When it comes to building a business, are you “Gung Ho?”

By John Taylor


Here are two great phases that have an important meaning to me. The first is Gung Ho. Now that is Chinese and it means working together. It’s also a mantra of the Drill Instructors at Parris Island South Carolina. Legend has it that the US Marines borrowed this word from the peasants who worked in the Chinese Cooperatives during the 1930’s. Major Evans Carlson of Carlson’s Raiders fame was trying to build up the same sort of working spirit that he had seen in China where all the soldiers dedicated themselves to one idea and worked together to put that idea over. He told his men about it again and again. He told them of the motto of the Chinese Cooperatives, Gung Ho. It means Work Together-Work in Harmony. As a former Marine I have always felt this motto should be incorporated within every company no matter their products or services. If it works for the Corps it should work for just about any other endeavor. So to all the Marines out their past, present and future I wish you a Happy 237^th Birthday on November 10^th 2012.

Now to the second word which is companion. It comes from two Latin words com and panis meaning “with bread”. So a companion is a person with whom you have broken bread. Here at Nova Data testing we have all shared bread together. We certainly eat lunch at the same time when we are out of town on a shut down inspection. Many times due to the time constraints of leaving the site we will get sandwiches, burgers or a pizza delivered to our work area. And in the evenings when we are out of town it isn’t unusual for us to all have dinner together as well. In fact we also try to have a behind the shop cookout once or twice a month when we all are in town.

Team Nova Data

Sinoch Pum (Left), Darrell Henderson (center), Sina Tith (Right)

Kyle Stevenson (ndt chef of the year)

So what’s the link between Gung Ho and companions? Well it’s whatever your organization wants it to be. Here at Nova Data we put a lot of emphasis on our team. When a company works in harmony things get done quickly, efficiently and without the constant problem with organizational communication. Sure Nova Data has challenges to overcome. Everyday issues regarding reports, manning jobs, equipment repairs and just plain old technology glitches. By working in harmony the team overcomes the daily problems and looks toward their shared goals. Those goals become more defined when instead of just a co-worker you are dealing with your companion, someone with whom you have broken bread. We all have our family life, our social life and our working life. Each one is a journey that we take with others and the harmony we have with our fellow travelers, our companions, makes for either a pleasant trip or a tough road to travel. Everyone at Nova Data Testing works hard to make our journey less stressful, more enjoyable and totally effective for our customers and our team. We are and we will remain Gung Ho.



John Taylor is president of Nova Data Testing, a prominent non-destructive testing contractor.  Visit his site at http://ultrasonictestingndt.com/

Better use of your Gazintas and Gazoutas will save you money.

By John Taylor

First I want to thank Chip Rennie with Emerson Global for his new words but since he hasn’t registered them as a trademark I will borrow. Let’s define them. “Gazintas” means what goes in and “Gazoutas” just means what goes out. Now Chip uses these terms when he is discussing his company’s product. Emerson Controls sells devices that monitor energy use and consumption for industry. In fact 30% of the cost of production is directly tied to energy costs. Businesses know that they can’t easily control the cost of raw materials or labor costs. However by measuring what goes into making their energy and how much power comes out, they are able to control as much as 30% of their costs. That is you want your gazintas to equal your gazoutas.

So why aren’t we as energy consumers doing that?  Do you know what your monthly cost of energy really is?  While everyone is painfully aware of gasoline prices, do we control our driving in order to maximize the output of our engines? Well that goes for electricity costs as well.  How much is a kilowatt hour in the area where we live? Do we adjust the climate in our home and or is the thermostat always on max? Have you ever calculated what it costs you if you keep your exterior illumination going all night long?

Just as industry takes a realistic look at the energy consumed in plants and factories so should Americans who work there or buy their products look at the large amounts of energy that we waste as consumers. Look, business has maintenance personnel, engineers, analysts and vendors to help with this problem. And business knows it can save lots of money if it invests a little time and energy in this type of project. We own energy consuming items just like big businesses. We all have a car or a house or something that drains the money from our wallet. Why not be proactive and see if it’s not possible to save 10, 20 or even 30% of our income by reducing our energy costs. Because one fact is a certainty; the prices of fuel, gas and electricity will continue to rise.

