_______________________________________________________________________________________

OISD-STD-128
FOR RESTRICTED CIRULATION ONLY

INSPECTION
OF
UNFIRED PRESSURE VESSELS

OISD - STANDARD-128
First Edition, November 1988
Amended edition, August, 1999
Revised edition October, 2010

OIL INDUSTRY SAFETY DIRECTORATE

Government of India
(Department of Petroleum & Natural Gas)
Website : www.oisd.gov.in

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I
_______________________________________________________________________________________

OISD–STD-128
First Edition, November, 1988
Amended edition, August, 1999
Revised edition October, 2010
FOR RESTRICTED CIRULATION ONLY

INSPECTION
OF
UNFIRED PRESSURE VESSELS

Prepared by

FUNCTIONAL COMMITTEE ON
INSPECTION OF UNFIRED PRESSURE VESSELS

OIL INDUSTRY SAFETY DIRECTORATE

7TH Floor, NEW DELHI HOUSE,
27, BARAKHAMBA ROAD,
NEW DELHI - 110 001.
Website : www.oisd.gov.in

II
_______________________________________________________________________________________

NOTE

OISD publications are prepared for use in the Oil and gas
industry under Ministry of Petroleum and Natural Gas. These are the
property of Ministry of Petroleum and Natural Gas and shall not be
reproduced or copied and loaned or exhibited to others without written
consent from OISD.

Though every effort has been made to assure the accuracy

and reliability of the data contained in these documents, OISD hereby
expressly disclaims any liability or responsibility for loss or damage
resulting from their use.

These documents are intended only to supplement and not to

replace the prevailing statutory requirements.

III
_______________________________________________________________________________________

FOREWORD

The Oil Industry in India is nearly 100 years old. Due to

various collaboration agreements, a variety of international codes,
standards and practices have been in vogue. Standardisation in
design philosophies and operating and maintenance practices at a
national level was hardly in existence. This, coupled with feed back
from some serious accidents that occurred in the past in India and
abroad, emphasized the need for the industry to review the existing
state of art in designing, operating and maintaining oil and gas
installations.

With this in view, the Ministry of Petroleum & Natural Gas, in

1986, constituted a Safety Council assisted by Oil Industry Safety
Directorate (OISD), staffed from within the industry, in formulating and
implementing a series of self regulatory measures aimed at removing
obsolescence, standardising and upgrading the existing standards to
ensure safer operations. Accordingly, OISD constituted a number of
Functional Committees comprising of experts nominated from the
industry to draw up standards and guidelines on various subjects.

The present document has been prepared by the Functional

Committee on “Inspection of Unfired Pressure Vessels”. This
document is based on the accumulated knowledge and experience of
industry members and the various national and international codes
and practices. It is recognised that failure of internals of a pressure
vessel may only affect its performance and at most times may not
materially affect the safety of the vessel. However, it is also
recognised that failure of an internal component may lead to unit
upsets which in turn could lead to a leak of hydrocarbons. Keeping
this in view the Committee decided to include inspection of internals
also as a part of this standard. This document is meant to be used as
a supplement and not as a replacement for existing codes and
practices. It is hoped that the provisions of this document, when
adopted may go a long way to improve the safety and reduce
accidents in the Oil and Gas Industry. Users are cautioned that no
standard can be a substitute for the judgment of a responsible
qualified inspection Engineer. Suggestions are invited from the users,
after it is put into practice, to improve the document further.

This standard in no way super cedes the statutory regulations

of CCE, Factory Inspectorate or any other Govt. body which must be
followed as applicable.

Suggestions for amendments to this document should be

addressed to

The Co-ordinator,
Functional Committee on
“Inspection of Unfired Pressure Vessels,
Oil Industry Safety Directorate,
7th Floor, “New Delhi House”
27, Barakhamba Road,
New Delhi – 110 001

Website : www.oisd.gov.in

IV
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V
_______________________________________________________________________________________

FUNCTIONAL COMMITTEE MEMBERS

(Second edition October 2010)

S.N. Name Organisation Position in Functional

Committee
1. Mr. R. Wadhawan BPCL, Mumbai Team Leader
2. Mr. K.R. Soni IOCL Member
3. Mr. Krishna Hegde MRPL Member

4. Mr. D. Arthur Manohar CPCL Member

5. Mr. Balagangadharan, BPCL, Kochi Member

6. Mr. P.S. Murthy HPCL Member
7. Mr. L.R. Jain BPCL Member
8. Mr. J.P. Sinha IOCL, P/L Member
9. Mr. Debashis Mitra HPCL Member
10. Mr. S.C. Gupta OISD Member
11. Mr. Shamsher Singh OISD Member, Co-ordinator

FUNCTIONAL COMMITTEE MEMBERS (August 1999)

---------------------------------------------------------------------------------------------------------------------------
S.N. Name and Designation Position in Organisation Committee
---------------------------------------------------------------------------------------------------------------------------
1. Sh. R.K. Sabharwal CMNM-IOC (R & P) Leader
2. Sh.A.S. Soni DGM (P)-ONGC Member
3. Sh.R.H. Vohra DGM-(E) IOC (Mktg.) Member
4. Sh.D.P. Dhall CH INSP & AE MGR-BPC (REF) Member
5. Sh.P. Dasgupta Sr.Manager( Inspection) IOC Member
(R & P)
6. Sh.I.M. Advani MGR (PROJ) HPC (REF) Member
7. Sh.R.M.N. Marar Jt.Director OISD Member
Co-ordinator.
---------------------------------------------------------------------------------------------------------------------------
In addition to the above, several other experts from the industry contributed in the preparation, review
and finalisation of this document.

VI
_______________________________________________________________________________________

CONTENT
S. N. SECTION PAGE

1.0 Introduction 01
2.0 Scope 01
3.0 Definition 01
4.0 Role of Inspection 02
5.0 Stages of Pressure Vessel Inspection 02
6.0 Frequency of Inspection 03
7.0 Inspection Checks 05
8.0 Inspection During Maintenance 16
9.0 Re-rating of pressure vessels 16
10.0 Documentation 17
11.0 References 18

ANNEXURES:
I A Typical Pre-commissioning Check List 19
II A Typical Checklist for In service Inspection 21
III Guidelines on Pressure Testing of Pressure Vessels 23
IV Corrosion Rate and Remaining Life Calculation 25
V Inspection Documentation Cards (Forms) 26
VI Inspection of Welding 31
VII Hydrogen Blisters-inspection, Evaluation and Repair of 34
VIII Inspection Tools 36
IX Likely Areas of Metal Deterioration 37

VII
 OISD-128 1
__________________________________________________________________________________________

INSPECTION OF UNFIRED PRESSURE VESSELS

1.0 INTRODUCTION 3.4 HOLD POINT

Safety in petroleum installations comes A point in the repair or alteration

through continuous efforts at all stages. process beyond which work should not
It can be ensured by observing that proceed until the required inspection
plant & equipment are designed, has been performed and documented.
constructed, tested and maintained as
per established engineering standards; 3.5 INJECTION POINT
and subsequent modifications and
repairs are conforming to the same Locations where relatively small
standard. quantities of materials are injected into
process streams.
2.0 SCOPE 3.6 IN-SERVICE
This standard covers minimum Pressure vessel that have been placed
inspection requirements, types of in operation, as opposed to new
inspections, inspection frequencies, pressure vessel prior to being placed in
inspection procedures and repair service.
methodology for unfired pressure
vessels, including underground 3.7 MAXIMUM ALLOWABLE WORKING
pressure vessels installed in PRESSURE (MWAP)
hydrocarbon industry. This standard
excludes all mobile and portable The maximum gauge pressure
pressure vessels such as truck & rail permitted at the top of a pressure
wagon mounted, gas cylinders which vessel in its operating position for
are covered in other OISD Standards. designated temp

3.0 DEFINITIONS 3.8 NDE

3.1 AUTHORISED PERSON Non Destructive Examination

A qualified and experienced person 3.9 ON STREAM

authorized to perform pressure vessel
inspections by the owner organization. Pressure vessel has not been prepared
for an internal inspection and it is
3.2 APPLICABLE STANDARD containing any amount of process fluid.
.
Applicable standard refers to the 3.10 OUT OF SERVICE
original standard of construction,
unless the original standard of Pressure vessel containing no amount
construction has been superseded or of process fluid and has been taken out
withdrawn from publication, in this of stream/ service for performing
event, applicable standard means the inspections/ repair.
current edition of the appropriate
standard. 3.11 PRESSURE VESSEL
A pressure vessel is a closed container
3.3 DEFECT designed to hold gases or liquids at a
pressure different from the ambient
An imperfection, whose type or size, pressure.
exceeds the applicable acceptance
criteria
 OISD-128 2
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3.12 SHALL 5.0 STAGES OF PRESSURE

VESSEL INSPECTIONS
Indicates mandatory requirement.

