IRC Engineering Services (I) Pvt. Ltd.

IRC is carrying out Chemical Cleaning services by the name of its sister concern company RA CHEMTECH PVT. LTD. Till date we have carried out cleaning for units upto 660 MW capacity . We have carried out cleaning of boilers using Citric Acid, HCL and EDTA as major chemicals. In case of Condensers we have used majorly Sulphamic acid as a cleaning agent, and have got Repeat Orders from clients like NTPC,RVUNL etc.. We have carried out Acid Pickling and cleaning of Pipings.

At Present ,RAC has procured lot of material such as pump, motor ,pipings, valves and tanks to make cleaning activity successful. We can carry out a minimum of 3 Chemical Cleaningsof Boiler and 2 Chemical Cleaning of Condensers at a time. Our pump and motors have been procured recently so issues like wear and tear at site donot take place. Also, we are regularly getting the maintainance done for our Pump and Motor after each site to maintain the reliability of our equipments.

Our main motto is to be able to make our client equipment deposit free. To achieve it we are fully committed to provide a safe, leakage free cleaning process.

IRC Engineering due to its Power Plant expertise has now also entered into Boiler and Turbine Maintenance Services. IRC has been accredited by Uttar Pradesh Boiler Board as a special class repairer of Boiler and now can carry out jobs for EPC and Maintenance of Super –Critical Boilers.

We have approved IBR welders , welding machines and various other equipments required for these maintenance activities. We have carried out these jobs for Boilers in Gail Pata, IFFCO Aonla and TATA Chemicals, Babrala. These jobs included Erection of Scaffolding material, Removal and fixing of Insulation, Tube Cutting and Welding and the job was completed after successful completion of Hydrotest.

IRC has people retired from NTPC who have carried out such services under their supervision and knows the importance of timely deliverance of our activities. We shall be happy to assist you if there are any queries.

IRC Engineering is recognised for carrying out Statutory Inspection of Pressure Vessels (Bullets, Mounded Bullets, Horton spheres etc.) under SMPV rule 18,19 & 33 :-

The chief controller of Explosive Nagpur has accorded and approved competent persons of M/s IRC Engineering Services (I) Pvt. Ltd. for testing, inspection & certification of storage vessels covered under explosive acts.

1.  SMPV rule 18 :- Fixture of safety valves (SRV) in storage vessels for LPG, Profane ammonia etc and certification there of. The SRV are fitted on storage vessels or mounted on vehicles.

2. SMPV- rule 19:- Certificate of periodic Hydro testing of compressed gas vessels under rule 19 of SMPV rules 1981 and results of following tests ;

• Vessel & fitting details
• Fire Protection & Fire extinguishers
• Pipe lines & fittings
• Electrical fittings
• Pumps .
• Painting
• Foundation

3. SMPV-rule 33:- Certification of safety under rule 33 for storage of compressed gas installations.The certificate under rule 33 issued after inspecting the installations in respect of the following

• Vessel & fitting details
• Fire Protection & Fire extinguishers
• Pipe lines & fittings
• Electrical fittings
• Pumps .
• Painting
• Foundation

4. Third Party Inspection (TPI) :- IRC Engineering Services (I) Pvt. Ltd. is an approved third party inspection (TPI) agency for in- stage inspection and certification of Storage Pressure Vessels , Piping , Heat Exchangers and Reactors during fabrication , welding , installation and hydraulic testing of the equipments .

IRC Engineering has carried out various inspections on the below Tanks across the country. In a number of occasions we have acted as a Third Party Inspector to even NDT Techniques. We have also carried out Non-Destructive Testing and Inspection during Settlement, Calibration and Hydrotest. IRC acts as certifying authority for these Pressure Vessels.

Bullets

IRC Engineering Services (I) Pvt. Ltd. has a wide experience in the Non- Destructive Inspection of Bullets. Its team of experts & engineers carry out quality testing of the storage vessel. During the testing of these storage vessels safety of technicians and labors is a major concern is well to be taken care of, IRC is regularly carrying out safety drill for its employees working in field.

As name suggests, it is similar to Bullet in shape but bigger in sizes. It is used for storage of Bulk LPG gas for further filling of LPG cylinders for domestic use. The Bullets of different capacity are after used by IOCL, BPCL, HPCL refineries & other agencies.

Mounded Bullets

IRC Engineering Services (I) Pvt. Ltd. has a huge experience in the Non- Destructive Inspection of Mounded Bullets. IRC has a team of experts & engineers are regularly deputed to carry out inspection and testing of storage vessels. During the testing of these storage vessels safety of technicians and labors is always cared for .For that purpose , safety drills for concerned team members IRC is regularly carrying out safety drills for concerned team members are regularly conducted .

