GENERAL PROJECTS

Contact Doug Sherman for to find out how we can help you with your piping and fitness-for-services evaluations

CPI completed a condition assessment and corrosion survey of the fire protection system piping for a major aerospace firm. The purpose of the assessment was to ensure the safety of plant personnel and protection of the very expensive, high-tech manufacturing equipment at the facility should a fire event occur. The CPI team identified two active leaks and severe corrosion on the internal surfaces of the piping in a critical assembly building; heavy corrosion on the exterior surfaces of the steel fire system pipe a few inches below the surface of the ground; and significant internal deposits that may have rendered the system ineffective in the event of a fire. This was deemed an invaluable service to the facility owner, as it uncovered certain anomalies in the fire protection system that could possibly have resulted in catastrophe at this facility where "failure is not an option".

Corrosion Probe has been helping customers in diverse industries determine what to do about service-related flaws in their equipment: operate the equipment as is, run and monitor, repair, alter or replace. Often the flaws are discovered during a scheduled equipment shutdown, so timely decision making is important for avoiding extended, costly shutdowns of equipment.<more>

SPORTS AND CONVENTION FACILITIES PROJECT

Doug Sherman is available to answer your questions about the Javits Center project below and also about your sports center and/or convention facilities

As part of a huge renovation project in mid-town Manhattan, the Jacob K. Javits Center had a roof and façade replacement, along with new paint for the roof frame and structural components. The Javits Center was originally completed in 1986, and had not undergone any renovation or expansion in 25 years. Working as a subcontractor to construction manager, Tishman Construction, CPI developed and oversaw a pilot project for the full-scale recoating program for the facility — a three-year, phased effort designed to keep the Center in continuous operation during the renovation. CPI also provided coating system selection for the roof frame and structural members, and is currently performing coating inspection and quality control services on the project.

PULP AND PAPER PROJECTS

Contact Jason Hinely for additional information specific to your Pulp and Paper needs

CPI has developed and implemented mechanical integrity programs for fiberglass-reinforced plastics (FRP) in two large southeastern pulp mills. Program development included preparing an overarching management framework document and separate guidelines for inspection and repair of used FRP laminates. Additionally, in a team effort with the Fiberglass Reinforced Plastics Institute (FRPI) in Worcester, MA, CPI provided quality verification and design review for a variety of new scrubbers, tanks, and piping to be installed in a new chlorine dioxide generation plant. Drawing and other submittal review, vendor proposal vetting, and field & shop fabrication quality verification were performed to ensure the highest quality of FRP laminates. CPI has seen a steady increase in the need for FRP equipment support at North American mills.

CPI’s Rincon, GA office was contacted by a southern US pulp and paper mill to provide materials selection and oversight for the construction of a new Tall Oil Reactor and Separation Tank. Due to the hot and highly corrosive environment generated by diluting or mixing high concentration sulfuric acid, many traditional designs of tall oil reactor have suffered aggressive localized thinning, and have required frequent inspections and repairs. Through analysis of the different steps in the reaction process and experience in the chemistry involved, CPI was able to select materials for piping, the settling tank, and the reactor for different configurations requested by the client. CPI's review of the designs prevented approval of a layout that would require exotic and costly alloys or be subject to rapid failure. CPI was also involved in verifying the overall quality of the tank fabrication to ensure high standards were followed. CPI has frequently performed this type of upfront design engineering and quality verification for both metals and non-metals, particularly fiberglass reinforced plastics (FRP).

The structural integrity and fitness for service of 4th effect evaporators suffering from severe corrosion can be difficult to assess, with varying degrees of localized internal and external corrosion as well as operating conditions of both positive and negative pressures. With the addition of external stiffener rings, domed heads, and internal tubes/plates, an engineering evaluation can be quite complex. CPI has assisted two southeastern pulp mills with engineering assessments of their 4th effects. One falling film, plate bundle design suffered from severe external CUI directly above stiffener rings, as well as internal erosion due to high-flow liquor. Detailed finite elemental analysis showed that the addition of several, additional stiffener rings would increase structural integrity to an acceptable level until a new duplex stainless steel evaporator could be installed at the next shutdown. <more>

RockTenn contracted with CPI to assist with development of pressure vessel and tank inspection and integrity programs at several of their North American mills. Using our Systematic Inspection Design (SID) process, we helped to develop and implement corporate best practices and training for inventorying equipment; prioritizing inspections, setting initial inspection frequencies, and also developed and updated inspection plans for each tank/vessel.<more>

A multi-year initiative was setup to prioritize maintenance goals at three Canfor Mills in Prince George, British Columbia. The client performed a comprehensive, proprietary risk-based inspection (RBI) & reliability-centered maintenance (RCM) program to identify key maintenance issues. Our expertise and knowledge in: corrosion and materials engineering; damage mechanisms; fitness-for-service technology was used to address the items in order to reduce maintenance costs and improve equipment reliability. <more>

The original design of the bleaching stage towers, vats and chests were reviewed and compared to the new operating conditions. Based on the process design changes and deterioration from 30 years of service, remediation and corrosion protection measures were developed for installation. Construction procedures were audited for quality assurance and adherence to the drawings and specifications. <more>


