Significance of Pressure Vessel Inspection

Pressure Vessel Inspection Melbourne.jpg

A pressure vessel contains fluids under intense pressure or vacuum. Due to this feature, a pressure vessel can be potentially dangerous if it fails. There are authorised inspectors for pressure vessels who specify any faults to ensure that the units are safe for use. Pressure vessel inspection is a detailed review of the same to assure that it complies with the technical standards.

Pressure Vessels can be dangerous if faulty

The massive expansion of energy released from a pressure vessel can cause devastating damage. Even a simple compressed air cylinder can claim lives if it explodes. But do you know that pressure vessels are everywhere in our daily life? From refineries to mineral processing plants, dry cleaners, wineries, hospitals, your local tire dealer and even the pressure cooker all fall in the category of pressure vessels. They just differ in size and functionality but have the same working procedures.
However, heavy duty industrial pressure vessels are very complex processing structures. They may weigh hundreds of tons and are connected to a variety of pipelines, other pressure vessels and boilers. AICIP pressure vessel inspector in Melbourne can help you to detect faults in such intricate heavy machineries.

Now, what is AICIP?

AICIP is a non profit organisation in the field of Australian Institute for the Certification of Inspection Personnel. It is a body which certifies NDT inspectors so that they can have the appropriate authorisation to conduct the inspection job. It is incorporated with the Department of Fair Trading (a NSW Consumer Protection Agency) under the Associations Incorporation Act 1984. It has Australian Registered Body status with the Australian Securities Commission.

Manufacturing Pressure Vessels to comply with standards

At the manufacturing phase, it is essential that an experienced pressure vessel designer produces a suitable design. The manufactured vessel must then be inspected through an inspector to determine correct fabrication and welding. For the production purpose, the vessel inspector figures out the manufacturing and load taking capability of the vessel.
The qualified AICIP inspector verifies the entire process as per the Australian standards. It is the inspector’s responsibility to determine future faults of a welding or the material itself. This is why it is recommended to hire an inspection team to work as per the legal requirements and caring for your employees.
For designing and inspecting the volume and pressure, the processes and types of product under pressure are all considered to determine hazard level of the pressure vessel.

Pressure vessel inspection is a crucial part of an industry dealing with heavy duty machineries. If you haven’t made such a consideration yet, call an AICIP certified inspector right away to carry on your business safely.

Advertisements

What Is NDT? Which Is The Most Common NDT Method?

Non Destructive Testing Melbourne.jpg

 

This blog is all about providing a general information about NDT to people familiar with the process. So what is NDT and what are the techniques applied in it?

NDT stands for Non Destructive Testing, which is a process of evaluating, testing and inspecting different materials and their components. In other words, the part of the machine again becomes useful after conducting this specialised testing.

The test is conducted to determine a material’s physical components like ductility, impact resistance, fracture toughness, fatigue strength, and tensile strength.

Different NDT methods and their benefits

There are various types of NDT methods. Some of the common ones are Magnetic Particle Testing, Electromagnetic Testing, Guided Wave Testing and many more. Each of the techniques are conducted on different applications with various advantages. The tests are a form of solution to upgrade industrial environment and provide commercial independence.

The most common method of NDT

1.Welding Corrosion Testing  is one of the most common methods of non destructive testing. Welding inspection is further categorised into two forms, Radiographic Testing and Ultrasonic Testing. Obviously, these tests are conducted to determine the internal integrity of a weld without destroying the welded component. Let’s take a deeper look into these specialised tests.

2. Radiographic Testing – In this method X-rays are used from a tube which is X shaped. In some cases, gamma rays are also used from a radioactive isotope. The main objective of radiographic testing is similar to medical radiography. In this case, rather than passing the penetrative radiation through human body, it is passed through a solid object on a photographic film. The photographic film is the final image of an object’s internal structure. If the image appears whitish, it means the body of the object is thin or porous. On the contrary, if an image appears dark, it means that the walls of the object are at their best quality. In actual, an object’s thickness and density depend upon the amount of energy (radiation) absorbed.

3. Ultrasonic Testing – In this method, mechanical vibrations are used which are similar to sound waves in a high frequency. A beam of ultrasonic energy is passed through an object without damaging it. If the energy reflects it means it is a cause of discontinuity.

