This article presents two case studies that show how having a holistic approach, along with the right technology and experience, is essential to identifying smaller damage mechanisms like fretting in fired heater coils.

This article illustrates the value of digital radiography as an efficient tool to visualize corrosion and other small bore piping anomalies without disturbing insulation, as well as using PRT in conjunction with UTT to survey small diameter lines.

Recent advances in UT technology now allow for inspection and continuous monitoring of sulfidic corrosion to be undertaken while the components are on-stream, at temperature, with high-resolution thickness data.

This case study of a CO2 absorber tower in a remote location investigates the use of a new type of wireless ultrasonic sensor for monitoring the thickness of equipment while on or offline.

This article will discuss a statistical analysis method that was developed to evaluate the integrity of pipelines that can identify, in a first phase inspection, whether the nature of the active damage mechanism(s) are uniform (general) or localized.

Equity Engineering Practices® (EEPs) are a collection of detailed & customizable Best Practices integrated with a customizable management system. EEPs include: 650+ branded and customizable Best Practice Documents, 225+ Pre-Engineered &...

This retrospective takes a quick look at two of the most popular topics that were covered in Inspectioneering Journal last year: the accuracy of thickness readings and corrosion under insulation.

Temporarily or permanently installed thickness monitors can help to overcome shortcomings and uncertainties associated with manual ultrasonic inspections and can lead to significantly improved maintenance and asset replacement forecasting.

Inspectioneering chats with Gecko Robotics about the new rapid ultrasonic gridding technique and how it can be utilized to increase the speed and effectiveness of equipment inspections.

This article dives into continuous thickness monitoring, which in the opinion of the author is one of the more innovative technologies for corrosion control in the refining industry to come about in the last two decades.

This article demonstrates how the use of TFM/FMC can be an effective method to screen for potential problem flanges before a planned shut down and can be a very useful tool in planning which flanges require further evaluation.

What do you need: CONSULTING - Subject matter experts, consultants, or team of highly skilled engineers to help solve my problem. SOFTWARE - My team requires software, products, or resources that will solve the problem. TRAINING - I require...

Universally, smart or intelligent pigging is now a standard practice for the inspection of fired heater and serpentine boiler coils. Understanding this technology can greatly assist with maintenance planning and the prevention of unexpected failures.

There are tools available that can achieve nearly 100% corrosion monitoring coverage. The use of robotics and ultrasonic inspection methods such as rapid ultrasonic gridding have shown to be highly effective in acquiring these data points.

This case study discusses costly repairs that were needed on newly fabricated pressure vessels as a result of poor UT practices. The author shines a light on some industry problems that can be fixed with an understanding of what is actually required.

We’re excited to announce a new section of our website that is dedicated to equipping inspectors with greater knowledge and proficiency across various subject matter areas.

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.

Piping accounts for roughly 40% of “accidental releases” at major petroleum facilities. Modern robots can inspect every inch of piping while still in service, giving you a clear picture of your most concerning areas.

This article discusses two common challenges for inspectors taking thickness readings in high temperature environments and ways to overcome those challenges.

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.

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.

Here are 8 tips to help you overcome certain challenges encountered when taking thickness measurements at high temperatures.

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.

Gecko's robots cover up to 150 square feet per minute and can perform inspections internally or externally. We combine logistical simplicity, speed, and a range of inspection strategies to provide a targeted and economical solution for tank...

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.

UT couplant auto-ignition is a surprise event that puts the safety of inspectors at risk. In an effort to reduce occurrences, API SCIMI plans to address this issue by including new paragraphs in the upcoming rewrites of API RP 572 and API RP 574.

The challenge to find CUI is difficult and one single NDE technique cannot be used to identify it. This remains the case today as we combine NDE techniques to perform CUI assessments. The techniques and strategies commonly used today are summarized...

Nondestructive testing (NDT) careers are on the rise in today’s economy. These fields are constantly advancing, and there is an ever-growing need for technicians, quality assurance specialists and inspectors as infrastructure in the United States...

HTHA of hydrogen-containing equipment can be prevented with appropriate material selection and fabrication, appropriate welding procedures, regular inspection of equipment using proven, effective technologies and equipment operated by qualified...

Floodlight Software digitalizes inspection and testing operations and eliminates paper forms, filing cabinets, and spreadsheets. Your inspection forms plus our software equals a user-friendly mobile interface for inspectors and a robust reporting...

This article features a case study on the feasibility of a wall-sticking drone for effectively conducting ultrasonic testing and other NDT methods on equipment at elevated heights.

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...

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.

The availability of high quality UT data is often the cornerstone for FFS and RBI decisions. As such, the API Subcomittee for Inspection and Integrity Management (SCIIM) has initiated a program for the Qualification of Ultrasonic crack Sizing...

