1. Introduction
1.1 Overview:
Curran International is a leader in the provision of advanced grit blasting services, specializing in the cleaning of heat exchangers, fin fans, and other critical industrial equipment. Our proprietary grit blasting techniques utilize high-velocity abrasive particles to effectively remove scale, corrosion, and other contaminants, ensuring optimal performance and longevity of the equipment.
1.2 Document Objectives:
This document aims to provide a comprehensive guide on the grit blasting services offered by Curran International. It covers the detailed process, equipment used, safety procedures, and the benefits of our grit blasting services. Additionally, it includes quality control measures, case studies, and references to highlight the effectiveness and reliability of our methods.
2. Process
2.1 Description of the grit blasting process
Grit blasting involves propelling a stream of abrasive material at high velocity to clean surfaces. This process is highly effective in removing contaminants, rust, and old coatings, leaving a clean and prepared surface. Curran International uses a dry grit blasting technique, which ensures no moisture is introduced into the equipment, preventing further corrosion and contamination.
2.2- Step involved in the process
- Preparation: Inspect equipment and set up staging areas.
- Equipment Setup: Position blast pots, air compressors, and dust collectors.
- Blasting: Execute the blasting process with precise control over dwell times.
- Inspection: Utilize video probes to ensure thorough cleaning.
- Clean-up: Remove spent grit and verify cleanliness.
2.3- Patented Nozzles
Curran International employs patented nozzles designed to deliver high-velocity air and grit at twice the standard speed, ensuring efficient and thorough cleaning.
2.4- Equipment used
Curran Equipment: High-velocity air compressors, patented grit blasting nozzles, blast pots, dust collectors, and video inspection probes.
Client Provided Equipment:
2.5- Environmental and safety
Curran International adheres to strict environmental and safety standards. Our processes include dust containment systems to minimize environmental impact and ensure the safety of personnel through comprehensive PPE requirements and safety protocols.
3. Procedures
3.1 Straight Tube Blasting Procedure overview:
For straight tube heat exchangers, the process involves staging equipment, ensuring clean and dry air, determining dwell times, and executing the blasting process with precision to avoid any damage to the tubes
3.2 U-tube Blasting Procedure overview:
The U-tube blasting procedure requires careful attention to the inner radii to prevent through-wall damage. Dwell times are incrementally increased and inspected to ensure thorough cleaning without compromising tube integrity
3.3 Fin Fan Blasting Procedure Overview:
Fin Fan blasting involves a systematic approach to staging equipment, ensuring no obstruction to other crafts, and executing the pitch and catch method for effective cleaning. Each tube is numbered and blasted with controlled dwell times to achieve optimal cleanliness
3.4 Field Exchanger Blast Procedure Overview:
Field exchanger blasting involves on-site assessment and equipment setup, followed by a systematic cleaning process. This includes staging, air quality checks, and methodical blasting with real-time inspections to ensure thorough cleaning
3.5 Best practices
- Always use moisture and oil-free air.
- Incrementally adjust dwell times to avoid damage.
- Utilize video probes for continuous inspection.
- Adhere to safety protocols and PPE requirements.
3.6 Safety protocols
- Comprehensive JSA (Job Safety Analysis) and pre-job meetings.
- Use of appropriate PPE including full-face air-supplied hoods and respirators.
- Regular equipment inspections and functionality checks.
- Strict adherence to containment and waste disposal guidelines.
4. Benefits
4.1 No Rework
Curran’s precise and thorough cleaning process eliminates the need for rework, ensuring first-time quality results.
4.2 No Water
The dry grit blasting process ensures no water is introduced, preventing corrosion and reducing environmental impact.
4.3 Precise Inspection Data
Clean surfaces allow for accurate NDE (Non-Destructive Evaluation) data, facilitating better maintenance decisions.
4.4 Predictable Cleaning Times
Establishing cleaning times during the initial phase ensures predictability and efficiency in project timelines.
4.5 Faster Cleaning Times
High-velocity grit blasting significantly reduces cleaning times compared to traditional methods.
