Table 1 - Pressure Vessel & Exchanger / Visible External Deterioration / by External Visual

Combined Criticality Rating

Low Medium Medium-High High
Minimum
External Visual
coverage
1,2,3
100% External
Visual
100% External
Visual
100% External
Visual
100% External
Visual
Maximum
RBMI Interval
(Yr.), or 1/2
remaining life
4
15 10 10 5
Maximum
Interval
allowed by
jurisdiction
Depends on
J urisdictional
Requirements
Depends on
J urisdictional
Requirements
Depends on
J urisdictional
Requirements
Depends on
J urisdictional
Requirements
Insp.
Confidence:
Non-insulated
Insulated

Very High
Medium

Very High
Medium

Very High
Medium

Very High
Medium
NOTES for Table 1:
1. External visual inspection should also include a count of potential inspection locations for
expected failure modes.
2. Formal external visual inspections are performed on pressure vessels to prevent failures by
identifying those components that are deteriorating externally. External deterioration may
include external corrosion, corrosion under insulation, fatigue, factors that may contribute to
flange leaks, or indications of other failure modes.
3. The relief device(s) associated with each pressure vessel should be inspected at the same
time as the pressure vessel external visual inspection.
4. Shorter intervals for external inspections should be set for identified equipment deterioration
that has not been corrected. External inspections can often be scheduled at the time of the
internal inspection.
5. See Generic Strategy Notes and Rules, WR-1 at the beginning of the strategy tables,
page.


Table 2 - Pressure Vessel & Exchanger / Internal Corrosion / by Internal Visual
Criticality Rating Based on Failure Mode


Low Medium Medium-High High
Minimum Internal
Visual coverage
1,2
25% coverage and
a minimum of 50%
of locations
defined by
Corrosion Study
50% coverage and
100% of locations
defined by Corrosion
Study
100% coverage 100% coverage
Coverage if only
partial internal
visual is possible
3
25% of all possible
VI locations
50% of all possible VI
locations
100% of all possible
VI locations
100% of all
possible VI
locations
Vessels from
Group
4
Minimum of 1 Minimum of 1 Minimum of 50% Not Applicable
Maximum
Interval (Yr.), or
1/2 remaining life
15 10 10 5
Maximum
Interval allowed
by jurisdiction
Depends on
J urisdictional
Requirements
Depends on
J urisdictional
Requirements
Depends on
J urisdictional
Requirements
Depends on
J urisdictional
Requirements
Eliminate Internal
inspections, if
allowed, when
this criteria is met
5
At any time 5 yrs of inspection
history and at least 1
internal for general
corrosion and 2
internals for localized
corrosion
10 years of
inspection history
and at least 2
internals for general
corrosion and 3
internals for localized
corrosion
Not Applicable
Inspection
Confidence
(vessels
inspected)
6
Medium High Very High Very High
Inspection
Confidence
(vessels in same
group not
inspected)
6

Low

Medium

High

Not Applicable
NOTES for Table 2:
1. Also perform External UT according to strategy Table 3 to support the Internal Visual
inspection. Thickness readings should be taken at all significant indications found during the
Internal Visual inspection.
2. Minimum coverage of 25% means spot internal looking through manways only, 50% means
actual entry at all manways for large vessels, but not full travel through vessel. Use inspector
judgment on heat exchangers.
3. If the vessel cannot be opened or if it is physically impossible to perform an adequate internal
inspection (such as small equipment or fixed tubesheet exchangers), perform External UT as
defined by strategy Table 4.
4. Vessels can be grouped and representative inspection results from a vessel can be used if
the group of vessels are in the same service (process environment), do not have a High
criticality rating, process conditions do not exceed the key variables, are constructed of the
same materials, the only failure mode is general internal corrosion or localized corrosion with
predictable locations, and the corrosion rate is less than 0.005 inches per year. Grouped
vessels not inspected internally will be inspected using external thickness inspection
according to strategy Table 4.
5. Vessels with a Low Criticality rating can be inspected using external methods according to
strategy Table 4. Internal vessel inspections can be eliminated if the prior inspections confirm
corrosion is either general or localized with predictable locations, the corrosion rate is less
than 0.005 inches per year, no hardware or process conditions will cause the corrosion type
or rate to change, and no process conditions exceed the key variables. Internal inspections
should be performed and documented when the vessel will be opened and entered for
process or maintenance reasons.
6. The inspection confidence defined assumes that external UT is also performed. The actual
credit for inspection confidence depends on the percentage of visual coverage and not the
criticality rating of the equipment. Assign a lower confidence if the inside surface is not clean.


