An overview of a decades-long non-intrusive inspection program that began in the early 1980s and progressed to full-scale global implementation.

By automating routine tasks, these technologies can provide a robust solution for improving the efficiency, accuracy, and reliability of industrial inspections.

Various NDE techniques are discussed that examine damage in pressure equipment: temper embrittlement, downtime SCC, stress relaxation cracks, and pitting.

A study of the application of inspections deployed with straight-beam ultrasonics technology to assess the condition of an FRP AST in a toxic chemical service.

This article explores the digitalization of inspection processes, its main challenges, and how to bridge the gap effectively.

Our proprietary furnace tube inspection system, FTIS is an ultrasonic inspection technology capable of rapid, automated fired heater coil inspection in refinery fired heaters. The data captured by our furnace tube inspection system is...

Software advances in laser scanning allow for examining noncylindrical equipment common in a plant environment. We’ll give six examples of how this is done.

A proven methodology is required to measure accurate temperatures in a repeatable process to capture the full capability of IR thermometry.

Our conversation explored the historical evolution of PACS, its applications, its impact on the NDT industry, and the anticipated advancements in PACS.

The article presents a methodology that involves subject matter experts to navigate data challenges, ensuring accurate interpretation and swift decision-making.

A comparative analysis of robotic nondestructive inspection tools used to locate floor defects in aboveground storage tanks.

Integrating a new digital technology that combines data-driven insights and data storage with innovative mobility can provide a new level of connected intelligence. Digitalization can improve workflow, increase worker productivity and allow better...

A look at the dominant damage mechanisms experienced by FRP during service and several detection methods to identify inspection information for FFS assessment.

The capabilities of automated radiographic testing (ART) make it the preferred method to manual techniques for detecting piping corrosion defects in the field.

This article covers how costs can be reduced by automating NDT management systems by using software that integrates inspection methods and associated processes.

Learn how a new generation of electromagnetic technology is aiding offshore asset owners in managing corrosion issues within splash zones.

The latest developments in microwave inspection of complex composites are summarized, including principles of multi-frequency microwave inspection.

Equity Engineering Practices® (EEPs) are a collection of design and maintenance focused corporate standards that include >850 engineering standards, and >300 piping classes. Enhance your mechanical integrity programs, improve equipment...

A discussion on the rationale for being cautious with an inspection of older vessels and how to decide when such inspection is appropriate.

This installment of Damage Control outlines the FFS methods available to analysts for evaluating wall loss such as sulfidation or high-temperature H2/H2S corrosion in pressure equipment

The key to unlocking the potential of AI in NDT is to implement the necessary technologies to digitize inspection workflows and create a structured digital database.

A look back to when phased array systems were first developed in the 1960s and how the uses and technology have evolved throughout the decades to present day.

Comprehension of the sulfidation corrosion reaction and the behavior of different materials in H2-free and H2/H2S environments is imperative for oil refineries.

In today's chemical and refining industries, sustained long term reliability of facilities is critical to profitability and competitiveness. In fact, history shows that differences in operating expenses between best-in-class refineries, and poor...

Data lakes are a powerful solution for storing and managing NDT data and inspection metadata. They allow for the centralization of large amounts of data that can be used as a valuable source of data for AI projects.

Utilizing automated ultrasonic testing (AUT) for corrosion mapping to detect and quantify damage can play an important role in an effective MI program. This article compares two common off-the-shelf AUT technologies used for corrosion mapping.

A focus on typical damage morphology and inspection methods used to identify and characterize high-temperature creep including examples of creep damage and in-service failures to offer insight into this complex damage mechanism.

Phase coherence imaging (PCI) is a new advanced ultrasonic inspection technique that produces live total focusing method (TFM) images with unprecedented clarity and sensitivity to small defects.

An investigation was conducted to challenge the paradigm that baseline inspections must be done for all piping and other static mechanical pressure equipment. This article introduces a new approach to baselining practices.

Are you truly prepared for your next Turnaround? Effective work processes are required to successfully plan, manage, review and supervise plant turnarounds. Inspection planning and work scope selection are critical aspects of any turnaround...

A case study of advanced digital technology was assessed to resolve the challenges of internal coating of small diameter pipes by accurately and rapidly measuring pipe-end dimensions, and then matching end-to-end pipes with software-based analysis.

Leveraging and combining the correct inspection tools on complex problems can yield the best overall data and understanding of actual conditions.

Resulting from developing a 20-year nonintrusive inspection strategy, a successful experience is presented using a volumetric examination on a modified storage tank shell-to-bottom weld, known in the industry as corner-weld.

The pursuit to develop and validate phased array/time of flight diffraction (TOFD) transducers and corresponding wedges to service high-temperature inspections with the hope to discover reliable, convenient, and cost-effective alternatives.

Of the nearly 70 damage mechanisms listed in the latest edition of API RP 571, the highest FEMI risk may be the ones that are highly localized in nature and, therefore, the hardest to find.

TEAM provides full inline, onsite and, shop valve repair services and maintenance programs for virtually all valve types, brands, sizes, materials, pressures, and operating conditions, including actuators and operators. Our valve repair solution...

A study of the level of deterioration on a catalytic reformer support structure, the challenges involved, the solutions presented, and the aggressive schedule that was required to complete the project.

This article describes HTHA predictive modeling advances that are designed to demonstrate a direct integration with inspection such that modeling and inspection can be leveraged together in a way never done before.

Within one unit, TriLat combines the power of two probes containing three angle beam sets to identify and quantify cracking at early stages. The result is inspection speeds up to ten times faster than traditional AUT systems, depending on probe size.

With the advent of digital technology, image processing can be done in digital radiographs which can be used for automated detection and quantification of defects. It is important to know the system's limitations and the probability of detection.

This article presents two case studies that show how having a holistic approach, along with the right technology and experience, is essential to identifying smaller damage mechanisms like fretting in fired heater coils.

Traditional pressure vessel inspections often require taking assets out of service. However, MISTRAS’ Non-Intrusive Inspection (NII) programs provide data as good or better than internal inspections, while assets remain in service. NII is...

