Preventive Maintenance (PM) Inspection Services

Overview
A Preventive Maintenance (PM) inspection program developed by FSE is a valuable tool used by owners of critical FRP process equipment and piping to evaluate condition, identify critical defects, and trend rates of degradation over time. Inspections are performed while the equipment or piping is in operation and also during scheduled shutdowns. Preventive Maintenance extends service life and prevents unnecessary repairs. Results of PM inspections are used to predict future repairs, assist planning of maintenance budgets, and to prevent unplanned outages caused by unexpected failures.

Engineering evaluation is often performed as a part of our integrated services to evaluate the impact of defects on equipment as well as determining appropriate repairs. This integrated service is one of the things that differentiates FSE anyone else in our industry.

When To Use These Services
FSE can provide inspection services in two steps:

1. Inspection during operation: "On-line" inspection of FRP piping prior to the plant shutdown is performed while the piping is in operation and combines visual inspection with Infrared Thermography (IRT) scanning and X-ray radiography non-destructive testing (NDT) techniques. This inspection targets areas of concern in the piping for further inspection and repair during the plant shutdown.
2. Inspection during plant shutdowns: Visual inspection of FRP equipment and piping during planned shutdowns is necessary to determine the condition of interior corrosion liners and structural laminates.

Services Provided

Inspection During Operation ("On-Line"):

1. Prior to the Inspection: Piping isometric drawings are reviewed, along with past inspection findings and repair history, to formulate a plan for the "on-line" inspection. Often, isometric piping drawings are generated prior to the inspection (by the plant or by FSE) or existing drawings are updated during the first "baseline" inspection. The drawings become the reference key for documentation of inspection findings.
2. "On-line" Inspection: This method combines external visual inspection with NDT (non-destructive testing) procedures, such as Infrared Thermography (IRT) scanning and X-ray radiography techniques to target significant defects and mechanical problems for further inspection and repair during the next plant shutdown. Based on an extensive knowledge of composite structures, FSE has augmented visual inspection techniques with modified NDT procedures and specialized data interpretation skills to provide reliable detection of flaws in equipment, piping and joining systems. On-line flaw detection is aided by the use of infrared instrumentation to sense defect heat signatures generated by process heat, and enhanced by the low heat conductivity of FRP composites.

Inspection During the Plant Shutdowns:

1. Prior to the Inspection: Previous FSE inspection reports, repair histories, photographs and other available documentation will be reviewed to target any areas of concern.
2. On-Site Inspection Services: Detailed inspections of the equipment will be performed during the planned shutdown. Inspection methods will vary, but generally include visual inspection, ultrasonic and magnetic thickness measurements, surface corrosion divot testing and other inspection techniques developed to determine relative FRP hardness, thickness, corrosion/abrasion rates and overall condition. Any mildly destructive testing, such as divot tests, will be repaired by the FRP repair contractor (usually contracted by the plant).
3. Inspection Report: An abbreviated inspection report will be provided on-site (with review by the home office), summarizing any needed repairs or other action required during the shutdown. A complete inspection report in the FSE format (to be used for trending the condition of equipment over several future inspections) will be provided. The report will document the current condition of the equipment and FSE's recommendations for planning future repair work and inspections. Electronic report publishing available.

Wind Energy – We provide Preventive Maintenance on wind blades and fiberglass structures in the wind energy field. Contact us for more information.

Fiberglass Wrapping – Fiberglass Reinforced Plastic and Glass Reinforced Plastic is commonly used to wrap concrete to reinforce for seismic loads and for structural maintenance. We inspect concrete reinforced with fiberglass to ensure it’s withstanding the elements properly. Contact us for more information.

Benefits of PM Inspection and Evaluation Services From FSE
FSE is continually developing new technologies that improve on-line and off-line non-destructive evaluation of FRP equipment. When visual and NDT inspection findings are evaluated by knowledgeable FRP engineers, confidence in the continued reliability of FRP piping systems is greatly enhanced. Engineering evaluation is often performed as a part of our integrated services to evaluate the impact of defects on equipment as well as determining appropriate repairs.

Considering the far-reaching and potentially costly consequences of foregoing maintenance inspections, performing regular inspections is cost-effective insurance. FSE's PM inspection service provides the high level of confidence you need to ensure that existing FRP equipment and linings will continue to operate reliably in the service for which they were designed.

Non-Destructive Testing (NDT) and Evaluation Services

Overview
FSE has combined state-of-the-art non-destructive testing (NDT) techniques with traditional visual inspection of FRP piping and joint systems to enable detection of serious defects. Results of NDT testing are used to plan future repairs and maintenance activities during plant shutdowns, and to address existing equipment failures.

Services Provided
FSE uses AE testing results, along with engineering analysis, as a proven method by which the structural integrity of new and in-service FRP equipment can be evaluated. Through the analysis of AE test data in combination with other inspection results and engineering, FSE determines the presence of actively growing laminate structural flaws and derives methods by which the laminates can be repaired.

Since most FRP equipment is custom designed and manufactured to meet specific corrosive and structural requirements, AE test data is difficult to evaluate without a well founded knowledge in FRP technology, manufacturing techniques and its industrial uses. The analysis must consider the significant physical property differences between various laminate constructions including the resin rich corrosion barrier and high glass content structure.

NDT Testing by FSE:

• Acoustic Emission (AE) Testing
• X-Ray Radiography
• Infrared Thermography (IRT)
• Ultrasonic Thickness Testing (UT)
• Magnetic Thickness Gauging
• Visual Inspection
• Control Area and Photographic Records
• Strain Gage Application and Monitoring
• Engineering Evaluation of Data

Benefits of Non-Destructive Testing Services
FSE is continually developing new technologies that improve Non-Destructive evaluation and testing of FRP equipment. When visual and NDT inspection findings are evaluated by knowledgeable FRP engineers, confidence in the continued reliability of FRP piping systems is greatly enhanced.

PM Seminars

When using outside consulting services is not convenient, owners may opt to upgrade their in-house FRP PM capabilities through FSE's technical seminars. In conjunction with a customer's existing or developing Preventive Maintenance Program, FSE can provide seminars that will address basic FRP equipment and piping systems inspection and repair techniques and well as NDT methods.

Established seminars cover inspection of existing equipment, process safety management (PSM) requirements and procedures, visual and non-destructive testing (NDT) techniques, "on-line" process equipment inspection (infrared thermography, X-ray, etc.), classification of defects and basic FRP repairs. When appropriate, seminar participants are given training in the field to provide "hands-on" practical skills.

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