Table 3 - Pressure Vessel & Exchanger / Internal Corrosion / by External UT
Complimenting Internal Visual
Criticality Rating Based on Failure Mode


Low Medium Medium-High High
Minimum spot UT
Locations with 100%
internal visual
coverage for General
Corrosion
1,2,3

1 UT reading per head,
1 UT reading per 20
shell band,
1 UT reading on 10%
of nozzles (Min. 1
nozzle)
1 UT reading per
head,
2 UT readings per 20
shell band,
1 reading on 25% of
nozzles (Min. 1 Inlet
and 1 Outlet nozzle)
2 UT readings per
head,
2 UT readings per
20 shell band,
1 reading on 50%
of nozzles. (Min. 1
Inlet and 1 Outlet
nozzle)
4 UT readings per
head,
4 readings per 20
shell band,
1 reading on 75%
of nozzles. (Min. 1
Inlet and 1 Outlet
nozzle)
Minimum spot UT
Locations with partial
internal visual
coverage for General
Corrosion
1,2,3,4

1 UT reading per head,
2 UT reading per 20
shell band,
1 UT reading on 10%
of nozzles (Min. 1
nozzle)
1 UT reading per
head,
2 UT readings per 20
shell band,
1 reading on 25% of
nozzles, (Min. 1 Inlet
and 1 Outlet nozzle)
Scan 1 strip across
liquid interfaces
2 UT readings per
head,
2 UT readings per
20 shell band,
1 reading on 50%
of nozzles. (Min. 1
Inlet and 1 Outlet
nozzle), Scan 2
strips across liquid
interfaces
4 UT readings per
head,
4 readings per 20
shell band,
1 reading on 75%
of nozzles, (Min. 1
Inlet and 1 Outlet
nozzle) Scan 4
strips across liquid
interfaces
Minimum spot UT
Locations with 100%
internal visual
coverage for
Localized Corrosion
1,2,3,4

1 UT reading per head,
2 UT reading per 20
shell band,
1 UT reading on 10%
of nozzles (Min. 1
nozzle),
2 UT reading per
head,
4 UT readings per 20
shell band,
1 reading on 25% of
nozzles (Min. 1 Inlet
and 1 Outlet nozzle),
4 UT readings per
head,
4 UT readings per
20 shell band,
1 reading on 50%
of nozzles (Min. 1
Inlet and 1 Outlet
nozzle),
4 UT readings per
head,
8 readings per 20
shell band,
1 reading on 75%
of nozzles (Min. 1
Inlet and 1 Outlet
nozzle).
Minimum spot UT
Locations with partial
internal visual
coverage for
Localized Corrosion
1,2,3,4

1 UT reading per head,
2 UT reading per 20
shell band,
1 UT reading on 10%
of nozzles (Min. 1
nozzle), Scan 1 strip
across liquid
interfaces, 25% of
locations defined by
Corrosion Study
2 UT reading per
head,
4 UT readings per 20
shell band,
1 reading on 25% of
nozzles (Min. 1 Inlet
and 1 Outlet nozzle)
Scan 1 strip across
liquid interfaces, 25%
of locations defined
by Corrosion Study
4 UT readings per
head,
4 UT readings per
20 shell band,
1 reading on 50%
of nozzles (Min. 1
Inlet and 1 Outlet
nozzle), Scan 2
strips across liquid
interfaces, 50% of
locations defined
by Corrosion Study
4 UT readings per
head,
8 readings per 20
shell band,
1 reading on 75%
of nozzles (Min. 1
Inlet and 1 Outlet
nozzle), Scan 4
strips across liquid
interfaces, 100% of
locations defined by
Corrosion Study
Maximum Interval
(Yr.), or 1/2 remaining
life
15 10 10 5
Reducing inspected
locations if allowed
5
No reduction permitted 25% reduction 25% reduction No reduction
permitted
Inspection Confidence Refer to Table 2 Refer to Table 2 Refer to Table 2 Refer to Table 2
NOTES for Table 3:
1. This strategy table assumes an adequate level of internal visual inspection is also performed
to confirm the condition of the vessel. If internal visual inspection will not be performed, use
strategy Table 4.
2. For vessels with a High Criticality rating, internal inspections are recommended.
3. Thickness readings should be taken at all significant indications found during the Internal
Visual Inspection.
4. Scans and specific locations to be determined by materials or corrosion engineer.
5. The number of locations per vessel can be reduced after three sets of readings if the prior
readings confirm corrosion is general or localized corrosion at a predictable location, at a
known rate, no hardware or process changes will cause the corrosion type or rate to change,
and no process conditions exceed the key variables.
6. See Generic Strategy Notes and Rules, WR-1 at the beginning of the strategy tables,
page.


