NON-DESTRUCTIVE TESTING

FULL SCOPE OF NDT SERVICES

WWW.SGS.COM/NDT
RIGHT SERVICE – MAXIMUM RETURN

Whether it is in fabrication, pipe systems, provided by qualified inspectors technologies, looking for the fastest
manufacturing, pipeline, plant to international standards. SGS inspection methods, integrating our
construction, chemical, petrochemical understands better than most that the workforce into your daily activities,
plants, shipyards or offshore industry, in excellence of any service commences combining technologies and carefully
conventional and nuclear power plants with quality and the implementation listening to your needs.
our Non-Destructive Testing (NDT) of detailed and effective inspection
services provide quality assurance and procedures, state-of-the-art equipment When you need to save costs, improve
process safety. SGS has a worldwide and most of all our professional people. quality and want to be sure of reliable
track record with proven performance on SGS’ fast growing network of NDT production or operating processes,
new construction, pipeline installation, inspectors is suitably trained, NDT is the tool set you need. In every
in-service inspection and expansion multifunctional and prepared to be stage of the life cycle of your assets
projects as the total NDT solution available whenever our services are SGS can contribute with added value
provider. SGS’ scope of services covers required. SGS creates added value to NDT services.
both, conventional and advanced NDT your business by applying improved

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)

11 RTJ Flange Special Ultrasonic Testing

12 Fast Corrosion Screening

13 Hydrogen Induced Cracking DETECTION

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

LNG carrier cargo tanks have been Membrane Type LNG Carrier Leak Test Methods
developed to high end material Structure n Ammonia (NH3) Leak Testing
engineered assets. Materials used In this containment system, developed This test is performed by introducing
and concepts applied are completely by Gaz Transport & Technigaz of France, an inert gas mixed with ammonia to
safeguarded by in-line monitoring of the cargo tanks are protected by a the internal space of the test material
possible leakages of the gas. To ensure complete double side/bottom, cofferdam and then over-pressurising. After
safe and reliable operation SGS offers between each tank and trunk at topside. ammonia sensitive paint is spread
pre-services leak testing of newly over the welding seams to be tested,
installed tanks. Also SGS introduces Cargo is carried at -163 °C at near the inert nitrogen/ammonia mixture
in-service leak testing and localisation atmospheric pressure, with the ranks gas is fed internally through the test
when the safety system indicates featuring a 250 mm insulation and a material. The leak site and size can be
possible unsafe operations. membrane of 1.2 mm thick corrugated detected by the location and diameter
stainless steel sheet. of the discoloration of the sensitive
Our services are compacted and highly paint. This method is specifically used
specialised to make the turn around Leakages detected during operation can for application on welding seams.
time as short as possible and will both occur due to surface cracks growing by
locate leaks and follow up any repair of ship movement and operation or as the n Helium (He) Leak Testing
leaks. Specifically for membrane type result of physical damages of the bottom This test is performed by introducing
tankers localisation is very difficult due of the tanks due to impact stress. helium gas into the internal space
to its volume and limited access to the of the test material and over-
concerned area. Regardless of type and To locate leakages multiple technologies pressurising. The helium gas will flow
size of leak, pin hole, arc strike, micro can be applied. Based on time frame, through any welding seam flaws,
crack and damage breakage should be expected damage and history, SGS cracks or pin holes. Any leaking
repaired once localised, and SGS has will select and apply the most suitable helium gas will be sucked into a
developed a proven and efficient technology. probe connected to a helium mass
concept for this. spectrometer. Then the gas will be

| 04
 ionised in the ion chamber by an Main applications
electronic beam generated by a n LNG carrier (Mark III type & NO 96
filament. A helium ion collector type as latest version)
gathers only helium ions and will n All kinds of storage tanks
send an amplified signal to the n Pressure chambers
indicator. The leakage can be n Heat exchangers
measured by the signal strength.
This method is specifically used SGS understands like no other the
for application on welding seams. importance of safe investment and
cargo. Our network covers all important
n Pressure Change Measurement ports around the globe and we will be
Testing at your service anywhere and anytime.
The total leakage can be measured Since the teams are specifically skilled
by evaluating the inside pressure and have a huge track record in these
change related to the time passed advanced inspections, expertise is not
in a decompressed or pressurised always available locally. Coordination
test object. This test is performed in takes place via our Korean expert office.
addition to other technologies in order We will make your docking time as short
to quickly locate easy detectable leaks as possible and will give clear and
that can be repaired in an early stage. reliable results.

