A Quest for Defect-Free Plant Operation - Part 3
An Effective Structural Integrity Program as Part of a Comprehensive Mechanical Integrity Program
CUI Robotics: Pushing the Envelope
FFS Forum: Thickness Grids & Critical Thickness Profiles
How Inferior UT Procedures and Practices on Pressure Vessels Cost $1 Million in Turnaround Repairs
Lessons from a Risk-Based Career
Maximizing the P-F Interval with Predictive Maintenance
The Current and Future State of Industry Training
The Eight Pillars of Excellent FEMI Programs
Automating and Optimizing the CML / TML Data Collection Process
Extended RBI for Exchanger Bundles
FFS Forum: What is a Major Structural Discontinuity?
Piping Leaks and Failures Can Be Substantially Eliminated – Here’s How
The Evolution of Robotics in Inspections
The Inspection of Mechanical Insulation Systems: More Important Today than Ever Before
The Significance of Piping Color Codes
The Value of a Baseline Inspection on New Fired Heater Tubes
A Framework for Conducting Analysis of Microbiologically Influenced Corrosion Failures
An Inspired Approach to Storage Tank Inspection Practices
Bridging Acoustic Emission Testing and Ultrasonics for FRP
Corrosion Damage Mechanisms Review and Inspection Guidelines For Gasification Units
Qualitative Risk Assessment of a Commercial Refrigeration System
Tales of Storage Tank Failures, Damage and Inspections of Storage Tanks
The Importance of Turnaround, Shutdown, and Outage Assessments
The Real Expense and Liability of a Dated Engineering Standards Program
Corrosion Under Insulation and Touch Point Corrosion - There Are No Silver Bullets
Corrosion Under Insulation of Chemical Plant Pressure Vessels
FFS Forum: Creep in Heater Tubes and Other Components – Part I: Understanding Creep
Getting the Most out of Your Corrosion Control Documents
Inspect Your Primary Process Small Bore Piping the Right Way, Using Profile Radiography
Managing Reliability of Ethane Crackers using DMR, RBI, and IOWs
A Quest for Defect-Free Plant Operation - Part 2: Implementing a Fully Integrated Management System
FFS Forum: Minimum Pressurization Temperature (MPT) Curves: Why and How they are Going to Change
How Logistics Impacts Shutdowns, Outages, and Turnarounds
More Than Meets the Eye: Manage Particle Contamination and Prevent Equipment Failures
FEMI Mountains We Have Climbed and Those We Still Need to Climb
FFS Forum: Primary & Secondary Stresses – What’s the Difference & Why Do We Care?
Heat Treatment: For Knives or Knockout Drums
Impact of Welding Defects on Integrity of Equipment & Piping
Make 2019 the Year You Improve the “Data Fidelity” of Your Inspection Program
Roadmap for Effective Risk-Based Inspection Implementation
2019 Inspectioneering Journal Article Index
A significant number of pipeline failures due to external or internal corrosion have resulted from MIC, some with catastrophic consequences. This article demonstrates a three-step failure analysis process used to investigate the failure mechanism.
A quest for a defect-free operation requires an effort to systematically reduce the current equipment failure rates. This series proposes a newer, leaner way of thinking to help discover and eliminate conditions that may lead to defects.
This article describes some strategies owner/users can implement to reduce failure rates, eliminate wasteful activities, reduce costs, increase capacity, improve safety, and achieve the goal of defect-free operations.
This article wraps up the three part series by combining management systems to work towards the ultimate goal of achieving a defect-free operation in process plants.
Effective asset management has become no less than a strategic requirement for asset intensive organizations. By integrating available standards such as ISO 9001 and PAS 55, companies can develop a sound asset management strategy.
This article discusses how a technology coupled with API 1177 allows construction crews, inspectors, and pipeline integrity engineers to quickly analyze inspection, NDT, and commissioning data in near real-time, as well as problem solve in the field.
This article shares some benefits of pro-actively performing RBI assessments during the design and construction phase of the plant with professionals involved in fixed equipment mechanical integrity programs.
Much like the equipment and piping they support, structures should be part of a comparable structural integrity (SI) program. This article will examine key components of a comprehensive SI program as an essential companion to an MI program.
