GE Modules, X-ray Accessories, XRD Tubes, WheelScan 5, Digital Cassettes Brochure

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. We have enormous depth and breadth of know-how which can be applied to your needs.

Corrosion & Erosion

The negative eects of corrosion and erosion cost the oil & gas and power generation industries billions of dollars every year in unscheduled plant or pipeline
shutdowns, inecient or lost production, high maintenance repair costs or imposed nes. Experts believe that 20% to 25% of corrosion-related costs could be avoided.

Corrosion and erosion detection, sizing and monitoring technologies are important elements toward realizing those savings.

Multi-Modal Oering

GE Inspection Technologies oers the most comprehensive selection of testing and inspection capabilities and other products for industrial applications. Our strength
lies in the use of eld experience and customer feedback to build the most productive inspection products in the market. With the industry's broadest complement of
nondestructive test methods to ensure our customers can be condent they are getting the optimal solution to meet their needs.

IN THIS GUIDE

Overview ...............................................................................................1

Oil & Gas Application Solutions.........................................................3—4

Power Generation Application Solutions ........................................5—6

Remote Visual Inspection ..................................................................7—8

Ultrasonic Testing ................................................................................9—10

Radiographic Testing ..........................................................................11—12

Eddy Current Testing ..........................................................................13

Software Solutions ..............................................................................14

Installed Sensors .................................................................................15—18

Technical Content ................................................................................19—26

Contact Information ...........................................................................Back Cover

DATA INFORMATION KNOWLEDGE DECISION

Our NDT technologies help you collect important data and convert it into useful information. Coupled with historical plant data, intelligent software, image
enhancement, databasing, applicable codes and additional knowledge, asset owners can make better-informed decisions regarding treatment, mitigation, remaining
life, component replacement or plant operating parameters.

1

Corrosion & Erosion

On the cover

1

1. Remote visual inspection of pitted boiler tubes

2. Ultrasonic phased array prole of boiler tube ID pit

3. Digital X-ray image of insulated pipe elbow

*These images were captured and/or stored using Rhythm Software.

2 3

4

*

*

5 6

4. Real-time, on-stream monitoring of pipe wall thickness

5. Computed Tomography of hydrogen-attacked boiler tube

6. Eddy current map of wall thinning

*

*

Corrosion & Erosion

2

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

Midstream Downstream

No other supplier can match GE's

breadth of capability and depth of

experience in the field of corrosion

detection, sizing and monitoring of

fixed and rotating equipment.

3

Corrosion & Erosion

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.

Ultrasonic phased-array
inspection assists in quickly

scanning, detecting, proling

and sizing of isolated pitting in
pipes.

Remote visual inspection of
compressor blades can help
identify erosion and thinning.

Phasor XS is a proven tool for
characterizing safety-critical

ange faces at reneries for

corrosion and cracking.

Apollo is a multi-channel,
multi-frequency eddy current
instrument used to locate and
size corrosion, erosion and

cracking in heat exchanger

tubes.

Corrosion & Erosion

4

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

Gas Turbine & Combined Cycle Nuclear Power

In addition to a broad product
and service offering, GE has vast

experience and expertise in BWR,

PWR and Candu nuclear power
applications, gas, coal and oil-fired
fossil stations, gas turbines and
hydro-electric assets.

3

Corrosion & Erosion

Remote Visual Inspection with
Menu Directed Inspection™ for
turbine blade viewing.

USM Go is an ultra-portable,

light-weight pulse-echo aw

detector for general purpose
testing.

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 of
service water piping systems for
MIC using robotic crawlers and
high-resolution video cameras.

Phased array ultrasonic testing
of reactor vessel and piping
systems.

Corrosion & Erosion

6

Remote Visual Inspection (RVI)

RVI is a cost-eective 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 nd localized corrosion and erosion.

Video Borescopes

We oer an array of technologically advanced video

borescopes, from the most portable to the most
capable, all designed for ease-of-use while delivering
video images of unsurpassed quality.

Our XLG3 VideoProbe is commonly used to diagnose operational

problems with heat exchangers and other xed and rotating
renery assets.

On-site Remote Visual Inspection Service

Our sta of experienced remote imaging specialists,

equipped with the latest remote visual inspection
equipment, is available around the clock. We can as­sist during planned and unplanned outages, preven­tive maintenance, emergency services or with state
or federal compliance issues.

