00 SAIP 80 Process Equipment Insp Guide

Inspection Procedure 00-SAIP-80

26 November 2007

Guidelines for Process Equipment Inspection Document Responsibility: Inspection Department

Saudi Aramco DeskTop Standards Table of Contents 1 2 3 4 5 6

Scope............................................................. 2 Purpose.......................................................... 2 Safety............................................................. 2 References..................................................... 2 Definitions and Abbreviations........................ 4 Inspection Guidelines…................................. 7 6.1 Vessels………………............................ 7 6.2 Reactor Vessels…………….……......... 9 6.3 Platformer Reactor Vessel.................. 10 6.4 Heat Exchanger………………............. 12 6.5 Reactor Effluent Heat Exchanger....... 15 6.6 Fin Fan Cooler.……………………...... 17 6.7 Process Heater….……………….....… 20 6.8 Reformer Heater…………………..….. 22 6.9 Industrial Boiler………...…………...… 24 6.10 Tanks………………………......………. 26

Attachment A – Flowchart-Process Equipment Inspection Attachment B-I~VI – Typical Inspection Plan (TIP) for Process Equipment Attachment C-I~XI – Inspection Checklist for Process Equipment Attachment D – Equipment, Nomenclature, Types and Items for Inspection

Previous Issue: New Next Planned Update: TBD Revised paragraphs are indicated in the right margin Primary contact: Abdulcader, Seyed Mohammed on 966-3-8747519 Copyright©Saudi Aramco 2007. All rights reserved.

Page 1 of 90

Document Responsibility: Inspection Department Issue Date: 26 November 2007 Next Planned Update: TBD

1

00-SAIP-80 Guidelines for Process Equipment Inspection

Scope This Saudi Aramco Inspection Procedure (SAIP) establishes guidelines for inspecting pressurized static process equipment that have been placed in service. This procedure supplements SAEP-325.

2

Purpose This SAIP is intended to assist the Plant and Equipment (P&E) Inspectors of Plant Inspection Units in their selection by providing Typical Plans and inspection checklist for all types of existing plant equipment, on stream evaluation, and tracking of existing equipment condition.

3

4

Safety 3.1

Radiographic examination personnel safety should be per SAEP-1143 paragraph 3 and GI-0150.003.

3.2

All pressure testing should be in compliance with GI-0002.102, "Pressure Testing Safely".

3.3

Use of personnel protection equipment and safe entry for inspection is the responsibility of the inspector/Inspection Engineer.

References The following standards were used in the preparation of these inspection guidelines and should be carefully reviewed by the inspectors/inspection engineers prior to performing inspection. All references should be the latest issued revision or edition. 4.1

Saudi Aramco References Saudi Aramco Engineering Standards SAES-A-004

General Requirements for Pressure Testing

SAES-A-206

Positive Material Identification

SAES-D-008

Repairs, Alteration, and Re-rating of Process Equipment

SAES-W-010

Welding Requirements for Pressure Vessels

SAES-W-011

Welding Requirements for On-Plot Piping

SAES-W-012

Welding Requirements for Pipelines

SAES-W-014

Weld Overlays and Welding of Clad Materials Page 2 of 90



SAES-W-015

Strip Lining Application

SAES-W-016

Weld of Special Corrosion-Resistance Materials

SAES-W-017

Welding Requirement for API Tanks

Saudi Aramco Engineering Procedures SAEP-20

Equipment Inspection Schedule

SAEP-302

Instructions for Obtaining a Waiver of a Mandatory Saudi Aramco Engineering Requirement

SAEP-325

Inspection Requirements for Pressurized Equipment

SAEP-1140

Qualification and Certification of Saudi Aramco NDT Personnel

SAEP-1141

Industrial Radiation Safety

SAEP-1142

Qualification and Certification of Non-Saudi Aramco NDT Personnel

SAEP-1143

Radiographic Examination

SAEP-1144

Magnetic Particle Examination of Welds and Components

SAEP-1145

Liquid Penetrant Examination of Welds and Components

Saudi Aramco General Instructions GI-0002.102

Pressure Testing Safely

GI-0150.003

Radiation Safety

Saudi Aramco Inspection Procedures 00-SAIP-07

Positive Material Identification Requirements

00-SAIP-74

Inspection of Corrosion under Insulation & Fireproofing

00-SAIP-75

External Visual Inspection Procedure

01-SAIP-01

Small Nipple Inspection Program

01-SAIP-02

Retirement Thickness of In-Plant Piping

01-SAIP-04

Injection Point Inspection Program

32-SAIP-11

Inspection of Air-Cooled Exchangers

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4.2


Industry Codes and Standards American Society of Mechanical Engineers ASME SEC V

Nondestructive Examination

ASME SEC VIII

Boiler and Pressure Vessel Code

ASME B 31.1

Power Piping

ASME B 31.3

Chemical Plants and Petroleum Refinery Piping

American Petroleum Institute

5

API STD 510

Pressure Vessel Inspection Code

API RP 571

Damage Mechanism Affecting fixed Equipment

API RP 572

Inspection of Pressure Vessels

API RP 573

Inspection of Boilers and Heaters

API RP 580

Risk Based Inspection

API RP 578

Material Verification

API STD 620

Design and construction of Large, Welded, Low Pressure Storage Tanks

API STD 650

Welded Steel Tanks for Storage

API STD 660

Shell and Tube Heat Exchangers

API STD 661

Air Fin-Coolers

API RP 932-B

Insp. Guideline for Effluent Air Coolers

NBIC

National Board Inspection Code

Definitions and Abbreviations Pressure Vessels: Is a container designed to withstand internal or external pressure. The vessels are constructed in accordance to ASME Boiler and Pressure Vessel Code, Section VIII. These vessels are subjected to internal or external operating pressure greater than 15 lbs/in2. Drums, Towers, Columns and Reactors, heat exchangers, condensers, air coolers, bullets, spheres and accumulators are common types of pressure vessels. Tanks: Tanks are built to API STD 650 covers, fixed roof, floating roof, floating and fixed roof tanks. The scope is limited to the tank foundation, bottom, shell, structure, roof, attached appurtenance and nozzles. Heaters: There are a variety of designs for fired tubular heaters. Some of the commonly used designs are the box, cylindrical, and cabin types. The tubes in the Page 4 of 90



radiant are called radiant tubes. The heat transfer in these tubes is mainly through the radiation from the heating flame and incandescent refractory. The shock or shield tubes are located at the entrance to the convection section and they receive more heat flux. Convection tubes are on top of the heater, heated by the out going flue gas from the radiant section. Boilers: Fired boilers are boilers in which fuel is burned in the combustion chamber associated with the boiler. The heat of the combustion is absorbed by the boiler to heat the water and convert it to steam. Boilers are mainly of two types, water tube and fire tube boilers, where water is in the tube is called water tube boiler and fire in the tube is called the fire tube boiler. Alloy Material: Any metallic material (including welding filler materials) that contains alloying elements such as chromium, nickel, or molybdenum, which are added to enhance mechanical or physical properties and/or corrosion resistance. Fabrication: The preparation of piping and small connection for assembly, including cutting, threading, grooving, forming, bending and joining of components into subassemblies. Face of the weld: The exposed surface of a weld on the side from which the welding was done. Filler material: The material to be added in making metallic or nonmetallic joints. Fillet weld: A weld of approximately triangular cross section joining two surfaces approximately at right angles to each other in a lap joint, tee joint, or corner joint. Crack: A fracture type discontinuity characterized by a sharp tip and high ratio of length to width to opening displacement. Lack of fusion: A weld discontinuity in which fusion did not occur between weld metal and base metal or adjoining weld beads. Incomplete Penetration: The weld beads unable to fill the weld bevel groove. Porosity: Cavity type discontinuities formed by gas entrapment during solidification of the weld metal. Rounded Indications: Indication’s with a maximum length of three times the width or less on the radiograph. Aligned Indications: A sequence of four (4) or more rounded indications should be considered aligned. Leg Length: is the thickness of a fillet weld, excluding any allowable reinforcement measured through the leg. Page 5 of 90



tm: Minimum thickness required (t) is equal to the design thickness as calculated by the applicable ASME SEC VIII D1, ASME B31.3 (Barlow’s/Hoop’s) formula. Hydrocarbon Services: Process streams of liquid or gaseous hydrocarbon (HC) materials, or HC streams that may contain phenols, carbon dioxide, and ammonia. Category "D" Fluid Service: A fluid service in which all the following apply: 1)

The fluid handled is nonflammable, non toxic, and not damaging to human tissues as defined in ASME B31.3 paragraph 300.2.

2)

The design gage pressure does not exceed 150 psi (1030 kpa)

3)

The design temperature is from -20°F (-29°C) through 366°F (180°C)

Category "M" Fluid Service: A fluid service in which the potential for personnel exposure is judged to be significant and in which a single exposure to a very small quantity of a toxic fluid, caused by leakage, can produce serious irreversible harm to persons on breathing or bodily contact, even if prompt restorative measures are taken. High Pressure Fluid Service: A fluid service for which the owner specifies the use of high pressure piping. Normal Fluid Service: A fluid service pertaining to most piping covered by the code (ASME 31.3), that is, not subjected to the rules for Category D, Category M, or High Pressure Service. Low-Chrome Alloy Steels: Alloy materials with nominal chromium contents of 1% to 12% chrome. Repair: The work necessary to restore the condition of the equipment suitable for safe operation at the design conditions, without any deviation from the original configuration. Abbreviations: ADIP

Amino-Di-IsoPropanol

DEA

Di Ethanol Amine

DGA

Di Glycol Amine

HAZ

Heat Affected Zone

HC

Hydrocarbon

MEA

Mono Ethanol Amine

MSAER

Mandatory SA Engineering Requirements

MT

Magnetic Particle Testing

NDT

Non Destructive Testing

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6


P&ID

Piping and Instrumentation Drawings

PFD

Process Flow Diagram

PMI

Positive Material Identification

PT

Penetrant Testing

PWHT

Post Weld Heat Treatment

RT

Radiography Testing

RTFI

Radiographic Film Interpretation

TEG

Tri Ethylene Glycol

UT

Ultrasonic Testing

VT

Visual Testing

PV

Pressure Vessel

TIP

Tipical Inspection Plan

Inspection Guidelines These guidelines are intended for inspectors and inspection engineers. Generally, the steps for static process equipment inspection are shown in the Flowchart in attachment-A. Equipment shall be inspected per Tipical Inspection Plan (TIP) and Checklist shown in attachment B and DI-DXI respectively. 6.1

Vessels 6.1.1

Check the vessel drawing, construction code, material of construction, internal parts, PWHT and dimensions (diameter, height and thickness)

6.1.2

Read the vessel file and note history of corrosion, repairs or replacement if any.

6.1.3

Carry out joint inspection for vessel entry permit (confirm if ventilation, blinds, scaffolds and lighting are provided) to ensure the vessel is safe and adequately ventilated for vessel entry and obtain vessel entry permit. At the time of entry arrange a man watch at the man way of the vessel for your safety.

6.1.4

Primarily carry out external inspection for external leaks, external damage, insulation or paint damage and external corrosion.

6.1.5

Gas tests the vessel internally before entry to the vessel for internal inspection. Check the vessel has adequate venting and free from any foul smell/toxic gas release while scales or deposit are disturbed. Page 7 of 90



Check for adequate lighting and scaffold as required for inspection. Also, at the time of vessel entry ensure a man stand by is available, for your safety and company loss prevention. 6.1.6

Start preliminary internal inspection at all man ways (man way inspection) going from bottom (If a column or tower) to the top or vise versa. Record the observations at each level on a note pad. Start entering the vessel from the top man way and assess the conditions of nozzles, vessel head, vessel wall, vessel internal hardware’s (Trays, bubble caps seal pan, support rings, demister pad, Glitch, etc.). Identify each item and note the observations for your evaluation. Request demister pad, packing removal and cleaning including packing beds if required for detailed inspection. Focus on flash zones, inlet areas, vapor phases, welds, etc.

6.1.7

While performing detailed inspection look for pitting corrosion, erosion/corrosion, channeling, weld erosion/corrosion and cracks, mechanical damages while opening and fixing, environmental cracking, bulging and blistering and the like are some to look for with in the vessel. A good cleaning and careful evaluation will help make a good decision. If Fitness for Service (FFS) assessment is required, a full evaluation will have to be done from design, operation, and history of operation to assess the possibility of extending the service life of the vessel.

6.1.8

After completion of the full inspection, request any additional cleaning or removal of internals for detailed inspection or repairs if any, repair procedure shall be issued by API certified or experienced senior inspector in consultation with PV engineer. Reference the applicable standards and codes in your recommendation.

6.1.9

Follow up the recommendations and the related repairs per Saudi Aramco standards, the codes, ASME and API.

6.1.10

Carry out the final inspection on completion of the repairs and cleaning as applicable. Assess the vessel condition for operation until the next T&I date. If FFS assessment is done and the vessel can go through minimally the EIS period, then request for change of EIS schedule. Request a new vessel on hand for replacement.

6.1.11

Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325, SAES-D-008, SAES-W-010, SAES-W-015, ASME SEC VIII D1 and API STD 510. Any repair to the main vessel will be hydrostatically tested per SAES-A-004 and SAES-D-008. Test procedure shall be provided by operation engineer of the unit or waivers shall be per

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SAEP-20 in advance. The test or waiver documents shall be filed for reference. 6.2

Reactor Vessels 6.2.1

Check the reactor vessel drawing, construction code, material of construction, internal Lining, attachment parts, PWHT and dimensions (diameter, height and thickness).

