Non Destructive Testing

NON-DESTRUCTIVE TESTING FULL SCOPE OF NDT SERVICES

WWW.SGS.COM/NDT

RIGHT SERVICE – MAXIMUM RETURN Whether it is in fabrication, pipe manufacturing, pipeline, plant construction, chemical, petrochemical plants, shipyards or offshore industry, in conventional and nuclear power plants our Non-Destructive Testing (NDT) services provide quality assurance and process safety. SGS has a worldwide track record with proven performance on new construction, pipeline installation, in-service inspection and expansion projects as the total NDT solution provider. SGS’ scope of services covers both, conventional and advanced NDT

systems, provided by qualified inspectors to international standards. SGS understands better than most that the excellence of any service commences with quality and the implementation of detailed and effective inspection procedures, state-of-the-art equipment and most of all our professional people. SGS’ fast growing network of NDT inspectors is suitably trained, multifunctional and prepared to be available whenever our services are required. SGS creates added value to your business by applying improved

technologies, looking for the fastest inspection methods, integrating our workforce into your daily activities, combining technologies and carefully listening to your needs. When you need to save costs, improve quality and want to be sure of reliable production or operating processes, NDT is the tool set you need. In every stage of the life cycle of your assets SGS can contribute with added value NDT services.

SGS IS YOUR RELIABLE PARTNER, PRESENT IN ALL MAJOR INDUSTRIAL COUNTRIES AROUND THE WORLD. SGS is the global leader and innovator in inspection, verification, testing and certification services. Founded in 1878, SGS is recognised as the global benchmark in quality and integrity. With over 55,000 employees, SGS operates a network of over 1,000 offices and laboratories around the world.

CONTACT US

WWW.SGS.COM/NDT WWW.SGS.COM/NDT-TRAINING WWW.SGS.COM/AIM OR [email protected]

CONTENTS 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)

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RTJ Flange Special Ultrasonic Testing

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Fast Corrosion Screening

13

Hydrogen Induced Cracking DETECTION

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guided wave

LNG carrier cargo tank tightness test Leak Detection and Integrity Evaluation for the Membrane

LNG carrier cargo tanks have been developed to high end material engineered assets. Materials used and concepts applied are completely safeguarded by in-line monitoring of possible leakages of the gas. To ensure safe and reliable operation SGS offers pre-services leak testing of newly installed tanks. Also SGS introduces in-service leak testing and localisation when the safety system indicates possible unsafe operations. Our services are compacted and highly specialised to make the turn around time as short as possible and will both locate leaks and follow up any repair of leaks. Specifically for membrane type tankers localisation is very difficult due to its volume and limited access to the concerned area. Regardless of type and size of leak, pin hole, arc strike, micro crack and damage breakage should be repaired once localised, and SGS has developed a proven and efficient concept for this.

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Membrane Type LNG Carrier Structure In this containment system, developed by Gaz Transport & Technigaz of France, the cargo tanks are protected by a complete double side/bottom, cofferdam between each tank and trunk at topside. Cargo is carried at -163 °C at near atmospheric pressure, with the ranks featuring a 250 mm insulation and a membrane of 1.2 mm thick corrugated stainless steel sheet. Leakages detected during operation can occur due to surface cracks growing by ship movement and operation or as the result of physical damages of the bottom of the tanks due to impact stress. To locate leakages multiple technologies can be applied. Based on time frame, expected damage and history, SGS will select and apply the most suitable technology.

Leak Test Methods n

Ammonia (NH3) Leak Testing This test is performed by introducing an inert gas mixed with ammonia to the internal space of the test material and then over-pressurising. After ammonia sensitive paint is spread over the welding seams to be tested, the inert nitrogen/ammonia mixture gas is fed internally through the test material. The leak site and size can be detected by the location and diameter of the discoloration of the sensitive paint. This method is specifically used for application on welding seams.

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Helium (He) Leak Testing This test is performed by introducing helium gas into the internal space of the test material and over- pressurising. The helium gas will flow through any welding seam flaws, 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



ionised in the ion chamber by an electronic beam generated by a filament. A helium ion collector gathers only helium ions and will send an amplified signal to the indicator. The leakage can be measured by the signal strength. This method is specifically used for application on welding seams.

