Table of Contents

1.0 Purpose
2.0 Scope
3.0 Summary
4.0 Scrubber Inspection Details
5.0 Separator Inspection Details
6.0 NDT Request
6.1 Separator NDT Inspection Plan
6.2 Scrubber NDT Inspection Plan
7.0 SS1A Primary Scrubber
7.1 External Inspection
7.2 Internal Inspection
7.3 Conclusion
7.4 Repairs Done
7.5 Recommendations
8.0 SS7 Separator
8.1 External Inspection
8.2 Internal Inspection
8.3 Conclusion
8.4 Recommendation
9.0 SS7 Scrubber
9.1 External Inspection
9.2 Internal Inspection
9.3 Conclusion
9.4 Repairs Done
9.4 Recommendation
10.0 SS4 Separator
10.1 External Inspection
10.2 Internal Inspection
10.3 Conclusion
10.4 Recommendation
11.0 SS4 Scrubber
11.1 External Inspection
11.2 Internal Inspection
11.3 Conclusion
11.4 Recommendation
12.0 SS6 Separator
12.1 External Inspection
 12.2 Internal Inspection
12.3 Conclusion
12.4 Recommendation
13.0 SS6 Scrubber
13.1 External Inspection
13.2 Internal Inspection
13.3 Conclusion
13.4 Recommendation
14.0 Unit 5 Scrubber
14.1 External Inspection
14.2 Internal Inspection
14.3 Conclusion
14.4 Recommendation
15.0 Unit 3 Scrubber
15.1 External Inspection
15.2 Internal Inspection
15.3 Conclusion
15.4 Recommendation
1. Purpose

The planned shutdown for the static equipment inspection provides key requirements for conducting risk
based inspection assessment for the pressure vessels based on its condition per API RP 580 methodology.

The intent of this inspection and condition monitoring is to provide reasonably accurate and timely
assessments in determining any changes in the condition that could compromise continued safe operation
needed to determine the integrity of pressure vessel.

2. Scope

This defines the role of inspection influences with the risk associated with the pressure equipment by
improving knowledge of the deterioration state and predictability of the probability failure. Although risk
does not reduce the risk directly, it is a risk management activity that may lead to risk reduction, risk
mitigation that change the probability failure.

3.0 Summary:

An internal and external inspection examinations were performed on vessels:

 SS5 Separator
 SS5 Scrubber

Inspection results conducted by the use of Non Destructive Methods were carried out (RT, UT, MT,
PT, UTG, VT, HT) to assess the overall service condition for each vessel. Inspection personnel are
certified Level 2 in accordance with the QAM and principles of ASNT SNT-TC-1A.

The contents of this are based on the data acquired during the inspection results gathered in the
scheduled plant shutdown. Ultrasonic Thickness Gauging data was taken at specific locations to
determine the remaining material thickness, Radiographic Testing to determine defects for the
groove weld joints, Ultrasonic Testing to determine flaw size and depth of the defect, Magnetic
Particle Testing to determine surface and sub - surface discontinuity, Liquid Penetrant Test to
determine surface breaking defects, Visual Test to determine the condition of the object observed
were defect is evident. Hardness Test to determine the mechanical properties of metal. This
inspection results is intended to provide an account of the vessels reliability and integrity. Inspection reports
are sources of site-specific data and information, which determines the inspection intervals, associated risks
estimating remaining life and what actions or steps need to be taken.

All records of each Vessel are maintained for Inspection, Planning and Engineering Assessment in
conducting risk-based program.
4.0 Scrubber Inspection Details:
5.0 Separator Inspection Details:
6.0 SS5 Scrubber

6.1 External Inspection:

Shell:
MT was carried out on vertical and circumferential seam welds and found no significant defect. No
traces of leaks was observed during the visual inspection. Minor corrosion was present due to
coating failure over the entire vessel and active oxidation is associated. Ultrasonic Thickness
Gauging was also carried out and metal thickness is determined to be above MAT.

