In recent years, industries have felt the importance and need for digital asset integrity systems.

An Asset Integrity Maintenance is a process that ensures that an asset (power, oil and gas, refinery, chemical and petrochemical process plants) can perform its function effectively and efficiently with increasing safety and profits. To ensure that an asset will function over its lifetime, well-run maintenance strategies ensure that the people, systems, processes, and resources are in place while maintaining health and safety laws and environmental legislation.

TCR Advanced’s AiOM (Asset Integrity & Optimizing Management) is a digital tool that manages an asset’s life cycle, from its design phase to its decommissioning and replacement. An industrial plant contains numerous assets, and managing a large amount of these assets through a conventional approach needs qualified and trained manpower. A sudden interruption is devastating for a company whose production runs 24 hours a day, seven days a week.

The first dilemma is to balance profitability and intervention while implementing an asset integrity management system. A company’s process reviews for signs of if anything is becoming dysfunctional. This observation indicates that your integrity management is not operating well if you experience frequent interruptions within processes or if it is difficult to pinpoint the source of small failures. In case when operators still feel unsafe and sense that the maintenance sector is not receiving the necessary investments, perhaps it is time to review procedures and find new ways to manage assets so their life cycle can be optimized so that critical flaws can be avoided.

The cost of inspections and maintenance directly influences asset integrity. Having assets that can continue functioning efficiently without causing risks or interruptions reduces maintenance costs as maintenance should only be interrupted when necessary.

How can an industry benefit from TCR Advanced- AiOM^®?

AiOM consists of various tools based on international standard practices such as –

• Risk-Based Inspection (RBI)
• Fitness-For-Service (FFS),
• Reliability Centred Maintenance (RCM),
• Integrity Operating Windows (IOWs),
• Quality Assurance (QA) Plans, &
• Root Cause Analysis.

API, ASME, SAE, and other internationally recognized institutions have developed these tools incorporated worldwide.

The advantages of asset integrity optimization & management are quite clear:

• Optimization of inspection and maintenance resources
• Minimization of downtime and planned outages
• Loss prevention
• Compliance with regulations and industry standards
• Mitigation of health, safety, and environmental exposures
• Proper documentation for Maintenance & Inspection data preservation for future retrievals
• Continuous monitoring of critical process parameters and instant emergency response
• Establishment of a single objective oriented working environment

Click here to check the entire process of AiOM^® by TCR Advanced.

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It is crucial to maintain the quality of industrial assets for quantitative productions. Industry experts at TCR Advanced are enthusiasts and keen to encourage industrial safety measures and provide support during unplanned setbacks faced by industries. TCR’s unique assessment approach and world-class instruments add life to the industrial assets for optimum production.

Illustrious businesses from all across the world, including-  India,  Saudi Arabia, Nigeria, Kuwait, Dubai, Bangladesh, Iraq, Qatar, Zambia, Kenya & Malaysia, entrust TCR Advanced with various services such as –

• Failure analysis, 
• Fitness for Service, 
• Remaining Life Assessment,
• In-situ metallography, 
• Risk-Based Inspection, 
• SEM & EDS, 
• Indigenization and Specialized Metallography. 
• Reformer Tube inspection 
• Advanced NDT

TCR Advanced NDT services like HTHA, TOFD & Phase-Array, Videoscopy, Eddy Current Testing, ARTiS and Helium Leak Testing help regain the strength of industrial assets and sustain longer than their retiring time.

An indigenously developed AiOM® by TCR Advanced allows industries to see the past damages, detect the live conditions & envision the future functionalities of industrial assets. This system abides by our motto of increasing efficiency, reducing shutdowns and booming profitability. Various tools such as Risk-Based Inspection (RBI), Fitness-For-Service (FFS), Reliability Centred Maintenance (RCM), Integrity Operating Windows (IOWs), Quality Assurance (QA) Plans, etc. are developed with internationally recognized bodies such as API, ASME, SAE, etc. that are widely used all over the world.

TCR Advanced is adhered by the savant pillars of Industrial Safety Experts with their highly experienced team along with Advanced DT & NDT instruments for testing and analysis. TCR Advanced is ranked one of the TOP 10 NDT service providers in India by Industrial Outlook. To extend the contribution, TCR took a step forward to unveil the curtains and share industry knowledge through Evolve by TCR, which focuses on training individuals in Advanced NDT, Metallography, Metallurgy for non-metallurgists and Boiler inspection.