3.13 SHOULD 5.1 INSPECTION DURING PRE-

COMMISSIONING
Indicates recommendation or that
which is advised but not mandatory The pre-commissioning inspection of
pressure vessels shall be performed to
3.14 Repair ensure that all examinations and tests
during fabrication, erection and hydro-
The work necessary to restore a testing have been carried out in line
pressure vessel to a condition suitable with the design standard/ approved
for safe operation at the design procedure. This inspection also
conditions. includes the scrutiny of all the related
records.
4.0 ROLE OF INSPECTION
A typical pre-commissioning checklist
The Authorized Person(s) performing is placed at Annexure- I.
the inspections shall be suitably
qualified and experienced. The 5.2 IN-SERVICE (EXTERNAL)
requisite criteria for deciding the INSPECTION
qualification and experience shall be
5.2.1 Each above ground pressure vessels
decided by the individual organization.
shall be subjected to external visual
Typical role of inspection personnel
inspection including aided visual
inter-alia is;
inspection techniques such as
thermography, X-ray profiling where
I) To prepare and implement ever applicable.
inspection schedules to meet
requisite standard, statutory and 5.2.2 The inspection shall determine the
or quality requirements condition of insulation, painting,
supports, cathodic protection, earthing
II) To measure and record the etc and allowance for expansion,
corrosion/ deterioration rates and general alignment of the vessel on its
to evaluate the current physical supports, small bore piping etc.
condition of the pressure vessel
for soundness for continuation in 5.2.3 Any deviation in the above or any sign
service. of leakage from nozzle flange/
mounting shall be investigated to
III) To co-relate the corrosion/ identify the cause to take corrective
deterioration rate with design life measures. Vessels shall be examined
for further run of the Pressure for visual indications of bulging, out of
Vessel. roundness, sagging and distortion

IV) To investigate the causes of 5.2.4 Inspection for corrosion under

deterioration and recommend insulation (CUI) shall be considered
remedial measures, such as short for externally insulated pressure
term and long term repairs/ vessels operating between - 4
replacements. degrees C & 120 degrees C and
vessels in intermittent service. This
V) To perform various stages of inspection may require removal of
inspections and maintain some insulation from suspected
inspection records & Pressure areas.
Vessel history.
5.2.5 Internally lined pressure vessels
operating at high temperatures shall
be checked for external hot spots to
assess lining condition.
 OISD-128 3
__________________________________________________________________________________________

5.2.6 Special attention shall be given to iii) Out of service for more than 6
pressure vessels in humid area, areas months
near to cooling tower and in areas
where corrosive chemical vapours are The duration of hydrostatic
present to check for external corrosion pressure testing shall be in line
and thickness reduction due to with the applicable code and not
exposure to corrosive stream. less than 30 minutes after
stabilization.
5.2.7 Whenever there is plant upset, those
pressure vessels which experience b) Austenitic stainless steel pressure
excessive pressure / temperature shall vessel shall be hydrostatic
be externally inspected immediately. pressure tested using water with
chloride content less than 50
5.3 OUT OF SERVICE PPM.
(COMPREHENSIVE) INSPECTION
c) Stress due to hydrostatic pressure
5.2.8 The out of service inspection of testing shall not exceed 90% of
pressure vessel shall be carried out to the yield stress of the material of
assess the integrity of the equipment, construction of the pressure
condition of internals and to determine vessel.
the corrosion rate to estimate the
remaining life. The inspection strategy/ d) Hydrostatic pressure test shall not
program shall be designed based on be carried out at metal
the likely hood and consequences of temperatures near the ductile-to-
damages because of the prevailing brittle transition temperature of the
internal service/ environment material.
conditions. The appropriate NDT
techniques such as Liquid penetrant e) Wherever the foundation,
test (LPT), Magnetic particle test internals like column trays and
(MPT), Ultrasonic test (UT), supports of the pressure vessel
Radiography etc. shall be deployed for are not designed for hydrostatic
condition assessment. load, suitable NDT or pneumatic
test shall be considered with due
5.2.9 The thickness for all major components approvals.
(shells, heads, and cone sections) and
a representative sample of vessel The guidelines on pressure testing
nozzles shall be measured, remaining of pressure vessels are given in
life and next inspection interval shall be Annexure III.
calculated for the limiting component.
Adequate number of thickness 6.0 FREQUENCY OF INSPECTION
measurement locations (TMLs) shall
be defined to establish general and The pressure vessel inspection
localized corrosion rates in different frequency regime shall be arrived at
sections of the vessel. so as to provide adequate
information, necessary to declare
5.2.10 Hydrostatic Pressure Testing that all the sections/ components of
the pressure vessel, including the
a) Hydrostatic pressure testing shall mountings, are safe to operate until
be carried out for pressure the next scheduled inspection.
vessels as per statutory
requirements and also under the The following factors shall be
following conditions; considered while arriving at the
inspection frequency regime for
i) After any major alteration / re- pressure vessels:
rating / replacement/ exposure
to fire. a) The nature of the fluid handled
along with its pressure and
ii) After chemical cleaning temperature
involving metal loss
 OISD-128 4
__________________________________________________________________________________________

b) The risk associated with In case, high corrosion rates are

operational shutdowns and start- observed and half the remaining life is
ups less than the above mentioned interval,
then the out of service inspection
c) Corrosion rates/ trends and interval shall be suitably reduced to
remaining corrosion allowance ensure that maximum inspection
interval shall not be more than half the
d) Increased corrosion rate due to remaining life. This is elaborated
exposure of surfaces to changed through examples as explained below;
environments
Example-1:
e) Findings and recommendations
of previous inspections 1. Total thickness allowance
available is 3 mm.
f) The location of pressure vessels
such as in isolated, high-risk and 2. Corrosion rate is 0.5 mm per
highly corrosive areas. year

g) The potential of air, water and 3. Remaining life = 3/0.5= 6 years

other environmental
consequences. 4. Half remaining life = 3 years

h) Corrosion prevention and leak 5 Hence out of service

detection systems. (comprehensive) inspection
interval shall not exceed 3
i) Applicable Statutory regulations years

Identifying and evaluating, potential

degradation mechanisms are important Example-2:
in assessment of probability or
likelihood of pressure vessel failure. 1. Total thickness allowance
Combining the assessment of likely available is 3 mm.
hood of failure and the consequences
of failure in the form of a risk matrix 2. Corrosion rate is 0.25 mm per
may also be considered. year.

6.1 IN-SERVICE INSPECTION 3. Remaining life = 3/0.25= 12

years.
Each above ground vessel shall be
externally visually inspected, once in 4. Half remaining life = 6 years
two years. Insulated vessels operating
between -4 deg C & 120 deg C shall 5. Hence out of service
also be externally inspected by (comprehensive) inspection
removing insulation pockets at select interval shall not exceed 5
locations. years

6.2 OUT OF SERVICE INSPECTION The corrosion rate and remaining life
shall be calculated as detailed in
The frequency of out of service Annexure-IV
inspection shall be determined based
on history, corrosiveness of the fluid 6.3 SPECIFIC INSPECTIONS
handled and operating conditions. The
periods between these inspections i) Pressure vessels installed in new
shall not exceed one half of estimated process plants shall be inspected
remaining life of the vessel based on based on licensor
corrosion rate. However, the interval of recommendations or within first 2
out of service inspections shall not years of operation to assess the
exceed five years. internal conditions at select
locations.
 OISD-128 5
__________________________________________________________________________________________

ii) Settlement shall be checked

ii) The internal inspection of initially within the first month
reactors and catalyst filled of operation till it gets
pressure vessels shall be carried stabilised and subsequently
out as and when the catalyst is along with external inspection.
dumped/ replaced. However, it is
recommended that in-situ iii) Foundation bolts shall be
metallography be carried out at inspected for corrosion and
the time of replacement of damage.
catalyst, if necessary. The
reactors and catalyst filled iv) The nuts on anchor bolts shall
pressure vessels shall be be inspected for tightness.
inspected externally every two
years and the internal inspection b) Skirts and Supports
shall be carried out within 10
years. i) Skirts shall be inspected for
corrosion, distortion and
iii) For pressure vessels where size cracking from outside as well
and configuration or lack of as from inside.
access makes vessel entry for
internal inspection physically or ii) Condition of steel shall be
operationally impossible, hydro- checked for external
test and external inspection shall corrosion by removing the
be carried out. concrete at cracked
locations.
7.0 INSPECTION CHECKS
iii) The weather proofing on the
Prior to initiating the inspection of extremities and fire proofing
pressure vessels, the complete history of structural supports shall
of the vessel, design parameters, be checked for water
service, original thickness, corrosion tightness.
allowance, corrosion rate and
vulnerable locations of corrosion shall iv) The condition of fire proofing
be ascertained. on support beams and skirts
shall be inspected for bulging
A sample list of tools required for and cracks.
pressure vessel inspection is attached
v) Skirt to shell weld joint shall
at Annexure-VIII. A Typical Checklist
be checked for cracking.
for In service Inspection is attached at
Annexure-II. The likely area of metal
deterioration are described in c) Support of Horizontal Vessels
Annexure-IX
Horizontal vessels resting on
concrete saddle supports where
Typical inspection procedures for major
water can accumulate and cause
pressure vessels are as detailed
external corrosion shall also be
below;
inspected. Horizontal vessels
operating at high temperatures
7.1 IN-SERVICE INSPECTION
shall be checked to ensure free
thermal expansion.
The following shall be checked during
the external inspection.
II) LADDERS,
I) FOUNDATION AND SUPPORTS STAIRWAYS,PLATFORMS
AND STRUCTURES
a) Foundations
a) These shall be inspected for
i) The foundations shall be corrosion, cracks, paint failure
checked for spalling and etc.
cracking.
 OISD-128 6
__________________________________________________________________________________________

b) Bolts and nuts shall be checked d) Check for full length engagement
for evidence of crevice corrosion. of thread connections.

c) Ladders shall be examined for VI) EXTERNAL INSPECTION OF

free movement to take up METAL SURFACE
expansion of the vessels.
a) The external surface shall be
d) Drain holes on the platforms inspected for any sign of
shall be checked for proper deterioration due to atmospheric
draining. corrosion, hydrogen blistering,
cracks, mechanical damage,
III) INSULATION AND buckling & bulging etc.
PROTECTIVE COATINGS

a) Insulation shielding shall be b) The weld joints and heat affected

checked for proper sealing at zones (HAZ) shall be checked
joints. visually for cracks. In case of
doubt it should be checked by
b) Condition of the metal dye penetrant test.
underneath shall be checked at
inspection window. c) Hot spots, which might have
developed on the outer surface
c) Paint or protective coating shall due to the failure of internal
be examined for peeling or linings of lined vessels, shall be
rusting. checked. The areas, which have
developed hot spots during
d) The insulation retaining rings service, shall also be checked for
shall be checked for moisture mechanical damage such as
trapping. gouges and dents, leaks, cracks
and oxidation of any external
IV) EARTHING CONNECTIONS stiffeners.

a) Earthing connections shall be d) Thickness measurement of the

examined for loose bolting, shell and domes may be taken
proper welding, and electrical from outside. Exact location of
continuity. thickness measurement may be
decided after internal inspection
b) The cable shall be examined for only.
broken strands.
e) LPG Bullets and spheres having
c) Earthing resistance shall be fire proofing on the outside
checked at intervals as outlined surface shall be examined for
in OISD-STD-137. cracks, spalling, bulging and
deterioration of fire proofing.
V) NOZZLES AND SMALL Appearance of rust stains on the
CONNECTIONS surface of fire proofing is an
indication of presence of
a) The nozzles shall be inspected corrosion of metal underneath. If
for any visible corrosion, damage above indications are apparent
and leaks. the fire proofing in suspected
areas shall be removed and the
b) The tell-tale hole in the external surface shall be
reinforcement pad shall be inspected for any corrosion.
checked for possible leaks.

