As a certified FROSIO Level III expert, I have repeatedly experienced exciting and new fields of application for specific inspections during my many years of professional experience. Here I share my experience, because the targeted use of FROSIO inspectors makes a valuable contribution to the longevity and efficiency of steel structures.
Inspection and non-destructive testing
Regular inspections and condition monitoring form the basis for quality assurance and maintenance management. The inspector's tasks can be summarized under "inspect, observe and report". Inspection ensures that work is performed in accordance with project specifications, procedures, and standards. The final report documents the findings and any discrepancies. StS provides condition monitoring and inspection of welding, surfacing and insulation work performed by specialists with professional experience and relevant certification such as FROSIO and NDT. A positive pressure habitat provides excellent working conditions for performing NDT in conjunction with hot work suction as welding operations often require NDT inspection upon completionTo address difficult access, StS offers NDT and FROSIO inspectors trained in industrial rope access.
1. Non-destructive testing methods
In addition to the already presented test methods HT Visual testing, VT Magnetic particle testing, MTEindentation testing, PT Eddy current testing, ET Ultrasonic testing, UT Radiography testing, there are further methods: RT Positive material identification PMI and hardness measurement HT.
2. PMI Positive material identification
Positive Material Identification (PMI) is used to analyze and identify material quality and alloy composition for quality and safety control. A rapid, non-destructive method of positive material identification is performed on a variety of components and assets and provides semi-quantitative chemical analysis. It is used for both material verification and identification. The method is used for quality control and safety compliance and is an essential part of managing the production and integrity of assets in many industries, including oil and gas, energy, chemical, pharmaceutical, nuclear, aerospace, and manufacturing. Positive material identification can prevent a potential product failure during manufacturing. In oil and gas, power generation and pharmaceutical companies, inspecting critical components and welds with PMI before and during operation can prevent failures and their costly consequences.
PMI can:
Ensure products/components are made from the correct alloy Find potentially mixed alloys Determine if the wrong material was used Ensure material is to the correct standard and specification (both customer and industry). Ensure welded components have used the correct filler material Positive material identification is performed using one of the following two techniques: X-ray fluorescence analyzer (XRF): this is the most commonly used method. Due to the portability of the handheld equipment, Intertek can perform PMI on-site at our customers' facilities. The instrument scans the metal material and identifies its key elements. However, it cannot detect carbon and some lighter elements and is not suitable for identifying pure carbon steel materials. Optical Emission Spectroscopy (OES): this method can detect almost all types of elements, including carbon and lighter elements as well as carbon steel. Although the instrument is not as portable as XRF analyzers, it can be transported to sites and used at high altitudes with appropriate lifting equipment. Intertek's experienced PMI inspectors can provide on-site results, followed by certification of the results in a written report. We also interpret and advise on the results. In addition, our response times ensure that we meet your production or inspection schedules. If further analysis is required, Intertek can provide the fully quantitative laboratory techniques to confirm the results. When you turn to us for positive material identification, you can count on fast, reliable service with accurate results that provide full quality assurance that your products or assets meet the required quality and safety standards in today's markets and industries.
3. HT Portable hardness test
Portable Hardness Testing (HT) is a non-destructive testing method used to determine the hardness value of a material. This method is used to test ferrous and non-ferrous metals and alloys, as well as selected non-metallic materials, welds and weld pads, weld heat affected zones (HAZ), castings and forgings, piping, stress relieved materials, machined parts, pressure vessels and structural steel. Damaged materials are inspected as part of a failure analysis for welds and to verify material conformance to: ASME Section IX NACE MR0175 / ISO 15156 requirements ADVANTAGES Rapid results and reporting to customer Field ready Highly portable tools can be used at most locations RESTRICTIONS Brinell hardness testing cannot be performed on thin material, in weld affected weld zones, and on surfaces where indentations are unacceptable, e. g. For example, finished surfaces MicroDur measurements require a surface that is polished to a near mirror finish The Equotip should only be used for parts with a thickness of ½ inch or more When electrical hardness testers are used, the temperature of the test material must not exceed approximately 200 ° F.
Enhancing Steel Structure Durability with FROSIO-Approved Surface Techniques
Industrial coating performance and life cycle are determined by various forms such as appropriate surface pretreatment methods, coating system selection, environment and cost.
Just how do you guarantee your steel framework can hold up against the coming atmosphere?
