Topside Inspection Procedure for Pressure Vessel

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PHE ONWJ Ltd.
Topside Inspection Procedure: Pressure Vessel
Revision Log Register
Document Number : PHEONWJIPRC-0005
Document Title
: Topside Inspection Procedure: Pressure Vessel
Revision
: 0
Pag
All
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All
7
Date
Previous
27-Oct-
2009
17-Jan-
2010
17-Jan-
2010
13 to
17-Jan-
40
2010
24Feb-2010
24-Feb-2010
24-Feb-2010
Revise
Newly
developed Procedure, pages
remain the same as in previous IFA
revision
BPWJ to PHE ONWJ
Thorough
changes of any BP leftover
in both content and headers/footers
Added: The Inspector should at least
have attended FFS workshop level 1
and gain the related certificates
Rewriting and rearrangement of almost
all the contents and sections to
properly suit the need and workflow of
inspection, plus comments from PHE
ONWJ
Added in section 7 : Inspection and
Migas Recertification
Added in Section 1 : This procedure also
can be used for Migas recertification.
Added in section 7 : Inspection and
Migas Recertification Procedure
PHE ONWJ Reviewer
PHEONWJ-I-PRC-0005 Rev 0
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PHE ONWJ Ltd.
Table of Contents
Topside Inspection Procedures: Pressure Vessel.......................................................1

Revision Log Register ....................................................................................................2
Table of Contents............................................................................................................3
1. Purpose........................................................................................................................6
2. Scope ...........................................................................................................................6
3. Responsibilities...........................................................................................................8
4. Definitions....................................................................................................................8
5. References...................................................................................................................9
6. Safety Requirements ..................................................................................................9
7. Inspection and Migas Recertification Procedures...................................................9
7.1. General................................................................................................................................. 9
7.2. Preparations....................................................................................................................... 10
7.2.1. Reviewing Documents................................................................................................. 10
7.2.1.1. Operating Permit ..................................................................................................10
7.2.1.2. Documents Dossier..............................................................................................10
7.2.1.3. Owner Documentation..........................................................................................10
7.2.1.4. Records................................................................................................................11
7.2.2. Inspection Preparation ................................................................................................ 11
7.3. Inspection Methods............................................................................................................ 11
8. Visual Inspection.......................................................................................................13
8.1. Internal Inspection.............................................................................................................. 14

8.1.1. Internally Lined Vessel:............................................................................................... 15
8.1.2. Loose Lining:............................................................................................................... 15
8.1.3. Integral Lining:............................................................................................................. 15
8.1.4. Protective Coating:...................................................................................................... 15
8.2. Main Points for Internal Visual Inspection.......................................................................... 15
8.2.1. Corrosion..................................................................................................................... 15
8.2.2. Erosion ........................................................................................................................ 15
8.2.3. Dents........................................................................................................................... 16
8.2.4. Distortion ..................................................................................................................... 16
8.2.5. Cuts or Gouges ........................................................................................................... 16
8.2.6. Linings......................................................................................................................... 16
8.2.7. Vessel Connections..................................................................................................... 16
8.2.8. Vessel Closures .......................................................................................................... 16
8.2.9. Vessel Internals........................................................................................................... 16
8.3. External Visual Inspection.................................................................................................. 16
8.3.1. Shell and Head............................................................................................................ 16
8.3.2. Manways, Nozzles, and Other Vessel Connections................................................... 17
8.3.3. Drains.......................................................................................................................... 17
8.3.4. Piping........................................................................................................................... 17
8.3.5. Safety Controls............................................................................................................ 17
8.3.6. Pressure Safety Relief Valve....................................................................................... 17
8.3.7. External Corrosion - General:...................................................................................... 17
8.3.8. Lined Vessel:............................................................................................................... 17
8.3.9. External Coating:......................................................................................................... 18
8.3.10. Corrosion/Pitting:....................................................................................................... 18
8.3.11. Insulation or Other Coverings:................................................................................... 19
8.3.12. Intrusion:.................................................................................................................... 20
8.3.13. Foundation, Supports, Skirts, Attachments including Bolts & Nuts:.......................... 21
8.3.14. Weld Joints................................................................................................................ 21
8.3.15. Non-welded Joints:.................................................................................................... 22
8.3.16. Mechanical Damage:................................................................................................. 22
8.3.17. Dissimilar Metals:...................................................................................................... 22
8.3.18. Vibration: ................................................................................................................... 22
8.3.19. Non-Conformity to design:......................................................................................... 22
8.4. Digital Photography:........................................................................................................... 22
9. Non-Destructive Examinations (NDE).....................................................................23
9.1. Commonly Used NDE Techniques .................................................................................... 23
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9.1.1. UT Compression Technique (UT Wall Thickness Measurement)............................... 23

9.1.2. Liquid Penetrant Examination ..................................................................................... 23
9.1.3. Magnetic Particle Examination.................................................................................... 23
9.1.4. In-situ Metallographic Examination............................................................................. 24
9.1.5. Infrared Thermographic Examination.......................................................................... 24
9.2. Determination on the Location of Deterioration ................................................................. 24
9.3. Marking, Identification, and Numbering Method ................................................................ 24
9.3.1. Reference Location Marking: ...................................................................................... 24
9.4. Rubbing Name Plate.......................................................................................................... 25
9.5. Determining Locations for Wall Thickness Measurements................................................ 25
9.5.1. Shell............................................................................................................................. 26
9.5.1.1. Longitudinal Orientation........................................................................................26
9.5.1.2. Circumferential Orientation...................................................................................26
9.5.2. Head............................................................................................................................ 28
9.5.2.1. Ellipsoidal Head....................................................................................................28
9.5.2.2. Flat / Disk Head...................................................................................................30
9.5.3. Nozzle Blind Flanges and Couplings .......................................................................... 30
9.5.4. Special Condition ........................................................................................................ 31
9.6. Ultrasonic Scanning for Flaw Detection & Corrosion Survey............................................. 31
9.6.1. Oil and Gas Separator / Heat Exchanger.................................................................... 31
9.6.1.1. Horizontal Installation...........................................................................................31
9.6.1.2. Vertical Installation ...............................................................................................32
9.6.2. Water Tank and Diesel Fuel Storage.......................................................................... 32
9.6.2.1. Horizontal Installation...........................................................................................32
9.6.2.2. Vertical Installation ...............................................................................................33
9.7. Weld Joint Inspection......................................................................................................... 33
9.7.1. "T" joint........................................................................................................................ 33
9.7.2. Longitudinal Weld Joint (excluding "T" joint)............................................................... 34
9.7.3. Circumferential Weld Joint .......................................................................................... 34
9.8. Magnetic Particle Inspection.............................................................................................. 34
9.9. Hardness Tests.................................................................................................................. 34
9.9.1. Shell Side .................................................................................................................... 35
9.9.2. Head Side.................................................................................................................... 35
9.9.3. Nozzle and Reinforcement Pad................................................................................... 35
9.10. Combination of UT Scan and Wall Thickness Measurement .......................................... 35
9.10.1. Map for Combination of UT Scan and Wall Thickness Measurements (WTM),
General Head and Shell Sketch for WTM:........................................................... 35

Group 1 ID or OD of up to 18 inches:....................................................................... 36
Group 2 ID or OD of over 18 inches up to 48 inches: .............................................. 37

Group 3 ID or OD of over 48 inches up to 144 inches: ............................................ 37

Group 4 ID or OD of over 144 inches up to 288 inches: .......................................... 38

9.11. Insulated Vessels............................................................................................................. 39
9.11.1. Size of Wall Thickness Measurement Windows in Insulated Vessels...................... 39
9.11.2. Location of Wall Thickness Measurement Windows in Insulated Vessels ............... 39
15. Reviews and Revisions ..........................................................................................44
Attachments and Reference Forms ........................................................................... 44
10. Corrosion Rate Calculation....................................................................................40

11. Calculations of the Maximum Allowable Pressure (MAWP) ...............................40
12. Unknown Document Record..................................................................................41
13. Conclusions and Acceptance Criteria ..................................................................42
14. Reports and Recommendations............................................................................42
14.1. Reports............................................................................................................................. 42
14.2. Recommendations........................................................................................................... 44
Attachment A. Vessel Inspection Report ....................................................................... 45

