Advancing industrial plant advantage - TÜV SÜD · Advancing industrial plant advantage Driving industrial plant performance through advanced NDT methods. White paper ... PCN and

Advancing industrial plant advantage

Driving industrial plant performance through advanced NDT methods.

White paper

AbstractThe ever growing global demand for electricity and industrial production capacity is putting significant pressure on our ageing industrial infrastructure. In an increasingly competitive marketplace, industrial plant owners and operators simply cannot afford plant downtime.

Radiography was first developed as a non-destructive testing (NDT) technique that would maximise plant uptime, ensure safety and assure plant owners and engineers of legislation compliance. Market evolution means it now bites the hand that feeds, as the use of radiation necessitates long periods of plant downtime, which industries can no longer accept. This white paper reviews the development and application of new NDT approaches that will support industrial plants to meet 21st Century market demands.

TÜV SÜD

2 Advancing industrial plant advantage | TÜV SÜD

Contents

1 INTRODUCTION 3

2 STAKEHOLDER CHALLENGES 5

3 NEW TECHNIQUES DELIVER COMMERCIAL ADVANTAGE 6

4 EXPERTISE TO RING THE CHANGES 8

5 BUSINESS BENEFITS 9

6 CONCLUSION 10

Gerhard MaritzHead of the Advanced Services Department, TÜV SÜD South Africa Pro-TecGerhard Maritz has more than 14 years of experience in non-destructive testing (NDT) related to boilers and pressure vessels, and is responsible for developing and implementing new and advanced NDT techniques. He has performed various functions in this field, including quality control on all NDT companies working for the power utilities in South Africa. He currently holds SAQCC, PCN and ASNT qualifications in numerous methods of NDT, including advanced methods such as Phased Array Ultrasonic Testing and Time of Flight Diffraction (TOFD).

About the TÜV SÜD experts

3TÜV SÜD | Advancing industrial plant advantage

Non-destructive testing (NDT) is critical in ensuring plant reliability and minimising downtime, as well as safety and conformance to legislative requirements for which plant owners and on-site engineers have responsibility.

The purpose of performing NDT is mainly to detect wear and irregularities, such as those in material and welds, as well as to detect wall thickness and to evaluate the condition and lifetime of equipment. It also delivers assurance relating to manufacturing quality, and repair and maintenance activities. NDT methods are advantageous as they involve the examination of an object without impacting its current or future usefulness.

Global industry drivers

NDT inspection services is a global growth market as governments increase their scrutiny of regulations and compel industries to perform inspections at specific intervals of time. Frost & Sullivan’s research

indicates that the total world market for NDT inspection services is expected to be valued at $5,590.4 million by 20171 (Figure 1), with other research2 predicting that the total market will generate revenue of $6.88 billion by 2020, at a CAGR of 8.96% between 2014 and 2020.

1. Introduction

600.0

1,600.0

2,600.0

3,600.0

4,600.0

5,600.0

6,600.0

2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017

CAGR: 9.0%

North America Europe Asia Pacific Rest-of-World Note: All figures are rounded; the base year is 2010. | Source: Frost & Sulivan

FIGURE 1: TOTAL NDT INSPECTION SERVICES MARKET: REVENUE FORECAST BY GEOGRAPHIC REGION (WORLD), 2007 - 2017


Power generation

The power generation industry is the main driver of NDT inspection growth. With a rise in global energy demand, there has been an increase in the number of power plants under construction and for the availability of existing ones. Hence, Frost & Sullivan expects the power generation industry to witness the highest growth in the NDT inspection services, with CAGR of 11.7%.

Oil & gas

The oil and gas industry has also seen dramatic growth, contributing over 50 percent of overall NDT global revenues1, as the stringent government safety regulations for this industry creates high demand (Figure 2). This is due to some incidents in such installations in the past, as well as ageing infrastructure.