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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 performed in addition to other technologies in order to quickly locate easy detectable leaks that can be repaired in an early stage.

Main applications n n n n

LNG carrier (Mark III type & NO 96 type as latest version) All kinds of storage tanks Pressure chambers Heat exchangers

SGS understands like no other the importance of safe 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 specifically skilled and have a huge track record in these advanced inspections, expertise is not always available locally. Coordination takes place via our Korean expert office. We will make your docking time as short as possible and will give clear and reliable results.

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Acoustic emission Testing Detecting and Locating Defects using Acoustic Emission

Acoustic Emission Testing (AET) is a Non-Destructive testing method that is used to analyse emitted sound waves caused by defects or discontinuities. These acoustic waves are induced by small deformations, corrosion or cracking which occur prior to structure failure. Therefore with AET it is possible to locate structural defects and to monitor the tendency of discontinuities.

of some meters in between. The information collected by each of the sensors is monitored through a computer. If defects exist in some areas, the signal character of the sensor attached near to the discontinuation appears in a different way. By analysing the discontinuous signals, it is possible to grasp the defect position and suspicious area of the structure.

Inspection Technique Ultrasonic testing is one of the traditional Non-Destructive testing methods. In contrast to general ultrasonic testing, AET is a method which evaluates elasticity waves caused by the defect formed in the inward of the specimen. In a large-sized structure, several sensors are attached to the wall, leaving a space

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Application n n n n

Monitoring of pressure vessel during hydrostatic pneumatic testing Leak detection of valves In-service loose part monitoring Leak detection of a LNG ship’s tank (Secondary barrier – new building and in-service)

Advantages n n n n n n n

In-service continuous monitoring with alarms is possible Entire structure can be monitored from a few locations Global testing Integrated service of AET and pressure control Increased sensitivity compared to conventional testing methods Shorter testing time than other NDT Real time monitoring

Acoustic Leak Testing of Pipelines Leakage Detection of In-Service Pipeline by Acoustic Leak Testing

Pipelines are the most safe way of transporting chemicals and oil. However, pipelines are impacted both by the media the transport and the environment around them. To monitor the integrity of pipelines they need to be inspected regularly but what if 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 from impacting the environment as any leak location and size will be accurately identified. SmartBall SmartBall is a free swimming leak detection sphere, containing acoustic sensors that record leaks in liquid gas, oil and chemical transport pipelines. This cost-effective and easy to deploy system is highly accurate in detecting and locating leaks. SmartBall contains proprietary acoustic sensing technology to identify 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 of any leak can be located with an accuracy of a couple of meters.

The system is able to provide the pipeline operator with an approximation of any leak rate discovered. SmartBall is easily deployed using existing pig launching and receiving facilities, and can easily navigate through bends, diameter changes, valves and other potential obstructions.

Application n Routine Leak Surveys of any fluid transport pipeline (also when standard ILI tools are not applicable) n Emergency leak location, minimising product loss and clean-up costs n Validation of alarms generated by Computerised Pipeline Monitoring (CPM) systems (with leak location) n Leak location during hydro tests n Product theft 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 of a few meters. SmartBall’s leak detection sensitivity is far superior to that offered by CPM systems. n SmartBall is easy to use (similar to as a cleaning pig), and its cost effectiveness allows to routinely deploy the device. No additional equipment needs to be installed on the line. n SmartBall provides pro-active monitoring to identify small, pin-hole leaks that are not detected by conventional leak detection systems. Thereby allowing easier and less costly repairs, and avoiding more significant leaks down the road that may result in environmental damage and cost clean-up. n SmartBall reduces false alarms often generated by other systems. n SmartBall allows on-site processing for immediate results. n SmartBall can be deployed in pipelines as small as 4 inches in diameter. n SmartBall is also capable of traversing non-piggable pipelines as the ball can be much smaller than the pipeline diameter.

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Industrial 3D Tomography Nothing to hide?

