Inspectioneering

Article Index

Executive Q&A with Clay White, Director of Mechanical Integrity for Phillips 66
March/April 2017 Inspectioneering Journal
By Greg Alvarado at Inspectioneering Journal

Inspectioneering 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.

The Piping Integrity Management Challenge
March/April 2017 Inspectioneering Journal
By Fernando Vicente at ABB, and Laza Krstin at ABB

Myths, 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.

Dead Leg Integrity Management System
November/December 2016 Inspectioneering Journal
By Mohamed Amer at TUV Rheinland

This article describes a high-level dead leg integrity management program overview and is based on experience, knowledge, and adaptation of inspection management philosophies currently being implemented within the Oil & Gas and the petrochemical industry.

A History of In-Line Inspection Tools
March/April 2017 Inspectioneering Journal
By Matt Ellinger at DNV GL

The 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.

Piping Inspection – Much More Than Thickness Monitoring
January/February 2017 Inspectioneering Journal
By Israel D. Martinez at ORPIC

Evaluating remaining wall thickness of an asset is not enough to ensure its continued safe operation. Proactive strategies should be implemented to assess the entire environment affecting an asset’s condition, including the development of more effective inspection plans.

January/February 2017 Inspectioneering Journal

Historically, if asked when or how likely an austenitic series stainless steel component is to crack, corrosion engineers usually answered “very” or “maybe” or, later, “I didn’t see that coming.” With the introduction of API’s formal risk assessment methodology, that situation has changed over the past 20 years.

Safe Operation of Aging Hydrogen Generation Plants
March/April 2017 Inspectioneering Journal
By Vibha Zaman, P.E. at Asset Optimization Consultants, and Leomar Penuela at Asset Optimization Consultants

This 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.

Risk Management (RBI/Reliability) in a Lean Operating Environment and Uncertain Future
January/February 2017 Inspectioneering Journal
By Edwin A. Merrick, PE at The Augustus Group

This article presents a perspective on the human factor and emphasizes the value of using risk tools at all levels in the organization to help provide management focus during times of severe economic pressure.

Identifying Common Mistakes in Inspection Interval Determination
January/February 2017 Inspectioneering Journal
By Chuck Provost at Sentinel Integrity Solutions

Some facilities lead the industry with streamlined RBI/IOW programs, and some facilities are just implementing standard calendar-based programs. Both are still susceptible to inspection interval gaps.

Top Integrity Challenges: Oil and Gas Surface Facilities
January/February 2017 Inspectioneering Journal
By Abdelmounam Sherik at Saudi Aramco Research and Development Center, Mark Rosa, PE at Harvard Business School, and Abderrazak Traidia at Saudi Aramco Research and Development Center

This article summarizes a comprehensive survey conducted by the Research & Development Center (R&DC) of Saudi Aramco to understand top corrosion damage mechanisms experienced by its operating onshore surface facilities.

Partner Content

Our proprietary furnace tube inspection system, FTIS™, is an ultrasonic inspection technology capable of rapid, automated fired heater coil inspection in refinery fired heaters. The data captured by our furnace tube inspection system is exceptionally powerful when combined with our LifeQuest™ remaining life assessment capabilities, providing an integrated solution set for refinery fired heaters in the refining and chemical industries.

An Overview of Flare Systems for the Oil and Gas Industry
March/April 2017 Inspectioneering Journal
By Ibrahim Kodssi at ADGAS

Flare 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.

Fifty Important Roles & Responsibilities of the Plant Corrosion/Materials Specialist
January/February 2017 Inspectioneering Journal
By John Reynolds at Intertek

In this article, the roles and responsibilities of the corrosion and materials SME will be outlined as I see them, fully recognizing that there is probably no one person out there with all the knowledge and skills suggested herein.

7 Questions You Need to Answer when Establishing an Integrity Management Program
November/December 2016 Inspectioneering Journal
By Loganatha Pandian at Meridium, Inc.

This article summarizes seven key questions that an organization needs to answer to create a robust mechanical integrity program that is properly designed to monitor corrosion and indicate when issues increase to a level requiring review or maintenance.

Examining the Latest Changes to API RP 581 Risk-Based Inspection Methodology Thinning and the Probability of Failure Calculations
November/December 2016 Inspectioneering Journal
By Lynne Kaley at Trinity Bridge LLC / Trinity Bridge Digital

This paper provides the background for the technology behind the Third Edition thinning model as well as step-by-step worked examples demonstrating the methodology for thinning in this new edition of API RP 581.

Calculating the Required Structural Thickness of Pipe Using Beam Stress Theory
November/December 2016 Inspectioneering Journal
By Nolan L. Miller at SASOL North America

This article will go through the methodology of each process that could be used in determining the structural component for the required pipe wall thickness, but will focus on the use of Beam Flexural Stress calculations and Beam Deflection calculations to determine the structural component of the required pipe wall thickness calculation.

