Inspection of serpentine or arbor coils in process fired heaters is difficult using conventional NDT methods. Quest Integrity Group offers a comprehensive solution with its furnace tube inspection system, or FTIS, and advanced engineering assessment capabilities. FTIS is an intelligent pig that quickly and accurately inspects the convection and radiant coil sections of fired heaters per API Recommended Practice 573. It is an ultrasonic inspection technology that is launched following the mechanical cleaning, or decoking of the furnace coil’s interior surface.
FTIS detects and measures existing damage mechanisms such as internal or external corrosion, erosion and pitting, along with deformation such as bulging, swelling and ovality in serpentine or arbor coils. These damage mechanisms are quickly identified and quantified in an inspection report and an onsite preliminary assessment is typically delivered to the client within 24 hours of the inspection. Based on the inspection results, an advanced engineering assessment using the company’s proprietary software, LifeQuest™ Heater, calculates the remaining life and fitness-for-service of the fired heater tubes in accordance to the API 579 / ASME FFS-1 standards. Accurate corrosion rate information helps decrease the risk of failure and helps operators improve extended run times, which translates to increased fired heater efficiency and reliability.
View this animation to learn more about our inspection and assessment solutions for fired heater coils:
Integrity management programs that include process or plant piping are challenging to implement and accurately maintain when applying traditional NDT methods. Quest Integrity provides a comprehensive solution which includes intelligent pigging technology and advanced engineering assessment capabilities. HYDRA is used to inspect piping systems fabricated from austenitic, ferritic and some non-metallic materials, ranging from 3”- 24” in diameter, including varying pipe thicknesses. It addresses specific challenges, such as inspection of short piping lengths in complex configurations, buried or insulated piping, elevated piping or piping systems which have limited space for launching/receiving the instrument.
Following the inspection and generation of the preliminary inspection report, the data is analyzed to identify many damage mechanisms outlined in API 571 and ASME such as wall loss degradation (e.g. corrosion, erosion, pitting, fretting, etc.) and deformation damage (e.g. denting, bulging and ovality). Inspection reports are quickly delivered for each inspection project and tailored to satisfy API 570 and API 574 process piping and system component inspection codes. Based on the inspection results, an advanced engineering assessment using the company’s proprietary software, LifeQuest™ Piping, calculates the remaining life and fitness-for-service of the piping in accordance to the API 579 / ASME FFS-1 standards.
View this animation to learn more about our inspection and assessment solutions for process facilities:
Steam reformers are critical assets to many refining, chemical and syngas plants, and one of the most challenging assets to maintain and operate. Our proprietary Laser Optic Tube Inspection System, LOTIS, utilizes laser profilometry to conduct internal steam reformer tube inspections. The data captured by LOTIS is exceptionally powerful when combined with our LifeQuest™ Reformer remaining life assessment capabilities, providing an integrated solution set for the process and syngas industries.
View this animation to learn more about our steam reformer inspection and assessment solutions utilizing LOTIS:
Our proprietary steam reformer external tube crawler, MANTIS™, conducts reformer tube inspections utilizing proprietary sensors and eddy current technology to inspect steam reformer tubes, as well as several other critical applications. MANTIS is unique in that it does not require catalyst removal prior to inspection. When catalyst removal is indicated, MANTIS can be combined with our LOTIS® system for a more complete inspection.
View this animationto learn more about our inspection and assessment solutions for steam reformers utilizing MANTIS:
Effective pipeline integrity management has been problematic for the large number of pipelines that were not designed for in-line inspection (traditionally unpiggable pipelines). Quest Integrity understands the complexities involved with this challenging segment and offers a comprehensive pipeline integrity management solution – the InVista ultrasonic (UT) in-line inspection tool, advanced data analysis and engineering assessment capabilities.
