CONTENTS

• Section 1: Inspection and NDT

• Section 2: Onstream and Shutdown Inspection

• Section 3: Corrosion in Refineries

• Section 4: Selection of Materials used in Refineries

• Section 5: Quality assurance and Inspection of Welds

• Section 6: Advanced NDT Techniques

 ON-STREAM
&
SHUTDOWN INSPECTIONS
REQUIREMENT OF INSPECTION

 To ascertain the physical / metallurgical condition during service for

safe and reliable plant operation.

 To assess the health of the equipment and predict the life expectancy
of the equipment and decide plant / equipment shutdown for repair /
replacement.

 To analyse the reason of deterioration and recommend techno-

economic suitable measures to meet the desired un-interrupted plant
operation by metallurgy upgradation / modifications.
ON STREAM INSPECTION (OSI)

 Carried out when the equipment/ plant is in service/ operation.

 Carried out to determine the extent of general damage &

deterioration.

 Helps to indentify & rectify unsafe conditions arising out of

faulty operation.

 Observations of osi form the basis to determine the repairs to

be carried out during the next shutdown.
SHUTDOWN INSPECTION

 Carried out when the equipment/ plant is taken out of service.

 Thorough internal & external inspection is carried out.

 All parts of the equipment are thoroughly inspected and corrective

action(s) taken for a safe run until the next planned shutdown.
PARAMETERS FOR ON-STREAM INSPECTION
• HEATER:
 Metal skin temp. Of heater tubes.
 Thermography
 Visual inspection of burner flame.
 Hot spots on radiant heater tubes.
 Vibration of heater tubes.
 Condition of tube supports
 Heater draft.
 Casing temperature
PARAMETERS FOR ON-STREAM INSPECTION
REACTOR / COLUMN / VESSEL
 Skin temp. Of refractory lined reactors & regenerators.
 Discolouration of temperature indicative paint
 Leak through tell-tale hole
 Column top temp. (Above dew point)
 Ph of reflux drum boot water.
 Water analysis of boiler feed water.
 Chemical dosing pumps operation.
FREQUENCY FOR ON-STREAM INSPECTION
HEATER

 Metal skin temp. Tubes.- Daily

 Thermography- half yearly

 Visual inspection of Burner flame. Daily

 Hot spots on radiant Heater tubes. Daily

 Sagging/bowing of tubes. Daily

FREQUENCY FOR ON-STREAM INSPECTION
HEATER

 Condition of tube supports Daily

 Heater draft. Daily

 Casing temperature Weekly

 Refractory condition Daily

FREQUENCY FOR ON-STREAM INSPECTION
REACTOR / COLUMN / VESSEL

• Skin temp. Of refractory lined reactors & regenerators. Daily

• Discolouration of temperature indicative paint Daily

• Leak through tell-tale hole Daily

• Column top temp. (Above dew point) Daily

FREQUENCY FOR ON-STREAM INSPECTION
REACTOR / COLUMN / VESSEL

 ph of reflux drum boot water. Daily

 Water analysis of boiler feed water. Daily

 Chemical dosing pumps operation. Daily

STATUTORY EXTERNAL INSPECTION OF VESSELS

 Inspection of all the vessels shall be done as per existing rules of the
country / state

 External inspection should be conducted at least every 5 years or at

the same interval as internal inspection, whichever is less.

 As per smpv rules- 5 yrs with hydrotest.

Check List For External Inspection of Columns
/ Vessels / Reactors
1. Foundation & supports
• Steel reinforced concrete / steel fireproofed with concrete to be
checked for spalling, cracking & settling
• Steel skirts to be checked for corrosion, distortion & cracking.

2. Anchor bolts
• Should be checked for corrosion & damage
• Nuts to be checked for proper tightness.

3. Ladders, stairways, platforms

• Checked for external corrosion, cracks, paint failure etc.
Check List For External Inspection of Columns
/ Vessels / Reactors
4. Nozzles
• Checked for distortion & cracking
• Visual inspection & thickness survey
• Hammer testing (out of service)
• Checking of flange gasket faces for corrosion
• Tell-tale holes of lined nozzles should be checked for leakage.
Pressure testing to be done.