Here are some simple steps to take. First you will need to get everyone in your family to become involved in this project. Come up with a set temperature that everyone in the household can agree on and then leave the thermostat alone. Better yet install an inexpensive automated thermostat that can adjust for day or night or when the family is not home.  Be sure to close your doors and windows when the A/C or heat is on. Those units are a big draw on your electric bill.

Watch your electric meter as a family. Let everyone see what it takes to slow down that revolving cash wheel. Provide incentives for achieving positive results, such as a pizza party or a trip to the movies.  Make sure everyone knows that every dollar saved on energy can be spent elsewhere. There are hundreds of simple things that we all know can reduce our energy consumption. Tire pressure, conservative driving, food preparation, water consumption, the list goes on and on. But consider the phase that Chip used, the gazintas need to equal the gazoutas. If you want to control what’s going out (your hard earned cash) then control what’s coming in (expensive energy). 

John Taylor is president of Nova Data Testing, whose main business is insuring that the power generation facilities we all need are safe and efficient through nondestructive testing and inspection. Visit his website at http://novadatatesting.com

Ultrasonic Testing NDT - When is it time to hang up your spurs?

By John Taylor

Since I have been trying to blog on a weekly basis the biggest problem has been coming up with the theme. While I think I have a great idea others might think it a bit dated or even nostalgic. And we all know these blogs need to be relevant, up to date and progressive. Here in lies the problem. The other day I was watching the news on NBC and along comes a promotion for Saturday Night Live. Now I used to watch the show before my bedtime was pushed back to 10:00 P.M., but I have not seen it in while. But when the commercial announced the guest host and the musical act I had not heard of either of them. So much for staying current.

But maybe blogging is just part of the challenge to stay hip, upbeat and in the social loop. This stimulated another discussion in my mind. When should an active upbeat and relevant boomer think about hanging it up? Here are my top ten reasons that it might be time to retire:

10.  They’re playing Amazing Grace and you are the only one lying down.

  9.  The nursing home has unplugged your scanner, computer and your respirator 

  8.  You need to take a week long vacation just to visit the doctor.

  7.  Your company car is a motorized wheel chair.

  6.  The only sales people who call on you represent mortuaries.

  5.  You have 2 gold watches.

  4.    Your secretary doubles as an intensive care nurse.

  3.  You are showing your great great grandchildren your office.

  2.  The new employee’s job has something to do with diapers.

      And the number one reason you need to retire.

1.      Your postponed Social Security payments exceed the entire value of the fund.

Since none of these reasons are on the horizon yet I will continue to think of more blogs and relevant topics. The most relevant I can think of is within my own Nondestructive Testing Industry. One of the most important aspects of any person’s career is to constantly study and train in their own profession. 

One of the best resources for continuing education as well as developing professional contacts is the association or society that is most identified with your industry. For the Nondestructive Testing field that is the American Society for Nondestructive Testing. This organization has a monthly magazine, continuing training and certification programs and local, national and international conferences. The organization was founded in 1941 and it has over 12,000 members worldwide.

No matter what field of endeavor an individual may be in, these organizations can help foster a real professional culture that allows its membership to stay relevant in a changing world of technology and globalization. Whether it be a blog or a training class or just a discussion with another worker the opportunity for success stays with the person who will invest the time and study in developing his or her own skill sets.

John Taylor is president of Nova Data Testing, a leading Ultrasonic Testing NDT firm.  For more information, go to http://ultrasonictestingndt.com/

Getting There First With the Most

By John Taylor

"I got there first with the most" was General Nathan Bedford Forrest's contribution to the doctrine of mobile warfare. Now Forrest was a notorious and controversial figure even for the 1860's and this blog is not about him, but about this one tactical idea that made him successful on the battlefield.

Modern business is not the bloody conflict that was the American Civil War.  It is however very competitive and strategies and tactics for success are taken from many different aspects of life. So let's take a closer look at old General Forrest's notion to be there first with the most. If you were to name just a few of the businesses that are major winners in the world of commerce all of them have this one characteristic in their business plan.