c) Special attention shall be given

for suspected leaks/ corrosion at
nipples used for instrumentation
connections.
 OISD-128 7
__________________________________________________________________________________________

VII) MOUNDED STORAGE c) Cathodic Protection System

VESSELS
CP system of the vessel shall be
a) Vessel Settlement monitored as per the
requirements of OISD-STD-150.
i) Settlement of the vessel shall
be monitored once in six 7.2 OUT OF SERVICE INSPECTION
months and the readings shall CHECKS
be compared with the original
readings for identifying the The out of service inspections shall
overall and differential include both external and internal
settlements. inspections.

ii) The bottom nozzle supports 7.2.1 GENERAL CONSIDERATIONS

shall be adjusted so as release
undue stresses on it and also i) Pressure vessel entry shall be
provide support to it. made only with an applicable work
permit as detailed in OISD-STD-
iii) The frequency of monitoring of 105 on work permit systems.
the readings can be reduced to
once in a year if no differential / ii) The area to be inspected internally
further settlement is observed shall be decided based on the
in two consecutive inspections. history of the equipment. The
history shall supplement the
b) Mound External Surface standard inspection procedure of
the equipment.
i) The erosion protection layer of
the mounds shall be inspected iii) The tray man-ways shall be
for damage at six months opened and the complete
intervals and corrective action inspection shall be carried out.
for restoration shall be taken.
iv) Carbon steel nozzles may be
ii) Special attention shall be given hammer tested.
to the run wild vegetation on
the damaged spots. Drooping v) Small bore nozzles (less than
vegetation may indicate 50mm) are difficult to be thickness
presence of gas in the mound. surveyed ultrasonically. The
thickness may be determined by
iii) The bleeding of water along deploying digital radiographic
the mound bottom might techniques.
indicate the damage to the
impervious layer (e.g. UPVC vi) The lined nozzles shall be checked
sheet) laid on top of the thoroughly for leaks. Any leakage
mound. Similarly, visual will indicate damage of the lining.
inspection shall be carried out
in the bottom sand drains (if vii) If caustic is stored or used in a
provided) for the bleeding of vessel it shall be checked for
sand through drains. In such caustic embrittlement. The areas
cases, remedial action around the nozzles and in or
including repairs / replacement adjacent to weld seams are
of UPVC layer shall be under susceptible to cracking.
taken. Rain water
accumulation inside the mound 7.2.2 VESSELS IN HIGH TEMPERATURE
shall be avoided as this can SERVICE
lead to instability of the mound.
 OISD-128 8
__________________________________________________________________________________________

a) Pressure vessel which operates The inspection of a column can be

on thermal cycle like coke divided into the top, feed and bottom
chamber and at high temperature zones.
like orifice chamber in FCCU,
shall be thoroughly inspected from
outside for any possible bulging/
cracking.
a) Top Zone
b) In case of coke chamber, if the
entry of feed is at the bottom, i) Top dome, shell and internals in
insulation of at least 2 to 3 the top zone shall be visually
courses all around shall be inspected to locate corrosion,
removed. The skirt to shell weld erosion, hydrogen blistering,
joints shall be thoroughly checked cracking, mechanical damage
for cracks. The bottom flange etc.
welding with the shell shall also
be inspected. The weld joints, ii) Special attention shall be given to
heat affected zone (HAZ) and weld joints and surface
shell of 2 to 3 courses shall be conditions. If pits are noticed,
checked for cracks and apparent depth of pits should be
bulging etc. measured.

c) Presence of suspected cracks iii) Shell plates below the reflux

should be confirmed by using nozzle shall be inspected for any
suitable NDT techniques. possible grooving. Reflux
collector shall be checked for
7.2.3 Preliminary visual inspection thinning.

i) Prior to scheduled shutdown of iv) Spouts and counter spouts shall

the unit the pressure vessel shall be checked by hammer testing
be examined from the outside to for finding any possible
detect any unusual condition deterioration.
during operation, such as leaks in
nozzle welds through tell-tale v) The trays and valves/ bubble
holes or gaskets, the condition of caps shall be checked for pitting
the bolts and flanges, the and cracking.
apparent condition of insulation
and any other visible defects. vi) Thickness of dome and shell
shall be checked in all four
ii) During shutdown, before cleaning compass directions (E, W, N and
the column/ vessel from inside, S). Thickness in dome section
preliminary internal inspection shall also be taken in the knuckle/
shall be done. Observations crown area. Thickness around all
regarding internal dislodging etc. the nozzles shall be taken.
shall be noted. Samples of
deposits shall be collected for vii) Sample thickness of column
analysis. Preliminary inspection internals like downcomer,
shall reveal the areas having downcomer collectors and
deposits, scales etc. requiring support plates should be taken.
thorough cleaning to detect metal Besides this, if at certain
wastage underneath the deposits locations of shell or dome,
during detailed inspection. After corrosion is observed thickness
the preliminary inspection, internal shall be measured at these
cleaning shall be undertaken. locations to know the exact loss.
Shell at the downcomer collector
7.2.4 DETAILED INTERNAL INSPECTION level shall be checked for any
possible liquid level corrosion in
I) VERTICAL VESSELS (COLUMNS) the form of grooving.
 OISD-128 9
__________________________________________________________________________________________

viii) Reference points should be spool piece shall be thickness

marked on shell, dome and surveyed.
nozzles and same should be
monitored for thickness during vii) All nozzles in distributor shall be
every inspection to determine checked for blockage, erosion
rate of metal wastage. etc.

ix) To check the condition of tray viii) In case of insulated column,

support ring (TSR) at select insulation around nozzles should
locations, the tray sections shall be removed to check for surface
be removed. condition and facilitate thickness
survey.
b) Feed Zone
ix) Wherever, it is not possible to
i) The impingement plate shall be measure thickness from both
checked for any corrosion, inside and outside, ID
erosion and proper attachment measurements from inside shall
with shell. be taken to determine thickness.

ii) Shell plates shall be inspected II) PRESSURE VESSELS IN

near the impingement plate for SPECIFIC SERVICE
erosion and attachment weld -
cracks. a) Hydrogen Service

iii) The internals shall also be Pressure vessels in hydrogen

inspected. Thickness of the service shall be thoroughly
shell plates in four directions and inspected for possible hydrogen
the impingement plate shall be damage like blistering, cracking,
taken. embrittlement etc. Hydrogen
damage shall be inspected and
iv) Sample thickness shall also be evaluated as outlined in Annexure
taken on internals. VII.

c) Bottom Zone b) DEA/ MEA/ Caustic Service

i) Bottom dome and shell shall be Spot checking of T-weld joints

inspected to measure the shall be carried out for possible
thickness around bottom draw- surface/ sub-surface cracks in the
off. heat affected zone (HAZ). If
defects or cracks are detected,
ii) If pitting is observed, pit depth 100% weld joints shall be
should be measured. checked.

iii) At steam injection points, the c) Vessels in Sour Service

shell plate opposite to steam
nozzles shall be thoroughly Vessel operating in sour service
inspected for possible of carbon steel metallurgy shall be
impingement. inspected with suitable NDT like
Wet Fluorescent Magnetic Particle
iv) All internal piping etc. shall be Inspection (WFMPI), Eddy
inspected for any thinning, Current etc. to identify the
corrosion, deterioration, surface / sub surface cracks.
mechanical damage etc. Ultrasonic shear wave is deployed
for sizing of defects after
v) Thickness and hammer testing detection. Longitudinal Ultrasonic
wherever possible should be examination is deployed to find
carried out. out metal loss and sizing / location
of blistering. Avoid high hardness
vi) All the nozzles including the zones at weld / HAZ area. Limit
manhole nozzles and retractable
 OISD-128 10
__________________________________________________________________________________________

the weld / HAZ hardness to 22 stainless steel which are prone

HRC and below. for Polythionic Acid attack shall
be passivated as per the
d) Vessels in Liquid Nitrogen procedure given NACE RP 0170
Service before opening. Passivation shall
be done as per the process
i) The liquid nitrogen storage vessel licensor’s recommendations.
is typically jacketed, made of
inner & outer vessels. The ii) All the integral cladding shall be
metallurgy of inner vessel is checked for bulging, erosion,
austenitic stainless steel and the disbonding etc.
outer vessel is carbon steel. The
annulus between inner & outer iii) In case of strip-lined vessels
vessel is filled with Perlite individual strips and associated
insulation and vacuum is welding shall be visually checked
established. The outer shell and for bulging and cracks. Special
nozzles shall be checked for attentions shall be given to the
metal loss and the welds shall be weld joints and heat affected
checked for any visible external zones (HAZ), where cracking can
corrosion. take place. If cracks are
suspected, dye penetrant test
ii) The annulus space vacuum shall should be carried out. The
be monitored to identify inner integrity of strip lining should be
vessel leaks checked with air and soap
solution. Thickness of the strips
iii) Pneumatic test or test with liquid shall be measured at select
nitrogen (operating medium) for locations to ascertain the thinning
inner vessel is done at 1.1 times out of strips. The areas where the
the design pressure. strip lining leaks have been
noticed, a detailed inspection
Before carrying out the test, the shall be carried out to check the
safety valve should be set to the base metal condition. Thickness
designated pneumatic test survey of the strip lined column
pressure to avoid over shall be done from outside to
pressurization of inner vessel check the parent material
and the condition of burst / thickness.
rupture discs in the vessel shall
be checked for healthiness. iv) The integrity of nozzle liner shall
be pneumatically tested at
While using operating medium as pressure not exceeding 0.5
the test fluid (cryogenic liquid), Kg/cm2.
the inner vessel shall be
pressurized by allowing the v) The junction of lined and unlined
cryogenic liquid to vapourize and sections shall be checked for
to develop the test pressure. The galvanic corrosion.
pressure shall be held for at least
one hour. f) Internally Painted/ Coated
Vessels
After satisfactory completion of
pressure test, the cryogenic i) Painting shall be visually
liquid is gradually released from inspected and dry film thickness
the inner shell to reach the (DFT) shall be measured and
operating pressure and the compared with original DFT.
safety valve is reset to the design
set pressure. ii) FRE/ FRP linings shall be visually
checked for mechanical damage,
e) Internally Lined Vessels cracks and holidays. Thickness
of the pressure vessel shall be
i) Austenitic stainless steel columns measured from outside
and columns lined with austenitic
 OISD-128 11
__________________________________________________________________________________________

The temperature limitations of the subjected to erosions due to

painting/ coating systems used catalyst movement. Therefore,
inside the vessel should be each internal parts and the
known. While shutting down a abrasive resistant lining shall be
unit, water flushing shall be checked for erosion damage.
resorted to instead of steam
flushing or as recommended by The additional specific checks for
the paint manufacturer. The reactor are as follows;
painted surface shall be cleaned
by water washing and then i) Thermo-wells shall be inspected
mopped. Cleaning with wire for oxidation, cracking or
brush shall not be resorted to. distortion.
Man entry shall be by wearing
soft-shoes. ii) Cyclone assembly shall be
inspected at locations like inlet
7.2.4 SPECIFIC INSPECTION CHECKS horns, volute, dust bowl, gas
FOR PROCESS UNITS risers etc for erosion.

