Saudi Nondestructive Testing Laboratory SNTL

A Proposal to Establish an NDT Lab to Conduct

Testing of Local and Imported Products

Submitted to the Saudi Specialized Laboratories Company(SSLC)

Extended Abstract

AuthorsDr. Khalid A. Al-Saif

Associate Professor of Mechanical EngineeringKing Saud UniversityRiyadh Saudi Arabia

Dr. Khalid A. Al-Dakkan

Assistant Research ProfessorKing Abdulaziz City of Science and TechnologyRiyadh Saudi ArabiaLarge Diameter Pipeline Scanner (PLS-B)

Document # NDT-2007-00 1

May 2007

EXECUTIVE SUMMARY

This proposal is concerned with an establishment of the state of the art NDT laboratory which uses Ultrasonic and acoustic emissions technologies to identify internal and external dam-ages or faults of pipelines , welded joints and major auto spare parts. The authors propose a joint venture format, to conduct this project, the details of which are highlighted in the next section.

This proposal covers the common applications of the prospective NDT lab and its services to the Saudi Market, the typical equipment needed for such applications and the minimum qualified manpower needed to conduct its business. Once approved, a detailed proposal will be prepared which includes a comprehensive budget for equipment, manpower, training and running costs. The lab structure will be presented in more depth and the required lab space and specifications will be included. The policy of the government in inviting the privet sector to assist in quality testing of imported goods in collaboration with the Saudi Arabian Standards Organization is a great opportunity to adopt this important service.

JOINT VENTURE PLAN

The authors of this proposal are referred to as The Technical Team. The Technical Team foresees the following responsibilities:

1. Setting up and Establishment of the lab and ensuring its integrity

2. Laboratory operation and maintenance

3. Technical documentation and all testing forms

4. Laboratory Layout and equipment procurement

5. Team Assembly and Training

6. International Collaboration

It is expected that The Saudi Specialized Laboratories Company (SSLC), after approving this proposal, will take into account the following responsibilities;

1. Laboratory Licensing

2. Recruiting logistics (overseas employees entry visas, application forms, etc).

3. Contact of relevant government agencies to facilitate the LAB functions.

4. Financial support

Finally, there are issues which can be worked out mutually between our team and SSLC Company. The following items can be negotiated once the proposal is approved;

1. Joint venture agreement: to discuss the percent of the shares to be allocated for the

technical team in this LAB project.

2. Conducting a Feasibility Study.

3. Selection of the Laboratory location and the leasing agreement.

4. Stakeholders contact

5. Marketing.

Scope

This short proposal is concerned with an establishment of an NDT laboratory which uses Ultrasonic and acoustic emissions techniques to identify internal and external damages or faults of pipelines , welded joints and major auto spare parts.

The policy of the government in inviting the privet sector to assist in quality testing of imported goods in collaboration with the Saudi Arabian Standards Organization is a great opportunity to adopt this important service.

Introduction

Nondestructive testing (NDT) is defined as examining an object, material, or even system integrity without introducing any damage to it. The test can discover inner defects that can not be seen on the surface. Not only this, NDT techniques can be used for other discontinuities including porosity, wall thinning from corrosion, detect variations in structure, minute changes in surface finish, the presence of cracks or other physical discontinuities, measure the thickness of coatings and many sorts of disbonds.

NDT is being a must in any modern industry to participate in the following;

1- Ensuring product integrity, and reliability

2- Avoiding failures prevent accidents and save human life.

3- Ensuring customer satisfaction and maintain the manufacturer's reputation.

4- Aiding in better product design.

5- Adjusting manufacturing processes that tend to lower manufacturing costs.

6- Maintaining uniform quality level and ensuring operational readiness.

Laboratory Vision

The vision of the NDT lab is to take the lead in Non-Destructive Testing in the kingdom and ensure defect-free object available in the market.

Laboratory Mission

The NDT center mission is to provide clients with the highest quality testing services that in full compliance with industry testing standards, with fast response and acceptable cost, and provide clients with proper consultations to benefit their business.

Laboratory Objectives

In order to achieve the vision and the mission of the center, the following objectives are to be fulfilled:

Conduct accurate and reliable testing with proper certification which complies with ISO standards and/or Saudi Arabian Standards Organization.

Provide technology transfer platform in NDT testing for local citizens and collaborate with local industries

Provide proper consultation along with the service

Be the regional leading provider of NDT latest service.

Encourage local industries to implement NDT methods in product quality control and improvement of manufacturing process.

Provide a lab facility for periodic calibration and inspection of instrumentation performance, with the purpose of assuring accuracy and precision specifications.

Maximize profit with minimum overhead cost according to a dynamic business plan.

