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Traditional methods of non-destructive control -are time-tested methods for diagnosing the condition of materials and products without damaging them. These methods include visual inspection, ultrasound, X-ray, and magnetic powder testing. These methods are effectively used to identify defects at different stages of production and operation, ensuring high reliability and safety of equipment.

VISUAL AND MEASURING CONTROL

Our visual inspection staff is certified to provide quality assurance and control services in the oil and gas, manufacturing, and energy industries. We offer a wide range of services, including:

  • Plant overhaul planning:Develop and implement effective strategies for major repairs that ensure minimal downtime and maximum efficiency
  • Visual inspection of welds and dimensions:Conducting thorough inspections of welds and dimensions, ensuring their compliance with high quality and safety standards.
  • Documentation quality control:Ensuring complete and accurate documentation for new and used equipment that meets all requirements and regulations.

Our specialists have the necessary knowledge and experience to perform the most difficult tasks, ensuring the high quality and reliability of the services provided.

Visual methods are often used as a complement to other non-destructive testing methods. They allow you to identify defects that may not be noticeable when using other technologies. Our specialists use a wide range of tools for visual inspection, including:

  • Pressure gauges: Measuring the pressure in systems to detect deviations from the norm.
  • Micrometers: High-precision measurements of dimensions and thickness.
  • Calipers: Universal tools for measuring internal and external dimensions.
  • Magnifying devices: Magnifying glasses and microscopes for detailed inspection of minor defects.
  • Remote video equipment: Cameras and video endoscopes for checking hard-to-reach areas.

Surface preparation equipment:Tools for cleaning and preparing surfaces before performing inspections. And many other measuring equipment.

These tools ensure high accuracy and efficiency of visual inspection, which allows us to guarantee the high quality and safety of the objects being checked.

CAPILLARY CONTROL

This method of non-destructive testing is used to detect defects and/or irregularities that destroy the surface. A low-viscosity liquid, known as a penetrant, is applied to the part and allowed to linger on the part for a certain amount of time. The excess penetrant is carefully removed and a developer is applied, which pulls the penetrant out of defects and/or irregularities due to capillary action and provides a contrasting background to improve the visibility of the readings.

The materials being tested include non-ferrous metals and ferrous metals, although ferrous metals are usually tested using a magnetic powder test to detect the subsurface layer. This method is used to detect surface defects in casting, forging, and welding and/or discontinuities such as cracks, surface porosity, leaks, fatigue cracks on operational components, and inherent manufacturing defects.

Surface preparation is crucial, so it is important to ensure that the surfaces are free of oil, grease, scale, paint, rust or other residues that may affect the quality of inspection.

MAGNETO-POWDER CONTROL

This method is used to detect surface and subsurface defects and/or discontinuities in ferromagnetic materials. The magnetic field acts on the part, and the iron particles are magnetized while the part is being magnetized. Defects and/or discontinuities are detected when particles collect and form an indication in a magnetic field, which gives an indication of the size and location of the indication.

Magnetic powder is applied to welds, fittings, pipelines, castings, forgings, pressure vessels, machined parts, shafts, valves and structural steel.

X-RAY INSPECTION (X-RAYS AND GAMMA RAYS) This is a non-destructive testing method that uses electromagnetic energy in the form of X-rays or gamma rays. An X-ray is a two-dimensional negative image of an object on a film that is sensitive to radiation exposure. Radiography can detect surface and subsurface defects and/or irregularities. Cobalt-60 (Co60) and iridium-192 (Ir192) are the most commonly used industrial isotopes of gamma radiation, which continuously emit gamma rays, are stored and transported in protected shielded exposure devices. An X-ray generator (also known as an X-ray tube) converts electrical energy to produce X-rays and is controlled in such a way as to stop X-rays when the equipment’s power supply is cut off. Radiography is performed on most metallic and non-metallic materials, including welds, surfacings, castings, forgings, fittings, valves and components, pipes, machined parts, pressure vessels, oil storage tanks, and structural steel. Radiography is carried out in general industrial sectors, including: energy facilities, gas production, pulp and paper mills, oil refineries and refineries, pipelines and foundries. Radiography is also widely used to determine the degree of internal and/or external corrosion/erosion in process pipelines, pressure vessels, and valves. The X-ray film provides a permanent record of the object under study. Due to the fact that the X-ray image is two-dimensional, the depth of the defect and/or discontinuity requires additional non-destructive testing, which is usually performed using ultrasound. Access to both sides of the object is required, and the processed film image is viewed and interpreted in high-intensity alternating white light. The practical thickness limit for carbon steel gamma radiography is approximately 2.5 inches for Iridium 192 (Ir-192) and 9 inches for cobalt 60 (Co-60), while the energy of the X-ray generator determines the penetration depth, which typically averages up to 1.5 inches with portable equipment. Materials with a thickness of more than 1.5 inches require stationary equipment with a high-energy X-ray generator.