Integrating a new digital technology that combines data-driven insights and data storage with innovative mobility can provide a new level of connected intelligence. Digitalization can improve workflow, increase worker productivity and allow better...
Tank inspection to achieve regulatory compliance has often been viewed as just another expense. This article takes the opposite view by utilizing regulatory compliance as a means for enhancing overall efficiency, awareness, safety, and profitability.
The quality of the thousands of factory and field welds present in pressure part modules is critical for assuring reliable operation over the life of a plant. Companies should be doing more than paying lip service to quality. Don't just tick a box.
Thickness readings are critical for today's inspectors to accurately judge the state of their equipment. Recent advancements in sensors, software, and data management tools have made this easier, safer, and more efficient than ever before.
This article is written to provide a brief case study of an acoustic emission test of an FRP storage tank. A method combining acoustic emission with ultrasonics is proposed to ensure reliable long term operation.
Gasification technology has emerged in oil and gas due to the high combustion energy of Syngas and less environmental concerns than flue gas. This article discusses proper inspection and corrosion monitoring techniques for gasification units.
Inspectioneering and PinnacleART recently hosted a roundtable discussion for a select group of mechanical integrity experts to discuss strategies for managing corrosion under insulation and corrosion under pipe supports, a.k.a. touch point corrosion.
This article details an experience assessing the mechanical integrity of a feed pressure vessel, and describes the methodology carried out for detecting CUI and how results were managed for this pressure vessel.
This article examines multiple trials that entailed testing robotic systems on different non-magnetic surfaces to identify the feasibility of detecting CUI using robotics in combination with NDE technology.
The author discusses a method being used in most of their refineries and petrochemical facilities that allows them to optimize the scope of NDT during turnarounds, while improving the reliability of bundles.
This article provides a summary of the 2019 API Inspection & MI Summit keynote address, which offers a past, present, and future outlook on fixed equipment mechanical integrity from an industry professional with 50+ years of experience.
This is the first of a two-part column on “Creep”. It presents an engineering overview of the phenomena, answers the question: “What is Creep?”, and provides readers with foundational knowledge for evaluating and managing remaining...
This is the second of a two-part column on “Creep.” This second part discusses the approach to creep assessment in plant equipment.
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.
Brittle fracture and material toughness issues are important concerns in equipment design and FFS. These issues increase when temporary start-up and shutdown conditions require more detailed assessments than provided for in vessel and piping codes.
The distinction between primary and secondary loads is certainly important in analysis of pressure systems. But this distinction is also important for plant operations and reliability engineers to keep in mind when dealing with day-to-day problems.
A cornerstone of Level 1 and 2 metal loss assessment methods in API 579 is the concept of measuring thickness on a grid and constructing a “critical thickness profile.” These concepts are fundamental to Level 1 & 2 assessments in both Parts 4...
MSDs are an important, but often misunderstood, element of FFS analyses. This column will help readers understand what an MSD is and why it is so important to Fitness-For-Service analysis under API 579.
CCDs are critical components of a well-maintained MI program and encompass all necessary and relevant MI information for a given process unit. This article defines the value of having CCDs and addresses how to effectively develop and implement them.
Understanding how steel can change and be manipulated is crucial to our ability to spot potentially harmful situations in the field. Whether it is a blade made too brittle or a weld that needs post-weld heat treat, knowledge is power.
This article helps shine light on some common industry problems that can occur by having inferior UT procedures and practices, while providing several lessons learned through a case study that resulted in nearly $1 million in turnaround repairs.
Creating a proper work scope and developing and executing an effective work plan are essential for a successful turnaround. However, behind the scenes exists the glue that pulls the entire effort together: logistics.
In today's chemical and refining industries, sustained long term reliability of facilities is critical to profitability and competitiveness. In fact, history shows that differences in operating expenses between best-in-class refineries, and poor...
AET is a powerful, non-intrusive inspection technique to verify the structural integrity of pressure vessels, spheres, high-temperature reactors and piping, coke drums, above-ground storage tanks, cryogenic storage tanks, and more.