The refineries in the oil and gas sector are regulated to perform

compliance-based maintenance inspections, particularly so in North America where there is a high level of government safety regulations that stipulate inspection must be carried out periodically.

Manufacturing and process

Manufacturing and the related aspects of quality control/quality assurance is another main driver for NDT services in the process plant industry, especially in the automotive and aviation sectors, where quality and safety are paramount.

The expectations of products’ capability, as well as their quality, is steadily rising across all industries. Quality issues are often related to highly expensive corrective actions and repair, especially where serial products are involved. Consequently, serial products in mass-goods are increasingly subject to NDT inspections in order to avoid fatal breakdowns.

As global economies recover and grow, demand for NDT inspection in the manufacturing industry is also expected to grow.

NDT growth sectors

This growth is due to:

■■ Rapid rate of large-scale infrastructure projects in emerging economies (Brazil, South-Africa, China, India) drives demand, particularly in the power generation sector.

■■ Ageing infrastructure needs periodic condition monitoring and supervision of the residual life time of components and installations.

■■ Increasing demand for higher availability of installations (e.g. power plants) due to growing demand for electricity and production capacity. This means that there is greater demand on the flexibility of industrial production, which has changed operation conditions. Shutting down operations also has high cost implications.

■■ Increasing risk awareness and focus

on prevention ignites demand for NDT inspection. This is a key driver for the market in geographic regions such as Asia Pacific, Americas, the Middle East, and Africa where traditionally a lack of awareness has inhibited demand. But, with a drive towards safety from end users and an improved understanding of the importance of NDT, demand for NDT inspection services has increased.

Oil and Gas

Power Generation

Petrochemical and Chemical Industries

Manufacturing and Process Industries

Other

FIGURE 2: TOTAL NDT INSPECTION SERVICES MARKET: PERCENT OF REVENUES BY END USER (WORLD), 2010

Note: All figures are rounded; the base year is 2010. Source: Frost & Sulivan Analysis

53.0%

15.5%

12.3%

9.2%

10.0%


2. Stakeholder Challenges

Plant owners and engineers require NDT services to ensure compliance with design codes and statutory regulations for new construction projects, as well as for maintenance of existing plants.

Downtime

In the present highly competitive world, shutting down operations even for a few minutes, has high cost implications. Plant owners, and the engineers responsible for safety, output, production and maintenance, must therefore minimise plant downtime to avoid loss of production in order to maximise revenues.

As well as a commercial requirement to maintain a high level of personnel safety and plant operation uptime, government safety regulations have also resulted in an increased demand by owners and engineers for compliance-driven inspections, which can increase operation downtime. However, end users of NDT inspection services are also realizing the importance of prevention as failures can incur severe financial penalties.

Life extension

The costs involved in building new infrastructure have resulted in stakeholders’ desire to extend the useful life of existing infrastructure. This has resulted in ageing assets being required to run at higher capacities.

These ageing assets therefore have to be inspected periodically to keep availability at a reasonable level and to be assured of installation safety. The high level of maintenance required to preserve and run these assets at full capacity has therefore created immense demand from stakeholders for NDT inspection services.

Tighter regulation

Compliance-driven inspection due to strict government regulations is also a key driver for stakeholder demand for NDT inspection services. Fatal accidents, especially in the oil & gas industry in the past, have resulted in tighter regulations to cover a wide range of industries. Consequently, there has been an increase in the amount of inspection that must be

undertaken, irrespective of financial viability.

Knowledge gap

There is a need to maintain high quality inspection to avoid accidents, which cause not only monetary but also human loss. However, the amount of training required for new advanced techniques, and the growing scrutiny of inspection and safety aspects, has increased the costs of having this expertise permanently in-house. It has therefore made it more financially viable for stakeholders to outsource NDT services to professional suppliers.

