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Project

15KL Horizontal Tank NDT Crack test for Food Safety and Operational Compliance

Opportunity

The Lactalis (Sunfresh Agro Industries) team required an integrity evaluation of their 15 KL Horizontal Process Tank as part of their preventive maintenance and quality assurance program. Due to observing minor leakage issues and the tank being deemed unfit for operation under the client's stringent food safety standards, it could not be taken into process. The objective was to identify Cracks, Crevices, Dents, micro-cracks or surface flaws, carry out necessary rectifications, and retest the tank to ensure all gaps were closed before resuming operations. This involved high-stakes testing within a strict food-grade environment and under tight timelines.

Solution

PMG Engineering deployed a qualified NDT team, including Level II certified technicians, to carry out integrity testing using three non-destructive examination (NDE) methods: Visual Inspection, Ultrasonic Thickness Measurement, and Dye Penetrant Testing (DPT). All testing was performed in accordance with ASME Section V standards. Upon identification of surface defects and micro-cracks, PMG recommended a comprehensive repair plan that included complete re-welding of carbon steel (CS) joints and repositioning of the thermal jacket by certified welders. PMG further advised sharing the detailed test report with the original equipment manufacturer (OEM) and design consultants to assess the remaining useful life (RUL) of the tank. To enhance long-term reliability and ensure compliance with food safety standards, PMG recommended supplementary steel life assessment tests. Additionally, periodic integrity evaluations—at least once annually—were advised to proactively identify potential risks and prevent unexpected equipment failure.

Outcome

PMG Engineering successfully identified and documented the defects, supervised on-site rectification activities—including welding and polishing—and validated the effectiveness of the repairs through repeat Dye Penetrant Testing (re-DPT), achieving “satisfactory” post-repair results. However, given the client-imposed limitations on rectification methods—driven by concerns over contamination risks in a running plant and adherence to stringent food and personnel safety protocols—PMG flagged a high likelihood of defect recurrence. To mitigate this risk and ensure long-term equipment integrity, PMG recommended advanced metallurgical testing and the implementation of annual NDT audits as part of a proactive maintenance and food safety assurance program.

Project Highlights

NDT Level II team performed multi-method testing per ASME standards

Supervised safe rectification under strict conditions in a running plant

Repairs completed within tight timelines to resume production quickly

Recommended additional metallurgical testing for thorough equipment assessment

Supervised on-site welding and retesting till compliance for successful repair validation

Key Challenges

Insulated

jacketed tank complicated identification of external defects

Tank needed urgent return to production while plant was running

Tank leakage prevented operation due to strict food safety protocols

Repair methods limited by contamination risks during ongoing operations

High risk of defect recurrence despite satisfactory repairs.

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Location

Ahmadnagar, Maharashtra, India

Client

Sunfresh Agro Ltd

FOOD PRODUCTION

15 Ton / Day

Project Status

Completed

Services Provided