The mounded storage of LPG is considered to be safer compared to above ground storage vessels. It provides intrinsically passive and safe environment and eliminates the possibility of Boiling liquid expanding vapor explosion (BLEVE). Horizontal pressure vessels are commonly used for storage or transportation of infallible gases by rail/road.

Horton Sphere

IRC Engineering Services (I) Pvt. Ltd. Is also approved to carry out inspection of Horton Sphere, as a third party agent which includes all the relevant non-destructive tests, hydraulic Test, setting of safety valves and post inspection protective painting .The capacity of spheres that we serve varies from 600 to 1500 Mt.

IRC is carrying out Chemical Cleaning services by the name of its sister concern company RA CHEMTECH PVT. LTD. Till date we have carried out cleaning for units upto 660 MW capacity . We have carried out cleaning of boilers using Citric Acid, HCL and EDTA as major chemicals. In case of Condensers we have used majorly Sulphamic acid as a cleaning agent, and have got Repeat Orders from clients like NTPC,RVUNL etc.. We have carried out Acid Pickling and cleaning of Pipings.

At Present ,RAC has procured lot of material such as pump, motor ,pipings, valves and tanks to make cleaning activity successful. We can carry out a minimum of 3 Chemical Cleaningsof Boiler and 2 Chemical Cleaning of Condensers at a time. Our pump and motors have been procured recently so issues like wear and tear at site donot take place. Also, we are regularly getting the maintainance done for our Pump and Motor after each site to maintain the reliability of our equipments.

Our main motto is to be able to make our client equipment deposit free. To achieve it we are fully committed to provide a safe, leakage free cleaning process.

• Universal Testing Machine 600 KN
  
• Universal Testing Machine 1000 KN
• Universal Testing Machine 600 KN
• Metallurgical Microscope
• Universal Testing Machine 1000 KN

Tensile Test

 Is carried out to determine materials ultimate strength, yield stress, and ductility in terms of percentage elongation and reduction in area. The test comprises application of axial load to a specifically designed test specimen, to cause rupture. Yield Point is the first stress in a material, less than the maximum obtainable stress, on which an increase in strain occurs without an increase in stress. Yield point is generally characterized by a sharp knee or a discontinuity in stress versus strain is an auto graphic recording. Tensile strength is determined by dividing the maximum load the specimen sustains during a tension test by the original cross-sectional area of the test specimen. The Elongation is the increase in length of the gage length, expressed as a percentage of the original gage length. The Reduction of Area is determined by measuring the mean diameter or the width and thickness of the smallest cross-section of the ruptured test specimen. The difference between the area thus found and the area of the original cross-section expressed as a percentage of the original area is the reduction of area. Tensile Test is generally carried our as per . ASTM A 370, IS: 1608, API-SL, API-1104, ASME SEC-IX, BS etc

Rockwell Hardness Test

Rockwell Hardness Testing Machine

In this test a Hardness Value is obtained by determining the depth of Penetration of a diamont point or a steel ball in to the test specimen under certain arbitrarily fixed conditions. An initial penetration is caused by applying a minimum load of 10 kg which sets the penetrator on the sample and holds it in position. Depending on the scale being used, a major load is then applied, which increases the depth of indentation. The major load is removed and with minor load still acting, the Rockwell number which is proportional to the difference in penetration between the major and minor load is determined. This is an arbitrary number which increases with increasing Hardness. The Rockwell scales frequently used are B and C.  APPLICABLE TEST PROTOCOL: ASTM E18.

Brinell Hardness

Hardness is generally defined as resistance offered by a material to penetration. In this test, a specified load is applied to a flat surface of the test sample through a hard ball of specified diameters. The average diameter of the indentation is measured and used as a basis for calculating the Brinell Hardness number (BHN) by the equation:

BHN = P/ [ (∏D/2) (D- √ D2-d2) ]

Where P = applied load (kgf)

D = diameter of the steel ball in mm, and

d = average diameter of the indentation in mm.

