Inspection Of Pressure Vessels Research Articles

Design and Engineering of Nitrogen Receiver

Within numerous industrial applications, pressurized nitrogen gas plays a critical role. Nitrogen receiver pressure vessels function as the secure storage tanks for this gas, guaranteeing its safe and on-demand availability. These vessels are constructed from high-strength steel in accordance with ASME Boiler and Pressure Vessel Code (BPVC) standards. This ensures they can withstand the internal pressure of the contained nitrogen. ASME BPVC, a comprehensive set of rules, dictates the design, fabrication, inspection, and testing of pressure vessels. By adhering to these stringent standards, manufacturers guarantee the safety and reliability of these vessels. In conclusion, nitrogen receiver pressure vessels, designed and built following ASME standards, are an integral part of industrial gas storage and distribution. Their ability to safely store pressurized nitrogen in compliance with strict safety regulations makes them essential for various processes across numerous industries

Inspection and evaluation of damage mechanisms in two-phase vertical separator

Pressure vessels are critical components in various industries that store or transport fluids under pressure. Ensuring their mechanical integrity prevents catastrophic failures and maintains safe and reliable operations, regular inspections are necessary to identify potential defects and damages that can compromise the vessel's integrity. However, practical guidelines for pressure vessel inspection are often not readily available in educational institutions and require specialized certification courses or on-field experience. This article aims to provide a comprehensive and practical approach to inspecting a two-phase vertical separator commonly used in oil and gas based on industry standards and codes, specifically targeting mechanical engineers, engineering students, and professionals entering the inspection field. It demonstrates the application of a standardized methodology for inspecting a pressure vessel and analyzing its damage mechanisms. The inspection standards applied in this study include API-510, API-571, API-572, API-579, and API-580. The inspection process encompasses both external and internal evaluations. External inspections focus on identifying conditions that may affect the mechanical integrity of the vessel, such as support structures, corrosion, or external damage. Internal inspections utilize visual and non-destructive testing (NDT) techniques to detect damage or discontinuities within the vessel. It includes inspection planning, component selection, thickness measurements, and NDT techniques. The external inspection findings include thickness measurements of the shell, nozzle, and coupling areas. The identified material loss percentages are compared to design limits, enabling the determination of remaining structural integrity and the need for repairs or further evaluations.

Development of HOIS guidance for ultrasonic NDT for non-intrusive inspection at elevated temperatures

The non-intrusive inspection (NII) of pressure vessels using external in-service ultrasonic NDT has multiple advantages compared to internal visual inspection, including the significant reduction of down-time related costs and safety benefits from avoiding manentry into vessels. The HOIS joint industry project, with support from the Net Zero Technology Centre (NZTC), has recently been focussing on NII of components with operating temperatures of up to 250°C (typical of upstream applications). These inspections are challenging because they require probes to be in contact with the hot surface much longer than for spot thickness measurements. The aim of the work has been to develop recommendations for in-service inspection of components at relatively high operating temperatures, thereby extending the benefits of the NII process, including avoiding or deferring internal visual inspection, to a wider range of vessels. Experimental trials have been performed on test components at up to ~250°C, with an emphasis on scanning ultrasonic systems used for corrosion mapping and weld inspection using TOFD and angled-beam phased-array (PA). The most successful trials gave corrosion mapping and TOFD weld examination results that had similar differences from benchmark values to those achieved in earlier ambient temperature trials. For angled-beam PA, it was found that some trials appeared to have issues with accurate correction of the data for the effects of the elevated component temperature on both the refracted beam angle and signal arrival times. Other trials were more successful in this respect. The lessons learned from trials on both ex-service and manufactured samples are leading to the development of specific guidance for NII at elevated temperatures. The paper highlights the technical challenges associated with ultrasonic scanning systems at elevated temperatures, share the lessons learned from the experimental trials and summarise the guidance developed.

Phased Array Ultrasonic Testing of Stainless Steel Pipe Welds

Weld inspection of stainless steel pipes and pressure vessels is one of the most challenging and difficult inspections for ultrasonic testing. This is due to variations in grain structure and associated anisotropy. Anisotropy causes grain scattering and adversely affects propagation of sound waves. The effect is more telling for shear waves, which, in many cases, have almost no ability to penetrate the weld volume. Longitudinal waves are affected to a lesser degree by anisotropy and can be applied for such tests. Angle beam or refracted longitudinal waves are, therefore, the accepted method for stainless steel weld inspections.

