1.

Asset Integrity
 RCM
 RBI
 SIL
 FFS
 HAZOP

2. Third Party Inspections (TPIs)

 Project Quality Management
 QC Surveillance
 Vendor Inspection and Expediting Services
 Pipe mill Surveillance & Steel Mill Inspection

2.1 Project Quality Management

VELOSI’s Quality Assurance & Quality Control services can be combined to provide a Total Solution-
supervising the work of the nominated EPC (Engineering, Procurement, and Construction) or
Execution / Construction Contractor during the Engineering Design, Procurement and Construction
phases of the project.
Our complete project verification services ensure that the Construction Contractor’s internal
operations and procedures meet the requirements of internationally recognized Quality
Management Systems, such as ISO 9001-2000 during the Design, Procurement, Fabrication,
Construction and Commissioning phases.

Project Quality

• Development of a project quality manual to incorporate procedures and flowcharts. Once

in place, the manual is extended to encompass second and third tier documentation
covering all aspects of the operations.
• Development of the execution Project Quality Plan, audit schedules, and data packages
and to give advice on their suitability to achieve effective control of the management of the
project.
• The maintenance of the system is verified by ongoing Auditing of the Construction
Contractor’s Project Quality Management System to ensure compliance with the agreed
internationally recognized Quality Management System such as ISO 9001-2000 and/or
projects specifications.
• Complete any additional Auditing of the Execution Contractor’s compliance with statutory
laws.
• Maintain a project non-conformance register, issue non-conformances (NCR), follow up on
corrective action and closeout.
• All design activities are reviewed to ensure conformance with project specifications. This
encompasses conceptual and detail design activities relevant to all engineering disciplines
including mechanical, electrical, electronic, instrumentation, process and civil.
• Perform criticality assessments to establish the focus for quality related activities to ensure
that resources are directed to essential systems and processes within the overall project
requirements.

Procurement Quality

• Advise the client regarding the Construction Contractors Quality Assurance / Quality
Control methodology, plans or schemes for critical systems and structures, with emphasis
on process and pressure related items.
• Undertake auditing and surveillance at the vendor’s works during the manufacturing of
equipment or modules to ensure compliance with the required code, standard, or project
specification. Surveillance is undertaken against the approved Project Quality plans and
can cover mechanical and electrical packages.
Construction Quality

• Provide site surveillance and auditing during fabrication, construction, installation and
pre-commissioning to ensure quality compliance, relating to construction Management &
Supervision, Engineering Specialists and Inspection Specialist.
• Witness and report results of inspections, providing recommendations to address any area
of non-conformance by the Execution Contractor.

2.2 QC Surveillance

To meet both statutory and client requirements, manufacturers need independent

Welding Procedure Qualification and Welder Approvals. VELOSI’s accreditation for
approval of procedures covers all types of permanent jointing to EN Standards. We
also offer approval for other codes and processes such as brazing and various joining
methods for plastics, such as solvent welding.

The process involves:

• Review and provisional approval of the procedure.

• On site surveillance of the test piece production against Written
Procedures
• Witnessing laboratory testing of the test pieces
• Review of any Non-destructive or other Test Results
• Approval of the Weld Procedure (and welder if appropriate)

Welder Approval
Once a procedure is approved, individual welders can then be assessed against the procedure, using the same
process. The approval of a welder is usually valid for 2 years (3 for brazing) as long as the welder is regularly
using the process defined in the procedure. The prolongation of the Welder Approval is possible as long as
determined criteria are met.

Material Services

With the EC Directives such as the Pressure Equipment Directive (PED), there is an increasing requirement that
materials prove they meet the parameters in their chemical and mechanical properties. This has led to the
authentication of material certificate requirements.

VELOSI offers surveillance at the mill to taking samples of material and subjecting them to a rigorous regime of
laboratory testing. Assessment and endorsement by VELOSI of the material certification meets the requirements
of a 3.2 certificate as defined in EN 10204 ‘Metallic Products - Types of inspection document’. also It also covers
the assessment of plastic materials soon to be incorporated in the above specification.

One result of the introduction of European Directives, such as the PED, has been a requirement for total material
traceability. This means that all materials must be fully traceable and documented from the mill to the manufacture
of the pressure equipment, or the repair of such equipment.

VELOSI is authorized to supervise and endorse material transfers and material certificates. In practice, material
stockists can now issue material certificates for cut pieces with the same validity as the original certificate. Velosi
will supervise and record the cutting of the piece, the transfer of the identification, heat or cast number and
endorse a copy of the original certificate with an endorsement stamp.

In addition, if you have valuable material in stock that has lost traceability, VELOSI can authenticate it with
mechanical and chemical testing at a recognized laboratory. A valid material can then be used in the manufacture
of pressure equipment.