I) Fluidized Catalytic Cracking Unit iii) Dip leg along with flapper/ trickle
(FCCU) valve shall be inspected for
erosion/ perforations/ plugging.
a) Reactor/ Regenerators/
Strippers of FCCU iv) Other internals like deflector
plate lining, grid cone lining and
i) In catalytic Reactors and riser pipe shall be checked for
Regenerators, the supporting bars erosion.
for internal equipment such as
cyclones shall be closely v) Stripper shell and steam nozzle
examined for erosion, crack etc. shall be inspected for erosion.
The cyclone assemblies, air
distributor, disengaging device, vi) Condition of the lining in the feed
internal abrasion resistant lining riser pipe shall be checked.
etc. are susceptible to catalyst
erosion and shall be closely vii) Inspection of steam and catalyst
examined. feed injections piping and
nozzles shall be carried out.
ii) Welding of the air grid supporting
rings shall be checked for erosion viii) In the plenum chamber, shell
and cracking. Out of roundness shall be inspected for erosion
or bulging may be evaluated by and thickness measurements
measuring the diameter of the shall be taken.
vessel at the cross section of
maximum deformation and ix) In the anti-coking chamber,
comparing it with the original peripheral holes shall be
diameter. If the bulging is at checked for plugging.
intervals, the measurement can
be done by dropping a plumb line x) Cyclone supports should be
and taking the measurements at checked for erosion/cracking.
selected intervals. This shall also
reveal the contour of the shell. xi) Dissimilar weld joints exist in the
riser pipe these should be
b) REACTORS checked for cracks.

The reactor vessel operates in xii) The Reactor and Regenerator

creep range; hence it is subjected stand pipes shall be examined
to metallurgical degradation due for failure of internal lining and
to high temperature exposure. It is metal deterioration.
mandatory to assess the creep
damage levels by micro structure xiii) The expansion bellows in the
examinations. The internals are stand pipes shall be checked for
 OISD-128 12
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internal erosion of sleeve, viii) Air distributor/ grid plates shall be

refractory lining, perforation of checked for bulges/ erosion and
convolutions etc. thickness.

xiv) The slide valve internals shall be ix) Nozzles in the air distributor
examined for erosion and proper assembly shall be checked for
operation. internal erosion. Grid plate shall
be inspected for cracks or
perforations. Overflow well and
seal boxes shall be checked for
c) REGENERATOR erosion and perforations.

The regenerator vessels are x) Lining of the cone below the air
normally provided with internally grid shall be inspected for
erosion resistant insulating cast- possible refractory damage.
able refractory. Based on the in
service thermography survey, the xi) Auxiliary burner tips, air door and
identified areas of possible the pilot shall be inspected
refractory damage shall be visually.
internally inspected.
d) ORIFICE CHAMBER/ DOUBLE
The additional specific checks for DISC SLIDE VALVE (DDSV)
regenerator are as follows;
i) The orifice chamber shell shall be
i) The refractory lining shall be inspected for erosion and bulging
checked for erosion, spalling, at baffle locations.
cracking etc.
ii) The areas just after the Double
ii) Particular attention should be Disc Slide Valve (DDSV) shall be
given just near big manway and inspected critically.
in the areas of possible
turbulence. iii) The holes/ sleeves on the grid/
baffle plate shall also be
iii) Aeration connections, thermo- examined for increased diameter
wells and trickle valves shall be due to erosion.
inspected for possible erosion
and damage. iv) The DDSV internals shall be
examined for erosion and proper
iv) Cyclone assembly shall be operation.
inspected at locations like inlet
horns, volute, dust bowl, gas II) HYDROCRACKER/
risers etc for erosion. HYDROTREATER

v) Dip leg along with flapper/ trickle Reactor / pressure vessels including PSA
valve shall be inspected for (pressure swing absorber) vessels are
erosion/ perforations/ plugging. subjected to following degradation
mechanisms;
vi) Lining of the plenum chamber
and stack above the plenum a) Metallurgical Degradation
chamber shall be inspected. If
the plenum chamber is of SS i) High Temp. Hydrogen attack
material, the bimetal weld joint
ii) Temper Embrittlement
between chamber and shell shall
be examined from inside. iii) Sigma phase formation /
Sensitization of class 300 SS
vii) Steam rings shall be inspected
for oxidation/ erosion. iv) High temperature Stress Rupture

b) Corrosion Degradation
 OISD-128 13
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In case of any defects are found then

i) Ammonium Bi-sulfide corrosion Carry out fitness of Service analysis
and avoid repairs if possible. The
ii) Polytheonic acid corrosion equipment with Carbon steel / C-1/2
Mo steel is most likely affected
iii) Wet H2S cracking equipment of hydrogen attack.

• Sulphide stress corrosion Reactor screens are mostly affected by

cracking Sulfidation corrosion. The equipment
• Hydrogen induced cracking which are operating beyond design
limit are to be checked thoroughly for
• Stress oriented hydrogen Sulfidation corrosion. Fractionator flash
induced cracking zone is prone to Sulfidation attack.

iv) High temperature H2-H2S Specialized Ultrasonic inspection

techniques like back scatter; velocity
v) Naphthenic acid Corrosion ratio, high sensitivity shear wave etc
may be deployed for detection of high
Common problems with Reactor temp hydrogen attack (HTHA).
vessels are Gasket ring groove Normally SS cladding reduces the
cracking, Cracks near bottom cone effective hydrogen diffusion since it is
attachment, Tray attachment weld much slower when compared to ferritic
cracks, Nozzle weld cracking, Mid wall steel hence it is generally exempted
weld cracking etc. from HTHA attack.

Typical checks for reactor components Injection points including small bore
are as given below; piping and instrument tapings are to be
carefully examined using B-scan or
radiographic inspection techniques.
S.N. Component Inspection
Techniques III) MOUNDED STORAGE VESSEL

1 Tray & Catalyst Visual, Liquid a) All the weld joints of the vessel shall be
support cone penetrant examined through NDT techniques like
attachment welds Testing Wet Fluorescent Magnetic Particle
method, Dye Penetration Test
hardness survey, and ultrasonic flaw
2 Wire Mesh Visual detection to ensure the integrity of the
joints.

3 Thermo well Visual, Liquid b) The wall thickness of the vessel shall
penetrant be measured ultrasonically.
Testing
c) In case of any indication of defect or
metal loss, the mound cover of the
4 Gasket Ring Liquid vessel shall be removed to expose
Groove penetrant the outer surface for necessary
Testing examination from outside, if required.

Any repairs or modifications

5 Nozzle & Manway WFMPI, AUT
undertaken shall be after due approval.
Welds
d) Vessel shall be subjected to hydro test
6 Skirt Attachment LPT,WFMPI,
once every 10 years or at every
welds AUT
welding to the vessel (repairs or new
connections) whichever is earlier, by a
7 Girth / WFMPI & AUT
competent person and records
Longitudinal
maintained.
welds
 OISD-128 14
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e) The settlement of the vessel shall be

checked at least at 3 points along the Corrosion coupons are installed in the
length of the vessel. pressure vessels to evaluate
accurately the corrosion rate or to
Special attention shall be given to
evaluate a new material in the existing
those areas where external coating
environment. While doing the internal
deterioration is more likely to occur viz.
inspection the corrosion coupons if
near supports, fittings, reinforcement
installed should be taken out. Nature
rings, field welds, bottom nozzles etc.,
of corrosion attack on the corrosion
while carrying out NDT.
coupons shall be studied. The
coupons are then thoroughly cleaned
During visual inspection on the
and weight loss in a specified length of
internals of the vessels, special
time shall be calculated. This gives the
attention shall be given to the stiffeners
corrosion rate and cleaned coupons
for identifying the following:
are again installed for future
evaluation. Corrosion probes may be
installed at vulnerable locations on the
i) Local instability in the stiffeners
pressure vessels for on-stream
ii) In-plane buckling monitoring of corrosion rates.
Coupons and probes can be either
iii) Shear buckling of the web
fixed or retractable type.
iv) Flange induced buckling
7.5 SAFETY RELIEF DEVICES

IV) RUBBER LINED PRESSURE The safety valves and safety relief
VESSEL valves on the pressure vessels should
be periodically inspected and tested as
The rubber lining shall be inspected for per OISD-Std-132.
mechanical damage, holes, cracking,
blistering, bonding etc. Holes in the 8.0 SPECIFIC INSPECTIONS,
lining are evidenced by bulging. A REPAIRS AND CHECKS
holiday detector should be used to
thoroughly check the lining for leaks AFTER REPAIRS
and holiday. Care must be taken so
that the test voltage does not approach 8.1 WELD BUILD UP
a value that might puncture the lining.
The test voltages shall be selected In pressure vessels where metal loss
based on the thickness of the rubber observed is limited to a small localized
lining. Inspection of rubber lined area and the remaining thickness is
vessels shall be carried out in line with less than the minimum required
IS-4682-Part-I. thickness, repair by local weld filling
may be required to build up the
V) RIVETED VESSELS thickness. The area to be repaired
should be marked and should be
Riveted vessels shall be examined for cleaned thoroughly. The area is filled
tightness of rivets, soundness of with weld deposits, in a staggered
caulking and seal welds and other manner to avoid warping, with suitable
conditions. For the insulated riveted electrodes matching with the base part.
vessel, insulation should be removed After weld build up, the area should
from all joints for checking as per inspected for cracks and defects.
statutory requirements. Thickness shall be measured
ultrasonically to check whether
7.3 MINIMUM/ RETIRING THICKNESS requisite thickness has been obtained.
Preheating and post weld heat
The limiting or retiring thickness of any treatment whenever required should be
pressure vessel shall be determined as carried out as applicable.
per the applicable design code to
which it has been manufactured. 8.2 NOZZLE REPLACEMENT

