Meeting industry needs

Managing the integrity of engineered assets – to

achieve operational excellence, maximum performance
and the highest safety and environmental standards,
while simultaneously minimising costs – is complex and
challenging for today’s industrial operators.

In response to this, TWI offers world-leading asset

integrity management services based on more than 50
years of accumulated experience in engineering R&D,
deployment and consultancy.

Over 150 engineers, technicians and consultants work in

collaboration to conceive and implement asset integrity
management strategies designed to avoid engineering
failure, ensure compliance and optimise operating and
maintenance expenditure. We offer a full range of services
including tailored inspection, component testing and
failure investigation.

Using our state-of-the-art laboratories, we provide

mechanical and non-destructive testing for structures
and components of all shapes, sizes and specifications,
in ambient and aggressive environments. We continue to
invest in new equipment and facilities in order to exploit
the opportunities provided by evolving technologies and
processes.

As an Industrial Member company of TWI, you can draw

on our multi-disciplinary teams of experts for independent
and impartial advice and solutions to technical issues. We
undertake single client projects as well as joint industry
projects where several Member companies join forces to
address a particular industrial or sector-based issue.

TWI sits on many European and international standards

committees, giving us a unique insight into the dynamic
needs of industry. Our integrity management services
are utilised across major industries including oil and
gas, aerospace, nuclear, defence, wind energy, power,
automotive, rail and construction.

Advanced non-destructive testing

TWI provides advanced and conventional non-destructive testing (NDT) services for the inspection of structures, both
on and off-site, including pipelines, storage tanks, risers, rail tracks, ship hulls, wind turbines and more. We develop and
optimise inspection systems to meet industry needs and our field services are in demand worldwide.

Our expertise includes developing techniques and procedures for: array ultrasonic methods such as phased array and full
matrix capture; long-range guided wave methods; digital radiography; eddy current arrays; and electro-magnetic acoustic
transducer based methods. In addition, we have developed a method for long-term testing of polyethylene pipe joints.

