The inspection, maintenance, repair and demolition of industrial chimneys remains our core activity. The successful external and internal refurbishment of these structures requires a thorough survey to establish the true extent of the repair work required. A full digital survey is the first stage in a five-phase operation that includes access equipment design, installation, load testing and repairs. We offer an online hot camera inspection as digital photography can reveal weaknesses and defects that require attention, for example to the interior lining and brickwork, baffle walls and flue inlets. Critically, it also enables engineers to plan in advance of a shutdown.
Zenith has decades of experience in the inspection, maintenance and repair of industrial steel chimneys. Overseen by our world leading team of structural engineers, we perform detailed inspections and structural engineering analysis, including design and execution scopes. We work for global leading companies in the power, petrochemical and cement sectors.
The inspection, maintenance, repair and demolition of industrial chimneys remains our core activity. The successful external and internal refurbishment of these structures requires a thorough survey to establish the true extent of the repair work required. A full digital survey is the first stage in a five-phase operation that includes access equipment design, installation, load testing and repairs. We offer an online hot camera inspection as digital photography can reveal weaknesses and defects that require attention, for example to the interior lining and brickwork, baffle walls and flue inlets. Critically, it also enables engineers to plan in advance of a shutdown.
We are able to generate 2D and 3D models from captured survey information and existing drawings. We can accurately determine revised capacities and assess the life extensions of existing structures and structural elements. Decay, loss of section, material properties, geometry and change of use are a number of variables that can affect the performance and life span of any building or structure. This can all be modelled to represent a snapshot in time and assist with determining the structural integrity of existing assets.
All of our software interfaces with our drafting resource allowing us to accurately schedule components for fabrication purposes or cost analysis. By merging this data with our software we can generate powerful and detailed 3D graphical representations of any structure, or structural element, to better present our analysis results to our clients. These models can also be used to assists in desk top reviews of operational requirements where lifting or sliding of complex fabrications require to accurately interface with (or bypass) existing structural components or services.
Zenith has a wealth of experience in the inspection and maintenance of ducts, flues and cyclones both internally and externally. We have developed safe and innovative access methods to facilitate time saving inspections and repairs in confined spaces. In addition, we offer a comprehensive replacement service.
Our inspection services are overseen by our dedicated team of structural engineers.
Working in demanding industrial environments including refineries, power stations and cement plants and often having to perform welding repairs during tight shutdown periods, Zenith provides a comprehensive range of welding repair services.
Whether welding is required at low level or even where welding at height requires the design and installation of safe and innovative access, Zenith provides industry leading solutions.
Welding Certification
BS EN 1090-3: 2019
BS EN 1090-2: 2018
BS EN 1090-1: 2009 and A1:2011
Flange Management Certification
Hand Torque Bolted Connection Techniques
Dismantle, Assemble and Hand Torque Flanged Joints
Hydraulically Torque Bolted Connection Techniques
LOKRING®
Zenith is a trained and approved installer of the LOKRING® system and we are able to install:
• MAS-3000 Carbon Steel Series Pipe Fittings
• SS40 and SS-3300, 316L Stainless Steel Series Pipe Fittings
• CN-200 90/10 Copper Nickel Series Pipe Fittings
• CN-700 Copper Nickel Pipe and Tube Fittings
The main advantage in using the LOKRING® method is that it eliminates the need for hot works at height in a refinery environment or offshore.
We design and erect new steel chimneys, replacement liners for both steel and concrete chimneys, ducting design and installation, access ladders and platforms. Repairs and maintenance also fall within our remit, and where this is not feasible we undertake the demolition of the existing chimney.
This is in itself a complex operation as the chimneys can be up to 6500mm in diameter with each section running to 50m in length. Coupled with the fact that the chimneys are often in the proximity of other plant and facilities, this places considerable emphasis on completing the process with the minimum of disruption and the greatest of care.
Our online internal inspection using remote ‘hot camera is a proven safe method which allows for the identification of defects internally prior to the shutdown thereby permitting adequate planning time to pre-order materials and compile an accurate scope of works to carry out any repairs during the shutdown.
Utilising a combination of Zenith specialist access techniques, we provide a safe and extremely cost effective solution for the supply and replacement of expansion joints. Very often access proves to be an issue. Our world class structural engineers design innovative access methods proving to save significant time, which is a crucial aspect of any turnaround.
In addition, we perform a comprehensive range of industrial cladding services to structures throughout the industrial sector.
Zenith provides a comprehensive guy wire service for structures such as flare stacks, steel chimneys and masts. In addition, we specify and supply complete guy wire requirements.
Our dedicated team of fully qualified inspection engineers also facilitate all on-site access requirements throughout the full length of the guy wires. Following the survey, all of the information obtained is fed back to our Structural Engineers who compile detailed inspection reports complete with recommendations.
Please refer to the list below for our full range of guy wire services.
Magnetic Inspection (LMA and LF)
Of particular note is our Magnetic Inspection (LMA and LF) service. Electromagnetic tests provide valuable additional information on the condition of wire ropes and are regarded as a useful addition to the visual inspection, particularly, where difficult access precludes a meaningful visual survey.
The permanent magnets induce a magnetic field around the rope, any defect within the wire rope creates a stray field, and this is detected and recorded on the data logger.
As part of Zenith’s expanding portfolio of services, we are pleased to provide our clients with our PfCO CAA licensed UAV Inspection and Surveying Service carried out by our team of 7 qualified pilots.
We are able to generate 2D and 3D models from captured survey information and existing drawings. We can accurately determine revised capacities and assess the life extensions of existing structures and structural elements.
Decay, loss of section, material properties, geometry and change of use are a number of variables that can affect the performance and life span of any building or structure. This can all be modelled to represent a snapshot in time and assist with determining the structural integrity of existing assets.
A UAV inspection allows for a visual examination of structures providing photographic and video records. Following the survey, a comprehensive report is compiled by our dedicated team of Structural Engineers. UAV inspections allow engineers to identify and assess the general condition of the structure. This combined with Zenith’s hands on survey capability offers clients a full suite of inspection services.
Our UAS platforms can be tailored to suit the prospective operation, whether it be for extended flight duration, thermography, high definition photo or video imagery.
Visual Survey
Using our 30x optical zoom camera we can capture detailed close-up video and still imagery, even when the survey environment does not allow us to fly close to the subject, such as operational flare tips and chimneys. Ideal for condition surveys and defect identification on buildings and elevated structures.
Our high-resolution cameras are capable of 20Mp images and up to 5.2k definition video for high quality media for project highlights and marketing.
Thermographic Survey
Our thermal camera uses a specialized FLIR Tau 2 thermal sensor and a 4K visual camera along with image processors to render the results on a visual display. We have the capability to interrogate and interpret the survey data to identify temperature differentials and defects.
Orthomosaic and 3D Point Cloud
We can create high resolution orthomosaic images and 3D models of sites and structures by collecting a large number of individual overlapping photographs and processing them using specialised orthorectification software.
Topographic Survey and Volumetric Measurements
3D point clouds can be further developed and interrogated using specialist software to produce topographic (contour) maps and surfaces. Surfaces can be compared to enable volumetric calculations.
ROV Survey
Zenith also own an ROV for underwater inspections providing photo and video images.