January/February 2017 Inspectioneering Journal
By Justin Nickel at PK Technologies

Today’s intelligent technology can provide is interoperability, mobile data collection, cascading questions, picture referencing, photo annotation, data funneling and cost savings. Take a closer look at some of the benefits intelligent technology can provide.

The Impact of Drones on Industrial Facilities
March/April 2017 Inspectioneering Journal
By Rami Mattar at Amerapex Corporation

Application 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.

Harnessing the Power of Big Data to Drive Improvements in Reliability and Maintenance
January/February 2017 Inspectioneering Journal
By David Aldrich at North Highland, and Teri Mendelovitz at North Highland

This article covers where to start, what to look for, and how to execute a data and systems-focused performance improvement project that can drive large overhead savings.

Understanding Code Compliant Ultrasonic Testing
March/April 2017 Inspectioneering Journal
By 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.

November/December 2016 Inspectioneering Journal
By Blake Stermer at Sentinel Integrity Solutions

As the industry strives to maintain PSM/OSHA compliance through owner/user mechanical integrity programs, inspection professionals should fully understand technical standards to generate an adequate repair recommendation or request further inspection and testing

Partner Content

Our proprietary furnace tube inspection system, FTIS™, is an ultrasonic inspection technology capable of rapid, automated fired heater coil inspection in refinery fired heaters. The data captured by our furnace tube inspection system is exceptionally powerful when combined with our LifeQuest™ remaining life assessment capabilities, providing an integrated solution set for refinery fired heaters in the refining and chemical industries.

September/October 2016 Inspectioneering Journal
By Greg Alvarado at Inspectioneering Journal

Risk-based inspection (RBI) programs and processes are front and center, both as a challenge to get it right, and as an integral tool and process to help us achieve success in risk management and equipment reliability. It has to be implemented, maintained, sustained, and in a state of continuous improvement over time in order to achieve the desired results.

Advancements in CUI Detection and Overview of MsS Guided Wave
November/December 2016 Inspectioneering Journal
By Adam Gardner at PinnacleART

Beyond the financial hits, undetected degradation from corrosion can also lead to critical safety risks. To effectively manage mechanical integrity, organizations need reliable methods of identifying the current states of corrosion occurring within their assets.

Integrating and Planning Maintenance Activities  in Oil and Gas Installations
September/October 2016 Inspectioneering Journal
By Tata L.N. Murthy at Gujarat State Petroleum Corporation Ltd

For all operators, a system made up of a variety of equipment must be available to carry out continued operations. Planning plays a vital role in the success of major maintenance projects. Integrating all departments in the maintenance plan can save operators time and money, can increase equipment availability, and can help ensure the activities are conducted in a safe and efficient manner.

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.

Using Rolling Averages for IOW “Informational” Monitoring
March/April 2017 Inspectioneering Journal
By 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.

November/December 2016 Inspectioneering Journal
By Grady Hatton at Versa Integrity Group, and Marc McConnell, P.E. at Versa Integrity Group

The concept of reducing Condition Monitoring Locations (CMLs) is misguided, and the number and location of CMLs should be OPTIMIZED, not systematically reduced. CML allocation in piping requires a good process, otherwise, you can run into a lot of dead ends before arriving at your intended destination.

Auto-Ignition of Ultrasonic Couplants During Thickness Gauging and Corrosion Mapping
July/August 2016 Inspectioneering Journal
By Gene Larson at ECHO Ultrasonics

This article details the basis for the lack of understanding about the potential for ultrasonic couplant auto-ignition and outlines an ALARP operating practice for mitigation.

Detecting and Quantifying Cracks Using Eddy Current Array
September/October 2016 Inspectioneering Journal
By Kimberley Hayes at Olympus

Detecting, quantifying, and sizing indications characterized as a “crack” in critical equipment have long been the global benchmark of asset integrity programs. Therefore, the increased precision that inspection programs obtain using advanced technologies can dynamically improve the overall assessment.

Remote Integrity Monitoring of High Criticality Equipment in Real Time
September/October 2016 Inspectioneering Journal
By Dr. Jake Davies at Permasense Ltd.

Remote monitoring solutions are making it possible to avoid sending personnel into harsh environments without forgoing the essential data gathering that keeps assets safely operating.

World
November/December 2016 Inspectioneering Journal
By Joey Johnston at DronePro, LLC

In the first quarter of 2016, Texas-based DronePro LLC completed the first ever inside-the-derrick inspection of an offshore drilling rig utilizing a proprietary unmanned aircraft system (UAS), or drone, with its associated technology and equipment.

Have you determined whether or not your equipment is subject to Brittle Fracture?
Partner Content

Auto-refrigeration can impose low temperatures onto process vessels and piping causing them to be at risk of brittle fracture, the sudden break-before leak phenomena that can result in catastrophic rupture of the equipment.

