NON-DESTRUCTIVE
TESTING
RIGHT
SERVICE
\u2013 MAXIMUM
RETURN
SGS IS YOUR RELIABLE PARTNER, PRESENT IN ALL MAJOR INDUSTRIAL COUNTRIES AROUND THE WORLD.
SGS is the global leader and innovator in inspection, veri\ue000cation, testing and certi\ue000cation services. Founded in 1878, SGS is recognised as the global benchmark in quality and integrity. With over 55,000 employees, SGS operates a network o\ue001 over 1,000 o\ue001\ue000ces and laboratories around the world.
Whether it is in \ue001abrication, pipe manu\ue001acturing, pipeline, plant construction, chemical, petrochemical
plants, shipyards or o\ue001\ue001shore industry, in conventional and nuclear power plants
our Non-Destructive Testing (NDT) services provide quality assurance and process sa\ue001ety. SGS has a worldwide track record with proven per\ue001ormance on new construction, pipeline installation,
in-service inspection and expansion projects as the total NDT solution
provider. SGS\u2019 scope o\ue001 services covers both, conventional and advanced NDT
systems, provided by quali\ue000ed inspectors to international standards. SGS
understands better than most that the excellence o\ue001 any service commences with quality and the implementation
o\ue001 detailed and e\ue001\ue001ective inspection procedures, state-o\ue001-the-art equipment
and most o\ue001 all our pro\ue001essional people. SGS\u2019 \ue001ast growing network o\ue001 NDT inspectors is suitably trained,
multi\ue001unctional and prepared to be available whenever our services are required. SGS creates added value to your business by applying improved
technologies, looking \ue001or the \ue001astest inspection methods, integrating our
work\ue001orce into your daily activities, combining technologies and care\ue001ully listening to your needs.
When you need to save costs, improve quality and want to be sure o\ue001 reliable production or operating processes,
NDT is the tool set you need. In every
stage o\ue001 the li\ue001e cycle o\ue001 your assets SGS can contribute with added value
04 LNG CARRIER CARGO TANk TIGHTNESS TEST
06 ACOUSTIC EMISSION TESTING
07 ACOUSTIC LEAk TESTING OF PIPELINES
08 INDUSTRIAL 3D TOMOGRAPHY 09 DIGITAL RADIOGRAPHY
10 HEAT EXCHANGER LIFE ASSESSMENT SYSTEM (HELAS)
11 RTJ FLANGE SPECIAL ULTRASONIC TESTING 12 FAST CORROSION SCREENING
13 HYDROGEN INDUCED CRACkING DETECTION
14 GUIDED WAVE
LNG carrier cargo tanks have been developed to high end material engineered assets. Materials used and concepts applied are completely sa eguarded by in-line monitoring o possible leakages o the gas. To ensure sa e and reliable operation SGS o ers pre-services leak testing o newly installed tanks. Also SGS introduces in-service leak testing and localisation when the sa ety system indicates possible unsa e operations.
Our services are compacted and highly specialised to make the turn around time as short as possible and will both locate leaks and ollow up any repair o leaks. Speci cally or membrane type tankers localisation is very di cult due to its volume and limited access to the concerned area. Regardless o type and size o leak, pin hole, arc strike, micro crack and damage breakage should be repaired once localised, and SGS has developed a proven and e cient concept or this.
MEMBRANE TYPE LNG CARRIER STRUCTURE
In this containment system, developed by Gaz Transport & Technigaz o France, the cargo tanks are protected by a
complete double side/bottom, co erdam between each tank and trunk at topside. Cargo is carried at -163 °C at near atmospheric pressure, with the ranks
eaturing a 250 mm insulation and a membrane o 1.2 mm thick corrugated stainless steel sheet.
Leakages detected during operation can occur due to sur ace cracks growing by ship movement and operation or as the result o physical damages o the bottom o the tanks due to impact stress. To locate leakages multiple technologies can be applied. Based on time rame, expected damage and history, SGS will select and apply the most suitable technology.
