API

 

Zuuk was founded in 2009.  Its foundation was based on a single, multi-million dollar API inspection contract.  Since inception, it has grown to encompass a full service tank program, including inspection, maintenance and repair.

 

Inspection

  • API 653 Certified Tank Inspection

  • API 510 Certified PV Inspection

  • API 570 Certified Piping Inspection

NDT/NDE

Alternating Current Field Measurement (ACFM)

  • Alternative Eddy Current test method for the detection of leaks

    in tank bottoms

Visual Testing (VT)

  • Direct

  • Indirect (i.e. Borescope)

Ultrasonic Testing (UT)

  • Longitudinal Wave (Straight Beam) for the determination of

    thickness

  • Transverse/Shear Wave (Angle Beam) for the detection of

    discontinuities in test subjects

  • Phased Array (PAUT) for the multi-angled detection and graphic

    display of discontinuities in test subjects

  • Vessel Crawler / B-Scan / C-Scan

Penetrant Testing (PT)

  • Visible

  • Fluorescent

Magnetic Particle Testing (MT)

  • Dry Particle

  • Wet Visible

  • Wet Fluorescent

Magnetic Flux Leakage (MFL)

  • MFL scanning of tank bottoms for the detection of soil side

    corrosion

 

Maintenance and Repair

 • Bottom replacements

 • Cleaning

 • Cone roof & structure repair & replacements

 • Fire-fighting foam systems

 • Fittings and appurtenances

 • Fixed and floating roof repairs

 • Floating roof drain system repair

 • Heat Exchangers

 • Internal and external floating roof repairs

 • Out-of round or buckled tank shell repairs

 • Painting and Coating

 • Piping fabrication and installation

 • Pressure vessel fabrication, installation and repairs (“R”, “U”)

 • Rolling ladders and stair treads

 • Shell nozzles, manways & appurtenances

 • Shell repairs

 • Stairways, handrails, & platforms

 

 

Boilers

 

Boiler Inspection, Renewals, Repair and Service

 • Firetube, All Types

 • Hot Water Heating

 • Steam

 • Vaporizers

 • Watertube, All Types

 

Services

 • 24 hour boiler / burner service

 • Contract Maintenance

 • Control Systems design and service

 • Drum and Header Repair

 • Efficiency Evaluations

 • Emergency Services

 • Forced Draft Combustion of Multiple Fuels

 • Fuel Air Mixtures for various boiler and process burners

 • Hand-hole Seat Rebuilding and Grinding

 • Hydrostatic Testing

 • Inspections

 • Installation

 • Maintenance Evaluations

 • Maintenance Management Training

 • Emission compliance and combustion services

 • Non-destructive (NDT/NDE/NDI)

 • Operations Support Programs

 • Outage/Shutdown/Turnaround

 • Overhaul and Adjustment

 • Preventive Maintenance Programs

 • Refractory Renewal and Repairs

 • Soot Blower Repairs

 • Tube Replacement

 • Tube Surveys (Ultrasonic Thickness)

 • Valves and Piping

 • Waterside and Fireside Cleaning and Evaluation

 

BPE / Hi-Purity

 

System Construction, Installation, Inspection and Repair

 

Zuuk understands certain clients demand impeccable design and construction of clean, corrosion-resistant systems.  Our teams are highly skilled, certified tradesman capable of completing projects governed by the strictest codes and standards.  Zuuk holds the “S”, “U”, “PP”, “NB” and “R” stamp certifications issued by the American Society of Mechanical Engineers (ASME) and the National Board of Boiler Inspectors (NBBI), which allows it to perform fabrication and installation of systems in accordance with the most quality-critical requirements.

 

Industries that employ high-purity/critical-needs autogenous orbital welding typically join stainless or corrosion resistant high-alloy and non-ferrous metals.  These industries include:

 • Aerospace

 • Bio-Pharma

 • Food and Beverage

 • Specialty Chemicals

 • Semiconductor

 • Research and Development

 

Orbital Welding

 

Orbital welding gives the welding operator the ability to make consistent, repeatable, high-integrity welds at speeds impossible to achieve by manual processes.  Zuuk specializes in an orbital welding process which operates by establishing an arc between a non-consumable tungsten electrode and the base metal being welded.  The process is conceptually simple: tubes/pipes are held in place while an orbital weld head rotates an electrode, creating a welding arc around the weld joint. This application is used when the integrity of the weld joint has the highest quality requirements.