November/December 2016 Inspectioneering Journal
By Greg Alvarado at Inspectioneering Journal

Human factors, inspection effectiveness, and RBI all play an important role in running an effective asset management program. This article discusses how each is applicable to inspecting equipment in processing facilities.

Embracing a New Approach to Retroactive PMI
July/August 2016 Inspectioneering Journal
By Brian Wilson at Thermo Fisher Scientific

The instrumentation available to detect inadvertent material substitutions through positive material identification (PMI) has never been more available, portable or powerful than it is today. For one industrial services company, Tacten Industrial, Inc., embracing the latest technological advances in PMI while using rope access to conduct inspections has helped to transform their business. It has found the ideal formula for retroactive PMI that allows its team and its clients to rest assured that they’ve conducted their testing right – the first time.

September/October 2016 Inspectioneering Journal
By James Cheng at Bureau Veritas

Having a systematic, proven methodology for effectively qualifying suppliers is extremely important. Supplier Technical Assessments, or “vendor assessments,” help buyers evaluate suppliers’ qualifications when considering their capabilities to manufacture specified industrial components or provide the desired services.

Detection of Defects and Corrosion Under Pipe Supports and Inaccessible Areas Using EMAT Medium Range UT Techniques
May/June 2016 Inspectioneering Journal
By Borja Lopez at Innerspec Technologies, Inc.

In the last few years, electromagnetic acoustic transducer (EMAT) has come to prominence for its ability to quickly scan exposed pipelines for corrosion, cracks, and other defects using medium-range guided waves and without the requirement for liquid couplants.

The Hierarchy of a Fixed Equipment Asset Integrity Management Program
September/October 2016 Inspectioneering Journal
By John Reynolds at Intertek

Did you ever wonder where you fit into the entire hierarchy of a fixed equipment asset integrity management (FE-AIM) program? Or who is responsible and accountable for what aspects of FE-AIM at your site? All the way from top management down to those doing the work at the field level? That’s what I will try to address in this article.

Piping Vibration Assessments
July/August 2016 Inspectioneering Journal
By Jacob Manuel, P.E. at Stress Engineering Services, Inc., and Ralph E. King P.E. at Stress Engineering Services, Inc.

An overview of process piping vibration and evaluating piping systems in vibration service to reduce harmful vibrations.

What Is Refractory?
July/August 2016 Inspectioneering Journal
By Jackson Espinoza at Sentinel Integrity Solutions

An explanation of refractory including its uses and recent advancements in abrasion-resistant materials, dry-out/cure times, improved installation methods, and anchoring systems.

July/August 2016 Inspectioneering Journal
By Grady Hatton at Versa Integrity Group, and Melissa Guerra at Chevron Products Company

Many plants inspect PRDs on preset intervals as recommended by inspection code API 510, and implement inspection practices such as API RP 576. Just seeking PRD compliance with codes and standards usually results in mediocre mechanical integrity and process safety. Companies must go further to climb the ladder to “excellence.”

The Application of Response Surface Methodology in Modeling Corrosion Rates
May/June 2016 Inspectioneering Journal
By Mohammed Siddiqui at Air Liquide

The main intention of this article is to introduce the Response Surface Methodology (RSM) using some of the elements of critical thinking as a guide. This methodology is not often used in the industry, but can be widely used by corrosion/process engineers to identify hot spots where local maximums of corrosion rates exist.

July/August 2016 Inspectioneering Journal
By Guy Bogar at HollyFrontier - Tulsa Refinery

Turnarounds operate at a different pace than routine work. Most plant-based inspection departments have historically struggled with Turnaround document control, such as integrating contractor reports into their routine data management system. Our solution was to execute RBI updates in real time during Turnaround execution.

Fitness for service: a powerful tool to keep your plant running safely
Partner Content

FFS assessment techniques are applicable to a wide range of damage types: LTA's, cracks, creep damage, dents, and more. These are very powerful analytical tools that often allow operators to not only keep the plant running, but to keep it running safely.

Improving Confidence in On-Stream Inspections of Pressure Equipment
May/June 2016 Inspectioneering Journal
By Dr. Yury Sokolov at SVT Engineering Consultants

RBI and NII are designed to achieve significant cost savings and risk mitigation benefits over a piece of equipment’s lifetime in the long term (e.g. through greater reliability and inspection optimization). It is important to strategically consider new NDE technologies to obtain data of sufficient confidence to satisfy the requirements of the risk model.

Choosing the Right Smart Pigging Technology – Lessons Learned
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.

May/June 2016 Inspectioneering Journal

This paper identifies the attributes and benefits of a data and metrics-driven management system focused on process safety design integrity and reliability relative to loss of primary containment (LOC). This management system process focuses on the four key business drivers of risk (i.e. regulatory compliance, operations, and profits), and involves several distinct business methods involving people, processes, and tools/technology.

