CONTROL REPORT SPRAY DRYER 1

Transcription

1 CONTROL REPORT SPRAY DRYER 1 CUSTOMER : CLIENT 1 SITE : SITE 1 CONTACT : NAME 1 DATE OF TEST : 01/01/2018 REF SAP SPX : MAGNERSCAN SERIAL N : MAG THIS CERTIFICATE OF INSPECTION WAS ESTABLISHED IN THE NAME OF THE APPOINTED INSPECTOR. THE RESULTS OF THIS INSPECTION CONCERN THE CUSTOMER SUCH AS NOTICED, AND, UNLESS OTHERWISE STIPULATED, MAGNERSCAN BIOSCAN LIMITED, United Kingdom. TEST CONSULTANTS & TECHNICIANS PROCESS PLANT VALIDATION

2 METHOD STATEMENT WHICH USE THE MAGNERSCAN INSPECTION DEVICES Object: The statement of this method aims to define modes of operation of the MAGNERSCAN device, for the examination of internal surfaces for a wide range of tanks for process, subjected to the standards (DESP) or not, from the biggest drying towers to the small sized aseptic tanks, normally situated in the production part, in situ, in order to detect cracks, holes, welding defects susceptible to contaminate the production. Description of the MAGNERSCAN control device: MAGNERSCAN is a system which detects, electronically, the different defaults like cracks, incomplete welds (lines or spots), cavities caused by corrosion, porosities and other defects which can cause cross-contaminations and/or bacteria in the finished product. MAGNERSCAN is used for a wide range of tanks for process, subjected to the standards (DESP) or not, from the biggest drying towers to the small sized aseptic tanks. This method offers a better sensibility in the detection of microscopic cracks and other defects, reducing the risk considerably. The system is made of two control units: - A unit of multi-channel scanning which allows a fast analysis and specifies wide surfaces. - A probe of scanning mono-channel which allows to scan the small surfaces hardly accessible as the angles and the details of connecting of pipes and sheet steels. LOCATION OF DEFECTS (DEFECT MAPPING SYSTEM FOR CONDITION MONITORING) The defect location shall be assessed as follows for condition monitoring purposes; 1. Always view the vessel in plan position with DATUM point at zero degrees. 2. DEFECT MARKING will be carried out using indelible inks. Firstly, the defect will have a line drawn through the centre of the defect, then, a highlighting marker/chalk will be used around the outer area of the defect to enable the Inspector to return to the said defect with ease. This defect will then be given a unique identification number for certificate traceability. 3. Defect location in the vessel wall shall be measured in degrees from DATUM and listed as ANGLE degrees in chart. For example, if the defect was detected at 45 degrees, it will be listed under ANGLE as 45. Page 2 / 8

3 4. Defects in Large vessels (spray dryers for example) shall be measured from roof position (TOP) downwards, and identified in the chart as DISTANCE T for TOP. Measurements are in meters. For example, if the defect was detected at 10.2 meters from the top, it will be listed as T under DISTANCE T/B/W in the chart. 5. Defects in small vessels (process tanks for example) shall be measured from base position upwards if the base is flat. If the base is coned the measurement shall be taken from wall to cone circumferential weld, and identified in the chart as B for BOTTOM. For example, if the defect was detected at 1.45 meters from the bottom, it will be listed as 1.450B, under the DISTANCE T/B/W in the chart. 6. Defects in the roof or base areas shall be measured from the outside wall inwards, and also measured in degrees from 0. For example, if a defect is detected at 45 degrees and 1.8 meters from the outside wall, it will be listed as 45 under ANGLE and 1.800W under DISTANCE T/B/W 7. IDENTIFICATION in the chart will show length and type of defect. 8. PARENT PLATE in the chart shall show min and max wall thickness (AT CLIENTS REQUEST ONLY). EXAMPLE OF TYPICAL WELDING DEFECTS IN THIN WALL STAINLESS STEEL Incomplete fusion / incomplete penetration or excess penetration To achieve a good quality join it is essential that the fusion zone extends the full thickness of the sheets being joined. Thin sheet material can be joined with a single pass and a clean square edge will be a satisfactory basis for a join. 1 - Lack of fusion results from too little heat input and / or too rapid traverse of the welding torch (gas or electric). Excess penetration arises from to high a heat input and/or too slow transverse of the welding torch (gas or electric). Excess penetration - burning through - is more of a problem with thin sheet as a higher level of skill is needed to balance heat input and torch traverse when welding thin metal Porosity and/or oxidization 2 - This occurs when gases are trapped in the solidifying weld metal. These may arise from damp consumables or metal or, from dirt, particularly oil or grease, on the metal in the vicinity of the weld. This can be avoided by ensuring all consumables are stored in dry conditions and work is carefully cleaned and degreased prior to welding. Oxidized root may result from the inability to purge the root area with a gas shield (coking). Cracking 3 - This can occur due to thermal shrinkage or due to a combination of strain accompanying phase change and thermal shrinkage. Weld metal composition is dominated by the filler and as this is usually cleaner than the metal being welded, cracking is less likely with low dilution processes such as MMA and MIG. Parent metal composition becomes more important with autogenously welding techniques, such as TIG with no filler. Food processing vessels such as storage tanks, mixers, dryers and the like are subjected to extreme temperature variations, bearing this in mind, areas where high stress zones are apparent, may be subjected to material cracking due to the said temperature variations. Areas Page 3 / 8