Discover a new ultrasonic inspection approach that provides quantified mechanical integrity and conservative remaining service life information on fiberglass reinforced plastic equipment.

In this interim report, Pinnacle analysts take data from the oil refining industry and dive into how that key sector is being affected by reliability today. Download your free copy!

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.

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.

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.

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...

This article highlights the evolution of corrosion monitoring from conventional ultrasonic to ultrasonic phased array manual and automated solutions and their use for both general purposes and complex applications.

Download Pinnacle's Economics of Reliability Report - Refining to see how reliability is affecting profitability.

While there are many types of advanced NDT, this article will focus on the use of acoustics and electromagnetism as the bases for conducting examinations.

While there are many methods for measuring equipment wall thickness, a predominant method used in the O&G and power generation industries is portable ultrasonic equipment. Ultrasonic testing is non-intrusive because it is applied to the outside of a...

Fixed equipment in a refinery can be susceptible to corrosion from the process side, necessitating an inspection strategy to understand the condition of that equipment. Online measurement of pipe and pressure vessel wall thickness is made possible...

While they is very efficient and popular, liquid couplants used for ultrasonic inspection have some inherent limitations and disadvantages. An alternative method to using liquid couplant is Dry-Coupled Ultrasonic Testing (DCUT).

This article provides a discussion of a recent inspection performed at a U.S. refinery. Industry HF lines are experiencing piping failures in increasing numbers due to the presence of residual elements entrained within their carbon steel components.

Traditional, paper-based inspection processes can prevent plants from being as effective as they can be. By digitalizing your mechanical integrity process and data with MISTRAS Digital®, plants have realized up to 75% gains in IDMS data entry and...

The introduction of PAUT is a challenging effort initially, but can have a very positive impact on your first TAR and become a routine inspection for future TARs. When fully implemented, radiation safety boundaries can be reduced significantly or...

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...

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.

New inline inspections and integrity management systems allow operators to understand the complexities and economics of terminals’ and station’s complex aging pipeline infrastructure.

Technicians inspecting oil & gas installations and petrochemical plants employ a wide variety of nondestructive testing (NDT) techniques. A new technology has recently been developed that utilizes a real-time portable imaging device which has...

Gecko's TOKA Flex robot is designed to give unprecedented access to piping systems with a robust ultrasonic data-collection capability. The Flex, our most advanced RUG robot, is equipped to find and collect the critical inspection data you need....

To understand the current non-destructive testing (NDT) world, it is perhaps a good idea to look back at things historically. By doing this, changes which have taken place become apparent, and very soon one can conclude that this is actually quite...

Maintaining the mechanical integrity of above ground storage tanks (AST’s) is the focal point of tank inspection programs. Performing internal inspections is an integral part of a tank integrity program, however, deciding when to take a tank out...

Non-contact ultrasonic testing with EMAT was formally introduced in part one of this series found in the March/April issue of Inspectioneering Journal. Readers were introduced to the practical advantages of EMAT Ultrasonic Testing.

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.

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...

The OmniScan X3 flaw detector is a complete phased array toolbox. Powerful tools, like total focusing method (TFM) images and advanced visualization capabilities, enable you to complete your inspection with greater confidence.

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...

A unique technique for inspecting and cleaning the floors of an Above Ground Storage Tank (AST) emerged in the late 90’s based on In-Service Robotic Technology. The technology has come a long way since then, with new inspection and tank cleaning...

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.

Over the past 100 years, Nondestructive testing has made tremendous advances. New NDT methods have been introduced, while old "tried and true" methods continue to be improved. Although some NDT methods have drastically changed or "evolved" over...

EPRI is investigating improved inspection technologies as part of a multi-faceted effort to enhance the understanding and management of underground piping and tanks at nuclear power plants. An ultrasonic immersion technique tested on an...

Pro-Surve recently invested in the latest portable Higher Order Modes Clusters (HOMC) Guided Wave Testing tool, a new concept for the inspection of inaccessible regions using short-range guided waves. Inspection is carried out from the accessible...

High Temperature Hydrogen Attack (HTHA) is a long known and still occurring degradation issue for fixed equipment construction materials in the hydrocarbon process industry where hydroprocess plants (hydrogen plus hydrocarbons) are in service....

Understanding, predicting, detecting and controlling high-temperature hydrogen attack (HTHA), have been elusive goals of materials engineers and scientists for over 70 years. The destruction of low alloy steel components exposed to hydrogen through...

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...

Ultrasonic thickness gages have progressed a long way since their early development in the 1960's. The first thickness gages were large and bulky although they used the same conventional longitudinal (compressional wave) techniques still in use...

The integrity of pipelines is a natural concern for pipeline operators, and so the ability to detect corrosion, erosion and mechanical damage in pipes is therefore of significant interest. Traditional methods of detection, such as pigging and...