For decades we have studied on 2D representations of materials to identify defects and possible causes to failure. 3D Tomography adds a new dimension to defect recognition, sizing, and characterisation. This originally purely medical applied technology has high added value in failure analysis, 3D modelling and NDT validations.

3D-Computerised Tomography Computerised Tomography (CT) visualises the physical structures in the interior of an object without physically opening or cutting it. This tool is extremely powerful to analyse root causes of failure. But also when other technologies need to be applied in the field or performance tests are conducted, 3D Tomography delivers excellent insight in defect characteristics and calibration data.

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Especially composite materials, light metals and smaller parts can be 100% inspected and analysed.

Inspection technique X-Ray generator and detector (Image Intensifier) are stationary and the sample is rotated during the examination. The digital detector registers 100’s of single cross sectional X-Ray images from 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 powerful systems to cover both micro structures and electronics as well as larger components.

Application n n n n n n n

Micro systems acceleration sensor (pores in glass adhesive, inclusion in cavity) Crack detection inside the cement or polymer parts Inspection of GRP and CRP for internal discontinuities Evaluation tests of NDT procedures to detect certain defects Generate calibration data to set up other NDT technologies Generate 3D CAD data of an existing object for reproduction (reverse engineering) Optimising production methods of components and materials

SGS integrates material testing and field application of the best NDT methods for both steel, polymer and GRP materials.

DIGITAL RADIOGRAPHY LOCATING, SIZING AND MONITORING OF CORROSION ON PIPING

On-stream radiographic imaging is one of the most used techniques for locating, sizing and monitoring of corrosion on piping when insulated. In the industrial environment of refineries and chemical plants, inspections have to be performed on a variety of difficult 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 of Computed Radiography is similar to conventional radiography, yet it has several important advantages. First of all for CR weaker isotopes can be used to expose the “films” and the other advantage is the digital readout of the wall thickness which highly improves accuracy and reproducibility. In addition to abandoning the use of chemicals, fast archiving of images is possible. The results can be fully integrated into any Asset Integrity Management (AIM) system to reliably monitor and follow up degradation. Computed Radiography uses an imaging plate instead of a film. 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 information 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 for interpretation and measurements, thus a larger range of wall thicknesses can be inspected. These images can be produced using an appreciable lower radiation dose or in less time.

INSPECTION TECHNIQUE The execution of Computed Radiography is similar to conventional radiography for the on-stream technique. The image handling is different as a phosphor image plate is used instead of a conventional film.The image plate stores 4096 grey values, which can be visually distributed in several numbers of grey values Because of this, a wide variety of 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 following piping can be done n Metal and plastics n Insulated piping n Diameter range up till 22 inches in special applications n During process (filled) and even at high temperatures up to 250 °C n Problem solving on pipelines and appendages (valves reducers, etc.)

ADVANTAGES n n n n n n n

Wall thickness can be measured digitally with higher accuracy and reproducibility Due to the higher sensitivity of the plates less radiation dose is needed The CR reports can be embedded in AIM software Results available direct after exposure No chemicals, darkroom or developer needed Images are digitally archived; no quality loss and easier to trace and view Image can be digitally enhanced and optimised for digitally interpretation

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Heat Exchanger Life Assessment System (HELAS) Remaining Life Assessment by Measuring Depth of Corrosion

Heat exchangers are vital components in your processes and good performance ensures safe and energy efficient operations throughout time. Therefore, heat exchangers are regularly inspected and taken out of operation. SGS offers a complete package of inspection in and around heat exchangers in order to create a full set of data, which is easy accessible and ready for follow-up. Several technologies and tools can be applied depending on your preference, history built so far and technical requirements. HELAS has been developed to quickly inspect heat exchangers where corrosion is expected only inside of tubes. The inspection speed is much higher than with IRIS which makes the inspection faster and more efficient. All data is directly analysed and leads to a complete life time assessment and not only a ‘wall thickness’ report. The basic principle is

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the measurement of ultrasonic immersion length converted into corrosion depth inside cooling water/air fin type tubes. Based on the maximum value of corrosion measured, extreme value analysis is performed and remaining life of the heat exchanger estimated by evaluating the maximum corrosion depth which can exist in the whole heat exchanger.

