Paper Mill Mechanical Integrity Programs
Frazier Reliability Solutions has set up complete mechanical integrity programs for several paper mills. First, we develop a set of written mechanical integrity procedures that describe risk ranking of equipment, risk based inspection frequencies, inspection criteria, inspection procedures and documentation requirements. Then we populate a data base inventory of all boilers, pressure vessels and tanks at the facility. We then inspect all of the equipment based on the risk based criteria. The end result is an efficient, cost effective and comprehensive mechanical integrity program that captures all assets, provides code based inspections, ensures regulatory compliance and helps the customer achieve their long-term reliability goals.
The problem: A chemical plant had a large potable water tank that required internal inspection every 5 years. However, the potable water supply to the site could not be interrupted, even for inspection. So, every 5 years, the site had to pipe up a large sterilized bladder to the tank, fill the bladder with potable water, drain the tank, scaffold the tank, perform the inspection, fill the tank back up and then dismantle the bladder. Costly. Time consuming. Painful.
Our solution: Drop a submersible camera into the tank from the top manhole and complete the inspection in one day while the tank remained in service. Simple. Inexpensive. Quick. Painless.
The problem: A very large manufacturing facility, originally constructed during WWII, did not have a complete and accurate inventory of electrical breakers and starters. Without a good inventory, they were unable to populate their computerized maintenance system with functional locations for all of their breaker and starters. Equipment not in the maintenance system received no maintenance. They were run to failure. Also, without functional locations for all the breakers and starters, they were unable to populate their electrical system model for fault current/short circuit studies. Without complete studies, they were unable to determine precise arc flash hazards. Therefore, they had to default to the worst-case arc flash hazard, which meant that even a 220 V breaker operation would require a cumbersome Level 4 arc flash suit. A less than ideal situation.
Our solution: Working with their electricians, we located and inventoried every breaker, starter and transformer at the location. We completed a cloud based data form including all name plate data required for the fault current/short circuit study. We also added photos of the object and the equipment label. We documented the physical location and added a bar code. All data was imported into the sites electrical system model and computerized maintenance system. Now the site has a complete and accurate cloud based inventory, proper fault current and coordination studies, correct arc flash labeling, proper preventive maintenance activities and efficient infrared survey routes that can be documented by scanning equipment bar codes. Under control. In compliance.
Building Site Drone Survey
The problem: The management of a construction company building a multi-story office building at a remote location wanted to monitor the progress of the construction from their headquarters several miles away. Travelling to and from the site was time consuming for busy executives. A stationary surveillance camera provided only a limited view of the site and ground based photos taken by the site superintendent didn’t provide an overall view.
Our solution: Each day, we performed a 360° flight around the entire site and building with a drone equipped with a high definition camera. The video capture taken by the drone and selected screen shots were uploaded to an ftp site accessed by the construction company management. Each day, management could watch the progress of the construction from their office.
Bonus solution #1: At the end of the project, management asked us to edit a time lapse video of the entire project. The construction company was so impressed, they now include the video in their web site marketing.
Bonus solution #2: The GPS data we developed during our flights of the site allowed us to generate a complete, detailed 3D digital map of the building which we then printed out with a 3D printer. The plastic reproduction of the building is one of the CEO’s most prized possessions.
High Voltage Aerial Feeder Inspection
The problem: A chemical plant had several miles of pole mounted high voltage aerial feeders that needed to be inspected on a regular basis. Usually, these types of inspections can be performed from a bucket truck, however, many of the poles were located in swampy areas with no dry roads. How could they get good close up imagery of the cross arms, insulators and switches? Do the inspection from a boat?
Our solution: We inspected the entire system using a drone equipped with a visual light camera and an infrared camera. This allowed us to perform up close, 360° inspections of each pole, the cross arms, brackets, switches, insulators etc. This was a level of inspection never achieved before.
Bonus solution: As we inspected the feeder system, we collected GPS data for each pole, allowing us to produce an accurate digital map of the entire system.
The problem: A paper mill wanted to perform an internal inspection of a very large stainless steel tank with a sloped floor. In the past, the mill would scaffold the entire tank to complete the inspection. They asked us if there was a better, faster, smarter, safer way?
Our solution: We launched a drone with a high definition camera and lights from outside the tank, flew the drone through the man hole and inspected the entire tank. We saved the mill thousands of dollars and entirely eliminated the confined space and dropped scaffolding/tool risks. Better, faster, smarter, safer…and cheaper