Mellitah Oil and Gas BV- HSEQ- Corporate Procedure for Visual Inspection of Pressure Vessels

Table of Contents

1. Introduction

2. Scope

3. References

4. Responsibility

5. HSEQ Requirements

6. Preparation & Tools Used

7. Inspection Methods

8. Limits of Thickness

9. Documentation

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 Mellitah Oil and Gas BV- HSEQ- Corporate Procedure for Visual Inspection of Pressure Vessels

1 Introduction

This document determines the type of visual examination and the compliance of a
product with specified requirements.
This procedure covers the general visual inspection of pressure vessels both internal
and external. Maximum internal or external inspection intervals should be in
accordance with API 510 Section 8. The form of the deterioration may be
electrochemical, chemical, mechanical, or a combination of the three. The causes of
deteriorations are mentioned in API RP 572 Chapter 8. All information shall be carefully
documented after each inspection. The procedure may be used in conjunction with
other procedures.

2 Scope

This procedure specifies the methods and requirements for visual inspection of
pressure vessels at Wafa Field to determine the type, rate, and cause of deterioration
to minimize downtime of vessels.

3 References

The following documents shall be referred to in conjunction with these standards.

a. API RP 572 - Inspection of Pressure Vessels.

b. API 510 - Pressure Vessel Inspection Code.
c. WA-VI-PR-01 - Visual Inspection Procedure – General Principles
d. ASME Section V - Boiler and Pressure Vessel Code, Non-destructive Examination -
Article 9 - Visual Examinations.
e. ASME Section VIII - Boiler and Pressure Vessel Code, “Pressure Vessel”
f. European Standard EN 473 – Qualification and certification of NDT personnel –
General principles.
g. ASNT Recommended Practice SNT-TC-1A

4 Responsibility

Personnel who carry out tests shall be shown to be familiar with relevant standards,
rules, specification, equipment and procedures/instructions; to be familiar with relevant
manufacturing procedure used and/or with the operating conditions of the component to
be tested.

All personnel performing visual inspection shall have an annual vision test in
compliance with British standard.

All personnel performing visual inspection shall be a person qualified in accordance

with EN-473 level II, ASNT Recommended Practice SNT-TC-1A level II or approved
equivalent.

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 Mellitah Oil and Gas BV- HSEQ- Corporate Procedure for Visual Inspection of Pressure Vessels

5 HSEQ Requirements

Prior to any inspection taking place the following MUST be completed where
applicable. These forms should be completed and if they are not applicable then they
should be marked as such.

a. Toolbox Talk / Safety meeting

b. Permit to Work
c. Entry Permit
d. Risk Assessment
e. Tag Out / Lock Out
f. Hot / Cold Work Permit

Correct PPE should be used at all times prior to any inspection taking place. MSDS
sheets should be available at work site to ensure correct PPE and chemical showers are
available. Prior to any personnel entering a vessel a gas free certificate should be
issued by a qualified person using a certified Gas Free Monitor. Any vessels that require
personnel entry for inspection should have at least one man to remain outside the
vessel entrance at all times. Vessel entry point should NEVER be left unattended. For
vessels where line of sight cannot be maintained an entry and exit log should be in
place and radio communication maintained. All personnel are to be evacuated during
any alarm. Vessel entry should be barriered off during inspection.

6 Preparation and Tools Used

The tools needed for vessel inspection, including tools and equipment needed for
personnel safety, should be checked for availability prior to the inspection.
Some of the tools that should be available for pressure vessel inspections follow:

• Portable lights, including a flashlight.

• Flashlight with bulb on flexible cable.
• Thin-bladed knife.
• Broad chisel or scraper.
• Pointed scraper.
• Mirrors.
• Inside callipers.
• Outside callipers.
• Pocket knife.
• Steel tape [50 feet (15 meters)].
• Flange square.
• An inspector’s hammer or ball peen hammer (4 ounce or 8 ounce).
• Ultrasonic thickness-measurement equipment.
• Pit depth gage.
• Paint or crayons.
• Notebook and pencils.
• Wire brush.
• Plumb bob and line.
• Magnet.
• Magnifying glass.

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 Mellitah Oil and Gas BV- HSEQ- Corporate Procedure for Visual Inspection of Pressure Vessels

• Plastic bags for corrosion product samples.

• Steel rule
• Straightedge

The following tools should be available if required:

• Surveyor’s level.
• Carpenters or plumbers level.
• Magnetic particle inspection equipment.
• Micrometer.
• Radiographic equipment.
• Portable hardness-testing equipment.
• Eddy-current testing equipment.
• Fibre optic flexible scopes.
• Thermocouples.
• Metal sample-cutting equipment.
• Material identification kit or machine.
• Camera.
• Ultrasonic flaw-detection equipment.
• Liquid Penetrant inspection equipment.
• Borascope.
• Plumb lines and levels.
• Spotting scope or binoculars.
• Neutron backscatter equipment for moisture
• Magnetic flux leakage equipment.