Common Joint Integrity Challenges on CAPEX Projects
May/June 2016 Inspectioneering Journal
By Neil Ferguson at Hydratight

Large scale capital projects present a myriad of challenges for owner-users in the oil and gas and petrochemical industries. Budgets are constantly being stretched and project deadlines are often exceeded. One area that deserves attention from all parties involved is joint integrity management.

July/August 2016 Inspectioneering Journal
By Neil Ferguson at Hydratight

Joint integrity management remain at the top of many operators’ priority list.  The discipline considers risk and drives safety to ensure we learn necessary lessons from past catastrophic failures, such as the Piper Alpha explosion in 1988, where leaking gas condensate ignited and killed 167 of the 229 people on board the offshore rig.

July/August 2016 Inspectioneering Journal
By Mike Johnston at T. A. Cook Consultants, Inc.

This article will examine what can occur during the course of a Front Line Supervisor’s day that may hinder the execution of their expected duties, and what can be put in place to overcome those obstacles.

Program Evergreening and Sustainability Assistance is Key to Establishing Successful Integrity and Reliability Programs
September/October 2016 Inspectioneering Journal
By Kevin Birkby at PinnacleART

Integrity and reliability personnel at processing facilities are no strangers to initiatives to improve processes in the pursuit of establishing best-in-class reliability programs. It is common practice for operators to enlist help from third parties that specialize in implementation of programs like Risk-Based Inspection (RBI) and Asset Management.

Clearing out the Data Clutter: How well-maintained data can add value to your reliability program
May/June 2016 Inspectioneering Journal
By Jeffrey Foushee at Pinnacle Advanced Reliability Technologies, and Ryan Myers at Pinnacle Advanced Reliability Technologies

Data, in pure form, consists of raw, unorganized facts that need to be processed. Data can be found in databases, documents, drawings, reports, spreadsheets, and numerous other sources. Having data on hand is useful, however, it’s often inefficient and counterproductive to make decisions based on data in its raw form.

Digital Radiography of Welds Using Flat Panel Detector Base Image Sensors
July/August 2016 Inspectioneering Journal
By Sanjoy Das at Bhabha Atomic Research Centre, and D. Mukherjee at Bhabha Atomic Research Centre

The structural integrity of components is controlled by material properties, the presence of flaws, and levels of applied stress. Several factors such as temperature, type of loading, toughness, corrosion resistance, micro-structural stability, cost etc. dictate the suitable material for the desired application.

Powering Impressed Current Cathodic Protection – Part 2
May/June 2016 Inspectioneering Journal
By Gary Mulcahy at Astrodyne TDI

This is the second article of a two-part series published in Inspectioneering Journal, which is intended to provide a basis for understanding the differences between traditional tapped-transformer, fixed voltage type rectifiers, and High Frequency Switched Mode (HFSM) units, as well as highlight some opportunities for optimization provided by HFSM.

Partner Content

Offshore platforms are exposed to some of the roughest conditions on earth and require regular attention to ensure they are structurally sound and safe for continued operation. With so many components and major joints at elevated locations, it is clear why a well-trained rope access technician can be an invaluable resource for offshore operators.

The Use of Miniature Test Specimens in  Fitness-for-Service Evaluation
May/June 2016 Inspectioneering Journal
By Douglas Marriott at Stress Engineering Services Inc., Shannon Read at Stress Engineering Services Inc., and Arun Sreeranganathan at Stress Engineering Services Inc.

Aging equipment, along with more aggressive service, makes it more important than ever to carry out fitness-for-service (FFS) assessments in support of run/repair/replace decisions. Testing material in the service-degraded condition enables quantification of the material condition and provides increased accuracy in FFS evaluations of these components.

Highlights from API’s 2016 Spring Refining Standards Meeting: Subcommittee on Inspection (SCI)
May/June 2016 Inspectioneering Journal
By John Reynolds at Intertek

This brief article contains updates and highlights related to the Subcommittee on Inspection (SCI) at the 2016 API Spring Refining Equipment and Standards Meeting.

Remaining Life Sensitivity to Longitudinal Weld Seam Peaking in High-temperature Low Chrome Piping
July/August 2016 Inspectioneering Journal
By Phillip E. Prueter at The Equity Engineering Group, Inc., Jonathan D. Dobis at The Equity Engineering Group, Inc., Mark Geisenhoff at Flint Hills Resources, and Dr. Michael S. Cayard at Flint Hills Resources

This article summarizes a recent finite element analysis (FEA)-based study that employs creep simulation techniques to investigate the elevated temperature response of piping with peaked longitudinal weld seams.

Improving the turnaround lifecycle through careful planning, proper execution, and thorough documentation
Partner Content

Turnarounds 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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