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Radiography Testing
Industrial Radiography is one of the best and widely used non-destructive testing methods throughout the engineering industry worldwide. It is similar to the process used in hospitals to locate problems within the human body. Industrial radiography is used the same way to detect defects and discontinuities in Welding, Castings and all different kinds of Material. ARL use X-Ray and Gamma Ray sources to produce the required results on film imagining along with a detailed NATA report of the findings. This method enables you to know exactly what the internal quality of your product, equipment or welding is. A permanent film record is keep for future reference.
Ultrasonic Testing
Ultrasonic Testing in industry uses sound waves the same way they are used in hospitals to check an unborn child still in the womb. When used in Industry, Ultrasonic Testing determines the quality of the internal structure of Weld Joints, Castings and various Materials for soundness and for detecting any internal flaws or defects. Using specially designed probes, sound waves are sent through the item being tested. Once these sound waves hit a defect or flaw within the body of the material, the sound waves then bounces back and the technician interprets the results on the Ultrasonic Testing machine’s viewing screen. Ultrasonic Testing Machines are designed so the technician is able to size up the defect or discontinuity that has been detected. If the item being tested is free of defects or internal flaws, the sound waves pass right through without any interruptions allowing the technical to prove soundness of the item being tested.
Return to TopMagnetic Particle Testing is a method that is used to locate surface and sub-surface defects in Ferro Magnetic Steel. Testing is carried out, by introducing a magnetic field into the test area and dusting or spraying onto the surface, iron particles. These iron particles are either applied dry or suspended in a liquid. Surface imperfections will distort the magnetic field and concentrate the iron particles in and around the imperfections that are present in the surface or sub-surface region of the item being tested. This is due to an interruption in the magnetic induced field caused by a surface or sub-surface defect in the material while being subjected to Magnetic Particle Testing.
Dye Penetration Testing otherwise known as Liquid Penetrant Testing or Colour Check Testing and is most widely used as an NDT method for surface testing of material. It can also be used as a medium to check for leaks as well in various items. The test area is coated with a visible or fluorescent dye solution and allowed to soak and dwell on the surface for around 15 mins. The excess dye is removed from the surface, and then the developer applied. The developer acts like blotter and will draw the penetrant out from any imperfections that are open and exposed to the surface. Visible dye and the vivid colour contrast between the penetrant and developer makes the bleed-out process easy to view by the technician performing the test. With fluorescent dyes and an ultraviolet lamp the bleed-out becomes fluoresce bright, thus allowing the imperfection to be seen readily in the dark.
Eddy current testing creates an electrical current in a conductive material by introducing a magnetic field. Interruptions in the flow of this electrical current (Eddy Currents) generated by imperfections or changes in a material’s conductive properties will cause changes. These changes allow the operator to detect a defect or discontinuity in the item being examined.
On-site hardness testing is carried out by means of a portable hardness-testing unit. This unit is capable of converting values such as Brinell, Vickers, Rockwell and Shaw. On-site hardness testing is required to compare the hardness values between the production weld metal, the parent metal, and Heat Affected Zone (HAZ) mainly after Post Weld Heat Treatment has been carried out. This is to ensure the hardness values are acceptable within each zone of the weld joint. Usually 3 spots are tested within each zone and an average reading is then qualified. The advantage of on-site hardness testing is you are able to ensure that parameters have been keep for Welding and Post Weld Heat Treatment during both processes.
This is usually performed by an experienced Welding Engineer who is an expert in the field of all types of welding. The Welding Engineer/Consultant will implement the development of all the required Welding Procedures for a particular job or project. This person will cross-reference all the requirements against the specifications and welding codes that are relevant to a particular project or job being welding.
This person will guide the welding supervisor in the direction that is needed to ensure there are no problems before, during and after welding has been completed.
When you bake a cake you require a recipe to ensure the final product is what you are after. The same must be said when performing all types of welding. A welding procedure must firstly be developed and tested to ensure you obtain a sound weld in accordance with the relevant specification. When developing a welding procedure, all the variable essentials must be considered. Such things as material, joint preparation, welding consumables, welding wire/electrodes, welding gas, amperage, voltage, travel speeds and gas flows. In some cases other items such as pre-heating and post heating may also become part of the final welding procedure requirements. Once the Welding Procedure has been developed, a sample simulating the production welding is welded and then subjected to various Non-Destruction and Destructive tests. If all the tests results comply, then this welding procedure can be used to carry out the associated production welding. With special alloys it may require specialized development to achieve a satisfactory welding procedure that will satisfy the welding requirements.