SAFETY INSPECTION OF PRESSURE VESSELS AT AN ENGINE GRINDER IN AGRESTINA-PE

Pressure vessels are critical components in internal combustion engines as they withstand high pressures of oil, air, steam or other fluids. Failure of a pressure vessel can result in loss of containment, personal injury, equipment damage and, in severe cases, even explosions. Therefore, it is crucial to carry out periodic and rigorous inspections of these vessels in an engine overhaul to ensure their integrity and safety. This article discusses the steps of inspection in pressure vessels in an engine grinding plant, including inspection of pressure vessels containing argon gas stored to perform aluminum welding, as well as verification of design specifications, external visual evaluation, dimensional verification, ray inspection, visual inspection on compressors, which is important to extend its useful life and prevent accidents, inspection is performed according to specific standards and codes, such as ASME and API, and can be performed by internal or external inspectors, depending on the complexity of the equipment

Guardian of Pressure Vessel Inspection Safety

Guardian of Pressure Vessel Inspection Safety

Analysis of Problems in Supervision and Inspection of Pressure Vessels

Analysis of Problems in Supervision and Inspection of Pressure Vessels

Application of Nondestructive Testing in Inspection of Boiler and Pressure Vessel and Pressure Piping

Application of Nondestructive Testing in Inspection of Boiler and Pressure Vessel and Pressure Piping

Structural Health and Condition Monitoring with Acoustic Emission and Guided Ultrasonic Waves: What about Long-Term Durability of Sensors, Sensor Coupling and Measurement Chain?

Acoustic Emission (AE) and Guided Ultrasonic Waves (GUWs) are non-destructive testing (NDT) methods in several industrial sectors for, e.g., proof testing and periodic inspection of pressure vessels, storage tanks, pipes or pipelines and leak or corrosion detection. In materials research, AE and GUW are useful for characterizing damage accumulation and microscopic damage mechanisms. AE and GUW also show potential for long-term Structural Health and Condition Monitoring (SHM and CM). With increasing computational power, even online monitoring of industrial manufacturing processes has become feasible. Combined with Artificial Intelligence (AI) for analysis this may soon allow for efficient, automated online process control. AI also plays a role in predictive maintenance and cost optimization. Long-term SHM, CM and process control require sensor integration together with data acquisition equipment and possibly data analysis. This raises the question of the long-term durability of all components of the measurement system. So far, only scant quantitative data are available. This paper presents and discusses selected aspects of the long-term durability of sensor behavior, sensor coupling and measurement hardware and software. The aim is to identify research and development needs for reliable, cost-effective, long-term SHM and CM with AE and GUW under combined mechanical and environmental service loads.

Design of a cleaning robot for the interior of a mobile pressure vessel

Mobile pressure vessel in operation, will produce a lot of impurities inside the container, Up to tens of kilograms to hundreds of kilograms. The impurities are not only flammable and explosive, but also toxic and harmful. Moreover, the internal structure of the container is complicated, and it is difficult to remove it with conventional water cleaning or steam purging. which will cause explosions, personnel poisoning and other hazards during welding and inspection. In this article, for the inspection and cleaning of mobile pressure vessels, how to design a semi-automatic robot to remove impurities inside the container and ensure the safety of the inside of the container, The authors published their own design ideas.

Application Research on Corrosion Scanning of Coated Pressure Vessel with Ultrasonic Phased Array Inspection Technology

Ultrasonic testing is a commonly nondestructive testing method used in the periodic inspection of pressure vessels. The coating on the surface of the vessel should be polished before testing. In order to solve this problem, in this paper, ultrasonic phased array detection is used to detect the coating without removing the coating, and the experimental study is carried out on the painted test plate, the test results are basically the same as the actual size of defects. The results show that the application of ultrasonic phased array detection technology in the corrosion scanning of pressure vessels is feasible. It lays a foundation for the application of ultrasonic phased array detection technology in the corrosion sweep of pressure vessel insulation coating.

Periodic Inspection Program of Nuclear PWR reactor Pressure Vessel

This work aims to present a methodology that guides the operating organization to carry out periodic inspections in the nuclear PWR reactor pressure vessels. At first, fundamental concepts of nuclear energy and their application were discussed. This discussion allowed the presentation of: functions and characteristics of PWR reactor pressure vessels and the understanding of damage and effects of irradiation in the materials used in the manufacture of these vessels. From the recommendations of codes and publications related to pressure vessel integrity and inspections, for nuclear applications, the minimum requirements that should be considered in the inspection program preparation for this equipment were established. Furthermore, this paper shows the advantages of using computational tools to manage inspection results allowing the operators to plan and monitor the activities for the maintenance so as to avoid financial loss and environmental damage.

Annual inspection of pressure vessel

This paper systematically discusses the significance of pressure vessel inspection, defines the main body of annual inspection of pressure vessel, and puts forward the matters needing attention in the process of annual inspection according to the existing annual inspection situation, so as to provide a certain reference for the smooth development of annual inspection of pressure vessels.

