This article explores failure mechanisms in carbon steel and stainless steel pressure vessels operating under high temperature, pressure, and insulation. It covers CUI, HTHA, Cl-SCC, creep, and fatigue, and outlines inspection and mitigation strategies per API 510, 571, 579, and 941. Acoustic emission testing and risk-based approaches are highlighted for proactive integrity management.

This article explores failure mechanisms in carbon steel and stainless steel pressure vessels operating under high temperature, pressure, and insulation. It covers CUI, HTHA, Cl-SCC, creep, and fatigue, and outlines inspection and mitigation strategies per API 510, 571, 579, and 941. Acoustic emission testing and risk-based approaches are highlighted for proactive integrity management.

Destructive Testing of Fiberglass Storage Tanks: Ensuring Strength, Durability, and Compliance

Ensuring the safety and integrity of critical components in industries such as aerospace, automotive, and construction is paramount. One of the most reliable methods to detect surface and near-surface defects in ferromagnetic materials is magnetic particle testing. This non-destructive testing technique helps identify flaws that could lead to catastrophic failures if left undetected. In this article, we will explore the fundamentals of magnetic particle testing techniques, th

The Importance of Wire Rope Sockets Wire ropes serve as critical lifelines in countless engineering structures—from towering suspension bridges to powerful cranes and expansive cable-stayed constructions. At the heart of their reliability are wire rope sockets, essential mechanical connectors that anchor and transfer immense loads safely and securely. Often overshadowed by the wire rope itself, the sockets are equally important from a load-bearing, fracture-critical, and fitn

Suspension Bridge cables are exposed to a spectrum of load and environmental conditions that create susceptibility to a variety of deterioration mechanisms including corrosion, fatigue, wear and abrasion [1].  Bridge cable damage occurs in the corrosion protection system, cable exterior and interior, and anchoring system.  The primary damage mechanism driving suspension cable mechanical defects includes corrosion and complex cyclic loading.  The damage mechanisms may be visib

A Pipeline Mechanical Integrity (MI) program is a critical component of a Process Safety Management (PSM) system under OSHA’s Process Safety Management (PSM) standard — specifically addressed in 29 CFR 1910.119(j) [1]. A well-structured MI program is designed to continuously monitor and assess the condition of pipelines and associated equipment. By regularly inspecting, testing, and maintaining components such as valves, pressure vessels, and piping, the program helps to iden

Steel wire rope used in industrial and recreational applications are manipulated through sheaves and drums.  The wire rope bearing surface hardens and beyond a certain point, fatigue cracks will initiate.  Under optimal conditions, the wire rope bearing surface will wear at a rate faster than the crack initiation rate.  Similarly, steel railroad surfaces develop rolling contact fatigue cracks over time and if the crack propagation rate exceeds rail surface wear rate, small fa

Introduction Steel pressure vessel fabricated to United States Department of Transportation (U.S. DOT) and American Society for Mechanical Engineer Boiler and Pressure Vessel Code (ASME BPVC) required periodic recertification based on local, state, and federal regulations.  This article focuses on the nuances involved in rebuilding and recertifying tube trailers for continued safe use.  Figure 1:  Tube trailers transporting U.S. DOT steel cylinders Overview of Tube Trailer Re

Weld inspection and repair is a multi-step process that includes non-destructive testing, inspection data interpretation against the relevant code, weld metal excavation, follow-up  non-destructive testing, weld repair per relevant construction code and final non-destructive testing. This article walks the reader through a steel weld that failed an inspection, was subsequently repaired, re-inspected and cleared for use. Figure 1: Nondestructive testing and repair of structura

Introduction Excellent quality non-destructive testing (NDT) data is required to ensure the structural integrity of bridges, piping systems, pressure vessels and other pressure and load bearing structures.  The data quality must be assured before leaving the inspection site to assure sound engineering conclusions are made on the future performance of the asset.  The cost to repeat non-destructive testing extends beyond the actual inspection costs and may include traffic contr

Non-destructive testing (NDT) training is essential for developing a skilled workforce, whether for new employees with little to no NDT experience or for enhancing the skills of existing NDT personnel. Virtual, remote, or online NDT training provides an economical option for both employers and students to gain foundational knowledge, while also confirming the necessary aptitude through general, specific, and practical exams. This article explores the feasibility of completing

Carbon and stainless steel aboveground storage tanks are constructed in accordance with guidelines set forth by API-650 Welded Tanks for Oil Storage and other standards based on the intended service [1-5].    In the context of aboveground storage tanks (ASTs), a door sheet refers to a temporary opening created in the tank's shell to provide access for inspection, maintenance, repairs, or cleaning. These door sheets are typically cut into the side of the tank to allow personne

Non-destructive testing of welds per ASME pressure vessel and piping codes [1-3] is outlined within the codes and additionally in ASME BPVC Section V.    As it relates to pressure vessels, ultrasonic testing may be used in lieu of radiography for all welds in which the thinner of the members joined is 0.250” and greater [4].  The power piping code calls out volumetric examination, radiographic or ultrasonic, as minimum requirements for butt welds and welded branch   The proce

Figure 1: Conventional ultrasonic immersion scanner retrofitted with phased array ultrasonic testing (PAUT) technology. Introduction to Ultrasonic Immersion Testing Automated ultrasonic immersion testing (AUT) offers a high-speed, high-resolution method to scan primary, formed, and finished materials for material defects. Ultrasonic immersion testing may be performed using full immersion, water jet, and bubbler configurations. While initially developed for steel, aluminum, a

Explore the nuances of acoustic emission testing of concrete structures

Measurement of strain and upstream stress analyses can be used before non-destructive testing to identify areas of abnormal stress levels for targeting non-destructive testing.  Similarly, strain gaging and stress calculations can be used downstream of non-destructive testing to assess stress levels of assets.  This article explores the how strain gaging and stress analyses can be used in conjunction with ultrasonic and acoustic emission testing.  Figure 1: Uniaxial strain ga

Non-destructive testing personnel are qualified to perform NDT based on accumulated in-person or remote classroom training, in-person practical training, written and practical exams, and in some cases demonstration or qualification exams.   Performance demonstration (PD) or Inspection Qualification (IQ) are interchangeable terms.  NDT PD and IQ are supplemental to the core certification process that verifies the competency skills of an NDT technician. It demonstrates that the

A Mechanical Integrity (MI) program is an important element of the OSHA Process Safety Management standard which was established to prevent or minimize the consequences of catastrophic releases of toxic, reactive, flammable, or explosive chemicals which may result in toxic, fire or explosion hazards.  An integral part of a mechanical integrity program per the OSHA standard is Inspection and testing.   Section (j) Mechanical integrity [1] requires that testing be performed on

Natural gas dehydration units are typically installed at well pads to remove water vapor from the natural gas stream. These “dehy” units help prevent pipeline corrosion, hydrate formation, and other issues associated with water content in the gas. The dehydration process can involve various technologies such as glycol dehydration, molecular sieve adsorption, or membrane separation. There are many pieces of expensive equipment used for NG dehydration that require periodic insp