Nuclear plant containment building steel liner is visually inspected

with a custom 5-megapixel imaging system to meet ASME's IWE

code requirements.

Pan-Tilt-Zoom (PTZ) Cameras

GE has a full range of rugged industrial PTZ cameras
for remote viewing in large areas. Three interchange­able zoom camera head diameters with high-inten­sity lighting, pan-and-tilt mechanisms and industrial

waterproof packaging for protection from extreme

environments.

A PTZ camera system is used to inspect the integrity of glass- and
refractory-lined vessels.

NDT Equipment Rental

Access to GE’s vast selection of nondestructive testing
and remote visual inspection equipment is a phone

call away. Regional eld oces provide application
expertise, equipment selection assistance and timely

deliveries to your facility. Daily, weekly and monthly
rates are available.

Flexible NDT equipment rental structure program – daily, weekly,
monthly, or annually – to suit your needs. We also have lease-to-

own arrangements available.

Menu Directed Inspection™ (MDI)

MDI is the rst software tool in the NDT industry to

standardize the inspection process. A GE video bore­scope operating MDI software helps guide inspectors
through the inspection process and intelligently auto­generates a report, saving time, improving quality
and increasing productivity.

MDI can be customized to guide inspectors through any remote
visual inspection process.

Rhythm® Software

Rhythm Visual software combines advanced image
acquisition, review and data management tools for
remote visual inspection. Its advanced data shar-

ing capabilities allow signicant improvements in
productivity and enable faster identication of quality

problems, leading to reduced production defects or
better in-service asset management.

Rhythm provides a solution to analyze assets over time to increase

asset lifetime. Rhythm utilizes ASTM standard image-le format:

DICONDE

7

Corrosion & Erosion

Corrosion & Erosion

8

Ultrasonic Testing (UT)

Ultrasound technique has been used in non-destructive testing for almost 50 years and is used to nd 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.

Conventional Flaw Detectors

Flaw detection is a fast and accurate inspection
method to evaluate internal product integrity. Ultra­sound penetrates deeply into materials searching for
metal loss and material degradation associated with
corrosion and erosion.

USM Go is an ultra-portable ultrasonic aw detector weighing only
850 g (1.87 lb). This product has gained wide-spread acceptance

for rope-access applictions.

Corrosion Flaw Detector

Ultrasonic phased array instruments dedicated to

locating and sizing pits can signicantly improve

inspection productivity.

The Phasor CV/DM ultrasonic aw detector is optimized with

software and special dual-element phased array transducers for
increased coverage and probability of detection on tank walls,

pipes, bolts and anges.

Phased Array Flaw Detectors

Ultrasonic phased array inspection continues to
evolve rapidly and can be applied to many corrosion
and erosion applications for upstream, midstream
and downstream plant assets.

Phasor XS can be applied to the important challenge of detecting

and sizing corrosion on ange faces at HF Alky units at oil reney

units.

Corrosion Thickness Gages

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.

The DMS Go corrosion thickness gage is a simple, easy-to-use
instrument for measuring remaining wall thickness of corroded
tubes, pipes, tanks and vessels.

Transducers

GE manufacturers a wide range of standard and
custom ultrasonic testing transducers including con­ventional, phased array and permanently installed for
corrosion and erosion applications.

Phased-array and dual-element transducers are optimized for

performance extended wear-and-tear, elevated temperatures and

detection of isolated pitting.

Rhythm® Software

Rhythm UT oers the same advanced viewing and

measurement tools as the Phasor XS so you can work

oine without sacricing capabilities. Rhythm UT is a

DICONDE image management platform with addition­al tools to enhance reporting and analysis of corro­sion/erosion data to assist in better decision-making.

Phasor XS phased array sector scans post-processed on Rhythm
UT.

9

Corrosion & Erosion

Corrosion & Erosion

10

Radiographic Testing (RT)

Radiography is one of the oldest, most reliable and proven nondestructive testing methods and oers unique benets, such as revealing changes in thickness,
internal and surface defects, large-area coverage and more. We oer conventional lm radiography, digital technologies, including computed radiography and

direct radiography, portable or stationary X-ray sources, 3D computed tomography and analytical X-ray.

Film Radiography

We oer a comprehensive range of radiographic
lms, processing equipment and chemicals, perfectly

geared to one another. No object is too large or too

small—a radiographic lm of the appropriate size is
available for almost every exposure.