Attachment B. Vessel Thickness Measurement Report ............................................... 46
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Attachment C. Change of Pressure Vessel Condition Form ........................................ 47
Attachment D. History Card ............................................................................................. 48
Attachment E. Quick Opening Closure Visual Inspection Report ..................... 49 - 54
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PHE ONWJ Ltd.
1. Purpose
This procedure was developed for general topside facility inspection as well as risk
based inspection of pressure vessels / equipment operated in PHE ONWJ. This
procedure also can be used for Migas recertification. It was intended to ensure that all
inspections are carried out to the correct standards, and in a safety and uniform manner.
2. Scope
This procedure applies to pressure equipment constructed in accordance with the API /
ASME codes, and other recognized pressure vessel codes. The procedure is applicable
to both new pressure vessels and those already placed in service. The pressure
vessels to be inspected and re-certified are those considered to be in good condition to
be re-certified (no repair works are required).
Scope of the procedure covers:
External inspection,
Internal inspection,
Repair,
Alteration,
Re-rating,
PSV re-testing,
Evaluation, and
Work team coordination.
Normally, all inspections should be conducted without opening up the equipment. The
pressure vessels need only be opened up for thorough internal inspection when:
a. It is not possible to carry out a meaningful inspection using non-intrusive inspection
techniques applied externally (i.e. capable of detecting those defects which might
reasonably be expected to exist), and
b. Internal inspection becomes a requirement, i.e. when a probability of deterioration
mechanisms related to process environment induced cracking exists , and where
critical there is a requirement to inspect internal parts (i.e. tubes, baffle plate , etc).
Followings are the reasons when inspection becomes a requirement:
ACTIVITIES
Un-Insulated Vessel:
Head
Manways
Nozzles
External inspection of shell
Foundation & Support
Attachments support feet/skirt
Associated platforms and access
ladders
Earth connections
Anchor Bolts
Auxiliary Equipment (Bridle)
REASONS
Possible cracks, blister, bulges, and
other sign of deterioration
Possible breakdown of External paint
coating
Corrosion at water traps
Evidence of leakage
Presence and tightness of holding
down bolts
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PHE ONWJ Ltd.
ACTIVITIES
The table is continued from the previous page
For skirted Vessel with fire proofing
Examine for cracking or detachment of
fire-proofing
Evidence of staining from corrosion
product
Adequacy of weather sealing
For insulated Vessel:
Head
Sample area insulation removal at
lagging intrusions around nozzles and
shell attachments
At discretion of Inspection Authority:
Shell, Head, and Nozzles
Key point thickness survey of vessel
shell and nozzles
If stress survey identifies high stress
connections:
External crack check on weld and HAZ
areas
If vessel is lined:
An internal inspection is required
REASONS
Deterioration of fireproofing allowing
access of moisture with subsequent
hidden corrosion.
Moisture ingress with subsequent
corrosion. Evidence of shell paint
coating breakdown
Internal general corrosion
For insulated vessel, also checked for
external corrosion at key-point plugs
Detachment of lining or breakdown of
coating
Bulging of either lining or coating
Corrosion of lining or cladding
material
Internal inspection of all attachments to

Localized preferential corrosion at
lining or shell
coating breakdown or discontinuities
Failure of attachments
Crack detection on all internal welds of

Stress cracks in weld and Heat
identified high stress nozzles
Affected Zone
If vessel is not lined or cladded:
Close visual inspection of all welds/HAZ
for corrosion or cracking
Note: Every window of opportunity should be taken for conducting internal inspection; for
example, when the pressure vessel is opened up for process clean up, or for the
recharge of catalysts or other bed materials.
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PHE ONWJ Ltd.
3. Responsibilities
3.1. Authorized Inspector (AI) is responsible for issuing this procedure, as required for
the implementation of recertification program, RBI assessment result and ad hoc
inspection.
3.2. Only Authorized Inspector/s shall perform internal and / or external visual inspection,
in accordance with this procedure
3.3. Only Certified Examiner/s, using a qualified Procedure that has been reviewed and
endorsed by the related Authorized Inspector, shall carry out Non Destructive
Examination in accordance with this procedure.
3.4. The Inspector should at least have attended FFS workshop level 1 and gain the
related certificates.
4. Definitions
Alteration
: A physical change in any component or a rerating that has
design implications that affect the pressure-containing
capability of a pressure vessel beyond the scope of the
items described in existing data reports.
Authorized Inspector (AI) :

Personnel who is qualified and certified to perform
the functions specified in API 510.
Consequence Rating : The consequence of failure based on the evaluation of 8
criteria representing operational, economic and
environmental factor. Consequence rating is divided into 3
categories: high, medium & low.
Criticality Rating
: Risk ranking on the basis of risk matrix, that representing
risk as the result of probability of failure and the
consequence of failure.
Inspector
: An authorized Pressure Vessel inspector.
MAWP
: Maximum Allowable Working Pressure for a Vessel is the
maximum gauge pressure permissible at the top of the
vessel in its normal operating position at the designated
coincident temperature specified for that pressure.
NDT Examiner
: Person who assist AI in performing specific Non Destructive
Examination. The examiner shall hold the related NDT
certification to the method being used.
Probability Rating
: The probability of failure based on the evaluation of
appropriate failure modes according to a model or a set of
agreed rules. Probability rating is divided into 3 categories:
high, medium & low.
RBI
: Risk Based Inspection
Repair
: A repair is the work necessary to restore a pressure vessel
to a condition suitable for safe operation at the design
conditions.
Rerating
: A change in either or both the design temperature or the
maximum allowable working pressure of a pressure vessel.
TMLs
: Thickness Measurement Locations, designated areas of
pressure vessels where periodic inspections and thickness
measurements are conducted.
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PHE ONWJ Ltd.
5. References
Keputusan Direktur Jenderal MIGAS No. 84.K/38/DJM/1998
NBIC ~ 23 National Board Inspection Code
API ~ Guide for Inspection of Refinery Equipment, Chapter II, Conditions Causing
Deterioration of Failures
API 510 ~ Pressure Vessel Inspection Code
API RP 572 ~ Inspection of Pressure Vessel
API 579 ~ Fitness for Service Standard
API RP 580 ~ Risk-Based Inspection
API Publication 581 ~ RBI Resource Based Document
API 660 ~ Shell & Tube Heat Exchanger for General Refinery Service
API 750 ~ Management of Process Hazard
ASME ~ Section II, V, VIII, and IX
ASME ~ Boiler & Pressure Vessel Code Sect. V-1, Non Destructive Examination
ASME ~ Boiler & Pressure Vessel Code Sect. VIII Div.1, Pressure Vessels
ASME ~ Boiler & Pressure Vessel Code Sect. X, Welding and Brazing Qualification
ASNT ~ SNT-TC-IA, Standard of Qualification & Certification of Non Destructive
Testing Personnel
NACE RP-0169 ~ Control of External Corrosion on Underground of Submerged
Metallic Piping System
TEMA ~ Standard of Tubular Exchanger Manufacturing Association
TEMA Class "R" for Heat Exchanger
PHEONWJ-PRC-201-A ~ Procedure of Pressure Vessel for Inspection and
Recertification
NDT Manual No. PHEONWJ-PRC-211-A
ARII Specification: ARII-MS-600 for Air Cooler Heat Exchanger
ARII Specification : ARII-MS-250 for Unfired Pressure Vessel
Other Code and Practices, Standard, Specification related to design, construction,
and maintenance of In-Service Pressure Vessels.
6. Safety Requirements
The Inspection of Pressure Vessel may be performed in both on stream or shutdown
conditions. If the Pressure Vessel is insulated, the user shall prepare the access
windows to perform NDT. Details of inspection windows are attached in Section 8.3.2.
The implementations of this procedure, either related to Personnel, Equipment, Methods,
or Techniques, shall fully comply with all the requirements of Health Safety and
Environmental (HSE) Standards & Practices, without jeopardizing any of Government
Regulation and Legislation.
7. Inspection and Migas Recertification Procedures
7.1. General
The Inspection and recertification of Pressure Vessels consist of 4 main activities, i.e.:
Inspection Preparations, which include reviewing documents and supporting
data,as well as other pre-inspection activities, such as removing inspection plugs,
Performing actual Field Inspection,
Preparing Recommendations, and
Reporting & Documenting.
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PHE ONWJ Ltd.
For the sake of this procedure, the Pressure Vessels (PVs) are classified into 4 groups,
based on their diameter (either internal or external), as the followings:
Group 1
Group 2
Group 3
Group 4
:
:
:
:
for PV of up to 18-inches in diameter (internal or external),
for PV of over 18-inches up to 48-inches in diameter,
for PV of over 48-inches up to 144-inches in diameter, and
for PV of over 144-inches up to 288-inches in diameter.
7.2. Preparations
In this preparation section, two major items are gathering and reviewing the information,
and the pre-inspection activity which mainly involve the removal of inspection plugs.
The following information should be made available to support the inspection, and
inspection results evaluation:
Process Description and Process Flow Diagram
Process and Instrument Diagram (P&ID)
Design and Operating Condition Data
Pressure Vessel Manufacturing Design & Inspection Data Report
Service and Fluid Composition Data, if required
Insulation Material Specification, if any
Protective Coating Specification
Corrosion Control & Corrosion Monitoring Data, if any
Pressure Vessel Inspection, Repair, Alteration & Maintenance Historical Data
7.2.1. Reviewing Documents
The following document should be reviewed before the inspection:
7.2.1.1. Operating Permit
Date of the last inspection
Design pressure and temperature
Location of installation
Item and Serial number
Current jurisdictional inspection certificate (if any)
National Board and/or jurisdictional registration number (SKPP)
7.2.1.2. Documents Dossier
Manufacturer data report / Form U1
ASME Code Symbol Stamping or mark of code of construction
Item and Serial number
Material of the shell, head, nozzle, etc.
Corrosion Allowance
Design pressure and temperature
As built drawings
Copy of Name plate
7.2.1.3. Owner Documentation
Inspection Organization Chart
Quality Assurance Inspection Manual
Maintenance Record / History Card
P&ID Drawings
Non Conformity Record
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PHE ONWJ Ltd.
HSE Manual
PSV Data Sheet I Certificate
7.2.1.4. Records
A review of any Pressure Vessel logs, maintenance records, or any other tests
should be made by the inspector. The owner or user should be consulted
regarding repairs made since the last inspection. The inspector should review
such repairs for compliance with applicable requirements.
Besides, the following records shall also be reviewed prior to performing
inspection
History of operating condition,
Normal contents of the vessel,
Records of wall thickness checks and corrosion monitoring data, especially on
vessel where corrosion is a consideration.
7.2.2. Inspection Preparation
Special preparation should be performed as requirement to support the inspection,
especially for complete internal inspection during shutdown:
1. Inspection plugs and covers should be removed.
2. Vessel should be sufficiently cleaned to allow for visual inspection of internal and
external surfaces.
If the pressure vessel has not been properly prepared for an internal inspection, the
works shall be postponed.
7.3. Inspection Methods
The Consequence of Failure shall determine the extent of the inspection High
Consequence items require a more extensive of inspection than Medium or Low
Consequence items.
Each Examination shall incorporate an evaluation of the various inspections:
visual and supplemental NDT carried out on the vessel during the previous
endorsement period,
a review of operating parameters, and any changes in duty, which may have
occurred, and
an assessment of any corrosion monitoring measurements taken during the
endorsement period (if any).
The inspection scope should include an external visual inspection and assessment of
internal condition. Internal inspection may not be required, if the vessels internals
condition can be accurately assessed by using non-intrusive inspection methods (such
as ultrasonic mapping). Alternately, at may be possible to utilize supplemental visual
inspection aids (such as video cameras or boroscopes), to negate the need for full
vessel entry.
Table 1 suggests minimum requirements for Limited, Partial and Close (Detailed) Scope
of internal assessment. The selection of method should be done during inspection
planning based on the technology available and on an economic assessment of cost and
benefit of non intrusive inspection.
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Table 1. Minimum Requirements for Internal Assessment
Low Consequences of
Medium Consequences of
Failure Limited
Failure General Assessment
Assessment
Boroscope
Boroscope and External NDT
Or
Or
High Consequences of
Failure Detailed
Assessment
External NDT and
Corrosion Monitoring and
Process Review
Or
External NDT
Internal Entry
Internal Entry
Process Review
Process Review & External NDT
Or
Or
The choice of non-destructive inspection method is based on the probability of failure.
Methods are chosen to detect the likely failure modes.
The guidance is shown on Table 2. The final selection of method should be made at the
time that inspection is being planned based on the available technology and on
economic choice.
Table 2. NDT Inspection Methods
Failure Mode
Mechanisms
NDT Methods
Internal Wall Thinning
Internal Corrosion
Erosion
Cavitations
Weld Corrosion
External Corrosion
Corrosion Under Insulation
Ultrasonic
Radiography
External Wall Thinning
Cracking
Other
Visual Inspection
Radiography
Thermography
Advanced Eddy
Current Test
Fatigue
Ultrasonic
Stress Corrosion Cracking
Radiography
Wet Hydrogen Damage
Magnetic Particle
Liquid Penetrant
Creep
Ultrasonic
Hot Hydrogen Damage
Radiography
High Temperature Embrittlement