TWI can also help review inspection procedures for clients from across all industry sectors and provide an independent
critical assessment. Where required, we can generate novel techniques to meet pre-determined criteria as well as
formulate and implement new procedures.
Non-destructive testing for additive
manufacturing
We undertake X-ray computed tomography (XCT), a
powerful non-destructive testing technique highly suited
to additive manufacturing (AM) part inspection, for
clients in our own laboratories. It provides volumetric
3D density data on the entire internal structure of the
scanned object and can output detailed, 2D cross-
sectional images. Alternatively, we can deploy ultrasonic
techniques on large additive manufactured parts and
during manufacture on site. Surface defects can be
reliably detected using eddy current inspection and dye
penetrant techniques.
Robotics and automation
TWI’s 6-axis industrial robot system, for the automated
inspection of complex geometries, deploys advanced
ultrasonic testing sensors and can automatically inspect
pre-programmed components in a fraction of the time
it usually takes. As a result, we offer clients timely
services in offline scan path planning using CAD input;
pulse echo and through transmission; phased array and
full matrix capture; and water squirts or full immersion.
The system is scalable to suit component size and
incorporates a full suite of acquisition and analysis tools
with 3D data display. In exciting developments, we are
now engineering wall-climbing and swimming prototype
NDT robots toward the final technology readiness levels Non-destructive testing product
and are on course to commercialise at least two robotic
NDT systems. One mobile system will operate in oil and
development
petrochemical storage tanks to detect corrosion and
We have a long history of new product development
pitting on the floors and walls while submerged in liquids.
based on NDT research and collaboration with
The other will climb on wind towers to inspect blades
international industry partners. This combined knowledge
using shearography.
and capability enables us to take NDT technologies to
higher technology readiness levels (TRLs) and provide
support for fast-track innovation, enabling pioneering new
NDT products to reach commercial readiness and achieve
market success. An example of this is TWI’s PolyTest™ –
a portable system for the volumetric NDT of electrofusion
and butt fusion joints in polyethylene pipe.
Clear ultrasonic imaging software
Crystal™ by TWI is a real-time, versatile, ultrasonic, full
matrix capture/total focusing method inspection software
package. Built around a robust, scalable architecture, it
can be deployed in a wide variety of industry scenarios
from small-form-factor systems comprising a laptop and
portable pulsar/receiver, through to factory solutions
utilising rack-mounted hardware with support for up to
three pulsar/receiver units. We provide services using
TWI’s Crystal™ and it is also available to purchase
separately.
Qualification and validation
TWI’s qualified personnel provide help, advice and
information on the complete testing qualification
process, including selection of appropriate standards
and codes, preparation of technical justifications and the
manufacture of qualification trials specimens.
Third party inspection
We undertake third party oversight in all NDT inspection
techniques, overseeing levels of qualification up to EN 473
and ASNT NDT Level 3.
Condition and structural
health monitoring
TWI provides complete monitoring solutions for plant
and components, helping companies and organisations
to reduce inspection and maintenance costs, increase
efficiency and improve safety and reliability.
Structural health monitoring is concerned with the overall
structure of assets, for example wind turbines, bridges,
cranes and offshore platforms. Condition monitoring deals
with machinery; mainly moving components such as gears
and bearings as well as boilers and heat exchangers.
The monitoring outputs provide owners and operators
with objective and reliable data that shows any changes
to the structure or component; an assessment can be
made of its overall health and it provides a tool for safely
extending useful life in the future. Unplanned shutdowns
can therefore be avoided and the life expectancy of plant
and machinery more accurately calculated.
Structural health monitoring
Our structural health monitoring service involves
observing a complete structure over time, periodically
sampling response measurements from an array of
sensors, extracting damage-sensitive features from
the measurements and making a statistical analysis to
determine current state of health. This process enables
early intervention and may prevent catastrophic failure
from corrosion, fatigue, or cracking.
TWI’s Acoustic Emission Hydrogen Induced Cracking
detection system (AEHIC) provides a means of identifying
whether hydrogen induced cracking is going to occur, or
is already in progress, including how it is evolving. The
resulting information can then be applied to limit the
potential for pipework damage or failure, giving greater
control over a plant’s operation and performance.
The Vibration Monitoring and Risk Analysis System for
Process Piping (VARA) from TWI uses vibration analysis
to detect structural damage. It gives operators vital data
to inform their process piping maintenance strategy;
providing a link between vibration analysis of pipework
and the likelihood of the occurrence of fatigue crack
initiation.
Condition monitoring
Condition monitoring facilitates intervention in the
early stages of machinery deterioration. We look at
components on an individual basis, using a variety of
different technologies such as acoustic emission or
guided wave and vibration analysis, to gather data which
can be analysed for signs of change. This is particularly
beneficial for machines not suited to regular inspection
access, such as offshore wind turbines or those in
continuous service.
We are currently developing digital twin technology for
condition monitoring of wind turbines, building on our
longstanding experience in the wind energy sector.
A condition monitoring system encompasses the entire
physical wind turbine, providing ongoing structural health
analysis. Simultaneously, this is mirrored virtually using a
