Ultrasonic testing service

Ultrasonic Testing Service – Accredited Flaw Detection and Thickness Measurement for Metals, Welds, and Composites

For Bangladeshi importers, fabrication contractors, power plant operators, and quality assurance teams, the integrity of critical components – pressure vessels, pipelines, structural steel, and rotating machinery – depends on reliable non‑destructive evaluation. Our ISO/IEC 17025 accredited laboratory offers a comprehensive ultrasonic testing service that combines advanced pulse‑echo, phased array, and time‑of‑flight diffraction techniques to detect internal flaws, measure remaining wall thickness, and characterise material properties. With decades of experience in non‑destructive testing (NDT) across the oil & gas, power generation, marine, and infrastructure sectors, we help you ensure safety, extend asset life, and comply with the rigorous requirements of the Bangladesh Standards and Testing Institution (BSTI), the Department of Explosives, and international project codes.

Product Samples We Regularly Test

We accept a wide range of components and raw materials, from small precision parts to large welded fabrications. Our portable and automated ultrasonic systems accommodate flat, curved, and complex geometries. Common samples include:

• Welded joints and butt welds – on pipelines, pressure vessels, storage tanks, and structural beams.
• Steel plates, bars, and forgings – for shipbuilding, bridge construction, and heavy machinery.
• Pipe and tube stock – seamless and welded, in carbon steel, stainless steel, and non‑ferrous alloys.
• Castings and forgings – valve bodies, pump casings, turbine blades, and gear blanks.
• Boiler tubes and heat exchanger tubing – for power plants and chemical process equipment.
• Composite and fibre‑reinforced components – used in aerospace, automotive, and renewable energy.
• Railway axles and wheels – for rolling stock maintenance and manufacturing.
• Subsea and marine components – risers, mooring chains, and thruster shafts.

Ultrasonic Thickness Measurement for Corrosion Monitoring

Wall thickness reduction due to corrosion or erosion is a major concern in aged plant and infrastructure. Our ultrasonic testing service provides accurate thickness data using both single‑element and dual‑element transducers, with the ability to measure through coatings without removal:

• Digital thickness gauging (ASTM E797, ISO 16831) – We use precision ultrasonic thickness gauges with A‑scan display to measure remaining wall thickness on pipes, plates, and vessel shells. Measurements are taken at multiple grid points and reported as minimum, average, and maximum values, with statistical analysis to identify localised thinning.
• Corrosion mapping with automated scanners (ASTM E1816, ISO 16831) – For large areas such as tank floors and ship hulls, we employ robotic or manual scanning systems that record thickness at thousands of points, generating colour‑contour maps that highlight corrosion zones and guide repair decisions.
• High‑temperature thickness gauging (up to 400°C – ASTM E797, custom probe) – Using specialised high‑temperature transducers and couplants, we measure wall thickness of in‑service piping and headers without shutdown, enabling on‑stream inspection.
• Through‑coating thickness measurement (ASTM E797, with delay‑line transducers) – We can accurately measure metal thickness even with up to 5 mm of paint, epoxy, or bitumen coating, eliminating the need for costly coating removal.
• Pipe and tube internal corrosion assessment (using internal rotating scanner – IRS) – For small‑diameter tubes, we deploy rotating ultrasonic probes that provide 360° wall thickness profiles and detect pitting, grooving, and erosion.

Flaw Detection – Weld and Base Material Inspection

Ultrasonic flaw detection is our core capability for identifying cracks, lack‑of‑fusion, porosity, and inclusions. We apply conventional and advanced techniques to meet diverse inspection codes:

