2005 Nondestructive Testing Guide

Equipment condition assessment is fundamental to equipment reliability and maintenance

and to equipment asset management. The predictive maintenance technologies of
vibration analysis, infrared thermography, oil analysis, motor circuit analysis, and
ultrasound detection get most of the attention. However, there is a wider spectrum of
nondestructive testing (NDT) techniques that can be used to keep tabs on equipment
condition.

Some NDT techniques can be used in a time-based program to monitor equipment

components; others are employed for examining suspected failures identified by other
means or as a check of the condition of critical components when they are returned to
service after a maintenance intervention.

Impediments to technology use

When suppliers of NDT products and services were asked about the major impediments
companies face when considering use of nondestructive testing technologies, answers
centered around people, equipment, and money.

"Personnel qualifications" was the reply from William Blum of NDT Consulting Group,
and Kathie Green of Magaflux, a division of ITW, said "environmental issues and lack of
training."

Some noted the perceived difficulty of understanding and operating equipment, and
suggested equipment with more user friendly interfaces. Also, it was suggested that more
economical systems and products would lessen the impact of expensive systems.

To combat the cost issue, Betsy Blazar of the American Society for Nondestructive
Testing urged technicians to stress "risk reduction, downtime reduction and expense
exposure, product integrity, and safety" with management.

Norman Eisenberg of Thermotest Inc. advised staffers to "be persistent" if there are
budgeting problems and people are too busy to give them time to demonstrate what can
be done with these technologies.

Alan Bandes of UE Systems defined the impediments as "a need for training and
understanding of the technologies as well as where, when, and how to use each type of
technology and getting management committed to supporting a comprehensive condition
monitoring program." His suggested solutions were to "attend courses and conferences,
consult with colleagues, and plan ahead. Then work on educating management to
understand the impact the program will have on the company's bottom line."

Resources for reference

The accompanying guide is presented as a foundation for building an NDT reference file
of appropriate contacts and resources for your organization.
The guide is arranged in five sections: NDT for mechanical equipment, NDT for
electrical systems, ultrasonic inspection for both electrical and mechanical equipment,
NDT training, and NDT services. The technology supplier guide lists companies and
indicates their product or service offerings. The company directory lists specific
information about these suppliers.

The American Society for Nondestructive Testing (ASNT) defines NDT as the
examination of an object, material, or system with technology that does not affect the
object's future usefulness. It is also noted that NDT includes many methods that can
detect internal or external imperfections; determine structure, composition, or material
properties; and measure geometric characteristics.

NDT for mechanical equipment

 Eddy current testing induces an electromagnetic field into nonferromagnetic tubes

or parts and detects changes in signal that indicate discontinuities.
 Magnetic flux leakage inspection of ferrous tubes induces a magnetic field and
detects magnetic flux lines "leaking" from a discontinuity in the magnetized area.
 Remote field or transmission eddy current uses a transmitter and receiver coil
arrangement that can provide qualitative reports on nonferrous tube wall loss as a
percent of nominal wall thickness.
 Magnetic particle inspection uses magnetic particles spread on the surface of
ferromagnetic parts to reveal surface cracks transverse to an applied magnetic
field. Particles can be coated with a fluorescent to render them more visible under
ultraviolet light.
 Liquid penetrant inspection, for magnetic or nonmagnetic parts, reveals
discontinuities open to the surface by indicator stains formed by capillary action
of liquid dye drawn from cracks to a developer spread on the part's surface.
 Remote visual inspection techniques use optics, often in prehensile fiberoptic
instruments, to give an inspector a close-up view of interior surfaces through
access openings without disassembling the equipment.
 Radiography provides views of parts similar to an x-ray photograph or real-time
fluoroscopy. The thickness and type of material can be revealed with various
techniques and exposure sources.

NDT for electrical systems

 Motor current analysis techniques use a current transformer and datalogger to

collect motor current spectra that can be analyzed for indication of defects
associated with the rotating element.
 Motor circuit analysis instruments measure resistance in conductor path,
inductance, capacitance to ground, and resistance to ground off-line using closely
controlled ac and dc signals to detect a variety of motor problems.
 Conductor path resistance detection techniques detect "hot spots" or mismatched
circuit conditions using milliohmmeter testing.
  Insulation testing instruments or high-potential testing devices use off-line
application of high voltage to evaluate the integrity of ground insulation systems.
 Ground resistance testers measure the leakage current flowing to and through an
insulation system to ground under the pressure of a known voltage. The results are
returned in (meg) ohms.
 Surge comparison testers insert controlled electrical pulses into an off-line motor
and examine return pulses to derive information about the condition of motor
windings.

Ultrasonic inspection

 Airborne ultrasound detection instruments can be used to identify leaks, arcing,

corona discharge, bearing noise, and other problems in mechanical and electrical
equipment.
 Pulse echo technology detects flaws or measures thickness by measuring the
elapsed time between transmission of an ultrasonic pulse into the material to be
tested and the receipt of reflected echo.

