On site testing

In-Situ Metallography ( Replica Method)

The regions susceptible to metallurgical degradations will be subjected to metallography examination and evaluation will be made on both optical as well Scanning Electron Microscopy. The recommendations derived are pragmatic and would ensure the utilization of full life cycle of the component.

Small area is polished by the portable grinder and polisher and made to mirror finish by employing various steps. The microstructures are prepared by applying suitable etching and subsequently transferred on a plastic tape by replication method. Replication is carried out to arrive at microstructure degradation of the components.

As corrosion damage is concentrated in narrowly limited zones or on uniform zones, replication is most suitable method of detecting these zones. Replica spots may be selected based on metallic thickness and oxide scale measurement and susceptible areas. In general, corrosive failures initiate mostly at surface of the components of complex component geometry associated with major branch connections selected for replica spots as these are vulnerable for corrosion damage.

Microstructures are being viewed under high powered microscopes in the laboratory and judgments are made for different damages mechanisms like to check the heat treatments/ amount of cold worked /carbide precipitation and presence of any ferrite content in the stainless-steel surfaces.

PMI (Positive Material Identification) by portable XRF

Positive Material Identification (PMI) is the analysis of a metallic alloy to establish composition by reading the quantities by percentage of its constituent elements. Typical methods for PMI include X-ray fluorescence (XRF). It cannot detect elements like aluminium, carbon, sulphur, phosphorous etc.

MMS provides Positive Material Identification (PMI) services for site testing for various applications like:

- Non- Destructive Metal Analysis and Verification for all kinds of ferrous as well as non-ferrous metals.

- Quality Control Activities.

- Segregation of metal mix-up at site.

- RoHS Screening of various electrical, electronic, composite, coated and many other metallic and non-metallic components.

- Scrap Sorting

- Measurement of heavy metals in soils, liquids, minerals, etc.

Armed with state of the art Portable Spectrometers, MMS's highly skilled and qualified personnel are capable of carrying out flexible, reliable and precise analysis of all kinds of materials.

By Non-Destructive means, we can analyze large or small samples, chips or turnings, pipes, welds, pressure equipment, finished products, metal powders, wires (even less than 1 mm in diameter), large machinery,etc irrespective of shape and size. This is a very versatile kind of test wherein no sample needs to be cut for testing.

MMS has two types of testing equipment for PMI:

- X-ray Fluorescence (XRF) Spectrometer and

- Spark Emission Portable Spectrometer

X-ray Fluorescence (XRF) Spectrometer :

This is used for material identification and segregation at site. All ferrous and non-ferrous material can be identified by using this equipment.This instrument is factory calibrated and therefore no calibration but only standardization at site is required.

OUR EQUIPMENT

OXFORD INSTRUMENTS, USA

XRF X-MET 8000 smart alloy analyzer

Spark Emission Portable Spectrometer

This instrument works on the principle of Optical Emission Spectrometry. This again can be used for ferrous as well as non-ferrous materials and alloys. It can detect whole range of elements (with Carbon). Therefore it can be used for segregation and identification of grade material also, namely, 304 as well as 304L materials. This instrument is also factory calibrated and only setting up at site is required.

Spectro ametek

Portable OES Spectrometer spectroport by spectro ametek

MMS has completed PMI projects all over India and has an esteemed list of clients.

Cost of Testing

MMS provides highly competitive rates depending on Time (half day or full day at site) or on Material as per request.

Portable Hardness Testing by UCI Hardness Tester

MMS provides UCI Hardness test service with NOVOTEST T-U3 portable hardness tester having ultrasonic contact impedance principle. It is designed for rapid non-destructive testing of hardness:

• Metals and alloys on standardized international scales of hardness: Rockwell (HRC), Brinell (HB), Vickers (HV);

• Metals with distinctions in properties of steel (e.g., non-ferrous metals, alloys of iron and others) and using five additional scales for calibration

• Use of the scale of tensile strength (Rm) for determining the tensile strength of carbon

• Steel products pearlitic by automatically converting from the scale of hardness Brinell (HB).

Portable Hardness Testing by Leeb rebound Hardness Tester

The Leeb hardness testing method is a dynamic hardness testing procedure. Over the spring force a impact device (Carbide balls, for special applications a diamond tip) is fired onto the sample surface. The measurand is the difference between the impact and rebound speed of the impact body. The loss of the velocity is directly related to the hardness, taking account of the calibration and in accordance to influence of the mass and the surface of the sample.

PORTABLE ARC/SPARK OPTICAL EMISSION SPECTROMETRY (OES) METALS ANALYZER

MMS has stat of art mobile spectro SPECTROPORT applies more advanced OES technology — in a unit as easy to use as a handheld analyzer. Sparking a revolution in mobile metals analysis, SPECTROPORT delivers many advantages of SPECTRO’s mobile OES flagship, SPECTROTEST, in a smaller, lighter package. It is as fast as a handheld XRF, with many analyses taking only a few seconds. But unlike handheld XRF, it accurately analyzes elements such as carbon, sulfur, phosphorus, boron, lithium, beryllium, calcium, silicon,magnesium, and aluminum at low and critical levels. And it enables effortless point-and-shoot performance, to minimize operator intervention and decision-making.

