. Is the valve, for example, normally open or normally closed? To ascertain valve conditions such as leakage or obstruction: We encountered two test points upstream of the valve (points A and B). Reduce the instrument's sensitivity (received amplitude) at the first test point (test point "A") until the intensity indicator on the display panel reads approximately 50% of scale. If the instrument is capable of frequency tuning, you can also use this feature to hear the valve sound quality more clearly by altering the frequency. Simply adjust the frequency (typically 25 kHz) until the expected sound becomes audible. That is all.
Following that, compare the intensity levels of two test points downstream of the valve (points C and D). If the sound is louder downstream (C) than it is upstream (B), the fluid may very well be passing through. If the downstream sound level is low in comparison, the valve is closed. If the second downstream test point (D) is louder than the first downstream test point (C), the sound is being transmitted from a source further downstream and indicates that the valve is not leaking. Ultrasonic valve inspection is considered a "positive" test because it enables an operator to quickly identify differences in sound quality and intensity and thus accurately determine the operating condition. Additionally, sound analysis can be used to determine the amount and rate of fluid movement between the upstream and downstream test points.
Advantages
- Ultrasonic sound has the advantage of being much more directional than sonic sound. The sensor can be turned away from the source of background noise and toward the leak to eliminate the majority of the interference.
- Ultrasonic leak detectors have demonstrated superior performance in situations where other methods have failed. Therefore, keep in mind that when selecting a leak detector, it is critical to consider the situation and the factors that may affect the performance of a particular type of leak detector. Choose the instrument that is most appropriate for the job at hand. It is quite possible that this is an ultrasonic leak detector.
Bubble Leak Testing or Vacuum Box Testing
Bubble leak testing, also known as vacuum box testing, is a critical component of the tank inspection process, as recommended by API and other international standards, for determining the condition of a tank bottom plate weld or shell to bottom plate weld.
Vacuum box testing is a non-destructive examination (NDE/NDT) technique used to determine the location of welding leaks. A vacuum box and a compressor create a high or low-pressure vacuum, and the test area is sprayed with a detergent solution. The detergent bubbles aid in identifying pressure envelope leaks. The vacuum box testing technique is primarily used to locate leaks in welds caused by through-thickness discontinuities. This is accomplished by applying a solution to the weld and creating a differential pressure across it, resulting in the formation of bubbles as the leakage gas passes through the solution. This testing must be performed prior to any main vessel or tank testing after all welding has been completed. This article will briefly describe the leak testing procedure for all metals using the vacuum box method.
Advantages:
Vacuum box testing is a non-destructive examination (NDE/NDT) technique used to determine the location of welding leaks. A vacuum box and a compressor create a high or low-pressure vacuum, and the test area is sprayed with a detergent solution. The detergent bubbles aid in identifying pressure envelope leaks. The vacuum box testing technique is primarily used to locate leaks in welds caused by through-thickness discontinuities. This is accomplished by applying a solution to the weld and creating a differential pressure across it, resulting in the formation of bubbles as the leakage gas passes through the solution. This testing must be performed prior to any main vessel or tank testing after all welding has been completed. This article will briefly describe the leak testing procedure for all metals using the vacuum box method.
Advantages:
- Cost effective seal integrity testing.
- Simple and easy leak test.
- Practical testing of leaking pouches and packages.
- Visual detection and location of package leaks.
- Quick sample prep.
- Versatile testing method.
- Minimum detectible leak rates.
- Bubble leak test on permeable materials.
- Subjectivity of Visual Detection of Bubbles.
- Limited Air trapped inside of Specimen for Bubbles Emission.
- Small Improvement if the Specimen is Already Pressurized.
Post Weld Heat Treatment (PWHT)
In order to ensure the material strength of a part is retained after welding, a process known as Post Weld Heat Treatment (PWHT) is regularly performed. PWHT can be used to reduce residual stresses, as a method of controlling hardness, or even to increase the strength of a material.
A post-weld heat treatment is a procedure that involves raising the temperature of a material or combination of materials following the welding process. A post-weld heat treatment is used to relieve residual stresses, increase strength, change the hardness of the weld, and decrease the risk of cracking. A variety of heating processes are available for post-weld heat treatment.
PWHT may be required in certain circumstances, depending on the thickness/material combination, to relieve the locked-up stresses caused by the welding process in materials. PWHT may be required during welding operations to relieve weld metal and heat affected zone stresses created during welding for service environment reasons regardless of thickness. Stress that has been trapped in the weld and its heat-affected zone can cause stress corrosion cracking, distortion, fatigue cracking, and premature failures, as well as accelerated corrosion at the weld and its heat-affected zone.
Advantages:
PETROMINE has the capability to perform PWHT on-site as well as at our customers' locations. Our on-site facilities include large furnaces capable of welding/machining numerous weldments/surfaces for PWHT. Furthermore, we offer a pick-up and delivery service.
PETROMINE can perform PWHT on-site at our customers' locations, both offshore and onshore, using our portable equipment.
Our highly skilled and trained PWHT technicians ensure that all weldments/machined surfaces brought in for treatment comply with all applicable welding codes and are fit for purpose.
A post-weld heat treatment is a procedure that involves raising the temperature of a material or combination of materials following the welding process. A post-weld heat treatment is used to relieve residual stresses, increase strength, change the hardness of the weld, and decrease the risk of cracking. A variety of heating processes are available for post-weld heat treatment.