In the rapid growth, emerging economies of BRICS (Brazil, Russia, India, China and South Africa)2 this in-house skills shortage is even more evident, as they experience a rapid rate of infrastructure development. As the industry is still in its infancy in these countries, stakeholders face a knowledge gap of how to maximise plant uptime through proactive inspection and maintenance procedures. This necessitates outsourcing for certain advanced techniques.

STAKEHOLDER NDT CHALLENGES

Stakeholder NDT

Challenges

Downtimeshutting down

operations even for a few

minutes has high cost implications

Life extensionageing assets are required to run at higher capacities

Knowledge gapfinancially viable for stakeholders

to outsource NDT services

Tighter regulation

tighter regulations

cover a wide range of

industries


The key difference between traditional (radiography) and advanced technologies (phased array ultrasonic testing & time-of-flight diffraction) is that the advanced technologies provide qualitative and quantitative information.

If phased array ultrasonic testing (PA) and time-of-flight diffraction (TOFD) techniques are performed correctly, the quality of performance is therefore superior when compared with radiography. This means that the confidence level of the structural integrity of products inspected using such advanced approaches is higher than for those using more traditional techniques.

Comparing traditional with advanced technologies Radiography (RT)

RT is the oldest established NDT method used for volumetric inspections. However, there have always been valid concerns about using radioactive sources and radiation creating devices to conduct internal inspections. Its application also means long downtimes for site evacuation, and potential safety risks.

RT is also more costly and less time efficient than newer techniques, consequently there is a distinctive trend toward the use of PA for weld inspection in the pipeline industry, using a combination of phased array and TOFD inspection techniques.

Phased array ultrasonic testing (PA)

Phased array (as shown in Figure 3) offers significant technical advantages for testing and plant monitoring over

conventional ultrasonics, as the beams can be steered, scanned, swept and focused electronically from a fixed probe position.

This means that high-speed inspections can be achieved, minimising plant downtime using single-axis scans instead of conventional raster scan. Areas of complex parts or thick components can also be more easily and accurately assessed, including better detection in austenitic materials and dissimilar metal welds.

Time-of-flight diffraction (TOFD)

TOFD (as shown in Figure 4) is an advanced computerised NDT technique and has now been accepted as an alternative to RT in pre-service inspections with standards such as ASME 2235. TOFD delivers many advantages,

including improved sizing and probability of defect detection (POD), as well as more rapid scanning speeds. Due to its sensitivity and sizing accuracy, TOFD is also an excellent tool for in-service material and flaw monitoring. For example, boiler engineers who are monitoring root erosion, stress corrosion cracking, vessel cladding, hydrogen attack, as well as weld and steam chest cracks, often use TOFD as part of an ongoing inspection regime.

Advanced ultrasonic regulations

The American Society for Mechanical Engineers’ (ASME) full series of Mandatory AUT (Automated Ultrasonic Testing) and Phased Array (PA) Appendices in Section V (NDE)4, cover most aspects of advanced ultrasonic inspection (adding in TOFD), and are specifically aimed at boiler and piping inspections.

3. New techniques deliver commercial advantage

PHASED ARRAY RADIOGRAPHY

DETECTABILITY CHARACTERISATION DETECTABILITY CHARACTERISATION

Porosity Acceptable Acceptable Good Good

Inclusions Acceptable Acceptable Good Good

Lack of root fusion Good Good Poor Poor

Lack of side wall fusion Good Good Poor Poor

Weld toe crack Good Good Acceptable Good

Excess penetration Acceptable Acceptable Good Good

Wormhole / piping Acceptable Acceptable Good Good

Weld root crack Good Good Acceptable Acceptable

Root concavity Good Acceptable Acceptable Acceptable

Lack of root penetration Good Good Good Good

COMPARISON BETWEEN INSPECTION PERFORMANCES OF PA AND RT


This is used within the North America market, and is mandatory for any manufacturers importing products into the region. Consequently, ASME is also used by American companies which build industrial plants all over the world, and provides an excellent benchmark for inspection practices globally.