5. External metal surfaces

• Shell to be checked for buckles or bulges
• Checking for hot spots due to failure of internal lining
• Skirt to shell weld joint to be checked for cracks.
• Thickness survey of vessels walls & heads
Check List For External Inspection of Columns
/ Vessels / Reactors
6. Grounding connections
• Checked for good electrical contact
• Cable to be checked for broken strands

7. Insulation & protective coatings

• Visual inspection of insulation for any damage
• Paint or protective coating checked for peeling
PRE-MONSOON INSPECTION OF TANKS
FREQUENCY : YEARLY

 CHECK POINTS:
• Earthing connection
• Tank pad damage
• Water on deck
• Roof drain/ emergency drain
• Pontoon leakage
• Foam seal condition
• Breather valve testing
• Flame arrestor cleaning
• Insulation / paint damage
ON-LINE MONITORING OF PIPING
• Corrosion probe in jacketed lines- Weekly

• ph Monitoring of cooling water system- Daily

• Corrosion coupons in water lines-

Monthly

• Impressed current measurement of cathodic protected lines- Monthly

• Vibrations of pumps connected- mostly of small bore piping- Weekly

• Supports failure- Monthly

PRE-MONSOON INSPECTION

PAINT DAMAGE SUPPORT STUCK UP

SHUTDOWN INSPECTION

 Thorough inspection of plant equipments done during planned

shutdown of unit.

 Inspection of offsite equipments like tanks & piping done as per OISD
norms.

 The frequency of inspection of various unit equipments & offsite

equipments is decided as per OISD norms.
INSPECTION OF FIRED HEATERS
DEFINITION
 Fired heater is an internally insulated enclosure where the heat
liberated by the combustion of fuels is transferred to fluid contained
in tubular coils.

 Fired heaters are primarily used to heat hc of all types from crude oil
to light hydrocarbons.

Types of heaters
• Box heater with vertical coil
• Box heater with horizontal coil
• Cabin heater with horizontal tube coil
• Cylindrical heater with vertical coil
• Cylindrical heater with helical coil
HEATER CONSISTS OF:

1. HEATING COIL
2. SETTING
3. STACK

1. HEATING COIL
a. Carries the process fluid to be heated.
b. Consists of lenghts of tubing connected to form continuous coil.
c. Tubes in radiant section are called radiant tubes. Heat pick up
through direct radiation from flame.
d. Tubes in convection section called convection tubes. Mostly
studded tubes are used for better heat heat pick up from
combustion gases through convection.
HEATER CONSISTS OF:
e. Shock tubes located at bottom of convection receive highest heat
density as they absorb both radiant & convection heat.

f. Some of the typical metallurgy of coils – cs, 5cr-1/2 mo, 9cr-1mo, ss

321, ss 347

2. SETTING CONSISTS OF :
a. Supporting members
b. Heater casing – metal casing, refractory / insulation, tube sheet and
header boxes.
c. Auxillary equipment – burners, air heaters, fans / blowers, dampers,
thermocouples

3. STACK
a. Flue gas stacks of heaters are usually made of concrete and steel.
b. Stacks are refractory lined from inside to protect from corrosive action
of flue gases.
BOX TYPE HEATER WITH HORIZONTAL TUBES
EXTERNAL CLEANING OF HEATER TUBES
• Tubes cleaned by wire brusing or sand blasting to remove all deposits.
• Use of steam lancer water washing.

INTERNAL CLEANING OF HEATER TUBES

• Done when fouling or coking is indicated by increased pr. Drop
• Steam / air decoking & chemical cleaning are effective methods to
remove hard coke deposits
• High pressure water jet – used for tubes with plug type fittings
SPECIAL PRECAUTIONS FOR AUSTENITIC STAINLESS STEEL TUBES IN H2 &
H2S SERVICE
• Fes Film forms on ss tubes operating above 425 0C and when
exposed to moisture & air forms polythionic acids.
• Polythionic acids can cause intergranular scc of ss tubes
• To protect from polythionic acid attack maintain positive flow of
inert gas .
• 2% soda ash solution with 0.5% sodium nitrate is circulated to
neutralize the acids.
CHECKLIST POINTS FOR SHUTDOWN INSPECTION
EXTERNAL VISUAL INSPECTION OF HEATER TUBES
• Check for sagging, bowing & bulging
• Check for oxidation, scaling, deposits, corrosion, cracks, grooving.
• Check for roll leaks & plug leaks which can be found by observing
the location of coke or oily deposits around headers.
• Special attention should be given to the entry & exit points of inlet
& outlet tubes.
• Special attention should be given in the area from fire box floor to
5 m above the floor.
INSPECTION OF HEATER TUBES WELD JOINTS
• All accessible weld joints should be thoroughy inspected visually.
• Mpi, dpt, radiography, ultrasonic flaw detector may be used to
supplement visual inspection.