ELECTRICAL CONTROL

Electrical control (EC) is one of the types of non-destructive testing (NC), which is based on the registration and determination of parameters of electric fields interacting with objects of control (OK), or arising in them when exposed to external forces. The EC methodology and its varieties are regulated by the GOST 25315-82 standard.

EC methods can be used to identify various defects in OCS: cracks and other irregularities in products made of ferrous and non-ferrous metals, as well as alloys; in insulating coatings: pores, delaminations, blisters, looseness, cracks, thinning. These methods make it possible to determine the thickness of extended products (rods, pipes, rods, tapes, threads) made of conductive and non-conductive materials. Indirectly, using EC, it is possible to determine the physical and mechanical characteristics of many materials: density, humidity, degree of polymerization, radio transparency, percentage of components in heterogeneous systems, etc.

The electric spark control method is mainly used to detect defects in dielectric control objects and protective insulating coatings of electrically conductive control objects. The method is based on the registration of an electrical breakdown of a section of such a coating, or the dielectric object itself.

During the inspection of insulation coatings, a test voltage is applied to the electrically conductive base of the inspection object and a special electrode that scans this coating. When monitoring dielectric objects, voltage is applied to the electrodes located on both sides of the control object.

EDDY CURRENT CONTROL Eddy current control is one of the electromagnetic non-destructive testing methods applicable to conductive materials. In flaw detection, the eddy current method is used to indicate and evaluate surface and subsurface defects. This method is also used to measure the thickness of coatings or layers, determine the electrical conductivity and magnetic permeability of a material, and evaluate the metallurgical, mechanical, and other properties of a product. The peculiarity of the eddy current method is that the control can be carried out without direct contact of the transducer with the object. This method is used everywhere to control electrically conductive objects:
  • sheet metal and plates of different sizes;
  • wires of various diameters;
  • pipelines of different diameters, with different wall thicknesses;
  • Railway rails;
  • bearings and other critical components and parts;
  • nuclear reactor buildings , etc.
Advantages:
  1. High work rate. Electromagnetic fields propagate at speeds close to the speed of light. This significantly speeds up the eddy current control procedure. It is actually possible to achieve speeds of up to 10 m/ s, but depending on the speed of the device, it may deviate from this indicator.
  2. No contact is required. Despite the attenuation of the electromagnetic field in the air, it is possible to carry out monitoring with a gap using insulation. In addition, you do not need to use contact fluid and prepare the surface in a special way.
  3. It does not depend on the weather. The procedure can be performed under any weather conditions, even in case of precipitation.
  4. Showing the results. Eddy current devices of the new generation, whose operation is based on matrices, make it possible to save data in the form of a C-scan by coordinates. Due to the reference to the coordinates, it is possible to estimate the size of the defect. At the same time, if the data is saved, it will be possible to return to them later to analyze the dynamics of the defect development