2.3 Vendor Inspection and Expediting Services

Quality Control, Vendor inspection and expediting are an integral part of a Project’s
purchasing activities. VELOSI offer a complete range of services that comprise
Engineering Inspection of mechanical and electrical equipment at the vendor’s works,
complete quality control of plate and tubular steel mills, Pre-shipment Inspection for
letter of credit purposes, Expediting at vendor’s works and Technical Capability
Audits. Whether for new construction or ongoing maintenance, our services provide
confidence that purchased equipment will arrive on time and to the correct
specification.

Inspection

Vendor Inspection, sometimes referred to as Source Inspection or Third-Party Inspection, covers activities
performed at manufacturer’s works of all types of mechanical, electrical, electronic, and instrumentation
equipment purchased for the Petrochemical, Oil and Gas, Pharmaceutical and Mining Industries.

We can accommodate from a single to multiple orders for an entire project. The scope or level of inspection is
determined by the client’s requirements which are normally controlled by a Quality Plan. This
scope can range from final inspection to an intensive inspection regime starting from the pre-production meeting,
through identification and inspection of all raw materials, inspections at all prescribed hold-point stages,
witnessing all tests, verification of all documentation and certificates and a final release inspection.

We carry out inspection using our resource base of field Engineers and our global network of offices. All field
Engineers are inducted in accordance with our Quality Management System and are assessed on an ongoing
basis for capability and competency. This has a direct positive impact on the quality of the inspection services we
provide.

Field and Desk Expediting

Today, expediting is an integral part of the procurement process. In the past, it was
considered a corrective rather than preventive function. However, as both the schedule and
the pricing of projects become increasingly critical, expediting should be incorpo rated into
the project planning at the onset to ensure timely delivery.
Expediting is a continuous process, of ensuring that final delivery to the job site is achieved
within the shortest possible timeframe. An expediting service should be implemented
i nd e p en de nt l y o f i ns pec ti on ac ti vit ie s a nd b e c arr i ed ou t b y e xp e ri enc ed f ie ld e xp e di to rs .
D e pe nd ing on cli en t requ i rem en ts , e xp e di tin g s er vi ces m a y ap pl y at di ffe r en t st ag es o f a
project such as fabrication and assembly, rectification work, material deficit, failure on test or
inspection, shipment and packing, and submission of documentation.

Technical Capability Audits

Qualit y Assurance Engin eers carry out Pre -Cont r act Award Sur ve ys, Sup plier Evalua tions,
Third Party Quality Assurance Audits and Vendor Surveillance.
VELOSI has a good relationship with the vast majority of oil & gas -related vendors around
the world enabling us to conduct pre -contract award surveys by QA Engineers with regular
experience of these manufacturers.
This can be a very useful to ol for clients who are considering placing orders with vendors
they are unfamiliar with or those they may have reservations about.
I n a d d i t i o n , i t m a y b e be n e f i c i a l , a s p a r t o f a ‘ le s s o n s l e a r n t ’ e xe r c i s e , t o r e c e i ve a f u ll
assessment of a manufacturer, on ce a problematic order has been completed. Supplier
Evaluation will include though -not be limited to -details of the vendor’s Quality System,
Traceability, Capacity, Current W orkload, Manpower, Affiliations, History/Client base,
Number of Personnel and their qualifications.

Import Supervision

The scope for import supervision or pre -shipment inspection may include the verification of
t h e g o o d s w i t h r e s p e c t t o q u a l i t y , q u a n t i t y , e xp o r t m a r k e t p r i c e , l a b o r a t o r y t e s t i n g a n d
analysis, import eligibility, labelling, and value for Customs purposes. The quality and
quantity inspection may be for verifying that the goods conform to contractual specifications
a n d t h a t t h e va l u e a n d C u s t o m s t a r i f f c o d e f o r C u s t o m s p u r p o s e s , P a c k i n g r e vi e w , a n d
Loading supervision.

2.4 Pipe mill Surveillance & Steel Mill Inspection

VELOSI’s Mill Surveillance assures our clients that the pipe or steel being produced
is available for their projects and is in compliance to the required specification, code
or standard. Our team across the globe maintains extensive knowledge throughout
the seamless and welded manufacturing processes by using our membership of
societies such as API. Our services not only cover line pipe and steel production but
include OCTG (Oil Country Tubular Goods), including drill pipe and specialized
casings.

Clients have the range of options from a full inspection team to random
surveillance. The inspection team may be made up of expatriate
personnel, local personnel or a combination of the two to suit the project
requirements. This may include a team consisting of inspection
supervision, hydro-test inspection, final bench inspectors, load out
inspection, coating, etc.

During the production monitoring, VELOSI personnel use their own

tracking and reporting documentation or, if necessary, use the mill’s own
internal system and verify the activities to that system. The system
includes the tracking of defects rates and the actions taken for rejected
items.