INSPECTION FOR WEAR AT SUPPORT LOCATIONS

• Due to thermal expansion / contraction and vibrations, rubbing action
takes place on tube surface at supports.
• Tubes should be inspected for thinning and grooving at all support
locations.
INSPECTION OF RADIATION TUBES
1. Ultrasonic thickness survey of tubes should be done along the length
to determine the metal loss and rate of deterioration.

2. Typical locations of thickness measurement are listed below:

a. Outermost curvature of bends
b. Near the weld joint of bend to tube
c. Upstream & downstream of tube weld joint
d. Every 2 m straight length of tube
3. Tubes should be checked for sagging & bowing. It should not exceed
0.5 times the dia. Of tube.
a. Sagging due to decrease in structural strength caused by over
heating, improper spacing of hangers, failure of tube supports
b. Bowing due to unequal metal temp. From flame impingement or
due to restriction in thermal expansion of tubes.

4. Tubes should be checked for bulging, especially which may be

subjected to flame impingement.
a. If the increase in diameter of tube at the bulge is 5% or more,
tube are rejected.
b. In case of reformer tubes, increase in dia. Is limited to 3%.
INSPECTION OF CONVECTION TUBES
1. The convection tubes should be cleaned from outside to the extent
possible and visually inspected for any deterioration.
2. The last few rows of tubes at the exit of flue gases should be checked
for external corrosion due to dew point of flue gases.
3. The accessible studded tubes should be inspected for any sign of
oxidation of studs due to overheating or corrosion due to sulphurous
deposits.
4. Thickness survey of all return bends and tubes up to the extent
possible should be done.
5. Corrosive sulphurous deposits should be removed by water washing.
During operation, soot blowing should be done once in a day.
TUBE HANGERS
1. Tube hangers are generally made of 25cr-20ni (HK-40) Material.
2. Tube hangers are prone to oxidation, corrosion and cracking at high
temp.
3. Tube hangers are prone to sigma phase formation due to prolonged
exposure at high temp. Which makes them brittle at room temp.
4. All the hangers should be inspected for cracks.
REFRACTORY LINING
1. (Castable, cf blanket / module)
2. Visually inspected for breakage, crumbling & open joints.
3. Fallen refractory exposes the supporting steel casing to high temp.,
Rapid oxidation & corrosion by hot flue gases.
4. The clearance in expansion joints of lining should be checked for
deterioration from heat / debris. Clearance should be filled with
asbestos rope / cf.
5. After major refractory repairs , it should be dried properly during
start up.
FURNACE CASING & ACCESSORIES
1. Exposed parts of heater casing should be visually inspected for signs of
any damage, paint peel off etc.
2. Casing should be inspected for thinning / perforation due to acidic
flue gas corrosion.
3. Header boxes should be checked for warpage as it leads to:
a. Excess air into the heater resulting in additional fuel
consumption.
4. Proper alignment of burners is essential as misaligned burners will
lead to
a. Flame impingement on radiation tube.
b. Damage of burner housing.
5. Burner tips should be checked for oxidation, corrosion & choking.
THERMOCOUPLE CONNECTIONS
1. Weldment of thermocouple tips on radiation & convection tubes often
crack in service.
2. The weld should be d.P checked during every shutdown.

HYDROSTATIC TESTING
1. Hydrostatic test should be performed in all heater tubes in each m&i
shutdown and decoking shutdown.
2. Hyd. Test pr. – 1.5 times the max. Opr. Pr. (Corrected for temp. Or
shut-off pr. Of pump)
3. Testing to be done whenever tubes or fittings are replaced.
4. Under test pr., Inspection should be made from inside the heater to
locate any leak.
5. Austenitic stainless steel tubes should be hydrotested with dm water.
INSPECTION TOOLS AND INSTRUMENTS
1. Inside & outside calipers
2. Go-no-go gauge
3. Saftey torch
4. Ultrasonic thickness gauge
5. Infrared pyrometer
6. Dye penetrant testing kit
7. Inspection mirror
8. Magnifying glass
9. Inspector’s hammer
10. Pit depth gauge
11. Pointed scraper
12. Thermal crayons
13. Radiography testing equipment
INSPECTION OF HEAT EXCHANGERS
WHAT ARE HEAT EXCHANGERS ?
 Heat exchangers – reduce the temperature of one fluid by transfering
the heat to other fluid without intermixing.

