12 Things to Do After Discovering a Mechanical Failure
Advancements in Network-distributed Ultrasonic Sensors
Combating Sea Cooling Water Corrosion
How to Develop a Proactive Risk-Based Integrity Management Framework for Plant Assets
Observations on Flaw Tolerance and Brittle Fracture: The Effect of Post Weld Heat Treatment
Spending Your Turnaround Budget Contingency: Is it Inevitable?
Thermal Decomposition: A Technique for Cleaning Process Equipment
Using Digital Data Management Systems to Streamline Work Processes
Achieving the Full Potential of Asset Performance Management Platforms
Asset Integrity Management Enablers
Connecting the Proper Inspection Strategies to Damage Mechanisms
Convection Section Failure Analysis and Fitness-for-Service Assessment
Determining Pipeline Corrosion Growth Rates
Hamstrung by Hydrogen Damage Mechanisms
Non-intrusive FRP Inspection for Avoiding Premature Asset Retirement
Best Practices for Implementing a Risk Based Inspection (RBI) Program
Ensuring the Integrity of Oil and Gas Assets
Establishing a Mechanical Integrity Program for Fired Heater Tubes
Process-Based Risk Management: Layers of Protection to Avert Production Losses
The Role of Operations in Shutdown and Startup Best Practices
Advanced Buckling Analysis of a Reactor Tank Supported by Four Legs
Are Your FEMI KPIs Getting Old and Stale?
Beyond Hazardous Area Classification Mechanical Equipment Ignition Sources
Drone Inspection and NDT in the Oil, Gas and Petrochemical Industry
Establishing Risk Thresholds or Targets for RBI
Fight-or-Flight Inspection: Don't Let Big Findings Cloud the Big Picture
Investigating Pipeline Corrosion Failures
Making Bad Actor Elimination Programs Work
Microwave Inspection Technology Applied to Composite Pipeline Repair
Avoiding Corrosion Related Leaks in Processing Facilities
CML Optimization: Effective and Efficient Coverage and Placement
Fixed Equipment Mechanical Integrity (FEMI) Resources – Past vs. the Present
Novel Inspection System Aligns FRP and Metallic Asset Management Approaches
Pay Attention to the Condition of Your Passive Fire Protection and the Potential Risk It Hides
Risk Based Methodology for Industrial Steam Systems
Risk: An Ever Present Challenge
The Power of Proper Post-Weld Heat Treatment
A History of In-Line Inspection Tools
An Overview of Flare Systems for the Oil and Gas Industry
Executive Q&A with Clay White, Director of Mechanical Integrity for Phillips 66
Safe Operation of Aging Hydrogen Generation Plants
The Impact of Drones on Industrial Facilities
The Piping Integrity Management Challenge
Understanding Code Compliant Ultrasonic Testing
Article Index
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January/February 2018 Inspectioneering JournalBy Neil Burns at Stress Engineering ServicesThe actions you take immediately after a failure are critical in understanding the cause and appropriate steps to remedy the problem. However, the wrong moves might prevent you from getting the answers you need.
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March/April 2017 Inspectioneering JournalBy Matt Ellinger at DNV GLThe purpose of this article is to describe the various in-line inspection (ILI) technologies that are currently available to the market. The pros, cons, and applicability of each type of tool will be discussed in greater detail.
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November/December 2017 Inspectioneering JournalBy Stephen Flory at PinnacleARTAPM implementation is anything but a pain-free process. Blame tends to fall on vendors, but there are oftentimes activities that do not get completed that tend to have a larger effect on the success of implementation. This article addresses some of those activities.
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July/August 2017 Inspectioneering JournalBy Michael Turnquist at Quest Integrity GroupThis article outlines the engineering and assessment methodologies applied during the analysis of a failure of a 15-foot diameter reactor tank supported by four legs.
