IRISNDT Nondestructive testing

fabricators & manufacturers Petroleum & Petrochemical Power Generation Chemical Industries Pipelines oil & gas

 

PETROLEUM AND PETROCHEMICAL PLANTS

Weclome to IRISNDT's QUALITY NONDESTRUCTIVE TESTING AND MATERIALS ENGINEERING SERVICES.

Offering services to the refineries and petrochemical plants entails meeting their shutdown and every day emergency requirements. IRISNDT's commitment to customer service allows us to address these daily requirements. However, it also entails understanding that specialized chemical process equipment requires:

  • Knowledge of the mechanical and corrosion damage mechanisms that impact equipment reliability.


  • Using specialized tools and procedures to examine for these types of damage.


  • Having knowledgeable and committed personnel who know our customers' equipment history and safety requirements.

We showcase our knowledge through the following inspections and industry experiences:

ASME PRESSURE VESSEL AND PIPING AS-BUILT INSPECTIONS

The inspection of as-fabricated piping and pressure vessels has been at the core of our company's services since its creation in 1953. Then, the industry required us to perform radiography using isotopes and film. Today, while radiography continues to be the staple technology for as-fabricated vessels, we also inspect piping and pressure vessels using time of flight diffraction (ASME Code Case 2235). As well, we perform computed radiography which based on the ASME Code Case 2476 can be used in lieu of traditional radiography.

Inspecting nondestructively as-fabricated pressure vessels and piping built to meet ASME requirements requires skill, and an extensive quality assurance and safety program. In essence, the local pressure vessel safety authority must approve IRISNDT personnel as the fabricator's NDT Level III personnel. IRISNDT fulfills this role for over 50 fabrication shops within Alberta.

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MODULAR FABRICATION - INSPECTIONS

Many of our more recent plant construction projects have required inspection of modules. This construction maximizes the inspections required at modular fabrication yards and minimizes the field welding and field radiography required during installation. In the field, our services must be available at all times to insure that critical examinations such as those of root passes and tie-in inspections are timely. Material Verification tests and their documentation are also critical in modular fabrication.

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INTEGRAL MATERIALS ENGINEERING AND INSPECTIONS FOR PETROCHEMICAL COMPLEX CONSTRUCTION

Between 2000 and 2003 IRISNDT was the sole NDT Inspection and Materials Engineering supplier for the AOSD Shell SCOTFORD UPGRADER PROJECT in Fort Saskatchewan, Alberta. At times, 65 inspectors provided NDT and metallurgical welding tests simultaneously and continuously (for weeks) for this project. All the IRISNDT offices had to pool their personnel so that we could have the instant response necessary for the expansion while continuing to provide the services required by our everyday customers. Finally, some of the equipment being built was made using specialized materials and welding processes. Challenges regarding specialized inspection methods and engineering assessments of equipment flaws were addressed and rectified with the cooperation of the expansion personnel, IRISNDT's Engineering and NDT personnel.

This project was one of the largest Petrochemical Plant Construction Projects ever undertaken in Canada. The services we offered during the construction and commissioning of this plant were:

We also have assisted in other expansions and construction projects such as the NOVA E-3 expansion in Joffre, the Union Carbide LP7 expansion in Prentiss, the Shell Scotford Refinery Construction, the Dow hydrocarbons and POLY expansions in Fort Saskatchewan and the Petro Canada Refinery Edmonton SIG Project.

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PIPING, PSV AND PRESSURE VESSEL CORROSION MONITORING AND DATA MANAGEMENT

Until the 1990's, monitoring the integrity of pressure vessels consisted mainly of recording some thickness values, and of keeping those records in files until several years later when re-inspections were needed. Today, pressurized equipment owner-users have a more challenging task, they manage:

  • Older equipment that must remain reliable.

  • More numerous components than previously.

  • Components with many more mandated documented inspections.

Advanced information technologies allow us to track large volumes of data, but only after inputting their lengthy inspection histories into databases. As a consequence, IRISNDT has assisted our equipment owner-users by developing and inputting the data necessary in equipment integrity management programs such as MAXI-TRAK, Visions, UltraPIPE, PCMS and others. Our projects include:

  • Developing the "as-built" piping and pressure vessel corrosion monitoring databases for a series of large new petrochemical plants. This entailed our personnel, in combination with our customer's personnel, developing/classifying piping corrosion circuits for piping inspection programs. The projects have required several years of work and are still progressing.


  • Storing and maintaining the Canadian corrosion database for one of the world's largest energy companies. As part of this project we have been transferring the PSV and vessel visual reports into UltraPIPE for multiple facilities. To this end, we have developed programs that systematically translate and transfer data from multiple types of computer programs to corrosion databases such as those named above. The data is available to customers via web based interfaces that allow immediate data queries.


  • Developing a reliability program for 40-year-old piping for a chemical processing and mining plant. Several of our piping inspectors have been assisting in the development and implementation of this program over a period of several years.


  • Assisting in the development of corrosion databases that encompass the multiple production sites for several upstream and mid-stream piping and pressure vessel Oil and Gas Equipment Owners.