Technology Suppliers
NDT For Mechanical Equipment
1–Eddy current testing
2–Magnetic flux leakage
3–Remote field eddy current
4–Magnetic particle inspection
5–Liquid penetrant inspection
6–Remote visual inspection (optical
enhancement)
7–Radiography (field)
American Society for Nondestructive Maintenance Technologies R/D Tech (1, 2, 3)
Testing (1, 2, 3, 4, 5, 6, 7) Intl (5)
Spectronics (4, 5)
ASC Systems (1, 6) NDT Automation (1)
Thermoscan (1, 4, 5,
Conam Inspection and Engineering NDT Consulting Group (1, 7)
Services (1, 2, 3, 4, 5, 7) 2, 3, 4, 5, 7)
Thermotest (1)
L&S Electric (1, 2, 3, 4, 5) NDT International (2)
Thielsch Engineering
Lenox Instrument (6) Physical Acoustics (1) (4, 5, 6, 7)

MAGNAFLUX, a division of ITW Predictive Maintenance Western Instruments

(4, 5) Inspection (1, 5) (4)

Magnetic Analysis (1, 2) Quality Services Zetec (1, 2, 3)

Laboratories (1, 2, 3, 4, 5,
 6, 7)
NDT For Electrical Systems
1–Motor current analysis
2–Motor circuit analysis
3–Conductor path resistance
4–Event monitor/recorders
5–Power quality analyzers
6–Insulation testing instruments
7–Ground resistance testers
8–Surge comparison testers
9–TDR cable fault locaters
Acoustic Emission Consulting (6) Iris Power Engineering (1) Predictive
Technologies (2)
American Society for Nondestructive Kernco Instruments (4)
Testing (1, 2, 3, 4, 5, 6, 7, 8, 9) QuadTech (6, 7)
L&S Electric (1, 2, 3, 4, 5,
ASC Systems (4) 6, 7, 8) Quality Services
Laboratories (1, 2)
Baker Instrument (1, 2, 3, 4, 5, 6, 7, Maintenance Technologies
8) Intl (1, 2, 3, 4, 5, 6) Thermoscan (1, 2)

Conam Inspection and Engineering Microphonics (4) Thermotest (1, 2, 3, 4,

Services (1, 2, 3, 4, 5, 6, 7, 8, 9) 5, 6, 7, 8, 9)
Mohler Technology (1, 2,
Emerson Process Management (1, 4) 6, 8) UE Systems (4)

EMP Engineering Services (1, 2) PdMA (1, 2, 3, 4, 5, 6, 7) Universal Utility

Services (1, 2, 6, 7)
Hanover Technical Sales (5, 6, 7) Predictive Maintenance
Inspection (1, 4, 5, 6, 7)
Ultrasonic Inspection
1–Airborne (leaks, etc.)
2–Pulse echo (thickness)
3–Integrity testing
Acoustic Emission Consulting (1) Microphonics (1) R/D Tech (2)

ASC Systems (1, 2) NDT Automation (1, 2, 3) Superior Signal (1, 3)

Conam Inspection and Engineering
Services (1, 2, 3)
Dakota Ultrasonics (2)
NDT Consulting Group (2, Thermoscan (1, 2, 3)
3)
Thermotest (1)
NDT International (1, 2, 3)
Thielsch Engineering
Emerson Process Management (1) Panametrics-NDT (2, 3) (2, 3)

EMP Engineering Services (1) Physical Acoustics (1, 2, 3) UE Systems (1)

L&S Electric (1, 2, 3) Predictive Maintenance Western Instruments

Inspection (1, 2) (2, 3)
Magnetic Analysis (2)
Predictive Technologies Zetec (2, 3)
Maintenance Technologies Intl (1, 2) (1)

Quality Services
Laboratories (1, 2, 3)
NDT Training
American Society for Nondestructive NDT Consulting Group R/D Tech
Testing
Panametrics-NDT Snell Infrared
Baker Instrument
PdMA Thielsch Engineering
Conam Inspection and Engineering
Services Physical Acoustics UE Systems

Emerson Process Management Predictive Maintenance Zetec

Inspection
Maintenance Technologies Intl
Predictive Technologies
Microphonics
Quality Services
NDT Automation Laboratories
NDT Services
Acoustic Emission Consulting NDT Automation Thermoscan

