Preventive Maintenance Inspection and Evaluation

• Review Existing Documentation
• Review Operation and Maintenance History
• Inspection Planning and Equipment Prioritization
• Visual Inspection
• Data Collection
• Non-Destructive Testing (NDT)
• Engineering Evaluation
• Reparability Assessment
• Inspection and Maintenance Programs
• Repair Specifications and Recommendations

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. Results of PM inspections are used to predict future repairs, assist planning of maintenance budgets, and to prevent unplanned outages caused by unexpected failures.

• Services Provided
• Benefits of PM Inspection and Evaluation Services

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. Specialized NDT techniques used by FSE to verify mechanical integrity include the following:

   • Acoustic Emission (AE) Testing records sounds emitted by a laminate under load and assists in determining the presence of propagating flaws. Acceptability of new and in-service equipment can be enhanced with this method.
     
     
   • Infrared Thermography images record variations in heat transmission through FRP composite laminates during on-line equipment inspections which can be used to determine the location of defects.
     
     
   • X-ray radiography is used to evaluate cutaway and side views of laminates while equipment is on-line. This method is most effective for equipment diameters below 30".
     
     
   • Strain Gauge Testing is used to measure the level of strain in laminates during test or while in-service in support of engineering evaluation.

3. Inspection Report: Following the "on-line" inspection, a brief summary of findings and recommendations will be provided to the owner before the FSE inspector leaves the plant, to aid planning for the next plant shutdown. A complete "on-line" inspection report will be issued, documenting all findings and recommendations. This report will become the baseline for trending the condition of the FRP piping in the future.

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.

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.

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.