7.4 CORROSION COUPONS/PROBES

 OISD-128 15
__________________________________________________________________________________________

Thinned and deteriorated nozzles shall times the thickness of base metal
be replaced. New nozzles fabricated thickness measured from weld. The
out of piping having thickness PWHT shall be monitored by suitable
equivalent to original nozzles are number of thermo-couples.
installed. Welding including preheating
and post weld heat treatment shall be 8.3 PARTIAL REPLACEMENT OF SHELL
carried out as per approved procedure. PLATES AND DOMES
The weld joints shall be checked
visually and also by dye penetrant test. Some portion of shell plates and
Defects, if any, shall be repaired. The domes of pressure vessels may get
leaks from the nozzle welds shall be thinned due to corrosion or erosion.
checked by pressurising with air at a The thickness of the affected area may
pressure 1.03 kg/cm2 through the tell- reach the retiring thickness. In such
tale hole provided in the reinforcing cases, partial replacement of shell
pad. The integrity of repaired weld shall plate or dome is carried out as weld
be checked either by pressurizing the repair of the big area is not practically
entire vessel or by pressurizing local possible. The affected portion is cut
area. In some cases where the area is and removed. The new plates
accessible from inside, a box may be matching with the metallurgy and
provided externally around the nozzle. thickness of the original plate is made
The box is pressurised with water to available.
the test pressure of the column/vessel
calculated by applicable code. The The edge preparation shall be done as
weld joints and HAZ are checked for per the code requirement by grinding.
possible leaks. If any defect is found in The prepared edges shall be checked
the weld joints, these are gouged, re- for cracks, flaws and defects by
welded and retested. magnifying glass and by using dye
penetrant kit. The welding procedure
Pre heat and controlled deposition is developed for welding the old and
welding is to be considered in lieu of new piece as per the relevant code.
post weld heat treatment where PWHT The welding may be performed either
is unadvisable or mechanically from inside or outside. The root run
unnecessary. Prior to use any shall be thoroughly inspected for
alternative method a metallurgical cracks and flaws. After completing the
review needs to be conducted to find welding from one side, the other side is
out whether proposed alternative is chipped and grounded. Before welding
suitable for application. The review again, the groove is checked for cracks
should consider reason for original and defects. Welding is then
PWHT, susceptibility to cracking, completed from the other side.
stresses in the location of welding, high Complete welding shall be visually
temperature Hydrogen attack, checked and radiographed as per the
susceptibility to creep damage etc. applicable code. Detailed inspection of
welding shall be done as outlined in
The controlled deposition welding shall Annexure VI.
be considered for material limited to P-
1, P-3 & P-4 steels only. A detailed Preheat and post weld heat treatment
weld procedure specification shall be shall be carried out as per the
developed and qualified for each requirement of relevant code. In order
application. to check whether post weld treatment
has been carried out properly,
The welding technique shall be hardness readings on the weldment
controlled deposition temper bead or and HAZ shall be taken after PWHT.
half bead technique. The hardness readings should be
minimum as the indentation marks
Local PWHT may be substituted for all required during hardness
materials provided application is measurement act as stress riser and
reviewed and a detailed procedure is this leads to stress concentration. If
developed. The required post weld post weld heat treatment is required it
heat temperature shall be maintained is recommended to carry out
for a distance of not less than two radiography before post weld heat
 OISD-128 16
__________________________________________________________________________________________

treatment also. The defects in the 5 shall be examined for cracking by

welding are repaired by gouging and ultrasonics.
re-welding. In lieu of radiography,
ultrasonic inspection of weld joints may In case of low alloy steel vessels these
be carried out. examination needs to be carried out
after a delay of 24 hours in order to
8.4 REPAIR OF CLADDING AND take care of delayed cracking.
STRIPLINING
8.5 REPAIR OF PAINTED AND
The bulged, cracked or heavily pitted RUBBERLINED AREAS
cladding inside the pressure vessels
shall be repaired. The deteriorated If the painting in a small area of a
cladding is removed by cutting. The vessel has peeled off or has been
edges of the remaining cladding are damaged patch painting repair can be
sealed by welding, using proper done. The damaged areas shall be
electrodes as per cladding and shell painted with original painting system
metallurgy. If the area of the damaged with proper curing time etc. If the area
cladding is small, the area is weld of damage is large, the area is shot
overlayed using suitable electrodes. blasted to Swedish, standard Sa 2-1-/2
The area is then ground smooth. The to clean the surface and original
repaired portion shall be checked painting system is applied with proper
visually and by using D.P. for defects curing time. DFT is measured with
and cracks etc. The welding should be paint thickness gauge. If internal
done in a staggered manner to avoid rubber lining of vessels has bulged or
distortion of the shell. When the cracked in a small area, the
damaged area is big, after sealing the deteriorated lining shall be removed
remaining cladding, strip lining of the and fresh rubber lining is put in that
area can be done. (Details of strip small area. New lining shall be
lining and welding procedure is given in checked for holes and flaws. Local
Annexure - II). Bulged strip lining is curing should be done to achieve
replaced by puncturing the lining to hardness of 65 + 50A (shore hardness
remove entrapped air. The bulged A). When a large area of the rubber
portion of the lining is flattened by light lining has cracked and bulged, the
hammering and then welded. If the damaged lining is taken out. Bare
strip lining has cracked or heavily pitted metal is cleaned by shot blasting. New
the damaged lining should be removed rubber lining is provided. Curing shall
and fresh lining put. The weld joints be done to achieve 65 + 50A (shore
are checked for flaws and cracks by hardness A). The lining shall be
DP and visual examination. While visually checked for cracks, holiday
removing or puncturing the and bulging. The holidays shall be
cladding/strip lining, necessary checked by using holiday detector. For
precautions should be taken as inspecting the rubber lining IS-4682-
hydrocarbon may be entrapped in Part I shall be referred.
between the lining and shell.
8.6 HYDROSTATIC TEST
The equipment operating in high
temperature hydrogen service the After satisfactory repair & inspection,
following precaution shall be the column/ vessel shall be
considered. hydrostatically tested as per clause
5.3.3
a) Out gassing of base metals
The guidelines on pressure testing of
b) Hardening of base metals due to
pressure vessels are placed at
welding, grinding or arc gauging.
Annexure-III.
c) Pre-heat and inter pass
8.7 PNEUMATIC TESTING
temperature control
Pneumatic testing may be used when
Repairs shall be monitored closely. DP
hydrostatic testing is impracticable
testing shall be carried out after
because of temperature, foundation,
repairs. Vessels made of P-3, P-4 & P-
 OISD-128 17
__________________________________________________________________________________________

refractory lining or process reasons.

However, the potential personnel and iv) Pressure vessel shall be checked to
property risk of pneumatic testing shall affirm that required pressure relieving
be evaluated before such test is devices are present; are set at
carried. appropriate pressure; and have the
appropriate capacity at set pressure.
9.0 RE-RATING OF PRESSURE
v) All pressure vessel components in
VESSELS the system, such as valves, flanges,
bolts, gaskets etc. are adequate for
Re-rating pressure vessels by the new combination of pressure and
changing the temperature rating or the temperature.
MAWP shall be done only after all the
following requirements are met vi) Appropriate engineering records are
updated.
i) All re-rating shall be established in
accordance with the requirements of vii) A decrease in the minimum operating
the code to which the pressure temperature is justified by impact test
vessel was built or by computing results, if required by the applicable
using the appropriate methods in the code.
latest edition of the applicable code.

ii) Current inspection records verify that 10.0 DOCUMENTATION

the pressure vessel is satisfactory for
the proposed service conditions and Observations of each inspection shall
that the appropriate corrosion be properly recorded. After
allowance is provided. determining the corrosion rate and
remaining corrosion allowance, repair
iii) Re-rated pressure vessel shall be and replacement of a pressure vessel
leak tested in accordance with the can be planned. The following cards
code to which the pressure vessel as attached at Annexure-V shall be
was built or the latest edition of the used for proper documentation of the
applicable code for the new service Inspection findings:
conditions, unless documented
records indicate a previous leak test i) Data card (Ref. Form No. 1)
was performed at a greater than or
ii) Index card (Ref. Form No. 2)
equal to the test pressure for the new
conditions. An increase in the rating iii) History card (Ref. Form No.3)
temperature that does not affect
iv) Data record card (Ref. Form No. 4)
allowable tensile stress does not
require a leak test. v) Development sketch (Ref. Fig.5 & 6)
OISD-128 18
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11.0 REFERENCES

The following codes standards and publication have either been referred or used in the
preparation of this standard, and the same shall be read in conjunction with this standard.

i) API Guide for Inspection of Refinery Equipment - Chapter VI - Unfired Pressure Vessels.

ii) API Guide for Inspection of Refinery Equipment - Chapter V - Preparation of Equipment for
Safe Entry and Work.

iii) ASME - Pressure Vessel Code. Section VIII Divn. I & II.

iv) Indian Standard for Unfired Pressure Vessels - IS-2825.

v) BS-5500-Specification for Unfired Fusion Welded Pressure Vessels.

vi) API-510-(2007) Pressure Vessels, Inspection Code-Maintenance, Inspection, Rating,

Repair & Alteration.

vii) API-RP-572, Inspection of Pressure Vessels (Towers, Drums, Reactors, Heat Exchangers
and Condensers)

viii) IS-9964 Part-I, Preparation of Tank for Safe Entry and Work.

ix) IS-4682 part I, Code of practices for lining of vessels and equipment for chemical
processes-Rubber Lining.

x) Pressure Vessel Inspection Safety Code-Part 12 Institute of Petroleum.

xi) Engineering Equipment Manufacturers and Users association - EEMUA 190

OISD-128 19
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Annexure-I page 1 of 2

A TYPICAL PRE-COMMISSIONING CHECKLIST

The check list format shall contain the following minimum information.

a) Equipment No.
b) Serial No.
c) Date of Inspection
d) Equipment Type
e) Plant
f) Service
g) Design Code
h) Manufacturer
i) Main Dimensions
j) Material of Construction
k) Max. Allow. working pressure/Vacuum
l) Max. Allow. Working Temperature
m) PWHT Radiography (Spot/Full)
n) Hydrostatic Test Pressure

CHECKLIST

1.0 Check documentation like Material Test Certificate (MTC), Procedure Qualification
Record (PQR), welding procedure Specification (WPS), Welders Qualification Records
QAP etc.