Inspecting the metals makeup of incoming and outgoing components is a critical task for countless companies. It’s a quality control necessity in metal producing, processing, recycling, service contracting, and more. Metal alloys must be accurately tested, identified, and verifi ed based on defi ned chemical composition.

Mistakes matter. An alloy mixup at the shipping dock or on the factory floor can cause an inconvenient batch rework — or a lostcontract.

Many firms use a handheld X-ray fl uorescence (XRF) analyzer for these jobs. However, this can cause problems. For instance, a handheld XRF can’t determine precise levels of carbon content: the only way to distinguish among many low-alloy steels. It also has trouble handling elements like phosphorus or sulfur at critical levels.

Ferrite Testing of ASS and Duplex SS by Feritescope

The FERITSCOPE FMP30 measures the ferrite content in austenitic and duplex steel according to the magnetic induction method. All magnetisable structure sections are measured i. e., in addition to deltaferrite also strain-induced martensite, for example,or other ferritic phases. It is suited for measurements according to the Basler- Standard and according to DIN EN ISO 17655. Areas of application are onsite measurements, e. g. of austenitic platings as well as weld seams in stainless steel pipes, containers, boilers or other products made of austenitic or duplex steel. Duplex steel is used increasingly in the chemical and petrochemical industries, e. g., for boilers and pipelines.

A ferrite deficit in the weld seam area leads to strength reduction, an excess ferrite content to a reduction intoughness and ductility. In particular when welding duplex steel, the ferrite content in the welding area can easily assume unfavourable values either due to unsuitable welding filler materials or through poor heat input or heat removal. Only an onsite measurement can provide the assurance that the processing did not change the optimum ferrite content in an unfavourable manner at the expense of mechanical or corrosion-resistance properties.

Thermography Solution

Thermal NDT methods involve the measurement or mapping of surface temperatures as heat flows to, from and/or through an object. The simplest thermal measurements involve making point measurements with a thermocouple. This type of measurement might be useful in locating hot spots, such as a bearing that is wearing out and starting to heat up due to an increase in friction.

In its more advanced form, the use of thermal imaging systems allow thermal information to be very rapidly collected over a wide area and in a non-contact mode. Thermal imaging systems are instruments that create pictures of heat flow rather than of light. Thermal imaging is a fast, cost effective way to perform detailed thermal analysis.

Thermal measurement methods have a wide range of uses. They are used by the police and military for night vision, surveillance, and navigation aid; by firemen and emergency rescue personnel for fire assessment, and for search and rescue; by the medical profession as a diagnostic tool; and by industry for energy audits, preventative maintenance, processes control and nondestructive testing. The basic premise of thermographic NDT is that the flow of heat from the surface of a solid is affected by internal flaws such as disbonds, voids or inclusions. The use of thermal imaging systems for industrial NDT applications will be the focus of this material.

RevealPRO is the most advanced handheld thermal imaging camera yet. Highly durable and easy to use, RevealPRO combines a high- performance 320 x 240 thermal sensor with intuitive software to help you work smarter. And, when you need it, a powerful 300- lumen LED light is available at the touch of a button. Offering adjustable thermal span, level, and emissivity settings.

Boroscopy/Videoscopy Solution

Boroscope (Optical instrument designed to assist Visual Inspection)

A boroscope is an optical instrument designed to assist visual inspection of narrow, difficult-to-reach cavities, consisting of a rigid or flexible tube with an eyepiece or display on one end, an objective lens or camera on the other, linked together by an optical or electrical system in between. The optical system in some instances is accompanied by illumination to enhance brightness and contrast. An internal image of the illuminated object is formed by the objective lens and magnified by the eyepiece which presents it to the viewer’s eye.

Boroscope (Videoscope) is used for visual inspection work where the target area is inaccessible by other means, or where accessibility may require destructive, time consuming and/or expensive dismounting activities. Boroscope is mostly used in NDT testing techniques for recognizing defects or imperfections. Boroscope commonly used in the visual inspection of- Aircraft engines. Aero derivative industrial gas turbines Steam turbines, Diesel engines Tube inspection in Heat Exchanger •Boiler parts like Header, Boiler tube, steam drum linked lines Chiller tubes Gas and steam turbines require particular attention because of safety and maintenance requirements. It is also used in manufacturing of machined or cast parts to inspect critical interior surface for burrs, surface finish or complete through-holes. Other common uses include forensic applications in law enforcement and building inspection, and in gun smithing for inspecting the interior bore of a firearm.

Oxide scale measurement solution

MMS has the latest 38DL PLUS is an advanced ultrasonic thickness gauge. Uses dual element transducer for internal corrosion applications, and has features that include THRU-COAT technology and echo-to-echo. Uses single element transducers for very precise thickness measurements of thin, very thick, or multilayer materials.

The very high temperatures found inside steam boilers (in excess of 1500 °F (800 °C) 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 according to the formula: 3 Fe + 4 H 20 = Fe 3O 4 + 4 H 2

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; as the scale grows thicker, the tube wall becomes hotter and that, in turn, increases the rate of 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 enables 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