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INTRODUCTION
Often when reviewing the thickness database for pressure vessels, the installation thicknesses found at CMLs is nothing but
the nominal plate or component thickness at that location, as
it was considered that the new vessel had no need for baseline
thickness data and would be collected at the next appropriate
inspection interval. Unfortunately there can be a significant variance in actual plate or component thicknesses when installed,
and the ability to compare the first set of actual thickness readings against original readings to get a more accurate estimate of
metal losses and estimates for corrosion rates are lost for this first
processing period.
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It is important that this localized on-stream monitoring be performed by qualified NDE personnel utilizing proven procedures.
Diligent NDE and owner/user companies now perform training and demonstration testing to verify the capabilities of an
examiner. Demonstrations can include calibration, temperature
compensation, the ability to read drawings, preparing surfaces,
understanding the owner/user taxonomy, and reporting requirements. In addition, very effective programs include blind demonstration testing of samples with some thickness variation to
PITFALL #4: CML COVERAGE NOT ADJUSTED BASED
pre-qualify examiners. This should include a localized corrosion
ON INTERNAL INSPECTION FINDINGS
One of the most aggravating and common problems in preparing detection and measurement blind test, typically done on a comfor a risk based assessment of a piece of equipment is compar- ponent with well-known, very localized thin areas that are to be
ing the database of CML thicknesses and corrosion rates with the scanned and reported.
findings from internal vessel inspections and finding that they
PITFALL #5: LOCALIZED CORROSION THICKNESS
do not match. Very often the internal inspection may report local
MONITORING NOT CONSISTENTLY PERFORMED
corrosion or pitting problems with measured depths of losses, but
If the corrosion found during internal or external inspections is
for some reason, the CML database for the vessel has not been
localized or pitting-based type corrosion, single point CMLs are
updated to reflect these findings. The original CML pattern data
not very effective in ensuring accurate detection and measureis still in place and the data may not reflect the internal inspection
ment of the minimum thicknesses within the corroding zone. In
findings, making it difficult to establish a minimum thickness
the authors opinion, the most effective technique for monitorand corrosion rate basis for remaining life and risk assessments.
ing localized corrosion is automated UT mapping with x-y raster
There are two steps to improve monitoring effectiveness to bet- scanning, which provides consistent minimum thickness identiter ensure that thickness monitoring data is consistent with the fication with the added advantage of mapping detail that could
internal inspection findings.
also support fitness-for-service analysis.
At a minimum, it is recommended that CML data entry(s) be cre- Often though, this technique may not be available and may
ated in the database to define the minimum thickness findings be costly. Another alternative and effective technique is using
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Inspectioneering Journal
CONCLUSION
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