vessel inspection procedure

7/31/2019 Vessel Inspection Procedure

1/16

Trust International for Industrial and

Petroleum Services- Limited -

:002 03 4256262-:002 03 4256162

Al Saraya Towers, Ali Bin Abi-Talib Square, Alpansi Tower, 2nd

Floor, Smouha, Alexandria, Egypt

Tel: 002 03 4265252 - Fax: 002 03 4265152 - www.trusteg.com - Email: [email protected]

ONSHORE

REGENERATION GAS SUBCOOLER

E-2521

DATEREF NO

S/N SUBJECT 0 1 2 3

1

SCOPE

2

REFERENCES

3 DEFINITIONS


2/16



:002 03 4256262-:002 03 4256162




4

ITEM

DESCRIPTION

5

PREINSPECTION

REQUIREMENTS

6

TYPES OF

INSPECTION

7

INSPECTION

PROCEDURE

8

REPORTING

9

ATTACHMENTS

1- SCOPE

This procedure delineates the internal inspection of the onshore regeration gas sub cooler E -2521

during the scheduled shutdown to determine the status of internal surfaces of the vessel, and the

need for repair or re rating according to the code requirements.

2- REFERENCES;


3/16



:002 03 4256262-:002 03 4256162




2.1 API STD 510 Pressure vessel inspection code : maintenance inspection, re

rating , repair and alteration.

2.2 API RP 572 Inspection of pressure vessels

2.3 ANSI/NB-23 National board inspection code

2-4 R7126 guidance notes and supporting information for rashpetco

(Egypt) written schemes of examination managed by the

pressure system data base.2-5 vessel drawings and

data sheets

3. DEFINITIONS:

3.1 API The American Petroleum Institute

3.2 ANSI The American National Standards institute

3.3 ASME The American Society for Mechanical Engineers

3.4 MAWP Maximum allowance working pressure

3.5 MDMT minimum design metal temperature

3.6 NB ASME national board

3.7 WSOE Written scheme of examination

4. ITEM DESCRIPTION:

The onshore regeration gas subcooler E-2521, located horizontally at roseta gas field,

was fabricated by JOY INDUSTRIES , under manufacturer's number 1101 at 1999 from

stainless steel in accordance with ASME code sec. VIII Div. 1,1998 edition, and stamped by "U"

stamp. The medium inside the vessel is HS gas shell side / HC gas tube side.


4/16



:002 03 4256262-:002 03 4256162




SHELL:

The shell is constructed from two courses of "SA-240-316. with dimensions of 660.4 ID * 25.4

mm thick and length of shell is 5870 mm, the corrosion allowance is 0.0 mm.

HAEDS :

The heads are constructed from one piece of SA-240-316 formed to be elliptical 2:1 with

dimensions of 660.4 ID * 25.4 mm thick, the corrosion allowance is 0.0 mm.

NOZZELS :

The nozzles are fabricated from SA-213-316, total number of tubes are 321 in one pass, tube

outside diameter is 25.4 with 2.1 mm thickness and 6096 mm length.

BOLTS :

Stud bolts / nuts are constructed from SA -193-B7/SA-194-2H

COATING :

No cating exists on internal or external surfaces.

NAMEPLATE :

The name plate is fabricated from stinless steel material and includes the following information:

Manufacturer :

Manufacturer's S/N :

Tag number :

Year built :

MAWP shell side :

MDMT shell side :


5/16



:002 03 4256262-:002 03 4256162




MAWP shell side :

MDMT shell side :

MAWP tube side :

MDMT tube side :

Test pressure :

Construction code :

Code stamp :

ACCESS :

No access is available to inside the vessel, however inspector shall use 8"N3,N4 and other

available nozzles to inspect the internal surface of the shell.

5. PREINSPECTION REQUIREMENTS:

5.1 Operation and inspection history of the tank shall be available for review by the

inspector. For example: operating conditions, including process upsets that may affect

mechanical integrity, inspection reports, and data for each type of inspectionconducted (for example, internal, external, thickness measurements), and inspection

recommendations for repair.

5.2 For an internal inspection, the tank shall be isolated by blinds or other positive

methods from all sources of liquids, gases, and / or vapors. The vessel shall be drained,

purged, cleaned, ventilated, and gas tested. Where required , protective equipment

shall be worn that will protect the eyes, lungs, and other parts of the body from

specific hazards that may exists in the vessel.