6.2.2

Refer to the vessel file and read the history, if any cracking (welds, vessel wall or lining), corrosion, disbonding of clad, Ring joint gasket and grooves, repairs or replacement if any.

6.2.3

On dumping the catalyst carry out joint inspection (confirm ventilation, blinds, scaffolds and lighting are provided) to ensure the vessel is safe for entry and then obtain vessel entry permit. Arrange a man watch at the man way of the vessel at the time of entry to the vessel for your safety. Do not enter the vessel if the temperature is above 90ºF approximately.

6.2.4

Primarily carry out external inspection of the vessel for signs of external leaks, external damage, insulation damage, external corrosion and cracks in external attachment welds which can be detected by MT and sized by UT, (common occurrence).

6.2.5

Gas tests the vessel internally before entry to the vessel for internal inspection. Check the vessel has adequate venting and free from any foul smell/toxic gas release while scales or deposit are disturbed. Check for adequate lighting and scaffold as required for inspection. Also, at the time of vessel entry ensure a man stand by is available, for your safety and company loss prevention.

6.2.6

Start preliminary inspection at manway (manway inspection) going from top to the bottom dished head internally. Record the observations on a note pad at each level. Start entering the vessel from the top manway and assess the conditions of nozzles, vessel head, vessel wall, vessel internal lining and hardware’s (Trays, Valve caps, support rings, Liners, etc.). Identify each item and note the observations for your evaluation. Request catalyst screen to be removed if required for detailed inspection. Focus on inlet/outlet areas, vapor phases, welds, clad, attachments and WFMPT test all welds or minimum 10% of the welds externally, PT test clad welds internal and all ring joint flanges for crack initiation.

6.2.7

While making a detailed inspection, look for pitting corrosion, erosion/corrosion, channeling, weld erosion/corrosion and cracks, Page 9 of 90



mechanical damages while opening and fixing, environmental cracking, bulging and blistering and the like are some that will be noted with in the vessel. A good cleaning for careful evaluation of the defect will help to make a good decision. If Fitness for Service (FFS) assessment is required, a full evaluation will have to be done from design, operation, and history of operation to assess the possibility of extending the service life of the vessel. This can be done sizing the defects by UT and assessing the results. All the ring joints must be PT checked for cracks including the ring gasket. Cracks on them are very common due to the corners of the ring groove which are considers high stress raising points.

6.3

6.2.8


6.2.9


6.2.10

Carry out the final inspection on completion of the repairs and cleaning as applicable. Assess the reactor vessel condition for operation until the next T&I date. If FFS assessment is done and the vessel can go through minimally the EIS period, then request for change of EIS schedule. Request a new vessel on hand for replacement. This is not applicable to rector vessels, unless the reactor vessel experienced extreme temperature runaway causing severe metallurgical damage.

6.2.11

Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325, SAES-W-010, SAES-W-015, SAES-D-008, SAES-A-004, ASME SEC VIII D1, and API STD 510. Any repair to the main vessel will be hydrostatically tested. Test procedure shall be provided by operation engineer of the unit or waivers shall be submitted per SAEP-20 in advance. The test or waiver documents shall be filed for reference.

Platformer Reactor Vessel 6.3.1

Check the reactor vessel drawing, construction code, internal parts, material of construction, PWHT and dimensions (diameter, height and thickness).

6.3.2

Refer to the vessel file, read file and note history of corrosion, replacement of internal parts, and repairs or replacement if any.

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6.3.3

On dumping the catalyst carry out joint inspection (confirm ventilation, blinds, scaffolds and lighting are provided) to ensure the vessel is safe for entry and then obtain vessel entry permit. Arrange a man watch at the man way of the vessel at the time of entry to the vessel for your safety. Do not enter the vessel if the temperature is above 90ºF approximately.

6.3.4

Primarily carry out external inspection for external leaks, external damage, insulation damage, external corrosion and cracks in external attachment welds which can be detected by MT and sized by UT, (common occurrence).

6.3.5

Gas tests the vessel internally before entry to the vessel for internal inspection. Check the vessel has adequate venting and free from any foul smell/toxic gases are released while scales or deposit are disturbed. Check for adequate lighting and scaffold as required for inspection. Also, at the time of vessel entry ensure a man stand by is available, for your safety and company loss prevention.

6.3.6

Start preliminary inspection at manway (manway inspection) at the top dished head internally; ensure proper ladder is fixed to go down the vessel. Record the observations on a note pad at each level. Start entering the vessel from the top man way and assess the conditions of nozzles, vessel head, vessel wall, vessel internal such as the deflectors, scallops, scallops keeper bar gap, scallop position, seats & seat tack welds, heat damage and perforation to scallops and center pipe, dents, seat rings and other hardware’s. Identify each item and note the observations for your evaluation. Request scallops and center pipe removal for detailed inspection if required. Focus on inlet/outlet areas, vapor phases, welds, clad, attachments and WFMPT test all welds or minimum 10% of the welds internally and externally for crack initiation.

6.3.7

While performing detailed inspection, look for pitting corrosion, erosion/corrosion, channeling, weld erosion/corrosion & cracks, mechanical damages while opening and fixing, environmental cracking, bulging and blistering and the like are some that will be noted with in the vessel. A good cleaning and careful evaluation will help make a good decision. If Fitness for Service (FFS) assessment is required, a full evaluation will have to be done from design, operation, and history of operation to assess the possibility of extending the service life of the vessel. This can be done sizing the defects by UT and assessing the results.

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If deep channeling or pits are noted, do not attempt weld build up but patch the location.

6.4

6.3.8


6.3.9


6.3.10

Carry out the final inspection on completion of the repairs and cleaning as applicable. Assess the reactor vessel condition for operation until the next EIS period. If FFS assessment is done and the vessel can go through minimally the T&I date, then request for change of EIS schedule. Request a new vessel on hand for replacement. This is not applicable to rector vessels, unless the reactor vessel experienced extreme temperature runaway causing severe metallurgical damage.

6.3.11

Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325, SAES-W-010, SAES-W-015, SAES-A-004, SAES-D-008, ASME SEC VIII D1, and API STD 510. Any repair to the main vessel will be hydrostatically tested. Test procedure shall be provided by operation engineer of the unit or waivers shall be submitted per SAEP-20 in advance. The test or waiver documents shall be filed for reference.

Heat Exchangers 6.4.1

Check the Exchanger drawing, construction codes, material of shell, tubes, tube sheet, baffles, heads, and dimensions (diameter, length and thickness).

6.4.2

Read the Exchanger file and note history of corrosion, tube failures, retubing frequency, other repairs, replacement and outstanding recommendations if any.

6.4.3

Carry out joint inspection (check includes ventilation, blinds, scaffolds and lighting) to ensure the exchanger shell is safe for entry. Obtain exchanger work permit (including shell entry). At the time of shell entry keep a man watch out side the shell for your safety.

6.4.4

Primarily carry out external inspection for external leaks, external damage, insulation or paint damage, external corrosion to the shell.

6.4.5

Gas tests the exchanger internally before entry to the exchanger for internal inspection. Check the exchanger has adequate venting and Page 12 of 90



free from any foul smell/toxic gas release while scales or deposit are disturbed. Check for adequate lighting and scaffold as required for inspection. Also, at the time of vessel entry ensure a man stand by is available, for your safety and company loss prevention. 6.4.6

Start preliminary inspection after removal of the channel head cover and floating head cover. Note the fouling condition. Do the same when the tube bundle is pulled out. Inspect the extent of fouling. Collect samples of fouling both from the shell and tube side for laboratory analysis. Request adequate cleaning of the shell, heads, covers and the tube bundle for full inspection.

6.4.7

Inspect the exchanger if adequately cleaned for inspection. If cleaning is not adequate to perform inspection, request for further cleaning. After adequate cleaning for inspection inspect as follows:

6.4.8

6.4.7.1

Check gasket faces of all parts (shell, heads, covers and tube sheets).

6.4.7.2

Inspect the channel, floating heads and covers for coating and anode failure if any, corrosion/erosion, any mechanical damage. Check the thickness to ensure no signs of uniform corrosion.

6.4.7.3

Inspect the shell for corrosion/erosion of shell and seam welds, any mechanical damage. Check the thickness to ensure no signs of uniform corrosion.

6.4.7.4

Check all nozzle condition to ensure they are free of corrosion/erosion and check the thickness is with in the allowable condition.

Tube bundle has to be thoroughly inspected as follows: 6.4.8.1 Inspect the tube sheets for corrosion/erosion, tube end thinning (assess severity of Grooving at tube to tube sheet contact. PT tests if tube to tube sheet seal welded, for cracks or deep pits). 6.4.8.2

Go along the tube external surface, note for corrosion thinning of tubes and impingement plates, pitting corrosion, dents and the like. Take OD and ID measurement and compare to the original for discrepancy. Check for enlarged baffle holes and grooving to tubes. Take thickness measure of the baffles to evaluate corrosion thinning. See if scales remains between tube rows and if severe request re-cleaning.

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6.4.8.3


Inspect tube ID for un-removed scales. Check for pits with in the tubes and measure the depth and compare it to the original thickness. Measure tube end thickness and compare to the original thickness. Use a boroscope, eddy current or MFL as applicable to ensure the condition for further service.

6.4.9

While performing detailed inspection of the shell, look for pitting corrosion, erosion/corrosion, channeling, weld erosion/corrosion & cracks, mechanical damages while opening and fixing, environmental cracking, bulging and blistering and the like are some damages that will be noted with in the shell wall. A good cleaning and careful evaluation will help make a good decision.

6.4.10

If Fitness for Service (FFS) assessment is required, a full evaluation will have to be done from design, operation, and history of operation to assess the possibility of extending the service life of the shell. This can be done sizing the defects by UT and assessing the results.

6.4.11

After completion of the full inspection, request any other needs for cleaning, repair or re-tubing, renewal of anodes if any as required.

6.4.12

Follow up the recommendations and the related repairs per Saudi Aramco standards SAEP-317, the codes, TEMA, ASME and API STD 660.

6.4.13

Carry out the final inspection on completion of the repairs if any and cleaning as applicable. Assess the exchanger condition for operation until the next EIS period. If FFS assessment is done and the exchanger can go through minimally the T&I date, then request for change of EIS schedule. Request a new exchanger on hand for replacement or tube bundle as applicable.

6.4.14

On completion of inspection and repairs if any, hydrostatically test the exchanger both from the shell and tube side at its test pressure (Design pressure x 1.5 for exchangers built before 1999 and design x 1.3 after 1999.). Note: The reactor effluent and some exchangers with bellow design will require to be tested at differential test pressure only. Refer to the name plate for the test pressure in addition to the SIS for the test pressure. Tube leaks at hydrostatic test should be plugged and retested. 10% tube plugging is allowed per operating requirements (Usually Plug seal weld is not required if plugs are driven tight confirmed by hydrostatic test. However, dissimilar metal are used, then yes and at high temperature service as a precaution) may be required if different material. Minimum of two tests to be done followed by hot bolting depending on service condition, equipment gasket faces, new gaskets and workmanship for floating head type Page 14 of 90



exchangers, otherwise, three tests shall be required per SAEP-317, at the discretion of the inspection engineer. 6.4.15

6.5

Applicable standards and codes: SAEP-20, SAEP-317, SAES-W-010, ASME SEC VIII D1, API STD 660, TEMA and API STD 510. Any repair to the main exchanger or otherwise, will be hydrostatically tested. Test procedure shall be provided by operation engineer of the unit or waivers shall be submitted per SAEP-20 in advance. The test or waiver documents shall be filed for reference.

Reactor Effluent Heat Exchangers 6.5.1

Check the Exchanger drawing, construction codes, material of shell, tubes, tube sheet, baffles, heads, lining material and dimensions (diameter, length and thickness).

6.5.2

Read the Exchanger file and note history of corrosion, tube failures, retubing frequency, lining failures, and other repairs or replacement if any.

6.5.3

Carry out joint inspection (check includes ventilation, blinds, scaffolds and lighting) to ensure the exchanger shell is safe for entry. Obtain exchanger work permit (including shell entry). At the time of shell entry keep a man watch out side the shell for your safety.

6.5.4

Primarily carry out external inspection for external leaks, external damage, insulation or paint damage, external corrosion to the shell nozzles and the heads.

6.5.5

Gas tests the exchanger internally before entry to the exchanger for internal inspection. Check the exchanger has adequate venting and free from any foul smell/toxic gas release while scales or deposit are disturbed. Check for adequate lighting and scaffold as required for inspection. Also, at the time of vessel entry ensure a man stand by is available, for your safety and company loss prevention.

6.5.6

Start preliminary inspection after removal of the channel head cover and floating head cover. Note the fouling condition. Do the same when the tube bundle is pulled out. Inspect extend of fouling and collect fouling samples both from the shell and tube side for laboratory analysis. Request adequate cleaning of the shell, heads, covers and the tube bundle for full inspection.

6.5.7

Inspect the exchanger if adequately cleaned for inspection. If cleaning is not adequate to perform inspection, request for further cleaning. After adequate cleaning for inspection:

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6.5.7.1 Check gasket faces of all parts (shell, nozzles, heads, covers & tube sheets).

