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Ultrasonic Corrosion Mapping

Ultrasonic Corrosion Mapping

Ultrasonic Corrosion Mapping

A non-destructive testing (NDT) method used to find corrosion on metallic structures and gauge its severity is called ultrasonic corrosion mapping (UCM). It is an effective method for determining the structural integrity of objects like pipelines, tanks, and vessels because it gives precise and thorough details regarding the location and extent of corrosion damage. Ultrasonic waves are used by UCM to scan the surface of the material being tested. A transducer, which is positioned on the material’s surface and emits a high-frequency sound wave, produces the waves.

Any flaws or rust on the surface reflect the sound wave back as it passes through the material. The transducer picks up the reflected waves and transforms them into a picture of the corrosion damage. The uniform, localized, and pitting corrosion damage can all be found using the UCM approach. Additionally, it can be used to find other kinds of flaws like voids, inclusions, and cracks.

The transducer, a pulser/receiver, a data collecting system, and software for data analysis and visualization are just a few of the parts that make up the UCM system. Ultrasonic waves are emitted by the transducer, which then picks up reflected waves. The electrical signals are delivered to the transducer via the pulser/receiver, which also collects the reflected signals. The pulser/receiver’s signals are gathered and processed by the data collecting system, and the software then analyzes the data to produce a visual representation of the corrosion damage. UCM can be carried out in two different ways, including pitch-catch and pulse-echo. In the pulse-echo mode, the transducer sends out a sound wave, which the corrosion or defect reflects back and the transducer picks up on.

Two transducers are employed in the pitch-catch mode, one to generate the sound wave and the other to pick up the reflected wave. For finding corrosion and flaws in hard-to-reach places, utilize this mode.

Compared to other corrosion detection methods including optical inspection, radiography, and magnetic particle inspection, UCM provides a number of advantages. Since the material being tested is not harmed, it is non-destructive. Additionally, it can find corrosion damage that is hidden by insulation or coatings, which is difficult or impossible to find using other methods. Additionally, UCM offers a thorough image of the corrosion damage, which can be used to evaluate the damage’s severity and organize the necessary repairs.

Need for UCM in Marine offshore inspection 

Since offshore structures like platforms, pipelines, and vessels are constantly exposed to harsh environmental conditions like saltwater, corrosion, and fatigue, it is crucial to ensure their safety and integrity in the marine offshore industry. Ultrasonic Corrosion Mapping (UCM), which can identify and assess the extent and seriousness of corrosion damage that may jeopardize the structural integrity of the offshore asset, is a useful method for assessing these structures. Pipelines, tanks, risers, and other offshore structures, as well as subsea machinery, can all be inspected using UCM.

It offers precise and thorough information about the corrosion damage, which can be used to evaluate the corrosion’s underlying cause and the best course of maintenance or repair. For instance, UCM can spot localized corrosion, which may call for repairing or replacing the afflicted components locally. Additionally, it can identify uniformly corroded areas that might need more extensive repair work or replacement. Additionally, corrosion damage under insulation, a problem that frequently affects the marine offshore industry, can be found using UCM. Corrosion beneath insulation (CUI) is a serious structural problem that can go unnoticed for a long time and result in expensive repairs and downtime. By scanning through the insulation and producing a thorough view of the corrosion damage, UCM can identify CUI. Additionally, UCM can be used to track the efficiency of corrosion prevention strategies like coatings and cathodic protection. It can spot regions of corrosion that might be developing beneath coatings or in places where cathodic protection is insufficient.


Efficiency and precision of Ultrasonic Corrosion Mapping

A highly effective and accurate way of examining metallic structures for corrosion damage is ultrasonic corrosion mapping (UCM). High-frequency sound waves are used by UCM to enter the material being examined and produce a picture of the internal structure. With the help of this method, it is possible to measure the metal’s thickness precisely as well as the position and severity of any corrosion damage. Because it doesn’t require extensive disassembly or shutdowns, UCM can quickly and accurately inspect large areas of metallic structures, like pipelines or storage tanks. UCM is also non-destructive, which means that it doesn’t hurt the object being examined, making it possible to evaluate crucial equipment without risk. Due to its non-destructive nature, UCM can be used to repeatedly inspect equipment, enabling ongoing monitoring and maintenance. Due to its ability to identify corrosion damage as small as a few millimeters, UCM is also incredibly accurate. Additionally, UCM can distinguish between various forms of corrosion damage, such as uniform, localized, or pitting corrosion, giving a clear picture of the harm.


