MECHANICAL INTEGRITY ASSESSMENT OF OGDCL ASSETS DURING

ATA-2021 AT KPD (JT-PP-KPD-031)

PO # 4614/769809/2020 VELOSI Report No. VISP-031-0120-A-4301

TECHNICAL REPORT

MECHANICAL INTEGRITY ASSESSMENT OF CPI

SEPARATOR TANK A-4301 AT KPD, KUNNAR

Rev Description Prepared By Reviewed By Approved By

00 Final Report Saad Bin Sharf Muhammad Muhammad
(API-510) Hassnain Hashim
Certificate # 42968 (PM)/Nadir Abbas (OM)

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PO # 4614/769809/2020 VELOSI Report No. VISP-031-0120-A-4301

VELOSI INTEGRITY & SAFETY PAKISTAN PVT. LTD.

Suite # 401, 4th Floor , Business Centre, Block-6 P.E.C.H.S,
Karachi - PAKISTAN
Telephone: +92 21 34549503/04 Facsimile: +92 21 34549505
Website: www.velosi.com

Date of first issue: 30th December, 2021 Project No: VISP-031-120

Approved by: Organizational unit:
Muhammad
KARACHI, PAKISTAN
Hashim Operation
Manager
Client: Client Ref.:
Omer Sabahat (Sr. Mechanical Engineer, P&P)
OGDCL
OBJECTIVE:
This report contains the results of mechanical integrity assessment conducted on CPI Separator Tank
(A-4301) located at Kunnar Oil Field & LPG Gas Processing Plant-OGDCL. The report presents the
objective of the study, the scope of work, the methodology applied and the analysis results including
remaining life assessment as well as appropriate recommendations arising out of the assessment.
Indexing terms
Report No: Subject Group:
VISP-031-0120-A-4301 -- Mechanical Integrity Assessment.

Report title: Keywords Service Area

Mechanical Integrity Assessment of CPI Separator Kunnar Oil Technical Services

Tank A-4301 at Kunnar Oil Field, OGDCL Field, Sindh. Market Sector
Mechanical Oil and Gas
Integrity
Assessment
Work carried out by:
No distribution without permission from the client or
Saad Bin Sharf responsible organizational unit (however, free distribution
for internal use within VELOSI after 3 years)
Work verified by: No distribution without permission from the client or
responsible organizational unit.
Muhammad Hashim/Muhammad Hassnain/Nadir Abbas
Strictly confidential
Date Revision No: Number of Un restricted distribution
pages:
30th December, 00 17
2021
All rights reserved. This publication or parts thereof may not be reproduced or transmitted in any form or by any means, including
photocopying or recording, without the prior written consent of VELOSI.

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PO # 4614/769809/2020 VELOSI Report No. VISP-031-0120-A-4301

Contents
1.0 INTRODUCTION ........................................................................................................................................................... 4
1.1 Objective .................................................................................................................................................................... 4
1.2 Scope of Work .......................................................................................................................................................... 4
1.3 Deliverables .............................................................................................................................................................. 4
1.4 References ................................................................................................................................................................ 4
1.5 Abbreviations ........................................................................................................................................................... 5
2.0 ACTION TAKEN DURING ATA-2021 ....................................................................................................................... 6
2.1 External Inspection ................................................................................................................................................. 6
2.2 Internal Inspection .................................................................................................................................................. 6
2.3 Inspection Finding Summary ............................................................................................................................... 6
2.5 Inspection Findings And Recommendations................................................................................................... 7
3.0 CALCULATIONS ........................................................................................................................................................ 13
4.0 CONCLUSIONS .......................................................................................................................................................... 14
APPENDIX I .................................................................................................................................................................... 15
ULTRASONIC THICKNESS REPORT .......................................................................................................................... 15
APPENDIX II ................................................................................................................................................................... 16
CML/NDT SKETCHES ...................................................................................................................................................... 16

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 MECHANICAL INTEGRITY ASSESSMENT OF OGDCL ASSETS DURING
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PO # 4614/769809/2020 VELOSI Report No. VISP-031-0120-A-4301