2.0 Check records of stage inspections such as joint fit ups, pre/ post weld heat treatment,
Radiography & other NDT tests, hydro test etc.

3.0 Check and inspect all nozzle connections including drains and vents

4.0 Check and inspect all threaded connections for proper tightening

5.0 Check for adequate engagement of threads, back welding and gusseting

6.0 Check for any alteration/ deviation from the drawing during fabrication

7.0 Ensure proper installation of internals.

8.0 Check for internal cleanliness before final boxing up.

9.0 Measure and record base line data of wall thicknesses.

10.0 Check and ensure installation of specified gaskets, especially at the untested joints.

11.0 Check installation and set pressure of pressure relieving devices.

OISD-128 20
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Annexure-I page 2 of 2

12.0 Check correct installation (direction) of check/ globe/control valves.

13.0 Check proper bolting of flange joints.

14.0 Check for proper alignment

15.0 Check for tension free jointing of piping connected to pressure vessel

16.0 Check painting for Dry Film Thickness (DFT).

17.0 Check insulation and fire proofing for proper installation/ sealing etc

18.0 Check records of coating on under grounded/ mounded vessels for bonding/ thickness/

holiday testing.

19.0 Check performance of cathodic protection system

20.0 Check earthing connections

21.0 Ensure free movement of vessel (thermal expansion) with respect to adjoining

structure, platforms etc.

22.0 Ensure ladders and landing platforms are meeting the standard norms and practices.
OISD-128 21
_______________________________________________________________________________________

Annexure -II

A TYPICAL CHECKLIST FOR IN SERVICE INSPECTION

i) Carry out Ultrasonic thickness gauging of the vessel operating at lower temperature.
Larger the vessel, more readings are required to be assured of its condition. Record of
previous internal inspections can be utilized to locate the areas subject to corrosion.

ii) Inspect the equipment for any local hot spots by thermography / visual inspection
particularly for internally refractory lined vessels, local corrosion, and gasket leaks.

iii) Check for condition of protective coating, insulation and fire proofing of structural
members for adequacy of protection.

iv) Check the condition of bottom dished end to skirt weld for any rain water corrosion.

v) Check for bulging, out of roundness, sagging and distortion. If abnormality observed, the
overall dimensions of the vessel shall be checked to determine the extent of the distortion

vi) Check the condition of platform, hand rails and ladders for safety.

vii) Check the protective devices like safety valves, rupture discs for any passing / rupture.
Thermo-graphy may be used to detect the passing of safety valves. Ensure that the block
valves upstream and downstream of safety valves (if provided) are kept opened and car-
sealed.

viii) Check and monitor the process parameters like pressure, temperature, throughput,
change in feed stock, pH control, sulphur, chloride content which will have a slow but long
term impact on health of columns and vessels.

ix) Check the effectiveness and performance of corrosion inhibitors, caustic, ammonia and
other chemicals injected for corrosion protection.

x) Ensure the functioning of pressure gauges, temperature indicators and level gauges.

xi) Check the condition of anchor bolts and earthing connections.

All observations shall be recorded and filed in history file. In service inspection report shall be taken into
account for shutdown work list and planning.
OISD-128 22
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Annexure-III page 1 of 3

Guidelines on Pressure Testing of Pressure Vessels

1) Introduction

It is a statutory obligation and a requirement to carry-out a pressure test on certain equipment at

prescribed intervals. This section provides guidance on the pressure testing which may be carried-
out once the service life has begun.

2) Purpose

Pressure testing of pressure vessel is carried-out for a variety of purposes in addition to that
highlighted above.

a) Exposing inherent, major faults in a design or materials nature or serious errors

following a modification / repair.
b) Ensuring that no significant defect has been missed on inspection, either inadvertently
or because of inadequate access for visual or NDE.
c) Also, acts as a form of providing mechanical stress relief by levelling out of local areas
of high stress following a repair.

3) Circumstances calling for pressure test

a) Statutory requirements and as required by codes and standards

b) To verify basic design, strength and integrity of the equipment following a repair or
modification on it.
c) Following a change in design conditions (pressure / temperature combination)
d) Inadequate access preventing a meaningful inspection and a pressure test is
acceptable in lieu
e) To check the tightness of joints

4) Pressure test preparation

i) When a pressure test is to be conducted in which the test pressure will exceed the set
pressure of the pressure relieving device(s), the pressure relieving device(s) should be
removed. An alternative to removing the pressure relieving device(s) is to use test clamps
to hold down the valve disks.

ii) All gages shall be calibrated against a standard dead weight tester or a calibrated master
gage. Gages shall be recalibrated at any time that there is reason to believe that they are
in error.

iii) Dial indicating pressure gages used in testing shall be graduated over a range of about
double the intended maximum test pressure, but in no case shall the range be less than
1½ nor more than 4 times that pressure. Digital reading pressure gages having a wider
range of pressure may be used provided the readings give the same of greater degree of
accuracy as obtained with dial pressure gages.

iv) An indicating gage shall be connected directly to the vessel. If the indicating gage is not
readily visible to the operator controlling the pressure applied, an additional indicating gage
shall be provided where it will be visible to the operator throughout the duration of the test.
For large vessels, it is recommended that a recording gage be used in addition to indicating
gages
OISD-128 23
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Annexure-III page 2 of 3

5) Test pressure

Actual pressure used during a test depends on the objective of the test.

a) Strength Testing: In this case a stress level greater than that experienced in service is
induced (but lesser than that which would cause damage). Strength testing necessarily
demonstrates that the equipment can safely withstand the maximum service pressure
(at maximum operating temperature). The test pressure can be at the same level as
the original test pressure (new equipment), but normally it is slightly less to allow for
loss in thickness due to corrosion.

b) Leak Testing: It is carried-out where the objective is not to test the strength of the
equipment, but to detect the leakage (sometimes leakage rates). The pressure applied
is generally less than design pressure. Normally, it is carried-out to detect leak
tightness of gasket joints, tube to tube sheet joints etc.

6) Practical & Safety Aspects

6.1 Hydrostatic Testing

a) Some of the considerations which should be borne in mind during a pressure test are
equipment foundations & supporting structure, ability of line supports and vessels
nozzles to carry the test weight, ensuring that connected ancillary equipment
(instrument, valves etc) are capable of withstanding the test pressure, including static
head in the specified test pressure etc.

b) Other aspects to be considered are actual condition of the equipment. Usually,

equipment is not in the ‘new & cold’ condition of original construction. The test pressure
should be gradually applied – initially to a value of 50% of the specified test pressure;
thereafter the pressure shall be increased in stages of approximately 10% of the
specified test pressure until this is reached.
c) The required test pressure shall be maintained for not less than 30 minutes except in
the case of vessels less than 500mm diameter and 10mm thick. In such cases, it is
permissible for the test period to be subject of agreement. As a general practice,
minimum test duration of 30 minutes is considered adequate.

d) At no stage shall the vessel be approached for close inspection until the pressure has
been positively reduced to a level lower than that previously attained. “Previously
attained” pressure indicates maximum operating pressure attained by the vessel during
its service life. The pressure(s) at which the vessel will be approached for close
inspection shall be specified in the test procedure. Such pressures need not exceed
design pressure. Under such situations, after the equipment has withstood the
pressure for required time it is recommended to reduce the pressure to the equipment
design pressure before it is approached for a thorough inspection. However, this
precaution is not applicable in the case of leak testing (for gasket joints) since the test
pressure in this case will be normally less than design pressure.

e) Under similar safety precaution (new) equipment tested for integrity may be reduced to
2/3rd the test pressure before carrying-out close inspection. The reduced pressure so
stated incidentally corresponds to the design pressure or slightly less than the design
pressure.

f) On completion of hydraulic test, adequate venting shall be ensured before drainage.

This should be particularly taken care in the case of large thin vessels to prevent
collapse.
OISD-128 24
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Annexure-III page 3 of 3

g) The specified test pressure includes the amount due to static head acting at any point
under consideration. Particular care should be taken when applying a hydraulic test to
a vertically mounted vessel, which may have been tested initially in the horizontal
plane.

h) A point worth mentioning in this context refers to the precautions to be taken in case of
vessel supports fireproofed both from inside as well as outside. The internal condition
of the supports needs to be ascertained prior to water filling, especially in case of
equipment that have seen over 10 years of service. LPG spheres and some high-
pressure vessels/columns (will be fire-proofed on both sides) are some equipment that
come under this category.

i) For compartmented vessels, especially those with bellows, due attention shall be paid
to allowable internal pressure differences.

j) If a crack-propagation mechanism exists for the equipment, repeated pressure testing

can cause the crack to grow. Care needs to be taken in this respect. e.g; this can
include equipment in Amine, Caustic service etc and also equipment under cyclic loads
– Pressure Swing Absorbers (PSA) etc. The “care” to be taken in this respect refers to
pressure gradually applied as indicated in point ‘b’ above. However, care prior to
pressure testing also has to taken by carrying-out suitable NDT for any other crack
detection.

k) No vessel undergoing pressure testing shall be subjected to any form of shock loading.
e.g: hammer testing.

