Session Abstracts & PowerPoint Presentations
PowerPoint presentations as presented at the NDTMA 2004 Annual Conference may be downloaded at the bottom of this page. PLEASE NOTE: SOME FILES ARE LARGE AND MAY TAKE A LONG TIME TO DOWNLOAD. The file sizes are as indicated. This page will be updated as the various presentations become available for download.
As U.S. facilities' environmental compliance programs have become more sophisticated, the nature of their environmental activities has evolved from reactive to proactive management, most often through environmental management systems (EMS). An increasing number of these facilities have registered their EMS to ISO 14001, an international environmental management standard initially introduced in 1996. Through case studies and concrete examples, we will explore the drivers and incentives for pursuing ISO 14001 implementation as well as the benefits experienced by ISO 14001 certified facilities. Common benefits to be considered include cost savings, increased efficiency, better overall environmental performance, improved regulatory compliance, reduced regulatory burden, improved customer satisfaction, and enhanced public image.
The cost of health care as well as the delivery of health care has received a great deal of press in recent years. The purpose of this presentation is to provide a clear understanding of the present environment including specific elements and behaviors that are driving health care costs. An overview of current and future health care spending will be provided and will outline the impact that an aging population and individual behaviors have on the cost of health care for individuals during their pre-retirement years. Post-retirement health care needs, from a cost perspective, will be modeled based on retirement income estimates to gage income adequacy for individuals with and without employer-provided subsidies. Some real cost control strategies will be outlined that address the more traditional approaches to cost mitigation as well as real solutions to begin to change the behavior of consumers by making them take a more active role in the delivery of health care.
While health care cost trends may moderate, health care costs will rise dramatically over the next 3 to 5 years. If some of these real solutions are deployed, the long-term cost of health care may be significantly reduced as opposed to the former cost-shifting solutions.
“The Business Case for a Health and Safety Program”
Northrop Grumman Newport News
Northrop Grumman Newport News has developed a world-class health and safety program. Newport News is the only shipyard recognized by OSHA as a STAR site, and is the largest site in the U.S. Utilizing the principles of management commitment, employee involvement, hazard identification and control, and training, the company has avoided $10 million in direct costs associated with safety incidents over the past ten years. This presentation will describe in detail the development, implementation, and sustained performance of this solid program.
NDT MANAGEMENT SESSION I
Imagine 50 miles of tubing exposed to furnace temperatures as high as 2500°F, containing water or steam at pressures up to 2500 psi and temperatures over 1000°F. Picture 10 miles of piping systems that pass this steam through the plant, sometimes right outside your office. Also, picture 12 ton fan elements rotating at 600 rpm in a 300°F environment and 20,000 brass tubes that have a constant stream of untreated river water running through them. Now, take all these pieces and a few more, and perform a thorough condition assessment with an estimation of remaining life and do it in 3 weeks with only half the money you initially requested.
These are a few of the challenges that the utility industry faces with accelerating frequency. Utilities attempting to be proactive instead of reactive face the daunting task of prioritizing these inspections, while remaining accountable to schedule, budget and issues of availability between outages (normally 36 months). This requires that discussions and planning with your NDE service providers begin at the end of one outage and continue until the next. NDE service providers must be ready to meet these challenges from day one of the outage and also be prepared to address items discovered during these inspections that require immediate attention. It requires technicians who are capable and properly equipped, familiar with the eccentricities of power plant NDE.
This paper will discuss the experiences of Xcel Energy – Colorado, both the successes and the failures. It will also outline our plan for remaining proactive and our informal partnerships with local companies.
An effective inspection data management program will allow the Owner/User to employ fewer resources while gaining the knowledge to make educated decisions affecting the maintenance of their facilities.
The program must provide comprehensive information that will satisfy the needs of the user. It must also evolve to incorporate changes in code and industry requirements. This paper provides insight into the creation, evolution and maintenance of an effective inspection data management program.
“What a Customer Such as B&W Looks For From an NDT Service Provider”
Babcock & Wilcox
NDT service providers are expected to provide a variety of “services” while performing NDT. The things service providers should consider and offer include the following:
- - Complete spectrum of NDE services
- - Leading technology of NDE methods
- - Highly skilled NDE technicians for the boiler industry
- - Availability of NDE and capital equipment
- - Geographically located to cover the entire US while minimizing travel costs
- - Consistent service in all regions
- - Familiarity with the alliance agreement in all service regions
- - Consistent rates and billing practices in all regions
- - Management commitment to make the alliance work
- - Streamlining of the invoicing and report generation between companies.