View this animation to learn more about our in-line inspection and assessment solutions for unpiggable pipelines:
November/December 2016 Inspectioneering Journal
By Michael Turnquist at Quest Integrity Group
This article exhibits how modern inspection methodologies combined with innovative computational analysis practices demonstrate the value of conducting fitness-for-service (FFS) assessments on sectional piping.
September/October 2016 Inspectioneering Journal
By Tim Haugen at Quest Integrity Group
Although all ultrasonic smart pigging providers claim the ability to detect wall thinning and tube deformations to some degree, the inspection surface coverage, resolution, minimum wall thickness detection and reporting capabilities may vary drastically from one service provider to the next. Knowing your provider’s capabilities is crucial for ensuring the integrity of your assets, as one refinery recently discovered.
March/April 2016 Inspectioneering Journal
By Tim Hill at Quest Integrity Group
Achieving fired heater reliability in conjunction with meeting performance standards can be a challenging feat. Performance is a measure of the degree to which the fired heater is in an operable condition at any given time.
May/June 2015 Inspectioneering Journal
For traditional in-line inspection (ILI) vendors, considering 21.4 miles of a piggable 4” diesel pipeline is typically not a big deal. However, significant threats like 3rd party damage and external corrosion seem to come with the territory in nearly any pipeline territory.
November/December 2014 Inspectioneering Journal
By Kelsey Hevner at Quest Integrity Group
Steam reformers are critical assets for the successful operation of hydrogen, ammonia, and methanol plants. The steam reformer is also one of the most expensive assets in these facilities. Catalyst tubes inside the reformer are one of the most important and costly components.
September/October 2014 Inspectioneering Journal
By Tim Hill at Quest Integrity Group
For the past 30 years, infrared (IR) thermometry has been used to monitor tube metal temperatures in refining and chemical furnaces. Tracking temperature levels and variations determine performance capability limits and reliable tube life. However, the application of IR thermometry has often been characterized as highly operator dependent, which can result in less-than-optimal data accuracy as a consequence of poorly applied and interpreted results.
May/June 2014 Inspectioneering Journal
The following interview with Rich Roberts provides answers to some of the questions our readers have about small, specially designed pigs carrying NDE technologies that can inspect nearly every area of a tube from the coils interior surface.
March/April 2014 Inspectioneering Journal
New inline inspections and integrity management systems allow operators to understand the complexities and economics of terminals’ and station’s complex aging pipeline infrastructure.
November/December 2013 Inspectioneering Journal
By Michael Turnquist at Quest Integrity Group
While there are many types of damage mechanisms that can occur in a piece of equipment, localized metal loss is one of the most common. If an inspection reveals that metal loss has occurred, many questions are raised...
July/August 2013 Inspectioneering Journal
By James Widrig at Quest Integrity Group
Inspection and fitness-for-service assessments of critical in-plant piping systems are a concern for the chemical industry. This presents a potentially insurmountable task and discovery of a number of areas where the condition is at risk.
May/June 2013 Inspectioneering Journal
Refineries and chemical plants own and operate numerous process heaters (e.g. gas reformers, CCRs, etc.) as part of the standard assets throughout the facilities. Many heater coil configuration designs are flanged at both ends; however, there are also coil designs which contain common headers, linking the individual coil passes together at the inlet, outlet, or even at both ends in some cases.
March/April 2013 Inspectioneering Journal
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.
January/February 2013 Inspectioneering Journal
By Devon Brendecke, P.E. at Quest Integrity Group
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.
November/December 2012 Inspectioneering Journal
Various fired heater designs in refineries and chemical plants contain common headers (e.g. Arbor coil configurations, CCRs, etc.) as part of their overall serpentine coil design. Accessing the interior of individual coils through the common header is challenging; however, advanced engineering firms and mechanical decoking companies have developed unique common header snorkel delivery systems.
September/October 2012 Inspectioneering Journal
The refining industry has applied ultrasonic-based intelligent pigging to inspect serpentine coils in fired heaters since the 1990s. Today, thousands of serpentine coils in fired heaters are inspected annually at process facilities around the globe.