AGFA Structurix lm remains a global industry standard for quality

and reliability with corrosion applications.

Computed Radiography (CR)

Our wide range of CR scanners, imaging plates and
software solutions provide an overall imaging solution

to our customers. In addition, we oer proprietary

high-performing CR imaging plates for a wide range
of NDT applications including corrosion, erosion and
crack detection.

The CRxFLEX computed radiography scanner can be used in oce,
labs or eld environments. Image quality sets the CRxFLEX and our

phosphor imaging plates apart from the competition.

Direct Radiography (DR)

GE ultilizes a variety of digital detector arrays to
ensure optimal image quality and throughput for
each application. We have the unique advantage
of designing and manufacturing custom systems,

allowing us to inuence every stage of the process
to provide a solution tailored specically for eld and

shop industrial applications.

DXR250V is a 16 in x 16 in active area, eld-hardened portable im­aging digital detector array with a detachable cable. This product
plugs directly into a laptop computer for direct radiographic testing
and imaging analysis.

Industrial X-ray Tubes & Generators

160-300kV portable and 160-450kV stationary

equipment with directional or panoramic tubes and

dierent combinations of focal-spot sizes provide
the appropriate X-ray source to meet your specic
requirements. In addition, we oer a complete line of

micro- and nanofocus X-ray generators and tubes.

Field portable ERESCO X-ray generators are used for a wide variety

of lm, CR and DR corrosion detection and sizing applications.

3D Computed Tomography (CT)

3D computed tomography machines are laboratory
instruments and can be applied to many materials
engineering and failure analysis applications. "Point
cloud" data from 3D scans can be measured very ac­curately and sliced with software imaging tools.

A CT scan of a medium-sized furnace tube helps to analyze the

failure's root cause.

Rhythm® Software

Rhythm can acquire image data from CR and DR

sources or from lm digitizers. This data can be

displayed on the monitor of a standard PC. Rhythm

oers standardized reporting capability in easy-to-

understand formats, with DICONDE-tagged images.
This allows fast historical and meaningful comparison

of reports from dierent inspectors.

Flash! Filters™ for welds provides one-click image optimization,
improving the speed and accuracy of defect detection and sizing
by using the Wall Thickness Measurement Tool (WTMT) software.

11

Corrosion & Erosion

Corrosion & Erosion

12

Eddy Current Testing (ET)

Software Solutions

Eddy current is a fast, accurate and cost-eective electro-magnetic NDT method for detection of surface or near-surface aws 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.

Multi-Channel/Multi-Frequency Instrument

These systems are laptop compatible for easy data
capture, viewing, analysis and mapping.

Probes

GE designs and manufacturers a complete line of

eddy current tubing probes for many heat exchanger

tube diameters and materials including ferrous and
non-ferrous. Custom probes are also available.

Area Coverage

Special eddy current array probe technology allows
for wide-area scanning on metal surfaces of unusual

or complex geometry.

GE Inspection Technologies oers advanced and user-friendly software that improves productivity by helping you make smarter and quicker decisions in the
eld and in the oce. 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.

Menu Directed Inspecton™ (MDI)/Reporting

MDI guides inspectors through the inspection process
and generates automatic reports. Rhythm Reporting
does the same for all NDT modalities on a PC.

Rhythm® - Remote Expert

Rhythm makes it easy for experts to share images

and information simply and quickly via removable
media, LAN connections, or on the web.

Rhythm - Data Management

Manage all your NDT inspection data in one platform.
Rhythm makes querying and retrieving previous
inspection data as simple as a few clicks. All data is
stored in DICONDE, an industry standard, reducing
any risk of data or information loss over time. Rhythm
can tie directly to your ERP system.

Apollo is a multi channel/multi-frequency digital eddy current
instrument, which can drive conventional eddy current testing,

remote eld as well as large array probes.

13

Corrosion & Erosion

Detachable probe heads allow for quick change and re-use of

the probe's push-pull cable. This unique design and construction
increases eld crew productivity, while lowering operating cost for
heat exchanger inspection.

GE's unique eddy current array probes increase coverage while
improving probability of detection of complex geometries, such as

turbine rotor dovetails.

MDI provides image inspection labels and one-click professional
reporting.

By moving data instead of people, Rhythm allows real-time sharing
of information with experts anywhere in the world.

Whether you're reporting, archiving or sharing, Rhythm provides a

consistent platform for your NDT data.

