BMI

CAPSTONE ENGINEERING SERVICES, INC.
RBMISM SITE COORDINATOR’S MANUAL
2004
RBMI SITE
COORDINATOR’S
MANUAL
0
C AP S T O N E E N G I N E E R I N G SE RV I C E S, I N C .
RBMI Site Coordinator’s Manual
 Capstone Engineering Services, Inc.

1505 Highway 6 South • Suite 250 South
Houston, Texas 77077-1700
Phone 281.493.2236 • Fax 281.493.5161
www.cap-eng.com
Table of Contents
CHAPTER 1 - INTRODUCTION 1
Purpose of Site Coordinator’s Manual 1
Using this Manual 2
The RBMI Process 3
CHAPTER 2 – PROJECT SAFETY 5
Removed 5
CHAPTER 3 – STARTING AND ORGANIZING THE PROJECT 6
Set Up Project 6
Project Kickoff Meeting 7
Preparation for the meeting 7
Scheduling the meeting 7
The meeting agenda 7
Documenting the meeting 14
Prepare Site Offices 14
Site Orientation 15
Defining the Project Scope 15
Defining Piping Systems 16
Defining Piping Circuits 18
Developing Tracking Lists 20
Setting up Files 21
Project Files 21
Equipment Files 23
Approve Inspection Strategies 25
CHAPTER 4 – MANAGING THE PROJECT 26
Project Communications 26
Project Correspondence 27
Time and Expense Reporting 28
Filling out a Time Report 28
Filling out an Expense Report 32
Filling out an Expense Report 33
Filling out a Daily Log 36
Reviewing and Transmitting Time and Expense Reports 37
Reviewing and Transmitting Time and Expense Reports 38
Reviewing and Transmitting Time and Expense Summaries 38
Invoicing 39
Project Reporting 40
Table of Contents
Scope Changes 43
Project Summary 44
Vessel Cost Comparison 51
Piping Cost Comparison 53
Pressure Relief Device Cost Comparison 54
Project Meetings 55
Planning the meeting 55
Documenting the meeting 55
Project Quality Assurance and Quality Control (QA/QC)56
Task Training 56
Reviewing Deliverables 57
Quality Audits 61
Subcontractors 62
Selecting Contractors 63
Managing Subcontractors 63
CHAPTER 5 – USING THE RBMI SOFTWARE 65
Removed 65
CHAPTER 6 – COLLECTING EQUIPMENT DATA 66
Data Collection 66
Assets and Components 66
The Data Collection Process 67
Pressure Vessels 70
Columns 78
Air Cooled Exchangers 86
Shell and Tube Heat Exchangers 94
Piping Circuits 104
Storage Tanks 112
Relief Devices 123
Documenting Data Discrepancies and Redlines 133
CHAPTER 7 – CALCULATING CRITICALITY 134
Reviewing Inspection and Maintenance History 134
Process Review 136
Corrosion Study 139
Review Measured Corrosion Rates 139
Internal Corrosion 139
External Corrosion (CUI) 140
Prepare Documents for the On-site Review 140

Table of Contents
Perform the On-site Review 141
Document the Corrosion Study 142
Screening NDE Inspections 143
Calculating Criticality 144
Assign Inspection History Information 144
Internal Corrosion 144
External Corrosion (CUI) 146
Environmental Cracking 146
Enter Process and Corrosion Information 147
Calculate Criticality 147
Mass Criticality 148
Relief Devices 153
Review Baseline Criticality 155
Updating Criticality 156
Fixed Equipment and Piping 156
Relief Devices 160
CHAPTER 8 – VISUAL INSPECTIONS 162
Inspection Drawings 162
The General Drawing Process 162
Piping Circuits 163
Vessels and Heat Exchangers 164
Storage Tanks 165
External Visual Inspections 166
The External Visual Inspection Process 166
Piping Circuits 168
Storage Tanks 184
Relief Devices 192
Documenting Pressure Relief Valve Visual Inspections 194
Documenting Rupture Disk Visual Inspections 199
Internal Visual Inspections 203
The Internal Visual Inspection Process 203
Storage Tanks 210
Finding and Entering Visual Inspections 214
Finding and Entering Visual Inspections 215
Finding Visual Inspections 215

Table of Contents
Finding Visual Inspections for a Single Equipment Asset 215
Finding Visual Inspections for Multiple Equipment Assets 217
Entering Visual Inspections 220
Evaluating and Reporting Non-conformances 221
Identifying Non-conformances 221
Ranking Non-conformances 222
Reporting and Tracking Non-conformances 224
Finding and Entering Non-conformance Reports 229
Finding NCRs 229
Entering NCRs 234
CHAPTER 9 – BASELINE INSPECTION PLANNING 235
Baseline Inspection Planning 235
Piping Circuits 236
Storage Tanks 262
Relief Devices 262
Follow-up Inspection Planning 263
Determine if Follow-up Inspections are Required 263
Plan and Perform Local Follow-up Inspections 263
Plan and Perform General Follow-up Inspections 267
Tracking Baseline/Follow-up Inspection Locations 270
CHAPTER 10 – NDE INSPECTIONS 271
(UT) Ultrasonic Thickness Testing 272
(RT) Profile Radiographic Testing 276
(PT) Liquid Penetrant Testing 280
(MT) Magnetic Particle Testing 281
CUI Visual Inspection 282
Finding, Entering, and Evaluating NDE Inspections 284
NDE Inspection 284
Accessing the NDE Inspection Module 285
Defining Inspection Locations 285
Removing Inspection Locations 286
Replacing an NDE location 287
Entering Inspection Data 288
Finding/Editing Inspection Data 289
Evaluating Inspection Data 289
Reviewing Inspection History 291

Table of Contents
Other Inspections 293
Adding an Other Inspection Record 293
Editing an Other Inspection 295
CHAPTER 11 – INSPECTION WORK PLANS 296
Developing Inspection Work Plans 296
Updating Inspection Work Plans 302
APPENDIX 1 – FORMS 304
Safety Meeting Record 305
Piping System/Circuit Identification Log 306
Piping Data Collection Form 307
Field Verification Datasheet 310
Pressure Vessel Data Collection Form 311
Column Data Collection Form 313
Air Cooled Exchanger Data Collection Form 316
Shell and Tube Heat Exchanger Data Collection Form319
Storage Tank Data Collection Form 324
Relief Device Data Collection Form 327
Data Collection Discrepancy Log 329
Documents Transmitted/Received 330
Inspection History Summary 331
Piping Visual Inspection Report 332
Pressure Vessel External Visual Inspection Report 333
Storage Tank External Visual Inspection Report 334
Pressure Relief Valve Visual Inspection Report 335
Rupture Disk Visual Inspection Report 336
Pressure Vessel Internal Visual Inspection Report 337
Storage Tank Internal Visual Inspection Report 338
Other Inspection Report 339
Non-conformance Report 340
Additional Comments 341
Non-Conformance Tracking Log 342
Ultrasonic Thickness Report 343
Additional UT Thickness Report 344
Profile Radiographic Testing Report 345
Additional RT Report 346
Inspection Tracking Log 347
APPENDIX 2 – REFERENCES 348
Pressure Vessel Material Specs. and Grades 348

Table of Contents
RBMI Typical Representative Fluids 360
Resource Codes 363
This page has been removed and left blank 364
Task Codes 365

