Inspectioneering Codes and Standards Updates

101 Essential Elements in a Pressure Equipment Integrity Management Program for the Hydrocarbon Process Industry Part 2

This paper outlines the 101 essential elements that need to be in place, and functioning well, to effectively and efficiently, preserve and protect the reliability and integrity of pressure equipment (vessels, exchangers, furnaces, boilers, piping, tanks, relief systems) in the refining and petrochemical industry.

101 Essential Elements in a Pressure Equipment Integrity Management Program for the Hydrocarbon Process Industry

This is the first of a series of articles that outlines the 101 essential elements that need to be in place, and functioning well, to preserve and protect the reliability and integrity of pressure equipment (vessels, exchangers, furnaces, boilers, piping, tanks, relief systems) in the refining and petrochemical industry.

Extending the Life of an Offshore Pipeline

Active corrosion in onshore and offshore pipelines is an increasing problem. Consequently, pipeline operators regularly use intelligent inspection pigs to detect and size corrosion. Inspection data can be combined with probability based “Fitness-For-Purpose” assessment methods, to determine the effect of corrosion on the immediate and future integrity of the pipeline.

Concrete Corrosion

Deterioration of concrete structures has plagued petrochemical production facilities. As a result of sulfur compound exposure, concrete corrodes and weakens continuously over time. The proper operation of the structure deteriorates with it until management undertakes repair or replacement of the affected sections. While the concrete degrades, productivity can be lost and product quality can suffer. The repairs undertaken can be costly. The production downtime during repairs can cost even more.

INSPECTION OF UNDERGROUND PIPING EPRI Update on Nuclear Power Plant Activities

Leaks or spills over the life of nuclear power plant operation can lead to undesirable consequences. The nuclear industry’s GroundwaterProtectionInitiativeandthelessonslearnedand experiences gained from implementing groundwater protection programs have led to the development of another voluntary industry initiative, the Underground Piping and Tank Integrity Initiative, which aims to better understand the conditions of and mitigate leaks from these components.

Effective Planning for Utilization of Contractor API Inspectors For Turnarounds

We have discussed most of the pre-turnaround planning details. We are ready for the next step. The cost for the Turnaround is normally the most important item right behind SAFETY. In many cases the salary, per diem and travel costs have been part of early discussions with the client. Now it is time to examine these inspector costs in-depth. What affects these costs? How can we increase our efficiency in this area?

Reducing Plant Asset Losses and Environmental Incidents (Part 1)

Regulatory, civic and competitive pressures require we change to a proactive, rather than a reactive culture or environment with a supportive infrastructure. The concurrent evolution of cultural and infrastructural change relies upon effective leadership, communication and commitment (both philosophically and financially) to create an environment which not only promotes but supports/facilitates (no mixed signals) “healthy” progress, that can be measured.

Can TOFD Replace Conventional UT for Weld Inspection?

The debate about advantages and drawbacks of the application of the TOFD (time of flight diffraction) approach for ultrasonic weld inspection should not forget the original reasons for it’s introduction in the 1960’s. The major advantage at that time had been the better crack detection in comparison to x-ray techniques, especially in view of an increased use of steels and welding technologies with a the presence of diverse cracking phenomena (e.g. cold cracking, transverse cracks etc.).

Pendulum Effect No. 3

In a past issue, we discussed one solution to the instrument line block valve pendulum problem. This was where the valve assembly can be mounted remote from the vibrating product line, such as at grade. This issue covers two possibilities where the valves need to remain close to the vibrating line.

Post-weld Inspection Using Laser Vision

Visual inspection is the most common non-destructive testing method. For critical applications, machine vision technology provides advantages over visual inspection.

Non-Contact Ultrasonic Testing with EMAT - Part 1: Introduction to EMAT

This is the first in a series of three articles that will introduce Electro Magnetic Acoustic Transducer (EMAT) and its practical applications in the field of nondestructive testing (NDT). EMAT, or Electro Magnetic Acoustic Transducer, is an Ultrasonic Testing (UT) technique that generates the sound in the part inspected instead of the transducer.

Transient Computational Fluid Dynamics

Fitness-for-Service Assessment: Severe Local Corrosion

If an operator finds cracking in a furnace waste heat boiler, excessive thinning in an absorption tower, or severe bulging in a converter, FFS assessments—not standard code analyses—are needed to evaluate the unit’s mechanical integrity. FFS assessments, according to the American Petroleum Institute (API), are “quantitative engineering evaluations that are performed to demonstrate the structural integrity of an in-service component containing a flaw or damage.”

Crude Flexibility Management Threat Awareness

Safely Operating Steam Reformers between Turnarounds

Steam reformers are critical assets to many refining and chemical manufacturing plants and facilities, and it is well known that the reformer is one of the most challenging assets to maintain and operate. Common problems in reformer operations include burner firing, flue gas distribution, and catalyst damage.