How about Henry Ford? He certainly was the first when it came to producing motorcars for the masses. What about Motown Records and Berry Gordy Jr.? Most folks can't even name all of his top groups, but he practically owned the music of the 60's. A more contemporary list would include touchstones such as Google and Face Book along with maybe the company that makes those funny shoes called Crocs.

But the real question that is of foremost importance to small business owners and customers alike is “How do I do that?”  What tactic can I use to be the first with the most? For a business owner the unique selling point is paramount to this strategy. Find out what product or service in your inventory makes you different and unique from all of the competition. Once you have that point identified work on it and hone it to a fine edge. Make sure that your customers also know what the unique selling point is for your company. Use it in all your marketing and correspondence. Drive it home to all people who are interested in your business product. Make sure they realize that you alone will be able to deliver it first and with the most reliable and progressive product that is available.

Now if you are the customer don't you also want to be the first one to have this fantastic product or service? Customers will search through volumes of information to know that they are getting the most value, the most innovation and the most reliable product available. Customers want to be the first to try and the first to buy.  If you don’t believe me, wait until the new IPad 5 hits the shelves.

Getting there first with the most is no easy no matter what product or service you are trying to provide. The competition always strives to beat you to the punch. But with solid commitment and a little bit of creativity any small business can get there first with the most.

John Taylor strives the get there first with the most when it comes to inspecting industrial sites and tanks.  His company, Nova Data Testing is a leader in Ultrasonic Testing NDT.  Visit his site for a fascinating look at this industry.  http://www.ultrasonictestingndt.com

Ultrasonic Testing NDT – Plan the Work & Work the Plan

By John Taylor

What can a backpacking trip in the wilderness and an ultrasonic boiler survey inspection possibly have in common? Well two important things, one is planning and the other is execution.

Let’s just get a little background on both of these endeavors. Backpacking into the wild is not just an afternoon walk in the woods. You take “everything” you need to survive for a week or maybe more into an environment where there are no Wal-Mart’s, Holiday Inns, cell phones or highway signs. There aren’t even many people.

Now a boiler survey requires you to take “everything” you need as well, since Home Depot doesn’t carry any of the equipment and supplies required for these inspections. And like the outdoors, you can’t just go back to the office and retrieve what you forgot since you are miles away from base.

With backpacking you need a route and a map. With a boiler inspection you need a scope of work and a sketch of the boiler. Here is a quick summary of the types of questions that need to be answered before you can begin either one of these adventures.

1.        What is our general plan, what do we want to accomplish?

2.        How much time do we have to complete the plan?

3.        How much are we going to spend?

4.        What is the environment going to be like?

5.        What equipment do we need?

6.        Who is going with us?

7.        What is the condition of our equipment?

8.        How much training do we have in using the equipment?

9.        How do we get there and back?

10.      What emergency plans are in place?

Now let’s apply those ten basic questions to a wilderness trip. We have a weeklong trip in mind in a location where we have not hiked before. This location should afford us some spectacular vistas, great fishing and a good loop route that doesn’t require any backtracking of our trail. It can fall within our budget depending on whether we can fly or drive to the location.  If flying, we can either rent a car or use public transportation.

Let’s make our environment mountain terrain between 4,500 and 6,000 feet toward the end of summer. That makes packing our equipment an easy option.  With a little research we can predict the weather conditions, the insects and the fishing conditions. Now we can load our packs with the right clothing, sleeping gear, tent and supplies. Most trips are 2 to 3 people. Anymore and you are defeating the purpose of a true wilderness experience. By yourself you tempt fate if lost or injured. Let’s decide on you and a friend. You share preparations, food choices and equal out the loads for both food and equipment.

Better make sure the stuff you stored in the attic has not dry rotted or been chewed by critters. Can you be sure that new tent or cook stove has all the kinks worked out and you don’t hesitate to use them?  And you will need a start and stop point that is accessible to the trail head. You also might want a schedule of any shuttle services that may be available. Be sure those emergency plans are in place. The park service likes to get a detailed route and an estimated return time for you. Pack a complete first aid kit and be sure to have enough rope to hang a bear bag if you are in their territory.

So what about that boiler inspection? Well you need a complete scope of work detailing the amount of inspection points. The customer will have a spreadsheet for a time line to follow on the shutdown schedule. It might be 1 or 2 days or broken down into so many 12 hour shifts. And of course the whole job was awarded on how much money the customer has to spend on the inspection.