Applications and benefits of Ultrasonic Corrosion Mapping

There are several uses for ultrasonic corrosion mapping (UCM) in a variety of industries, including manufacturing, petrochemical, aerospace, and oil and gas. The metallic structures’ integrity and safety can be jeopardized by corrosion damage, which can be found and assessed using UCM. Inspection of pipelines, tanks, pressure vessels, and subsea equipment are a few specialized applications of UCM. Additionally, corrosion under insulation and coatings, which is a frequent issue in numerous industries, can be found using this method.

Significant advantages of UCM include improved safety, decreased downtime, and cost savings. UCM can increase the life of equipment by spotting corrosion problems early on and preventing catastrophic breakdowns. Companies may save a lot of money on repair and replacement costs as a result. UCM is also non-destructive, which reduces downtime and production losses by inspecting vital equipment without inflicting any harm or necessitating shutdowns. Additionally, UCM offers precise and thorough details regarding the extent and location of corrosion damage, enabling timely and effective repairs that raise equipment reliability and safety.


Scope and significance of Ultrasonic Corrosion Mapping

Ultrasonic Corrosion Mapping (UCM) has a huge and encompassing scope and significance. In a number of industries, including oil & gas, petrochemicals, aerospace, and manufacturing, UCM is a useful tool. Its main objective is to identify and assess corrosion damage to metallic structures by giving precise and in-depth details regarding the extent and location of the corrosion. With the aid of this knowledge, corrosion’s underlying causes may be found, the best course of maintenance or repair can be chosen, and catastrophic failures can be avoided. There are several uses for UCM, including examining pipes, tanks, vessels, and other machinery. It is capable of identifying many kinds of corrosion damage, including uniform, localized, and pitting corrosion, as well as other kinds of flaws, including fractures, inclusions, and voids. Corrosion behind insulation and coatings, which can be challenging or impossible to detect with other techniques, can also be found using UCM. 

The importance of UCM is found in the fact that the material being examined is not harmed due to its non-destructive nature. Because of this, it is possible to inspect important machinery without spending money on time-consuming and expensive shutdowns. Additionally, UCM offers a thorough image of the corrosion damage that can be used to evaluate the damage’s severity and organize the necessary repairs. Additionally, UCM is a trustworthy and accurate inspection technique that can help avoid catastrophic failures and increase equipment longevity. Early corrosion damage detection allows for repairs to be undertaken before more extensive corrosion damage necessitates more expensive repairs or replacement.

Finally, Ultrasonic Corrosion Mapping is an effective NDT method for identifying and assessing the degree of corrosion damage on metallic structures. It is a useful instrument for determining the structural integrity of buildings and organizing necessary repairs because it is accurate, non-destructive, and gives thorough information on the extent and location of corrosion damage.  It offers a trustworthy and precise inspection technique that can identify and assess corrosion damage, helping to avert catastrophic failures and increase the lifespan of offshore infrastructure. It is a useful instrument for guaranteeing the safety and integrity of equipment and averting catastrophic failures due to its capacity to identify and analyze corrosion damage precisely and non-destructively.


Why NDT and PHWT solutions

The industry leader in non-destructive testing (NDT) and plant health and wellness tracking (PHWT) systems is NDT and PHWT systems. The business provides clients in a variety of industries with a range of services, including Ultrasonic Corrosion Mapping (UCM), thanks to a staff of highly qualified employees. The business has a history of providing its customers with top-notch UCM services. To achieve precise and trustworthy inspections, NDT and PHWT Solutions uses the most recent tools and technology. The company’s staff of professionals is skilled and knowledgeable in UCM methods, and they are able to produce thorough and accurate reports on the scope and location of any corrosion damage.

Safety and dependability are crucial in the industries that NDT and PHWT Solutions supports. In order to ensure that all inspections are carried out to the highest standards, the company employs a strict approach to quality control. To safeguard the safety of its workers and customers, the business also complies with all applicable safety standards and recommendations. The UCM services offered by the organization are also quite effective. Without extensive disassembly or shutdowns, NDT and PHWT Solutions can swiftly and accurately test broad sections of equipment.

Client downtime and production losses are reduced, which increases the cost-effectiveness of the inspection process. NDT and PHWT Solutions provides a variety of other NDT and PHWT solutions, including thermography, magnetic particle inspection, and radiographic testing, in addition to its UCM services. These services assist customers in preserving the integrity and safety of their equipment, averting catastrophic breakdowns, and boosting productivity.

In general, NDT and PHWT Solutions is a trustworthy and dependable supplier of UCM services. The organization is a beneficial partner for clients in a variety of industries thanks to its dedication to quality, safety, and efficiency. NDT and PHWT Solutions is well-positioned to provide clients with high-quality UCM services, assuring the safety and dependability of their equipment thanks to its team of professionals and cutting-edge equipment.


We provide Inspection Services to the Oil, Gas, Petroleum, Energy, Marine, Offshore and Fertilizer industries with primary focus in the field of NDT.