4 that have previously been welded repaired, and/or dressed with abrasive polishers/grinders may result in thinning of the weld/haz/parent material, thus more prone to cracks emanating from the said areas. Material hardness is another anomaly to consider. Undercut 4 - In this case the thickness of one (or both) of the sheets is reduced at the toe of the weld. This is due to incorrect settings / procedure, and/or welding technique. There is already a stress concentration at the toe of the weld and any undercut will reduce the strength of the join. End Result from said defects 5 - Any of these defects are potentially disastrous as they can all give rise to high stress intensities which may result in weld or HAZ failure, creating an area for bacterial contamination from product residues remaining inside of the said defects, and/or chemical contamination from coolants leaking into the product path ACCEPTANCE ASSESSMENT FOR THE MAGNERSCAN METHOD The quality of the vessel examined is determined by the size and depth of defects detected. If the depth of defect/s are above ½ T ( T = material thickness ), and L = x 1.5T ( L = length of defect ) the vessel is considered to be unacceptable and requires immediate remedial work / weld repair for example, see comments section( Requires immediate attention). When acceptable repair work is undertaken and the said defects re-examined, they should be listed as Accept after repair, in the summary of examination listing. If there is evidence of surface defects and the estimated size is below the reject criteria, but considered to be a future risk by the Qualified Inspector, they should be regularly monitored to assess growth of defect/s, see comments section (6 monthly monitoring recommended). If there is no evidence of any rejected defects, the item is considered to be acceptable and should be re-examined at 12 monthly intervals (12 monthly monitoring recommended). After repair work has been carried out, defective areas shall be re-examined using the same technical procedure. Page 4 / 8

5 Health and Safety: The internal rules, of the site, must be handed by the customer and they must be followed permanently, the wearing of any specific personal protective equipment is compulsory. The customer internal procedures must be respected, according to the requirements and the recommendations of the customer. Calibration: The equipment is tested and calibrated every year, according to the requirements of the quality management system BIOSCAN LIMITED Qualifications and Training Level of the Inspectors: All of our inspectors have to be trained and certified for the controls they are responsible for. They are subjected to an internal examination qualifying in the conduct of tests MAGNERSCAN. Period of Validity: 12 months from the date of examination. All the inspectors have to be holders of a certificate of qualification. Below, Information extracted from the sheet of the statement of defects. Page 5 / 8

6 Manufacturer: MANUFACTURER 1 Plant: TYPE1 SERIAL NUMBER: CHAMBER DEFECTS & REPAIRS Defect n 1: Identification Defect length 50mm, Defect found in the cone Location Defect present 6.515m from the roof; 250 from the main door Observations Approved after repair (Photo below) Comments Re-test recommended in 12 months Defect n 2: Identification Location Observations Comments Defect length 70mm, Defect found in the cone Defect present 8.36m from the roof; 295 from the main door Approved after repair (Photo below) Re-test recommended in 12 months Page 6 / 8

7 Defect n 3 : Identification Location Observations Comments Defect length 50mm, Defect found in the cone Defect present 7.5m from the roof; 2955 from the main door Approved after repair (Photo below) Re-test recommended in 12 months Defect n 4: Identification Location Observations Comments Defect length 80mm, Defect found in the cone Defect present 7.9m from the roof; 295 from the main door Approved after repair (Photo below) Re-test recommended in 12 months Page 7 / 8

8 Defect n 5: Identification Location Observations Comments Defect length 10mm, Defect found in the cone Defect present 5.81m from the base; 250 from the main door Approved after repair (Photo below) Re-test recommended in 12 months Page 8 / 8