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Partner Content
It is difficult to cover all inspection applications with basic inspection procedures like radiography, ultrasonics, magnetic particle testing, and dye penetrant inspection. Owner-operators are finding that advanced NDE services such as guided-wave ultrasonics, AUT corrosion mapping, and eddy current testing are essential tools to keep their facilities operating safely and efficiently.
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January/February 2018 Inspectioneering JournalBy Bruce A. Pellegrino at Sensor Networks, Inc., and Mark Feydo at Sensor Networks, Inc.Over the past few years, network technologies have been developed to eliminate the need for long cables for UT thickness monitoring. Coupled with a software back-end, permanently-installed UT sensors have become much more competitive in the industrial landscape.
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March/April 2017 Inspectioneering JournalBy Ibrahim Kodssi at ADGASFlare systems provide hydrocarbon facilities with safe and efficient discharge of relief and waste gases by controlled open flame burning. This article provides information on the selection, inspection, and maintenance of various types of flares.
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July/August 2017 Inspectioneering JournalBy John Reynolds at IntertekAre your key performance indicators actually driving improvement? Could they be more effective? In this actionable and concise article, John Reynolds is back again to discuss some KPIs you could be using to monitor your progress down the path to FEMI excellence.
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November/December 2017 Inspectioneering JournalBy Hossam Aboegla at Lloyd's Register EnergyThe goal of achieving effective asset integrity management (AIM) throughout an asset’s life cycle requires certain “integrity enablers.” This article discusses six integrity enablers and their importance to a successful AIM program.
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Partner Content
InVista is a lightweight, hand-held ultrasonic in-line inspection tool (intelligent pig) capable of detecting pipeline wall loss and corrosion in unpiggable or difficult-to-inspect pipelines. The pipeline geometry inspection data captured by the InVista tool is exceptionally powerful when combined with the LifeQuest™ Pipeline fitness-for-service capabilities, providing an integrated solution set for the pipeline industry.
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May/June 2017 Inspectioneering JournalBy David E. Moore at Becht Engineering, PONO DivisionRead a firsthand account of how organizing Process, People, Plant, and Performance can reveal breakdowns in your corrosion management practices and drive down corrosion related leaks.
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September/October 2017 Inspectioneering JournalBy Stephen P. Webb at MetegrityThe challenges companies face when implementing an RBI program from scratch can make the practice seem daunting. To ensure that implementation is completed smoothly and the benefits of RBI are quickly realized, there are considerations that should be taken into account.
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July/August 2017 Inspectioneering JournalBy Richard W. Prugh at Chilworth Technology (a DEKRA Insight company)In deflagration incidents, electrical arcs and electrostatic sparks are often considered to be primary ignition sources. However, there are a variety of other ignition sources. Do you consider mechanical equipment and the significant non-electrical ignition hazards they may present?
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Building Your Reliability Program: An Interview with Eddie Acosta, Reliability Manager at Placid Refining
November/December 2017 Inspectioneering JournalIn this exclusive Inspectioneering interview, you’ll hear from Eddie Acosta, Reliability Manager at Placid Refining. During our discussion, he shared some of their challenges, strategies, and a transparent glimpse into some the real issues in his 82,000 bpd facility.
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May/June 2017 Inspectioneering JournalBy Ryan Myers at PinnacleART, and Brian Marino at PinnacleARTEffective condition monitoring location selection is a key component of a best-in-class mechanical integrity program. Learn how moving beyond traditional qualitative approaches to optimized CML selection can reduce risk and maximize the value of each inspection.
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January/February 2018 Inspectioneering JournalBy Ashfaq Anwer at Abu Dhabi National Oil Company (ADNOC)Sea water corrosion and erosion issues can affect almost all commonly used metallurgy in a refinery or petrochemical plant. This brief article explains the dangers behind sea water used in plant cooling systems and discusses several metallurgical and material solutions to resist sea cooling water corrosion.