Magnetic Particle
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Table 3 shows the Summary of Inspection Plan developed for Pressure Vessels as
recommended following the results of RBI assessment tools.
Table 3. Summary of NDT Inspection Plan
No.
Damage Mechanism
External Corrosion (Corrosion Under
Insulation) for Carbon Steel Material
2
3
4
5
Inspection Methods
External Visual, and Infrared
Thermography, or Advance Eddy
Current Test as required
External Crack (SCC due to Corrosion

External Visual, and (Liquid Penetrant
Under Insulation) for Austenitic
Test, as required) and (Infrared
Stainless Steel Material
Thermographv, as required)
Internal Crack (Stress Corrosion
Internal Visual, and Liquid Penetrant
Cracking)
Test or Magnetic Particle Test (and In-
situ Metallographic, if found)
Internal Crack (Wet Hydrogen Cracking)

Internal Visual and Wet Magnetic
for Carbon Steel Material
Particle Test (and In-situ metallographic,
if found)
Internal Corrosion
Internal Visual or (Ultrasonic Corrosion
Scanning) and Corrosion Monitoring (for
High Consequences Ratings)
8. Visual Inspection
The extent of visual inspection includes:
Shell and Head:
The surface of a shells and heads of possible cracks, blisters, bulges and other
evidence of deterioration, giving particular attention to the skirt and to support
attachment and knuckle region of the heads. If evidence of distortion is found, it
may be necessary to make a detailed check of the actual contours and
dimensions with the original design details. A detailed check on the contours
may be performed using a contour gauge.
Quick Opening Closures:
The quick opening closures include pig launchers and pig receivers doors.
Depending on the type of the closures, the visual inspection of these quick
opening closures should cover:
- caps
- cap pins
- hinges/davits
- weld joints
- hinge bolts and nuts
- handles
- head lugs
- cam handle
- eye bolt
Man-ways, nozzles and other openings:
Inspect the surface of man-ways, nozzles, and other openings for possible
distortion, cracks and other deteriorations. Examine accessible flange faces for
distortion and to determine the condition of gasket seating surfaces.
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Drains:
Check the drainage is provided where required. Where provided and when
practicable, the drain should be opened to ensure that it function properly.
Piping:
Piping components attached to the vessel should be checked for indications of
inadequate support or provisions for expansion, which may cause excessive
loading on the vessel.
Appendages:
Any safety and instrument device installed for safety of the vessel should
demonstrate it function by verification of its correct and proper operation.
Pressure Relieving Device
Should be checked for the set pressure, and the date of the last inspection
against the requirements
Insulation:
Where there is evidence of leakage shown on the coverage or through the
insulation, the insulation shall be removed to the extend necessary, to make a
complete investigation.
Vessel Identification:
Inspect and ensure that all marking (included name plate and other
stamps/marking) are meeting the related statutory/legislation requirements.
The Authorized Pressure Vessel Inspector, using his experience and judgement to
determine the extent of the inspection during the development of the work-pack.
8.1. Internal Inspection
The vessel needs to be opened up for thorough internal inspection when it is not
possible to carry out a meaningful inspection using non-intrusive inspection
techniques applied externally (i.e. capable of detecting those defects which might
reasonably be expected to exist).
In addition, internal inspection is a requirement when a probability of deterioration
mechanisms related to process environment induced cracking exists.
In the event that internal access is necessary, it may require the removal of internal
fittings to enable access to all internal surfaces. In case of shell-and-Tube with
retractable tube-bundle type Heat Exchanger, internal inspection is conducted on
shell, channel and other parts of the exchanger, once tube-bundle is fully or partially
retracted on shell. The vessel shall be clean and free from deposits, which may
mask a likely defect. It is essential that Inspectors are aware of the condition prior to
cleaning and have the opportunity to collect deposit samples for later analysis should
it prove necessary. In addition, the effects of such deposits on the local corrosion
regime must be assessed and the examination requirements modified accordingly. In
such cases, care shall be taken of any hazard the deposits may pose to individuals
handling them and that all necessary precautions are taken to prevent any harm
coming to these individuals.
If internal inspection has been demanded, the following areas or components shall be
subject to a visual inspection to detect evidence of corrosion or stress or deformation:
All internal plate surfaces with particular attention paid to areas associated
with:
a) External support attachments, and
b) Liquid interfaces and
c) Internal deposits;
All nozzle attachments with particular attention paid to those with external
re-enforcing pads or those, which are subject to high or fluctuating stresses;
All shell attachments for internal fittings.
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8.1.1. Internally Lined Vessel:
Where a vessel is internally lined, every effort shall be made to adopt inspection
techniques, which will negate the need for internal entry, as this could have a
detrimental effect on the condition of the lining. If an examination cannot be
carried out without an internal inspection being performed, the internal and
external requirements shall be modified, having consideration of the following:
8.1.2. Loose Lining:
Any perforation may result in severe corrosion in the void between shell and
lining. Examination practices shall therefore seek to detect both the perforations
and the consequent corrosion. This will require the application of a range of NDT
techniques applied internally and externally. Where tell-tale holes are provided
in the shell, evidence of lining perforation should be sought on a routine basis
during operation.
The results of such monitoring inspections must be considered before a thorough
examination is carried out.
8.1.3. Integral Lining:
Should the lining be of the integral type (i.e. hot roll clad; explosive bond or weld
deposit) wall thickness measurement is likely to detect the-lining-to-shell
interface and may prove unsatisfactory. In these cases, both internal and
external measurements must be taken where areas of disbanding are significant.
Particular attention shall be paid to vessel heads. Since these areas have been
formed after lining application, disbandment is likely to be significant. In the
case of lining of the weld deposit type, visual inspections of surfaces shall seek
to find areas of localized corrosion at weld deposit inclusions or areas of weld
metal dilution from parent plate.
8.1.4. Protective Coating:
Where a protective coating has been applied to the internal surfaces, a visual
inspection shall be carried out to determine whether any coating breakdown,
blistering or other coating defects have occurred.
8.2. Main Points for Internal Visual Inspection
Pressure Vessels containing non-corrosive substances may require only an External
Inspection. Such Vessels may not be provided with manholes or other Inspection
openings. In this case the Inspector may accept nondestructive testing (NDT)
methods of examination to determine the condition of the Vessels. All of the visual
inspection finding shall be documented using digital camera. The Inspector should
check the surfaces of the shells, heads, man ways, nozzles and other opening for
possible deterioration on the Internal of Vessel as follows:
8.2.1. Corrosion
Where active or excessive Corrosion is found, remedial action should be taken.
The Inspector should thoroughly examine the Vessel for the following types of
Corrosion:
Pitting
Line Corrosion
General Corrosion
Grooving
Galvanic Corrosion
8.2.2. Erosion
The Inspector should note any action caused by abrasives and high velocity
streams which may erode the surfaces of the metal.
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8.2.3. Dents
Dents in a Vessel are deformations caused by their coming in contact with a
blunt object in such a way that the thickness of metals is not materially impaired.
In some cases, a Dent can be repaired by mechanically pushing out the
deformation.
8.2.4. Distortion
If any Distortion is suspected or observed, the overall dimensions of the Vessels
shall be checked to determine the extent and seriousness of the Distortion.
8.2.5. Cuts or Gouges
Cuts or Gouges are caused by contact with sharp objects in such a way as cut
into the metal decreasing the wall thickness. Cuts and Gouges can cause high
stress concentrations and depending upon the extent of the defect, it may be
necessary to repair the area by welding or patching. Blend grinding may be a
useful method of eliminating some minor types of Cuts or Gouges.
8.2.6. Linings
Where evidence on the lining is found, it may be necessary to make a detailed
check with nondestructive testing methods.
8.2.7. Vessel Connections
Threaded connections should be inspected to ensure that an adequate number
of threads are engaged. All openings leading to external fittings or controls
should be examined as thoroughly as possible to ensure they are free from
obstruction.
8.2.8. Vessel Closures
Any special closures including those on autoclaves, normally termed quick
actuating (quick opening) closures which are used frequently in the operation of
a pressure vessel, should be checked by the Inspector for adequacy and wear.
A check should also be made for cracks at areas of high stress concentration.
8.2.9. Vessel Internals
Where pressure vessels are equipped with removable internals, these internals
need not be completely removed, provided assurance exists that deterioration in
regions rendered inaccessible by the internals is not occurring to an extent that
might constitute a hazard or to an extent beyond that might constitute a hazard
or to an extent beyond that found in more readily accessible parts of the vessel.
If a preliminary inspection reveals unsafe conditions such as loose or corroded,
internals or badly corroded internal ladders or platforms, steps should be taken
to remove or repair such parts so that a detailed inspection may be made.
8.3. External Visual Inspection
The examination consists of an external visual examination supported by
supplemental non-intrusive NDT on those areas most likely to suffer deterioration.
Operating conditions shall be confirmed as remaining substantially the same and any
excursions from normal operation shall be reviewed for their on corrosion or other
failure mechanisms. The external inspection should be able to report the following
items:
8.3.1. Shell and Head
Inspect the surfaces of shells and heads for possible cracks, blisters, bulges and
other evidence of deterioration, giving particular attention to the skirt and to
support attachment, and knuckle regions of the heads. If evidence of distortion
is found, it may be necessary to make a detailed check of the actual contours
and dimensions with the original design details.
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8.3.2. Manways, Nozzles, and Other Vessel Connections
Manholes, reinforcing plates, nozzles or other connections should be examined
for cracks, deformation or other defects. The bolts and nuts should be checked
for corrosion or defects. The weep holes in reinforcing plates should remain
open to provide visual evidence of leakage as well as to prevent pressure build
up between the vessel and the reinforcing plate.
Also inspect the surfaces of manways (including ladders, platform, walkways,
and stairways), nozzles, and other openings for distortion, cracks, and
accessible defects. Examine accessible flange faces for distortion and to
determine the condition of gasket seating surfaces including the condition of
bolts. Also check yhe anchot bolts and grounding connections.
Any auxiliary equipment should also be checked for its condition.
8.3.3. Drains
Check that drainage is provided where required. Where provided and when
practicable, the Inspector should have the drain opened to ensure that it
functions properly.
8.3.4. Piping
Piping components attached to the Vessel should be checked for indications of
inadequate support or provisions for expansion which may cause excessive
loading on the Vessel shell.
8.3.5. Safety Controls
Any safety device (pressure gauge, temperature gauge, level glass, etc) installed
for safety of the Vessel should be demonstrated by operation for verification of
correct and proper operation.
8.3.6. Pressure Safety Relief Valve
The Inspector should check that the required set pressure and the date of the
last Inspection. The Valve should be removed from service at the time of
shutdown or at a frequency agreed to by the Owner and the Inspector.
8.3.7. External Corrosion - General:
Where the vessel is un-insulated, atmospheric corrosion must be considered at:
pipe support attachments,
platform attachments,
expansion bellows,
and other locations where moisture traps are possible.
Note:
Where the associated piping materials are subject to Stress Corrosion Cracking
or Corrosion Fatigue, supplemental NDT such as:
liquid penetrant testing,
magnetic particle testing, or
eddy current testing
should be applied at those nozzle areas most likely to exhibit the deterioration.
If deterioration is found, the remaining life of the component must be assessed,
although in the case of Stress Corrosion, the material shall be considered
unsuitable for any further service regardless of whether or not leakage is found.
8.3.8. Lined Vessel:
Where "tell-tale" holes are provided, these shall be checked for evidence of
leakage. In the event that these are fitted with valves, they should be checked as
being open and clear. Any closed valves should have been logged in the
operating records and this must be checked.
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Note: If either leakage or close valves are found, external NDT should be
applied to detect corrosion at the inner shell surface.
8.3.9. External Coating:
The condition of the external coating on the various coating on the various
components shall be reported against the following criteria, which shows the
percentage of area having coating breakdown in comparison to the total coated
area. If the equipment is insulated, the condition of any exposed steel shall be
reported against the same criteria.
(G) Good : 0% 5% Coating Breakdown
(F) Fair : 5% 20% Coating Breakdown
(P) Poor : 20% 70% Coating Breakdown or a breakdown of coating in soil
encroachment areas
(B) Bad : 70% 100% Coating Breakdown
(G) and (F) are considered Acceptable but (P) and (B) should be reported.
The following table of photos illustrates the ratings based on coatings condition:
Ratings Example 1
Example 2
8.3.10. Corrosion/Pitting:
The condition of the exposed steel shall be reported against the following
criteria:
(G) Good : No evidence of corrosion taking place affected should be
carefully noted for future inspection and possible removal.
(F) Fair : Some light surface corrosion has taken place but only sufficient
to produce a light, powdery corrosion product.
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(P) Poor : Scattered patches of corrosion/pitting producing a significant rust
film.
(B) Bad : Large areas of corrosion/pitting have resulted in thick corrosion
products.
(G) and (F) are considered Acceptable but (P) and (B) should be reported.
Where the condition is (P) Poor or (B) Bad, the report shall detail the location,
extent and depth of the anomaly together with the thickness of the adjacent
pipe/pipe, fitting/vessel wall.
The following table of photos illustrates the ratings based on visual inspection
of corrosion level:
Ratings Example 1
Example 2
8.3.11. Insulation or Other Coverings:
If it is found that the external coverings such as insulation and corrosion
resistant linings are in good condition and there is no reason to suspect any
unsafe condition behind them, it is not necessary to remove them for inspection
of the vessel.
However, where there is evidence of leakage of gas, vapor, or liquid showing
on the coverage or through the insulation, the cover should be removed to the
extent necessary to make a complete investigation until the source is
established.
For an evidence of damage on the surface painting, the surface should be re-
painted.
The condition of the insulation on the various components shall be reported
against the following criteria:
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(G) Good
: No signs of damage are apparent and there is no
evidence of water ingress or corrosion having occurred.
(F) Fair
: Slight damage has occurred to the cladding e.g. small
indents, buckling etc. but with no loss of seal integrity.
(P) Poor : Significant damage has occurred such that water ingress
could occur. Underlying insulation is not exposed.
(B) Bad
: Significant damage has occurred such that water ingress
could occur. Underlying insulation is exposed to the
elements.
(B1) Staining : The outer cladding or adjacent steel is showing signs of
rust staining indicative of corrosion of the underlying steel
having occurred. (Care must be taken when reporting on
this that the staining is not caused by another source, e.g.
due to chemical).
(B2) Exposed : The condition of the cladding is good but areas have
either been removed or have never been installed such
that the underlying steel or insulation is exposed, e.g.
where insulation is terminated at a flanged joint.
(B3) Wet
: The underlying insulation is observed and found to be wet.
When damaged insulation is to be repaired and opened for inspection, pay
attention to check the condition of the underlying steel and see if water has
ingressed or corrosion has occurred. The following picture shows an example
of an opened insulation to inspect the underlying steel.
See illustration below.
8.3.12. Intrusion:
It is important that the condition of the insulation around any intrusions into the
insulation (i.e. pipe hangers, supports, branch connections etc.) is reported as
these sites are the ones most likely to allow water ingress to occur. The areas
affected should be carefully noted for future inspection and possible removal.
Please note if removal would cause any specific problems in that area.
(G) and (F) are considered Acceptable but (P) and (any B) are reportable. Where
the condition is (P) Poor, (B) Bad, (B1) Staining, (B2) Exposed, or (B3) Wet the
report shall detail the location and nature of anomaly.
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8.3.13. Foundation, Supports, Skirts, Attachments including Bolts & Nuts:
Foundation and supporting components attached to the Vessel should be
checked for indications of inadequate support or provisions for expansion that
may cause excessive loading on the Vessel shell. The pressure vessel
mountings should be checked for adequate allowance for expansion and
contraction, such as provided by slotted bolts holes or unobstructed saddle
mountings. Attachments of legs, saddles, skirts or other supports should be
examined for distortion or cracks at welds.
The condition of supports, skirts, non-pressure attachment, including bolting shall
be reported against the following criteria:
(G) Good : No evidence of deterioration, no thread loss
(F) Fair : Powdery corrosion product easily removed to reveal little or no
loss of thread integrity.
(P) Poor : Several areas where scale fills thread.
(B) Bad : Significant build-ups of scale showing significant loss of thread
and beyond.
The following table of photos illustrates the criteria for attachments:
Ratings Example 1
Example 2
If corrosion and scale build up has occurred on bolts, obviously the inspection
can only be carried out on exposed surfaces. (G) and (F) are considered
Acceptable but (P) and (B) are Reportable. Where the condition is (P) Poor
or (B) Bad the report shall cover details of its (their) location(s), extent, and depth
relative to the threads.
8.3.14. Weld Joints
Welded joints and the adjacent heat affected zones should be examined for
cracks or other defects, Magnetic particle or liquid penetrant examination is a
useful means for doing this.
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8.3.15. Non-welded Joints:
Anomalies shall be reportable where the following criteria have been met or
exceeded:
Leakage of gas or liquid
Visible degradation of sealing medium e.g. evidence of the gasket being wet,
dirty etc
Loose or missing fittings/attachments
Deformation of joint or adjacent pipe work
Details about the location, extent, size, and orientation of the anomaly should be
given in the comments box.
8.3.16. Mechanical Damage:
Mechanical damage shall be reported when the vessel wall has sustained
damage resulting in distortion, flattening, indent, buckling etc.
Details about the location, extent, size, and orientation of the anomaly should be
given in the comment / report.
8.3.17. Dissimilar Metals:
Where dissimilar metals are found to be in direct contact with each other e.g.:
a) stainless fitting to carbon steel on a Pressure Vessel that contains liquid,
b) an insulating gasket set is not fitted, or
c) an insulating set has been fitted but is found to be incomplete or
damaged.
If either of these conditions is found, the report shall contain:
detailed location,
nature of the anomaly,
the metals involved,
the description of the circumstances, and
the geometry.
8.3.18. Vibration:
Vibration shall be reportable where visible movement is evident.
If vibration is found, detail and the extent of any movement should be reported.
8.3.19. Non-Conformity to design:
Non-Conformity to design shall be reported when it is apparent that any part of
the vessel has been changed. Any changes note will be checked against the
latest revisions of Drawings.
Detail of the location and nature of the anomaly should be reported.
8.4. Digital Photography:
Any defects or suspect locations shall be photographed using a digital camera. The
camera should have a minimum of 8 (eight) mega pixels of resolution in order to have
a good quality detail. A camera with 5 (five) X optical zoom is highly recommended.
The number of photographs taken will depend on the length of the pipe and severity
of its condition but the first frame shall be a general photograph such that plant north
is to the top left-hand corner of the photograph wherever possible.
Where this is not practical, the orientation shall be recorded in the "comments"
section.
A log shall be kept of photograph numbers. This sequential number should be written
in the photographic log sections of the Pressure Vessel Inspection Report and the
front summary sheet.
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9. Non-Destructive Examinations (NDE)
The Inspector should examine welded joints and the adjacent heat affected zones for
cracks or other defect with NDT methods such as Ultrasonic testing; Magnetic Particle,
or Liquid Penetrant Testing.
9.1. Commonly Used NDE Techniques
9.1.1. UT Compression Technique (UT Wall Thickness Measurement)
An Ultrasonic Compression Technique (UT wall thickness Survey) is carried out
periodically as determined by the requirements of the Operational Criticality
Assessment. The scheduling is dictated by the operational criticality of the
equipment, and the system attached to it.
A wall thickness survey may consist of point thickness checks, hand scans or
more sophisticated computer based scanning techniques according to the
anticipated level and mode of internal damage mechanism.
It is recommended that RBI Assessment Tools be used to support the activity.
The Assessment Tools will incorporate all the vessels and tag numbers. The
vessel selected for inspection and the locations on these vessels will then be
configured within the RBI Assessment in the development of the inspection
program. The selected locations can then be downloaded into an Automated UT
device, if such device is to be used.
When a defect of significant metal loss is found, an FFS (Fit for Service)
assessment is to be conducted. An area of 25 X 25 shall be prepared, within
which webs of 1.5 X 1.5 area are to be drawn. Progressive UT wall thickness
measurements are to be performed in this webs, and the results are plotted both
horizontally and vertically to statistically see the extent of metal loss. The web
creation is shown in the illustration provided here:
In addition, alternative FFS grid system based on API-579 can be used to plot
the inspection results.
Only a Qualified Examiner using a Qualified Procedure in accordance to ASME
Section V Article 5 Code should do the examination.
9.1.2. Liquid Penetrant Examination
Liquid Penetrant Examination may be required as supplemental to Visual
Examination, where probabilities of Stress Corrosion Cracking of Austenitic
Stainless Steel, fatigue cracks or other types of open to surface discontinuities
are indicated by the RBI Engineering Software results.
9.1.3. Magnetic Particle Examination
Supplemental Magnetic Particle Examination may be required if open to surface
or sub-surface discontinuities of ferromagnetic material are indicated by the RBI
Engineering Software results. Wet Magnetic Particle type of examination, such
as white background Magnetic Particle technique is preferable.
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9.1.4. In-situ Metallographic Examination
In-situ Metallographic Examination may be required to confirm the morphology of
discontinuities, when either Liquid Penetrant or Magnetic Particle Examination
finds and open to surface defect. Micrographic replication using cellulose acetate
film technique is acceptable method or in-situ metallographic examination
purpose.
Only trained and qualified personnel with enough Scientific Metallurgical
background should conduct the examination.
9.1.5. Infrared Thermographic Examination
Infrared Thermo graphic Examination may be required to survey and define the
piping insulating system anomalies.