The Mutual Inductance Bridge (MIB) scans waterwalls for multiple defects including fireside corrosion and erosion. This electromagnetic approach does not require surface contact and senses only the mass of underlying ferromagnetic material. Fireside corrosion, scale and clinker deposits as large as 0.5” do not interfere with measurement accuracy or speed. The robot has a total weight of 57 pounds and uses treads of permanent magnets with a combined attractive force of almost 1,800 pounds. This platform contains a position measuring laser, video cameras and MIB electronics to achieve scan speeds of 500 ft2 per hour while a hand held unit scans 125 ft2 per hour. Results include graphical displays describing the condition of all areas, and individual tube profiles.
Results of several applications will be given.
NDT MANAGEMENT SESSION II
Employee Stock Ownership Plans (ESOPs) have been part of the federal tax code for 30 years, but significant misinformation exists regarding the key applications of the ESOP idea for successful private companies. This presentation focuses on the four primary uses of an ESOP for healthy, viable private companies—and outlines numerous ways an ESOP can be structured for a particular company, given the shareholders’ objectives and timetable, and the company’s current-and-projected financial profile. The four primary private-company uses of an ESOP are (1) a flexible and tax-advantaged “exit strategy” (or cash-out mechanism) that provides liquidity and diversification for selling shareholders; (2) an employee incentive/benefit plan whereby longer-term employees can earn an equity interest in their own company—for the financial benefit of direct shareholders and the employee participants; (c) a pretax financing mechanism that reduces a company’s taxable income; and (4) a business-succession plan for a company to perpetuate itself as an independent company.
“Cost Effective Industrial Radiography”
This presentation will be a “back-to-the-basics” review of some of the techniques that can and should be used for the radiographic examination of a wide range of industrial products. Far too many radiographs end up in the “scrap film barrel” due to unsuccessful trial and error radiography. Through the use of some simple basic procedures, unacceptable film can be minimized and high quality images can be achieved. Film artifacts are also a source of unnecessary waste. The cause of many of these conditions and how to prevent them will be covered. Pointers on how to effectively interpret radiographs to minimize disputes will also be presented.
“Management of Silver in Wastewater with A Real Time Monitoring System”
A novel real-time monitoring device now exists for use in conjunction with silver recovery systems that typically follow B&W film processor waste streams, where the purpose is not only the efficient recovery of silver but also strict compliance to Federal or local limits on silver discharged into a public sanitary sewer. The monitor can presently track ionic silver in the effluent down to a lower limit of 0.1 ppm, but will eventually be made to work down to 0.01 ppm.
“Implementing Computed Radiography (CR) Within the NDT Marketplace”
Johnny Gibson & Steve Zahorodny,
GE Inspection Technologies
Download (397 Bytes)
For many decades, radiographic film has been the detection media of choice for most X-ray inspection applications requiring stringent image quality. This typically holds true for both field and in-house X-ray operations. While film radiography has been implemented successfully for many years, there are many drawbacks that must be accepted as part of the radiographic process. These include consumable film and chemical costs, hazardous material handling, darkrooms, silver recovery and cumbersome film storage/archival. Recent advances in a variety of digital X-ray imaging systems have offered NDT professional’s choices other than film when dealing with a variety of applications. Computed Radiography (CR) systems, which implement reusable phosphor screens instead of film, are one of the most versatile digital imaging modalities available on the market today.
The typical Computed Radiography (CR) system utilizes a phosphor screen which, when exposed in the same manner as film, creates a latent image through an “electron trapping” process. The latent image is then read through a “photostimulated luminescence” process. The phosphor screen is optically scanned with a high-resolution laser to stimulate trapped electrons. Photostimulation causes visible luminescence to be emitted from the screen; its intensity is electronically measured, digitized and stored in computer memory as a function of laser position. The stored data is processed by the workstation to render a viewable digital radiographic image that is displayed on a high-resolution monitor. At the end of the scanning process, the phosphor screen is erased and is immediately ready for reuse.
Computed Radiography systems offer some major advantages over traditional film radiography, including faster exposures, faster processing times, extremely high imaging latitude, minimized consumable costs and streamlined image archiving/storage. CR systems have been successfully implemented in many industries including petrochemical, nuclear, aerospace, ordnance, automotive, casting, test labs and many others. CR systems are offered in a few different designs, and certain CR system designs are better suited for certain applications. This technical paper will cover the basics of CR technology, the technical differences in the various CR scanner designs and an application review of successful CR installations.