 

There are many reasons to use orbital welding over other processes, including:

 • Weld Integrity – Orbital welding systems outperform the best skilled

   welder.

 • Productivity – An orbital welding system can drastically out perform

   the speed of manual welders

 • Consistency – Eliminates normal variability, inconsistencies, errors

   and defects of manual welding

 • Safety - the need for radiographic inspections are reduced or

   eliminated.

 • Application - Orbital welding systems are capable of joining both

   piping and tubing.

 

Passivation

 

Welding alters the chrome/iron ratio (measure of corrosion resistance).  In order to return this ratio to its original state, the weld surface and tangible boundary must be returned to a passive state.  This is accomplished by removing free iron (anodic contaminants) from the surface of the corrosion-resistant specimen, resulting in chromium and iron oxides as the primary metal components.

 

Inspection

 

Zuuk Inspection, a division of Zuuk International, provides a third-party inspection service (and subsequent record keeping) for industries such as aerospace, bio-pharma, semi-conductor and food/beverage.

 

Almost 100% of tube welding conducted in the construction of biopharmaceutical facilities is high-purity, autogenous orbital gas tungsten arc welding (GTAW).  These welds must be validated before governing agencies will approve the commencement of manufacturing.  Moreover, if a facility is constructed in accordance with the ASME BPE2002, 100% of the weld is subject to visual examination of its outside diameter (OD) and inner diameter (ID).  All welds and materials are documented and recorded.

 

While some defects may be obvious from the outside, more critical defects can only be seen from the inside. The most common ID inspection for this type of construction is remote visual inspection (RVI) by means of a boroscope.  This form of VT inspection will ensure that all welds are completed having the same integrity throughout, having no visible impurities.

 

 

Code

 

What is “CODE” (in pressure related equipment and systems)

 

The word “code” [in construction] is used frequently and generally means:

 

A set of rules and standards covering the design, manufacture, and testing of construction or existing subjects.

 

For us, in the industrial sector, it more commonly applies to fabrication, installation and repair of pressure vessels, boilers and piping.

 

Prior to the establishment of the Uniform Boiler and Pressure Vessel Laws Society in 1915, some 50,000 Americans died or were injured each year from boiler accidents. The Society was formed to inform and guide the jurisdictions toward acceptance of what has now evolved into the ASME Code.

 

Often, it is difficult for the owner to determine if a repair is governed by “code”.  The more taxing questions relate to boilers, heat exchangers and other pressure vessels.  First, it is imperative to know the boundaries that define a code repair or alteration.  Second, the extent of repairs dictate the involvement of a third party, commissioned inspector.

 

The most important questions a client should ask when evaluating their pressure related equipment:

 • What are my legal responsibilities?

 • What are my insurance requirements?

 • What is the firm’s social responsibility (safety)?

 

Power or HP Boilers are governed by ASME Section I.  This group of equipment is defined as any fired, electric, or waste heat boiler designed to generate steam or vapor at a pressure more than 15 psig.

 

Pressure Vessels are governed by ASME Section VIII.  This group of equipment is defined as any containment of solid, liquid, or gaseous material under internal or external pressure, capable of withstanding the pressure of the contained materials and various other loadings.

 

Steam Heating and Hot Water Boilers are governed by ASME Section IV.  This group of equipment is defined as a boiler in which steam is generated at a pressure not exceeding 15 psig.  The hot water pressure shall not exceed 160 psig and the temperature must not exceed 250F at or near the boiler outlet.

 

Power Piping is governed by ASME Section I.  These systems are Boiler Proper (BP) and Boiler External Piping (BEP).  Superheaters, Economizers, and other pressure parts connected directly to the boiler without intervening valves are considered parts of the BP.  BEP is considered as that piping which begins where the boiler proper or a separately fired superheater terminates. Note that BEP falls out of the boundaries of Boiler Proper and is covered by ASME B31.1 Code.