Welding imperfections vary in impact from being acceptable to requiring repair. It is important to ensure the quality of welds using NDT and to ensure the strength of the entire piping system with hydrotesting.
While planning methods for thickness data acquisition in any Inspection Data Management Program, PRT should be considered as a cost-efficient, effective way to increase the value of your program for small bore piping or any other suitable situation.
I have been involved with risk-based inspection and risk-based work process development for much of my career. The one thing I have learned as I’ve walked this path is that the concept of ‘risk’ extends far beyond our industry.
Take advantage of every reasonable opportunity to properly organize your databases. As the information moves toward High Fidelity, you can achieve improved effectiveness and efficiency in your reliability and mechanical integrity programs.
A well-implemented and managed reliability program incorporating RBI, DMR, and IOWs can identify potential damage mechanisms, optimize maintenance and inspection activities, reduce risks, and improve the governance in managing Ethane Crackers.
This article introduces the P-F Interval and its importance in predictive maintenance, describes methods to detect failures early, and maps out a path to begin an effective Predictive Maintenance program at one’s facility.
According to industry experts, particle contamination in lubricants is the number one cause of lubricant-related equipment failure. Fortunately, there are steps operators can take to reduce contamination and increase the service life of equipment.
In order to utilize data most effectively and realize the full power of AE testing, it is necessary to bring the capabilities of laboratory testing tools to industrial sites.
Everyone wants fewer leaks and failure of their equipment and piping; but I find very few sites that effectively use one method to make substantial reductions in their piping leaks and failures.
This case study is intended to demonstrate how a Qualitative Risk Assessment can be a cost-effective and resource-efficient means to prioritize equipment which is often “under the radar”.
An effective RBI system implementation results in, not only safeguarding your assets & people, but can also reduce unnecessary inspection activities that may be required due to conventional & nonsystematic approaches.
Tanks are ubiquitous and essential in industrial societies. When they fail, the consequences can be dire if products/volumes they store are explosive and/or toxic.
In this article, Inspectioneering interviews Tye Beard at ASTM, a leading standards organization that develops and publishes consensus standards for the process industries, to discuss the current and future state of industry training.
A refinery or process facility FEMI program consists of eight Pillars that are fundamental to achieve FEMI excellence. This article describes these Pillars in detail and suggests what distinguishes good Pillars from those that are less than adequate.
The refining and petrochemical industries will continue to benefit from the evolution of robotics and data management. The biggest hurdle will be to accept this evolution and embrace the new capabilities that come with it.
Major maintenance events require proper planning, scheduling, and execution to achieve a successful outcome. An outage assessment process can deliver an effort that is safe, on budget, on schedule, and ensures long term plant equipment reliability.
There are inspection requirements in many construction disciplines, including electrical, welding, coating, and the list goes on, but not for mechanical insulation. The need for a certified mechanical insulation inspection program is long overdue.
This article provides a case study showing the real costs and effects of having a dated engineering standards program, as well as the financial benefits through increased reliability of having a thriving engineering standards program.
If an inspector knows both the content and material of construction of piping, it would be useful when performing inspection. However, this is only possible when there’s a system in place at the site for identifying piping.
This article presents two cases studies demonstrating how properly conducting baseline fired heater tube inspection aids in early discovery and correction of defects, avoiding unexpected in-service failures, and more.
A damage mechanism review, or DMR, is a structured process performed by a qualified team to gain a better understanding of unit operations, corrosion loops, materials of construction, and potential damage types and locations.
The use of drones for confined space inspection is proving to reduce safety risks and create efficiencies in both time and cost. These benefits have been realized particularly in the oil, gas and petrochemical industry in internal tank inspection.
This article discusses how drone data can impact asset integrity management (AIM) programs, the challenges associated with drone data management, and where the technology is heading.
Today's operators are implementing a myriad of Mechanical Integrity and Reliability programs to realize greater results from their facilities. However, for each of these programs to be effective, they must be fueled by quality and up-to-date data.
This article demonstrates how substituting inspection reports that originate from pen and paper to reports generated using a stylus and tablet at the time and location of inspection can eliminate data entry errors and other common mistakes.