1.0 INTRODUCTION
OGDCL has contracted Velosi for Asset Integrity services through contract# PROC-SERVICES/CB/ CORR-
4614/769809/2020. This job was done to perform the inspection and remaining life assessment of CPI
Separator Tank A-4301 during ATA-2021 at Kunnar Oil Field based on visual inspection as per API-510. As
per contract conventional NDT performed by M/s Bureau Veritas and advance NDT by M/s SGS. This report is
prepared based on inspection data available and contains details calculations, conclusion and
recommendations.
During Inspection, the following activities were conducted on A-4301

 External visual inspection by API-510 inspector(performed by Velosi)

 Internal visual inspection as per API-510 code (performed by Velosi)
 Ultrasonic thickness gauging inspection(UTG) (performed by Bureau Veritas)
VELOSI mobilized a team consisting API inspectors on June 21, 2021 for ATA . Thorough internal & external
inspection was performed for separator tank. On the basis of the data provided by Process owner of Kunnar
Oil Field personal(s), metal loss rate and remaining life assessment was performed as per the requirements of
API 510, API 571, API 572, API 576.

1.1 Objective
The objective of inspection is to find the mechanical integrity of Process Pressure Vessels, to recommend
corrective actions, to calculate remaining life and to determine next inspection interval.

1.2 Scope of Work

Inspection of CPI separator tank A-4301 was carried out to meet the objectives. Following activities make part
of scope as per agreement.

 External and Internal Visual Inspection as per API-510 (performed By Velosi)

 Ultrasonic Thickness Gauging (performed by Bureau Veritas)

1.3 Deliverables
After completion of job, the final report shall be issued in accordance with the scope of work that must
include:
a) Field external visual inspection findings.
b) UT examination results.
c) Recommendations, discussion & remediation
1.4 References
 API 510 In-service Inspection, Rating, Repair, and Alteration of Pressure Vessels Edition-May 2014,
Addendum 2018.
 API 571 Damage Mechanism Affecting Fixed Equipment in the Refining Industry Third Edition- 2020
 API 572 Inspection Practice for Pressure Vessel Fourth Edition-December 2016
 American Society of Mechanical Engineer (ASME) Boiler and Pressure Vessel Code (ASME SEC.VIII
DIV.I) 2019 Edition.
 ASME Sec V Nondestructive Examination 2015 Edition.
 ASME Sec IX Welding, Brazing & Fusing Qualifications 2015 Edition.

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1.5 Abbreviations
Abbreviation Description
API American petroleum institute
ACFM Alternating current field measurement
ASME American society of mechanical engineers
DPT Dye penetrant test
EC Eddy current test
HAZ Heat affected zone
HB Brinell hardness
HIC Hydrogen induced cracking
HSAS Heat stable amine salt
MPI Magnetic particle inspection
MIN. Minimum
MIA Mechanical integrity assessment
MAWP Maximum allowable working pressure
NDT Nondestructive testing
RT Radiographic testing
SOHIC Stress oriented hydrogen induced cracking
SCC Stress corrosion cracking
TML Thickness measurement location
TOFD Time-of-flight diffraction
UFD Ultrasonic flaw detection
N/A Not Available
NA Not Applicable
LS Longitudinal Seam
CS Circumferential Seam
UT Ultrasonic thickness
VT Visual inspection
API American petroleum institute

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2.0 ACTION TAKEN DURING ATA-2021

During ATA-2021, CPI separator was inspected externally and internally to find damages/flaws/defects or any
recordable findings for future monitoring to ensure equipment’s’ integrity for future use up to next ATA. External
condition of paint coat, H beams/C channels and foundations/supports, associated structure/ladder was found
satisfactory. Inspection was performed by API inspector through Manways M1& M2. Internal condition of shell,
attachment welds, corrugated plates pack was observed and found satisfactory. Some coating damage was
noticed which shall be repaired during next ATA. Flange facing of Nozzle N-6 Ø2” shall be done during next
ATA.

2.1 External Inspection

Visual examinations, NDT activity UTG were performed No major anomalies found during inspection. Refer to
section 2.5 for further findings recommendations and pictorial evidence.