Other loads and different size indentors are also used when so specified. In recording the Hardness Values, the diameter of the ball and load are stated except when a 10mm ball and 3000 kg load are used. In Reporting, the Hardness value precede the scale symbol; for example : 353 BHN. Note : Steel Ball as an indenter is used for materials having hardness up to 450 BHN. For materials having hardnees > 450 BHN, a carbide ball is applied. APPLICABLE TEST PROTOCOLS : ASTM E10, IS: 1500

Vickers Hardness Testing Machine

Vickers Hardness

The Vickers Hardness test is carried out for measuring Hardness of metals and alloys of all types, load or soft, flat, round or of irregular shapes. A regular pyramid having a square base and a smoothed off point made of diamond is pressed in the material to be tested under a certain load. The produced impression is projected to the screen through an optical mechanism and diagonals of the impression are measured by means of measuring equipments, which generally forms a part of the test equipment. Depending upon the materials characteristics, the application of load is predetermined from the available load selectors of 1,5,10,20,30 and 50kgf. APPLICABLE TEST PROTOCOLS : ASTM E92, IS:1501

The mathematical formula for calculating the Vickers Hardness number is VHN=1.854 F/d2 where F – Force applied in Kgf

d – Mean diagonal distance of the edges of the diamond impression

Charpy Impact Test

A Dynamic Test in which a notched specimen is struck and broken by a single blow in a specially designed testing machine. The values thus obtained are absorbed energy (resistance offered by the test specimen to shear fracture)., the lateral expansion opposite the notch and percentage shear area.

Test temperatures other than room temperature are specified in product or general requirement specifications. The laboratory is well equipped to conduct impact tests up to minus 200c.

About charpy impact Charpy Impact machine is the one in which a notched specimen is broken by a single blow of freely swinging pendulum. The pendulum is released from a fixed height. Since the weight to which the pendulum is raised prior to its swing and the mass of the pendulum are known, the energy of the blow is predetermined. A scale is provided to indicate the energy absorbed in breaking the specimen. The machine is equipped with a fixture to support a test specimen at a precise location so as to facilitate pendulum strike directly opposite the center of the notch.

For impact testing other than at Room temperature, the test specimens are soaked in a media at specified test temperature under controlled conditions, generally deployed low temperature media are chilled fluids, solidified CO2 , Liquid N2 , plus organic solvents having low freezing points.

Handling equipments : Specially designed SELF CENTERING Tongs are used for precise placement of test specimens en-route from cooling bath to machine anvil. The entire cycle of specimen taken from cooling bath, its placement at anvil and subsequent release of pendulum from its latched position and breaking of the sample is completed well within the specified time limit of 5 Seconds. The laboratory has two impact test machines, one each confirming to ASTM E-23 and BS EN 10045-2. APPLICABLE TEST PROTOCOLS : ASTM A 370, IS : 1757, BS : EN 10045-2.

Optical Emission Spectrometer & Temperature and Humidity Indicator

Optical Emission Spectrometer & Temperature and Humidity Indicator

Spectro

IRC Lab is Equipped with ARL Qualntodesk optical emission Spectrometer for the quantitative analysis of metals and their alloys. The instrument can be used for :

• Quantitative Analysis
  
• Grade Identification / Alloy Verification
• Go / No Go Sorting

The instument contains a solid-state spectrometer with a source unit poweing a full size conventional spark- stand. The Hardware is PC Controlled by software running microsoft windows XP and W in DPI.

The procedure followed for spectro analysis includes :

• Versample for its adequacy ification of for spectro analysis.
  
• Selection of proper base w.r.t. probable chemistry of the sample and standardization / calibration of equipment with applicable certified reference materials.
• Initiation of spark in purged Argon gas which is completed in following three stages:

              1.  Argon Flush

               2. Pre-Spark

               3. Exposure

Average of three consistant observations is calculated for declaring the final test results.

Vickers Hardness Testing Machine

Positive Material Identification

IRC Engineering Services has been carrying out jobs for identification of alloys. Using various X-Ray Florescence (XRF) instruments, engineers at IRC can provide elemental identification and quantitative determination without regard to form, size and shape. It is a non-invasive procedure of chemical analysis which can be used at the location of object by a portable instrument .

With Positive Material Identification (PMI) , alloy composition, or identity of materials can be determined. In the event, reference certificate of material is not traceable or missing or/and material composition needs to be established , PMI as an NDT method is the best solution.

IRC has been frequently rendering its PMI services, where a large quantity of products have been mixed up , Where component is an integral part of an assembly ,or specimen is large enough to restrain its transportation.

Feritscope

IRC laboratory has commissioned the Feritscope Instrument from Fischer Technologies. The engineers were given exclusive training for the usage of the instrument .The instrument is robust, easy-to-use handhold instrument FERITSCOPE , the probe with plug-in allows rapid non-destructive and accurate measurement of ferrite content on-site or in the laboratory. Based on the magnetic induction method, the device measures the ferrite content in austenitic and duplex steel.

The measuring range is 0.1 to 80 % delta ferrite or 0.1 to 110 FN. Different units of measurement are possible: either measurable in measured variable “percent ferrite % delta ferrite” or alternatively “ferrite number FN”.

IRC has now provided services to know the ferrite content in:

• Welded joints
  
• Surfacing or cladding
• Duplex steel.

