Company Background

Figure [1]: An overview image of TNB Research Sdn. Bhd.

For our site visit purposes, we chose TNB Research Sdn. Bhd which also known as
(TNBR) located near our University Tenaga Nasional. Located at Kajang, Selangor, TNBR
the research and development center has been the in-house solution provider for Tenaga
Nasional Berhad. (TNB) since 1993. To summarize, they act as a base for technical solutions
and innovation for TNB. Over the years, they have developed different kinds of innovations
and solutions under variety of applied research projects for their parent company TNB. This
has been a major contribution for the growth of TNB in terms of performance at power
plants, transmission system minutes and so on. Moreover, TNBR has also embarked on
projects regarding national interest as they have started floating solar project at Labu Lake. In
2012, TNBR established its own subsidiary, TNBR QATS Sdn. Bhd. to focus on delivering
World Class Services to industries. On 1 March 2019, TNBR QATS was renamed to TNB
Labs Sdn. Bhd. [1]

Vision A Leading Research and Solution Provider For The Energy Industry
Globally.
Mission 1. We Are Committed To Excellence In Research & Services.
2. We Want To Enhance Our Stakeholders Interest Through Leading
Edge Solution.
Aspiration Energizing Research, Enlivening Innovation

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Products manufactured by the company

During the site visit, we learned that TNBR actually do not manufacture their own
products as TNB in general have very strict regulations and policy in terms of products
manufactured. Thus, TNBR provides various non-destructive testing services to potential
clients. Along with it, they also do provide some other services and training as well. All the
services provided by TNBR along with brief explanations are listed as below:

1. Built Environment and Climate Change (BECC)

- Carbon Footprint Measurement & Management
- Carbon Footprint Assessment
2. Cable Diagnostics
- Research and services in electrical distribution system
- Cable diagnostics
- Reliability testing
3. CO2 Capture and Utilization (CCU)
- To deal with issues regarding carbon dioxide
- Innovative absorption and adsorption methods to capture carbon dioxide
4. Environmental Impact Assessment (EIA)
- Screening possible environmental major impacts due to a project
- Preliminary and Detailed EIA
5. Hydro Optimization
- Optimization of TNB hydropower plants
6. Lighting Detection and Earthing
- Focus on real-time detection of lightning activities in Peninsular Malaysia
7. Materials Engineering and Testing Group (METG)
- Carry out metal testing and study properties of metals
- Various kinds of testing available
8. Power System
- A platform to carry out power system testing and provide solutions
- Innovations in the power system
9. System Verification and Simulation Lab
- Testing of IEC 61850 devices and systems are offered

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All the services are offered to any potential customers and TNBR is also looking for
collaborations and strategic partnerships in some of the services offered. All information
regarding the services offered can be found at their official website at tnbr.com.my.

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Identify, observing and discussing the NDT methods used by the company

During our visit, we were given briefing by on what are the NDT methods utilized by
the company in their services and also to carry out testing at a particular site. The NDT
methods utilized by the company is stated as below:

A) Liquid Penetrant Testing

Liquid Penetrant Testing is one of the most common and widely utilized NDT techniques in
the industry. It is also can be described as dye penetrant inspection method. In this method, a
type of liquid which is called penetrant is applied upon a specimen to be tested in order to
ensure that the flaws present on the surface is more visible to the eyes. The penetrant used for
this testing is usually a visible dye which is red in color and fluorescent dye which is in
green-yellow color. Along with the dye, two more substances are used which are the cleaner
and developer with each having it’s own functionality. This method does not cause any harm
to the specimen which is tested upon and it is very efficient in detecting defects such as
cracks, fractures that are open to surface of the test piece. This method is often applied to
welded area to check upon any surface defects by TNBR. [2]

B) Magnetic Particle Testing

Magnetic particle inspection can be described as a fusion of two different nondestructive

testing methods which are the visual testing and flux leakage. Magnetization is the main
principle behind this method, whereby a specimen to be tested is magnetized in order to
produce flux or magnetic lines of force in the material This method is can only be applied to
ferromagnetic materials such as iron, cobalt and nickel only as paramagnetic and diamagnetic
materials are unable to hold a flux which is strong enough to attract particles. Before carrying
out the magnetic particle inspection, the sample has to be magnetized beforehand. Any
defects that are present will create leakage field due to this and iron particles can be applied
to the surface of the magnetized part. This particles will be drawn to and cluster at the flux
leakage and will form a visible indication that the inspector can detect.