Table 4 - Pressure Vessel & Exchanger / Internal Corrosion / by External UT
Without Internal Visual
Criticality Rating Based on Failure Mode


Low Medium Medium-High High
Minimum spot UT
Locations for General
Corrosion
1,2

2 UT reading per head,
4 UT reading per 20
shell band,
1 UT reading on 10%
of nozzles (Min. 1
nozzle)
2 UT reading per
head,
4 UT readings per 20
shell band,
1 reading on 25% of
nozzles (Min. 1 Inlet
and 1 Outlet nozzle),
Scan 1 strip across
liquid interfaces
4 UT readings per
head,
4 UT readings per
20 shell band,
1 reading on 50%
of nozzles (Min. 1
Inlet and 1 Outlet
nozzle), Scan 2
strips across liquid
interfaces
4 UT readings per
head,
8 readings per 20
shell band,
1 reading on 75%
of nozzles (Min. 1
Inlet and 1 Outlet
nozzle), Scan 4
strips across liquid
interfaces
Minimum spot UT
Locations for
Localized Corrosion
1,2,3

2UT reading per head,
4UT reading per 20
shell band,
1 UT reading on 25%
of nozzles (Min. 1
nozzle), Scan 1 strip
across liquid
interfaces, 25% of
locations defined by
Corrosion Study
4 UT reading per
head,
4 UT readings per 20
shell band,
1 reading on 25% of
nozzles (Min. 1 Inlet
and 1 Outlet nozzle),
Scan 1 strip across
liquid interfaces, 50%
of locations defined
by Corrosion Study
4 UT readings per
head,
4 UT readings per
20 shell band,
1 reading on 50%
of nozzles (Min. 1
Inlet and 1 Outlet
nozzle), Scan 2
strips across liquid
interfaces, 50% of
locations defined
by Corrosion Study
4 UT readings per
head,
8 readings per 20
shell band,
1 reading on 100%
of nozzles, Scan 4
strips across liquid
interfaces, 100% of
locations defined by
Corrosion Study
Maximum Interval
(Yr.), or 1/2 remaining
life
15 10 10 5
Reducing inspected
locations if allowed
4
No reduction permitted 25% reduction 25% reduction No reduction
permitted
Inspection Confidence
5
Low Low Medium Medium
NOTES for Table 4:
1. This strategy table is intended for vessels that match any one of the following descriptions:
Cannot be opened or if it is physically impossible to perform an adequate internal
inspection to confirm the condition of the vessel (such as small equipment or fixed
tubesheet exchangers)
Included in a group (refer to Note 4 for Table 2)
Has Low criticality rating
Has Medium or Medium High criticality rating and internal visual inspection history
has met the requirements to eliminate internal visual inspection (refer to Note 5 for
Table 2).
2. Scans and specific locations to be determined by materials or corrosion engineer.
3. If the corrosion study indicates the localized corrosion is random or pitting (i.e. unpredictable
locations), the inspector will work with the corrosion engineer to determine an appropriate
inspection strategy or use strategy Table 3 that includes some internal visual inspection.
4. The number of locations per vessel can be reduced after three sets of readings if the prior
readings confirm corrosion is general or localized with predictable locations, the corrosion rate
is known, no hardware or process changes will cause the corrosion type or rate to change,
and no process conditions exceed the key variables.
5. The actual credit for inspection confidence depends on the amount of inspection performed
and not the criticality rating of the equipment.
6. See Generic Strategy Notes and Rules, WR-1 at the beginning of the strategy tables,
page.


Table 5 - Pressure Vessel & Exchanger / CUI / by CUI Inspection
Criticality Rating Based on Failure Mode
8


Low Medium Medium-High High
Baseline
1
Number of Vessels
2,3
Note 4 10% 25% 50%
Number of Locations
by Location Category
5

Note 4

10%


25%


50%

Follow-up Total Number of
Vessels
6
Note 4 25% 50% 100%
Total Number of
Locations by Location
Category
6