Thus, radiographic and ultrasonic testing are simplified.

The advantages of NDT are enormous when the quality and productivity are considered. After conducting all these tests, manufactured items are considered safe and legal.

The Working Processes Of A Good Welding Inspector

Welding InspectionA typical welding inspector is entrusted with the task of overseeing each and every activity as well as duty of a welding staff so as to ensure that all things are in ideal working manner. The job of the professional is making sure that welders conduct their tasks within the fixed deadline and quality specifications. It is also important for him or her to possess advanced knowledge about welding processes and procedures in order to be capable of providing guidance in problematic scenarios.

A good welding inspector is also expected to visually assess the welded products in order to check for room to improve or eliminate deformities. They can even utilise stress equipment for putting stress on weld joints. They are responsible for collecting records of readings from tests for future reference. They primarily work in the field of manufacturing processes and building construction.

Let’s take a quick look at the the different duties performed by professionals of welding inspection in Melbourne:

Welding Inspection

  • Interpretation of purpose as well as requirements of the various standards, codes and specifications.
  • Making sure that a specific process is available, approved and employed in the production.
  • Verifying the availability of enough legitimate welder approvals, and also making sure that only the approved ones are utilised in production.
  • Checking the parent material against markings and documentation.
  • Inspecting the correctness of different welding consumables like gases, fluxes, filler wires, electrodes, consumable inserts, etc.
  • Inspecting that the fit-up, weld preparations and dimensions are according to the specifications.
  • Verifying that the required preheat complies with the particular procedure.
    Assistance & agreement along with preparation of ITPs or Inspection & Test Plans.
  • Surveillance at the time of welding for ensuring compliance with required procedures like preheat, post heat and interpass temperature control requisites.
  • Inspecting to ensure conduction of post weld heat treatment as per specification requirements.
  • Dimensional check and visual inspection of the completed weld against specification drawings and requirements.
  • Utilising various methods of non destructive testing like magnetic particle, ultrasonic inspection, radiography or liquid penetrant to study their results on a specific welding work.
  • Evaluating and preparing inspection reports for a client or employer.
  • Maintaining each and every record of all inspections that they have carried out.

So, basically, these are the things that comprise the regular working processes of a certified welding inspector in Melbourne or anywhere else in Australia. They play a very important role in ensuring the quality & safety of different manufactured products.

Hiring A Welding Inspector – Smart Business Practice

Welging

Welding inspections and supervision are among the most important requirements of any manufacturing business to ensure a high quality product that promotes efficiency and safety. Hiring a welding supervisor in Melbourne is an act of high ROI for the company.

What is the requirement of inspection?
Inspection of welds is significant for a number of reasons, the most basic one being to determine whether its current state is considerable enough for its proposed application. It is a necessity to have a list of measurements for enhancing the quality of the weld. Valuation of the weld characteristics includes the size of it and the current existence of cessation. The size of the weld is very important as it correlates with its strength and performance. Undersized welding machines may not hold off stresses that are applied during a service. On the contrary, oversized machines can cause overstress, which will lead to distortion of the welded component.

Why hire a welding supervisor?
When the frustration of dealing with the loss is compared with the time spent in dealing with the issue, it has 1468669114.jpgbeen seen that the latter has won in most of the cases. However, this (spent) time can be avoided by hiring a welding supervisor who puts in their effort to make sure a business produces quality goods and runs on profit. One can stay calm knowing that they have
the service of trained and experienced specialists at their disposal. In addition, a welding supervisor ensures efficacy of all the fine details that are reviewed during an inspection performed by the professional. It means nothing is overlooked that might jeopardize the quality of the products later.

At the end of the inspection, a final report is provided mentioning the following:

The confirmation of the welding level to comply with the relevant standards

The dimensional checks for future references

The confirmation of all specifications and requirements have been met

The review of the Operator’s Manual

Getting deeper into the inspection
Welding inspections not only ensure the welder for quality craftsmanship, but also let him understand the procedure and concern of the work. Special training and a mock test may be held if required. The inspection includes testing of filler materials, fluxes, O2 analysis and inert gas composition. The experts determine the welding technique, progression, bead overlap, etc. The inspector himself is an experienced welder who has earned a certification. He is not only limited to welding machines but also conducts all types of inspections like coating inspection, AICIP pressure vessel inspection, radiography, ultrasonic testing, etc.