Other related equipment that might be provided for inspection includes planking,
scaffolding, boson’s chairs, chain or rope ladders, safety devices for climbing flares or
ladders, stages for lifting by cranes, radios, and portable ladders. If external scaffolding
is necessary, it may be possible to erect it before the inspection starts.

7 Inspection Methods

Before starting the inspection of a pressure vessel, especially one in severe service,
the inspector should determine the pressure, temperature, and service conditions under
which the vessel has been operated since the last inspection. The inspector should
also be aware of equipment construction details including materials of construction, the
presence of internal attachments, and weld details.
If external or internal coverings such as insulation, refractory linings, or corrosion-
resistant linings are in good condition and without evidence of an unsafe condition
behind them, it may not be necessary to remove them for inspection of the vessel.
When any covering is found to be defective, a sufficient amount of the covering in the
vicinity of the defect should be removed to find out whether the base metal is
deteriorating and to determine the extent of the deterioration.

7.1 External Inspection

7.1.1 Ladders, Stairways, Platforms, and Walkways.
The external inspection of pressure vessels and exchangers should start with ladders,
stairways, platforms, or walkways connected to or bearing on the vessel.

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 Mellitah Oil and Gas BV- HSEQ- Corporate Procedure for Visual Inspection of Pressure Vessels

Where corrosion appears to be severe, the actual thickness should be determined by

callipering or by other means.

ƒ A careful visual inspection should be made for corroded or broken parts, cracks, the
tightness of bolts, the condition of paint or galvanizing material, the wear of ladder
rungs and stair treads, the security of handrails, and the condition of flooring on
platforms and walkways.
ƒ Crevice corrosion may exist around the heads of bolts and nuts, at bracket
connections between stair treads and angle supports, and at connections between
intermediate supports and the vessel wall.

7.1.2 Foundations and Supports.

Foundations for vessels constructed of steel-reinforced concrete or structural steel
fireproofed with concrete should be inspected for deterioration such as spalling,
cracking, and settling due to excessive heat, mechanical shock, corrosion of reinforcing
steel, or the freezing of entrapped moisture. Inspection for this type of damage should
consist of visual observation.
Measurements of the depth of such damage can be measured with dimensional checks
Inspection for crack in concrete or fireproofing should be mostly visual.
If some settling is expected in any foundation a rough check for uneven settling can be
made with a plumb line and steel rule.
The crevice formed between an exchanger shell or a horizontal vessel and a cradle
support should be carefully checked.

7.1.3 Anchor Bolts.

Although the condition of anchor bolts cannot always be completely determined by
visual inspection, the area of contact between the bolts and any concrete or steel
should be scraped and closely examined for corrosion.
The nuts on anchor bolts should be inspected to determine whether they are properly
tightened. Ultrasonic may also be used to test bolts.

Severe deterioration of anchor bolts

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 Mellitah Oil and Gas BV- HSEQ- Corporate Procedure for Visual Inspection of Pressure Vessels

7.1.4 Concrete Supports.

Inspection of concrete supports is similar to inspection of concrete foundations.

7.1.5 Steel Supports.

Steel support should be inspected for corrosion, distortion, and cracking. Visual
examination of the support surfaces should be supplemented by wire brushing, picking
and tapping with a hammer. On large skirt supports, ultrasonic thickness measuring
devices can be used.

Columns and load-carrying beams should be inspected for buckling or excessive

deflection. This can be inspected visually with the aid of a straightedge or plumb line.
Vessel support lugs should be inspected to see that they are sound. Scraping will
usually reveal corrosion. Tapping with a hammer will disclose extreme thinning.
Magnetic particle (wet or dry), Liquid Penetrant, or ultrasonic shear-wave methods may
be used to supplement visual examination. These methods will often require further
surface preparation.

If supporting skirts are insulated, the insulation should be inspected. Visual inspection
will usually disclose any deterioration of the insulation. If there is reason to suspect that
water or moisture is seeping through to the steel, enough insulation should be removed
to determine the extent of any corrosion.

Piping attachments to vessels (i.e. supports and guides) should be inspected for
evidence of distortion due to pipe movement.

Fire proofing on support beams and skirts should be inspected. Visual examination
aided by scraping will disclose most defects. Very light taps with a hammer will disclose
lack of bond between concrete fire proofing and the protected steel.