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SHUTDOWN INSPECTIONS - PLANNING - VISUAL AND NONDESTRUCTIVE INSPECTIONS

Shutdown inspections are critical for the reliability of industrial plants. Significant deficiencies missed during maintenance shutdowns can result in large production losses during an unscheduled shutdown. At IRISNDT, we have extensive shutdown experience:

  • We have simultaneously provided up to 70 technicians and visual inspectors for shutdowns.


  • Our technicians have both the visual specializations and NDT certifications neccessary for shutdown inspections.


  • Most of our personnel perform the smaller, routine inspections required day-to-day at our customers` sites. These small jobs have short-notice and require our staff to be instantly responsive (in other words, these are challenging jobs). However, as a consequence, our inspection personnel have knowledge as to our customers` process equipment, safety and operating practices.

For large shutdowns, IRISNDT senior personnel meet with:

  • The customer planning team within two months of the shutdown to review:

    • The volume and type of work.
    • Inspection repair and reporting requirements.
    • The communication chains when NDT requisitions and repair NDT reports are required.
    • The NDT on-site facilities (darkrooms and reporting areas).
    • The NDT equipment required.

  • All the shutdown technicians, prior to the on-site work, to review reporting requirements and formats, job-site dispatching tools (inspection schedule and progress charts, visual aids), and job-site daily costing requirements.


  • The customers and technicians to review the indoctrinations, safety training requirements and personnel accommodation requirements.

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DEVELOPMENT OF PIPING AND PRESSURE VESSEL RELIABILITY PROGRAMS

Inspecting as-fabricated equipment has clearly established inspection and testing requirements (for example those specified in ASME Section VIII, Division 1 and ASME Section V). However, inspecting equipment that has been in service requires detailed knowledge of the operation, potential damage mechanisms and the impact of equipment malfunctions on production. IRISNDT inspection and engineering personnel work jointly with our customers to tailor inspections to the corrosion and mechanical damage mechanisms of pressurized equipment. These services have been integral in the following projects:

  • Replacement of 120" ID pressure vessel heads. The engineering support comprised details such as examinations to ensure that the older steel shell was weldable to a head made with a newer steel specification. A field temper bead welding procedure was developed to minimize heat damage to the vessel lead lining. Finally, to assess the quality of the welds, an inspection program was developed encompassing:



  • In conjunction with the pressure vessel owner/user of a high temperature water reactor, the following analyses/examinations were performed:


    • Optimization of the ultrasonic identification and sizing of stress corrosion cracks at ambient and at high temperature. The sizing and reporting were optimized so that the results could be readily interpreted in the fitness for service model developed for the cracks. The shear wave crack length and depth assessments were correlated to metallographic measurements.


    • Discussion on materials to be considered for building a replacement high temperature water reactor. The discussion entailed searching the data published for the last 25 years by the nuclear industry. Fully post weld heat-treated low alloy steels and nickel alloys were considered. The discussion on materials included information on deposited weld metal as well as plate.


    • Failure analysis of high temperature water pressure vessel low alloy steel. The investigation comprised the evaluation of failures of low alloy steels used in the nuclear industry for the last 25 years.


    • Data evaluation of high temperature water electrochemical tests of nickel and low alloy steels.


  • In conjunction with the owner/user of several liquid natural gas storage spheres, we developed a detailed inspection procedure for the equipment. The inspections were performed in lieu of the vessel being inspected internally. The program entailed:


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RUBBER SEALS, PLASTIC AND PLASTIC LINED EQUIPMENT FAILURE ANALYSES

Elastomer (rubber) seals improve our equipment and technology reliability daily. They prevent leakage of fuel into hot engine compartments in cars, airplanes and transport engines in general. They allow our air conditioning and heating glycol systems to function without leaks. They isolate contaminants so as to minimize industrial water and soil contamination.

In contrast to metal parts, elastomers can have an initial low cost. However, when seals fail, they can cause significant loss of production and secondary repair/replacement costs. At IRISNDT, our engineering group has examined the failures, developed testing programs and evaluated elastomers for challenging applications such as sealing steam, and solvent containing petrochemical fluids. We can assist in the failure analysis and selection of gaskets and o-rings. See elastomer failure analyses PPT file.

Plastic and plastic lined equipment is much more than a cheap replacement for metal parts. Plastic (TeflonŽ PTFE and/or thermoplastic) lined steel pipe can transport hydrochloric acid for many years with minimal corrosion and/or structural damage. Instead, for the same low pressure and low temperature fluids, steel piping can have extensive losses. Nevertheless, plastics and plastic lined steel fail. At IRISNDT, we have examined the failures of numerous process equipment components. We can assist you in optimizing the reliability of plastic components. See plastics failure analyses PPT file.

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FIRE DAMAGE ASSESSMENTS

Fire in industrial plants and buildings can cause significant permanent damage to pressure containing and structural components. Fire can result in vessels, piping and their supports being subjected to metal liquid embrittlement, oxidation, toughness and/or strength losses.

