Non-Destructive Testing Methods in Energy Operations

Underwater Non-Destructive Testing, MPI with fixed magnets Magnetic Particle Inspection (MPI) is a widely used non-destructive testing method designed to detect surface-breaking flaws in ferromagnetic materials. While it’s common in dry environments, MPI can also be performed underwater, a scenario that introduces unique challenges but also inspires creative adaptations. One particularly technical solution involves the use of fixed permanent magnets, a technique that blends simplicity with reliability. In underwater conditions, using electromagnets or electrical yokes poses logistical and safety issues. Power supply, waterproofing and diver mobility all become critical concerns. Fixed magnets offer a clean alternative: two powerful permanent magnets, typically made of neodymium, are positioned on either side of the area to be inspected. This creates a stable magnetic field through the component, without the need for cables or external power sources. To reveal cracks or defects, magnetic particles suspended in a liquid (usually water-based) are applied to the surface. These particles accumulate where the magnetic field is disturbed, such as at a crack, making the invisible suddenly visible. In clear water and with proper lighting, the indications can be observed directly by a diver or through a camera system. This method is not only efficient but also inherently safe and portable, making it ideal for inspections on offshore platforms, mooring systems and other critical marine structures. It’s especially useful in maintenance operations where speed, simplicity, and repeatability are essential. While it does have limitations, such as being restricted to ferromagnetic materials and requiring careful orientation, it remains a highly valuable tool. It’s a great example of how non-destructive testing adapts to challenging environments, maintaining structural integrity even beneath the surface. #NDT #CommercialDiving #UnderwaterInspection #MagneticParticleTesting #SubseaEngineering #NonDestructiveTesting #OffshoreMaintenance #AssetIntegrity #WeldingInspection #UnderwaterMPI #Tecnosub🇪🇸

Ever wanted to see inside a metal without cutting it open? In materials science, destructive testing gives us micrographs and tensile curves, but what if you don’t want to alter the part? That’s where Non-Destructive Testing (NDT) comes in. And while many NDT methods are known for finding cracks or flaws, some can also reveal phase information and composition, without damaging the metal. Here are a few powerful NDT techniques used for phase identification and elemental analysis in metals: ⸻ 1. X-Ray Diffraction (XRD) • Purpose: Phase identification, crystallinity, residual stress • How it works: Each phase has a unique diffraction pattern. XRD detects this “fingerprint.” • Bonus: Can detect retained austenite, martensitic transformation, or precipitation in alloys. • Non-destructive? Yes, as long as surface prep is minimal. ⸻ 2. X-Ray Fluorescence (XRF) • Purpose: Rapid elemental composition • How it works: Excites atoms and measures secondary X-rays emitted, which are element-specific. • Use cases: Sorting unknown alloys, verifying heat treatments, PMI (Positive Material Identification). • Portable versions? Absolutely. Perfect for field inspections. ⸻ 3. Neutron Diffraction • Purpose: Phase analysis, texture, and residual stress- even deep inside • How it works: Neutrons penetrate deeply and diffract from atomic planes, revealing internal structures. • Why it’s cool: You can analyze large components and still detect internal phase transformations. • Limitation: Access to a neutron source (reactor or spallation facility) might be hard. ⸻ 4. Optical Emission Spectroscopy (Arc/Spark OES) • Purpose: Elemental composition (with ppm-level detection for many metals) • How it works: A spark vaporizes a micro-region, and the emitted light is analyzed. • Non-destructive? Technically micro-destructive, but still categorized as NDT in many industries. • Best for: Verifying alloy grades (e.g., stainless steel vs. duplex steel). ⸻ 5. Mössbauer Spectroscopy • Purpose: Identifying phases of iron-based materials (like ferrite, austenite, martensite) • How it works: Measures hyperfine interactions via gamma-ray absorption. • Highly sensitive to magnetic and structural differences in Fe. • Used in: Nuclear steels, meteorites, archaeological metal studies! ⸻ So why does this matter? In real-world components, we often need to verify the presence of a phase, check composition, or track heat treatment effectiveness, without cutting, polishing, or etching. Understanding the right NDT tool for the job allows you to: • Confirm microstructural transformations in service • Monitor aging in alloys • Authenticate legacy or aerospace-grade materials ⸻ Curious which of these techniques is most used in your industry? Or do you have experience combining NDT with destructive methods like SEM or EDS? #MaterialsScience #NonDestructiveTesting #XRD #XRF #NDT #Metallurgy #PhaseIdentification #Microstructure #STEM #EngineeringInsights