January/February 2012 Inspectioneering Journal
By Devon Brendecke, P.E. at Quest Integrity Group
Thanks to constantly improving technology developments, inspection of atmospheric storage tanks has yielded better data which, when used as input, improves the accuracy of advanced assessment techniques. Coupling the improved inspection data with an advanced engineering assessment often means that tank operators are able to postpone repairs until the next shutdown, eliminate the need for repairs or be exempt from hydrostatic testing.
January/February 2010 Inspectioneering Journal
For years refinery and chemical plant operators have utilized ultrasonic-based intelligent pig technology to inspect coils in convection and radiant sections of fired heaters. This proven technology provides accurate inspection data which allows reliability engineers to make critical decisions about the operation and maintenance of fired heaters. Recent advances have increased the capabilities of these tools and extended these benefits to coker heaters containing 3" (76.2mm) nominal piping size and plug headers with radial inserts.
November/December 2009 Inspectioneering Journal
By Stefan Papenfuss at Quest Integrity Group
Pipeline integrity management programs are largely driven by regulatory compliance and are typically budgeted years in advance. Operators of all sizes are looking for ways to reduce expenditures related to operational efficiency and safety in order to maintain optimal profitability while sustaining safety and compliance.
November/December 2004 Inspectioneering Journal
Reliable "intelligent pig technology" is now readily available to the refining industry which can provide quick / comprehensive inspection to both "convection" and "radiant" sections in process furnace piping coils. Both tabular data formats along with 2D / 3D high-resolution color graphics of the test results are immediately produced on site showing tube/pipe wall thinning, bulging, swelling, and ovality.
November/December 1995 Inspectioneering Journal
By Ted L. Anderson at Quest Integrity Group
An inescapable law of nature is that engineering materials contain flaws. Perfect materials and welds simply do not exist in the real world. A newly fabricated pressure vessel, for example, contains numerous imperfections and will probably degrade further in service.
February 27, 2013, Webinar
Discover how FFS Assessments can influence efficiency and cost effectiveness. Signal FFS provides the quantitative support you need to make decisions to run as-is, repair or replace flawed equipment, reducing the risk of operational failure. If Fitness-for-Service assessments are performed quickly and accurately, this prevents the need to manually perform an assessment and the need to understand a 1,000 page manual of standards and procedures. This Webinar will address remaining life estimates for in-service equipment and how to make confident decisions about repair,...
Quest Integrity Group, October 5, 2016
Quest Integrity, a global leader in the development and delivery of advanced inspection and engineering assessment services and software products, today announced the release of Signal™ Fitness-for-Service (FFS), Version 5.0, which features compliance with the new API 579/ASME FFS-1 2016 standard.
October 28, 2014
Quest Integrity Group, a global leader in the development and delivery of advanced inspection and engineering assessment services, announces flow loop simulation capabilities, including client-specific pipeline configurations, to validate its InVista™ ultrasonic in-line inspection (ILI) technology in demanding environments.
Quest Integrity Group, March 14, 2014
Quest Integrity Group, a global leader in the development and delivery of advanced inspection and engineering assessment services and software products, announces Pacifica™, a new software solution to perform pressure cycle fatigue analysis on seam crack flaws in pipelines.
Press Release, July 11, 2013
Quest Integrity Group, a global leader in the development and delivery of advanced inspection and engineering assessment services and software products, introduces a new animation focused on the inspection and assessment of buried or inaccessible piping in nuclear facilities utilizing HYDRA™, an ultrasonic-based intelligent pigging technology.
March 18, 2013
Quest Integrity Group, a global leader in the development and delivery of advanced inspection and engineering assessment services and software products, introduces a new animation of its LOTIS (Laser Optic Tube Inspection System) technology.
February 25, 2013
Quest Integrity Group, a global leader in the development and delivery of advanced inspection and engineering assessment services and software products, announces the expansion of its RDVI service offering to North America.