Inspection Project on a Chemical Plant in Belgium


                                                                   Project Objectives
The primary goals of the inspection were to:

  • Validate the iSensPro inspection technique for detecting moisture and corrosion.

  • Assess practicality for routine inspection in line with company procedures.

  • Detect pipeline segments requiring maintenance to scope maintenance stop.

                                                   Pipeline Set up and Conditions
5 pipelines on a pipe-bridge with different characteristics
were inspected.
•Segmentation by repositioning shielding during inspection.
•Inspection with iSensPro handheld sensor placed at
outside of cladding.
•Measurements to identify segments with moisture, coating
degradation or corrosion.
•Visual validation after removing insulation by the asset
owner



  • PL 2: Regeneration gas, DN150 Carbon
    Steel, 210 mm mineral wool, no tracing,
    segment of 29 m, normal corrosion risk.
  • PL 4: Turbine condensate, DN250 carbon
    steel, 80 mm mineral wool, no tracing,
    segment of 29 m, normal corrosion risk.








                       Pipeline Characteristics

  • PL 1: Regeneration gas, DN150 Carbon
    Steel, 80 mm mineral wool, no tracing,
    segment of 29 m, normal corrosion risk.
  • PL 3: Regeneration gas, DN80 Carbon Steel,
    70 mm mineral wool, no tracing, segment of
    7,5 m with bend, high corrosion risk.

    PL 5: Regeneration gas, DN150 Carbon
    Steel, 30 mm mineral wool, no tracing,
    segment of 29 m, high corrosion risk
                                                  Key  Findings and Conclusions
Key Findings
 3 measurements over complete pipe length indicating issues around supports.


PL 1
  • 9 measurements
  • Moisture and corrosion detected in one segment
  • Other segments identified as dry
PL 2
  • 12 measurements
  • Moisture and corrosion detected in two segments
  • Other segments identified as dry
PL 3
  • 4 measurements
  • No detection of corrosion in a segment due to presence of chalk around pipe 


 



PL 4 
  • 17 measurements
  • Moisture and corrosion detected in one segment 
  • Other segments identified as dry 
PL 5
  • 16 measurements 
  • No moisture nor corrosion detected in one of the segments
Conclusions
  • The inspection campaign successfully
    demonstrated the reliability and
    effectiveness of the iSensPro handheld
    sensor
  • 61 measurement points were inspected in
    2 days.
  • More than 91% of measurement results
    were in line with visual inspections.
  • Supports are critical points for
    inspection.
  • Continuous monitoring is recommended to
    further improve detection of moisture and
    corrosion.




  • Adjustment of procedure around supports
    improving probability of detection.
  • Identification of chalk on pipe segment
    influencing measurement.

                                         Key Benefits of iSensPro Technology
  • Efficiency: 61 measurements were completed in 2 days, with each one taking only 10-15 minutes 
  • Accuracy: Probability of Detection of moisture and corrosion is higher than with risk-based inspection.
  • Ease of Use: Minimal setup required, handheld sensor provides full analysis indicating wetness and corrosion speed in under 5 minutes.
  • Cost reduction: Identification of segments with dry insulation and intact coating reduces
    maintenance scope and costs.