This technique may be needed for
selection of insulation section I areas to be opened foe visual examination. This
examination may be required when probability of Corrosion under Insulations
indicated by RBI Engineering Software results.
It should also be noted that the non-invasive technique available for detection of
corrosion under insulation are not definitive and their use must be carefully
judged. Thermograph detects moisture in insulation, not the presence of
corrosion. Insulation is not always wet. The worst corrosion may not be at the
point of greatest moisture content. Conversely, the probability of damaging well
sealed insulation and leading in a search for CUI must be considered.
Only an experienced Qualified Examiner using a Qualified Procedure should
conduct the examination.
9.2. Determination on the Location of Deterioration
The likelihood, where deterioration is most likely to occur will be used for determining the
number and the location of inspection points. Examples of these locations are as follows:
Low points area in liquid space
High points area in vapor service space
Liquid - vapor interface
In the case of thickness measurement location (TML), the examination shall be taken
according to the above regimes. The location, method and extend of the inspection shall
be developed based on the RBI Engineering Software results. It is the Authorized
Inspector responsibility to develop such inspection requirements, and be included in the
Inspection Work Pack.
9.3. Marking, Identification, and Numbering Method
Any Pressure Vessel subject to be inspected shall be referenced with a Pressure
Vessel Record and a Vessel Inspection Sheet (Form), complete with sketch, prior to
any type of inspection being carried out.
Permanent Pressure Vessel Record and Vessel Inspection Sheet forms as shown in
API RP 572 Appendix B may be used for developing such forms.
Reference shall be made on the Pressure Vessels sheet/form to the associated P&ID.
9.3.1. Reference Location Marking:
The reference Point Measurement at Pressure Vessels may be as follows:
The area to be inspected is divided into four quadrants:
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Area I: between 12 oclock and 3
oclock
Area II: between 3 oclock and 6 oclock
Area III: between 6 oclock and 9
oclock
Area IV: between 9 oclock and 12
oclock
The areas to be inspected are illustrated in the following table:
1
Head of
Pressure
Vessel
2
Shell of
Horizontal
Vessel
(a)
(b)
Area at quadrant I & IV
at between 11 and 1
oclock for vapor
space
Area at quadrant II &
III at between 5 and 7
oclock for liquid space
Scan at least 1 square
foot area (regardless
of vessels size)
3
Opening
(Nozzle)
straight to the
flow
9.4. Rubbing Name Plate
Data resulting from Rubbing Name Plate is to be compared with the manufacturers data.
9.5. Determining Locations for Wall Thickness Measurements
To determine the remaining thickness of sound base material could be using NDT
methods such as Ultrasonic testing. The maximum allowable working pressure (MAWP)
should be based on the remaining thickness.
The following are the locations of thickness measurements:
Shell
Heads
Nozzles
Blind flanges
Manways
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Reinforcement pads (If any)
9.5.1. Shell
The wall thickness measurement of shell shall be performed on two orientation
side as below:
9.5.1.1. Longitudinal Orientation
If the length of the vessel is less than 6 ft, the number of segment should be at
least 3 (three) segment. This requirement is also applicable for vertical type
installation of pressure vessel.
9.5.1.2. Circumferential Orientation
Group 1 ID or OD of up to 18 inches:
The number indicates the location of measurement point.
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Group 2 ID or OD of over 18 inches up to 48 inches:
The number indicates the location of measurement point.
9.5.2.
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Head
The
points of thickness measurement on head shall be located in critical area
(knuckle) and distance between segments is an equal.
9.5.2.1. Ellipsoidal Head
a. Horizontal pressure vessel orientation (at both

