One stop source for Asset Life Extension -...
Transcript of One stop source for Asset Life Extension -...
Laboratories for Materials Advanced Testing Services
LMATS Capabilities guide 20170201 , Page 1 of 16 LMATS Pty Ltd ABN 41 107 100 925 9 Melbourne 9 Dandenong 9 Sydney 9 Newcastle 9 Albury 9 Brisbane 9 Perth 9 Malaysia
Third Party Inspection
WPS/PQR develop &
qualify
Mechanical tests
Failure Analysis
Metallurgy services
Corrosion Resistance
tests
OES chemical analysis metals
& XRF PMI
Advanced NDT PEC, ECA, PAUT, TOFD, CRT, LFET,
LRUT
NDT & Hydrostatic
test
Pressure vessel Inspection & Tank Survey
NDT on concrete
structures
One stop source for Asset Life Extension
Replication microscopy
Welder training &
qualification
Strain gauging
Heat Exchanger tubes tests - IRIS,
ECA, RFT, NFA, MFL
Coatings, Adhesive &
Sealants tests
LMATS Capabilities guide 20170201, Page 2 of 16
Accredited in accordance with ISO/IEC 17025 by NATA, Australia
About LMATS
LMATS
LMATS
LMATS
LMATS
LMATS
LMATS
• 2017 – Perth, WA (MTS Metallurgical Services)
• 2016 – Perth (Australian Welding Academy)
• 2016 – Branched in Newcastle, NSW
• 2015 – Branched in Malaysia
• 2014 – Brisbane, QLD
• 2013 – Branched in Indonesia
• 2012 – Sydney, NSW
• 2011 – Albury, NSW
• 2010 – Branched in Dandenong, VIC
• 2009 – Melbourne VIC
• 2008 – Commenced in Ballarat, VIC
LMATS
¾ 9 Locations
¾ Capability > 160 types of Tests
¾ Capacity = 60+ permanent Staff
200+ Project personnel
¾ Online instant reporting
Australian company
LMATS Capabilities guide 20170201, Page 3 of 16
Pulsed Eddy Current testing (PECT) Corrosion & Thickness measurement without Insulation removal
• Measure corrosion & thickness o Through up to 150mm insulation, concrete, brickwall, HDPE o On ferrous in-service pressure equipment pipes, vessels & tanks. o On 4-65mm thick wall and pipe diameter above 100NB o On underwater structures, marine environment
• Scan over o Cladding - Stainless, Aluminium, Galvanize o Steel surface up to 5500 C (Hot or Cryogenic) o Protective or polymer coating, bitumen
• Not affected by chicken or hog wire reinforcing, straps • Battery powered, remote controlled using extension arm Advantages: • Non-radioactive test method. Hence exclusion zone not required. Eliminate
o Operating asset downtime o Insulation removal/reinstate and save cost o Expensive surface preparation before test o Grinding hazards on in-service equipment.
Limitations: • Measures % Av. relative thickness (PART) at the probe footprint (35-200mm) which
depends on insulation thickness, clad material and test material wall thickness. • Measurements vary near edges of test part
Capabilities - Advanced NDT
Scan directly on corrosion scab or blister
Fast, Accurate (±10%) and digital Plan imaging
Elbows, near nozzles, flanges & pipe
Max. speed - 2m/min or 1 second/spot)
Detect Corrosion
under Insulation
Mapping of corrosion shape and size
Scan directly on corrosion scab or blister
LMATS Capabilities guide 20170201, Page 4 of 16
ECA – Eddy Current Array testing (Precise surface defect sizing with computed 3D imaging)
Ferrous weld (measure 10mm height crack)
Single scan 50mm wide (weld, HAZ) at 6m/min.