LEAk TEST METHODS
n Ammonia (NH3) Leak Testing This test is per ormed by introducing an inert gas mixed with ammonia to the internal space o the test material and then over-pressurising. A ter ammonia sensitive paint is spread over the welding seams to be tested, the inert nitrogen/ammonia mixture gas is ed internally through the test material. The leak site and size can be detected by the location and diameter o the discoloration o the sensitive paint. This method is speci cally used
or application on welding seams. n Helium (He) Leak Testing
This test is per ormed by introducing helium gas into the internal space o the test material and
over-pressurising. The helium gas will fow through any welding seam faws, cracks or pin holes. Any leaking helium gas will be sucked into a probe connected to a helium mass spectrometer. Then the gas will be
LNG CARRIER CARGO TANk
TIGHTNESS TEST
ionised in the ion chamber by an electronic beam generated by a
lament. A helium ion collector gathers only helium ions and will send an ampli ed signal to the indicator. The leakage can be measured by the signal strength. This method is speci cally used
or application on welding seams. n Pressure Change Measurement
Testing
The total leakage can be measured by evaluating the inside pressure change related to the time passed in a decompressed or pressurised test object. This test is per ormed in addition to other technologies in order to quickly locate easy detectable leaks that can be repaired in an early stage.
MAIN APPLICATIONS
n LNG carrier (Mark III type & NO 96 type as latest version)
n n n
All kinds o storage tanks Pressure chambers
Heat exchangers
SGS understands like no other the importance o sa e investment and cargo. Our network covers all important ports around the globe and we will be at your service anywhere and anytime. Since the teams are speci cally skilled and have a huge track record in these advanced inspections, expertise is not always available locally. Coordination takes place via our Korean expert o ce. We will make your docking time as short as possible and will give clear and
Acoustic Emission Testing (AET) is a Non-Destructive testing method that is used to analyse emitted sound waves caused by de ects or discontinuities. These acoustic waves are induced by small de ormations, corrosion or cracking which occur prior to structure ailure. There ore with AET it is possible to locate structural de ects and to monitor the tendency o discontinuities.
INSPECTION TECHNIqUE
Ultrasonic testing is one o the traditional Non-Destructive testing methods. In contrast to general ultrasonic testing, AET is a method which evaluates elasticity waves caused by the de ect
ormed in the inward o the specimen. In a large-sized structure, several sensors are attached to the wall, leaving a space
o some meters in between. The in ormation collected by each o the sensors is monitored through a computer.
I de ects exist in some areas, the signal character o the sensor attached near to the discontinuation appears in a di erent way. By analysing the discontinuous
signals, it is possible to grasp the de ect position and suspicious area o the structure.
APPLICATION
n Monitoring o pressure vessel during hydrostatic pneumatic testing
n n n
Leak detection o valves
In-service loose part monitoring Leak detection o a LNG ship’s tank
(Secondary barrier – new building and in-service)
ADVANTAGES
n In-service continuous monitoring with alarms is possible
n Entire structure can be monitored rom a ew locations
n Global testing
n Integrated service o AET and pressure control
n Increased sensitivity compared to conventional testing methods
n Shorter testing time than other NDT n Real time monitoring
ACOUSTIC
EMISSION TESTING
Pipelines are the most sa e way o
transporting chemicals and oil. However, pipelines are impacted both by the media the transport and the environment
around them. To monitor the integrity o pipelines they need to be inspected regularly but what i In-Line Inspection (ILI) is not possible and Guided Wave Ultrasound is not applicable because the pipeline is buried? Acoustic Leak
Detection will prevent your asset rom impacting the environment as any leak location and size will be accurately identi ed.
SMARTBALL
SmartBall is a ree swimming leak detection sphere, containing acoustic sensors that record leaks in liquid gas, oil and chemical transport pipelines. This cost-e ective and easy to deploy system is highly accurate in detecting and locating leaks. SmartBall contains proprietary acoustic sensing technology to identi y and locate very small leaks (< 0.5 gpm). SmartBall travels inside the pipeline whereby the device directly passes any leak – clearly capturing the noise created by even the smallest leaks.
