Top 5 Non-Destructive Testing Methods for Industrial Facilities: What You Really Need

Industrial facilities depend on the reliability, performance, and safety of critical equipment — from pressure vessels and pipelines to structural components, welds, motors, and electrical systems. Failures in these assets can lead to costly downtime, safety hazards, and regulatory consequences.

This is why choosing the best NDT methods is essential for maintaining asset integrity.

Non-Destructive Testing (NDT) allows facilities to inspect equipment without causing damage, without disassembly, and without interrupting operations, providing powerful insights into defects that cannot be seen with the naked eye.

At Assured NDT, we specialize in helping industrial facilities implement the right combination of NDT techniques based on their equipment, risk level, and compliance needs. Below are the top 5 NDT methods you truly need for a high-performing industrial maintenance program.

1. Ultrasonic Testing (UT)

Ultrasonic Testing is one of the most widely used and versatile NDT methods for industrial environments. UT uses high-frequency sound waves to detect internal defects in metals and composites.

What UT Detects

• Internal cracks

• Thickness loss (corrosion/erosion)

• Weld defects

• Lamination flaws

• Voids or inclusions

Why Industrial Facilities Need UT

• Ideal for high-pressure equipment

• Supports API & ASME compliance

• Provides highly accurate, quantitative results

• Essential for pipeline and pressure system integrity

This is one of the best NDT methods for early defect detection.

2. Infrared Thermography (IR)

Infrared thermography is the only NDT method that detects temperature variations in real time — and it's now required annually by NFPA 70B for electrical systems. IR is one of the top non-destructive testing methods for industrial facilities.

What IR Detects

• Overheating motors and bearings

• Failing electrical connections

• Imbalanced loads

• HVAC inefficiencies

• Moisture in roofs and building systems

Why Industrial Facilities Need IR

• No shutdown required

• High ROI through failure prevention

• Supports predictive maintenance

• Identifies electrical hazards before arc flash incidents occur

IR is a top choice for facilities seeking to improve uptime and electrical safety.

3. Magnetic Particle Testing (MT)

Magnetic Particle Testing is used to detect surface and near-surface defects in ferromagnetic materials.

What MT Detects

• Surface cracks

• Fatigue damage

• Weld defects

• Grinding cracks

• Heat-treated failures

Why Industrial Facilities Need MT

• Ideal for welds, structural components, and machinery

• Highly sensitive to small cracks

• Quick, reliable, and cost-effective

MT is commonly used in manufacturing, power plants, and heavy industrial applications.

4. Liquid Penetrant Testing (PT)

Liquid Penetrant Testing is a simple and effective method for identifying surface-breaking defects on non-porous materials.

What PT Detects

• Surface cracks

• Porosity

• Leaks

• Fatigue fractures

• Incomplete weld penetration

Why Industrial Facilities Need PT

• Works on metals, plastics, ceramics, and composites

• Highly effective for weld inspections

• Essential for quality control and fabrication

PT is often paired with MT or UT to provide comprehensive inspection coverage.

5. Radiographic Testing (RT)

Radiography uses X-rays or gamma rays to reveal internal defects without damaging the component.

What RT Detects

• Internal cracks

• Voids and inclusions

• Porosity

• Weld defects

• Corrosion under insulation (CUI)

Why Industrial Facilities Need RT

• Provides a permanent image record

• Excellent for weld integrity verification

• Essential for high-pressure systems and critical structures

RT is commonly used in petrochemical plants, refineries, and power generation facilities.

How to Choose the Top Non-Destructive Testing Methods for your Industrial Facility

Industrial facilities rarely rely on just one technique. Instead, the best NDT programs use a combination of methods based on:

• Asset criticality

• Operating environment

• Regulatory requirements

• Material type

• Failure history

• Cost and inspection frequency

Assured NDT helps facilities develop custom inspection plans that align with OSHA, API, ASME, NFPA, and insurance requirements.

Why Industrial Facilities Choose Assured NDT

Assured NDT provides:

• Certified inspectors

• Nationwide service coverage

• Full NDT method portfolio

• NFPA 70B compliance support

• Predictive maintenance integration

• Clear reporting with actionable recommendations

Whether you manage a manufacturing plant, chemical facility, refinery, or commercial operation, our team ensures your equipment is safe, reliable, and performing at its best.

Strengthen Your NDT Program Today

Contact Assured NDT to schedule non-destructive testing services anywhere in the United States. Request a quote at assuredndt.com/contact

FAQs: Top 5 NDT Methods for Industrial Facilities

1. What are the most important NDT methods for industrial facilities?

The top NDT methods include ultrasonic testing, infrared thermography, magnetic particle testing, liquid penetrant testing, and radiographic testing.

2. How do I choose the best NDT method for my facility?

Selection depends on the material, equipment type, risk level, and regulatory requirements. Most industrial sites use a combination of methods.

3. Is infrared thermography required by NFPA 70B?

Yes. NFPA 70B requires annual infrared inspections for energized electrical equipment.

4. How often should NDT inspections be performed?

Frequency varies, but many facilities schedule inspections annually or during planned maintenance outages.

5. Do NDT methods require shutting down equipment?

Most NDT techniques — including IR, UT, MT, and PT — can be performed without shutting down operations.