Vessel Inspection Procedure

Trust International for Industrial and Petroleum Services- Limited
ONSHORE REGENERATION GAS SUBCOOLER E-2521
REF NO
DATE
S/N
SUBJECT SCOPE
REFERENCES 2
DEFINITIONS
002 03 4256162 : : 2626524 30 200 - nd Al Saraya Towers, Ali Bin Abi-Talib Square, Alpansi Tower, 2 Floor, Smouha, Alexandria, Egypt Tel: 002 03 4265252 - Fax: 002 03 4265152 - www.trusteg.com - Email: trust@trusteg.com
ITEM DESCRIPTION
PREINSPECTION REQUIREMENTS
TYPES OF INSPECTION
INSPECTION PROCEDURE
REPORTING 8
ATTACHMENTS 9
1- SCOPE
This procedure delineates the internal inspection of the onshore regeration gas sub cooler E -2521 during the scheduled shutdown to determine the status of internal surfaces of the vessel, and the need for repair or re rating according to the code requirements. 2- REFERENCES;
Trust International for Industrial and Petroleum Services- Limited 2.1 API STD 510
Pressure vessel inspection code : maintenance inspection, re rating , repair and alteration. Inspection of pressure vessels National board inspection code guidance notes and supporting information for rashpetco (Egypt) written schemes of examination managed by the pressure system data base.
2.2 2.3 2-4
API RP 572 ANSI/NB-23 R7126
2-5 vessel drawings and data sheets
3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7
DEFINITIONS: API ANSI ASME MAWP MDMT NB WSOE The American Petroleum Institute The American National Standards institute The American Society for Mechanical Engineers Maximum allowance working pressure minimum design metal temperature ASME national board Written scheme of examination
4.
ITEM DESCRIPTION:
The onshore regeration gas subcooler E-2521, located horizontally at roseta gas field, was fabricated by JOY INDUSTRIES , under manufacturer's number 1101 at 1999 from stainless steel in accordance with ASME code sec. VIII Div. 1,1998 edition, and stamped by "U" stamp. The medium inside the vessel is HS gas shell side / HC gas tube side.
Trust International for Industrial and Petroleum Services- Limited SHELL:
The shell is constructed from two courses of "SA-240-316. with dimensions of 660.4 ID * 25.4 mm thick and length of shell is 5870 mm, the corrosion allowance is 0.0 mm.
HAEDS : The heads are constructed from one piece of SA-240-316 formed to be elliptical 2:1 with dimensions of 660.4 ID * 25.4 mm thick, the corrosion allowance is 0.0 mm. NOZZELS : The nozzles are fabricated from SA-213-316, total number of tubes are 321 in one pass, tube outside diameter is 25.4 with 2.1 mm thickness and 6096 mm length. BOLTS : Stud bolts / nuts are constructed from SA -193-B7/SA-194-2H COATING : No cating exists on internal or external surfaces.
NAMEPLATE : The name plate is fabricated from stinless steel material and includes the following information:
Manufacturer
Manufacturer's S/N : Tag number Year built MAWP shell side MDMT shell side : : : :
Trust International for Industrial and Petroleum Services- Limited MAWP shell side MDMT shell side MAWP tube side MDMT tube side Test pressure : : : : :
Construction code : Code stamp :
ACCESS : No access is available to inside the vessel, however inspector shall use 8"N3,N4 and other available nozzles to inspect the internal surface of the shell.
5. 5.1
PREINSPECTION REQUIREMENTS: Operation and inspection history of the tank shall be available for review by the inspector. For example: operating conditions, including process upsets that may affect mechanical integrity, inspection reports, and data for each type of inspection conducted (for example, internal, external, thickness measurements), and inspection recommendations for repair.
5.2
For an internal inspection, the tank shall be isolated by blinds or other positive methods from all sources of liquids, gases, and / or vapors. The vessel shall be drained, purged, cleaned, ventilated, and gas tested. Where required , protective equipment shall be worn that will protect the eyes, lungs, and other parts of the body from specific hazards that may exists in the vessel.
5.3
No access is available to inside the vessel , however inspector shall use 8" N3,N4 and other available nozzles to inspect the internal surfaces of the shell using fiberscope
Trust International for Industrial and Petroleum Services- Limited and/or the inspection mirror as access permits. 5.4
Nozzles shall be opened as required by inspector, isolation kits ( if required ),shall be available at site during the S/D to enable of the nozzles. Electrical line source terminal of 220 V shall be available near to vessel. Powerful light source shall be available to inspect the inside surface of the vessel.
5.5 5.6
5.7
The vessel shall be prepared for hydraulic pressure testing of both the shell and the tube side at 127 barg using tap water as a test medium and hold for 1 hour. The required pump, calibrated pressure gauges and blind flanges/ spades shall be available for hydraulic pressure testing . the inspector shall witness the hydraulic pressure testing. ( use guidelines for hydraulic pressure testing PT/01) NDT and other inspection equipment shall be available for inspector to conduct the internal inspection (required inspection equipment are attached).
5.8
6.
TYPES OF INSPECTION:
The internal inspection of the tank included, visual inspection, dye penetration and UT wall thickness measurements and supplements with NDT as required per examination specification RPCO-05, issue 1 ( WSOE ), and hydrostatic testing for both the shell and tube side at 127 barg for 1 hour hold.
7. 7.1
INSPECTION PROCEDURE: Check the tank tag number and name plate.
7.2
Obtain the safe entry permit from the appropriate HSE personnel.
Trust International for Industrial and Petroleum Services- Limited 7.3
Check that cleaning of the vessel is adequate and the internal surface of the shell, heads, and nozzles are clearly visible.
7.4
Check that inspection and NDT equipment that shall be used during the inspection are available and valid. Check that the light source that shall be used is operating and powerful and check for the availability of electrical line source terminal that be used to operate the NDT equipment.
7.5
7.6 If the vessel is not properly prepared for internal inspection, the inspector shall decline to make the inspection until the tank is ready for that inspection. inspection.
