INTRODUCTION

The continuous operation of your smoke stacks is essential for the operation of the plant and that operational or structural failure would have catastrophic consequences for the plant, surrounding support facilities and possibility human life?

 

It is recommended by international standards that all smoke stacks be inspected?

CHALLENGES

  • Under normal circumstances - inspection and maintenance has to coincide with planned shut downs/outages.
  • Old generation = half station shut.
  • Time constraints.
  • Very expensive access.
  • Extreme heights.
  • Confined space.
  • Potential toxic environment
  • Asbestos
  • Lead
  • Various toxins

 

Should a station have to shut down a unit for the recommended inspection –

  • The resultant revenue loses can be as much as R10 million* per day (based on a 350MW unit), R300 million over 30 days?
  • Should there be a half station shut, the resultant revenue loses can be as much as R30 million* per day (based on a 3 x 350MW unit), R900 million over 30 days?

SOLUTION

  • Comprehensive inspection programme using JOANE™

 

  • Dramatic reduction of the inherent risks - machine and not a person that performs the inspection. (Prevention of risks at work Act [5] (European Directive 89/391/CEE).
  • Allows for detailed planning (bill of quantities, programme, sourcing of material and contractors etc.) so once stack/flue is off line, the repair scope can start straight away.
  • Ensuring long term structural integrity and operational effectiveness.
  • Minimise maintenance spending.
  • Prevent unplanned outages/shutdowns.
  • The ability to carry out the international recommended inspections without shutting down a unit/units.
  • The ability to inspect internally while on load (operational).

 

  • Live visual feedback for engineers, managers and decision makers.
  • Reports
  • 3D rendered model allowing the decision makers (engineers) to view smoke stack virtually. This coupled with a complete summary of findings allow for swift comprehensive maintenance planning (post inspection).
  • All abnormalities are highlighted. (Analytical software)
  • All data is loaded onto a “plant care database” (CT type) this allows one to compare results, analyse trends and compare year on year.

GUIDELINES AND REGULATIONS

 

  • Chimney and Stack Inspection Guidelines - American Society of Civil Engineers.
  • The International Committee on Industrial Chimneys (C.I.C.I.N.D.)
  • “Guide to the Inspection and Maintenance of Reinforced Concrete Chimneys and Natural Draught Cooling Towers.” Atlas.
  • “Guide to the Inspection of  Single Flue Industrial Steel Chimneys”. Atlas.
  • US Environmental Protection Agency
  • International Standards
  • ASME STS-1
  • ASTM C 1298
  • ASTM D   4619
  • ASTM D 5364

 

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