rs v services jan 2011

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RSV Service Manual

Plant & Equipment Non-Destructive Testing (NDT), APIInspection, NDT Level III Services, Corrosion Control,

Risk-Based Inspection and Training


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ContentsIntroduction

Conventional NDT TestingVisual Inspection (VT)

Ultrasonic Flaw Detection (UFD)Ultrasonic Thickness Measurement (UTM)Magnetic Particle Testing (MPT)Dye Penetrant Testing (DPT)

Hardness Testing (HT)Vacuum Box Testing (VBT)

Paint Dry Film Thickness (PDFT)

Advance Inspection TechniquesTime of Flight Diffraction (TOFD)Magnetic Flux Leakage (MFL)

C-Scan Corrosion Mapping

NDT Level-III Services

API Services

API 510 servicesAPI 653 Services

API 570 Services

Third Party QA/QCQA/QC Inspections

Third Party Vendor Surveillance

Risk Based Inspection (RBI)

Failure Analysis

Corrosion Control ConsultancyCorrosion Inhibitor Injection

Corrosion MonitoringCathodic Protection

Material SelectionPainting & Coating

Courses & Training ServicesConventional NDTAdvanced NDT

Plant InspectionWelding Inspection

Corrosion ControlRisk-Based Inspection


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Introduction: RSV offers Plant & Equipment Non-Destructive Testing (NDT), APIInspection, NDT Level III Services, Corrosion Control, Risk-Based Inspection andTraining during routine-inspection, in-service inspection, shutdown & turnaround andnew construction to Oil & Gas Exploration Industries, Petroleum Refineries, FertilizerIndustries, Oil & Gas Distribution Facilities, Power Generation Plants, Maritime

Industries, Chemical Industries, Nuclear Plants, Automotive Manufacturing Industries,Cement Industries, Plant, Equipment, Ship and Pipeline Construction Companies andMechanical Engineering Companies.

Reliance Swift Veritas with its highly qualified/certified field team ofEngineers, Technicians and equipment has significant experience in

managing and performing conventional and advance NDT, equipmentintegrity and corrosion control works for operating and developing projects.

Conventional NDT Testing

Visual Inspection: Visual Inspection (VI) is one of the most widely usedNon-Destructive Testing (NDT) methods for the detection of discontinuities

before they cause major problems, e.g. poor welding, surface defects,

corrosion pits, general condition, degradation, blockages and foreignmaterials. Visual Inspection means the inspection of equipment and

structures using a combination of human senses such as vision, hearing,touch and smell. Visual Inspection is sometimes carried out in conjunction

with devices such as a low power magnifying glass, boroscopes, fiberscope,

digital video boroscopes, camera systems and robotic crawler systems.

Ultrasonic Flaw Detection: Ultrasonic Testing (UT) uses high frequencysound energy to conduct examinations and make measurements. Ultrasonic

inspection can be used for flaw detection/evaluation, dimensional

measurements, material characterization, and more. Of all the applicationsof industrial ultrasonic testing, flaw detection is the oldest and the most

common. Since the 1940s, the laws of physics that govern the propagation
http://www.sgs.com/non-destructive_testing?serviceId=10061644&lobId=5550http://www.sgs.com/non-destructive_testing?serviceId=10061644&lobId=5550


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of sound waves through solid materials have been used to detect hiddencracks, voids, porosity, and other internal discontinuities in metals,

composites, plastics, and ceramics. High frequency sound waves reflectfrom flaws in predictable ways, producing distinctive echo patterns that can

be displayed and recorded by portable instruments. Ultrasonic testing is

completely nondestructive and safe, and it is a well established test methodin many basic manufacturing, process, and service industries, especially in

applications involving welds and structural metals.

Ultrasonic Thickness Measurement: Ultrasonic NDT characterizing

material thickness, integrity or other physical properties by means of high

frequency sound waves. Accuracies as high as 1 micron or 0.0001 inchare available in some applications. Precision ultrasonic thickness gauge

usually operate at frequencies between 500 KHz 100 MHz, usingpiezoelectric transducers to generate bursts of sound waves when excited by

electrical pulses. Typically, lower frequencies will be used to optimizepenetration when measuring thick, highly attenuating, or highly scatteringmaterials, while higher frequencies will be recommended to optimize

resolution in thinner, non-attenuating, non-scattering materials.


