An introduction to the services offered by. Quality Maritime Surveyors Pty Ltd

Transcription

1 An introduction to the services offered by Quality Maritime Surveyors Pty Ltd

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3 Contents Introduction 4 Terms and De nitions Surveying NATA Accredited/AICIP Certi ed - In Service Pressure Vessel Inspection NATA Accredited/NACE Certi ed - Coating Surveying NATA Accredited/ACA Accredited - Corrosion Surveying Pitting/Defect Replication Borescopic inspection Portable Microscopy Non-Destructive Testing NATA Accredited Dye Penetrant Inspection NATA Accredited Magnetic Particle Inspection NATA Accredited Ultrasonic Weld Inspection NATA Accredited Ultrasonic Thickness and Corrosion Mapping Copper Sulphate Inspection Silver Nitrate Inspection: Production Services Linishing, Burring and Blending corrosion removal to speci ed tolerances Quality Control / Quality Assurance Professional Witnessing ISO 9001 Auditing ISO Auditing AINDT Level III Consultancy / Lab Management 15

4 Introduction 4 This document has been written to provide both customers and engineering personnel a brief introduction to the capabilities and services offered by Quality Maritime Surveyors Pty Ltd (QMS). This document will continue to be updated by Quality Maritime Surveyors. For the most recent revision of this document, please contact us via the details supplied at: After reading this document, you will have an understanding of the different types of inspection services offered by QMS, the relevant information which can be gained from employing each particular service and the relative advantages and disadvantages of each. Regards, Shaun Kennedy Director Quality Maritime Surveyors Pty Ltd Shaun.Kennedy@q-m-s.com.au

5 Terms and De nitions ACA Australasian Corrosion Association AICIP Australian Institute for the Certi cation of Inspection Personnel AINDT Australian Institute for Non-Destructive Testing ISO International Organisation for Standardisation NACE National Association of Corrosion Engineers NATA National Association of Testing Authorities 5

6 1.0 Surveying 1.1 NATA Accredited/AICIP Certi ed - In Service Pressure Vessel Inspection In service pressure vessel inspection is a visual survey conducted on boilers, pressure vessels and associated pressure equipment to determine its operational condition and to ensure the safety of the system and plant. 6 Inspections are usually carried out visually or with the aid of a bre optic camera and a detailed photographic report describing all signi cant or non-compliant areas is produced. Owners of boilers and pressure vessels and pressure equipment have an ongoing obligation to ensure that their plant is maintained in a safe operational condition for its service life and that they have in place a safe system of work associated with that plant. Regular checks, relevant tests and maintenance inspections are to be conducted at intervals as required by the manufacturer or a code of practice, where one exists. These checks, relevant tests and maintenance inspections should be recorded for the service life of the item of plant. Inspection of boilers, pressure vessels and pressure equipment should be conducted by an AICIP certi ed pressure vessel inspector and should be conducted: Before being placed in service in the workplace for the rst time. After being returned to service after major structural repairs. After being relocated, if it is normally xed plant. When signi cant alteration or addition are made to pressure retaining parts. At intervals speci ed by a code of practice (where one exists) or as determined by the manufacturer.

7 1.2 NATA Accredited/NACE Certi ed - Coating surveying Coating inspections are conducted non-destructively using visual assessment and calibrated ultrasonic or electromagnetic equipment to ascertain coating thickness, however destructive testing to determine adhesion effectiveness is also sometimes necessary on new coating procedures. NACE certi ed coating inspections can be conducted on: In service equipment to determine the extent of any coating degradation, breakdown or damage. On material substrates prior to coating application. On a newly applied protective coating system to determine if the coating complies with the manufacturing standard or applicable code. On completion of the inspection, QMS provide a detailed photographic report outlining any areas of concern or areas which fail to comply with the relevant industry standard or code. 1.3 NATA Accredited/ACA Accredited - Corrosion surveying 7 Corrosion surveying is a visual assessment to determine the type and extent of corrosion on in-service plant and equipment. Corrosion is estimated to cost $13 trillion dollars to global industry each year, or 3% of the global GDP. Early corrosion detection and prevention can help reduce down time of equipment, reduce equipment operation costs and prolong the running life of plant and equipment. QMS ACA accredited corrosion surveyors can assess any in-service plant or equipment and produce a detailed photographic report outlining the type of corrosion, the incidence of corrosion and the location to help organisations make informed decisions on plant and equipment life. As well as detection and reporting, QMS are also able to offer a full service package whereby corrosion is detected and reported, then removed and non-destructively inspected for cracking and material loss. 1.4 Pitting/Defect Replication Pitting and defect replication works by caulking a special liquid on to the surface or feature of interest. After the liquid is cured, a negative 3D replication is formed. This replication, with a dimensional accuracy of less than 0.1μm, can be used for further microscopic investigation, defect sizing and depth measurement or storage for future reference and comparison. QMS technicians can perform surface replication on virtually any solid, dry material with a temperature range between -10 C and 180 C. Areas, unable to be visually inspected such as internal thread roots may also be replicated to provide additional information.

