Understanding the Cost of NDT Equipment Repair vs. Upgrade

Any asset-owner wants to get the most out of a piece of equipment. But with nondestructive testing (NDT) equipment, there comes a point where legacy equipment no longer performs at the required level. When that happens, it is time for an upgrade. 

The reason why upgrades can be more efficient than repairs for legacy NDT equipment has everything to do with advances. Advances in functionality, advances in performance, and advances in the market. Across global industries, using quality NDT testing tools is crucial to compete, comply, and control costs. 

Defining Legacy NDT Equipment

By saying “legacy” NDT equipment, we’re talking a fairly short time frame. Although NDT has been around for many decades, the advancements have been rapid for an industrial category. So rapid, in fact, that the idea of legacy has shifted. 

There is no absolute hard and fast rule, but a good rule of thumb is equipment that is more than five years old can become less valuable. This isn’t because the equipment no longer works, but that it might be more reliant on repairs to function properly. Older equipment can suffer from:

• Substandard data results and imagery 
• Slower testing processes
• Difficulty integrating with current software
• Longer and more cumbersome training
• Heavier equipment
• Limited or no support and parts availability

The compounding problem with legacy equipment is that it can no longer handle upgrades that can help a company truly compete. Every year, equipment gets better, and equipment that can be regularly modified and updated is the most valuable. To guarantee safety and regulatory compliance, as well as improve inspection efficiency, we recommend using up-to-date NDT equipment. 

Example: When testing for a High Temperature Hydrogen Attack, a plant needed equipment that could detect flaws smaller than .004 inches. That required advanced focusing techniques and powerful tools to confidently discover all flaws. Legacy equipment couldn’t deliver on this, leaving them potentially exposed to destructive challenges. 

What to Look For in NDT Equipment Upgrades

When upgrading NDT equipment, the goal is to make testing processes more efficient and accurate. Whether considering ultrasonic testing (UT) or eddy current testing (ECT), a few common features warrant careful consideration: 

• Advanced software: All software should be easy-to-use, intuitive, and efficient for on-site inspections or lab work. The best software delivers an easy interface with a range of powerful tools that enhance the entire inspection process from acquisition to reporting.
• Hardware: From portable units to high-end systems, hardware should feature capabilities that meet specific inspection needs, offer paths to upgradeability, provide multiple connectivity options, and be able to integrate seamlessly with the software. 

Hardware and software may seem basic, but using higher quality solutions with advanced features are what set more reliable equipment apart. Ideally, equipment will provide the following values:

• Fast calibration
• Better signal quality
• Advanced processing and reporting
• Screens that provide clear visuals, even in harsh environments
• Easy handling, ruggedness, and portability
• Less equipment needed for one job

The last point is one we can’t stress enough. It is possible, in theory, to create a functional NDT process by piecemealing together a lot of legacy equipment. But doing so leaves a lot of potential gaps, difficult use cases, and an inability to upgrade all at once. 

The Need For Ever-Improving NDT Testing

The market for NDT continues to evolve. As supply chains go global and new inspection application needs spring up from Chennai to Charleston, technicians have to be able to test quickly and confidently. 

There are a few factors that are making non-destructive testing even more important, including: 

• Stricter safety regulations in both established and emerging markets
• Aging infrastructure
• Asset uptime needs

Of course, many of these elements work together. As infrastructure ages in all markets, the need to inspect without disruption grows. And as governments continue to regulate supply chains, following those complex mandates means erring on the side of no errors at all. 

NDT Equipment Repair Is Not Enough

It’s understandable to want to put off upgrades. It is a cost that won’t result in a return popping up on the books. There might not be a ledger entry for “flaws detected early” or “fines not levied” or “lawsuits avoided,” but the benefits of upgrading are critical. 

The market is changing, and NDT equipment continues to advance. The future of testing isn’t coming; it’s already here. And that means upgrading NDT equipment to meet the speed of these rapid advancements.

Zetec is a major provider of multiple cutting-edge solutions for nondestructive testing equipment. If you’re ready for an equipment upgrade, contact us today.