6.2 Pneumatic Testing

The consequences of failure during a pneumatic test can be devastating and such testing
requires special precaution. Some of the precautions to be taken are as follows:

a) The equipment should be subjected to thorough testing including NDT as considered

necessary to ensure that there are no inherent defects / operating deterioration which
may cause failure of the equipment during testing.

b) Except where it is necessary to meet design codes or statutory requirements, the test
pressure should be limited to 110% of design pressure for strength and to 100% of
design pressure for leak testing. Pressure should be applied in small increments. As a
practice of safety, equipment should not be subjected to pneumatic pressure beyond 1
kg/cm2g except for vessels/ piping systems that are specifically designed for pneumatic
pressure and where water entry into the system is not tolerated due to operational
reasons.

c) The pressure should be reduced to a pressure not exceeding design pressure before
any close examination is carried-out.
OISD-128 25
_______________________________________________________________________________________

Annexure-IV

CORROSION RATE AND REMAINING LIFE CALCULATION

The process/ procedure for Corrosion Rate calculation/ estimation shall be duly approved.

A. Remaining life of the pressure vessel shall be calculated as per the following procedure

Corrosion Rate = T (previous) – T (present)

---------------------------------------
Time between present and
previous inspections

T (previous) – Thickness reading taken during inspection

T (present) -- Thickness reading taken at present

Remaining life (Years) = T (actual) – T (minimum)

------------------------------------
Corrosion Rate
Where:

T (actual) = Actual minimum thickness

T (minimum) = Minimum required thickness as per applicable design code

B. For new pressure vessel and pressure vessels where service conditions are being changed,
the probable corrosion rate for determination of remaining life shall be determined using
following method;

i) Corrosion rate may be calculated from data collected on similar material and service

ii) If data on similar material or service is not available, then it can be estimated from
published data

iii) If corrosion rate can not be established from above, the thickness determination shall
be made immediately after 3 months of service by thickness measurement.
Subsequent measurements shall be made after appropriate intervals until corrosion
rate is established.
OISD-128 26
_______________________________________________________________________________________

Annexure-IV
INSPECTION DOCUMENTATION CARDS (FORMS)
FORM 1
VESSEL DATA CARD

INFORMATION WEIGHTS
DESIGN CODE_________________________ SHELL______________________________

MANUFACTURER_______________________ INTERNALS_________________________

MANUFACTURER’S INSULATION_________________________
ORDER NO.____________________________

DRG.NO.______________________________ EMPTY VESSEL______________________

JOB NO._______________________________ FULL OF WATER

DIMENSIONS OPERATING CAPACITY________________

TOTAL HEIGHT________________________ MATERIALS

HEIGHT BETWEEN TANGENTS__________
SHELL_________________________________

DIAMETER___________________________ HEADS_____________________________

WALL THICKNESS____________________ SKIRT_______________________________

TYPE OF HEADS______________________ BASE PLATE_________________________

CORR. BENCH MARKS_________________ MANWAY NOZZLE______________________

CONDITIONS
DESIGN TEMPOC_____________________ OPERATION TEMPO C_______________________

DESIGN PRESSURE KG/SQ.CM__________ OPERATING PRESSURE KG/SQ.CM____________

HYDROTEST PRESSURE KG/SQ.CM_____ CORROSION ALLOWANCE mm________________

STRESS RELIEVED____________________ RADIOGRAPHED____________________________

JOINT EFFICIENCY LONG SEAM________ HEAD_____________________________________

OISD-128 27
_______________________________________________________________________________________
OISD-128 28
_______________________________________________________________________________________
OISD-128 29
_______________________________________________________________________________________
OISD-128 30
_______________________________________________________________________________________

FORM 4

DATA RECORD CARD

UNIT_________

INSP. DESCRIPTION SIZE SCHDL ORG. RET. YEAR WISE THICKNESS

POINT THICKN THICKN
OISD-128 31
_______________________________________________________________________________________

UJ+
OISD-128 32
_______________________________________________________________________________________

ANNEXURE-VI page 1 of 3

INSPECTION OF WELDING

1. DUTIES OF WELDING INSPECTOR

The duties of a welding inspector usually involve the performance of a number of operations,
including:

i) Interpretation of drawings and specifications.

ii) Verification of the metal being welded.
iii) Verification of procedure and welder qualification.
iv) Checking application of approved welding procedures.
v) Verification of proper heat treatment.
vi) Assuring acceptable quality of welds.
vii) Preparation of records and reports.

2. INSPECTION PRIOR TO WELDING

i) The faces and edges of material should be examined for laminations, blisters, scabs
and seams.

ii) Heavy scale, oxide films, grease, paint, oil and moisture should be removed.

iii) The pieces to be welded should be checked for size and shape. Warped, bent or
otherwise damaged material should be detected in the early stages of fabrication.

iv) Edge preparations, bevel angle, alignment of parts and fit up should be checked. The
groove surface should be smooth (equivalent to machined/filled/ground surface). The
root gap should be uniform.

v) Tacks to hold alignment of joint must be checked for soundness. Tacks which are to
be included in weld must be done by qualified welders in accordance with the welding
procedure and must be of the same quality as root pass.

3. INSPECTION DURING WELDING

Visual inspection is employed to check details of the work while welding is in progress. The
details to be considered are:

i) Welding process
ii) Cleaning.
iii) Preheat and interpass temperatures.
iv) Joint preparation.
v) Distortion control.
vi) Filler Metal.
vii) Interpass chipping, grinding or gouging.

The inspector should be thoroughly familiar with the items involved in the qualified welding
procedures. Compliance with all details of the procedure should be verified. The root pass is
most important from the point of view of weld soundness. The root pass may be checked by
OISD-128 33
_______________________________________________________________________________________

ANNEXURE-VI page 2 of 3

dye-penetrant testing. The inspection of root pass offers another opportunity to inspect for
plate laminations.

In the case of double-groove welds, slag form the root pass on the side of the plate may from
slag deposits on the other side. Such deposits should be chipped, ground or gouged out prior
to welding the opposite side. Where slag removal is incomplete, it will remain in the root of the
finished welds. Emphasis should be placed on the adequacy of the tack welds and clamps or
braces used to maintain the root opening to assure penetration and alignment.

4. INSPECTION AFTER WELDING

Visual examination is the first stage in the inspection of a finished weld. The following quality
factors should be checked:

i) Dimensional accuracy of the weldment (including distortion).

ii) Conformity to specification requirements regarding extent, distribution, size, contour

and continuity of the welds.

iii) Weld appearance, surface roughness, weld spatter etc.

iv) Surface flaws, such as cracks, porosity, unfilled craters and crater cracks particularly
at the end of welds, undercutting, overlap, excessive weld reinforcement, excessive
grinding etc.

v) The areas where fit-up lugs were attached or where handling lugs, machining blocks
or other temporary attachments were welded on, must be checked carefully after the
attachment is removed. The area must be ground smooth and any pits or tears shall
be filled in with weld metal ground smooth Air hardening materials should be
preheated before any thermal cutting.

vi) Post-weld heat treatment time, temperature and heating/cooling rates. For groove
welds, the width of finished welds will fluctuate in accordance with the groove angle,
root face, root opening and permissible tolerances. The height of reinforcement
should be consistent with the specified requirements. Where not specified the
inspector may have to rely on his judgement, guided by what he considers a good
welding practice.

The finished weld should be thoroughly cleaned of oxides and slag for its final inspection.

After visual inspection the finished weld may be examined by one or more than one of the
following techniques.

5. NON DESTRUCTIVE TESTS

i) DYE PENETRANT TESTING: Unless otherwise specified, the extent of this test will
be 100% for all root runs for alloy steel welds. Adequate precautions as specified in
applicable code should be taken while interrupting the welding cycle.

ii) MAGNETIC PARTICLE TESTING

iii) RADIOGRAPHY: Unless otherwise specified the extent of radiographic examination

will be as follows:

a) carbon and carbon molybdenum steels-10% of the welds.

b) alloy steel - 100% of the welds. The weld joint for radiography will be marked
by the inspector.
OISD-128 34
_______________________________________________________________________________________

ANNEXURE-VI page 3 of 3

Radiographic examination of weld joints of two dissimilar materials shall be considered as per
the higher metallurgy stipulations.

iv) ULTRASONIC TESTING.

v) EDDY CURRENT TESTING.
vi) FERRITE DETERMINATION.
vii) ULTRASONIC HARDNESS TESTING

Hardness testing by portable hardness testers may be considered as NDT method. Hydraulic
testing may be done to check for leaks through welds, cracks etc.

6. DESTRUCTIVE TESTS

i) Mechanical tests like tensile, bend, impact, hardness, drift, flattening tests etc.

ii) Chemical analysis, microscopic examination, grain size determination etc.

The method and extent of examinations will be governed by applicable code requirements.

7. REPAIR OF WELDS

i) No repair should be carried out without prior permission of the inspector.

ii) Weld discontinuities which are beyond acceptable limits shall be removed from the
joint completely by the process of chipping and grinding.

iii) Where random radiography is specified, the first weld of each welder shall be
completely radiographed. In case of pipe size 150 mm dia. and below, the first two
welds shall be completely radiographed.

iv) For each weld found unacceptable due to a welders fault two additional checks
should be carried out on welds performed by the same welder.
OISD-128 35
_______________________________________________________________________________________

Annexure-VII page 1 of 2

HYDROGEN BLISTERS-INSPECTION, EVALUATION AND REAPIR OF

PRESSURE VESSELS

1. INSPECTION

A. Visually inspect exterior and interior of vessel to determine location of all hydrogen blisters.

B. Determine blister thickness by ultrasonic survey or by drilling.

C. Conduct magnetic particle inspection at the edge and crown of any blister 2 inches and greater
in diameter to locate cracks which originate at, or have progressed near to the surface.

D. In order to detect plate cracks (fissures), conduct magnetic particle inspection of the plate for a
distance of 6 inches beyond the limits of blisters 2 inches and greater in diameter appearing on
the inside of the vessel. See Figure 1.

2. EVALUATION

A. If the blisters are clustered and originate at varying depths, replace the plate.

B. If plate fissures are detected under Paragraph II. F, replace the affected plate.

C. Hydrogen blisters visible in the cylindrical section of the shell, the crown of flanged and dished
or elliptical heads or in hemispherical heads and those that are away from seams of localised
loading such as support pads should be considered acceptable.

D. Hydrogen blisters visible in and very near highly stressed areas such as head knuckles,
openings, seam and seam junctures, and support pads should be considered unacceptable in
pressure vessels.