HARDNESS MEASUREMENT Hardness Hardness is one of the mechanical characteristics of the material of the object of control (OK); it determines its ability to resist when pressed into its surface layer by an indenter– another, more solid body. This characteristic is evaluated in units of hardness and based on this, a conclusion is made about the quality of the material. To date, many methods have been developed to control the hardness of various materials; these methods are divided into static and dynamic and depend on the speed of application of the load. Many famous inventors and scientists have been involved in the development of such methods, and they are named after them.:
  • the Brinell method;
  • The Rockwell method;
  • The Vickers method;
The Brinell method является статическим и регламентируется ГОСТом 9012-59. Определение твёрдости по Бринеллю производится путём вдавливания индентора в виде стального шарика соответствующего диаметра (D) в ОК при определённой нагрузке (P), приложенной к индентору строго перпендикулярно поверхности ОК. По истечении заданного времени выдержки нагрузка снимается и измеряется диаметр (d) получившегося отпечатка. Значение твёрдости по Бринеллю (HB) определяется делением нагрузки (Р) на сферическую площадь (F) отпечатка. Однако, для упрощения пользованием, таблицы твёрдости по Бринеллю составляются исходя из диаметра шарика (D), диаметра отпечатка (d) и величины нагрузки (Р). Число твёрдости обозначается цифрами и символом (например, 300 НВ). Метод Роквелла (относится к статическим методам и определяется стандартом: ГОСТ 9013-59 (ИСО 6508-86). Для проведения этого контроля применяют в качестве индентора либо стальной шарик, либо алмазный конус, у которого угол при скруглённой вершине равен 120о. Определение твёрдости производится по глубине погружения индентора в материал ОК. Нагрузка на индентор прикладывается последовательно в три этапа:
  1. приложение предварительной нагрузки (P0 = 10 кгс);
  2. приложение основной нагрузки (P), состоящей из предварительной (P0) и рабочей (Pраб) нагрузок, P = P0 + Pраб;
  3. снятие рабочей нагрузки, измерение глубины погружения индентора.
Измеряется твёрдость по Роквеллу в условных единицах, где за единицу принята величина погружения индентора на 0,002 мм. Из 11 шкал определения твёрдости наибольшее распространение получили шкалы A, B и C. К символу обозначения твёрдости (HR) добавляется буква, указывающая шкалу, по которой проводились измерения (HRA, HRB, HRC и т. д. до HRT), например, HRC 64. Контроль твёрдости по Виккерсу также статический и регламентируется ГОСТом 2999-75. Проводится он путём внедрения в материал ОК индентора в форме алмазной пирамидки с квадратным основанием и углом при вершине, равным 136о. Нагрузка на индентор при этом может составлять: 1; 2; 2,5; 3; 5, 10, 20, 30, 50, 100 кгс, в зависимости от материала ОК и характера испытаний. Вычисление значения твёрдости по Виккерсу (HV) выполняется после снятия нагрузки с индентора, затем определяется средняя диагональ (d) отпечатка индентора на ОК и, при известной нагрузке (P), делается расчёт по формуле: HV = 1,854×Р/d2 кгс/мм2 (Н/мм2, Мпа). На практике такие вычисления не делаются, а пользуются готовыми таблицами. Метод Шора включает в себя два способа измерения твёрдости:
  1. способ упругого отскока;
  2. способ вдавливания.
Способ упругого отскока (динамический) регламентируется ГОСТом 23273-78 «Металлы и сплавы. Измерение твердости методом упругого отскока бойка (по Шору)». Суть этого способа (рис. 2) заключается в определении твёрдости материала ОК (2) по высоте (h2) отскока индентора (4), падающего с определённой высоты (h1), после его удара о поверхность ОК. Приборы-склероскопы (рис. 2) для таких измерений разработаны сами́м автором метода и, в зависимости от исследуемого металла, имеют некоторые отличия. Так склероскоп типа С комплектуется индентором массой 2,5 г и высота его отскока (h2) фиксируется визуально. Склероскоп типа D имеет индентор массой 36 г, а величина отскока регистрируется электронным либо механическим устройством. Число твёрдости включает в себя цифровое значение величины твёрдости и символ (HS) с указанием шкалы, по которой произведён отсчёт – например, 95 HSD.

