INSPECTION TECHNIQUES

Kashif Ashfaq Randhawa

MS-1923

SCOPE OF INSPECTION

Inspection of Operating Equipment. Inspection of Non-Operating Equipment. Inspection of Incoming Stationary Items. Coating & Painting Inspection. Welding Inspection. Inspection of Equipment at Vendor site. Vibration Monitoring of Pumps and Compressors.

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Inspection Dept. Organizational Setup

Manager Inspection Sr. Engr. Inspection Inspection Engineer Foreman Technician

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PRIMARY FUNCTION AND RESPONSIBILITIES

The primary function of Inspection Department is to assure that operating equipment is in a reliable condition during periods of operation. This equipment is typically towers, vessels, reactors, fired heaters, tubular heat exchangers, Air cooled heat exchangers, storage tanks, relief valves, process and off-site piping.

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continue

The inspection Department is responsible for work performed by outside and testing agencies. Human safety is stressed Failure of equipment Cost effective

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INSPECTION TECHNIQUES

Non-Destructive Examinations (NDE)

Destructive Examinations.

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Destructive Techniques

Chemical Analysis of Metals.

Carbon (C), Iron (Fe), Phosphorus (P), Sulfur

(S),

Mechanical Analysis of Metals.

UTS. Yield Strength. Elongation Structure Analysis

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NDE Techniques

Liquid or Dye Penetrant Testing (PT). Ultrasonic Testing (UT). Magnetic Particle Testing (MT). Eddy Current Testing (ET). Radiography Testing(RT). Visual Examination (VT). Leak Test (LT).

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LIQUID PENETRANT EXAMINATION (PT)

The liquid penetrate method is used to detect discontinuities which are open to the surface of the material being examined. This method may be used on both ferrous and nonferrous materials.
Liquid penetrate examination may be used for the detection of surface discontinuities such as cracks, seams, laps, laminations and porosity.
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ULTRASONIC EXAMINATION (UT)

This method provide indications of surface and sub-surface discontinuities, The depth of which can be determined by the use of the proper technique. The skill, experience and integrity of the personnel performing the test are of prime importance. Ultrasonic examination for thickness determination may be made.
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RADIOGRAPHIC EXAMINATION (RT)

This method is commonly used for surface and subsurface discontinuities. Radiography will not give an indication of the depth of discontinuities unless special procedures are used. The techniques used for radiography depends largely on the equipment used and the experience will produce best results. The interpretation of radiographic films of welds requires not only a knowledge of welding and welding discontinuities but also the exercise of good judgement as to whether the discontinuities are actually defects.
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MEGNETIC PARTICLE EXAMINATION (MT)

The magnetic particle method can be used only on ferromagnetic materials to reveal surface discontinuities and to a limited degree, those located below the surface. The sensitivity of this method decreases rapidly with depth below the surface being examined and therefore, it is used primarily to examine for surface discontinuities.
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EDDY CURRENT EXAMINATION (ET) OF TUBULAR PRODUCTS

The eddy current method is used to detect discontinuities in pipe by subjecting the material to a strong external magnetic field. A test coil which induces eddy currents in the material is used for this purpose. If a discontinuity exists, there will be variations in the eddy currents produced and these will be indicated by a signal in the test apparatus.
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VISUAL EXAMINATION (VT)

Visual examination is generally used to determine such things as the surface condition of a part, reinforcement and undercutting of welds, alignment of mating surfaces, shape or evidence of leaking.
Direct visual examination. Visual examination using artificial directional

lighting.
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LEAK TESTING (LT)

The leak tests are performed using gas and bubble formation testing, vacuum testing, & hydro test. Leak test is used for detection of leaks in welds. Advantages: o Often only way of revealing leak. Limitations: o The leak detected only indicate a discontinuity is present, but not the type (and hence the cause) of discontinuity. o Leak tests do not test structural integrity and are therefore often used in conjunction with other type of tests.
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PRESSURE TEST

A pressure test is intended to assure against leakage and to detect gross defects. Pressure test should not exceed 1-1/2 times the maximum allowable working pressure (MAWP) adjusted for temperature. When contamination of the vessel contents by any other medium is prohibited or when a hydrostatic test is not possible, other testing media may be used providing the precautionary requirements of the applicable section of ASME Code.
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INSPECTION OF OPERATING EQUIPMET

Pressure Vessels. Shell and Tube Exchangers. Air Cooled Exchangers. Boilers. Furnaces and Stacks. Piping. Pressure Relieving Valves. Pumps & Compressors.
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INSPECTION OF NON OPERATIONG EQUIPMENT

Structures. Foundations. Tank Farm Area.

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Inspection of Incoming Stationary Items

Pipes and Tubes. Pipe Flanges & Flanged Fittings. Welding Fittings. Valves. Metallic Gaskets.

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CODES & STANDARDS

American Petroleum Institute(API) American Society for Testing and Material(ASTM) American Society of Mechanical Engineers(ASME) American National Standard Institute(ANSI) National Association of Corrosion Engineers(NACE)
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Inspection of Vessels & Columns

Visual Inspection Thickness Measurement. Past History Corrosion Rate Etc.

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Inspection of Vessels & Columns (Count..)

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Deterioration of Old coating

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:(N)
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