Hydrostatic testing ensures that pressure systems, such as tanks, pipelines, and pressure vessels, meet the required safety standards. The test helps detect:

• Leaks in the system.
• Weak spots in the material or construction.
• Structural integrity issues under pressure conditions.
• Compliance with industry standards and regulations.

Hydrostatic tests are commonly performed on systems that will operate under high-pressure conditions. These include:

• Pipes and pipelines (oil, gas, water).
• Pressure vessels (storage tanks, reactors).
• Boilers and heat exchangers.
• Hydraulic systems.
• Tanks (fuel tanks, chemical storage tanks).
• Fire suppression systems.

The test pressure is generally 1.5 times the system’s design pressure (also known as the maximum operating pressure). The exact pressure and duration will depend on the system’s specifications and the applicable codes and standards (e.g., ASME, API).

The duration of a hydrostatic test depends on several factors:

• Size of the system (larger systems will take longer).
• Complexity of the system (more complex systems may require additional time for setup and inspection).
• Test duration is typically 10-30 minutes of holding pressure, but the entire process (including setup and inspection) may take several hours to a full day.

While some companies may have the necessary equipment to perform hydrostatic testing in-house, it is generally recommended to hire professional hydrostatic test services to ensure the test is done accurately, safely, and in compliance with industry standards. Professionals are trained to handle the complexities of the testing process and provide reliable results.

An NDT company supports managers and operators by drafting maintenance strategies for any organisation that needs periodic testing of vital assets. Our specialised technicians enhance maintenance plans, prolong asset lifespans, and streamline operations. By hiring a third-party NDT agency, you can pinpoint defects and problems in your product systems before they do significant damage that could mean business loss.

Our MONDIAL's team takes replica samples of the actual products on-site and bring them to the laboratory for further evaluation. This technique offers a more efficient and accurate data analysis. The replica is made by a softened plastic film or by moulding with plastics or silicone rubber.

NDT services are necessary to ensure many of our machine or product systems’ safety and reliability, such as aircraft, motor vehicles, pipelines, bridges, power stations, trains, buildings, and oil platforms. Besides that, NDT has also allowed many companies in Malaysia to enhance their competitiveness and rise to the top of their market niche by creating high-quality products through cost-effective methods.

Most NDT methods do not pose a hazard to the testing personnel, such as ultrasonic or eddy current testing. However, certain NDT techniques do involve potentially harmful exposure to ultraviolet radiation, ionising radiation or X-rays. Hence, you require highly skilled technicians who are properly trained to take the highest safety measures while conducting these NDT services.

NDT application can extend to almost all the manufacturing industries, from food processing to aerospace missile manufacturing industries. MONDIAL’s  have worked for many industries in Malaysia, including oil and gas, construction, petrochemical, automotive, aerospace, power generation, fabrication, and general engineering

Liquid penetrant testing detects hairline cracks, surface porosity, leaks, and fatigue cracks. It uses liquid dye to see defects that are otherwise not visible to the naked eye.

Liquid penetrant testing can be applied to any non-porous clean material, metallic or non-metallic. It is unsuitable for dirty or rough surfaces.

It is typically a six-step process:

 1) Surface cleaning

2) Application of a penetrant liquid

3) Removal of excess penetrant liquid

4) Application of developer

5) Inspection of test surface

6)  Post-inspection cleaning

• X-Ray Fluorescence (XRF): Uses the principle of X-ray interaction with atoms to analyze the material’s composition.
• Optical Emission Spectroscopy (OES): Uses a spark to excite atoms in a material, causing them to emit light at specific wavelengths, which is then analyzed to determine the material's composition.
• Portable XRF: A compact, handheld device for field testing.
• Other techniques: Neutron activation analysis (NAA), chemical spot testing, and inductively coupled plasma (ICP) are sometimes used.