 Condensers – condense vapour into liquid by trasfering heat to water.

 Coolers – cool liquid by transfering heat to water.

TYPES OF HEAT EXCHANGERS
1. Shell & tube bundle exchangers
 One fixed tube sheet with floating head
 Two fixed tube sheets
 One fixed tube sheet with u-tubes
 Kettle type ( reboilers & evaporators)

1. Plate heat exchangers

2. Breech lock heat exchangers
3. Double pipe heat exchangers
4. Air fin coolers
SPECIFIC FEATURES FOR DIFFERENT TYPES
OF HEAT EXCHANGERS
• ONE FIXED TUBE SHEET WITH FLOATING HEAD
-Most common type / permits free expansion & contraction

• TWO FIXED TUBE SHEETS

- Limited to clean service / small expansion & contraction.

• ONE FIXED TUBE SHEET WITH U-TUBES

- Limited to clean fluid service at tube side. Free expansion &
contraction.

• KETTLE TYPE ( REBOILERS & EVAPORATORS)

-Large vapour space above tube bundle.
MATERIAL OF CONSTRUCTION
TUBES:
• Carbon steel , alloy steel, stainless steel, duplex ss, copper, ad. Brass,
titanium
[Common grades: SA179,SA210GRA1, SA213 T2 /T11 /T22/T5, SA213TP304,
304L, 316,316L,321, 410, SA789UNS31803(DUPLEX SS), SB111C43400]

SHELL:
• CS , AS, CS & AS + SS CLADDED, SS [COMMON GRADES: SA516GR60/70,
SA515GR60/70, SA387GR2,GR11,GR22, SA240TP304/316/321,
SA264( SA516+SA240)]

TUBE SHEETS:
• Common grades: SA266, SA336 F2/F11/F22, SA182F304/316/321, NAVAL
BRASS
CAUSES OF DETERIORATION

 Attack from hydrocarbons, chemicals, steam, water, cooling water

 Influenced by – temp., Stress, fatigue, impingement, high velocity of

flow.

 Deviation from design operating conditions

CAUSES OF DETERIORATION

A. CORROSION;
1. Corrosion from hydrocarbon streams
- H2S attack, hcl attack, stress corrosion, erosion corrosion, under
deposit corrosion.

2. Water corrosion
-Galvanic corrosion, dezincification, under deposit, erosion-corrosion,
pitting, general corrosion, condensate corrosion, mic / srb induced
corrosion.
CAUSES OF DETERIORATION
• Mechanical deterioration:
• Cracks – welding , high stresses.
• Buckling of tubes
• Cleaning damage
• Loosenenibg of tubes
• Handling damage
• Collapse of tubes
• Gasket failures
FREQUENCY & TIME OF INSPECTION
A. FACTORS GOVERNING FREQ. OF INSPECTION:
1. Rate of deterioration
2. Remaining corrosion allowance
3. Type of deterioration
4. Local factors related to each exchanger
5. Service history record
6. Change in process operating conditions
7. Operational needs – chokage etc.
FREQUENCY & TIME OF INSPECTION
B. OPPORTUNITIES FOR INSPECTION:
1. When it is taken out of service for cleaning
2. During unit shutdown

C. INSPECTION SCHEDULE:
1. Done thrrough joint collaboration with process / production &
maintenance.
 INSPECTION TECHNIQUES & PROCEDURE
A. GENERAL EXTERNAL INSPECTION DURING OPERATION

1. Visual inspection of foundations, paint, insulation, ladders, platforms,

pipe connections

2. Thickness measurements on shell / channel box / nozzles ( except for

high temp. Service) using ultrasonic thickness measuring instruments.

