Alpha Sonix NDT Solutions Private Limited

Ultrasonic weld inspection is a widely used non-destructive testing (NDT) method to evaluate the integrity and quality of welded joints. It utilizes high-frequency sound waves to detect internal flaws such as cracks, voids, or incomplete penetration within the weld. This method is especially valued for its ability to inspect both surface and subsurface defects without damaging the material.

Manual ultrasonic testing is a form of NDT used to detect internal discontinuities, material thickness, and part integrity.  

Ultrasonic testing is used to carry out the inspection in casting, forging, welded components in all industrial sectors.

The method can be performed on all types of materials: 

· Defects that are small and deep in the surface.

· To detect object thickness.

· Assessment of part integrity.

Its major advantage is quick and portable inspection.

Alpha Sonix uses advanced ultrasonic equipment and we can inspect customers’ components and structures according to industry codes and standards or customer specifications, ensuring that components or structures meet the highest quality standards for safety and reliability.  We offer both off-site and on-site ultrasonic testing.

The technique uses a pulse unit to power an ultrasonic transducer. The transducer is placed into contact with the tested object with a thin layer of Couplant and sound waves are generated into the object. The reflected waves are assessed and the signals from the echo are shown on the display unit.

 Skilled interpretation of the signals indicates if there are any defects or discontinuities. 
Our experienced ultrasonic inspectors are certified according to industry standards in ASNT level 2 and 3. They offer guidance in the selection of suitable testing methods and regiment.

By choosing Alpha Sonix for your ultrasonic testing, we can meet your production and maintenance schedules. And our highly experienced inspectors use advanced equipment to give you the Total Quality Assurance that your products or components are compliant with industry standards. 

 

Other advanced ultrasonic testing methods provide by Alpha Sonix:

Alpha Sonix not only provide manual ultrasonic testing, but we also offer advanced ultrasonic testing that includes:

· Time of flight diffraction (TOFD)

· Ultrasonic Thickness Measurement

· Phased array

·   Immersion ultrasonic testing

Being a leader in this industry,we are devoted towards providing a premium quality Dye Penetrant Testing Service This service is performed as per the requirements of our precious clients. The provided service is highly appreciated by our clients owing to its hassle free execution and cost-effectiveness features. This service is carried out by our highly qualified professionals using excellent grade tools and modern technology. The offered service is executed within a scheduled time-frame. Furthermore, provided services can be availed by our valuable clients at most competitive prices.

Ultrasonic Thickness Gauge Testing Hardness testing makes it possible to determine material characteristics such as strength, ductility and wear resistance. It also shows whether the heat treatment process has been carried out properly. These properties can be critical for the intended application of a material.

Hardness tests are typically performed by pressing a specifically dimensioned object (indenter) into the surface of the material. The hardness is determined by measuring the depth of indenter penetration or by measuring the size of the impression left by the indenter.

Based on the used method, the measured hardness is expressed in Rockwell (HRC), Vickers (HV) or Brinell (HBW) values. If required, the test result can be translated to another scale using conversion tables. Hardness tests can be carried out on location using portable equipment 

Portable Hardness Testing (HT) is a non-destructive testing method utilized to obtain the hardness value of a material. ALPHA SONIX NDT uses the latest GE Portable Hardness Testing Technology to provide clients the information they require about the materials they are utilizing. ALPHA SONIX NDT also employs full time metallurgists within our mechanical testing facility.

ALPHA SONIX NDT APPLIES HT TO INSPECT

 

·       Ferrous and non-ferrous metals and alloys, and select non-metallic materials

·       Welds and weld overlays, weld heat affected zones (HAZ’s), castings and forgings, piping, stress relieved material, machined parts, pressure vessels, and structural steel

·       Damaged materials as part of a failure analysis

·       Welds and to verify material compliance to:

·       ASME Section IX

·       NACE MR0175/ISO 15156 requirements

  ADVANTAGES

·       Fast results and reporting to the client

·       Field Ready

·       Highly portable tools can be used in most locations

Magnetic Particle Inspection (MPI)Magnetic Particle Inspection (MPI) is an NDT method that can use magnetism to detect surface and subsurface discontinuities in ferromagnetic materials.

MPI is generally used to determine parts fitness for use. It is a relatively easy and quick method that is widely used in various sectors such as automotive, oil and gas, aerospace,      petroleum,                   power generation, etc.

This method detects surface or subsurface discontinuities such as cracks, porosity, laps, seams, inclusions in ferromagnetic materials. One of the major advantages of this method is, it is a relatively fast method and gives an immediate indication on the surface.