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Magnetic Particle Inspection: Magnetic Particle testing is a surface andsub-surface testing method which uses electromagnetic energy for probing

and ferromagnetic particles as indicators. This method is limited to testferromagnetic materials. It is a simple method and more sensitive to linear

defects. As the depth of defect increases, the sensitivity decreases rAPIdly.

It is a cheap and fast testing method. A defect under the influence ofmagnetic field produces leakage field which attracts the magnetic particle

sprayed on the specimen surface. Maximum response obtained from thedefects that are perpendicular to the magnetic lines of force. Either dry or

wet particles are used to detect indications. Fluorescent particles are used to

increase sensitivity. MPI uses magnetic fields and small magnetic particles(i.e. iron filings) to detect flaws in components. The only requirement from

an inspection standpoint is that the component being inspected must bemade of a ferromagnetic material such as iron, nickel, cobalt, or some of

their alloys. Ferromagnetic materials are materials that can be magnetized

to a level that will allow the inspection to be effective.

Dye Penetrant Testing: Dye Penetrant Testing is a surface testing method.

All non-porous materials can be inspected by this method. In order to bedetected, the defect must be open to surface. This is an easy and cheap

testing method most widely used in all industry. When a penetrant is applied

on the suitably cleaned material surface, it is driven into the defect bycapillary action. The capillary force depends on the physical properties such

as surface tension, the contact angle, and the size of the defect opening. Thedeveloper applied on the surface after the excess Penetrant removal bleed

out the penetrant trapped inside the defect and produce visible indication.The advantage that a liquid penetrant inspection (LPI) offers over anunaided visual inspection is that it makes defects easier to see for the

inspector. There are basically two ways that a penetrant inspection processmakes flaws more easily seen. First, DPT produces a flaw indication that is

much larger and easier for the eye to detect than the flaw itself. Many flawsare so small or narrow that they are undetectable by the unaided eye. Due

to the physical features of the eye, there is a threshold below which objects


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cannot be resolved. This threshold of visual acuity is around 0.003 inch for aperson with 20/20 vision.

Hardness Testing: Hardness is a characteristic of a material, not a

fundamental physical property. It is defined as the resistance to indentation,and it is determined by measuring the permanent depth of the indentation.

More simply put, when using a fixed force (load)* and a given indenter, thesmaller the indentation, the harder the material. Indentation hardness value

is obtained by measuring the depth or the area of the indentation.

Vacuum Box Testing:Vacuum Box is used to check for any leaks or faults

in the welding of bottom and annular plates of the tank. It is a containerwith an acrylic sheet on top with an inlet valve connecting to the Vacuum

Pump. Vacuum box bubble test is one of the safest and reliable non-destructive test method. The test is performed by applying a detergent

solution on the test area and creating a vacuum around the test surface byexternal mechanism.


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Paint Dry Film Thickness:paint dry film thickness or Coating thickness isan important variable that plays a role in product quality, process control,

and cost control. Measurement of film thickness can be done with manydifferent instruments.Understanding the equipment that is available for filmthickness measurement and how to use it is useful to every coating

operation.Dry Film Thickness is a critical measurement in the coating application

process. It provides vital information as to the expected life of the substrate,the products fitness for purpose, its appearance and ensures compliance

with a host of International Standards.

Advance Inspection Techniques:

Time of Flight Diffraction (TOFD): The TOFD technique is an ultrasonic

image-generating technique, which offers the capabilities of detection,location and sizing.

Permanent data recording with B-scan type imaging (side view)

Accurate sizing capability (height)-through-wall height most critical forfracture mechanics

Technique allows for rapid scanning

Detection and sizing almost orientation independent

Based on Time of Flight to avoid common amplitude technique sizingerrors

TOFD has a potential through-wall dimension accuracy of 1 mm and acrack growth monitoring capability of 0.3mm.

Setup virtually independent of weld configuration

Wide coverage area

The depth sizing is not dependent on the amplitude of the signals and the

corresponding errors

Because no ionizing radiation is used, the inspection does not interferewith the production process.


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TOFD inspections can therefore in general take place in parallel toproduction work during day shift.

Magnetic Flux Leakage: MFL Tank Floor Scanning is a method that candetect underside corrosion from the top and can give a full coverage of the

floor as corrosion may occur anywhere. Typically storage tanks suffer fromcorrosion at the underside of the floor bottom. Often this type of corrosion

will be localized (pitting), sometimes larger areas may be corroded MFL tools

are suited for inspection of exposed bare, painted or thinly coated carbonsteel components.