WATER & WASTEWATER

Kevin Krawiec can respond to all of your Water and Wastewater questions with regards to the following projects and more

Wastewater treatment plant clarifier environments often present challenges for selecting materials of construction. Coated steel, hot-dip galvanized (HDG) steel, and stainless steel are most commonly specified for new or refurbished clarifier mechanisms, and all have their advantages and disadvantages with regard to achieving the intended design life. Over the past few years, CPI has performed condition assessments on several primary and secondary clarifier mechanisms on which HDG steel exhibited moderate to severe corrosion. While there are certainly regions of the US and water conditions that favor the use of HDG steel, these condition assessments reinforced the need by clarifier owners and equipment designers to fully understand the corrosive environments in primary and secondary clarifiers; how various process conditions can affect the corrosion mechanisms; in what situations particular construction materials are/are not appropriate; and how fabrication quality and other details can affect corrosion resistance.

CPI has investigated a number of instances in which stainless steels and aluminum alloys have suffered accelerated deterioration in water and wastewater treatment plants. The 300-series stainless steels are widely used in these environments, but are susceptible to localized corrosion and stress corrosion cracking. Their limitations should be considered carefully. CPI has considerable expertise and experience in the use of stainless steel and aluminum alloys for water and wastewater plants, and we can offer selection advice, guidance for specification and design, welding support and failure analysis.

The Massachusetts Water Resources Authority's Deer Island Treatment Plant (DITP) maintains 12 anaerobic, egg-shaped sludge digesters. The configuration of the digesters, while providing for efficient treatment of municipal wastewater residuals, also presents challenges to the performance of the internal inspection and condition assessment necessary for asset management.<more>

Springfield Water and Sewer Commission suffered a catastrophic failure in a 54” diameter water transmission pipeline. The pipe section, put into service in 1928, failed along a longitudinal, shop-made weld seam near the top of the pipe.<more>

CPI was asked to determine the cause of severe corrosion of a Type 304L stainless steel threaded rod in a wastewater plant aeration basin. A second identical rod was found without deterioration. Initial speculation was that the two rods were, in fact, of different materials; however, chemical analysis showed them both to be 304L. CPI’s investigation found that the rods were seeing different process conditions in the aeration basin. The corroded rod appeared to have been exposed to stagnant bio-solids build-up, while the non-corroded rod was not. All of the data strongly pointed to microbiologically influenced corrosion (MIC) in an anaerobic environment as the cause of the deterioration. During the investigation, CPI was also able to rule out other possible causes, such as high chloride ion concentrations from a ferric chloride feed system and stray current effects.

Corrosion Probe was contracted by the city of Las Vegas, NV to audit the condition of all metal structures, piping, and equipment across three of Clark County’s plants. From this audit, a baseline condition of the plant’s facilities was established, and a restoration/maintenance plan was setup for each of the three sites: Central Plant, Desert Breeze Plant, and Laughlin Plant. <more>

A Field Test and Analysis Plan was developed and implemented to study soil and pipe conditions within the water distribution system. Next, the test and analysis plan was used to assist Malcolm Pirnie and the MDC (Hartford) in development of "Life Expectancy Curves" for the MDC's Water Distribution System. <more>

The original brick-lined-concrete arch aqueduct was constructed in the late 1800's and was undersized for the new flow demand. The aqueduct was retrofitted using a reinforced concrete lining system over its entire length of 4 miles. The new design provided over 150% more flow capacity, which exceeded the present day demand. <more>

 

Industries

Service Areas

  • Corrosion and Materials Engineering
    • Corrosion Control/Protection Design
    • Corrosion Analysis and Material Selection Consulting
    • Failure Analysis - Mode and Root Cause Analysis
    • Cathodic Protection System Design and Evaluation
  • Structural and Mechanical Rehabilitation Services
    • Structural Design Engineering
    • Mechanical Design Engineering
    • Condition Assessment Evaluations
    • Structural Evaluation and Analysis
    • Shop and Field QC Inspection and Support
  • Mechanical Integrity and Inspection Design Services
    • Pressure Vessel and Tank Program Development and Implementation
    • Systematic Inspection Design (SID)
    • Risk-Based Inspection
    • Integrity Evaluation and Analysis
    • Fitness-for-Service Evaluations
    • Welding Consulting and Inspection
  • Coatings and Linings Engineering
    • Consulting
    • Failure Analysis
    • Project Management
    • Quality Control and Inspections
  • Project and Quality Management Services
    • Cost Estimating Services for all Construction Disciplines
    • Project Management Services, Including Planning, Scheduling, and Project Controls
    • Quality Control Inspection and Testing Services
    • Quality Assurance Program Development for New and Rehabilitation Construction
    • Quality Assurance Program Auditing and Oversight Services
  • Training Services
    • Alloy Selection for Corrosive Environments
    • Solving Corrosion and Materials Problems for Plant Engineers
    • Welding Essentials for Plant Engineers
    • Brick and Tile-Lined Equipment Inspection and Repair
    • FRP Essentials for Pulp and Paper Mills
    • Concrete Restoration and Protection
    • Quality Assurance for Capital Projects

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