ends)
b. Vertical pressure vessel installation (at the top and bottom view)
a. Horizontal pressure vessel orientation (at both ends)
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30
10
11
12
13
c
d
20
Side view orientation of
points to be inspected
Segment to be inspected
14
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9.5.2.2. Flat / Disk Head
The number of circle should be regarded to the size of head (diameter)
9.5.3. Nozzle Blind Flanges and Couplings
The wall thickness of nozzles shall be measured including reinforcement pads.
Nozzle sizes and flange ratings shall be included in the report.
There should be at least 8 measurement points for nozzles with diameter of up to
8 inches and 12 points for nozzles with diameter of above 8 inches.
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For nozzles with reinforcement pads, the pad sizes and thickness shall be
reported. The thickness measurement points on reinforcement pads shall be in
accordance with the number of points on representative nozzle size.
The number of measurement points on blind flanges is 8. The size and rating of
the couplings shall be included in the report.
9.5.4. Special Condition
In case corroded areas are found during the inspection performed on a vessel,
those areas should be inspected intensively. Report all data separately, such as
below:
Corroded area, square inches,
Average remaining thickness, inches, and
The minimum remaining thickness, inches.
9.6. Ultrasonic Scanning for Flaw Detection & Corrosion Survey
The flaw detection and corrosion survey of shell and head wall shall be performed by
using USK 57 ultrasonic flaw detector or equivalent qualified equipment approved by
PHEWJ. The scanning area shall be mapped into segment as directed by third party
inspection on board.
Below is the location on pressure, vessel need to be scanned in accordance with type of
service and installation.
9.6.1. Oil and Gas Separator / Heat Exchanger
9.6.1.1. Horizontal Installation
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9.6.1.2. Vertical Installation
9.6.2. Water Tank and Diesel Fuel Storage
9.6.2.1. Horizontal Installation
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9.6.2.2. Vertical Installation
9.7. Weld Joint Inspection
Spot of weld joint inspection is conducted by using calibrated USK 57 ultrasonic flaw or
equivalent qualified equipment,
Each inspection point should be minimum 6 inches weld length. Sketch drawing below
is an example on determining the location of welds to be inspected.
Area to be scanned:
Facing Side
Opposite Side
Below is weld joint location that must be inspected:
9.7.1. "T" joint
All T joint shall be inspected. Removal of paint/coating is required prior to the
inspection
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9.7.2. Longitudinal Weld Joint (excluding "T" joint)
Every longitudinal weld joint (excluding T joint) should be inspected for every 3
feet distance of weld joint, and at least 1 (one) inspection point for longitudinal
seam with length of less than 3 feet.
9.7.3. Circumferential Weld Joint
Every circumferential weld joint (excluding "T" joint) should be covered by the
minimum inspection point as the following:
Group Pressure Vessel Diameter (ID or OD)