8 8 1.5 Borescopic Inspection Borescopic inspection is a visual inspection which uses a small manoeuvrable bre optic camera to photograph or video inspection areas. Borescopic inspection is useful when access to the inspection area is dif cult or impractical e.g. engine blocks, heat exchanger tubes or pressure vessels, the small size of the inspection camera often reduces the requirement for equipment disassembly prior to inspection. QMS technicians can perform borescopic inspection and provide a detailed photographic or video report outlining the ndings.

9 1.6 Portable Microscopy Portable microscopy is used to gain high magni cation and high resolution images of defects or features unable to be inspected with a conventional metallographic or stereo microscope due to location or geomertry. QMS technicians are able to capture images with a laptop and portable USB microscope to determine defect type, defect size or for future comparison. QMS can provide a detailed photographic report of the inspection area with photographs magni ed up to 400x. Each photo included in the report contains a scale bar calibrated from a stage micrometre for reference. 2.0 Non-Destructive Testing 2.1 NATA Accredited Dye Penetrant Inspection 9 Dye penetrant inspection is a non-destructive surface test method designed to aid the visual inspection of surface breaking discontinuities. Parts being inspected using this method rst need to be thoroughly cleaned to remove any surface grease, oil, paint, scale or other contaminants which may mask any surface breaking discontinuities. Once the surface has been thoroughly cleaned and dried, the penetrant material is applied by spraying, brushing, or immersing the part in a penetrant bath. The penetrant is left on the surface for a suf cient time to allow as much penetrant as possible to be drawn into any discontinuities breaking the part surface. The excess penetrant is then removed from the surface of the sample while removing as little penetrant as possible from any discontinuity. Depending on the penetrant system used, this step may involve cleaning with a solvent, direct rinsing with water, or rst treating the part with an emulsi er and then rinsing with water. A thin layer of developer is then applied to the sample to draw penetrant trapped in aws back to the surface where it will be visible. Developers come in a variety of forms that may be applied by dusting (dry powdered), dipping, or spraying (wet developers). The developer is allowed to stand on the part surface for a period of time suf cient to permit the extraction of the trapped penetrant out of any surface aws. This development time is usually a minimum of 10 minutes. Signi cantly longer times may be necessary for tight discontinuities. Primary Applications: Inspection of material after grinding for the detection of cracks or remaining corrosion. Inspection of non-magnetic/non-metallic materials e.g. SS316, plastics etc. Inspection of large or batch components.

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11 2.2 NATA Accredited Magnetic Particle Inspection Magnetic particle inspection is a surface inspection method used to aid the visual inspection of ferrous parts for surface breaking discontinuities. Magnetic particle method involves rst cleaning the part by to remove any excess contaminants from the part surface which may mask any surface breaking discontinuities or interfere with the migration of magnetic particles during the test. After cleaning, the part surface is lightly coated with a white lacquer to aid visibility. The part is then magnetised by use of a portable magnetic yoke or by introducing an electric current into the part. Any defects open to the part surface will create a small localised north-south magnetic eld. Whilst magnetised, magnetic lings are applied to the part surface. Any surface breaking discontinuities which have created their own localised magnetic eld, attract the powdered iron lings to create a visible indication. Primary Applications: Inspection of welds in ferro-magnetic materials. Batch inspection of cylindrical components e.g. bolts, head studs, rod bar etc. Inspection of surfaces, too rough to be inspected reasonably by dye penetrant e.g. cast surface, porous materials etc. 11

12 2.3 NATA Accredited Ultrasonic Weld Inspection 12 An ultrasonic transducer pulses sound into the inspection part at a given angle. Any discontinuities perpendicular to the inspection beam re ect the sound back to the transducer and form a response. Using multiple probes of differing angles, the technician can size the internal discontinuity, classify it and plot its location within the inspection material to determine its compliance or inform production where to conduct the repair. Primary Applications. Inspection of welds following fabrication. 2.4 NATA Accredited Ultrasonic Thickness and Corrosion Mapping Ultrasonic thickness testing uses high frequency sound to measure a material thickness with the use of specialist equipment and probes. Ultrasonic thickness inspection works by pulsing sound into the test part and listening for the echo response. The thickness is determined using the time taken for the sound to travel through the part as well as the known velocity of sound in the inspection material. QMS technicians are able to perform thickness testing on both localised areas, i.e. pipe elbows or blends or over broad regions to ascertain the material pro le. Primary Applications: Determination of blend depth after corrosion removal. Detection of corrosion. Determination of plate thickness following machining. Determine the extent of corrosion/erosion of wall thickness.