2.2 Internal Inspection

Visual examinations and UTG was done for Tank, Heavy sludge deposit was noted on shell bottom during Pre-
cleaning inspection. Coating damages were noted on the bottom of the shell at 09 in nos. locations. Superficial
corrosion was also noted on these locations. Refer to section 2.5 for further findings recommendations and
pictorial evidence,

2.3 Inspection Finding Summary

Visual examinations, UTG were performed assess metal loss rate. No major anomalies found during
inspection. Some coating damage was noticed which shall be repaired during next ATA. Flange facing of
Nozzle N-6 Ø2” shall be done during next ATA.

2.4 UT Gauging:
UT gauging was performed on all shell and nozzles. No major metal loss observed with comparison of design
thickness.
Design Thickness shell = 10 mm
Average thickness on shell = 10.25 mm

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2.5 Inspection Findings And Recommendations

Sr.# Findings Recommendations Photo Ref.
01 CPI Separator Tank-Overall view NA
Paint/coat condition found
satisfactory, nozzles, weld
seams, stiffener ribs intact/in
satisfactory condition. Attachment
welds and associated
structure/ladders found intact.

02 Name Plate NA
Manufacturer: PEERLESS
EUROPE LIMITED
DOM:2016
Design Data
Design P=Atmospheric
Design Temp.=0/80 Deg C
(min/max.)
Test Pressure=Full of Water
Operating Pressure=Atmospheric
MAWP=ATM.
C.A=3mm
Medium/Service=Oily Water
Dimension=60035x3676x3785
Sr#J2648-01-2015

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03
Pre-cleaning inspection:
Heavy sludge on bottom of shell
noted during Cleaning was
carried out by water flushing.
NA

04 Pre-clean condition of corrugated

plates pack.
Post clean inspection was done
and condition found satisfactory.

NA

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05 Post clean inspection: Shell NA

surface free from sludge. No
major abnormality noticed

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06 Sump compartment: Localized Need to be re-coated as per

coating damage inside sump original specs with proper
compartment surface preparation during next
ATA.

07 Separation Compartment.: Need to be re-coated as per

Coating damage was noticed original specs with proper
on the shell bottom inside. surface preparation during
next ATA.

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08 Treated water compartment.: Need to be re-coated as per

Coating damage aggravated by original specs with proper
corrosion was noted on the shell surface preparation during
beside ladder inside next ATA.

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09 Ageing/cuts noted Need replacement.

on the rubber
sealing gasket used
on manway and
Compartments.

10 Nozzle N-6 Ø2” Need to be done during next

flange facing ATA.
required as
serration is corroded
away

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DURING ATA-2021 AT KPD (JT-PP-KPD-031)

PO # 4614/769809/2020 Report No. VISP-031-0120-A-4301/FR-01

3.0 CALCULATIONS
Calculations are done based on API-510 & ASME Sec VIII DIV 1 for corrosion rate, remaining life, MAWP,
minimum required thickness.

NOTE: Data used for calculation is taken from either name plate &/or General Arrangement /Engineering
detailed drawing &/or historical data.

Equipment ID A-4301 Equipment Name CPI Separator Tank Sheet No 01 of o1

Date of Last VISP-031-

Date of Inspection June, 2021 August, 2019 Job No
Inspection 0120

DESIGN DATA AND CALCULATION:

PEERLESS
EUROPE
Manufacturer Date of Cons. 2016 Radiography No MOC Head -
LIMITED -
UK

3676
Design Pressure (P) ATM Size (ID) Initial thk. Head N/A MOC Shell SA-516 Gr 70
mm

Design Temp. 80 °C Initial thk. Shell 10 mm H.T. Pressure - MOC Nozzles SA-516 Gr 70

4 Joint Eff. (E)

C.A 3 mm Heat Treatment N/A Service Life 1
years Shell / Heads

Previous Thk. Head Actual Thk.