A strong magnet is used to establish a magnetic flux in the material to be

inspected. When there is no defect the uniform flux remains in the metal.

Near the defect, the flux "leaks" out of the metal. Sensors which can detect

this flux leakage are placed between the poles of the magnet and generatean electric signal proportional to the magnetic leakage flux.

Defects causing a leakage flux exceeding a predetermined threshold are

detected. The amount of leakage flux is dependent on depth, orientation,type and position (topside/bottom-side) of the defect. Defects exhibiting

various combinations of volume loss and depth can produce the same fluxleakage level. Therefore truly quantitative depth information can not be

obtained by this method. It is a qualitative not a quantitative inspection tool.

For accurate sizing of the defects ultrasonic testing can be applied after

detection.


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C-Scan Corrosion Mapping: Large volumes of plant and equipment suchas pipe work, pressure vessels, bends and elbows can be inspected using C-

Scan that produces color graphic imaging of the area scanned. For non-intrusive work, scans typically cover 0.25sq meter per scan as a maximum,

multi-scans are then are compiled into a composite to show the complete

color graphic image of the inner surface. Recent developments include thecapability to inspect plant on-line in temperatures of up to 250C.

Corrosion mapping involves scanning by straight beam probes over a

prescribed, dual axis scan pattern over a pipe or pressure vessel surface

whilst taking thickness measurements. The measurements are convertedinto digital values which are color-coded to create topographic maps of the

vessel or pipe wall thickness profile. Images (C-scans) from individual scanareas can be assembled together to create composite images covering large

areas of material. This is a very powerful technique for management

reporting or to observe widespread effects. The Micro Map system enablesdifficult access or awkward geometry components to be inspected by

ultrasonic C-scan or corrosion mapping.


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NDT UT Level III Services

Personnel qualification services, procedure development and review, thirdparty overview, witness and problem resolution.

Personnel qualification services include documentation review, training, and

qualification examinations.

Documentation review is performed to assure education, training, experience

and qualification examinations meet your code, specification and clientrequirements.

Written general and specific examinations meeting your code, specificationor client requirements for each NDT method can be developed and

administered in accordance with ASNT Recommended Practice SNT-TC-1A.

Procedure development and review can be outsourced to relieve the burdenof finding the dedicated time needed to accomplish such tasks. Industry

experience combined with extensive involvement with ASNT and ASTM

standards development ensures document(s) acceptable for use by yourNDT personnel and to your clients.

Third party overview, witness and problem resolution is a valuable resource

to ensure expected results and reduce conflict. Outsourcing the overview or

witnessing of quality activities is cost effective in assuring that specification

requirements have been met. The services provide a qualified, objectiveevaluation for problem resolution that is usually acceptable to clients andreduces the potential conflicts of direct involvement with customers.


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API Services

Inspection of Pressure Vessel, Boilers, Heat Exchangers, Storage Tank,Piping, Valve and any other pressurized equipments in Petroleum and Oil

Refineries, Chemical Plants and Power Station Shutdown and MaintenanceInspection.

API 510 services: RSV offers Professional Pressure Vessel Inspectionservices for Vessels, Boilers, Heat Exchangers and other pressurized

equipments in petroleum and oil refineries.

API 510 covers the in-service inspection, repair, alteration, and re-rating

activities for pressure vessels and the pressure-relieving devices protectingthese vessels. This inspection code applies to all refining and chemical

process vessels that have been placed in service unless specifically excluded

per 1.2.2. This includes: vessels constructed in accordance with an applicable construction code

vessels constructed without a construction code (non-code)A vessel not

fabricated to a recognized construction code and meeting no known

recognized standard

vessels constructed and approved as jurisdictional special based upon

jurisdiction acceptance of particular design, fabrication, inspection,

testing, and installation

Non-standard vesselsA vessel fabricated to a recognized construction code

but has lost its nameplate or stamping.

RSV has a qualified team of inspectors having vast experience to carry outsuch inspections.

API 653 Services: RSV offers Professional storage tank inspection and for

all kinds of above ground tanks.

API 653 covers Tank Inspection, Repair, Alteration, and Reconstruction. This

inspection method promotes safe storage and material handling of

petroleum products in a manner that protects employees, the public, and theenvironment. It was developed with the participation of storage tank

owner/users, and establishes a uniform national program that will assistcompanies as well as state and local governments in above ground storage

tank regulations.

