Measurement and Testing 51


Indonesian Refinery Increases Inspection Productivity


By replacing conventional X-ray inspection of pipework butt welded joints with ultrasonic inspection using the new USM Vision from the Inspection Technologies business of GE Measurement & Control (USA), the Plaju refinery in Sumatra has been able to increase inspection efficiency by 67%. This has provided significant time saving, as the refinery can typically inspect over 600 welds in a short turn round period.


The Plaju refinery at Palembang is the fourth largest refinery in the Pertamina group. Pertamina is the Indonesian state-owned oil & gas company and operates six refineries, some of which, including Plaju, produce Liquefied Petroleum Gas (LPG). Plaju is integrated with petrochemical plant and also produces purified terapthalic acid (PTA) and Paraxylene. The refinery is constantly being enlarged and adapted and


this involves much on-site construction. This is fabricated and inspected on-site.


As Mister Rinaldi, the Senior Station Inspector at the refinery explains, “Weld inspection is a vital part of the work we do. Previously this had all been done by X-ray. This was mainly because inspection codes have historically been written covering X-ray. Today, codes are available for ultrasonic inspection and particularly for phased array. As we were already aware of the many benefits of ultrasonics over radiography, in terms of greater convenience, as there is no need for film processing, radiation screening and waste chemicals disposal, we decided that automated ultrasonics could provide a more efficient inspection solution.


Most of the ultrasonic Level II inspectors at the refinery only had experience of manual ultrasonics but USM Vision’s intuitive, 100% guided operation soon allowed teams of two inspectors per shift to carry out code-compliant inspection of 50 welds per day. These inspections were carried out without the need to shut down production or transport welded pipe to screened areas, as would have been the case with radiography. Furthermore, the inspection productivity could have been doubled by using a second USM Vision in the same production area, which, again, is something which is not possible with radiography.


USM Vision can operate in phased array and TOFD mode and is supplied with its operating software and GE’s Rhythm analysis software, as well as the probes and wedges to suit the selected codes and pipe ranges. Set-up is menu-directed allowing the operating software to calculate the ultrasonic parameters for each weld and pipe combination and create an easy-to-follow inspection plan. The operator can then scan the weld, with an encoded scanner, using TOFD or Phased Array in parallel or linear scanning mode. Inspection data is transmitted to a review station in the industry-accepted protocol, allowing advanced analysis tools, such as real time volume-corrected imaging, to allow easier and more reliable image interpretation. By using GE’s Rhythm software platform, inspection data can be reviewed and shared, reports generated and inspection results archived for tracking or further analysis. Recent developments have seen the introduction of USM Vision 1.2, which allows both sides of a weld to be inspected in one scan, effectively doubling productivity. This capability is available in all new USM vision systems and can be retrofitted to existing systems.


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On-line Viscometer Takes the Heat and the Pressure


The XL7-HT series of in-line viscometers from Hydramotion Ltd (UK) have been developed specifically for continuous real-time viscosity measurement under conditions of extreme high pressure and high temperature (XHPHT) with the demanding applications of the oil industry very much in mind.


Ideal for the monitoring of drilling or fracturing fluid viscosity at the wellhead, the XL7 viscometer can measure any viscosity range at temperatures up to 400°C in pipes of any diameter or tanks of any capacity. The sensor is a single solid probe whose unique architecture imposes no real limit on pressure. The ability to withstand harsh measurement conditions makes the XL7 the instrument of choice for a great many applications. XL7 viscometers have been supplied to a leading oilfield services provider for the measurement of heavy crude at 5000 psi and 100°C (345 bar at 212°F). The company’s XL7-900-d15 model viscometer is rated up to 20,000 psi (1380 bar), and even higher ratings are possible. Unlike many other instruments, the XL7 viscometer is unaffected by plant noise or vibration, flow rate, or the presence of “slugs” of air or gas.


“We have a lot of industry experience,” comments Danny Morbey, Product Manager at Hydramotion. “Our instruments are used in many of the world’s oilfields and oil refineries for the measurement of many products, from quench oil to heavy distillates. The XL7 is also used in all aspects of fuel oil handling, for example during transportation, blending, or to control viscosity during burning.”


Every XL7 is available as an Intrinsically Safe version to EEx 'ia' IIC T6 and carries certificates for ATEX II 1G, CENELEC and TIIS, allowing transducers to be operated even in the most hazardous (Zone 0) environments (Div1 Class 1 Group A in North America). Customised instruments have also been supplied for High Pressure Cell (HPC) measurements in the laboratory. “With our technology we can design a system for any application,” says Morbey. “We have many years’ experience of designing sensors to suit very specific requirements.”


Eminently practical, Hydramotion viscometers are “fit and forget” devices, engineered for simple installation, long-term reliability and unrivalled ease of use. When hooked up to a temperature sensor, the XL7 can display either “live” viscosity or viscosity corrected to a reference temperature. It can be supplied with any process fitting: while flanged, threaded or clamp connectors are typical, custom fittings can be provided where required. Fully calibrated in the company’s own temperature-controlled manufacturing facility, the instruments need no on-site calibration. In addition, there are no moving parts to wear out or fail in service, so maintenance is virtually nil.


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Get Comprehensive Analysis and Reporting of Machinery Lubrication Conditions


Industries in which high value equipment assets are used such as in mining, military, oil and gas, transportation, and construction, will benefit from the latest software release from Spectro, Inc (USA). SpectroTrack, Version 2.0, is an information management system (IMS) that provides a comprehensive, historical view of fluid conditions for a single piece of equipment or an entire fleet. The information provided by the IMS can help extend the life of machinery by providing trending, imaging, numerical and textual data. Lab and maintenance personnel can spot trends and conduct maintenance routines before mechanical problems arise. Other benefits include increasing machinery uptime, reducing unscheduled maintenance due to machine failures, and lengthening the time between oil changes. The database keeps records of equipment information relating to service intervals, maintenance actions, locations, and statuses.


According to the company the latest release, SpectroTrack V2.0, incorporates new features and functionality based on customer feedback. “For example,” says Eric Olson, Spectro’s Vice President of Engineering, “a new multi-lab module integrates the workflow of multiple testing labs in an enterprise and enables each lab to view samples from various locations. Also the ability to visualise important trending at a glance has been enhanced with a multi- parameter graph. There is a more efficient method for results notification and the email options have been expanded as well.”


Relevant to the improved communications protocols, Rob Corak, Spectro’s Software Manager, says, “Communication between our customers and development group are an ongoing priority. SpectroTrack Version 2.0 was enhanced in direct response to our customers’ needs and feedback. We continue to grow and facilitate this dialogue through user groups, forums, and interactive webinars. We encourage all of our customers to participate.”


SpectroTrack is a browser-based application, and thereby eliminates the need for installation of separate seats on individual workstations. Customers can access and view reports anywhere, anytime to support remote applications, such as those in the military. The software comes pre-configured to automatically import data obtained from testing devices – Spectro’s and other brands. It can also integrate with other predictive maintenance techniques such as vibration, thermographic and performance data.


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