This article summarizes the fundamentals of wet H2S-related damage mechanisms, offers some practical inspection guidance, and reviews a notable industry failure caused by different forms of wet H2S damage.

This article illustrates the value of digital radiography as an efficient tool to visualize corrosion and other small bore piping anomalies without disturbing insulation, as well as using PRT in conjunction with UTT to survey small diameter lines.

Recent advances in UT technology now allow for inspection and continuous monitoring of sulfidic corrosion to be undertaken while the components are on-stream, at temperature, with high-resolution thickness data.

The scope of the subject case study reviews an inspection and corrosion control assessment conducted on subsea flowlines and includes evaluating the flowlines’ associated inspection programs and identifying all available NDT technology solutions.

Asset owners can realize economic and HSE benefits from utilizing internal in-service robots for hazardous fluid tank inspection. Achieving high levels of coverage and collecting enormous amounts of quantitative data are possible for clean tanks.

Traditional, paper-based inspection processes can prevent plants from being as effective as they can be. By digitalizing your mechanical integrity process and data with MISTRAS Digital®, plants have realized up to 75% gains in IDMS data entry and...

Hydrogen-induced damage mechanisms have been studied endlessly, leading to changes in equipment design and development of new inspection practices. However, the highly localized nature and difficulty of detection of HTHA add additional complexities.

This case study of a CO2 absorber tower in a remote location investigates the use of a new type of wireless ultrasonic sensor for monitoring the thickness of equipment while on or offline.

A safety-focused mindset and awareness of the dangers associated with the process, environment, and associated tasks through planning and execution is essential for the safe completion of a single stud replacement campaign.

This article addresses some of the advantages and disadvantages of acoustic emission testing and discusses a few examples of its typical applications.

In this article, FFS assessment methods are summarized and practical guidance is offered for qualifying CUI damage on carbon and low-alloy steels.

Antea delivers highly flexible risk-based asset integrity software with 3D Digital Twin integration to optimize maintenance, reduce risk, and improve mechanical integrity for oil and gas, power generation, and chemical plants and facilities....

This article will discuss a statistical analysis method that was developed to evaluate the integrity of pipelines that can identify, in a first phase inspection, whether the nature of the active damage mechanism(s) are uniform (general) or localized.

As more are educated on the benefits of utilizing ropes and drones, skepticism has become far less common, and we’re sure to see adoption grow in the coming years of both of these methods—and, perhaps, of this new hybrid approach to work as well.

FFS assessments usually originate from inspection results and often end with a recommended inspection plan. This FFS Forum tries to provide a little better understanding of one particular inspection method: Acoustic Emission Testing.

Corrosion under insulation is a form of external corrosion that is caused by trapped water on insulated surfaces. It is an industry problem affecting equipment in the oil and gas, petrochemical, specialty chemical, fertilizer, and related industries.

This retrospective takes a quick look at two of the most popular topics that were covered in Inspectioneering Journal last year: the accuracy of thickness readings and corrosion under insulation.

The OmniScan™ X3 64 phased array and TFM flaw detector is equipped with enhanced phased capabilities and even faster TFM. The rugged and portable instrument features powerful 64-element probes with a 128-aperture TFM.

The purpose of baseline inspections is to provide cost savings upfront versus the cost incurred during operations. So, what are the possible heat exchange tubing defects or anomalies and how are they validated?

When you are dealing with an inspection technique that is poorly understood and a company representative that is downright combative, you get a perfect storm that can quickly lead to that particular technique losing its credibility.

Temporarily or permanently installed thickness monitors can help to overcome shortcomings and uncertainties associated with manual ultrasonic inspections and can lead to significantly improved maintenance and asset replacement forecasting.

Inspectioneering chats with Gecko Robotics about the new rapid ultrasonic gridding technique and how it can be utilized to increase the speed and effectiveness of equipment inspections.

This article demonstrates how the use of TFM/FMC can be an effective method to screen for potential problem flanges before a planned shut down and can be a very useful tool in planning which flanges require further evaluation.

Ethos has assembled a team of experts who apply what they learned through years of process safety experience in the industry and dealing with OSHA and EPA. Click here to learn more about our services.

Nelson curves, which are the foundation of the industry’s HTHA programs, can be tied to mechanistic models from several sources, allowing the recreation of Nelson curves for different operational histories and time durations.

FMR is a useful tool in many situations. It allows nondestructive evaluation of the surface microstructure that is entirely adequate in many cases. However, it is not a panacea, and there are many conditions where it is inadequate.

This article reviews the effectiveness of AET for inspecting tank bottoms in two ways; namely, benchmarking regulations in different countries and comparing AET and MFLT results through a case study.

Universally, smart or intelligent pigging is now a standard practice for the inspection of fired heater and serpentine boiler coils. Understanding this technology can greatly assist with maintenance planning and the prevention of unexpected failures.

This article describes the construction of corrosion-resistant fiber reinforced polymer (FRP), commonly used for pressure vessels and piping in the chemical processing industry, and the practices used for inspecting corrosion-resistant barriers.

Whether you decide for a Computed Radiography scanner with flexible imaging plates or a flat panel detector with the fastest imaging, or even combine the advantages of both technologies, DÜRR NDT's innovative systems offer high reliability and...

Inspectioneering and PinnacleART co-hosted their 5th Meeting of the Minds roundtable last November in Atlanta. This meeting’s focus was on notable technologies and how they are changing the MI landscape.

This article helps shine light on some common industry problems that can occur by having inferior UT procedures and practices, while providing several lessons learned through a case study that resulted in nearly $1 million in turnaround repairs.

A refinery or process facility FEMI program consists of eight Pillars that are fundamental to achieve FEMI excellence. This article describes these Pillars in detail and suggests what distinguishes good Pillars from those that are less than adequate.

This article examines multiple trials that entailed testing robotic systems on different non-magnetic surfaces to identify the feasibility of detecting CUI using robotics in combination with NDE technology.

In this article, Inspectioneering interviews Tye Beard at ASTM, a leading standards organization that develops and publishes consensus standards for the process industries, to discuss the current and future state of industry training.

