inspection services
DESCRIPTION
Inspection ServicesTRANSCRIPT
-
PO Box 2507 5581 Creel Road Harrison, AR 72601 Pho: 870-741-8917 FAX: 870-741-8975
Al Newberry, PE
Jess Richter, Manager of Inspection
THIRD PARTY INSPECTION
Third party inspection of custom designed and fabricated industrial equipment is prudent, given the fact
that the cost of failure is always high. High costs result from plant shutdowns, chemical spills, chemical
cleanup, lost product and combinations thereof. An example of the latter occurred some years ago when
an improperly designed and fabricated FRP tank suddenly failed at a cosmetics factory. The tank
contained a very expensive cosmetic ingredient and the resulting losses were in the hundreds of
thousands of dollars.
While many companies employ inspectors who are qualified for conventional materials, such as metal and
concrete, few companies have staff inspectors qualified for corrosion resistant fiberglass reinforced plastic
(CR FRP).
FEMech Engineering is staffed with qualified individuals having extensive experience in the inspection of
CR FRP new and in-service equipment. An exhaustive technical knowledge of CR FRP and decades of
experience, combined with high ethical standards, result in inspection which is practical, yet thorough.
We know what is important and what is unimportant.
Inspection of CR FRP falls into two major categories: new equipment and in-service equipment. New
equipment should be inspected during and at the completion of the fabrication process, to make sure the
laminates, the materials, the assembly details, the reinforcements and work schedule are in compliance
with the specifications, the applicable codes or standards, the calculations and the approved shop
fabrication drawings. In-service equipment should be inspected periodically, depending on the chemical
service, the operating temperature and any upset conditions which may have occurred.
Third party inspectors are in a position either to facilitate solutions or to create undue fears, require
unnecessary testing, bring about delays and increase costs for everyone concerned. The latter behavior
typically results from an unqualified inspection firm or an inspection firm whose business philosophy is to
profit by fueling controversy. The FEMech Engineering business model is very simple: Promote solutions
which benefit all parties and result in good quality, while avoiding the incubation of controversy and
problems.
Some of the major aspects of new equipment inspection are:
Material verification and documentation
Resin gel and viscosity testing
Mold and mandrel inspection
Observation of the winding process and ply counting
Inspection of nozzle cut-outs
Verification of thickness and ply sequence
Internal and External laminate inspection for visual defects
Barcol hardness for indication of laminate cure
Dimensional checks
Verification of fitting location and installation
Witness of hydro/pressure test
-
Proof tests of laminate cutouts to verify physical properties
Jobsite inspection to verify the absence of shipping damage and to ensure proper foundation fit-
up.
In 1732, Benjamin Franklin wrote in Poor Richards Almanac A stitch in time saves nine. There are two
steps in that stitch in time: the first is to determine the need for the stitch and the second is to apply the
stitch.
Upon the failure of one of its CR FRP vessels, the plant engineers at an edible oil company remarked We
thought FRP tanks last forever. Nothing lasts forever. The tank which failed had been in service many
years in a difficult environment. Sulfuric acid and live steam sparging made the service of particular
concern and the tank should have been inspected every 2 or 3 years and repaired and relined as required.
As it was, the tank was neglected and catastrophically failed, causing a lot of unnecessary damage and
cost. Periodic inspection of in-service CR FRP equipment should be based on a careful evaluation of the
service conditions. FEMech Engineering can work with your engineering staff in developing a periodic
inspection and documentation plan.
The inspection of in-service equipment can be very challenging, as different corrosive environments have
different effects on CR FRP. In addition to broad-based experience in the inspection of in-service CR FRP
equipment, FEMech Engineering has a long standing relationship with the FRP testing labs and FRP resin
polymer chemists for assistance in evaluating difficult situations.
Some of the major aspects of in-service equipment inspection are:
Full and friendly compliance with the customers safety regulations and confined space entry
requirements as well as good industry practice.
Detailed external inspection of the equipment, anchor bolts, supports, etc.
Verification the vessel is clean and safe and that oxygen levels are being monitored prior to
entry.
Detailed internal inspection of the equipment using some or all of the following:
o Industry standard visual criteria
o Barcol hardness testing
o Grinding of cracks or delaminations if significant in nature
o Taking biopsy samples using FEMechs small diameter diamond core bit.
o Sending samples for lab testing.
Once the inspection is completed, FEMech will issue a formal report and, if repairs are required,
issue a recommended repair procedure. FEMech can provide a follow-up inspection of any
repairs prior to putting the equipment back in service.