inspection Services

Inspection Services
gap assessment

GAP Analysis is an examination of your current facilities compliance program and documentation. Following the examination, an assessment is performed to compare what your current state is compared to what your actual requirements are. Our Compliance Specialists and Engineers will then compile all the recommendations necessary to fill out your current programs. Often NEAS has all the resources required to complete any services you may need.

IIAR 6 inspections

IIAR (International Institute of Ammonia Refrigeration) continues to work diligently to help keep the industry as safe and vigilant as possible. They’re latest development of standards has set forth the minimum requirements for inspection, testing, and maintenance for closed-circuit ammonia refrigeration systems, the IIAR – 6 Inspections. All ammonia refrigeration systems, above and below the PSM/RMP 10,000lb threshold, will soon be REQUIRED to adhere to these specific inspections annually.

mechanical intergrity

Mechanical integrity (MI) is just one of the 14 elements included in Process Safety Management (PSM), driven by the OSHA 1910.119 standard, which reads that “Mechanical Integrity means the process of ensuring that process equipment is fabricated from the proper materials of construction and is properly installed, maintained, and replaced to prevent failures and accidental releases.” Mechanical Integrity is primarily centered around fixed equipment. Some examples might be pressure vessels, dispersion tanks, piping systems and attached hardware (valves, fittings, etc), relief devices, vent hardware, and emergency shutdown/control systems. Rotating equipment/assets, such as pumps, blowers, fans, and compressors that may be used to move hazardous materials within these systems, are also included. In many cases, this means that all equipment within the boundaries of a facility is subject to the Mechanical Integrity PSM standard.

 

Mechanical Integrity (MI)

It is a priority of the PSM standard to maintain the mechanical integrity (MI) of critical process equipment to ensure it is designed and installed correctly and operates properly. Such MI requirements apply to the following equipment:

  • Pressure vessels and storage tanks;
  • Piping systems (including piping components such as valves);
  • Relief and vent systems and devices;
  • Emergency shutdown systems;
  • Controls (including monitoring devices and sensors, alarms and interlocks) and;
  • Pumps.

Of particular interest to us here at Bacharach is the “controls” part of the Mechanical Integrity section, which is clarified as “including monitoring devices and sensors, alarms and interlocks” (29 CFR 1910.119(j)(v)). This is because our ammonia refrigerant detectors and monitors, like the MGS-400 Gas Detection Series, are applicable.

Engineered for use in cold storage facilities, MGS-400 gas detectors feature ammonia-specific sensors and are flush mounted in the enclosure to optimize the response time. For instance, when ammonia is detected, the leak detectors integrated audio/visual alarms alert personnel to the leak.
Now, to get back to the point, an employer must establish and implement written procedures to maintain the ongoing integrity of process equipment. Inspection and testing must be performed on process equipment, following recognized and generally accepted good engineering practices.

Traditional Non Destructive Testing Inspection

An employer shall develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and must address the steps for each operating phase; operating limits; safety and health considerations; and safety systems and their functions. (See 29 CFR 1910.119(f) for full details on these elements.)

Compliance Audits

An employer must certify that they have evaluated compliance at least every three years to verify that the procedures and practices developed under the standard are adequate and are being followed.

It is important to determine and document an appropriate response to each of the findings of the compliance audit, and document that deficiencies have been corrected.

The two most recent compliance audit reports should be on-hand.

visual testing (VT)

The oldest and most basic form of non-destructive testing, traditional visual testing involves our technicians inspecting equipment with their eyes to determine any visual defects. We offer visual inspectors that are certified to a variety of industry codes and regulations.

Often the first technique that we utilizes at the outset of a project, we provide a variety of visual inspection (VT) services to multiple industries. The method is useful for determining a project’s scope, establishing the extent of existing damage, and informing the technician of where more advanced, in-depth inspections are needed.

ultrasonic Testing (UT)

Conventional Ultrasonic Testing (UT) inspection is a commonly-used non-destructive testing (NDT) technique that measures the propagation of mechanical vibrations (ultrasonic waves) through a material to examine properties, measure thickness, determine elasticity, and detect a range of discontinuities, including corrosion/erosion, flaws, cracks, and more.

An NDT) staple, our technicians utilize conventional ultrasonic testing (UT) to detect surface and sub-surface defects and supply accurate readings regarding discontinuity size and shape. Ultrasonic surveys are used as the main inspection technique for a plant’s erosion/corrosion programs, and are utilized extensively at our multiple evergreen site locations around the world.