05 |
Acoustic emission Testing
Detecting and Locating Defects using Acoustic Emission

Acoustic Emission Testing (AET) is a of some meters in between. The Advantages

Non-Destructive testing method that is information collected by each of the n In-service continuous monitoring
used to analyse emitted sound waves sensors is monitored through a with alarms is possible
caused by defects or discontinuities. computer. n Entire structure can be monitored
These acoustic waves are induced by If defects exist in some areas, the signal from a few locations
small deformations, corrosion or cracking character of the sensor attached near to n Global testing
which occur prior to structure failure. the discontinuation appears in a different n Integrated service of AET and
Therefore with AET it is possible to way. By analysing the discontinuous pressure control
locate structural defects and to monitor signals, it is possible to grasp the defect n Increased sensitivity compared to
the tendency of discontinuities. position and suspicious area of the conventional testing methods
structure. n Shorter testing time than other NDT
Inspection Technique n Real time monitoring
Ultrasonic testing is one of the traditional Application
Non-Destructive testing methods. In n Monitoring of pressure vessel during
contrast to general ultrasonic testing, hydrostatic pneumatic testing
AET is a method which evaluates n Leak detection of valves
elasticity waves caused by the defect n In-service loose part monitoring
formed in the inward of the specimen. n Leak detection of a LNG ship’s tank
In a large-sized structure, several sensors (Secondary barrier – new building
are attached to the wall, leaving a space and in-service)

| 06
Acoustic Leak Testing of Pipelines
Leakage Detection of In-Service Pipeline by Acoustic Leak Testing

Pipelines are the most safe way of The system is able to provide the SmartBall pipeline monitoring
transporting chemicals and oil. However, pipeline operator with an approximation Advantages
pipelines are impacted both by the media of any leak rate discovered. SmartBall n SmartBall maps a pipeline at high
the transport and the environment is easily deployed using existing pig resolution – locating leak as small
around them. To monitor the integrity of launching and receiving facilities, and as 0.5 gpm, leak locations are
pipelines they need to be inspected can easily navigate through bends, accurately located up to an accuracy
regularly but what if In-Line Inspection diameter changes, valves and other of a few meters. SmartBall’s leak
(ILI) is not possible and Guided Wave potential obstructions. detection sensitivity is far superior
Ultrasound is not applicable because the to that offered by CPM systems.
pipeline is buried? Acoustic Leak n SmartBall is easy to use (similar
Detection will prevent your asset from to as a cleaning pig), and its cost
impacting the environment as any leak effectiveness allows to routinely
location and size will be accurately deploy the device. No additional
identified. equipment needs to be installed
on the line.
SmartBall n SmartBall provides pro-active
SmartBall is a free swimming leak monitoring to identify small, pin-hole
detection sphere, containing acoustic leaks that are not detected by
sensors that record leaks in liquid gas, conventional leak detection systems.
oil and chemical transport pipelines. Thereby allowing easier and less
This cost-effective and easy to deploy costly repairs, and avoiding more
system is highly accurate in detecting significant leaks down the road that
and locating leaks. SmartBall contains may result in environmental damage
proprietary acoustic sensing technology Application and cost clean-up.
to identify and locate very small leaks n Routine Leak Surveys of any fluid n SmartBall reduces false alarms often
(< 0.5 gpm). SmartBall travels inside the transport pipeline (also when standard generated by other systems.
pipeline whereby the device directly ILI tools are not applicable) n SmartBall allows on-site processing
passes any leak – clearly capturing the n Emergency leak location, minimising for immediate results.
noise created by even the smallest product loss and clean-up costs n SmartBall can be deployed in pipelines
leaks. n Validation of alarms generated by as small as 4 inches in diameter.
Computerised Pipeline Monitoring n SmartBall is also capable of traversing
Conventional pig tracking units are (CPM) systems (with leak location) non-piggable pipelines as the ball
used to track the device as it travels n Leak location during hydro tests can be much smaller than the pipeline
through the pipeline, whereby the n Product theft detection diameter.
location of any leak can be located with
an accuracy of a couple of meters.

7|
Industrial 3D Tomography
Nothing to hide?