5.3 No access is available to inside the vessel , however inspector shall use 8" N3,N4 and

other available nozzles to inspect the internal surfaces of the shell using fiberscope


6/16



:002 03 4256262-:002 03 4256162




and/or the inspection mirror as access permits.

5.4 Nozzles shall be opened as required by inspector, isolation kits ( if required ),shall be

available at site during the S/D to enable of the nozzles.

5.5 Electrical line source terminal of 220 V shall be available near to vessel.

5.6 Powerful light source shall be available to inspect the inside surface of the vessel.

5.7 The vessel shall be prepared for hydraulic pressure testing of both the shell and the

tube side at 127 barg using tap water as a test medium and hold for 1 hour. The

required pump, calibrated pressure gauges and blind flanges/ spades shall be available

for hydraulic pressure testing . the inspector shall witness the hydraulic pressure

testing. ( use guidelines for hydraulic pressure testing PT/01)5.8 NDT and other inspection equipment shall be available for inspector to conduct the

internal inspection (required inspection equipment are attached).

6. TYPES OF INSPECTION:

The internal inspection of the tank included, visual inspection, dye penetration and UT wall

thickness measurements and supplements with NDT as required per examination specification

RPCO-05, issue 1 ( WSOE ), and hydrostatic testing for both the shell and tube side at 127 barg for1 hour hold.

7. INSPECTION PROCEDURE:

7.1 Check the tank tag number and name plate.

7.2 Obtain the safe entry permit from the appropriate HSE personnel.


7/16



:002 03 4256262-:002 03 4256162




7.3 Check that cleaning of the vessel is adequate and the internal surface of the shell,

heads, and nozzles are clearly visible.

7.4 Check that inspection and NDT equipment that shall be used during the inspection are

available and valid.

7.5 Check that the light source that shall be used is operating and powerful and check for

the availability of electrical line source terminal that be used to operate the NDT

equipment.

7.6

If the vessel is not properly prepared for internal inspection, the inspector shall

decline to make the inspection until the tank is ready for that inspection. inspection.

7.7 Examine the internal surfaces of shell and heads carefully, as access permits, for

possible cracks, general corrosion , pitting , and other signs of deterioration. If there is a

suspect indication, use Dye penetrates according to approved NDT procedures; to

verify the indication. Ultrasonic testing may be used for determining the depth ofindication. Pit depth shall be measured by depth gauge or venire caliber

7.8 If evidence of distortion is found, it may be necessary to make a detailed check of the

actual contours or principal dimensions of the vessel and to compare those contours

and dimensions with the original design details.

7.9 Examine welded joints and the adjacent heat-affected zones for service-induced cracks

or other defects.


8/16



:002 03 4256262-:002 03 4256162




7.10 Carry out PT on 10% of all seam and girth welds on the shell, plus all "T" weld

inspections, to distance of 300 mm from inspection of weld looking for signs of cracking

and other weld defects ( including transverse cracking where appropriate ).

7.11 Carry out PT on nozzles.

7.12

Examine the surfaces of. Nozzles and other openings for distortion, crack, and other

defects, using a mirror as necessary, paying particular attention to the welding used toattach the parts and their reinforcements.

7.13 Examine accessible flange faces for distortion and determine the condition of gasket-

seating surfaces.

7.14

Examine the tubing and tube sheets externally for possible cracks and other signs of

deterioration.

7.15 Examine the earthing conditions, and describe the status in the final inspection report.


9/16



:002 03 4256262-:002 03 4256162




7.16 Measure the wall thichness of the shell at 500 mm intervals ( as access permits ) from

the datum points ( shell-to-front head weld seam ) till the shell-to-rear head weld

seam. The readings will be taken in four directions (3,6,9,12 o'clock ). Readings also will

be taken on heads and nozzles and shall be included in the report.

7.17 Clearly mark all defects found with a permanent marker on place. Sketch the size and

location of defects and document the findings on the final inspection report.

81.7 Witness the hydraulic pressure test at 127 barg for both shell and tube side using tap

water as a test medium and hold for 1 hour . ( use guidelines for hydraulic pressure

testing ( PT/01)

81. Sate areas not accessible and reasons why.

8. REPORTING:

8.1 All findings shall be reported in the attached final inspection report form.

9. ATTACHEMENTS:

9.1 Sketch for onshore registration gas subcooler E-25219.2 List of required inspection equipment.

9.3 Inspection check list.

9.4 final inspection report.