6.5.8

6.5.7.2

Inspect the channel heads and covers for corrosion/erosion, any mechanical damage. Check the thickness to ensure no signs of uniform or localized corrosion exists.

6.5.7.3

Inspect the shell for corrosion/erosion at seam welds, shell plate and any mechanical damage. Check the thickness to ensure no signs of uniform or localized corrosion exists. Carry out PT test at random locations for cracks on shell clad or lining (if any), and all ring joints.

6.5.7.4

Check all nozzle condition to ensure they are free of corrosion/erosion and check the thickness is with in the allowable condition and gasket faces free from damages.

Tube bundle has to be thoroughly inspected as follows: 6.5.8.1 Inspect the tube sheets for corrosion/erosion, tube end thinning (assess severity of grooving at tube to tube sheet contact. PT tests if tube to tube sheet, seal welded for cracks or deep pits).

6.5.9

6.5.8.2

Go along the tube external surface, note for corrosion thinning of tubes & impingement plates, baffle plates & tie rods, pitting corrosion, dents and the like. Take OD and ID measurement and compare to the original for discrepancy. Check for enlarged baffle holes and grooving to tubes. Take thickness measure of the baffles to evaluate corrosion thinning. See if scales remains between tube rows and if severe request re-cleaning.

6.5.8.3

Inspect the tube ID for un-removed scales. Check for pits with in the tubes and measure the depth and compare it to the original thickness. Measure tube end thickness and compare to the original thickness. Use boroscope, eddy current or MFL as applicable to ensure the condition of the tubes for further service.

While performing detailed inspection of the shell, look for pitting corrosion, erosion/corrosion, channeling, weld erosion/corrosion and cracks, mechanical damages while opening and fixing, environmental cracking, bulging and blistering and the like are some damages that will be noted with in the shell wall. A good cleaning and careful evaluation will help make a good decision. Page 16 of 90


6.6


6.5.10

If Fitness for Service (FFS) assessment is required, a full evaluation will have to be done from design, operation, and history of operation to assess the possibility of extending the service life of the shell. This can be done sizing the defects by UT and assessing the results.

6.5.11

After completion of the full inspection, request any other needs for cleaning, repair or re-tubing, renewal of tubes or tube bundle.

6.5.12

Follow up the recommendations and the related repairs per Saudi Aramco standards, the codes, TEMA, ASME and API STD 660.

6.5.13

Carry out the final inspection on completion of the repairs if any and cleaning as applicable. Assess the exchanger condition for operation until the next EIS period. If FFS assessment is done and the exchanger can go through the T&I date, then request for change of EIS schedule. Request a new exchanger on hand for replacement or tube bundle as applicable.

6.5.14

On completion of inspection and repairs if any, the exchanger will be tested both from the shell and tube side at its test pressure (Design differential pressure x 1.5 for equipment built before 1999 and 1.3 x for equipment after 1999). Note: The reactor effluent and some exchangers with bellow design will require to be tested at differential test pressure only. Refer to the name plate for the test pressure in addition to the SIS for the test pressure. Tube leaks at hydrostatic test pressure should be plugged and retested. 10% tube plugging is allowed per codes.

6.5.15

Applicable standards and codes: SAEP-20, SAEP-317, SAES-W-010, ASME SEC VIII D1, API STD 660, TEMA and API STD 510. Any repair to the main exchanger or otherwise, will be hydrostatically tested. Test procedure shall be provided by operation engineer of the unit or waivers shall be submitted per SAEP-20 in advance. The test or waiver documents shall be filed for reference.

Fin Fan Cooler 6.6.1

Check the Fin-Fan cooler’s drawing, construction code, material of heads and tubes, material and dimension (diameter, length and thickness).

6.6.2

Read the Fin-Fan cooler file and note history of corrosion, tube failures, re-tubing frequency, failures if any and other replacement or repairs if any.

Page 17 of 90



6.6.3

Carry out joint inspection (check includes blinds, scaffolds and lighting) and obtain work permit to ensure the Fin-Fan cooler’s is safe to inspect. At the time of inspection keep an assistant with you for your safety.

6.6.4

Primarily carry out external inspection for external leaks, external damage to shroud, fans, and structure’s, Tube fins and or paint damage, external corrosion to the header and nozzles.

6.6.5

Before tube internal inspection, the fin fan header should be visually seen inside through the plug holes and gas test to ensure the headers are free from toxic gas release. While inspecting have an assistant with you for your safety and company loss prevention.

6.6.6

Start preliminary inspection after removal of all header plugs from both headers or removal of 10% plugs as applicable. Note the fouling condition. Do the same when the tubes and headers are cleaned. Inspect extent of fouling and collect samples from both header and tubes for laboratory analysis. Request maintenance to clean adequately the headers and tubes for boroscope, MFL and eddy current inspection as applicable.

6.6.7

Inspect the Fin Fan whether adequately cleaned for inspection. If cleaning is not adequate to carry out inspection, request for further cleaning. After cleaning for inspection: 6.6.7.1 Check gasket faces of all plugs and bolts. Check the bolt and header treads for any significant damage. 6.6.7.2

Inspect the headers for corrosion/erosion, tube end thinning and any mechanical damage. Check the thickness to ensure no signs of uniform or localized corrosion exists on the header and nozzles.

6.6.7.3

Check all nozzle condition to ensure they are free of corrosion/erosion and check the thickness is with in the allowable condition.

6.6.7.4

Tube bundle has to be thoroughly inspected as follows: 6.6.7.4.1

Inspect the tube sheets for corrosion/erosion, tube end thinning and severity of grooving, at tube to tube sheet contacts.

6.6.7.4.2

Go along the tube external, note corrosion thinning of tubes and fin damage. Check if the bolting arrangement of the cooler is adequate. Page 18 of 90



Look if scales remain between tube rows and if severe, request re-cleaning. 6.6.7.4.3

Inspect the tube ID for un-removed scales. Check for pits with in the tubes and measure the depth and compare it to the original thickness if possible. Measure tube end thickness and compare to the original thickness if possible. Use a boroscope to reach inaccessible locations of the tubes to ensure the condition of the tubes or arrange to carry out eddy current testing as applicable. If tubes indicate a range more than 60%, carry out 100% and plug those above 60% for safe operation.

6.6.8

After completion of the full inspection, request any other needs for cleaning, repair or re-tubing if any as required.

6.6.9

Follow up the recommendations and the related repairs per Saudi Aramco standards, the codes, ASME and API STD 661.

6.6.10

Carry out the final inspection on completion of the repairs and cleaning as applicable. Assess the cooler condition for operation until the next T&I period. If Fin Fan inspection reveals that the equipment do not comply with the inspection finding for further service, then FFS assessment has to be done and the Fin Fan can go through minimally the EIS period, then request for change of EIS schedule. Request a new cooler on hand for replacement.

6.6.11.

After the completion of inspection and repairs if any, the exchanger will be tested from the tube side at its test pressure (Design pressure x 1.5 for equipment prior to 1999 and 1.3 x design for equipment built after 1999). Refer to the name plate for the test pressure in addition to the SIS for the test pressure. Tube leaks at hydrostatic test should be plugged and retested. 10% tube plugging is allowed per codes. It is required to observe leaks from both the header plugs and tube rolls at the back of the headers.

6.6.12

Applicable standards and codes: SAEP-20, SAES-A-004, SAES-W010, ASME SEC VIII D1, API 661 and API STD 510. Any repair to the main cooler will be hydrostatically tested. Test procedure shall be provided by operation engineer of the unit or waivers shall be submitted per SAEP-20 in advance. The test or waiver documents shall be filed for reference.

Page 19 of 90


6.7


Process Heaters 6.7.1

Check the heater drawing, construction code, material of radiant & convection tubes, tube support & tube guide, refractory, Skin Thermocouple and or Thermo well, Damper and Baffle plates and dimensions of individual items (diameter, length/height and thickness) as applicable to the heater type (Cylindrical or horizontal). Check the burner assembly and orientation of burner tip and material.

6.7.2

Read the heater file and note history of corrosion, tube failures, history of over heating, failures and re-tubing frequency, if any and other replacement or repairs.

6.7.3

Carry out joint inspection (verify if, blinds and ventilation, lighting, scaffolding provided) and obtain entry permit to ensure the heater is safe to enter and inspect. At the time of inspection keep a man watch for your safety.

6.7.4

Primarily carry out external inspection for external flue gas leaks, external damage to heater casing, and structure’s, Burner blocks and fuel leaks. It is suggested an infrared survey is done prior to shutdown of the heater to identify hotspots and hot tubes and any refractory damage to heater casing.

6.7.5

Gas tests the heater internally before entry to the heater for internal inspection. Check the heater has adequate venting and free from any foul smell/toxic gas release while scales or deposit are disturbed. Check for adequate lighting and scaffold as required for inspection. Also, at the time of vessel entry ensure a man stand by is available, for your safety and company loss prevention.

6.7.6

Start preliminary visual inspection of the heater internally, pay attention to the heater floor, burner assembly, burners and snuffing steam connections, the refractory walls, bottom, mid and top tube guides and the seat as applicable and accessible. Inspect tubes, elbows/U-bends, and skin thermocouples for significant over heating, bulging, bowing /distortion and scaling of tubes and recommend cleaning for detailed inspection.

6.7.7

Evaluate if the heater tubes are adequately cleaned for inspection. If cleaning is not adequate to carry out inspection, request for further cleaning. Inspection after adequate cleaning: 6.7.7.1

Check tube surfaces externally for any significant corrosion, mechanical damage, bulge, tube distortion or bowing.

Page 20 of 90



6.7.7.2

Request for UT check on full length of tubes including elbows at top and bottom, random hardness at the most over heated area/flame impinged area. RT the inlet and outlet tubes including U bends (for metal loss, coking, cracking etc.). Also, concentrate on the shock and hip tubes if any. Compare and Evaluate results well in advance to predict problem areas.

6.7.7.3

Get Thermo-wells removed and skin thermocouple cleaned for visual and DP test and evaluates results. Request Thermowell continuity test for acceptance.

6.7.7.4

Check snuffing steam nozzles/connection for plugging and corrosion.

6.7.7.5

Check the floor bricks or refractory and wall refractory for any significant damage and request repairs as applicable.

6.7.7.6

Inspect the bottom U-bend and attachment tube guide for corrosion damage externally.

6.7.7.7 Inspect closely the interim tube guides, top tube guides and tube supports for damaged bolts, erosion/corrosion and damage to tube contact. 6.7.8

After completion of the full inspection, request any other needs for cleaning, repair or re-tubing if any. Hydrostatic test will be required if major repairs are executed for acceptance.

6.7.9


6.7.10

Carry out the final inspection on completion of the repairs and cleaning as applicable. Assess the heater condition for operation during the next EIS period. If heater inspection reveals the heater do not comply with the inspection finding for further service, then FFS assessment has to be done and the heater can go through minimally the EIS period, then request for change of EIS schedule. Request a partial or full re-tubing of the heater next time with spare tubes on hand for replacement.

6.7.11

On completion of inspection and repairs if any, the heater will be tested from the tube side at its test pressure (Design pressure x 1.5 for heater built before 1999 and 1.3 x design for those built after 1999) only if repairs are performed. Refer to the name plate for the test pressure in addition to the SIS for the test pressure. Tube leaks at hydrostatic test should be renewed partially or in full as deemed and retested.

Page 21 of 90


6.7.12

6.8


Applicable standards and codes: SAEP-20, SAES-W-010, SAES-A004, ASME SEC VIII D1, API STD 530 and API STD 510. Any repair to the heater will be hydrostatically tested per SAES-A-004 and ASME SEC VIII D1. Test procedure shall be provided by operation engineer of the unit or waivers shall be submitted per SAEP-20 in advance. The test or waiver documents shall be filed for reference.

Reformer Heater 6.8.1

Check the heater drawing, material of radiant and convection tubes, tube support/tube guide, refractory, Thermo well, Damper plates and dimensions of individual items (diameter, length and thickness) as applicable to the heater (horizontal). Check the burner assembly and orientation of burner tip and material.

6.8.2

Read the heater file and note history of corrosion, tube failures, history of over heating, failures and re-tubing frequency, if any and other replacement or repairs.

6.8.3


6.8.4

Primarily carry out external inspection for external flue gas leaks, external damage to heater casing, and structure’s, Burner blocks and fuel leaks. It is suggested an infrared survey is done prior to shutdown of the heater to identify hotspots and hot tubes and any refractory damage to heater casing.

6.8.5

Gas tests the heater internally before entry to the heater for internal inspection. Check the heater has adequate venting and free from any foul smell/toxic gas release while scales or deposit are disturbed. Check for adequate lighting and scaffold as required for inspection. Also, at the time of vessel entry ensure a man stand by is available, for your safety and company loss prevention.

6.8.6

Start preliminary visual inspection of the heater internally, pay attention to the heater floor, burner assembly, burners, snuffing steam connections, and the refractory walls. 6.8.6.1

Number the tubes per cell starting from north to south or west to east vice versa.

6.8.6.2

Inspect individual tube, for overheating, bulging, bowing, surface discontinuities, such as micro fissuring, cracks and

Page 22 of 90



the like. Attention to be paid in locations opposite to the burner or flame area. 6.8.6.3

6.8.7

Carry out creep measurement on all tubes; compare the results with the previous creep measurement results. Evaluate the creep behavior. Recommend all tubes with creep above 3.5% for renewal. Arrange Magnetize, LOTIS or H-scan to carry out creep measurement and evaluate the results aided by computer, which will give the tube renewal criteria based on creep and crack initiation in the tube. Crack indication above 30% should be considered for renewal if not sooner.

