Advanced Inspection

FIRST COMPANY is at the forefront of providing Advanced Inspection Services to our clients and we have been instrumental in bringing new worldwide inspection techniques into Egypt . Through our work we have the knowledge, expertise and experience to perform advanced NDT inspections from our offices and project network. Our comprehensive service includes a variety of techniques:

  • Guided Wave
  • Time of Flight Diffraction (ToFD) and Phased Array (PA)
  • Positive Material Identification (PMI)
  • Magnetic Flux Leakage (MFL)
  • ACFM
  • Leak Testing
  • Thermography
  • Electromagnetic Testing (ET)
  • RFEC
  • IRIS
  • Digital Radiography
  • RVI and
  • Endoscopy Inspections.

    1. Internal Rotary Inspection System

FIRST COMPANY has the knowledge, expertise and experience to perform inspections using a range of systems to inspect tubes in Heat Exchangers, Air Coolers, Feed Water Heaters, Condensers and similar items. This allows tubes to be inspected periodically to detect and size discontinuities e.g. pits, erosion, cuts, grooves, and wear. Correct technique selection is critical and depends on the tube material, ferromagnetic or non-ferromagnetic and the type of discontinuities expected.

Techniques include:

  • Internal Rotary Inspection System (IRIS)
  • Eddy Current Testing (ET)
  • Remote Field Testing (RFT)

Eddy Current Testing, and Remote Field Testing are electromagnetic techniques and tend to be used as screening tools in order to select tubes for IRIS, especially in the case of ferromagnetic materials e.g., Carbon Steels.

2. Long Range Guided Ultrasonic

FIRST COMPANY uses the state of the art Wavemaker (4) which generates waves propagating long distances, even beneath a layer of insulation. The ultrasound is transmitted and received from one single location. The response from the metal loss feature is a function of the depth and circumferential extent of the metal loss.

Guided Wave tools are available in fixed ring and modular ring format. The fixed ring designs are suitable for pipe diameters up to 8-inches. For larger diameters, a modular ring up to 42-inches has been adopted. Guided Wave inspections help you to limit follow-up inspection and maintenance to the areas of real interest where the piping was found to be defective.

 

3.Ultrasonic Phased Array

FIRST COMPANY uses the state of the art OmniScan MX Mainframe with Phased Array TOFD Acquisition Modules, combined with multipurpose scanners and modulators.

Phased Array (PA) provides sharper detection capability for off-angle cracks, and is capable of displaying multiple presentations simultaneously. PA applies computer-controlled excitation to individual elements in a multi-element probe. It is an advanced pulse-echo technique that utilizes multiple miniaturized transducers and time-delays to shape the ultrasonic sound beam to a desired angle and focus. The versatility of the system permits simultaneous views of different presentations, such as sectoral views as well as A-Scan, B-Scan and C-Scan representations.

When compared with manual pulse-echo techniques, the advantages of Phased Array testing are its excellent repeatability, increased inspection speed, more accurate results. Moreover, PA allows the digital storage of all data, location and system settings, and is very much safer to operate within a working environment, compared with Non-Destructive Testing methods that use X-rays and gamma rays for detecting imperfections

4. Automated Ultrasonic Inspection

FIRST COMPANY has the knowledge, expertise and experience to perform Phased Array and automated ultrasonic (AUT) on both onshore and offshore operations. We use different technologies from several manufacturers to provide complete automated inspection capabilities. FIRST COMPANY’s AUT capability has been used on a variety of projects and for numerous clients. Pipe sizes inspected have ranged from 5″ to 48″, wall thickness from 12mm to 33mm and to a variety.AUT uses conventional and specialized transducers to introduce sound in the test materials. These transducers are mounted to automated robotic crawlers, which articulate to cover large areas of the vessel or piping surface. The data collected is then displayed in color in multiple A-Scan, B-Scan, C-Scan and D-Scan images.
A-scan representation is the view in which the signal amplitude is shown as a vertical excursion from the horizontal sweep time trace. The B-scan and D-scan presentations are two-dimensional views of cross-sectional planes through the test object on different axis. This imaging is helpful in distinguishing mid-wall inclusions such as laminations and blistering, from back-wall discontinuities like erosion and corrosion.

The C-scan image is a two-dimensional plan view of the object. Indication of depth is color coded to provide the image with qualities, which resemble a topographical map viewed from the inspecting surface.