Affected components should be repaired or replaced following duly approved procedure.

E. If the diameter of any blisters listed in paragraph III.C exceeds the thickness of the plate, and
the vessel is operated below the metal transition temperature, the material should be replaced.

USE ASME Code, Section VIII Division 2, impact Test Exemption Curves for Carbon Steels.' as
a measure of transition temperature.
OISD-128 36
_______________________________________________________________________________________

Annexure-VII page 2 of 2

3. REPAIRS

A. Cracked blisters on the outside surface of vessels in hydrofluoric acid service and cracked
blisters on either inside or outside surfaces of vessels in other services shall be repaired as
follows:

1. Drill 1/8" diameter holes at ends of each crown crack or edge crack to a depth equal to
blister depth as determined by thickness measurement.

B. Relieve hydrogen pressure in uncracked blisters 2 inches and larger in diameter by drilling a
1/16 inch diameter hole in the centre of the crown as follows:

1. Blisters showing on outside of vessels.

a. Drill from outside.

2. Blisters showing on inside of vessel.

a. Drill from inside.
b. For vessels in hydrofluoric acid service, drill from outside.

3. Blisters showing on both inside and outside of vessel.

a. Drill from inside.
b.For vessels in hydrofluoric acid service, drill from outside surface only.

C. Vessels in hydrofluoric acid service.

1. If blisters 2 inches and larger in diameter on the inside surface have crown or edge cracks,
gouge out complete blister, fill with weld metal and grind smooth with plate surface.

2. If blisters on the outside surface are cracked, treat as in Paragraph III A.

D. Preheat, welding procedures, stress-relief, etc. should be in accordance with current

acceptable practice for the specific vessel material.

E. Spheres and other vessels with tubular legs.

1. Hydrogen may diffuse through the vessel wall and become trapped inside tubular legs that
are welded to the vessel. This can form an explosive mixture with air in the legs.

2. Prior to any welding or cutting on or near the legs of a blistered vessel, the legs should be
purged of any explosive gases as follows:

a) Drill 1/4" diameter holes at top and bottom of legs, with a non-sparking drill.

b) Flush with inert gas or with air from the bottom hole.

3. Other dead spaces of significant volume should be treated in a similar manner.

OISD-128 37
_______________________________________________________________________________________

Annexure-VIII

INSPECTION TOOLS

Tools required for Pressure Vessels Inspection are as follows:

i) Ultrasonic Thickness Gauge.

ii) Ultrasonic Flaw Detector.
iii) Radiography Equipment.
iv) Magnetic Particle Testing Kit. (Wet Fluorescent Type)
v) Metallographic Equipment.Infra-red Scanner for Thermography.
vi) Dye Penetrant Kit.
vii) Paint Thickness Gauge.
viii) Shore Hardness Meter.
ix) Adhesion Testing Kit.
x) Holiday Detector.
xi) Spark Tester.
xii) Pit Depth Gauge.
xiii) ID & OD Gauges.
xiv) Plumb & Bob.
xv) Magnet.
xvi) Measuring Tape.
xvii)Magnifying Glass.
xviii)Temp. Indicating Crayons.
xix) Inspector’s Hammer.
xx) Straight Edge.
xxi) Safety Torch.
OISD-128 38
_______________________________________________________________________________________

Annexure-IX page 1 of 3

LIKELY LOCATIONS OF METAL WATAGE

A. MAIN FRACTIONATING TOWERS OF CRUDE DISTILLATION UNIT

The fractionating column bottom and internals are subjected to high temperature corrosion due
to presence of sulphur whereas column top is prone to low temperature acidic corrosion
because of salts and H2S present in the crude. The crude containing naphthenic acid also
causes the corrosion of the column shell, and the same is pronounced in the sections where
temperature ranges from 200oC to 400oC. Severity of naphthenic acid attack is higher where
the turbulent conditions exist. The impingement plate particularly in the columns where the
feed nozzle is radial is subjected to severe erosion. Noticeable corrosion or erosion is also
generally observed where the steam impinges the shell. The dislodging of the trays
(particularly valve trays) is common due to steam surge.

Galvanic corrosion is also observed at the location where cladded shells and uncladded shells
join together. Where the lining is bulged, the parent metal is subjected to corrosion. Liquid
level corrosion is noticeable in the top tray downcomer collectors particularly at the reflux
collector trays.

B. CRUDE DISTILLATION UNIT- OVERHEAD ACCUMULATORS

Pronounced corrosion is generally noticed at the interface level of water and hydrocarbons.
Mostly the corrosion is noticed in the bottom portion of the accumulators, which are not
internally protected.

C. DEHYDRATOR, LP/HP SEPARATORS

Dehydrators & LP/HP separators of crude stabilising units are likely to get corroded in the
bottom portion from 5 to 7 O’ clock position due to presence of salt & water.

D. VACUUM DISTILLATION COLUMNS

The sections where the turbulent conditions exist like impingement plate/flash zone are
subjected to corrosion erosion due to naphthenic acid and sulphur in the crude. Columns,
shells are also liable to corrode opposite to impingement plate due to rebound of fluid.
Weldments and Heat Affected Zone are also susceptible to corrosion.

E. REACTORS IN REFORMERS

Generally the reactors are of low alloy steels like 2-1/4Cr-1 Mo or cladded with stainless steel.
Due to this superior metallurgy metal wastage is generally not observed. However, the
following locations give indication of deterioration/cracking.

i) Cracking of weldment of grid with shell at the bottom.

ii) Baskets for collecting the catalyst dust are also prone to corrosion.
iii) Liners installed in the big diameter nozzles are susceptible to bulging due to failure of weld
joints at the end.
iv) Reactors made of low allow steel specially 2-1/4Cr-1 Mo are prone to temper embrittlement.
(Temper embrittlement is defined as a loss of ductility and notch toughness due to post weld
heat treatment or high temperature service above 3700 C.)

F. REACTORS IN FCCU
OISD-128 39
_______________________________________________________________________________________

The shell, riser O.D. and portion of the cyclone dip leg O.D. are severely attacked in the riser
extension type of installation. Where the grids are still used, erosion is found fairly uniform over
most of the grid when high velocities are employed through cyclones. Some erosion occurs to
Annexure-IX page 2 of 3

the wall of the plenum chambers and to the top head where small plenums are in use. For
those reactors with only two cyclones, high swirl of catalyst through the nozzles cause severe
erosion.

The refractory lining generally stands up quite well in reactor cyclones. Normal repairs require
some resurfacing of small areas or replacement of small localised sections. There are two
kinds of valves at the bottom of dipleg. The one mostly in use is the flapper type with counter
weight. The other is the trickle valve type, with the flapper plate hanging over the opening
suspended by rings. The flapper type of valves are subjected to erosion.

G. REGENERATOR IN FCCU

In the plate type of distribution grid, erosion to the grid plates is a common phenomenon. Due
to considerable vibration and heat differentials cracking of the grid plate can also take place.

In pipe type of grid design where seals are still in use, these seals may leak. Migration of
catalyst past the seal could destroy a pipe grid in a very short time.

The branches (pipe coming off each lateral) experience metal loss, mainly to the top
circumference. Occasionally the steam coming out of jet blowing directly into another branch,
lateral or end plate creates erosion. Warpage of pipe grids can take place due to overheating
during start-up and during operation. Many 5% Cr. grids experience weld cracking.

The failure of refractory lining on the shell is another common problem. During operation, it
may cause hot spots on the shell. Erosion of cyclone dip legs, failure of cyclone welds along
with weld of cyclone supports may also take place.

H. ORIFICE CHAMBER IN FCCU

Erosion of the double disc sliding valve gates, erosion at the core near the inlet and at
holes/sleeves in the grid plate are common problems. Bulging or cracking on the shell
adjacent to the grid-plate also may take place. The erosion problems in orifice chamber are
caused by the catalyst carryover from the Regenerator.

I. CHOKE CHAMBERS

Cracking of skirt and shell weld joints is quite common particularly in the coke chambers where
the skirt is not of slotted type. In the coke chambers generally feed, stripping steam and water
quench nozzles are installed at the bottom. Due to thermal cyclic shocks lower portion of the
coke chamber gets bulged. At the advanced stages of bulging, circumferential welds which act
as stiffeners get cracked in the axial direction. However, the effect is pronounced just opposite
the feed entry nozzle at an elevation of about 1 meter. The chambers where the feed enters
from the top, bulging is confined in the top portion. The conical portion of the coke chamber
where the feed enters is also prone to cracking at the knuckle portion. Bottom flange to shell
weld joint, weld joints of feed, water quench and steam nozzles are also likely to crack under
thermal cyclic conditions.

J. BULLETS AND SPHERE

The corrosion and scaling is generally confined to the bottom between 5 to 7 O’ clock positions
probably due to the presence of corrodents like H2S and water. LPG storage vessels are also
prone to stress corrosion cracking. The circumferential weld joints below the equatorial plates
in the LPG Horton spheres are more prone on such cracking.
OISD-128 40
_______________________________________________________________________________________

Annexure-IX page 3 of 3

K. VESSELS IN LOW TEMPERATURE SERVICE

Vessels in low temperature service e.g. in KTU of refineries and propane circuit of LPG
recovery units of Gas Processing Plants are prone to external corrosion due to faulty insulation,
which causes condensation of the vessels. The severity of corrosion increases in case of
corrosive atmosphere as in KTU.

In these vessels internal corrosion due to moist So2 where condensation can take place, also
occurs. Internals and shell are affected due to this.

L. AMMONIA STORAGE VESSELS

Generally the storage vessels are fabricated from Carbon steel and Nickel steels. For the
operating conditions prevailing at refineries, material of construction used for Ammonia storage
vessels in the refineries are carbon steels. The weld joints of C.S. vessels are prone to stress
corrosion cracking particularly in the vessels, which have not been stress relieved initially or
after fabrication repairs.

M. COLUMNS & VESSELS IN DIETHYL AMINE OR MONOETHYL AMINE SERVICE

The weld joints and heat affected zone of the columns and vessels in DEA and MEA service
which have not been stress relieved are also prone to cracking due to presence of H2S or H2S
and H2.

Further details about corrosion in pressure vessels are available in corrosion Manual-OISD
Publication No. 136.

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