DATA INFORMATION KNOWLEDGE DECISION

GE's Rhythm Software plays a key role in enabling asset owners to integrate NDT data and other information with additionally available knowledge in order to
make well-informed decisions regarding plant components and their remaining life.

Corrosion & Erosion

14

Installed Ultrasonic Sensors

More Than Just "Wall Thickness Measurement"

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). Once tted, the system provides continuous real-time access to corrosion data
via direct & acquired wall thickness data, eliminating the need to erect scaolding, remove insulation or shut down plant systems. Online monitoring also reduces

labor-intensive traditional inspection routines by providing data that can be used for proactive maintenance planning.

• Non-intrusive inspection—Sensors simply bond or are clamped onto the

inspection area

• Remote locations—Oshore platforms (manned and unmanned), remote

pipeline sites or inaccessible areas

• No scaolding or rigging costs—Once installed no need to revisit the site
(t & forget)

• Early warning systems—Software provides trending, warning and alarm

information with data on demand

• Accuracy—Measurement repeatability to 0.2 mm (0.008”) (low temp) or

0.0025 mm (0.0001”) (high temp)

• Operator safety—Eliminates the need to send operators into hazardous

environments or remote locations to carry out wall thickness monitoring

• Increased asset integrity—The application of monitoring techniques can
easily be justied when you consider the consequences of internal wall
loss:

• Improved outage planning

• Minimize unscheduled shutdowns

• Eliminate hazard to personnel

• Reduce probability of environmental issues

• Enhanced API-RBI protocols

Before After Risk Reduction

Make well-informed decisions; reduce total corrosion costs

• Provide accurate feedback to manage opportunity
crude processing in a renery by monitoring

eects 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

• Provide support for chemical injection programs

thickness data

Asset Integrity

OPC, Modbus
communication

activities to save cost on unexpected material

orders and spare inventory

by supplying accurate and reliable pipe wall

Optimization

• Interface with plant asset management systems,
such as GE O&C System 1, viewing xed and

rotating asset conditions in a single system

• Real-time, highly accurate thickness data

Process Management

Crude Quality
PH
Temperature
Pressure
Flow

Pressure

Flow

Wall thickness
sensors

15

Corrosion & Erosion

Rightrax System
(corrosion rates,
absolute thickness)

Management Systems

Distributed Control

Systems

Historical DataPlant Asset

Temperature

Process Variables

Corrosion & Erosion

16

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. 450 m (1476 ft) for

all attached sensors

single coaxial cable

260 m (853 ft)

RS-232 cable

600 m (1968 ft)

RS-485 cable

Hazardous

area rating

None

ATEX Ex-proof

type

Transducer

M2 Pad

14 elements

M2 Pad

14 elements

diameter

Transducer

frequency and

8.0 MHz

measurement

area 200 mm x 12

mm

8.0 MHz

measurement

area 200 mm x 12

mm

/ system

Max number

of transducers

14 elements

Ulimited DL

storage 100

sensors

10 M2

(14-elements)

Pads/DL

Unlimited DLs

range min/

Transducer

temperature

-40˚ C to 120˚ C

(-40˚ F to 248˚ F)

-40˚ C to 120˚ C

(-40˚ F to 248˚ F)

max

Operational

5 mm - 100 mm

(0.197 in - 3.937 in)

5 mm - 100 mm

(0.197 in - 3.937 in)

max)

range (min/

measurement

accuracy

Resolution /

+/- 0. 1 mm

(+/- 0.004 in)

+/- 0.2 mm

(+/- 0.008 in)

(single coaxial

(230 ft) max for

single sensor. 450

m (1476 ft) max for

all attached

(single coaxial

"A"

Maximum

cable distance

70 m

(230 ft)

cable)

70 m

sensors

cable)

"B"

Maximum

cable distance

NA NA NA

260 m

(853 ft)

(RS-232)

"C"

Maximum

cable distance

600 m
(1968 ft)
(RS-485)

Interface /

MODBUS

SCADA

System 1

3rd Party

protocol

M2 transducer sensors Instrumentation

User interface

Rightrax High-Temperature (HT) Sensor Automated System (- 10°C up to 350°C) (- 40°F up to 662°F)

HT-350C transducer

sensors

17

Corrosion & Erosion

5 m (16.4 ft) max

single coaxial cable

"A" "B"

CMX Sensor interface

600 m (1968 ft)

RS-485 cable

600 m (1968 ft)