CHAPTER 2 – PROJECT SAFETY
R E M O VE D
1
Chapter
Chapter 1 - Introduction
Purpose of Site Coordinator’s Manual

This manual provides guidance for successful implementation and management of a RBMI
project. Personnel may use sections of this manual to assist them in performing specific tasks
such as data collection, data entry, and visual inspections.
Since using the RBMI software has become an integral part of an implementation project,
descriptions of its use will be included in this manual.
Issue Date: 8/9/04, 2004 Rev. Copyright © 1996-2004 by Capstone Engineering Services, Inc. Page 1
R E M O VE D
Using this Manual

The following conventions are used throughout this manual:
 If a RBMIsm software button is displayed this indicates that it should be pressed
Example: Press and select Pressure Vessels.
 Text that should be typed appears in quotes:
Example: Type “Asset” in the text box and press enter.
 RBMIsm software menu selections are identified by bold text:
Example: Select File, then Print Setup.
 Links to additional information or forms (hyperlinks) will appear as follows:
Example: The table of contents lists all topics in the Site Coordinator’s manual.
R E M O VE D
The RBMI Process

The basic RBMI process is as follows:
Collecting Equipment Data
Implementation
Visual Inspections Calculating Criticality
Inspection Planning
Maintenance
NDE Inspections
Evaluating and Reporting

Nonconformances
Update:
Criticality
Insp. Plans
As seen in the figure above, the RBMI process is broken into tasks needed to implement the
program and tasks needed to maintain the RBMI program.
The tasks are described as follows:
Collecting Equipment Data (see Chapter 6) – Equipment information is collected primarily so

that Criticality calculations can be performed, inspection plans can be developed, and NDE data
can be evaluated. Equipment information is recorded on datasheets and stored in the RBMI
database. An information overview is performed with the client prior to data collection to
R E M O VE D
determine which data sources are to be used. Data discrepancies and P&ID redlines identified
during the data collection process are reported to the client.
Visual Inspections (see chapter 8) – External visual inspections should be performed on all
equipment included in the RBMI program. Visual inspections are performed to determine the
external condition of the equipment and to identify potential NDE inspection locations. These
inspections are recorded on forms and stored in the RBMI database.
Calculating Criticality (see chapter 7) – Criticality calculations are performed to help prioritize
and focus the inspection efforts in the process facility. Criticality values should be calculated on
all equipment items included in the RBMI program. A review of equipment
inspection/maintenance history and a unit corrosion study are performed prior to initial criticality
calculations. Criticality calculations are performed and stored in the RBMI software/database.
Inspection Planning (see inspection planning, inspection work plans) – Inspection Work Plans
(IWP) are developed to identify the types, amounts, and frequency of inspections that should be
performed to ensure the integrity of each equipment item. Every equipment item included in the
RBMI program should have an IWP. Inspection Plans are developed using information from
Criticality calculations, external visual inspection results, and inspection strategies. IWPs are
created and updated in the RBMI software/database.
NDE Inspections (see chapter 10) – NDE inspections are performed to address potential
damage mechanisms identified during the corrosion study. Inspections are performed according
to the defined inspection plan for each equipment item. NDE inspections are documented on
inspection forms and stored in the RBMI database.
Evaluating and Reporting Nonconformances (see visual inspections, NDE inspections) –

Inspection results are evaluated to determine if follow-up inspections are required and
acceptance criteria are met. Those conditions that do not meet acceptance criteria are reported
as nonconformances.
Updating Criticality and Inspection Plans (see criticality, IWPs) – Criticality values for
equipment items are updated when an inspection is performed or any other key process or
design information has changed. IWPs are updated when criticality values and/or inspections
have been performed.
APPENDIX 2 – REFERENCES
P R E S S U R E V E S S E L M ATE R I A L S P E C S . A N D G R A D E S
3
Chapter
2
Chapter
Chapter 2 – Project Safety
Removed
Please refer to the Capstone Safety Manual for the components of Capstone Engineering
Services safety program.
Chapter 3 – Starting and Organizing

the Project
Set Up Project
A project starts when the client authorizes Capstone to start work; usually by issuing a
Purchase Order or signing a contract. The MI Manager or Project Manager should then do the
following with increasing involvement by the Site Coordinator:
 Assign Site Coordinator

 Assign Site Project Resources
 Complete Project Set Up Sheet – be sure to define Resource Code and Billing Rate for
each project person (do not assume the office staff knows which rate sheet to use),
also include Administrative or Engineering support personnel.
 Make travel arrangements (airfare, hotel, transportation)
 Schedule any special site safety training; especially for new hires
CHAPTER 3 – STARTING AND ORGANIZING THE PROJECT
D E F I N I N G T H E P R O J E C T S C O P E
For long-term projects, the Project Manager and Site Coordinator should address the following
logistics, which may require client approval (all of these should be addressed in proposal – at
least to define what we have assumed as a basis to estimate the cost):
 Transportation – lease vs. rent vehicles; travel “home”, etc.
Note: Employees may not drive lease vehicles until they have been added to an
official list of drivers maintained by the leasing company (e.g. Enterprise
Leasing). This is different than how rent car companies deal with short-term
rentals.
 Accommodations – Apartments vs. Hotel
 Per Diem – any increase/reductions based on local costs, travel “home” or
accommodations
Project Kickoff Meeting

A project kickoff meeting is used to:
 Clarify the project deliverables and schedule.

 Identify and introduce key personnel
 Discuss project logistics – number of personnel, office space, training requirements,
etc.
 Identify sources of project information – people and locations
Preparation for the meeting
The Project Manager and Site Coordinator should review the proposal, and the following
meeting agenda to identify key items that need clarification. The Project Manager or Site
Coordinator prepares an agenda and a list of information/documentation requirements and
transmits it to the Client Project Coordinator as far in advance of the kickoff meeting as
possible so that they can be prepared for a 4 to 8 hour working meeting.
Scheduling the meeting

The kick off meeting is scheduled after the contract is awarded, but before project work
begins. It usually occurs at the project site. Personnel who should attend the meeting include:
 Capstone-
o Project manager
o Site coordinator
 Client –
o Project Coordinator
o Unit/Area Inspection Personnel
o Unit/Area Process Engineer(s)
o Unit/Area Mechanical Engineer(s)
o Unit/Area Corrosion Engineer(s)
o Unit/Area Operations Supervisor/Foreman
The meeting agenda
The kick off meeting agenda will vary depending on the project scope. However, the following
topics usually should be discussed:
1. Deliverables:
 Identify the Capstone proposal number that is the basis for the project.
 List and discuss the deliverables from the proposal. Show samples/examples of each
deliverable so there is no confusion at the end of the project. Examples should include
data collection forms, visual inspections, inspection drawings, IWPs, NDE reports, and
NCRs. Show sample summaries from the Project Summary report (final report)
including Criticality, IWP, NDE, and NCR. Point out any assumptions that were used to
prepare the cost estimate such as match client drawings to circuits instead of sketching
isometrics or that only Level 1 non-conformances are reported immediately. Any
changes to the deliverables may constitute a scope change.
Here is a typical list of deliverables for an RBMI implementation project:
Phase I Deliverables
 Confirm Covered Equipment and get equipment list

