GE Inspection Technologies Corrosion & Erosion Inspection solutions for detection, sizing & monitoring DATA INFORMATION KNOWLEDGE DECISION
Overview GE Inspection Technologies is a leading innovator for inspection solutions that deliver accuracy, productivity and safety to customers in a wide range of industries, including oil & gas, power generation, aerospace, transportation and government infrastructure. Our advanced nondestructive testing and imaging technologies utilize the electromagnetic, radiographic, ultrasonic or visible energy spectrum to test and inspect a wide range of components.
IN THIS GUIDE Overview................................................................................................1 Oil & Gas Application Solutions.........................................................3—4 Power Generation Application Solutions.........................................5—6 Remote Visual Inspection...................................................................7—8 Ultrasonic Testing.................................................................................
Oil & Gas Application Solutions Oil & Gas Application Solutions GE Inspection Technologies addresses all major inspection needs for our oil and gas customers. We strive to deliver high-quality products & services that detect, size and monitor corrosion and inspect welds in a variety of situations and field conditions. Our leadingedge inspection solutions boost productivity, help you improve safety and solve your toughest oil and gas inspection challenges.
Upstream RightraxTM installed-sensor system continuously monitors wall loss due to sand erosion at critical elbows on production platforms. Digital radiography detects and measures corrosion under insulation (CUI) without removing the insulation. Midstream Ultrasonic phased-array inspection assists in quickly scanning, detecting, profiling and sizing of isolated pitting in pipes. Remote visual inspection of compressor blades can help identify erosion and thinning.
Power Generation Application Solutions We provide nondestructive testing and inspection solutions for key power generation corrosion applications, including those for fossil, nuclear, renewable generation as well as transmission and distribution. Our reliable, advanced technology and support services enable power generation customers to help maximize efficiency, minimize downtime and enhance productivity with unyielding integrity.
Fossil Power Remote Visual Inspection with Menu Directed Inspection™ for turbine blade viewing. USM Go is an ultra-portable, light-weight pulse-echo flaw detector for general purpose testing. Gas Turbine & Combined Cycle Rotating equipment inspection with computed radiography. Apollo™ eddy current test instrument performs volumetric interogation of heat exchanger tube bundle for corrosion and erosion.
Remote Visual Inspection (RVI) RVI is a cost-effective inspection technique used to capture real-time views and images from inside voids such as tubes, pipes, rotating machinery, engines, heatexhangers, tray towers, refractory-lined vessels and enclosed structures. RVI can be a perfect complementary technique to other NDT disciplines and is frequently used as the primary or initial inspection screening method to find localized corrosion and erosion.
Menu Directed Inspection™ (MDI) Rhythm® Software Access to GE’s vast selection of nondestructive testing and remote visual inspection equipment is a phone call away. Regional field offices provide application expertise, equipment selection assistance and timely deliveries to your facility. Daily, weekly and monthly rates are available. MDI is the first software tool in the NDT industry to standardize the inspection process.
Ultrasonic Testing (UT) Ultrasound technique has been used in non-destructive testing for almost 50 years and is used to find a variety of defects or non-conformities within almost any kind of solid material. The Krautkramer name has been synonymous with excellence in ultrasound during this period and is now part of our heritage at GE Inspection Technologies.
Corrosion Thickness Gages Transducers Rhythm® Software These useful and productive tools are designed to help improve safety and ensure reliability of equipment and materials subject to corrosion or erosion. Data can be imported and exported from these devices for mapping and trending. GE manufacturers a wide range of standard and custom ultrasonic testing transducers including conventional, phased array and permanently installed for corrosion and erosion applications.
Radiographic Testing (RT) Radiography is one of the oldest, most reliable and proven nondestructive testing methods and offers unique benefits, such as revealing changes in thickness, internal and surface defects, large-area coverage and more. We offer conventional film radiography, digital technologies, including computed radiography and direct radiography, portable or stationary X-ray sources, 3D computed tomography and analytical X-ray.
Industrial X-ray Tubes & Generators 3D Computed Tomography (CT) Rhythm® Software 160-300kV portable and 160-450kV stationary equipment with directional or panoramic tubes and different combinations of focal-spot sizes provide the appropriate X-ray source to meet your specific requirements. In addition, we offer a complete line of micro- and nanofocus X-ray generators and tubes.
Eddy Current Testing (ET) Eddy current is a fast, accurate and cost-effective electro-magnetic NDT method for detection of surface or near-surface flaws such as metal loss due to corrosion or erosion. It is commonly used for the inspection of heat exchanger tubing and piping, shell-side components such as support plates and rotating equipment such as turbine blades.
Software Solutions GE Inspection Technologies offers advanced and user-friendly software that improves productivity by helping you make smarter and quicker decisions in the field and in the office. Our software covers all Nondestructive Testing (NDT) applications and methods, including software for data input, analysis, image review, reporting, data management, remote collaboration and storage.
Installed Ultrasonic Sensors GE’s Rightrax™ LT and Rightrax HT systems are changing the way that critical corrosion data is measured and managed. This breakthrough technology helps increase safety and productivity while reducing overall inspection costs. The Rightrax system uses permanently-installed sensors that permit remote monitoring of restricted, hard-to-access and/or high-temperature areas up to 350°C (662°F).