The environment of the job location is important as well. There are many hazards at industrial facilities and each plant has its own rules and procedures to follow regarding the contractors who work on-site. There is the analysis of how many technicians will be needed for the project. Just like a backpacking trip there is that perfect blend of enough but not too many participants. Remember each person must be supplied and costs must be accounted for in the job scope.

Check all the equipment before use. Sometimes machines and supplies will sit on a shelf or get put back without being marked for repairs. Double check it all. You don’t want to go hungry the last two days in the wilderness and you don’t want to tell your customer that you can’t get the inspection completed because you ran out of a vital supply item. Of course everyone on the job knows all about the testing equipment and can use it without hesitation.

There are plenty of logistic pitfalls when planning an inspection. Trip routes, driving delays, airline hassles, motel reservations and vehicle breakdowns are just a few of the dilemmas that can occur. And what happens when one job extends over into the start time of the next inspection. It’s like getting a late start on a cold rainy morning when your sleeping bag won’t let you go.

And of course there are the emergencies. Some are the same like the occasional cut or bruise that may require a band aid or some other small fix. Others are more serious and the importance of prevention rather than reaction is paramount.

One other thing, on the job site you must also be alert for bears. While not the four-legged variety, your customer can turn into one pretty quickly if you are not following his or her directions. That maintenance supervisor or reliability engineer has a real nose for finding mistakes and incomplete inspection details. Just like in the wilderness plan the work and work the plan.

John Taylor is president of Nova Data Testing, an authority in Ultrasonic Testing NDT inspections.  Visit his website at http://ultrasonictestingndt.com/

Ten Commandments of the Road Warrior

Ultrasonic Testing NDT: Eating Healthy on the Road

(Or, why my pants still fit after all these years.)

By John Taylor

Being in the non-destructive testing business means that I spend a good deal of time on the road.  Now you would think with all the climbing in and around all manner of storage tanks and the like that this would burn off any given amount of calories that I cared to ingest on the job.  The problem is that when a job takes me out of town, this means that I could wind up falling into the great American conundrum of eating in restaurants and out of vending machines.  So to avoid adding needless padding to my frame, I have come up with a list of do’s and don’ts that I have come to refer to as the Ten Commandments of Road Warriors.

1. Thou shall avoid alcohol at all cost

2. Snack on fruits, nuts and raw vegetables instead of junk food

3. Frequent supermarkets instead of restaurants

4. Pack it in, pack it out

5. Remember the salad and keep it handy

6. Take the stairs and avoid the elevator

7. Read

8. Stay hydrated

9. Get a good night’s sleep

10. Try to schedule some relaxation time every day.

Let’s just discuss these options one at a time. First on the list is alcohol of course. It’s one of the benefits of an expense account. But alcohol is high in calories and it can be an appetite booster for many people. Mixed drinks, beer and wine are pretty empty nutritionally and can make the next morning a little more trying.

Speaking about nutrition, this brings up the next commandment: Fruits, nuts and vegetables. Have you ever seen an unhealthy gorilla? These foods are high in vitamins and minerals, easy to carry and come in a great variety of flavors, colors and textures. And preparation is just a crunch away.

This brings us to no on the restaurants and yes to the supermarkets. Particularly because you can’t buy apples and grapes at The Olive Garden (they do have salad but it comes with a deadly portion of bread sticks), you need to create your own.   Luckily, all supermarkets have prewashed, prepackaged salads that are ready to eat.  Just add the low-cal dressing.  They also have containers of precut carrot and celery sticks.

Buy a lunch box. Not a Little Mermaid or Angry Birds but a cheap $10.00 insulated fabric job. You put ice in the freezer bags you bought at the grocery store and fill the box with canned fruit, juice, a tuna sandwich or anything else you like. Use a little imagination and try different foods for a change.

Grazing is the best part. No time wasted at a fast food stop or waiting in traffic. Put your hand in your lunch box and pull out a surprise and munch it right down. You have 55 minutes that now belong to you.

Take the stairs, walk, run, strut, hop, skip, MOVE. If your hotel has an exercise room, use it. If not, try anything that keeps you from sitting around thinking about breaking commandment number 1.