For decades we have studied on 2D Especially composite materials, light Application

representations of materials to identify metals and smaller parts can be 100% n Micro systems acceleration sensor
defects and possible causes to failure. inspected and analysed. (pores in glass adhesive, inclusion
3D Tomography adds a new dimension in cavity)
to defect recognition, sizing, and Inspection technique n Crack detection inside the cement
characterisation. This originally purely X-Ray generator and detector (Image or polymer parts
medical applied technology has Intensifier) are stationary and the sample n Inspection of GRP and CRP for
high added value in failure analysis, is rotated during the examination. internal discontinuities
3D modelling and NDT validations. The digital detector registers 100’s of n Evaluation tests of NDT procedures
single cross sectional X-Ray images to detect certain defects
3D-Computerised Tomography from all angles in the computer which n Generate calibration data to set up
Computerised Tomography (CT) visualises reconstructs the inner-structural image. other NDT technologies
the physical structures in the interior of High speed computers process the data n Generate 3D CAD data of an existing
an object without physically opening or into a complete 3D visual comprehensive object for reproduction (reverse
cutting it. This tool is extremely powerful to understand and interpret. As the engineering)
to analyse root causes of failure. But technology still develops, both accuracy n Optimising production methods of
also when other technologies need to be and object size are continuously components and materials
applied in the field or performance tests improving. SGS operates extreme
are conducted, 3D Tomography delivers accurate and powerful systems to cover SGS integrates material testing and field
excellent insight in defect characteristics both micro structures and electronics application of the best NDT methods for
and calibration data. as well as larger components. both steel, polymer and GRP materials.

| 08
DIGITAL RADIOGRAPHY
LOCATING, SIZING AND MONITORING OF CORROSION ON PIPING

On-stream radiographic imaging is phosphors, which retain the latent image. APPLICATIONS
one of the most used techniques for When the imaging plate is scanned On-stream radiography on the following
locating, sizing and monitoring of with a laser beam in the digitizer, the piping can be done
corrosion on piping when insulated. latent image information is released n Metal and plastics
as visible light. n Insulated piping
In the industrial environment of refineries n Diameter range up till 22 inches
and chemical plants, inspections have This light is captured and converted into in special applications
to be performed on a variety of difficult a digital stream to compute the digital n During process (filled) and even
to reach locations, on pipes that might image. No chemical developer is needed. at high temperatures up to 250 °C
be isolated and where people are working The image can be digitally enhanced n Problem solving on pipelines and
around the clock. This is where Computed for interpretation and measurements, appendages (valves reducers, etc.)
Radiography (CR) comes in. The thus a larger range of wall thicknesses
execution of Computed Radiography is can be inspected. These images can ADVANTAGES
similar to conventional radiography, yet be produced using an appreciable lower n Wall thickness can be measured
it has several important advantages. radiation dose or in less time. digitally with higher accuracy and
reproducibility
First of all for CR weaker isotopes can INSPECTION TECHNIQUE n Due to the higher sensitivity of the
be used to expose the “films” and the The execution of Computed Radiography plates less
other advantage is the digital readout is similar to conventional radiography radiation dose is needed
of the wall thickness which highly for the on-stream technique. The image n The CR reports can be embedded
improves accuracy and reproducibility. handling is different as a phosphor image in AIM software
In addition to abandoning the use of plate is used instead of a conventional n Results available direct after
chemicals, fast archiving of images is film.The image plate stores 4096 grey exposure
possible. The results can be fully values, which can be visually distributed n No chemicals, darkroom or
integrated into any Asset Integrity in several numbers of grey values developer needed
Management (AIM) system to reliably Because of this, a wide variety of n Images are digitally archived;
monitor and follow up degradation. thickness ranges can be inspected in no quality loss and easier to trace
only one image. The images can be and view
Computed Radiography uses an imaging produced using an appreciable lower n Image can be digitally enhanced and
plate instead of a film. The imaging radiation dose compared to conventional optimised for digitally interpretation
plate contains photo-stimulable storage radiography.

09 |
Heat Exchanger Life Assessment System (HELAS)
Remaining Life Assessment by Measuring Depth of Corrosion

Heat exchangers are vital components the measurement of ultrasonic Advantages of HELAS technology
in your processes and good performance immersion length converted into n All materials can be inspected
ensures safe and energy efficient corrosion depth inside cooling water/air n High speed inspection of max.
operations throughout time. Therefore, fin type tubes. Based on the maximum 200 mm/sec
heat exchangers are regularly inspected value of corrosion measured, extreme n Corrosion data acquisition max.
and taken out of operation. SGS offers value analysis is performed and 10,000 point/sec
a complete package of inspection in and remaining life of the heat exchanger n High precision data presentation
around heat exchangers in order to estimated by evaluating the maximum (±0.15 mm of corrosion depth)
create a full set of data, which is easy corrosion depth which can exist in the n Remain Life Assessment & Transition
accessible and ready for follow-up. whole heat exchanger. Graphs
Several technologies and tools can be n Very comprehensive and portable
applied depending on your preference, Extreme Value Analysis system
history built so far and technical The depth distribution of corrosion
requirements. which occurs in specific instruments Our service offer is a complete answer
or equipment is different according on your primary request to ensure safe
HELAS has been developed to quickly to particular probability distribution. operation. Our job does not end with
inspect heat exchangers where corrosion Each sample’s basic distribution follows the report only. It will end with full
is expected only inside of tubes. The an index distribution and its maximum calculation of remaining life time and
inspection speed is much higher than distribution follows Gumbel distribution. follow-up inspections.
with IRIS which makes the inspection SGS calculates the remaining life by
faster and more efficient. All data is estimating the maximum corrosion
directly analysed and leads to a complete with MVLUE (Minimum Variance Linear
life time assessment and not only a ‘wall Unbiased Estimate) and MLH (Maximum
thickness’ report. The basic principle is Likelihood) methods.