More Than Just "Wall Thickness Measurement" Make well-informed decisions; reduce total corrosion costs • Provide accurate feedback to manage opportunity crude processing in a refinery by monitoring effects on pipe wall thicknesses • Drive down probability of failure with data on demand/data on PCs • Provide reliable and highly repeatable data that can be used to drive maintenance planning activities to save cost on unexpected material orders and spare inventory • Interface with plant asset management sys
3 Rightrax Solutions for Many Applications Rightrax Portable Low-Temperature (LT) Installed-Sensor Manual System (- 40°C up to 120°C) (- 40°F up to 248°F) 70 m (230 ft) single coaxial cable M2 transducer sensors DL2 ultrasonic instrument with data logger Rightrax Low-Temperature (LT) Sensor Automated System (- 40°C up to 120°C) (- 40°F up to 248°F) 70 m (230 ft) for single sensor.
Intrinsically safe Single-element delay-line sensor 5 MHz x single point Interface / protocol 8.0 MHz measurement area 200 mm x 12 mm Maximum cable distance "C" M2 Pad 14 elements Maximum cable distance "B" ATEX Ex-proof -40˚ C to 120˚ C 5 mm - 100 mm (-40˚ F to 248˚ F) (0.197 in - 3.937 in) Maximum cable distance "A" Max number of transducers / system 14 elements Ulimited DL storage 100 sensors Resolution / accuracy Transducer frequency and diameter 8.
Corrosion Under Insulation/Fireproofing Heat Exchanger Damage Boiler Tube Hydrogen Damage Radiographic Testing (RT) Eddy Current Testing (ET) Remote Visual Inspection (RVI) • Insulation and fireproofing can accumulate moisture and cause accelerated corrosion • Heat exchanger tube problems can cause unit outages and environmental impact • Hydrogen damage can be caused by condenser in leakage and failures can lead to unit outages • Breaches of weather jacketing increases with age and mechanical
Turbine Blade Erosion Remote Visual Inspection (RVI) • Turbine blade erosion can lead to decreased performance and blade failure • Pitting may occur before vibration analysis can detect a problem • RVI can rapidly assess blade condition and equipment can be scheduled for more detailed preventative maintenance • See page 7 - 8 for general description Offshore Riser Sand Erosion via Installed Ultrasonic Testing (UT) Sensors HF Unit Flange Face Corrosion Ultrasonic Phased Array (UT-PA) • Sand erosion
Flow-Assisted Corrosion Utility Steam Pipe Creep of High-Pressure Steam Pipe Air Fin-Fan Tube ID Condition Radiographic Testing (RT) Ultrasonic Phased Array (UT-PA) Remote Visual Inspection (RVI)/Eddy Current Testing (ET) • Flow-assisted corrosion can occur in all piping that contains water and water/steam mixtures • Single liquid phase or dual phase (wet steam) as shown below can cause severe local metal wastage • Water treatment, design and metallurgy can help prevent for damage • High-pressur
Compressor Blade Damage Refractory Vessel Damage Weld Heat-Affected-Zone Inspection Remote Visual Inspection (RVI) Remote Visual Inspection (RVI) Radiographic Testing (CR & DR) • Compressor blade rubbing and damage can lead to loss of efficiency and potential catastrophic failures • Tip damage may be significant before serious vibration damage is noted • RVI can allow rapid, recordable assessment of compressor blade condition for evaluation by experts in remote locations • See pages 7 - 8 for
Bottom Mounted Instrumentation (BMI) Hydro-Processor Effluent Air Cooler Service Water Piping Corrosion Remote Visual Inspection/Ultrasonic Testing (RVI/UT) Rightrax Installed Sensor (UT) Remote Visual Inspection/Ultrasonic Testing (RVI/UT) • Instrument Penetrations have caused significant reliability concerns at nuclear plants • Difficult access and need for detailed inspection data required multi-modal approach for proper integrity assessment • Combination of RVI, UT and Eddy Current techniqu
High-Pressure Piping Ring-Joint Cracking Tank Bottom Pitting Injection Point Corrosion Remote Visual Inspection/Ultrasonic Testing (RVI/UT) Ultrasonic Testing Phasor DM (UT) Rightrax Installed Sensors (UT) • Ring Joint flanges have had significant cracking from mechanical and Stress Corrosion Cracking • API 653 mandates periodic internal tank floor inspection with volumetric assessment • Typically discovered by PT or manual UT after flanges have been opened during Turnaround.
Nuclear Containment Building: IWE/IWL Dead-End Dead-Leg Corrosion Crude Unit Overhead Corrosion Remote Visual Inspection (RVI) Digital and Computed Radiography (DR & CR) Rightrax Installed Sensor (UT) • 10CFR 50.
Naphthenic Acid Corrosion Heat Exchanger Tubing Failures Corrosion Damage Sizing Rightrax Installed Sensor (UT) Remote Visual Inspection (RVI) Ultrasonic Testing (Phasor CV/DM) • Crude Unit Overhead heater tubes and lower alloy convection crossover piping when higher TAN opportunity crudes are processed • Periodic piping TML’s and spot UT may be not capture events that could cause significant wall loss of piping • Inaccessible locations generally do not allow for periodic monitoring • Right
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