Design of Control System for Pressure Vessel Inspection Robot Based on PLC

In order to improve the detection efficiency and quality of pressure vessels, a pressure vessel inspection robot control system based on programmable logic controller PLC is designed. First, the basic structure of the inspection robot is briefly introduced, and then the software and hardware of the control system of the inspection robot are designed in detail. Hardware design includes overall hardware design, hardware selection, hardware electrical circuit design, actual layout of hardware, etc. Software design includes software design process and program design, among which Mitsubishi FX5U series PLC and FX5-40SSC-S motion control module are the core of the control system. Finally, it is experimentally verified that the control system can control the detection robot well and has high engineering value.

Filament-wound composite pressure vessel inspection based on rotational through-transmission laser ultrasonic propagation imaging

In this paper, we introduce a rotational through-transmission ultrasonic propagation imaging system to inspect the full thickness of the entire cylindrical section of filament-wound composite overwrapped pressure vessels. This system can achieve high signal-to-noise ratio throughout the cylindrical section of pressure vessels by using a rotational scanning method. Based on the advantages of the laser ultrasonic system that can generate and detect ultrasound waves by using a small-diameter laser beam and making an inspection path in a narrow environment, this system directs the laser beam inside the pressure vessel via a mirror to enable the through-transmission mode for vessel inspection. A type-3 pressure vessel was inspected using the system developed, which successfully detected two impact damage spots and showed the filament winding direction clearly. The test results show that the system developed is highly reliable and can replace the current hydrostatic sample test for pressure vessel safety certification.

Preliminary Design of a High-Frequency Phased-Array Acoustic Microscope Probe for Nondestructive Evaluation of Pressure Vessel and Piping Materials

In pressure vessel and pipe inspection, ultrasonic nondestructive evaluation plays a pivotal role in both in-situ and laboratory examinations. Scanning acoustic microscopy (SAM) has been a well-recognized laboratory tool for both visualization and quantitative evaluation of pressure vessel and piping materials at the microscale since its invention in 1974. While there have been multiple advances in SAM over the past four decades, some issues still remain to be addressed. First, the measurement speed is limited by the mechanical movement of the acoustic lens and the sample stage. Second, a single-element transducer with an acoustic lens forms a predetermined beam pattern for a fixed focal length and incident angle, thereby limiting control of the inspection beam. Here, we propose to develop a phased-array probe as an alternative to overcome these issues. Preliminary studies to design a practical high-frequency phased-array acoustic microscope probe were explored. A linear phased-array, comprising 32 elements and operating at 5 MHz, was modeled using PZFlex, a finite element method software. This phased-array system was characterized in terms of electrical input impedance response, pulse-echo and impulse response, surface displacement profiles, mode shapes, and beam profiles. Details of the construction of the model and the results are presented in this paper. Development of a phased-array acoustic microscope probe will significantly enhance scanning acoustic microscopy techniques for detecting surface and subsurface defects and microstructural changes in laboratory samples of pressure vessel and piping materials.

Pressure relief valve inspection interval

Determining the correct interval for pressure relief valve inspection, testing, and maintenance remains a major challenge for facilities covered by the U.S. Occupational Safety and Health Administration Process Safety Management Standard. To this end, guidance is provided by API Standard 510, Pressure Vessel Inspection Code: In‐Service Inspection, Rating, Repair, and Alteration, by API Recommended Practice 576, Inspection of Pressure‐relieving Devices, by API Standard 520, Sizing, Selection, and Installation of Pressure‐Relieving Devices, Part II‐Installation, and by NB‐23, National Board Inspection Code—Part 2 Inspection. Furthermore, ASME BPVC, Sections I and VIII, provide general guidelines for the repair of pressure relief valves.However, the testing and inspection interval listed, up to ten years, is the maximum time span between shop inspections and overhaul. Further direction is often requested for determining the proper interval for valves in typical process services, especially in cases of PRV chattering. Recent API STD 520 Part II guidance on performing engineering analyses for PRV installations, based on service and specific installation, is included here.In this paper, a decision‐making approach to determining these intervals based on a combined understanding of risk‐based inspection, quality assurance, engineering analyses, and facility experience is presented. The approach provides process operators and managers with additional assistance in making this determination. © 2017 American Institute of Chemical Engineers Process Process Saf Prog 37:37–41, 2018

Technology Focus: Production and Facilities (December 2016)

