PAUT (Phased Array Ultrasonic Testing) 

Performing PAUT on the component

Traditional pulse-echo ultrasonic testing has evolved into phased array ultrasonic testing. Both the tests involve generating Echoes by transmitting high-frequency ultrasonic waves into a physical object, such as a weld. The ultrasonic testing records, analyses, and reports on the echoes found through the equipment. NDT professionals can identify discontinuities in echo patterns that indicate the existence of fractures, defects, or corrosion in metallic structures.

Compared with traditional ultrasonic, a phased array uses several transducers that help scan at different angles. A computer controller allows technicians to fire timed pulses from the instrument’s transducers simultaneously or in succession based on dynamic angles. These pulses combine to generate self-reinforcing interference patterns, resulting in a coherent sound beam that may “sweep” across the component.

To create a viewable image with previous ultrasonic technology, technicians must move their transducer across the entire component. Instead, in PAUT, a technician can simply shift the beam electronically. 

TOFD (Time-of-Flight-Diffraction) 

Performing TOFD on the component

TOFD is an ultrasonic image creation technique. It employs diffraction instead of reflection. The transducer generates pulsed ultrasonic waves, which are diffracted to varying degrees by imperfections in the scanned material before being captured by a receiver on the material’s far side. The device can identify and visualize the ‘size and position’ of ‘faults and imperfections’ by assessing changes in beam travel time from the transducer to the receiver.

TOFD can detect flaws regardless of their direction, making it an excellent complement to PAUT. However, TOFD, like PAUT, has some imaging flaws. Technicians may experience a lateral wave dead zone, off-axis problems, timing issues, and resolution faults with a single scan. Technicians must employ phased array methods to alter beam width, angle, and point-of-entry to obtain a comprehensive view of flaws. The most accurate location of even minor defects can be found when TOFD imaging is combined with phased array technology.

It is suggested that NDT personnel should employ a mix of PAUT and TOFD scanning methods to accomplish quick, precise scans of welds, pipelines, and other essential metallic components. Modern ultrasonic test software, contained in portable equipment, is capable of producing composite pictures from these two technologies, providing a complete depiction of components’ interior. With a combined scanning regimen, the risk of overlooking defects and subsequent equipment breakdowns reduces.

TCR Advanced expertise in phased array ultrasonic and time-of-flight diffraction methods. Find out why we are the Best NDT service provider in India. Contact us and learn more about the finest Advanced NDT services. 

The post Which is better? PAUT or TOFD?  appeared first on TCR Advanced Engineering.

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.

The post TCR Advanced: Expanding Industry Integrity appeared first on TCR Advanced Engineering.

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  

The post Helium Leak Test: Techniques and Components appeared first on TCR Advanced Engineering.

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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