Alpha Sonix NDT Solutions Private Limited

Fitness for Service is a best practise and industry standard used in the oil and gas and chemical process industries to determine the fitness of in-service equipment for continuing operation.Corrosive conditions and/or excessive temperatures are frequently encountered by a process, facility, or equipment. The material used in the equipment can decay or age over time in these settings. When critical equipment, such as pressure vessels, pipes, and storage tanks, reaches the end of its useful life, the plant operator must decide whether it can continue to run safely and reliably to avoid accidents to employees and the public, environmental damage, and unplanned shutdowns. The plant operator can use fitness for service assessment techniques to make informed judgments based on recognised engineering principles.
Provider fitness Assessment is a multidisciplinary engineering examination that assures that all process and plant equipment, such as pressure vessels, pipes, and tanks, perform safely and reliably throughout the duration of the operation and until the next turnaround or planned downtime. ASME, API, BS 5500, and other internationally recognised design codes give rules/guidelines for determining suitability for service. This technique assesses the equipment's residual strength in its current state, which may have deteriorated from its initial state. Corrosion, localised corrosion, pitting and crevice corrosion, hydrogen attack, embrittlement, fatigue, high-temperature creep, and mechanical deformation are all common degradation mechanisms.
Fitness-for-service evaluations look at the structural integrity of components as well as their appropriateness for long-term use. The integrity of critical pressure components and welded structures can be tested against multiple failure modes utilising established engineering procedures such as BS 7910:2013, API 579/ASME FFS-1, ASME B31G, DNV-OS-F101, and FITNET.

Residual Remaining Life Assessment & Condition Assessments of Boilers
Considering the operational conditions to which the equipment is subjected, determining the remaining life of an asset necessitates a thorough understanding of the degradation mechanisms and their progression.
RLA assessments are performed by ALPHA SONIX in the most difficult markets. ALPHA SONIX uses advanced analytical and simulation techniques in addition to its multidisciplinary in-house team to give accurate results and superior value to the decision-making process.
Many businesses and power plants have the challenge of predicting the remaining operational life of plant equipment that has been in use for many years. The issue is particularly acute for businesses with plants that have been in operation for 15 to 25 years or longer.In the maintenance decision-making process, reliability data analysis is critical. The ability to accurately estimate the remaining life of equipment and system components can be a valuable asset when planning preventative maintenance. To achieve high operational availability and maintenance stability in order to extend the life of equipment.

BOILER AND ITS COMPONENTS CONDITION EVALUATION

RLA is a method/test for inspecting and testing boilers and heaters that have been in use for a long time. RLA is a maintenance tool that can be used to predict and avoid problems before they occur.

 

Using both non-destructive and destructive procedures, condition assessment is carried out to determine the current status of component property degradation. Condition evaluation is critical for keeping facilities running smoothly and meeting increasingly demanding environmental laws, planned outages, adequate maintenance, and data collecting in new and old plants alike. Rather of being a one-time event, it is a continuous process.

Approach to Determining How Much Time Is Left In My Life

1. Determining the true process of degradation • High Cycle Fatigue • Low Cycle Fatigue • Thermal Fatigue • Thermo Mechanical Fatigue • Thermal Aging • Wear • Creep • Embitterment • Corrosion

2. Physical Property Visual Inspection

3. Nondestructive testing (NDT) that includes in-situ metallography, ultrasonic testing, magnetic particle inspection, DP testing, and ferrite measurement.

4. Stress analysis: To determine the material's strength and check for ruptures.

5. Non-Destructive Testing (NDT): To determine the component's integrity.

6. Laboratory testing: To provide useful information regarding the material's structural integrity.

7. Equipment fitness assessment: based on data provided.

8. Maintenance Suggestions: If necessary, equipment repair is recommended to extend its life.

9. Remaining Life Judgment Based on Analysis: Estimates for remaining life are made. In addition, periodic inspection processes are written out to keep track of the equipment's health while it's in use.

Our Integrated Third-Party Inspection team represents interest of client throughout the project and our service ensures right & cost-effective solutions for the project requirements. We are providing the services by our experienced AWS/CSWIP/NACE /BGAS certified inspectors to carry out QA QC inspection as mentioned our scope below to our esteemed client with excellent customer satisfaction

Our services include fresh & hardened concrete mortar and screed tests.

• Concrete strengths
  • Cube strength
  • Coring
  • Rebound hammer
• Tensile & Flexural strength
• Mix designs and Trial mixes
• Durability
• Water penetration
• Forced load deflection
• Shrinkage
• Heat of hydration (thermal cracking)
• In-situ load testing
• Temperature match curing
• Screed compliance testing
• Carbonation
• Elastic Modulus
• Creep

NDT stands for Non Destructive Testing It refers to an array of inspection methods that allow inspectors to evaluate and collect data about a material, system, or component without permanently altering it.

