NDT Is Quality Assurance

WHAT IS NDT?

Non-destructive testing (NDT) is an essential and descriptive term in the field of material examination. It encompasses a range of techniques used to evaluate the properties and integrity of materials and components without altering or damaging their utility. NDT enables the detection, sizing, and localization of both surface and subsurface flaws and defects, providing crucial insights into the condition and safety of various structures and components.

NDT plays a vital role in ensuring the safety and reliability of numerous aspects of everyday life. It is a key component in the maintenance and assessment of a wide array of structures and systems. Common applications of NDT include the inspection of pipelines, bridges, trains, power stations, and refineries. Additionally, it is extensively used in inspecting infrastructures like buildings and bridges, offshore oil platforms, and aircraft. These inspections are critical for preventing failures and accidents, ensuring that these structures and systems are safe for public use and operation.

Beyond its practical applications, NDT is also a significant aspect of Quality Assurance management. Effective NDT requires a deep understanding of the various methods available, including their capabilities and limitations. It also necessitates knowledge of relevant standards and specifications to perform the tests accurately and effectively. This comprehensive understanding is crucial for ensuring that NDT inspections are conducted with the highest degree of precision and reliability, thereby upholding the safety and integrity of the inspected items.

WHY IS NDT ESSENTIAL?
Non-destructive testing (NDT) is an invaluable process that can be applied at every stage of an item's construction and lifecycle. The importance of NDT is multifaceted and includes several key aspects:

1. Accident Prevention and Cost Reduction: NDT helps in identifying potential flaws and weaknesses in materials and structures before they lead to accidents or failures. This early detection is crucial in preventing costly repairs, downtime, and, most importantly, ensuring the safety of people and the environment.
2. Enhancement of Product Reliability: Regular NDT inspections ensure that products and components meet the desired standards of quality and reliability. This helps in maintaining the trust and confidence of customers and stakeholders. 
3. Verification of Compliance with Requirements: NDT is essential in determining whether a particular component or structure complies with the specified requirements and standards. This aspect of NDT is crucial for quality control and regulatory compliance. 
4. Guidance on Repair Criteria: NDT provides valuable information about the condition of materials and components, which can be used to make informed decisions regarding repair, maintenance, or replacement.

At Applied Inspection Systems, Inc. (AIS), we focus on delivering precise and insightful evaluations as an integral part of our NDT services. Choosing AIS allows you to receive thorough and lucid data analysis, which is critical for the effective management of your equipment and facilities. Our approach is centered on providing you with clear and actionable insights, helping you make informed decisions that contribute to the enhanced performance, safety, and longevity of your assets.

High-energy piping (HEP) systems in power plants contain critical components that demand meticulous maintenance and inspection. Applied Inspection Systems, Inc. (AIS) provides clients with a comprehensive and integrated High-energy piping (HEP) management program specifically designed to ensure the safe and reliable operation of these vital systems. Our team of experts specialize in Creep Strength Enhanced Ferritic (CSEF) steels, including Grades 91 and 92, which are commonly used in high-energy piping systems.

AIS offers a complete suite of HEP services, with a particular focus on the development and management of HEP programs. These services are designed to be cost-effective, helping clients maximize the efficiency of their lifecycle management budgets. With our Fitness-For-Service (FFS) analysis, Non-Destructive Testing (NDT), and metallurgical lab analysis, we tailor each HEP program to meet the specific needs of each plant, ensuring a customized approach that addresses the unique challenges and requirements of different power plant environments.

Once an HEP management program is established, in-service measures are implemented to control and mitigate damage in high-temperature piping systems, which are susceptible to creep. These specialized services are crucial for maintaining the quality of assets and require a distinct set of skills and procedures compared to standard code-acceptance inspections. Our NDT professionals are adept in advanced NDT techniques, uniquely designed to detect damage in equipment operating under high temperature and high pressure, including components made from advanced materials like Grade 91 and Grade 92 steels. This comprehensive approach ensures that power plants can maintain their HEP systems in top condition, safeguarding their operation and extending the lifespan of their assets. 

AIS is committed to providing outstanding boiler inspection services to our clients, ensuring comprehensive evaluations and detailed reports. Our team of NDE specialists utilize state-of-the-art ultrasonic testing techniques, enabling them to non-invasively identify and assess damage such as cracks or corrosion, within boiler components. Identifying these issues early is critical in maintaining the operational efficiency, safety, and longevity of your boilers, guaranteeing their optimal performance.

Flow-accelerated corrosion (FAC) is a significant issue in carbon steel components of power plants, where the protective magnetite layer dissolves under the influence of flowing water or wet steam. This process involves three main factors: hydrodynamics, water chemistry, and the materials used in the components. FAC leads to wall thinning in piping, tubing, and vessels, which can cause sudden ruptures. These ruptures pose serious safety risks, as they can release high-temperature steam and water, potentially injuring plant personnel and damaging equipment. FAC has been responsible for numerous failures in various types of power plants, including fossil, industrial steam, and nuclear facilities, as well as in heat recovery steam generators (HRSGs).

To manage and mitigate FAC effectively, a comprehensive, corporate-wide program is essential, supported by senior management and involving personnel from operations, mechanical maintenance, NDE, chemistry, and metallurgy. This program should combine inspection-based and cycle chemistry-based activities. Inspection-based activities include reviewing feedwater piping and heater metallurgy, operating practices, and existing component damage. Techniques like pulsed eddy current (PEC) and ultrasonic testing (UT) are used for detecting and quantifying FAC-induced wall loss. Effective documentation and evaluation of inspection data are crucial for assessing the condition of affected components and planning for future inspections. This includes scheduling component inspections during unit outages, preparing necessary scaffolding, and ensuring proper data collection and record-keeping to maximize the utility of the inspection data for the overall FAC program.