The Value of Nondestructive Testing for New Transmission & - - PowerPoint PPT Presentation

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The Value of Nondestructive Testing for New Transmission & - - PowerPoint PPT Presentation

The Value of Nondestructive Testing for New Transmission & Substation Foundations Presented by Rakesh Anthony Khan, P.E., CWI, FDH Infrastructure Services SEPTEMBER 5 - 7, 2018 Definition of NDT Webster defines nondestructive testing or


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The Value of Nondestructive Testing for New Transmission & Substation Foundations

Presented by Rakesh Anthony Khan, P.E., CWI, FDH Infrastructure Services

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Definition of NDT

Webster defines nondestructive testing or non-destructive testing (NDT) as a wide group of analysis techniques used in science and technology industry to evaluate the properties of a material, component or system without causing damage.[1] The terms nondestructive examination (NDE), nondestructive inspection (NDI), and nondestructive evaluation (NDE) are also commonly used to describe this technology.[2] Because NDT does not permanently alter the article being inspected, it is a highly valuable technique that can save both money and time in product evaluation, troubleshooting, and research. The six most frequently used NDT methods are eddy-current, magnetic-particle, liquid penetrant, radiographic, ultrasonic, and visual testing.[3] NDT is commonly used in forensic engineering, mechanical engineering, petroleum engineering, electrical engineering, civil engineering, systems engineering, aeronautical engineering, medicine, and art.[1] Innovations in the field

  • f nondestructive testing have had a profound impact on medical imaging, including
  • n echocardiography, medical ultrasonography, and digital radiography. With the

advent of machine learning, computer vision and data-driven techniques, nondestructive testing has been improved in different fields. [4] applied data-driven and machine learning techniques to predict damage state based solely on visual

  • bservations in infrastructures.

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Background

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Testing

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Nondestructive Testing

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Measure material properties. Structures are assets too.

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Nondestructive Testing - Metals

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Nondestructive Testing - Concrete

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Nondestructive Testing of Foundations

Variable medium. Very little access. Visual inspection can be misleading. Types of Testing

  • Crosshole Sonic Logging (CSL)
  • Gamma Gamma Logging (GGL)
  • Thermal Integrity Profiling (TIP)
  • Sonic Echo/Impulse Response (SE/IR)

Technician experience is required to collect meaningful data. Engineer experience is required to interpret test results.

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Crosshole Sonic Logging

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Gamma Gamma Logging

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Thermal Integrity Profiling

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Impact Time (in μs) Amplitude t Length

Sonic Echo

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Dispersive Wave

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Substation Construction Example

Project in construction phase. Several foundations poured. Some structures already set. Potential Integrity Issues

  • Known geotechnical challenges
  • Additional concrete poured in many

locations

  • CSL testing had unclear results
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  • Formed by the dissolution of rocks, such as limestone or

dolomite

  • Sink holes, disappearing streams, springs
  • Highly variable subsurface conditions, soft soils, variable

water conditions, voids

Geotechnical Challenge - Karst Geology

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Karst Prevalence

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FDH Testing at this Site

  • Dispersive Wave (DW) testing was

carried out on the foundations

  • Piers were segmented into 6 or 8

sections (depending on the foundation size)

– 2 testing setups were performed in each section

  • Setup 1 – Direct
  • Setup 2 – Across Pier
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Dispersive Wave Testing Results

Site GEO, construction notes, and CSL testing results were also reviewed as part

  • f the investigation

Likelihood of integrity issues presented

  • n a color scale based on DW analysis as

well as other information available

Possible Issues

  • Soil intrusions propagating past the

rebar cage

  • Bearing depth concerns
  • Voids or inclusions of soil

Coring location selected to determine magnitude of issue

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Concrete Core Process

  • Results reviewed with plan to

determine the magnitude of the indicated issues by coring at select locations

  • Coring locations just inside the

rebar cage to quantify the extent of the integrity issue and evaluate if it would affect the foundation’s capacity

  • Cores performed along the inside
  • f rebar cage
  • Core Results:
  • Major soil intrusion inside rebar cage
  • Bearing depth discrepancies
  • ‘Golf ball to baseball’ sized inclusions
  • Small zones where concrete was not

fully mixed

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Corrosion Assessment

Prior to Construction

  • 13 samples tested by three different consulting companies
  • Slightly to moderately aggressive
  • 12 of 13 tests are slightly aggressive
  • 1 of 13 tests is moderately aggressive
  • Resistivity 1100 (ohm.cm) to 15000 (ohm.cm)
  • pH > 7.9
  • Chloride < 146 ppm
  • Sulfate < 169 ppm

Corrosion Evaluation

  • 3 processes to classify the corrosion risk were utilized

1) FHWA

  • Undisturbed soil: No corrosion
  • Disturbed soil: 3 samples qualified for

0.08 (mm/yr) for 50 years 2) CALTRANS:

  • Non corrosive Environment

3) Mughabghab (1989):

  • Corrosion rate of 0.03 (mm/yr) for 50 years

Conclusion

  • Average of 1.5 mm of corrosion after 50 years: 4% of the

rebar size

  • Include this in Capacity Calculations and any Remediation

Methods

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Capacity Determination

  • Capacity evaluations performed based on the soil

intrusion size and corrosion risk

  • The voids were conservatively sized
  • Evaluation for compression and section loss in rebar

within the tension zone

  • Identified the overall capacities of the foundations
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Transmission standards group within the Utility was involved in assumption processes for analysis and performed verification calculations. Worst case foundations would live past their intended service life. No further action necessary. Exploratory cores pressure grouted. No removal of structures already placed. No major project delay.

Result

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Key Learnings

  • Karst soil conditions present

construction difficulties.

  • Conservative design valuable in karst

soils.

  • Knowledge of NDT options is important.
  • Experience in applying NDT for

actionable results is critical.

  • NDT techniques can confirm installation

quality, resolve issues, and save costs.

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Questions?

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  • Founded in 1994 by Civil Engineering PhDs
  • Infrastructure engineering & NDT services
  • company. 180+ employees
  • Headquartered in Raleigh, NC
  • Licensed across the US
  • Patented and proprietary NDT methods
  • Services for Telecom, Heavy Civil, Power,

Industrial, Commercial, and Government

Structural Engineering Civil Engineering Geotechnical Engineering Nondestructive Testing

  • Structure Design
  • Foundation Design
  • Structural Evaluation
  • Modification Design
  • Rigging Plans
  • Mount Analysis
  • Permitting Support
  • New Site Development
  • Site Remediation
  • Bridge Scour Analysis
  • Environmental Compliance
  • Temporary Access Matting
  • Lab Analysis
  • Resistivity Testing
  • Drilling Portfolio
  • Geotechnical Reports
  • Dispersive Wave
  • Ground Penetrating Radar (GPR)
  • Infrared (IR) Thermography
  • Concrete Strength
  • Ultrasonic Testing
  • Corrosion
  • Post-Tensioned Rod Solutions

Field Investigations Construction Services Research & Development Value Added

  • Inspection
  • Foundation Mapping
  • Structure Mapping
  • Mount Mapping
  • Line & Antenna Mapping
  • Construction
  • Construction Management
  • Painting & Lead Abatement
  • Emergency Restoration
  • PhD-led group
  • Structures Laboratory
  • Refine existing NDT
  • Develop new NDT
  • Training & Investigation
  • Research & Development
  • Failure/Forensic Investigations
  • Expert Witness Testimony