Advanced NDT Services

Advanced Non-Destructive Testing (NDT) refers to a set of sophisticated techniques and technologies used to inspect and evaluate the integrity of materials, components, or structures without causing any damage or altering their state. These methods are typically more precise, sensitive, and capable of detecting flaws or defects that basic NDT methods might miss. This allows for detecting microscopic defects, such as cracks, voids, or inclusions, which might not be visible with traditional methods.

Advanced Nondestructive Testing (NDT) services incorporate state-of-the-art techniques to assess material integrity and detect flaws with unparalleled precision. These methods include Phased Array Ultrasonic Testing (PAUT), Guided Wave Testing (GWT), and Pulsed Eddy Current (PEC), among others.

ECA – Eddy Current Array

Eddy Current Array (ECA) is an advanced NDT technique that enhances traditional Eddy Current Testing by utilizing multiple coils arranged in a specific configuration. This setup enables the simultaneous inspection of larger areas without compromising sensitivity, reducing inspection time significantly.

ECA is particularly effective for detecting surface and subsurface defects in complex geometries, such as curved or irregular surfaces, making it highly suitable for aerospace, power generation, and petrochemical applications. Additionally, its ability to provide real-time imaging aids in precise defect characterization.

Eddy Current Array (ECA) testing offers several advantages over conventional Eddy Current Testing (ECT), primarily due to its ability to collect data over a larger area with more detail and in a shorter period. Specific benefits of ECA over traditional ECT:

Increased Coverage per Scan
Higher Resolution and Detail
Faster Inspections
Better Adaptability to Complex Geometries
Enhanced Probability of Detection (POD)
Real-Time Visualization and Imaging
Reduced Operator Dependency
Data Archiving and Comparison

Tubing Eddy Current Array (ECA) is a specialized eddy current testing method used specifically to inspect tubing and pipes, commonly in heat exchangers, boilers, and condensers.

This method is critical in industries such as power generation, petrochemical, and HVAC, where metal tubing is susceptible to various forms of degradation like corrosion, pitting, cracking, and wear. Tubing ECA enhances traditional eddy current testing by using multiple coils arranged in an array that can scan the tubing more thoroughly and quickly, providing comprehensive coverage and high-resolution imaging.

Key Features of Tubing Eddy Current Array

1. Full Circumference Inspection

2. Detection of Small Defects

3. Flexible and Adaptable Probes

4. Increased Speed and Efficiency

5. Real-Time Data Visualization

TECA – Tangential Eddy Current Array

Tangential Eddy Current Array (TECA) is an advanced NDT technology optimized for detecting surface-breaking cracks and corrosion, particularly in ferromagnetic materials like carbon steel. TECA stands out for its ability to inspect weld caps, toe areas, and heat-affected zones simultaneously, without requiring extensive surface preparation.

It achieves high accuracy in sizing cracks, even under coatings or paint, making it highly efficient for assessing structural integrity in challenging conditions. Additionally, its real-time C-scan imaging provides detailed, intuitive data for faster evaluations.

ECT – Eddy Current Testing

Eddy Current Testing (ECT) is a non-destructive technique widely used to detect surface and subsurface defects in conductive materials.

It works by inducing an electromagnetic field in the material through an alternating current, analyzing variations in the resulting eddy currents to identify flaws, such as cracks or corrosion.

ECT is ideal for inspecting components like tubes, welds, and fasteners, offering rapid, accurate results without damaging the test material. The method is extensively utilized in industries such as aerospace, power generation, and petrochemical to ensure safety and quality compliance.

RFT – Remote Field Eddy Current Testing

Remote Field Eddy Current Testing (RFECT) is a specialized non-destructive testing (NDT) method used primarily for inspecting ferromagnetic materials such as carbon steel tubes.

It employs a probe to generate a magnetic field that travels through the material and detects internal and external defects by analyzing changes in the returning field.

This technique offers high sensitivity to flaws while ensuring minimal disruption, making it ideal for applications in industries like power generation and petrochemicals

IRIS – Internal Rotating Inspection System

The Internal Rotary Inspection System (IRIS) is an advanced ultrasonic testing method designed for precise evaluation of tube integrity in heat exchangers, boilers, and similar equipment.

By using a rotating mirror and ultrasonic transducer, IRIS provides a detailed helical scan of the tube wall, measuring wall thickness and detecting internal or external defects such as corrosion, pitting, and thinning. This system requires water as a couplant to transmit ultrasonic waves effectively.

IRIS is suitable for both ferrous and non-ferrous materials and is known for its high accuracy, although it operates at slower speeds compared to other techniques like Eddy Current Testing.