C) Ultrasonic Testing

In ultrasonic testing, high frequency sound energy waves are used to carry out the testing
procedure. The main principle behind this testing can be explained in terms of the travel of
sound energy in the form of waves in a certain object. When a discontinuity is present in the
wave path, a part of the energy will be then reflected from the surface. The reflected signal is

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then transformed into an electrical signal by the transducer and is displayed on a screen. By
studying the signal obtained, inspectors can learn more about the defects detected. Under
ultrasonic testing, TNBR carry out three different testing which are thickness measurement
testing, hardness testing and ultrasonic floor detection. In terms of thickness measurement
and hardness testing, particular device such as the OLYPMUS 38DL plus is used to carry out
the testing purposes by TNBR. They use this device to detect the flaws and then later study
the data obtained in order to identify the type of defects seen. As for ultrasonic floor
detection, this method is used to identify hidden cracks, porosity, voids and other internal
discontinuities in metals, plastics, ceramic and so on. TNBR also carry out even more
advanced ultrasonic testing whereby, we were not given much info as that information was
highly classified according to their company’s policy. [3]

D) Replication Testing

The final NDT method used by TNBR is replication testing. It’s a method used by TNBR in
order to determine the conditions of microstructure of a particular specimen. Replication can
be described as a method of copying the topography of a surface via impressing material or
casting on to the surface. It’s a very low cost effective method and can be done on site
without much of a hassle. There are three process involved in this method which are
polishing, etching and replication media.

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Procedure in carrying out the NDT methods

As per our request we were given a special demonstrations on how actually the NDT
methods such as liquid penetrant method and thickness measurement testing were carried out.
Unfortunately, we were not given demonstration on magnetic particle testing as the device
was not available due to usage on a site.

Liquid Penetrant Testing Procedure:

1. Before starting with this method, first of all the specimen to be tested was cleaned
using the cleaner and a cloth.
2. The cleaner was sprayed on to the cloth and it was used to wipe the surface of
specimen.
3. Once it was cleaned completely, the penetrant was sprayed upon the surface of the
welded section on the specimen.
4. A dwell time of 10 minutes is then given in order to allow the penetrant to fully
penetrate the structure of specimen.
5. After dwell time, excess penetrant is removed with the use of a cleaner. The cleaner is
sprayed on top of the area and it is wiped of using a cloth.
6. The developer is then applied on the surface in order to make the defects present
visible to our eyes.
7. After a while, defects in terms of linear and rounded allocations could be seen on the
surface of the specimen. This defects was then studied by the visual inspector.
8. Finally, once relevant data is obtained, cleaner is sprayed directly on to the specimen
and cloth is used to clean the specimen.

Figure [2]: Cleaning of the specimen to be tested

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Figure [3]: Sample given dwell time after penetrant application

Figure [4]: Removal of excess penetrant

Figure [4]: Developer applied to observe defects

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Thickness Measurement Testing Procedure:

1. The OLYPMUS 38DL plus device is turned on and set up accordingly

2. Couplant is applied onto the step calibration block to carry our calibration process.
3. The OLYPMUS 38DL plus device is then calibrated using the step calibration block
as a reference.
4. Once calibration was complete, couplant was then applied on to the cylindrical tube to
be tested.
5. The transducer of the device is then placed upon the cylindrical tube to measure the
thickness of the specimen.
6. The result could be seen on the monitor of the OLYPMUS 38DL device.

Figure [5]: Initial setup for the demonstration

Figure [6]: Calibration of the device using step calibration block

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Figure [7]: Measuring the thickness of cylindrical tube

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Discussion on why these particular methods are chosen by the company

In general, the NDT methods used by the company are actually chosen based on the
services provided by the company. As TNBR provide various services over various field, the
NDT techniques used varies for each field; thus, they chose this methods based on the
suitability for the situation or the service required by their clients. Moreover, this methods are
chosen as the methods are easy to be carried out and they have highly skilled and trained
inspectors to carry out the techniques. For example, thickness measurement testing,
(ultrasonic testing) is chosen for the services provided by them at various power plants. This
method is used to test the boiler tubes at the power plants. As high pressure steam flows
through the boiler tubes, overtime chances of erosion occurring increases as the boiler tube is
continuously used. Thus, it is crucial to check the thickness of the tubes in order to ensure the
tubes at least meet the minimum requirements in terms of thickness to avoid any unwanted
incidents.

