Industrial plants typically implement mechanical integrity programs, which include specific inspections for each equipment subject to pressure loads.
These periodic inspections will depend on the type of equipment and its service. Some operate with mildly corrosive fluids, while others use highly corrosive fluids. Depending on this and other parameters, such as pressure, temperature, importance, risk (probability and consequence of failure), etc., the frequency of certain inspections for each equipment is determined.
Over time, and due to the interaction of construction materials with process conditions, external conditions, including environmental conditions, give rise to the appearance of different deterioration mechanisms in the equipment, such as corrosion, cracking, erosion, dents, deformations, among others, which can generate defects that affect the structural integrity of the equipment.
The effects caused to the equipment by these deterioration mechanisms are precisely what is sought when performing periodic inspections. These inspections must be evaluated according to the respective inspection codes to determine whether the equipment can continue operating or if repair is necessary to restore its structural integrity before failure occurs.
Any condition classified as a defect that jeopardizes the integrity of the equipment and, therefore, the integrity of the plant and the safety of personnel must be repaired.
Now, how should this repair be performed?
A repair involving welding is a CRITICAL TASK.
Welding new materials, as is the case with pressure vessel workshop manufacturing, is not the same as welding used materials at in-service pressure-retaining equipment. These used materials may be subject to fatigue, overheating, and contaminants that embrittle the weld, among other factors; therefore, certain additional considerations must be taken into account before welding.
Additionally, the defect to be repaired may be due to causes other than the service's own deterioration mechanisms. Therefore, a root cause analysis (RCA) is necessary to determine all the causes that led to the defect or failure and prevent its recurrence.
Each equipment in service was designed and manufactured according to specific service conditions, design requirements, and the rules of a Construction Code. Therefore, the repair must be carried out taking this information into account in order to select the appropriate repair methods for each case.
Failure to consider the equipment's original design and manufacturing information, previous inspection and repair records, and applicable deterioration mechanisms can further complicate the defect. A poor repair can put the equipment at risk in the same way as the defect being repaired.
For this and other reasons, it is essential that a repair be performed by experienced personnel.
Many companies consider this unimportant and leave it in the hands anyone’s hands. It's no wonder they later have so many problems in their plants.
Repair or alteration of pressure vessels, process towers, heat exchangers, air coolers, power boilers, fired heaters, oil separators, process and power piping systems, among other industrial pressure-retaining equipment.
A REPAIR is the work necessary to restore pressure-retaining equipment to a safe and satisfactory operating condition.
A REPAIR, since it does not alter the equipment's pressure-retaining capacity, may not require drawings or design calculations when the Original Construction Code is known and the drawings and/or Manufacturer's Data Report (MDR) are available.
For example: repair of a defect in a weld, repair of a crack, replacement of pressure parts (with equal parts), weld buildup a wasted area, etc.
An ALTERATION is a change to any item described in the original Manufacturer Data Report (MDR) that affects the equipment's pressure-retaining capacity.
Since an alteration affects the equipment's pressure-containing capacity, the corresponding calculations shall be performed before any physical work on the equipment begins. These calculations must be available for review and acceptance by the Inspector.
For example: an increase in the MAWP or design temperature (even if there are no physical changes), the replacement of a part with a different material than the original, the installation of a new nozzle whose dimensions require reinforcement and strength calculations according to the Original Construction Code, etc.
We use a quality system evaluated and approved by The National Board of Boiler and Pressure Vessel Inspectors (NBBI) specifically for the repair or alteration of pressure-retaining equipment.
We have a Certificate of Authorization for the use of the "R" Certification Mark.
In addition, we have a Certificate of Authorization for the use of the "NB" Certification Mark for registering repairs or alterations with the NBBI (The National Board of Boiler and Pressure Vessel Inspectors).
A repair or alteration registered with the NBBI allows you to access the details of the work performed at any time, simply by requesting to the NBBI the Form R registered by the repair company.
The "R" Certification Mark is a guarantee of trust, and above all, SAFETY, for repairs and alterations of pressure-retaining equipment in any industry.
An "R" stamped repair or alteration includes a series of design, material, welding, post-weld heat treatment (PWHT), non-destructive examination (NDE), inspections, testing, and other considerations, as well as specific repair methods, to ensure the integrity of the repair. Therefore, it can be performed on any pressure equipment.
All of these considerations, including Form R certification and the "R" stamp, are established in NBIC Part 3, and the "R" Certificate of Authorization Holder shall comply with these considerations in order to perform the respective repair or alteration of the equipment.
No.
The fact that equipment has been constructed to the requirements of codes other than the ASME Code does not prevent any defect from being repaired, stamped, and certified "R." This includes equipment constructed to the ASME Code but not originally stamped and certified as U, S, etc. and equipment whose Original Construction Code is unknown.
Yes.
As long as the holder of the "R" Certificate of Authorization complies with the provisions of NBIC Part 3 to perform the respective repair or alteration of the equipment.
Regardless of the Original Construction Code, the equipment can be repaired, stamped, and certified "R."
Yes.
We repair equipment made of materials such as carbon steel, low-alloy steel (Cr-Mo), high-alloy steel (austenitic, ferritic, and duplex stainless steel), non-ferrous materials (copper, nickel, aluminum, and titanium alloys), and cladding materials.
Our repairs or alterations, when carried out in accordance with the NBIC Part 3 Code, already guarantee the mechanical integrity of the work. However, we offer a warranty of up to 18 months for workmanship or material defects.
It will depend on the type of repair or alteration and the materials required, as well as the plant's shutdown planning where the equipment is located.
It typically ranges from 4 to 16 weeks when imported materials are required.
Emergency repairs that do not require imported materials will depend on the plant's planning.
Simply send us your information and a message below with your requirements. We will contact you within the next few hours to analyze your case and see if we can help you.
Office Address: Av. Eloy Alfaro y Av. Mariana de Jesús. Edificio GAIA.
Quito – Ecuador
(+593) 99 304 3668 / (+593) 95 918 5464
info@aeim.com.ec
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