Context: A chemical manufacturer uses industrial spray dryers in its production process. The equipment had never, or rarely been inspected since commissioning.

Problem: Lack of regular inspections led to the accumulation of undetected cracks, resulting in unexpected production stoppages and contamination risks.

Solution: The company utilised Bioscan’s spray dryer inspection services for an in-depth inspection of its equipment.

Project Execution:

• The technology used: Electronic crack detection scanner with eddy current technology, allowing detection of visible and invisible defects and measurement of their depth.
• Access methods: Use of a portable platform assembled section by section, covering spray dryer diameters from 1.5 meters to 14 meters, combined with rope access methods with IRATA-qualified technicians.
• Repairs: Repairs were carried out by specialised welders according to industry standards, with precise finishing and polishing to below 0.8 μm.
• Reinspection: Rescanning and roughness checks after repairs to validate the quality of the repairs.
• Report and certificate: Delivery of a detailed report within 7 to 14 days with before/after photos, defect causality, depth, and length, polishing finish, and a control or compliance certificate.

Results:

• Identification and repair of critical defects: Reduction of production stoppages due to rapid crack detection and repair.
• Establishment of new inspection frequencies: Implementation of appropriate vessel crack testing frequencies to prevent future problems, thus increasing the equipment’s lifespan.
• Improvement in product safety and production process reliability: Reduced contamination risks and long-term costs through effective preventive maintenance.