• Conventional pulse‑echo (ISO 17640, ASTM E114, ASME V) – Using longitudinal and shear wave probes at frequencies from 1 MHz to 10 MHz, we scan weld volumes and parent materials to detect and size internal discontinuities. All scans are performed with calibrated reference blocks, and indications are evaluated against acceptance criteria (e.g., AWS D1.1, API 1104, ASME VIII).
• Phased array ultrasonic testing (PAUT – ISO 13588, ASTM E2700, ASME V) – Our PAUT systems use electronically steered beams to create real‑time sectorial and linear scans, enabling faster coverage and more accurate sizing of defects. We provide high‑resolution S‑scans, C‑scans, and 3D volumetric reconstructions, particularly useful for complex geometry and thick section welds.
• Time‑of‑flight diffraction (TOFD – ISO 10863, ASTM E2373, ASME V) – This technique uses the time difference between diffracted signals from crack tips to size defects with exceptional accuracy, independent of signal amplitude. We routinely use TOFD for critical pressure vessel and pipeline girth welds, providing defect height and depth for fracture mechanics assessments.
• Creeping wave and surface wave testing (ASTM E1106, ISO 16810) – For detecting surface‑breaking and near‑surface cracks in plates and shafts, we employ creeping (longitudinal) and Rayleigh wave probes, which are sensitive to very shallow defects.
• Immersion ultrasonic testing for fully automated inspection (ASTM E1001, ISO 16823) – For high‑volume production of bars, tubes, and plates, we use immersion tanks with multi‑axis manipulators, providing 100% coverage with constant coupling and high repetition rates.

Specialised Ultrasonic Techniques for Complex Components

Many critical parts have limited access, high surface roughness, or anisotropic materials. Our laboratory applies customised solutions to overcome these challenges:

• Dual‑element angle beam and contact probes for rough surfaces (ASTM E587, ISO 16831) – For castings and coarse‑grained materials (e.g., austenitic stainless steel), we use low‑frequency (0.5‑2 MHz) probes with wear‑resistant tips, minimising surface noise and improving signal‑to‑noise ratio.
• Long‑range guided wave testing (LRUT – ASTM E2775, ISO 18273) – For inaccessible pipelines and rods, we deploy magnetostrictive or piezoelectric sensors that generate guided waves to scan long lengths (up to 100 m) from a single access point, identifying significant corrosion or cracking.
• Ultrasonic velocity and attenuation measurements for material characterisation (ASTM E494, ISO 16814) – We measure longitudinal and shear wave velocities to determine elastic moduli, Poisson’s ratio, and detect material degradation (e.g., hydrogen attack, graphite spheroidisation).
• Debond and disbond detection in clad and lined materials (ASTM E114, custom) – For plate clad with corrosion‑resistant alloy, we use a low‑frequency angle beam technique to detect lack of bond at the interface, critical for the integrity of lined pressure vessels.
• Through‑transmission and pitch‑catch for composite laminates (ASTM E1065, ISO 18278) – For fibre‑reinforced composites, we use two probes on opposite sides (or a single side with a reflector) to detect delamination and porosity, which are not readily detected by pulse‑echo.

On‑Site Ultrasonic Inspection and Field Services

We recognise that many assets cannot be transported to our laboratory. Our team is fully mobile and equipped to perform ultrasonic testing at your site, anywhere in Bangladesh:

• On‑site manual ultrasonic inspection (ASME V, API 570, AWS D1.1) – Our certified technicians (ASNT Level II / III) bring portable flaw detectors, thickness gauges, and calibration blocks to your plant, construction site, or shipyard. We perform inspections to your specified codes and provide immediate verbal results with formal reports within 24 hours.
• Field PAUT and TOFD for pipeline girth welds (ISO 13588, API 1104) – We deploy lightweight phased array and TOFD scanners with encoded scan heads to inspect girth welds on cross‑country pipelines, providing high‑probability detection of cracks and lack‑of‑fusion.
• Ultrasonic corrosion mapping on storage tanks and vessels (API 653, API 510) – Using our automated grid scanners, we map thickness on tank floors and shell courses while the tank is in service (or during turnarounds), supplying data for fitness‑for‑service assessments.
• High‑temperature thickness monitoring on live process piping (ASTM E797, with high‑temp couplant) – We perform quick point‑thickness measurements on piping operating at up to 400°C without plant shutdown, allowing you to prioritise replacement schedules.
• In‑service bolt and stud tension measurement (using ultrasonic elongation – ASTM E1602, ISO 16831) – We measure bolt stress by ultrasound to verify pre‑load and detect relaxation, essential for pressure vessel flange integrity.