Traditional inspection methods used to detect internal corrosion and corrosion under insulation (CUI) in piping and pipeline assets can be time-consuming and costly. With ART, you’ll discover CUI detection best practices that can help save you up...

Much like the equipment and piping they support, structures should be part of a comparable structural integrity (SI) program. This article will examine key components of a comprehensive SI program as an essential companion to an MI program.

This article discusses two common challenges for inspectors taking thickness readings in high temperature environments and ways to overcome those challenges.

API RP 578 identifies 7 areas of consideration & general concern in material verification, mainly focusing on systems most susceptible to corrosion. Knowing which assets are at high-risk for degradation & what elements should be tested is critical...

The refining and petrochemical industries will continue to benefit from the evolution of robotics and data management. The biggest hurdle will be to accept this evolution and embrace the new capabilities that come with it.

This article presents two cases studies demonstrating how properly conducting baseline fired heater tube inspection aids in early discovery and correction of defects, avoiding unexpected in-service failures, and more.

With class-leading thermal performance, superior CUI defense, and complimentary engineering support, our aerogel insulation solutions are a top choice in helping facilities drive energy efficiency, improve safety, increase yields, and reduce downtime

Thickness readings are critical for today's inspectors to accurately judge the state of their equipment. Recent advancements in sensors, software, and data management tools have made this easier, safer, and more efficient than ever before.

Here are 8 tips to help you overcome certain challenges encountered when taking thickness measurements at high temperatures.

This article is written to provide a brief case study of an acoustic emission test of an FRP storage tank. A method combining acoustic emission with ultrasonics is proposed to ensure reliable long term operation.

Tanks are ubiquitous and essential in industrial societies. When they fail, the consequences can be dire if products/volumes they store are explosive and/or toxic.

In this latest guest blog, our friends at Olympus America share some of their most frequently fielded questions regarding X-Ray Flourescence (XRF) and some considerations for using XRF for Positive Material Identification (PMI).

Companies have developed detailed programs for managing wide range of assets. However, unsustainability negatively impacts effectiveness of these programs. Reach out to us on how we can address sustainability through digital transformation.

Inspectioneering and PinnacleART recently hosted a roundtable discussion for a select group of mechanical integrity experts to discuss strategies for managing corrosion under insulation and corrosion under pipe supports, a.k.a. touch point corrosion.

While planning methods for thickness data acquisition in any Inspection Data Management Program, PRT should be considered as a cost-efficient, effective way to increase the value of your program for small bore piping or any other suitable situation.

Over the last six months, Inspectioneering has released a plethora of interesting and educational content that has been read more than 150,000 times online. In case you missed it, here's a recap.

In order to utilize data most effectively and realize the full power of AE testing, it is necessary to bring the capabilities of laboratory testing tools to industrial sites.

Welding imperfections vary in impact from being acceptable to requiring repair. It is important to ensure the quality of welds using NDT and to ensure the strength of the entire piping system with hydrotesting.

Lessen downtime by enhancing your plant infrastructure, ensuring mechanical integrity, and extending equipment lifespan. Contact us for on-demand engineering expertise in assessment, problem-solving, specialized testing, and preventative solutions.

An effective RBI system implementation results in, not only safeguarding your assets & people, but can also reduce unnecessary inspection activities that may be required due to conventional & nonsystematic approaches.

In this edition of the FFS Forum, Greg addresses some issues associated with inspection of vessels that have been in service for a number of decades, and offers some tips for reliability and inspection to follow when inspecting these older vessels.

The challenge to find CUI is difficult and one single NDE technique cannot be used to identify it. This remains the case today as we combine NDE techniques to perform CUI assessments. The techniques and strategies commonly used today are summarized...

Nondestructive testing (NDT) careers are on the rise in today’s economy. These fields are constantly advancing, and there is an ever-growing need for technicians, quality assurance specialists and inspectors as infrastructure in the United States...

The benefits and advantages of drone inspection over other methods have made this technology a viable solution in industry. As utilization of drone technology continues to grow and expand, it’s important to not only understand what they can do but...

With the IMS Suite, you can calculate optimal intervention periods and lay out efficient maintenance strategies. Click here to learn more.

With no industry consensus documents in existence that provide guidance for determining FFS of FRP, this article provides a case study that illustrates how an existing European design standard on GRP tanks can be used to calculate expected changes...

HTHA of hydrogen-containing equipment can be prevented with appropriate material selection and fabrication, appropriate welding procedures, regular inspection of equipment using proven, effective technologies and equipment operated by qualified...

This article features a case study on the feasibility of a wall-sticking drone for effectively conducting ultrasonic testing and other NDT methods on equipment at elevated heights.

Over the past few years, network technologies have been developed to eliminate the need for long cables for UT thickness monitoring. Coupled with a software back-end, permanently-installed UT sensors have become much more competitive in the...

Infrared (IR) thermometry has been used for over forty years to monitor tube metal temperatures in refining and chemical furnaces. Recently, IR thermometry has been criticized in the industry for delivering inaccurate readings; however, this is...

Learn how you can safeguard integrity, reliability, instrumentation safety, and more.

This article explains the Statistically Active Corrosion Assessment, which is a tool for determining appropriate and realistic corrosion growth rates which can assist pipeline operators in optimizing the value of in-line inspection data.

Thanks to the development of documents such as API RP 571 and API RP 586, as well as the emergence of qualification demonstration testing, we can align NDT techniques and inspection strategies better than ever. This article examines this progression...

This article, part two in a series, provides a case study of an inspection and evaluation of a Fiberglass Reinforced Polymer (FRP) column using nondestructive ultrasound readings on the outer surface of the FRP.

Due to its high-cost, Level 3 FFS is typically carried out after Levels 1 or 2 and only in extreme cases. However, advancements in inspection technology and improved use of inspection data have made Level 3 analysis more practical and affordable,...

3 common repair scenarios include routine maintenance, scope repairs, and major discoveries. An inspector’s ability to properly manage each situation can mean the difference between mechanical integrity success and failure.

Say goodbye to juggling multiple tools! Our all-in-one solution automates NDT data acquisition and seamlessly transfers it to your inspection data management system. Simplify your workflow today - use DIMATE PACS!

