NDT IN MANUFACTURING:
In the manufacturing industries, from construction sites, pipelines and refineries to shipyards and nuclear power plants, you need to monitor and improve the reliability of your processes and equipment. Non-destructive testing (NDT) strives in complete or sample examination of the assets, using well-designed procedures.
NDT methods have been applied by all the railways for several decades. Indian railway system is also using the well-equipped NDT instruments for detecting the flaws & making Indian railways as safer as possible with new inventions. Penetrant and magnetic testing methods were used. After World War Two the aid offered to our country by Western countries, the equipment for the detection of flaws in the material of machine parts, particularly axles, pistons, shafts, studs, and crankshafts of diesel engines, was donated too. Since 1981 NDT’s expertise and experience is based on electromagnetic, eddy current, laser, optical and ultrasonic technologies.
NDT IN RAILWAYS:
NDT is widely used in the huge manufacturing industries and the in the railways this is the crucial in respect of maintaining the railway tracks. Now a days this is one of the major problems that railroads are facing in respect of service failures in tracks.
Maintenance Inspection of Train Wheels, Maintenance Inspection of Hollow and Solid Train Wheel Axles. In-service Train Rail Inspection, Inspection of Cast Manganese Frogs (crossing point) After Manufacturing, “In Lieu of RT”.
NDT IN CASTING:
As we know die-casting products made of aluminum, copper, magnesium and zinc base alloys, are used in car manufacturing. Many of these products are safety-related that must not fail and therefore have to be tested nondestructively. For cost-effective optimization of the production process also non-destructive testing (ndt) of the castings is required. Due to the manufacturing process die-casting components show inner volume porosity.
They may have effects on their strength, tightness, and surface structure. by using Radiographic and Ultrasonic testing, NDT can examine casting for subsurface indications. NDT specialist can handle a variety of casting sizes.
NDT IN COLUMNS:
By means of a sustained theoretical approach, several objectives were established to evaluate through modeling and simulation methods that could be useful for non-destructive testing in structural concrete columns. Given these variables (positions and diameters of reinforcements) were established mathematical models of the physical principles that constitute the operation of the respective nondestructive testing methods and computational models were made of reinforced concrete column. Modeling and simulation of physical principles of methods that can be used to perform non-destructive testing on reinforced concrete columns, aimed at identifying the positions of the reinforcements on such structures.
NDT IN REFINERIES:
Adopt advanced NDT methodologies in Refinery is basically due to the fact that hydro cracker or hydro treating plant is a very sophisticated and complex secondary processing unit and the reaction sections operate at a relatively high Pressure, Scientific advancement in NDTs overcome many limitations in conventional NDT methodologies. Ageing of equipment affects the probability of defect growth and thereby reliability.
NDT IN POWER PLANTS:
Power plants are meant for the Condition Monitoring and Maintenance operations at the Thermal Power Stations have played vital roles to resist against this national disaster in power supply. Various advanced methods of Non Destructive Testing like Ultrasonic Inspection for Wall Thickness Measurement and Scale Detection, Eddy Current techniques for crack detection, Remote Visual Inspection at the Turbine sections during short term overhauling have proved to be technical remedial measures to prevent capital overhauling and thereby reducing forced outage at Thermal Power Stations.
NDT IN OIL & GAS:
The most effective methods which guarantee capacity for work of oil & gas equipment and tools are systematic nondestructive testing and technical diagnostics of their working state. Besides, the nondestructive methods allow to detect available defects and appreciate the working state of equipment and tools for all their working cycle and forecast working state during operating. The conducted by different expert’s analysis of accident rate showed that quantity of failures of oil and gas equipment and tools, especially of pipes, is very considerable (20% of pipes (even new) are scarping) and tends to rising.
NDT IN FABRICATION:
Fabricating process can cause breakdowns in the materials used and, in some cases, defects or failures in the finished product. As it’s an industrial view it refers to building metal structures by cutting, bending, and assembling. Welding is one of the most common processes used in assembling and is usually the focal point of non-destructive testing (NDT). Welders and fabricators are commonly tested and certified to meet specific welding requirements. Typically, fabrications with welds requiring certified welding also include a non-destructive testing inspection. These inspections can play a vital role in defect detection and initial failure prevention as well as future preventive maintenance.