Calibration, Reference Standards, and Quality Assurance

Accurate ultrasonic testing demands meticulous calibration and traceable reference blocks. Our laboratory maintains a comprehensive set of standards to ensure reproducibility:

• Calibration of all ultrasonic instruments (ISO 16811, ASTM E1316) – Our flaw detectors, thickness gauges, and phased array units are calibrated daily using certified reference blocks traceable to national or international standards (e.g., NIST, BAM). We document calibration parameters, including gain, delay, sound velocity, and beam spread.
• Reference blocks for common materials – carbon steel, stainless, aluminium, etc. (ASTM E428, ISO 2400) – We maintain a library of IIW, DSC, and custom‑made blocks with artificial defects (side‑drilled holes, notches, flat‑bottom holes) to set sensitivity and sizing scales for various wall thicknesses and weld configurations.
• Verification with actual production samples – cross‑sectioning and macro‑etching – For critical inspections, we validate our ultrasonic findings by destructive sectioning and macroscopic examination of a representative sample, ensuring the reliability of our detection and sizing.
• Inter‑laboratory comparison (ILC) and proficiency testing (EN 473, ISO 9712) – Our NDT team participates in regular ILC schemes, and our results are benchmarked against global laboratories to confirm consistent performance.
• Qualification and certification of all inspectors to ISO 9712 / ASNT SNT‑TC‑1A – Every technician performing ultrasonic testing is certified to Level II or III in the relevant method and has specific experience in the application area (weld inspection, thickness, casting, etc.).

Data Recording, Reporting, and Digital Storage

We provide comprehensive documentation that serves both quality records and long‑term plant life management:

• Full A‑scan, B‑scan, and C‑scan data files (ISO 16831, ASTM E2905) – All inspection raw data are stored in encrypted digital formats, enabling re‑analysis and comparison with future inspections. We also provide high‑quality printouts of key indices.
• Thickness measurement reports with tabulated readings and statistical summaries – For corrosion surveys, we deliver Excel‑based data sheets with minimum, maximum, average, and standard deviation, plus histograms and percentile analysis.
• PAUT and TOFD reports with sectorial and 3D views (ISO 13588, ASME V Appendix VII) – We produce clear graphical representations of weld flaws, including depth, height, and through‑wall location, along with sizing uncertainty bands.
• Comparison with previous inspection data – trend analysis – When historical data is available, we overlay current results to highlight corrosion growth rates or crack propagation, supporting your risk‑based inspection (RBI) programmes.
• Non‑conformance and deviation reports – with suggested remedial actions – When defects are detected that exceed acceptance limits, we provide a detailed report describing the defect, its location, and our engineering recommendation for repair or further evaluation (e.g., follow‑up with radiography or magnetic particle testing).

Report Accreditation and Compliance for Bangladesh

All ultrasonic testing services described above are performed within our ISO/IEC 17025:2017 accredited quality system, with all inspectors certified to ISO 9712 / ASNT Level II or III. Our test reports are accepted by the Bangladesh Standards and Testing Institution (BSTI) for import clearance and material certification, and they meet the technical requirements of the Department of Explosives for pressure vessel registration, the Bangladesh Power Development Board (PDB) for turbine and boiler inspections, and Petrobangla for pipeline integrity. We also align our reporting with international codes such as ASME Boiler & Pressure Vessel Code, API 570/510/653, AWS D1.1, ISO 17640, and EN 12668, which are frequently referenced in Bangladeshi and multilateral projects (World Bank, ADB). Each report includes the inspection procedure, calibration records, scan plans, raw data (or data summary), defect evaluation against acceptance criteria, and a professional conclusion on the component’s fitness‑for‑service – giving you the confidence to operate safely and comply with all regulatory obligations.

Why Choose Our Ultrasonic Testing Service

We understand that ultrasonic inspection is often a critical gate‑keeper for plant safety and project progress. Our team provides rapid response, flexible scheduling (including night and weekend shifts to minimise production downtime), and clear communication of results – we don’t just identify flaws, we explain their significance and propose practical next steps. We work with your maintenance, engineering, and procurement teams to select the most appropriate technique (conventional, PAUT, TOFD, or guided wave) based on material, geometry, access, and defect types to find. Whether you are a local fabricator qualifying welds for a bridge contract, an importer verifying the integrity of imported pressure pipe, a power plant operator conducting a statutory annual inspection, or an EPC contractor executing a major pipeline project, our ultrasonic testing service delivers the technical excellence, regulatory compliance, and operational agility you need. Contact us to discuss your inspection scope, locations, and acceptance criteria – we will deploy the right technology and skilled personnel to ensure your assets are safe, reliable, and compliant.