At IRISNDT our fire investigations in industrial plants and tanker trucks comprise:


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IN-SERVICE EQUIPMENT INSPECTIONS

  • Crack Growth Monitoring for Fitness for Service Applications

    If a vessel is cracked, repairing the flaws or replacing the cracked component is the most direct method for preventing leaking and/or a catastrophic failure. However, repairs/replacements are not always viable since:

    • Some vessels may require a post weld heat treatment that cannot be performed in the field.


    • Some vessels may require the removal of linings (coatings, bricks, insulation and others) or internal parts that cannot be replaced.


    • Some vessels may require access to areas that are inaccessible due to surrounding components/parts.


    • Some repairs can result in residual stresses that make the equipment more susceptible to cracking.


    • Specialized vessels often require 2 or more years of fabrication.


    • Some vessels may not be shutdown easily on short notice.

    In these instances, monitoring cracks so that they do not leak or reach critical sizes may give an industrial plant the time to organize a suitable repair/replacement. IRISNDT personnel have ample experience in:


  • Pressure Vessel Cladding Inspections

    • Roll or explosion-bonded cladded vessels are used to decrease the overall fabrication cost of vessels; they allow one to make a carbon steel shell that has a chemical or erosion resistant inside surface. On the other hand, inspecting the cladding from the carbon steel side is challenging. IRISNDT inspection personnel have performed critical and successful cladding inspections exemplified in Pressure Vessel Cladding Inspections. Standard inspection techniques are liquid penetrant on the overlay welds from the ID and/or UT or AUT to check cladding bond quality from the OD.

  • Acoustic Emission of In-service Pressure Vessels and Tanks

    • Acoustic emission can be used to perform an overall structural integrity inspection for specific pressure vessels and tanks. Tanks and vessels that have a benign service can be tested with acoustic emission during an over-pressurization. Suspect areas, if found, can be further evaluated and sized with ultrasound (capturing computerized images). Based on a fitness for service evaluation:

    • If suspect areas are found, they can be categorized as to whether they require immediate repairs or not. If immediate repairs are not required, the vessel/tank can remain in-service without having to be shutdown, emptied, cleaned for inspection and then refurbished for service.


    • If significant flaws are found, the time for opening the tank/vessel can likely be deferred allowing planning time.


  • Corrosion Mapping

    • Knowing the profile of corroded areas allows the owner/user to periodically check the metal loss progress and determine when repairs are essential. IRISNDT ultrasonic inspection personnel perform both ambient and High Temperature Corrosion Mapping (see Matrix Website). These high resolution maps of corroded areas facilitate fitness for service evaluations.

    High Temperature Corrosion Mapping, measurements at temperatures greater than 130°F, is challenging:

    • Special high temperature transducers are usually needed.


    • Critical equipment with large suspect areas requires the entire area map to be compared periodically. However, the temperature of the transducer changes every time that it is lifted from the scanned surface. As the temperature changes, so do the electrical signals that are translated to a thickness value.


    • Special couplants are required to insure that ultrasound is transferred effectively between the examined surface and the transducer.

    All of this adds to the challenge. In response, Matrix Inspection & Engineering (a subsidiary of IRISNDT) has developed unique scanning systems that allow for longer transducer residence time and more reproducible data.

  • Pressure Vessel API 510, Tank API 653, and Piping API 570 In-Service Inspections

    • Vessels, tanks and piping require in-service periodic visual inspections and corrosion monitoring. At IRISNDT, we have inspectors certified to all of these industrial standards who perform these periodic inspections.

  • Tank Bottom Inspections

    • The tank (floor) condition can be assessed qualitatively with acoustic emission while in service:

    • More AE indicates more damage.


    • Experimental work shows scale build-up is a significant factor during tank AE tests.


    • AE activity is generated from corrosion processes, scale fracture and leaks.

    For more details see Tank Bottom Testing.

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ADVANCED AND AUTOMATED UT

We have a strong AUT group that performs these field inspections for many IRISNDT customers. The techniques performed include TOFD, phased array, and crack sizing. Typical applications are:

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TANK INSPECTIONS

Since API 653 was introduced, operating companies have adopted a more comprehensive approach to the inspection of their storage tanks. The API 653 document describes the minimum requirement for the maintenance of storage tanks. Traditionally, all of this inspection was performed using manual techniques. However, the availability of new technology to scan large tank surfaces is altering the inspection methodology.

  • Tank Floor Inspection

    • Before the 1990's, tank floors were inspected by cutting coupons from the floor to establish a baseline for the soil side condition of the floor. Since the introduction of a magnetic floor scanner, during 1989, the floor integrity no longer needs to be destroyed by removing coupons. Today, IRISNDT uses various magnetic flux exclusion (MFE) floor scanning tools.

    These innovative MFE tools allow us to screen tank floors at rates as high as one thousand square feet per hour for soil side corrosion. The MFE tool detects corrosion whether it is located on the process or the soil side of the tank floor. Since the data is qualitative we perform additional inspections to quantify the corrosion depth. This is quantified using a mechanical pit gauge for top side corrosion, and ultrasonic inspections to assess soil side losses.

    For further information, please view the following brochures:

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