Buffalo Inspection Services has been supporting the pipeline industry in Western Canada with full spectrum NDT services for over 30 years.

Our geographic footprint allows us to respond to all requests along the major Oil and Gas pipeline and development corridors, quickly and cost effectively.

We actively update our equipment, technology and personnel’s certifications to maintain currency with our clients and industry requirements.

From new build to pipeline digs, our depth of experience and body of knowledge are available upon request to ensure your pipeline project is done to the highest quality and in the most cost effective manner.

All of our pipeline activities are fully supported by our Quality and Safety Program; all personnel and projects are audited consistently to ensure compliance with client and current regulatory requirements.

We offer an extensive list of pipeline specific NDT solutions all designed to prevent unexpected losses by our clients.

Pipeline Radiography (RT)

Buffalo Inspection Services provides radiography services at both our gigantic shooting bay and in the field right at your pipeline’s location. Our expertise is in utilizing penetrating X (generated x-ray) or Gamma (Iridium 192) radiation to examine pipeline welds for flaws that could be detrimental to continued operation or lead to unexpected asset loss.

Mobile Radiography & Darkrooms

When you need radiography on location trust Buffalo to be there. With a massive network of RT inspection crews across Western Canada, we’re always close by to perform scheduled or 24/7 emergency NDT inspections on your pipeline network.

Bunker & Darkroom

Our Edmonton inspection facility consists of an advanced shop and large concrete x-ray bunker perfect for inspecting pipeline welds before entering the field. Engineered to provide safety to surrounding areas while offering a large enough space to allow for a wide variety of pieces to be examined, our bunker and darkroom offer cost effective solutions for your new-construction pipeline installations.

Two men from Buffalo Inspections conducting welding inspections

Welding Inspections: Examining the Various Types of Welding Inspection

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Welding inspections are extremely important for several reasons. Machinery, buildings, pipelines and other essential equipment and materials require welding that must be inspected to ensure safety and reliability.

Welding inspectors can employ various types of welding inspection. With the help of these welding inspection techniques, codes, and standards, welding inspectors can determine if a weld is suitable for its intended purpose.

But, what are these techniques and what types of welding inspection are the most common and reliable?

Let’s take a look.

 

What is the purpose of welding inspections?
What kind of inspections can be done on a weld?
How many types of welding inspections are there?
What is the most commonly used method of weld inspection?

What is the purpose of inspection in welding?

Welding inspections are important to determine if a weld meets certain codes and standards. In Canada, weld characteristics must meet the standards set out by the Canadian Standards Association (CSA). These regulations help inspectors ensure that machinery and materials can safely and effectively be used.

Certified welding inspectors conduct examinations using a number of tools and techniques. These inspections reveal data related to the size and quality of the weld. Most importantly, they identify any flaws or defects.

Flaws and defects can result in poor performance and safety issues. Therefore, welding inspections also help companies save money by detecting possible failures before they occur. This helps to reduce costs related to incidents, and asset loss, as well as protects employees, the public, and the environment.

 

Welding inspection being conducted by certified welding inspector

What kind of inspections can be done on a weld?

A weld can be inspected using both destructive and non-destructive techniques.

Destructive techniques physically destroy the weld to determine its viability. Commonly, when an inspector is conducting a destructive weld test, they will break a sample of the weld off to evaluate its strength and other characteristics.

On the other hand, non-destructive testing (NDT) techniques allow a welding inspector to examine the weld and its characteristics without causing harm. These techniques are commonly used by welding inspection companies in Canada.

Buffalo Inspections, for example, is a non-destructive testing company that employs NDT methods when evaluating welds.

How many types of welding inspections are there?

There are five common NDT welding inspection methods used in Canada. These include:

  1. Visual
  2. Radiographic (or X-ray)
  3. Ultrasonic
  4. Magnetic Particle
  5. Liquid Penetrant

Each type of welding inspection offers different advantages and disadvantages. The type of inspection that should be used depends on the asset, as well as the tools and technicians available.

Visual Inspection

Visual inspection, or VT, is the simplest form of NDT welding inspection. In this case, the welding inspector examines the weld visually to determine if any surface flaws are present. Weld size can also be examined to determine any possible issues.

