Safety Management > Integrity Management

Auto Crawling&CMMS

We offer automatic safety assessment with life / damage analysis using Automatic Crawler Robot for reformer & heater tubes in a severe environment process with high temperature & high pressure. Furthermore, we can establish CMMS (Computerized Management Maintenance System) with data collected by the Crawler.

Scope

Heater & reformer tubes of refineries, petrochemical plants

Equipment

Auto Crawler : Auto moving system embedded with outer diameter inspection equipment, and ECT equipment
- - O.D. measurement : non-contact laser sensors detect changes in outer diameter resulting from damage by heat
- - Eddy current testing : Detects cracks and damages by using multi-channels
CMMS : Efficient management system of the new or old high temperature facilities.
- - Composed of inspection drawing system, equipment management system and document management system
- - Possible to establish independent or network linkage systems
- - Possible to establish customized system reflecting user requirements

Strengths

Productivity : Fast and accurate inspection reduces shut-down time
Accident Prevention : Tool for effective equipment management
Cost Reduction : Optimum replacement period of tubes by life-time assessment.
Economy & Safety : Reduce accessory costs like scaffolds, etc and prevents fall accidents

Experience

GS Caltex Reformer Safety Assessment
LG Chemical Heater Safety Assessment
YNCC Heater Safety Assessment
Hanwha Chemical Heater Safety Assessment
Honam Petrochemical Heater Safety Assessment

Auto Crawer
CMMS

Facility Safety Assessment (FSA)

Derive potential harmful factors through a comprehensive precise safety inspection of high risk facilities such as specific manufacturing facilities and manufacture, storage, sale and use facilities of LPG, city gas and high-pressure gas and propose ways to improve safety management that are most appropriate for the plants.

Scope

Petrochemical & refining industry, Gas storage & use facilities
LPG / city gas storage and use facilities

Key Technology

Process Safety
- - Risk and operability analysis to improve safety and prevent accidents.
- - Checking safety devices, operation surveillance equipments and interlock system.
- - Evaluation of safety management conditions in operation manual, safety measures.
Electrical & Instrumentation
- - Evaluation of adequacy of the explosion-proof facilities
- - Check measuring instruments and Inspect gas leakage alarm device
Mechanical & Equipment
- - Gas leak Inspection using RMLD and infrared thermal imaging camera
- - Checking the installation status of equipments and compare with related standards and code
- - Thickness / hardness measurement and non-destructive testing
- - Analyze composition of the pipe using PMI (Positive Material Identification)
Fire Protection
- - Check and review domestic and international laws and codes (ANSI, CCPS, API, ASME, NFPA, etc.) related to fire protection in petrochemical plants and facilities

Equipment

Electrostatic measuring instrument, Digital multimeter, Clamp meter, Earth resistance meter, Multi-gas detector, Piping thickness gauge, Hardness tester
Infrared thermal imaging camera, Gas detection, RMLD, Ultrasonic thickness gauge

Experience

GS Caltex
SK Energy
Honam Petrochemical
LG Chemical
Hyundai Steel, etc.
Samsung Electronics
Samsung Everland
Korea Hydro & Nuclear Power
Korea Midland Power

Pre Service Assessment

For the safe operation of the plant during the new construction work and maintenance or change of existing facilities in operation, the inspection team that consists of specialists in each field such as process, electrical instrumentation, mechanical equipments conducts the safety verification and provide direction for improvement about the potential risk before the operation.

Scope

Petrochemical, petroleum refining facility
Manufacture and storage of gas, Facilities that risks exist such as use facilities, refrigeration facilities, facilities processing a toxic gas and so on.

Diagnostic Technology

- - Provide and review technical details that need to be considered about safety field during the design of engineering company.
- - Coverage : Flare Load, Safety Valve, Earthquake-resistant design, HAZOP and etc.
- - Inspect the construction compliance concerning facilities, equipments, piping, buildings and etc under construction.
- - Coverage : Fire-proofing, Construction status of piping(buried pipeline) and explosion proof equipment
- - After the completion of construction and before the plant start-up, finally check safety of related facilities and safety systems.
- - Coverage : Process safety field, Electrical & instrumentation field, Mechanical & equipments field, Fire protection field and so on.

Anticipated effect

Presenting the correct design direction and contributing the timely start-up by reviewing the results
Contributing the safety of plant start-up
Improving unsafe elements rapidly on site and cutting construction costs

Experience

22 plants such as LG Chemical Co., Ltd. NCC/ GS Caltex Co., Ltd. HOU/ Samsung Total Co., Ltd. NCC and etc.