Lab Activities and Service

The lab will use the NDT technology to detect faults and hidden damages to the following products;

A- Testing of Pipelines

Pipes are commonly used for water distribution, sewage, rain-water drainages, and salted water desalination pipelines. NDT is used to inspect pipelines corrosion and internal defects and cracks to prevent leaks that could damage the environment. Visual inspection, radiography and electromagnetic testing are some of the NDT methods used. Pipelines have become the life-lines of many countries and industrial operations, and a major problem associated with pipeline operation is associated with pipe material corrosion of various types. A pipeline can be as simple as product transportation from one vessel to another, or as complex as a product transfer mechanism across countries with widely varying climatic conditions. Pipe-lines are both surface and buried structures, and in most cases may be considered as long thin pressure vessels. The center will be able to test plastic, cast-iron and metal pipelines.

B- Testing of automotive components

For automotive industry for example, premature failure of components used in braking, sus-pension and wheel systems can have dire consequences and therefore must be verified prior to use. Premature failure of drive train components such as axles, transmission shafts, valves and engine blocks can lead to catastrophic events. Spare parts that enter the kingdom can be tested for possible internal defects. Ultrasonic testing will be used to detect hidden cracks, voids, porosity, and other internal discontinuities in metals, composites, plastics, and ceramics

C- Welding

It is very important to check the quality of the welding using NDT methods. The most commonly occurring defects in welded joints are porosity, slag inclusions, lack of side-wall fusion, and lack of inter-run fusion, lack of root penetration, undercutting, and longitudinal or trans-verse cracks. With the exception of single gas pores all the defects listed are usually well detectable by ultrasonic.

Most applications are on low-alloy construction quality steels, however, welds in aluminium can also be tested. Ultrasonic flaw detection has long been the preferred method for nondestructive testing in welding applications. This safe, accurate, and simple technique has pushed ultrasonic to the forefront of inspection technology.

Laboratory Structure

Human Resources

The aim of the lab management is to structure a multi-nationality team who can handle management, marketing, and technical activities. International experts will be recruited to conduct the testing and to assist the Saudi engineers. A training program will be designed to assist the Saudi technical team to pursue the international certification for the relevant NDT techniques. It is expected that the Saudi engineers will apply for the Level II certificate after 2 years from their recruitment in the lab. The plan for recruiting for the first three years is depicted in the tables below;

Saudi Citizens recruiting planSpecialtyEducational

QualificationYear

1Year

2Year

3

Mechanical EngineerB.Sc111

Electrical EngineerB.Sc111

MarketingB.Sc11

ManagementB.Sc.1

International experts recruiting planSpecialty

Educational Qualification

Expected qualifications for the Lab management and technical staff:

Lab Director Minimum of bachelor degree in mechanical or industrial engineering

Sufficient understanding in NDT field and NDT equipment

Ability to write and edit English technical report

Good understanding in strength of material theory, solid design, and supporting software

Personal skills to deal with the centre staff and centre clients

Team work spirit

Marketing Coordinator Minimum of bachelor degree in business or marketing

Marketing local experience for at least 3 years

Ability to speak English fluently and write good English reports

Experience in initiating (or participating) business plan

Creative thinker in Marketing

Lab Engineers- for pipe testing Level II in Ultrasonic and acoustic emission techniques from internationally recognized NDT organizations.

Experience in NDT testing of pipes and mechanical parts for at least 2 years.

Speak and write English

Good communication skills

Lab Engineers - for welding quality assurance Level II in Ultrasonic and acoustic emission techniques from internationally recognized NDT organizations.

Experience in NDT testing for welding applications for at least 2 years.

Speak and write English

Good communication skills

Laboratory Facility

Typical Ultrasonic and acoustic emission equipment:

Micro stepping x-y-z system

Pulser-receiver units

Ultrasonic transducers

Air coupled ultrasonic instrument for composite material analysis and as

sociated transducers

16-bit A/D digitizer

Phase array system

Acoustic microscopy system

Ultrasonic leak detector

Ultrasonic thickness gage

RF Power Amplifiers

Digital storage oscilloscopes

Function generators

Analysis software

AE inspection system with 32 channels

AE preamplifier

AE probes

Acoustic signal pre-processor

Transient recorder

The cost of the equipment is expected to be between 600,000 to 800,000 SR. Detailed facilities and equipment budget will be provided after the approval of this proposal.

Time line of Plan Implementation

Remarks

A detailed proposal will be prepared which includes a comprehensive budget for equipment, manpower, training and running costs. The lab structure will be presented in more depth and the required lab space and specifications will be included too.

Ultra-sonic Level II or IIIPreferable(B.Sc in ME

ex ertor EE

p

)

Acoustic emission Level II or III expert

General NDT testing technician

Preferable (B.Sc in ME or EE )

Preferable (B.Sc in ME or EE )

YearYearYear12311111111