 

Code Boundaries

 

The boundaries for the boiler and pressure vessel are quite simple. However, the Code boundaries for the piping systems connecting boilers to Main Steam, Feed Water, Blow Down, and Control Piping can be confusing. The difficulty or confusion often results from the erection, installation, modifications and or additions after initial install/construction.

 

Typically, the original manufacturer’s data sheet defines the boundaries in accordance with Section VIII; however, where external piping is connected to the vessel, the boundary is defined as:

  • the welding end connection [for the first circumferential joint for

   welded connections]

 • the first threaded joint [for screwed connections]

 • the face of the first flange [for bolted flanged connections]

 • the first sealing surface [for proprietary connections or fittings]

 • where non pressure parts are welded directly to the internal or

   external pressure retaining surface of a pressure vessel

 • the pressure retaining covers for vessel openings (i.e. manhole or

   hand-hole covers)

 • the first sealing surface for proprietary fittings or components for

   which rules are not provided by this division, such as gages,

   instruments, and non-metallic components

 

Types of Repair

 

There are three distinctions of repair covered by the National Boiler Inspection Code (NBIC):

 • Repair

 • Routine Repair

 • Alteration

 

All repairs must be inspected by a third party inspector, who has the authority to set any hold or inspection point necessary to ensure the work is acceptable to the specific code.

 

A common misconception surrounds the “inspection” involved in Code repairs.  An Authorized Inspector (AI) is an independent subcontractor commissioned by the NBBI.  He or she does not perform nondestructive testing or other standard practice quality assurance.  These functions fall on the owner or contractor.  Zuuk Inspection, a division of Zuuk International, provides MT, PT, UT, VT and other services to determine the integrity of the repairs; however Hartford Steam Boiler is Zuuk’s governing AI and is required to review the work package and in certain cases, witness the repair.

 

A repair is defined as:

“The work necessary to restore a component or system to a safe and satisfactory operating condition, such that existing design requirement are met.”

 

The primary difference between a Repair and a Routine Repair is the involvement of the AI.  Under the Routine Repair, the AI need not look at the work.  He/she will only review the completed work package and sign the R-1 form (Report of Repair form).  There are four definitions of routine repairs:

 • Welded repairs of replacement of valves, fittings, tubes, or pipes (NPS

   5 (DN 125) in diameter and smaller, or sections thereof, where neither

   postweld heat treatment nor NDE other than the visual is required by

    the original code of construction.  This includes their attachments

   such as clips, lugs, skirts, etc., but does not include nozzles or

   pressure retaining items.

 • The addition or repair of any non-load bearing attachment to a

   pressure boundary where postweld heat treatment is not required.

 • The weld buildup of wasted areas of shells, heads, tubes, pipe when

   the total area of buildup does not exceed 100 sq. inches or the

   thickness does not exceed 25% of the wall thickness at the point of

   repair of ½” whichever is less.

 • Repair of the corrosion overlay not exceeding a total of 100 sq.

   inches.

 

A (“full-blown”) repair requires the AI to be present and witness the repair and a repair name plate is physically attached to the equipment.

 

Take-aways

 • ASME are the construction codes covering original fabrication of

   pressure related equipment.

 • NBIC is the code used for repairing the constructed equipment with

   respect to the ASME standards.

 • The AI is a subcontractor and required by the NBIC.

 • The AI does not do NDT.

 • A Contractor’s Quality Program mandates welding procedures are in

   compliance with governing codes.

 • All participating welders have to be qualified to proven welding

   procedures owned by the Certificate Holder (contractor).

 

 

 

 

 

 

Exchangers / Condensers

 

Zuuk has shop and field teams that are capable of performing repairs in the field and/or retrieving a unit from service to perform complete turnkey service off-site.