NDT IN MINING:
A recent development has seen the use of computed tomography (essentially three-dimensional radiography) in the examination of core samples and geological specimens to aid decisions on where to sink a shaft or drill a well. Safety can be improved as NDT assists in spotting numerous safety hazards, including fraying ropes, cracked axles, sticking valves and corroding pipes. This prevents equipment from failing while in use and injuring personnel.
NDT IN TANKS INSPECTION:
There are a number of different methods used to perform NDT test tanks, such as bins and pressure vessels including Magnetic Particle Testing, Ultrasonic Testing, and Vacuum Box Testing. These methods are each incredibly useful in looking for deficiencies in a different way. When a tank needs to be inspected from the inside, a number of test methods can be used. But first we have to remember all the safety that is required before we enter a tank! A tank is a confined space and careful attention needs to be made to the air quality and to the access and egress of the unit. Once the safety plan is in place, and the space has adequate air quality, the inspector enters the vessel with their tools to begin the inspection.
NDT IN PRODUCTION:
Many producers have adhered to the practice of using NDT solely to satisfy customer and industry requirements for finished products acceptance. These tests may be conducted at the producer’s plant. This practice provides a high degree of quality assurances. Consequently, NDT is used only for finished product inspection, whereas a significant portion of its cost-saving can be realized only from using in-process NDT in addition to the final inspection. Some of these savings are evident. If the product that is flawed or out of tolerance because of dimensions or mechanical properties is identified early in production, it can be diverted or scrapped, thus avoiding further processing and related costs.
NDT IN AVIATION:
In the aviation, two of the most-despised words are “leaks” and “cracks.” While the former have the decency to let their presence be known, cracks are insidiously stealthy, and by the time you find them you are already too late. While penetrant inspections assist in detecting surface cracks, they cannot reveal trouble below. In addition, it has been shown that improperly applied penetrant can actually hide cracks. The most-common and effective method for detecting subsurface cracks is the eddy current method. For a maintenance manager, it may be difficult to justify developing and maintaining in-house NDT capability.
NDT IN MARINES:
NDT inspectors have gained valuable experience, including intuitively knowing the needs of their clients. Sometimes emergency or even urgent situations occur, necessitating an inspection at times other than during regular business hours. Consequently, the NDT inspectors at Marine Chemist Service are on-call 24/7 to help their clients, especially in these types of situations. And since time is of the essence, preliminary results and field-drawn sketches are made available upon request. Of course, they are always followed-up with formal, computer generated reports and drawings at a later date. Consequently, regularly scheduled Nondestructive Testing helps prevent catastrophic failures by keeping everything running smoothly, and the NDT inspectors at Marine Chemist Service are ready to help.
NDT IN HEAT EXCHANGERS:
Examination and condition monitoring of heat exchangers are performed using a variety of techniques. Selection of the best suited technique depends on whether the objective is fabrication control, preventive in-service inspection, or inspection due to failure as for example leakage and depends on the type of defects which is expected to be detected by the examination. Heat exchangers are vital components in numerous processing plants. Usually they are of bimetallic construction and work with various chemicals at high temperatures. In these conditions corrosion, cracking, erosion, thinning and other damage can occur during operation. For example, unnecessary process downtime, change-out costs and pressure testing can be avoided with these services. Inspector offers you methods such as IRIS and eddy current testing, which provide high-speed results in finding defects that threaten the safe usage of your heat exchanger tubing.
NDT IN PRESSURE VESSELS:
The use of high-pressure vessel systems is crucial to a number of industries and applications. The applications range from the manufacturing of aeronautical components to medical implants. This inspection applies detection methods to verify there are no defects that would diminish the effectiveness of the pressure retaining structure to continue to withstand in-service operating loads. It also evaluates the condition of the vessel to detect any maintenance or operating conditions that could reduce the life of the vessel. To ensure maximum effectiveness and optimal vessel operation, periodic inspection is highly recommended.