5.Magnetic Flux Leakage

FIRST COMPANY has the knowledge, expertise and experience to perform Magnetic Flux Leakage (MFL) on tanks.

We use the MFL 2000 which is a high speed, motorized magnetic flux leakage corrosion detection scanner capable of inspecting approximately 8000 square feet per shift. The ergonomic design, coupled with the latest magnetic technology have resulted in an easy to operate, accurate, reliable and cost effective inspection tool. The motorized scanner takes all the strain giving you more consistent results and less operator dependency.

Key Features High Speed, Cost Effective Inspection

  • Easy to Use Ergonomic Design
  • Automatic Defect Detection System
  • Minimal Maintenance Requirement

The MFL 2000 corrosion detection floor scanner from Silverwing is a combination of magnetic technology and customer led ergonomic mechanical design. The system is designed specifically with the operator in mind and the availability of a new consistent high quality magnetic material has allowed a complete redesign of the MFL 2000. In addition the new mechanical design has overcome some of the more difficult and time consuming set-up procedures and also eliminated the vulnerable cabling, so reducing maintenance costs.

6. Time of Flight Diffraction

FIRST COMPANY uses the state of the art OmniScan MX 2 Mainframe with Phased Array ToFD Acquisition Modules, combined with multipurpose scanners and modulators.

With ToFD, a single line scan of a pair of angle compression wave probes held at a fixed separation can provide full volumetric coverage of both weld and heat affected zone (HAZ) and generate an immediate scale image of through wall condition with defects shown in true location and size. The wide beam used defines the test surface by generating a lateral wave and the inner surface by reflections off the material ‘backwall’. Any anomalies lying between these two surfaces are highlighted by signals diffracted and reflected off their extremities. The lateral location and length of these discontinuities is reported as a function of encoded scan position.  (ToFD), which was originally developed for crack-sizing in nuclear applications, established itself as a widely used tool for flaws detection in welds. This unique ultrasonic technique has big advantages in speed, detection of defects and is the most accurate defect sizing technique in general use. One of the important advantages of using ToFD for weld inspection is the absence of radiation. Furthermore, in several validation projects ToFD has proved itself to be a technique which combines a high detection rate with a very high reliability in pre-service and in-service inspections.

7. Automated Corrosion Mapping

CONDITION MONITORING

Corrosion and erosion monitoring

  • Corrosion and erosion mapping utilizing Automated system and a Combination of ToFD, Phased Array and Pulse Echo
  • Ultrasonic imaging
  • Detection, imaging and monitoring of material degradation
  • Defect sizing and propagation monitoring
  • Real time Inspection

 

8. Stress Corrosion Cracking

FIRST COMPANY utilizes the Time of Flight Diffraction method for detection of Stress Corrosion Cracking.

9. Long Range CHIME Inspection

Long range ultrasonic Chime

  • Under clamp/pipe support corrosion
  • Corrosion under annular plate

Guided wave ultrasonic

  • Buried pipelines

10. Eddy Current Testing

FIRST COMPANY, by utilizing Eddy Current techniques, can examine large areas very quickly and it does not require the use of coupling liquids.

In addition to finding cracks, EC can also be used to check metal hardness and conductivity in applications where those properties are of interest and to measure thin layers of nonconductive coatings like paint on metal parts.

Applications

  • Surface Breaking Cracks
  • SBC using Sliding Probes
  • Metal Thinning (Corrosion)
  • Heat Exchanger Tube Inspection
  • Conductivity
  • Heat Treat Verification
  • Thickness inspection of Thin Materials
  • Thickness inspection of Coatings

11.Boiler Inspection

FIRST COMPANY utilizes EMAT technology to perform boiler tube inspection without scale removal. Scale is used as a couplant to transfer electromagnetic signal into boiler tube for thickness detection. Utilizing this method saves time as tube cleaning is not required, therefore reducing boiler downtime.

12. Digital Radiography

Digital Radiography is a powerful technique that can be used in nondestructive inspection of internal features of an object to obtain two-dimensional computed tomography images needed to characterize material properties, identify defects and measure part geometry.

Multiple slices can also be assembled to create accurate three-dimensional CT that can be used for a variety of different purposes as viewing the shape of defects. FIRST COMPANY can provide site inspection utilizing method above for all your needs and requirements.

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