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SA-International Ltd 29 Ahmed Allam Street, ElIbrahimaya Alexandria - Egypt Tel./Fax: +2 03 591 89 68 Web: www.sa - egypt.org E-mail: md@sa egypt.org - Technical Service Details

Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

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Page 1: Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

SA-International Ltd29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

Web: www.sa -egypt.org

E-mail: md@sa egypt.org-

Technical Service Details

Page 2: Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

1. Background on SA

Technical Papers

2. Management Vision

3. Non-Destructive Testing

4. NDT Methods

5. Oil and Gas Inspection Services

6. Rope Access Services

29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

md@sa egypt.org-

SA-International Ltd.

Page 3: Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

Rope Access technician doing EC inspection on harbour container crane

1. Background on SA

SA-International , Robe Access Inspection is based in Alexandria - Egypt and strategically placed specialized rope Access and NDT company that delivers safe‚ cost effective solutions for areas of difficult access, maintenance and inspection problems.We service a broad spectrum of industries including petrochemical (oil and gas), power generation (power stations, wind turbines), mining (diamond vessels, mines), marine (LNG, oil, bulk carriers and passenger liners), chemical (refineries), and construction (buildings, fabrication).

Through the selective application of our teams and rope access qualified inspectors we are able to truly improve turnaround time on any project and as a result save our clients a lot of time and money.

2. Management Vision

To become the most sought-after Rope Access and NDT company world wide. Never sacrificing quality; relying on the integrity and honesty of our inspector is a key to the success of the work being done. Making every effort to ensure that our client's needs are met in a professional and safe manner. We at Rope Access Inspection (RAI) believe that our employees are our biggest asset. Therefore we continue to invest in our employees, their education and their training.

29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

md@sa egypt.org-www.sa-egypt.org

SA has established itself as a safe, effective and cost effective solution to the Petrochemical industry.

SA-International Ltd.

Page 4: Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

SA-Rope Access Inspection in conjunction with its partner company Tech Corr & EIL provide several High technology NDT The most common are as following: - Power Plant Inspection - Pipeline Inspection - In Tank Robotic Inspection - Expandable Eddy Current Spinner System - Robe Access - Guided Wave ultrasonic Testing - Pressure Vessel Inspection

3. Non-Destructive Testing

The field of Non-destructive Testing (NDT) is a very broad, interdisciplinary field that plays a critical role in assuring that structural components and systems perform their function in a reliable and cost effective fashion. NDT technicians and engineers define and implement tests that locate and characterize material conditions and flaws that might otherwise cause planes to crash, reactors to fail, trains to derail, pipelines to burst, and a variety of less visible, but equally troubling events. These tests are performed in a manner that does not affect the future usefulness of the object or material. In other words, NDT allows parts and material to be inspected and measured without damaging them. Because it allows inspection without interfering with a product's final use, NDT provides an excellent balance between quality control and cost-effectiveness. Generally speaking, NDT applies to industrial inspections. The technologies that are used in NDT are similar to those used in the medical industry, but nonliving objects are the subjects of the inspections.

In the oil and gas industry, particularly in the new construction and maintenance stage for refineries, offshoreand onshore installations, NDT is widely used and compulsory to check the integrity of the vessel, tank, piping and other equipment. Most widely used nowadays including RT (radiographic x-ray), UT (ultrasonic), MPI (magnetic particle inspection), LPI (Liquid penetrant inspection), and EC (Eddy Current).

29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

md@sa egypt.org-www.sa-egypt.org

SA-International Ltd.

Page 5: Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

4. NDT Methods

RADIOGRAPHIC X-RAY TESTING (RT)

Material property evaluation includes the determination of composition, density, uniformity, and cell or particle size. Manufacturing and assembly property evaluation is normally concerned with dimensions, flaws (voids, inclusions, and cracks), bond integrity (welds, brazes, etc.), and verification of proper assembly of component pieces.

WHAT IS THE 'SCAR' SYSTEM?Radiography is a well-established conventional NDT technique with inherent risks associated with the use of radiation. Managing the safety risk by the setting of ‘controlled areas’ has the adverse affect of reducing clients’ production time. The system enables radiography to be performed in the heart of the workplace without disruption to normal operations.