13 Copper Sulphate Inspection Copper sulphate (CuS04) Inspection is a chemical spot test used by QMS technicians to identify the presence of nonferrous coatings on a ferrous substrate i.e. nickel plating on carbon steel. Copper sulphate crystals, are dissolved into a solution and sprayed or swabbed onto a part surface. When the blue copper sulphate solution comes into contact with a ferrous material, the copper plates on to the material and forms a pinkish indication, however, when the solution comes into contact with a non-ferrous material no reaction occurs. Because of this reaction, copper sulphate can be used to identify breaches in coating and identify machined areas that have been machined back to the substrate quite easily. Primary Applications: Inspection of electroplated coatings to detect breaches. Inspection of clad surfaces to detect breaches. Inspection of machined surfaces to con rm the removal of coatings.

14 2.6 Silver Nitrate Inspection Silver Nitrate (AgNO3) Inspection is a chemical test method used by QMS technicians to identify selective phase corrosion in NAB castings subjected to saltwater. Selective phase corrosion or SPC is a form of corrosion where the aluminium in the NAB is leached out of the material and replaced with a porous copper matrix. The copper can mask any visible signs of corrosion or pitting within the material even though the mechanical properties have been greatly reduced. Silver Nitrate, which is a clear solution, reacts with the free copper on the areas affected by SPC to form a visible black indication. These areas can be marked and ground out to assess the depth of damage to the item. Primary Applications: Inspection of NAB castings subjected to salt water Production Services 3.1 Linishing, Blending and Burring of corrosion removal to speci ed tolerances Areas of corrosion, detected during non destructive or visual inspection, need to be removed before coating application or weld repair. Depending on the allowable design tolerances of the part being inspected, QMS technicians can address the areas affected by corrosion in these 3 ways: Linishing linishing is generally conducted after blasting, on broad areas which have been affected by clusters of shallow corrosion pits. The peaks of these pits, which affect how paint keys or binds to the material, are removed to achieve sound coating adhesion. Blending corrosion pits, which are generally too deep to have all oxides and corrosion product removed before coating application are blended to remove all corrosion product and to create a smooth pro le which reduced the internal stresses in the part and allows for a more affective coating adhesion. Burring burring of corrosion is conducted on localized areas requiring weld repair. The affected area is grooved out with a tungsten grinding tool to remove corrosion and create a suitable pro le for nal weld repair. QMS technicians can perform all of the above production services in conjunction with survey and measuring equipment to ensure that allowable tolerances are not exceeded.

15 4.0 Quality Control / Quality Assurance 4.1 Professional Witnessing Professional witnessing is required when a client or speci- cation requests an objective, unbiased third party to witness a critical process, procedure or hold point. Primary Applications: Hydrostatic testing of pressure vessels, tanks or piping systems. Torqueing of joints and fasteners. Temperature and humidity validation prior to coating application. 4.2 ISO 9001 Auditing ISO 9001:2008 auditing can be performed on any process or procedure conducted by clients who hold ISO 9001:2008 accreditation or for those wishing to gain future accreditation. Audits, required by section 8.2 of ISO 9001:2008 can be conducted by suitably trained QMS staff and results compiled for corrective action and review at the next management meeting. Primary Applications: Con rming an organisations compliance to ISO 9001:2008. Work pack auditing prior to close out. Document and report reviewing. 4.3 ISO Auditing are looking to engage a consultant to guide them through NATA laboratory accreditation. Audits are performed on both the technical and administrative capabilities of the laboratory against the requirements of ISO and advice given on areas requiring resolution. Primary Applications: Con rming an organisations compliance to ISO Auditing technical procedures. Document and report reviewing. 4.4 AINDT Level III Consultancy / Lab Management Laboratories who currently hold or who are wishing to gain NATA accreditation for Non-Destructive Testing may wish to contract an external Level III consultant to sul ll the requirements of the laboratory manager. A level III consultant can work part time with the organisation and provide, training guidance and support on: I. Written procedure and practice II. Staff training and pro ciency III. Equipment suitability IV. Reporting and documentation requirements V. Adherence to ISO and relevant inspection standards 15 ISO auditing can be performed by the QMS NDT Laboratory Manager/Level III on any Non-Destructive Testing laboratories which hold ISO accreditation or who

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