 

Zuuk provides the following Condenser and Heat Exchanger services:

 • Cleaning

 • Fabrication (New)

 • Inspection

 • Re-Pack Tube Ends

 • Tube Plugging

 • Tube Renewal

 

ZuukCM has the ability to repair or replace:

 • Baffles

 • Headers

 • Individual Tubes

 • Tube Bundles

 • Tube Sheets

 

Zuuk has welding procedures covering:

 • Aluminum

 • Bronze Alloys

 • Carbon Steel

 • Carpenter 20 CB3

 • Chrome Molybdenum (including P-91 and P-92)

 • Copper Alloys

 • Copper Nickel

 • Duplex Stainless Steel

 • Hastelloy

 • Nickel Copper (Monel)

 • Stainless Steel

 • Stellite

 • Titanium

 

 

 

 

 

Fabrication

 

Systems and Components:

 • Autoclaves

 • Boilers

 • Chillers

 • Columns

 • Condensers

 • Duct Systems

 • Heat Exchangers

 • Hoppers

 • Modular Systems

 • Piping

 • Pressure Vessels (ASME)

 • Reactors

 • Silos

 • Tanks

Welding

 • Shielded Metal Arc Welding (SMAW) - Stick

 • Gas-Tungsten Arc Welding (GTAW) - Tig

 • Gas-Metal Arc Welding (GMAW) - Mig

 • Flux-Core Arc Welding (FCAW)

 • Orbital Welding (Autogenous)

 • Oxy-Fuel Welding

Shop and Field Assembly, Parts, and Installation for:

 • Power Boilers, ASME Code Sec. I  (“S” Stamp)

 • Pressure Vessels, ASME Code Sec. VIII, Div. 1 (“U” Stamp)

 • Power Piping,  ASME B31.1 (“PP” Stamp)

Qualified Welding Procedures For:

 • Aluminum

 • Bronze Alloys

 • Carbon Steel

 • Carpenter 20 Cb3

 • Chrome Molybdenum (Incl.P-91/P-92)

 • Copper Alloys

 • Copper Nickel

 • Duplex Stainless Steel

 • Hastelloy

 • Nickel Copper (Monel)

 • P-91

 • Stainless Steel

 • Stellite

 • Titanium

 

 

 

 

 

Inspection / NDT / NDE

 

API Inspections

 • Aboveground storage tanks (653)

 • Piping (570)

 • Pressure Vessels (510)

Magnetic Flux Leakage (MFL)

 • MFL scanning of tank bottoms for the detection of soil side corrosion

Magnetic Particle Testing (MT)

 • Dry Particle

 • Wet Visible

 • Wet Fluorescent

Nuclear

 • ASME NQA-1 and 10CFR50 Appendix B compliant

Penetrant Testing (PT)

 • Visible

 • Fluorescent

Ultrasonic Testing (UT)

 • Longitudinal Wave (Straight Beam) for the determination of thickness

 • Transverse/Shear Wave (Angle Beam) for the detection of

   discontinuities in test subjects

 • Phased Array (PAUT) for the multi-angled detection and graphic

   display of discontinuities in test subjects

 • Vessel Crawler / B-Scan / C-Scan

Visual Testing (VT)

 • Direct

 • Indirect (i.e. Borescope)

 

Test Subject Include:

 • Airframes

 • Autoclaves

 • Boilers

 • Bridges

 • Castings

 • Condensers / Chillers

 • Engine Parts and Frames

 • Forgings

 • Forgings, Castings, etc.

 • Gas Turbine Engines

 • Heat Exchangers

 • Lifting Hooks

 • Machined Parts / Machinery

 • Mechanical Components, Gears

 • Metals, Alloys

 • Pipelines

 • Piping

 • Pressure Vessels

 • Propellers

 • Reciprocating Engines

 • Roller Journals (Paper Machines)

 • Storage Tanks

 • Structural Parts

 • Structures (Buildings)

 • Tanks

 • Turbine Bores

 • Turbines

 • Welds

 

 

 

 

 

NQA-1

 

Zuuk Inspection, a division of Zuuk International has an ASME NQA-1 and 10CFR 50 Appendix B compliant Non-Destructive Testing program.   We provide support to spent fuel storage programs, new construction, maintenance, refurbishment and life management.