 Define piping systems and piping circuits
 Identify mandatory and desired data fields in client inspection database.
 Data collection and data analysis
 Review existing inspection data from the plant
 Develop number and confidence of prior inspections by item
 The corrosion study and process study will be organized by equipment ID and will
include descriptions of damage mechanisms and expected damage rates.
 The risk prioritization of the equipment and piping circuits using Capstone’s
Criticality based approach to Mechanical Integrity
Phase II Deliverables
 Perform the on-site visual inspections of the piping circuits and fixed equipment.
Develop piping isometric sketches and fixed equipment inspection sketches as
necessary. Additional costs may be required to match client’s drawings to RBMI-
defined piping circuits and to add the missing information for inspection planning
(e.g. pipe supports, barrier penetrations)
 Plan the Criticality Based Screening Inspections
(The plant may go through a screening inspection step to verify corrosion rates and
damage mechanisms prior to a full baseline inspection program.)
 Develop inspection strategies that incorporate equipment types, criticality ranking,
and failure mechanisms.
 Update the Criticality Study based on the information gathered in Phase II.
 Develop the Baseline Inspection Plan for the plant
Phase III Deliverables
 Perform the NDE required to implement the Baseline Inspection Plan Evaluate the
baseline inspection results.
 Report non-conformance’s with recommended corrections
 Develop a fifteen year inspection plan
 Project summary report
2. Capstone Methodology –
 Discuss the basic RBMI process and answer any technical questions the client may
have about the Capstone approach.
 Identify how RBMI implementation may change the client’s way of doing business:
o Will the client use Capstone forms for inspections (VI checklists and NDE
reports)?
o Will the client adopt Capstone-defined piping circuits as the basic inspection
units for piping?
o Will the client utilize the Capstone inspection strategies and IWPs for
planning/performing inspections?
o Will the client utilize RBMI software to maintain/update the plant/unit RBMI
program?
3. Scope of Work:
 Covered Processes and Equipment – Clarify with the client what processes are to
be included in the scope of work and where to stop at the unit boundary (i.e. ISBL).
In addition to equipment items containing processes defined by OSHA Process
Safety Management (PSM), others equipment items and processes may be
included due to reliability, environmental, or other regulatory concerns (EPA, DOT,
Coast Guard, and HF Alky). Examples of processes that should be considered
include: flare system, vents and drains, steam, cooling water, plant air, and lube oil.
Also need to clarify definition of details like dead legs and injection points. The
proposal should clearly define what equipment or processes are included or
excluded from the scope of work; even if we have to state what we’ve assumed.
Otherwise we have no foundation to identify scope changes.
 Fixed Equipment Lists – Verify the equipment types and lists of items that the
client wants included in the scope of work. Will storage tank shells, tank bottoms,
heat exchanger tube bundles, fired heaters, and relief valves be included?
Compare with the proposal to identify any scope changes.
 Piping Circuits – Determine whether the client will provide a specific list of piping
circuits or line numbers to be included in the scope of work. If the client does not
provide a piping list, confirm what the limits of the study will be (battery limits of the
unit) and what piping processes should be included. Will utilities like steam and
chemical sewers be included? Does the client want vessel trim piping (level bridles
for example) included with piping circuits, with the vessels, or should these be
excluded from the project scope? Will client supply piping isometric drawings or will
sketches be created?
 Scope Changes – Discuss scope change process with the client when additional
equipment and/or tasks are added (see Scope Changes). Provide the client with
estimated costs of typical scope changes. Typical scope changes include:
o Adding an equipment asset to the project scope (cost per item)
o Performing the process review
o Collecting additional data (beyond required fields)
o Providing and/or modifying inspection strategies
o Providing fitness for service analysis (cost per item)
o Purchase or lease of RBMI software
4. Schedule:
 Identify and agree to hold points, if applicable. Hold points are established for client
approval of a particular deliverable. For example, the client may want to review the
corrosion study before the damage mechanisms and corrosion rates from the study
are used in the baseline criticality calculations.
Note: Approval of the baseline criticality calculations is a mandatory project hold

point (see Review Baseline Criticality).
 Communicate to the client approximately how long the project will take to complete
and in what general order tasks are going to be. A detailed project schedule can be
developed once the project has begun and the site coordinator has a better idea of
the tasks involved and the number of resources that are available. The client may
desire a different task order to accommodate his or her own maintenance/inspection
schedules or turnaround deadlines. For example, if the project involves multiple
process units, the client may want RBMI performed in one unit before another due
to an upcoming turnaround or shutdown. Changes to the sequence of process units
normally does not affect the cost, however changes to sequence of steps in the
RBMI process (i.e. starting data collection before tracking list established) should be
discouraged and if changed may constitute a scope change.
 Work Schedule – 4 ten-hour days, 5 eight-hour days, 10 eight-hour days, etc. The
proposal may not have included OT in the cost estimate therefore some work
schedules may constitute a scope change.
5. Site Requirements
 Safety – Determine site requirements for entry into the facility, frequency of safety
meetings, and PPE.
 Access to Site – Discuss vehicle access, parking, and access badges/cards.
 Office space – Ensure that the office space:
o is located in close proximity to the process unit(s) included in the project (if
possible)
o includes chairs and desks to accommodate the expected number of Capstone

site personnel
o includes a networked computer to communicate with the client, access client
databases, and internet access for the RBMI software.
o includes at least one phone and access to a copier and fax machine
o includes sufficient file storage cabinets for the number of expected equipment
items in the project
6. Personnel:
 Capstone -Identify the key Capstone personnel who will be working on the project
including: Project Manager/Responsible, Site Coordinator, Materials and Risk
consultants. Inform the client of the names and/or number of Capstone personnel
expected to be working at the project site on a daily basis.
 Client – Confirm who the client personnel resources will be for each unit. Collect the
names, phone numbers, and email addresses for each for the following:
o Project Coordinator – the direct contact for Capstone project personnel
o Process/Operations Resource – typically a process engineer or operations

supervisor that Capstone personnel can contact to obtain process information.
Also determine who “owns” these resources (i.e. Operations or Plant manager)
because that person may need to be contacted if information is not provided
timely. This is important because the “owner” is not usually our main contact for
the project.
o Unit Engineer – point of contact for information and questions regarding

equipment design, construction, maintenance, and equipment history
o Corrosion Engineer/Metallurgist – point of contact for information and

questions related to potential damage mechanisms, expected corrosion rates,
and equipment history
o Inspection Resource – point of contact for information and questions regarding

inspection data and equipment history
7. Client-Provided Information – Inform the client what information is required to complete

the project, determine the location and person to contact for each information item.
Information that is typically required includes:
 P&ID’s (1 set full size, 1 set 11 x 17)

 Systemized and Circuitized P&ID’s (if available)
 PFD’s, Materials balance and composition (11 x 17 or smaller)
 Material/Corrosion Diagrams (if available, 11 x 17 or smaller, at least one color
copy)
 List of fixed equipment operating pressures & temperatures
 Copy of piping isometric sketches (if available)
 Equipment files (U1 forms and data sheets)
 Equipment Plot Plans
 Access to computerized inspection records (e.g. UT, RT, visuals, etc)