Superior inspection results, a best-in-class user interface, great ergonomics and rugged design, unrivaled connectivity options, and much more. The Krautkrämer USM 100 is a revolutionary ultrasonic flaw detector that uncomplicates your...

The ultrasonic Time of Flight Diffraction (TOFD) technique was developed for the UK nuclear industry during the 1970s to provide a method for measuring the height of planar flaws. TOFD is now generally recognized as the most accurate ultrasonic...

The impetus for the development of LRUT is that ultrasonic thickness checks for corrosion, erosion, etc. are localised, in that they only measure the thickness of the area under the UT transducer.

Exactly two years ago, an interview with John Nyholt appeared in the “IJ”. New ground will be covered in this interchange. We at the IJ thought it might be valuable to spend some time chatting about his background, challenges he has faced...

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,...

We have discussed various factors that can affect the reliability of NDE techniques (i.e., probability of detection - POD and sizing accuracy) in Part 1. In general, it is difficult to quantify these uncertainties. In fact, it is impossible to fully...

The recently released API RP-579 Fitness-for-Service Recommended Practice highlights the need for a measurable degree of reliability in NDE results. In fact, the industry has been asking for a process to assure a minimum level of inspection quality...

In part 1 of this article we covered the importance of quality assurance of UT data, that is, understanding for each particular application, the accuracy required of the UT data, and new ways/graphical program to analyze and show the...

The American Paper Institute Recovery Boiler Reference Manual Volume 1, October 1979, indicates that the two main goals of conducting ultrasonic thickness (UT) inspections are to determine (1) the current tube wall thickness and (2) the rate of...

Do You Know All You Need To Know About The People Who Perform Your NDT? Could the following scenario be played out in your plant, on your equipment, on your watch? The year is 1968. The time is 3 PM on Friday. Two fairly young men are...

This article covers the use of permanently attached ultrasonic transducers for inspection and process plant equipment condition monitoring while in service.

This paper describes the use of a UT fixture for detection of stress corrosion cracking in ferrous heat exchanger tube-to-tubesheet welds and external tube corrosion or pitting near the tubesheets including crevice OD corrosion.

Southwest Research Institute (SwRI) has developed an innovative method for rapid screening of heat exchanger tubing using Guided Wave technology. This screening method can lead to an improvement in heat exchanger reliability and a reduction in the...

EMATs (Electromagnetic Acoustic Transducers) have been used for over six years for field service inspection of in-service piping. Recent advances in technology have allowed us to inspect new types of on-stream piping.

Inspection data analysis tools, like risk-based inspection, help us to focus on quantitative reliability targets. When considering thinning mechanisms, there is a certain probability that a piece of equipment will reach retirement thickness before...

The API Subcommittee on Inspection (SCI) has determined to initiate a program covering the qualification of ultrasonic (UT) technicians conducting inspections.

Ultrasonic thickness monitoring programs represent one of the most intensive inspection activities in refining and petrochemical facilities. Despite numerous improvements in ultrasonic testing equipment and inspection techniques, however, there has...

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 its introduction in the 1960s. The major advantage at that time...

New inspection technology, when added to the proven practice of using tell tale holes (TTHs), proves effective in reducing significant releases and or catastrophic events that are related to internal corrosion / erosion of process piping. In fact,...

Furnace tubes in the petrochemical and refining industries lengths' can exceed 2,000 ft., often with multiple serpentine bends. This can make them extremely difficult to inspect using conventional NDE methods. The following inspection tool (FTIS)...

This is the second in a series of articles on piping inspection. In the last article, I enumerated four inspection issues that I believe contribute to inadequate piping mechanical integrity in the hydrocarbon process industry.

Nelson Curve changes in the late 1980's provided cause for Shell Oil Company to look at more reliable NDE non-destructive evaluation methods for assessment of materials/equipment in high temperature hydrogen service. The primary change motivating...

Low-energy piping system failures in power-generating facilities are often the result of fouling and corrosion. These degradation mechanisms can affect the capacity of piping for fluid-carrying, the heat transfer rates of heat exchangers, and the...

With miles of piping and tons of equipment to consider for on-stream inspection or monitoring you probably have:

Petrochemical and energy utility industries require a methodology which will allow them and the governing regulatory authorities to make technical and financially sound decisions for the repair or replacement of pressure vessels which suffer damage...

For reason of economy, the hot reheat pipework in many US power plants is fabricated from seam-welded low chrome-moly carbon steel spools. Unlike girth butt welds, where the critical weldment microstructures can off-load stress to the stronger...

High energy piping (HEP) systems, main steam lines and hot reheat lines (typically low chrome molydbdenum steels), are susceptible to creep damage. Such damage can lead to leaks, and in extreme cases, catastrophic failure.