Assessment of Technical Condition of Structures (ATCS A comprehensive analysis evaluating the condition and continued usability of industrial structures. This includes visual inspections and both destructive and non-destructive testing to identify risks such as deformation, cracks, or corrosion. Results provide recommendations for monitoring, upgrades, or repairs.

Scope:

• Technical condition analysis
• Reliability assessment (load-bearing capacity, usability, durability)
• Notch and crack analysis for fatigue life and brittle fracture resistance
• Determination of load impact and potential combination

Visual Testing (VT) enables the detection of surface discontinuities such as cracks, deformations, corrosion, or erosion. Inspections are performed both with the naked eye and using specialized optical tools such as borescopes and videoscopes. This method is applicable at various stages of an asset’s lifecycle — from manufacturing to operation — providing fast and effective assessment of a structure’s technical condition.

Ultrasonic Thickness Testing enables precise measurement of a material’s actual wall thickness at the point of inspection. The technique is based on measuring the travel time of a longitudinal ultrasonic wave through the test object, making it possible to assess the condition of structural components such as pipelines, tanks, and steel plates.This method is especially valuable for components exposed to corrosion, where wall thinning can pose serious safety risks. Because UTT can be performed from a single side, it is widely used in the petrochemical, shipbuilding, and construction industries.

Hardness testing is a vital method for evaluating the mechanical properties of materials in industrial diagnostics. Using UCI (Ultrasonic Contact Impedance) technology, enables quick and accurate hardness measurements without the need for large, stationary equipment. This approach allows testing even in hard-to-reach locations, making it especially practical in field conditions. Hardness testing is particularly useful for assessing weld quality, evaluating heat treatment effectiveness, and monitoring the condition of components subject to wear or degradation.

• Method Used: UCI (Ultrasonic Contact Impedance) — ultrasonic wave reflection-based hardness measurement.
• Evaluates material degradation, heat treatment effectiveness, and weld quality.
• Performed with portable hardness testers equipped with diamond indenters and vibrating rods.

Penetrant Testing is one of the oldest and most versatile non-destructive testing (NDT) methods, used for detecting surface-breaking discontinuities in materials. The process involves applying a penetrant to a properly prepared surface, removing the excess, and using a developer to reveal defect indications. Its simplicity and effectiveness make it widely applicable for evaluating welds, castings, and structural components.

• Based on capillary action, allowing the penetrant to seep into surface discontinuities.
• Detects and localizes flaws such as cracks, laminations, laps, and lack of fusion.
• Suitable for non-porous materials including metals, ceramics, and plastics.
• Applied during production, maintenance, or quality control phases.

Magnetic Particle Testing enables the detection of both surface and near-surface discontinuities in ferromagnetic materials such as steel and cast iron. The object is magnetized, and a magnetic powder or suspension is applied, which accumulates in areas of magnetic flux leakage — indicating the presence of defects.

Used during both manufacturing and operational phases.• Applied to welds, castings, and forgings.• Performed using visible (color) or fluorescent techniques under white or UV light.• Offers rapid, reliable results and can be used on coated surfaces.• Commonly used in automotive, aerospace, energy, and petrochemical industries.

The Magnetic Memory Method allows for the detection of stress concentration zones and structural defects in ferromagnetic materials. It uses the natural magnetization that occurs due to stress and operational loads to register the distribution of inherent magneti

leakage fields (WMPR). This enables real-time identification of surface and subsurface flaws such as cracks and deformations. Applied in the diagnostics of welds, pipelines, pressure vessels, turbines, and other critical structures.• No need for surface preparation or artificial magnetization.• Offers high precision and fast execution.• Widely adopted in the energy, petrochemical, transport, and construction sectors

MPM-BMD Testing enables non-invasive assessment of entire pipeline sections without excavation. It utilizes the natural magnetization of ferromagnetic materials, caused by operational stress and the Earth’s magnetic field, to register the distribution of their inherent magnetic leakage fields (WMPR). This helps identify stress concentration zones (SCZs), which are potential failure points due to cracks, deformations, or corrosion.

