Pressure Vessel

Inspection

Amerya Petroleum Refining

Co.

Pressure Vessel

A pressure vessel is a container designed to

withstand internal or external pressure.

As per ASME Boiler and Pressure Vessel Code Section VIII ,these vessels typically are subject to
an external or internal operating pressure greater
than 15 lbf/in2 (103 kPa).

ASME Code - Section VIII

.( 103 ) 2 / 15

Common types of industry

pressure vessels.

towers,
drums,
reactors,
heat
exchangers,
condensers,
Air coolers,
spheres,
accumulators

Towers

Drums

Reactors

Heat Exchanger

Condensers

Pressure vessels are

designed in various shapes

Cylindrical (with flat, conical, toriconical,

torispherical, semiellipsoidal, or
hemispherical heads),
Spherical,
Spheroidal, boxed (with flat rectangular
or square plate heads, such as those used
for the headers of air-cooled exchangers),
Lobed.
They may be of modular construction.

Shapes and supports

Cylindrical vessels, including exchangers and

condensers, may be either vertical or
horizontal and may be supported by steel
columns, cylindrical plate skirts, or plate lugs
attached to the shell.
Spherical vessels are usually supported by
steel columns attached to the shell or by skirts.
Spheroidal vessels are partially or completely
supported by resting on the ground.
Jacketed vessels are those built with a casing
or outer shell that forms a space between itself
and the main shell.

Methods Of Construction

For all Shapes

Welding (Most pressure vessels are

constructed with welded joints).

For Cylindrical section

Hot forging is another method of
making cylindrical vessels.
Multilayer method.

Materials Of
construction

Carbon steel is the most common material

used to construct pressure vessels.
For special purposes, a suitable austenitic or
ferritic alloy, Alloy 400, nickel, titanium,
high nickel alloys or aluminum may be used.
Copper and copper alloys (except Alloy 400)
are seldom used in refinery vessels but may
be found in petrochemical plant vessels.
Non metals (in lining) such as reinforced
concrete, acid brick, refractory material,
insulating material, carbon brick or block,
rubber, glass, and plastic.

Material Selection

Safety

Corrosion Resistance

Materials used to construct the various parts of exchangers are

selected to safely handle the service and the heat load required.
Pressure vessels' shells or Internals may be made of a corrosionresistant alloy or clad with corrosion-resistant material.

Economy

Materials that will most economically resist the type of corrosion

expected are selected.
Vessels may be lined with other metals or nonmetals. A lined
vessel is usually more economical than one built of a solid
corrosion-resistant material. However, when the pressure vessel
will operate at a high temperature, a high pressure, or both,
solid alloy steels may be both necessary and economical.

Metallic Liners

Metallic liners are installed in

various ways. They may be an
integral part of the plate material
rolled or explosion bonded before
fabrication of the vessel.
They may instead be separate sheets
of metal fastened to the vessel by
welding.

Principal Strip-Lining
Methods

Internal Equipment

Many pressure vessels have no internals.

Others have internals such as baffles,
distribution piping trays, mesh- or strip type
packing grids, catalyst bed supports,
cyclones, pipe coils, spray nozzles, demister
pads, and quench lines.
Large spheroids may have internal bracing
and ties and most vacuum vessels have
either external or internal stiffening rings.
Some pressure vessels have heat exchangers
or reboilers located in the lower shell area.

Reasons for Inspection

To determine the physical condition of the vessel

To determine the type, rate, and causes of deterioration.
Inspection Reports should be carefully documented after each
inspection. With such data, safety can be maintained, the period of
operation without a shutdown can be extended, the rate of
deterioration can sometimes be reduced, and future repair and
replacement requirements can be estimated.
Periodic inspection can lead to a well-planned maintenance program.
Corrosion rates and remaining corrosion allowances determined by
inspection are the normal bases for predicting replacement or repair
needs. These predictions provide for planned maintenance and
continuity of operation and help to ensure a safe, reliable plant.
External inspections performed while the equipment is in operation
using acoustic, ultrasonic, or radiographic instruments or other
nondestructive techniques may reveal important information without
requiring entry inside of the equipment. Defects such as leaks, cracks,
improper installation of parts, plugged lines, undue vibration, unusual
noises, and other evidence of malfunctioning may be found. If these
symptoms are properly analyzed and corrective steps are taken, the
overall reliability of operations will improve.

Causes of Deterioration

Corrosion, Erosion and

Corrosion/Erosion.
Metallurgical And Physical Changes
Faulty Material
Faulty Fabrication

Inspection Activities

Before starting the inspection of a pressure vessel,

especially one in severe service, the inspector should
determine the pressure, temperature, and service
conditions under which the vessel has been operated since
the last inspection.
The inspector should also be aware of equipment
construction details including materials of construction,
the presence of internal attachments, and weld details.
He should also confer with operations to determine
whether there have been any abnormal operating
conditions or disturbances such as excessive pressures or
temperatures.
This data may offer valuable clues to the type and location
of corrosion and to other forms of deterioration that may
have occurred such as scaling, bulging, and warping.