Evaluate if the heater tubes are adequately cleaned for inspection. If cleaning is not adequate to carry out inspection, request for adequate cleaning. Inspection after adequate cleaning: 6.8.7.1

Check tube surfaces externally for any significant corrosion, mechanical damage, bulge, tube distortion or bowing and fissuring.

6.8.7.2

Get Thermo-wells removed and cleaned for visual and DP test and evaluate results. Request Thermowell continuity test for acceptance.

6.8.7.3

Check snuffing steam nozzles/connection for plugging and corrosion.

6.8.7.4 Check the floor bricks, refractory and wall refractory for bulge or any significant damage. Request repairs if required as applicable. 6.8.7.5

Inspect the bottom transfer/pigtail pipe over heating and for crack damage externally. Carry out PT test on all weld joints for cracks.

6.8.7.6 Inspect the inlet pigtail pipe for crack damage at the weld joints at inlet header and catalyst tube. Open the blind nozzle flanges on the inlet header, check for fouling. If required get it cleaned free of the foulant. 6.8.7.7

Inspect the steam generator, economizer and super heater coils visually and by UT gauging.

6.8.7.8

Check the dampers and their operability. Page 23 of 90



6.8.7.9 Inspect the stack where accessible for cleanliness and refractory damage.

6.9

6.8.8


6.8.9


6.8.10

Carry out the final inspection on completion of the repairs and cleaning as applicable. Assess the heater condition for operation during the next EIS period. If heater inspection reveals the heater do not comply with the inspection finding for further service, then FFS assessment has to be done and the heater can go through minimally the EIS period, then request for change of EIS schedule. Request a partial or full re-tubing of the heater next time with spare tubes on hand for replacement.

6.8.11

On completion of inspection and repairs if any, the heater will be tested from the tube side at its test pressure (Design pressure x 1.5 for heaters built before 1999 and 1.3 x after 1999). Refer to the name plate for the test pressure in addition to the SIS for the test pressure. Tube leaks at hydrostatic test should be renewed as deemed and retested. Hydrostatic test in the case of this heater shall not be practical due to the catalyst and the refractory. Therefore, the heater shall be tested pneumatically with prior approval or leak tested with a waiver in lieu of hydrostatic test.

6.8.12

Applicable standards and codes: SAEP-20, SAES-W-010, ASME SEC VIII D1, API STD 530 and API STD 510. Any repair to the heater will be hydrostatically tested per SAES-A-004 and ASME SEC.VIII D1 if not a waiver shall be processed and leak test shall be performed at the available plant nitrogen pressure. Test procedure shall be provided by operation engineer of the unit or waivers shall be submitted per SAEP20 in advance. The test or waiver documents shall be filed for reference.

Industrial Boilers 6.9.1

Check the boiler drawing, material, size of tubes, fire bricks and refractory, Steam drum internals, Baffle plates and dimensions of individual items (diameter, length and thickness) as applicable to the boiler. Check the burner assembly, orientation of burner tip and material.

6.9.2

Read the boiler file and note history of corrosion, tube failures, history of overheating, boiler failures and re-tubing frequency, and other forms of repairs or replacement if any. Page 24 of 90



6.9.3


6.9.4

Carry out preliminary external inspection for external flue gas leaks, external damage to boiler casing, and structure’s, Burner assembly and fuel leaks.

6.9.5

Gas tests the boiler internally before entry to the boiler for internal inspection. Check the boiler has adequate venting and free from any foul smell/toxic gas release while scales or deposit are disturbed. Check for adequate lighting and scaffold as required for inspection. Also, at the time of vessel entry ensure a man stand by is available, for your safety and company loss prevention.

6.9.6

Start preliminary visual inspection of the boiler internally, (furnace or fire box, bank and super heater section, flues gas duct, steam and mud drums, economizer if available) pay attention to the boiler floor, bank tubes, burner assembly, burners, the refractory to the walls and roof, flue gas duct and stack.

6.9.7

Inspect tubes, bends, significant overheating of target wall tubes, bulging, bowing /distortion and scaling of tubes. Recommend tube external and internal cleaning for detail inspection.

6.9.8

Evaluate if the boiler tubes are adequately cleaned for inspection. If cleaning is not adequate to carry out inspection, request for further cleaning. Inspection after adequate cleaning: 6.9.8.1

Check tube surfaces externally for any significant corrosion or mechanical damage, bulge, tube distortion or bowing. Concentrate on the target wall and roof tubes for possible flame impingement and tube surface bulge.

6.9.8.2

Request UT for full length of tubes including bends, Hardness at random locations most affected by flame. Compare and Evaluate results well in advance to predict problem areas.

6.9.8.3

Inspect the steam drum and internals for cracks, corrosion and other damages. Inspect all tubes internally using boroscope to assess the tube ID condition. Evaluate if chemical cleaning is to be performed. Also, mark a meter length tube for scale measurement if tube ID’s are heavily scaled or every other T&I.

Page 25 of 90


6.10


6.9.8.4

Inspect the mud drum for corrosion accumulated deposit. Tube ends and tube end thinning and the like.

6.9.8.5

Inspect the flue gas duct, stack for accumulated ash, clean and inspect for cracks and damage to the refractory that may eventually result in flue gas leaks while in operation.

6.9.9


6.9.10


6.9.11

Carry out the final inspection on completion of the repairs and cleaning as applicable. Assess the boiler condition for operation during the next EIS period. If heater inspection reveals the heater do not comply with the inspection finding for further service, then FFS assessment has to be done and the heater can go through minimally the EIS period, then request for change of EIS schedule. Request a partial or full re-tubing of the heater next time with spare tubes on hand for replacement.

6.9.12

On completion of inspection and repairs if any, the boiler shall be pressure tested at its test pressure (Design pressure x 1.5). Refer to the name plate for the test pressure in addition to the SIS for the test pressure. Tube leaks at hydrostatic test should be renewed partially or in full as deemed and retested.

6.9.13

Applicable standards and codes: SAEP-20, SAES-W-010, ASME SEC VIII D1, API STD 530 and API STD 510. Any repair to the heater will be hydrostatically tested per SAES-A-004 and ASME SEC VIII D1. Test procedure shall be provided by operation engineer of the unit or waivers shall be submitted per SAEP-20 in advance. The test or waiver documents shall be filed for reference.

6.9.14

After the commissioning the boiler, the safety valves should be floated prior to full operation. An in-place test procedure should be followed strictly in performing the test.

Tanks 6.10.1

Check the tank drawing, construction codes, and material of construction, internal parts, and dimensions (diameter, height and thickness).

6.10.2

Read the tank file and note history of corrosion, repairs and replacement if any.

Page 26 of 90



6.10.3

Carry out joint inspection (check includes ventilation, blinds, scaffolds and lighting) and obtain entry permit to ensure the Tank is safe to enter and inspect. At the time of inspection keep a man watch for your safety.

6.10.4

Primarily carry out external inspection for external leaks, external damage, insulation or paint damage, external corrosion.

6.10.5

Ensure the tank is isolated with proper blinds. Obtain entry permit from operation. Prior to internal inspection entry gas test to make sure no toxic gases are released. While entry to the tank, have a man stand by at the manway for your safety and company loss prevention.

6.10.6

Start preliminary inspection at all manways (manway inspection) going from bottom (all around) to the top. Record the observations on a note pad at each level. Start entering the tank from the bottom man way and assess the conditions of nozzles, tank bottom plates, tank shell plates, tank internal hardware’s (Columns, float, supports/legs, sumps, etc.). Identify each item and note the observations for your inspection evaluation.

6.10.7

While performing detail inspection look for pitting corrosion, erosion/corrosion, channeling, weld erosion/corrosion and cracks, mechanical damages while opening and closing, environmental cracking, bulging and blistering and the like are some that will be noted with in the tanks. Coating conditions, if coated. A good cleaning and careful evaluation will help make a good decision. Some time Fitness for Service inspection (FFS) assessment will be required and full evaluation will have to be done from design, operation, and history of operation to increase the service life of the tank.

6.10.8

After completion of the full inspection, request any other needs for cleaning or removal and cleaning of internals for detail inspection and repairs or renewal if any.

6.10.9

Follow up the recommendations and the related repairs per Saudi Aramco standards, the codes, ASME and API. Carry out the final inspection on completion of the repairs and cleaning as applicable. Assess the tank condition for operation during the next EIS period. If FFS assessment is done and the tank can go through minimally the EIS period, then request for change of EIS schedule. Request replacement of the tank plates.

6.10.10 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-326, SAES-D-008, SAES-W-010, SAES-W-015, ASME SEC VIII D1, API Page 27 of 90



STD 510, and API STD 653. Any repair to the tank will be hydrostatically tested per SAES-A-004. Test procedure shall be provided by operation engineer of the unit or waivers shall be submitted per SAEP-20 in advance. The test or waiver documents shall be filed for reference.

26 November 2007

Revision Summary New Saudi Aramco Inspection Procedure.

Page 28 of 90



Attachment – A FLOWCHART-PROCESS EQUIPMENT EXTERNAL AND INTERNAL INSPECTION PER TYPICAL INSPECTION PLAN (TIP)

Page 29 of 90



Attachment – B I

TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT VESSELS Inspection Phase Reference 1

Reference and Records: Review the following: • Operation Procedure • SIS sheet information • EIS periods, revision and deviations • Equipment as built drawing • Design data 1. Material 2. Dimensions and Thickness 3. Pressure/Temperature 4. PWHT • OSI drawings and TML points

Project Data Books.

Equipment File Information: Review the following: • Historical T&I’s information • OSI information • Corrosion information • Repairs and frequency • Recommendation

Equipment file

3

Work permit (WP) and personnel safety: • Ensure your WP is valid. • Make sure what process products in the equipment • Have a joint inspection before accepting the permit • Have your own assessment before entry

GI-0002.1 & self

4

External inspection: Inspect the following: • Insulation and painting • Foundation, skirts, fire proof and support bolts and nuts • Nozzles including the manway • Flange Leaks • Any other leaks from the equipment • Enter findings in Operation/Inspection Log Book

00-SAIP-75

5

Internal inspection: Inspect the following: • Fouling and cleanliness • Top Head and Nozzles including manway • Demister Pad • Trays, scallops, catalyst, packing, support and support rings • Shell wall , clad, epoxy, in/out nozzles and manway • Bottom head and nozzles • Corrosion, Erosion, mechanical damage, etc., on internal • Enter findings in Operation/Inspection Log Book Worksheets and Tracking: • Issue worksheets on major findings • Follow up worksheet implementation and closure.

SAEP-20, SAEP-325, SAES-D-008, SAES-A004, API STD 510, API STD 572. Checklist-DI, DII, DIII

2

6

7

Equipment file

SAIF

Final Inspection: • Carry out final inspection on completion of maintenance activities and issue box up report.

Page 30 of 90



Page 31 of 90



Attachment – B Ii TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT HEAT EXCHANGERS Inspection Phase Reference 1

2

3

4

5

6

7

Reference and Records: Review the following: • Operation Procedure • SIS sheet information • EIS periods, revision and deviations • Equipment as built drawing • Design data 1. Material 2. Dimensions and Thickness 3. Pressure/Temperature 4. PWHT • OSI drawings and TML points Equipment File Information: Review the following: • Historical T&I’s information • OSI information • Corrosion information • Repairs and frequency • Recommendation Work permit (WP) and personnel safety: • Ensure your WP is valid. • Make sure what process products in the equipment • Have a joint inspection before accepting the permit • Have your own assessment before entry External inspection: Inspect the following: • Insulation and painting • Foundation, skirts, fire proof and support bolts and nuts • Nozzles including the manway • Flange or any other leaks from the equipment • Enter findings in Operation/Inspection Log Book Internal Inspection: Inspect the following: • Fouling and cleanliness of heads, shell and tube bundle. • Anodes and Epoxy if any. • Stationary Head welds, Pass Partician plates for weld damages and corrosion • Shell head and Floating Head welds for damages and corrosion • Nozzles, flange gasket faces • Shell, shell welds, nozzles and faces • Tube bundle • Tube sheets for damages and corrosion • Tubes inside and outside for corrosion thinning • Dimensional check of tubes, baffles • Tie rods and fasteners • Shell and Tube side hydro test • Enter findings in Operation/Inspection Log Book Worksheets and Tracking: • Issue worksheets on major findings • Follow up worksheet implementation and closure. Final Inspection: • Carry out final inspection on completion of maintenance activities and issue box up report

Project Data Books. Equipment file

Equipment file SAIF

GI-0002.1 & self

00-SAIP-75

SAES-A-004, SAEP-325, SAES-D-008, SAEP-317, API STD 510, API STD 660, API RP 572, ChecklistDIV, DV, DX.

Page 32 of 90



Attachment – B Iii TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT AIR FIN COOLERS Inspection Phase Reference 1

Reference and Records: Review the following • Operation Procedure • SIS sheet information • EIS periods, revision and deviations • Equipment as built drawing • Design data 1. Material 2. Dimensions and Thickness 3. Pressure/Temperature 4. PWHT • OSI drawings and TML points

Project Data Books.