Nozzles:
RT was carried out on N1 (30” Nozzle to Flange Steam Outlet) neck and found to have crack at
segment 10, 21 to 24, 29, 39.5, 53.to 56 and 73. The rest of the Nozzles were in serviceable
condition and flange-sealing surfaces has visible serrations. Magnetic Particle Test was also
carried out on the reinforcing pads weldments and found no significant defects.

Heads:
There were no visible distortions observed. UTG readings also determined that it is still above
MAT. MT was carried out on circumferential weld and found no evident defects.

Data Plate:
All information in the data plate is intact and legible.

6.2 Internal Inspection:

Shell:
RT was carried out on tee joints randomly in the circumferential and vertical seam and found no
significant defects. MT was carried out on fillet weld grating circumferential welds and crack was
determined to be present.

Nozzles:
MT was carried out on top head nozzle vertical weld and cracks were present. Steam inlet nozzle
was also diagnosed to have crack on the reinforcing pad weld.

Heads:
MT detected that crack is present on the top head reinforcing pad weld and transverse crack
protrusion on the base material. UT flaw was conducted to validate the size and depth of the cracks
and determined it critical.

6.3 Repairs Done:

The flange of N1 was replaced and steam inlet nozzle repaired. Damage flange was removed by
grinding and re-welded by an approved WPS. All welder’s who performed the repairs were verified
as per WQT.

6.4 Post Weld Heat Treatment

After welding, PWHT was performed to as per the parameters set in ASME VIII Table UCS 56-1.

6.5 Conclusion:

The UT data shows that entire vessel is still above MAT, which can still be used for its designed
pressure. However, critical defects are present on the nozzle steam inlet flange neck. The defects
present appears to be fatigue cracking were service related due to cyclic vibration, which lead the
degradation of the vessel. Root cause failure analysis is yet to prove the basis of the failure.
6.6 Recommendations:

The vessel should be power tooled and painted to mitigate future external corrosion. All flange
gasket surfaces should be mechanically cleaned and evaluated to ensure suitability for service.
External of the entire vessel to be insulated to avoid heat loss and exposure to atmospheric
conditions. To conduct UTG every 5 years in the entire vessel and visually examined annually from
the date of last inspection.

Procedures complying with API 510 will need to be followed to ascertain the future service
limitations, design conditions, and MAWP. Any applicable rules for the jurisdiction and a future
inspection plan will need to be developed in accordance with RBI. An API 510 certified inspector
should be present in the time of vessel repair or alteration and should certify after conforming its
acceptance.

7.0 SS5 Separator

7.1 External Inspection:

Shell:
RT was carried out on the circumferential and vertical seam welds and found no sub-standard or
significant indications. No traces of leaks was observed during the visual inspection. Minor coating
failure over the entire vessel was observed. Ultrasonic Thickness Gauging was also carried out and
metal thickness is determined to be above MAT.

Nozzles:
The nozzles necks were in serviceable condition and flange sealing surfaces has a visible
serrations. Magnetic Particle Test was also carried out on the reinforcing pads weldments and
found no significant defects.

Heads:
There were no visible distortions observed. UTG readings also determined that wall thickness is
still above MAT. MT was carried out on circumferential weld and found no evident defects.

Data Plate:
All information in the data plate is intact and legible.

7.2 Internal Inspection:

Shell:
RT was carried out on vertical and circumferential seam welds and found 330 mm crack on VSW 2.

Nozzles:
The nozzles necks were in serviceable condition and flange sealing surfaces has a visible
serrations. Magnetic Particle Test was also carried out on the reinforcing pads weldments and
found no significant defects present.

Heads:
MT was also conducted on the welds and found no significant defects.

7.3 Conclusion:

The UTG data shows that entire vessel is still above MAT which can still be used for its designed
pressure. As a result of the NDE test conducted it is safe for normal operation.
7.4 Repairs Done:

Vertical Seam Weld 2 (VSW 2) was excavated by grinding technique and re-welded on the location
were RT shown to have defect by an approved WPS. After repair, RT was conducted to verify that
crack has been eliminated.

7.5 Post Weld Heat Treatment

7.4 Recommendations:

External of the entire vessel to be insulated to avoid heat loss and exposure to atmospheric
conditions. To conduct UTG every 5 years in the entire vessel and visually check every year from
the date of last inspection.