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Leak detection on process plant or systems using a helium trace in a nitrogen carrier gas, is the most accurate and quantifiable method available. On an offshore production platform module, or within a petrochemical complex, the elimination of hydrocarbon leakage is an operational priority. Such loss of containment can lead to hazardous situations, environmental impact and financial loss.
As a technical enhancement of nitrogen purging and testing offshore industry over 25 ago, and it remains international commissioning years and turnaround standard methodology, helium leak detection was introduced to the the for hydrocarbon processsystems.
Helium is the 2 nd smallest available gas molecule and like nitrogen it is inert. Injected as a 1% trace into the nitrogen during the pressurisation of a process system, every flange and joint can be tested using a hand held probe, and every leak can be precisely identified and quantified.
The hand held probe or ‘sniffer’ is connected by a small diameter hose under vacuum to a mass spectrometer – an instrument which counts the number of particles of a certain mass, and can be tuned specifically to helium. In turn the small electrical current created is directly proportional to the size of leak being detected.
Particularly in the oil and gas industry, pre-commissioning and maintenance schedules are placing an increased emphasis on ‘flange management’ from the design stage, with the objective of a ‘leak free’ start up.
Indunit as a fully integrated bolt tensioning and torqueing contractor, promote the benefits of ‘controlled tightening’ being the use of specially designed equipment, proven bolt loading calculations and written procedures, to tighten joints to the desired tolerances in a controlled and safe manner. This is complementary to the discipline of helium leak detection, and provides the client with documented confidence in the ‘leak tight’ condition of his facility, prior to the introduction of hydrocarbons.
Nitrogen purging is an industry standard technique for the replacement of a hazardous or undesirable atmosphere with an inert dry atmosphere. The two most common methods of purging are displacement and dilution.
The geometry of the process system determines which method is used. For simple systems, displacement purging is usually more effective in terms of time and cost but, for more complex systems, dilution purging is used.
Using nitrogen offers a number of advantages for drying operations. Cryogenic nitrogen contains only trace quantities of moisture, making it very effective in drying operations (nitrogen gas dew point is between -80°F and -90°F [-62°C and -67°C]).
Nitrogen provides an preservation once the inert atmosphere for long-term drying process is completed. This environment reduces oxidation and no purge is required after drying is complete. Nitrogen also provides time savings since it can be used to rapidly pressurize a system.
Another important application for nitrogen is to use it to cool and inert reactors filled with catalyst during the shutdown process for maintenance work. The inert environment created from nitrogen prevents any combustible reactions from occurring.
Flowing cold nitrogen through a unit can also substantially reduce the amount of time it would take to cool the unit than if it were allowed to cool naturally.
We fully understand the unique challenges imposed by the cryogenic nature of the LNG industry. We have an experienced team of specialists who have successfully engineered the commissioning and cool-down on some of the largest LNG installations across Europe.
Our early involvement through construction and into start-up has enabled us to tailor our service offerings to improve safety, efficiency and quality during the complete project.
In some circumstances, when hydrostatic testing is not possible, components or systems may be tested with nitrogen. However, system design specifications must be reviewed and a detailed risk analysis completed before testing with a compressible medium.
The pneumatic strength test uses nitrogen, to pressurize the system to 110% of its designed pressure limit. A holding period is then applied for a fixed amount of time and the results monitored to determine the safety and integrity of the system.
Shrink Fitting, or “compression fitting,” is a process that inserts a pin or bushing into a housing or other assembly requiring an extremely tight tolerance fit.
The shrink fitting process can be used as an alternative to conventional press fitting, or more likely, to permit a mechanical fit that otherwise could not be accomplished via the mechanical force of press fitting.
Pipe freezing involves the use of liquid nitrogen in the controlled formation of a solid ice plug inside the pipeline using specialist equipment and techniques. Once formed, the plug is able to withstand very high differential pressures and provide reliable and effective isolation of the line while modifications or repairs are carried out
A vital aspect of the integrity management of pipeline networks, cleaning is necessary at every stage throughout the lifecycle of any pipeline. We recognize that each pipeline is unique and that cleaning needs may vary depending on its operational purpose and lifecycle stage.
Failure to clean your pipeline at regular intervals leads to reduced efficiency and may result in damages that impact its integrity
Pipeline testing also known as hydrostatic testing, pipeline testing is used to test the integrity of a pipeline. This is used in the commissioning stage as well as during pipeline maintenance schedules.