Reading takes your mind off food unless you are reading a recipe book which is not recommended.  Since reading keeps your hands occupied you can’t use then to put junk food in your mouth, or break commandment number 1.

Don’t let your destination lead you to dehydration. Most of us do not drink enough water and this is especially true when we are out of town. Sometimes it is just not handy or it can be hard to keep beverages cold if you buy them by the bottle. This is another good reason to invest in that little lunch box. But a good way to remember to drink plenty of water is to stop drinking everything else. And did you know water has zero calories. Isn’t that cool?

Get plenty of sleep just like your mother said when she used to tuck you in at night. It takes some training to sleep in a room that’s totally alien from your own home. You can always bring a small item that reminds you of your own sleep chamber. A pillow, bathrobe or slippers, maybe even a teddy bear.  Anything that will add a touch of the familiar to an otherwise alien landscape is sure to reduce stress.

Finally learn to relax while you are on the road. Time will melt by if you concentrate on your assignment and focus on your goals. Give yourself permission to spend some quality time every day, even if it’s only thirty minutes spent reading a novel or magazine. With the right nutrition, hydration and rest those road trips will not lead to that other great American conundrum: the crash diet.

John Taylor is president of Nova Data Testing, a leading Ultrasonic Testing NDT firm.  For more information and helpful videos, visit his website at http://ultrasonictestingndt.com/

Lighting a Fire Under Management is Cheaper Than Putting One Out

By John Taylor

Last week I wrote about the need to take care of the little preventive maintenance items before they turn into big problems. Apparently this message did not get to the management people at Chevron. Here is a brief excerpt from the San Francisco Chronicle from Monday August 6^th.

                                              Chevron Refinery, Richmond, C.A.

Thousands of East Bay residents were ordered to stay in their homes with the windows and doors closed Monday night after a series of explosions and fires tore through Chevron's Richmond California refinery.  The explosions started about 6:15 p.m., and at least two large fires spewed thick, black smoke into the darkening sky.

The fire started at the refinery's No. 4 Crude Unit, Chevron officials said. Just before 6:30 p.m., an inspection crew discovered that there was a diesel leak in a line in the unit - and that the leak was growing.  Shortly after the crew evacuated the area, the diesel ignited, said the manager of the refinery.

All employees had been accounted for and there were no fatalities, but one refinery worker suffered burns to his wrist and was treated at the on-site clinic.   About five minutes after the explosions, sirens tore through the air, alerting residents to stay indoors to prevent breathing tainted air. Some people got in their cars and drove away from the smoke that spread throughout the neighborhoods east of the refinery.

The Chevron Richmond refinery was founded more than a century ago and is Northern California's largest, capable of processing more than 242,000 barrels of oil each day. A prolonged closure could push up gasoline prices, which are already rising nationwide because of a rally in the market for crude oil.

The refinery has suffered fires before. In January of 2007, the seal on a pump in a crude unit failed, triggering a fire that lasted almost 10 hours.

Make no mistake that this kind of incident is a preventable failure. Chevron was fortunate to have dedicated fire and emergency personnel to contain this incident. 

As inspectors we hate to say “I told you so”, but facts are facts. Leaks just don’t happen. They are caused by a variety of conditions which can and should be monitored by experienced personnel. The questions that come to mind are:

1. What types of corrosion mechanisms are present?       

2. How often are nondestructive inspections conducted?

3. What systems are in place to report findings?

5. Who reviews these results?

6. What follow up is conducted if repairs or replacement is warranted?

Chevron needs to determine the factors that were responsible for this loss of containment as well as what inspection criteria needs to be changed to prevent any future occurrence. If companies would use basic investigation tools and learn to ask the right questions these catastrophic failures can be avoided or at the very least minimized.  It doesn’t take a seasoned professional to realize that lighting a fire under management is far cheaper than putting one out.

John Taylor is president of Nova Data Testing, a leading non-destructive testing company.  For all your ultrasonic testing needs, go to, http://ultrasonictestingndt.com

Nova Data Testing: An ounce of prevention can save a ton of money

Wikipedia defines preventative maintenance as:

1.    The care and servicing by personnel for the purpose of maintaining equipment and facilities in satisfactory operating condition by providing for systematic inspection, detection, and correction of incipient failures either before they occur or before they develop into major defects.