Inspection Activities

The inspector should develop and exercise sound

judgment on the extent and kinds of inspection
required for each vessel.
Careful visual inspection of every vessel is of
paramount importance to determine other forms of
inspection that may need to be made.
Appropriate surface preparation is essential to all
inspection methods.
The extent to which special surface preparation may
be required depends on the particular circumstances
involved. Wire brushing, sandblasting, high-pressure
water blasting, chipping, grinding, or a combination of
these operations may be required in addition to
routine cleaning.

Inspection Activities

If external or internal coverings such as insulation,

refractory linings, or corrosion-resistant linings are in
good condition and without evidence of an unsafe
condition behind them, it may not be necessary to
remove them for inspection of the vessel.
However, it may sometimes be advisable to remove
small portions to investigate their condition and the
condition of the metal behind them, particularly if
previous inspections have indicated corrosion.
When any covering is found to be defective, a
sufficient amount of the covering in the vicinity of the
defect should be removed to find out whether the
base metal is deteriorating and to determine the
extent of the deterioration.

Inspection Activities

Where operating deposits such as coke are

normally permitted to remain on a vessel surface,
it is important to determine the condition of the
vessel surface behind the deposits.
This may require thorough removal of the deposit
in selected critical areas for spot check
examination. Where vessels are equipped with
removable internals, the internals need not be
completely removed, provided reasonable
assurance exists that deterioration is not
occurring beyond that found in more readily
accessible parts of the vessel.

Preparatory Work

The tools needed for vessel

inspection, including tools and
equipment needed for personnel
safety, should be checked for
availability and proper working
condition prior to the inspection.
Any necessary safety signs should be
installed prior to work in vessels.

Some of the tools that

should be available for
inspections
n. Tube gages (inside
a. Portable lights, including a

flashlight.
b. Flashlight with bulb on flexible
cable.

c. Thin-bladed knife.

d. Broad chisel or scraper.

e. Pointed scraper.

f. Mirrors.
g. Inside calipers.

h. Outside calipers.

i. Pocket knife.

j. Steel tape [50 feet (15 meters)].

k. Flange square.

l. An inspector's hammer or ball

peen hammer (4 ounce or 8 ounce).
m. Ultrasonic thicknessmeasurement equipment.

diameter).
o. Steel rule.
p. Pit depth gage.
q. Paint or crayons.
r. Notebook and pencils.
s. Straightedge.
t. Wire brush.
u. Plumb bob and line.
v. Magnet.
w. Magnifying glass.
x. Hook gage.
y. Plastic bags for corrosion
product samples.

The following tools should

be available if required

a. Surveyor's level.
b. Carpenter's or plumber's
level.
c. Magnetic particle inspection
equipment.
d. Micrometer.
e. Radiographic equipment.
f. Megger ground tester.
g. Sandblasting equipment.
h. High-pressure water blasting
equipment.
i. Portable hardness-testing
equipment.
j. Eddy-current testing
equipment.
k. Sonic and radiationmeasuring equipment.
l. Fiber optic flexible scopes.
m. Surveyor's transit.
n. Temperature-indicating
crayons.

o. Thermocouples.
p. Metal sample-cutting
equipment.
q. Material identification kit or
machine.
r. Camera.
s. Ultrasonic flaw-detection
equipment.
t. Liquid penetrant inspection
equipment.
u. Test-hole drilling equipment
(drill, tap, and plugs).
v. Sand- or water-blasting
equipment.
w. Borescope.
x. Plumb lines and levels.
y. Spotting scope or binoculars.
z. Neutron backscatter
equipment for moisture
detection.
aa. Magnetic flux leakage
equipment.

Other Equipments

Other related equipment that might be

provided for inspection includes
planking, scaffolding, boson's chairs,
chain or rope ladders, safety devices for
climbing flares or ladders without cages,
stages for lifting by cranes, radios, and
portable ladders. If external scaffolding
is necessary, it may be possible to erect
it before the inspection starts.

External Inspection

Ladders, Stairways, Platforms, and Walkways.

Foundations and Supports.
Anchor Bolts.
Concrete Supports.
Steel Supports.
Guy Wires.
Nozzles.
Grounding Connections.
Auxiliary Equipment.
Protective Coatings and Insulation.
External Metal Surfaces.

Ladders, Stairways,
Platforms, and Walkways

A careful visual inspection should be

made for corroded or broken parts,
cracks, the tightness of bolts, the
condition of paint or galvanizing
material, the wear of ladder rungs
and stair treads, the security of
handrails, and the condition of
flooring on platforms and walkways.

Foundations and
Supports

They should be inspected for deterioration such as

spalling, cracking, and settling.
The foundations for exchangers usually consist of steel
cradles on concrete piers.
The crevice formed between an exchanger shell or a
horizontal vessel and a cradle support should be
carefully checked.
Excessive heat, mechanical shock, corrosion of
reinforcing steel, or the freezing of entrapped moisture.
Records of settlement should be maintained on vessels
known to be settling. A rough check for uneven settling
can be made with a plumb line and steel rule. When
accurate measurements are desired, a surveyor's level
may be used.