Flexible probes to test complex parts, Rail,
gears, mining & infrastructure parts
Corrosion pits depth measurement
Ferrous or non-ferrous wall
Stress corrosion cracks – precise sizing Detect fatigue & Creep cracks
Detect small cracks around fasteners
Aerospace, Wind towers, marine, turbine parts
Case study - ø300mm petroleum pipeline surface scanned using flexible probe. ECA measured discontinuities
confirmed with microscopic measurement
Shark probe for Weld
Longitudinal Transverse Oblique Flat-bottom notches notches notches holess
6.4mm Slot hole 1.8 3.2 4.9
Advanced NDT
LMATS Capabilities guide 20170201, Page 5 of 16
ECA – Eddy Current Array (3D mapping) RFT – Remote Field testing NFT – Near Field testing
SS & non-Fe Tube testing with enhanced defect sizing Simultaneously detection (in a single pass) of Axial, Circ. and
long. discontinuities. Average scanning speed = 6m/min (fastest). 3D mapping of tube circumference and length
Ideal for ferromagnetic tubes testing Advantages - Detect both ID & OD indications
with same sensitivity Detect ID erosion, baffle wear, pitting, wall loss
Very sensitive to wall thickness variation
Ideal for Al. finned ferromagnetic tubes Advantages - Excellent for internal discontinuities, Detect ID corrosion, erosion, pitting & axial cracks High sensitivity for discontinuities near support plate and tubesheet. Very fast as compared to IRIS, RFT, MFL
IRIS – Internal Rotary Inspection System MFL – Magnetic Flux Leakage NFA – Near Field Array (3D mapping)
Ideal for ferromagnetic tube thickness testing Advantages – Detect ø1.6mm equivalent pitting,
Thickness accuracy of ±0.13mm. Scanning Speed = 1.5meter per minute. Test range = ø13mm & above
Limitations - Thorough cleaning essential before testing. Insensitive for radial cracks
Ideal for Al. finned ferromagnetic tubes
Advantages - Detect both ID & OD corrosion, erosion, pitting, axial, radial & circumferential cracks. High sensitivity for pitting & circumferential cracks. Tube testing diameter range = ø25mm & above
Ideal for Al. finned ferromagnetic tubes Advantages - Precise sizing, location, high speed
Av. Scan speed = 6m/minute (fastest). Detect ID pits, Axial & circ. cracks, cracks at tube sheet, erosion, corrosion, wall loss. Tube testing diameter range = ø19-38mm
Tube wall circumference
Aluminium finned Carbon steel tube
Heat exchanger tubes
LMATS Capabilities guide 20170201, Page 6 of 16
PAUT – Phased Array Ultrasonic testing LRUT – Guided Wave Long Range UT (Chartered on request)
Critical crack sizing fatigue cracks, SSC, creep, etc, in of Welds, Rails, wheels, axles, shafts, bolts, HDPE, Composites, Corrosion
Ideal for rapid inspection of long distance pipelines Advantages – Inspect inaccessible underground pipelines, encased and insulated
piping. No need to remove coating or insulation except 1m at sensor location. Accuracy of 3% in metal loss flaws. 100% pipe surface inspection up to 40m in single scan.
Limitations – Not for in-service Cryogenic pipelines. Removal of Bituminous coating
TOFD –Time of Flight Diffraction SRUT – Short Range Ultrasonic Testing (Chartered on request)
Tank welds, Weld root erosion testing in fluid carrying pipelines, high pressure steam pipes in power station
Ideal for inspection of inaccessible areas – Annular ring, pipe support, Advantages –Detect wall thinning at concealed area of interest.
Inspect up to 2m length in a single scan. Thickness accuracy of ±10%. Test range – ø200mm & above. Thickness range 6 to 25mm
Limitations – Inspection at ambient temperature only. Cannot discriminate internal or external discontinuities.