RS-485 cable or ethernet

User interface

"C"

Interface / Protocol

Interface / Protocol

Intrinsically safe

Single-element

delay-line sensor

5 MHz x

single point

128 tranducers

-40˚ C to 350˚ C

(-40˚ F to 662˚ F)

3 mm - 17 mm

(0.118 in - 0.669 in)

+/- 0.0025 mm

(+/- 9.8x10-5 in)

5 m

(16.4 feet)

600 m
(1968 ft)
(RS-485)

600 m

(1968 ft)

(RS-485 or

ethernet)

MODBUS

SCADA

System 1

OPC

3rd Party

Corrosion & Erosion

18

Corrosion Under Insulation/Fireproofing

Radiographic Testing (RT)

Heat Exchanger Damage

Eddy Current Testing (ET)

Boiler Tube Hydrogen Damage

Remote Visual Inspection (RVI)

Turbine Blade Erosion

Remote Visual Inspection (RVI)

Offshore Riser Sand Erosion via Installed
Sensors

Ultrasonic Testing (UT)

HF Unit Flange Face Corrosion

Ultrasonic Phased Array (UT-PA)

• Insulation and reproong can accumulate

moisture and cause accelerated corrosion

• Breaches of weather jacketing increases with age

and mechanical damage

• Extensive stripping and abatement needed for

visual testing and ultrasonic testing

• Digital X-ray can give general condition a specic

thickness in recordable format for prioritization of

additional inspection/remediation can be scheduled.

• See pages 11 - 12 for general description

• Heat exchanger tube problems can cause unit

outages and environmental impact

• Damage can occur suddenly (titanium tube
support plate wear after 2 weeks of above design

ow conditions) or longer term

• RVI can provide internal condition. Leak testing

does not provide volumetric assessement

• ET is preferred method of tube inspection for non-

ferrous alloys

• See page 13 for general description

• Hydrogen damage can be caused by condenser in

leakage and failures can lead to unit outages

• External UT/EMAT scanning can be used to identify

suspected areas of wall loss

• RVI can rapidly conrm external inspections for
exact location and severity of boiler tubes for ID

damage

• See pages 7 - 8 for general description

• Turbine blade erosion can lead to decreased per-

formance 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

• Sand erosion can occur at change in direction/
diameter in oshore production risers due to solids
ingestion, typied by a smooth surface with a sand

dune pattern

• Riser locations where sand erosion may occur are
dicult to access and inspect with conventional

ultrasonic and X-ray testing

• Permanently-installed sensors can be applied to

suspect areas for accurate monitoring without the
need for repeated mobilization of inspection per-

sonnel

• See pages 15 - 18 for general description

• HF unit ange integrity must be assessed per API 751

• Manual ange opening and inspection nearly as

costly as outright replacement

• UT-PA imaging can signicantly enhance detection
and sizing of ange face corrosion damage for

replacement prioritization for turnaround

• Proven to be accurate and cost eective over

conventional inspection methodologies

• See pages 9 - 10 for general description

Industrial environments will promote signicant corrosion

of carbon steel piping components

19

Corrosion & Erosion

Heat exchanger tubing can suer specic damage that
can be precisely qualied by ET

Localized corrosion damage in carbon steel can be con-

rmed using visual methods

Catalyst and solid can cause severe damage to rotating
and stationary blades

Solid particles can generate rapid wall loss under proper

conditions in oshore risers

HF scale and corrosion can signicantly compromise
ange integrity

Corrosion & Erosion

20

Flow-Assisted Corrosion Utility Steam Pipe

Radiographic Testing (RT)

Creep of High-Pressure Steam Pipe

Ultrasonic Phased Array (UT-PA)

Air Fin-Fan Tube ID Condition

Remote Visual Inspection (RVI)/Eddy Current Testing (ET)

Compressor Blade Damage

Remote Visual Inspection (RVI)

Refractory Vessel Damage

Remote Visual Inspection (RVI)

Weld Heat-Affected-Zone Inspection

Radiographic Testing (CR & DR)

• 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

• Digital radiography can be used for volumetric
examination of specic suspect locations

• See pages 11 - 12 for general description

• High-pressure steam pipe may be exposed to
stresses above design and suer high-temperature

creep damage causing industry incidents with
multiple fatalities and major consequences

• Field metallographic replication (FMR), magnetic

particle testing can only detect creep damage on
outer surface, not a volumetric assessment