SA in conjunction with Tech Corr & EIL Ltd can Offer the Following Radiographic services:

* Conventional Gamma Radiography (Iridium 192).* Heavy Wall Gamma Radiography (Cobalt).* Conventional X-Radiography.* Micro Focus X-Radiography.

29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

md@sa egypt.org-www.sa-egypt.org

SA-International Ltd.

This technique involves the use of penetrating gamma or X-radiation to examine parts and products for imperfections. An X-ray machine or radioactive isotope is used as a source of radiation. Radiation is directed through a part and onto film or other media. The resulting shadow-graph shows the internal soundness of the part. Possible imperfections are indicated as density changes in the film in the same manner as an X-ray shows broken bones. Radiographic applications fall into two distinct categories evaluation of material properties and evaluation of manufacturing and assembly properties.

Page 6: Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

ULTRASONIC FLAW DETECTION and THICKNESS GAUGING (UT)

Ultrasonic Testing (UT) uses high frequency sound energy to conduct inspections and take measurements. UT inspection can be used in various ways, some of them are: flaw detection/evaluation, dimensional measurements, finding out characteristics of certain materials, thickness gauging and many more. Below is a basic diagram to illustrate how UT inspection works.

Ultrasonic Inspection is a very useful and versatile NDT method. Some of the advantages of ultrasonic inspection are:

* Able to detect both surface and sub-surface discontinuities.* The depth of penetration for flaw detection & measurement is far greater than that of any other NDT methods.* Usually only access to one side of the test piece is required. Easily able to determine corrosion on internal pipe walls.* UT is highly accurate in determining the flaw / reflector position and able determine size and shape.* Minimal preparation is required for test piece.* Specialized electronic equipment provides instant results.* No need for costly scaffolding to perform routine inspections on pipelines .* Small hand held machines un-cumbersome and make it easy for rope access technicians to access confined spaces and high locations.* Other areas UT is commonly used is on refineries, FPSO's, tank inspection, chemical plants and production platforms for corrosion monitoring and assessment of material.

As with other NDT methods, Ultrasonic testing has its limitations, these include:

* Surface must be accessible in order to conduct UT inspection.* High operator skill & extensive training is required.* It usually requires a coupling medium (i.e. Water, Ultrasonic Gel, Heat Gel).* Materials are hard to inspect when they; have a rough surface, are irregular in shape, are very small and exceptionally thin.* Certain materials i.e. Iron & coarse grained materials, are difficult to inspect due to high noise, sound scatter and low penetration.* Defects parallel to the sound beam may go undetected.

29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

md@sa egypt.org-www.sa-egypt.org

SA-International Ltd.

Page 7: Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

MAGNETIC PARTICLE INSPECTION / MAGNETIC TESTING (MPI / MT)

Magnetic particle inspection (MPI) is a non-destructive testing (NDT) method used for detection of surface defects. MPI is fast and relatively easy to apply, and component surface preparation is not as critical as for some other NDT methods. These characteristics make MPI one of the most widely used NDT testing methods in the world.

MPI uses magnetic fields, induced by a electric magnet and small magnetic particles (i.e. iron filings) to detect flaws in components. The only requirement is that the part being tested is a ferromagnetic material such as iron, nickel, cobalt, etc. Ferromagnetic materials means that the material can be magnetized enough to allow the inspection to take place and be effective.MPI is used to inspect a large variety of products including castings, forgings and welding. Many different industries use MPI to determine the fitness-for-use of components, among those industries are automotive, petrochemical, power generation, marine engineering and even the aerospace industry.

The advantages of MPI are:* MPI inspection is generally simple to operate and apply.* Can inspect parts with irregular shapes easily.* Precleaning of components is not as critical as it is for some other inspection methods. Most contaminants within a flaw will not hinder flaw detect ability.* The test is visual, so any indications can be seen and recorded (i.e. Photos).* Very fast and effective to test large areas for minor defects.* Considered low cost compared to many other NDT methods.* Is a very portable inspection method especially when used with battery powered equipment.