Fitness for Service (FFS)

Fitness for service assesment is performed to confirm that the degraded process plant equipment will operate safely and reliably for some desired future period by evaluating the remaining strength of the equipment based on API Recommended Practice 579. The evaluated common degradation mechanism include corrosion, localized corrosion, pitting and crevice corrosion, hydrogen attack, embittlement, fatigue, high-temperature creep, fire damage, and mechanical distortion

Scope

Pressure vessels, Reactor, Heat Exchanger, Piping, and Tanks

Software

Signal FFS Software (Quest Integrity Group , USA)
FractureGraphics Software (Structural Reliability Technology, USA)

Strengths

Maintaining the safety of plant personnel and the public
Protecting the environment for accidental releases of damaging substances
Reliably operating aging facilities
Maintaining safe and reliable operations with increased run lengths and decreased shutdown periods
Determining the feasibility of increasing the severity of operations

Experience

Samsung Total : Corrosion Under Insulation on Pressure Vessels
Green Air : Crack in Storage Tank
Cheil Industries : Crack in pressure vessels
Samsung Fine Chemicals : Life assessment of reformer tube

Vibration Analysis (VA)

The technique is used to find the causes of piping vibration, including compressor or pump induced pressure pulsations, flow turbulence, vortex shedding, resonance, etc. To decide the condition of piping system, it determines the piping system vibration amplitudes, frequencies, nodal points, and the pipe modal shape. And also it can identify defective supports, incorrectly placed supports, and the locations of maximum deflection requiring additional supports.

Scope

Analysing the cause of piping system vibration and noise

Equipment

Hardware : OR36 (OROS) 16ch.
Software : NVIGate (OROS)

Strengths

Having the state-of-the-art equipment and software to collect and analyse the measured data
Providing the vibration assessment of piping system, according to the guideline of ASME OM-3, Energy Institute, etc.
Predicting the vibration behavior by FSI (Fluid Structural Interaction) when operating conditions will be changed

Experience

The metering piping system of LNG plant : Korea Gas Corporation :
The process piping system of refinery and Petrochemical plant : Hanhwa Chemical, GS-Caltex, Samsung Petrochemical, etc.

External Corrosion Direct Assessment (ECDA)

ECDA is a comprehensive inspection for integrity confirmation of external corrosion in coated underground pipelines. This method can identify a latent risk and assess external coating conditions / retained strength. Finally, it can avert accidents and ensure the integrity of cathodic-protected pipelines.

Scope

Defective coating of underground pipelines with dis-functional CP facilities

Key Technology

Underground pipeline diagnosis through Close Interval Potential Survey (CIPS), etc.
Corrosive environment assessment and detection of coating pin-hole
External coating analysis and thickness survey
External Corrosion Direct Assessment (ECDA) to determine which indirect inspection indications are most severe and collect data to assess corrosion activity.
- - Pre-Assessment
- - Indirect Inspection
- - Direct-Examination
- - Post-Assessment

Equipment

Coating thickness measuring device, Pin-hole detector, Soil resistivity measuring instrument, Ultrasonic thickness measuring device, Corrosion rate measuring device, pH measuring electrode and so on.

Strengths

Actual repair of pipelines and reduction of repair cost
Selection of priorities for excavation and repair via DCVG and CIPS

Experience

Korea West Power Co., Ltd.
KP Chemical
Army Consolidated Logistics School, etc.

Underground Pipe Line Assessment

Comprehensive diagnosis for integrity confirmation of Cathodic Protection (CP) system, detection of interference current and coating conditions. Through reliable methods including location probing, CP facilities assessment, potential survey and relative size of coating defect, CP integrity of underground pipelines is identified.

Scope

Coating defect underground pipeline with dis-functional CP facilities
Underground pipelines with inadequate structure-to-soil potential

Key Technology

Installation inspection and CP system examination using buried depth measurement,integrity confirmation of CP facilities, soil resistivity survey and outside interference inspection.
Location probing of underground pipeline using a MPL (Magnetic Probing Locator)
Integrity assessment by Close Interval Potential Survey (CIPS) that confirms CP potential condition, current interference with other structure and so on
Coating Defect Survey by DCVG (Direct Current Voltage Gradient)
Administration of underground pipeline locations by DGPS location survey
Evaluation of retained strength and probable life by ECDA

Equipment

CIPS survey data logger, DCVG equipment, ACVG equipment, GPS synchronized current interrupter, Magnetic pipe locator, Insulation measuring instrument, Cathodic protection measuring instrument, Differential GPS equipment and so on

Strengths

Survey without shutdown, identify coating defects without excavation work
Retain the integrity of pipelines and prevent accidents through a selective repair of corrosive region

Experience

GS Caltex Co.
BASF Korea
S-Oil
SK Energy, etc.