Furthermore, time is a huge factor when it comes to choosing the NDT methods as
well. The NDT methods chosen by the company generally does not consume a lot of time as
it cone be done within a short period of time with ease. Complex analysis or calculation is not
needed as all they have to do is inspect accurately and check with the references. Thus,
results can be obtained very fast compared to other NDT methods that are not chosen by the
company. Overall this allows TNBR to work very efficiently both in terms of resources and
time as well. Finally, the methods are also chosen by company based on the high accurate
results that can be obtained via the methods chosen. All the NDT methods chosen by the
company provide very accurate results unless there is some errors from the inspector. Thus,
this ensures TNBR always provide reliable results which is extremely important in NDT
sector as false or inaccurate results can cause catastrophic failures or accidents.

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International standards adopted by the company

According to our instructor, the TNBR actually follows three different international
standards while performing NDT methods. The first standard followed by the company will
be the ASME BPV code, especially section V for NDT methods. The codes found in this
standard are divided into ten different articles that has strict rules. The ten articles was last
revised in the year 2017 and changes has been made accordingly. The articles are listed as
below:

1. General Requirements
2. Radiographic Examination
3. Ultrasonic Examination Methods for Welds
4. Ultrasonic Examination Methods for Materials
5. Liquid Penetrant Examination
6. Magnetic Particle Examination
7. Eddy Current Examination
8. Visual Examination
9. Leak Testing

The second international standard followed by the company is regulations set by

Department of occupational safety and health which is also known as DOSH. In general
DOSH regulations are followed by all companies who provide or carry out NDT techniques
as it is a must to ensure the safety and health of the people. DOSH was created under ministry
of human resources and they are in charge for the administration and enforcement of
legislations related to occupational safety and health of the country. [4]

The third international standard followed by the company will be the ASTM
International which was formerly known as (American Society for Testing and Materials).
The ASTM can be described as a development organization which provides technical
standards for products, materials, services and systems. Currently, over 180 ASTM NDT
standards are published in the ASTM Annual Book of Standards, Volume 03.03, Non-
destructive Testing. Among few of the often used ASTM NDT standards at TNBR are listed
as below:

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 1. ASTM E709
- Standard Guide for Magnetic Particle Testing
2. ASTM E1444
- Standard Practice for Magnetic Particle Testing
3. ASTM E1417
- Standard Practice for Liquid Penetrant Testing
4. ASTM E1208
- Standard Practice for Liquid Penetrant Testing using the Lipophilic Post-Emulsifying
Process
5. ASTM E2375
- Standard Practice for Ultrasonic Testing of Wrought Products
6. ASTM E164
- Standard Practice for Contact Ultrasonic Testing of Weldments

As can be seen from the list above, there are more NDT standards which is followed by
TNBR according to ASTM International.

Overall, all three standards mentioned above are applied by TNBR to their NDT
techniques in order to ensure that their techniques provide accurate results and also to ensure
the safety of their clients and the safety of their inspectors as well. When questioned
regarding, what will TNBR do if two different international standards have two different
regulations, we were explained that, TNBR will often follow the highest international
standard depending on the situation.

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Discussion on how the NDT methods help in relation to the component parts been
manufactured

In general, the main purpose of carrying out NDT testing techniques are to test out
products that have been manufactured or undergone a process over a particular time-frame.
Manufactured products are often checked to ensure there is no defects before being shipped
to clients, sent to further assembly or for further processing. This will ensure, that the entire
process is done smoothly and unwanted incidents can be prevented in the future and ensure
the quality of the product as well.

For example, during welding process, there is high chances of defects occurring in
terms of linear and rounded allocation over the heat affected areas on the component. If, NDT
techniques such as liquid penetrant or magnetic particle testing is not applied, this defects
which are not visible cannot be detected. Thus, when this component is sent for further
process or shipped to clients, this defects will cause huge errors and not safe for application
as well. All the components has to be checked for defects as only very minor defects are
usually acceptable when compared to the reference by the company or reference provided by
the client. This process ensures the reliability of the component as well. Overall by applying
NDT methods to manufactured components, the reliability, quality and most importantly
safety is highly ensured.