Extreme Value Analysis The depth distribution of corrosion which occurs in specific instruments or equipment is different according to particular probability distribution. Each sample’s basic distribution follows an index distribution and its maximum distribution follows Gumbel distribution. SGS calculates the remaining life by estimating the maximum corrosion with MVLUE (Minimum Variance Linear Unbiased Estimate) and MLH (Maximum Likelihood) methods.

Advantages of HELAS technology n n n n n n

All materials can be inspected High speed inspection of max. 200 mm/sec Corrosion data acquisition max. 10,000 point/sec High precision data presentation (±0.15 mm of corrosion depth) Remain Life Assessment & Transition Graphs Very comprehensive and portable system

Our service offer is a complete answer on your primary request to ensure safe operation. Our job does not end with the report only. It will end with full calculation of remaining life time and follow-up inspections.

RTJ Flange Special Ultrasonic Testing Detection of Groove Cracking without Bolt Dismantling

Many stainless steel flanges used in high pressure and temperature conditions are affected by cracking decreasing the process integrity. Up to now, general penetrant testing has been used for the flange examination but this method needs dismantling of the flange and rearrange afterwards. In case of standard ultrasonic testing the dead zone generated below bolt holes is very significant and decreases the effectiveness of inspections. SGS introduces an unique and very advanced inspection technique to inspect Ring Type Joint (RTJ) flanges for cracks inservice without a dead zone.

Inspection technique RTJ flange inspection is based on ultrasonic testing which sends ultrasonic waves to the flange top only. In contrast, SGS introduces the sound waves obliquely and vertically to the groove face and flange top as well. These scanning methods make it possible to cover all of the groove area including parts below bolt holes. With the SGS method flanges larger than 4 inches can be inspected. The time required to inspect one pair of flanges is very short, and all unnecessary cost of dismantling and mounting can be prevented unless defects have been found. This technology really supports our Asset Integrity Management (AIM) solution to make sure your assets operate safely and efficient. advantages n Inspect all the flange groove area n Unnecessary to dismantle bolts n Unnecessary to rearrange pipes

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Fast and accurate inspection for critical defects Used to determine which flanges need to be opened during turnaround projects Can be used in service up to 70 °C

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Fast Corrosion Screening Advanced Ultrasonic Screening Method

Most corrosion monitoring programmes are focused on time based monitoring of pre-defined measurement locations. But what if corrosion occurs in other locations or suspected locations are hard to access? New technologies like Fast Corrosion Screening and Guided Wave will identify the corrosion locations that need to be monitored. These technologies add value to your Asset Integrity Management (AIM) systems by increasing the effectiveness of inspection programmes. Fast Corrosion Screening Technology Fast Corrosion Screening is a medium range ultrasonic screening technique which provides full volume inspection of material between the transmitting and receiving probes. Fast Corrosion Screening can be used on both pipes and plates, and is especially suitable for inaccessible geometries such as clamps, saddles and pipe supports. This eliminates the need for expensive shutdown but provides sufficient information to indicate areas of

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corrosion, thereby allowing effective decision-making in ensuring long term integrity of 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 for screening large distances (hundreds of meters piping per day) Fast Corrosion Screening is better in assessing specific areas, i.e. saddles and clamps. Defect classification The ultrasound signals provide an indication of defect severity. The signal responses can provide an indication of 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 following defect extend A) Nominal wall thickness loss of < 10% (approximately) of through-wall extend for any defect present B) Defect present has a through-wall extend which is likely to be between ~10% and 30/40%

C) Defect 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 of material between the probes n Suitable for steel pipes and plates n Sensitive to both internal and external surface degradation n Signal response gives information on defect severity n Tolerant to typical field surface conditions and thin coating n Recommended for wall thickness ~3 to 100 mm n Pipe diameters > 4 inches n Suitable for inaccessible geometries such as inspecting under clamps and saddles, pipe supports, tank floors and half buried pipes

Hydrogen Induced Cracking detection Safety Evaluation and HIC Monitoring on Piping and Vessel