Advanced NDT
Annular ring
LMATS Capabilities guide 20170201, Page 7 of 16
CRT – Computed Radiography (Digital radiographs) LFET – Low Frequency Electromagnetic Test (Chartered on request)
Faster radiography with portability
Shorter Exposure and On-site instant results Radiography on welds and Corrosion detection
Boiler water wall testing
Advantages –Scan from outer surface of water wall tubes. Detect both OD & ID discontinuities. 100% scanning of tube length
Advanced NDT
Computed digital radiograph
Conventional film radiograph
LMATS Capabilities guide 20170201, Page 8 of 16
Welder training & Qualification (WQR) WPS / PQR Services
Increase productivity by reducing site weld repairs 9 Pre-mobilisation OR Pre-employment welder assessment 9 Welder Qualification and assessment 9 Weld booth at LMATS Facilities, Offsite Welder assessment 9 Onsite Welder training & assessment 9 Welder supervision for qualifying to specific WPS 9 Witnessing of Welder test coupon 9 Supervision of Welder test coupon welding 9 Welder continuity (6 monthly) test coupons 9 Welder skills upgrade OR basic welding training 9 Training in SMAW, GMAW, FCAW, GTAW, SAW welding 9 Trade Certificate – RPL – Cert III & Cert II 9 Welding Supervisor Training – AS2214 & AS1796 Cert 10 Experienced & Qualified trainers at LMATS’
9 WPS - Welding Procedure Specification Development 9 WPQR - Welding Procedure Qualification Recording 9 WPQR / PQR - Witnessing OR Supervision 9 Client representation - WPS review and verification 9 PWQ - Production Weld Qualification witnessing 9 Review & verification of PQR supporting documents 9 WPS for CS, SS, Duplex SS, Al alloy, Ti alloy, Inconel, etc 9 WPS for Australian Standards, ASME, AWS, ISO, EN 9 Fabrication Survey and Inspection - ASME, AWS, AS 1554 series 9 Baseline Inspection & Visual scanning – AS 1210, AS 4041, ASME 9 Manufacturing status Survey & Project Expediting Welding machine Verification – Amps, Volts, Flowmeter
Welding Consultancy
LMATS Capabilities guide 20170201, Page 9 of 16
9 Tensile / Compression – Range 100g (1N) - 300t (3000kN) 9 Rail testing (AS 1085.2) - Fatigue (250kN) & Slow bend test
9 Tensile - ‘Z’ direction, high temp., proof load, bond & notched 9 Cyclic load (fatigue) / Speed 0.01 to 500mm/min
9 Charpy ‘V’ and ‘U’ notch impact tests – Ambient to -1960C
9 Ductility, flattening test, Bend test, 3 or 4-point bend test
9 Fracture test, fillet break, Shear, flexural, torque, torsion
9 Vickers automatic traverse hardness test
9 Hardness – Rockwell, Brinell, Micro Vickers
9 Portable Brinell, Leeb (Equotip), Poldi, TIV Krautkramer
9 Electrical conductors test
9 Hydrogen Embrittlement test
9 Testing of thermal spray coatings
9 Load test – In-situ structures, guardrails, posts, balustrades,
Full scaffolds, Scaffold parts (fittings, planks), pool fences, etc
9 Tests on Reo bars, wires, etc plastics, HDPE, composites, straps
9 Surface roughness test 9 Fasteners testing – Nuts, Bolts, Screws and studs
9 Mechanical tests on grinding balls (including ISO 3506.1 bolt extensometer testing & wedge tensile)
9 Strain gauging 9 ROCAP (Rotational capacity) & assembly tests
Mechanical testing
Rail fatigue testing
300T test machine for Rail slow bend test
Grindingballs
Strain gauging
Ø 600mm polishing pads
LMATS Capabilities guide 20170201, Page 10 of 16
Metallurgical Services Chemical testing (Lab & onsite Spectrometry)
9 Failure Investigation & Metallurgical consulting 9 Replication & Microscopy 9 Etch structure classification 9 Grain size measurement 9 Case depth measurement 9 Ferite Count (ASTM E562) 9 Intermetallics assessment 9 SEM / EDS / XRD (Chartered) 9 Macro test on welds and wrought products 9 Macro deep etch tests to detect forging & inclusions 9 In-situ material microstructure by onsite Replication 9 Onsite Ferrite Fisher Feritescopy 9 Heat treatment consulting 9 In-house heat treatment of samples 9 Tests on Coatings 9 Research & development assistance
9 Chemical analysis (O.E.S.) and material Grade identification 9 NATA for Fe alloys including Boron to 0.001%
SS steel including Nitrogen, Cu alloys & Al alloys 9 Onsite OES Portable Spectrometry – Oxford – Carbon in steel 9 Sample collection, Grade ID on live O&G pipelines 9 NATA Accredited PMI – XRF using Olympus, Niton, Oxford XMET 9 Grinding media composition 9 CA of ceramics (chartered)
Corrosion resistance tests 9 Intergranular corrosion– ASTM A262, G48, G28, A923 & AS 2038
9 Intergranular corrosion test on Titanium alloys (ASTM F2111)
Water jet cutting (Omax) 9 Passivation test – Ferroxyl, CuSO4 & High Humidity (ASTM A380) No heat input and precision cutting (±0.01mm), as well as reduced preparation time. Cut up to 200mm thick sections in CS, SS, manganese, white metal and other wear hardening steels, glass, plastic, rubber, wood and other materials.
