Conventional NDT
1. Magnetic Particle Inspection (MPI) is a non-destructive testing method used to detect surface and near-surface flaws in ferromagnetic materials by magnetizing the component and applying magnetic particles that cluster at areas of magnetic flux leakage, indicating defects.
2. Liquid Penetrant Inspection (LPI), also known as Dye Penetrant Testing (DPT), is a non-destructive testing (NDT) method that uses a coloured liquid dye to detect surface-breaking defects in materials. It works by applying a penetrant, allowing it to seep into any surface cracks or voids, and then using a developer to draw the penetrant out, making the defects visible
3. Radiographic testing (RT) is a non-destructive testing (NDT) method which uses either X-rays or gamma rays to examine the internal structure of manufactured components, identifying any flaws or defects.In radiography testing the test-part is placed between the radiation source and film (or detector). The material density and thickness differences of the test-part will attenuate (i.e. reduce) the penetrating radiation through interaction processes involving scattering and/or absorption. The differences in absorption are then recorded on film(s) or through an electronic means. In industrial radiography there are several imaging methods available, techniques to display the final image
4. Ultrasonic inspection uses a piezoelectric transducer connected to a flaw detector, which in its most basic form is a pulser-receiver and oscilloscope display (A Scan display). The transducer is passed over the object being inspected, which is typically coupled to the test object by gel, oil or water. This couplant is required to efficiently transmit the sound energy from the transducer into the part.
5. Close Proximity Radiography (GAMCPR) is a method of radiographic testing that uses radiation sources normally a Se75 and shielding to reduce radiation scatter and emit low levels of radiation energy, allowing for inspections to be carried out closer to ongoing work, minimizing disruption and evacuation areas.
6. Vacuum box testing is a non-destructive method to detect leaks in areas that cannot be directly pressurized, often used to check welds, by creating a vacuum and applying a leak solution, where leaks will cause bubbles to form. The most common practise is in storage tanks and API inspections.
7. Delta ferrite testing is a non-destructive method used to measure the percentage of delta ferrite in austenitic and duplex stainless steels, ensuring proper material properties like corrosion resistance and crack prevention. It helps identify issues like hot cracking and ensures adherence to welding procedures.
8. Nital etching, a common metallographic technique, uses a solution of nitric acid and ethanol to reveal the microstructure of ferrous alloys, highlighting structural inconsistencies and flaws. Nital etching helps reveal the microstructure of metals, including grain boundaries, phases, and any defects or imperfections.
9. A borescope inspection involves using a specialized tool with a camera and light to visually inspect the internal components of machinery, engines, or pipes, allowing for remote visual inspection of otherwise inaccessible areas.
10. The copper sulfate test is a method to detect free iron or iron oxide on the surface of certain stainless steels, particularly austenitic 200 and 300 series and ferritic 400 series with 16% chromium or more, by observing copper deposits after immersion in a copper sulfate solution. The copper sulfate test is used to determine if a passivation process has successfully removed free iron from a surface, or to assess the presence of iron contamination. The test relies on an oxidation-reduction reaction where copper ions in the solution are displaced by free iron, causing copper to plate out on the surface.
Passivation Process Verification: To ensure that the passivation process has effectively removed free iron.
Clad Material Removal Inspection: To verify the complete removal of clad layers before welding on carbon steel.
Surface Integrity Assessment: To identify areas of potential corrosion or weaknesses in the material’s protective coating.
11. Positive Material Identification (PMI) is a non-destructive testing (NDT) method used to verify the chemical composition of metals and alloys, ensuring they meet specified standards and requirements for quality control and safety compliance. Positive material identification (PMI) is an essential non-destructive testing (NDT) method utilized to verify that supplied materials conform to the proper standards and specifications. Specifically, PMI is used to confirm that the chemical composition of the metallic parts has the correct percentage of key elements, this ensures that material properties such as corrosion resistance meets the requirements.
The PMI is utilized for quality control and safety compliance and is an integral part of both production and asset integrity management across many industries including oil and gas, power generation, chemical, pharmaceutical, nuclear, aerospace, and metal fabrication.
The material testing can be performed on-site before the parts go into the production process or for final products. Retroactive PMI is used to test in-service process equipment and piping systems. PMI can be utilized on a variety of part sizes – from large complex parts to things as small as the weld fill material or small fasteners.
Handheld X-ray Fluorescence (XRF) is the most common PMI method, and the portability of the hand-held equipment allows to perform PMI on-site at the production plant or factory floor. The handheld XRF instrument scans the material and provides chemical composition and alloy grade name.
12. Ultrasonic wall thickness inspection, also known as ultrasonic thickness measurement (UTM), is a non-destructive testing (NDT) method that uses high-frequency sound waves to gauge the thickness of materials, typically metals, from one side.
13. UCI (Ultrasonic Contact Impedance) hardness testing is a non-destructive method that uses ultrasonic principles to determine material hardness by measuring the frequency shift of a vibrating rod when pressed into the material, offering a quick and portable alternative to traditional methods.
14. Visual inspection is a fundamental method of examining objects or materials using the naked eye to identify defects, abnormalities, or damage, often used as a preliminary step in quality control and maintenance.