The device is equipped with a USB interface for PC and printer. There are storage facilities for up to 20,000 readings in up to 100 calibrated applications. Both numerous statistical and graphical analysis options are included in the unit.

India has huge 100’s of Km’s Pipeline Laid Underground for oil and Gas Transportation. Many of the Pipelines have been very old and require proper assessment. Since being Underground the pipelines are not inspected regularly and are also subjected to internal corrosion due to highly corrosive material being transported through them.

IRC has now developed a methodology to assess the Pipelines for its integrity. IRC shall carry out the assessment in three steps:

• ADVANCED NDT: Firstly IRC shall carry out the assessment using LRUT. Since LRUT has capabilities to scan the Pipeline 50 meters on both sides, it shall prove to be of great value for our assessment. We shall be able to inspect a very lage area of the Pipeline for its Thickness by digging only on a particular location. This will help us in getting a quantitative result. We may also perform Phased Array and Time Of Flight Diffraction Method on Weld joints if the Pipeline or Critical Piping is above ground and the weld joint is accessable for inspection. These inspection methods will get us the exact size of the defect which can then be used for Life Assessment.
• Stress Analysis: IRC has a separate team in case of Power Plants for there Critical Piping. IRC can perform inspections such as Stress Analysis and has carried out a number of such jobs which are used for Hanger Design Check. We have procured Caesar software. We have carried out such jobs in NTPC TANDA, NTPC FARAKKA etc. We look forward to carry out these assessments together with ADVANCED NDT Inspection since this will help us to get closer to life estimation. Since a lot of Piping have become very old it becomes a necessity for us to inspect where all the stresses are more due to long operational life.
• FINITE ELEMENT ANALYSIS: IRC has two such softwares ANSYS, and Crackwise which help us in estimation of life of the defects. A detailed investigation is done by our team, and data like operational data, and plant running history is taken. IRC NDT team then gives the data for the size of cracks or any other kind of defects, these details when inserted in the software a life is estimated. These softwares are widely recognised and are based on many years of mathematical research.

IRC is looking forward to create value for the Pipeline Industry as such assessments shall help in stopping failures which lead to losses which could be monetary as well as life.

IRC has been involved in the services for Residual Life Assessment since 2000. Our expertise in Residual Life Assessment has helped us in entering into the business of Fitness For service as per API 579. American Petroleum Institute has laid down certain guidelines for the assessment for the Energy Sector.

To carry out Fitness For Service Assessment 3 Levels of Assessment are carried out. IRC is fully equipped with specialised manpower as well as softwares to carry out such kind of assessment .

Fitness For Service assessment is the need of the hour as a lot of Pipelines , Critical pipings , Drums etc have been old and corroded. No measure is taken to inspect them properly so as to assess its life. As we can observe in real life examples like GAIL PIPELINE GAS FIRE, RAJAMUNDHARY , SAIL BHILAI PIPING EXPLOSION, the need of such inspections is increased. IRC has recently procured certain U.K Based Softwares which help in assessing the life of Defect. IRC shall carry out Inspection Using its ADVANCED NDT SOLUTIONS and the softwares with the in-house experienced corrosion specialist.

It will be our pleasure if we are able to answer some of your questions regarding the technology that we may use. We are very much certain that we will be able to create value for our customers through our High-Tech Services.

Boiler

Boiler is a pressure vessel in which steam is generated by the application of heat resulting from the combustion of fuel…

Turbine

IRC Engineering Services has been carrying out Residual Life Assessment of Turbines since 10 years now. Our team of Turbine experts comprises…

Generator & Transformer

IRC Engineering Services has a vision to diversify its range of services and is committed to provide the best quality and on time…

Civil Structure & Foundation

IRC Engineering has now ventured into this new field of Civil Testing of Structures and Foundations. All civil engineering structures…

IRC Engineering is the only company in the Northern part of the Country to be carrying out Advanced NDT inspection Services. Though it is a feeling in the industry that these inspections are costlier , but in the long run they have proven to be cheaper than the conventional methods. The following are the reasons for their Cost Affectiveness:

• In case of Conventional Methods of Inspection we are unable to carry out welding at a nearby location at the same time when we are carrying out Radiography Test but by Means of Techniques such as Phased Array we are able to carry out Welding and Inspection Round the clock.
  
• In case of Conventional Methods NDT Vendor is using consumables for every joint but in case of the newer techniques the amount of usage of consumables is reduced to once in around 800th joint, which in long term reduces the cost of services.
• The need to used Scaffolding is reduced due to techniques such as LRUT. Hence the cost of Scaffolding or making of Underground pits is reduced.
• Inspections can be carried out very fast and accurately , hence project can be completed quickly.