Your FROSIO certified assessor can assist you in choosing an effective surface therapy. It makes certain that your structures have a lengthy life span. All steel structures – tiny and large – are exposed to weather tensions as well as corrosion, which shortens their life span. Just how swiftly the degradation happens depends upon the environment to which the steel structures are subjected. It is crucial whether the setting is an interior office environment, a damp factory hall for e.g. B. for food preparation, a hillside in a rural area or by the sea. Paint as well as galvanizing are commonly used to shield the steel surface from corrosion strikes. In this context, it is really essential which paint system is chosen as well as just how the surface therapy procedure works if the structure is to be properly protected for several years. It is as a result necessary to work with the optimum requirements for surface area treatment. Numerous decisions should be made as to which requirements need to be stated in the spec. If the needs are not adequate, this influences the life span of the frameworks. If they come to be also requiring– in terms of what is essential– this makes surface area treatment needlessly challenging. The FROSIO licensed (NS 476) inspector is of excellent value in clarifying what requirements require to be met. To name a few points, it decides on: Requirements related to standards such as NORSOK M-501, ISO 12944, and so on. Requirements for the surface area high quality of the steel.
What material density reduction before pretreatment as well as surface area treatment can be approved?
Are there special needs for the steel type in regards to silicon content and wall surface thickness in order to attain the preferred zinc layer density by hot-dip galvanizing (bath galvanizing)?
What degree of pretreatment should the steel have in regards to welding and edges?
What degree of pureness after pressed air blasting with strong blasting media (sandblasting) is needed completely adhesion?
How much salt can be absorbed on the steel surface area?
What is the corrosion category?
What kind of paint system to choose?
Is the suggested surface area treatment good enough for this purpose and also what are the strengths/weaknesses of the paint framework?
What degree of reporting as well as paperwork should you require from the finisher?
What tests/inspections require to be accomplished en route to a perfect last layer? And what tests later on?
Who should perform tests/inspections? Self-constraint, customer control or 3rd parties?
What are the qualification requirements?
Are there any unique demands for the appearance of the finishing?
Alleviate of cleaning, color fastness and exposure of fixings?
Your FROSIO-certified specialist as well as examiner will certainly sustain you in all of these inquiries to determine the most ideal requirements for each certain project.
The specific requirements supplies the predicted outcome
The surface finisher must perform his work according to the specification. In the absence of a clear requirements, he can do what he sees fit. But good techniques are not the same everywhere. That’s why it is very important to include every little thing in one specification. For specifically this factor, the internationally acknowledged norms and also criteria for surface treatment such as DS/ EN ISO 12944, DS/ EN ISO 1461 as well as NORSOK M-501 were established. By defining according to requirements, the needs become clear. For instance, the surface area finisher knows that when specifying P3 according to DS/ EN ISO 8501-3, the welds have to be ground totally smooth, there should be no weld beads and all edges should be rounded to a distance of 2 mm, etc. The surface area finisher additionally knows that as soon as a paint system A5M.06 has actually been specified based on DS/ EN ISO 12944, a layer of zinc primer need to be keyed with either epoxy, polyurethane or ethyl silicate as a binder to a dry film thickness of 40-80um. Furthermore, 3-4 coats of epoxy or polyurethane must be complied with for an overall completely dry coat density of 320 μm. Optimum surface treatment calls for a sharp definition of expectations. An excellent, precise requirements ensures your finisher recognizes specifically what is expected of them. This implies that your steel framework– whether it is a wind turbine, a bridge, a tank or something totally different– is efficiently protected versus corrosion damage.
The specific specification provides the predicted outcome
The surface area finisher need to accomplish his job according to the spec. In the absence of a clear spec, he deserves to do what he sees fit. Yet excellent methods are not the exact same all over. That’s why it’s important to consist of every little thing in one spec. For exactly this reason, the worldwide acknowledged norms and also standards for surface area treatment such as DS/ EN ISO 12944, DS/ EN ISO 1461 and NORSOK M-501 were developed. By specifying according to standards, the needs become clear. As an example, the surface finisher knows that when specifying P3 according to DS/ EN ISO 8501-3, the welds must be ground totally smooth, there must be no weld beads and all sides must be rounded to a span of 2 mm, etc. The surface finisher likewise knows that once a paint system A5M.06 has actually been specified based on DS/ EN ISO 12944, a layer of zinc primer must be keyed with either epoxy, polyurethane or ethyl silicate as a binder to a dry film thickness of 40-80um. Furthermore, 3-4 layers of epoxy or polyurethane need to be followed for an overall dry coat density of 320 μm. Optimum surface area therapy requires a sharp definition of assumptions. A great, exact spec guarantees your finisher knows precisely what is expected of them. This suggests that your steel framework– whether it is a wind turbine, a bridge, a storage tank or something totally various– is efficiently shielded versus corrosion damages. This is what the FROSIO accredited inspector and specialist deals– an optimal requirements based on global standards. This likewise makes certain that if there is a conflict, there is no doubt regarding what you are qualified to.
Independent as well as specialized recommendations
Your professional as well as FROSIO accredited inspector can tell you impartially and professionally which surface area treatment you need to pick as well as what needs you require from your surface area finisher in terms of the implementation and control of the surface therapy. With a clear requirements you obtain the right and long lasting protection.