Services 1.0 Introduction BeadMet (Pty) Ltd – is a 100% black emerging private owned company with a B-BBEE level 4 verified status. The company was established in 2012 to provide Welding Engineering Services. Our services include Consultancy, Non Destructive Testing, Fabrication & Installation Support, Quality Control, Welding Administration, Inspection & Repair Coordination, Strategic Sourcing, Surface Painting & Coating Inspection, and Training services. Our target market being the power generation, petrochemical, manufacturing and authorized inspection houses, mining, metallurgical, rail, and related industries.
We oversee all quality control and welding related documentation on behalf of our clients during plant shutdown, maintenance, turnkey projects and shop or site equipment manufacture, repair or modification. BeadMet has capability to source and supply to client orders all welding related equipment and consumables during execution of welding and fabrication work. We assist our clients in the qualification of welding procedures and personnel to meet code manufacturing requirements and compile all associated documentation.
Our experience in the application of ISO 3834-2 welding quality standard and involvement in supplier accreditations gives us the edge in setting up such welding quality systems. Our approach will involve audits of client’s current welding practice with recommendations for improvement. This is then followed by detailing procedures that control input resources to the final product output.
BeadMet (Pty) Ltd offers a range of short courses tailor made to our client needs. These courses include but not limited to quality control, inspection, welding engineering and code specific fabrication.
As part of management consulting we offer reliability services. Our reliability department is supported by key expert partners in risk based inspection and component life assessment. Through our strategic sourcing we are geared to assist clients in sourcing the right key personnel during site projects, plant maintenance and plant shut down.
We have established quality, Safety, Health and Environment systems and procedures that are in line with ISO 9001: 2008 and ISO 14001/ OHSAS 18001. Our objectives and policies are thus aligned with these systems.
3.0 Mission Statement We provide quality control, inspection and welding engineering solutions within South Africa and beyond borders while exceeding customer expectation at competitive cost.
4.0 Vision To become the most valued service partner by going an extra mile to provide solutions to clients within all our service offers.
6.0 BeadMet Quality Policy Statement BeadMet (Pty) Ltd is committed to surpassing customer satisfaction through innovative and efficient service delivery. The company embraces cost effective and high quality standard in all executed work. BeadMet (Pty) Ltd further commit to foster a systematic business approach to ensure consistency in meeting client needs. We monitor our service and aim for continuous improvement in all our key deliverables.
BeadMet (Pty) Ltd shall ensure:
That all the activities which affect the Quality of our products/services are under control, whether hardware, software, materials or services.
That the Quality management control function has been orientated towards the reduction, elimination and, most importantly, prevention of Quality non-conformities, as well as ensuring customer satisfaction and continual improvement.
Efficiency and profitability.
Continuous conformance to environmental standards.
Timeous identification of potential deviations.
Improved communications and morale in BeadMet (Pty) Ltd and to have a good relationship with our customers and stakeholders.
That all necessary corrective and preventive actions are taken when deviations occur.
Optimum utilization of resources.
In reaching all the above-mentioned objectives BeadMet (Pty) Ltd shall utilize and conform to the requirements of SABS / ISO 9001:2008 in relationship with ISO 9004:2000 Quality Management System. All our welding related services and products are established upon the principles of ISO 3834-2 comprehensive requirements.
7.0 BeadMet Health, Safety & Environmental Policy BeadMet (Pvt) (Ltd) has an on-going commitment and vision to be a recognised world leader in the provision of all its service offers. In line with this vision, we aim to provide our services in a way that adds value to our clients’ businesses and achieve a higher level of client satisfaction.
And therefore commits to:
Implement and maintain ethical business practices and sound corporate governance processes.
Eliminate or prevent personal injury and occupational health hazards & diseases associated with client environments.
Eliminate, prevent or mitigate our impact on the environment through optimization of resource consumption, protection of environmental biodiversity, minimization of release of effluent and emissions &, waste minimization.
Comply with all applicable Occupational Health, Safety and Environmental legal requirements, as determined by industry requirements.
Ensure customer satisfaction by understanding our customer requirements, strive to exceed customer expectations, and providing consistent high quality product and service.
Set the framework for setting safety, health, environmental and quality objectives at relevant functions in the organization.
Operate appropriate systems to provide training to employees and contractors to ensure that they are competent to carry out duties and responsibilities towards achieving the objectives of this policy.
Continually improve our SHE program through risk assessments, analysis of data, audits, inspections, process monitoring, product monitoring, customer feedback, incident investigations, policy and management reviews.
Review this policy and SHE system performance periodically and/or when they are changes affecting its suitability and relevance.
Communicate this policy to all employees working for and on behalf of BeadMet. This policy will be displayed at conspicuous places and will be made available to all visitors, stakeholders, and interested and affected parties.
Assist manufacturers in the development, management, approval and issue of qualified welding procedure specifications (WPS's) to client/ manufacturing code requirements. Such codes include but not limited to ASME IX, AWS D1.1, EN 15614-1 & API 1104
Welding related support during product design, this includes assistance in material selection.
Failure investigation on welded equipment/ structures.
Welding related training, this includes QC level I and level II related courses, metallurgical & welding engineering courses, manufacturing codes & standards, etc.