7.7
Examine the internal surfaces of shell and heads carefully, as access permits, for possible cracks, general corrosion , pitting , and other signs of deterioration. If there is a suspect indication, use Dye penetrates according to approved NDT procedures; to verify the indication. Ultrasonic testing may be used for determining the depth of indication. Pit depth shall be measured by depth gauge or venire caliber
7.8
If evidence of distortion is found, it may be necessary to make a detailed check of the actual contours or principal dimensions of the vessel and to compare those contours and dimensions with the original design details.
7.9
Examine welded joints and the adjacent heat-affected zones for service-induced cracks or other defects.
Carry out PT on 10% of all seam and girth welds on the shell, plus all "T" weld inspections, to distance of 300 mm from inspection of weld looking for signs of cracking and other weld defects ( including transverse cracking where appropriate ). Carry out PT on nozzles.
7.11
7.12 Examine the surfaces of. Nozzles and other openings for distortion, crack, and other defects, using a mirror as necessary, paying particular attention to the welding used to attach the parts and their reinforcements.
7.13
Examine accessible flange faces for distortion and determine the condition of gasketseating surfaces.
7.14 Examine the tubing and tube sheets externally for possible cracks and other signs of deterioration.
7.15
Examine the earthing conditions, and describe the status in the final inspection report.
Measure the wall thichness of the shell at 500 mm intervals ( as access permits ) from the datum points ( shell-to-front head weld seam ) till the shell-to-rear head weld seam. The readings will be taken in four directions (3,6,9,12 o'clock ). Readings also will be taken on heads and nozzles and shall be included in the report. Clearly mark all defects found with a permanent marker on place. Sketch the size and location of defects and document the findings on the final inspection report. Witness the hydraulic pressure test at 127 barg for both shell and tube side using tap water as a test medium and hold for 1 hour . ( use guidelines for hydraulic pressure testing ( PT/01) Sate areas not accessible and reasons why.
7.17
81.7
81.7
8.
REPORTING: 8.1 All findings shall be reported in the attached final inspection report form.
9. 9.1 9.2 9.3 9.4
ATTACHEMENTS: Sketch for onshore registration gas subcooler E-2521 List of required inspection equipment. Inspection check list. final inspection report.
9.1
LIST OF REQUIRED INSPECTION EQUIPMENT
S/N
DESCRIPTION
QTY REQ.
RECOMMENDED TYPE
Trust International for Industrial and Petroleum Services- Limited Ultrasonic thickness meter. 1 Inspection mirror with telescopic hand, the mirror size shall fit into 2" pipe at least. 1 ANY
Any
Pocket size flash light 3 1 Any
Measuring tape 5 m. 4 Flexible fiberscope with light source and forward & side tip. Dye penetration material kit ( penetrant-remover-developer ) Ultrasonic instrument for crack detection with cables and 0, 45, 60, 70 degree angle probes, with IIW-V2 block. 1 Any
Olympus or equivalent From only one family product e.g. Ely , or magnaflux etc.
KRAUTKRAMER OR EQUIVALENT
Still photos digital camera. 8 1 Sony or equivalent
Depth gauge or vernier caliber. 9 Magnifier lens 2, 5, or 8X 10 1 Any 1 Any
Trust International for Industrial and Petroleum Services- Limited Permanent markers (Yellow/red color).
11 12
Any
9.2
INSPECTION CHECK LIST
S/N 1
ITEM Shell internal / external surface Head internal / external surface Shell-to-shell circumferential weld seam Shell-to shell longitudinal weld seam Shell-to-head circumferential weld seam N1 16" -900# tube inlet N1 16" -900# tube outet N3 8"-900# shell inlet N4 8"-900# shell oulet N1A 2"-900#P1 connection N2A2"-900#P1 connection N3A2"-900#P1 connection N4A2"-900#P1 connection
CODITION
ACCEPTANCE
REMARKS
5 6 7 8 9 10 11 12 13
Trust International for Industrial and Petroleum Services- Limited 14 15 16 17 18 19 20 N1B2"-900#T1 connection N2B2"-900#T1 connection N3B2"-900#T1 connection N4B2"-900#T1 connection Earthing External bolts & nuts Opened flange faces and gaskets State areas not accessible and reasons why
21
9.4
FINAL INSPECTION REPORT
PRESSURE VESSEL EXAMINATION REPORT
PART 1: VESSEL DESCRIPTION Pressure System Name Vessel serial number Tag number Installation Area Examination Specification Number
Trust International for Industrial and Petroleum Services- Limited Data of examination Data of last examination
Vessel Drawing Number
Data of manufacture
Manufacturer
Design Code
PART 2: VESSEL DATA Shell Contents Max/min design pressure (bar) Max/min design temperature (C degree) Material Thickness (mm) Corrosion allowance (mm) Material (lining) Insulation PART 3: EXETENT AND METHOD OF EXAMINATION Examination and/or tests carried out, plus no of attached sheets. Tube side
Parts not examined with reasons
PART 4: CONDITION OF VESSEL (SUMMARY) EXTELNAL
Trust International for Industrial and Petroleum Services- Limited Element Access ladders/platforms Man ways Heads Shell Nozzles Protective coatings insulation Condition
Comments
Bolted attachments Welded attachments Supports/ skirt/ mounts Ear thing Nameplate Internal Element Access ladders/platforms Man ways Heads Shell Nozzles Protective coatings Condition Comments
Trust International for Industrial and Petroleum Services- Limited Tubes Tube plates Welded attachments / supports Bolted attachments / trays Strainers /filters/demisters
Definition of vessel Condition C-Nothing to report B-Less significant Fault A2-significant and fault Surface rust, light scale or corrosion not exceeding 0.5mm and within the corrosion allowance-damage judged not to be dangerous Corrosion greater than 0.5mm possible cracking adjacent to welds-more significant damage than B but no immediate of failure A1-Imminent Danger
Vessel in excellent condition no signs of damage or corrosionnothing to report
Heavy corrosion and/or deep pitting or cracking of any description; vessel operating above SOLsignificant damage with risk of imminent danger
PART5: Anomalies and defects
PART6: Statement by Inspector