Some of the disadvantages are:* Cannot inspect non-ferrous materials such as aluminium, magnesium or most stainless steels.* Inspection of large parts may require use of equipment with special power requirements.* Some parts may require removal of coating or plating to achieve desired inspection sensitivity.* Limited subsurface discontinuity detection capabilities. Maximum depth sensitivity is approximately 1.0cm (under ideal conditions).* Post cleaning, and post demagnetization is most often necessary.* Alignment between magnetic flux and defect is important.

29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

md@sa egypt.org-www.sa-egypt.org

SA-International Ltd.

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DYE PENETRANT INSPECTION / PENETRANT TESTING (DPI / PT)

Dye Penetrant inspection (DPI), is also called Penetrant Testing (PT), and it is a widely applied, low-cost inspection method used to locate surface-breaking defects by use of bleed out of a coloured or fluorescent dye in the defect. This technique can only be on all non-porous materials, such as metals, plastics, or ceramics. PT is used to detect casting and forging defects, cracks, and leaks in new products, and fatigue cracks on in-service components.This technique uses the capillary action to draw the Penetrant in the flaw to the clean surface, thereby giving the inspector a visual indication of the defect.

Some of the Advantages of Penetrant Testing are:

* High sensitivity to be able to detect small surface discontinuities.* PT has few material limitations able to inspect metallic and non-metallic, magnetic and nonmagnetic, conductive and nonconductive materials.* Large areas, test pieces and large volumes of parts/materials can be inspected quickly with relatively low cost.* Parts with complex geometric shapes are often, easily inspected.* Indications are surface breaking, giving the technician a visual representation of the flaw.* It is very portable, due to the use of aerosol spray cans.

Some of the Disadvantages of Penetrant Testing are:

* Only defects that break the surface can be detected.* Only relatively nonporous materials can be inspected.* If pre-cleaning is insufficient, contaminants can easily mask defects.* Metal smearing from machining, grinding, needle gunning, grit or vapour blasting has to be removed prior to LPI.* The inspector must have direct access to the surface being inspected.* Surface finish and roughness can very easily affect the inspection sensitivity and results.* Temperature of materials can affect test results.* Post cleaning if generally required of acceptable parts after inspection is complete.

29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

md@sa egypt.org-www.sa-egypt.org

SA-International Ltd.

Page 9: Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

EDDY CURRENT INSPECTION / EDDY CURRENT TESTING (ECI / ET)

Eddy currents are created in the test piece through a process called electromagnetic induction. When alternating current (AC) is applied to the conductor, such as copper wire, a magnetic field develops in and around the conductor. The magnetic filed expands as the alternating current rises collapses as the current is reduced to zero. If another electrical conductor (i.e. Test Piece) is brought into the close proximity to this changing magnetic field, eddy currents will then be induced into this second conductor.

The major advantage of eddy current inspection is the variety of inspections and measurements that can be performed. Eddy current inspection can be used for:* Crack detection (i.e. Welding).* Material thickness measurement (with limitations).* Coating thickness measurements (i.e. Paint Thickness).* Conductivity measurements for:

Material identification.Heat damage detection.Heat treatment monitoring.

Some of the major advantages of eddy current inspection include:

* Sensitive to small cracks and other defects, this is a great tool when it comes to in service components or high stress components (i.e. Flare Drums, Flare Stacks and piping).* Detects surface and near surface defects.* Electronic equipment give immediate feedback.* Equipment is very portable, ideal for Rope Access use.* The item being tested need minimal surface preparation, i.e. crane boom can be inspected without removing coating system. Saving time and money…………!* Ability to inspect complex shapes and sizes of different conductive materials.

Some of the limitations of eddy current inspection include:

* Only materials that are conductive can be inspected.* High skill and extensive operator training is required.* Surface finish, roughness or even rust may interfere with inspection.* A individual reference standards is needed for each different conductive test piece.* Depth of penetration is limited.

29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

md@sa egypt.org-www.sa-egypt.org

SA-International Ltd.

