Author Archives: Samuel Peppin - Managing Director at Bioscan Ltd

Context and Challenges

A food processing company was facing leaks in a 100,000-litre storage tank, which posed a significant risk to the quality of the product. Visual inspections failed to detect the cracks responsible for the leaks. Immediate action was required by the vessel crack test inspection service provider to prevent contamination and minimise downtime. 

Our Task Was to…

Bioscan, a renowned provider of tank inspection services, was tasked with performing a full silo inspection of the tank using our electronic scanning technology, which provides precise detection of both visible and hidden defects. During the silo testing, we identified that the defect causing the leak was the result of a previous silo repair. The scanner revealed that the crack was transverse, meaning it passed through the full thickness of the metal, which made it a critical failure point. 

This is How We Spotted the Defect

The 100kL storage tank inspection was conducted by a silo maintenance team of rope access technicians and welders, who accessed all the necessary areas of the tank safely and efficiently. Using ropes, our silo service technicians reached the difficult-to-access spots, ensuring that all areas were inspected thoroughly. They worked autonomously, supported by our specialist rescue technicians, ensuring safety throughout the process.

Solution We offered

Once the problem area was identified, our specialised storage tank repair experts and welders performed the required repair work to the defective area following food industry standards. After the repair was completed, a re-inspection of the Heat Affected Zone (HAZ) was carried out, followed by a roughness test to ensure that the finish was below 0.8 μm. 

Outcome

After the repairs, the tank was returned to service with no further leaks, and the client has not experienced any more issues since. The entire process was completed in 5 hours, ensuring minimal disruption to operations. A detailed report was provided to the client, including photos before and after the repairs and a certificate of compliance confirming the quality and safety of the repair.

Conclusion

This comprehensive case study shows the effectiveness of Bioscan’s storage tank repair services. If you are looking for the best and result-oriented tank inspection services, we are just a call away. Contact us today!

Context and Challenge

A global leader in the dairy industry solicited Bioscan to conduct an audit of their complete tank listing, which is crucial for ensuring product quality and safety. The challenge was to detect and address any defects that could compromise the integrity of the tanks while ensuring compliance with food manufacturing standards, then perform repair works where required.

Solution in Two Phases

Phase 1: Comprehensive Inspection

• Internal Inspection: Inspections using Bioscan’s scanning technology for crack detection and integrity testing.
• External Inspection: Crack test the skirt, double jacket, and feet of the tanks to spot signs of damage and corrosion.

Phase 2: Repairs and Asset Management

• Crack Repair: Repair cracks and polish to food-grade standards.
• Asset Management: Identify any tanks that needed complete replacement due to extensive damage over a 1-to-10-year period depending on severity.

Results

Bioscan’s intervention achieved the following:

• Prevented Production Interruptions: Early detection of defects avoided potential disruptions in the future
• Reduced Costs: Timely tank inspection services avoided premature tank replacements, cutting costs.
• Ensured Compliance: Maintained adherence to food manufacturing standards.

Client Testimonial

“Bioscan demonstrated remarkable flexibility and exemplary professionalism. Thanks to their efforts, our tanks are now in a better condition and we have a clear vision of the costs that we need to invest in future years.” — Project Manager

Conclusion

Bioscan’s vessel crack inspection services enabled this dairy industry leader to improve conditions and extend the use of their tanks while ensuring strict compliance. Contact us to find out how we can achieve this for your facilities.

Context: A factory specialising in the production of acacia powder faced an urgent need to repair a critical component of its cyclone, which was threatening to severely disrupt production.

Problem: A sudden failure revealed a cracked zone in a critical part of the cyclone, requiring immediate cyclone inspection.

Solution: The factory called upon Bioscan’s crack test and repair services for a swift and effective response.

Project Execution:

• Problem Identification: The damaged area was visible and already identified by the client; however, a larger area was inspected using vessel crack inspection services as a precaution.
• Access Methods: Qualified IRATA rope access technicians safely accessed the damaged area inside the cyclone.
• Repairs: The damaged section was cut out and replaced with a stainless-steel 316L sheet by qualified welders. Repairs were carried out to the strict standards of the food industry, with finishing and polishing to a precision of less than 0.8 μm.
• Rechecking: Re-inspection of the zone and roughness checks were performed to validate the quality of the repair works.
• Report and Certificate: A detailed report with before and after photos of the repairs was provided.

Results:

• Quick and Effective Repair: The damaged area was repaired promptly in under 6 hours, minimising production downtime.
• Enhanced Equipment Lifespan: High-quality repair works and new inspection frequencies extended the cyclone’s lifespan.
• Reduced Maintenance Costs: Effective preventive maintenance reduces long-term costs and improves process reliability.

Conclusion

The urgent repair of the cyclone at the acacia powder plant demonstrates the effectiveness of Bioscan’s crack detection and tank inspection services in critical situations. By swiftly identifying the damaged area and performing the repairs the client was quickly back into production.