• Phase Array can easily be eld deployed to investi­gate volumetric creep damage in areas of concern
in steam pipes

• See page 9 - 10 for general description

• Carbon steel tubes can be inspected by eddy

current techniques

• RVI can be rapidly used to assess specic tube

conditions for assistance in run-replace decisions

• Tubes can be accessed with minimum preparation

for fast evaluation of tube condition

• See pages 7 - 8 and 13 for general description

• Compressor blade rubbing and damage can lead
to loss of eciency and potential catastrophic

failures

• Tip damage may be signicant 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 general description

• Many refractory lining conditions can not be

evaluated by UT or RT

• Manual inspection requires staging, scaolding
and proper conned space entry precautions

• RVI can be used to obtain refractory condition

assessment to prioritize internal inspection and

repair execution to expedite turnaround resources

• See pages 7 - 8 for general description

• Greatly enhance weld inspection and aw sizing

with digital radiography

• Digital radiography is both qualitative and quanti­tative

• Digital radiography produces fast scanning and

can go through insulation

• See pages 11 - 12 for general description

Carbon steel piping has failed catastrophically from FAC Elevated temperature damage can occur with increasing

21

Corrosion & Erosion

age and operation severity

Air n heat exchanger tube damage can cause signicant

operational problems

Tip damage (rubbing) can be identied by vibration analy­sis and monitored o line with RVI

Refractory damage can be unexpected and lead to signi-

cant turnaround repair

Weld defects can cause signicant equipment inspection

challenges

Corrosion & Erosion

22

Bottom Mounted Instrumentation (BMI)

Remote Visual Inspection/Ultrasonic Testing (RVI/UT)

Hydro-Processor Effluent Air Cooler

Rightrax Installed Sensor (UT)

Service Water Piping Corrosion

Remote Visual Inspection/Ultrasonic Testing (RVI/UT)

High-Pressure Piping Ring-Joint Cracking

Remote Visual Inspection/Ultrasonic Testing (RVI/UT)

Tank Bottom Pitting

Ultrasonic Testing Phasor DM (UT)

Injection Point Corrosion

Rightrax Installed Sensors (UT)

• Instrument Penetrations have caused signicant

reliability concerns at nuclear plants

• Dicult access and need for detailed inspection

data required multi-modal approach for proper
integrity assessment

• Combination of RVI, UT and Eddy Current tech­niques help assess BMI guide tubes to prioritize

need for repair

• See Pages 7 - 10 and 13 for general description

• Reactor Euent Air Coolers have suered numer-

ous Erosion/Corrosion incidents due to Ammonium
Bisulde erosion and Ammonium Chloride corro­sion

• Rigorous monitoring of operating conditions must
be followed by extensive UT and RT surveys

• Rightrax installed sensors allow continuous or

intermittent monitoring of suspect areas

• See Pages 15 - 18 for general description

• Extended downtimes and idle service water sys-

tems have promoted microbiological corrosion

• MIC can be highly localized and cause complete

penetration in short time periods

• Use RVI or RT or both in complementary mode

• See Pages 7 - 10 and 13 for general description

• Ring Joint anges have had signicant cracking

from mechanical and Stress Corrosion Cracking

• Typically discovered by PT or manual UT after
anges have been opened during Turnaround.
May extend unit downtime

• PA-UT signicantly enhances detection and sizing

of cracking damage while vessel is in service or

just o line to allow for repair/replace planning

• See Pages 7 - 10 for general description

• API 653 mandates periodic internal tank oor

inspection with volumetric assessment

• Magnetic Flux scanners provide rapid general oor

condition assessment

• Phasor DM can rapidly “prove-up” scanning results

with greater detail than conventional UT

• See Pages 9-10 for general description

• Chemical and Process injection without proper
control has been responsible for signicant indus-

try incidents

• API 570 mandates enhanced inspections of spe­cic locations downstream of these injections

• Rightrax permanently mounted sensors can be

installed in these locations and provide continuous

thickness and prole readings in these locations

• System installation can be responsive to process

changes without deploying personnel resulting in
increased data integrity at reduced costs

• See Pages 15 - 18 for general description

Bottom mounted Instruments present a challenge for

mechanical Integrity assessment.