VELOSI’s knowledge and experience is offered worldwide in the following services:

 Material Control Evaluation

 OIL & GAS Tank Lorries Compliance
 OGRA Compliance
 Procedure Verification
 Production Surveillance
 Traceability Surveillance
 Laboratory Material Testing Surveillance
 Non-Destructive Testing Surveillance (UT, MT, PT, RT and VT)
 Hydrostatic Testing Surveillance
 Visual & Dimensional Inspection
 Identification Inspection
 Transportation Inspections & Evaluations (Truck, Rail & Vessel)
 Claim Evaluation & Inspection
 Safety Inspection
 Thread Gauging (including specialist thread geometries)
 Coating Inspection
 Material Receiving Inspection

3. Plant Condition Based

Maintenance/Monitoring (CBM)
Plant Condition-Monitoring is a scheduled task used to detect the potential onset of a failure
so that action can be taken to prevent such failure. A potential failure is an identifiable
condition that indicates that a functional failure is either about to occur or is in the process of
occurring. Integration of condition monitoring is crucial to developing a robust, condition
based maintenance strategy or predictive maintenance approach for machinery and
equipment used in industrial applications.
Condition monitoring starts with using permanently installed sensors or hand held
equipments to collect data which is then used to analyze changes in the performance or
condition of a machine component while it is in operation.
Data Collection for Condition monitoring can be done solely or in combination by:

Vibration Analysis
Thermography Survey
Oil Analysis
Acoustic Emission Monitoring
Ultrasound Airborne Testing
Eddy Current Testing
Ultrasonic Testing
Visual & Optical Testing
Wear Debris Analysis
Motor Current Signature Analysis
Corrosion Monitoring
Temperature Monitoring

CBM Related Services

Laser Alignment
Dynamic Balancing
Reciprocating engine/compressor analysis
Operational deflection shape (ODS)
Ultrasonic Airborne Leak Detection
Maintenance Optimization Services
Maintenance Strategy

The benefits of using CBM

The application of data supplied by condition monitoring techniques has many benefits. By
informing root cause analysis, when to take preventative action to avoid failure and
assessment of a component’s full lifecycle capacity – it enables operators to manage risk
more effectively, and optimize their maintenance and service activities, this leads to
increased reliability and production output, helping to eliminate unplanned shutdowns by up
to 75% (in a typical plant with proper implementation) and minimized maintenance costs.

4. Pipeline Integrity Services

 Pipeline Construction Quality Services
 External Corrosion Direct Assessment (ECDA)
 Guided Wave Pipeline Screening
 4.1 Pipeline Construction Quality Services

VELOSI provides complete Quality Management Services for pipeline development

projects for both onshore and offshore projects. Our project verification services
include design review and approval, material selection and quality inspection at
pipe equipment suppliers, and during pipeline construction, audit, surveillance,
installation, and commissioning services. We are able to cover both steel and
plastic material constructions.

Onshore pipelines

During the construction of an onshore pipeline, VELOSI can provide the

full range of quality control services such as welding and other NDE -type
inspectors to monitor the actual jointing functions, coating inspectors to
ensure that on-site coating of the welded joints is completed, expert’s in
Cathodic protection systems, terrain specialists for road, rail or river
crossings, way-leave considerations such as agricultural and urban
experts, and environmental engineers for rainforests or areas of
scientific interest.
Clients can choose either a complete packaged management solution or
any of the individual elements mentioned above. A packaged solution
would include a Project Manager to oversee all quality aspects of the
construction project. He would then, in conjunction with the client,
assess the expertise required for each element.

Offshore Pipelines

VELOSI has extensive experience in verification services on major

offshore pipeline projects and supervision work on high specification,
dynamically positioned pipeline installation vessels during deep -water
construction. Our specialist personnel are fully conversant with S and J
lay installation systems, automated welding techniques and advanced
N D E t e c h n i q u e s , s u c h a s a u t o m a t e d u l t r a s o n i c t e s t i n g .
As part of the project management, we can mobilize personnel to ensure
that project staff are supported during the project. This support service is
provided by our local offices at both the point of embarkation and point
of arrival. All personnel are checked for medicals and visas and have
emergency support, and other rotational leave assistance.

VELOSI’s knowledge and experience is offered worldwide in the following services:

• Project Management
• Review and verification of quality plans
• Supervision of all welding procedures and welder qualification tests prior to operations
• Quality audits during pipe-lay program
• Materials control services
• Health & Safety Inspection
• Double Jointing Inspection
• Procedure Verification
• Welding Qualification & Inspection
• Inspection of Automated UT Systems
• Road / rail / river crossings
• Weld Identification & Mapping
• Cathodic protection review and testing
• Blasting / Explosives experts
• Bend Inspection
• Backfill Inspection
• NDE Inspection
• Coating Inspection

4.2 External Corrosion Direct Assessment (ECDA)

External Corrosion Direct Assessment (ECDA) is a structured process to evaluate buried onshore
ferrous pipeline integrity. The ECDA goal is to enhance safety by managing the risk of pipeline
corrosion failures while minimizing the cost required for excavations and repairs.