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November/December 2017 Inspectioneering JournalBy Greg Alvarado at Inspectioneering Journal, and John Nyholt at John Nyholt Consulting, LLCThanks to the development of documents such as API RP 571 and API RP 586, as well as the emergence of qualification demonstration testing, we can align NDT techniques and inspection strategies better than ever. This article examines this progression and applies it to some sample NDT methods.
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November/December 2017 Inspectioneering JournalBy James R. Widrig at Quest Integrity GroupIn-service equipment failures present a considerable challenge to reliability engineers. This article presents a case study of a convection tube failure in a furnace and the analyses that were performed to understand the root cause and determine the remaining tube life.
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November/December 2017 Inspectioneering JournalBy Elizabeth Allen at DNV GL, and Michelle Havlock at DNV GL
This article explains the Statistically Active Corrosion Assessment, which is a tool for determining appropriate and realistic corrosion growth rates which can assist pipeline operators in optimizing the value of in-line inspection data, remediation programs and excavation costs, and determine a re‑inspection interval; all while maintaining safety.
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July/August 2017 Inspectioneering JournalBy Chris Leightell at Industrial SkyWorksThe adoption of drones for use in industry is a trend that has grown rapidly over the past few years. As the technology increases in popularity, its capabilities continue to evolve beyond basic visual imaging, boosting the list of ever-growing applications.
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September/October 2017 Inspectioneering JournalBy Tata L.N. Murthy at Gujarat State Petroleum Corporation LtdEnsuring the integrity of oil and gas assets is a challenge for oil and gas operators. This article discusses several “pillars” of asset integrity management on which successful O&G operations rely, including Material Selection, Process Safety, Inspection, and more.
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September/October 2017 Inspectioneering JournalBy Arun Sreeranganathan at Stress Engineering Services Inc., and John Norris at Stress Engineering ServicesFired heaters are among the most critical equipment in refineries and chemical plants, and failure of heater tubes presents significant safety and financial concerns. This article provides an overview of what a fired heater tube mechanical integrity program should include.
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July/August 2017 Inspectioneering JournalBy Greg Alvarado at Inspectioneering JournalEstablishing risk targets is an important aspect of any risk-based inspection (RBI) program and is a requirement of API RP 580. Metrics and consistency are important considerations for those using RBI to measure and manage risks as part of their decision-making process.
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Establishing the Right Mindset as Industry Seeks Improved Performance - An Important Challenge as We Move into 2018
January/February 2018 Inspectioneering JournalBy Greg Alvarado at Inspectioneering JournalMost of us that work integrity and reliability understand what we do and how we do it. But how many of us understand WHY we do things? Understanding the motives behind our activities, initiatives and programs can help to galvanize and lay a foundation for long term success.
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March/April 2017 Inspectioneering JournalBy Greg Alvarado at Inspectioneering JournalInspectioneering Founder and Chief Editor, Greg Alvarado, recently had the privilege to sit down with Clay White, Director of Mechanical Integrity for Phillips 66 (Downstream), to discuss the world of fixed equipment reliability in the refining and petrochemical industry.
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July/August 2017 Inspectioneering JournalBy Mark Savage at Sentinel Integrity Solutions, Inc.3 common repair scenarios include routine maintenance, scope repairs, and major discoveries. An inspector’s ability to properly manage each situation can mean the difference between mechanical integrity success and failure.
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May/June 2017 Inspectioneering JournalBy John Reynolds at Intertek35 years ago, an inspection supervisor, some inspectors, and a project engineer could cover an entire refinery. So why are so many more mechanical integrity resources needed today?
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Partner ContentTurnarounds are costly in terms of lost production. In many respects a turnaround can be even more complicated than the initial construction of the facility, so a carefully designed plan will reduce overall costs. After execution, safety reviews, Corrosion Monitoring Program updates, MOC documentation, and PHA Revalidations are a must.