Penetrant Testing (PT)

A traditional, relatively simply method of field or lab non-destructive testing, Penetrant Testing (PT) is used for finding surface-breaking discontinuities on relatively smooth, nonporous surfaces. It is based on the properties of capillary action, or the phenomenon of a liquid rising or climbing when confined to a small opening. After the excess penetrant is removed and a developer is applied, a trained inspector can identify any remaining penetrant that may indicate a flaw.

Also referred to as Liquid Penetrant Inspection (LPT), Penetrant Testing (PT) is used on non-ferrous materials such as metals, composites, and ceramics, identifying surface anomalies such as cracks, seams, laminations, blow holes, laps, external bursts and welding defects.

Real Time Radiography (RTR)

Real-Time Radiography (RTR) –  Real-Time Radiography (RTR), emits radiation into one side of a material and uses sensors on the other side to convert the rays into light, producing a digital image that reveals corrosion, and internal/external defects in real time. RTR is a safer and quicker alternative to traditional radiography, requiring no need for a dark room to produce images. NEAS uses an industry leading third party to supply RTR services to customers who are interested in this level of inspection.

Predictive Maintenance (PDM) Testing Services and Programs

 

A well-designed PDM program enables facilities to predict potential damages and equipment failures before they happen, enhancing safety and maximizing operational uptime. As a OneSource provider of asset protection solutions, we offer the high level of technical knowledge and proficiency in inspection, engineering consulting, and vibration testing solutions necessary for your predictive maintenance program to deliver maximum value.

Our custom-tailors predictive maintenance services and programs to our client’s individual facility needs. This can be as simple as supplying an inspector to collect and analyze equipment vibration data, or as complex as having our engineering, inspection, and mechanical teams design, implement, and execute a comprehensive PDM program.

(PdM) Program Implementation Services

Whether your facility needs to design and implement a brand-new PdM program, or upgrade an existing one, MISTRAS offers engineering support and fully-developed PdM procedures and guides.

Our PdM program implementation consulting services include:

  • Gap Analyses
  • Failure Modes and Effects Analysis (FMEA)
  • Key Performance Indicator (KPI) definition
  • Procedure Development
  • Root Cause Engineering Analysis
  • Third Party Acceptance Testing
  • Training of In-House Personnel

Our PdM engineers bring expertise in database construction/management and data collection, reporting, analysis and documentation. We are also able to assist you maximizing the value of your capital investments and performing a cost-benefit analysis of your program.

(PdM) Inspection & Testing Services

In addition to designing PdM programs, we will also execute a full range of PdM inspection and testing services.

We can conduct the entire PdM program for you by assessing your machines and writing your entire database, including analysis parameters and vibration limit specs. We’ll provide an engineering report that diagnoses possible problems and recommends maintenance actions.

Our goal is to provide an integrated solution that lowers facility maintenance costs and increases production and profits.

Our other predictive maintenance services include:

  • On-line Vibration Monitoring
  • Walk-Around Vibration Services
  • Advance Vibration Diagnostics
  • Field Balancing Services
  • Infrared Thermography Inspections
  • Lube Oil and Grease Analysis
  • Ultrasonic Lubrication and Leak Detection Services
  • Motor Condition Monitoring (Motor Current Signature Analysis)
  • Strain Gage Materials Testing and Stress Analysis
  • Laser Shaft Alignment
  • Installation of Permanent Online Vibration Monitoring Systems

vibration analysis Inspection

Vibration analysis are used heavily in predictive maintenance (PdM) programs, where our technicians measure and identify signs of irregular or excessive in-service movement occurring within rotating equipment. Vibration analysis measures amplitude, intensity, and frequency to detect mechanical failures, such as core/winding loosening.

Vibration analysis is one of the most popular techniques utilized in PdM programs. We analyze vibrations of machinery and rotating equipment as part of condition assessments, enabling us to more accurately predict failures before they cause more costly damages.

Our vibration sensors and monitoring equipment include local read-out meters and alarms that can be wired to your control room for trending and shutdown capabilities. These sensors and systems are useful for machinery in locations that may be difficult or unsafe for personnel to access. Vibration systems also provide consistent and accurate trending data on operating conditions, helping operators make more informed maintenance decisions.

 

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