 Inspection and maintenance histories
 Piping specifications
 Relevant Incident Investigations
 Relevant Management of Change documentation (e.g. changes to P&IDs,
materials of construction, process conditions, etc.)
 MSDS Sheets for covered process fluids, PEL’s for Toxics
 Process description for each Unit
 List of injection points (for piping)
 List of plant/unit T-mins for vessels and piping
8. Inspection Constraints –
 Discuss equipment minimum thickness guidelines with client: Capstone

minimums (see NDE Inspections) will be utilized unless the client provides
otherwise
 Determine client’s requirements for inspection including procedures, preferred

inspection contractors, preferred inspection methods, and any other constraints
that may affect inspection planning.
 Review Capstone inspection strategies with the client so that they understand
them and agree to their use for inspection planning during the project.
Communicate that the strategies are Capstone’s and will not become property of
the client unless they want to purchase them.
9. Mechanical Integrity Guidelines / Procedures / Work Instructions – Does the client

require or desire procedures or guidelines as part of the project?
Note: Procedures are not provided to clients as part of a typical project scope and
will require a scope change.
10. Project Reporting:
 Progress – Inform the client that project progress and information will be
communicated on a weekly and monthly basis and will include: tasks completed,
tasks planned, cost summaries, and any other pertinent issues. Show example of
Project Status Report worksheet and project schedule Gantt chart.
 Time and Expense Approval –
o Determine and agree to approval requirements for time and expenses. For
example, some clients may want to review/sign individual employee Time and
Expense Reports in addition to approving the weekly Time and Expense
Summaries.
o Inform client that off-site time for project management and other tasks (process
review, corrosion review, criticality, etc.) will be charged to the project and be
reflected on the weekly Time and Expense Summaries.
o Determine if the client approves of overtime hours by Capstone employees and
discuss the impact of overtime on the project budget/schedule.
 Invoicing – Project will be invoiced based on percentage complete or completed tasks

for fixed fee projects; or based on man-hours worked and expenses for time and
expense projects. Determine what information the client requires on the invoices
(e.g. PO, cost center, Unit, etc), what information is required for backup (i.e.
Capstone T&E sheets, just Capstone’s T&E Summary, or special client time and
expense sheets), who the invoices should be submitted to for timely processing, and
whether the client project coordinator needs a copy so they can in turn provide
accounting with proper approval for payment.
 Non-conformances – Discuss with client how non-conformances are ranked and how
they should be communicated (see Evaluating and Reporting Non-conformances).
The cost estimate is based on immediately transmitting a hard copy report of all rank
1 non-conformances and including all other non-conformances in the project report.
Changes to this basis will constitute a scope change.
 Meetings – Determine and agree to requirements including agenda, attendees and

time limits for the following meetings:
o Weekly/Monthly Progress Reporting
o Corrosion Review
o Process Review
o Initial Criticality Review
o Project Closeout
11. Client Responsibilities and Involvement – Discuss with the client that client cooperation
and resources will be required for a successful project.
 Time - Typical time requirements for the project coordinator will be 20% involvement for
the duration of the project. All other resources require approximately 20%
involvement for a two-week period.
 Data and Hold Points – Discuss with client that if requested data or hold point
approvals are incomplete, not provided, or not provided in a timely manner, the
project may be delayed and/or scope changes may be required (see Scope
Changes).
12. Electronic Interfaces –
 Inform client that information from the RBMI project will be stored in the RBMI
software
 Determine client and Capstone access requirements and method for the RBMI
software. Will the software be accessed from client computers? What client and
Capstone personnel will have access to the software and what will be their individual
user/security rights (read only, etc.)?
 Determine what client electronic databases/tools are available that may hold
information beneficial to the project. Examples include process monitoring,
maintenance management, and inspection data programs. Determine if Capstone
personnel will have access to these and have the ability to import electronic
information from these sources directly into the RBMI software.
13. Unit Overview – After items 1 to 12 above have been discussed, perform a unit overview
with the attendees of the kickoff meeting. The unit overview is a series of questions
designed to identify sources and gather some initial equipment information. The most
efficient and effective unit overview is performed at the kickoff meeting because key unit
personnel are all together in one place (typically a rare occasion). The overview
questions are listed on the Project Kickoff Meeting Notes document. The answers to the
questions should be recorded there as well.
Documenting the meeting

The Site Coordinator or Project Manager documents the list of attendees, decisions made,
collected information, action items, and unit overview from the kickoff meeting. Use the Project
Kickoff Meeting Notes document for this purpose. It is extremely important to identify any
confirmed or potential scope changes.
The Site Coordinator or Project Manager transmit the completed Project Kickoff Meeting Notes
and sample project deliverables (data collection forms, visual inspections, inspection drawings,
NDE inspections, IWPs, and NCRs) to the Client Project Coordinator for review/approval (see
Project Correspondence).
Prepare Site Offices

A smooth running project requires a well-organized work area. The Site Coordinator should
ensure the following details are addressed within the first days of the project:
 Obtain copy of proposal, cost estimating worksheet used to develop proposal, Project
Set Up Sheet, and contract (store in secure location such as locked drawer)
 Complete work instruction for Site Orientation.
 Organize work area for maximum efficiency – (close proximity to the process unit(s),
enough chairs and desks for expected number of site personnel, networked computer
available and log on name/password provided by client.
 Establish 3-bin system (QC, Data Entry, Equipment File)
 Establish sufficient file storage for equipment files
 Establish file folder containing original forms to be used on project
 Complete Unit Overview of first unit(s)

 Set up computer file structure for data and communication (notice that this is the last
item on the list and does not immediately follow when the computer is set up)
Site Orientation
The Site Coordinator should provide an orientation to all project personnel the day after the
Kickoff meeting and any day new personnel are added to the project. The orientation should
cover the following items:
 Safety – rally point, site first aid, local hospital, procedure for handling incident, site and
unit entry requirements, PPE, monthly meetings, etc.
 Project Details:
o Information from “Onsite Orientation” and Unit Overview
o Site team organization (PM, assistant SC, VI’s, API’s, Corrosion Engineer, Risk
Engineer)
o Scope of work (i.e. limits of study, types of equipment included/excluded) – the
list of equipment is determined in the next step
o Summary of Kickoff Meeting (e.g. changes to scope, decisions made, other data
to be collected, how to document nonconformances, etc.)
o Contract requirements such as confidentiality
 Clarify initial project assignment and priorities for each person
Defining the Project Scope

The project scope is the list or lists of equipment items that other project deliverables such as
data collection, criticality analysis, visual inspections, etc. will be performed on. Work on project
deliverables including data collection and visual inspections should not begin until the
equipment lists are well defined and approved by the client.
Ideally, the project scope should be defined at the proposal stage of the project and finalized at
the project kickoff meeting. However, defining the project scope is typically the first on-site
task that is performed.
Confirming the equipment lists for fixed equipment types other than piping is a fairly simple
process. A good approach is to review the P&IDs to verify that every equipment item on the
P&IDs that contains a covered process is also on the equipment list. As final confirmation of
the equipment list, perform field verification and collect the information that was agreed to in
the Kickoff Meeting.
The equipment lists should be maintained as an MS Excel worksheet so that changes and the
reasons for the changes can be saved.
Any additions or deletions to the equipment lists shall be communicated to the client project
coordinator for signature approval (see Project Correspondence) with appropriate
documentation of scope changes (see Scope Changes). The Site Coordinator will report
equipment list/scope changes in Weekly Reports.
Once the equipment list is approved, the tracking list for fixed equipment (excluding piping) can
now be prepared.
Ensure that all fixed equipment items and piping systems in the scope of work are shown on
the PFDs; even if they have to be added. PFDs that show all equipment are also required for
the Corrosion Study.
Defining the project scope for piping typically requires more effort.
If the client’s piping circuits are already defined, the Capstone Process Engineer reviews the
circuitized P&IDs to look for circuits that contain changes in processes, operating conditions, or
materials of construction. In many cases, client’s piping circuits correlate with Capstone piping
systems and will need to be subdivided prior to data collection. An existing circuit can be
subdivided by identifying the separate parts on the circuitized P&IDs and by adding a suffix to
the circuit number. For example, if the client’s circuit P-20111 is divided into 2 circuits for the
RBMI project, the new circuits could be named P-20111A and P-20111B. Any added, deleted,
or subdivided circuits should be communicated to the client project coordinator for approval.
For projects and/or units where the piping circuits are not already defined, the following
sections describe the process of defining systems and circuits. Piping systems are defined first
and then subdivided into circuits.
Defining Piping Systems