Close Interval Potential Survey
Coating Defect Survey

CFD

Computational Fluid Dynamics (CFD) technology helps to predict real gas (fluid) flow and diffusion combustion, explosion phenomena by a three-dimensional computer-simulation. The cause and process of accidents can be estimated by visualization of the blast overpressure and heat radiation damage caused by runaway reaction, explosion in large-scale petrochemical and gas facilities

Scope

Phenomenon of toxic and flammable gas explosion and diffusion in shipbuilding, semiconductor and petrochemical industries
Leak and fire phenomenon at liquid pools around LNG storage tanks and vessels
In-building gas diffusion and explosion, relief system validation

Software

Gexcon FLACS v9.2

Strengths

Various possible accident scenarios that may occur due to fire or explosion and determine the impact damage in facility
Safety designs and actual emergency measures to improve the safety of the facility can be reflected by more realistic results using 3D.

Experience

Tech-Ross Co., ballast water disinfection facility safety assessment for hydrogen gas
Korea Gas Safety Corporation, accident investigations, etc

CBSA

Stress analysis provides an approximate prediction of stiffness, stress distribution and deformation by linear or nonlinear numerical computation when structures such as storage tanks or piping are subject to external forces. The simulation results are presented by 3D modeling, so weak points are found easily and quickly. Whenever a structure is reinforced or changed, the effect of safety improvements can be compared numerically

Scope

Piping and facilities safety assessment because of settlement and earth pressure
Work on protection measures due to pipe stress analysis

Software

Structural Analysis Software: Midas Nastran FX

Key Technology

Linear Static Analysis
Free Vibration Analysis
Linear Buckling Analysis
Analysis of Heat Transfer
Nonlinear Analysis
Contact Analysis

Experience

STX Offshore & Shipbuilding Co., Ltd.
Samsung Electro-Mechanics Co., Ltd.
Korea East·West Power Co., Ltd.
Korea National Oil Corporation / Praxair Korea

Acoustic Emission (AE)

A new and novel NDE technique to evaluate fitness of storage and tanks in plants by attaching sensors on the surface of the tank, and analyze / evaluate received signals from sensors.
- AE (Acoustic Emission) : Elastic wave generated when tanks and storage are pressurized.

Scope

Safety assessment of storage and pressure vessels when on-stream
Safety assessment of bottom of above-ground storage tanks
Safety assessment of internal leak in closing-valve, safety valve, etc.

Equipment

SAMOS 112CH : For Assessment of Large Structures and Equipment (PAC, USA)
DISP 56CH : For Assessment of Spherical Storage Tanks (PAC, USA)
SAMOS 32CH : For Assessment of Pressure Vessels and Bottom Corrosion in Above-Ground Storage Tanks (PAC, USA)
AMSY-6 12CH : For Assessment of Bottom Corrosion in Above-Ground Storage Tanks
Sensor Highway II 8CH : For Assessment of On-Line Monitoring (PAC, USA)
V-5131 : For Assessment of Internal Leaks in Closing-Valve, Safety Valve (PAC, USA)

Strengths

On-Stream Inspection is Available
Can be Alternative way instead of Open-Inspection
No Need to Remove Insulation; Environment Friendly
1 test covers whole volume of storage tank
- - Reduced Inspection Cost (Less than of 1/3 of Open Inspection)
- - Reduced Inspection Period (Less than of 1/4 of Open Inspection)

Experience

Safety Assessment of pressure vessels, storage tanks and tube trailers in about 40 domestic companies
- From 1999~Present : Pressure vessels and storage tanks (about 230 items), Tube trailers (about 160 items)

Alternating Current Field Measurement (ACFM)

ACFM makes electric field at the surface of a subject to find crack and has a feature that ACFM find defects between ferrous and non-ferrous metal without calibration.

Scope

Pressure Vessels, Drum, Reactor, Tower, Storage Tanks
Piping, Support
Bridge, Crane
Turbine, Piping etc in Power Plants
Ship, Amusement Facilities etc.

