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Coke Drum Inspection
Delayed coke drums are operated under severe conditions of cyclic heating and forced cooling that apply repetitive thermal stresses to the drum walls. It has long been recognized that the ultimate failure mechanism for coke drums is weld cracking due to low cycle fatigue caused by these thermal stresses. It is also known that coke drums distort and bulge in service and that these bulges can be used as pointers to potential weld failure areas.
Pipeline Inspection
Fabrication of Heavy wall stainless steel (SS) vessels is still a challenge for the Heavy Fabrication Industries, because of the inherent limitations in the quality check methods employed for volumetric examinations such as Radiographic Examination (RE) and Ultrasonic Examination (UE).
The anisotropic dendritic grain structures formed during welding acts as a hindrance for the volumetric NDE. Furthercoarse dendritic grain structure plays a major role in scattering of ultrasonic sound waves and beam skewing, especially in Austenitic SS weld metal which havecoarser grain boundaries compared to its base metal.
Boiler Tubes
The most important element in a recovery boiler corrosion inspection is a careful and thoughtful visual inspection by an experienced boiler inspector. Additional non-destructive test methods are available to locate and size each type of defect produced by the various damage mechanisms that operate in recovery boilers before they can grow to cause leaks in pressure parts.
Piping Inspection
In Process Inspection is intended to ensure that all phases of fabrication work are being conducted in accordance with the requirements of other related approved procedures
Austenitic Weld Inspection
Fabrication of Heavy wall stainless steel (SS) vessels is still a challenge for the Heavy Fabrication Industries, because of the inherent limitations in the quality check methods employed for volumetric examinations such as Radiographic Examination (RE) and Ultrasonic Examination (UE).
The anisotropic dendritic grain structures formed during welding acts as a hindrance for the volumetric NDE. Furthercoarse dendritic grain structure plays a major role in scattering of ultrasonic sound waves and beam skewing, especially in Austenitic SS weld metal which havecoarser grain boundaries compared to its base metal.
Storage Tank Inspection
The k-weld must be inspected for potential failures and defects due to operation. The k-weld is an important part of the tank, as it ”unites” the bottom plate and the tank wall making sure there are no leaks. The tank was built and welded at a time where non-destructive testing was at a lower technological level compared to today.
CUI Inspection
On most sites CUI tends to be a medium to long-term
problem
– Risk increasing significantly after 5 to 10 year “holiday
period”
– General pattern conspires to give false sense of security
– Routine inspection and maintenance of thermal insulation
systems tends to be avoided or deferred until a process leak
actually occurs
– Resulting failures can have serious H, S & E implications
VESSEL INSPECTION
There have been many advancements in the field of pressure vessel engineering such as advanced non-destructive examination, phased array ultrasonic testing and radiography, new material grades with increased corrosion resistance and stronger materials, and new ways to join materials such as explosion welding, friction stir welding, advanced theories and means of more accurately assessing the stresses encountered in vessels such as with the use of Finite Element Analysis, allowing the vessels to be built safer and more efficiently.
Long Seam Inspection
Seams may be present in the billet due to non-metallic inclusions, cracking, tears, subsurface cracking or porosity. During continuous casting loss of mold level control can promote a host of out of control conditions which can reseal while in the mold but leave a weakened surface. Seam frequency is higher in resulfurized steels compared to non-resulfurized grades. Seams are generally less frequent in fully deoxidized steels.
Structural Inspection
The general rule for ultrasonic examination is to inspect the weld from the surface on which the bevel is made. For T,K,Y welds this will be dependent on the preparation type. As with butt welds, the preparation can be single or double-sided. Similar considerations must be given for access (probe size) and volume coverage as was done for butt welds. Access to the vertical face (un-bevelled) may be limited or the wall thickness may be such that no practical skip effect can be used to approach the weld from those surfaces. Fusion faces provide a major concern for weld quality and the vertical land at the root is again given extra coverage where possible.
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Plan
Identified the goals and objectives of the project and created a project plan to achieve them. Make sure that all the tasks are completed by the deadline, you’ve organized them by priority and have mapped them on a timeline
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Prepare
The plan can’t be executed without a team. They are your most valuable resource. Assign them tasks according to their abilities. Make sure you give them direction.
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Execute
Monitor how much money the project is spending. Stay in communication with your team. Use key performance indicators (KPIs) to track your project.