NDT Inspection

Conventional Inspection Services

FIRST COMPANY has been carrying our conventional inspection services in Egypt for more than 10 years and has an experienced team consisting of qualified inspectors to undertake this work. We have used the latest techniques to build on our success, enabling us to provide our clients with a safer, quicker and reliable service. Through our work we have the knowledge, expertise and experience to perform conventional NDE inspections from our offices and project network. Our conventional services include:

NDE/NDT Inspections, Liquid Penetrant, Magnetic Particle, Radiographic,  Ultrasonic, Visual Inspection, Electromagnetic Testing, Remote Visual Inspection and Quality Assurance.

1.1 Liquid Penetrant (LP)

FIRST COMPANY utilizes Liquid Penetrant inspection to detect surface discontinuities in both ferromagnetic and non-ferromagnetic materials. In castings and forgings, these may be cracks or leaks in new products or fatigue cracks in in-service components.

Testing is performed using visible red dyes under visible light conditions or fluorescent dyes under ultraviolet light. As the name implies, the dyes penetrate into the surface discontinuities by capillary action. After the excess material is removed from the material being tested, indications will appear. Evaluation and classification of material is based on code or customer requirements.

1.2 Magnetic Particle Inspection (MPI)

MPI detects surface and near-surface imperfections such as cracks, seams and laps in ferromagnetic materials, and is used to assess location, size, shape and extent of these imperfections. When the test object is magnetized, flaws perpendicular to the magnetic field direction cause flux leakage. Magnetic particles applied to the surface are held at the location of the imperfection by flux leakage. In this magnetic particle testing technique, dry particles are dusted onto the surface of the test object as the item is magnetized.

Dry particle inspection is well suited for the inspections conducted on rough surfaces. When an electromagnetic yoke is used, the AC or half wave DC current creates a pulsating magnetic field that provides mobility to the powder.

The primary applications for dry powders are unground welds and rough as-cast surfaces.

Dry particle inspection is also used to detect shallow subsurface cracks. Dry particles with half wave DC is the best approach when inspecting for lack of root penetration in welds of thin materials.

Half wave DC with prods and dry particles is commonly used when inspecting large castings for hot tears and cracks.

1.3 Radiographic Testing (RT)

Conventional Radiography (RT) is a nondestructive examination method that uses X-ray and Gamma ray for detecting internal imperfections, for measuring wall thickness and for detection of corrosion. With RT, the material is exposed to a homogenous ray from a radioactive isotope or an X-ray tube while a negative film is positioned behind the material to be examined. After development of the film, thickness and density differences (material imperfections) will show as blackness differences. Acceptance criteria define whether or not the indication is non-acceptable (a defect) or not. FIRST COMPANY licensed technicians and equipment meet all the ROK radiography regulations.

FIRST COMPANY pipeline inspection capability benefits from decades of experience in the pipeline industry. Our procedures meet standard inspection specifications for Workmanship Acceptance Criteria or Alternative Acceptance. We ensure that welding repairs are kept to a minimum by providing welders with quick and accurate process control feedback derived from our inspection data.

1.4 Radiographic Testing (Close Proximity)

Conventional Radiography is a nondestructive examination method that uses X-ray and Gamma ray for detecting internal imperfections.

FIRST COMPANY introduced Close Proximity Radiography to Egypt  in early 2006. Radiography provides a quality, cost effective, permanent record with high volume capabilities due to simple operation and portability. However, its use is restricted by the inherent risks associated with the use of radiation and the need to establish and manage a controlled area during the process. The associated problems are greatly reduced by the use of the “Small Controlled Area Radiography” (SCAR) system. SCAR has set the precedent for safer working in the industry.

1.5 Ultrasonic Testing

FIRST COMPANY Provides Manual (Conventional) Ultrasonic Testing and Automated Ultrasonic Testing. Both techniques transmit ultrasound through a material and receive the reflected echoes from the back wall or from any defects.

This makes it possible to locate discontinuities in a material or weld. During Manual Ultrasonic Testing the operator measures the material thickness by reading from the screen. UT uses high frequency ultrasonic waves to detect surface breaking and internal imperfections, measures material thickness and determines acceptance or rejection of a test object based on a reference code or standard. Our UT techniques provide instant results, and are sensitive to both surface and subsurface discontinuities throughout the material. UT is capable of detecting imperfections throughout the entire material thickness, and may be used with access to only one surface.

1.6 Positive Material Identification

FIRST COMPANY’s Positive Material Identification (PMI) quickly and accurately identifies the composition of more than 100 different engineering alloys onsite. FIRST COMPANY can perform PMI on virtually any size or shape of pipe, plate, weld, welding materials, machined parts or castings. Team performs both x-ray fluorescence (XRF) and Spark Emission Spectrography (SES), two methods of conducting a PMI examination.

Both methods ensure compliance with Process Safety Management (PSM) requirements.

 

1.7 Quality Control

NDT Service provides a comprehensive Egypt i Vendor Inspection, QA/QC and expediting service for all types of mechanical, rotating, electrical and electronic equipment as well as Oil Country Tubular Goods (OCTG).

Services include:

  • Expediting
  • New Build Equipment Inspection
  • Surveillance
  • Temporary and Portable Equipment
  • Vendor Audits (Prior to PO Award)

QA inspection of equipment being fabricated repaired and/or refurbished in a vendor’s facility. The equipment can be for upstream application or from a client’s facility for a capital project as well as maintenance repairs or replacement of original equipment. No matter what the requirements of your project are, we can provide qualified inspection personnel to assure those requirements are met. FIRST COMPANY inspectors are qualified and/or hold certifications through API, AWS, DOT, NACE, NEMA or ASNT. The inspection activities are guided by the company’s Quality Manuals and ITP plans that are developed and managed by FIRST COMPANY Quality Program Management.

1.8 Remote Visual Inspection

Visual Inspection (VI) is one of the most widely used Non-Destructive Testing (NDT) methods for the detection of discontinuities before they develop into major problems. Areas where visual inspection can be utilized are; poor welding, corrosion and pitting, general condition monitoring, surface degradation & defects and protective coating monitoring.

Visual Inspection means the inspection of equipment, structures or vessels using a combination of the following human senses; vision, hearing and touch. Visual Inspection often works in conjunction with a number of the following NDT methods; UT, EC, MT, PT or RT.

 

Visual Inspection can also be carried out with the aid of devices such as a magnifying glass, flash lights, borescopes, digital video borescopes and camera systems to provide Remote Visual Inspection (RVI).

FIRST COMPANY highly trained inspectors employ robotics, fiber optic cameras, borescopes and other instrumentation and recording systems to conduct RVI on equipment such as piping systems, vessels, turbines, boilers and heat exchangers. Data can be recorded onto various storage media for viewing and storage.