7.1.6 Nozzles
Nozzles and adjacent shell areas should be inspected for distortion and cracking. If
there is any evidence of distortion or cracks in the area around the nozzles, all seams
and the shell in this area should be examined for cracks. Magnetic particle (wet or dry),
liquid penetrant, angle beam ultrasonic, or replication techniques may be used to
supplement visual examination. When accessible, nozzles should be internally
inspected for corrosion, cracking, and distortion. The inspection can be visual with a
scraper and a flashlight.
To monitor corrosion, wall thickness of nozzles should be measured. Calipers,
ultrasonic thickness instruments, or radiographic techniques may be used.
These measurements should be recorded and compared with previous or original
thickness readings. Any losses should be analyzed, and appropriate action should be
taken.

7.1.7 Grounding Connections

Grounding connections should be visually examined to verify that good electrical
contact is maintained. The continuity of all ground wires should be checked.
Recommended resistance is 5 ohms or less, and resistance is not to exceed 25 ohms.

7.1.8 Auxiliary Equipments

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 Mellitah Oil and Gas BV- HSEQ- Corporate Procedure for Visual Inspection of Pressure Vessels

Auxiliary equipment, such as gauge connections, float wells, sight glasses, and safety
valves, may be visually inspected while the unit is in service. Undue vibration of these
parts should be noted.

7.1.9 Protective Coatings and Insulation

The condition of the protective coating or insulation on a vessel shell should be
determined. Rust spots, blisters, and film lifting are the types of paint failures usually
found.
Visual examination of insulation is normally sufficient to determine its condition. A few
samples may be removed to better determine the condition of the insulation and the
metal wall under it.
Inspection for corrosion under insulation (CUI) shall be considered for externally
insulated vessels subject to moisture ingress and which operate between (-4 °C to 121
°C), or are in intermittent service. This inspection may require removal of some
insulation.

7.1.10 External Metal Surfaces

The external metal surfaces of a vessel may be inspected visually by picking, scraping,
and limited hammering to locate corroded areas.
Under normal conditions, thorough cleaning to bare metal will be needed only at those
points where ultrasonic thickness measurements are taken
Hand tools such as a pointed scraper, an inspector’s hammer, a wire brush, a scraper,
and a file can be used to clean small spots.
Any evidence of corrosion should be investigated and the depth and extent of the
corrosion should be determined.
Thickness measurements of the vessel walls, heads, and nozzles are usually required
at each complete vessel inspection. Under normal conditions, at least one
measurement in each shell ring and one measurement on each head should be taken.
However, if much corrosion is evident, several readings should be taken in the most
corroded areas. Ultrasonic instruments may be used for these measurements.

7.1.11 External Evidence of Corrosion

Certain types of corrosion may be found on external surfaces of a vessel as
atmospheric corrosion, caustic embrittlement, hydrogen blistering, and soil corrosion.
The external surfaces of the vessels should be examined also for leaks, cracks (in
welded of nozzle connections, in welded seams, and at bracket and support welds),
buckles and bulges, defects in the metal plates, and deformation and corrosion of any
external stiffeners.
The external surfaces should be checked for laminations and mechanical damage.
Generally the visual inspection is aided using the magnetic particle (wet or dry), liquid
penetrant, UT thickness and angle beam ultrasonic examinations

7.2 Internal Inspection

NO INTERNAL INSPECTIONS ARE TO TAKE PLACE PRIOR TO HSEQ REQUIREMENTS LISTED IN

SECTION 5 BEING IMPLEMENTED

7.2.1 General

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 Mellitah Oil and Gas BV- HSEQ- Corporate Procedure for Visual Inspection of Pressure Vessels

All necessary inspection equipment (including tools, ladders, and lights) should be
assembled in advance to minimize downtime for the vessel. Tool log can be
implemented to ensure all tools are accounted for prior to vessel closure.

Not all internal inspections have to be carried out from the inside of the vessel.
Techniques are available to inspect aspects of the vessel non-intrusively using acoustic
emission, magnetic scanning and automated ultrasonic systems.

If flaw mechanisms are well defined the techniques may frequently be applied from the
outside of the vessel, while the plant is in service.

7.2.2 Surface preparation

Usually the cleanliness required by the vessel operators will be sufficient for inspection
purposes. This would entail the usual cleaning methods of washing with hot water,
steaming, using solvents (MSDS Sheets to be available), and ordinary scraping.
Extra cleaning methods are necessary when stress-corrosion cracking, wet sulphide
cracking, hydrogen attack, or other metallurgical forms of degradation are suspected.
Correct PPE to be worn whilst cleaning.