Points
1
up to 18-inches
2
over 18-inches up to 48-inches
3
4
Minimum
Inspection
1 (one)
2 (two)
2 (two)
3 (three)
This requirement of weld joint inspection is also applicable for vertical pressure
vessel.
9.8. Magnetic Particle Inspection
The parts of pressure vessel that will be subjected to MPI are:
"T" weld joints,
The weld joint between nozzles / couplings and shells,
Weld joint between reinforcement pad and shell or head.
Below is the list of nozzles that needs to be MPI-ed:
Manholes or hand hole nozzles,
Oil inlet nozzles,
Gas inlet nozzles,
Oil outlet nozzle, and
Water inlet / outlet nozzles.
The sketch drawing of weld joint to be inspected such as follows (for examples):
Weld joints to be
inspected
This requirement is also applicable for vertical pressure vessels. In such cases where
the MPI cannot be performed because of the unavailability of access points, the dye
penetrant test shall be carried out as an alternative to MPI.
9.9. Hardness Tests
This inspection is required to identify the material strength of a pressure vessel that has
no material specification records or the records have been missing.
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9.9.1. Shell Side
Each segment of shell wall between two adjacent weld joint shall be measured at
least on 20 (twenty) different location.
9.9.2. Head Side
Each segment of head between two adjacent weld joint shall be measured at
least on 20 (twenty) different location.
9.9.3. Nozzle and Reinforcement Pad
Each segment of nozzle or reinforcement pad between two adjacent weld joint of
head wall shall be measure at least on 10 (ten) different location.
9.10. Combination of UT Scan and Wall Thickness Measurement
When UT Scan is used in combination with wall thickness measurements, the inspected
areas for both applications are as recommended in the mapping summary provided on
the following pages.
Each map is categorized by the vessels group, as mentioned earlier in the procedure,
which is based on the vessels diameter.
To avoid discrepancies, vessels nameplate (NP) is used as the reference point.
General Head and Shell Sketch for WTM:
a) Horizontal
b) Vertical
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c) Flat Head
d) Horizontal
e) Vertical
9.10.3.
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Map for Combination of UT Scan and Wall Thickness Measurements (WTM),
a) Horizontal
b) Vertical
a) Horizontal
b) Vertical
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a) Horizontal
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b) Vertical
9.11. Insulated Vessels
For insulated vessels, inspection windows have to be provided for periodic NDE.
The size and locations of the windows are described below.
9.11.1. Size of Wall Thickness Measurement Windows in Insulated Vessels
The size of wall thickness measurement windows to be prepared is 8 in x 6 in
(200 mm x 150 mm).
9.11.2. Location of Wall Thickness Measurement Windows in Insulated Vessels
Below is the sketch of accessibility windows to be prepared before performing
inspection on insulated pressure vessel:
1. Head
The windows are located in knuckle area on 2 (two) sides of the heads (if any
and if possible), at 0, 90, 180, 270 and centered positions.
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2. Shell
The windows on the shell are to be located at 0, 90, 180, and 270
positions. The distance of point to point (example A to B) is 5 feet (1.5
meter) from the left side and minimum measurement is 2 (two) point
(pressure vessel size less than 10 feet).
Horizontal Pressure Vessel
Vertical Pressure Vessel
270
90
180
Shell
The physical condition of insulation shall be examined and particular attention
shall be paid to damage resulting from maintenance activities or walk-on i.e.
where personnel have stood on insulation and damaged the outer cladding to
allow the ingress of water (vertical vessel top heads are very likely to suffer such
damaged). A thermo graphic scan may be carried out to determine whether
there are areas of wet insulation if the vessel operates either above or below
ambient temperature. Any such areas shall be investigated for corrosion.
10. Corrosion Rate Calculation
Corrosion rate calculation should be based on average value (spot value is not valid to
be used for estimating the corrosion rate calculation). The method of arithmetic means
shall be used to determine the average value.
11. Calculations of the Maximum Allowable Pressure (MAWP)
To determine the Pressure Vessel MAWP, the following formula shall be used:
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MAWP (Shell) =
MAWP (Head) =
S x E x t
(Ri + CA) + 0.6 x t
2 X S x E x t
(Di + 2 x CA) + 0.2 x t
t = ta CA
Where: S
E
Ri
Di
t
ta
CA
=
=
=
=
=
=
=
Maximum Allowable Stress
Joint Efficiency
Inside Radius before corroded
Inside Diameter before corroded
calculated thickness
Actual Thickness
Corrosion Allowance
The existing MAWP of the nozzles are to be determined as well. The MAWP is by
definition calculated in the corroded condition and at the operating temperature.
However, there is not a single equation available for calculating the Nozzles MAWP.
ASME Section VIII and BS 5500 refer to different charts and factors. Several criteria
must be met when determining the MAWP of a nozzle, which include:
a. The nozzle wall thickness (UG-47),
b. The vessel wall thickness (UG-47),
c. The reinforcing area required (which cannot exceed the reinforcing area available),
d. UG-45 minimum nozzle wall thickness,
e. UG-41(b)(1) weld strength calculations,
f. UW-16 minimum weld size requirements,
g. For large openings, the rules of Appendix 1-7 of ASME section VIII are applied, and
h. Stresses due to pressure combined with external nozzle loads (WRC-107 & PVP Vol.
399)
Because multiple criteria must be met there is no single equation that provides a direct
calculation of the nozzle MAWP. The use of computer-aided tools is recommended to
solve nozzles MAWP by iteration. The inspectors are to determine suitable tools.
12. Unknown Document Record
When the pressure vessel is found to have no nameplate, or has minimal or no design/
construction documentations, the following steps may be used to verify its operating
integrity:
Perform inspection to determine condition of the vessel.
Define design parameters and prepare drawing and design calculation.
Base calculation on applicable codes and standards on the allowable stress value
shall use allowable stress for SA-283 Grade C; and for alloy and nonferrous
materials, use x-ray fluorescence analysis to determine type on which to base
allowable stress value.
When the extent of originally performed radiography is not known, use joint factor of
0.7 for butt weld.
Perform pressure test as required by code of construction used for design calculation.
Page 41 of 54
PHE ONWJ Ltd.
13. Conclusions and Acceptance Criteria
The Inspector should discuss with the owner or user, any defect or deficiencies in
condition, maintenance practices or misuse of the Pressure Vessel and, if necessary,
recommend corrective action. All repairs should be carried out in accordance with the
applicable codes.
Acceptance criteria of Discontinuity shall be in accordance with the reference
documents.
14. Reports and Recommendations
The Inspector should make reports and recommendations based on the results of the
inspection, and the key points are to be described in a document called Executive
Summary. For recertification, the report should be submitted to government to obtain
the new/updated operating permit.
For MiGas purposes, the report shall be in Migas format and contains:
Manufacturer data report (form U1),
Result of inspection,
As built drawings, and
Previous report/certification.
Results of inspection shall be contented with:
Technical data,
Calculation evaluate of remained thickness,
Field inspection report, and
Recommendations.
For PHEWJ purposes, the reports shall contain the followings:
1. Third Party Certificate of Inspections,
2. Record of Wall Thickness Measurements,
3. Report of all other NDTs (non destructive tests),
4. Report of Visual Inspections,
5. Design Reviews, and
6. Report of Pressure Test (if any).
The inspector shall prepare the summary of pressure vessels latest condition based on
the results of inspection in forms given in attachments.
The contractor shall be responsible for re-certification process in Dit. Jen. MiGas and
obtain the certificates. Once re-certification is completed, the contractor shall provide
the company with 1 (one) original and 1 (one) copy of inspection reports.
All data that will be used in RBI assessment were obtained from General Inspection and
MIGAS Re-certification Inspection.
14.1. Reports
All reporting should be as brief as possible. However, it is imperative to use the
"Comment" section to even provide fuller details where necessary. A report form should
be developed for traceability purposes, which may contain:
A cross-reference to any other forms of NDT, which may
NDT Report Number
have been carried out on the Pressure Vessel Part.
Report should be sequenced in a logical numerical order
The number of sketch used for the inspection locations
Sketch Number
Page 42 of 54
PHE ONWJ Ltd.
Minimum Recorded Wall

Record the lowest reading taken on the pressure vessel
part
Thickness
Enter the location where the lowest reading was
At TML Number
recorded
Inspection Requirements
The type of inspection to be carried out on this vessel
Inspection Comments
Comments regarding any reportable aspect of the
inspection
The report details of all photographs taken
Photographic Log
General Condition of
Report the results of the visual inspection. Refer to the
visual inspection procedure for details on this
Line
The inspection location cannot be accessed from
Access Required
ground level
If an anomaly is reported
Anomaly Reported
A unique number should be allocated to every
Report No.
inspection report
Inspector
Name, sign and date
Information relating to the wall thickness may be summarized as follows:
Nominal Wall Thickness

Nominal manufacturing wall thickness for this pressure
vessel part
Corrosion allowance as specified in the pressure vessel
Corrosion Allowance
design
Maximum allowable wall thickness loss permissible for
Maximum Loss
the section
Minimum Wall Thickness

Minimum wall as calculated using the hoop stress
calculation defined in the Original Code of the
construction
Retirement Thickness
Minimum acceptable wall thickness for the pressure
vessel
Wall Thickness readings
Location
The location number should match that recorded on the
pressure vessel inspection sheet
Wall Thickness Reading

Record the minimum reading at areas as defined in
Chapter 7.3.4. All readings will be in inches
Page 43 of 54
PHE ONWJ Ltd.
Note:
Based on the AI recommendation, additional inspection, repair, alteration or rerating
shall be conducted in accordance to a qualified procedure authorized by an Authorized
Piping Inspector, and consulted with the piping engineer, where required. The procedure
shall meet all the requirements of API 510.
14.2. Recommendations
Following the RBI evaluation, Inspection Tasks in accordance to this Guide shall be
conducted by the appropriate Inspection Personnel, outlined in Chapter III
Responsibilities and shall be comprehensively reported.
Based on the results of the above Inspection, the Authorized Pressure Vessel Inspector
shall prepare recommendation for any inspection, repair, alteration or rerating that might
be required, to comply with the API 510 requirement, so that the Pressure Vessel can be
safely operated until nest endorsement period.
All of the inspection results, reports, recommendation and repair, alteration or rerating
shall be recorded against a traceable documented procedure.
It is important that historical record be developed and maintained for every Pressure
Vessels to be inspected in accordance on this Guide.
15. Reviews and Revisions
This procedure shall be reviewed for compliance and effectiveness and revised as
necessary (Refer to Technical Document Control Procedure PHEONWJ-G-PRC-1001
every two years).
ATTACHMENTS and REFERENCE FORMS
Attachment A.
Attachment B.
Attachment C.
Attachment D.
Attachment E
Vessel Inspection Report
Vessel Thickness Measurement Report
Change of Pressure Vessel Condition Form
History Card
Quick Opening Closure Visual Inspection Report (sheets 1 to 6)
Page 44 of 54
Tag
No.
Serial
Attachment A
Label
P & ID Number
Year(s) Built
Material Spec.
Insulation Code
Content
VESSEL INSPECTION REPORT
Location :

