In-Service (Plant Inspection and Shutdown Inspection)

An In­service plant or Shutdown inspection of industrial equipment is important in oil refineries, petroleum refining, petrochemicals and power generation sectors. The problems associated with the "New Construction" or new equipment main focus on metal cutting ,selection of Welding Process,Qualification of Welders. But in­service equipment are different. The main cause which create problems for oil refineries is "Corrosion and their associated metallurgy". During the in­service or shutdown the detection of corrosion and metal loss is major problematic issue. With the help of this an inspection Engineer can decide whether to equipment is to be keep in service or Rum, Repair, Replace or retired. To perform the RBI or FFS the data required from NDT department or the thickness readings are important,that which NDT is performed and what is the next date of Inspection Interval. NDT is a noninvasive technique for determining the integrity of a material component or Pressure Equipment such as Boiler, Pressure Vessel, Heat Exchanger, Piping, PSV,PRV and Above Ground Storage Tank (ASTI). NDT/NDE allows inspection without interfering with a product's final use that provides an excellent balance between quality control and cost­effectiveness. The main goal of NDT is to detect material defects such as corrosion/cracks, to predict corrosion rates or to assess equipment mechanical integrity, to calculate corrosion risk and to assess remnant life. We will detect with the help of NDT

Metal Loss (including corrosion averaging)

b. Corrosion Rates

c. Remaining Corrosion Allowance

d. Remaining Service Life

e. Inspection Interval

f. Bottom plat thickens for tanks

g. Heat Exchanger Tube Thickness or metal loss.

During the Shutdown or In­service following points are very important and the availability of time is very less and too crucial also.

It will stop the Plant production and Financial loss to management and country too, where the economy is mainly depend on the Oil and Gas Exploration, such countries in Middle East Asia or Gulf.(Where Oil and Gas Exploration is main source of Leaving and Geographic conditions of Deseret sand)

Decision making for the repairs depending on location and nature of defect within the Pressure Vessel as per applicable manufacturing and In­service code.

WPS­Welding Procedure Specification, PQR­Procedure Qualifications Records and WPQ Welder Performance Qualification. Required prior to start any Repair or Alteration.

Obtaining the Authorization from AIA Authorized Inspection Agency, under whom the repaired work to beperformed and offer for inspection as per NB­23 and R Stamp requirement. Prior to performing the Repair work.

Selection of NDT method and Approving the NDT procedure.

Obtaining the Authorization from AIA Authorized Inspection Agency, under whom the repaired work to be performed and offer for inspection as per NB­23 and R Stamp requirement. Prior to performing the Repair work.To detect flaws in the repaired location.To classify them discontinuity of defect as per the specified acceptance code.

Obtaining the Clearance from Local State Statutory Body and Jurisdiction where the equipment is placed. Understanding the Formats and Forms to be filled , before during and after inspection.

Materials and Welding consumables to be used for procedure qualification.

By using preheating methods where Impact testing is not a requirement.

Method of "Temper bead techniques".

Method of "Half bead technique".

NDT that can be employed before,during and after welding.

Necessity of PWHT and Hydrostatic tests.

Repairs and precautions during overlay weld repairs.

Methods and precautions to be taken during alterations and re­rating of pressure vessels.

Aspects of reporting and re­inspection.

NDT/NDE Testing and Inspection

Deterioration of Steel

Detection of Damage Mechanisms Affecting Fixed Equipment in the Refining and Petrochemical Industries

Stress Analysis

Risk Based Inspection (R.B.I.)

In­service Inspection

Life Extension Studies

Failure analysis and litigation

Corrosion Assessment

Thermal Spraying

Advance Coating

Residual Stress Measurement

Crystallographic Examination

Metalographic Examination

Microscopic examination of metals

macroscopic examination of metals

Decarburisation of steel

Equipment Fitness for Service Assessment and Certification

Welding Process and consumable requirements

Cathodic Protection of Piping and Above Ground Storage Tanks

Heat Excahnger Ferrous and Non­Ferrous NDT Conventional and Advanced NDT

Corrosion Under Insulation (CUI) detection with the help of advanced NDT

Mapping of CML/TML (Thickness Gagging ) Location on Pressure Vessel or equipment

Above Ground Storage Tank Entry with the qualified Inspector

Magnetic Flux Leakage Testing of ASTI

Magnetic Flux Leakage Testing of Heat Exchanger Tubes and Corrosion Mapping

Magnetic Flux Leakage Testing of Pipelines

Electromagnetic or Eddy Current Testing

Near Filed Eddy Current Testing (Electromagnetic or Eddy Current Testing)

Remote Filed Eddy Current Testing (Electromagnetic or Eddy Current Testing )

UT Ultrasonic Testing Thickness Gagging (UTG)

UT Ultrasonic Testing Flaw Detection (UTF)

UT Ultrasonic Testing Shear Waves for Weld Joints (UT Shear Wave)

AUT

IRIS

TOFD

PHASED ARAY

RT Radiographic Testing

DR Digital Radiographic Testing

CR Computer Radiographic Testing

How we help to you, We have qualified inspector as below to support to you.

ASNT, ISNT ,PCN NDT Level­II/2 Certified NDT Technicians and Inspectors

ASNT, ISNT ,PCN NDT Level­III/3 Certified NDT Specialist and Auditor.

API 510/570/653 Certified Inspectors

AWS Certified Welding Inspectors (CWI)

AWS Senior Certified Welding Inspectors (SCWI)

AWS Certified Radiographic Interpreter (CRI).

NACE Certified Inspectors in BASIC Corrosion

NACE Certified Inspectors in CIP Level­1,Level­2 and Level­3

NACE Certified Inspectors in Cathodic Protection CP Level­1 and Level­2

Experienced Engineering Personnel

AutoCAD Staffing and Services

Document Control Staffing and Services

Refractory (API 936) Staffing

Turnaround and Shutdown Inspection Support

Vendor Surveillance

Project/Construction Management Support

New Construction Project Support

Safety Management

Process Safety Management (PSM) Programs and Implementation

Positive Material Identification (PMI)

Risk Based Inspection (RBI)

Welding Guidelines for the Chemical, Oil, and Gas Industries