PMI is commonly used to analyze:

• Metals and alloys (steel, aluminum, copper, titanium, etc.)
• Stainless steel grades
• Non-ferrous metals
• Welds
• Coatings or corrosion layers

PMI is widely used in industries such as:

• Oil and gas
• Aerospace and aviation
• Automotive manufacturing
• Power generation (nuclear, fossil fuel, and renewable energy)
• Chemical processing
• Construction and infrastructure
• Metal recycling

• Ensures Compliance: Verifies that the welder’s skills meet the standards of regulatory bodies like AWS, ASME, or ISO.
• Quality Control: Ensures that welds are strong, durable, and free from defects, minimizing the risk of failures.
• Safety: Prevents safety hazards by ensuring welds can withstand the stresses and environmental conditions for which they were designed.
• Industry Recognition: Certified welders are recognized for their skill and adherence to industry standards.

• Visual Inspection: Welds are inspected for external defects such as cracks, lack of penetration, or surface porosity.
• Destructive Testing: Includes testing like tensile strength, bend testing, and impact testing to assess the weld’s performance and strength.
• Non-Destructive Testing (NDT): Methods like X-ray, ultrasonic, or magnetic particle testing can detect internal flaws without damaging the weld.
• Welding Procedure Testing: Verifies the welder’s ability to follow specific welding procedures, including the materials and positions specified.

Yes, for certain industries and applications (especially in high-risk environments), welder qualification testing is mandatory to comply with safety and industry standards. It is required for certifications to ensure that welders can meet the performance requirements of the materials and procedures.

Yes, many testing services provide on-site welder qualification testing, especially for industries like construction, oil and gas, or shipbuilding. Portable testing equipment for visual and non-destructive testing can be brought to the location.

The time required for qualification testing can range from a few hours for simpler tests to several days for more complex tests involving destructive testing or multiple welding procedures. The testing time depends on the type of welding process, the number of tests to be conducted, and the complexity of the welds.

After the test, the welder receives a certification if they pass. The certification document typically includes the details of the test (e.g., process, position, material) and serves as proof of their qualifications. Failed tests may require requalification or corrective action.

WPS services are crucial for:
• Code Compliance: Ensuring that your welding procedures meet industry codes (e.g., AWS, ASME, ISO).
• Quality Control: Standardizing welding processes to ensure consistency and quality across all welding operations.
• Safety Assurance: Preventing defects that could compromise structural integrity or create safety hazards.
• Documentation: Providing necessary documentation for inspections, audits, and regulatory compliance.

A complete WPS includes several key elements:
• Base Material: Type and grade of the material being welded.
• Filler Metal: Specifications for the filler material, including type, diameter, and brand.
• Welding Process: The welding technique used (e.g., TIG, MIG, Stick).
• Joint Design: Details about the joint configuration and welding positions (flat, horizontal, vertical, overhead).
• Preheat and Interpass Temperature: Temperature requirements to prevent cracking or distortion.
• Shielding Gas: Type and flow rate of shielding gases used.
• Welding Parameters: Voltage, amperage, travel speed, and other process controls.

WPS documents are developed based on:

• Welding Codes and Standards: They are created according to industry standards like AWS, ASME, API, or ISO.
• Material Specifications: A WPS must match the materials being welded (e.g., steel, aluminum, alloys).
• Process Requirements: The WPS defines which welding processes are appropriate for the material, joint configuration, and required strength.
• Testing: Some WPSs require qualifying tests (Procedure Qualification Records or PQR) to verify that the procedure produces acceptable results.

A WPS is typically valid as long as the conditions outlined in it (e.g., materials, welding processes) remain unchanged. However, if the materials, processes, or codes change, a new WPS or update to the existing WPS might be required. Requalification is also necessary if there are changes in the production environment or welding personnel.

WPS services help ensure compliance with industry codes and regulations (e.g., AWS, ASME, ISO), which is crucial for project approvals, inspections, and audits. Well-documented and well-executed WPSs also provide a traceable record of welding procedures, which is important for quality assurance, legal purposes, and ensuring consistent results.