This is where a Third Party acting on behalf of the client performs progressive and final inspections at contractor’s workshop as well as on site to provide a constant update to the client of the current status of fabrication, material inventory, inspection and delivery dates for work being performed. Non-complying items will be subject to the issuing of Non-Conforming Reports (NCRs), This will reduce the risk of delays in the completion of the project. It also enables the client to monitor quality of the work as it is being manufactured along specified time lines.
Above Ground Storage Tank Survey
This allows for a speedy and complete storage tank surveys. This is carried out in accordance with API 650 and 653. Using the Tank Floor Tester (TFT) you are able to scan and map the tank floor 100%. For the Internal and External Tank Shell Thickness Survey, a tank crawler is used. This is carried out from the ground without the need of support scaffolding or staging. The crawler can also be used for Tank Roof surveys and mapping when it is unsafe to walk on the tank roof. Settlement surveys are carried out with a dumpy level to check for any movement underneath the tank. In-services tanks inspection and testing procedures are formulated so as to carry out testing while the tank is still in operation.
Using current up to 20KV, 40KV and 60KV for detection of porosity and holiday testing of carbon impregnated coating such as coating and wrapping, carbonated rubber, thick coating like rubber linings and over plastic / fibreglass type coatings likely to become electrostatically charged. This system can also be used to determine if the required Dry Film Thickness (DFT) has been applied over the total covered areas.
Positive Material Identification
“State of the Art” X mate 3000TX portable X-ray tube based metal alloy analyser (ever safe) is used to perform chemical analysis of ferrous / non ferrous material either in our laboratory or at client’s workshop or site.
X mate recognises the important role of the scrape industry in today world. High standards demanded by the end users mean that the quality and precision of metal sorting have to be second to none.
ARL’s expertise and X mate have the capability to determine the exact chemical composition of your material. We can even help you to determine the group of your material.
It is also used to confirm that the correct welding metal has been used during production welding.
Background
Lightweight, hand-held, XRF analyser for fast and reliable elemental analysis, quality control and scrap sorting.
Advantages of the X-MET3000TX from Oxford Instruments:
- Bring the analyser to the test site
- No limit on sample size
- Point and shoot analysis
- Intuitive user interface
- Brief operator training
Quality Control and Positive Material Verification (PMI)
The X-MET3000TX has been designed specifically for material verification functions where metals analysis is required.
- Monitor assay to confirm goods meet specification
- Inspect pipes, welds etc for corrosion resistance, and pressure equipment for alloy composition
- Avoid material mix-ups
- Wires of less than 1mm in diameter, or small objects of the same size, can be identified in seconds
Scrap Sorting and Metals Analysis
In metal recycling the quality and precision of metal sorting have to be second to none.
- Be confident that the accurate analysis of Ni, Co, Cu, Mo, Sn, Ti will allow you to get maximum value for your scrap, even with the tight tolerances demanded by the industry
Avoid penalties by the accurate detection of tramp elements - Grade ID in 2 - 5 seconds
- Full assay in 5 - 10 seconds
- Withstands all weather conditions and rough treatment
- Proven track record for reliability and endurance
- Minimal service costs and down-time
- 5 year X-ray tube warranty and 2 year instrument warranty
- Fundamental Parameter (FP) and empirical calibrations
- Identification Mode for quick sorting
This is a process that is used on site to stress relieve completed welds joints. The process uses special electric blankets, which are wrapped, around the weld joint area. Then by means of a special programmer/recorder and transformer, the settings are imputed and the heating cycle then runs its desired course. This usually consists of quickly climbing to a starting temperature then climbing gradually at a set rate/time to a soaking temperature, which is then held for a required period of time. This soaking period is where the material has all the internal welding stresses relieved from the material. Once the soaking period is completed during the cycle, the temperature then drops gradually at a set rate/time to allow slow cooling. This equipment can also be used to hold Pre-Heating temperatures during weld on large and thick weld joints.
Oldest and most common method of NDT is visual examination. It has numerous industrial and commercial applications. Inspectors follow procedures ranging from simple to very complex when viewing items during an inspection. Some of which involve comparison of workmanship samples with production parts and against visual inspection tables found in most engineering and welding codes and specifications. Visual techniques are used along with all other NDT methods.