:
:
:
:
:
Op. Pressure
Op. Temp.
Op. Low Temp.
Nom. Wall Thick.
Corr. Allowance
External
Acceptable
:
:
:
:
:
psig
F
F
inches
inches
Design Pressure
Design Temp.
Des. Low Temp.
Design Code
Test Pressure
Vessels Condition
Reportable
Manway/Pig Launcher Door

Head/Dome End/Exchanger End Box
Shell/Plate Exchanger Frame
Protective Coating/Paint
Nozzles
Insulation
Fire Proofing
Bolted Attachment etc.
Welded Attachments
Reinforcement Pad Pipe over 4
Name Plate
Earting
Support
Ladders
Platform
Level Gauge
Pressure Gauge
Temperature Gauge
Pressure Safety Valve
Internal
:
:
:
:
:
psig
Acceptable
Manway/Pig Launcher Door

Head/Dome End/Exchanger End Box
Shell/Plate Exchanger Frame
Protective Coating
Nozzles
Tubes
Tubeplate
Welded Attachments
Bolted Attachment
Strainers/Filter
psig
Reportable
Comments
Use this section to comment on all reportable items. Record the details of all photographs taken, drawing references etc. Attach sketches if necessary.
Also record any remedial actions which have been carried out and Personnel who have been informed.
Inspectors Details
I declare that the above equipment has been inspected in accordance with the relevant procedures and that this document is a true report of
the inspection carried out.
Inspected by:
Inspection Date:
Approved by:
Attachment B
VESSEL THICKNESS MEASUREMENT REPORT
User
Requested By
P & ID Number
Label
Tag No.
Serial No.
User
Design Pressure
Operating Pressure
Design Temperature
Operating Temperature
RISK BASED INSPECTION
psig
psig
F
F
Equipment
Serial No
Type Of Probe
Test Block
Couplant
Date of Inspection
Location
Report No
Sheet Number
Year(s) Built
Remaining Life
Detailed Measurements, all dimensions are in inches
Part
Ident.
Thickness Measurement Point, Oclock

12
3
6
9
Center
Size of Corrosion
Length
Width
Years
Depth of
Pitting
Nom.
Thick.
Min.
Thick.
Inspectors Details
I declare that the above measurements have been done in accordance with the relevant procedures and that this document is a true report of
the thickness measurements.
Inspected by:
Reviewed by:
Approved by:
Attachment C
CHANGE OF PRESSURE VESSEL CONDITION FORM
Original Vessel Identification Number

: .
1. Original Vessel Location

: .
2. Manufacturer
: .
3. Serial No.
: .
4. See attachments for additional data?

Yes
No
5. Original Maximum Allowable Working Pressure

:
Year Built : .
6. Original Design Temperature

: ...
Year Used : .
7. Original Minimum Design Metal Temperature

: ...
At Pressure : .
8. Original Test Pressure : .

Fluid : .
Position : ....
9. Shell Material
: .
Head Material
:
10. Shell Thickness

: .
Head Thickness :
11. Original Joint Efficiency : .
12. Original Radiography

: .
Yes
No
13. Original PWHT:

Yes
No
If yes, .F .. Hrs
14. Original Corrosion Allowance

: ..
15. Pressure Vessel Condition

:
Operational
Shutdown
Not Used
Not Exist/Not Found
Tag No.not Valid
16. New Vessel Identification Number (If Applicable)

: ..
17. New Vessel Location (If Applicable)

: ..
18. New Maximum Allowable Working Pressure

: ..
19. New Design Temperature

: ..
20. New Minimum Design Metal Temperature

:
At Pressure: ..
21. New PWHT:

Yes
No
F .. Hrs
22. New Joint Efficiency, If Applicable E

=
23. New Pressure Test If Yes, Pressure

: .
Test Medium
Test Position .
24. New Corrosion Allowance

: .....
25. Describe work performed (attach drawings, calculation, and other pertinent data):
..........
Statement of Compliance
We certify that the statements made in this report are correct and conform to the MAXIMO DATA, P&ID, Name Plate and
actual condition pressure vessel.
PHE Field Representative
Signed :
Name :
Date :
Statement of Inspection:
I, the undersigned, an inspector employed by PT. RADIANT UTAMA INTERINSCO Tbk., having inspected the pressure vessel
above
PHE ONWJ Ltd.
Topside Inspection Procedure: Pressure Vessel }
Attachment D
Description
Tag No.
Serial No.
Location
Type of Vessel
Dimensional
Manufactured by
Design Pressure
Design Temperature
Max. Allow. Working Pressure
Test Pressure
Nominal Shell Thickness
Nominal Head Thickness
Year Built I Year Used
Code and Standard Used
Date of
No.
Inspection
HISTORY CARD
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
.........................................................................................
INSPECTION & MAINTENANCE RECORD
Fact Finding
Recovery Action
Taken
Inspection
Report
Initial
Inspector
Date of
Insp.
Shell (mm)
1
2
3
Head (mm)
1
2
3
Nozzle (mm)
1
2
3
Remarks
Insp.
Prepared by:
Reviewed by:
Approved by:
Page 48 of 54
PHE ONWJ Ltd.
Attachment E Sheet 1
Page 49 of 54
PHE ONWJ Ltd.
Page 50 of 54
PHE ONWJ Ltd.
Page 51 of 54
PHE ONWJ Ltd.
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PHE ONWJ Ltd.
Page 53 of 54
PHE ONWJ Ltd.
Page 54 of 54

Topside Inspection Procedure for Pressure Vessel

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Topside Inspection Procedure for Pressure Vessel

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PHE ONWJ Ltd.

Topside Inspection Procedure: Pressure Vessel

Revision Log Register

Document Number : PHEONWJIPRC-0005

: Topside Inspection Procedure: Pressure Vessel

developed Procedure, pages

remain the same as in previous IFA

BPWJ to PHE ONWJ

changes of any BP leftover

in both content and headers/footers

Added: The Inspector should at least

have attended FFS workshop level 1

and gain the related certificates

Rewriting and rearrangement of almost

all the contents and sections to

properly suit the need and workflow of

inspection, plus comments from PHE

Added in section 7 : Inspection and

Added in Section 1 : This procedure also

can be used for Migas recertification.

Added in section 7 : Inspection and

Migas Recertification Procedure

PHE ONWJ Reviewer

PHE ONWJ Ltd.

Topside Inspection Procedure: Pressure Vessel

Topside Inspection Procedures: Pressure Vessel.......................................................1

8.1. Internal Inspection.............................................................................................................. 14

9. Non-Destructive Examinations (NDE).....................................................................23

9.1. Commonly Used NDE Techniques .................................................................................... 23

PHE ONWJ Ltd.

Topside Inspection Procedure: Pressure Vessel

9.1.1. UT Compression Technique (UT Wall Thickness Measurement)............................... 23

General Head and Shell Sketch for WTM:........................................................... 35

Group 2 ID or OD of over 18 inches up to 48 inches: .............................................. 37

Group 3 ID or OD of over 48 inches up to 144 inches: ............................................ 37

Group 4 ID or OD of over 144 inches up to 288 inches: .......................................... 38

15. Reviews and Revisions ..........................................................................................44

Attachments and Reference Forms ........................................................................... 44

10. Corrosion Rate Calculation....................................................................................40

Attachment A. Vessel Inspection Report ....................................................................... 45

PHE ONWJ Ltd.

Topside Inspection Procedure: Pressure Vessel

Attachment C. Change of Pressure Vessel Condition Form ........................................ 47

Attachment D. History Card ............................................................................................. 48

Attachment E. Quick Opening Closure Visual Inspection Report ..................... 49 - 54

PHE ONWJ Ltd.

Topside Inspection Procedure: Pressure Vessel

based inspection of pressure vessels / equipment operated in PHE ONWJ. This

vessels to be inspected and re-certified are those considered to be in good condition to

be re-certified (no repair works are required).

Scope of the procedure covers:

Work team coordination.

a. It is not possible to carry out a meaningful inspection using non-intrusive inspection

reasonably be expected to exist), and

b. Internal inspection becomes a requirement, i.e. when a probability of deterioration

mechanisms related to process environment induced cracking exists , and where

Followings are the reasons when inspection becomes a requirement:

External inspection of shell

Foundation & Support

Attachments support feet/skirt

Associated platforms and access

Auxiliary Equipment (Bridle)