Advanced Inspections Details

IRC is carrying out at present the below mentioned Advanced Inspections:

• Long Range Ultrasound Testing
  
• Pulsed Eddy-Current Testing
• Phased Array Ultrasound Testing
• Time OF Flight Diffraction
• Eddy-Current Testing
• Helium Leak Detection
• Computed Radiography
• Corrosion Mapping

It will be our pleasure to create value for our clients by usage of any of the above techniques.

LONG RANGE ULTRASOUND TESTING

Long range ultrasonic testing is a rapid way of screening for corrosion in pipelines. The method enables screening of up to 120 meters of pipeline in one test, i.e. 60 meters in both directions. By fitting a ring of transducers around the pipeline, a wave maker device directs low frequency (20-100 kHz) ultrasonic waves via the transducers, longitudinally into the pipeline wall. The method effectively detects changes in the pipeline’s cross-section, enabling it to indentify corrosion and other abnormalities. At the same time this provides the possibility of using welds and flanges as distance references. IRC has qualified experts in using this method to help you get a cost-effective report on the condition of your pipelines. The test results are displayed in an easy-to-interpret visual interface on a laptop computer – enabling us to draw conclusions quickly and correctly. Upon identifying a defect we carry out follow-up detailed testing of the affected area, using complementary ultrasonic or x-ray methods. With this highly advanced testing method you will get an accurate status report of your pipelines in the most effective way. Benefits of long range ultrasonic testing

• More than 100 times faster than traditional ultrasonic methods
  
• Up to 100 meters screening distance on pipelines above ground
• Up to 10 meters screening distance on pipelines buried in the ground
• Possibility to do sub-sea scanning
• Saves time since there is no need to remove insulation, apart from 1 meter for the transducer ring.
• Easy to screen wall penetrating pipelines (both built-in and sleeved penetrations)

Pulsed Eddy-Current Testing

IRC offers Pulsed Eddy Current (PEC) inspection technology for the detection of corrosion areas in carbon and low alloy steels. Measurements are taken through any non-conductive material e.g. insulation, protective coatings, concrete and marine growth.

Technique

It is an electromagnetic inspection technique used for measuring the thickness of steel objects, such as pipes and vessels, without the need for contact with the steel surface. This makes PEC very suitable for inspections where the surface of an object is not accessible. Readings are generated when a transmitter coil within a protective housing produces a magnetic pulse which induces eddy currents within the component wall. The eddy currents in turn produce a second magnetic pulse, which is detected by the receiving coil. The system monitors the rate of decay of the eddy current pulse within the steel wall and produces an average thickness value from the comparison of a calibrated signal.

Capability

• Provides the average remaining wall thickness measurement within the interrogated area (footprint).
• Direct contact is not required and wall thickness can be measured through any non-conductive material up to 150mm thick, e.g. insulation material, paint, bitumen, dirt, ice or sludge
• Works through Stainless Steel and Aluminum sheeting less than or equal to 1mm
• Surface preparation is not required enabling measurements to be taken through corrosion products
• Wide temperature range -100°C to 550°C
• Good reproducibility of PEC readings at the same locations makes it ideal for corrosion monitoring
• Rope Access deployable
• Subsea and splash zone deployable
• Battery operated and robust design
• Fast and reliable data collection typically 700 to 1000 readings per day

Applications

• Vessel and pipe work inspection
• In-service corrosion/erosion monitoring
• Wall loss measurement through corrosion product
• Riser inspection above and below splash zones
• Ship hull surveys
• Refractory lined vessels
• Subsea Inspections

PEC Limitations

• Applicable to carbon steel and low alloy steels
• PEC is suitable for general wall loss. Isolated pitting defects cannot be detected.
• PEC wall thickness readings are relative values, showing variations in wall thickness on the object being inspected.
• Geometry of the test object should be simple.
• Wall thickness readings are affected by nearby nozzles, welds, internals, near supports and on sharp bends not possible.
• Requirements to test through Galvanised Steel sheeting is not possible

TIME OF FLIGHT DIFFRACTION

TOFD is another advancement in Ultrasonics and IRC Engineering is the only company presently in the Northern Part of India to have procured it. In a TOFD system, a pair of ultrasonic probes sits on opposite sides of a weld. One of the probes, the transmitter, emits an ultrasonic pulse that is picked up by the probe on the other side, the receiver. In undamaged pipes, the signals picked up by the receiver probe are from two waves: one that travels along the surface and one that reflects off the far wall. When a crack is present, there is a diffraction of the ultrasonic wave from the tip(s) of the crack. Using the measured time of flight of the pulse, the depth of a crack tip can be calculated automatically by simple trigonometry. This method is even more reliable than traditional radiographic, pulse echo manual and automated weld testing methods. IRC Engineering has PCN and ASNT NDT LEVEL-II experts who can perform these specialised tests. TOFD has been widely used due to its capability of getting accurate results of defect size.