Composite technology developed for pipeline repair can be a cost-effective method of improving safety while keeping maintenance costs down. However, composite materials present significant challenges to conventional NDT methods.

The adoption of drones for use in industry is a trend that has grown rapidly over the past few years. As the technology increases in popularity, its capabilities continue to evolve beyond basic imaging, boosting the list of ever-growing applications.

The availability of high quality UT data is often the cornerstone for FFS and RBI decisions. As such, the API Subcomittee for Inspection and Integrity Management (SCIIM) has initiated a program for the Qualification of Ultrasonic crack Sizing...

Discover a new ultrasonic inspection approach that provides quantified mechanical integrity and conservative remaining service life information on fiberglass reinforced plastic equipment.

Myths, challenges, and good practices related to process piping integrity management activities that help inspection and maintenance managers make the right decisions to develop cost-effective piping inspection plans without compromising the...

Increase the efficiency of your mechanical integrity programs through the design, implementation and optimization of inspection databases.

Inspectioneering Founder & Chief Editor, Greg Alvarado, recently had the privilege to sit down with Clay White, Director of Mechanical Integrity for Phillips 66 (Downstream), to discuss the world of fixed equipment reliability in the refining and...

The purpose of this article is to describe the various in-line inspection (ILI) technologies that are currently available to the market. The pros, cons, and applicability of each type of tool will be discussed in greater detail.

Flare systems provide hydrocarbon facilities with safe and efficient discharge of relief and waste gases by controlled open flame burning. This article provides information on the selection, inspection, and maintenance of various types of flares.

Ultrasonic phased array allow for a variety of structures to be inspected without radiation or taking equipment out of service. Codes are now being developed which allow phased array systems as an acceptable inspection technique for many procedures.

Beyond the financial hits, undetected degradation from corrosion can also lead to critical safety risks. To effectively manage mechanical integrity, organizations need reliable methods of identifying the current states of corrosion occurring within...

FER's extensive TA experience, combined with our custom software (RAMI Scope) that tracks all aspects of TA activities, we have the ability to keep your turnaround flowing flawlessly with the methodology to maximize your value of premium time.

This article exhibits how modern inspection methodologies combined with innovative computational analysis practices demonstrate the value of conducting fitness-for-service (FFS) assessments on sectional piping.

Remote monitoring solutions are making it possible to avoid sending personnel into harsh environments without forgoing the essential data gathering that keeps assets safely operating.

Detecting, quantifying, and sizing indications characterized as a “crack" in critical equipment have long been the global benchmark of asset integrity programs. Therefore, the increased precision that inspection programs obtain using advanced...

Although all ultrasonic smart pigging providers claim the ability to detect wall thinning and tube deformations to some degree, the inspection surface coverage, resolution, minimum wall thickness detection and reporting capabilities may vary...

ASNT’s 2016 Annual Conference took place this week in Long Beach, CA and was a special event celebrating “75 years of Success in Creating a Safer World.” The event brought together over 2,000 technicians, researchers, and other professionals...

Introducing the IGS Tube Tech rover system, the next generation in autonomous cleaning technology, capable of removing more than 90% of fouling and restoring your fired heater convection sections to their original design thermal efficiency.

This article details the basis for the lack of understanding about the potential for ultrasonic couplant auto-ignition and outlines an ALARP operating practice for mitigation.

The instrumentation available to detect inadvertent material substitutions through positive material identification (PMI) has never been more available, portable or powerful than it is today. For one industrial services company, Tacten Industrial,...

The structural integrity of components is controlled by material properties, the presence of flaws, and levels of applied stress. Several factors such as temperature, type of loading, toughness, corrosion resistance, micro-structural stability, cost...

In the last few years, electromagnetic acoustic transducer (EMAT) has come to prominence for its ability to quickly scan exposed pipelines for corrosion, cracks, and other defects using medium-range guided waves and without the requirement for...

RBI and NII are designed to achieve significant cost savings and risk mitigation benefits over a piece of equipment’s lifetime in the long term.

Tired of manually collecting and transferring NDT data? DIMATE PACS transfers data from field inspections directly into your management system, saving you time and effort. Revolutionize your inspection workflow with DIMATE PACS!

In numerous industries that require elemental and material testing, including the oil and gas, power generation, and petrochemical industries, positive material identification (PMI) is at the forefront of any operation. In fact, an increasing number...

This article highlights the evolution of corrosion monitoring from conventional ultrasonic to ultrasonic phased array manual and automated solutions and their use for both general purposes and complex applications.

While there are many types of advanced NDT, this article will focus on the use of acoustics and electromagnetism as the bases for conducting examinations.

While there are many methods for measuring equipment wall thickness, a predominant method used in the O&G and power generation industries is portable ultrasonic equipment. Ultrasonic testing is non-intrusive because it is applied to the outside of a...

Fixed equipment in a refinery can be susceptible to corrosion from the process side, necessitating an inspection strategy to understand the condition of that equipment. Online measurement of pipe and pressure vessel wall thickness is made possible...

We at Inspectioneering would like to take this opportunity to thank all of our subscribers, followers, clients, and industry partners for a great 2015, and wish every member of the Inspectioneering community a happy and healthy 2016!

It is often best to rely on properly trained and experienced inspection service providers to determine the proper method for any inspection project. Thus, inspection companies can suggest utilizing the most effective and efficient inspection...

It is often best to rely on properly trained and experienced inspection service providers to determine the proper method for any inspection project. Thus, inspection companies can suggest utilizing the most effective and efficient inspection...

While they is very efficient and popular, liquid couplants used for ultrasonic inspection have some inherent limitations and disadvantages. An alternative method to using liquid couplant is Dry-Coupled Ultrasonic Testing (DCUT).

While they is very efficient and popular, liquid couplants used for ultrasonic inspection have some inherent limitations and disadvantages. An alternative method to using liquid couplant is Dry-Coupled Ultrasonic Testing (DCUT).

Once upon a time in the land of Ooze, there were two processing plants that boiled oil to make fuels and various other valuable petrochemical products. On one side of the river, rests a site called Perfecto Process Plant, while just across the river...