ECDA may also be used when more established methods such as in-line inspection (ILI) and
pressure testing are not possible or practical.

VELOSI offers pipeline operators a comprehensive approach to all four

stages of the ECDA process. Our techniques are based on

state-of-the-art experience of industry best practices and an extensive

corrosion database. In all our operations, our goal is to deliver the

highest levels of confidence achievable with the fewest number of digs –

for a more thorough understanding of your pipeline’s integrity. You have

the flexibility to choose only those service areas of specific inter est to

you, or to utilize our expertise for the entire process. These ECDA

services execute the complex requirements identified in NACE RP 0502,

simplifying the entire process and yielding results which help to ensure

pipeline safety and prolong asset life.

Service Overview
We combine the in-field and analytical experience of our NACE-certified corrosion professionals with advanced
data-integration, visualization capabilities and innovative inspection technologies to achieve highly reproducible
results in each of the following areas:

Pre-Assessment – Combining a pipeline’s physical characteristics, operating history and prior inspections. Pre-
assessment is the first step in the ECDA process. All pertinent historical information is compiled, falling
generally into five categories:

• Pipe data
• Construction data
• Soil/environmental conditions
• Corrosion protection data
• Operating parameters/history

Indirect Assessment – The purpose of indirect inspection is to identify the locations of coating faults,
insufficient Cathodic protection, electrical shorts, interference, geologic current shielding, and other anomalies
along the pipeline. The technique also defines areas where corrosion may be occurring or has occurred. Typical
pipeline survey techniques that may be used are:
• Close-interval, on/off potential surveys
• DCVG surveys
• Electromagnetic current attenuation surveys
• Alternating current voltage gradient surveys

Direct Examination – Exposing the pipe for verification of the above-the-ground surveys results and physical
inspection of pipe coating, pipe surface and soil electrolyte. Direct examination includes:

• Ranking and prioritizing indications identified during the indirect

inspections
• Excavating to expose the pipe and collecting data where
corrosion activity is most likely
• Measuring coating damage and corrosion defects
• Performing a root-cause analysis
• Evaluating the process

Post Assessment – Integration of the results gathered in tier 1, 2, & 3 for overall integrity assessment, validation
of the ECDA process and determination of the interval period to re-do the ECDA process.
Post-assessment can determine the overall effectiveness of direct assessment and define reassessment intervals.
Reassessment intervals are based on remaining-life calculations. Various methods can be used to calculate the
remaining life - from the corrosion growth rate, wall thickness, calculated failure pressure, yield
pressure, maximum allowable operating pressure, and appropriate safety margin. Under some conditions,
corrosion rates can be estimated by measuring linear polarization resistance or using coupons.

4.3 Guided Wave Pipeline Screening (LRUT)

Guided Wave enables volumetric screening of pipes which covers 100% of the cross sectional area
of the pipes within the diagnostic length of test. In most cases, tens of meters can be screened from
a single test position making it a rapid and cost effective NDT method. Additionally, access to the
pipe under test is only required at the test position (remote inspection) which makes guided wave
screening technology an ideal solution for inspecting pipes that are difficult to access, such as cased
and insulated pipes.

Pipe Screening System

Guided Wave Screening System (LRUT) is a screening method by means of ultrasound. A probe
ring is placed around the pipe and transmits guided waves through the pipe in either direction
of the probe ring. The pulse echo type operation provides information on feature position and
severity.

Standard Application:
 Seamless, longitudinally or spiral welded pipe types
 Pipe size 1 – 72 inches
 Surface temperature -40°C to 120°C (diameter < 10”) or -40°C to 80°C (diameter >8”)
Typical pipe screening applications are:

 Screening of insulated pipe for external or internal corrosion without removing the
insulation (other than at the test positions)
 Screening of pipe in racks with limited access requirements
 Screening of inaccessible areas such as cased road and dike crossings
 Screening of pipe passing through bund walls

Operational Benefits

There are many advantages of using the Wave Maker Pipe Screening System for
rapid long-range pipe screening:

 The test can be carried out at elevated temperatures without taking the pipe out of service
100% of the pipe is inspected (within the diagnostic length of a test)
 Ability to detect metal loss and planar defects at long range
 Metal loss may be internal or external
 Sensitivity can be as good as 1% loss of cross-section in ideal conditions (but is typically set
at 5%)
 5. Industrial In-Service Inspection
 Pressure Vessel In-Service Inspections
 Piping In-service Inspections
 Storage Tanks In-Service Inspection
 Corrosion Under Insulation (CUI)
 Evaluation & Condition Monitoring of CP System

5.1 Pressure Vessel In-Service Inspections

Any pressure vessel represents extreme potential danger due to the high pressure under which it
operates. They frequently at the source of serious accidents due to explosions. Even non dangerous
gases and liquids, such as air and water, may become hazardous in the event of an accident
involving high pressure equipment. In-service inspection helps effective maintenance, inspections,
performance verification and preventive failure analyses to maximize productivity and reduce costly
downtime.