Advantages

• Results obtained are digital and can be stored for life time period.
• Defect Sizing is highly accurate and thus the system can be used to carry out Fitness For Service and Residual Life Assessment.
• Due to exact defect sizing, Acceptance and Rejection of flaw is possible during erection activities.
• No Radiation Hazard.
• Erection activities can be performed in parallel with inspection activities.

Eddy Current Testing (ET)

Eddy Currents are closed loops of induced current circulating in planes perpendicular to the magnetic flux. They normally travel parallel to the coils winding and the flow is limited to the area of the inducing magnetic field. Eddy Currents concentrate near to the surface adjacent to an excitation coil and their strength decreases with distance from the coil i.e. Eddy Current density decreases exponentially with depth. Eddycurrent testing is a rapid and accurate technique used to detect discontinuities in tubing, heat exchangers, condensers. IRC has defecto-meters working on the principle of eddy current testing, i.e., it has a probe coil which can also detect surface and near surface discontinuities in the turbine blades. Eddy current testing is also performed for alloy separation i.e, sorting and for the determination of treatment conditions. The location of repair welds, girth welds and seam welds may also be detected on ground machined surfaces. IRC is having OLYMPUS MS-5800 and TECHNOFOUR Machine using which we are performing Eddy-current and Remote Field Eddy-Current Services. IRC has even carried out successfully these services in Saudi Arabia for SAFCO Plant. IRC can take such kind of jobs for overseas shutdown jobs.

Applications

• This Technique is usually used for Inspection Heat Exchanger Tubes.
• Sorting of Components.
• Detection of Defects in Turbine Blades.

Helium Leak Detection

The Helium Leak test method is totally dry. There is no soap bubble residue or water droplets to clean and dry after testing. The costs associated with cleaning supplies and drying equipment can be eliminated, along with the mess and unpleasantness of running a bubble test operation. The Atomic Weight of Helium Gas is very less that it can penetrate easily through a smaller leak faster than a water or air molecule can. Being an inert gas, it doesn’t react with anything. IRC’s specialised technicians carries out Helium Leak Detection using both Pressurized Method as well as Vacuum Method. Helium Leak Detection is also used these days for Online Detection Of Leakages in Piping from Turbine to Heat Exchanger. IRC presently has Alcatel Equipment and has been carrying out services during both Manufacturing and In- Service inspection. IRC Engineering Services provides services for Helium Leak Detection in Refineries, Fertilizer plants, Power plants and other process industries . The ASNT NDT Level-II and ASNT NDT Level-III experts are committed to render quick response and efficient service to its esteemed clients . IRC has carried out jobs even in Saudi Arabia, Kuwait and Oman for Helium Leak Detection and is exploring more opportunities to carry out these services.

Computed Radiography (CR)

Computed radiography (CR) is used to assess internal or external corrosion/erosion losses in process piping, pressure vessels and valves. Based on it one can estimate remaining thickness and wall losses. The computerized images allow easy data sharing and result in significant improvements in radiographic inspection productivity as well as faster identification of defects. Computed Radiography system can be used for following below mentioned applications.

• Piping for internal corrosion or for corrosion under insulation (CUI).
  
• Valves and their internals for internal or external corrosion/erosion
• Piping and valves for build-up of products and for blocks.
• Newly fabricated welds according to:

             1. ASME Section V for pressure vessels

             2. ASME B31.1 and B31.3 for piping

             3.API 1104 for pipelines

• For losses in boiler tubes at temperatures of the order of 350 ⁰C.
• Asbestos insulated equipment and assess losses around the circumference (not only those perpendicular to the radiation source)
• In-service welds

ADVANTAGES

• The images can be readily shared, e-mailed and stored electronically by anyone needing reliability information for the equipment.
• The imaging plates practically eliminate re-shots by providing a greater range over which exposures can be useful.
• Significant exposure reductions

              1. Reduction of exposure times from 40-60% when using IR 192

              2. Similar or better results are obtained when utilizing Se 75, Co60 and X-rays

              3.Highly reproducible

• Images on film or digitized
• Data is stored for future comparison or audit

LIMITATIONS

• Radiation safety considerations are the same for CR as standard radiography
• An equipment reading station is required to scan the imaging plates
• Physical space and on-site electrical power are required to set up the equipment
• Requires access to both sides of the part

From Our Blog

Conventional NDT

IRC ENGINEERING has a very experienced and hardworking team to undertake specialized services for Automated Ultrasonic testing using Time of Flight Diffraction (ToFD), Helium Leak Testing, Eddy Current Testing,Conventional Ultrasound Testing, Magnetic Particle Testing, Dye penetrant Testing, Radiography Testing, Thermography, Ultrasonic Thickness Measurement Heat Treatment Services, In-Situ Metallography, Failure analysis, Remaining Life and Condition Assessments, Energy Audits, Corrosion Mapping, Weld and Paint Inspection, ASNT Level III consultancy, Positive Material Identification, Ferrite Measurement, Third Party Inspection as well as several other advanced NDT and inspection related services.

