Case Study

Context: A factory specialising in the production of acacia powder faced an urgent need to repair a critical component of its cyclone, which was threatening to severely disrupt production.

Problem: A sudden failure revealed a cracked zone in a critical part of the cyclone, requiring immediate cyclone inspection.

Solution: The factory called upon Bioscan’s crack test and repair services for a swift and effective response.

Project Execution:

• Problem Identification: The damaged area was visible and already identified by the client; however, a larger area was inspected using vessel crack inspection services as a precaution.
• Access Methods: Qualified IRATA rope access technicians safely accessed the damaged area inside the cyclone.
• Repairs: The damaged section was cut out and replaced with a stainless-steel 316L sheet by qualified welders. Repairs were carried out to the strict standards of the food industry, with finishing and polishing to a precision of less than 0.8 μm.
• Rechecking: Re-inspection of the zone and roughness checks were performed to validate the quality of the repair works.
• Report and Certificate: A detailed report with before and after photos of the repairs was provided.

Results:

• Quick and Effective Repair: The damaged area was repaired promptly in under 6 hours, minimising production downtime.
• Enhanced Equipment Lifespan: High-quality repair works and new inspection frequencies extended the cyclone’s lifespan.
• Reduced Maintenance Costs: Effective preventive maintenance reduces long-term costs and improves process reliability.

Conclusion

The urgent repair of the cyclone at the acacia powder plant demonstrates the effectiveness of Bioscan’s crack detection and tank inspection services in critical situations. By swiftly identifying the damaged area and performing the repairs the client was quickly back into production.

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.

Confined production equipment have become the integral for the manufacturing of complex and sensitive products, especially in the pharmaceutical, chemical, and food sectors. These critical equipments can present significant risks to safety and product quality. This case study examines how Bioscan, a leader in electromagnetic “crack testing” without chemical penetrants, has revolutionized how companies ensure operational safety in these complex and demanding environments.

Problem Statement

Effectively managing operational safety in confined production equipments is a major concern for companies focused on consumer safety and regulatory compliance. Specific challenges include early detection of defects and potential cracks, minimizing unplanned downtime, and preserving product quality in demanding working conditions.

Bioscan’s Solution

Bioscan offers an innovative solution that involves the application of electromagnetic technology for equipment inspection within confined spaces. Unlike traditional methods involving the use of chemical penetrants, this non- destructive approach is environmentally friendly and offers a high sensitivity for crack detection, while minimizing operational disruptions.

Implementation

The implementation of Bioscan’s technology involves meticulous planning regular inspections. This planning optimizes preventive maintenance, while reducing unplanned downtime. The non-destructive and rapid approach allows real-time analysis of critical equipment, helping companies anticipate potential issues.

Implementation of Controls and Certification

In addition to the application of our innovative electromagnetic technology, Bioscan places paramount importance on quality and compliance. All our equipment and processes undergo rigorous controls and are certified to the industry’s strictest standards. 

This certification not only ensures the reliability of our services, but also the safety of our clients. It attests to our commitment to operational excellence and regulatory compliance, which is crucial when operating in sensitive environments. 

Results

Companies that have adopted this approach have seen a significant improvement in operational safety. Early defect detection has significantly reduced the risk of contamination and major failures, thereby preserving product safety. Moreover, unplanned downtime has been significantly minimized, contributing to maintaining productivity and product quality at optimal levels. 

Client Testimonial

Testimonials from our client attest to the effectiveness of this solution:

Conclusion

Operational safety within confined space production equipment remains a major concern in the industry. Bioscan, with its innovative electromagnetic technology, is committed to helping companies effectively and environmentally responsibly address this challenge. Our approach not only preserves the end consumers safety, but also ensures product quality, strengthening the reputation and regulatory compliance of our clients. 

To discuss how Bioscan can help you optimize downtime, please contact us today or send an email to sales@bioscanltd.co.uk.