 

Zuuk Inspectors provide:

 • Accelerated Corrosion Inspections

 • CWI Certified Weld Inspections

 • MFL Magnetic Flux Leakage

 • MT Magnetic Particle Testing

 • PAUT Phased Array Ultrasonic Testing

 • PT Liquid Penetrant Testing

 • UT Ultrasonic Testing (Shearwave)

 • VT Visual Testing

 

The United States has the most operating nuclear reactors in the world. One hundred and four (104) nuclear reactors currently operate in 31 states.  Nuclear power contributes 19% of the electricity in the U.S. today, providing 800 billion kilowatt-hours.  It comprises 70% of the nation’s carbon-free electricity and is the third largest source of electricity behind coal and gas.  After thirty years of near dormancy, there has been a resurgence in the nuclear power industry with four new nuclear units planned to be commissioned within the next ten years.

 

Nuclear Quality Assurance-1, normally referred to as “NQA-1”, is a standard maintained by the American Society of Mechanical Engineers (ASME) that provides requirements of controls needed in specific areas of a nuclear quality program.  As with most of ASME codes, the NQA-1 standard and certification is focused on safety standards of products, processes and documentation.

 

NQA-1 was developed using Mil Q 9858 and the Navy’s Nuclear Program, which was the Quality Assurance Program for the military as early as 1955.  The only major change since the 1960’s has been the addition of one new word — “software.”  By 1975, the American National Standards Institute (ANSI) was assigned overall responsibility for coordination among technical societies, development, and maintenance of nuclear power quality assurance standards to the ASME.   ANSI/ASME NQA-1, Quality Assurance Program Requirements for Nuclear Power Plants was first issued in 1979.  In the 1980’s, further guidelines were added (NQA-2, and NQA-3); however, in the early 1990’s the three standards were merged into one under the original NQA-1 title.

 

The standard is split into four parts:

1.      Requirements for Quality Assurance Programs for Nuclear

         Facilities.

2.      Quality Assurance Requirements for Nuclear Facility Applications.

3.      Non-mandatory Guidance and Application Appendices.

4.      Non-mandatory Appendices: Positions and Applications Matrices.

 

Part 1 includes (18) eighteen basic requirements of a quality operation including Inspection, Design Control, and Inspection, Test, and Operating Status.

 

The Nuclear Regulatory Commission (NRC) endorsed parts of the NQA-1 as far back as 1983, but was not always ready to adopt the standard in its entirety.  By 2010, the NRC reported the latest version of NQA-1 to be more definitive than the ISO 9001 requirements.  Historically, the Department of Energy (DOE) was more supportive of the standard at nuclear facilities, including next generation nuclear power plants, mixed oxide fuel fabrication facilities, defense waste processing facilities, and others.

 

NQA-1 is constantly being revised to ensure operational safety and to keep pace with technology.  The current version was released in 2013 (NQA-1-2012), however the most commonly used version is NQA-1-2008 [with the NQA-1a-2009 addendum], which is endorsed by the NRC.

 

 

 

 

PAUT

Phased Array

 

Phased array ultrasonic testing is based on principles of wave physics.  The term phased refers to the timing, and the term array refers to the multiple elements.  The PA probe consists of many small elements, each of which can be pulsed separately. One element is pulsed first, and emits a pressure wave that spreads out like a ripple on a pond (largest semicircle). The next element is pulsed, and emits a ripple that is slightly smaller than the first because it was started later. The process continues down the line until all the elements have been pulsed. The multiple waves add up to one single wave front travelling at a set angle.  Beam steering and focusing capabilities are key in enhancing resolution, which results in faster inspection time and increased probability of detection.

 

Unlike conventional and automated ultrasonic testing, which is performed for fixed angles of 45, 60 and 70 degrees, phased array testing can cover all angles in this range simultaneously. This is significant as a single phased array inspection can cover all angles from 40 to 75 degrees and displays the image in real time. The real time image is a direct superimposition of the ultrasonic illumination on the test piece and is easy to interpret. Using swept angle S-scans, PAUT requires smaller surface distance for inspection compared to AUT or manual UT. PAUT can cover a large cross-section of the test piece from a single probe location.  Through the testing of sample plate and pipe sections, PAUT has proven its ability to detect weld flaws such as:  toe cracks, center line cracks, lack of fusion, lack of penetration, slag and porosity.  Additionally, the ability of PAUT to minimize the focal spot size at a defect location has allowed for increased accuracy of flaw sizing.