ASME published all three AUT Codes [16-18] and two phased array codes in July 2010. One mandatory appendix is for workmanship criteria, one for fracture mechanics, and one for procedure qualification. These mandatory appendices include:

■■ Calibrate all waveforms, independent of angle or path length.

■■ Scan Plans, are required and can be done using an appropriate computer program.

■■ Scanning speed and step size. ASME has defined what is tolerable, as if you scan too quickly there will be data drop outs. Likewise, thicker components require less coverage.

FIGURE 3: PHASED ARRAY PULSE-ECHO TECHNIQUE

Source: Ultrasonic Weld Inspection Solutions, Olympus

FIGURE 4: TIME-OF-FLIGHT DIFFRACTION (TOFD) TECHNIQUE

Improved accuracy

The quality of performance for PA and TOFD techniques is superior, meaning that the confidence level of the structural integrity of products inspected is higher than for those where radiography has been used.

RT only produces a two-dimensional image. Consequently, unlike PA and TOFD, depth information is not included, so the exact location of the flaw cannot be definitively identified.

It is also possible to characterise and size many defects using the newer approaches. Flaws can also be characterized and sized in terms of length, height, depth and volumetric position for better engineering assessment.

RT is also often unable to detect the delicate flaws which PA can, especially in thick sections of material. For example, lack of both penetration and fusion are two of the most dangerous defects, and are

sometimes difficult to distinguish with RT.

The use of the direct creeping wave technique (Figure 5) is useful for the detection of surface breaking defects. This is because the Phased Array and TOFD application guarantee the coverage of the entire volume of the weld. Consequently, the simultaneous use of the direct creeping wave ensures accurate detection of defects on the inspection surface, in particular for the TOFD technique.

Advancement delivers advantage

FIGURE 5: SURFACE WAVE TECHNIQUE


Cost reductions

The push for cost reductions within industry, coupled with the growing restrictions in the use of RT, has driven the need for alternative weld inspection methods, such as TOFD and PA. Indeed, such new technology has now made inspections commercially viable as they are now more cost effective.

At first sight, the inspection costs of PA and/or TOFD appear higher than the costs of conventional RT. However, because radiation is not a factor when using the more advanced techniques, there can be

huge savings associated with the avoidance of the disruption of works on site.

Also, relatively large costs and space allocations are required for a radiographic laboratory. Operating costs are often high because as much as 60% of the total inspection time can be spent in setting up for an RT inspection. This means that PA and TOFD operating costs are lower and there are no extra costs for processing or the interpretation of film3.

The speed of PA and TOFD therefore shortens the overall inspection time

and also eliminates plant downtime and the other costs associated with RT, as fast inspection is carried out in near real time. By using a more accurate inspection technique, there is also a higher repair rate due to the more stringent acceptance criteria of PA and TOFD.

Health & safety

With TOFD and PA, there are much less health & safety implications, as compared to RT. This means that costs and time associated with personnel training are removed. Also, less people are required to carry out the testing.

Understanding commercial pressures, TÜV SÜD supports clients with specialist NDT services across the energy (power plant and upstream oil & gas) and production industries. Our plant engineering experts understand the commercial pressures that clients face and the importance of minimising plant downtime during inspection. Consequently, we ensure that our engineers have the technical expertise and experience to support you in carrying out challenging NDT tasks across all relevant fields of applications.

Maximise availability

To maximise plant availability, reduce the risk of production failure and maximise safety, TÜV SÜD’s inspections provide assurance that equipment is in the correct condition. As a basis for damage reports, our

experts therefore carry out NDT on components, systems and materials for quality assurance. We also offer services to address turnaround at industrial plants, including turnaround management and evaluation of results.

Inspection expertise

In the NDT industry, methods for inspection are complex and require well-trained technicians to operate the equipment and analyse data to maintain a high-level of inspection quality. In particular, PA and TOFD

4. Expertise to ring the changes


requires operators skilled in the phased array technique and these are not always readily available in-house, which is where TÜV SÜD’s team of experts can support your business.