A Capstone API-570 Inspector defines piping systems. A Piping System is defined as an
assembly of interconnected pipelines built to the same design code and containing the same or
similar process stream. Piping systems include the piping associated with multiple pieces of
fixed process equipment. Piping systems start and stop at pieces of fixed equipment that affect
the chemical composition of the process stream. Process piping is defined and identified on
PFDs and P&IDs provided by the customer to organize piping into manageable segments as
an initial step in the development of a criticality based inspection program.
Basic information needed to define piping systems includes:

 One copy each of the P&IDs and PFDs
 The battery limits/boundaries of the process unit
 The list of covered processes to be included in the project scope (see project kickoff
meeting)
 Material balance sheets that include the list of the chemical composition of various process
streams within the unit.
 Unit process description
Steps to Define Piping Systems:
1. Obtain a current copy of the PFD's, P&ID’s, and Material Balance Sheet for the unit you are
working on. If material balance sheets are not available, obtain a process description from
the process engineer or operations. The process description can be verbal if a written
description is unavailable. If the process description is verbal, information should be
recorded and maintained for reference.
2. Using the material balance sheet or process description as a reference, select a particular
process stream and determine if it is included in the RBMISM program’s scope of work.
3. Once you have resolved that a process stream is included in the scope of work, review the
PFD to determine the extent of the piping on that PFD. Process streams, and
consequently piping systems, usually start and stop at major pieces of equipment such as
towers, columns, and reactors, etc.
4. Highlight the piping that includes the process stream on the PFD using unique color
schemes or cross-hatching to distinguish that process stream from other process streams
within the same unit. Some process streams originate in one unit and terminate in a
different unit. As a rule, piping systems will “belong” to the unit where the piping system
originates. If client defined boundary limits for the project, stop the piping system at that
limit (see project kickoff meeting).
5. Record each System ID on the Piping System/Circuit Identification Log listing a unique
identifier, the system ID number, and the system description. The unique identifier is the
representative color scheme or cross-hatching used to identify the system on the P&ID.
The system ID number is the number that will identify the system separately from the other
piping systems in the database and on reports. Define the system ID using the format
XXYY where XX is a unique identifier for the process unit and YY is a sequential number
identifying different process systems. Example: 1301 (The first piping system within Unit
13)
6. Enter a system description on the Piping System Identification Log. The system description
is a short narrative description of the system that includes the name of the process stream,
the starting point of the system, and the termination point of the system. Example: Treated
Ethane from (V-1) Contactor to (V-2) Scrubber
7. Record the System ID on the PFD.
8. Repeat steps 2 through 7 until all process piping within the unit and included in the scope of
work is uniquely identified on the PFD and recorded on the system ID Log.
9. Using the PFD as a reference, select a specific piping system. Locate the initiation point on
the P&ID’s. Identify the piping system on the P&ID’s with the same unique identifier used
on the PFD's. Keep in mind that P&ID’s usually have more piping lines on them than those
indicated on the PFDs (i.e., bypass lines, small bore branch connections, etc.). When
identifying these additional lines, always stop the system at a piece of equipment or at a
block valve if the system ties into another piping system. Record the System ID on the
P&IDs and record the starting P&ID number for the piping system on the Piping
System/Circuit Identification Log .
10. Repeat step 9 until all process piping within the unit and included in the scope of work is
uniquely identified on the P&ID. In some cases, there will still be piping represented on the
P&ID’s that has not been identified as belonging to a piping system. Review these lines to
determine if they connect piping systems that have already been identified. All piping
included in the scope of work should be uniquely identified. Highlight these lines
appropriately and break the system at a valve or other piece of equipment.
11. Evaluate the remaining lines that have not been identified to determine if the process fluids
that they contain are included in the RBMI scope of work. Assistance from operations or
process engineering may be required to determine what the process streams contain. If
additional process streams within the project scope of work are found, identify these
additional systems using the instructions outlined above.
12. Review the P&IDs one final time to ensure that all-applicable process piping has been
identified in a piping system.
13. File and maintain these P&IDs in the piping section of the appropriate unit equipment files.
Note: The Capstone Process Engineer will make a color copy of the Systemized P&IDs for
retention in the project files at the Capstone office.
Defining Piping Circuits