This type of inspection is cost-effective and can be employed while work continues on a structure or material. However, visual welding inspections are limited, as only surface defects can be recognized. As well, in many cases, VT must be conducted throughout a project, especially if more than one layer of material is being deposited.

Often welding inspection companies will begin with a visual inspection to ensure there are no obvious defects.

Radiographic Testing

Radiographic inspection (RT), or X-ray, is a non-destructive testing method that is versatile and commonly used in Canada. This NDT method is employed to evaluate the internal quality of a weld. It can be used to identify internal flaws such as cracks, non-metallic inclusions, burn-through and more.

This inspection method is beneficial because the inspection is recorded on film. This film can then be used for subsequent examination, if necessary. However, several limitations also exist. First and foremost, the quality of the inspection relies on the skills and ability of the inspector and the equipment being used. As well, not all welds are suitable for this type of inspection.

Magnetic Particle Inspection

Magnetic Particle Testing, or MT, detects surface and near-surface flaws.

This NDT method will identify welding defects immediately. As well, sensitivity can be adjusted. This allows for various levels of flaw detection. As a result, welding inspections using MT can identify minor imperfections, including tight cracks and discontinuities.

Unfortunately, Magnetic Particle Testing can only be used on ferromagnetic materials, such as iron and steel. As well, some surfaces, such as those with a thick coat of paint, will not allow for this method of inspection. In addition, like other NDT techniques, a skilled inspector is needed to effectively conduct the inspection and identify any discontinuities.

Liquid Penetrant Testing

Liquid Penetrant Inspection, or PT, is used to identify surface cracks that cannot be detected by the naked eye. This method is common for detecting leaks due to welding flaws.

Unlike Magnetic Particle Inspection, PT can be used to evaluate magnetic and nonmagnetic materials. This method of inspection can help to detect very slight flaws. PT can also detect defects in materials with complex shapes.

However, Liquid Penetrant Inspection is limiting. This is because only surface flaws can be detected. Proper pre and post-inspection cleaning is also required.

Ultrasonic Inspection

Ultrasonic Testing, or UT weld inspection, can identify both internal and surface flaws. As well, UT can identify the location and measurement of a discontinuity.

This method is extremely sensitive, allowing inspectors to detect minor imperfections that other NDT methods will not recognize.

Using phased array technology allows for even more complex and accurate inspections. Phased Array Ultrasonic Testing (PAUT) allows welding inspectors to evaluate a component from multiple angles. This means components with complex geometry can be quickly and accurately inspected. However, this method requires the most skill and experience to properly interpret the results.

What is the most common weld test?

The two most common types of weld tests include Radiographic and Ultrasonic testing. These NDT methods are commonly used because they can detect internal flaws and irregularities. In addition, they can do so without destroying or affecting the integrity of the weld.

 

Two men from Buffalo Inspections conducting welding inspections

Do you require accurate welding inspections?

Buffalo Inspection Services offers NDT inspection services for CSA Standard W178.1. Our certified technicians inspect buildings, industrial structures, machinery, pipelines, piping, and more using the most advanced and up-to-date technology.

Our CWB certified inspection personnel and CWB level 3 Welding Inspector offer in-depth knowledge and valuable experience. As a result, we provide the most accurate and efficient welding inspections.

Contact Buffalo today to request a quote or schedule an inspection.

NDT inspection

NDT Inspection Technology: What’s New and Leading-Edge in 2020

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NDT inspection technology, including training and tools, is continuously evolving.

With changes in government regulations, innovations in technology and the ever-changing needs of industries requiring surface and subsurface analysis, non-destructive testing continues to evolve to ensure the safety, productivity, and integrity of materials, products, and structures.

Interested in knowing more about what’s new and leading-edge in non-destructive testing (NDT)? This article will cover:

Why NDT is important
The advantages of NDT
What’s new in NDT training
What’s new in NDT technology
Pipeline inspection improvements

Why NDT is important

Non-destructive testing is vital for the timely detection of faults in products, materials, and equipment. If left undetected, defects and flaws can result in expensive and premature repairs or replacements. Unplanned shutdowns and failures can also result and have devastating health, safety, and economic impacts.