We are able to support you with an understanding of NDT practices and regulations as our experts have between four to six years Phased Array and TOFD experience – all are qualified to PCN Level 2 Phased Array and TOFD. Also, trained to perform testing in accordance with all international standards, our specialists are certified in accordance

with UIC 960 (DIN 27201-7), EN ISO 9712 (superseding EN473), ISO 9712 , PCN, SNT-TC-1A and EN4179/NAS410.

Minimise the knowledge gap

TÜV SÜD offers a complete package of knowledge services, testing and training solutions to assist you with all aspects of the NDT process including organisation, coordination, testing and recommendation of measures.

To expand your in-house knowledge, we can assist you in developing a written practice describing staff

training, experience and examination requirements. We also train and certify your staff in accordance with SNT-TC-1A of the American Society for Non-destructive Testing, EN ISO 9712 (superseding EN473), ISO 9712.

Asset Integrity Management (AIM)

TÜV SÜD can build an AIM system on top of the NDT results to maximise data analysis that ensures service and performance integrity while protecting health, safety and the environment - major concerns for all plant owners and operators.

TÜV SÜD is able to support you with an unrivalled understanding of NDT practices and regulations. Our experts’ in-depth experience of Phased Array and TOFD makes it more financially viable for you to outsource, rather than maintain in-house support, enabling you to:

■■ Optimise plant safety, minimise environmental and liability risk – through local expertise backed-up by TÜV SÜD’s international team of NDT experts, assuring a consistently high level of quality and safety in plant construction, refurbishment and maintenance.

■■ Improve operational availability and minimise downtime – working with TÜV SÜD to identify weaknesses before they result in unscheduled downtime of your plants to maximise plant productivity.

■■ Minimise cost – by using cost-effective support for critical

decisions in defect determination and component replacement.

■■ Reduce liability risk – and prove due diligence in the maintenance of boiler systems, using the support from TÜV SÜD.

■■ Outsource expertise to TÜV SÜD – means that there is no requirement to maintain in-house expertise, just ‘buy-in’ when needed.

■■ Benefit from impartial services – as TÜV SÜD does not have a preference for specific vendor product offerings, we are focused on maximising your business’s compliance and commercial success.

NDT trials maximise plant uptime

A major TÜV SÜD client recently invited our team to perform phased array inspection trials on small bore piping. Until this time, the client had relied on RT, experiencing a loss of production when the site had to be

cleared to perform inspections.

During the blind and site trials, TÜV SÜD was able to prove the increased benefit of using PA and TOFD, particularly as these techniques are better able to detect the more serious planar defects. Consequently, defective components were flagged for replacement during normal maintenance, rather than only becoming apparent when the components completely failed and caused an unplanned and costly shutdown of the plant.

Also, during the inspection process, welders, fitters and general labourers were not required to vacate the site, maximising plant production levels. The TÜV SÜD team also proved that TOFD provides a faster solution than PA to identify any major problems on the weld, and is thus a very quick GO/NO-GO technique.

5. Business benefits


6. Conclusion

Commercial pressures, created from the demand for ageing infrastructure to expand capacity while fulfilling the requirements of increasingly stringent regulations, necessitates a new approach to NDT that has evolved to meet 21st Century market demands.

PA and TOFD are the new NDT approaches that will support industrial plants in their quest to minimize downtime and remain competitive in the global marketplace. Both deliver

significant advantages over the old RT approach, including faster inspection times, greater accuracy and reduced cost, while minimizing downtime and liability risk.

However, while these new techniques deliver significant benefits, their advanced approach has created a knowledge gap within the industries.Consequently, stakeholders are recognizing the value in outsourcing inspection services to expert

organizations such as TÜV SÜD.