Driving Better AIM Decisions Through Crude Assays

XRF Inspection of Piping Systems to Reduce Sulfidation Corrosion Risk

Integrity Management Programs, KPIs and PSM

99 Diseases of Pressure Equipment: Soil Corrosion

Soil corrosion (underground corrosion) is another one of those extensively researched and documented types of corrosion, since so many pipes and pipelines are buried and nearly all storage tanks rest on the soil. An entire industry/ technology is associated with preventing soil corrosion (cathodic protection).

99 Diseases of Pressure Equipment: External Corrosion

For purposes of this article, external (atmospheric) corrosion is what afflicts process equipment and structural members that are not insulated and exposed to moisture associated with atmospheric conditions, ie rain, condensation from humidity, marine spray, cooling tower mists, industrial pollutants, etc.

99 Diseases of Pressure Equipment: External Chloride Stress Corrosion Cracking (ECSCC)

Chloride cracking of austenitic stainless steels (300 series SS) is an off-shoot of CUI, and there’s nothing really magical about it. If you have insulated solid stainless steel equipment operating in the CUI temperature range you are likely to eventually experience ECSCC.

Interview with John Nyholt, BP NDE Specialist

John has primary responsibility for NDE consulting and troubleshooting for BP around the world in the refining, chemical and gas processing industries. We at the IJ thought it might be valuable to spend some time chatting about his background, challenges he has faced recently and what he feels are some of the biggest challenges ahead for the Inspectioneering community.

IJ 2006 Survey Talley

Preliminary results of this survey were published in the January February 2006 Inspectioneering Journal. Since then an additional 34 surveys have been received.

Leaking Dryers and Scrubbers Located at Natural Gas Well Facilities

In this article you will find the failure investigations of six 0.094 inch thick carbon steel vessels. These vessels were in service in natural gas well facilities; some functioned as dryers and were subjected to cyclic loads. Metallographic tests, hardness tests, and fracture surface scanning electron microscopy (SEM) examination results are presented for each of the vessels.

Real-time Operating Decisions Made Easier

The benefits of adding fitness-for-service (FFS) assessments to energy sector reliability projects are numerous. The acceptance of API 579/ASME FFS-1 is increasing across the energy sector and other industries, as these benefits have been demonstrated in a wide range of projects. Several of these benefits are illustrated in this article using real-world examples.

A Discussion on the Piping Thickness Management Process: Part 3 - Data Collection with Ultrasonics and Radiography

This article is the third of a series of articles that will focus on one critical sub process within a PEIP that is key in managing the integrity of process piping: thickness monitoring programs for internal corrosion. These articles will discuss what constitutes an effective piping thickness monitoring process and will present several practices that may be new to some readers, but these practices have produced beneficial results in other major piping reliability programs.

A New API Inspector Certification Program for Source Inspectors

A new API Individual Certification Program (ICP) will be offered soon to certify inspectors who perform quality assurance (QA) surveillance and inspection activities on new materials and equipment for the energy and chemical (E&C) industry. It is being developed by the API with the assistance of numerous, experienced subject matter experts (SMEs) involved in source inspection activities.

2012 in Review - Growing Value, Expanding Content, Leveraging Synergies

In response to reader feedback, we implemented some important improvements in 2012. As we broaden our scope to include all aspects of Asset Integrity Management, its synergy and leverage become increasingly important. We will sustain this forward movement in 2013 by continuously seeking ways to serve the Inspectioneering community at maximum value, as you will see by the comprehensive Inspectioneering client survey soon to launch.

The Role of Continuous Improvement in Achieving Excellence in Pressure Equipment Integrity and Reliability

In the first article in this series entitled How to Put It All Together – Guide to Organizing a Successful PEI Program, I provided an overview of the ten necessary Management Systems (MS) for a successful program to achieve excellence in pressure equipment integrity and reliability (PEI&R). This is the last out of the ten articles in this series. Clearly, Continuous Improvement (CI) has a major role in achieving excellence in PEI&R. All the advances we’ve made over the years in achieving excellence in PEI&R stems from our continuous improvement programs to apply new and better techniques and methods by learning from what has already occurred.

99 Diseases of Pressure Equipment: Corrosion Under Insulation (CUI)

CUI may be the most well known and widespread corrosion phenomena in our industry. It’s also one of the most difficult to prevent because by and large no matter what precautions we take, water eventually gets into the insulation and begins to do it’s dirty work, sometimes sight unseen until process leakage occurs. And it’s not isolated to just insulation. Corrosion under fire-proofing (CUF) is also prevalent in our industry and requires the same type of inspection planning, design prevention, and mitigation that is required for CUI.