Conam Inspection and Engineering Physical Acoustics Thermotest

Services
Predictive Maintenance Thielsch Engineering
Emerson Process Management Inspection
UE Systems
EMP Engineering Services Predictive Technologies
Universal Utility
Maintenance Technologies Intl Quality Services Services
Laboratories
Microphonics Zetec
Sensor Products
Company Directory
Acoustic Emission Magnetic Analysis Corp. R/D Tech
Consulting, Inc. 535 S. 4th Ave. 505 blvd du Parc
5000 San Juan Ave., Ste. D Mount Vernon, NY 10550 Technologique
Fair Oaks, CA 95628 (800) 4-NDT-MAC Quebec, QC G1P 4S9
(916) 965-4827 www.mac-ndt.com (418) 872-1555
www.aeconsulting.com www.rd-tech.com
Maintenance Technologies
American Society for Intl. Sensor Products Inc.
Nondestructive Testing, 121 W. Main St. 188 Rt. 10 West, Ste. 307
Inc. Milford, CT 06460 East Hanover, NJ 07936-
P.O. Box 28518 (800) 510-0181 2108
Columbus, OH 43228-0518 www.mtillc.com (800) 755-2201
(800) 222-2768 www.sensorprod.com
www.asnt.org Microphonics
10 Quality Way Snell Infrared
ASC Systems Nashville, TN 37207 P. O. Box 6
Mack PL, Box 566 (615) 262-0626 Montpelier, VT 05601-
St. Clair Shores, MI 48080 www.microphonics.com 0006
(313) 882-1133 (800) 636-9820
www.geocities.com/einspect Mohler Technology, Inc. www.snellinfrared.com
ors P. O. Box 669
Boonville, IN 47601-0669 Spectronics Corp.
Baker Instrument Co. (800) 258-5258 956 Brush Hollow Rd.
P.O. Box 587 www.mohler.com Westbury, NY 11590
Fort Collins, CO 80525 (800) 274-8888
(800) 752-8272 NDT Automation www.spectroline.com
www.bakerinst.com 195 Clarksville Rd.
Princeton Junction, NJ 08550 Superior Signal Co., Inc.
Conam Inspection and (609) 716-4000 P.O. Box 96
Engineering Services, Inc. www.ndtautomation.com Spotswood, NJ 08884-9984
195 Clarksville Rd. (800) 945-8378
Princeton, NJ 08550 NDT Consulting Group www.superiorsignal.com
(800) 229-3134 304 Wanda Way
www.conaminsp.com Hurst, TX 76053 Thermoscan, Inc.
(877) 638-2441 375 W. 83rd St.
Dakota Ultrasonics www.ndt-cgi.com Burr Ridge, IL 60527
300 El Pueblo Rd., #100 (800) 833-1740
Scotts Valley, CA 95066 NDT International Inc. www.thermoscaninc.com
(831) 431-9722 711 S. Creek Rd.
www.dakotaultrasonics.com West Chester, PA 19382-8013 Thermotest, Inc.
(610) 793-1700 3070 Kerner Blvd., Ste. A
Emerson Process www.ndtint.com San Rafael, CA 94901
Management (800) 640-3133
835 Innovation Dr. Panametrics-NDT www.thermotestinc.com
Knoxville, TN 37932 A unit of R/D Tech Instruments
(800) 675-8033 Inc. Thielsch Engineering
www.mhm.assetweb.com 48 Woerd Ave. Corp.
Waltham, MA 02453 195 Francis Ave.
EMP Engineering (800) 225-8330 Cranston, RI 02910
Services, Inc. www.panametrics-ndt.com (401) 467-6454
1580 Derry Dr. www.thielsch.com
Dresher, PA 19025-1212 PdMA Corp./MCE
(215) 793-9783 5909-C Hampton Oaks Pkwy. UE Systems, Inc.
www.empes.com Tampa, FL 33610 14 Hayes St.
(800) 476-6463 Elmsford, NY 10523
Hanover Technical Sales, www.pdma.com (800) 223-1325
Inc. www.uesystems.com
P. O. Box 70 Physical Acoustics Corp.
Battery Park, VA 23304 195 Clarksville Rd. Universal Utility Services,
(800) 304-9043 Princeton Junction, NJ 08550 LLC
www.empowercompany.co (609) 716-4000 P. O. Box 30608
m www.pacndt.com Amarillo, TX 79120
(806) 378-4185
Iris Power Engineering Predictive Maintenance www.uus-llc.com
Inc. Inspection
1 Westside Dr., Unit 2 P. O. Box 429 Western Instruments Inc.
Etobicoke, ON M9C 1B2 Madison, AL 35758 Box 72, Site 2, RR 1
(416) 620-5600 (256) 721-0100 St. Albert, AL T8N 1M8
www.irispower.com http://home.hiwaay.net/~pmi/ (780) 459-6720
www.westerninstruments.c
Kernco Instruments Co. Predictive Technologies Inc. om
Inc. 50 Sunset Blvd.
420 Kenazo Ave. Pittsford, NY 14534 Zetec, Inc.
El Paso, TX 79928-7339 (800) 842-8401 P. O. Box 140
(800) 325-3875 www.predictivetechnologiesinc Issaquah, WA 98027-0140
www.kerncoinstr.com .net (800) 643-1771
www.zetec.com
L&S Electric, Inc. QuadTech, Inc.
P. O. Box 740 5 Clock Tower Pl., 210 East
Schofield, WI 54476 Maynard, MA 01754-2530
(800) 283-8332 (800) 253-1230
www.lselectric.com www.quadtech.com

Lenox Instrument Co. Quality Services

265 Andrews Rd. Laboratories, Inc.
Trevose, PA 19053 5 Nealy Blvd.
(800) 356-1104 Trainer, PA 19061
www.lenoxinst.com (888) 972-9633
www.qslplus.com
MAGNAFLUX, a division
of ITW
3624 W. Lake Ave.
Glenview, IL 60025
(847) 657-5300
www.magnaflux.com