Advanced Non Destructive Testing Services

Helium Leak Testing could be used to determine leakages in condenser unit of any power plant.

There are various challenges faced by the teams looking after the operation of turbines in any power plant. The most common of such challenge is maintaining proper vacuum in the condenser to ensure proper output. If the vacuum gets reduced below certain point due to any leakage, then the turbine cannot generate sufficient or desired electricity it is designed for. This leads to significant loss of revenue. Over a period of time, ITE Has developed capabilities in providing solutions to the customers in identification of Air Ingress Points throughout the negative pressure part of the condenser unit just below the turbine without the need of switching of the turbine. The system could be tested in the running condition and areas could be identified for repair and maintenance at the next opportunity. Helium Gas is used as a tracer gas which is sprayed over the areas suspected for leakages. If there is any leakage, the helium gas will be sucked in the system and detected at the exit point where Sniffer probe of the Helium Leak Detector is held. ITE has been providing these Online Condenser Leak Testing services also sometime referred as Negative Pressure Part Online Leak Testing to organizations like NTPC, Gujarat State Electricity Corporation Limited, Madhya Pradesh Power Generation Corporation Limited, etc. to name a few.

ITE offers these Non Destructive Testing services (NDT) at various places across India which include, Delhi, Uttar Pradesh (Ghaziabad, Sahibabad, Greater Noida, Noida, Lucknow, Agra, Kanpur, Mathura, Jewar, Sikandrabad, Meerut, Sonbhadra, Pata, Anpara, Allahabad, moradabad, gajraula, hapur, etc.), Madhya Pradesh, Punjab, Rajasthan, Haryana, Himachal Pradesh, Uttarakhand (pantnagar, haridwar, nainital, kashipur), Bihar, Chattisgarh, Gujarat, Maharashtra (Mumbai, Pune, Nagpur), Jammu Kashmir, West Bengal, Nepal, Sikkim, Arunachal Pradesh, Assam, etc.

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The Phased Array Technique of Ultrasonic Testing is a process wherein UT data are generated by controlled incremental variation of the ultrasonic beam angle in the azimuthal or lateral direction while scanning the object under examination. This process offers an advantage over processes using conventional search units with fixed beam angles because it acquires considerably more information about thereflecting object by using more aspect angles in direct impingement. Each phased array search unit consists of a series of individually wired transducer elements on a wedge that are activated separately using a pre-selectable time delay pattern.Flaw sizing is normally performed by measuring the vertical extent (in the case of cracks) or the cross-sectional distance (in the case of volumetric/planar flaws) at the 6 dB levels once the flaw has been isolated and the imagenormalized. Tandem sizing and analysis uses techniques similar to pulse-echo but provides images that are easier to interpret since specular reflection is used for defects oriented perpendicular to the surface. For cracks and planardefects, the result should be verified using crack-tip-diffraction signals from the upper and lower ends of the flaw, since the phased array approach with tomographic reconstruction is most sensitive to flaw tip indications and isable to give a clear reconstruction image of these refraction phenomena. As with other techniques, the phased array process assumes isotropic and homogeneous material whose acoustic velocity is constant and accurately known.Sectorial scans (S-scans) with phased array provides a fan-like series of beam angles from a single emission point that can cover part or all of a weld, depending on search unit size, joint geometry, and section thickness. Such a series of beam angles can demonstrate good detectability of side-drilled holes because they are omni-directional reflectors. This is not necessarily the case for planar reflectors (e.g., lack of fusion and cracks) when utilizing linescanning techniques where the beam could be misoriented to the point they cannot be detected. This is particularly true for thicker sections when using single line scanning techniques.ITE has expert manpower with years of expertise in performing PAUT of various components including Welding, Castings, Pipes, Tubes, Plates, etc.As a recent addition to the portfolio of our services we have started performing Phased Arrau Ultrasonic Testing of Boiler Tubes as well with diameter as low as .75 inch to 4.5 inches. This is done used a specialised attachment called Cobra scanner. Cobra scanner is used with Olympus Omniscan MX2 with other necessary accessories to perform reliable scanning of Boiler Tubes welded joints. With Cobra Scanner, we have been able to remove various challenges and limitations faced by customers in the power sector. One of them being reduced dependence of Radiography Testing, since PAUT using cobra scanner give better and faster result that Radiography Testing.

ITE offers these Non Destructive Testing services (NDT) at various places across India which include, Delhi, Uttar Pradesh (Ghaziabad, Sahibabad, Greater Noida, Noida, Lucknow, Agra, Kanpur, Mathura, Jewar, Sikandrabad, Meerut, Sonbhadra, Pata, Anpara, Allahabad, etc.), Madhya Pradesh, Punjab, Rajasthan, Haryana, Himachal Pradesh, Uttarakhand, Bihar, Chattisgarh, Gujarat, Maharashtra, Jammu Kashmir, West Bengal, Nepal, Sikkim, Arunachal Pradesh, Assam, etc.

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Oxide Scale Measurement is generally used for detetion of deposition of oxides on the inside of the tubes used in power plants.