Discussion on what other NDT methods can be used

When asked about what other NDT methods, if given the chance will be utilized by
TNBR, we were explained that, TNBR are content with current NDT methods that they use
as these methods are proven in terms of efficiency and as well as results. This is due to the
fact that, TNBR at times apply two different NDT techniques to a specific specimen while
carrying out testing in order to further validate their results and not to miss out any defects.
For example, while testing out at power plants, they often carry out both ultrasonic and
penetrant testing and then cross check the results obtained to get a clear indication of the
defects obtained. This is done based on the situation as some of the specimen tested can be
highly sensitive.

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NDT methods in relation to the environment and NDT recyclable

In terms of affect that caused by the NDT methods utilized by TNBR it is actually
very minimum or none for both the inspector and the environment as well. For example, first
let’s discuss the effect due to liquid penetrant testing. As mentioned earlier, two different
types of penetrant are used during penetrant testing which can be categorized as post-
emulsify and water-washable. Both this penetrants does not cause any harm to the
environment as there is no CFC content in this products. This ensures that the ozone layer is
not affected as we all know how much of a negative impact can CFC cause on our ozone
layer. Moreover, the penetrant too is odorless and when done in controlled environment there
is no side effect except maybe for spilling if aerosol cans are not handled properly. The
aerosol cans used for NDT are also ensured that the substances inside are specifically chosen
and mixed to reduce the risk of fire. This ensures that the spray is not highly flammable in
case of any emergency or an issue.

For the next example, we would took a look at ultrasonic testing. As mentioned
earlier, only the device, calibration block and couplant are used to conduct the entire testing.
The device itself does not cause any effects or whatsoever and the calibration block usually
lasts for a longer period of time unless it is mishandled. As for the couplant, it is very user
friendly as we can directly apply it with just using our bare hands. The couplants generally
composed of water, oil, and few other types of liquid. Couplant does not cause any harm to
the environment as it can easily be wiped off and as for the inspector it only will cause
irritation if they are in contact with a longer period of time.

Based on research, it can be said that the only NDT method which causes harmful
effects to the environment and the inspector is radiography testing as radioactive substances
are used. However, if all the strict safety protocols are followed and done carefully, the
effects too can be avoided. Finally, in terms of components that have been rejected due to
defects and that cannot be repaired, when questioned we were explained that some of the
components still can be used as long it meets the minimum requirements. This is only
applicable in cases whereby there are no other alternatives. However, the specific component
has get licensed from DOSH before using it on order to ensure that it is actually safe to use.

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Conclusion

To begin with, this site visit was highly successful as we managed to achieve the
objectives that were required for this visit as part of assessment for our subject. We managed
to gain valuable knowledge and insight to NDT methods while our visit at TNBR.

Unfortunately for us, there were not any products manufactured by TNBR; but still
the inspectors assigned to us that day were very friendly and helpful when it came to
explaining and teaching us. They also gave us demonstration on how to carry out both liquid
penetrant and thickness measurement testing. We got to experience on how we should do it
and what are the precautions that we shall take as previously we only learned it in terms of
theory. Any doubts and questions that we had were cleared and answered exceptionally by
the inspectors and they were very patient as well. We also learned the importance of safety
and international standards that has to be followed while carrying out this NDT techniques.

Overall, we would like to thank the university for making this as part of the
assessment as we gained a lot of knowledge and experience during this site visit. We were
able to relate all the theories that were taught my Mdm.Rogemah previously in class as well.

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References

1. Basic Principles of Ultrasonic Testing. (n.d.). Retrieved from NDT Resource Center:
https://www.nde-
ed.org/EducationResources/CommunityCollege/Ultrasonics/Introduction/description.
htm
2. DOSH Profile. (n.d.). Retrieved from Official Website of Department Of
Occupational and Health: http://www.dosh.gov.my/index.php/en/about-us/dosh-
profile
3. Liquid penetrant inspection. (n.d.). Retrieved from The British Institute of Non-
Destructive Testing: https://www.bindt.org/What-is-NDT/Liquid-penetrant-
inspection/
4. Our Company Profile. (n.d.). Retrieved from TNB Research:
http://www.tnbr.com.my/about-us/

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Appendix

Group picture taken with the TNBR inspectors

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