 

PAUT’s Advantages

 • More Information about a defects characteristics

 • Repeatability

 • Portability

 • Ease of set-up

 • C-Scan

 • Easy to Interpret

 • Compatible software that can export measurements into

   spreadsheets

 • A three-dimensional image that provides the exact location of defects

 • Ultrasonic waves successfully interact with planar defects

 • The scan is in real time, so the operator can see potential problems

   as soon as the transducer(s) crosses over it

 • A flaw can be immediately examined without additional setup or

   development

 • There is no radiation / inherent hazard

 • It is not necessary to clear an area for testing, nor is it necessary to

   stop production

 • Only one inspector is required

 

 

 

 

 

 

 

Piping

 • BPE and High Purity

 • Food and Beverage (FDA)

 • Modular Skid Systems

 • Power Piping B31.1

 • Process Piping  B31.3

 • System Design

Zuuk provides Process Piping for:

 • Chemical

 • Gas/Oil

 • Hydraulics

 • Pneumatics

 • Potable Water

 • Steam Piping

 • Underground Utilities

Welding Capabilities:

 • Shield Metal Arc Welding (SMAW) – Stick

 • Gas-Tungsten Arc Welding (GTAW) – Tig

 • Gas-Metal Arc Welding (GMAW) – Mig

 • Flux-Core Arc Welding (FCAW)

 • Oxy-Fuel / Braze Welding

 • Orbital Welding (Autogenous & Wire-Fed)

Materials Welded:

 • Aluminum

 • Bronze Alloys

 • Carbon Steel

 • Carpenter 20 CB3

 • Chrome Molybdenum (Including P-91 and P-92)

 • Copper Alloys

 • Duplex Stainless Steel

 • Hastelloy®

 • Nickel Copper (Monel)

 • Stainless Steel

 • Stellite

 • Titanium

 

 

 

 

Welding

 

 

Zuuk Industrial maintains a skilled welding staff, all of whom must qualify to Zuuk’s welding procedures in accordance with:

 • ASME

 • AWS

 • Lloyds Phases

 • Mil. Std. 248

 • US Coast Guard

 

Welding Capabilities:

 • Shield Metal Arc Welding (SMAW) – Stick

 • Gas-Tungsten Arc Welding (GTAW) – Tig

 • Gas-Metal Arc Welding (GMAW) – Mig

 • Flux-Core Arc Welding (FCAW)

 • Oxy-Fuel / Braze Welding

 • Orbital Welding (Autogenous & Wire-Fed)

 

Materials Welded:

 • Aluminum

 • Bronze Alloys

 • Carbon Steel

 • Carpenter 20 CB3

 • Chrome Molybdenum (Including P-91 and P-92)

 • Copper Alloys

 • Duplex Stainless Steel

 • Hastelloy®

 • Nickel Copper (Monel)

 • Stainless Steel

 • Stellite

 • Titanium

 

 

 

 

 

Other Industrial

 

 

Field Erection & Equipment Setting

 • Baghouses

 • Boilers

 • Economizers

 • Hydraulic Units

 • Modular Units

 • Paper Machines

 • Precipitators

 • Process Equipment

 • Pumps

 • Vessels

 

Leak Repair

 • Expansion Joint

 • Flange

 • Furnace

 • Heat Exchanger

 • Piping and Fitting

 • Pressure Seal Valve Bonnet

 • Pressure Vessel

 • Valve Body

 • Valve Packing

 • Valve Seat

 

 

 

 

 

Mailing Address
PO Box 70276
Charleston, SC 29415 ﷯

Phone Number
843.414.8500
Toll-Free: 888.421.0225

 

 

 

Fax Number
843.566.7258

 

 

 

Email
info@zuukmail.com

 

 

 

 

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