Equipment file

3


GI-0002.1 & self

4

External inspection: Inspect the following: • Insulation and painting • Foundation, skirts, fire proof and support bolts and nuts • Nozzles including the manway • Flange or any other leaks from the equipment • Enter findings in the log book

00-SAIP-75

5

Internal Inspection: Inspect the following: • Headers: Inspect header plugs, headers and plug sheets and gaskets • Tubes ID and OD for corrosion and damages • Nozzles, vents and drains • Tube fins, Shroud and hood, structure, fan assembly, ladders and platform • Hydro test • Enter findings in the log book

SAES-A-004, SAES-D-008, SAEP-317, API STD 510, API STD 661, API RP 572,Checklist-DVI

6

Worksheets and Tracking: • Issue worksheets on major findings • Follow up worksheet implementation and closure. Final Inspection: • Carry out final inspection on completion of maintenance activities and issue box up report

2

7

Equipment file

SAIF

Page 33 of 90



Attachment – B Iv TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT -HEATERS Inspection Phase Reference 1

2

3


Project Data Books.


Equipment file


Equipment file

SAIF

GI-0002.1 & self

4


00-SAIP-75

5

Internal inspection: Inspect the following: • Heater casing and painting • Burners and burner tips • Heater floor and fire bricks/refractory • Wall and roof refractory • Radiant tubes • Tube guides-bottom, mid and top • Convection tubes and tube guides • Repairs and hydro test • Enter findings in the log book Worksheets and Tracking: • Issue worksheets on major findings • Follow up worksheet implementation and closure. Final Inspection: • Carry out final inspection on completion of maintenance activities and issue box up report

SAES-A-004, SAES-D-008, SAEP-325, API STD 510, API STD 530, API STD 560, API RP 573, Checklist-DVII

6

7

Page 34 of 90



Attachment – B V TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT - BOILERS Inspection Phase

Reference


Project Data Books.


Equipment file

3


GI-0002.1 & self

4


00-SAIP-75

5

Internal inspection: Inspect the following: • External inspection of casing, foundations and stacks. • Furnace, burners, floor bricks and refractory • Furnace tubes, super heater tubes, bank tubes and economizer tubes • Inlet and outlet ducts • Steam drum and internals • Mud drum and internal • UT, RT, MPI, boroscoping boiler tubes and drums • Gauge glass, side glass, man ways • Soot blower elements • Stack and internal refractory • Enter findings in the log book Worksheets and Tracking: • Issue worksheets on major findings • Follow up worksheet implementation and closure. Final Inspection: • Carry out final inspection on completion of maintenance activities and issue box up report

SAES-A-004, SAES-D-008, SAEP-325, API STD 510, API RP 573, Checklist-DIX

1

2

6

7

Equipment file

SAIF

Page 35 of 90



Attachment – B Vi TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT -TANKS Inspection Phase Reference 1

2

3

4

5

Reference and Records: Review the following: • Operation Procedure • SIS sheet information • EIS periods, revision and deviations • Equipment as built drawing • Design data 1. Material 2. Dimensions and Thickness 3. Pressure/Temperature 4. PWHT • OSI drawings and TML points Equipment File Information: Review the following: • Historical T&I’s information • OSI information • Corrosion information • Repairs and frequency • Recommendation Work permit (WP) and personnel safety: • Ensure your WP is valid. • Make sure what process products in the equipment • Have a joint inspection before accepting the permit • Have your own assessment before entry External inspection: Inspect the following: • Insulation and painting • Foundation, skirts, fire proof and support bolts and nuts • Nozzles including the manway • Flange or any other leaks from the equipment • Enter findings in the log book Internal Inspection: Inspect the following: • Overview • Tank External • Bottom Interior service • Shell seams and Plates • Roof Interior surface • Fixed Roof Supports • Fixed roof appurtenance • Breathers and vents • Emergency P/V Hatches • Floating roof • Floating roof pontoons • Floating roof supports • Primary shoe and toroidal assembly • Rim mounted secondary’s • Floating roof appurtenances 1. Roof manways, 2. Rim vents, 3. Vacuum breakers 4. Roof drains, open & closed, 5. autogauge systems & alarms • Common Tank Appurtanaces • Shell Nozzles • Diffusers and rolling systems • Swing lines • Accesses structures • Platform Frames • Deck plates and gratings • Rolling ladder • Enter findings in the log book

Project Data Books. Equipment file

Equipment file SAIF

GI-0002.1 & self

00-SAIP-75

API STD 620, API STD 650, API STD 653, ChecklistXI, SAES-A-004

Page 36 of 90



Attachment – B Vi (Cont'd) TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT -TANKS Inspection Phase Reference 6

7

Worksheets and Tracking: • Issue worksheets on major findings • Follow up worksheet implementation and closure. Final Inspection: • Carry out final inspection on completion of maintenance activities and issue box up report

Page 37 of 90



Attachment: C I – Inspection Checklist For Process Equipment-Vessel Report No.: Equipment No. & Service Reason for Inspection: P&E Inspector:

Date prepared: Location/ Area: Field insp. Supervisor:

Equipment data: Shell Material Shell thickness (mm or in) Cladding/ Lining

Plant No.: Date Inspected Unit Supervisor :

Design Pressure, Kg/ cm²g or psig: Design Temp. °C or °F: Corrosion Allowance (mm or in) A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected

#

1.0 1.1 1.2

ITEM

Weld condition/corrosion, perform WFMPT for cracks.

1.4

Condition of manway gasket surface

1.5

UT measurement- Top head & Nozzles including Manway Internal and external cracks, erosion/corrosion, foreign deposit Insulation condition Condition of attachment welds (Includes Lift lugs, pipe supports etc.) External and Internal coating/painting

1.7 1.8 1.9

2.0 2.2 2.3


2.4

UT measurements-shell, cone section and heads Inspect distributors (channel and pipe with holes) for corrosion, erosion, fouling and blockage Inspect the inlet outlet and draw off nozzles for corrosion, erosion and thinning Condition of Internal coating, External paint, Insulation

2.5 2.6 2.7

3.0 3.1 3.2 3.3 3.4

4.0 4.1 4.2 4.3

NA

NI

COMMENTS

Shell: Cylindrical and Conical Internal Corrosion (scales, pits, buildup)/Cracking Describe location, appearance and depth Excessive scale presence. Describe

2.1

U

Internal Corrosion (scales, pits, buildup)/Cracking Describe location, appearance and depth. Excessive scale presence. Describe

1.3

1.6

A

Top Head and Nozzles

Demister Pad (DP) Check if demister pad is not disturbed Get DP removed and inspect vessel wall above and below including the attachments Inspect DP for fouling, damage and if compressed and assess if can be reused for another cycle Inspect DP fit up and attachment wires (size and material) on completion of DP fit up

Packing, Packing Beds, Shell and Distribut. Check the packing and beds for loss and disturbances. Check the packing and support beds and attachments for corrosion, mechanical damage and looseness Inspect the shell wall under the packing bed for corrosion, grooving and pitting

Page 38 of 90

Document Responsibility: Inspection Department Issue Date: 26 November 2007 Next Planned Update: TBD Report No.: Equipment No. & Service Reason for Inspection: P&E Inspector:

Guidelines for Process Equipment Inspection Date prepared: Location/ Area:

Field insp. Supervisor:

Equipment data: Shell Material Shell thickness (mm or in) Cladding/ Lining 4.4

00-SAIP-80


Design Pressure, Kg/ cm²g or psig: Design Temp. °C or °F: Corrosion Allowance (mm or in)

A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected Based on the finding (item 3.7) recommend complete removal of packing for shell wall inspection

Attachment: C I – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT-VESSEL (cont'd) Report No.: Equipment No. & Service Reason for Inspection: P&E Inspector:


Equipment data: Shell Material Shell thickness (mm or in) Cladding/ Lining


Design Pressure, Kg/ cm²g or psig: Design Temp. °C or °F: Corrosion Allowance (mm or in) A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected

ITEM

#

5.0

Check both top and bottom of trays for fouling

5.2

Check the tray floor for bulge/ level and corrosion Check the valves on trays for corrosion, looseness and mechanical damage Check the tray support ring condition and welds for corrosion/erosion Carry out dimensional check on trays and fittings.

5.4 5.5

6.0

Check if the lining clad or strip lining

6.2

Check if the vessel section or fully lined

6.3

Check the lining for disbanding and inspect all welds

6.4

Check for cracks or damage if lined with cement

6.5

Perform PT on welds

7.0

Bottom Head

7.2


7.3


7.4

Condition of man way gasket surface UT measurement- Top head and Nozzles including Manway Internal and external cracks, erosion/corrosion, foreign deposit

7.5 7.6

NA

NI

COMMENTS

Clad/Lining

6.1

7.1

U

Trays

5.1

5.3

A

Page 39 of 90

Document Responsibility: Inspection Department Issue Date: 26 November 2007 Next Planned Update: TBD Report No.: Equipment No. & Service Reason for Inspection: P&E Inspector: Equipment data: Shell Material Shell thickness (mm or in) Cladding/ Lining

00-SAIP-80 Guidelines for Process Equipment Inspection Date prepared: Location/ Area:



Design Pressure, Kg/ cm²g or psig: Design Temp. °C or °F: Corrosion Allowance (mm or in)

7.10

A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected Insulation condition Condition of attachment welds (Includes Lift lugs, pipe supports etc.) Check the Vortex breaker for weld cracks, corrosion or mechanical damage Check internal and external coating/painting

8.0

Foundation/Supports

8.1

Condition of skirt and fire proofing

8.2

Condition of support bolts

8.3

Condition of foundation

7.7 7.8 7.9

NOTES:

Page 40 of 90



Attachment: C-Ii – Inspection Checklist For Process Equipment- Reactor Vessel Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector:

Date prepared: Location/ Area: Field Insp. Supervisor:

Equipment data: Material Size/ Thick. Mm/in Cladding / Lining

Plant No.: Date Inspected: Unit Supervisor:

Design Press. Kg/ cm²: Design Temp. °C: Corrosion Allowance mm:

PSIG: O F: In:

A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected

#

1. 0 1.1 1.2 1.3

2. 0 2.1 2.2

ITEM

2.5

UT measurement- Top head and Manway

2.6

2.8

Inspect the internal clad for bulge, cracks, disbonding etc Check the condition of attachment and reinforcement pad welds (Includes Lift lugs, pipe supports etc.) for cracks Check the condition of insulation

2.9

Check the inlet distributor for damages

3. 0

Shell and Internals:

4. 0

Check the shell and top head clad for cracks, bulge channeling, disbonding etc. DP check the clad welds for cracks Check distributor tray and support ring for any abnormality

Bottom Head

4.3

Check the outlet grid and screen and grid support beam, attachment welds for any abnormalities Inspect the bottom head, oulet nozzle and catalyst dumping nozzle PT check all welds including the clad

5.

External

4.1 4.2

COMMENTS

Internal Erosion/Corrosion (scales, pits, buildup)/Cracking Describe location, appearance and depth. Excessive scale presence. Describe Weld condition/corrosion, perform WFMPT for cracks.

3.3

NI

Manway Nozzles and Top Head

Condition of manway gasket and groove

3.2

NA

Check inlet elbow for scaling, Mechanical damage Check both flanges, gasket faces and gasket for damage DP test the ring gasket and the flange groove for cracks

2.4

3.1

U

Inlet Elbow

2.3

2.7

A

Page 41 of 90

Document Responsibility: Inspection Department Issue Date: 26 November 2007 Next Planned Update: TBD Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector:


Field Insp. Supervisor:




PSIG: O F: In:


0 5.1 5.2 5.3

MPI and UT shear wave test all nozzle and attachment welds for cracking Test all vertical and circumferential seam welds by MPI and UT shear wave Technique Remove all Thermo wells and DP test Flanges, barrel for cracks and continuity test

Attachment: C-II – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT- REACTOR VESSEL (cont'd) Report No.: Equipment No. & Service:

Date prepared: Location/ Area:

Reason for Inspection: P&E Inspector:

Date Inspected: Unit Supervisor:



Plant No.:


PSIG: O F: In:


ITEM

#

5.5

Check all bolts used for closure are in good condition (Sample one bolt for tensile test) Check all gaskets are renewed in kind

5.6

Check the external insulation condition finally

6. 0

Foundation/Supports

6.1 6.2

Check condition of skirt and fire proofing Check condition of foundation and support bolts

5.4

A

U

NA

NI

COMMENTS

NOTES:

Page 42 of 90



Attachment: C-Iii – Inspection Checklist For Process Equipment - Platformer Reactor Vessel Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector:






PSIG: °F in


#

1.0 1.1 1.2

2.0

ITEM

2.3

Weld condition/corrosion

2.4

Condition of man way gasket face

2.5

2.8

UT measurement- Top head and Manway Inspect the internal deflection plates, Scallop keeper bars (for bending), breaking, missing or loose bolts and weld defects Check the condition of attachment and welds (Includes Lift lugs, pipe supports etc.) for cracks Check the condition of insulation

3.0

Internal, Scallops & Support Rings

2.7

3.1 3.2 3.3

3.4

4.0 4.1 4.2 4.3

5.0 5.1 5.2

NA

NI

COMMENTS

Top Head and Manway Nozzles

2.2

2.6

U

Check inlet elbow for excessive scaling, Mechanical damage Check both flanges and gasket faces

Internal Erosion/Corrosion (scales, pits, buildup)/Cracking Describe location, appearance and depth. Excessive scale presence. Describe