Our Pressure Vessel Inspection services include:

 Remaining Life assessment

 Risk assessment and analysis
 Pressure Safety Valves Calibration (Online)
 Coating inspection and failure analysis
 Commissioning and in-service inspections
 Corrosion monitoring
 Failure analysis and failure prevention
 Inspection and technical assistance during turnarounds
 Mechanical integrity management system
 Non-destructive testing
 Pressure equipment certification
 Statutory and voluntary inspection
 Instrumentation calibration and maintenance
 Witnessing of hydrostatic testing
key benefits
Our API 510 Certified Inspector will insure Pressure Vessel safety, especially regarding explosions
Potential risks assessed, appropriate precautionary measures determined Numerous complex
requirements complied with Independent advice and support given by knowledgeable technical
experts in all critical areas Reassurance of running your site without worrying about non-compliance
Benefit from experts who are aware of the latest technology and equipment

5.2 Pipeline In-Service Inspections

Piping used in petrochemical applications and in other selected industry are subject to continual
pressure and stresses under the scope of normal use. Such operating conditions can lead to leaks
or spills that can have a number of significant impacts on operators, including the disruption of
normal operations, repair and clean-up costs, and potential fines related to environmental
contamination. A comprehensive inspection program can identify potential risks, thereby helping
to ensure uninterrupted operations.

The American Petroleum Institute (API) has a standards applicable to these critical infrastructure
components. API Standard 570, “Piping Inspection Code: In-service Inspection, Rating, Repair and
Alternation of Piping Systems,” provides similar requirements applicable to metallic and fiberglass
reinforced plastic (FRP) piping.

This standard is applicable to all hydrocarbon and chemical process piping that have been placed
into service. However, the standard can also be applied to piping used in other industries.

The performance of mandated inspections can be conducted only by those professionals who have
been certified by the API, consistent with the technical requirements of the respective standard.
However, owners/operators of pressure vessels and piping interested in implementing integrity
maintenance programs will benefit by having a basic knowledge of the requirements of each
standard.

Our Piping Inspection services include:

 Remaining Life assessment

 Cobra Scanner PAUT
 Risk assessment and analysis
 Pressure Safety Valves Calibration (Online)
 Coating inspection and failure analysis
 Commissioning and in-service inspections
 Corrosion monitoring
 Failure analysis and failure prevention
 Inspection and technical assistance during turnarounds
 Mechanical integrity management system
 Non-destructive testing
  Pressure equipment certification
 Statutory and voluntary inspection
 Instrumentation calibration and maintenance
 Witnessing of hydrostatic testing

key benefits
Our API 570 Certified Inspector will insure Piping safety, especially regarding explosions Potential
risks assessed, appropriate precautionary measures determined Numerous complex requirements
complied with Independent advice and support given by knowledgeable technical experts in all
critical areas Reassurance of running your site without worrying about non-compliance Benefit from
experts who are aware of the latest technology and equipment

5.3 Storage Tank In-Service Inspections

Storage of large quantities of hazardous substances entails risk for the population, the environment
and the surrounding area. Spills of hazardous substances into the soil can lead to expensive
decontamination processes. Leakage from storage tanks containing oil, gas or chemicals can be
caused by the influence of weather on the external surfaces, or material can be affected by internal
temperature variations. These situations could lead to a disaster. Periodic inspections, conducted in
good time, can prevent such disasters from happening.

Our API 653 Certified Inspector compliance API 650 or 653 or Clients’ Specifications. These
Inspections include

 Fugitive emission and leak detection through infrared camera

 Mechanical integrity study
 Tank Calibrations
 NDT techniques
 Traditional NDT techniques
 floor scan/Magnetic Flux Leakage
 Corrosion Mapping
 Tracing of system leaks and determination of material strengths
 Hydrostatic pressure
 Determination of subsoil corrosiveness
 External thickness measurements and calculation reviews
 Tank foundation and settlements evaluation
 Tank bottom evaluation
 Tank shell evaluation
 Tank roof evaluation

By offering a complete range of Conventional & Advance NDT Techniques and Special
Examinations, Velosi is in the position to provide not just a list of standard techniques but solutions
using a combination of multiple techniques.
key benefits
Our API 653 Certified Inspector will insure Storage Tank safety, especially regarding Spill, bulging
Potential risks assessed, appropriate precautionary measures determined Numerous complex
requirements complied with Independent advice and support given by knowledgeable technical
experts in all critical areas Reassurance of running your site without worrying about non-compliance
Benefit from experts who are aware of the latest technology and equipment

5.4 Corrosion Under Insulation (CUI)

Corrosion under insulation (CUI) is a severe form of localized external corrosion that occurs
in carbon and low alloy steel equipment that has been insulated. This form of corrosion occurs when
water is absorbed by or collected in the insulation. The equipment begins to corrode as it is exposed
to water and oxygen. CUI is common in refineries and process plants that typically operate
equipment at high temperatures.