3D model of the wind turbine in the form of a digital twin,
including input from different sensors positioned across
the physical entity, to continually feedback monitoring
data. The output is a fully comprehensive, real-time
assessment of the structural condition of individual wind
turbine assets. In the longer term, we will expand our
application of digital twin technology into other industries.
Instrumentation and monitoring Life-cycle assessment
TWI has a substantial track record in the design
and installation of instrumentation and data logging
We help companies take a through-life-cycle approach
to their assets and support run-inspect-repair-replace
systems for the measurement of service-loading or decision making. Our life-cycle assessment process
stress histories. Client services include the design and addresses each asset as a system, taking into account
application of monitoring systems; data recording such environmental factors and long-time horizons, thereby
as during trial, hydro-tests and other services operations; helping clients to calculate component life-cycle costs.
and the analysis and interpretation of data. We have
assessed a wide range of structures and components
including pressure vessels, process plants and earth
moving equipment.
The CrackFirstTM fatigue sensor system is an alternative
method of monitoring steel welded structures for long-
term fatigue usage. It enables the estimation of remaining
fatigue life and the setting of usage-based inspection
intervals. When attached adjacent to a fatigue-critical
detail, the sensor responds to the cyclic loading, changing
its output in proportion to the cumulative fatigue damage
for a typical fillet welded joint. We can advise on the use
of CrackFirst sensor systems for new structures or those
already in service.
Risk based inspection
Fitness-for-service-
TWI works with clients to develop inspection plans
assessment
based on knowledge of the risk of failure of structures
and equipment. We assess the likelihood of failure
due to damage, deterioration or degradation and the
consequences of such failure. The outcome is a cost- Our experts carry out fitness-for-service assessments,
effective inspection process, centred on the API 580/581 in accordance with API 579-1/ASME FFS-1, to determine
standards and safety compliance, which can be used with the structural integrity of plant and equipment and judge
confidence for making risk-based decisions. Using an its suitability for continued service. These incorporate
established methodology and TWI’s RiskWISE® software, fracture and fatigue management approaches such
we also develop tailored maintenance and replacement as designing to minimise failure; assessment of flaws;
solutions and provide guidance on assess management, joint and structural performance assessment using
from individual component studies through to turnkey, TWI’s IntegriWISE® fitness-for-service software; and
plant-wide projects. TWI’s RiskWISE plant inspection experimental and computational stress analysis. TWI’s
and maintenance software is integral to our risk based IntegriWISE software is also available to purchase
inspection services and is also available to purchase separately.
separately.
Engineering critical
assessment
Engineering critical assessment (ECA) uses fracture
mechanics principles to determine the defect tolerance of
structures or components due to brittle fracture, fatigue,
creep or plastic collapse. Our engineers have in-depth
knowledge of ECA codes (BS 7910 and R6) and provide
a prompt and accurate response to fracture related
problems. We use TWI’s fracture and fatigue assessment
software CrackWISE®, developed in accordance with BS
7910, which is also available to purchase separately.
Specialist mechanical
testing
Fracture toughness testing is a key input for fitness-for-
service assessments, encompassing routine tests that
require fast turnaround times through to bespoke, non-
standard fracture mechanics tests.
TWI’s knowledge of fracture toughness tests is based
on extensive involvement in standards committees,
fracture research and the design and build of customised
test facilities for ambient and aggressive environments.
We interpret complex results, such as fitting tearing
resistance curves, and explain low results or tests that do
not fully meet qualification criteria including whether the
data can safely be used.
Our services cover standard and custom fracture and
fatigue testing, including high and low-cycle fatigue tests;
resonance testing for pipelines; high speed fracture tests;
fracture toughness tests at high or low temperatures;
and fatigue crack growth tests. Bespoke test rigs can
be designed and built at TWI, tailored to clients’ specific
mechanical testing needs.
We also provide environmental testing of polymers
and non-metallic materials, which are increasingly
being selected for deployment in harsh locations. This
includes developing custom tests, interpreting results and
evaluating products.
Corrosive environment testing
TWI has specialist equipment for testing materials in
corrosive environments such as the mooring chain test
rig, with a 6000kN load capacity and a dedicated facility
for fatigue endurance and fatigue crack growth tests in
high-pressure gas. Many of our large and small-scale
mechanical, fracture and non-destructive tests can be
adapted to provide simulated service situations including
sour (H2S) and sweet (CO2); brine; seawater; high pressure;
and high or low temperature. Data from the tests we
conduct provides designers and engineers with additional
assurance of fatigue integrity before materials or
components are exposed to cyclic loading.
Full-scale pressure testing
We operate a purpose-built pressure pit test facility,
designed, built and commissioned in-house, that can
be used to test components up to 10m in length and
weighing up to 10 tonnes. Applications include full-scale
burst, wide plate, biaxial and pipe bend testing. The
facility has inbuilt CCTV for recording and monitoring
tests remotely via video and clients receive a copy of
their test footage.
Standard testing
Standard tests we undertake include Pellini, Charpy,
hardness, tensile and bend testing. Our express testing
service for standard types of fracture mechanics
specimen can provide results as test certificates with a
fast turnaround.
We also offer training in fracture toughness testing.