7.2.3 Detailed Inspection

All areas of the vessel should be inspected for corrosion, erosion, hydrogen blistering,
deformation, cracking, and laminations.
Welded seams in vessel, nozzles connected to the vessel, supports for tray, bafflers,
screen, grids, piping, internal stiffeners, and other internal equipment should be
inspected carefully. Most of this inspection will be visual.
A careful record should be made of the types and locations of all deterioration found.
Thickness measurements should be taken at all locations. At those locations that show
the most deterioration further measurements can be taken to correctly determine the
area of deteroration. When deterioration appears to be widespread, enough readings
should be taken to assure an accurate determination of the remaining thickness. When
deterioration is slight, one thickness measurement on each head and each shell course
may be sufficient on small vessels, but more measurements should be taken on large
vessels.
Ultrasonic instruments can be used to obtain the necessary measurements.
Pitting Corrosion - Pitting corrosion can usually be found by scratching suspected
areas with a pointed scraper. When extensive and deep pitting or grooving is found,
and depth measurements are wanted, the areas may have to be abrasive blasted. The
depths of pits or grooves can be measured with a depth gauge, a pit gauge, or (in the
case of large pits or wide grooves) with a straightedge and a steel rule.
Crack - When cracks are suspected or found, their extent can be checked with liquid
penetrant or magnetic particle (wet or dry) techniques. Angle beam ultrasonic
inspection methods provide a volumetric inspection of potential flaw areas. To use any
of these methods effectively, the suspected areas must be prepared by abrasive
blasting, grinding, or other methods acceptable to the inspector.
Vessels containing amines (absorbers, accumulators, coalescers, condensers, coolers,
filter vessels, flash drums, knockout drums, reboilers, regenerators, separators,
skimmers, sour gas drums, stills, strippers, surge tanks, treating towers, treated fuel
gas drums, etc.) are subject to cracks in their welds and the heat-affected zones of the
welds.

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Erosion - Erosion is characterized by a smooth, bright appearance marked. Metal loss

is usually confined to a clearly marked local area: in shells of exchangers and vessels,
next to bundle baffles, wear plate and inlet impingement plates;
Laminations - Laminations in vessel plates have an appearance similar to cracks, but
they run at a slant to the plate surface, while cracks run at right angles to the surface.
Manual and scanning ultrasonic techniques may be used to trace the lamination.

7.2.4 Inspection of Metallic Linings

Many vessels are provided with metallic linings. The primary purpose of these linings is
to protect the vessels from the effects of corrosion or erosion. The most important
conditions to check for when examining linings are the following:

a. That there is no corrosion.

b. That the linings are properly installed.
c. That no holes or cracks exist.

Special attention should be given to the welds at nozzles or other attachments.

Cracks in metallic linings can usually be located by visual inspection and light
hammering.
Where a lining leaks, it should be determined whether or not corrosion has taken place
behind the lining. In some cases, ultrasonic testing from the outside may be used.

8 Limits of Thickness

The limits of wall loss, due to corrosion and other deterioration mechanisms that may be
tolerated must be known, or an inspection will lose much of its value.
There are a great many variables, such as size, shape, material, and method of
construction, that affect the minimum allowable thickness. API 510 recognizes that
corrosion rate, corrosion allowances, re rating, and component assessment by ASME
Section VIII, Division 2 methodology may all be used to establish retirement and next
inspection criteria.
When corrosion or erosion is causing deterioration, the rate of metal loss can usually be
obtained by comparing consecutive inspection records. Data and graphs showing this
information should be kept with the vessel records.
When the safe limit of thickness is approached or reached, decisive action is necessary.
The minimum thickness or the methods of calculating the thickness should be known in
advance for each vessel.

9 Documentation

9.1 Records
Inspection records are required by API 510 and jurisdictions. These records form the
basis of a scheduled maintenance program, and are very important. A complete record
file should contain three types of information:

Basic data include the manufacturer’s drawings, data reports and specifications, design
information, and the results of any material tests and analyses.

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Field notes consist of notes and measurements recorded on site either on prepared
forms (see Appendix B) or in an either written or electronic field notebook. These notes
should include in rough form a record of the condition of all parts inspected and the
repairs required.

The continuous file includes all information on the vessel’s operating history,
descriptions and measurements from previous inspections, corrosion rate tables (if any),
and records of repairs and replacements.

The data is kept up-to-date.

9.2 Reports
The reports should include metal thickness measurements, corrosion rates, descriptions
of the conditions found, repairs required, and allowable operating conditions,
estimations of remaining life, and any recommendations.
General inspection reports may be sent to interested parties, such as the operating,
maintenance, and engineering departments. Who the interested parties are will depend
on the organization of the plant or company.

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