kbonner@fostermarketing.com

When processing plant systems are at risk, time is critical, and stakes are high. With the help of XCEL’s NDT service team, clients are fully supported through disastrous events. On Christmas Day, 2023, one of XCEL’s Midstream clients, a Natural Gas Cryogenic Processing plant, experienced a catastrophic piping rupture and subsequent fire in their Amine unit.

Challenge

The high-pressure piping rupture caused a raging fire, quickly destroying vital infrastructure. The fire caused damage to two processing skids, three pressure vessels, and 110 feet of the main pipe rack. In ad-dition, trapped gas inside the pipeline systems posed an extreme safety risk.

The client required immediate attention from inspectors to assess their plant and guide next steps. Inspec-tors needed to act quickly to mitigate excess damage.

Solution

The client’s Mechanical Integrity Project Manager reached out to XCEL at 8 a.m., and XCEL quickly deployed a specialized NDT team. The team set a response plan in motion, showcasing their speed, preci-sion, and expertise. They delivered:

1. Swift Mobilization: Within just 24 hours, XCEL deployed a team of API Piping and Vessel Inspectors, NDT technicians, and all necessary equipment to the site.
2. A Strategic Action Plan: XCEL’s Onsite Project Manager collaborated closely with the client to develop an inspec-tion strategy, prioritizing their most critical systems.
   - The team performed a Structural Steel inspection, including Hardness readings and visual assessments, to evaluate the pipe rack.
   - The team carefully inspected damaged piping systems to determine which were oper-ationally safe and which were unusable.
3. Recovery Support and Results: XCEL technicians maintained consistent communication with the client, providing re-al-time updates and detailed findings. This enabled quick, confident decision-making.

Outcome

Over the span of just 72 hours, XCEL’s NDT team:

• Restored Safety: The team identified piping sys-tems safe for operation, while isolating unsafe areas, allowing the client to evacuate trapped gas without harm.
• Provided Valuable Insight: XCEL supplied a de-tailed damage map of the pipe rack’s structural steel components, allowing the client to build a temporary shoring system.
• Supported Recovery Efforts: With timely re-ports and evaluations, XCEL empowered the cli-ent to regain control of the situation and initiate recovery efforts immediately.

XCEL minimized downtime during recovery and mitigated risks to ensure better site recovery. These focuses are what makes XCEL’s NDT services stand out.

CTA

When the unexpected happens, XCEL is your trust-ed partner in providing rapid, effective solutions with precision and integrity. Discover how our ad-vanced Mechanical Integrity and NDT services can help you safeguard your operations.

When a long-standing customer discovered significant corrosion during an external visual inspection, they turned to XCEL for quick and reliable solutions. Leveraging our expertise, we performed corrosion evalua-tion, remediation, and pipeline restoration.

Challenge

The client needed assistance to effectively:

• Assess the scope and severity of the corrosion across multiple piping lines.
• Replace damaged piping to minimize operational downtime.
• Apply long-term protection to prevent future corrosion.

Solutions

XCEL’s team took a step-by-step approach to repair and prevent corrosion onsite. The team:

1. Collaborated with the client’s team, who pre-planned insulation removal to save time.
2. Conducted visual inspections, pit measurements, and used Digital Radiography (DR) to
   assess corrosion severity.
3. Replaced severely corroded piping sections to restore system integrity.
4. Sandblasted damaged areas to clean and prepare surfaces for coating.
5. Applied industrial-grade coatings tailored to the client’s specifications.
6. Installed foam glass insulation to ensure thermal stability and prevent future corrosion.

Outcome

The project delivered lasting results and XCEL’s team:

• Successfully replaced and restored compro-mised piping, eliminating immediate risks.
• Created an anti-corrosion barrier with special-ized coatings and insulation.
• Completed the project on schedule with mini-mal disruption to operations.

CTA

At XCEL, we are committed to protecting your assets and maintaining system integrity with cus-tomized corrosion management solutions. Learn More about our range of mechanical and pipeline integrity services.

Improving Inspection Procedures for Hydrolyzers

Industrial equipment failures can lead to costly shutdowns, lost productivity, and significant financial risks. When a major client faced recurring cladded nozzle failures in their 5R Hydrolyzer Column, they required a partner who could deliver innovative solutions to prevent future setbacks. XCEL stepped in to provide a comprehensive API inspection and Phased Array inspection to resolve issues with their column.

Challenge

The client faced several challenges with their 5R Hydrolyzer Column, including:

• Recurring Failures: The cladded nozzles had a history of defects, forcing multiple unexpected plant shutdowns for maintenance and repairs. Failed NDE Attempts
• Several local NDE companies attempted to locate the defects but failed to provide viable solutions.
• Risk of Failure and Financial Loss: The inability to resolve the underlying issues posed a risk of catastrophic failure and significant financial loss.