3. Survey / review of operating conditions

 INSPECTION TECHNIQUES & PROCEDURE
B. DETAIL INSPECTION – OUT OF SERVICE (EXTERNAL & INTERNAL)

1. Preliminary observations of components (before cleaning)

• Nature of deposits, extent of chokage, presence of oil at water
side, anyphycal damage of components etc.

2. Inspection (after cleaning)

• Shell / channel box/ shell cover / floating head
• General visual inspection both inside & outside ( look for thinning,
pitting, weld crack / corrosion, corrosion on gasket faces, erosion
at nozzle internal surface, hydrogen blisters, bulging, shell surface
erosion / corrosion near baffles)
 INSPECTION TECHNIQUES & PROCEDURE
• Thickness survey of shell / channel box/ shell cover / floating head
• If required, dye penetrant testing of weld joints for cracks

3. INSPECTION OF TUBE BUNDLE

• Visual inspection of all components
-External surface of tubes
-Internal surface at both tube ends
-Tube ends for thinning
-Seal welding of tubes with tube sheet
-surface of tubes below inlet nozzles
-Area of tubes around baffles
-tie rods / sleeves
-Tube sheets
-Check for tube bowing / cracking near tube sheets
 INSPECTION TECHNIQUES & PROCEDURE

INSPECTION OF TUBE BUNDLE (Contd…..)

• ID measurement of tubes by tube id gauge
• OD measurement
• DP check of seal welding on tubesheets
• Cutting of sample tube & splitting for internal inspection , if
required
TESTING OF EXCHANGERS

1. SHELL TESTING
• Effective for detection of individual tube leak, if any.
• Soundness of shell weld joints / gasket joints with fixed tube sheet
and channel box tested
• In case of floating head type, separate test ring is required to conduct
shell testing.

2. TUBE TESTING
• Tubes are under tensile stress.
• Floating head gasket / channel cover gasket tested.
• Tube leaks get detected but identification of individual tube test is
not possible.
TESTING OF EXCHANGERS
3. COVER TEST
• Pressurisation of shell side after boxing up of shell cover
• Shell to shell cover gasket gets tested.

4. INDIVIDUAL TUBE TEST

• Testing of individual tube by pressurising each tube.

5. TEST PRESSURES
• Both shell or tube test pressure
= 1.5 x design pressure ( as new)
= 1.5 x operating pressure (in use)
INSPECTION TOOLS FOR H/E INSPECTION
• FLASH LIGHT
• INSPECTOR’S HAMMER
• SCRAPER
• WIRE BRUSH
• INSIDE CALIPERS & TUBE ID GAUGE MEASURING
• OUTSIDE CALIPERS
• PIT DEPTH GAUGE
• MAGNIFYING GLASS
• MARKING CRAYON
• SMALL MAGNET
• MEASURING TAPE
• BOROSCOPE / FIBRESCOPE
INSPECTION TOOLS FOR H/E INSPECTION
• ULTRASONIC THICKNESS SURVEY METER

• DYE PENETRANT TESTING KIT

• MIRROR
COLUMNS/ REACTORS/ PRESSURE VESSELS
Inspection of unfired pressure vessels(columns,
reactors & vessels)
DEFINITION
• A pressure vessel is a container that falls within the scope of asme sec
viii code and that is subjected to an internal or external design
pressure greater than 15 psi.

USE OF PRESSURE VESSELS

• Used as a surge drum for storing liquids (volatile or dangerous)
• Used as a thermal reactor or a catalytic reactor
• Used as a fractionator
• Used as a separator
• Used as a regenerator
• Used as an exchanger
TYPES OF PRESSURE VESSELS
• Trayed columns
• Reactors process vessels
• Packed columns
• Drums & misc. Vessels
• Storage vessels like bullets & spheres
SHAPES OF PRESSURE VESSELS
• Cylindrical having
 Flat, conical, toriconical, torispherical, semiellipsoidal or hemispherical
heads
• Spherical
SUPPORTS OF PRESSURE VESSELS
• Cylindrical vessels may be horizontal or vertical. They are supported by
skirts or steel columns attached to the shell.
• Spherical vessels are usually supported by steel columns attached to the
shell.
METHODS OF CONSTRUCTION
• Most pressure vessels constructed with welded joints having longitudinal
seam.
• Shell rings made by rolling plates and welding of ends done to form a
cylinder.
• Hot forging for high-pr, heavy wall vessels used for hydrocracker reactors.
No longitudinal seam.
• Multilayer method
MATERIALS OF CONSTRUCTION
• Carbon steel
• Ferritic or austenitic alloy steel
• Metallic liners for corrosion / erosion resistance (austenitic / ferritic ss,
monel, lead)
• Non-metallic liners (rf concrete, acid brick, refractory material, rubber,
plastic)
FREQUENCY OF COLUMN / PRESSURE VESSELS INSPECTION DEPENDS ON:
• Rate of deterioration
• Remaining corrosion allowance
• On the basis of service history, inspection interval set in accordance
with API 510
• Statutory requirements (SMPV rules – all vessels to be hydrotested
every 5 years)