No need to drain or shut down pipelines or prepare complex infrastructure, Significantly reduces diagnostic time and costs, Ideal for energy, petrochemical, and gas industries, especially for assessing buried pipelines with diameters that preclude use of traditional inspection pigs (ILI)

Overhauls in the energy sector are multi-stage processes aimed at modernizing, maintaining, and restoring the full functionality of energy infrastructure.

Key areas of operation:

• Budowa rusztowań – zapewnienie stabilnych i bezpiecznych konstrukcji umożliwiających realizację prac remontowych. Montaż i utylizacja izolacji w punktach modernizowanych.
• Insulation dismantling, installation, and disposal at modernization point.
• Delivery and replacement of components, including installation and servicing.
• Regulacja zamocowań po modernizacji – dostosowanie zamocowań dla zapewnienia stabilności i bezpieczeństwa konstrukcji, regulacja zamocowań.
• Preparation of as-built documentation and detailed project reports.

We specialize in the production of steel structures, serving both in-house projects and custom client orders. Our modern production facility supports the full cycle — from executing technical designs (e.g., sleeves, shafts, counterweight baskets), to fabrication, and final assembly at the installation site.

Welding Methods Used:

• MIG/MAG
• TIG
• MMA
• Plasma welding

Each method allows for precise joining of steel elements, adapted to specific project requirements and material types.

As of December 19th, 2022, Alioth Engineering is certified for compliance with PN-EN ISO 3834-2:2021-09 and has implemented a Factory Production Control system in accordance with EN 1090-1:2009+A1:2011.

Following the decision of auditors from TÜV Thüringen Polska, we meet the quality requirements for welding metallic materials and welded steel structural components up to execution class EXC4. We invite you to cooperate with us.

The work of our specialists goes far beyond the borders of the Mazowieckie region.

In recent months, we supported the overhaul of steam drums at the pulp and paper plant in Kwidzyn. Additionally, we assisted our consortium partner with non-destructive testing (NDT) works for a major European manufacturer of paper used in corrugated board production, based in Świecie.

Alioth Engineering has completed the modernization of another power unit at the Enea Wytwarzanie power plant in Świerże Górne. This time, our team carried out servicing and overhaul works on unit K6.

Thanks to the work of our skilled team, we successfully prepared the surfaces for non-destructive testing, restored anti-erosion coatings on mill fans, and repaired key structural components of the boiler.

Repair and modernization works on unit K10 at the Enea Świerże Górne power plant have been completed. The first quarter of 2022 was dedicated to preparing for the restart of one of the plant’s steam boilers.

Surface preparation for testing, adjustment of suspension systems, and repairs of the main structural element mounts were carried out.

A consortium formed by Alioth Engineering and the Polish Academy of Sciences has submitted a funding application for the project titled "An innovative method for measuring deformation and actual stress levels in components operating under elevated temperatures using point and distributed fiber optic sensors", under the TANGO V programme.

TANGO is a joint initiative of the National Centre for Research and Development (NCBR) and the National Science Centre (NCN), aimed at bridging the gap between basic research and industrial research and development activities.

The application was submitted in June of this year and has successfully passed the initial evaluation stages. Final results are expected by February 2022. The maximum funding amount for the project is PLN 3,000,000.

After a month of intensive work for the Łódź Combined Heat and Power Plant, our company completed the regeneration of the third-stage steam superheater coils. The scope of work included surface cleaning, thermal spray metalizing, and application of a sealing paint coating. All activities were carried out in accordance with the highest technical and material standards.

Together with the Institute of Power Engineering – Research Institute, we completed the modernization of the main components of the K1 OP-650 boiler at the power plant located in Ostrołęka.

Prace polegały na przygotowaniu powierzchni do badań NDT, w tym badania nieniszczące w części maszynowej. Ponadto wykonaliśmy regulację zawieszeń kotła oraz wszystkich głównych elementów bloku K-1 OP-650.