A qualified Capstone employee defines piping circuits. Piping circuits are defined as sections
of continuous pipelines exposed to an environment of similar internal corrosivity, similar
operating conditions, and similar materials of construction. Piping circuits are defined and
identified on P&IDs provided by the customer to organize the piping into manageable
segments as an intermediate step in the development of a criticality based inspection program.
The piping circuit ID will be used as a reference for all RBMI SM related activities associated with
the piping included in the piping circuit (i.e., the Circuit ID becomes the equipment ID).
The information needed to define piping circuits includes:
 A set of P&ID’s or flow diagrams identifying the individual piping systems
 Operating temperatures and pressures for the fixed equipment included in the piping
systems
 Piping specifications which identify materials of construction for the piping in the unit
Steps to Define Piping Circuits:
1. Obtain the systemized P&IDs and the System Identification Log for the unit you are working
on. All piping highlighted on the systemized P&IDs will eventually be included in a piping
circuit.
2. From the System Identification Log, select one piping system to work on and note how it is
identified on the systemized P&IDs. Review the piping system on the systemized P&IDs to
determine its extent, specifically noting the fixed equipment included in the piping system,
any changes in piping specification, and any potential injection point locations. Piping
circuits start and stop at the following locations:
 Fixed equipment including towers, columns, reactors, tanks, drums, heat exchangers,
air coolers, furnaces, and filters
 Rotating equipment including pumps, turbines, and compressors
 Locations where the material of construction changes
 Injection points
 Block valves where the piping system ties into another piping system
 Control valves where the pressure differential is greater than 50 psig.
Note: Flare and drain systems maybe started and stopped at different header’s to subdivide them
into manageable circuits.
3. With a red pen on a clean set of P&IDs draw a line perpendicular to the pipeline at each
spec break where there is a change in the material of construction. You will have to review
the customer’s piping specification to determine where these materials of construction
changes occur. A change in pipe specs without a material change, (i.e., going from
Schedule 40 Carbon Steel to Schedule 80 Carbon Steel), does not constitute a circuit
change and should not be marked on the P&IDs.
4. Review the piping system and circle in red ink on the clean set of P&IDs, any injection
points that are included in the system. Occasionally, injection points are not identified on
the P&IDs. Under these circumstances, consult with the process engineer or operations
representative to determine where injection points are located within the unit.
5. Determine the starting point of the piping system on the systemized P&IDs. This will also
become the starting point for the first piping circuit. Highlight the piping on the clean set of
P&IDs from the starting point of the system to the next piece of fixed equipment, material of
construction change, or injection point location using unique color schemes or cross-
hatching to distinguish that piping circuit from other piping circuits within the same piping
system. This highlighted line will represent the basic extent of the piping circuit.
6. Review the highlighted piping circuit to determine if any branch connections are attached.
Highlight all branch connections with the same unique identifier it is attached to until you
reach the next block valve fixed equipment item, material of construction change, or
injection point. Note: If a circuit terminates at a valve, the valve is included with the
“upstream” circuit.
7. The System ID/Circuit ID is a five-character alphanumeric that will identify the circuit
separately from other piping circuits, and essentially serve as the equipment ID. Define the
System ID/Circuit ID using the format XXYYZ where XXYY is the System ID that has
already by defined, and Z is a letter from A to Z which differentiates it from other piping
circuits within the same facility. Confirm the System/Circuit ID convention with the client to
ensure that it fits with the way they do their business. Note: Do not use the letters “i” and
“o” for Circuit ID because they are easily confused with numbers.
8. Record the System ID and Circuit ID on the P&IDs at the starting point, ending points, and
any other point in between that will make it easy to identify. Note: Also record any
connecting System IDs on the Circuit P&IDs.
9. Record the Circuit ID on the Piping Circuit Data Sheet along with the System ID and the
Unit Name.
10. Label injection point circuits with: “Injection Point Circuit” on the P&IDs, as they can
occasionally appear to start and stop at unidentifiable locations on the P&ID. API 570
specifically identifies the minimum upstream and downstream limits of injection point
circuits. The upstream limits of an injection point circuit are 12 inches or 3 pipe diameters
upstream, whichever is greater. The downstream limits of an injection point circuit are at
the second change in flow direction past the injection point, or 25 feet beyond the first
change in flow direction, whichever is less. The individual identifying an injection point
circuit in the field on an isometric field sketch should be familiar with these limits so that the
circuit limits are established properly.
11. Starting at the termination point of the previous circuit, repeat steps 5.0 through 9.0 until all
process piping included in the system as defined on the systemized P&IDs in included in a
piping circuit. In some cases, there will still be piping represented within a piping system on
the systemized P&IDs that has not been identified as being a part of a piping circuit.
Review these lines on the systemized P&IDs to determine if they connect to other piping
circuits or other piping systems and highlight these lines appropriately. All piping
highlighted on the piping system should be included in a piping circuit.
12. After identifying all of the piping circuits included in a specific piping system, record all of the
applicable circuit designations (A-Z) for that system under the Circuit ID column on the
Piping System/Circuit Identification Log .
13. Repeat steps 2 to 12 until all process piping highlighted on the systemized P&IDs is
included in a piping circuit. Each time you begin a new piping system; a clean set of P&IDs
should be used.
14. Upon completion of the unit, compare the Circuit P&IDs for each piping system with the
systemized P&IDs to verify that all applicable process piping in each piping system is
included in a piping circuit.
15. If the client has authorized piping visuals, then field verification will be done at the same
time as the visuals. If visual inspection will not be performed, then field verify the piping
circuits before completing the tracking list.
16. File and maintain the Circuit P&IDs in the piping section of the appropriate unit equipment
files.
Developing Tracking Lists

Tracking lists are developed to:
 Identify equipment items included in the project scope
 provide a quick reference identifying tasks to be performed, tasks completed and

incomplete tasks for planning/organizing on-site work and for progress reporting
Tracking Lists include all equipment items within the RBMI SM scope of work. Each row on a
tracking list represents an equipment item, and the columns identify the tasks/deliverables to
be completed for the RBMISM project. Tracking lists are separated by unit and equipment type.
Developing Fixed Equipment Tracking Lists - When Capstone and client personnel have
agreed on which equipment should be included in the project scope, tracking lists for fixed
equipment can be generated using the RBMI Progress Tracking List. Tracking lists may vary
depending upon project scope. (It may require modification to accommodate varying projects
and/or tasks.)
Generate a separate tracking list for each equipment type in the unit. For example, pressure
vessels and heat exchangers would be on separate lists.
Developing Piping Circuit Tracking Lists - Use the Piping System/Circuit Identification Log
to generate the tracking list for piping circuits. The log identifies how many circuits are in each
piping system.
Note: Leave several rows between each piping system set of circuits to allow for additional
ones to be added if necessary.
Using and Maintaining Tracking Lists – Once developed, the tracking lists should be kept in
a binder that is accessible to all project personnel. Project personnel indicate the completion
of a task by putting the completion date and their initials in the appropriate column on the
tracking list.
Setting up Files
Files need to be created to organize project information so that it is readily accessible when it is
needed. Two types of files that shall be established are the project files and the equipment
files. Project files contain project information including reports, timesheets, safety information,
and project correspondence. Equipment files are used to organize and store project
deliverables including criticality information, equipment data, and inspection reports.
Project Files
A successful project demands that the Site Coordinator retain and organize important project-
related documents including:
 Project Scope documents – proposals and contracts (store in secure location)
 Progress Reports – monthly and weekly
 Invoices (store in secure location)
 Employee Time and Expense Reports
 Project Correspondence – memos, meeting notes, NCRs, etc.
 Document Transmittal Log

 Nonconformance Tracking Log
 Safety – safety meeting records, incident investigation reports, first aid reports, etc.
 Subcontractor information – safety information, quality manuals, NDE procedures,

contracts, invoices, rate sheets, etc.
The Site Coordinator can organize the project files in file drawers/folders, binders or any other
effective filing method. For project files, consider the confidentiality of information in
determining where and how to store documents. For example: proposals and contracts should
be filed so that they are not accessible to client employees or employees of other contractors.
Equipment Files
Project deliverables are organized and stored in the equipment files. These files are typically
set up in file cabinets that the client provides. Files are separated by unit and equipment type.
Piping files and relief device files are organized differently from fixed equipment files as shown
below. Unless specified by the client, the equipment files should be organized as follows:
Fixed Equipment Files

Unit
Fixed Equipment
Criticality File - contains criticality summaries for the fixed

equipment in the unit
General File - PFDs, corrosion study, CMDs, inspection
histories, IWP summaries, unit information,
inspection tracking logs etc.
Heat Exchangers
E-1001(Equipment File) - project deliverables including

datasheet, design info., inspection
E-1002 reports, inspection plan, NCRs
Pressure Vessels
Storage Tanks
Relief Devices
Piping Files
Unit
Piping
Criticality File - contains criticality summaries for the piping

circuits in the unit
General File - contains piping specifications and/or any other
unit-specific piping information
Piping System File - contains piping system P&IDs
PL0001A(Circuit File) - project deliverables including

datasheet, design info.,
PL0001B drawings, inspection reports,
inspection plan, NCRs
Relief Device Files
Relief device folders that

are currently unassigned to
a device location are stored
here.
Contains Criticality Summaries for Relief Devices
Contains IWP summaries, Inspection Histories, etc.
The device location file contains project deliverables for the device
location including location datasheet, IWP, visual inspections for
device currently installed at this location
The relief device folder is stored in the device location file and
contains the device datasheet, NCRs for the device, and relief test
reports for the device installed at this location
The history file is stored in the device location file and contains old
IWPs, visual inspections, and NCRs for relief devices that are no
longer installed at this location
4
Chapter
Approve Inspection Strategies