2.1

A

Inlet Elbow

Center pipe: Inspect for any damage caused( perforation burnt or holed ) Scallops: Inspect individually all for mechanical, heat damage and fouling or blocked ports Check all support rings for twisting and cracking Check the scallop support ring at the bottom of the reactor for mechanical, weld and seat damage

Shell Check the shell wall for corrosion, pits, channeling, cracking, bulge and mechanical damage UT measurements-shell and attachments DP or WFMPI test the seam, nozzle and attachment welds for cracks

Bottom Head Inspect the bottom head for pitting gouging and cracking Inspect the packing condition of the center pipe with the bottom head for tightness

Page 43 of 90



Attachment: C-III – Inspection Checklist for Process Equipment - Platformer Reactor Vessel Report No.:

Date prepared:

Equipment No. & Service:

Location/ Area:

Reason for Inspection:

Plant No.: Date Inspected:

P&E Inspector:


Unit Supervisor:

Equipment data: Material

Design Press. Kg/ cm²:

PSIG:

Size/ Thick. Mm/in

Design Temp. °C:

°F

Cladding / Lining

Corrosion Allowance mm:

in


ITEM

# 5.3

6.0 6.1 6.2 6.3

7.0 7.1 7.2

8.0 9.0

A

U

NA

NI

COMMENTS

UT measurement- Bottom head and Nozzles

Internal Assembly Check all internals are assembled correctly. Check clearance between internals are with in allowable limits Ensure the excess clearance are compensated by KAO wool packing if required

External MPI test all seam, nozzle and attachment welds for cracking Check the external insulation is in good condition Check all bolts used for closure are in good condition (Sample one bolt for tensile test) Check all gaskets are renewed in kind

10.0 Foundation/Supports 10.1

Check condition of skirt and fire proofing

10.2

Check condition of foundation and support bolts

NOTES:

Page 44 of 90



Attachment: C-Iv – Inspection Checklist For Process Equipment - Heat Exchanger Report No.: Equipment No. & Service:



Date Inspected: Unit Supervisor :


Equipment data: DESCRIPTION

Shell

TUBES

Plant No.:

DESCRIPTION

Material

Design Pressure Kg/cm²g/psig

Thick. mm/in

Design Temperature °C / °F

Corrosion Allowance mm /in

SHELL

TUBES

Hydro Test Pressure Kg/cm²g/psig A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected

# ITEM 1.0 Channel Head, Cover and Nozzles 1.1 1.2 1.3 1.4 1.5 1.6 1.7

A

U

NA

NI

COMMENTS

Internal Corrosion (scales, pits, buildup)/Cracking Describe location, appearance and depth. Excessive scale presence. Describe Weld condition/corrosion & condition of Pass partition plate Condition of gasket surfaces UT measurement- Channel and Nozzles Internal and external cracks, erosion/corrosion, foreign deposit Insulation condition

1.8

Condition of attachment welds (Includes Lift lugs, etc.)

1.9

Channel cover

1.10

Check instrument connection for corrosion damage

1.11

Internal/External coating/painting

2.0 Shell: Cylindrical and Conical

2.7

Internal Corrosion (scales, pits, buildup)/Cracking Describe location, appearance and depth. Excessive scale presence. Describe Weld condition/corrosion (both longitudinal and circumferential) UT measurements-shell, cone and nozzles Inspect lining and distributors if provided for corrosion, erosion, fouling and blockage Inspect the inlet, outlet nozzles for corrosion, erosion and thinning Inspect gasket faces

2.8

Condition of external paint, insulation

2.1 2.2 2.3 2.4 2.5 2.6

3.0 Demister Pad (DP) 3.1 3.2 3.3 3.4

Check if demister pad is not disturbed Get DP removed and inspect shell wall above and below including the attachments Inspect DP for fouling, damage and if compressed and assess if can be reused for another cycle Inspect DP fit up and attachment wires (size and material ) on completion of DP fit up

Page 45 of 90



Attachment: C-IV – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - HEAT EXCHANGER Report No.:

Date prepared:


Location/ Area:





Shell

TUBES

Plant No.:

DESCRIPTION

Material


Thick. mm/in



SHELL

TUBES


ITEM

#

A

U

NA

NI

COMMENTS

4.0 Tube Bundle 4.1 4.2 4.3 4.4 4.5 4.6

Check tube ID & OD fouling. Describe the extend of fouling and locations Measure ID and OD and compare to the original for metal loss Visually inspect ID and OD for pits measure the depth of pit Inspect tube ends for corrosion thinning. If tube to tube-sheet welded, then perform DP test to ensure no crack Check the tube sheet for corrosion, erosion and any mechanical damage

Notes:

4.7 4.8 4.9 4.10

Eddy current testing and evaluation of the tube condition Mark defective tubes for plugging or re-tubing as required Check baffle plates for corrosion, thinning and enlarged tube holes Check tie-rods for corrosion & damage

5.0 Floating Head Cover 5.1 5.2

Check for corrosion, erosion & pits Check gasket face for corrosion, erosion, pit or mechanical damage

Page 46 of 90



Attachment: C-IV – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - HEAT EXCHANGER

Report No.: Equipment No. & Service:



Plant No.:




Shell

TUBES

DESCRIPTION

Material


Thick. mm/in



SHELL

TUBES


ITEM

#

A

U

NA

NI

COMMENTS

6.0 Shell Cover 6.1 6.2 6.3 6.4

Check for corrosion, erosion & pits Check gasket face for corrosion, erosion, pit or mechanical damage UT check Check vent and drain for blockage and corrosion thinning

7.0 Foundation/Supports 7.1

Condition of support saddle and fire proofing

7.2


7.3


8.0 Hydrostatic Test 8.1 8.2 8.3

Test from shell side # Design x 1.5 (Built before1999 and 1.3 after 1999) Test from Tube side # Design x 1.5 (Built before1999 and 1.3 after 1999) Final Test from shell side # Design x 1.5 (Built before1999 and 1.3 after 1999)

NOTES:

Page 47 of 90



Attachment: C-V – Inspection Checklist For Process Equipment - Vertical Heat Exchanger Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector:


Equipment data: DESCRIPTION Material Thick. mm/in Corrosion Allowance mm/in

Shell

TUBE

Plant No.: Date Inspected: Unit Supervisor :

DESCRIPTION Design Pressure Kg/cm²g/psig Design Temperature Deg °C /°F Hydro Test Pressure Kg/cm²g/psig

Shell

Tube


# 1.0

ITEM Channel Head, Cover and Nozzles

1.2


1.3


1.4

Condition of gasket surfaces

1.5

UT measurement- Channel and Nozzles

1.1

1.6

Internal and external cracks, erosion/corrosion, foreign deposit

1.7

Insulation condition

1.8


1.9

Channel cover

1.10


1.11

External coating/painting

2.0

Shell

2.2


2.3

Weld condition/corrosion (both longitudinal and circumferential)

2.4

UT measurements-shell, cone and nozzles Inspect lining if provided. Check for corrosion/erosion, disbanding and bulges Inspect the inlet, outlet nozzles for corrosion, erosion and thinning

2.1

2.5 2.6 2.7

Inspect gasket faces

2.8

Condition of external paint, insulation

3.0

Check if bellow is dimensionally not disturbed

3.2

PT check the bellow for cracks Request and Witness the Pressure test of the bellow at 1.5 x design differential pressure

4.0

NA

NI

COMMENTS

Tube Bundle

4.2

Check tube ID and OD fouling. Describe the extend of fouling and locations Measure ID and OD and compare to the original for metal loss

4.3

Visually inspect ID and OD for pits, measure the depth of pit and record

4.1

U

Bellow

3.1

3.3

A

Page 48 of 90

Document Responsibility: Inspection Department Issue Date: 26 November 2007 Next Planned Update: TBD Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector: Equipment data: DESCRIPTION Material Thick. mm/in Corrosion Allowance mm/in 4.4


Field insp. Supervisor: Shell

TUBE



Shell

Tube

A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected Inspect tube ends for corrosion thinning/weld erosion/cracks.

Page 49 of 90



Attachment: C-V – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - VERTICAL HEAT EXCHANGER Report No.: Equipment No. & Service: Reason for Inspection:



P&E Inspector:


Unit Supervisor :

Equipment data: DESCRIPTION Material Thick. mm/in Corrosion Allowance mm/in

Shell

TUBE


Shell

Tube


ITEM

# 4.5

If tube to tube-sheet welded, then perform PT test to ensure no crack

4.6

Check the tube sheet for corrosion, erosion and any mechanical damage

4.7

Eddy current testing and evaluate tube condition

4.8

Mark defective tubes for plugging or re-tubing as required

4.9

Check baffle plates for corrosion, thinning and enlarged tube holes

4.10

Check tie-rods for corrosion and damage

A

U

NA

NI

COMMENTS

Notes:

5.0 5.1 5.2

6.0

Floating Head (cone type) Check for corrosion, erosion and pits Check gasket face for corrosion, erosion, pit or mechanical damage

Shell Cover

6.1 6.2 6.3

Check for corrosion, erosion and pits Check gasket face for corrosion, erosion, pit or mechanical damage UT check

6.4

Check vent and drain for blockage and corrosion thinning

7.0 7.1

Foundation/Supports Condition of support saddle and fire proofing

7.2


7.3


Page 50 of 90



Attachment: C-V – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - VERTICAL HEAT EXCHANGER Report No.: Equipment No. & Service: Reason for Inspection:



P&E Inspector:


Unit Supervisor :


Shell

TUBE

DESCRIPTION

Shell

Material


Thick. mm/in

Design Temperature Deg °C /°F

Tube

Hydro Test Pressure Kg/cm²g/psig

Corrosion Allowance mm/in


ITEM

#

8.0 8.1 8.2 8.3

A

U

NA

NI

COMMENTS

Hydrostatic Test Hydro test shell and tube side at 1.5 x differential pressure-Test from shell side # Design x 1.5 (Built before1999 and 1.3 after 1999) Test from Tube side # Design x 1.5 (Built before1999 and 1.3 after 1999) Final Test from shell side # Design x 1.5 (Built before1999 and 1.3 after 1999)

NOTES:

Page 51 of 90



Attachment: C-Vi – Inspection Checklist For Process Equipment - Fin Fan Cooler Report No.:

Date prepared:

Equipment No. & Service: Reason for Inspection: P&E Inspector:

Location/ Area: Field insp. Supervisor:



HEADERS

TUBES

DESCRIPTION

Material

Design Press.: Kg/cm²g/psig

Shell Thick: mm/ in

Design Temp.: oC/oF

Corrosion Allowance: mm/ in

Corrosion allowance: mm/in A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected

# 1. 0

ITEM

1.2 1.3

Weld condition/corrosion and condition of Pass partition plate

1.4

Condition of all plug gasket surfaces and threads

1.5

UT measurement- Header box plates and Nozzles

1.6

Internal and external cracks, erosion/corrosion, deposit

1.7


1.8

Header plug seat/gasket face and threads

1.9


1.10

Check the vent and drain for plugging and corrosion

1.11


2. 0 2.2 2.3

condition of Pass partition plate and Weld/ corrosion

2.4

Condition of all plug gasket surfaces and threads

2.5

UT measurement- Header box plates and Nozzles

2.6

Internal and external cracks, erosion/corrosion, foreign deposit

2.7


2.8

Header plug seat/gasket face and threads

2.9


2.10


3. 0 3.1 3.2

NI

COMMENTS

Outlet Header and Nozzles Internal Corrosion (scales, pits, buildup)/Cracking Describe location, appearance and depth if accessible. Excessive scale presence. Describe

2.1

NA

Inlet Header and Nozzles Internal Corrosion (scales, pits, buildup)/Cracking Describe location, appearance and depth if accessible. Excessive scale presence. Describe

1.1

A U

Tubes Visually see through the plug holes for tube end thinning and fouling at both headers Check tube leak marks behind the tube sheet

Page 52 of 90



Report No.:

Date prepared:

Equipment No. & Service: Reason for Inspection: P&E Inspector:

Location/ Area: Field insp. Supervisor:



HEADERS

TUBES

DESCRIPTION

Material


Shell Thick: mm/ in

Design Temp.: oC/oF


Corrosion allowance: mm/in

3.4

A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected Get random RT taken on accessible tubes, around headers and at mid section and evaluate corrosion Check if tubes are sagged/bowed

3.5

Check condition of tube fins for damage or flattening

3.3

Page 53 of 90



Attachment: C-VI – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - FIN FAN COOLER Report No.:

Date prepared:


Location/ Area:

Plant No.:

Reason for Inspection:

Date Inspected:

P&E Inspector:


Unit Supervisor :

Equipment data: HEADERS

DESCRIPTION

TUBES

DESCRIPTION

Material


Shell Thick: mm/ in

Design Temp.: oC/oF



ITEM

# 3.6

Inspect tube ends for thinning at both headers

3.7

Carry out MFL test to all or 10% of tubes and evaluate the results

3.8

Unacceptable tubes for plugging to be marked on site

3.9

Check the side frames for any possible damage Check the condition of stiffeners, tube spacers, tube keepers and tube support cross members

3.10

4. 0

Foundation/Supports

4.1

Condition of supporting columns/ beams and fire proofing

4.2


4.3


5. 0

General

5.1

Check the fan blades for cleanliness

5.2

Check the Plenum, fan ring, fan deck

5.3

Check the drive assembly for any abnormality

5.4

Check ladder and platforms if they are intact

A

U

NA

NI

COMMENTS

NOTES:

Page 54 of 90



Attachment: C-VI – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - FIN FAN COOLER Report No.:

Date prepared:


Location/ Area:

Plant No.:


Date Inspected: Field insp. Supervisor:

Unit Supervisor :


HEADERS

TUBES

Details

DESCRIPTION 2

Material

Design Pressure Kg/cm , psig

Shell Thick: mm/ in

Design Temperature Deg °C / °F


Hydro Test Pressure in Kg/cm2 , psig A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected

#

ITEM

A

U

NA

NI

COMMENTS

Notes:

6.0

Hydrostatic Test

6.1

Test from Tube side # Design x 1.5 (Built before1999 and 1.3 after 1999)

NOTES:

Page 55 of 90



Attachment: C-Vii – Inspection Checklist For Process Equipment - Heater Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector:


Equipment data: Description Tube Material Size/ Thick.: mm/in Thickness: mm/in

Tubes


Description Design Press.: Kg/cm²g/psig Design Temp.: oC/oF Corrosion allowance: mm/in


# 1.0 1.1

ITEM Tubes - Radiant

1.3

External scale External corrosion-describe location appearance and depth Sagging/bulges/blisters

1.4

Tube OD measurement

1.5

Externally cleaned

1.2

1.6

Internally cleaned

1.7

UT measurement- Tubes and bends

1.8

Hardness measurement

1.9

Radiographic Inspection

1.10

Internal cracks, erosion/corrosion, foreign deposit

1.11

Tube supports and hardware

1.12

Weld condition

2.0

External scales/debris

2.2

Tube fin condition

2.3

Tube supports and hardware’s

2.4

UT measurements, accessible locations

2.5

Tube distortion and bulges

NA

NI

COMMENTS

Fittings

3.1

Corrosion-describe location appearance and depth

3.2

Distortion

3.3

Condition of tube rolls, plugs and threads

3.4

UT measurement

4.0

U

Tubes - Convection

2.1

3.0

A

Casing and Internals

4.1

Insulation/Refractory

4.2

Insulation clips

4.3

Fire bricks

4.4

Inspection doors/ burner view port

4.5

Convection section

Page 56 of 90



Attachment: C-VII – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - HEATER Report No.:

Date prepared:


Location/ Area:




Equipment data: Description

Plant No.:

Tubes

Description

Tube Material


Size/ Thick.: mm/in

Design Temp.: oC/oF

Thickness: mm/in


ITEM

# 4.6

Thermowells

4.7

Explosion door condition

4.8

Casing condition

4.9

Condition of external coating

4.10

Condition of access doors

5.0

Corrosion, deterioration of burner tips, coking

5.2

Condition of pilot burner

5.3

Thermocouple condition

5.4

Burner tiles condition

6.0

Heater Stack

6.1

External condition

6.2

Condition of support bolts and guy wire

6.3

Internal refractory

6.4

External insulation and coating

6.5

Condition of damper

6.6

Check if the damper blade is scaled or overheated

7.1

NA

NI

COMMENTS

Foundation/Supports Condition of concrete support

7.2

Condition of steel support

7.3

Condition of fireproofing

8.0

U

Burner Assembly

5.1

7.0

A

Hydrostatic Test

8.1

Witness pressure test

8.2

Look for flange, and tube leaks.

NOTES:

Page 57 of 90



Attachment: C-Viii – Inspection Checklist For Process Equipment - Reformer Heater Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector:

Date prepared: Location/ Area: Date Inspected: Unit Supervisor :


Equipment data: Description Tube Material Size/ Thick.: mm/in Thickness: mm/in

Tubes

Plant No.:

Description Design Press.: Kg/cm²g/psig Design Temp.: oC/oF Corrosion allowance: mm/in


#

1.0 1.1 1.2 1.3 1.4 1.5

ITEM

Internally cleaned

1.7

UT measurement- Tubes and bends

1.8

Hardness measurement

1.9

1.12

Radiographic Inspection Internal or external cracks, erosion/corrosion, foreign deposit Tube supports & hardware and lugs Condition of Counter weight, connecting cable and obstruction to movements Tube weld condition

2.0

Tubes - Convection

1.11 1.12

2.1

External scales/debris

2.2

Tube fin condition

2.3

Tube supports and hardware’s

2.4

UT measurements, accessible locations

2.5


3.0 3.1

NA

NI

COMMENTS

Fittings Corrosion-describe location appearance and depth

3.2

Distortion

3.3

Condition of tube rolls, plugs and threads

3.4

UT measurement

4.0

U

External scale External corrosion-describe location appearance and depth Sagging/bulges/blisters Tube OD measurement, Manual, eddy current or Lotis, H Scan Externally cleaned

1.6

1.10

A

Tubes - Radiant

Casing and Internals

4.1

Insulation/Refractory

4.2

Insulation clips

4.3

Fire bricks

Page 58 of 90



Attachment: C-VIII – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - REFORMER HEATER Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector:


Equipment data: Description


Tubes

Description

Tube Material


Size/ Thick.: mm/in

Design Temp.: oC/oF

Thickness: mm/in


ITEM

# 4.4

4.5

Inspection doors/ burner view port Convection section Condition of tubes, elbows/bends and refractory

4.6

Thermowells

4.7

Explosion door condition

4.8

Heater casing condition

4.9


4.10


5.0

Burner Assembly

5.1


5.2


5.3


5.4


6.0

Heater Stack

6.1

External condition

6.2


6.3

Internal refractory

6.4


6.5

Condition of damper

7.0 7.1

U

NA

NI

COMMENTS

Foundation/Supports Condition of support and fire proofing

7.2


7.3

Condition of fireproofing

8.0

A

Pneumatic or Hydrostatic test

8.1


8.2

Look for flange, roll and tube leaks.

NOTES:

Page 59 of 90



Attachment: C-Ix – Inspection Checklist For Process Equipment - Boiler Equipment No. & Service: Reason for Inspection: T&I Equipment data: Boiler Type:

Location/ Area: P&E Inspector:

Manufacturer:

Design Pressure,

Model:

Design Temperature,

Design Code Equipment Data: Data: Steam Drum


Hydrotest pressure Water Drum

Furnace tubes

Super heater tubes

Bank tubes

Wall headers

Material OD or ID Thickness A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected

#

1.0 1.1 1.2

ITEM

NA

NI

COMMENTS

Corrosion (scales, pits, buildup)/Cracking Describe location, appearance and depth. Excessive scale presence. Describe Tubes free of blockage, scales

1.4


1.5

UT measurement- Drums

1.6

Condition of man way gasket surface

1.7

Tube boroscope inspection

1.8

Internal cracks, erosion/corrosion, foreign deposit

2.0

Tubes, Drums-Fireside

2.3

External tube corrosion, erosion, pitting (describe location and size) External drum corrosion, scales & deposits and insulation loss. Tube supports and hardware’s

2.4

UT measurements

2.5


2.2

U

Tubes, Drums-Waterside

1.3

2.1

A

2.6

External signs of roll leaks

2.7

Evidence of erosion from soot blowers

2.8

Condition of soot blowers

3.0

Headers

3.1

Internal scale and corrosion

3.2

Condition of hand hole plugs

3.3

External corrosion, erosion, deposits, scales

4.0

Water Column

4.1

Gage glass condition

4.2

Illuminators, reflectors, view glasses

Page 60 of 90



Attachment: C-IX – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - BOILER Equipment No. & Service: Reason for Inspection: Equipment data: Boiler Type: Manufacturer: Model: Design Code Equipment Data: Data: Steam Drum

Location/ Area: P&E Inspector:


Design Pressure, Design Temperature, Hydrotest pressure Water Drum

Furnace tubes

Super heater tubes

Bank tubes

Wall headers

Material OD or ID Thickness A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected

ITEM

# 4.3

Gage cocks and valves

4.4

Condition high and low water alarms

5.0

Casing

5.1

Condition of insulation/refractory

5.2

Condition of casing structures

5.3

Casing distorted, cracked, corroded or burnt

5.4

Any obstruction to thermal expansion

5.5

Condition all baffle tiles and caulking

5.6


5.7

Condition of external paint

6.0

Burner Assembly

6.1


6.2


6.3


6.4


7.0

Foundation/Supports

7.1

Condition of concrete support

7.2


8.0

Boiler Stack

8.1

External condition

8.2


8.3

Internal refractory

8.4


9.0

Hydrostatic Test

9.1

Witness pressure test Pressure tested # Design x 1.5 for boilers built before 1999 and Design x 1.3 after 1999 Look for flange, roll and tube leaks.

9.2 9.3

A

U

NA

NI

COMMENTS

NOTES:

Page 61 of 90



Attachment: C-X – Inspection Checklist For Process Equipment - Unfired Boiler Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector:


Equipment data: DESCRIPTION Material Thick.: mm/ in Corrosion Allowance :mm / in

Shell

Tube

--


DESCRIPTION Design Pressure Kg/psig Design Temperature Deg °C/ °F Hydro Test Pressure in Kg/psig

Shell

Tube


#

ITEM

1.0

A

U

NA

NI

COMMENTS

Tube-Waterside

1.2

Corrosion (scales, pits, buildup)/Cracking Describe location, appearance and depth. Excessive scale presence. Describe

1.3

UT measurement

1.4

Tube Distortion

1.5

Boroscope inspection

1.1

2.0

Tube/ Fireside

2.2

corrosion, erosion, pitting (describe location, appearance and size) Tubes blockage, scales, deposits

2.3

UT measurements

2.4

Tube boroscope inspection

2.5

Signs of tube roll leaks

2.6

Evidence of Tubesheet cracks

2.1

2.7

Refractory cracking and spalling

2.8

Ferrule conditions

3.0

Shell

3.1

Internal scale and corrosion

3.2

UT measurement

3.3

External condition

3.4


4.0

Gas Inlet/Outlet

4.1

5.0

Condition of insulation/refractory

Foundation/Supports

5.1

Condition of concrete support

5.2


6.0

Hydrostatic Test

6.1


6.2

Look for flange, roll and tube leaks.

NOTES:

Page 62 of 90



Attachment: C-Xi – Inspection Checklist For Process Equipment - Tank Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector:

Date prepared: Location/ Area: Date of Commissioning: Field insp. Supervisor:

Equipment data: Shell Material Shell thickness: mm/in


Design Pressure, Kg/ psig: Max. Operating level meters /ft:

Checklist Per API 653

CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected

# 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7

2.0 2.1 2.2 2.3

3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 3.14 3.15

ITEM

CA

NC

NI

COMMENTS

Overview Check the tank is cleaned, gas free and safe for entry Check the tank is completely isolated from service. Check the roof is adequately supported including fixed roof structures and floating roof legs Check for presence of falling objects hazards, such as corroded roof items and appurtenance, etc. Inspect slipping hazards on the tank floor and roof. Check structural welds on the accessways and clips Check surfaces required for inspection is free from debris and oily surfaces where welding is to be performed. Note areas requiring more cleaning or sand blasting

Tank External Inspect appurtenances opened during cleaning such as lower floating swing sheave assemblies, nozzle interior after removal of valves. Hammer test or UT check the roof Enter and inspect floating roof pontoon compartments

Bottom Interior Surface Use flash light parallel to the bottom plates and inspect the plates, welds and hammer test the entire bottom. Measure the depth of pitting and describe the appearance ( sharp, lake like, dense scattered etc. Mark areas for further inspection or patching Mark areas for coupon sampling for inspection. Inspect all welds for corrosion and leaks, particularly the shell to bottom plate weld. Inspect sketch plate for corrosion Check the internal sump. If liquid found, recommend for removal and inspect the welds and for corrosion. Locate and mark voids under the bottom plates Record bottom data on a lay out bottom drawing and list the number of plates to renew or patches required Vacuum test the bottom plate lap welds. Inspect closely any discolored or wet areas by hammer or UT scan. Check all reinforcement pads, supports and clips Inspect floating roof leg pads for pits, cuts etc Inspect column bases of fixed roof support pads for adequacy Check the area beneath the swing line cable for

Page 63 of 90



Date of Commissioning: Field insp. Supervisor:

Equipment data: Shell Material Shell thickness: mm/in CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected indication of cable cutting or damage




Page 64 of 90



Attachment: C-XI – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT – TANK (cont'd) Report No.:

Date prepared:


Location/ Area:



Equipment data: Shell Material


Design Pressure, Kg/ psig:

Shell thickness: mm/in

Max. Operating level meters /ft:



# 3.16 3.17

4.0

ITEM

4.8 4.9

Check tank overflow nozzle internally & externally

4.2 4.3 4.4 4.5 4.6 4.7

5.0 5.1. 0 5.1.1

5.1.2 5.1.3 5.1.4

5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.2.6

NC

NI

COMMENTS

Shell Seams and Plates Check the bottom 2” to 4” for corrosion /erosion due to water accumulation. Inspect and measure the depth of pits on each course plate and measure the amount of metal loss. Inspect shell to bottom plate weld Inspect grooving damage from seal assembly protrusion. Inspect the existing coating for damage deterioration and disbanding. Check for seal rubbing Visually check the shell plates for indication leaks and leak marks Survey the tank for roundness or bulges.

4.1

CA

Identify and report low areas on the bottom that does not drain adequately. Inspect coating for discoloration, blisters, holes and disbonding.