9 Tinning Test as per AS 1574 Cl 2.8
9 Coatings mass - Strip & dissolve 9 Dezincification (AS 2345)
9 Neutral Salt spray test
Materials Engineering
Thermal fatigue failure
LMATS Capabilities guide 20170201, Page 11 of 16
Pressure vessel Inspection & Risk based assessment In-situ Replication assessment
Baseline, Commissioning, In-service Inspection of 9 Pressure vessels, boilers, Heat exchangers, condensers 9 Petroleum, chemical plant process vessels 9 Low pressure petroleum storage tanks 9 Transportable vessels, Road Tankers & LPG storage tanks 9 Air receivers & pressure piping Fitness for purpose & Structural integrity assessment - AS 3788 Pressure Vessel Conformity Assessment - AS 1210 & AS 3920.1 Pressure gauges Verification
9 Power generation 9 Petroleum refineries 9 O&G and Chemical industries
Coating Inspection & tests Third Party Inspection
NACE Level 2 /BGAS CSWIP inspection services Galvanising coating Inspection (AS 4680) Blast profile measurement (Testex) Coating thickness test (WFT and DFT) Degree of cure test & hardness test Coating Adhesion test / Bonding pull off test Film continuity - Holiday test (High Voltage porosity test) Coating ductility (bend) test & Coater qualification test Cathodic disbonding test & Soak test on coatings to AS 4822 Passivation contamination tests – Ferroxyl, Copper Sulphate Coating mass thickness test by strip & dissolve/weigh method PMI on coatings – Detection of heavy elements e.g. Pb, Ti
Pressure equipment Conformity assessment - AS 1210 & AS 3920 Fabrication Survey and Inspection - ASME, AWS, AS 1554 series Baseline Inspection & Visual scanning – AS 1210, AS 4041, ASME Manufacturing status Survey & Project Expediting Vendor Approval assessment / Third party quality audit Expert Witnessing – NDT, Mechanical test and Hydrostatic test MDR / DMDM compiling, review & verification NDT Level 3 - Facility proficiency and L1 & 2 Competency test Experience in Australia, Canada, Italy, France, Japan, Korea, South Africa, USA, Malaysia, India, Indonesia, Philippines, Bangladesh, Vietnam, Brazil, Belgium
Materials Engineering
LMATS Capabilities guide 20170201, Page 12 of 16
9 Tank Inspection (AS 1940, AS 3788, API 653) 9 Tank bottom, wall & roof thickness mapping
using TFT, PAUT, UT or ECA Settlement (Laser) Survey – API 653
9 Plumb assessment – Digital protractor 9 Corrosion (Wastage) Rate – API 653 9 Structural integrity assessment
tmin = {[2.6 * (13.12-1) * 13.12 * 0.8171 ] / [23200 x 0.85]}
Tank Inspection services
LMATS Capabilities guide 20170201, Page 13 of 16
Non-destructive testing Pressure testing9 RT – Conventional Radiography (Film) & CRT 9 Vacuum box test (differential pressure leak)
9 ET – Eddy Current flaw detection in ferrous welds 9 Hydrostatic test, Stress or Burst test up to 40MPa (NATA Endorsed) with live computerised pressure & temperature chart. 9 ET – Eddy Current tube testing & ECA, IRIS
9 ET – Eddy Current Coating thickness test 9 Test on vessels, cylinders, pipes, hoses, valves, fittings and SRV
9 ET – Conductivity / Material sorting / Aluminium grade ID
9 ET – Crane inspection without paint removal Portable carry-on baggage testing unit
9 ET – Ferrite measurement by Fisher Feritescope
9 UT – Ultrasonic flaw detection / lamination / thickness test
9 UT – ‘A’ Scan ultrasonic hollow axle flaw detection
9 PT – Penetrant - Colour & fluorescent Pneumatic tube (Heat Exchanger) leak test 9 MT – Magnetic particle test
9 VT – Visual and Boroscopic inspection
9 Residual magnetism test
9 Replication microscopy
9 Onsite hardness test – TIV Krautkramer
Conventional NDT
leak test (very low pressure Pneumatic test)
LMATS Capabilities guide 20170201, Page 14 of 16