Hydrogen Induced Cracking (HIC) is a failure mechanism resulting in sudden exposures and cracks due to growing laminations inside the base material and welds. Hydrogen Induced Cracking is a mechanical fracture caused by penetration and diffusion of atomic hydrogen into the internal structure of steel, which changes into molecular hydrogen at internal interface between non-metallic inclusion and base material. Due to its nature it is extremely important to follow this process closely whenever first signs have been detected. Codes like API RP579 and NACE RP0296-96 give good direction for assessment of high temperature/high pressurised equipment but expertise and experience in HIC inspections is critical to assess correctly the damage stage of materials and determine when

replacement has become absolutely critical. HIC Inspection technique Our system scans steel plates and pipes. The system transfers acquired ultrasonic data to digital images with a resolution of 0.5*0.5 mm unit. After printing sections, scan plans, and side views calculations are made. Connectivity and distribution of defects and maximum damaged zones are reported. By using materials and fracture mechanical strength calculation, your assets are evaluated for safe use and monitoring. Application n Pipelines, towers, vessels, heat exchangers in aqueous sulphide environment of oil industry facilities, petrochemical plants and oil transportation

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Parts where hydrogen corrosion has occurred and accurate testing is needed Scanner range: axial radius max 300 mm Possible testing specimen: pipe, curved pipe, spherical surface, flat 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 of real defect size n Quantitative analysis, permanent integrity of data, periodic monitoring and side by side analysis n Identify the need to apply further NDT to confirm or increase integrity

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guided wave ADVANCED CORROSION INSPECTION TECHNOLOGY FOR PIPELINES AND PROCESS PIPING

Are you sure about the condition of your piping? What about the buried sections or the insulated parts? It is not easy to asses their condition in an effective way. The piping may be located high above the ground where they cross roadways or other pipe racks. What do you know after some local spot measurements? As process piping is a vital element of your facilities, good understanding of their reliability is preventing unexpected shutdowns or delays during maintenance periods. Guided Wave technology is a relatively new inspection technology with significant advantages above any other spot measurement. The Guided Wave technology screens 100% of the volume of the piping inspected for metal loss features such as corrosion and erosion. The piping can be in operation, insulated and even be buried. Guided Wave technology will

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supply more data than ever to take decisions about further inspection or even replacement.

METAL LOSS DETECTION IN PIPELINE AND PROCESS PIPING The Guided Wave technology uses low frequency guided ultrasound waves travelling along the pipe, providing 100% coverage of the pipe length. In normal application, tens of meters of piping may be inspected from a single location. Affected areas are precisely located in terms of distance from the transducer ring and highlighted for further local examination by visual or other conventional NDT methods. This non-destructive screening technique can be used without extensive scaffolding and minimises the requirement of removing insulation along the piping. Our state-of-the-art Guided Wave equipment generates waves propagating long distances, even beneath a layer of

insulation. The ultrasound is transmitted and received from one single location. The response from the metal loss feature is a function of the depth and circumferential extent of the metal loss. Guided Wave tools are available as fixed ring and modular ring. The fixed ring designs are suitable for 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 follow-up inspection and maintenance to the areas of real interest where the piping was found to be defective. This considerably reduces the time and total cost of these activities. With Guided Wave you lift your inspection plan to a much more effective level than ever before.

APPLICATIONS n n n n n n n n n

Diameters 2“ to 42“ Temperatures from -40 to 120 ºC Road crossings and buried pipelines Testing of elevated or complex piping from convenient locations Detection of corrosion/erosion under insulation Offshore process piping/riser inspection Refinery piping Chemical plant Power generation plant

FEATURES n n

Screens pipelines and process piping for metal loss features 100% coverage at rates of up to ½ km per day, dependent upon the attenuation characteristics and geometry of the pipe

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Able to distinguish between metal loss and pipe features (welds, supports, bends, etc.) Incorporation in your inspection plan aligned with VT, UT and RT inspections

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Our Enhanced Focussing Capability result in better localisation of defects Unique presentation of the inspection result with “Unrolled pipe display” software

CONTACT US 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]

www.sgs.com/NDT 15 |

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