N/A N/A Allowable Stress Value (S) at Shell - -
(A) Head A Avg.
Previous Thk. Head -
N/A Actual Thk. N/A Allowable Stress Value (S) at Head -
(B)
Head B Avg.
10.25 20000 Psi
Previous Thk Shell 9.66 mm Actual Thk Shell Allowable Stress Value (S) at Shell
mm

Minimum Required Thickness: tr t = Design – C.A = 7 mm

Corrosion Rate Long Term (LT) CRLT = initial - tactual___ = Shell = - mm/year (Note-2)
(Note 02) Service Period

Remaining Corrosion Allowance Head A Head A Shell = 3 mm

Remaining Life = t actual – t req = Shell = 25 years Inspection Interval:

CR External = 5 year
Internal = 10 year
Is Tank satisfactory to continue service on current operating parameters? Yes

Next inspection interval of detail inspection External 5 years

Internal/On-stream 10 years

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External -
Midterm Inspection Interval
Internal -
Legends:
Ri = Inside Radius
D = Inside Diameter
Head (A) = (Left )Dish A
Head (B) = (Right) Head or Dish B
NOTE-1: MAWP calculated is greater than current operating pressure. Equipment is safe for service on current operating
parameters.
NOTE-2: tactual was greater than initial for shell.

4.0 CONCLUSIONS
Following conclusions are drawn after inspection and evaluation of minimum required thickness,
corrosion rate, remaining life.
 Next internal inspection would be due on June 2031.
 Next external inspection would be due on June 2026.
 The actual thickness determined for shell with respect to current inspection is 10.25 mm that is greater
than the initial thickness.
 MAWP for CPI Separator Tank (A-4301) installed at Kunnar oil field was the same as designed i.e.,
Atmospheric temperature.
 Hence the equipment is safe to operate at current operating parameters.
 Based upon findings and calculations, equipment shell is safe to operate at operating pressure
on current thickness as data provided by representative of OGDCL – Kunnar Oil Field.

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APPENDIX I
ULTRASONIC THICKNESS REPORT

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 Sheet 1 of 4
ULTRASONIC THICKNESS GAUGING
FFS OF PRESSURE VESSELS
Client: Oil and Gas Development Company (OGDCL) Object: Oily water Treatment (A-4301) Date: 25-06-2021

Project: ATA 2021 KPD- TAY Equipment: OLYMPUS MG2DL Job No: PAK-BV-JT-PP-KPD-031
Location: Kunnar Gas and Condensate Field Equipment Serial No: 18090094 Report No: BV-TH-KPD-0065-21

Reference Code: ASME SEC V Probe: D7906-SM Calibration block: Step Wedge
Acceptance Code: API-510 Probe Freq: 5MHZ Couplant: Gel
UTG Procedure No: EPP/PAK/PR-NDT-03 Probe Serial No: 1236 Surface Condition: Painted
Drg. Ref No.: ____ Cable Type: Integrated Material: Carbon Steel
Size Measuring Location
Sr No. TML / CML # Item Description Min Max Average
(inch) 1 2 3 4 5 6 7 8