PWHT may be required in certain circumstances, depending on the thickness/material combination, to relieve the locked-up stresses caused by the welding process in materials. PWHT may be required during welding operations to relieve weld metal and heat affected zone stresses created during welding for service environment reasons regardless of thickness. Stress that has been trapped in the weld and its heat-affected zone can cause stress corrosion cracking, distortion, fatigue cracking, and premature failures, as well as accelerated corrosion at the weld and its heat-affected zone.
Advantages:
- Enhancement of the material's ductility.
- Hardness has been increased or decreased.
- Risk of brittle fracture is decreased.
- Thermal stress that has been alleviated.
- Metal which has been tempered.
- Elimination of hydrogen that is vaporizable (to prevent hydrogen induced cracking).
- Metallurgical structure has been enhanced.
PETROMINE has the capability to perform PWHT on-site as well as at our customers' locations. Our on-site facilities include large furnaces capable of welding/machining numerous weldments/surfaces for PWHT. Furthermore, we offer a pick-up and delivery service.
PETROMINE can perform PWHT on-site at our customers' locations, both offshore and onshore, using our portable equipment.
Our highly skilled and trained PWHT technicians ensure that all weldments/machined surfaces brought in for treatment comply with all applicable welding codes and are fit for purpose.
Holiday Detector Coating Inspection
DC Holiday detects pinholes and flaws in coatings on conductive substrates. When coatings are used to protect against corrosion, it is important to find any pinholes or flaws that will eventually lead to corrosion as soon as possible.
Advantages:
Advantages:
- Fast, accurate, reliable defect detection.
- Real time display, data analysis and results.
- Detects a range of coating discontinuities, including runs, tears and sags, cissing, cratering, pinholes and undercoating faults.
- Handheld, highly economical single operator cordless devices.
- Safer and less intrusive than high voltage testing.
- Less likely to cause cosmetic and functional damage to coatings or linings.
- Safe and environmentally friendly: no radiation or chemicals produced.
Coating thickness, Paint Thickness, or Dry Film Thickness (DFT)
A coating thickness gauge (also known as a paint meter) is used to determine the thickness of the dry film. Due to its impact on the coating process, quality, and cost, dry film thickness is probably the most critical measurement in the coatings industry. Dry film thickness measurements can be used to determine the expected life of a coating, as well as the appearance and performance of the product, as well as to ensure compliance with a variety of International Standards.
Dry film thickness (DFT) can be determined in two ways: destructively by cutting the coating to the substrate with a cutter, or non-destructively by using techniques that do not damage the coating or the substrate, such as magnetic, magnetic induction, or eddy current thickness measurement.
Measurements of non-destructive coating thickness can be taken on magnetic steel surfaces or non-magnetic metal surfaces such as stainless steel or aluminum. Digital coating thickness gauges are ideal for determining the thickness of coatings applied to metallic substrates. Electromagnetic induction is used to coat non-magnetic substrates such as steel, whereas the eddy current principle is used to coat non-conductive substrates such as aluminum.
Dry film thickness (DFT) can be determined in two ways: destructively by cutting the coating to the substrate with a cutter, or non-destructively by using techniques that do not damage the coating or the substrate, such as magnetic, magnetic induction, or eddy current thickness measurement.
Measurements of non-destructive coating thickness can be taken on magnetic steel surfaces or non-magnetic metal surfaces such as stainless steel or aluminum. Digital coating thickness gauges are ideal for determining the thickness of coatings applied to metallic substrates. Electromagnetic induction is used to coat non-magnetic substrates such as steel, whereas the eddy current principle is used to coat non-conductive substrates such as aluminum.
- The primary benefit is maintaining high-quality coatings that perform properly and adhere to external standards.
- Another significant benefit is cost savings, as adhering to specifications consistently can reduce material and labor waste.
Lifting equipment inspection
Petromine Group is committed to ensuring that all your lifting equipment complies with international health and safety regulations, ensuring the safety of your employees, visitors, and the overall site.
All your lifting equipment, both onshore and offshore, will be inspected, tested, and certified by us.
The cranes and lifting equipment that must be inspected include drilling equipment and tools, pedestal and overhead cranes, ROV/Dive spreads, fixed lifting equipment, lifeboats, and loose lifting equipment.
We provide not only quality assurance, robust procedures, HSE standards, and detailed process controls, but also through-life management to ensure that equipment is always reliable and safe.
All your lifting equipment, both onshore and offshore, will be inspected, tested, and certified by us.
The cranes and lifting equipment that must be inspected include drilling equipment and tools, pedestal and overhead cranes, ROV/Dive spreads, fixed lifting equipment, lifeboats, and loose lifting equipment.
We provide not only quality assurance, robust procedures, HSE standards, and detailed process controls, but also through-life management to ensure that equipment is always reliable and safe.
Environmental Testing
Environmental testing for water, soil, air, sludge, petroleum, chemicals, and other samples for trace chemical compounds and pollutants.
Petromine chemists operate analytical instruments and conduct tests in accordance with government, regulatory, and industry standards. It includes:
Petromine chemists operate analytical instruments and conduct tests in accordance with government, regulatory, and industry standards. It includes:
- CO2 Emission Calculation.
- Contamination Analysis.
- Elemental Trace Analysis.
- Air Emissions Testing.
- Environmental Microbiology Consultancy and Testing.
- Industrial Plant Environmental Monitoring and Safety.
- Sludge, Residue and Unknowns Analysis.
- Soil Testing.
- Soil and Environmental Analysis for Pharmaceutical Contamination.
- Water Quality Testing.