| 10
RTJ Flange Special Ultrasonic Testing
Detection of Groove Cracking without Bolt Dismantling

Many stainless steel flanges used in high Inspection technique

pressure and temperature conditions RTJ flange inspection is based on
are affected by cracking decreasing the ultrasonic testing which sends ultrasonic
process integrity. Up to now, general waves to the flange top only.
penetrant testing has been used for the In contrast, SGS introduces the sound
flange examination but this method waves obliquely and vertically to the
needs dismantling of the flange and groove face and flange top as well.
rearrange afterwards. These scanning methods make it
In case of standard ultrasonic testing possible to cover all of the groove
the dead zone generated below bolt area including parts below bolt holes.
holes is very significant and decreases
the effectiveness of inspections. SGS With the SGS method flanges larger than
introduces an unique and very advanced 4 inches can be inspected. The time
inspection technique to inspect Ring required to inspect one pair of flanges
Type Joint (RTJ) flanges for cracks in- is very short, and all unnecessary cost
service without a dead zone. of dismantling and mounting can be
prevented unless defects have been
found. This technology really supports n Fast and accurate inspection for
our Asset Integrity Management (AIM) critical defects
solution to make sure your assets n Used to determine which
operate safely and efficient. flanges need to be opened during
turnaround projects
advantages n Can be used in service up to 70 °C
n Inspect all the flange groove area
n Unnecessary to dismantle bolts
n Unnecessary to rearrange pipes

11 |
Fast Corrosion Screening
Advanced Ultrasonic Screening Method

Most corrosion monitoring programmes corrosion, thereby allowing effective C) Defect present that has a through-wall
are focused on time based monitoring of decision-making in ensuring long term extend which is likely to be greater
pre-defined measurement locations. integrity of equipment. Fast Corrosion than 30/40%
But what if corrosion occurs in other Screening provides reliable data between
locations or suspected locations are hard an extended probe separation up to 1 m. Advantages
to access? Fast Corrosion Screening is a good n Probe separation up to 1 m
addition to Guided Wave inspections. n 100% coverage of material between
New technologies like Fast Corrosion Where Guided Wave inspections are the probes
Screening and Guided Wave will identify more suitable for screening large n Suitable for steel pipes and plates
the corrosion locations that need to be distances (hundreds of meters piping n Sensitive to both internal and
monitored. per day) Fast Corrosion Screening is external surface degradation
better in assessing specific areas, i.e. n Signal response gives information on
These technologies add value to your saddles and clamps. defect severity
Asset Integrity Management (AIM) n Tolerant to typical field surface
systems by increasing the effectiveness Defect classification conditions and thin coating
of inspection programmes. The ultrasound signals provide an n Recommended for wall thickness
indication of defect severity. The signal ~3 to 100 mm
Fast Corrosion Screening Technology responses can provide an indication n Pipe diameters > 4 inches
Fast Corrosion Screening is a medium of any changes in the vessel wall n Suitable for inaccessible geometries
range ultrasonic screening technique (either external or internal) and based such as inspecting under clamps and
which provides full volume inspection on current experience the responses saddles, pipe supports, tank floors
of material between the transmitting are divided into three categories that and half buried pipes
and receiving probes. Fast Corrosion correspond to the following defect
Screening can be used on both pipes extend
and plates, and is especially suitable A) Nominal wall thickness loss of < 10%
for inaccessible geometries such as (approximately) of through-wall extend
clamps, saddles and pipe supports. for any defect present
This eliminates the need for expensive B) Defect present has a through-wall
shutdown but provides sufficient extend which is likely to be between
information to indicate areas of ~10% and 30/40%

| 12
Hydrogen Induced Cracking detection
Safety Evaluation and HIC Monitoring on Piping and Vessel