NFT – Near Field Testing

Near Field Testing (NFT) is an electromagnetic NDT technique designed for assessing the condition of carbon steel tubing, particularly in fin-fan heat exchangers and similar systems.

It utilizes two closely positioned coils a transmitter and a receiver to generate and measure eddy currents within the near-field zone of the tube wall.

NFT is highly effective for detecting localized defects such as corrosion, erosion, and pitting. Its sensitivity to flaws near support structures like tube sheets and its ability to inspect without penetrating the tube wall make it a valuable method for proactive asset management and maintenance planning.

NFA – Near Field Array

Near Field Array (NFA) is an advanced electromagnetic testing technique designed for inspecting finned carbon steel heat exchanger tubes commonly found in petrochemical and power generation facilities.

It improves upon traditional Near Field Testing (NFT) by using an array of coils to provide comprehensive coverage, enhanced sensitivity, and faster inspection speeds.

Unlike remote field testing, NFA is unaffected by the presence of external aluminium fins and delivers detailed wall thickness measurements even in challenging conditions, such as elevated or restricted locations.

PAUT – Phased Array Ultrasonic Testing

Phased Array Ultrasonic Testing (PAUT) is an advanced non-destructive testing (NDT) method used to detect material defects with high precision.

Unlike traditional ultrasonic testing, PAUT utilizes a series of transducers that can be electronically controlled to emit ultrasonic waves at various angles, allowing operators to create detailed 2D or 3D images of internal structures.

This capability makes PAUT ideal for inspecting complex geometries and areas that are difficult to access in advantages of PAUT include faster inspection times, enhanced defect detection, and the ability to capture detailed data that can be stored for future analysis. This makes it widely used across industries such as aerospace, oil and gas, and manufacturing.

TOFD – Time of Flight Diffraction

Time of Flight Diffraction (TOFD) is a highly effective Non-DestructiveTesting (NDT) method used for detecting and characterizing flaws in welds and other materials.

It relies on the measurement of the time it takes for ultrasonic waves to travel to and from a flaw, allowing for precise location and sizing.

TOFD is particularly useful for detecting cracks and other defects that may be difficult to identify with traditional methods like pulse-echo ultrasonic testing. This method is widely valued in industries such as pipeline inspection and structural integrity assessments for its ability to provide accurate data with minimal ambiguity.

ACFM – Alternating Current Field Measurement

Alternating Current Field Measurement (ACFM) is a non-destructive testing (NDT) technique primarily used to detect surface-breaking cracks in metallic structures.

By applying an alternating current to the surface of a material, ACFM measures the resulting electromagnetic field’s distortion caused by cracks or other surface defects.

This method is highly effective for inspecting difficult-to-access areas and can be used in challenging environments such as underwater or while the component is still in service. It provides real-time results, enhancing the speed and reliability of inspections.

LRUT – Long-Range Ultrasonic Testing

Long-Range Ultrasonic Testing (LRUT) is an advanced NDT method primarily used for inspecting pipelines and other large structures where access is limited. Unlike conventional ultrasonic testing, LRUT employs low-frequency guided waves that can propagate over long distances (up to 180 meters in some cases) from a single test point. This capability enables comprehensive inspections of hard-to-reach or buried sections without the need for excavation or scaffolding. LRUT is highly effective for detecting issues like corrosion or metal loss across a full pipe wall, including areas such as welds, clamps, and coatings

This technique relies on a transducer ring placed around the structure to generate these guided waves, which travel along the material. When these waves encounter defects, they reflect back, allowing for the detection of flaws. LRUT can inspect a variety of materials and sizes, with the ability to cover extensive areas efficiently. It is commonly used in industries such as oil & gas, aerospace, and rail.

SRUT – Short-Range Ultrasonic Testing

Short-Range Ultrasonic Testing (SRUT) is a non-destructive testing technique utilizing guided ultrasonic waves to detect internal flaws in components that are hard to access due to obstructions like pipe supports, insulation, or concrete coatings.

It is particularly effective in inspecting steel structures and pipeline systems for corrosion, erosion, or metal loss in areas such as tank annular plates or beneath pipe supports. SRUT provides precise defect quantification, enabling targeted repairs and extended asset life.

MFL – Tank Floor Inspection

Magnetic Flux Leakage (MFL) inspection is a widely used non-destructive testing (NDT) method for assessing the integrity of tank floors, particularly in industries like oil and gas, where tanks are used to store liquids such as petroleum products. MFL is effective in detecting corrosion, pitting, and other forms of deterioration that might compromise tank integrity. Tank floor inspection is critical to ensuring the structural integrity and safety of storage tanks.