Conventional pig tracking units are used to track the device as it travels through the pipeline, whereby the location o any leak can be located with an accuracy o a couple o meters.
The system is able to provide the
pipeline operator with an approximation o any leak rate discovered. SmartBall is easily deployed using existing pig launching and receiving acilities, and can easily navigate through bends, diameter changes, valves and other potential obstructions.
APPLICATION
n Routine Leak Surveys o any fuid transport pipeline (also when standard ILI tools are not applicable)
n Emergency leak location, minimising product loss and clean-up costs
n Validation o alarms generated by Computerised Pipeline Monitoring (CPM) systems (with leak location) n Leak location during hydro tests n Product the t detection
SMARTBALL PIPELINE MONITORING ADVANTAGES
n SmartBall maps a pipeline at high resolution – locating leak as small as 0.5 gpm, leak locations are
accurately located up to an accuracy o a ew meters. SmartBall’s leak detection sensitivity is ar superior to that o ered by CPM systems. n SmartBall is easy to use (similar
to as a cleaning pig), and its cost e ectiveness allows to routinely deploy the device. No additional equipment needs to be installed on the line.
n SmartBall provides pro-active
monitoring to identi y small, pin-hole leaks that are not detected by
conventional leak detection systems. Thereby allowing easier and less costly repairs, and avoiding more signi cant leaks down the road that may result in environmental damage and cost clean-up.
n SmartBall reduces alse alarms o ten generated by other systems.
n SmartBall allows on-site processing or immediate results.
n SmartBall can be deployed in pipelines as small as 4 inches in diameter.
n SmartBall is also capable o traversing non-piggable pipelines as the ball
can be much smaller than the pipeline diameter.
ACOUSTIC
LEAk TESTING OF PIPELINES
INDUSTRIAL
3D TOMOGRAPHY
For decades we have studied on 2D representations o materials to identi y de ects and possible causes to ailure. 3D Tomography adds a new dimension to de ect recognition, sizing, and characterisation. This originally purely medical applied technology has
high added value in ailure analysis, 3D modelling and NDT validations.
3D-COMPUTERISED TOMOGRAPHY
Computerised Tomography (CT) visualises the physical structures in the interior o an object without physically opening or cutting it. This tool is extremely power ul to analyse root causes o ailure. But also when other technologies need to be applied in the eld or per ormance tests are conducted, 3D Tomography delivers excellent insight in de ect characteristics and calibration data.
Especially composite materials, light metals and smaller parts can be 100% inspected and analysed.
INSPECTION TECHNIqUE
X-Ray generator and detector (Image Intensi er) are stationary and the sample is rotated during the examination.
The digital detector registers 100’s o single cross sectional X-Ray images
rom all angles in the computer which reconstructs the inner-structural image. High speed computers process the data into a complete 3D visual comprehensive to understand and interpret. As the technology still develops, both accuracy and object size are continuously
improving. SGS operates extreme
accurate and power ul systems to cover both micro structures and electronics as well as larger components.
APPLICATION
n Micro systems acceleration sensor (pores in glass adhesive, inclusion in cavity)
n Crack detection inside the cement or polymer parts
n Inspection o GRP and CRP or
internal discontinuities
n Evaluation tests o NDT procedures to detect certain de ects
n Generate calibration data to set up other NDT technologies
n Generate 3D CAD data o an existing object or reproduction (reverse
engineering)
n Optimising production methods o components and materials
SGS integrates material testing and eld application o the best NDT methods or both steel, polymer and GRP materials.
On-stream radiographic imaging is one o the most used techniques or locating, sizing and monitoring o corrosion on piping when insulated. In the industrial environment o re neries and chemical plants, inspections have to be per ormed on a variety o di cult to reach locations, on pipes that might be isolated and where people are working around the clock. This is where Computed Radiography (CR) comes in. The
execution o Computed Radiography is similar to conventional radiography, yet it has several important advantages. First o all or CR weaker isotopes can be used to expose the “ lms” and the other advantage is the digital readout o the wall thickness which highly improves accuracy and reproducibility. In addition to abandoning the use o chemicals, ast archiving o images is possible. The results can be ully integrated into any Asset Integrity Management (AIM) system to reliably monitor and ollow up degradation.