The generic inspection strategies (contained in the appropriate Equipment Technology
document) should be reviewed and approved by the client. The level of detail for the review
depends on each client, but an approval step is required prior to completion of the preliminary
criticality. Normally the best time to schedule the strategy review meeting is immediately
following or even part of the first corrosion review. The following individuals should be invited:
 Unit Engineer – point of contact for information and questions regarding equipment
design, construction, maintenance, and equipment history
 Corrosion Engineer/Metallurgist – point of contact for information and questions related
to potential damage mechanisms, expected corrosion rates, and equipment history.
Some clients may have both site and corporate metallurgists so confirm with the client
project coordinator who should be invited.
 Inspection Resource – point of contact for information and questions regarding
inspection data and equipment history
 Capstone Project Manager
 Capstone MI Manager (optional)
The formal review meeting should confirm all details of the strategies including list of damage
mechanisms, inspection methods, number of circuits or vessels in a group, number of
inspection locations, inspection intervals and when to eliminate certain inspections (i.e. internal
visual inspection).
After the meeting, the revised strategies should be issued to the client and then formally
approved for use on the project. Get the client’s approval in writing and send the original
signed copy to the project files in the Capstone office.
Chapter 4 – Managing the Project
Project Communications
Project communications include all written contact between Capstone site personnel and the
client; and between Capstone site personnel and the Capstone office. Project communications
are used to report and document the status of a project. The Site Coordinator is responsible
for controlling the flow of project communications to/from the client and to/from the Capstone
office (see Project Correspondence).
In order to establish effective project communications, the site coordinator should determine
methods of contact with the client including: project coordinator (client contact) name, phone
number/extension, fax number, physical address, mailing address, and email address. This
information should be supplied to the Capstone office via the project setup form (see Set Up
Project).
The site coordinator shall also provide contact information for Capstone on site personnel to
the Capstone office. This information should include: phone numbers/extensions, fax
numbers, physical addresses, mailing addresses, and email addresses for all on site Capstone
personnel.
Project Managers and Site Coordinators should keep the Capstone office informed of where
they can be contacted if they will not be at their project site.
Examples of project correspondence include:
 Time and Expense Reports – weekly summaries of time and expenses for each
employee and for each project or unit in which work is being performed. These reports
are transmitted to the Capstone office so that employee payroll and expenses can be
prepared; and so that office personnel can generate invoices for the project (see Time
and Expense Reporting).
 Weekly and Monthly Progress Reports – summarize personnel, costs, work

performed, safety, and other issues. These reports are transmitted to the client and
Capstone project manager to communicate the status of the project (see Project
Reporting).
 Invoices – list all reimbursable costs for the project for a specific period that the client is
responsible for paying. Invoices are generated by the Capstone office and then
transmitted to the client for approval and payment (see Invoicing).
 Project Summaries – summarize the project deliverables, work performed, results,

costs, and recommendations. Project summaries are usually transmitted to the client at
the completion of the project during the project closeout meeting (see Project
Summary).
 Other correspondence – includes any communications from the client,

communications with subcontractors (NDE, data entry, etc.), and discrepancies/redlines
(see Documenting Data Discrepancies and Redlines), safety incident investigations,
and nonconformances (see Evaluating and Reporting Non-conformances).
Project Correspondence
The site coordinator manages the flow of correspondence to and from the client.
Correspondence includes all project-related written (including email) communications
transmitted between the client and Capstone on-site personnel.
It is important to manage correspondence for several reasons:
 History – project correspondence defines the status, changes, and agreements made
with the client and must be retained as project records.
 Control – the site coordinator or project manager must control the flow of project
correspondence to manage an effective project.
Transmitting/Receiving Correspondence
All project correspondence should be routed through the site coordinator for review and/or
approval before transmitting it to the client. The site coordinator will ensure that a Documents
Transmitted/Received form is properly filled out for all correspondence sent to or received from
the client. The information on the form is as follows:
Field Description
Date Date the document(s) were transmitted or received.
From Person sending document(s).
To Person receiving document(s).
Approval, Indicate why the document(s) being sent or received by circling the either
Information, approval, information, or review.
Review
Action Specify the action required or to be taken.
Required by Specify the date the action is required by.
Signature/Date The approval signature of the person receiving the document. (Required for
kickoff meeting notes, scope changes, equipment list changes, and non-
conformances)
Number Assign a sequential number to each of the documents if there is more than one
being transmitted/received.
Description A general description of each document being transmitted/received
Pages The number of pages of each document.
Retaining Correspondence
For transmitted project correspondence, make a copy of the document(s) and the Documents
Transmitted/Received form before sending it to the client. All project correspondence
transmitted and received shall be retained (along with the Documents Transmitted/Received
form) and filed in the project files (see Project Files).
Time and Expense Reporting

Time and expense reporting involves accounting for hours worked (and on what tasks) and
expenses for all personnel working on a project.
There are four documents associated with time and expense reporting:
 Time Reports – (also called timesheets) define (on a weekly basis) all hours worked,
vacation time, and sick time for each employee. Projects are invoiced (billed) and
employees are paid based on hours reported on time reports.
 Expense Reports – define (on a weekly basis) all work-related expenses for each
employee. Projects are billed and employees are reimbursed based on expenses
reported on expense reports.
 Daily Logs – define (on a weekly basis) hours worked on specific project tasks as well
as the number of tasks completed for each employee. Daily logs are used along with
tracking lists to determine and report project progress.
 Time and Expense Summaries – summarize all hours worked and expenses for a
project in a specific week. T&E summaries are generated for approval by the client to
serve as justification for project invoices.
Filling out a Time Report

Each Capstone employee is responsible for accurately completing a time report (timesheet) for
each work week. The Time Report form is filled out as follows:
Enter the project numbers applicable to the work being performed. If you
work on more than one project during the course of the week, all applicable
project numbers should be entered as rows on the time report.
If you are performing activities not related to, and not billable to, a specific
project, enter an overhead code from the following list in the project number
column.
Overhead Code
OH 1
OH 2
OH 3
OH 4
OH 5
OH 6
OH 7
OH 8
Record the employee
OH 9
number. Employee
OH 10
numbers can be obtained
Description
from Capstone
Vacation
administrative personnel.
Holiday
Record employee name:
Sick Time
Last Name, First Name
Other Paid Leave
Administrative
Office - Non Project
Marketing
Business Development
Seminars/Training
Other - explain in description column #8
Enter a brief
description and
Enter the client the project
name for which you location
are performing the
project. If you are
Enter the resource code for
performing
the employee for the
“overhead” tasks,
project. Resource codes
not relating to a
are assigned to each
specific project,
project employee by the
enter “Capstone” in
site coordinator.
the appropriate
client name space.
Enter the appropriate work code for the work being performed. Enter a new row for each work code used. The
work codes are included below.
Description
Project Hours - Onsite
Project Hours - Offsite
Travel Time - Full Rate
Travel Time - Half RateRegular
10
20
30
40OT 1
11
21
xx
xxOT 2
12
22
xx
xx
Prior to performing work, all overtime hours must be approved by the Site Coordinator and the client. OT1 hours
are defined by the terms of the contract with the client, but generally for short term projects (2 weeks or less in
continuous duration) OT1 is all billable hours worked in excess of 8 hours per day or Saturdays, when such work
is performed at the clients requestCopyright
and with ©
his1996-2004
pre-approval. OT1 hours for long term projects (generally longer Enter the start
Issue Date: 8/9/04, 2004 Rev. by Capstone Engineering Services, Inc. Page
and end 29
dates
than two weeks in duration) are usually defined as all billable hours worked in excess of 40 hours per week.
OT2 hours are defined as billable hours worked Enter the weekor holidays. In addition, OT2 is generally charged
on Sundays for the week
number
on short-term projects for billable (1worked
hours – 52) in excess of 12 hours per day. (MM/DD/YY)
Travel at half rate is only used for travel time for salaried employees who travel during non-business hours. The
Enter dates for