9.1 LIST OF REQUIRED INSPECTION EQUIPMENT

S/N DESCRIPTION QTY

REQ.

RECOMMENDED TYPE


10/16



:002 03 4256262-:002 03 4256162




1

Ultrasonic thickness meter.

1 ANY

2

Inspection mirror with telescopic

hand, the mirror size shall fit into 2"

pipe at least. 1 Any

3

Pocket size flash light

1 Any

4

Measuring tape 5 m.

1 Any

5Flexible fiberscope with light source

and forward & side tip.1 Olympus or equivalent

6Dye penetration material kit (

penetrant-remover-developer ) 1From only one family product

e.g. Ely , or magnaflux etc.

7

Ultrasonic instrument for crack

detection with cables and 0, 45, 60, 70

degree angle probes, with IIW-V2block.

1KRAUTKRAMER OR

EQUIVALENT

8

Still photos digital camera.

1 Sony or equivalent

9Depth gauge or vernier caliber.

1 Any

10

Magnifier lens 2, 5, or 8X

1 Any


11/16



:002 03 4256262-:002 03 4256162




11Permanent markers (Yellow/red

color).1 Any

12

9.2 INSPECTION CHECK LIST

S/N ITEM CODITION ACCEPTANCE REMARKS

1Shell internal / external

surface

2Head internal / external

surface

3Shell-to-shell circumferential

weld seam

4Shell-to shell longitudinal weld

seam5

Shell-to-head circumferential

weld seam6 N1 16" -900# tube inlet7 N1 16" -900# tube outet

8 N3 8"-900# shell inlet

9 N4 8"-900# shell oulet

10 N1A 2"-900#P1 connection

11 N2A2"-900#P1 connection




12/16


13/16



:002 03 4256262-:002 03 4256162




Data of examination Data of last examination Vessel Drawing Number

Data of manufacture Manufacturer Design Code

PART 2: VESSEL DATA

Shell Tube side

Contents

Max/min design pressure (bar)

Max/min design temperature

(C degree)

Material

Thickness (mm)

Corrosion allowance (mm)

Material (lining)

Insulation

PART 3: EXETENT AND METHOD OF EXAMINATION

Examination and/or tests carried out, plus no of attached sheets.

Parts not examined with reasons

PART 4: CONDITION OF VESSEL (SUMMARY)

EXTELNAL


14/16



:002 03 4256262-:002 03 4256162




Element Condition Comments

Access ladders/platforms

Man ways

Heads

Shell

Nozzles

Protective coatings

insulation

Bolted attachments

Welded attachments

Supports/ skirt/ mounts

Ear thing

Nameplate

Internal

Element Condition Comments

Access ladders/platforms

Man ways

Heads

Shell

Nozzles

Protective coatings


15/16



:002 03 4256262-:002 03 4256162




Tubes

Tube plates

Welded attachments /

supports

Bolted attachments / trays

Strainers /filters/demisters

Definition of vessel Condition

C-Nothing to report B-Less significant Fault A2-significant andfault

A1-Imminent Danger

Vessel in excellent

condition no signs of

damage or corrosion-

nothing to report

Surface rust, light

scale or corrosion not

exceeding 0.5mm and

within the corrosion

allowance-damage

judged not to be

dangerous

Corrosion greater

than 0.5mm possible

cracking adjacent to

welds-more

significant damage

than B but no

immediate of failure

Heavy corrosion

and/or deep pitting or

cracking of any

description; vessel

operating above SOL-

significant damage

with risk of imminent

danger

PART5: Anomalies and defects

PART6: Statement by Inspector

I declare that the above equipment has been inspected according to the examination described in part 3

and that this document is a true report of the inspection carried out

Inspectors name signature data

PART 7: Statement by competent person


16/16



:002 03 4256262-:002 03 4256162




The vessel is suitable for its design specified in part 2 subject to the relief system remaining in order:

YES/NO

The written scheme of examination require amending as result of this examination : yes / no

Description of amendments required

The above equipment may be used within the duty specified in part 2, subject to the following conditions

Next thorough examination due before

Name signature

vessel inspection procedure

Documents