1.1.1 Steam piping network data:
Joint sizes: Record the sizes of the steam piping joints, 2-inch and 3-inch joints.
Schedule: The schedule of the steam piping joints is 160, which represents the pipe thickness.
According to API 574, Fourth Edition, Nov 2016. Steam pipe 2-inch Sch 160 nominal thickness
is 8.74 mm, and 3-inch Sch 16 nominal thickness is 11.13 mm which matches with the actual
thickness of pipe in site.
Total number of inspected joints: Determine the total count of joints that have been inspected in
the steam piping network. No of 2-inch joints =559 joints & No of 3-inch joints =546 joints. The
total number found was 1105 joints.
1.1.2 Inspection time & cost data:
Inspection time per joint: Collect the data on the time taken to inspect each joint using the PAUT
technique.
Table 1 PAUT Inspection Times
Joint Size
Inspection Time (PAUT)
2 inches /Sch 160
6 minutes
3 inches /Sch 160
5 minutes
Inspection time per joint: Record the inspection time required for each joint when using the RT
technique.
Table 2 Radiography Inspection Times
Joint Size
Inspection Time (Radiography)
2 inches /Sch 160
30 minutes
3 inches /Sch 160
25 minutes
Inspection cost per joint: Gather data on the cost incurred for inspecting each joint using RT
Inspection 25 USD/Joint and PAUT inspection:11 USD/Joint.
By collecting and analyzing this data, the research project will be able to compare the inspection
time and cost between PAUT and RT techniques in the steam piping network. This data will
provide valuable insights into the efficiency and cost-effectiveness of each method, supporting the
evaluation of PAUT as a potential replacement for RT.
1.2 Inspection Time Comparison
1.2.1 Time Calculation
Total time for 2-inch PAUT inspection: 6 minutes/joint * 559 joints = 3,354 minutes
Total time for 3-inch PAUT inspection: 5 minutes/joint * 546 joints = 2,730 minutes
Total time for 2-inch radiography inspection: 30 minutes/joint * 559 joints = 16,770 minutes
Total time for 3-inch radiography inspection: 25 minutes/joint * 546 joints = 13,650 minutes
Table 3 Inspection Time Comparison
Joint Size
Inspection Time (PAUT)
Inspection Time (Radiography)
2 inches
3,354 minutes
16,770 minutes
3 inches
2,730 minutes
13,650 minutes
Total
6,084 minutes
30,420 minutes
1.2.2 Time Savings Calculation:
Total time savings with PAUT: 30,420 minutes (radiography) - 6,084 minutes (PAUT) = 24,336
minutes
Time Savings Percentage:
Time savings percentage = (24,336 minutes / 30,420 minutes) * 100 = 79.94%
Based on the provided data, PAUT offers significant time savings compared to radiography for
both 2-inch and 3-inch joints. The total time savings with PAUT in this scenario is approximately
24,336 minutes, resulting in a time savings percentage of nearly 79.94%.
PAUT vs RT inspection time comparison
35000
30420
Time/minutes
30000
25000
20000
16770
13650
15000
10000
6084
5000
3354
2730
0
2-inches
Inspection time/minutes (PAUT)
3-inches
Total
Inspection time/minutes (Radiography)
Figure 1 Inspection time comparison using bar chart showed time optimization after PAUT
adoption.
1.3 Inspection Cost Comparison:
To calculate the cost reduction percentage, we can compare the total costs of PAUT and RT
inspections for each month.
Figure 2 Inspection cost comparison on the 1st &2nd quarter of 2023.
Using the calculated total costs from excel sheet calculations stated in figure:
-January:
PAUT total cost: $2,684 USD
RT total cost: $6,100 USD
-February:
PAUT total cost: $1,397 USD
RT total cost: $3,175 USD
-March:
PAUT total cost: $1,034 USD
RT total cost: $2,350 USD
-April:
PAUT total cost: $1,705 USD
RT total cost: $3,875 USD
-May:
PAUT total cost: $2,530 USD
RT total cost: $5,750 USD
-June:
PAUT total cost: $2,805 USD
RT total cost: $6,375 USD
To calculate the cost reduction percentage, we can use the formula:
Cost Reduction Percentage = [(RT Total Cost - PAUT Total Cost) / RT Total Cost] * 100
Calculating the cost reduction percentage for each month:
January: [(6100 - 2684) / 6100] * 100 = 56.06%
February: [(3175 - 1397) / 3175] * 100 = 55.99%
March: [(2350 - 1034) / 2350] * 100 = 56.07%
April: [(3875 - 1705) / 3875] * 100 = 55.98%
May: [(5750 - 2530) / 5750] * 100 = 55.97%
June: [(6375 - 2805) / 6375] * 100 = 56.05%
The cost reduction percentages for each month range from approximately 55.97% to 56.07%.
Cost Reduction (Phased Array)
7000
USD 6 375
USD 6 100
USD 5 750
6000
Cost/USD
5000
USD 3 875
4000
USD 3 175
USD 2 684
3000
USD 2 530
USD 2 350
2000
USD 2 805
USD 1 705
USD 1 397
USD 1 034
1000
244
127
94
1
2
3
155
230
255
4
5
6
0
0
Month
No of inspected joints
PAUT cost
RT cost
Figure 3 Cost reduction achieved by adoption of PAUT as alternative to RT.
7