Plant Inspection Services
The main reasons for inspection of in-service equipment are to:
- Determine the physical condition
- Determine the type, rate, and causes of equipment degradation
- Decide the following activities, which interpret and solve monitored state of inspected operated device
Active damage mechanisms and rates of degradation will vary markedly depending on the process flow and its contaminants or corrosion levels, temperature of exposure, and structural materials. One of the primary reasons for performing periodic inspections is to identify deficiencies and defects that could result in a safety incident – e.g. leaks, loss of containment, fire, toxic exposure. When identified, these are evaluated and (if needed) fixed through repair and further inspection immediately.
ATG Group inspectors utilize multiple DT and NDT methods and techniques in the inspection and evaluation of equipment condition. Inspectors consider the types of active degradation mechanisms and corresponding degradation modes active in the devices to determine the best methods and techniques to be used during the inspection process.
All information analyzed by ATG Group is carefully documented, provided to the Customer and after each inspection and contributes to the planning of future inspections, repairs and replacements. Moreover this information may form the equipment history basis for remnant life assessment (RLA) and risk-based inspection (RBI).
Inspections according to API
For specific types of equipment working in Oil & Gas, in order to protect the public from fire, contamination or explosions, guidelines must be in place to ensure proper construction, installation, inspection, operation, maintenance, alterations, and repairs. Inspections according to API procedures are in principle similar to the “general” plant inspections, with exception of specific methodical requirements, evaluation algorithms and acceptance criteria that are applied.
Inspections are performed according to procedures encompassing the requirements outlined in industrially accepted codes as API 510 (pressure vessels), API 570 (piping systems), API 653 (storage tanks) or other standards for repair, maintenance, in-service inspections, and alteration.
ATG Group provides, as one of the very few training centers on the market, the qualification of Plant Inspectors according to API 510, API 570, API 580 and API 653. This is a noncompulsory, however highly recommended course, that targets at full understanding of the responsibilities of the plant inspector, including the extent of technical knowledge as well as comprehensive understanding of API standards.
The philosophy of API guides is the best methodology for maintenance of operated devices. This philosophy is even adopted out of Oil & Gas industry and can bring very beneficial results for the Customer in general.
Corrosion Inspections
ATG Group inspection activities in the field of corrosion cover main problems that the plant inspectors have to solve in everyday work. There are two principal subjects of ATG Group activities in this field that are applicable for both, design and production as well as in-service operation (maintenance):
- Corrosion/degradation of inspected part/equipment material
- Protective coatings and protective systems applied on inspected part/equipment and its state
Both of these topics are considered together as one system and together with API methodology can solve many challenges.
Material analysis
Material analysis is focused particularly on assessment of its applicability in defined working conditions, evaluation of type and extent of corrosion including corrosion rate and assessment/prediction of remnant life of the part.
Protective coatings analysis
Protective coatings are examined for compliance with required application conditions (surface preparation, cleanliness, temperature, relative humidity, curing time) and with required thickness, integrity, surface smoothness etc. Coating inspection of parts in service is focused on its damage, wear, erosion and other factors that can influence negatively corrosion resistance of the part.
Also temporary protective coatings (preservation) for transport or shut-down of equipment and protective systems, cathodic & anodic protections, can be inspected by ATG Group specialists including independent consultancy.
Residual / Remnant life Assesment
Industrial sites, as they are operated for longer time, may change their original conditions significantly. The site and its devices/parts may be subjected to many aspects, as mechanical damage, stress and strain from operation, corrosion and others. All these may cause, in the worst case, even a collapse of the site.
Remnant (or also Remaining/Residual) Life Assessment is an important type of inspection that assesses the remaining life by application of on-site inspection, series of calculations and extrapolation. It allows the owner to operate industrial sites longer than was the original projected life and due to that make significant cost and time savings.
Standard RLA consists of following steps:
- Collection of historical data
- Operational parameters vs. material properties evaluation
- Actual part condition inspection including destructive testing of samples
- Damage mechanism evaluation
- Remnant life calculation according to procedure/practice used
- Formulation of corrective measures and conditions for future operation including date of subsequent inspection
ATG Group possesses enough qualified staff with background from various fields and experience from real-life inspection on operating sites to provide the Customer with top-end quality of this complex and difficult service.