Non Destructive Testing Australian Standards

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Nondestructive testing or NDT refers to a range of inspection methods and tools or analysis techniques used in the science and technology industry to evaluate the properties of a material, system or component without altering it permanently or causing any damage.

When it comes to testing the integrity and proper functioning of mining equipment, NDT is considered incredibly useful. The reason for this is that NDT methods can be used to inspect the properties of a material without altering the item permanently or causing undue damage to it.

NDT saves companies time and money, making it a convenient time and money-saving product evaluation, troubleshooting, and research technique. It can also yield data useful for conducting a root cause analysis.

There are various NDT methods, although the ones most frequently used are eddy-current, liquid penetrant, magnetic-particle, radiographic, ultrasonic, and visual testing. These methods depend on the application of electromagnetic radiation, sound or other kinds of signal conversion for material inspection.

Aside from being widely used in the mining industry, different NDT methods are utilised in several other sectors, including aeronautical engineering, civil engineering, electrical engineering, mechanical engineering, medicine, petroleum engineering, and systems engineering.

Non-destructive testing involves the inspection of a component or material in a cost-effective, reliable, and safe manner. It is a popular material testing method as it can often be done without the need to shut plant operations down, so a company does not lose income, and since it does not alter the structure of the material or damage it, NDT is considered safe.

The purpose of non-destructive testing is to detect, identify or measure the presence of certain elements like corrosion, surface cracks, sub surface cracks, or anomalies in the component being evaluated.

In the mining industry, there are several possible issues that can significantly impact the profitability and sustainability of mining projects. All projects rely on various equipment whose reliability and proper working condition are crucial for operations to proceed smoothly.

Therefore, regular testing is a primary concern among project managers and entire companies. Moreover, mining companies are also subject to Australian and internationally agreed sets of regulations and standards that they must always be in compliance with.

Components that can fail in a mining operation include electrical wiring, wire ropes, hydraulic cylinders, drills, bearings, circulating pumps, pressure vessels, cranes and motors. These need to be tested for flaws, especially since mining equipment tends to be complex, with many different moving parts. Even a seemingly insignificant flaw in any component, no matter how minute, can cause serious system-wide issues down the line.

It must also be noted that sometimes, the same assets may exhibit different failure behaviour depending on the environmental conditions. An example of this would be a completely, normally functioning asset in a highly silicified gold mine whose performance deteriorates substantially when used in a bituminous coal mine.

By using NDT to assess the materials used in different mining equipment components, project managers and companies can choose suitable products designed for optimum functionality, reliability, and suitability.

The first level of NDT is a comprehensive visual inspection, which although important, more in depth NDT techniques such as Ultrasonic Testing (UT), Eddy Current Testing (ET) and Magnetic Particle Testing (MT) can tell an experienced inspector if and what needs to be repaired.

NDT is carried out at all stages of the asset life cycle from the construction of plant and equipment through to regular testing during planned shut downs or at set intervals throughout its asset life to ensure compliance to the applicable standards and that there has been no deterioration of the plant or equipment between inspections.

However, to be able to establish the aforementioned qualitative or mechanical properties, NDT methods cannot be applied. You will have to apply load on the material which, in turn, can damage or ruin the material, rendering it unusable.

When it comes to the advantages of non-destructive over destructive testing, the one benefit that stands out the most is the fact that NDT does not damage the material or component being inspected. Hence, if the material is intact or is fixed, it can still be reused.

Eddy current testing or ECT uses electromagnetic induction using AC current to detect surface and sub-surface flaws in conductive material. Eddy current array probes are customisable depending on the application and required coverage.

Magnetic particle testing detects surface and near-surface defects in ferromagnetic materials like steel by using magnetic fields. Magnetic particle tests require the use of a fine pigmented ferromagnetic powder that becomes drawn into the magnetic leakage field caused by a flaw.

Unlike other testing or inspection methods, non-destructive testing technology allows you to evaluate materials, structures, and components quickly and accurately without the need to apply load that can damage them and possibly even render them useless.

Our NDT services are suitable for any and every stage of a project, from initiation through to ongoing maintenance and support. AME has a diverse range of inspection services to supply customers with manufacturing and maintenance inspection and testing support.

The item in question that requires destructive testing will be installed into our testbed, and a tensile force is then applied until we reach the Ultimate Break Load of the item. This type of testing is performed in a controlled environment, and usually at approved testing laboratories. This is so that the trained personnel that carry out the testing remain safe and so that the results of the tests are recorded accurately.

Destructive testing ensures your rigging and lifting components meet specific equipment standards (Australian Standards, DNV-GL, EN, International etc). These standards dictate certain safety factors that Lifting and Rigging equipment must meet before it can be used for lifting, pulling or other applications.

Revised international standards for non-destructive testing (NDT), which underpin certification for NDT technicians have impacted units in the MEM Manufacturing and Engineering Training Package (MEM).

The ISO standards, which are internationally recognised benchmarks for various industries, have been adopted in Australia. As a result, there is a need to ensure that the MEM units and qualifications reflect current industry practice. Adapting the MEM units and qualifications to adhere to these standards guarantees that learners and workers possess skills that are aligned with contemporary manufacturing expectations.

We have established a Technical Committee to provide expert advice, a pivotal step as we commence development work on the project. As we move forward, we encourage your active involvement in public consultations where you can provide valuable input on the draft training products.

Manufacturing Industry Skills Alliance recognises the Traditional Custodians of Country throughout Australia and recognises their connection to land, sea and community. We pay our respects to their Elders past, present and emerging and to all Aboriginal and Torres Strait Islander people.

Our commitment to excellence extends to the provision of detailed NDT inspection reports. These reports play a crucial role in assisting our clients with safe and cost-effective maintenance planning and repair solutions. By leveraging our expertise, you gain valuable insights that empower informed decision-making, contributing to the overall efficiency of your operations.

A key advantage of choosing Tasman Rope Access is our ability to execute works via rope access instead of relying on Elevated Work Platforms (EWPs) and Scissor Lifts. This not only eliminates the need for additional equipment on-site but also significantly reduces costs and time associated with mobilisation and demobilisation. Our efficient approach ensures minimal disruption to your operations while maintaining the highest safety standards.

Ultrasonic testing includes thickness testing, corrosion mapping, lamination detection, weld testing, and wear management reporting. Inspection methods utilised inspect the fixed plant, sacrificial wear liner thickness, heavy machinery, ball mills, tank inspections, process piping, and structural steel components.

Eddy current testing allows technicians to discover indications of damage without having to remove protective coatings. Eddy current surface flaw detection in welds and stress points is commonly used on machinery like cranes, car dumpers, and rock breakers.

Visual testing is used in conjunction with other NDT methods and is carried out by our certified technicians utilising a range of visual inspection tools and equipment. Assets are examined for evidence of corrosion, pitting, deterioration of welded products such as structural steelwork and pipework.

Vacuum box testing is a non-destructive method used to detect leaks in welds and other sealed joints. It involves applying a vacuum to one side of the test area and observing for soap bubbles, indicating the presence of leaks.

Radiography testing is a non-destructive inspection method that uses X-rays or gamma rays to view the internal structure of a component, identifying flaws or defects by capturing variations in radiation absorption on film or digital detectors.

AICIP inspection in NDT involves the certification and evaluation of non-destructive testing personnel, ensuring they meet Australian standards for inspecting the integrity and safety of industrial components and systems.

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