The outcomes of TCR Advanced services have instigated trust in renowned industries worldwide. The presence of TCR echoes in national and international clients such as Reliance, TATA, SAIL, Alembic, IFFCO, Apollo, ONGC, Shell, Essar, BHEL, SIEMENS, SWCC, SEC (Saudi Arabia), MEW (Kuwait), Sewage Power Plant (Egypt) and the list goes on. Associating with TCR Advanced can lead sectors like Power, Oil & Gas, Fertilizers, Petrochemical, EPC, Fabrication, Manufacturing, Automobiles, or pharmaceuticals, resist significant losses and attain holistic abundance.

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Industrial facilities like Chemical Plants, Power Plants and Oil & Gas industries demand helium leak tests regularly.  Components and equipment in these sectors work 24/7 with highly sensitive elements which have a high potential for generating leakage. The timely inspection with Helium Leak Test can detain the risks of fatal accidents.  

Industries that integrate the below-mentioned components often need the Helium Leak Test for regular intervention  – 

• Heat exchangers & Condensers, Power Plant Turbines
• Fugitive Emission of Valves, Manifold seals & Bellows 
• Vacuum vessels and systems, Medical devices 
• Fuel lines & Hydraulic lines, Radiators & glove boxes, 
• Systems used in hazardous environments.
• Vacuum furnaces & vacuum coaters,  
• Semiconductor process equipment
• Laser process equipment & Gas handling systems, 
• Hermetically sealed packages, Liquid gas facilities & Cryo tanks

Helium leak test is widely used in industry sectors such as Petrochemical Industry, Manufacturing Industry, Pharmaceutical and Fertilizer.

Three Basic Techniques to perform Helium Leak Testing 

Process of helium leak detection changes as per the component’s characteristics. There are three methods to conduct helium leak tests that give precise results – 

1. Sniffer Technique

Pressure Testing is a technique for Helium Leak Detection

This technique uses Helium as a tracer gas coordinating with instruments that help detect the presence of Helium in the environment. This method locates the leak by sniffing the possible leak path. Leaks that are detected in sniffer techniques can also be repaired. Sniffer Technique is not quantitative and requires an operator’s skill in determining leaks. Immense care has to be taken as sniffing is indicative at a level of 1×10-5 atm.mm3/sec. diluting Helium and exiting leak path due to significant air movement. The primary purpose of the sniffer technique is to elevate the internal pressure within the part of the above ambient. As Helium is in the internal volume, the sniffer probe identifies the source of leakage where the leak might exit.

2. Vacuum Technique

Vacuum Testing is a technique for Helium Leak Detection

This technique has the same set-up as the sniffer method. The only difference is that the Helium is sprayed on the component through a vacuum probe to search for possible leakage in the component. Helium passes through the passage on the test object connecting to the detector, indicating whether the leak is present in the area where the helium search gas is exposed.

The tracer probe test is best used on seals, flange connections, weld seams and many more industrial assets. 

3. Hood Technique 

The Hood Technique includes covering the component with plastic before the test begins. The area between the component and the hood is filled with Helium from the search gas reservoir. The total outer surface of the component exposed to the Helium. Further, the Helium enters through all leaks present in the component detecting the total leak rate on the machine. The hood test is considered the best to examine small vessels.

TCR Advanced is an expert in bifurcating the component’s requirements as per its configuration. Thus, never pick the less but the best asset integrity management services. Click on this link to explore our website – www.tcradvanced.com  

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TCR Advanced’s innovation – ARTiS™, an automated robotic crawler, is a revolutionary inspection system for reformer tubes. This system is an aid for holistic tube inspection that includes creep strain measurement, bowing assessment, thickness measurement and Ultrasonic testing. Reformer Tubes are an integral part of many industries such as oil & gas, petroleum, fertilizers, etc. The failure of reformer tubes can lead to massive loss. Thus, ARTiS is an advanced non-destructive test that gives the remaining life assessment of reformer tubes. 

ARTiS Expert, Mr Ketan Upadhyay quotes –

” so far we have conducted more than 12,000 tube scans and for every test, we have an active feedback system that ensures100% reliable life assessment”

ARTiS™ offers several key advantages, such as:

• It provides an overall condition of the tubes in the reformer and identifies troublesome areas if any.
• With point-by-point measurements of ultrasound attenuation and creep strain all along the length of each tube, inspection work becomes more systematic and reproducible.
• It avoids the time-consuming scaffolding process and inspections are completed faster optimizing the shutdown time. 
• Automating the coupling process terminates the need for overhead water drums, eliminating water spillage and damage to the cerawool refractories. 