Once upon a time in the land of Ooze, there were two processing plants that boiled oil to make fuels and various other valuable petrochemical products. On one side of the river, rests a site called Perfecto Process Plant, while just across the river...

While computed tomography (CT) scans are common and well-known as a critical evaluation tool in the medical field, they are becoming increasingly important in industrial settings. Recent automation, speed, and accuracy developments are driving the...

While computed tomography (CT) scans are common and well-known as a critical evaluation tool in the medical field, they are becoming increasingly important in industrial settings. Recent automation, speed, and accuracy developments are driving the...

Readers were previously introduced to some of the practical advantages of EMAT Ultrasonic Testing (UT) in the March/April 2013 and July/August 2013 issues of Inspectioneering Journal. In this article, I will cover the practical advantages of EMAT...

Refinery, petrochemical, and storage tank operators are responsible for properly cleaning facility tanks on a periodic maintenance basis, typically in 20 to 30 year increments. This article provides a suggested “checklist” of inspection...

Verifying pipeline integrity is particularly challenging due to the difficulty of pipeline access, as well as the limitations in available technology to perform subsea wall thickness inspections. These challenges require action rather than reaction.

Nondestructive Testing (NDT) makes up the majority of testing performed in our industry. There many different types of nondestructive testing techniques. Each method has its own advantages and disadvantages; each can detect different types of flaws....

These are interesting times when it comes to inspection technology in the process industries. With the advent of big data, mobile and wireless technology, and various other technological advances, we thought it would be a good idea to provide a...

Because radiography involves the use of large amounts ionizing radiation, safety is integral for the technician, the public, and the environment.

Rope access allows for a wide variety of work to be performed at high elevations or other hard to reach areas without the use of scaffolding or heavy equipment. It has evolved from techniques used in rock climbing and caving to become an extremely...

Refractory materials have significantly evolved during the past 15 years, testing technology is much more sophisticated, and the need for test technicians to be properly trained and experienced to use that technology is much more important than it...

The tubes of heat exchangers (HX), whether for a shell and tube bundle or an airfin, are typically subject to some form of nondestructive examination (NDE) to try and quantify the remaining wall thicknesses and corrosion rates to help a plant to...

Weld inspection using lasers is not new, but doing it 75 meters inside a pipe or streaming inspection data wirelessly is new. As laser technology has improved, more industries such as oil & gas are beginning to require laser inspection as part of...

The ability to gain this unique perspective has recently become easier and safer with today’s technological advancements. This new technology comes in the form of a miniature flying machine, better known as a drone or small Unmanned Aerial System...

We talk about heat exchangers quite a bit here on Inspectioneering, most recently in the January/February issue of the Journal. This is because heat exchangers are vital pieces of equipment in nearly every type of plant or facility.

This article provides a discussion of a recent inspection performed at a U.S. refinery. Industry HF lines are experiencing piping failures in increasing numbers due to the presence of residual elements entrained within their carbon steel components.

The 2015 API Spring Refining and Equipment Standards Meeting will be held at the Seattle Sheraton during the week of April 13-16, with plenty of interesting meetings for Inspectioneers.  You do not need...

The future of inspection will be based on predictive and proactive technologies that effectively monitor material properties of structures and systems over their entire service life.

The development of advanced NDE techniques/tools is one of the reasons the inspection trade has taken significant steps forward in the last couple decades; and the advancements appear to be accelerating.  One of the many ways to keep up with...

Dual mode pulse reflectometry shows promising results in detecting a wide range of defect types and sizes in heat exchanger mock-ups.

The introduction of PAUT is a challenging effort initially, but can have a very positive impact on your first TAR and become a routine inspection for future TARs. When fully implemented, radiation safety boundaries can be reduced significantly or...

Steam reformers are critical assets for the successful operation of hydrogen, ammonia, and methanol plants. The steam reformer is also one of the most expensive assets in these facilities. Catalyst tubes inside the reformer are one of the most...

Over recent years large strides have been made in application, development, and utilization of Digital Detector Arrays (DDAs) in field radiography environments. The use of industrial digital radiography shows benefits of significantly reduced...

Maintaining mechanical integrity for aging power boilers can be challenging. This article provides a case study on how mitigating one damage mechanism led to the discovery of another, and how refinery engineers collaborated with industry experts to...

For the past 30 years, infrared (IR) thermometry has been used to monitor tube metal temperatures in refining and chemical furnaces. Tracking temperature levels and variations determine performance capability limits and reliable tube life. However,...

A small leak from top tubesheet-to-tube welds prompted further inspection of the 1¼Cr- ½Mo Ammonia Converter Boiler Feed Water (BFW) Exchanger during a planned shutdown. Further cracks were identified in the top channel to tubesheet butt weld that...

The following interview with Rich Roberts provides answers to some of the questions our readers have about small, specially designed pigs carrying NDE technologies that can inspect nearly every area of a tube from the coils interior surface.

New inline inspections and integrity management systems allow operators to understand the complexities and economics of terminals’ and station’s complex aging pipeline infrastructure.

A question was posed to me regarding guidelines for routine external inspection of spheres, including procedural approaches along with any nondestructive examination (NDE). Here are two approaches to inspection of spheres, and a mixture of the two,...

UAS (Unmanned Arial System) drone technology has numerous applications, including anything at elevated heights or where human access and/or occupancy are prohibited, or in the case of confined spaces, limited.

Technicians inspecting oil & gas installations and petrochemical plants employ a wide variety of nondestructive testing (NDT) techniques. A new technology has recently been developed that utilizes a real-time portable imaging device which has...

Over recent years large strides have been made in application, development, and utilization of Digital Detector Arrays (DDAs) in field radiography environments (an application previously limited to film and computed radiography [CR] techniques).

To understand the current non-destructive testing (NDT) world, it is perhaps a good idea to look back at things historically. By doing this, changes which have taken place become apparent, and very soon one can conclude that this is actually quite...

Maintaining the mechanical integrity of above ground storage tanks (AST’s) is the focal point of tank inspection programs. Performing internal inspections is an integral part of a tank integrity program, however, deciding when to take a tank out...