Technology Focus I keep a sign on my desk, purported to be a Chinese proverb, that says, “Those who say it cannot be done should not interrupt those who are doing it.” This bit of wisdom certainly applies as we recap the impressive progress made in a wide range of technologies related to production and facilities. Significant advances were reported in materials, field optimization, safe operations, corrosion, and wellbore-related technologies. In each area, progress was reported toward more-efficient field development, extended equipment and pipeline service life, and reduced environmental-release risks. In materials, papers described new liquid coatings (SPE 176048, SPE 179933) as well as new alloy coatings (SPE 176930) that provide improved corrosion- and erosion-resistance properties. The strength and fit-for-service range is being extended for pipelines by the development of new polymeric and composite materials (OTC 26506, OTC 27179). On the flip side, a material for fully degradable fracturing plugs was also reported (SPE 176917). Who knew that sometimes we want things to fall apart in a timely manner? In field optimization, the development of an artificial-neural-network (ANN) model significantly reduced the amount of computational time required to generate an optimal well-placement strategy (SPE 177442). An ANN-modeling approach also improved the reliability and accuracy of a model for detecting gas-pipeline leaks from basic flow-rate, velocity, pressure, and temperature signatures of the pipeline (SPE 177459). Another paper reported on the development of an Excel-based tool that allows nonchemists, field personnel, and engineers to make rapid determinations of the threat to asset integrity by sour (hydrogen-sulfide-containing) production streams (SPE 179921). For safe operations, a model was developed to improve the reliability of blowout-preventer control systems that included the interaction of multidomain dynamically coupled systems rather than just taking a steady-state approach (OTC 27292). Another paper described advances in the use of robotic technology for internal pressure-vessel inspections, significantly reducing the required time and personnel hazards associated with conventional human-entry inspections (SPE 177913). A combination of drill-rig automation and improved inspection technologies reduces well-workover times (and costs) while also reducing personnel exposure to operational hazards. One paper described an online method for inspecting tubing as it was being pulled from a well by use of electromagnetic inspection (SPE 177741), while another described an automated pipe-racking system that removes personnel from this hazardous procedure (SPE 176336). These papers are only a limited sampling of the progress made this past year in the development of new technology for production and facilities. Several of these technical advancements may now allow operators to do routinely what many may have previously said cannot be done. Recommended additional reading at OnePetro: www.onepetro.org. SPE 176930 Boosting Performance of Component Assets Used in Unconventional-Resource Plays With Nanolaminated Alloy Coatings by Christina Lomasney, Modumetal, et al. SPE 177741 Application of Flux Leakage Technique and Hydrostatic Pressure Testing To Evaluate Imperfections in Used Tubing by Fajarul Majeed M, AlMansoori Inspection Services OTC 27292 Holistic Systems Analysis: A Case Study Demonstrating Simple Models Improving the Reliability of the BOP Control Equipment Ecosystem by Daniel C. Barker, Cameron SPE 176048 Next-Generation Damage-Resistant Liquid Coatings by Melvin Devadass, 3M, et al.

Methodology for the structural design of single spoke accelerating cavities at Fermilab

Fermilab is planning to upgrade its accelerator complex to deliver a more powerful and intense proton-beam for neutrino experiments. In the framework of the so-called Proton Improvement Plan-II (PIP-II), we are designing and developing a cryomodule containing superconducting accelerating cavities, the Single Spoke Resonators of type 1 (SSR1). In this paper, we present the sequence of analysis and calculations performed for the structural design of these cavities, using the rules of the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code (BPVC). The lack of an accepted procedure for addressing the design, fabrication, and inspection of such unique pressure vessels makes the task demanding and challenging every time. Several factors such as exotic materials, unqualified brazing procedures, limited nondestructive examination, and the general R&D nature of these early generations of cavity design, conspire to make it impractical to obtain full compliance with all ASME BPVC requirements. However, the presented approach allowed us to validate the design of this new generation of single spoke cavities with values of maximum allowable working pressure that exceeds the safety requirements. This set of rules could be used as a starting point for the structural design and development of similar objects.

Implementation of remotely operated vehicle for direct inspection of reactor pressure vessel and other water-filled infrastructure

To reduce the irradiation exposure time of inspection personnel inspecting the reactor pressure vessel and other water-filled infrastructure during overhaul period, a remotely operated vehicle (ROV) is developed to help monitor the underwater environment and salvage small parts like bolts and nuts in the reactor pool and other water-filled infrastructure of the nuclear power plants. It is designed to be compact, light and radiation resistant. The depth control strategy based on fuzzy proportion integration differentiation is proposed for the ROV to suspend at any depth of the reactor pool. And the integrated navigation algorithm based on the Kalman filter fuses data from sensors, including sonar, depth gauge, three-axis accelerometer, three-axis gyroscope and three-axis magnetometer. Radiation testing has been conducted to verify ROV's ability to work in the reactor pool and other water-filled infrastructure under the environment of high irradiation. Eventually, field experiment was conducted in the reactor simulation pool of the Daya Bay Nuclear Power Plant, and the result verifies the effectiveness of the depth control algorithm, the integrated navigation algorithm and also the leak tightness of the ROV.