This method works by inducing the magnetic flux in the part to be tested. If any discontinuities or detect is present on the surface or near the surface the magnetic field distorts and leaks around the defect. By application of magnetic medium on the surface, the particles attract the area where flux leakage has occurred producing a visible indication of the defect. This indication can be evaluated by the operator any necessary measures are taken if any.

Our techniques for magnetic particle inspection include:

· Yoke

· Bench (for headshot direct induction)

· Coil shot

· Prods

· Central conductor

ALPHA SONIX has skilled NDT personnel that have gained years of experience in performing MPI and are Level 2 and 3 qualified with ASNT. We provide the testing both on-site at our customers’ premises.

When selecting ALPHA SONIX for your magnetic particle inspection (MPI) needs, you have an assurance that your maintenance schedules will be met and you will benefit from the expertise that our inspectors provide. Our reports will provide you with the necessary data to take preventive measures and will help in the management of assets.

Dye Penetrant Testing DPI or Liquid Penetrant testing is the most common NDT technique used to detect surface-breaking discontinuities.

This non-destructive testing technique, also known as dye penetrant testing is a cost-effective method to locate is discontinuities in the test specimen it is a viable option when the surface to be tested requires a high amount of sensitivity. This method is commonly used to detect discontinuities that are open to the surface like undercut, porosity, LOP, LOF, cracks, etc. DPT can be applied to all ferrous, non-ferrous, and all non-porous materials.

It is commonly used to detect defects in the manufacturing process. Alpha Sonix works with all industry sectors including, power generation, aerospace, petrochemical and oil and gas, construction, marine applications we can provide dye penetrant inspection (DPT) on-site at our customer’s premises or at our highly modern laboratories.

The method is also useful for testing on-site as it is portable (usually due to spray canisters) and when applying certain techniques such as visible method contrast there is no need for additional resources such as electricity, water, or ultraviolet light source. This makes it highly convenient for inspecting surface discontinuities.
The tested item is first cleaned before the penetrant is applied, penetrant can be applied in a variety of ways like dipping, spraying, or brushing. The penetrant is given time to soak into any defects, the penetration time (dwell time) dependent on the chosen    penetrant      and     customer           requirement.

Afterward, the excess penetrant is removed and the component is dried depending on the process used. Then a developer is applied. The developer helps to draw the penetrant out of the flaw and onto the surface to form a visible indication this retrieval of penetrant back to the surface from the crack is known as Blotting action. A visual inspection is then performed under ultraviolet or white light, depending on the type of penetrant           used.

 

 

Classification of penetrants is by their sensitivity levels and content when selecting a penetrant, factors such as environment under which the test is to be performed, surface finish, size of defects sought, chemical stability, flash point, and the size to the part       are      considered.

 

Our Quality Assurance techniques for dye penetrant inspection include: 

· Visible solvent removable

· Water washable

·   Post   emulsifiable

Alpha Sonix’s well-qualified personnel hold a minimum of Level II in ASNT and are highly   experienced in      performing dye     penetrant            inspection.

By choosing ALPHA SONIX for dye penetrant inspection, round-the-clock testing as well as a regional collection and delivery service, reliable inspection. We can provide the inspection service that will ensure your products or equipment is fit for purpose and meets national and international standards, as well as our highly train manpower, are also best in class for inspection or training in today’s highly regulated markets.

 

 

Being a prominent firm in this domain, we are engaged in offering Radiography Testing Services.Offered service is performed under the strict supervision of our experts using optimum grade tools and latest technology. Our professionals perform this service as per the requirements of our clients. Moreover, this service can be availed by our clients at most reasonable price.

With enriched industrial experience and knowledge, we are providing a qualitative NDT Visual Testing Service. The provided service is executed as per the requirements of our precious clients. Our experts check all the steps and parameters associated to this service and carry out it in the best possible manner. Our professionals use high grade tools and latest technology to execute this service. Furthermore, the offered service can be availed by our precious clients at most reasonable price.

Magnetic Particle Inspection (MPI) is an NDT method that can use magnetism to detect surface and subsurface discontinuities in ferromagnetic materials.

MPI is generally used to determine parts fitness for use. It is a relatively easy and quick method that is widely used in various sectors such as automotive, oil and gas, aerospace,      petroleum,                   power generation, etc.

This method detects surface or subsurface discontinuities such as cracks, porosity, laps, seams, inclusions in ferromagnetic materials. One of the major advantages of this method is, it is a relatively fast method and gives an immediate indication on the surface.

This method works by inducing the magnetic flux in the part to be tested. If any discontinuities or detect is present on the surface or near the surface the magnetic field distorts and leaks around the defect. By application of magnetic medium on the surface, the particles attract the area where flux leakage has occurred producing a visible indication of the defect. This indication can be evaluated by the operator any necessary measures are taken if any.