Note 4

25%


50%


100%

Maximum Interval (Yr.), or 1/2
remaining life
Note 4 10 10 5
Inspection Confidence
(Vessels inspected)
7
Note 4 Low Medium High
Inspection Confidence
(Vessels in same Criticality Rating
and temperature range)
7
Note 4 Low Low Medium
NOTES for Table 5:
1. The term Baseline defines the minimum recommended inspections and Follow-up defines additional inspection
to be performed if the corrosion rate or extent confirmed during baseline inspections is worse than expected.
2. The purpose of CUI inspection is to identify deterioration to the external surfaces of the vessel under the
insulation. When the vessel surface is found to be significantly deteriorated or below the minimum required wall
thickness, the vessel should be restored to essentially like-new condition. The insulation generally must be
stripped in a window to provide adequate access for the CUI inspection.
3. CUI inspection is performed only on insulated vessels that are susceptible to corrosion. For CUI, all insulated
vessels in a unit made of the same materials of construction can be grouped by Criticality Rating then by
operating temperature range. The grouping allows one or a small number of vessels to represent a larger
population of vessels. The temperature range groupings in degrees F are [0 - 150], [150 - 200], [200-290], [290-
325], and [325-350]. When selecting representative vessels from each criticality rating and temperature range,
select the vessels with the highest likelihood for CUI and those that may have damaged or wet insulation or other
indications of external corrosion from the external visual inspection.
4. Vessels with Low Criticality rating for CUI will not be inspected unless the external visual inspection identifies a
condition that indicates significant CUI is occurring on the vessel.
5. The external visual inspection counts the number of potential inspection locations. As a minimum, Location
Categories for vessels subject to CUI should include barrier penetrations larger than 10 diameter and smaller
penetrations that are not properly sealed, termination of insulation, damaged insulation, and insulation support
rings.
6. Follow-up inspection, if required, will increase the number of locations up to the total number indicated and the
additional locations should address specific areas where CUI was confirmed by baseline inspection.
7. The actual credit for inspection confidence depends on the amount of inspection performed and not the criticality
rating of the equipment.
Inspections for CUI are only recommended for assets with a Probability of Failure ranking of 1, 2 or 3. Therefore,
for the CUI strategies, the High criticality criteria will apply to all assets in the High criticality category; the
Medium-High criticality criteria will apply to assets with External Inspection Priorities equal to 6, 7, 8, 9, or 11;
the Medium criticality criteria will apply to assets with External Inspection Priorities equal to 13, 14, 16, or 17.




Table 6 Pressure Vessel & Exchanger / Environmental Cracking / by MT, PT, Eddy
Current or ACFM
Criticality Rating Based on Failure Mode
8


Low Medium Medium-High High
Baseline
1

Number of Locations
2,3,4
Note 5 10% 25% 50%
Follow-up Total Number of
Locations
6

Note 5 50% 100% 100%
Maximum Interval (Yr.), or 1/2
remaining life
Note 5 10 10 5
Inspection Confidence
7


Note 5 Low Medium High
NOTES for Table:
1. The term Baseline defines the minimum recommended inspections and Follow-up defines additional
inspection to be performed if the failure mode is confirmed during baseline inspections.
2. Magnetic Particle Testing (MT) shall be performed to a written procedure that is in accordance with ASME
Section V, Article 7 along with internal visual inspection. Surface prep by cleaning the area to be inspected
in accordance with SSPC-6 at least 1 inch beyond the heat affected zone on both sides of all joints to be
inspected. Acceptance criteria shall be in accordance with ASME Section VIII, Appendix 6, in accordance
with the applicable construction code, or in accordance with Owner User specifications.
3. Penetrant Testing (PT) shall be performed to a written procedure that is in accordance with ASME Section
V, Article 6 along with internal visual inspection. Surface prep by cleaning the area to be inspected in
accordance with SSPC-6 at least 1 inch beyond the heat affected zone on both sides of all joints to be
inspected. Acceptance criteria shall be in accordance with ASME Section VIII, Appendix 8, in accordance
with the applicable construction code, or in accordance with Owner User specifications.
4. Eddy Current Testing shall be Performed to a written procedure that is in accordance with
5. Alternating Current Field Testing (ACFM) shall be Performed to a written procedure that is in accordance
with
6. The internal and external visual inspections, vessel drawings, and corrosion study are used to determine
the number of potential environmental cracking locations. It is recommended that location categories
include pressure-containing welds (category A, B, & D welds and if access permits category C welds [weld
categories defined by ASME Section VIII]) and where non-pressure components are attached by welding to
pressure retaining components plus any locations identified by the visual inspection, drawings or corrosion
study.
7. Vessels with Low Criticality rating for environmental cracking will not be inspected unless the internal visual
inspection of the equipment item or inspections performed on equipment in similar service identify a
condition that indicates cracking is occurring in the vessel.
8. Follow-up inspection, if required, will increase the number of locations to the total number indicated and the
additional locations should address specific areas where environmental cracking was confirmed by Baseline
inspection.
9. The actual credit for inspection confidence depends on the amount of inspection performed and not the
criticality rating of the equipment.