Anchor Bolts

Careful visual inspection, and the area of

contact between the bolts and any concrete or
steel should be scraped and closely examined
for corrosion.
Testing with hammer may reveal complete or
nearly complete deterioration of the anchor
bolt below the base plate.
Distortion of anchor bolts may indicate
serious foundation settlement.
The nuts on anchor bolts should be inspected
to determine whether they are properly
tightened. Ultrasonic may also be used to test
bolts.

Anchor Bolts

Severe Deterioration of
Anchor Bolts

Guy Wires

The connections to the tower and to each ground

anchor point should be inspected for tightness and
correct tension.
Visual examination should be sufficient.
If there is a question regarding the correct tension
in the cables, a structural engineer should be
consulted.
The cable should be inspected for corrosion and
broken strands. The threaded parts of any
turnbuckles are subject to crevice corrosion. Picking
with a pointed scraper will disclose this corrosion.
The wire rope clips on the guy wire cable at the
tower and at the ground anchor point should be
checked for correct installation.

Nozzles

If any settling of the vessel has occurred, nozzles and

adjacent shell areas should be inspected for distortion
and cracking.
Flange faces may be checked with a flange square for
distortion. If there is any evidence of distortion or
cracks in the area around the nozzles, all seams and the
shell in this area should be examined for cracks.
The area should be abrasive-grit blasted or wire
brushed. Magnetic particle (wet or dry), liquid
penetrant, angle beam ultrasonic, or replication
techniques may be used to supplement visual
examination.
Nondestructive testing (NDT) methods such as
magnetic particle (wet or dry), liquid penetrant, or
ultrasonic shear-wave techniques may be used to
supplement visual examination.

Nozzles

Wall thickness of nozzles should be measured.

Calipers, ultrasonic thickness instruments, or
radiographic techniques may be used.
Internal diameter measurements may be taken with
inside calipers to monitor corrosion.
Consideration of lining installation if feasible,
monitoring on shorter intervals, and use corrosion
inhibitors should be taken.
Leaks are likely to occur at piping attachments to the
vessel wall.
Leaks can be located visually while the vessel is in
service or under test conditions.
Evidence of a leak is usually left in the form of
discoloration to the vessel, insulation, fireproofing or
paint, or as damage to or wetting of the insulation.

Grounding Connections

Visually examined to verify that good electrical

contact is maintained.
The cable connections should be checked for
tightness and positive bonding to the vessels
and corrosion where it penetrates the
foundation, slab or ground.
The continuity of all ground wires should be
checked. No break should exist in the
grounding circuit. Test the system to see that
the resistance to ground does not exceed the
accepted values in the area.

Auxiliary Equipment

Auxiliary equipment, such as gauge connections,

float wells, sight glasses, and safety valves, may
be visually inspected while the unit is in service.
Undue vibration of these parts should be noted.
The vibrations should be arrested by adding
supports, or calculations should be performed
by a qualified engineer to assure that the
vibrations will not cause a fatigue failure.
Check for proper construction of auxiliary
equipment and connecting piping beyond vessel
block valves as they can be improperly modified
during unit operation for contingency reasons.

Protective Coatings and

Insulation

The condition of the protective coating or

insulation on a vessel shell should be
determined.
Rust spots, blisters, and film lifting are the
types of paint failures usually found. Rust
spots and blisters are easily found by visual
examination.
Film lifting is not easily seen unless the
film has bulged appreciably or has broken.
It can be found by picking at the film with a
scraper or knife in suspect areas.

Protective Coatings and

Insulation

Scraping paint away from blisters and rust

spots often reveals pits in the vessel walls.
The depth of such pitting can be measured
with a pit gauge or a depth gauge.
The most likely spots to search for paint
failure are in crevices, in constantly moist
areas, and at welded or riveted vessel seams.
The bottom heads of vessels supported on
skirts in humid locations are other likely
points of paint failure.

Protective Coatings and

Insulation

Visual examination of insulation is

normally sufficient to determine its
condition. A few samples may be
removed to better determine the
condition of the insulation and the
metal wall under it.
The supporting clips, angles, bands,
and wires should all be examined
visually for corrosion and breakage.

External Metal Surfaces

The external metal surfaces of a vessel

may be inspected visually by picking,
scraping, and limited hammering to locate
corroded areas.
Cleaning to bare metal will be needed only
at those points where ultrasonic thickness
measurements are taken.
Hand tools such as a pointed scraper, an
inspector's hammer, a wire brush, a
scraper, and can be used to clean small
spots.

External Metal Surfaces

Thickness measurements of the vessel

walls, heads, and nozzles are usually
required at each complete vessel
inspection.
Ultrasonic instruments may be used
for these measurements.
Inspect vessels in cyclic service at
external supports using either liquid
penetrant (PT) or magnetic particle
(MT) testing for fatigue cracking.

Internal Inspection