Our techniques for magnetic particle inspection include:

· Yoke

· Bench (for headshot direct induction)

· Coil shot

· Prods

· Central conductor

ALPHA SONIX has skilled NDT personnel that have gained years of experience in performing MPI and are Level 2 and 3 qualified with ASNT. We provide the testing both on-site at our customers’ premises.

When selecting ALPHA SONIX for your magnetic particle inspection (MPI) needs, you have an assurance that your maintenance schedules will be met and you will benefit from the expertise that our inspectors provide. Our reports will provide you with the necessary data to take preventive measures and will help in the management of assets.

The ID oxide scale is produced by oxidation in the reheater and superheater. The scale build up occurs when the tubes have experienced high temperatures for extended periods of time. The formation of ID scale reduces heat transfer and results in a further increase of tube metal temperature. Higher temperatures promote further growth of ID scale. The result is the ID scale feeds on itself and increases in thickness as it continues to grow.

The increase in ID scale and the associated tube metal temperature promotes creep in the tube metal. Formation of creep results in a loss of strength at high temperature and therefore a loss in remaining life. The final outcome of excessive scale is a thick lipped, long term overheat failure.

Ultrasonic technique

The ultrasonic method for measuring scale thickness is based on transmitting a wave through the tube thickness. The thickness is calculated by measuring the time difference between the signals reflected from the steel/scale interface and the tube ID surface. With advanced signal interpretation techniques, we can achieve Oxide scale Thickness measurements up to the resolution of 0.15 Microns.

At Alpha Sonix NDT Solution Pvt. Ltd. we use Advanced Ultrasonic Equipment’s and recommended accessories to perform Internal Oxide Scale Thickness measurements to ensure accuracy and repeatability.

Theory

The very high temperatures found inside steam boilers (in excess of 1500 degrees Fahrenheit or 800 degrees Celsius) can cause the formation of a specific type of hard, brittle iron oxide called magnetite on the inside and outside surfaces of steel boiler tubing. At very high temperatures, water vapor will react with the iron in the steel to form magnetite and hydrogen.

The speed of this reaction increases with temperature. Oxygen atoms will diffuse inward through the magnetite layer, and iron atoms will diffuse outward, so the scale continues to grow even after the tube surface is completely covered.

Magnetite scale acts as thermal insulation on the pipe, since the thermal conductivity of scale is only about 5% that of steel. When heat can no longer transfer efficiently from the flame through the tube into the steam inside, the tube wall will heat up to temperatures beyond the intended operating range. Long term exposure to overly high temperatures, combined with the very high pressure inside the tube, leads to intergranular micro-cracking in the metal and to creep deformation (a slow swelling or bulging of the metal), which in turn eventually leads to tube failure by bursting.

A secondary issue is oxide exfoliation, in which pieces of oxide scale break off (usually due to thermal stresses during boiler startup or shutdown). These hard pieces will be carried by the steam flow into the turbine, where over time they will cause erosion damage.

The growth of magnetite scale and the associated metal damage are primary limiting factors with respect to boiler tube service life. The process begins slowly and then accelerates, for as the scale grows thicker the tube wall becomes hotter, and that in turn increases the rate of both scale growth and metal damage. Studies in the power generation industry have indicated that the effect of scale is relatively insignificant up to thicknesses of approximately 0.012 in. or 0.3 mm, but that beyond that thickness the negative effects of scale increase rapidly. Periodic measurement of scale thickness allows a plant operator to estimate remaining tube service life and to identify and replace tubes that are approaching the failure point. Ultrasonic testing provides a quick and nondestructive method for measuring scale. In all cases the coupling surface must be smooth and in some cases surface preparation will be required.

We are ranked amongst the renowned organizations that are engaged to provide the best quality Vacuum Box Leak Testing Service. The offered service is executed by our highly qualified professionals using premium grade machines and latest technology. Our skilled professionals properly examine all the parameters associated to this service and carry out it in the best possible manner. Further, the provided service is performed as per the clients’ specific needs with respect to their budgetary constraints.