TCR Advanced is the sole service provider for ARTiS™.  ARTiS is making a booming space in reformer tube inspection in the national and international industrial domain.

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Let us understand the process, along with the mechanical test performed –

The categorisation of appropriate test methods is done by analysing the product’s specifications. Engineers often inspect product samples assembling with Finite Element Analysis (FEA) while designing the product. As the FEA does not guarantee appropriate results, mechanical testing is conducted as it provides verifiable data that can be used to refine the FEA. The product can be modified easily and reliably.

Types of mechanical tests performed on product samples – 

Tensile Test –

The tensile test is performed to ensure the product’s raw materials meet specified strength and ductility. Although many material suppliers have the means to conduct these tests, they recommend an independent laboratory like TCR Advanced to run tests for additional confirmation. An easy and inexpensive way to prevent future adversities is to confirm that raw materials are within acceptable specifications. 

 Impact Test – 

The impact test is a short-term test that compares the failure behaviour of materials when the component is under rapid load and extreme temperatures. An impact test determines the amount of energy absorbed by a material during fracture. With this test, whether the material is brittle or ductile is identified.

Hardness Test –

In mechanical engineering, indentation hardness tests are performed to measure a material’s resistance to deformation. Several tests involve indenting the inspected substance until an impression is made.

Fatigue Test – 

The goal of fatigue testing is to create a fatigue strength curve that describes the material’s capacity to resist cyclic loading across a range of stress levels or to determine the operating circumstances under which fatigue will not occur over the component’s lifespan. Once this curve has been generated, the findings are compared to the part design requirements to ensure that the material will allow the component to last the expected amount of time.

Bend Test – 

The bending test is an inexpensive qualitative test that evaluates the ductility and strength of a material. It is widely used as a quality control test. Specimens are easy to prepare, and this test ensures production consistency if conducted correctly and regularly. 

Flattening & Flaring Test – 

Flare and flat tests are important methods for checking the weld quality of weld pipes. The flattening test is a quality test whose purpose is to determine the ultimate plastics deformation ability of pipe determining whether or not the tube will rupture upon flattening.  On the other hand, the flaring test is another quality test that is done to check the ductility of the material by allowing the tube to flare under pressure as per standards.

Should the manufacturer keep a separate budget for these tests?

Yes, they should. The consequence of not performing these tests will lead to the product’s complete failure.  Let’s have a look at the consequences if mechanical testing has refrained – 

• Chances to fail quality checks increase as the product is restricted to migrate into the market. 
• High chances of losing a customer’s trust and potentially valuable contracts.
• In the absence of testing, products are most likely to fail catastrophically. 
• Failure Analysis is an integral part of product development. Thus, without these tests, there is no future for the product. 

Designated mechanical test laboratory – ‘TCR Advanced’ is one of the diversified and advanced laboratories for third party inspection, in-process testing and advanced material testing. Thus, the product’s lifecycle management becomes easy by conducting the mechanical and chemical tests at TCR Advanced. 

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Knowledge

Both the NDT services taker and service provider need to know the limitations and advantages of NDT methods. The NDT testing and techniques used to find flaws should be precisely selected. The common test methods are Visual Inspection, Ultrasonic Testing, Magnetic Particle Testing, Dye Penetration Testing and Radiography testing. The selection of test methods and techniques depends upon the purpose of inspection, finding discontinuity/ abnormality, or monitoring identified flaws. It is essential to select a specific NDT method before testing to get the best results.

To facilitate a better understanding, several examples can be quoted –

Examples – 

1. Consider a Forged shaft: Before proceeding with the machining, NDT is more or less sine-qua-non to ensure freedom from defects. One can perform Ultrasonic testing using normal beam technique to detect any internal/planar or volumetric defects and Magnetic particle testing for surface defects like forging laps which would normally escape in normal beam ultrasonic testing. If any unacceptable flaw is observed, the raw material is rejected, and the processing cost can be saved.
2. Once the raw material is satisfactory with respect to all the tests carried out, it can be processed. In the event of any heat treatment done, it becomes necessary to check for heat treatment cracks. At this stage, Ultrasonic will be seldom helpful, and Magnetic particle testing must be carried out to detect heat treatment cracks.
3. Another example of the selection of technique when inspecting ferrous material during the in-service inspection, it is much necessary to anticipate a damage mechanism of the component. WFMPI (Wet fluorescent magnetic particle inspection) is the best option for damages like fatigue. Since fatigue is a surface phenomenon, WFMPI is the most sensitive technique (in comparison to PT and visible MPI) for detecting surface cracks in ferromagnetic materials.