At IRC , we provide NDT and other various specialized services in India but can also provide these services at any offshore location.

• Radiography
  
• In-Situ Metallography
• Ultrasonic Inspection
• Dye Penetrant
• Magnetic Particle Testing
• Visual Inspection and Field Services
• Portable Hardness
• Non-Destructive Testing: ASNT Level III Consultancy in India and Abroad
• Positive Material Identification
• Training and Certification as per ASNT Level I and II

IRCinitially emerged to stand for Industrial Radiographic Center, however has expanded its horizon of activities in several other fields of eminance . By now , IRC is known for its knowledge based services. IRC is the only company approved by BARC in North India to provide training for RT-1 course..IRC is one of the leading companies in the field of Industrial Radiography, with an approach to provide services with a difference from others.

IRC not only provides services for traditional Radiography but has its own equipment to provide services for Digital Radiography. The equipment is from DURR NDT, GERMANY. IRC believes in updating its knowledge base according to the new technology.

Radiography Testing

Radiographic inspection is based on the exposure by Either an X-ray machine or a radioactive source (Ir-192, Co-60, or in rare cases Cs-137) can be used as a source of photons. Since the amount of radiation emerging from the opposite side of the material can be detected and measured, variations in this amount (or intensity) of radiation are used to determine thickness or composition of material. Penetrating radiations are those restricted to that part of the electromagnetic spectrum of wavelength less than about 10 nanometers.The principle of Industrial Radiography Testing is Differential Absorption. This means that different materials absorb different amount of radiation based on the thickness difference, density and presence of defect.

Generally for detection medium is films which consist of an emulsion-gelatin containing radiation sensitive silver halide crystals, such as silver bromide or silver chloride, and a flexible, transparent, blue-tinted base. When x-rays, gamma rays, or light strike the grains of the sensitive silver halide in the emulsion, some of the Br- ions are liberated and captured by the Ag+ ions. This change is of such a small nature that it cannot be detected by ordinary physical methods and is called a “latent (hidden) image.” However, the exposed grains are now more sensitive to the reduction process when exposed to a chemical solution (developer), and the reaction results in the formation of black, metallic silver. It is this silver, suspended in the gelatin on both sides of the base, that creates an image. IRC has both Gamma Radiography source and X-Ray. In the recent past IRC has also carried out Closed Proximity system of Radiography using Se-75 Source. IRC is committed to provide on time services during shut-down and Erection Activities.

In-Situ Metallography

In-situ metallography is performed on actual site by team of metallographers and metallurgists. The technique is extensively used to assess in-service degradation of critical components operating under high temperature/ high pressure/ corrosive atmosphere. Micro structure survey is an important tool to evaluate real health status and residual life assessment of Boilers, Turbine, Pipelines, Reactors and Vessels. IRC believes in translating the latest technology into its real application at field to find better solutions for clients. To meet these challenges, IRC has team of highly qualified engineers and scientists in its fold to deliver technology driven services. The captive laboratory of IRC is equipped with an image analyzer software, to providecredible results of failure analysis, residual life assessment and condition assessmentof critical components.

Ultrasonic Inspection

Ultrasonic methods of NDT use beams of sound waves (vibrations) of a certain wavelength and frequency as per the requirements of the client, transmitted from a probe and after reflection detected by the same or other probes. Usually, pulsed beams of ultrasound are used and in the simplest instruments a single probe, hand held, is placed on the specimen surface. An oscilloscope display with a time base shows the time it takes for an ultrasonic pulse to travel to a reflector in terms of distance traveled across the oscilloscope screen. The y-axis of the oscilloscope screen depicts to the flaw size as seen from the transmitter probe. IRC has ASNT/ISNT level II and IIIexperts to interpret the results displayed on screen. It requires sufficient exposure and experience to determine the nature and severity of flaw .Ultrasonic examinations are performed for the detection of internal flaws or discontinuities in piping, castings, forgings, welds of fabricated items.An accurate sizing techniques have been developed to detect and monitor progressive cracking in a variety of equipment.