ACCORDING TO API 510

• Period between internal inspections shall not exceed one half the
estimated remaining life or 10 years, whichever is less
• External inspection should be conducted at least every 5 years or at
the same interval as internal inspection, whichever is less.
Remaining life (years) = t(actual) – t (min.)
Corrosion rate
CAUSES OF DETERIORATION
1. CORROSION – Common corrodents are sulfur & chloride compounds.
Caustics, inorganic acids, water (LOW ph) etc. Are other corrodents

2. EROSION – Impingement of soild particles or liquid drops on the surface.

 Due to restrictions in flow, change in direction or high fluid
velocities.
 Found in inlet / outlet nozzles, vessels walls opposite inlet nozzles,
baffles etc.

3. METALLURGICAL & PHYSICAL CHANGES – due to exposure to service

conditions.
 Affects The Mech. Properties.
 Graphitization, Carbide Precipitation, Igc – Microstuctural Changes
CAUSES OF DETERIORATION

4. MECHANICAL FORCES- Thermal shock, vibration, excessive pr. Surge&

external loads.

5. FAULTY MATERIAL – Laminations in plate, casting defects.

6. FAULTY FABRICATION – Poor welding, improper heat treatment etc.

 CORROSION PRONE AREAS IN COLUMNS /
REACTORS / VESSELS
1. Bottom head & shell of fractionators processing high `s’ crude oils are
susceptible to sulphide corosion.

2. Top heads & upper shell of distillation columns are prone to chloride attack
in the form of pitting corrosion.

3. Fractionation & distillation coulmn, knockout drums & reflux drums in the
presence of wet H2S or cyanides are prone to cracks in welds & their haz.

4. Corrosion & erosion will take place in shell directly opposite to steam inlet &
inlet streams.

5. Corrosion occurs where two dissimilar metals are in close contact (cladded /
uncladded zone)
INTERNAL INSPECTION OF COLUMNS

1. All parts of columns should be inspected for corrosion, erosion,

hydrogen blistering, cracking & lamination.
2. Thickness measurements to be taken on heads, shell, nozzles to know
the extent of deterioration.
3. Top dome & shell to be checked for pitting. Depth of pits / grooves
measured by pit depth gauge.
4. Hammer testing done for shells & nozzles to identify thin spots by
resulting sound.
5. For wet H2S, amine or caustic service, magnetic particle testing (wfmpt)
done in welded seams to detect surface cracks.
6. Connected nozzles should be checked for internal corrosion.
INTERNAL INSPECTION OF COLUMNS

7. Supports for internals like trays, baffles, screens, grids, piping etc. Should
be visually checked.

8. General condition of internals like trays, packing m/l should be checked

for corrosion.

9. The flash (feed) zone should be thoroughly checked for erosion / corrosion
of impingement plate attached with the shell.

10. Bottom dome & shell near the draw-off nozzle are critically inspected for
pitting corrosion.

11. Shell opposite to steam injection nozzle should be checked for

impingement.
INSPECTION OF CLADDED COLUMNS
Cladding protects the base metal from erosion / corrosion. SS 410s, SS
316L, Monel are some of the cladding m/l used.
1. Careful visual inspection of lining is required for checking
corrosion, erosion, bulging etc.
2. Light hammer taps will identify corroded & cracked sections of
lining.
3. Thickness measurements at designated locations to be done to
check the bonding of cladded metal with base metal.
4. The junction of cladded & uncladded zone should be checked for
galvanic corrosion.
5. Weld joints & haz should be checked for cracks.
6. Pneumatic testing of nozzle liners should be done .
INSPECTION OF GUNITE / REFRACTORY LINED
VESSELS
• Visually inspect to check for spalling & cracks.