4.6 Operational Flexibility
The ability to adapt to various site conditions and equipment requirements provides operational flexibility and reliability.
| Data Inputs and Outputs | Description |
| Input 1: User registration data | Data provided by users during the registration process. |
| Output 1: User profiles | Profiles created for each registered user, containing their information. |
| Data Storage and Handling | Description |
| Storage Mechanism: NoSQL database (MongoDB) for flexible data storage. | Utilize MongoDB, a NoSQL database, to store user data in a flexible manner. |
| Handling Process: Asynchronous processing of data updates using message queues. | Implement asynchronous processing of data updates using message queues to improve performance and scalability. |
| Data Migration Requirements | Description |
| Requirement 1: Migrate existing user data from legacy system to [YOUR PRODUCT]. | Migrate data from the legacy system to [YOUR PRODUCT] to ensure continuity for existing users. |
| Requirement 2: Regular backups of user data to prevent data loss. | Perform regular backups of user data to prevent loss in case of system failure or data corruption. |
5. QC
5.1- QC procedures
Quality control is integral to Curran’s grit blasting services. Daily QC documents are maintained to track the performance and condition of equipment, dwell times, and inspection results
5.2- Example QC reports
| Authentication Mechanisms | Description |
| Requirement 1: User authentication: Secure login with OAuth 2.0. | Secure login mechanism utilizing OAuth 2.0 for user authentication. |
| Requirement 2: Two-factor authentication for enhanced security. | Implementation of two-factor authentication (2FA) for additional user security. |
Data Encryption Standards
| Data Encryption Standards | Description |
| Requirement 1: Data encryption: All user data stored in MongoDB should be encrypted at rest. | Encryption of user data at rest in MongoDB to maintain data security and privacy. |
| Requirement 2: Transport Layer Security (TLS) for secure communication between client and server. | Implementation of Transport Layer Security (TLS) to encrypt communication channels between client and server. |
Compliance with Regulations
| Compliance with Regulations | Description |
| Requirement: Ensure compliance with GDPR regulations for user data protection. | Adherence to General Data Protection Regulation (GDPR) standards for user data protection and privacy. |
6. Case Studies
6.1- Grit Blasting vs Hydroblasting
Studies demonstrate that grit blasting is more effective in removing stubborn deposits without introducing water.
6.2- Grit Blasting vs Metal Scraper/Darts/Bullet Cleaning
Grit blasting provides superior cleanliness and prepares the surface better for inspections compared to mechanical cleaning methods like scrapers and darts
6.3- Real-world applications and success stories
Case studies from various industries highlight the effectiveness of Curran’s grit blasting in improving equipment performance and extending the lifespan of heat exchangers and other critical components.
6.4- Client testimonials
West Coast Refinery Fixed Equipment Lead: “I am pleased to let you know that we have been very satisfied with the quality of your work and would not hesitate in recommending your services to any of our sister refineries. You have demonstrated that you are able to work on short notice, are able to deal with changing requests and most importantly to perform all your work safely. Heat exchanger tube inspection with IRIS requires a high level of cleanliness in order to be performed correctly and your grit-blasting technique has proven itself again and again in terms of providing this magnitude of cleaning, even where high pressure H2O (36,000 PSI) will not.”
Refinery Pressure Equipment Integrity Engineer – serviced 4” OD x 18’L convection furnace tubes: “These were the cleanest tubes…quality job, & timely execution.”
Gulf Coast Operations Manager – NDE Company: “As you’re aware, our ability to fully inspect internal surfaces with LOTIS is directly dependant on the cleanliness of the tubes, and there was no question that these tubes were the cleanest I’ve ever seen for this type of inspection.
Lead Inspection Analyst – Texas Petrochemical Plant: “I feel strongly that having cooling water tube side exchangers cleaned by grit blasting allows much greater confidence in determining relevant from non-relevant data.”
PEI Specialist/NDE Focal Point – Gulf Coast Refinery: “The results of the cleaning effort were excellent. We were never able to clean these tubes for IRIS using hydroblasting, thus were forced to use RFET. We will continue to use Curran International for cleaning when IRIS inspection is necessary.
Maintenance Superintendent/Turnaround – West Coast Refinery: I want to extend my appreciation for a job well done by the Curran International employees. This particular job was a real challenge, and it was very important to our operation. Curran crew worked long hours, under very tough and demanding conditions. They were interrupted numerous times to allow other critical path work to continue. Joe and his crew kept a positive attitude the whole time and helped us accomplish our goals. We wanted you to know how much we appreciated the help
Maintenance Superintendent/Turnaround, West Coast Refinery
| Types of Testing | Description |
| Unit Testing | Test individual components and functions. |
| Integration Testing | Test interaction between different modules. |
| System Testing | Test the application as a whole. |
Testing Tools and Frameworks
| Tool | Description |
| Tool 1: Jest | Jest is a JavaScript testing framework used for unit testing. |
| Tool 2: Postman | Postman is an API testing tool used for testing RESTful APIs. |