LEAK DETECTION is one of the types of non-destructive testing (NDT), which is capable of detecting end-to-end defects in industrial products, building structures, and technological structures; it is regulated by GOST 25136-82

GOST 24054-80, ART RK EN 1593-2016, ART RK EN 1779-2016, GOST 26790-85, GOST 3845-2017

All methods of this type of control are based on the ability of PV to penetrate through defects and be detected by visual inspection, or by special indicators and leak detectors.

Vacuum methods consist in determining the leakiness of the OK, which are fixed either by a drop in the vacuum meter readings.

THERMAL IMAGING INSPECTION Thermal imaging inspection is a type of thermal inspection using a thermal imager. The device converts infrared thermal radiation from the studied objects into a spectrum visible to humans. On the thermal imager screen, information is reproduced in the form of multi-colored zones that are superimposed on top of the object image. Each color on the screen indicates its temperature. For example, cold areas are shown in blue, and hot areas are shown in red. As a result, heat leaks are quickly detected. The scope of the thermal imager is very wide, but we will consider only the most common applications. Thermal imaging diagnostics can be performed:
  • During construction quality control – detection of hidden cracks in walls, errors in the installation of windows and doors, weak insulation of walls, roofs, floors, etc., insufficient tightness of joints in walls.
  • Detection of overheating of electrical wiring, aggregates, mechanisms and prevention of emergencies.
  • Leakage of heat carriers in heating mains, leakage of refrigerant in air conditioning systems, leakage of hot or cold water.
  • Checking the insulation of the walls, searching for weak points in the insulation.
  • Using a thermal imager, you can find wires and pipes hidden in the walls.
  • And many other ways to use the thermal imager in both domestic and industrial premises.
The main advantage of such studies is the ability to see all heat losses in real time. Without having to open walls, roofs, and so on. The device allows the owner of the room to see the causes of heat loss and take actions to correct them. It will be useful! Before buying a room, you can conduct a thermal study to understand how comfortable the room will be and assess the possible costs of insulation. For lessors, this is an opportunity to demand solutions to heat loss problems from the lessee, thereby saving on heating. При тепловизионном обследование теплотехнического оборудования определяются следующие деффекты:
  • - defects in thermal insulation between the lining and the pipe trunk; • tracing of heating mains, specifying the locations and sizes of expansion joints; • defects in thermal insulation in underground pipelines (destruction, wetting); - defects in the pipe trunk (cracks, leaky concreting seams, areas of porous concrete); -defects in pipe lining (cracks, falling bricks, loose mounting openings); • defects in the thermal insulation of furnaces, pipelines, etc. • identification of pipeline rupture sites
При тепловизионном обследование нефтегазового оборудования определяются следующие деффекты:
  • gas leakages; • damage to pipeline insulation; • defects in tank walls; • detection of leaks and oil spill sites; • determination of the liquid level in the tank.
Important things to know The examination is possible only under appropriate weather conditions.
  • The required temperature difference should be at least 10-15C degrees. The greater the temperature difference, the more accurate the research data.
  • The room must not be exposed to direct or reflected sunlight for at least 12 hours, otherwise the data will be inaccurate.

METAL MAGNETIC MEMORY METHOD

The metal magnetic memory method is one of the most effective methods of non-destructive testing in industry. This method uses the features of the magnetic structure of the metal to detect defects and estimate their size.

The basis of the metal magnetic memory method is the use of an applied magnetic field to make temporary changes in the magnetic structure of the material. Then, using sensors, the deviation of the magnetic memory from its original state is recorded. Based on these data, it can be concluded that there are defects such as cracks, deformations, or inhomogeneities in the magnetic structure.

One of the advantages of this method is its ability to detect hidden defects such as cracks and internal pores in metal products. This helps to prevent possible accidents and reduce the likelihood of equipment failures.

Another important advantage of the method is its high speed and accuracy. Magnetic metal memory allows you to quickly process large amounts of data and obtain accurate research results. Thanks to this method, it is possible to quickly and effectively assess the quality of building materials, machine-building products and other metal structures.

The magnetic memory of metal also has high sensitivity and the ability to quantize information, which facilitates the interpretation of the received data. This method allows for accurate measurements and analysis of the parameters of metallic materials, which helps to improve their quality and reliability.

CONTACTLESS MAGNETOMETRIC DIAGNOSTICS Contactless diagnostics of pipelines is an innovative method for detecting defects and damages in pipelines without the need for physical contact with them. This method, known as magnetometric control, uses special sensors to measure the magnetic fields created by various defects in the metal. Defects such as cracks, corrosion, or changes in the structure of the metal can cause local changes in the magnetic field. These changes can be detected using sensitive sensors that measure the magnetic field around the pipeline. Contactless pipeline diagnostics is an effective and safe way to maintain and monitor the condition of pipelines, allowing timely detection and elimination of possible problems. Advantages of this method: Contactless diagnostics has a number of advantages over traditional methods:  Бесконтактная диагностика имеет ряд преимуществ перед традиционными методами:
  • Safety: The absence of direct contact with the pipeline reduces the risk of damage to equipment and ensures the safety of personnel.
  • Efficiency: Fast and accurate detection of defects allows you to quickly take measures to eliminate them.
  • Cost-effective: Reduced maintenance and repair costs due to early detection of problems.
Versatility: The method is suitable for diagnostics of various types of pipelines, including steel, plastic and composite.

VIBRATION CONTROL

Vibration flaw detection is used to detect various defects such as cracks, material destruction, improper fastening and other malfunctions in the operation of machines and structures. During the flaw detection, the vibrometer measures the vibration level, analyzes it and finds the location of the defect.

The principle of vibration flaw detection is based on the fact that each defect in a machine or structure causes a certain level of vibration, which can be measured and analyzed. The vibrometer device used for vibration flaw detection has a sensor that measures vibration fluctuations and an electronic unit that processes this data and outputs the results.

The vibrometer is installed on the surface of the machine or structure to be checked. Then, using the built-in vibration generator, the vibrometer creates mechanical vibrations that are transmitted through the surface and detect any defects inside the structure. The received data is read by the device and analyzed to determine the location of the defect. This allows you to quickly and accurately detect any malfunctions in the operation of machines and structures, which helps to prevent emergencies and reduce repair costs.