2.    Preventive maintenance can be described as maintenance of equipment or systems before fault occurs. It can be divided into two subgroups:

§  planned maintenance and

§  condition-based maintenance.

Here is a true story :

My name is Darrell Henderson and I am a technician and field inspector for Nova Data Testing. As of last week I am without a car. The other day I was driving my car from my home in Jacksonville, FL to my sister’s house in Kingsland, GA. I knew that my car needed an oil change soon and that my car also leaked oil, but I kept putting it off although I was warned of what could happen. I was told more than once, “Make sure your oil level is good and check it frequently, especially if you know the car has a small leak”.  Well I didn’t listen even after the oil light flickered on and off, on and off and I continued to ignore the warning signs.

One day after working out at the gym, I was on my way to my sister’s house in Kingsland. I felt good after the workout and proud of myself for taking the time to take care of my health.  As luck would have it I heard a loud rumbling sound from the engine compartment. Of course the car had waited for me to get on I-95 before reacting to its lack of lubrication. Maybe the timing was bad and it knew I had chosen gym time over oil checking time. When I pulled over to check out the problem guess what? No oil. This meant that I had probably been running nearly dry for a week or more. What could I do but place a call to the other Techs at Nova Data for a rescue. They showed up, gave me some oil which the car quickly sucked it all down. Unfortunately  it was too late and the damage was done. When I tried to start my car up all I got was a loud pop and some blue smoke. Now I’m paying the price for this error in more ways than one. Not only do I not have a car. For neglecting a $30.00 oil change I am now going to be out $2,000.00 for a new engine.

Oil change that suppose to happen.

Instead this happen "Blown motor"

What is the purpose of this sad but true tale?  Since I am an inspector it is an embarrassing story, although one that I felt needed to be shared. Nova Data Testing inspects all types of industrial equipment for many customers. However there are many who never bother to check their operating systems like piping, storage tanks and power boilers. If they do inspect equipment it might just be a quick check rather than a complete inspection. While most cars have only one owner to look after an oil change, industrial facilities have plenty of maintenance personnel and engineering support to track and document inspections. These plants also have the money and the time to develop precise and focused equipment testing. A blown engine might cost a few thousand dollars to repair but a ruptured boiler or storage tank can be in the millions. Remember that we all need to react to that flashing light on the dashboard.

The moral of the story:

Preventive maintenance is probably one of the biggest problems for failures.  Inspecting and maintaining a regular schedule on your equipment or facilities will keep costs down dramatically.  We have seen power boilers shut down due to pressure tubes exploding and bursting or tanks that had corrosion that led to leaks.  These can be prevented if the tank is inspected by a trained and certified technician.  Darrell was told plenty of times to check his oil and he just put it off one time too many.  Even though he was always concerned with the situation, he kept on pushing his car because he thought it could take another week or two without an oil change. A $30.00 oil change turned into a $2,000. 00 engine repair.  Just like a Full API-653 out of service inspection on a tank can range from $5,000.00-$10,000.00, a tank failure can cost up to $100,000.00 in repairs, inspections fee, fines from OSHA, and lost time.  That’s why it pays to do preventive maintenance on your equipment and facilities.

Nova Data Testing is a leader in Non-Destructive Testing.  To find out more about NDT Testing or to schedule an inspection, go to http://novadatatesting.com

Magnetic Flux Inspection: The Bottom of a tank floor tell you a lot with an MFL scanner.

by John Taylor

When it comes to insuring the safety of any storage tank, no news is not necessarily good news.  The problem with storage tanks is that even when everything looks good on the outside, inside the tank can be a ticking time bomb, where an unseen defect or spot of corrosion can lead to a catastrophic and costly failure.  That's why magnetic flux testing leakage (MFL) testing is vital to the continued longevity of storage tanks across the nation.

Most out of service inspections use magnetic flux leakage (MFL) as a great detector for locating underside floor corrosion. This is often referred to as soil side corrosion caused by the contact of the steel floor with the moisture and chemical make up of the soils underneath the tank. MFL however cannot give an accurate assessment of the remaining wall thickness due to some of the limitations imposed by the inspection environment. The only reliable and accurate quantitative assessment must be obtained by using ultrasonic thickness techniques. These techniques include appropriate operator training and not just the ability to take digital thickness measurements.