Equipment

Hardware : AMIGO ACFM instrument (Main Equipment)
Software : ASSISTant Software (Analysis Software)
Manufacturer : TSC, UK

Strengths

Applicable for Both Ferric and Non-Ferric
No Need to Remove Paint
Sizing Defects (Width, Depth, Location)
On-Stream Inspection of Pressure Vessels, Storage Tanks, Pipings
Record All Inspection Data in Computer, an Operator Can Review the Inspection Result

Experience

Korea Gas Corporation : LNG Procurement Department (In-Cheon, Pyeong-Taek, Tong-Young) Safety Assessment
SK Energy : Pressure Vessels in Ulsan and In-Cheon Plant Safety Assessment
GS Caltex : Piping Safety Assessment
LG Chemical : Pressure Vessels and Storage Tanks Safety Assessment
Samsung Total : Pressure Vessels Safety Assessment etc.
Honam Petrochemical Corporation : Pressure Vessels Safety
Yeochun NCC Corporation : Pressure Vessels Safety Assessment

PAUT

Phased array ultrasonics (PA) is an advanced method of ultrasonic testing that has applications in industrial nondestructive testing. To test or interrogate a large volume of material, the beam from a phased array probe can be moved electronically, without moving the probe, and can be swept through a wide volume of material at high speed. The beam is controllable because a phased array probe is made up of multiple small elements, each of which can be pulsed individually at a computer-calculated timing.

Scope

Safety Assessment of Welds in Pressure Vessels, Pipings, Steel Structures, etc.
Corrosion Mapping
On-Stream Detection of Fatigue Cracks in Welds

Equipment

Omniscan MX 16:128 1 Set (Olympus, Canada)

Strengths

Save Inspection Result in Image File
High Sensitivity and High Resolution
Can Inspect Complex Objects
Obtain Volumetric Image Without Moving Probe

Benefits of phased array technology conventional UT

Ability to use multiple elements to steer, focus and scan beams with a single transducer assembly
Beam steering, commonly referred to as sectorial scanning, can be used for mapping components at appropriate angles. This can greatly simplify the inspection of components with complex geometry. The ability to test welds with multiple angles from a single probe greatly increases the probability of detection of anomalies
Electronic focusing permits optimizing the beam shape and size at the expected defect location, as well as further optimizing probability of detection The ability to focus at multiple depths also improves the ability for sizing critical defects for volumetric inspections

Experience

Korea Gas Corporation, Samnam Petrochemical Pressure Vessels Safety Assessment, etc.ons

TOFD

Time-of-flight diffraction (TOFD) method of ultrasonic testing is a sensitive and accurate method for the nondestructive testing of welds for defects. It is summarized as tip-diffraction techniques which utilized the principle that the tips of a crack when struck by a wave will diffract the signals back to the other location on the surface. The use of TOFD enabled crack sizes to be measured more accurately, so that expensive components could be kept in operation as long as possible with minimal risk of failure.

Scope

Safety Assessment of Welds in Pressure Vessels, Pipings, Steel Structures etc.

Equipment

ISONIC 2005 (SONOTRON, ISRAEL)

Strengths

Offers highly reliabe data for FFS (Fitness For Service) due to its high precision (error less than 1mm) in measuring crack`s depth and height.
Result is shown in images and can be stored in computer
Inspection result can be checked immediately and on-stream inspection is possible when operating temperature is less than 150 C
In case of plate thicker than 25mm, it is economic due to speed of inspection with respect to RT
TOFD defect detection does not depend on defect orientation
Defect height can be precisely determined
Higher POD improves risk reduction and calculation

Experience

Samsung Total Storage Tank Safety Assessment
HYUNDAI STEEL Pressure Vessel Safety Assessment
SK Energy, POSCO
Honam Petrochemical
Yeochun NCC

Guided Wave

The technique, analyzing guided waves which can propagate a long distance (typically 50m) of piping and may be reflected from defects, is designed for the rapid screening of long lengths of piping. It detects corrosion defects, such as corrosion under insulation and internal corrosion due to corrosion, erosion and erosion-corrosion, removing.

Scope

Overhead piping
Insulated piping
Road Crossing pipe and Culvert
Buried piping
Heater Tube, etc.

Equipment

Hardware : G3 (GUL, UK)
Solid Ring
Inflatable Ring
T-scan
Software : Wavepro G3 (GUL, UK)

Strengths

Minimizing the removal (300mm in length) of insulation and testing long distance of piping
(Max. 200m in length)
Inspecting the area hard to approach
On-Stream inspection

Experience

On-stream piping : Fuel piping of 5 companies including SK Energy
Underground piping : City gas piping of 2 companies including Ultra Construction co.
Heater tube
Road Crossing pipe and Culvert : S-OIL

Overhead pipe
Insulated pipe
Piping through the wall