Elevate your material testingcapabilities with our advancedMagnetic Particle Wet Benchesfeaturing both AC and DCmagnetization, proudly offered byDAKSTOOLS. These cutting-edgebenches are specifically engineeredfor non-destructive testing, allowingfor the detection of surface and nearsurfacedefects in ferromagneticmaterials.
Our wet benches provide the flexibility ofdual magnetization modes: ACmagnetization for revealing shallow defectsand DC magnetization for identifying deeperflaws. Designed with user-friendly controlsand a robust construction, these systemsensure reliable performance and ease ofoperation in any testing environment.Perfect for a variety of industries, ourMagnetic Particle Wet Benches deliveraccurate results while accommodatingdifferent part sizes and shapes. Transformyour inspection processes withDAKSTOOLS innovative solutions andexperience the precision and reliabilityneeded for effective non-destructive testing!

The oil and gas, as well as the petrochemical industries, are under constant pressure to decrease risks and enhance safety and environmental challenges. Owners continue to make ongoing efforts to minimise production costs and improve maintenance procedures.In the hydrocarbon and chemical process sectors, as well as offshore pressure systems, the ALPHA SONIX team has extensive expertise designing risk-based inspection (RBI) procedures on fixed equipment and pipelines. These programmes are based on API RP 580, API RP 581, DNV-RP-G101, and best engineering practises and client specifications, as well as API RP 580, API RP 581, and DNV-RP-G101. Software and technology implementation are used to supplement the programmes.
WHAT IS RISK-BASED INSPECTION (RBI) AND HOW DOES IT WORK?Risk-Based Inspection (RBI) is an analysis methodology and process that, unlike condition-based inspection, necessitates a qualitative or quantitative assessment of the probability of failure (PoF) and consequence of failure (CoF) associated with each equipment item in a process unit, including piping circuits. Individual pieces of equipment are categorised by their hazards in a fully implemented RBI programme, and inspection activities are prioritised according on this category. A proper inspection and maintenance programme is then designed based on an estimate of the possibility and implications of failure associated with each piece of equipment, component, or structure.
WHAT IS THE IMPORTANCE OF RISK-BASED INSPECTION AND MAINTENANCE?RBI is used to detect and comprehend risk, risk drivers, and the lifecycle of equipment. RBI can determine whether an inspection is required; however, this requires additional data that is highly targeted in order to reduce the underlying uncertainties connected with the hazards associated with the equipment's existing and expected damage status. When an inspection will not improve knowledge of the damage situation, RBI should not be used to recommend it. RBI should highlight to alternate risk mitigation measures such as replacement, repair, or other activities that satisfy the risk criteria in those circumstances where PoF is driving the risk.
RBI is critical for maximising the efficiency of industrial plants in a variety of industries. It enables you to meet the industry's financial, dependability, and regulatory requirements by enhancing the performance, availability, and safety of your facility. It establishes a long-term testing and inspection programme, which extends the life of your plant.

Rebound hammer test is conducted to find out the compressive strength of concrete by using rebound hammer. The rebound of an elastic mass depends upon the hardness of the surface when it strikes.

When the plunger of rebound hammer test is pressed against the surface of the concrete, the mass rebounds and the extent of such a rebound depends upon the surface hardness of the concrete.

The spring-loaded hammer must travel with a consistent and reproducible velocity. The rebound distance of the steel hammer from the steel plunger is measured on a linear scale attached to the frame of the instrument.

The tests can be performed in horizontal, vertically upward, vertically downward or any intermediate angled positions in relation to the surface. The devices are furnished with correlation curves by the manufacturer.

ASTM C805 now states that these references to the relationship between the rebound hammer and compressive strength provided by the manufacturer shall be used only to provide indications of relative concrete strength at different locations in a structure.

To obtain greater accuracy of test results, it is recommended that the user develops a correlation for the device on each concrete mixture design to be tested and at the intended test angle.

Procedure to extract the appropriate result:

Prior to the test, the rebound hammer should be tested against the anvil to get reliable results for which the manufacturer of the rebound hammer. indicates the range of readings on the anvil, suitable for different types of rebound hammer.

On applying light pressure on the plunger, it will release it from the locked position and allow it to extend to the ready position for the test.

Press the plunger to the surface of the concrete, the instrument being used perpendicular to the test surface. Apply a gradual increase in pressure until the hammer impacts.

 

Take an average of about 15 readings.