In case of Ultrasound Inspection IRC has made various advancements by adding up new technologies like Long Range Ultrasound Testing, Phased Array Ultrasound Testing, Time Of Flight Diffraction and Automated Ultrasound Testing

Dye Penetrant Test

The technique employs a penetrating liquid applied over the surface of the component . The dyewhich enters in to discontinuity or fine crack. After the excess penetrant is wiped off from the surface, developer is sprayed over the object ..The penetrant exudes or drawn out of the crack makes it more defined and visible . Liquid penetrant testcan be applied to detect surface flaws of non-porous clean , metallic or non-metallic material , however not suitable for un clean or very rough surfaces. Penetrants can contain a dye to make the indication visible under white light, or fluorescent material under ultra-violet light. Fluorescent penetrants are used when maximum flaw sensitivity is required. Through DPT ,micro cracks, as narrow as 150 nanometers can be detected. This method is only used for detection of surface cracks. Subsurface cracks cannot be detected by this method.

IRC is manned by ASNT Level-II and Level-III experts in Dye Penetrant Test to carry out the test . The experts also provide training to individuals in this particular discipline..

Magnetic Particle Testing

The Magnetic Particle Inspection method of Non-Destructive testing is a method for locating surface and sub-surface discontinuities in ferromagnetic material. Those defects can be detected upon magnetization of the part which are perpendicular to the flux lines, The flux leakage would be observed by the use of finely divided ferromagnetic particles applied on the part being magnetized. If there is a leakage in the field , ferromagnetic particles shall gather together and held by the leakage field. These ferromagnetic particles indicate size , location, shape and extent of the defect or discontinuity.

Dry magnetic particle examinations and wet fluorescent magnetic particle examinations are performed on ferromagnetic materials to detect surface and slight subsurface discontinuities. Specialized wet fluorescent magnetic particle techniques are available for black light internal examinations of equipment through bore scopes.

Certification of welding procedure, welds & Welders

IRCs team of Certified Welding Inspectors (CWI) can define the tests , necessary to qualify a weld, welding procedure, or individual welder. Each welding code follows three main criteria viz. Welding Procedure Specification (WPS), Welding Procedure Qualification Record (WPQR), and Welder Performance Qualification (WPQ). IRC team is well equipped to inspect, conduct requisite tests and certify all the aspects,of welding.

Visual Inspection Services (Boroscope)

Non-Destructive visual inspections can be preformed on-site or at the laboratory facility, and are based upon the requirements of the client or specification. Industries utilizing this service include Fabrication, Construction, Automotive, Power Generation and Transportation. Inspections can be performed at the laboratory facility or at site. These inspections are executed in accordance with the provisionsof BIS, BS, DIN, ASTM, AWS, ASME (American Society for Mechanical Engineers) and other standards.

We have carried out many Boroscope Services in India for Power Plants, Refineries, Fertiliser and Chemical units. IRC is also having one ASNT NDT LEVEL-III in Visual Inspection who can inspect such activities and give appropriate results.

It will be our pleasure to serve you in any of your future requirements.

Portable Hardness

In accordance with ASTM E110, this testing is normally required to be conducted for on-site applications or on very large objects / samples which can not be easily transported . IRC has number of portable hardness testing units to perform the se tests by application of 5 kg. Vickers load indenter that electronically converts the value in the preferred scale.

Advanced Non-Destructive Testing Services

IRC Engineering is the only company in the Northern part of the Country to be carrying out Advanced NDT inspection Services. Though it is a feeling in the industry that these inspections are costlier , but in the long run they have proven to be cheaper than the conventional methods. The following are the reasons for their Cost Affectiveness:

• In case of Conventional Methods of Inspection we are unable to carry out welding at a nearby location at the same time when we are carrying out Radiography Test but by Means of Techniques such as Phased Array we are able to carry out Welding and Inspection Round the clock.
  
• In case of Conventional Methods NDT Vendor is using consumables for every joint but in case of the newer techniques the amount of usage of consumables is reduced to once in around 800th joint, which in long term reduces the cost of services.
• The need to used Scaffolding is reduced due to techniques such as LRUT. Hence the cost of Scaffolding or making of Underground pits is reduced.
• Inspections can be carried out very fast and accurately , hence project can be completed quickly.

IRC is carrying out at present the below mentioned Advanced Inspections:

1. Long Range Ultrasound Testing
   
2. Pulsed Eddy-Current Testing
3. Phased Array Ultrasound Testing
4. Time OF Flight Diffraction
5. Eddy-Current Testing
6. Helium Leak Detection
7. Computed Radiography
8. Corrosion Mapping

It will be our pleasure to create value for our clients by usage of any of the above techniques.