Proven on Site

Installation of 11 Flow Meters – Chiller Plant, KAUST

• LocationChiller plant, KAUST

Installation of 11 flow meters in the existing 20″ diameter carbon steel inlet piping system in the chiller plant, KAUST.

• Cutting of the existing 20″ carbon steel inlet piping
• Welding on the inlet piping for the flow meter installation

Flow meters

11

Line size

20″ CS

Super Duplex & Duplex Stainless Steel Piping – R.O Plant, KAUST

• ClientNesma United Industries
• LocationKing Abdullah University of Science and Technology, Thuwwal
• Purchase order2KAU11833 · 5 September 2021

Fabrication and erection of super duplex and duplex stainless steel piping in the R.O plant, including SWRO racks BV rectification works with fabrication and erection of new super duplex stainless steel grade A790/UNS No. S32750 piping. Job completion certificate issued by Nesma United Industries on 4 December 2022.

Material

A790 / UNS S32750

Integrity Assessment of Duplex Stainless Steel Piping – Rack D, KAUST

• ClientNESMA
• LocationReverse Osmosis Plant, Utilities Area, King Abdullah University of Science and Technology (KAUST), Thuwal
• Project No.2KAU09842

Integrity assessment of duplex stainless steel piping in the R.O plant at Rack D, KAUST, covering duplex stainless steel elbows and eccentric reducers conforming to ASTM A928 S2205, to report whether each component is safe for future serviceability. Assessment operations were conducted starting from process train D to C, B and A, respectively.

• Ultrasonic thickness examination with a Krautkrämer USM 36 pulse-echo flaw detector, calibrated according to ASME Section V, Article 4
• Calibration over a duplex stainless steel ASTM A928 S2205 NPS 10″ piece of 9.27 mm standard thickness
• UT performed by personnel qualified and certified to Level II in Ultrasonic Testing (ANSI/ASNT CP-189)
• Code calculations performed in accordance with ASME B31.3; components below the required minimum thickness were reported with a replacement recommendation

Material

ASTM A928 S2205

Method

UT thickness

Code

ASME B31.3

Reducers

14″ × 10″

Test Packages for 2 Power Plants (40MW) – Arabian Cement, Rabigh

• ClientArabian Cement
• SupervisionMAN Diesel and Turbo and KANOO group
• LocationRabigh

Quality documentation assessment, completion of all testing protocols and completion of test packages (European Standard) for 2 power plants of 40MW for Arabian Cement, Rabigh.

Power plants

2 × 40MW

Standard

European

Spruce Media Filter Vessels – R.O Plant, KAUST

• LocationR.O Plant, KAUST

Repairing and modification of Spruce Media Filter vessels in the R.O Plant, KAUST.

• Inspection of corroded openings in the vessel walls
• Welded repair patches installed inside the vessels
• Dye penetrant testing (DPT) of the repaired areas
• Ultrasonic testing (UT) inside the vessels

NDT

DPT · UT

Cracked Evaporator No. 3 – Chiller Plant, KAUST

• LocationChiller Plant, KAUST

Repairing and modification of cracked Evaporator no. 3 in the Chiller Plant, KAUST. On opening the bottom shell plate of the evaporator to install additional supports to the vessel’s internal bottom plate, heavy cracking was observed in the internal plate, extending to large lengths, including cracking in previously patched plates. Positive material identification (PMI) of the defected plate and its weldments was carried out by a third party, and the repair was executed in the following steps:

• Step 1 – Cutting the shell
• Step 2 – Visual inspection of the cracked plate
• Step 3 – Dye penetrant testing (DPT) of the internal plate
• Step 4 – Cutting of the internal plate
• Step 5 – Welding of the internal plate, reinforcement and DPT
• Step 6 – Outer shell plate bending and hole
• Step 7 – Final fit-up and shell welding

NDT

VT · DPT · PMI

Repair steps

7