The pipeline products used during this process include pipeline plugs and testers.
Internal weld testers and flange weld testers can also be designed to provide mechanical testing of the weld if required.
An extensive range of sizes from ½” through to 36” Class 1500 on the shelf for immediate delivery complete with pressure test reports worldwide and design, manufacture and test to client requirement up to class 2500.
The test will be carried out using an ultrasonic leak detector; the basic application of the instrument is to detect gas leaks from vessels, pipes, etc., which contain gas under pressure. Gas escaping through a small orifice produces a wide band noise in the upper audio and ultrasonic frequencies.
The instrument can detect a gas leak through an orifice of 0.25
mm (0.01”) at a pressure of less than 0.7 kgf/m2 (10 psi) at 4.5m
(15 ft) range. The size of the hole permitting this leak is such that
it will not leak water at the same pressure even though additives
may reduce the surface tension.
Helium tube leak testing with a mass spectrometer is the most accurate and sensitive method for finding tube leaks. Using this method, Projectile personnel are capable of locating leaks as small as2×10-9 atm cc/sec helium.
The process works by covering sections tubes with plenums, which directs the helium into the tubes. If there is a leak within a section, the technician uses smaller and smaller plenums until the exact tube is identified and then marked.
The key to effective and fast lube oil system flushing is high velocity and full-flow filtration. Our temporary equipment is sized to provide all bearing supply lines with a velocity of 15 feet/sec.
This ensures fully developed turbulent flow and fluidization of particles contaminating the oil system. Prior to starting any oil flush, we will show you exactly where we will be on the flush pump curve for the various flow loops in the system and show you the calculated Reynolds numbers for each loop satisfying even the most demanding OEM representatives and end clients. There is no guesswork in our design.
Even loading in each stud is important, especially in applications with gaskets. We recommends multiple Hydraulic Stud Tensioners for applications with more than one stud. These Hydraulic Tensioners are inner connected to each other and to the pump. As the hydraulic pressure increases, the tension in each stud is the same, and the flange comes together simultaneously and evenly.
Traditional joint and flange integrity management often meant poor data management and knowledge retention. Data wasn’t always available when it was needed. Our system gives you a secure, convenient alternative in one centralized database.
Heat treatment is a really important technological process in mechanical manufacturing. In comparison to other processing techniques, it generally doesn’t change the form of work piece is performance by changing the internal microstructure workpieces or changing the chemical component of actually integrated chemical compound. It can improve the of the workpiece surface.
The borescope, also called videoscope or videoboroscopio, a device is long and thin, flexible rod. Inside this tube is a telescopic system with many lenses, which provide a high image definition. It is also equipped with a powerful light source.
The resulting image can be seen in the apparatus main lens, on a monitor, or recorded on a video recorder for later analysis
Bulk removal of fluid is normally required during a shutdown to conduct maintenance or repairs on pipelines. We will use several different types of scrapers to ensure that when repairs are conducted, minimal fluid is left inside the pipe to prevent spills.
Several types of scrapers such as bush and gel pigs are used to remove deposits that naturally build up during operations, to leave piping in good working condition. A slug of fluid containing inhibitor is sent down the pipeline coating the piping internals as a measure to prevent corrosion.
New construction facilities often undergo a cleaning process prior to start-up. Piping and vessels may contain a variety of debris, scale, oxides, and oil that must be removed if the plant is to run effectively.
To continue to operate at peak efficiency, process systems, vessels, and pipelines must be kept as clean as possible. Some of the normal by-products of operating processes create deposits ranging from scales to sludge, precipitates, and even metal deposits. These types of build-up foul the vessels and piping and can significantly reduce system efficiency, eventually causing plugging and failure of the unit.
Chemical cleaning is a process that’s mandatory for a wide variety of products from industrial metals, to equipment surfaces, to sewage water and machinery pipeline. It is a process whereby chemicals are used to clean surfaces. The nature and type of chemicals used differ depending on the product that is to be cleaned.
There are special chemical cleaners for metals, for harbors, for industrial water etc. The basic purpose of chemically cleaning something is to remove the unwanted contaminant in the products that needs to be cleaned. Manufacturing units also need to chemically clean their equipment, raw material and plants.