OUR PROJECTS
OUR PROJECTS
Waikato 50 - 2021
Watercare’s new Tuakau Water Treatment Plant by the Waikato River provides up to 50 million liters a day to Auckland in response to historic draughts in the region.
X-Ray Laboratories was heavily involved in the non-destructive examination of various components and pipelines in the project. Like other plants of this kind, the design called for weld inspection in accordance with ASME B31.3 “Process Piping”.
Much of the testing involved radiographic examination of butt-welded joints as well as dye penetrant and visual examination of fillet welded joints on the various spools and lines. Weld maps and Spool identification were required to monitor quantities welded by each welder and ensure our inspection covered a minimum percentage of each welder’s production welds.
Much of the radiographic testing was conducted on spools at our lab before being taken to site, during other times the testing needed to be carried out after hours so that the X-Rays could be taken without harming other personnel or contractors.
Additionally X-Ray Laboratories was Involved in qualifying the welders and procedures for the project. These qualifications were conducted in accordance with ASME IX to link the welders to the ASME IX procedure and ASME B31.3 acceptance criteria.
Waterview Tunnel, 2016 – 2017
The Waterview Tunnel runs for 2.4km between Pt Chevalier and Mt Roskill and opened in July 2017. The stretch of road reduces traffic in Auckland connecting Manukau, the city, West Auckland and the North shore.
X-Ray Laboratories was heavily involved in the verification of a variety of materials and parts for fastening, employing a range of test method including, Tensile testing, Impact testing, and hardness testing. This material verification was carried out on all necessary components including Bolts, washers, nuts etc.
All job record and traceability details were recorded and conducted as per applicable standards and IANZ/ISO 17025 requirements. Preparation for testing of samples from areas as nominated in manufacturing standards.
Preparation and testing of specimens from samples to test programme B of AS/NZS 4291.1
Puhoi to Warkworth Motorway, 2020 – 2021
The Puhoi to Warkworth project extends the Northern Motorway (SH1) 18.5km from the Johnstones Hill Tunnels to just north of Warkworth. The stretch of road is an essential part of the infrastructure north of Auckland cutting travel times and reducing traffic for all travelers.
X-Ray Laboratories was involved in the non-destructive testing of welded joints required in the reinforcing bar of the structures in this project the welding with reinforcing bar warranted the use of AS/NZS 1554.3:2014 “Welding of reinforcing steel”.
With 100s of welds, a predefined percentage were inspected using a combination of visual and magnetic particle testing. with the knowledge that these welds were defect free and the QA Package to boot, the contractors and sub-contractors could continue with their work.
Mangere Wastewater treatment plant upgrade (Central interceptor), 2021-2022
The central interceptor is a supersized tunnel that reduces wastewater overflows into central Auckland waterways. The Watercare infrastructure is an important part of Auckland’s continued growth and future proof resilience.
X-Ray Laboratories was involved in the inspection of various welded pipelines from small diameters to large diameters. For many large diameter shots, panoramic methods were used with our Iridium 192 radioactive source. This method allows for large sections of weld to be examined in relatively short periods of time and enabled the welds to go up in quick succession.
Additionally, various spools and pipelines were inspected both visually and with dye penetrant, this often involved flange welds as radiographic examination could not be conducted on these welds. In general, the percentage of welds that were required to be inspected under the ASME B31.3 standard were examined and evaluated by our experienced technicians.
Auckland Hospital Calorifier replacement project, 2021 – 2022
The Auckland hospital calorifier replacement project is part of the ongoing works to upgrade the hospitals aging facilities to be in line with modern systems and expansion for a growing population.
X-Ray Laboratories work focused on the boiler room and associated pipelines. With thousands of welds to be inspected, most radiographic imaging was done at our laboratory while visual, dye penetrant & magnetic particle inspections were conducted both at our laboratory and onsite.
The nature of the project warranted frequent visits to site for inspections of lines before insulation was installed. A Detailed QA package with full weld maps, NDT control sheets and individual weld identification was planned and implemented alongside the fabricator’s accompanying documentation.
City Rail Link, 2021 – Current
The City Rail Link is New Zealand’s largest transport infrastructure project ever. The world class rail system will better connect Auckland’s entire rail network and allow for more trains and quicker journeys.
X-Ray Laboratories was honoured to be part of this amazing project in the non-destructive examination section. This involved conducting Radiographic examination of large diameter pipe welds for the commissioning of related water services. Additionally for these pipes, where lap welds were required, magnetic particle inspection was used for both internal and external welds. Our confined space and gas detection qualified personnel were able to complete these inspections efficiently.
On the Britomart station side, X Ray Laboratories was involved in the inspection of structural steelwork for the expanding of the station, this was highly time sensitive work as services and further steelwork were needing to be installed. With the X-Ray Labs service, we were able to help the fabricator’s progress without an issue.
Pukekohe Wastewater Treatment Plant Upgrade, 2018 – 2022
Watercare’s upgrade to the Pukekohe Wastewater Treatment Plant is a key piece of infrastructure for Auckland and the wider region to continue to support a growing population.
X-Ray Laboratories was involved in the inspection and testing of the welded joints for the project. This included radiographic inspection of a percentage of butt-welded joints as well as dye penetrant and visual inspections. Much of these inspections were conducted onsite and after hours to allow workers to continue to operate without the interruptions of exclusion zones.
Like other plants of this kind, the design called for ASME B31.3 “Process Piping” ASME code for pressure piping. With this in mind X-Ray Laboratories was also involved in the qualifications of the welders and welder procedures. These were custom procedures created specifically for the needs of the main contractors and were completed to ASME IX.
