Estimating Reduced Tensile Strength and Service Temperature of Fired Heater Coils Based on Hardness Readings
The article outlines a method to estimate the remaining tensile strength and inferred service temperature of fired heater coils using Brinell hardness readings, referencing the API 579‑1/ASME FFS‑1 Annex 2E correlation. It emphasizes that hardness testing is the primary diagnostic when tube‑skin temperature data are unavailable, especially for pre‑1986 heaters lacking skin thermocouples. The approach complements ultrasonic thickness measurements and can be validated with metallographic replication. By back‑calculating temperature exposure, engineers can determine if coils have entered the creep regime and decide on repair or replacement.
Reynolds Wrap Up: How Healthy Is Your FEMI Tree?
John Reynolds’ March/April 2026 Inspectioneering article introduces the ‘FEMI Tree’ analogy to illustrate how a healthy Fixed Equipment Mechanical Integrity (FEMI) program is built. He identifies twelve primary ‘nutrients’—programs such as design verification, corrosion control and competency training—that feed the canopy...
Mechanical Integrity and Damage Mechanism Concerns in Midstream Facilities
The article highlights that mechanical integrity (MI) programs in midstream gas processing are less mature than those in refining, despite growing natural‑gas infrastructure. It outlines common damage mechanisms such as stress corrosion cracking, liquid metal embrittlement, and general corrosion, referencing...
Let’s Be Frank: Management of Change – People Are So Much More Complicated Than Equipment
Inspector Frank’s latest column highlights the often‑overlooked management of change (MOC) processes for personnel in high‑risk roles. He contrasts three approaches: formal MOC or mentorship programs, reliance solely on documented procedures, and the reactive “lip‑service” model that only acts after...
Reconciling Measured Versus SME-Determined Corrosion Rates in DMR/RBI Development
The article examines the persistent gap between measured corrosion‑rate data from plant inspection systems and the rates estimated by subject‑matter experts (SMEs) during Damage Mechanism Review (DMR) development. It highlights how reliance on inconsistent IDMS records forces SMEs to reconcile...
MI Tools and Due Diligence – Overcoming a Black Box Mentality
The article warns that a "black box" approach to mechanical integrity (FEMI) software can mask hidden settings that jeopardize safety. It highlights how risk‑based inspection (RBI) platforms and digital twins increase data complexity, making robust inspection data management systems (IDMS)...
Understanding Casting Products, Properties, and Process Quality: Case Study of Ductile Iron Valve Deficiency
Saudi Aramco engineers examined a ductile‑iron valve that failed during hydrostatic testing at an oil‑and‑gas construction site. The valve’s ribs fractured, prompting a root‑cause study that linked the defect to inconsistent charge and recharge practices, improper grade selection under ASTM A395,...
My Most Successful Tips to Improve Asset Integrity, Reliability, Maintenance, and Turnarounds – Part 2: Asset Integrity Processes
Ricardo Valbuena’s second installment on asset integrity highlights two core pillars: people development and risk‑based inspection (RBI). He advocates establishing a structured inspector career ladder and supporting staff with API certifications to boost motivation, skills, and retention. The article also...
Phased Array Ultrasonic Testing as an Alternative to Traditional Radiographic Testing for HRSG Piping Weld Inspection: Triple Wins in Safety,...
Phased‑array ultrasonic testing (PAUT) is being promoted as a replacement for radiographic testing (RT) in heat‑recovery steam generator (HRSG) pipe weld inspections. PAUT removes ionizing radiation exposure, delivers instant defect data, and allows real‑time welding adjustments. The technology shortens inspection...
Highlights From the Fall 2025 API SCIMI Standards Meeting
The American Petroleum Institute’s Fall 2025 API Standards Conference, held November 9‑15 in Anaheim, convened the Committee on Refining Equipment to review and advance SCIMI initiatives. Six SCIMI standards were published in 2025, including addenda to RP 574, RP 580, RP 575 and RP 570,...
Guarding the Gate: What or Who Is the Foundation of Mechanical Integrity?
Inspectioneering’s Fall 2025 “Meeting of the Minds” roundtable in Anaheim revisited the core pillars of mechanical integrity (MI). Participants highlighted the Corrosion Control Document (CCD) and Integrity Operating Windows (IOWs) as essential data foundations. The discussion warned against the “shiny‑object” trap,...
Laser Surface Ablation for Surface Cleaning with Observations of Its Impact on Corrosion Control
Laser surface ablation is emerging as a precise, environmentally friendly alternative to traditional mechanical, chemical, and ultrasonic cleaning methods. By using controlled laser‑material interactions, it can selectively remove rust, coatings, and contaminants while preserving the substrate and eliminating abrasive waste....
Inspection Planning Process for Turnarounds
The article emphasizes that a structured inspection planning process, anchored by a risk‑based planning matrix, is essential for successful turnarounds (TAs). Developing a comprehensive Inspection Test Plan (ITP) early ensures clear communication of scope, methods, acceptance criteria, and hold points...
Asset Integrity Management of High Temperature Equipment Through Effective Thermal Hotspot Control
The Inspectioneering article outlines how thermal hotspots in refractory‑lined, high‑temperature equipment jeopardize structural integrity and operational continuity. It details damage mechanisms such as overheating, cracking, and corrosion that arise when refractory linings fail. The authors emphasize inspection techniques—infrared, acoustic, and...
API Inspection and Mechanical Integrity Summit 2026 Status Update
API’s Inspection and Mechanical Integrity Summit (IMIS) is slated for July 20‑23, 2026 at the Henry B. González Convention Center in San Antonio, Texas. Marking the event’s 10th edition, the summit will convene inspection planners, corrosion specialists, and fixed‑equipment decision‑makers....