Aerospace Sealants, Adhesives & Polymers NDT on structural concrete
9 Flow test for Class A, B, C, D & E sealants ( AS 5127/1C) 9 T-Peel strength test for structural adhesives (ASTM D1876) 9 Peel Strength for all sealants in both 4” & 5” configuration 9 Shore ‘A’ & ‘D’ hardness on rubber, polymers, gels & plastics 9 Lap Shear test for structural adhesives (ASTM D1002)
including PAA and thin film sulphuric acid anodizing test 9 Flatwise tensile testing of adhesives using metal honeycomb
core to BS EN 2243 / ASTM C297 9 Application Time for Cl A,B,C,D sealants & catalyst (AS 5127/1C9 Tack-Free time test for all classes 9 Initial Cure time test (ASTM D2240) 9 Adhesive Gel Time test (ASTM D2471) 9 Rubber testing to ISO 37/ ASTM D412 9 Volumetric distortion test/ Mass loss
of rubber products in Hexane 9 Deterioration test by subjecting to
exposure to oxygen (AS/NZS 1425)
9 Reinforcing material detection in concrete slab 9 Reinforcing material evaluation in concrete 9 Concrete cover / slab thickness test 9 Lamination detection in concrete slabs & structures 9 Conduit detection in concrete slabs & structures 9 Concrete hardness (Schmidt) & strength test 9 Concrete Adhesion (Pull-off) test 9 On-site anchors proof load test on buildings
LMATS Capabilities guide 20170201, Page 15 of 16
Major Projects
Assessment of HV electrical conductors TPI for QCLNG, APLNG
Defect monitoring - Westgate bridge, Melbourne
NDT & Mech testing on Swan bridge, Perth
NDT & Mech tests on Defence M113 Tanks Defect monitoring Melbourne Trams
NDT & Mech tests on Naval Ships
PVI since 2014 at Portland Aluminium smelter
NDT at various gas plants – Minerva, Roma
LMATS Capabilities guide 20170201, Page 16 of 16
Contacts Email: [email protected]
9 Melbourne 6 Techno Park Drive Williamstown, VIC-3016 ℡ 03 9399 9199 ª0437 716 574
9 Sydney 1C/137 Silverwater Rd, Silverwater, NSW – 2128 ℡ 02 9648 1989 ª0433 639 391
9 Brisbane 14/121 Kerry Road, Archerfield, QLD – 4108 ℡ 07 3875 2070 ª0437 706 716
9 Perth (Metallurgy & Mech) 3/52 Cocos Drive, Bibra Lake WA 6163 ℡ 08 9418 6380 ª0408 928 481
9 Perth (NDT & Welder training) 5/156 Bannister Road Canning Vale WA 6155 ℡ 08 9200 2231 ª0430 580 932
9 Albury / Wodonga Suite 4/10-12 High Street, Wodonga VIC 3690 ℡ 02 9648 1989 ª0437 690 841
9 Newcastle Bruce Crescent, Wallarah, NSW 2259 ℡ 02 9648 1989 ª0457 896 779
9 Dandenong workshop 63 Mark Anthony Drive Dandenong, VIC-3175 ℡ 03 9399 8145 ª0439 654 384
9 Malaysia Workshop Pahang, Kuantan ℡ 613 9399 9199 ª0439 654 384
9 National / International Managed from Australian laboratories ℡ 613 9399 9199 ª0439 654 384
Quality and Industry Credentials DiscriminatorISO 17025 NATA Accreditation in 9 NDT –ECA, PAUT, TOFD, CRT, ET, RT, UT, MT, PT, VT 9 Metallurgical, chemical & Mechanical tests 9 Metals C.A, Corrosion tests, Pressure tests
BAE UK approval for Aerospace Titanium IGA Representative on AINDT, APFNDT, WTIA, NATA (Ex), IMEA Certified Staff - AINDT, AICIP, WTIA, NACE, ENAC, ASNT, CSWIP
Australia wide single point of contact for comprehensive services Advanced NDT - PEC, ECA, IRIS, RFT, NFT, NFA, MFL, PAUT, TOFD
CRT, GW LRUT, SRUT, TFT, OES Material engineering in-house expertise to assist customers. Fatigue test, Rail bend test (300T), Water Jet Cut, 600mm ø polishing pads, etc Multi skilled and cross skilled staff. 24 hours on call availability Quickest web based online reporting to save client’s time
Download Quality certificates from http://lmats.com.au/about-lmats/accreditation
Confidentiality: This document SHALL NOT be supplied to any other laboratories without obtaining written permission from LMATS PTY LTD.
About LMATS