RSV has a qualified team of API 653 inspectors having vast experience tocarry out such inspections.


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API 570 Services: RSV offers Professional pressure piping inspection.

API 570 covers inspection, rating, repair, and alteration procedures for

metallic and fiber glass reinforced plastic (FRP) piping systems and their

associated pressure relieving devices that have been placed in service. Theintent of this code is to specify the in-service inspection and condition-

monitoring program that is needed to determine the integrity of piping. Thisprogram provides a reasonably accurate and timely assessment to

determine if any changes in the condition of piping could possibly

compromise continued safe operation. It is also the intent of this code thatowner-users shall respond to any inspection results that require corrective

actions to assure the continued safe operation of piping.

Third Party QA/QC

To provide Third Party Inspection services Implementation, monitoring,auditing and Review of procedures, certification, reporting etc.

QA/QC Inspections of New Construction and Repairs or Alterations

to Existing Equipment: RSV can serve as Quality Assurance/Quality

Control (QA/QC) representative at the manufacturer, repair facility, or on-site to assure quality and compliance of your specific standards. BAY

Technical maintains working relationships with several Non-DestructiveExamination (NDE) organizations. This allows us to offer NDE services such

as Infra-red, Airborne Ultrasonic, Radiography, Ultrasonic, Liquid Penetrant,and Magnetic Particle, to name just a few.

Third Party Vendor Surveillance for Owner/Users, Contractors andSubcontractors: RSV can represent the owner/user, contractors and

subcontractors during fabrication and erection of specific projects. We can

provide inspection to ensure contractual and codes/standards complianceduring equipment fabrication or installation. We can also provide

representation during repairs, alterations or maintenance activities.


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Risk Based Inspection (RBI)

Risk Based Inspection is a methodology that enables the assessment of thelikelihood and potential consequences of equipment vulnerable to different

forms of corrosion to fail prematurely. RBI quantifies the risk posed bycorrosion with a systematic approach.

RSV team of consultants work with potential clients to prioritize the clientsequipment for inspection, optimized inspection methods, frequencies and

resources and to develop specific equipment inspection plans, enabling theimplementation of the Reliability Centered Maintenance (RCM)

The Key Benefits:-

Improved Safety

Lower Failure Risk Fewer Forced Shut-downs

Reduced Operational Costs

Failure Analysis

Failure analysis is the process of studying and understanding a particularincident where a material or a system has experienced failure, to determine

the cause of the failure and most importantly to prevent it from happening

again. The significance of failure analysis is the latter half of the definition -impeding a recurrence of the failure. In the world of designing critical

products used on a daily basis by millions of people, the integrity ofmaterials is a number one priority. Businesses hire experts to perform failure

analysis to ensure the product's quality.


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Corrosion Control Consultancy

Corrosion Monitoring Consultancy: RSV provides Corrosion Monitoringand Consultancy Services for asset integrity assessments on plant, piping

and structural elements, including

Developing the Monitoring Program

Baseline surveysCathodic Protection surveys

Key point thickness measurementsCorrosion mapping.

Cathodic Protection Consultancy: Cathodic protection is commonly

applied to a coated structure to provide corrosion control to areas where the

coating may be damaged. It may also be applied to existing structures toprolong their life. Structures that are commonly protected by cathodic

protection are the exterior surfaces of:

Pipelines

Ships hulls

Storage tank bases Jetties and harbor structures

Steel sheet, tubular and foundation pilings

Cathodic protection is also used to protect the internal surfaces of:

Large diameter pipelines

Ships tanks (product and ballast)

Storage tanks (oil and water)

Water-circulating systems


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Material Selection Consultancy: The selection and formulation of newmaterials, whether for cost, supplier, performance, processing, quality or

environmental reasons, has become increasingly important across allindustries.

Raw material analysis fit for purpose & legal compliance testing Materials formulation and application advice on how properties can

affect and enhance performance

Materials selection advice on sourcing cost-effective alternatives without

compromising quality or performance

Failure analysis identifying material failures and contamination

Environmental analysis consultancy regarding the sustainability of the

product and process.

Painting & Coating Consultancy:


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Courses & TrainingConventional NDT

Advanced NDTPlant Inspection

Welding InspectionCorrosion Control

Risk-Based Inspection

rs v services jan 2011

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