TOPICS COVERED IN THIS ISSUE:

• INTRODUCTION
• CASE STUDIES
• MOVING FORWARD WITH 2D & 3D COIL MODELING SOFTWARE
• CONCLUSION

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INTRODUCTION:
After being approached by several of our clients it became apparent that their was a need in the industry to inspect piping coils in platformer furnaces. Access to the exterior of the coils limited any type of comprehensive inspection, intern providing plant engineers with limited/marginal test results and most times very inaccurate. The engineers were required to make sound engineering decisions based upon these poor test results. Access to the interior of the tubes was also challenging since the tubes enter into a common header at the top of the furnace. In late 2002 QUEST kicked off development our "Platformer" furnace coil inspection program. Since both "wall loss" and "creep strain" were potential failure mechanisms, it was critical to the programs success in insuring the ability to accurately detect and quantify both types of coil degradation mechanisms. To date QUEST has conducted numerous laboratory studies along with field surveys necessary to consider our inspection options viable. The following are two case studies which illustrate the use of two different technologies (FTIS & LOTIS) in two different refineries.

CASE STUDIES
Project #1
In the summer of 2003 the initial "platformer" program was finalized and the first joint project with a refinery in Australia was underway. The initial project employed our laser based LOTIS technology which is capable of measuring diametrical growth (creep strain) with +/-0.002" accuracy. A platformer furnace containing three sets of headers (129 individual "U" shaped coils) was examined. The individual coils were accessed from inside the header on a custom designed header buggy. The LOTIS laser probe was driven down each individual coil to acquire the inspection data.

The LOTIS inspection results revealed that the coils contained minimal damage, however even the early stage creep strain damages were easily detectable. The LOTIS software presented the inspection data from the coils in a high resolution 3D format along with pin point data measurements. The 3D tube model display allowed damage patterns to be quickly identified. The pin point measurements enabled the damages to be quantified very accurately. Both our customer and QUEST considered the project a success and step forward in the way coils in platformers are inspected today. The limitations were that the remaining wall thickness could not be measured with the LOTIS technology, however the creep strain could be very accurately measured.

Project #2
In the fall of 2003 the second program was finalized and a project was kicked off at a refinery in the Netherlands. During this project QUEST utilized our "ultrasonic based" FTIS intelligent pigging technology which is capable of measuring: a) remaining wall thickness, b) ovality, c) swelling and d) bulging. A platformer furnace containing four sets of headers (132 individual "U" harped coils) was examined. The individual coils were accessed from inside the headers by way of a custom FTIS extraction system. After each of the individual coils were filled with water (required to couple the ultrasonics) the FTIS intelligent pig was pulled through each of the coils.

The FTIS inspection results revealed a combination of creep strain and wall thinning type damages. The FTIS 2D and 3D tube modeling software enabled both the customers and our engineers to visually point out trending and damage patterns. The FTIS software also enables the analyze to output remaining thickness and radial growth measurements at any location in the coil. Both the customer and QUEST consider this inspection even a bigger success than the previous LOTIS exam. The limitations were that the coil had to be filled with water in order to apply the FTIS.

MOVING FORWARD WITH 2D & 3D COIL MODELING SOFTWARE
QUEST has continued to advance programming capabilities in the coil modeling software, which allows both 2D (rolled out flat) and 3-Dimensional (3D) modeling capabilities for "individual coil segments" and/or "100% of the coil network" all in one screen image. This powerful software utilizes the individual coil creep strain data collected by either LOTIS or FTIS to create very high resolution 2-Dimensional (2D) or 3-Dimensional (3D) color image. This allows the entire coil network to be rotated at any orientation to best illustrate the presence of existing wall thinning or creep type damages. This powerful visual aid enables plant engineers to make immediate engineering, maintenance or operational changes in tube replacement, refractory replacement/modification, burners, flue gas distribution, etc. resulting in maximized coil life extension.

CONCLUSION
Both FTIS and LOTIS technologies have proven to be viable, cost effective and accurate inspection methods for platformer furnace coils. One technique might be selected over the other based upon type of failure mechanism sought after, accuracy requirements, time allowed to carry out inspection and ability to place water inside the coils.

Please do not hesitate to contact us if you wish to obtain more detailed information on how our FTIS and LOTIS technologies can be applied to inspect platformer furnace coils.

Please visit our web site at www.qi2.com/field/fsddef.htm

Regards,
Richard D. Roberts
V.P. Field Services Division
QUEST Integrated, Inc.
1012 Central Avenue South
Kent, Washington 98032 USA

Direct Tel: 1-253 872-9500 ext. 1275
Toll Free Tel: 1-800 233-3345 ext. 1275
Cell: 1-206 571-4302
Fax: 1-253-872-8967
E-mail: richardr@qi2.com
Web Site: www.qi2.com/field/fsddef.htm