For pipelines, oil and gas, mining, lifting and industrial construction equipment, and tubing, NDT functions as quality assurance, ensuring the reliability and expected lifetime of equipment and materials is upheld.

Regular testing allows engineers to determine the current lifecycle stage of an asset and to proactively plan maintenance, repairs, or replacements. Regular inspections also ensure that catastrophic failures of your business/operational assets do not occur, potentially resulting in lengthy and costly downtime. Besides, routine testing ensures adherence to government regulations and standards, as well as the health and safety of your workforce and the environment.

Overall, NDT:

  • Prevents accidents
  • Reduces repair and replacement costs
  • Improves reliability of assets
  • Ensures adherence to regulations and policies


What are the advantages of NDT?

Non-destructive testing is ideal because it allows for the inspection of equipment, materials, and structures without the need to worry about downtime or damage.

NDT can save time and money by identifying problems early – before expensive repairs or replacements are needed.

What’s new in non-destructive testing

Advancements in technology and changes to government regulations and policies are continuously driving innovation in non-destructive testing. These changes affect all aspects of NDT, including training, inspection, and technology. The result – new and innovative methods and strategies.

NDT has come a long way since its origins. Simple VT has now evolved with the digital world, resulting in digital outputs, including 3D imaging and cloud connectivity that allows for remote testing and analysis.

NDT Training

NDT inspection technology and its applications are continuously improving and evolving. Inspection technology, equipment, and the services offered by inspection providers are ever-changing, including advancements in training and techniques.

Buffalo Inspection Services, for instance, recently implemented a Personal Certification in Non-Destructive Testing (PCN) course using Gekko and Mantis technology. This training is revolutionary, making Buffalo the first NDT company in North America to host PCN Certification on Gekko PAUT technology and the only non-union NDT inspection services provider in Western Canada with qualified PCN technicians.

NDT Inspection Technology

Advancements in technology drive change in non-destructive testing. As a result, hardware and software enhancements are continuously developed to improve testing and analysis.

Below are some of the most recent advancements that have been made in NDT technology:

The GEKKO

Buffalo NDT Inspectors uses the M2M Gekko for PAUT inspections.

The M2M Gekko is one of the most advanced and reliable options for Total Focusing Method (TFM) testing. The only unit that supports a 3-axis encoder for TFM, the Gekko is also the first system able to produce matrix arrays and perform TFM in real-time.

As the most versatile and advanced PAUT field unit, the Gekko can cover a wide range of inspections, and, recently, a new generation of the Gekko was released, with various ground-breaking advancements introduced.

Improvements to the new generation of the Gekko include:

  • Hardware – increased speed and channel sensitivity, longer battery life (up to 6 hours), improved touchscreen functionality (e.g. touchscreen can be used with gloves)
  • Data management – new USB 3.0 connector for rapid file transfer and wireless data or screen sharing, IP68 LEMO encoder connector for compatibility with most scanners
  • Software – the release of new Capture 3.1 software

Capture 3.1 software

The release of Capture 3.1 has brought many improvements to ergonomy, analysis, and TFM tools and options. The new advanced analysis tools offered by Capture 3.1 improve productivity and increase the quality of research and reporting, resulting in more efficient and reliable testing.

The new tools added to Capture 3.1 include:

  • Auto-sizing – for a quick analysis of whether an indication is critical
  • C-scan stitching – for inspections that require more than one file
  • Full 3D exporting
  • Improved indicators

TFM

The Total Focusing Method has come a long way since its inception. In 2013, portable TMF revolutionized non-destructive testing. Since then, TMF has seen significant changes to scan speed, the number of TFM options available on the market, and to code. These advancements have allowed TMF to remain one of the best and most reliable techniques for NDT.

  • TMF options on the market
    2013 – 1 TFM option
    2020 – more than 10 TFM options
  • Scan speed
    2013 – ¼ inch per second
    2020 – more than 4 inches per second
  • Code
    2013 – No TFM code
    2020 – Code-compliant

Along with the recent release of Capture 3.1 software, a new TFM method called Plane Wave Imaging (PWI) has also been introduced.