This shows that a welding inspector is a form of a highly qualified doctor to an overall commercial welding mechanism who treats them to be the best.

Why Should Pressure Vessels Be Inspected & Maintained Regularly?

1481362922

Routine maintenance as well as inspection are vital requirements of engineering, and no alternative can be a worthy substitute to them. Even equipment pieces which are tagged as maintenance-free are prone to damage because of general wear and tear. In order for expensive and high-utility gear to provide continued service, effective and regular inspection combined with proper upkeep is a must.

Nowadays, a majority of equipment used in different fields of engineering are defined by extremely toxic attributes. And in this context, pressure vessels deserve a special mention. To begin with, these units are filled with pressurised gases and toxic chemicals. The force inside them is so powerful that it alters the state of the fluids to a certain extent. For instance, gases turn into liquids first, and again get transformed into gases upon being placed in a cycle of condensation. In other words, it works in almost the same way as a freezing mechanism, but like one scaled for handling a stream of liquid nitrogen that has been processed cryonically.

In case a mishap was to occur, especially one involving deterioration or leaking of the pressurised vessels, that caused the contents of the units to escape, it would inflict great damage by allowing flammable substances to form dangerous clouds of toxic fumes. Fortunately, this kind of leak-out accidents are entirely avoidable – through a well-planned inspection and assessment strategy.

According to the mandatory guidelines of AS/NZS 3788, a typical AICIP pressure vessel inspection analyses a unit within an installation so as to check its operational viability. To put it simply, spotting a worn out seal or a damaged fastener, and then recording it for someone else to resolve, is not enough. There has to be a properly structured maintenance plan for impeding safety issues through replacement of potential weak points on time. Whatever the problem is, general wear and tear or inconspicuous, replacing or resolving it punctually is quintessential.

So if your engineering premises make use of pressure vessels, make sure you have the gears checked on a regular basis by licensed and certified inspectors. There are many organisations in Melbourne who offer welding inspection as well as non destructive testing services. All you need to do is choose a reliable and experienced business from among them and allow the pros to handle the maintenance duties of your pressure vessels.

Pressure Vessels – Popular Types & Uses

Pressure Vessels.jpg

Although pressure vessels can be found nearly everywhere, the general public is not aware of their features and characteristics properly enough to recognise them. These units play a very important role in the consistent processing as well as manufacturing processes by different commercial & industrial concerns. They also have a direct & substantial impact on physical and economic conditions of society.

Normally, pressure vessels exist in varying designs, but there are certain options which have extensive usage in a large number of commercial and industrial applications. In this blog, we are going to take a quick look at those options and their uses:

Heat Exchangers.jpg

Heat Exchangers :

Heat exchangers are used in literally every aspect of the society, right from industrial plants to food service units. In fact, they make modern manufacturing & processing easier than they actually are. Since heat can have a substantial adverse impact on various industrial processes by nature, it is vital for a heat exchanger to be designed for allowing lengthy operation even at peak optimisation. That is why, AICIP pressure vessel inspection services are in place for ensuring that.

Process Vessels :

process-vessels

They are primarily utilised for performing various procedures like combining different products, breaking them down, removing different elements, and so on. Process vessels generally work along with heat exchangers and storage vessels. They have specialised designs in order to be used for specific purposes. As such, their construction necessitates one or more material types.

Storage Vessels.jpg

Storage Vessels :

Storage vessels are the most prolific of the lot, as they are utilised for a wide range of industrial processes. Though manufactured more commonly in horizontal and vertical variety, they are also available in spherical units. They even come in a plethora of size options, and are mainly used for storing liquids. They are built using various materials, from among which carbon steel is the most preferred. However, a material different from that of the external body is used for the internal liners. This thing ensures that the manufacturing costs of the storage vessels remain low.

Thus, these 3 are basically the most popular pressure vessels in Melbourne, and find their usage in various aspects. The most vital requirements of these units are suitable constituent material, appropriate design and high quality construction. Ignorance of even one of these factors can result in serious challenges for processing as well as delivery of ultimate objectives.