Non-contact ultrasonic testing with EMAT was formally introduced in part one of this series found in the March/April issue of Inspectioneering Journal. Readers were introduced to the practical advantages of EMAT Ultrasonic Testing.

Remote metallography, in-place metallography, in-situ metallography, and field replication are all examples of typical trade names of this great tool used for assessing the condition of a metal component.

Refineries and chemical plants own and operate numerous process heaters (e.g. gas reformers, CCRs, etc.) as part of the standard assets throughout the facilities. Many heater coil configuration designs are flanged at both ends; however, there are...

This is the first in a series of three articles that will introduce Electro Magnetic Acoustic Transducer (EMAT) and its practical applications in the field of nondestructive testing (NDT). EMAT, or Electro Magnetic Acoustic Transducer, is an...

This article is the third of a series of articles that will focus on one critical sub process within a PEIP that is key in managing the integrity of process piping: thickness monitoring programs for internal corrosion. These articles will discuss...

A unique technique for inspecting and cleaning the floors of an Above Ground Storage Tank (AST) emerged in the late 90’s based on In-Service Robotic Technology. The technology has come a long way since then, with new inspection and tank cleaning...

The refining industry has applied ultrasonic-based intelligent pigging to inspect serpentine coils in fired heaters since the 1990s. Today, thousands of serpentine coils in fired heaters are inspected annually at process facilities around the globe.

Over the past 100 years, Nondestructive testing has made tremendous advances. New NDT methods have been introduced, while old "tried and true" methods continue to be improved. Although some NDT methods have drastically changed or "evolved" over...

The new capabilities being developed through the Nondestructive Evaluation (NDE) Modeling and Simulation Center are expect- ed to reduce the time, cost and complexity of approaches used to develop and demonstrate NDE techniques to meet regulatory...

Concerns about the reliability of ultrasonic in-service inspections conducted at nuclear power plants led the U.S. Nuclear Regulatory Commission (NRC) to draft a proposed qualification document in October 1984. Representatives from industry, the...

The design and fabrication of nuclear pressure vessels and piping components are governed by the rules of Section III of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code. This Code, which aims to to ensure high...

EPRI is investigating improved inspection technologies as part of a multi-faceted effort to enhance the understanding and management of underground piping and tanks at nuclear power plants. An ultrasonic immersion technique tested on an...

Once again there is a crack found in the inlet tubesheet in your high-pressure high temperature heat exchanger. As head of the maintenance engineering effort, you know that plant management will ask you if it can run safely and reliability until...

As the technology of NDT systems improve, it is important to assure that the people and processes using this technology are adequately prepared in order to take full advantage of the enhancements of the system.

Describes a non-destructive sampling procedure which records and preserves the topography of a metallographic specimen as a negative relief on a plastic film (replica).

Understanding, predicting, detecting and controlling high-temperature hydrogen attack (HTHA), have been elusive goals of materials engineers and scientists for over 70 years. The destruction of low alloy steel components exposed to hydrogen through...

Rapid industrial and technological growth throughout the world makes it necessary to develop new materials along with advanced Non-Destructive Testing (NDT) Methods to ensure their quality without premature failures. The complex modern system, where...

CUI (Corrosion Under Insulation) has always been a challenge for plant operators, quality assurance/reliability engineers and equipment owners. It is hard to identify the problem until it has become an emergency situation, often leading to unit shut...

We have been introduced to Infrared Thermography (IRT) since World War I and over the last decade the application of this technique has gained impetus. Today, the IRT application is widely used and accepted by many industries such as power...

History has taught us that we should trust, but verify! Verification of alloys to ensure they are composed of the correct alloying elements has been the realm of handheld x-ray fluorescence for the past four decades. Industries ranging from...

Ultrasonic thickness gages have progressed a long way since their early development in the 1960's. The first thickness gages were large and bulky although they used the same conventional longitudinal (compressional wave) techniques still in use...

High energy piping (HEP) systems, main stream lines and hot reheat lines (typically low chrome molybdenum steels), are susceptible to creep damage can lead to leaks, and in extreme cases, catastrophic rupture. To ensure safe and reliable...

A picture is worth a thousand words and thousands of dollars. There are many instances where in-service inspection reports are greatly enhanced by including photographic documentation. Using a conventional high quality 35 mm camera requires...

You're at 32,000 feet in an airplane when you look out the window. You observe the wing of the jet moving up and down with the turbulence, like a child bending a coat hanger over and over again until the wire fractures into two pieces. You wonder...

This paper covers most of the common (and some not so common) types of NDE methods for heat exchanger (HX) tubular in-service inspections. In addition to noting some of the various advantages and limitations with these methods, the paper covers heat...

The following is an interview with Scot Haines, (Corrosion Engineering Advisor). The IJ wishes to thank Scot and the Hess Corporation for taking the time to share with the "IJ" community.

A unique technique for inspecting the floors of aboveground storage tank's (AST) emerged in the late 90's based on in-service robotic technology. The technology has come a long way since then, with new inspection and tank cleaning capabilities,...

Most common radiographic practices for circumferential weld testing are single wall and double wall techniques with certain variations in technique details. Different Codes deal with the number of exposures required and applicability of the...

The integrity of pipelines is a natural concern for pipeline operators, and so the ability to detect corrosion, erosion and mechanical damage in pipes is therefore of significant interest. Traditional methods of detection, such as pigging and...

Degradation of materials with time during service is a common phenomenon for all engineering components. Hence periodic inspection is required to ensure structural integrity and availability for service. During in-service inspection (ISI), wall...

Tube Inspection is a vital tool for the refining and petrochemical industries. Heat exchangers and condensers are designed to sustain 100% separation between the products in the tube (tube side) and the products in the vessel (shell side). A...

On 11 December 2005, fuel at the Buncefield storage ter- minal near London exploded. The incident and immediate aftermath were described in the March-April 2006 edition of IJ. The investigation into the disaster began at the end of January. Three...

The term "certification" has been used and abused over the decades since the 1960's when American Society for Nondestructive Testing (ASNT) published its first Recommended Practice, SNT-TC-1A, 2001, our comments are meant to clear up an de-mystify...