23

Corrosion & Erosion

REAC pipe condition can be continuously assessed regard­less of process service conditions in typical operation

MIC can be highly localized and cause penetration in a
short period of time

Ring Joint Cracking can be signicant enough to neces-

sitate replacement. PA –UT can be used to detect and

size damage on line

Phasor DM can be used to accurately quantify the extent

and severity of general wall loss detected in tank bottoms
by global scanners

Rightrax sensors can be applied directly over an Injection

Point area of concern and provide continuous wall thick­ness monitoring

Corrosion & Erosion

24

Nuclear Containment Building: IWE/IWL

Remote Visual Inspection (RVI)

Dead-End Dead-Leg Corrosion

Digital and Computed Radiography (DR & CR)

Crude Unit Overhead Corrosion

Rightrax Installed Sensor (UT)

Naphthenic Acid Corrosion

Rightrax Installed Sensor (UT)

Heat Exchanger Tubing Failures

Remote Visual Inspection (RVI)

Corrosion Damage Sizing

Ultrasonic Testing (Phasor CV/DM)

• 10CFR 50.55a requires inspection of the entire

surface area of the containment building

• Containment liner and external extended surface

must be inspected in accordance with ASME Sec­tion XI Subsections IWE and IWL

• Auto pan-tilt-zoom functions based on plant ge­ometry & input grid for recordable, indexed, high
quality documentation with 100% repeatability

• Capable of VT qualication with reduced personnel
exposure and increased data integrity

• See Pages 7 -8 for general description

• Intentional and unintentional stagnant piping legs

and connections may have signigicantly higher
corrosion conditions than existing pipe compo­nents

• Piping TML’s and spot UT may be misleading as to

connection condition

• DR and CR images provide measurable, record­able, remotely accessible, high-quality documenta­tion of condition

• Images can be archived in typical plant Data Man­agement systems

• See Pages 11 - 12 for general description

• Crude Unit Overhead lines may suer high inter-

mittent corrosion rates due to crude slate changes
coupled with inadequate chemical corrosion con­trol application

• Periodic piping TML’s and spot UT may be not cap­ture events that could cause signicant wall loss of

piping

• Remote/inaccessible locations generally allow for
periodic monitoring with Crane/scaold access

only

• Rightrax permanently-mounted sensors provide

recordable, remotely accessible , high quality
documentation of wall condition

• See Pages 15 - 18 for general description

• 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 signicant wall loss of

piping

• Inaccessible locations generally do not allow for

periodic monitoring

• Rightrax permanently mounted sensors provide

recordable, remotely accessible , high quality
documentation of wall condition

• See Pages 15 - 18 for general description

• Rapidly assess damage mechanism for expedited

corrective actions

• Instant RVI diagnosis with experiences can pro­duce immediate repair/plug/bring in additional
NDT technique decisions

• Use of RVI with experienced plant personnel can

greatly reduce outage duration

• Inspection provides recordable, indexed, high qual­ity documentation for review

• See Pages 7-8 for general description

• Phased Array capability in readily portable equip-

ment

• Assess damage extent and improved sizing from
eld personnel

• Improved inspection productivity in a sharable

format

• Obtain better information for RBI and FFS Evalua­tions

• See Pages 9 - 10 for general description

Remote Visual Inspection provides recordable, indexed,

high quality documentation

25

Corrosion & Erosion

Dead Ends/Dead Legs may suer signicantly higher cor­rosion rates than adjacent piping components.

Crude Unit Overheads may suer severe corrosion due to

crude slate changes/treatment misapplications but require

signicant mobilization preparation for inspection

Crude Unit Convection Cross-Over’s may suer severe cor-

rosion due to crude slate changes to higher TAN Crudes

RVI with experienced personnel can provide rapid damage
mode identication

Phasor CV/DM has Dual Element Phased Array capability
for accurate, rapid damage sizing

Corrosion & Erosion

26

Global Contacts

Americas

United States

Lewistown, PA

[phone] (toll-free)
[phone]

Brazil

São Paulo

[phone]

Europe

Germany

Huerth
[phone]

Belgium

Berchem
[phone]

Russia

Moscow

[phone]

www.geit.com

Asia

China

Shanghai

[phone] (toll-free)
[phone]

Japan

Tokyo

[phone]

United Arab Emirates

Dubai

[phone]

© 2010 General Electric Company. All Rights Reserved. Specications subject to change without prior notice. Other company or product names
mentioned in this document may be trademarks or registered trademarks of their respective companies, which are not aliated with GE.

GEIT-10017EN (06/10)