Common inspection methods include visual inspection, ultrasonic testing (UT), vacuum box testing, and advanced technologies like phased array ultrasonic testing (PAUT), which provide more detailed analysis compared to conventional techniques. These inspections help detect corrosion, cracks, and other defects, particularly in the tank’s bottom and annular plate areas, which are prone to damage from water entrapment and structural stresses.

Modern practices incorporate robotics and AI-enabled tools for real-time monitoring and improved data analysis, enhancing both inspection efficiency and accuracy to ensure the tank remains fit for service, minimizing risks associated with corrosion and tank ruptures.

Tank Floor Vacuum Box Inspection

Vacuum box inspection is a critical non-destructive testing (NDT) method used to detect leaks or flaws in tank bottom welds. It involves creating a vacuum seal over the weld area using a vacuum box. A soapy solution is applied to the weld, and the area is observed for bubble formation, which indicates leaks. This method ensures weld integrity and helps prevent potential failures in storage tanks. Key steps include surface preparation, ensuring proper vacuum levels, and careful visual monitoring. The inspection complies with industry standards like API 650 or API 653. It is cost-effective, reliable, and widely used in tank maintenance programs. Safety precautions, such as proper lighting and ventilation, are essential during the procedure. Documentation of results aids in maintenance planning.

APRIS – Acoustic Pulse Reflectometry Inspection System

Acoustic Pulse Reflectometry (APR) is a cutting-edge, non-destructive testing (NDT) method designed for tube inspection, utilizing acoustic waves to detect structural flaws.

The system works by transmitting acoustic pulses through tubes, where reflections caused by changes in the tube’s geometry or defects (such as holes or cracks) are analyzed.

This technique offers several advantages, including high-speed inspections, the ability to examine complex tube shapes (e.g., U-bends or spiral tubes), and compatibility with a wide range of materials. It is particularly efficient, completing inspections in seconds per tube.

Remote Visual Inspection – Videoscopy / Borescopy

Remote Visual Inspection (RVI) using video scopes and borescopes is a powerful method for inspecting hard-to-reach areas within industrial systems, equipment, and infrastructure. This technique employs flexible, high-resolution probes equipped with cameras to capture real-time images or videos, often displayed on a portable screen for immediate analysis. These tools, commonly used in aerospace, manufacturing, and power generation industries, enable inspectors to examine internal components without disassembling equipment, reducing downtime and enhancing safety.

Advanced systems, 3D Video Borescope, provide 360-degree articulation, high-definition resolution, and 3D mapping for precise measurements. These systems allow us to generate detailed reports with accurate depth and dimensional analysis, streamlining inspection processes and ensuring high-quality standards.

RFT / IRIS of Boiler Bank Tubes

RFT (Remote Field Testing) and IRIS (Internal Rotary Inspection System) are critical non-destructive testing (NDT) methods for assessing the integrity of boiler bank tubes in industrial boilers.

RFT is particularly effective for detecting wall thinning and corrosion in tubes by using low-frequency electromagnetic waves, which are well-suited for detecting flaws in ferromagnetic materials. On the other hand, IRIS uses ultrasonic waves to provide detailed images of the tube’s internal structure, offering accurate thickness measurements and identifying potential damage mechanisms like erosion and corrosion.

IR – Infrared Thermography Inspection

Infrared Thermography (IRT) is a non-destructive testing (NDT) method that uses infrared radiation to detect temperature variations on the surface of materials.

This technique allows for the identification of issues like insulation defects, electrical hot spots, and mechanical failures without physical contact or disruption to the equipment.

IRT is especially beneficial in industries like construction, oil and gas, aerospace, and manufacturing for its speed, safety, and ability to detect problems early. It enables preventive maintenance, reduces downtime, and enhances the reliability of critical infrastructure.

Onsite Oxide Scale Thickness Measurement & Remaining Useful Life Hours Calculation

Onsite Oxide Scale Thickness Measurement and Remaining Useful Life (RUL) Hours Calculation are vital techniques used in the industrial sector to ensure the safety and integrity of equipment, especially in high-temperature environments like boilers and heat exchangers.

The oxide scale that forms on metal surfaces can act as an insulating layer, affecting heat transfer efficiency. Accurate measurement of its thickness helps identify when maintenance is needed to prevent operational failures. Additionally, calculating the RUL hours involves advanced techniques like Finite Element Analysis (FEA) or assessing material degradation through NDT methods such as high-temperature ultrasonic testing. These processes enable businesses to predict failure points and optimize the lifespan of critical assets.