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November/December 2017 Inspectioneering JournalBy Marc McConnell, P.E. at Pro-Surve Technical Services, and David A. Hansen, PhD, PE at Metallurgical Consulting, Inc.Hydrogen is a common culprit of equipment damage in the process industries. As hydrogen-induced damage can occur in multiple forms, it’s critical to identify the specific damage mechanism you’re dealing with before undertaking measures to prevent, mitigate, or repair.
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High Resolution Inspection Data and Advancements in Finite Element Analysis Make Level 3 FFS More Affordable
September/October 2017 Inspectioneering JournalBy Tyron Kimble at SonomaticDue to its high-cost, Level 3 FFS is typically carried out after Levels 1 or 2 and only in extreme cases. However, advancements in inspection technology and improved use of inspection data have made Level 3 analysis more practical and affordable, even in less critical cases.
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January/February 2018 Inspectioneering JournalBy Mohamed Attia at Saudi AramcoThis article, the first of a multi-part series, discusses the methodology and need for establishing an integrated and holistic framework for managing asset integrity on a day-to-day basis.
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Importance of Amine System H2S and CO2 Recovery Efficiency to Avoid Fouling and Elevated Corrosion Rates
September/October 2017 Inspectioneering JournalBy Massimo Capra at AggrekoAmine systems that scrub H2S from hydrogen-rich gas experience rapid fouling of the heat transfer equipment, especially in a hot summer. Learn how temporary cooling solutions can improve process conditions during critical periods of the year with no production interruption.
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July/August 2017 Inspectioneering JournalBy Rick Eckert at DNV GL - North America Oil & Gas, and Dr. Kathy Buckingham at DNV GLFailure analysis of piping that has experienced corrosion damage provides operators with valuable information needed to prevent future failures. Effective processes and procedures are essential when investigating the cause of corrosion on pipelines and piping systems.
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July/August 2017 Inspectioneering JournalBy Rick Hoffman at Becht EngineeringMost plants have pieces of equipment that are chronic problems. These problems impact profitability due to the frequency of outages, unexpected cost of repairs, and cost of lost production. It is critical that some specific actions are taken to identify and eliminate these “Bad Actors.”
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July/August 2017 Inspectioneering JournalBy Buddy Powers at Clock Spring Company, and Donald McNichol at Evisive, Inc.Composite technology developed for pipeline repair can be a cost-effective method of improving safety while keeping maintenance costs down. However, composite materials present significant challenges to conventional NDT methods.
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November/December 2017 Inspectioneering JournalBy Geoff Clarkson at UTComp, Inc.This article, part two in a series, provides a case study of an inspection and evaluation of a Fiberglass Reinforced Polymer (FRP) column using nondestructive ultrasound readings on the outer surface of the FRP.
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May/June 2017 Inspectioneering JournalBy Geoff Clarkson at UTComp, Inc.Discover a new ultrasonic inspection approach that provides quantified mechanical integrity and conservative remaining service life information on fiberglass reinforced plastic equipment.
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January/February 2018 Inspectioneering JournalBy Phillip E. Prueter at The Equity Engineering Group, Inc.Given the concern throughout industry regarding the potential for brittle fracture failures, PWHT guidance to address potential issues arising from the recent changes in PWHT code requirements for carbon steel is examined in this article, and commentary on the potential reduction in fracture toughness due to PWHT is provided based on a review of published literature.
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May/June 2017 Inspectioneering JournalBy Justin Nickel at PK TechnologiesAre you giving CUF the attention it deserves? Learn the vital role fireproofing plays in maintaining the integrity and reliability of what it protects as well as what's needed for managing potential CUF issues.
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September/October 2017 Inspectioneering JournalBy Daniel Cypriano at Petrobras, and Henrique Ventura at PetrobrasAlthough value-drivers often differ between facilities, all can agree that effective asset management strategies should lead to better decision making. In this case study, the authors detail how process-based risk management strategies can make for improved use of equipment.
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May/June 2017 Inspectioneering JournalSteam systems account for almost a third of the energy used in industrial applications for product output. Maintaining their integrity and efficiency is vital. Learn how an effective risk-management process aids in the optimization of these critical assets.