The client needed a solution to identify the root cause of these failures, while ensuring long-term reliability and safety.

Solution

XCEL collaborated closely with the client to devise a solution tailored to their needs. XCEL personnel:

1. Conducted pre-job discussions to fully understand the project’s requirements and evaluate feasibility.
   Requested test samples, which allowed our inspectors and technicians to carefully analyze the defects and assess potential inspection methodologies.
2. Detailed analysis confirmed that XCEL’s methods, including Phased Array Ultrasonic Testing (PAUT), could effectively detect the defects causing failure.
3. In response, XCEL scheduled an on-site shutdown inspection, deploying a dedicated team of one inspector and two technicians. The inspection spanned two 12-hour shifts. XCEL also mapped multiple defects meticulously for repair, ensuring the client had a clear plan of action to address issues.

XCEL’s extensive preparation and technical training alleviated the client’s concerns.

Outcome

The results of XCEL’s work were transformative. The client experienced:

• Substantial Cost Savings: They saved millions of dollars in potential unscheduled shutdowns each year.
• Reduced Risk: They addressed defects proactively, significant-y reducing risks of catastrophic failures.
• Improved Operations: The client implemented annual onstream inspections of all Hydrolyzers, to ensure emerging defects are detected prior to scheduled maintenance.

XCEL personnel resolved the recurring equipment failures but also set the foundation for long-term efficiency at the client’s facility.

CTA

At XCEL, we consistently protect assets, enhance operational safety, and deliver long-term results. Contact Us Today to learn more about our expertise and how we can help your facility.

Detecting Underground Threats with Guided Wave Technology

Underground piping failures can pose significant risks to industrial facilities, from costly repairs to disrupt-ing operations. Addressing these hidden issues requires advanced technology and skilled expertise. XCEL was approached by a Midwest refining client to tackle an issue involving their underground piping sys-tems, ultimately preventing catastrophic failures and setting a new standard for inspection programs.

Challenge

In 2019, the client experienced a piping failure at a road crossing within their plant, exposing vulnerabili-ties in their underground systems. Seeking an effective solution, the client contacted XCEL. The challenge was to identify defects in the underground piping, particularly at road crossings and piping supports.

1. After a thorough evaluation, XCEL personnel determined Guided Wave Technology was the optimal method to detect the defects in the underground piping. A team was de-ployed to conduct immediate inspections at several road crossings.
2. Guided Wave Technology was utilized to scan and assess the piping condition, especially at critical piping supports.
3. The XCEL team identified multiple areas with significant underground corrosion that had gone unnoticed. XCEL performed excavation and directly assessed the affected areas. This confirmed the presence of severe corrosion, with several areas being at or near failure.

Outcome

XCEL’s intervention addressed the immediate issue but also led to the client implementing more long-term preventive measures. The client established a full-time underground piping inspection program. This program now utilizes two Guided Wave units, operating daily by two two-man inspection teams.

Thanks to XCEL’s advanced methods and insights, the client mitigated risks, enhanced the reliability of their underground piping systems, and prevented costly failures.

CTA

XCEL leverages cutting-edge technology to deliver proactive solutions for facilities around the coun-try. Learn More about how our trusted inspection services can protect your assets and safeguard your facility.

Simplifying CUI Inspections and Maintaining Compliance

Corrosion Under Insulation (CUI) is a persistent challenge for industrial facilities, often requiring resource-intensive methods for identification and mitigation. XCEL, being the primary service provider at a large chemical facility in the Gulf Coast, provided a solution, which streamlined CUI inspections and enhanced operational efficiency.

CHALLENGE

The facility’s CUI project depended on Digital Radiography (DR) to inspect areas where long strips of insulation had to be removed. While effective, this process was time-consuming and labor-intensive, creating inefficiencies for the client. The challenge was to meet industry-standard inspection requirements while minimizing disruption and using resources effectively.

SOLUTION

After discussions with the client to understand their needs, XCEL recommended the use of Real Time Radiography (RTR) for targeted inspections. This approach provided several advantages:

1. Reduced Effort: RTR eliminates the need to remove insulation, saving time and resources while still fulfilling procedural requirements.
2. Efficient Screening: RTR allowed the client to quickly identify suspect areas, so they could focus efforts on actual problem points without exhaustive insulation removal.
3. Compliance: Both RTR and DR solutions aligned with the facility’s operator procedures.

Over the years, XCEL’s innovative techniques have become a standard part of the facility’s CUI inspection processes.

OUTCOME

Implementing RTR and DR resulted in measurable, long-term benefits for the Gulf Coast facility. The facility experienced:

• Streamlined inspections by enabling CUI detection without insulation removal where possible.
• A more proactive approach to CUI management with better screening solutions.

CTA

At XCEL, we design solutions that simplify inspections, achieve compliance, and deliver results. Contact Us Today to learn how we can help optimize your integrity management processes