In-Service (Plant Inspection and Shutdown Inspection)
An Inservice plant or Shutdown inspection of industrial equipment is important in oil refineries, petroleum refining, petrochemicals and power generation sectors. The problems associated with the "New Construction" or new equipment main focus on metal cutting ,selection of Welding Process,Qualification of Welders. But inservice equipment are different. The main cause which create problems for oil refineries is "Corrosion and their associated metallurgy". During the inservice or shutdown the detection of corrosion and metal loss is major problematic issue. With the help of this an inspection Engineer can decide whether to equipment is to be keep in service or Rum, Repair, Replace or retired. To perform the RBI or FFS the data required from NDT department or the thickness readings are important,that which NDT is performed and what is the next date of Inspection Interval. NDT is a noninvasive technique for determining the integrity of a material component or Pressure Equipment such as Boiler, Pressure Vessel, Heat Exchanger, Piping, PSV,PRV and Above Ground Storage Tank (ASTI). NDT/NDE allows inspection without interfering with a product's final use that provides an excellent balance between quality control and costeffectiveness. The main goal of NDT is to detect material defects such as corrosion/cracks, to predict corrosion rates or to assess equipment mechanical integrity, to calculate corrosion risk and to assess remnant life. We will detect with the help of NDT
Metal Loss (including corrosion averaging)
b. Corrosion Rates
c. Remaining Corrosion Allowance
d. Remaining Service Life
e. Inspection Interval
f. Bottom plat thickens for tanks
g. Heat Exchanger Tube Thickness or metal loss.
During the Shutdown or Inservice following points are very important and the availability of time is very less and too crucial also.
It will stop the Plant production and Financial loss to management and country too, where the economy is mainly depend on the Oil and Gas Exploration, such countries in Middle East Asia or Gulf.(Where Oil and Gas Exploration is main source of Leaving and Geographic conditions of Deseret sand)
Decision making for the repairs depending on location and nature of defect within the Pressure Vessel as per applicable manufacturing and Inservice code.
WPSWelding Procedure Specification, PQRProcedure Qualifications Records and WPQ Welder Performance Qualification. Required prior to start any Repair or Alteration.
Obtaining the Authorization from AIA Authorized Inspection Agency, under whom the repaired work to beperformed and offer for inspection as per NB23 and R Stamp requirement. Prior to performing the Repair work.
Selection of NDT method and Approving the NDT procedure.
Obtaining the Authorization from AIA Authorized Inspection Agency, under whom the repaired work to be performed and offer for inspection as per NB23 and R Stamp requirement. Prior to performing the Repair work.To detect flaws in the repaired location.To classify them discontinuity of defect as per the specified acceptance code.
Obtaining the Clearance from Local State Statutory Body and Jurisdiction where the equipment is placed. Understanding the Formats and Forms to be filled , before during and after inspection.
Materials and Welding consumables to be used for procedure qualification.
By using preheating methods where Impact testing is not a requirement.
Method of "Temper bead techniques".
Method of "Half bead technique".
NDT that can be employed before,during and after welding.
Necessity of PWHT and Hydrostatic tests.
Repairs and precautions during overlay weld repairs.
Methods and precautions to be taken during alterations and rerating of pressure vessels.
Aspects of reporting and reinspection.
NDT/NDE Testing and Inspection
Deterioration of Steel
Detection of Damage Mechanisms Affecting Fixed Equipment in the Refining and Petrochemical Industries
Risk Based Inspection (R.B.I.)
Life Extension Studies
Failure analysis and litigation
Residual Stress Measurement
Microscopic examination of metals
macroscopic examination of metals
Decarburisation of steel
Equipment Fitness for Service Assessment and Certification
Welding Process and consumable requirements
Cathodic Protection of Piping and Above Ground Storage Tanks
Heat Excahnger Ferrous and NonFerrous NDT Conventional and Advanced NDT
Corrosion Under Insulation (CUI) detection with the help of advanced NDT
Mapping of CML/TML (Thickness Gagging ) Location on Pressure Vessel or equipment
Above Ground Storage Tank Entry with the qualified Inspector
Magnetic Flux Leakage Testing of ASTI
Magnetic Flux Leakage Testing of Heat Exchanger Tubes and Corrosion Mapping
Magnetic Flux Leakage Testing of Pipelines
Electromagnetic or Eddy Current Testing
Near Filed Eddy Current Testing (Electromagnetic or Eddy Current Testing)
Remote Filed Eddy Current Testing (Electromagnetic or Eddy Current Testing )
UT Ultrasonic Testing Thickness Gagging (UTG)
UT Ultrasonic Testing Flaw Detection (UTF)
UT Ultrasonic Testing Shear Waves for Weld Joints (UT Shear Wave)
RT Radiographic Testing
DR Digital Radiographic Testing
CR Computer Radiographic Testing
How we help to you, We have qualified inspector as below to support to you.
ASNT, ISNT ,PCN NDT LevelII/2 Certified NDT Technicians and Inspectors
ASNT, ISNT ,PCN NDT LevelIII/3 Certified NDT Specialist and Auditor.
API 510/570/653 Certified Inspectors
AWS Certified Welding Inspectors (CWI)
AWS Senior Certified Welding Inspectors (SCWI)
AWS Certified Radiographic Interpreter (CRI).
NACE Certified Inspectors in BASIC Corrosion
NACE Certified Inspectors in CIP Level1,Level2 and Level3
NACE Certified Inspectors in Cathodic Protection CP Level1 and Level2
Experienced Engineering Personnel
AutoCAD Staffing and Services
Document Control Staffing and Services
Refractory (API 936) Staffing
Turnaround and Shutdown Inspection Support
Project/Construction Management Support
New Construction Project Support
Process Safety Management (PSM) Programs and Implementation
Positive Material Identification (PMI)
Risk Based Inspection (RBI)
Welding Guidelines for the Chemical, Oil, and Gas Industries