Roof Interior Surface General Visually inspect the under side surface of the tank roof plates for scaling/deposit buildup, pitting, and holes. Hammer test or thickness gage for corrosion thinning particularly in vapor space of floating roof and at the edge of cone roof. Check all clips, attachments to roof plates, welds for cracks and damage. Inspect the protective coating for any damage.

Fixed Roof Support Inspect the support columns for thinning Check the reinforcing pad on the bottom is seal welded to the tank bottom plate with horizontal movement clips welded to the pads Determine if the pipe column supports are concrete filled, if not they are provided with a drain hole. Inspect the drafters for corrosion, particularly near the center of the roof Check for loose or twisted drafters Inspect girders for corrosion and fixed properly

Page 65 of 90



Report No.:

Date prepared:


Location/ Area:



Equipment data: Shell Material Shell thickness: mm/in CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected




Page 66 of 90



Attachment: C-XI – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - TANK (cont'd) Report No.: Equipment No. & Service: Reason for Inspection: P&E Inspector:







# 5.3 5.3.1 5.3.1.1 5.3.1.2

ITEM Fixed roof Appurtenances

On light hatches check for safety rods

5.3.1.4

Check the gasket face on the hatch covers

5.4

Breathers and Vents

5.5 5.5.1 5.5.2

Inspect the pressure/vacuum hatches Inspect the liquid seal hatches for corrosion

5.6.1.1 5.6.1.2 5.6.1.3

Hammer test the area between the roof rim and shell Check the roof drain for plugging. In sour service check all welds for cracks

5.6. 2

Floating roof pontoons

5.6.2.3

COMMENTS

Emergency P/V Hatches

Floating Roof

5.6.2.2

NI

Inspect the breathers if they are functional Inspect screens on vents and breathers.

5.6 5.6. 1

5.6.2.1

NC

Inspection and light hatches Inspect the hatches for corrosion, paint and coating damages, holes and cover sealing On loose covers check if the safety chain in good condition

5.3.1.3

5.4.1 5.4.2

CA

Roof Deck

Visually check all the pontoons for leaks Check each pontoon for vapor tight, liquid tight and acceptable. Inspect the lockdown hatches each cover and the opening

5.6. 3

Floating Roof Cutouts

5.6.3.1 5.6.3.2 5.6.3.3 5.6.3.4

Inspect under side of cutouts for mechanical damage Inspect welds for cracks Inspect plates for thinning, pits and erosion Measure mixer cutout and plate thickness

Page 67 of 90




5.6.4.1 5.6.4.2 5.6.4.3 5.6.4.4

Guidelines for Process Equipment Inspection Date prepared: Location/ Area:


5.6. 4

00-SAIP-80




Floating Roof Supports Inspect fixed low and removable high floating roof legs for thinning Inspect notching at bottom of legs for drainage Inspect for leg buckling or fall off at the bottom Inspect pin hole in roof guide for tears

Page 68 of 90










# 5.6.4.5 5.6.4.6 5.6.4.7 5.6.4.8

5.6.4.9

6.0 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.1.8 6.1.9

6.2 6.2.1 6.2.2

6.3 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 6.3.6

ITEM

CA

NC

NI

COMMENTS

Check plum of all legs Inspect for adequate reinforcing gussets on all legs through a single portion of the roof Inspect the roof area for cracks, etc Inspect the sealing system and the vapor plugs On shell mounted roof support, check for adequate clearance based on the maximum floating roof movement as determined by the position of the roof relative to the gauge well and or counter rotational device

Floating Roof Seal Assemblies Primary shoe assembly Remove four sections of foam log ( foam filled seals) O for inspection on 90 locations Inspect hanger attachment to roof rim for thinning, bending, weld damage etc. Inspect clips welded to roof rim for thinning Shoes-inspect for thinning and holes in shoe Inspect for bit-metal bolts, clips and attachment Seal Fabrics-Inspect for deterioration, stiffening, holes and tears in fabrics Measure length of fabric from top of shoe to roof rim, and check the maximum annular space allowed for roof movement Inspect any modification of shoe over shell nozzles, mixers etc., for clearance Inspect shoes for damage caused by striking shell nozzles, mixers etc.

Primary Toroidal Assembly Inspect seal fabrics for wear, deterioration, holes and tear Inspect foam for liquid absorption and deterioration

Rim-Mounted Secondary’s Inspect the rim-mounted bolting bar for corrosion and weld defects Measure and chart seal to shell gaps Visually inspect from under side for holes as evident by light Inspect fabrics for deterioration Inspect for contacts and deterioration Inspect for mechanical damage, corrosion etc

Page 69 of 90




Equipment data: Shell Material Shell thickness: mm/in CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected




Page 70 of 90










# 7.0 7.1 7.1.1 7.1.2

7.2 7.2.1 7.2.2 7.2.3

7.3 7.3.1 7.3.2 7.3.3

7.4 7.4.1 7.4.2 7.4.3

7.5 7.5.1 7.5.2 7.5.3 7.5.4 7.5.5 7.5.6

7.6 7.6.1

ITEM Floating Roof Appurtenances Roof Manway

CA

NC

NI

COMMENTS

Inspect manway wall for pitting and thinning Inspect manway cover, gasket face and bolts

Rim Vent Check Rim Vent for pitting and holes Check the condition of vent screen On floating roof check the vent pipe to rim joint for corrosion

Vacuum Breaker, Breather Type Check breather valve operations Check the nozzle pipe projection is ½” below roof deck Inspect stem for thinning and measure how far the vacuum breather cover is when raised off the pipe when roof is resting high ,low

Roof Drains: Open System including Emergency Drains Check liquid level inside open roof drains for adequate free board. Report if there is insufficient distance between liquid level and top of drain If tank comes under Air Quality Monitoring District rules, inspect the roof drain vapor plug If emergency drain is not at the center of the roof, check at least there are three emergency drains

Closed Drain Systems: Drain Basins Inspect for thinning and corrosion Inspect protective coating Inspect basin cover or screen for corrosion Test operation of check valve Check for the presence of check valve where bottom of basin is below product level Inspect drain basin(s) to roof deck welds for cracking including reinforcement pad

Closed Drain System: Fixed Drain Line on Tank Bottom Hammer test the drain line for thinning and plugging

Page 71 of 90




Equipment data: Shell Material Shell thickness: mm/in CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected Inspect supports & reinforcing pads for weld failures 7.6.2 and corrosion




Page 72 of 90










# 7.6.3

ITEM

7.7

Closed Drain System: Flexible pipe system

7.7.1

Inspect any external damage to pipe

7.7.2 7.7.3

7.8 7.8.1 7.8.2 7.8.3

7.9 7.9.1 7.9.2 7.9.3 7.9.4 7.9.5 7.9.6 7.9.7 7.9.8 7.9.9 7.9.10

8.0 8.1

NC

NI

COMMENTS

Check for obstruction that pipe could catch Inspect shield to protect pipe from snagging

Closed Drain System: Articulated joint drain Hammer test the rigid pipe in flexible joint system for corrosion Inspect system for bending or strain Inspect landing legs and pads

Autogauge System and Alarms Check free movement of tape through autogauge tape guide Inspect sheaves for free movement Check operation checker Inspect tape and tape cable for twist and fraying Test tape’s free movement through the guide sheaves and guide pipes Check float for leakage Test float guide wire anchors for spring action by pulling on wire and releasing Inspect float wells in floating roofs for thinning and corrosion, just above the liquid level Check the autogauge wire is firmly attached to the float Inspect the tape cable and float guide wire fabric seals through the float well cover

Common Tank Appurtenances Gauge Well

8.1.2

Inspect gauge well pipe for thinning: check for thinning at the edge of the slots Check for corrosion on the pipe joint:

8.1.3 8.1.4

Check for cone at the bottom end of pipe Check the condition of well washer pipe and its flared

8.1.1

CA

Check that pipe is guided, not rigidly locked to support, to avoid tearing of bottom plate

Page 73 of 90




Equipment data: Shell Material Shell thickness: mm/in CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected end point towards the hold off pad Check that the support for gauge well welded to pad 8.1.5 or shell and not directly to the pad




Page 74 of 90










#

ITEM

8.1.6

Check operation of the gauge well cover Check the hold off distance in well pipe and record the mark. Identify and report pipe size & schedule, whether solid or slotted Check the hold off plate is seal welded to the bottom indirectly Inspect the vapor control float and cable Check for the presence of gauge well washer Inspect gauge well guide in floating roof for corrosion or thinning Inspect guide rollers and sliding plates for free movement Inspect the seal system of the gauge well Visually inspect inside of the pipe for weld protrusion, which may catch the float.

8.1.7 8.1.8 8.1.9 8.1.10 8.1.11 8.1.12 8.1.13 8.1.14 8.1.15

8.2 8.2.1 8.2.2 8.2.3 8.2.4 8.2.5 8.2.6

8.3 8.3.1 8.3.2 8.3.3 8.3.4

8.4 8.4.1 8.4.2 8.4.3 8.4.4 8.4.5 8.4.6

CA

NC

NI

COMMENTS

Sampling system: Roof Sample Hatches Inspect roof mounted sample hatches for reinforcing pad and cracking Inspect cover for operation Inspect sample hatch covers for proper sealing Check alignment of internal float roof sample hatch under fixed roof hatches Inspect the sealing system on the internal floating roof sample hatch cover Inspect floating roof sample hatch cover recoil reel and rope

Shell Nozzles Inspect shell nozzles for pitting and thinning Inspect hot tap nozzles for trimming of holes Identify types of shell nozzles Identify and describe internal piping including elbow up and elbow down types

For Nozzles Extended into the Tank Inspect the pipe pads welded to the tank bottom Inspect pipe is free to move with out strain Inspect nozzle valves for leaks Check which nozzle is fitted with thermal relief valve Inspect wear plate on the down fill nozzle Inspect impact of erosion in elbow up-fill in floating

Page 75 of 90




Equipment data: Shell Material Shell thickness: mm/in CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected roof




Page 76 of 90










# 8.5 8.5.1 8.5.2 8.5.3 8.5.4 8.5.5

8.6 8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 8.6.6 8.6.7

9.0 9.1 9.1.1 9.1.2 9.1.3 9.1.4 9.1.5

9.2 9.2.1 9.2.2 9.2.3

9.3 9.3.1 9.3.2 9.3.3

9.4 9.4.1

ITEM Diffusers and Air Rolling System

CA

NC

NI

COMMENTS

Inspect diffuser pipe for erosion /thinning Check holes in the diffuser for wear and enlargement Inspect diffuser supports for corrosion and damage Check that diffuser supports restrain and not anchored Inspect air spiders on bottom of the lube oil tanks for plugging, damage or breaking

Swing Lines Inspect flexible joints for cracks and leaks Inspect moving faces between swing lines Check flexible joints over 6” are supported Inspect swing pipes for pits and weld corrosion Check for pits & leaking pontoons Inspect the pull-down cables for damages Inspect bottom mounted supports and safety hold chain for integrity

Access Structure Handrails Identify and record the type of handrail Inspect attachment Inspect pitting, holes and paints Inspect sharp edges Inspect the hand rails between rollers

Platform Frames Inspect platform for corrosion and paint loss Inspect all attachment Check the grating for damages

Deck Plate and Grating Inspect the deck plate for corrosion, holes and paint failure Inspect plate to frame welds Inspect grating for breakage, damage

Stairway Stringers Inspect spiral stairway stringers for corrosion, paint and weld failure

Page 77 of 90




Equipment data: Shell Material Shell thickness: mm/in CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected 9.4.2 Inspect stairway welds to shell




Page 78 of 90



Attachment: C-XI – INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - TANK (cont'd) Report No.:

Date prepared:


Location/ Area:



Equipment data: Shell Material


Design Pressure, Kg/ psig:

Shell thickness: mm/in

Max. Operating level meters /ft:



#

ITEM

9.4.3

Inspect steel support attachment to concrete base for corrosion

9.5

Rolling Ladder

9.5.1

Inspect rolling ladder stringers for corrosion Identify and inspect ladder fixed rungs for weld attachment to stringers and corrosion

9.5.2

9.4.3 9.5.3 9.5.4 9.5.5 9.5.6 9.5.7 9.5.8 9.5.9

CA

NC

NI

COMMENTS

Inspect steel support attachment to concrete base for corrosion Check for wear and corrosion where rolling ladder attaches to gaging flatform Inspect pivot for wear and secureness Inspect corrosion of moving parts Inspect operation of self leveling stairway treads Inspect rolling ladder wheels for free movement Inspect rolling ladder alignment with roof rack Inspect rolling ladder welds for corrosion

NOTES:

Page 79 of 90



Attachment D – Nomenclature And Types Of Heat Exchangers

Page 80 of 90



Different Types of Heat Exchangers

Page 81 of 90



Page 82 of 90



Page 83 of 90



Vessel

Page 84 of 90



Typical Heater Arrangement

Page 85 of 90



Fin Fan Cooler

Page 86 of 90



CRUDE HEATER

Page 87 of 90


ISOMAX REACTOR


PLATFORMER REACTOR

Page 88 of 90


CRUDE COLUMN


VACUUM COLUMN

Page 89 of 90



TYPICAL CONCRETE LINED AND TRAYED VESSEL

Page 90 of 90

00 SAIP 80 Process Equipment Insp Guide

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