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May/June 2017 Inspectioneering JournalBy Mike Asquini at T.A. CookRisk is an inherent aspect of asset management. Unfortunately, controlling it is easier said than done. Risk must be managed beginning with the initiation of a project and lasting until completion. How can one implement a reliable risk management program while balancing organizational demands?
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March/April 2017 Inspectioneering JournalBy Vibha Zaman, P.E. at Asset Optimization Consultants, and Leomar Penuela at Asset Optimization ConsultantsThis article discusses the use of the RBI methodology supplemented by a well-designed IOW program to assess and manage aging in fixed equipment and piping in hydrogen generation units.
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January/February 2018 Inspectioneering JournalBy Mark Rigdon at T.A. Cook Consultants, Inc.Teams planning and executing turnarounds are obliged to not only stay within budget, but to reduce or eliminate the need to spend the contingency allowance. This article introduces a risk-based approach to help avoid squandering finances.
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March/April 2017 Inspectioneering JournalBy Rami Mattar at Amerapex CorporationApplication of drones in industrial inspections is not new, although it is still performed by only handful of companies. Market penetration of this technology in the industrial space has been relatively slow.
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March/April 2017 Inspectioneering JournalBy Fernando Vicente at ABB, and Laza Krstin at ABBMyths, challenges, and good practices related to process piping integrity management activities that help inspection and maintenance managers make the right decisions to develop cost-effective piping inspection plans without compromising the asset’s reliability or performance.
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May/June 2017 Inspectioneering JournalThe "simple" process of PWHT is more complicated than it may appear at first glance. Knowledge of the procedures, attention to details, and actual experience are indispensable in preventing failures caused by improper PWHT.
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May/June 2017 Inspectioneering JournalBy Hossam Aboegla at Lloyd's Register EnergyAsset integrity and life cycle management are unique but intertwined concepts. The dynamic process between these principles has a significant impact on the lifecycle of individual assets and, therefore, the integrity of an entire plant.
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September/October 2017 Inspectioneering JournalBy Lee Williamson at T.A. Cook Consultants, Inc.Detailed operations planning and scheduling is an essential, yet often marginalized, element of an effective turnaround. To increase the likelihood of executing successful turnarounds, facilities should create and update sound operational shutdown and startup procedures.
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September/October 2017 Inspectioneering JournalBy John Reynolds at IntertekAlthough commonly lumped together as a singular acronym, there are important distinctions between Quality Assurance (QA) and Quality Control (QC). This article defines and distinguishes the role of QA and, in particular, how source inspection factors into that role.
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January/February 2018 Inspectioneering JournalBy Kyle Dunn at Dunn Heat Exchangers, Inc.Cleaning of heat exchangers and other process equipment is typically done with the use of pressurized water (e.g., hydro-blasting). However, in some situations thermal decomposition, a technique that utilizes heat rather than water to break down foulants, might more effective.
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March/April 2017 Inspectioneering JournalBy Bob Lasser at Imperium, Inc.Ultrasonic phased array allow for a variety of structures to be inspected without radiation or taking equipment out of service. Codes are now being developed which allow phased array systems as an acceptable inspection technique for many procedures.
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January/February 2018 Inspectioneering JournalBy Jonathan Martinez at PK TechnologyInspection data is vulnerable to flaws in collection and retention. For example, data might be inaccurate, duplicate, or incomplete due to procedural breakdowns. This article introduces Digital Data Management Systems (DDMS) as a response to these widespread data inaccuracies.
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March/April 2017 Inspectioneering JournalBy A.C. Gysbers at The Equity Engineering Group, Inc.Integrity Operating Windows (IOWs) have a subset of operating variables that are important for degradation monitoring, but may not have direct operational controls. Per API RP 584 Integrity Operating Windows, these are known as IOW Informational Limits, which are often neglected or misunderstood by operations or technical personnel within a plant.