• Hot spot locations to be carefully checked.

• Lining to be checked for bulging & looseness by light hammer tapping.

• Thickness of shell to be measured from outside.

TOOLS FOR PRESSURE VESSEL INSPECTION
1. Safety torch
2. Scraper
3. Mirrors
4. Inside / outside callipers
5. Inspector’s hammer
6. Ultrasonic thickness gauge
7. Pit depth gauge
8. Magnet
9. Straight edge
10. Magnifying glass
11. Dye-penetrant kit
12. Radiographic equipmnent
13. Mpi equipment
STORAGE TANKS
TANK CODES
• API-650: WELDED STEEL TANKS FOR OIL STORAGE

• API-653: TANK INSPECTION, REPAIR

•

• OISD 129: INSPECTION OF STORAGE TANKS

FLOATING ROOF TANK
• PURPOSE
 Storage of volatile products
 Reduce hydrocarbon emission
 Safe & economical

• TYPES
 Fixed roof tank with internal floating roof.
 Double deck external floating roof.
 Pontoon type external floating roof.
 TANK COMPONENTS
• Annular plate/ sketch plates
• Syphon drain
• Inlet / outlet nozzles
• Manholes
• Shell courses
• Dip hatch
• Earthing connection
• Wind girders
TANK COMPONENTS

• Roof support legs

• Roof drain/ swivel joint
• Foam seal/ weather shroud
• Emergency drain
• Guide pipe/ rollers
• Rim vent / bleeder vent
• Pontoon box
• Rolling ladder
FLOATING ROOF SCHEMATIC
FLOATING ROOF
FLOATING ROOF FOAM SEAL
FIXED ROOF TANK
• FIXED ROOF
 Used for storing low toxic liquid

• TYPES
 With atmosphere vent
 Pressure-vacuum vent
TANK COMPONENTS
• Compression rings/ curb angles
• Breather valve
• Goose neck/ flame arrestor
• Clean out door
• Bottom drain
• Steam coil / support
• Sky light manhole
TANK TESTING
• Dimensional tolerances
 Plumbness
 Roundness
• Vacuum box test
• Pontoon box diesel chalk test
• Pneumatic test of roof joints.
• Hydrotest
• Leak detection
PRE-MONSOON SURVEY
TANK PROTECTION
• Epoxy painting

• Painting of roof underside / bottom plate

• Internal lining

• Cathodic protection of underneath surface

PNEUMATIC TEST OF BOTTOM PLATE

MANOMETERS

MUD SEALING

TANK PAD

ARRANGEMENT FOR PNEUMATIC TESTING OF TANK BOTTOM PLATE

OFF-SITE PIPING
PIPING TYPES
ABOVE-GROUND
1. INSULATED
a. Heating coil
b. Jacketed lines
2. UNINSULATED

UNDER-GROUND
INTERNAL CORROSION
• Uniform Corrosion due to low/high pH

• Localized Corrosion- In Crevices, Bends etc.

• Preferential Attack On Weld

• Stagnant Areas - In Dead Ends etc.

• Condensation/ Two Phase Systems

INTERNAL CORROSION
• Internal lining damage

• Stress corrosion cracking

• High temperature failures

• Hydrogen attack

• Areas downstream of chemical injection points

• Naphthenic acid/ polythionic acid corrosion

EXTERNAL CORROSION
• Corrosion under insulation

• Soil side corrosion of under-ground lines

• Atmospheric corrosion - sulfurous / acidic environment

• Spillage / impingement

• Corrosion at soil / air interface

STRESS RELATED FAILURE
• Overpressurization

• Vibration- as in pump connected piping

• Support failures- inadequate supporting system or stuck up

• Thermal stresses due to continuous wetting / drying- in connected

piping

• Fatigue due to cyclic loading

SACRIFICIAL ANODE
IMPRESSED CURRENT
NDT TECHNIQUES FOR PIPING
• Ultrasonic thickness survey

• For identification of leak in undergroud pipes- pigging

• Spark / hardness test of rubber lines

• Radiography
SHUTDOWN SCHEDULE OF UNITS

SL.NO UNIT FREQUENCY (YRS)