A testing method should not be selected because it is new and advantageous. For instance, an inspection of tubes of coolers where the damages anticipated are pitting, erosion etc., from inside, techniques like IRIS and Eddy current are used, as well as APR. While the damages from OD are expected, APR would be the least helpful, and eddy current testing would be the best.

Perseverance of NDT personnel

Probability of detection of defect decreases as the quantum of testing increases. NDT personnel must be mentally and physically fit to carry out the testing. To refresh oneself, it is advised to carry out the testing intermittently and take a break for 5-10 minutes after every hour of testing.

The integrity of NDT personnel 

Integrity is a part of the culture of the company providing NDT services. The Remuneration of NDT personnel should not be concomitant with the performance of an individual. For instance, the Remuneration of personnel should not be based on the number of samples tested, accepted or rejected.

Efforts made by NDT services taker 

One needs to make the necessary efforts to get the best of NDT. Surface preparation is one of the major areas wherein the efforts of NDT service takers are involved. If the service provider is responsible for surface preparation, his energy will be wasted in preparing the surface required for NDT. Service takers should take the initiative in arranging for the best surface preparation and congenial environment for NDT to get the best results. Inspection time should be sufficient to complete the inspection.

Precautionary innuendoes –

In the first case cited in point 1, it will require proof machining on the forged samples before carrying out UT and MT. It will be required to remove scaling after shaft heat treatment before carrying MT. For the 2nd example cited in point 2, it is necessary to carry out buffing/grinding to remove any oxide scales before conducting WFMPI for in-service inspection.

TCR Advanced Engineering incorporates all these above qualities, leading it to be one of India’s Top NDT service providers in 2021. Increase the efficiency of your industrial assets and regale safer programs for prosperous industrial productivity with TCR Advanced – the Best asset integrity and optimizing services providers.

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What is the Helium Leak Test?

With the continuous mass production in industries, heavy machinery often face ruptures that the naked eye cannot see. These ruptures obstruct the continuity forming a leakage in the containers that directly impedes the quality of production as well as creates an unsafe environment for people working around. To solve this dilemma, we at TCR Advanced offer NDT (non-destructive test) services like Helium Leak Detection that can help to identify unseen ruptures by spraying or sniffing the helium gas onto the component tracing the location for the type of leakage.

When should the Helium Leak Test be carried out?

Sometimes the output of working assets like heat exchangers or condensers fails to give their optimum results. This fluctuation takes place due to the leakage in tubes. It becomes highly essential to identify the leaking tubes as minor failures like this, invite the possibility of major process-upsets or accidents in the industry. Due to its high sensitivity, Helium leak testing can easily pinpoint the minuscule size of leakage.

Why Helium?

After hydrogen, helium is the second lightest element having properties such as non-toxic, inert and non-flammable. Helium molecules can pass through minor crevices in the component detecting the leakage’s path, location, and size even in the presence of process residue. As helium is not ordinarily present in the atmosphere (< 5 ppm), it can assuredly be traced through leaking containers. Compared to the pneumatic and hydro tests where water or other fluids are used, the Helium Leak Test is considered the most accurate detection method.

On which components HLT is usually performed?

Numerous apparatus are used in various industries in which the absence of leakage is of utmost importance. Majorly helium leak testing is performed on:

1.  Condensers
2.  Heat Exchangers
3.  Power Plant Turbines

In addition, it can be useful for Valves, bellows, Manifold seals, Vacuum vessels and systems, Medical devices, Fuel lines, Hydraulic lines, Refrigeration assemblies, Radiators, glove boxes, Vacuum furnaces, vacuum coaters, Semiconductor & Laser process equipment, Gas handling systems, Bioreactors, Hermetically sealed packages, Liquid gas facilities and Cryo tanks. The final benefit is time saved. Thus, without wasting time opt for our best NDT service – Helium Leak Test and let the machineries work smoothly.

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