Page 10: Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

5. Oil & Gas inspection services

PRESSURE VESSEL INSPECTIONS AND SURVEYSStatutory inspection, wall thickness surveys, visual inspection and pressure testing is carried out by qualified inspectors. All types and sizes of vessels can be handled. Inspection reports and certification is provided to satisfy legal requirements. Ideally suited for Refineries, FPSO's, production platforms and Mines

WELDING INSPECTION AND SURVEILLANCEIn process welding surveillances and final inspection is carried out by CSWAP qualified Welding Inspectors. This ensures that the welding processes and parameters comply with the stipulated weld procedure specifications. Final visual inspection supplemented with the relevant Non Destructive Examination Techniques is conducted to determine acceptability within the manufacturing codes acceptance criteria. Review of supporting welding documentation is also carried out to determine full compliance to code requirements.

WELD PROCEDURE AND WELDER QUALIFICATIONWeld Procedure Specifications can be generated according to specific client requirements and conditions. These procedures are then qualified by welding prepared test pieces under controlled conditions witnessed by an Welding Inspector. The relevant inspection and mechanical testing is then carried out under the auspices of SA following which the Procedure Qualification Record is issued. Welder Performance Testing is also carried out in a similar manner.

STRUCTURAL AND PIPING CORROSION SURVEYSMany structures and piping systems particularly in the mining, oil & gas, petrochemical, and marine industries are exposed to severe environmental conditions. Various forms and degrees of corrosion can leave members and pipes severely weakened or thinned and vulnerable to catastrophic failure. SA specialize in evaluating the integrity of structural steelwork and piping systems through an initial inspection survey. In addition inspection maintenance schedules can be set up in conjunction with a software package specifically developed by Euro-Technology whereby periodic inspections are carried out. Results are downloaded on to the system and in this way condition monitoring takes place identifying potential failure areas.

INSPECTION AND QUALITY CONTROL OF FABRICATION AND ERECTION ACTIVITIESSA supply inspection personnel to monitor sub -contractor performance on behalf of clients. Planned inspection and Q.C. activities can be applied to any fabrication or erection activity ensuring that client requirements and specifications are adhered to and satisfied.

29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

md@sa egypt.org-www.sa-egypt.org

SA-International Ltd.

Page 11: Technical Service Details - SA-INTERNATIONALsa-egypt.org/yahoo_site_admin/assets/docs/SA-Rope_Access.6640307… · Technical Service Details. ... ULTRASONIC FLAW DETECTION and. THICKNESS

29 Ahmed Allam Street, ElIbrahimayaAlexandria - EgyptTel./Fax: +2 03 591 89 68

md@sa egypt.org-www.sa-egypt.org

SA-International Ltd.

6. Rope Access services

The following services are available for the oil & gas, chemical, energy, mining and marine sectors. Locations could include: tanks, vessels, pipe work, pipe racks, tankers, FPSO's, ships, drill rigs, rigs, plants and refineries, barge cranes, shipyards, offshore cranes, offshore / onshore installations, derricks, flare stacks and any location at height.

ASSISTED INSULATION REMOVAL AND REINSTATEMENTThe removal and reinstatement of insulation plays such a vital role in the oil & gas, chemical, energy, mining and marine sectors, as condensation can accumulate under the insulation and cause sever damage to assets.RAI can strategically assign teams to assist insulators on projects, minimizing the cost of expensive scaffolding and dramatically reducing time on site. Then after removal SA can inspect, re -furbish and re-coat the asset.

COATING REMOVAL AND RE-APPLICATIONTo scaffold a tower, mast, derrick, flare tower, vessel, pontoon or anything large in size, takes time, money and a large labour force. All of this merely to gain access to inaccessible areas. Skilled experts then need to still be contracted in to perform the job. SA provides the solution by combining these tasks into one service. RAI's teams can access, clean, prep and coat in almost half the time it would take conventional methods, using HP water blasting, grit blasting or mechanical methods.

RIGGING, INSTALLATION AND REMOVAL of NEW or OLD EQUIPMENTSA has experienced riggers, welders, electrical or artisans available. Our expertise has been called on to install a variety of high-rise equipment and provide the regular in-situ maintenance and inspection, that are necessary for safe and lawful operation in the oil, gas, chemical and marine sectors