TÜV SÜD’s comprehensive service addresses the entire range of NDT coordination, implementation, documentation and training requirements. Offering unbiased inspection and assessment services, with an established international presence, our vast expertise means we can support you across the entire range of NDT applications.


COPYRIGHT NOTICEThe information contained in this document represents the current view of TÜV SÜD on the issues discussed as of the date of publication. Because TÜV SÜD must respond to changing market conditions, it should not be interpreted to be a commitment on the part of TÜV SÜD, and TÜV SÜD cannot guarantee the accuracy of any information presented after the date of publication.

This White Paper is for informational purposes only. TÜV SÜD makes no warranties, express, implied or statutory, as to the information in this document. Complying with all applicable copyright laws is the responsibility of the user. Without limiting the rights under copyright, no part of this document may be reproduced, stored in or introduced into a retrieval system, or transmitted in any form or by any means (electronic, mechanical, photocopying, recording, or otherwise), or for any purpose, without the express written permission of TÜV SÜD. TÜV SÜD may have patents, patent applications, trademarks, copyrights, or other intellectual property rights covering subject matter in this document. Except as expressly provided in any written license agreement from TÜV SÜD, the furnishing of this document does not give you any license to these patents, trademarks, copyrights, or other intellectual property. ANY REPRODUCTION, ADAPTATION OR TRANSLATION OF THIS DOCUMENT WITHOUT PRIOR WRITTEN PERMISSION IS PROHIBITED, EXCEPT AS ALLOWED UNDER THE COPYRIGHT LAWS. © TÜV SÜD Group – 2015 – All rights reserved - TÜV SÜD is a registered trademark of TÜV SÜD Group

DISCLAIMERAll reasonable measures have been taken to ensure the quality, reliability, and accuracy of the information in the content. However, TÜV SÜD is not responsible for the third-party content contained in this publication. TÜV SÜD makes no warranties or representations, expressed or implied, as to the accuracy or completeness of information contained in this publication. This publication is intended to provide general information on a particular subject or subjects and is not an exhaustive treatment of such subject(s). Accordingly, the information in this publication is not intended to constitute consulting or professional advice or services. If you are seeking advice on any matters relating to information in this publication, you should – where appropriate – contact us directly with your specific query or seek advice from qualified professional people. The information contained in this publication may not be copied, quoted, or referred to in any other publication or materials without the prior written consent of TÜV SÜD. All rights reserved

© 2016 TÜV SÜD.

FOOTNOTES[1] Frost & Sullivan - World Nondestructive Test Inspection Services Market Report[2] Markets and Markets - Non-Destructive Testing Equipment & Services Market - Analysis & Global Forecast to 2013.[3] UK Health & Safety Executive - Replacement of Radiography by Ultrasonic Inspection.[4] ASME Codes and Standards for Boiler Inspections, Michael Moles, Olympus NDT

NDTPA

TOFDRT

PODAUTNDEAIM

- non-destructive testing - phased array ultrasonic testing - time-of-flight diffraction - radiography - probability of defect detection - automated ultrasonic testing - non-destructive examination - asset integrity management

GLOSSARY OF ACRONYMS

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Find out more about TÜV SÜD’s NDT services for industrial plants and systems: www.tuv-sud.com/[email protected]

Choose certainty. Add value. TÜV SÜD is a premium quality, safety and sustainability solutions provider that specialises in testing, inspection, auditing, certification, training and knowledge services. Represented in over 800 locations worldwide, we hold accreditations in Europe, the Americas, the Middle East, Asia and Africa. By delivering objective solutions to our customers, we add tangible value to businesses, consumers and the environment.

GLOBAL HEADQUARTERSTÜV SÜD AGWestendstr. 19980686 Munich Germany+49 89 5791 0www.tuv-sud.com

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Advancing industrial plant advantage - TÜV SÜD · Advancing industrial plant advantage Driving industrial plant performance through advanced NDT methods. White paper ... PCN and