This discussion concerns the added requirements for the training and testing of NDT personnel who inspect storage tank floors during an API 653 out of service inspection. The America Petroleum Institute added Appendix G to the 653 code in 2003 to describe the precise requirements for this training and testing. It describes the number of training hours, the types of test questions and even details the construction of a tank floor mock-up with manufactured defects.

Magnetic Flux Inspection Picture 1: MFL (Magnetic Flux Leakage) Scanner.  Model: MFE 2412 MK2

It is essential that a quality A-scan be used to assess any corrosion detected. This equipment must be capable of determining location, size and the accurate measurement of remaining floor thickness. A 5 Megahertz dual crystal focused contact transducer of either .375" or .500" in diameter should be used. Either water or a gel type couplant should be used. It is essential that the amplitude of the signal from the corroded back wall must be raised to at least the same screen height as the calibration reflector. While it is true that a reflector from a straight back wall will give a clean signal the same is not true for a corroded surface. Since there is an irregular profile the energy being reflected back will be wider at the base and have much lower amplitude. In this case the operator's experience in adjusting the ultrasonic equipment is essential. This is the reason that code book now requires the advanced training for ultrasonic prove-up operators.

Here is a summary of the requirements now in place for API 653 tank bottom examiners.

1. A written procedure that address the essential and non-essential variables for a tank bottom inspection.

2. A record of the qualification test for a specific scanning operator.

3. A record of the qualification test for a tank bottom procedure.

4. Each scanning operator shall receive 40 hours of training. The training will include NDT principles and scanning equipment operation and calibration.

5. Specific dimensions of the tank bottom sample (70 square feet) and a minimum number and size of pits to be located during the operator testing.

Magnetic Flux Inspection Picture 2: Tank floor that been scanned and mark. Ready to be A-Scan

Recently we did a tank inspection at na air force base using MFL equipment.  The task, while routine involved the inspection of a tank contining JP-8 (Jet fuel). Everything looked good on the outside and on the inside.  Visually the tank would pass muster, sporting good plate weld lines, no obvious signs of corrosion, even a fresh coat of paint.  After our visual inspection, we took some thickness readings around the corner of the plates and in the middle in order to get an average.   Now the funs begins with the MFE.  As soon as I started to scan the surface of the plate I noticed that the MFE scanner’s screen was lighting up like a Christmas tree.  Usually we do a cross scan of the area so we can narrow down the area so it’s more accurate.  Once any defective area is found and marked, a technician will do an A-scan so we can get the lowest thickness reading of the area and note it in our report. Surprisingly all the areas that I inspected had a reading lower than the average. This meant that the tank was far from safe to refill with JP-8.  All I could say to myself as I climbed back out of the tank was, "Never judge a tank by its cover."

John Taylor is president of Nova Data Testing, a leading Magnetic Flux Inspection contractor.  For all your magnetic flux inspection needs go to http://magneticfluxinspection.com/

Ultrasonic Testing NDT - Risk Based Inspections

Ultrasonic Testing NDT - Risk Based Inspections 

  

By John Taylor 

Recently I had the opportunity to attend a three day class given by Equity Engineering Group on the American Petroleum Institute's Recommended Practice for Risk Based Inspections (API 580 & 581).

It was a great class held in a little Louisiana town known for great music and great food. While the petro-chemical industry is a major user of this inspection approach, it can be utilized in the pulp and paper, power generation and terminal storage industries as well as many others.

Since API 580/581 is based on risk based inspections the question is: how do you define risk? Quite simply it is the probability of failure multiplied by the consequences of failure. This analysis of risk is not only a common definition which relates to all of us and at any age but one that we use when making daily decisions. Do we sky-dive or play pool? It all depends on how well prepared we are to jump out of an airplane or what the environment is like at the bar where we shoot pool. The more you think about those choices the more information is needed to decide on the proper course of action. So the key to any good risk based program is information.

That was the great thing about the Equity Engineering's course. It led you through the initial steps to develop a program that would be appropriate for the facility and the types of equipment that was being utilized there.