Hydrogen Induced Cracking (HIC) is a replacement has become absolutely n Parts where hydrogen corrosion
failure mechanism resulting in sudden critical. has occurred and accurate testing
exposures and cracks due to growing is needed
laminations inside the base material HIC Inspection technique n Scanner range: axial radius max
and welds. Hydrogen Induced Cracking Our system scans steel plates and 300 mm
is a mechanical fracture caused by pipes. The system transfers acquired n Possible testing specimen: pipe,
penetration and diffusion of atomic ultrasonic data to digital images with curved pipe, spherical surface, flat
hydrogen into the internal structure of a resolution of 0.5*0.5 mm unit. plate (diameter > 150 mm)
steel, which changes into molecular After printing sections, scan plans,
hydrogen at internal interface between and side views calculations are Advantages
non-metallic inclusion and base made. Connectivity and distribution n Very high resolution equipment
material. of defects and maximum damaged giving clear data presentation
zones are reported. By using materials n Test speed: 150 mm/sec
Due to its nature it is extremely and fracture mechanical strength n Scanner accuracy: Maximum
important to follow this process closely calculation, your assets are evaluated ±0.5 mm
whenever first signs have been detected. for safe use and monitoring. n Possibility to print an image of real
defect size
Codes like API RP579 and NACE Application n Quantitative analysis, permanent
RP0296-96 give good direction for n Pipelines, towers, vessels, heat integrity of data, periodic monitoring
assessment of high temperature/high exchangers in aqueous sulphide and side by side analysis
pressurised equipment but expertise environment of oil industry facilities, n Identify the need to apply further
and experience in HIC inspections is petrochemical plants and oil NDT to confirm or increase integrity
critical to assess correctly the damage transportation
stage of materials and determine when

13 |
guided wave
ADVANCED CORROSION INSPECTION TECHNOLOGY FOR PIPELINES AND PROCESS PIPING

Are you sure about the condition of supply more data than ever to take insulation. The ultrasound is transmitted
your piping? What about the buried decisions about further inspection or and received from one single location.
sections or the insulated parts? It is even replacement. The response from the metal loss
not easy to asses their condition in feature is a function of the depth and
an effective way. The piping may be METAL LOSS DETECTION IN PIPELINE circumferential extent of the metal loss.
located high above the ground where AND PROCESS PIPING Guided Wave tools are available as fixed
they cross roadways or other pipe The Guided Wave technology uses low ring and modular ring. The fixed ring
racks. What do you know after some frequency guided ultrasound waves designs are suitable for pipe diameters
local spot measurements? travelling along the pipe, providing 100% up to 8 inches. For larger diameters, a
coverage of the pipe length. In normal modular ring up to 42 inches has been
As process piping is a vital element application, tens of meters of piping may adopted.
of your facilities, good understanding be inspected from a single location.
of their reliability is preventing Guided Wave inspections help you
unexpected shutdowns or delays Affected areas are precisely located in to limit follow-up inspection and
during maintenance periods. Guided terms of distance from the transducer maintenance to the areas of real interest
Wave technology is a relatively new ring and highlighted for further local where the piping was found to be
inspection technology with significant examination by visual or other defective.
advantages above any other spot conventional NDT methods. This
measurement. non-destructive screening technique can This considerably reduces the time and
be used without extensive scaffolding total cost of these activities.
The Guided Wave technology screens and minimises the requirement of With Guided Wave you lift your inspection
100% of the volume of the piping removing insulation along the piping. plan to a much more effective level than
inspected for metal loss features such ever before.
as corrosion and erosion. The piping can Our state-of-the-art Guided Wave
be in operation, insulated and even be equipment generates waves propagating
buried. Guided Wave technology will long distances, even beneath a layer of

| 14
APPLICATIONS
n Diameters 2“ to 42“
n Temperatures from -40 to 120 ºC
n Road crossings and buried pipelines
n Testing of elevated or complex
piping from convenient locations
n Detection of corrosion/erosion under
insulation
n Offshore process piping/riser
inspection
n Refinery piping
n Chemical plant
n Power generation plant

FEATURES
n Screens pipelines and process n Able to distinguish between metal n Our Enhanced Focussing Capability
piping for metal loss features loss and pipe features result in better localisation of defects
n 100% coverage at rates of up to (welds, supports, bends, etc.) n Unique presentation of the inspection
½ km per day, dependent upon n Incorporation in your inspection result with “Unrolled pipe display”
the attenuation characteristics and plan aligned with VT, UT and RT software
geometry of the pipe inspections

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 |
© 07/2009 SGS. All rights reserved.