In the simplest terms, corrosion under insulation (CUI) is any type of corrosion that occurs due to a
moisture buildup on the external surface of insulated equipment. The buildup can be caused by one
of multiple factors that are detailed below. The corrosion itself is most commonly galvanic, chloride,
acidic, or alkaline corrosion. If undetected, the results of CUI can lead to the shutdown of a process
unit or an entire facility, and in rare cases it may lead to a process safety incident.

Corrosion Under Insulation Processes

CUI is a blanket term that refers to several different types of corrosion processes. According to the
National Board of Boiler and Pressure Vessel Inspectors, the main CUI processes are:

Galvanic

Generally, results from wet insulation with an electrolyte or salt, which allows a current to flow
between different metals (e.g., the insulated metal surface and the outer jacket). The extent and
severity of the attack on the less noble metal depends on the difference in potential between the
two metals and their relative areas.

Alkaline / Acidic

Results from moisture and an alkali or acid in certain fibrous or granular insulations. Where service
temperatures exceed 121ºC (250ºF), most of the water evaporates, condenses at the edge of the
insulation, and then dissolves the alkaline or acidic chemicals there, which results in
corroding the jacket.

Chloride

Occurs on 300-series austenitic stainless steel surfaces when the insulation contains leachable
chlorides and moisture at temperatures above 60ºC (140ºF). A concentration of chloride ions
usually results from the evaporation of rain, water used in fighting fires, or process water.
Velosi Help Client identify CUI through:

• PULSED EDDY CURRENT (PEC)

• GUIDED WAVES (GW)
• REAL TIME DIGITAL RADIOGRAPHY
• THERMOGRAPHY
• VISUAL EXAMINATION

PEC:

PEC equipment is based on electromagnetism and helps effectively determine the average wall
thickness (AWT) of low-alloyed carbon steel components through their insulation, enabling the
detection and localization of CUI. PEC is successfully used in the industry for detection and semi-
quantitative sizing of CUI. The main advantage of PEC is its ability to ascertain general wall thinning
in insulated objects without removing the insulation and without any object surface preparation.

GW

Guided waves measurement is one of the key complementary technologies for the assessment of
corrosion under insulation for long lengths of pipe. Typically, it uses low-frequency guided ultrasonic
waves that propagate along the pipe wall and can detect external or internal corrosion. The
technology requires insulation be removed, however, only in a very small circumferential location.
This part is used to attach the ring with the ultrasonic sensors onto the pipe. This way, long and
difficult to access pipes can be examined from a single location with minimal preparation and without
further removing the insulation.

A test ranges of 50m (25m in each direction) or more is commonly obtained from a single transducer
position. Our guided waves technology is often used to assess CUI on sleeved road crossings, buried
pipe, wall penetrations, pipe racks, corrosion under supports, offshore risers and caissons, previously
unrecorded weld locations, subsea lines and similar.

REAL TIME DIGITAL RADIOGRAPHY

This technology makes use of a radiation source and an X-ray detector (often a linear array of
radiation detectors). These are positioned in such a way that an on-stream X-ray inspection can be
conducted, resulting in real-time imaging of potential anomalies under the insulation. With this
technology, both internal and external corrosion defects on stretches of pipe can be detected while
the pipe remains in service and without removing any insulation. As the unit and/or scanner are
positioned onto the pipe, X-ray data is acquired and displayed on the monitor in real time. Straight
piping segments as well as locations with bends and elbows can be inspected using this technology.
The system is sensitive enough to detect corrosion defects as small as 0.25 inch in diameter and 0.05
inch deep.

THERMOGRAPHY

Thermography and thermal imaging has been successfully used in the petrochemical industry for
inspecting and monitoring system performance as well as the integrity of insulated pipelines and
vessels for many years. Thermal imaging easily shows temperatures of materials and objects, and it
is an effective method for the detection of energy waste. It therefore contributes to determine the
insulation quality condition. Thermography can help locate water penetration and even leakages and
any anomalies in insulation performance.

VISUAL EXAMINATION

Visual examination is an effective method for locating CUI and it helps identify potential CUI hazards
resulting from damaged weather proofing, cladding and/or insulation layers. Weather proofing
protection in the form of cladding dents, sealing, junctions and overlapping are potential penetration
points for (rain)water, therefore this “barrier” needs to be monitored for effectiveness.