Plane Wave Imaging

PWI, introduced by Eddyfi Technologies, is a new data acquisition technique for TFM. This technique is conducted by first firing all the elements of the array concurrently on several different angles, with elementary signals received on all of the elements. After this initial process, a typical TFM is performed. The final result is a matrix containing M x N (number of angles x number of elements) elementary A-scans.

PWI - Plane Wave Imaging demonstration for NDT Inspections

The advantages of this new method include:

  • Improved productivity – PWI is able to maintain the spatial resolution offered by other TFM methods (e.g. FMC) while increasing scanning speed.
  • Increased sensitivity – depending on the number of angles used, PWI can offer an increase in sensitivity, resulting in the detection of smaller indications.


Pipeline inspection improvements

These new and leading-edge advancements in NDT allow for regular, comprehensive, accurate, and economical testing. The efficient and effective testing provided by a combination of this state-of-the-art technology ensures the safety and utility of large pipelines like the Transmountain.

Combining PAUT / TOFD and conventional UT with advancements like TFM, the Gekko is particularly useful for pipeline inspection in Alberta.

Radiography (x-ray inspection) and UT are commonly used; however, Phased Array Ultrasonic Testing (PAUT) offers several advantages for pipeline inspection. These advantages include NO:

  • Radiation
  • Risk
  • Additional licensing necessary

With the ability to detect manufacturing flaws, corrosion, cracking, erosion, parent metal flaws, and more in pipelines, all while in-service, regular non-destructive testing ensures cost efficiency, environmental and public safety, and reliable, long-term performance.

Want to discuss NDT pipeline inspection for your company? Contact Buffalo today.

3D images using the appropriate software

What is Phased Array Ultrasonic Testing

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With PAUT, the technician actually gets images of the scanned areas in A, B, C, and D forms, which then can be generated into 3D images using the appropriate software.

What if ultrasonic results were presented in picture form instead of a written report? What if 3D images of welds were available for a welder to review at any time? What if all this data could be kept in digital form? And what if your confidence for the probability of detection (POD) soared from 50 percent to over 90 percent?

These are the questions that Andrew Crawford, TQMS manager for Buffalo Inspection Services in Edmonton, posed at his presentation during this year’s CanWeld event as he introduced the audience to the latest in phased array technology.

Non-destructive testing (NDT) has been an essential component for the production of quality parts in the fabricating and welding sector for decades. For general methods of testing, including eddy current (ET), magnetic particle (MT), liquid penetrant (PT), radiographic (RT), ultrasonic (UT), and visual testing (VT), the physics behind them hasn’t changed significantly since their inception into the market. However, NDT has become more advanced through innovation and technology trends. The hardware for these methods will become more affordable, but it is the software that will determine functionality.

New ways to collect and interpret data will in time push methods to their limits, eventually phasing them out to make way for advanced methods. Crawford used the example of how shear wave single crystal technology, which has been around since the 1950s and still being certified in Canada, is slowly being phased out by more advanced technology like phased array ultrasonic testing (PAUT).

PAUT

PAUT

PAUT is a newer method of NDT that became commercially available in the 1990s in a portable form, after the release of Windows 3.1, and evolved from the traditional UT method of single-crystal technology combined with software and computing power to allow multiple crystals to work together to form focal laws.

With traditional manual UT, a technician manipulates the probe around a weld to complete the scan. Then, using his body of knowledge and pattern recognition skills concurrently with the scanning activity, he interprets the scan.

“The probability of detection for manual UT is around 50 percent,” said Crawford. “Moving into PAUT, the probability of detection dramatically increases to well above 80 percent. Using the total focusing methods (TFM), it’s approaching 95 percent.”

With PAUT, the technician actually gets images of the scanned areas in A, B, C, and D forms, which then can be generated into 3D images using the appropriate software. The different image forms provide a comprehensive perspective in 2D versus one single A-scan electronic trace as has been traditionally provided.

The UT technician can now see a picture of what the beam is seeing. This technology still requires some interpretation, analysis, and human intervention. Having a strong understanding of the physics, equipment operation, and welding details will help technicians interpret any anomalies indicated.