Provide recommendations for a sound welding practice.
Assist clients/ manufacturers in welding personnel qualification and documentation of welding performance qualification certificates.
Compilation and issue of job specific prequalified and preliminary welding procedure specifications (preWPS).
Advisory support towards implementation of a welding related quality system, e.g. ISO 3834-2.
Coordinate weld refurbishments of capital equipment.
Technical support during heat treatment of fabricated components.
8.2 Reliability Engineering 8.2.1 Risk Based Inspection BeadMet through its partners offers technical support in planning of Risk Based Inspection (RBI) on capital equipment. This involves a careful assessment of various damage mechanisms related to equipment service life and ranking failure probability and consequence. This process is then used to build inspection intervals which can lead to less equipment downtime and longer service life. We follow various widely accepted international engineering guidelines on RBI such as API 580; API 581; ASME PCC – 3; etc. Equipment of RBI relevance include but not limited to power generation equipment; storage tanks; steam turbines and equipment of high temperature service.
8.2.2 Component Life Assessment Boiler headers, tubes and pipework are designed for a finite life based on strength, stress rupture, fatigue and creep rate design limits. Even in the absence of an accelerating damage mechanism, components operating at high temperature are likely to fail due to long-term overheating or creep. Interval inspections of these components are important to predict the remaining life of these components and these inspections are critical in preventing failures. Evaluation of remnant life-time of high thermal components also gives possibilities for optimisation of plant maintenance and revitalization. Life time in service of particular components is highly dependent on material of fabrication. BeadMet provides plant life assessment by adopting destructive and non-destructive testing methods, at the same time ensuring adherence to relevant technical standards.
8.3 Training We offer a range of short courses for the welding and inspection personnel (engineers, QA/QC inspectors, inspectors of pressurized equipment - IPE’s, competent persons – pressure vessels & steam generators, welding specialist, welders, etc.) that can be tailor made to suit client needs.
These courses include but not limited to quality control, inspection (QA/QC), welding engineering and code specific fabrication.
9.0 INSPECTION & QUALITY MANAGEMENT 9.1 Non-Destructive Testing (NDT) 9.1.1 Conventional Inspection Services We offer the following conventional non-destructive testing techniques:
Visual Examination/ Testing (VT)
Our visual examination include but not limited to dirty boiler inspections, in-service component inspections, document review, inspections before, during and after welding, reporting and sign off.
9.1.2 Advanced Inspection Services In addition to conventional methods of inspection, BeadMet can offer advanced inspection techniques to its clients. These are basically employed to further identify and characterize indications and best provide more information of damage mechanisms. They can also be employed on members that are not accessible. Following is a list of advanced techniques that BeadMet can provide:
Time of Flight Diffraction (ToFD)
TOFD has extremely accurate defect sizing capabilities using diffraction of the ultrasonic wave when it encounters indications such as for example, cracks. Two probes are used, one is the transmitter of the ultrasonic wave and the other is the receiver. These probes are mounted on a buggy to pick up, record and size indications as the buggy is moved along the area under examination.
Phased Array (PA)
Phased Array can be employed as a stand-alone technique or in conjunction with TOFD. The technique offers capabilities of inspection of complex geometries or components with limited access.
Guided Wave Testing (GWT)
Inaccessible piping can be inspected using the Guided Wave Inspection Technique. Guided Wave Inspection offers the following advantages:
Minimal removal of insulation in cases where inspections of corrosion under insulation.
Large areas can be inspected rapidly.
Internal and external wall loss.
Possibility of long range piping inspections.
Less requirement for scaffolding when inspecting components in elevated heights.
Highly productive inspection technique.
Hundreds of meters of pipelines can be inspected from a single location.
In Service EMAT Boiler Tube Thickness Mapping
We are geared to offer this service using temate® TG-IS (B) which is a redesigned FST-GAGE or Fast Scanning Thickness Gage, first introduced in 1994. FST-GAGE was developed by Electric Power Research Institute (EPRI) and Babcock & Wilcox (B&W) specifically to scan boiler tubes and provide a continuous measurement of tube wall thickness.
The system works on ultrasonic EMAT (Electro Magnetic Acoustic Transducer) technique providing accurate thickness (with accuracy of +/- 0.127mm) readings with none or minimal tube surface preparation. The probe with integrated encoder and light indicators (for fast visual alert to the operator) is manually scanned along the boiler tube while the system records the thickness & alarms if the tube is below a pre-programmed threshold or other defect conditions are triggered. The system saves a complete record of each tube & the whole boiler for later post analysis & tracking.
Apart from detecting wall loss the system is capable of detecting hydrogen damage, pitting & caustic gouging (by measuring signal attenuation) which is not detected with conventional means. It works on carbon steel and clad tubes. Tube thickness ranges from 3.8mm to 12.7mm & the minimum tube diameter requirement is 22.2mm, the tube surface can be oxidized, rough or pitted (scale-free).
The technique permits 100% inspection of the boiler instead of spot checking at up to 15cm/s of scanning speed. The boiler mapping tool permits easy visualization of boiler walls with results of inspection for fast analysis and interpretation.