Ultrasonic Testing NDT – Plan the Work & Work the Plan
By John Taylor
What can a backpacking trip in the wilderness and an ultrasonic boiler survey inspection possibly have in common? Well two important things, one is planning and the other is execution.
Let’s just get a little background on both of these endeavors. Backpacking into the wild is not just an afternoon walk in the woods. You take “everything” you need to survive for a week or maybe more into an environment where there are no Wal-Mart’s, Holiday Inns, cell phones or highway signs. There aren’t even many people.
Now a boiler survey requires you to take “everything” you need as well, since Home Depot doesn’t carry any of the equipment and supplies required for these inspections. And like the outdoors, you can’t just go back to the office and retrieve what you forgot since you are miles away from base.
With backpacking you need a route and a map. With a boiler inspection you need a scope of work and a sketch of the boiler. Here is a quick summary of the types of questions that need to be answered before you can begin either one of these adventures.
1. What is our general plan, what do we want to accomplish?
2. How much time do we have to complete the plan?
3. How much are we going to spend?
4. What is the environment going to be like?
5. What equipment do we need?
6. Who is going with us?
7. What is the condition of our equipment?
8. How much training do we have in using the equipment?
9. How do we get there and back?
10. What emergency plans are in place?
Now let’s apply those ten basic questions to a wilderness trip. We have a weeklong trip in mind in a location where we have not hiked before. This location should afford us some spectacular vistas, great fishing and a good loop route that doesn’t require any backtracking of our trail. It can fall within our budget depending on whether we can fly or drive to the location. If flying, we can either rent a car or use public transportation.
Let’s make our environment mountain terrain between 4,500 and 6,000 feet toward the end of summer. That makes packing our equipment an easy option. With a little research we can predict the weather conditions, the insects and the fishing conditions. Now we can load our packs with the right clothing, sleeping gear, tent and supplies. Most trips are 2 to 3 people. Anymore and you are defeating the purpose of a true wilderness experience. By yourself you tempt fate if lost or injured. Let’s decide on you and a friend. You share preparations, food choices and equal out the loads for both food and equipment.
Better make sure the stuff you stored in the attic has not dry rotted or been chewed by critters. Can you be sure that new tent or cook stove has all the kinks worked out and you don’t hesitate to use them? And you will need a start and stop point that is accessible to the trail head. You also might want a schedule of any shuttle services that may be available. Be sure those emergency plans are in place. The park service likes to get a detailed route and an estimated return time for you. Pack a complete first aid kit and be sure to have enough rope to hang a bear bag if you are in their territory.
So what about that boiler inspection? Well you need a complete scope of work detailing the amount of inspection points. The customer will have a spreadsheet for a time line to follow on the shutdown schedule. It might be 1 or 2 days or broken down into so many 12 hour shifts. And of course the whole job was awarded on how much money the customer has to spend on the inspection.
The environment of the job location is important as well. There are many hazards at industrial facilities and each plant has its own rules and procedures to follow regarding the contractors who work on-site. There is the analysis of how many technicians will be needed for the project. Just like a backpacking trip there is that perfect blend of enough but not too many participants. Remember each person must be supplied and costs must be accounted for in the job scope.
Check all the equipment before use. Sometimes machines and supplies will sit on a shelf or get put back without being marked for repairs. Double check it all. You don’t want to go hungry the last two days in the wilderness and you don’t want to tell your customer that you can’t get the inspection completed because you ran out of a vital supply item. Of course everyone on the job knows all about the testing equipment and can use it without hesitation.
There are plenty of logistic pitfalls when planning an inspection. Trip routes, driving delays, airline hassles, motel reservations and vehicle breakdowns are just a few of the dilemmas that can occur. And what happens when one job extends over into the start time of the next inspection. It’s like getting a late start on a cold rainy morning when your sleeping bag won’t let you go.
And of course there are the emergencies. Some are the same like the occasional cut or bruise that may require a band aid or some other small fix. Others are more serious and the importance of prevention rather than reaction is paramount.
One other thing, on the job site you must also be alert for bears. While not the four-legged variety, your customer can turn into one pretty quickly if you are not following his or her directions. That maintenance supervisor or reliability engineer has a real nose for finding mistakes and incomplete inspection details. Just like in the wilderness plan the work and work the plan.
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