1. CDU / VDU 4

2. OHCU 4

3. HGU 4

4. RFCCU 2

5. CCRU 2

6. DHDS 4
SHUTDOWN SCHEDULE OF UNITS
SL.NO UNIT FREQUENCY (YRS)

7. SRU 2

8. SWSU 2

9. ARU 2

10. BBU 4

11. MEROX 4

12. VBU 4

13. BOILERS 1
INTERNAL INSPECTION SCHEDULE OF OFFSITE
TANKS
SL.NO SERVICE FREQUENCY (YRS)

1. CRUDE TANKS 6

2. HSD TANKS 5

3. NAPHTHA TANKS 6

4. ATF TANKS 7

5. KEROSENE TANKS 7

6. BITUMEN FEED TANK 6

7. BITUMEN PRODUCT 10
INTERNAL INSPECTION SCHEDULE OF OFFSITE
TANKS

SL.NO SERVICE FREQUENCY (YRS)

8. FFS TANK 6

9. OHCU FEED 6

10. DHDS FEED 5

11. VBU FEED 6

12. IFO TANK 6

INSPECTION SCHEDULE OF SMPV EQUIPMENTS

SL.NO EQUIPMENT FREQUENCY (YRS)

1. LPG HORTON SPHERES 5

2. PROPYLENE SPHERES 5

3. HYDROGEN BULLETS 5
INSPECTION SCHEDULE OF OFFSITE PIPING
(HYDROCARBON SERVICE)

SL.NO SERVICE FREQUENCY (YRS)

1. CRUDE 5

2. VISBREAKER FEED 5

3. IFO 5

4. REFORMER FEED 4

5. HYDROGEN FEED 4

6. HSD 5

7. MS 4
Inspection schedule of offsite piping
(hydrocarbon service)
SL.NO SERVICE FREQUENCY (YRS)

8. KERO 5

9. ATF 5

10. HYDROGEN 4

11. LPG 5

12. BITUMEN 5

13. FLARE 5

14. FUEL GAS 5

INSPECTION SCHEDULE OF OFFSITE PIPING
(UTILITY LINES)

SL.NO SERVICE FREQUENCY (YRS)

1. RAW WATER 4

2. FIRE WATER 2

3. DM WATER 6

4. AIR (INST/ . SERVICE) 6

5. STEAM 6
INSPECTION SCHEDULE OF OFFSITE PIPING
(UTILITY LINES)

SL.NO SERVICE FREQUENCY (YRS)

6. CAUSTIC 4

7. NITROGEN 6

8. SOUR WATER 3

9. LEAN AMINE 3
INSPECTION SCHEDULE AS PER SATUTORY
REQUIREMENTS

IBR (INDIAN BOILER REGULATION)

• Boilers are to be inspected & hydrotested every year.

• Waste heat boilers to be inspected & hydrotested every 2 years.

• Steam generation coils & piping are to be inspected & hydrotested

every 2 years.
INSPECTION SCHEDULE AS PER SATUTORY
REQUIREMENTS
OISD (OIL INDUSTRY SAFETY DIRECTORATE)
• Frequency of inspection of unit equipments done as per OISD norms.

• Inspection schedule of offsite tanks decided as per OISD standard 129.

• Inspection schedule of offsite piping decided as per OISD standard

130.
INSPECTION SCHEDULE AS PER STATUTORY
REQUIREMENTS
STATIC & MOBILE PRESSURE VESSELS (UNFIRED) RULES, 1981 (SMPV)
• Lpg horton spheres, propylene spheres & hydrogen bullets fall
under spmv rules.

• All vessels under smpv rules shall be hydraulically tested at

intervals of not more than 5 years.

• For vessesls containing toxic or corrosive gases, the periodic test

shall be done at an interval of 2 years.
LIST OF STATUTORY EQUIPMENTS

• LPG Horton spheres

• Propylene spheres

• Hydrogen bullets

• Power boilers

• Waste heat boilers

• Steam generation coils

THERMO HUNTER
THERMO HUNTER
X-MET ALLOY ANALYZER
X-MET ALLOY ANALYZER
POLDI HARDNESS TESTER
ULTRASONIC
HARDNESS TESTER
ULTRASONIC HARDNESS TESTER
DMEDL WITH STEP GAUGE
DMEDL
DMS
CYGNUS
FIBROSCOPE
RUBBER
HARDNESS
TESTER
BINOCULAR