A significant limiting factor that affects tube life in fossil fired steam boilers is the growth of iron oxide scale (magnetite) on the inside and outside tube surfaces. The oxide scale, which forms under long term exposure to very high temperatures, acts as a thermal insulator. While external scale limits heat transmission into the tube and reduces boiler efficiency, internal scale buildup represents a potentially more serious problem. The insulating effect of internal scale limits heat transmission into the water vapor inside the tube, which in turn causes chronic overheating of the tube wall and promotes accelerated metallurgical failure. Non Destructive measurement of internal oxide scale thickness is of major interest in the power generation industry and other users of fossil fuel steam boilers, since scale thickness may be used to predict remaining tube life. While very high frequency ultrasonic gaging techniques have been available for this measurement for a number of years, they involved use of cumbersome, expensive pulser/receiver and oscilloscope systems. Recent advances in instrumentation technology have made available small, hand-held ultrasonic gages with software optimized for measurement of internal scale and advanced data logging capability. Additionally, the use of normal incidence shear wave transducers improves resolution of thin scale layers, permitting measurement of scale buildup down to approximately 0.125 mm with hand-held equipment. ITE has uses Olympus 38 DL plus with suitable probes for testing of tubes for deposition of oxide scales. We have been providing these services for more than a decade and have various customers across the country in Power Sector who regularly use our services.ITE offers these Non Destructive Testing services (NDT) at various places across India which include, Delhi, Uttar Pradesh (Ghaziabad, Sahibabad, Greater Noida, Noida, Lucknow, Agra, Kanpur, Mathura, Jewar, Sikandrabad, Meerut, Sonbhadra, Pata, Anpara, Allahabad, moradabad, gajraula, hapur, etc.), Madhya Pradesh, Punjab, Rajasthan, Haryana, Himachal Pradesh, Uttarakhand, Bihar, Chattisgarh, Gujarat, Maharashtra, Jammu Kashmir, West Bengal, Nepal, Sikkim, Arunachal Pradesh, Assam, etc.

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Fugitive Emission Testing is done on valves as per ISO 15848 Part 1 and Part 2. Part 1 is for Type Testing of valves while part 2 is for Production Testing of valves. Helium gas is used as the tracer gas. In the type test, the valves is tested for its endurance, tightness and temperature capabilities.

Personnel or operator performing the FET are ASNT SNT TC 1A certified Level II in Leak Testing

ITE offers these Non Destructive Testing services (NDT) at various places across India which include, Delhi, Uttar Pradesh (Ghaziabad, Sahibabad, Greater Noida, Noida, Lucknow, Agra, Kanpur, Mathura, Jewar, Sikandrabad, Meerut, Sonbhadra, Pata, Anpara, Allahabad, moradabad, gajraula, hapur, etc.), Madhya Pradesh, Punjab, Rajasthan, Haryana, Himachal Pradesh, Uttarakhand (pantnagar, haridwar, nainital, kashipur), Bihar, Chattisgarh, Gujarat, Maharashtra (Mumbai, Pune, Nagpur), Jammu Kashmir, West Bengal, Nepal, Sikkim, Arunachal Pradesh, Assam, etc.

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Internal Rotatory Inspection System or IRIS is used of inspecting the internal of tupes/pipes which otherwise are not accessible for testing with any other methods. Unlike Eddy Current Testing or RFET, it can tell us the exact thickness of the are under inspection and the flaw itself.

With Internal Rotary Inspection System, we can detect corrosion, pitting and wall loss and is commonly used for tube inspection in boilers, heat exchangers, air coolers and feed water heaters. It is particularly versatile as it is suitable for both ferrous and non-ferrous materials, and IRIS can be used on a wide range of tube diameters and wall thicknesses. 

An IRIS probe is inserted into a tube flooded with water. The probe is fitted with a turbine and a transducer that generates an ultrasonic pulse along a path parallel to the axis of the tube. A rotating mirror directs the ultrasonic pulse into the tube wall. The mirror is driven by a small turbine that is rotated by the pressure of water pumped into the tube.

Ultrasonic Pulses are reflected from the outer dia of the tube and then return to the IRIS probe/sensor and gives us the indication of flaw, if any.

As the IRIS probe is pulled, the spinning motion of the mirror results in a helical scan path ensuring full coverage of the tube.

Benefits of using IRIS include:

Suitability for both ferrous and non-ferrous material

Detection of corrosion, pitting and thickness lo

Accurate wall thickness measurement

Sensitivity to both internal and external defect

Defect position can be located in relation to tube length

Complete coverage of the tube

Results data storage

Flexibility as a back-up to remote field, magnetic flux leakage and eddy current inspections.

ITE offers these Non Destructive Testing services (NDT) at various places across India which include, Delhi, Uttar Pradesh (Ghaziabad, Sahibabad, Greater Noida, Noida, Lucknow, Agra, Kanpur, Mathura, Jewar, Sikandrabad, Meerut, Sonbhadra, Pata, Anpara, Allahabad, etc.), Madhya Pradesh, Punjab, Rajasthan, Haryana, Himachal Pradesh, Uttarakhand, Bihar, Chattisgarh, Gujarat, Maharashtra, Jammu Kashmir, West Bengal, Nepal, Sikkim, Arunachal Pradesh, Assam, etc.

Locations serviced include :- Shrinagar, Jammu, Kargil, Shimla, Kullu, Manali, Ludhiana, Bathinda, Jalandhar, Amritsar, Chandigarh, Ropar, Talwandi, Jhajjar, Hissar, Gurgaon, Manesar, Panipat, Sonipat, Faridabad, Palwal, Ballabhgarh, Bahadurgarh, Delhi, Jaipur, Bikaner, Jodhpur, Alwar, Chittorgarh, Kota, Noida, Ghaziabad, Greater Noida, Aligarh, Kanpur, Allahabad, Agra, Gorakhpur, Meerut, Mathura, Varanasi, Sikkim, Arunachal Pradesh, Jhansi, Gwalior, Bina, Bhopal,Indore, Mumbai, Pune, Nagpur, Vadodara, Ahmedabad, Goa, etc.

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