There are two references that RBI uses. The first is API 580 which gives the minimum requirements and the basic elements for implementing an RBI program. It also details what makes up a good RBI team and many of the problems that the team can encounter while assembling information. API 581 is the procedure that gives the details and formulas for assessing the condition and inspection frequencies. It assigns the probability of failure and consequence in a logical mathematical sequence.

Insert Ultrasonic Testing NDT Video here. http://www.youtube.com/watch?v=YPZ2ulbn6Lo

Top ten lessons learned about RBI:

1. The mechanism for corrosion and deterioration must be known before an adequate RBI program can be started. It is important that a capable corrosion specialist be a member of the team.

 2. Inspections must be designed to reduce uncertainty. Without certainty probability becomes too elusive to measure. Inspections alone do not reduce risk.

 3. Everyone involved must understand and appreciate the measuring systems that are designed to reflect both the area risk and the financial risk associated with equipment failure.

4. In any RBI study, consistency is more important than accuracy.

5. The RBI program must follow a defined working process that will assure both consistency and reproducibility.

6. Always match the inspection technique with the damage mechanisms that are associated with the equipment type and process. Otherwise you may not find any defects.

7. While the probability of failure changes over time, the consequences of failure are not controlled by time.

8. Since risk is dynamic it is vital that the RBI process chosen can be updated easily when new information is discovered.

9. The consequence and risk results for atmospheric storage tanks are in financial terms alone. The consequences considered are from component damage, product loss or environmental penalties.

10. RBI can only define an acceptable level of risk to the owner-user. A Risk Based Inspection program is a blend of solid communication, quality information and good judgment. And good judgment comes from experience and experience as we all know comes from bad judgment.

Just as in any of life’s adventures, mitigating risk is all about understanding how to assess and manage the probability of failure. 

John Taylor is President of Nova Data Testing a leading Ultrasonic Testing NDT specialist.  For all your testing needs, go to http://ultrasonictestingndt.com/

    

Nondestructive Testing – What I Did on my Summer Vacation

Most people are unfamiliar with the world of nondestructive testing.  In fact, more people have heard of Quantum Physics and String Theory then have heard of the science of NDT. Like these other fields of scientific inquiry, once introduced to NDT, most folks immediately want to know more. Unlike theoretical physics, which is something that few people come into contact with on an everyday basis, the practice of NDT is one of the little known processes that keep our technological world spinning day in and day out.

Having just returned from a service trip to the North Rim of the Grand Canyon while working with the US Park Service, I met a number of other volunteers from all over the country. There was a doctor, two lawyers, a librarian, some teachers and even a retired park ranger. But of the twenty or so people who took part in the project, only one had any experience at all with NDT.

As is customary with groups like these, it wasn’t long before we started to introduce ourselves and what we did for a living.  When I told the group that I was an NDT professional, they all looked at me as though I had just admitted to being an alien from another planet.  Once I showed them some photos of the equipment used in my line of work, they were convinced of it.

 http://youtu.be/YPZ2ulbn6Lo 

Whether you realize it or not, NDT professionals are an integral part of the US work force. They are involved with all types of industries and are a necessary requirement for industrial safety and reliability. The reasons that bridges don’t fall and pipelines and storage tanks fail to burst is due to legions of nameless testing professionals who are responsible for inspecting the nation’s infrastructure.  The other big beneficiary of this kind of work is the environment.

NDT helps to prevent accidental releases and spills of all sorts of nasty products and chemicals into our soil and water sources of this country.  Maybe that’s why when talking about NDT to a group of volunteers for the Park Service they seemed so interested in the techniques and procedures surrounding nondestructive testing.

While there were many occupations represented by the group, the person most familiar with NDT was a retired park ranger. A few years back, some underground gas lines had been discovered on a parcel of land the park service was looking to acquire. As part of the land deal, the gas company that owned the pipeline was required to inspect the line.   The park ranger I met on my trip had been assigned the task of insuring the inspection was completed. After hearing what I did for a living, she questioned me at length on the various types of NDT inspections that I performed.  

I took the time to give her some technical insights about the inspection requirements for different types of above and below ground piping.   But all I kept worrying about was that