A new national research centre located in Port Talbot, Wales, is set to play a critical role in ensuring the future safety of materials and components. The Non-Destructive Testing (NDT) Validation Centre was officially opened on 6 February 2006 by...

Ever think there might be a better way to select an NDT services vendor other than fee simple bidding. Sure, you have - especially after getting knee deep into an important project only to discover that the low bidder for NDT services was unable to...

This survey did not make metrics the primary focus. More importantly, our focus was on practices that lead to better performance. You still have to link these practices to performance.

Have you ever thought of a more definitive way to express what we need today from people in all walks of life than INTEGRITY? As engineers and inspectors, have you stopped to think of how much you depend on the integrity of those charged with...

Part 1 in this 2 parts series laid the technical foundation for the methodology and technology. Part 2 will now demonstrate both through actual applications.

Is calibration of NDT or any other equipment necessary? The answer is certainly Yes! But a question still arises. Why? Because in the case of NDT it is required by national and international standards. Many NDT standards require that a system of...

The ultrasonic Time of Flight Diffraction (TOFD) technique was developed for the UK nuclear industry during the 1970s to provide a method for measuring the height of planar flaws. TOFD is now generally recognized as the most accurate ultrasonic...

Radiography is the most widely used volumetric examination technique for non-destructive evaluation of components, as it offers the advantage of direct viewing of the flaw image, judging the type of flaw and provides a permanent record. Flaw...

Having the ability to substantially extend tube life in Steam Reformers is essential in maximizing use of capital investments in Methanol, Hydrogen, and Ammonia Plants. With the price of nickel at an all time high, the cost of installing a single...

The figures included in this article provide visual evidence of the effectiveness of the microwave NDE technique. Note the clarity of the internal defects and structures of interest apparent in all of the scans.

We are happy to announce the 10-year anniversary of the inaugural issue of the Inspectioneering Journal!

Once the microwave inspection method was determined to be capable of providing reliable and meaningful inspection results for defects located on the exterior, interior, and interior surfaces of non-metallic components, potential industry...

The number of FFS assessments carried out by inspection engineers is expected to increase in the future, as operators "sweat" their ageing process equipment. The parameters required for assessments can be quite complex and interdependent. Therefore,...

Nearly ten years ago the magnetostrictive sensor (MsS) technology was reported in this journal (July/August 1996 Issue, Volume 2 Issue 4) as a method to detect corrosion in insulated piping. At that time, the MsS Technology consisted primarily of...

Several years ago, a need was identified to develop an improved nondestructive inspection method to volumetrically inspect dielectric materials. Specifically, an inspection method for detecting defects in rubber expansion joints was needed to assist...

Reliable "intelligent pig technology" is now readily available to the refining industry which can provide quick / comprehensive inspection to both "convection" and "radiant" sections in process furnace piping coils. Both tabular data formats along...

The impetus for the development of LRUT is that ultrasonic thickness checks for corrosion, erosion, etc. are localised, in that they only measure the thickness of the area under the UT transducer.

Zetec acquired Power Generation Business assets located in the R/D Tech facilities primarily in Quebec, Charlotte, North Carolina, and Deep River, Ontario, Canada. Assets include the rights to current and planned products developed by the Power...

Exactly two years ago, an interview with John Nyholt appeared in the “IJ”. New ground will be covered in this interchange. We at the IJ thought it might be valuable to spend some time chatting about his background, challenges he has faced...

During the past two years, a new High Resolution Gamma Ray Detector Array System to detect and measure small corrosion pits in real-time in the inservice piping in process industries, has been in development. This High Resolution Gamma Ray...

John has primary responsibility for NDE consulting and troubleshooting for BP around the world in the refining, chemical and gas processing industries. We at the IJ thought it might be valuable to spend some time chatting about his background,...

We have discussed various factors that can affect the reliability of NDE techniques (i.e., probability of detection - POD and sizing accuracy) in Part 1. In general, it is difficult to quantify these uncertainties. In fact, it is impossible to fully...

Safety, environmental and economic pressures are motivating process industry (e.g. refineries & petrochemical plants) operators to consistently improve equipment reliability performance, optimize expenses and more accurately target resources where...

A typical risk based inspection (RBI) analysis should include past inspection results, tempered by confidence in those results. For example, API's (American Petroleum Institute) RBI methodology and software when calculating the likelihood of failure...

Hydrogen-induced cracking is a damage mechanism commonly observed in the petroleum refining industry [1, 2]. The damage appears as laminar cracks and blisters, which can link up in the through-wall direction to form stepwise cracking.

Inspectioneering caught up with Dave Wang at the American Petroleum Institute’s (API) Spring 2001 Refining meeting in Atlanta, Georgia. We spent some time, near the pool at a break between meetings, discussing Dave’s background, experiences...

In a previous edition of IJ, we alerted readers to a proposal to the Texas PE Board that would require NDT inspector certification according to CP-189 (instead of SNT-TC-1A), which would effectively eliminate limited-scope certifications.

The objective of this joint industry project is to develop and commercialize a non-intrusive system for mapping the thickness of aboveground storage tank (AST) bottoms using Lamb wave tomography.

This article describes a new inspection technology for rapid, on-stream,quantitative examinations of piping under support areas. This portable production system has been in commercial operation in the major U.S. Gulf Coast refineries for the past...

I was certified within days of my entry into the business. Inside three months, I had performed as lead technician on several refinery inspection projects, as well as skid mounted oil and gas compressor units. I had also performed ultrasonic weld...

In the petrochemical industry, we have noticed that many separate organizations are attempting to improve the quality of engineering and inspection. For example, many readers are familiar with the efforts of ASME (Post-Construction Code...

In part 1 of this article we covered the importance of quality assurance of UT data, that is, understanding for each particular application, the accuracy required of the UT data, and new ways/graphical program to analyze and show the...

The American Paper Institute Recovery Boiler Reference Manual Volume 1, October 1979, indicates that the two main goals of conducting ultrasonic thickness (UT) inspections are to determine (1) the current tube wall thickness and (2) the rate of...