Computed Radiography uses an imaging plate instead o a lm. The imaging plate contains photo-stimulable storage
phosphors, which retain the latent image. When the imaging plate is scanned
with a laser beam in the digitizer, the latent image in ormation is released as visible light.
This light is captured and converted into a digital stream to compute the digital image. No chemical developer is needed. The image can be digitally enhanced
or interpretation and measurements, thus a larger range o wall thicknesses can be inspected. These images can be produced using an appreciable lower radiation dose or in less time.
INSPECTION TECHNIqUE
The execution o Computed Radiography is similar to conventional radiography
or the on-stream technique. The image handling is di erent as a phosphor image plate is used instead o a conventional
lm.The image plate stores 4096 grey values, which can be visually distributed in several numbers o grey values
Because o this, a wide variety o thickness ranges can be inspected in only one image. The images can be produced using an appreciable lower radiation dose compared to conventional radiography.
APPLICATIONS
On-stream radiography on the ollowing piping can be done
n n n
Metal and plastics Insulated piping
Diameter range up till 22 inches in special applications
n During process ( lled) and even at high temperatures up to 250 °C n Problem solving on pipelines and
appendages (valves reducers, etc.)
ADVANTAGES
n Wall thickness can be measured digitally with higher accuracy and reproducibility
n Due to the higher sensitivity o the plates less
radiation dose is needed
n The CR reports can be embedded in AIM so tware
n Results available direct a ter exposure
n No chemicals, darkroom or developer needed
n Images are digitally archived; no quality loss and easier to trace and view
n Image can be digitally enhanced and optimised or digitally interpretation
DIGITAL
RADIOGRAPHY
Heat exchangers are vital components in your processes and good per ormance ensures sa e and energy e cient
operations throughout time. There ore, heat exchangers are regularly inspected and taken out o operation. SGS o ers a complete package o inspection in and around heat exchangers in order to create a ull set o data, which is easy accessible and ready or ollow-up. Several technologies and tools can be applied depending on your pre erence, history built so ar and technical
requirements.
HELAS has been developed to quickly inspect heat exchangers where corrosion is expected only inside o tubes. The inspection speed is much higher than with IRIS which makes the inspection
aster and more e cient. All data is directly analysed and leads to a complete li e time assessment and not only a ‘wall thickness’ report. The basic principle is
the measurement o ultrasonic immersion length converted into corrosion depth inside cooling water/air
n type tubes. Based on the maximum value o corrosion measured, extreme value analysis is per ormed and remaining li e o the heat exchanger estimated by evaluating the maximum corrosion depth which can exist in the whole heat exchanger.
EXTREME VALUE ANALYSIS
The depth distribution o corrosion which occurs in speci c instruments or equipment is di erent according to particular probability distribution. Each sample’s basic distribution ollows an index distribution and its maximum distribution ollows Gumbel distribution. SGS calculates the remaining li e by estimating the maximum corrosion with MVLUE (Minimum Variance Linear Unbiased Estimate) and MLH (Maximum Likelihood) methods.
ADVANTAGES OF HELAS TECHNOLOGY
n All materials can be inspected n High speed inspection o max.
200 mm/sec
n Corrosion data acquisition max. 10,000 point/sec
n High precision data presentation (±0.15 mm o corrosion depth)
n Remain Li e Assessment & Transition Graphs
n Very comprehensive and portable system
Our service o er is a complete answer on your primary request to ensure sa e operation. Our job does not end with the report only. It will end with ull calculation o remaining li e time and
ollow-up inspections.
HEAT EXCHANGER
LIFE ASSESSMENT SYSTEM
(HELAS)
Many stainless steel fanges used in high pressure and temperature conditions are a ected by cracking decreasing the process integrity. Up to now, general penetrant testing has been used or the fange examination but this method needs dismantling o the fange and rearrange a terwards.