Ultrasonic thickness measurement UTM is a non-destructive testing method used to inspect the metal thickness of ship hulls, piping and structural steel.Thickness measuring is essential across many industries to monitor corrosion, erosion and damage. Ultrasonic thickness measurement (UTM) is commonly used and the method can be applied to a wide range of structures and components that includes ship hulls, piping, pressure vessels and structural steel.   Detection of metal loss caused by corrosion, erosion or damage is vital to ensure the continued safety and operation of the inspected item/structure.  It can also help determine if repair work or replacement is needed or if the item/structure should be retired. Ultrasonic thickness measurement data gives customers the necessary information required to determine if the tested item has the adequate metal thickness for which it was designed. An ultrasonic thickness gauge works by precisely measuring how long it takes for a sound pulse that has been generated by a small probe called an ultrasonic transducer to travel through a test piece and reflect back from the inside surface or far wall. From this measurement, the thickness of the test piece is calculated and displayed on a digital screen. The portability of the testing equipment allows for on-site inspection and results are instant. If a problem has been detected by the technique, additional non-destructive testing methods can be used to further investigate the findings. Alpha Sonix inspectors are highly experienced in performing ultrasonic thickness measurements and corrosion evaluations for all industry sectors including oil and gas, power generation, structural contractors and foundries. In addition, Alpha Sonix provides Total Quality Assurance solutions for all your thickness gauging and corrosion monitoring requirements as we can perform follow-up non-destructive testing to further investigate results. Our commitment to responsive turnaround times will ensure that we meet your schedules and our expertise means we guarantee your components are tested to industry standards, codes or customer specifications.

 A fast and non destructive testing method for verifying the chemical composition of metals and alloys. PMI can be used to verify that supplied materials conform to the proper standards and specifications

We have reached the pinnacle of success and earned a reputed name by providing the high-quality Eddy Current Tube Inspection Service.Offered service is widely demanded by our clients owing to its high reliability and perfect execution. This service is carried out under the supervision of our experts using optimum grade tools and high-end technology. Our professionals check all the steps related to this service and execute it in an excellent manner. Moreover, our precious clients can avail this service from us at most reasonable price.

Hardness testing makes it possible to determine material characteristics such as strength, ductility and wear resistance. It also shows whether the heat treatment process has been carried out properly. These properties can be critical for the intended application of a material.

Hardness tests are typically performed by pressing a specifically dimensioned object (indenter) into the surface of the material. The hardness is determined by measuring the depth of indenter penetration or by measuring the size of the impression left by the indenter.

Based on the used method, the measured hardness is expressed in Rockwell (HRC), Vickers (HV) or Brinell (HBW) values. If required, the test result can be translated to another scale using conversion tables. Hardness tests can be carried out on location using portable equipment 

Portable Hardness Testing (HT) is a non-destructive testing method utilized to obtain the hardness value of a material. ALPHA SONIX NDT uses the latest GE Portable Hardness Testing Technology to provide clients the information they require about the materials they are utilizing. ALPHA SONIX NDT also employs full time metallurgists within our mechanical testing facility.

ALPHA SONIX NDT APPLIES HT TO INSPECT

 

·       Ferrous and non-ferrous metals and alloys, and select non-metallic materials

·       Welds and weld overlays, weld heat affected zones (HAZ’s), castings and forgings, piping, stress relieved material, machined parts, pressure vessels, and structural steel

·       Damaged materials as part of a failure analysis

·       Welds and to verify material compliance to:

·       ASME Section IX

·       NACE MR0175/ISO 15156 requirements

  ADVANTAGES

·       Fast results and reporting to the client

·       Field Ready

·       Highly portable tools can be used in most locations

Vacuum Box Testing of butt, fillet and lap weld

Vacuum box testing is a non-destructive examination NDE/NDT used for locating welding leaks. A vacuum box and a compressor create a high or low-pressure vacuum and a detergent solution is applied to the test area. The detergent bubbles help to identify the leaks within the created pressure envelope. The main objective of the Vacuum box testing technique is to locate leaks in welds due to through-thickness discontinuities. This is accomplished by applying a solution to a weld and creating a differential pressure across the weld causing the formation of bubbles as leakage gas passes through the solution. This testing is to be performed prior to any main vessel or tank testing following the completion of all welding. This article will briefly explain the leak testing procedure using the vacuum box method that can be used for all metals.

Required Equipment for Vacuum Box Testing

Vacuum box test method employs the following equipment for welding checks

• a compressor: approximate flow 6 m^3 per minute under 7 bar
• An air pipe between the compressor and vacuum box.
• A vacuum box, which enables to obtain a depression of 500 m-bar, which can be controlled by means of a vacuum manometer located on the box. The manometer shall have a range of 0 psi (0 m-bar) to 15 psi (1020 m-bar).
• A liquid detergent mixed with water makes soapy water.
• Bubble solution which produces a film. That does not break away from the area to be tested and the bubbles formed shall not break rapidly due to air drying or low face tension.
• Soups or detergents for cleaning shall not be used.
• If the ambient temperature is below freezing, add ethylene glycol to the solution (antifreeze).
• General lighting or individual lighting if necessary. The minimum light level shall be 100 foot-candles (1000 lux)
• A brush (diameter not less than 50 mm)
• A metallic brush and/or a grinding machine.