Fatigue integrity
management
Fatigue is relevant to all industries because it is the most
common mode of failure in structural and mechanical
components. If unchecked, it can lead to major breakdown
with potentially severe consequences to plant, equipment,
the environment and human lives.
Numerical modelling to examine stresses in mooring chain links
TWI’s fatigue specialists draw on more than 50 years’
worth of research and expertise in fatigue analysis, design,
assessment and testing. They regularly work with clients
in the oil and gas, power, construction and other industries
on the monitoring and life extension of components such
as girth welds in pipelines and risers, joints in offshore and
bridge structures and road and rail vehicle parts.
Fatigue consultancy
Whether you are developing a small component or building
a major structure, fatigue assessment at the concept
or early design stage can provide you with significant
savings. It helps to minimise the risk of design errors,
avoids the need for design changes and re-working and
can subsequently prevent costly fatigue failures.
Our fatigue engineers carry out in-depth analysis and
testing of structures. They identify the areas in which
fatigue is likely to occur, provide information on the fatigue
life improvement of existing structures and advise on
current international standards for fatigue design and
assessment.
TWI is represented on many standards committees and
plays a lead role in the development of industry standards,
some of which are BS 7608, BS 7910, Eurocode 3 and IIW
guidance documents.
We also provide expert witness for litigation cases and
arbitration for disputes concerning liability.
Fatigue lifespan prediction
In many fatigue assessments, the most difficult and
critical step is characterising the in-service loads. Once
these are known, further analysis can be carried out
to assess the expected fatigue life. Measured strains
can be used directly for fatigue lifespan prediction.
Alternatively, instrumentation to measure applied forces
and displacements in relevant locations on a structure
allows for a realistic input into finite element analysis
(FEA) models or other methods of analysis, resulting in
more accurate predictions of fatigue life.
Numerical modelling and
optimisation
Numerical modelling, optimisation and, in particular, Finite
Element Analysis (FEA) enable innovation, provide cost
savings and guarantee reliability via simulation of the
behaviour of structures under static, dynamic, thermal and
cyclic loads.
TWI’s Numerical Modelling and Optimisation team provides
modelling as an integrated engineering solution for
consultancy, long-term R&D and failure investigation,
adding great value across the oil and gas, power,
construction, transport, electronics and other industries.
Comprising engineers, mathematicians, physicists and
NAFEMS-certified Professional Simulation Engineers, it
offers expertise in a number of areas.
Fracture and fatigue integrity
For structures ranging from fire-damaged pressure vessels
to petroleum road fuel tankers, TWI can analyse complex
3D cracks under multi-axial loading conditions to identify
the safe operating life and defect tolerance of safety-
critical components. The outputs of these simulations
support advanced fitness-for-service and engineering
critical assessment by providing code-compliant fracture
mechanics simulations.
Weld modelling and distortion prediction
TWI has an extensive track record in developing and
analysing weld models to predict residual stresses,
distortion and metallurgical evolutions. These models range
from multi-pass girth welds to ship panels comprising
hundreds of single pass welds. In conjunction with state-
of-the-art optimisation routines, TWI can identify optimal
process parameters and weld sequences to minimise
distortion and residual stresses, ultimately enhancing the
performance and flaw tolerance of fabricated structures.
Material performance in aggressive
environments
Leveraging multi-scale and multi-physics simulations, TWI
simulates damage accumulation and propagation across
multiple length-scales, enabling accurate predictions of
fatigue crack growth; wear mechanisms; environmental
degradation; and progressive failure in composite
aerospace parts, subsea equipment in the presence of
corrosive fluids and nanostructured coatings.
Modelling support for additive
manufacturing
Through collaborative R&D programmes, TWI provides
modelling support for the development and adoption of
additive manufacturing (AM) technology across multiple
industry sectors. Projects include topology optimisation;
light-weighting and design-for-AM; process simulations for
selective laser melting; direct energy deposition and wire-
fed AM; and the integration of metallic micro-lattices to
support the development of novel medical devices.
Simulation of inspection and testing
procedures
Combining analytical and numerical models with
experimental validation, TWI models non-destructive
testing procedures such as guided waves and ultrasonic
inspection methods to optimise the location of sensors
and inspection intervals, leading to improved input for
engineering critical assessments.
Ultrasonic inspection of complex geometries
in immersion tank
About TWI
TWI is one of the world’s foremost independent research
and technology organisations, with expertise in solving
problems in all aspects of manufacturing, fabrication and
whole-life integrity management technologies. Established
at Great Abington, Cambridge, UK in 1946 and with
facilities across the globe, the company has a first-class
reputation for service through its teams of internationally
respected consultants, scientists, engineers and support
staff. The company employs more than 900 staff, serving
700 Member companies across 4500 sites in 80 countries.
TWI also houses a professional institution, The Welding
Institute, with a separate membership of over 6000
individuals.

TWI offers a single, impartial source of service for joining

engineering materials. Technical services range from
initial design, materials selection, production and quality
assurance, through to service performance and repair.
TWI Ltd, Cambridge, UK

TWI Ltd, Granta Park, Great Abington, Cambridge CB21 6AL, United Kingdom
1493. 09/17

Tel: +44 (0)1223 899000 Fax: +44 (0)1223 892588 E-mail: twi@twi-global.com Web: www.twi-global.com