Advantages of Vibration control

Vibration monitoring has several advantages that can improve the safety and efficiency of machines and structures:

  • Vibration monitoring allows you to detect defects and problems at an early stage, when they have not yet led to serious consequences. This allows you to quickly take measures to eliminate problems and prevent emergencies.
  • Due to the early detection of defects and problems, VC reduces the cost of repair and maintenance of machines and structures.
  • VC helps to improve the reliability and safety of machines and structures. Due to the early detection of defects and problems, emergencies can be prevented or the likelihood of their occurrence can be reduced.
  • Vibration control allows you to optimize the performance of machines and structures. Through regular monitoring, it is possible to identify and eliminate machine inefficiency, which will increase productivity and work efficiency.
  • Vibration control can help improve the quality of products produced by machines or structures. Through monitoring, it is possible to identify problems related to mismatches in geometric parameters or other factors and eliminate them, which will improve product quality.

Vibration control has many advantages that increase the safety, reliability and efficiency of machines and structures. Regular vibration monitoring is an important tool to ensure the safe and efficient operation of various machines and structures.

SPECTRAL ANALYSIS

Spectral methods are widely used in various industries for quality control of raw materials and finished products, monitoring of technological processes. They allow you to quickly obtain information about the composition and properties of various materials, identify defects, and prevent defects.

Spectral analysis is performed on ferrous and non-ferrous metal materials, including welds, surfacings, castings, forgings, valves and components, pipes, fittings, machined parts, pressure vessels, structural steel, and components,

Spectral methods are widely used to control the composition and properties of metals and alloys. They allow you to determine the content of alloying elements, impurities, and also detect various defects, which is important for ensuring the quality of metal products.

The main purpose of spectral analysis is:

  • Steel grade confirmation;
  • selection of analogues of steels and alloys;
  • updating of technical documentation;

The key advantage of the method is that the analyzed material does not need to be destroyed directly during the spectral analysis.

ACOUSTIC EMISSION CONTROL

It is based on the emission and registration of stress waves during rapid local restructuring of the material structure. Defects that occur and develop in the material during operation cause a concentration of deformations. If, during loading, the local strain (overvoltage) caused by the presence of a defect exceeds the threshold level for emission, acoustic emission occurs. The higher the deformation caused by the defect, the higher the emission level and the lower the load level at which it appears. The total energy of the emission is a measure of the risk of a defect. A defect located in a more stressed area of the object causes a higher stress concentration and higher emission than a similar defect located in a less stressed area. From the point of view of the structural integrity of the object, a defect located in a more loaded area is more dangerous than a similar defect in a less loaded area. Acoustic emission tests allow us to establish this difference.

The classical sources of AE are the processes of plastic deformation and fracture. The rapid movement (growth) of the AE source causes the appearance of stress waves that propagate in the material structure and reach the piezoelectric transformer. The electrical emission signals received as a result of the voltage wave conversion by the sensor are amplified, recorded by the equipment and subjected to further processing and interpretation.

Modern systems measure both individual parameters of an AE signal: amplitude, duration, energy, oscillations, time of arrival, time of rise, and other parameters related to its frequency characteristics, as well as the shape of the digitized signal. The analysis of the set of parameters of the sequence of AE signals makes it possible to determine the location of the source, its type and degree of danger. A detailed analysis of the shape/spectrum of the digitized signal is used to clarify the type of source and propagation characteristics of the signal.

Since the source of acoustic emission energy is the field of elastic stresses in the material, AE control is usually carried out by loading the controlled object. This can be a pre-launch verification check, periodic monitoring during operation, or monitoring. Acoustic emission differs from most non-destructive testing (NDE) methods in three key aspects.

  1. The signal source is the material itself, not an external source, i.e. the method is passive (and not active, like most other control methods). This, in turn, leads to the fact that:
  2. Unlike other methods, AE detects developing, i.e. the most dangerous defects
  3. This method is remote, it does not require scanning the surface of the object to search for local defects, but only the correct placement of sensors on the surface of the object to locate the AE source

The opportunities associated with the remote use of the method offer great advantages over other control methods that require, for example, removing insulating shells, freeing control objects from internal contents, or scanning large surfaces. Due to the difference in their capabilities from traditional control methods, in practice it turns out to be very useful to combine AE with other methods. The use of the AE method significantly reduces the time of diagnostic work and saves money spent on their implementation and decommissioning of equipment.

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