Ultrasonic valve testing is an advanced non-destructive method for assessing valve integrity. It involves emitting high-frequency sound waves into the valve and measuring the time it takes for them to travel through and return. Any deviations from expected travel times indicate defects like leaks or passing issues. Expert technicians set criteria based on the valve's design and materials, enabling them to pinpoint the location and nature of defects. This method provides precise insights into valve health, facilitating timely maintenance or replacement, ensuring safe and reliable operation. #corrosion #inspection #maintenance #reliability #operation #refinery #operationexcellence #assetintegrity

🧪 What is Holiday Testing? Also known as Continuity Testing, this non-destructive testing (NDT) method is used to detect pinholes, voids, and other discontinuities in protective coatings that aren’t visible to the naked eye. 🔍 How it Works: Holiday testing involves completing an electric circuit across a coated surface: ⚡ If the coating is intact → No current flows ⚠️ If there’s a flaw (a “holiday”) → Current flows, triggering an audible or visual indicator 📦 Common Applications: • 🛢️ Tank interiors • 🧪 Chemical storage vessels • 🏗️ Buried structures (e.g., pipelines, foundations) 🛠️ Components of a Holiday Detector: • 🔋 Power source • 🧲 Ground wire • 🪫 Probing electrode • 💡 Indicator (light or sound) 🔌 Important Notes: Some coatings (like zinc-rich primers) conduct electricity and may not be suitable for this test. ✅ However, topcoating them with non-conductive materials (e.g., epoxy, urethane) enables effective holiday testing. 🎥 Watch the attached video for a real-time visual explanation of the process. #HolidayTesting #CoatingInspection #NDT #ProtectiveCoatings #HSE #CorrosionControl #AssetIntegrity #QHSE #InspectionTools #PipelineSafety

Angus Measurement Services, LP Special Services Group Good Thursday morning from the heart of the old Permian Basin, off the Frankle City Highway, on the southwest edge of the Llano Estacado, in beautiful Gaines County, Texas. In yesterday’s post, referring to the September 1 rollout of TXSB 900, I went over a how to establish a basic corrosion rate for the tank and the next out of service inspection interval. There are other processes that can be used, but I want to stick with the two most common that will be used by most if not all the owners and operators covered by TXSB 900. They are UT and MFE. UT or Ultrasonic Testing utilizes equipment and techniques that send ultrasonic waves transmitting into materials to characterize the material. Most UT equipment uses short pulse waves with frequencies ranging from 0.1-15 MHz, although frequencies up to 50 MHz can be used. MFE or Magnetic Flux Exclusion is a nondestructive examination method which uses a field to detect corrosion and pitting in carbon steel. A powerful magnet is scanned close to the surface to saturate the steel with the magnetic field. The magnetic field leaks from the steel where there is corrosion. This is detected by the scanner sensors and displayed to the operator. These indications are marked on the floor. The indications are “Proved Up” with UT and the corroded areas mapped for future reference. Back in the days of wooden tanks and iron men, we used UT to look for corrosion. But it is time consuming to inspect a tank floor, even small ones with enough readings to be comfortable there was enough coverage to determine and accurate corrosion rated and confidence the corroded areas are identified. Companies developed and some still use equipment that utilizes a mobile or “robotic” UT, and more coverage can be had, but it is time consuming and requires a very clean and smooth floor surface. Using spot or an “X” pattern on 12-inch centers at best may cover 15-25% of the floor plates. MFE on the other hand can inspect better than 95% of the floor plates. MFE is very operator dependent. The machine will give indications, but it is up to the operator to interpret these results. On a 20-foot diameter tank, a competent UT operator on a 12-inch center “X” pattern and 12-inch center 6-inches from the shell all around the tank edges and five 12-inch 1-inch scrubs at 4 corners and the center would take almost 2 days. This same 20-foot diameter tank could be scanned with MFE in less than four hours. Because of the time factor involved and the results of the two processes, MFE is the go-to equipment used in API 653 inspections. Keep in mind, API 653 does NOT mandate the use of either MFE or UT or any process. It just tells the owner they have to be able to determine a corrosion rate.   Tomorrow, I will cover basic MFE. It's going to be riveting. Well, if your a tankee. Jose Che DeLaO - 432-258-4351 Joey DeHoyos – 432-208-8933 Curtis Stewart – 806-438-4842