In case o standard ultrasonic testing the dead zone generated below bolt holes is very signi cant and decreases the e ectiveness o inspections. SGS introduces an unique and very advanced inspection technique to inspect Ring Type Joint (RTJ) fanges or cracks in-service without a dead zone.
INSPECTION TECHNIqUE
RTJ fange inspection is based on
ultrasonic testing which sends ultrasonic waves to the fange top only.
In contrast, SGS introduces the sound waves obliquely and vertically to the groove ace and fange top as well. These scanning methods make it possible to cover all o the groove area including parts below bolt holes. With the SGS method fanges larger than 4 inches can be inspected. The time required to inspect one pair o fanges is very short, and all unnecessary cost o dismantling and mounting can be prevented unless de ects have been
ound. This technology really supports our Asset Integrity Management (AIM) solution to make sure your assets operate sa ely and e cient.
ADVANTAGES
n n n
Inspect all the fange groove area Unnecessary to dismantle bolts Unnecessary to rearrange pipes
n Fast and accurate inspection or critical de ects
n Used to determine which fanges need to be opened during turnaround projects
n Can be used in service up to 70 °C
RTJ FLANGE
SPECIAL ULTRASONIC TESTING
Most corrosion monitoring programmes are ocused on time based monitoring o pre-de ned measurement locations. But what i corrosion occurs in other locations or suspected locations are hard to access?
New technologies like Fast Corrosion Screening and Guided Wave will identi y the corrosion locations that need to be monitored.
These technologies add value to your Asset Integrity Management (AIM) systems by increasing the e ectiveness o inspection programmes.
FAST CORROSION SCREENING TECHNOLOGY
Fast Corrosion Screening is a medium range ultrasonic screening technique which provides ull volume inspection o material between the transmitting and receiving probes. Fast Corrosion Screening can be used on both pipes and plates, and is especially suitable or inaccessible geometries such as
corrosion, thereby allowing e ective decision-making in ensuring long term integrity o equipment. Fast Corrosion Screening provides reliable data between an extended probe separation up to 1 m. Fast Corrosion Screening is a good addition to Guided Wave inspections. Where Guided Wave inspections are more suitable or screening large distances (hundreds o meters piping per day) Fast Corrosion Screening is better in assessing speci c areas, i.e. saddles and clamps.
DEFECT CLASSIFICATION
The ultrasound signals provide an indication o de ect severity. The signal responses can provide an indication o any changes in the vessel wall (either external or internal) and based on current experience the responses are divided into three categories that correspond to the ollowing de ect extend
A) Nominal wall thickness losso < 10% (approximately) o through-wall extend
C) De ect present that has a through-wall extend which is likely to be greater than 30/40%
ADVANTAGES
n Probe separation up to 1 m
n 100% coverage o material between the probes
n Suitable or steel pipes and plates n Sensitive to both internal and
external sur ace degradation
n Signal response gives in ormation on de ect severity
n Tolerant to typical eld sur ace conditions and thin coating
n Recommended or wall thickness ~3 to 100 mm
n Pipe diameters > 4 inches
n Suitable or inaccessible geometries such as inspecting under clamps and saddles, pipe supports, tank foors and hal buried pipes
FAST CORROSION
SCREENING
Hydrogen Induced Cracking (HIC) is a ailure mechanism resulting in sudden exposures and cracks due to growing laminations inside the base material and welds. Hydrogen Induced Cracking is a mechanical racture caused by penetration and di usion o atomic hydrogen into the internal structure o steel, which changes into molecular hydrogen at internal inter ace between non-metallic inclusion and base
material.
Due to its nature it is extremely
important to ollow this process closely whenever rst signs have been detected. Codes like API RP579 and NACE
RP0296-96 give good direction or assessment o high temperature/high pressurised equipment but expertise and experience in HIC inspections is critical to assess correctly the damage stage o materials and determine when
replacement has become absolutely critical.