5.5 Evaluation & Condition Monitoring of CP System

Cathodic Protection can be defined as the control of electrolytic corrosion by the application of
direct current in such a way the structure to be protected is made to act as the cathode of an
electrolytic cell.

Cathodic Protection is used to control the corrosion of a wide variety of buried and
submerged metallic structures. It is a cost-effective way to extend the life of a
structure and to ensure integrity throughout its operating life.

WHY Cathodic Protection

Cathodic protection provides effective corrosion control on steel

structures and pipelines by creating a potential (voltage) gradient
opposing the flow of ions away from the surface, thus preventing the
anodic corrosion reaction. Cathodic protection may be used alone or in
combination with an insulating coating. In such systems, the coating
forms the first line of defense and where it is adherent and undamaged,
the corrosive environment is kept away from the structure: where the
coating is damaged, however, corrosion can occur and Cathodic
protection provides protection. It is worth nothing that Cathodic protection
can only be applied in the presence of an electrolyte – it is not an
antidote for atmospheric corrosion.

Methods of applying Cathodic Protection

• Sacrificial Anode System

• Impressed Current System

VELOSI Methodology

The Job protocol is broadly classified into two parts:

• Data review & engineering works

• Field works – surveys, inspections and investigations

VELOSI has identified seven (7) key steps to carry out evaluation & condition
monitoring of CP system:

• Pre-Assessment Study
• Preparation of Methodology and Procedures
• Technical Audit of Existing CP System Installation of Main Pipelines &
Performance Assessment of Tank Form Area, Pump Stations Facilities and
associated piping network
• On/Off Potential Survey, CIP Survey and Line Current Survey
• Visual Inspection of Heat Shrinkable Sleeves
• Review & Evaluation of Remote Monitoring and Control System
• Post Assessment of the Project – Final Reports & Deliverables

6. Non-Destructive Testing (NDT) and

Corrosion Monitoring
Conventional NDT
Advance NDT
Remote Visual Inspection (RVI)

The field of non-destructive testing (NDT) comprises a vast array of analytical techniques that are
applicable to a wide range of industries. These techniques can identify and assess defects and
examine the properties of all kinds of materials and structures without causing any damage. As NDT
in no way alters the part or structure under inspection, it is an extremely useful technique that can
lead to cost and time savings when applied to product evaluations, asset management and fault
identification and repair.
6.1 Conventional Non-Destructive Testing
NDT methods such as ultrasonic inspection, magnetic particle inspection, liquid penetrant testing,
radiographic testing, remote visual inspection (using drones) and eddy current testing are now in
standard use in civil, aeronautical and systems engineering. Advances in NDT enable the generation
of 3D images of faults and have revolutionized many sectors.
Our Services includes:

Ultrasonic Testing
Magnetic Testing
Dye Penetrant Testing
Eddy Current Testing
Radiographic Testing

6.2 Advanced Non-Destructive Testing

Through our advanced NDT solutions, Velosi can reassure its clients that their assets are in
compliance with all applicable standards. The technical assurance delivered by Velosi also minimizes
the level of risk to the assets in question as well as helping to maintain productivity.
Integral to our range of services, VELOSI offers Specialized Non-Destructive Testing (NDT) and
inspection to complement our traditional Quality Assurance and Quality Control Services. These
services help our clients to improve plant reliability, reduce operational and maintenance costs,
enhance safety, extend plant life and meet regulatory requirements.

We believe our personnel are our greatest assets. Besides state of the art equipment for best results,
we have highly trained and certified inspectors to perform your inspection. Our inspectors are
experienced and have technical expertise to conduct the inspection surveys to international standard.
Our reputation within all industries is not only known for our quality of personnel and equipment but
equally our professionalism and knowledge.

VELOSI’s comprehensive range of inspection techniques ensures that we remain at the forefront of
specialized Non-Destructive Testing. Our services include:

Advanced UT (manual and automated)

Corrosion Mapping
Ultrasonic imaging of complex geometries, pipes, plates and curved surface for remaining wall
thickness measurement with different sectional viewing, side plan and end view.
Time of Flight Diffraction (TOFD)
An ultrasonic technique that can be used to examine welds in pressure vessels and pipes.
A & B Scan Enhancement Imaging (ABI Scan)
ABI scan imaging technique provides inspection of welds located in difficult access areas and
complicated geometries. Graphical records are kept for hard copy evidence and post processing.
Floor Map Imaging
Flaw detection and corrosion screening using guided and surface waves for inspecting annular plates
and corrosion under pipe supports.
Electro Magnetic Array Testing (EMA)

EMA is an electromagnetic technique for detecting and sizing surface breaking defects in metals, and
is particularly suited for inspecting painted and/or welded structures.