In response to the new DOT pipeline operator regulations, ASME committee is revising the B31Q standard for pipeline operator qualifications. The committee has produced a draft document that will be finalized in April 2004. The B31Q Standard specifies the requirements for the qualification of individuals performing tasks that impact (affect) the safety or integrity of gas and hazardous liquid pipelines. The standard establishes processes to determine which tasks require qualified individuals and processes that may be utilized to obtain (attain, demonstrate, achieve, ensure) qualification. The standard also includes processes for training, evaluation, qualification, documentation, monitoring effectiveness, qualify control and management of change. This presentation will outline the new requirements of this document and highlight the changes from the superseded requirements.
"An Overview of the TSA and the Industry"
Dept. of Homeland Security
On November 19 2001 the President signed into law the Aviation and Transportation Security Act (ATSA) that among other things established a new Transportation Security Administration (TSA) within the Department of Transportation. The TSA’s mission is to protect the Nation's transportation systems to ensure freedom of movement for people and commerce. The ultimate goal of TSA Service is to create an atmosphere that aligns the passenger's need to be secure while ensuring the freedom of movement for people. This talk will present an overview of the functions and activities of this newly created department. The talk will focus on screening activities for baggage and cargo, including radioactive and other hazardous material. The project to incorporate in-line screening into the process will also be addressed and discussed.
As a result of current world events, the NRC is assessing the need to revise regulations related to industrial radiography in order to further reduce the possibility of theft or diversion of radioactive materials for illicit uses. Although these requirements are still in the formulative stage, the presentation will summarize agency concerns and actions that should be considered by those who possess, use, and transport radioactive materials. Recent changes in regulations and directives will also be also discussed.
“Terrorism and the Radiological Threat”
Ultrasonic inspection has been established as one of the most effective manners for measuring and monitoring corrosion in tank and pipe walls. This acceptance has been the result of several advantages of ultrasonic inspection including the ability to measure wall thickness from one side, measurements can be taken at high temperatures and often while plant processes are ongoing, and there are no safety hazards inherent to ultrasonic inspection.
Since the 1980’s digital ultrasonic corrosion gages and flaw detectors have allowed unprecedented advances in the field of ultrasonic inspection. Digital advantages include improved stability, repeatability, precision, and storage capabilities compared to older analog instruments. These advances along with specialized software algorithms have allowed inspectors to successfully manage applications that were not possible before.
In this discussion I will cover some of the latest advancements in corrosion measurement. There are several new features available in corrosion thickness gages and flaw detectors that have advanced our capabilities in this field. These include new measurement algorithms, new display technology, and expanded portable B-Scan capability.
"Automated Florescent Penetrant Inspection (FPI) System is Triple A"
Pratt & Whitney
David H. Wehener
USAF – ASC/SMD
This paper describes how Fluorescent Penetrant Inspection (FPI) was used in the past, how it is used now and how it will be used in the future. The United States Air Force (USAF) and Pratt & Whitney (P&W) now use a fully-automated FPI process with manual visual inspection. With direction and funding provided by the USAF/Aeronautical System Center (ASC), these fully-automated FPI processors, located at Kelly Air Force Base in San Antonio, Texas were developed, manufactured, installed, qualified and put into operation by Pratt & Whitney. This paper will cover the following: the Qualification and Acceptance Tests, which include test objectives, test articles, test facility, test equipment, test results, and training.
This technology is affordable (lower processing cost resulting from increased throughput, reduced maintenance man-hours and reduced material consumption), adaptable (multiple industry applications, flexible layout accommodates simple, complex, large and small geometries), and accurate (improved reliability and detection capability through consistent processing). In addition, the FPI system is environmentally clean. P&W can design, manufacture, and install a customized FPI system for its customers. P&W is continually improving today’s technologies and techniques to assure global readiness for the 21st century.
Whether for national or local jurisdictional requirements or to monitor corrosion or quality, internal visual inspection of equipment is responsible for millions of dollars worth of downtime, cleanup, or emergency shutdowns. Exposure of personnel to vessel entry accounts for dozens of deaths or serious injuries each year in the petrochemical industry. Remote visual inspection (RVI) can help you meet code requirements while at the same time saving revenue associated with shutdown, cleanup and downtime. In addition, vessel entry exposure to personnel is greatly reduced or eliminated.
"High Temperature Ultrasonic Flaw Detection"
Mechanical Integrity, Inc.
Historically ultrasonic inspection has been limited to scanning materials, which are typically less than 4500F. The limitations of transducers, couplant and the scanning equipment cause this practical temperature limitation. This paper will explain the methods used to overcome these problems for flaw detection and sizing with compression and shear wave ultrasonic equipment. The equipment applies the transducers directly to the surface and the scanner operates directly on the surface adjacent to the transducers. Once the flaws are detected the operation of the equipment may be monitored by periodic inspection of the affected area or by the attachment of permanently mounted transducers over the flaw area. These transducers can then be accessed periodically to provide information on corrosion extension or flaw growth.