I declare that the above equipment has been inspected according to the examination described in part 3 and that this document is a true report of the inspection carried out
Inspectors name
signature
data
PART 7: Statement by competent person

The vessel is suitable for its design specified in part 2 subject to the relief system remaining in order: YES/NO The written scheme of examination require amending as result of this examination : yes / no Description of amendments required The above equipment may be used within the duty specified in part 2, subject to the following conditions Next thorough examination due before
Name
signature

Vessel Inspection Procedure

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Vessel Inspection Procedure

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Trust International for Industrial and Petroleum Services- Limited

ONSHORE REGENERATION GAS SUBCOOLER E-2521

Trust International for Industrial and Petroleum Services- Limited

2.2 2.3 2-4

API RP 572 ANSI/NB-23 R7126

2-5 vessel drawings and data sheets

3. 3.1 3.2 3.3 3.4 3.5 3.6 3.7

Trust International for Industrial and Petroleum Services- Limited SHELL:

Construction code : Code stamp :

Trust International for Industrial and Petroleum Services- Limited 7.3

Trust International for Industrial and Petroleum Services- Limited 7.10

Trust International for Industrial and Petroleum Services- Limited 7.16

9. 9.1 9.2 9.3 9.4

LIST OF REQUIRED INSPECTION EQUIPMENT

Pocket size flash light 3 1 Any

Still photos digital camera. 8 1 Sony or equivalent

Depth gauge or vernier caliber. 9 Magnifier lens 2, 5, or 8X 10 1 Any 1 Any

INSPECTION CHECK LIST

FINAL INSPECTION REPORT

PRESSURE VESSEL EXAMINATION REPORT

Vessel Drawing Number

Parts not examined with reasons

PART 4: CONDITION OF VESSEL (SUMMARY) EXTELNAL

Vessel in excellent condition no signs of damage or corrosionnothing to report

PART5: Anomalies and defects

PART6: Statement by Inspector

PART 7: Statement by competent person

Trust International for Industrial and Petroleum Services- Limited

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