Computed Radiography
CR uses an imaging plate (IP) to create the image, which contains critical and precise details far
greater than film. The digital image can then be viewed and enhanced using software that has
functions very similar to other conventional digital image-processing software, such as contrast,
brightness, filtration and zoom. CR is capable of measuring thickness and lengths of parts and defects
accurately electronically.
MFL Tank Floor Scanning
The Floormapis latest version of MFL corrosion detection, sizing & mapping floor scanner. The system
consists of a higher resolution scanning unit which has the ability to move with a forward speed of
450mm/s with a date capture rate of every 1mm. Filtered analysis is conducted at the end of each
scan to reduce the noise occurrence below a 20% thickness loss.

Incotest
Incotest is a unique corrosion survey method that allows ferrous pipes and vessels to be surveyed
through thermal insulation without disturbing the insulation or coating.
Phased Array
Ultrasonic phased array systems can potentially be employed in almost any test where conventional
ultrasonic flaw detectors have traditionally been used. Weld inspection and crack detection are the
most important applications. Phased array produces accurate, detailed cross-sectional pictures of
internal structures at fast inspection speeds. The benefits of phased array technology over
conventional UT come from its ability to use multiple elements and electronic time delays to create
beams that can be steered, scanned, swept, and focused electronically for fast inspection, full data
storage, and multiple angle inspections.
Tube Inspection Services
There is no single non-destructive testing (NDT) technique that can be applied to inspect all of the
tube materials. Selection of an NDT technique depends on the tube material and also on the defect
types expected.
The Tube Inspection technique we offer for inspection include Eddy Current Testing (ECT), Remote
Field Testing (RFT), ultrasonic IRIS, and Magnetic Flux Leakage (MFL) as well as laser optics. Each of
the NDT techniques has its advantages and limitations. For example, conventional eddy current is very
sensitive to pits and cracks but it is mostly limited to non-ferromagnetic materials. IRIS is accurate in
measuring wall thickness, but it will miss small defects such as pinholes and cracks. Optical techniques
are limited to ID detects. Proper selection of the NDT techniques is therefore a key to inspection of
heat exchangers.
Electro Magnetic Acoustic Testing (EMAT)
The big advantage of EMAT testing is the ability to produce accurate readings on scaled surfaces. This
is because the probes induce ultrasound in the steel itself rather than by transmitting it via a coupling
medium. In fact, the probes will work at a small distance from the material surface. This allows the
probe to function when the test surface is heavily corroded, has a large oxide scale build up or during
high temperature operation, a major cost benefits of these probes is that expensive and time-
consuming cleaning and surface preparation is no longer necessary.
Long Range UT Guided Wave Inspection
Long-Range Guided Wave UT pipe screening system is used for testing long lengths of pipe to rapidly
identify areas of internal/external corrosion and other defects. With minimal surface preparation and
only removing a small section of insulation, the transducer collar placed around the pipe have a typical
test range of up to 50 meters in each direction along the pipe.
6.3 Remote Visual Inspection (RVI)

Velosi combines smart and fast remote solutions with extensive Velosi visual inspection expertise. It
enables comprehensive thermal and visual inspections for quality assurance and asset integrity
management with the smartest and safest tools developed and tested.

Our highly qualified teams first assess customer needs and tailor inspection programs according to
structures of their assets. They identify where remote tools can be deployed along with other main
Velosi inspection services for optimal inspection results. Clients get comprehensive data reports with
geo tagged visual data that can be stored on clients’ ERP. Repeated inspections allow better insights
into material damage and degeneration patterns and enable preventive measures to manage assets’
integrity.

Thermal and visual inspections conducted with RVI equipment’s are currently brought in practice for
on –and offshore, Process, Fertilizers Cement and Aviation Industries

 Flare tips inspections

 Chimney inspections
 Structural inspections
 Overhead power lines poles
 Dams and bridges
 FPSO’s
 Wind turbine
 Inaccessible and confined places
 Boilers
 Geysers
 Storage tanks
 FPSO’s
 Pipe racks and supporting structures
 Tanks
 Other hard to reach assets

Services Includes:

 Inspections of confined, cluttered or indoor places

 Remotely operated aerial inspections
 Telescopic crane for inspections of hard to reach assets
 Borescopy Inspection
 Piping welding Inspection
 Turbine Visual Inspection
 Engine Visual Inspection
Benefits
 Full scope consultative approach with target based solutions gives a clear insight of our results and
deliverables.
 In house technical development / purpose modification possibilities, offers enhanced flexibility and
perspective to our clients.
 Safer and cost-effective alternative to conventional visual inspection.
 Comprehensive inspection visuals and reports.
 Data Integration in client’s systems.
 Faster results.
 No plant downtime.
 Solutions tailored to asset structures.