HIC INSPECTION TECHNIqUE
Our system scans steel plates and pipes. The system trans ers acquired ultrasonic data to digital images with a resolution o 0.5*0.5 mm unit. A ter printing sections, scan plans, and side views calculations are made. Connectivity and distribution o de ects and maximum damaged zones are reported. By using materials and racture mechanical strength calculation, your assets are evaluated
or sa e use and monitoring.
APPLICATION
n Pipelines, towers, vessels, heat exchangers in aqueous sulphide environment o oil industry acilities, petrochemical plants and oil
transportation
n Parts where hydrogen corrosion has occurred and accurate testing is needed
n Scanner range: axial radius max 300 mm
n Possible testing specimen: pipe, curved pipe, spherical sur ace, fat plate (diameter > 150 mm)
ADVANTAGES
n Very high resolution equipment giving clear data presentation n Test speed: 150 mm/sec n Scanner accuracy: Maximum
±0.5 mm
n Possibility to print an image o real de ect size
n Quantitative analysis, permanent integrity o data, periodic monitoring and side by side analysis
n Identi y the need to apply urther NDT to con rm or increase integrity
H
YDROGEN NDUCED
I
C
RACkING DETECTION
Are you sure about the condition o your piping? What about the buried sections or the insulated parts? It is not easy to asses their condition in an e ective way. The piping may be located high above the ground where they cross roadways or other pipe racks. What do you know a ter some local spot measurements?
As process piping is a vital element o your acilities, good understanding o their reliability is preventing unexpected shutdowns or delays during maintenance periods. Guided Wave technology is a relatively new inspection technology with signi cant advantages above any other spot measurement.
The Guided Wave technology screens 100% o the volume o the piping inspected or metal loss eatures such as corrosion and erosion. The piping can be in operation, insulated and even be buried. Guided Wave technology will
supply more data than ever to take decisions about urther inspection or even replacement.
METAL LOSS DETECTION IN PIPELINE AND PROCESS PIPING
The Guided Wave technology uses low requency guided ultrasound waves travelling along the pipe, providing 100% coverage o the pipe length. In normal application, tens o meters o piping may be inspected rom a single location. A ected areas are precisely located in terms o distance rom the transducer ring and highlighted or urther local examination by visual or other conventional NDT methods. This
non-destructive screening technique can be used without extensive sca olding and minimises the requirement o removing insulation along the piping. Our state-o -the-art Guided Wave
equipment generates waves propagating long distances, even beneath a layer o
insulation. The ultrasound is transmitted and received rom one single location. The response rom the metal loss
eature is a unction o the depth and circum erential extent o the metal loss. Guided Wave tools are available as xed ring and modular ring. The xed ring designs are suitable or pipe diameters up to 8 inches. For larger diameters, a modular ring up to 42 inches has been adopted.
Guided Wave inspections help you to limit ollow-up inspection and
maintenance to the areas o real interest where the piping was ound to be
de ective.
This considerably reduces the time and total cost o these activities.
With Guided Wave you li t your inspection plan to a much more e ective level than ever be ore.
GUIDED
WAV E
APPLICATIONS n n n n Diameters 2“ to 42“ Temperatures rom -40 to 120 ºC Road crossings and buried pipelines Testing o elevated or complex
piping rom convenient locations
n Detection o corrosion/erosion under insulation
n O shore process piping/riser inspection n n n Re nery piping Chemical plant
Power generation plant
FEATURES
n Screens pipelines and process piping or metal loss eatures
n 100% coverage at rates o up to ½ km per day, dependent upon the attenuation characteristics and geometry o the pipe
n Able to distinguish between metal loss and pipe eatures
(welds, supports, bends, etc.)
n Incorporation in your inspection plan aligned with VT, UT and RT inspections
n Our Enhanced Focussing Capability result in better localisation o de ects
n Unique presentation o the inspection result with “Unrolled pipe display”
so tware
SGS INDUSTRIAL SERVICES
COMPETENCE CENTRE NDT SPECIAL EXAMINATIONS
Malledijk 18, Postbus 200, 3200 AE Spijkenisse, The Netherlands T +31 181 693 703, F +31 181 693 587, [email protected]
