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The need for NDT

During their service lives, many industrial components


need regular non-destructive tests to detect damage that
may be difficult or expensive to find by everyday
methods. For example:

o Aircraft skins need regular checking to detect cracks;


o Underground pipelines are subject to corrosion and
stress corrosion cracking;
o Pipes in industrial plants may be subject to erosion and
corrosion from the products they carry;
o Reinforced concrete structures may be weakened if the
inner reinforcing steel is corroded;
o Pressure vessels may develop cracks in welds;
o The wire ropes in suspension bridges are subject to
weather, vibration, and high loads, so testing for broken
wires and other damage is important.
Applications
NDT is used in a variety of settings that covers
a wide range of industrial activity.

• Automotive
– Engine parts – Pressure vessels
– Frame – Storage tanks
• Aviation / Aerospace – Welds
– Airframes – Boilers
• Spaceframes
– Heat exchangers
– Powerplants
• Propellers – Turbine bores
• Reciprocating Engines – In-plant Piping
• Gas Turbine Engines • Miscellaneous
– Rocketry – Pipelines
• Construction • In-line Inspection using "pigs"
– Structures
• Pipeline integrity
– Bridges
• Leak Detection
• Maintenance
– Bridges – Railways
• Manufacturing • Rail Inspection
– Machine parts • Wheel Inspection
– Castings and Forgings – Tubular NDT, for Tubing material
– Corrosion Under Insulation (CUI)
Industrial plants such as Nuclear, Petrochemical, – Amusement park rides
Power, Refineries, Pulp and Paper, Fabrication
shops, Mine processing and their Risk Based – Submarines and other Naval warships
Inspection programmes. – Medical imaging applications
Methods and techniques
NDT is divided into various methods of nondestructive testing,
each based on a particular scientific principle.
These methods may be further subdivided into various techniques.
• Liquid penetrant testing (PT or LPI)
• Radiographic testing (RT)
– Digital radiography (real-time)
– Computed radiography
– SCAR (Small Confined Area Radiography)
– Neutron radiographic testing (NR)
– Computed tomography (CT)
• Impulse excitation technique (IET)
• Ultrasonic testing (UT)
– Phased array ultrasonics
– Time of flight diffraction ultrasonics (TOFD)
– Time of Flight Ultrasonic Determination of 3D Elastic Constants (TOF)
– Internal Rotary Inspection System (IRIS) ultrasonics for tubes
– EMAT Electromagnetic Acoustic Transducer (non-contact)
– laser ultrasonics (LUT)
• Electromagnetic testing (ET)
– Alternating Current Field Measurement (ACFM)
– Alternating Current potential drop measurement (ACPD)
– Direct Current potential drop measurement (DCPD)
– Eddy-Current Testing (ECT)
– Remote field testing (RFT)
– Magnetic-particle inspection (MT or MPI)
– Magnetic flux leakage testing (MFL) for pipelines, tank floors, and wire rope
Methods and techniques (cont.)
• Acoustic emission testing (AE)
• Positive Material Identification (PMI)
• Hardness testing (Brinell) (HT)
• Infrared and thermal testing (IR)
– Thermographic inspection
• Laser testing
– Profilometry
– Holographic interferometry
– Electronic Speckle Pattern Interferometry
– Shearography
• Leak testing or Leak detection (LT)
– Tracer-gas method testing Helium, Hydrogen and refrigerant gases
– Bubble testing
– Absolute pressure leak testing (pressure change)
– Halogen diode leak testing
– Mass spectrometer leak testing
• Magnetic resonance imaging and NMR spectroscopy
• Visual inspection (VT)
– Pipeline video inspection
Root Cause Analysis

Root cause analysis (RCA) is a class of problem solving methods


aimed at identifying the root causes of problems or events.

The practice of RCA is predicated on the belief that problems are best
solved by attempting to correct or eliminate root causes, as opposed
to merely addressing the immediately obvious symptoms.

By directing corrective measures at root causes, it is hoped that the


likelihood of problem recurrence will be minimized.

However, it is recognized that complete prevention of recurrence by a


single intervention is not always possible. Thus, RCA is often
considered to be an iterative process, and is frequently viewed as a
tool of continuous improvement.
General principles of root cause analysis

• Aiming performance improvement measures at


root causes is more effective than merely
treating the symptoms of a problem.
• To be effective, RCA must be performed
systematically, with conclusions and causes
backed up by documented evidence.
• There is usually more than one root cause for
any given problem.
• To be effective the analysis must establish all
known causal relationships between the root
cause(s) and the defined problem.
General process for performing and
documenting an RCA-based Corrective Action
• Define the problem.
• Gather data/evidence.
• Ask why and identify the causal relationships
associated with the defined problem.
• Identify which causes if removed or changed will
prevent recurrence.
• Identify effective solutions that prevent recurrence, are
within your control, meet your goals and objectives and
do not cause other problems.
• Implement the recommendations.
• Observe the recommended solutions to ensure
effectiveness.
Basic elements of root cause

• Materials
• Management
– Defective raw material – No or poor management involvement
– Wrong type for job – Inattention to task
– Lack of raw material – Task hazards not guarded properly
• Machine/Equipment – Other (horseplay, inattention....)
– Incorrect tool selection – Stress demands
– Poor maintenance or design – Lack of Process
– • Methods
Poor equipment or tool placement
– No or poor procedures
– Defective equipment or tool
– Practices are not the same as written
• Environment procedures
– Orderly workplace – Poor communication
– Job design or layout of work • Management system
– Surfaces poorly maintained – Training or education lacking
– Physical demands of the task – Poor employee involvement
– Forces of nature – Poor recognition of hazard
– Previously identified hazards were not
eliminated
Risk based inspection

Risk based Inspection (or RBI) is a risk-


based approach to inspection in the Oil
and Gas industries. This type of inspection
analyzes the likelihood of failure and the
consequences of the same, often in
industrial pipework. It is also called Risk
Based Asset Management (RBAM), Risk
Based Integrity Management (RBIM) or
simply Risk Based Management (RBM).
RBI objectives
RBI will assist a company to select cost
effective and appropriate maintenance and
inspection tasks and techniques, to
optimize such efforts and cost, to shift
from a reactive to a proactive maintenance
regime, to produce an auditable system, to
give an agreed “Operating window”, to
promotes Team work and to create a Risk
Management Tool.
RBI purposes
• To move away from time based inspection
governed by minimum compliance with rules,
regulations and standards for inspection.
• To apply a strategy of doing what is needed for
safeguarding integrity and improving reliability
and availability of the unit by planning and
executing those inspections that are needed.
• To provide economic benefits such as fewer
inspections, shorter shutdowns, longer run
length, and less frequent shutdowns.
• To safeguard integrity.
Sample of RBI process

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