Do You Know All You Need To Know About The People Who Perform Your NDT? Could the following scenario be played out in your plant, on your equipment, on your watch? The year is 1968. The time is 3 PM on Friday. Two fairly young men are...

This article covers the use of permanently attached ultrasonic transducers for inspection and process plant equipment condition monitoring while in service.

This is part three of a three part article for the IJ describing some of the advanced on-stream inspection (OSI) methods available for use in inspection of pressure equipment in the petroleum and petrochemical industry. These methods can be used,...

This three-part article describes some of the advanced on-stream inspection methods available for use in inspection of pressure equipment in the petroleum and petrochemical industry. These methods can be used, under the right circumstances, to...

Southwest Research Institute (SwRI) has developed an innovative method for rapid screening of heat exchanger tubing using Guided Wave technology. This screening method can lead to an improvement in heat exchanger reliability and a reduction in the...

Some Middle Eastern and European operators are now using AE successfully to screen tanks for internal inspection by listening for active tank bottom corrosion, and then grading the tank as high, medium or low need for internal inspection.

Faced with stricter OSHA regulations and increased competitiveness in the global market, process facilities have looked toward a technical solution, including man-less entry into vessels, pressure vessels, and tanks for their internal inspections.

Visual inspection is the most common nondestructive testing method. For critical applications, machine vision technology provides advantages over visual inspection.

The debate about advantages and drawbacks of the application of the TOFD (time of flight diffraction) approach for ultrasonic weld inspection should not forget the original reasons for its introduction in the 1960s. The major advantage at that time...

During the past year, WIS has presented a number of papers about EMATs. The type of discussions that have followed the presentations has surprised us. The overall view of industry to EMATs has been: "Aren't EMATs still just a good lab tool? There...

Furnace tubes in the petrochemical and refining industries lengths' can exceed 2,000 ft., often with multiple serpentine bends. This can make them extremely difficult to inspect using conventional NDE methods. The following inspection tool (FTIS)...

The use of Infrared Thermal Imagers, particularly for temperature measurement within an operating furnace environment, is reliant on the accurate evaluation of specific parameters, which the pyrometer requires in order to produce true temperature...

Radiographic film provides an inexpensive method of ensuring the quality and structural integrity of construction over time. Much of today's analysis being performed with Non Destructive Test (NDT) radiographic film is done visually using light...

This is an update on NDE research and development activities previously reported on in the Inspectioneering Journal. Companies wishing to join/contribute to these groups' activities, provide input and direction, and reap the benefits should contact...

This is the fourth in a series of articles on piping inspection that I'm writing for the Journal. One of the previous ones dealt with improving thickness data taking accuracy with digital ultrasonic methods. This article is a "sister article" that...

AWS, in conjunction with the Edison Welding Institute and The Welding Institute, are offering a program for the certification of NDE operators. The certification follows the operators. Areas for certification are PT (penetrant testing), MT...

Engineering, Procurement and Construction (EP&C) companies have a monumental task to maintain accurate NDE records on major new construction projects. Fluor Daniel has developed and put in use over the last several years a database program for...

The basic approach to the inspection and repair procedure for welding has barely altered for three decades. The normal practice has continued to be to inspect a weld only after the welding programme is complete. Thus by the time a defect is...

This article is a practical review of Nondestructive Examination (NDE) methods that can be used to find Erosion/Corrosion (E/C) and/or Corrosion wear in fossil fuel power piping systems. The article is based on experience with PG&E's E/C detection...

Engineers and scientists at Southwest Research Institute (SwRI) in San Antonio, Texas, may have found a cost-effective and practical method of detecting ID and OD corrosion of insulated piping systems.

We all have a responsibility to perform the best job we can for our employers/customers. That is why I am sharing my thoughts with you, my clients, the Inspectioneering Journal readers. In 12 years of being on the owner/user side of the fence, as...

A recent in-depth analysis of nondestructive Testing Services Markets indicates that after very slow overall growth in 1993 and 1994, these markets have resumed growing in 1995. The combined U.S. and Canadian market for nondestructive testing...

The Remote Field Electromagnetic Technique, often referred to as RFEC (remote field eddy current), is used to identify corrosion in ferromagnetic tubes. Available for less than ten years, many people are not familiar with its applications.

In our inspection organizations, we have identified a number of critical success factors (CSF's) which are vitally important if we are to achieve the level of pressure equipment reliability and integrity to which we aspire. One of our CSF's is the...

Nelson Curve changes in the late 1980's provided cause for Shell Oil Company to look at more reliable NDE non-destructive evaluation methods for assessment of materials/equipment in high temperature hydrogen service. The primary change motivating...

In May 1995, Omega International Technology, Inc., began testing a new system to measure pipe wall thicknesses using digital radiography (RT) scanning. This new system has the potential for being faster, less labor intensive, and shown improved...

PERF (Petroleum Environmental Research Forum), a mechanism used successfully for joint industry environmental projects, is being considered for NDE related research. Many of the same companies using the approach for environmental challenges make up...

The U.S. Department of Energy's Idaho National Engineering Laboratory (INEL) is leading an industry/university/national laboratory team to develop two NDE technologies that will economically extend refinery plant lifetime while continuing to protect...

Low-energy piping system failures in power-generating facilities are often the result of fouling and corrosion. These degradation mechanisms can affect the capacity of piping for fluid-carrying, the heat transfer rates of heat exchangers, and the...

Petrochemical and energy utility industries require a methodology which will allow them and the governing regulatory authorities to make technical and financially sound decisions for the repair or replacement of pressure vessels which suffer damage...

Over the past ten years a broad family of laser-based nondestructive testing systems has been in development. These tools are used for the inspection and measurement of internal surfaces of tubes ranging in size from 5/8-inch to 3-inches in...

For reason of economy, the hot reheat pipework in many US power plants is fabricated from seam-welded low chrome-moly carbon steel spools. Unlike girth butt welds, where the critical weldment microstructures can off-load stress to the stronger...

High energy piping (HEP) systems, main steam lines and hot reheat lines (typically low chrome molydbdenum steels), are susceptible to creep damage. Such damage can lead to leaks, and in extreme cases, catastrophic failure.