Case Study

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.

Context: A chemical manufacturer uses industrial spray dryers in its production process. The equipment had never, or rarely been inspected since commissioning.

Problem: Lack of regular inspections led to the accumulation of undetected cracks, resulting in unexpected production stoppages and contamination risks.

Solution: The company utilised Bioscan’s spray dryer inspection services for an in-depth inspection of its equipment.

Project Execution:

• The technology used: Electronic crack detection scanner with eddy current technology, allowing detection of visible and invisible defects and measurement of their depth.
• Access methods: Use of a portable platform assembled section by section, covering spray dryer diameters from 1.5 meters to 14 meters, combined with rope access methods with IRATA-qualified technicians.
• Repairs: Repairs were carried out by specialised welders according to industry standards, with precise finishing and polishing to below 0.8 μm.
• Reinspection: Rescanning and roughness checks after repairs to validate the quality of the repairs.
• Report and certificate: Delivery of a detailed report within 7 to 14 days with before/after photos, defect causality, depth, and length, polishing finish, and a control or compliance certificate.

Results:

• Identification and repair of critical defects: Reduction of production stoppages due to rapid crack detection and repair.
• Establishment of new inspection frequencies: Implementation of appropriate vessel crack testing frequencies to prevent future problems, thus increasing the equipment’s lifespan.
• Improvement in product safety and production process reliability: Reduced contamination risks and long-term costs through effective preventive maintenance.