“With PAUT, we are still using piezoelectric transducers, but with the current algorithms we can develop all manner of focal laws and applications,” said Crawford. “The end result of all of these improvements is the easier analysis and less interpretation of A-scan patterns, better accuracy, resolution, and, of course, imagery.”

PAUT technology scans

Advancements in PAUT technology have resulted in easier analysis and less interpretation of A-scan patterns, better accuracy, resolution, and 3D imagery.

Remembering that ultrasonic inspection is stochastic in nature, the more data we have, the more accuracy we can determine.

There are various methods of data acquisition, including total focusing method (TFM), matrix arrays, sectoral scanning, electronic scanning, and multi-salvo techniques. Full matrix capture (FMC) and TFM, the most comprehensive techniques, did not become a portable option until 2014 when computing power became adequate. Prior, it was an offline function only.

“The technology has evolved to allow for high-temperature in-service inspection,” said Crawford. “The future, however, is in the software. Hardware will become standardized, but the software and user interface elements will be the core advancements going forward. The current expansion of PAUT, TOFD, and FMC/TFM will inevitably result in the further evolution of these technologies, resulting in benefits in resolution and accuracy, along with applications.”

FMC/TFM is currently the highest level of commercially available phased array technology. This method offers inherently higher resolution, accommodates mode conversions, and gives high-resolution imagery of indications and profile morphology.

Weld Inspection

PAUT is especially suited for weld inspection. The technician can simply put the weld profile in the program along with dimensional offset info, and once it’s scanned, it will show the exact location of an indication, which from a welding perspective tells the welding engineer where problems are occurring.

“If it’s a fracture mechanics-based acceptance criteria, this will have higher accuracy and allow the welder to understand where they are making mistakes,” said Crawford. “From an engineering perspective, it provides a lot more information to inform future designs and make smarter decisions on whether defects will cause problems or not.”

Electronic scanning is primarily used for scanning geometric surfaces on weld profiles or at fixed depths. This method deploys all of the available beams to concurrently hit a geometric profile or a portion of that profile at a specific angle or position if there are areas of concern. With PAUT, the technician has the flexibility to use from four to 64 elements; these numbers could potentially grow in the future, depending on the need.

“From a simple weld inspection standpoint, our obligations are to do a full geometric and volumetric inspection; anything less is considered an incomplete inspection,” said Crawford.

Beyond welding, PAUT is also being used for corrosion assessment as well as testing on complex geometries, flange face corrosion, bolts, pulsation dampers, and anything with a configuration that is not traditional or uniform. The technician performs a blanket scan and the software is able to stitch it all together to end up with an appropriate view, which when combined within the software, essentially provides a 3D image.

PAUT, particularly for weld inspection and corrosion detection, offers a high probability of detection that can discriminate defects versus geometric ghosting. Having all the data and images also provides an auditable trail.

Bolt inspection.

Bolt inspection.

Corrosion Morphology

“With the latest technology, FMC/TFM, the technician can fire 64 elements independently and establish tens of thousands of points/pixels in a defined area and interrogate every one by firing each crystal and the receiving responses on all the others,” explained Crawford. “It builds a massive database of responses. Once geometries are put in as part of the TFM, it can determine what each point represents. Once a scan is done, technicians can use many different configurations to gain different insights because the data has already been accumulated in the area of interest. The data can be used to configure any scan or transferred digitally to anywhere it is needed.”

Data files for TFM are well into the gigabyte realm as opposed to a standard PAUT scan, which is in the hundreds of megabytes range. Crawford noted that industry has been using this technology since 2015, but it has only just made the ASME codes this year.

Advanced Technology

Crawford sees the next wave of PAUT technology being more automated. Historically, when a weld was inspected with PAUT, technicians would review the weld scan, evaluate areas of concern, and report it. This usually was done over an extended period of time or a night shift. But automation and integration allow for all these tasks to be done in an accelerated manner to increase production, which will help improve productivity, quality, and safety.