1 1 Side A, TML 1 -- 10.31 10.48 10.60 10.35 -- -- -- -- 10.31 10.60 10.46

2 2 Side A, TML 2 -- 10.68 10.41 10.58 10.58 -- -- -- -- 10.41 10.68 10.55
3 3 Side A, TML 3 -- 10.45 10.39 10.50 10.34 -- -- -- -- 10.34 10.50 10.42
4 4 Side A, TML 4 -- 10.40 10.52 10.61 10.39 -- -- -- -- 10.39 10.61 10.50
5 5 Side A, TML 5 -- 10.39 10.50 10.28 10.34 -- -- -- -- 10.28 10.50 10.39
6 6 Side A, TML 6 -- 10.29 10.65 10.58 10.52 -- -- -- -- 10.29 10.65 10.47
7 7 Side A, TML 7 -- 10.31 10.56 10.50 10.29 -- -- -- -- 10.29 10.56 10.43
8 8 Side A, TML 8 -- 10.29 10.32 10.61 10.27 -- -- -- -- 10.27 10.61 10.44
9 9 Side A, TML 9 -- 10.37 10.47 10.46 10.45 -- -- -- -- 10.37 10.47 10.42
10 10 Side A, TML 10 -- 10.42 10.42 10.25 10.50 -- -- -- -- 10.25 10.50 10.38
11 11 Side A, TML 11 -- 10.41 10.41 10.60 10.60 -- -- -- -- 10.41 10.60 10.51
12 12 Side A, TML 12 -- 10.39 10.39 10.34 10.35 -- -- -- -- 10.34 10.39 10.36
13 13 Side A, TML 13 -- 10.52 10.52 10.39 10.60 -- -- -- -- 10.39 10.60 10.50
14 14 Side A, TML 14 -- 10.50 10.50 10.34 10.58 -- -- -- -- 10.34 10.58 10.46
15 15 Side A, TML 15 -- 10.44 10.34 10.33 10.45 -- -- -- -- 10.33 10.45 10.39
16 16 Side A, TML 16 -- 10.51 10.39 10.44 10.65 -- -- -- -- 10.39 10.65 10.52
17 17 Side A, TML 17 -- 10.46 10.34 10.40 10.50 -- -- -- -- 10.34 10.50 10.42
18 18 Side A, TML 18 -- 10.40 10.47 10.30 10.61 -- -- -- -- 10.30 10.61 10.46
19 19 Side A, TML 19 -- 10.40 10.54 10.34 10.28 -- -- -- -- 10.28 10.54 10.41
20 20 Side A, TML 20 -- 10.37 10.33 10.60 10.33 -- -- -- -- 10.33 10.60 10.47
21 21 Side A, TML 21 -- 10.55 10.53 10.32 10.45 -- -- -- -- 10.32 10.55 10.44
22 22 Side A, TML 22 -- 10.46 10.29 10.25 10.45 -- -- -- -- 10.25 10.46 10.36
23 23 Side A, TML 23 -- 10.67 10.39 10.60 10.40 -- -- -- -- 10.39 10.67 10.53
24 24 Side A, TML 24 -- 10.39 10.34 10.34 10.39 -- -- -- -- 10.34 10.39 10.36
25 25 Side A, TML 25 -- 10.40 10.30 10.39 10.29 -- -- -- -- 10.29 10.40 10.35
26 26 Side A, TML 26 -- 10.36 10.36 10.52 10.31 -- -- -- -- 10.31 10.52 10.42
27 27 Side A, TML 27 -- 10.45 10.40 10.37 10.29 -- -- -- -- 10.29 10.45 10.37
28 28 Side A, TML 28 -- 10.43 10.37 10.55 10.33 -- -- -- -- 10.33 10.55 10.44
29 29 Side A, TML 29 -- 10.43 10.36 10.46 10.36 -- -- -- -- 10.36 10.46 10.41
30 30 Side A, TML 30 -- 10.34 10.39 10.45 10.38 -- -- -- -- 10.34 10.45 10.40
31 31 Side A, TML 31 -- 10.48 10.52 10.40 10.29 -- -- -- -- 10.29 10.52 10.41
32 32 Side A, TML 32 -- 10.43 10.35 10.39 10.40 -- -- -- -- 10.35 10.43 10.39
33 33 Side A, TML 33 -- 10.52 10.45 10.29 10.55 -- -- -- -- 10.29 10.55 10.42
34 34 Side B, TML 1 -- 10.48 10.29 10.60 10.60 -- -- -- -- 10.29 10.60 10.45
35 35 Side B, TML 2 -- 10.57 10.31 10.54 10.35 -- -- -- -- 10.31 10.57 10.44
36 36 Side B, TML 3 -- 10.38 10.29 10.60 10.38 -- -- -- -- 10.29 10.60 10.45
37 37 Side B, TML 4 -- 10.31 10.33 10.33 10.50 -- -- -- -- 10.31 10.50 10.41
38 38 Side B, TML 5 -- 10.40 10.36 10.38 10.45 -- -- -- -- 10.36 10.45 10.41
Legends:

Remarks: No major thickness loss has been observed from the average value, however, the minimum thickness of shell have been highlighted
above. Therefore UTG Reading verified on step wedge

Inspected By Reviewed By
Name: Usama Murtaza / Muhammad Taha Name: Mahmood ul Hassan
UT Level: II Manager IVS South
Signature: Signature:
Date: 25-06-2021 Date: 25-06-2021
 MECHANICAL INTEGRITY ASSESSMENT OF PRESSURE VESSELS
DURING ATA-2021 AT KPD (JT-PP-KPD-031)

PO # 4614/769809/2020 Report No. VISP-031-0120-A-4301/FR-01

APPENDIX II
CML/NDT SKETCHES

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