“What we are aspiring to with PAUT is digital twinning,” said Crawford. “We would put a technician in the field who doesn’t necessarily need to have the advanced technical skills but rather applies an approved and tested application designed by a level 3 and implements it with their operability skill set. In the shop or office, another technician could monitor his or her activities and implementation by a video that would be tied through a connected device. So you could see what the on-site technician is seeing, and if there are any issues, you can relay that back to them. This allows it to be done anywhere in the world. We believe digital twinning will continue to be adopted for cost and productivity reasons.

TFM/PAUT Inspection

Announcing: TFM/PAUT Inspection for On-Stream Monitoring

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Industry experience has shown that most companies are only able to inspect approximately 3-5% of their equipment a year. When the cost of inspection weighted against the cost of down time is incidental, cost effective approaches to inspection can be undertaken. Expensive emergency outages, the costly impact of spills on a company’s environmental reputation, or a very serious process safety event with potentially catastrophic endings can be avoided. One common theme heard is “we don’t know how to monitor {insert asset here} so we just wait until it washes out or fails”. Corrective Based Maintenance strategies like this can now be advanced to Condition Based with Buffalo’s new technology.

Through our industry experience, we have been able to assist clients in determining key locations for inspection, to enable them to pursue an online condition based assessment.

Buffalo Inspection has been utilizing cutting edge equipment, combined with best in class PCN PAUT training, to provide a complete inspection package to our clients. This isn’t a standard data collection inspection. We are in this to ensure not only the integrity of the asset, but to save our clients time, money, and headaches. Through our

industry experience, we have been able to assist clients in determining key locations for inspection, to enable them to pursue an online condition based assessment.

TFM/PAUT Inspection

We have developed inspection methods for specific client requirements such as Choke Valves, Flange Face Corrosion, Internal Current Transfer Corrosion, HDPE inspections, and an ever increasing variety of previously uninspectable situations. Conventional ultrasonic methods experience limitations that modern phased array technologies have been able to overcome. Permanent, Auditable data, has established itself as a necessity for integrity management.

Working with our clients, has allowed us to alleviate issues that hadn’t been solved for them in the past. It has also allowed clients to increase the integrity of their assets. Code minimums are exactly that, minimums, but what if it was faster, better, and cheaper, to get more? That is exactly what we at Buffalo Inspection Services are striving to provide.

Pipeline Inspection

Buffalo Inspection Services expands footprint with acquisition of Radius Inspection Services

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EDMONTON, Alberta, October 1, 2014 Canada’s largest non-union Non-Destructive Examination (NDE) services provider, Buffalo Inspection Services (2005) Inc. (Buffalo Inspection Services), has acquired Radius Inspection Services (Radius), and independent owned and operated NDE company in Northeastern British Columbia, to continue its expansion into under-served locations.

Radius primary operation is strategically located in Fort St. John, British Columbia, a growth market for oil and gas and pipeline development. The acquisition provides Buffalo Inspection Services with the capability of increasing its presence in North East British Columbia working in partnership with an experienced and capable team.

Radius will operate locally as Silver Shadow Inspection Services, a Division of Buffalo Inspection Services and as a result of this deal will now be in a position to provide additional services such as Phased Array and Mainline Crawler capabilities to its clients.

The company has appointed Glen Griffiths, Regional Manager of Buffalo, to work with the existing Silver Shadow and Radius teams to lead the transition, aligning the organizations together and to integrate Buffalo’s structure that has been refined over the last 38 years.

About Buffalo Inspection Services

Buffalo Inspection Services is the largest non-union NDE company in Canada. Headquartered in Edmonton, Alberta, Buffalo has been providing NDE services primarily to the oil and gas industry across Alberta, Saskatchewan and British Columbia for the last 38 years. The company offers a complete suite of NDT services including Radiography, Mainline Gamma Crawler, Magnetic Particle, Liquid Penetrant Examination, Visual Inspection, Phased Array, Ultrasonics, Ferrite Testing, Positive Material Identification, Hardness Testing, Tubing Inspection and Time of Flight Diffraction. The acquisition brings together the teams of Buffalo Inspection and Sliver Shadow to create a 226-strong workforce comprising skilled and certified professionals.