each day of the
week.
Enter the total

hours for this
Enter the number of row (Monday to
hours worked that Sunday)
day for that project
and work code.
Enter the total
invoiceable hours for Total number of
this row (Monday to invoiceable
Sunday) overtime hours for
this row (Monday
to Sunday)
Enter the total
Enter the total number of Enter the total hours number of
hours worked each day for worked for the week. invoiceable hours
which you will be paid at This is the sum of this worked for the week
regular (straight time) pay row (Monday to (sum of this column)
rates. Sunday).
Enter the total
number of hours
worked for each Enter the total number of hours worked each day for
day. This is a which you will be paid at overtime pay rates. For
summation of all short-term projects, projects with less than 2 weeks of
hours worked each continuous activity, overtime is applicable for all hours
day for all projects. worked beyond 8 hours each day. For all other
projects, overtime is considered for all hours worked
beyond 40 hours each week. OT hours plus regular
hours should equal total hours for each day.
Enter the total number of

hours worked for the week
that you will be paid at
regular (straight time) pay
rates. This is the sum of Enter the total number
this row (Monday to of hours worked for the
Sunday) week that you will be Enter the total
paid at overtime pay number of
rates. This is the sum of invoiceable
Record any special billing this row (Monday to overtime hours
instructions or other notes Sunday) worked for the week
that may apply to a (sum of this
project. column).
Indicate whether personal reimbursable expenses have

been incurred during the week. Always check either the
“yes” or the “no” box. If the “yes” box is checked, an
Expense Report should also be filled out.
D E F I N I N G T H E P R O J E C T S C O P E The Site Coordinator will
The Site Coordinator will record the straight time
hours worked during the week. For salaried record all OT2 hours worked
employees, straight time is 40 hours, less any during the week. OT2 hours
applicable holiday, vacation or sick hours. are defined in #10. OT2 hours
will be paid at two times the
normal pay rate and
consequently, must be
The Site Coordinator will record the total hours of
approved by the client and
special overtime (SOT) worked during the week.
project manager in advance.
Special overtime hours are defined as any billable
hours worked by salaried personnel in excess of 40
hours per week or on weekends. Special overtime
hours will be paid at a straight time hourly rate. The Site Coordinator will enter
any applicable holiday hours
taken during the week that you
The Site Coordinator will record all OT1 hours are eligible to be paid for.
worked during the week. OT1 hours are defined in Holiday hours should be
#10. OT1 hours will be paid at one and one half entered as 8 hours per day
times the normal pay rate and consequently, must regardless of your individual
be approved by the client and project manager in work schedule.
advance.
The Site Coordinator will

enter any vacation hours
taken during the week that you
are eligible to be paid for. The
minimum number of vacation
hours that can apply for a day
is 4 (1/2 day). The maximum
The employee The Site Coordinator will number of vacation hours that
signs and dates total the number of payroll can be taken for a day is 8,
the time report. hours applicable for the regardless of your regular
week. This is the sum of work schedule.
this column. The Site
Coordinator will also initial
the Total Payroll Hours
block after reviewing the The Site Coordinator will enter
Time Report indicating any sick time taken during the
approval. The Total week that you are eligible to be
The Project Manager signs Payroll Hours field is used paid for. The maximum sick
and dates the time report as a quick check to ensure hours that can be taken for a
indicating that it was reviewed each employee is day is 8, regardless of your
and approved. compensated properly. regular work schedule.
Filling out an Expense Report
When an employee has reimbursable project expenses (per diem, airfare, etc.), they shall
complete an Expense Report for the work week. Expense receipts should be submitted with
the weekly Time & Expense Reports. Any receipt not submitted with the Time & Expense
Report will require managerial approval prior for reimbursement. The following criteria must be
met for an expense receipt to be considered for reimbursement:
 Establishment name printed on the receipt
 Date
 Project Number (when applicable)
 The receipt must be original (no copies)
 If charges are divided between projects, the division must be detailed with the receipt
Expense receipts should be taped to an 81/2 X 11 sheet of blank paper with the employee
name, week number, project name, and project number (or applicable overhead code)
recorded on the sheet.
The Expense Report form is filled out as follows:

The Project
Enter reimbursable airfare expenses for each applicable project
Manager will sign
number. Airfare expenses are reimbursed at cost and should be
and date the
accompanied by the original receipt. Airfare charges should normally
expense report
be paid for by the employee. When it is impossible for an employee to
indicating approval.
pay for their airfare expenses, a direct billing to the travel agent can be
arranged with managerial approval and signature.
Same as time
report.
From time
report
Project number or Mileage is reimbursed at a

Enter reimbursable lodging accommodation rate of 30 cents per mile.
overhead code from expenses for each applicable project
time report for which the Enter reimbursable
number. Lodging expenses are reimbursed automobile mileage expenses
expenses were incurred. at cost. Original receipts are required for for each applicable project
reimbursement. Lodging expenses should number. In the explanation
be paid for by the employee, unless other box, enter the total mileage
arrangements have been previously used to arrive at the expense
established. total. Example: Auto mileage
-- 500 mi. @ .30/mi. = $150.00
CHAPTER 3 – STARTING AND ORGANIZING THE PROJECT Indicate whether the
D E F I N I N G T H E P R O J E C T S C O P E reimbursable
expenses are billable
Enter the total amount of to the project (Y or
expenses for each project N). If some expenses
number. This is the sum of are billable and
this row. others are not, enter
the project number
Same as time twice and enter
report billable expenses on
one row, and non-
billable expenses on
the other row.
Enter other reimbursable expenses, such as copy

Enter reimbursable charges, telephone, etc., for each applicable project
transportation number. Phone calls should be billed to the employee’s
expenses, such as personal Long Distance calling card. Project personnel
taxi, shuttle bus, working out of town will be reimbursed for five (5)
rental car, and minutes of personal phone time for each day that the
gasoline for a rental employee is away from home. This phone time can be
car, for each accumulated over the duration of the trip, and does not
applicable project have to be used daily. Personal phone time cannot be
number. transferred to other trips away from home or to other
Transportation projects. Original receipts are required for
expenses are reimbursement. In the explanation box, describe the
reimbursed at cost. “other” expense item.
Original receipts
are required for
reimbursement.
Enter reimbursable entertainment expenses, such as
business lunches, etc., for each applicable project
number. Entertainment expenses must be approved
in advance by a manager, and are reimbursed at cost.
The IRS imposes strict criteria for business
Enter reimbursable perdiem entertainment expenses. To obtain reimbursement for
expenses for each applicable entertainment expenses, original receipts should be
project number. Employees attached to the Time & Expense Report with the
working at an onsite billable applicable project number, names of all persons
project away from home for ten covered by the receipt, client name, and the purpose
(10) hours or more (including of the expenditure. Business entertainment expenses
travel time) without an overnight should be marked as non-billable on your expense
stay shall be reimbursed $15/day report.
for meals. Employees working at
an onsite billable project away
from home for fifteen (15) hours
Enter reimbursable parking and tollway expenses for each
or more in one day, or staying
applicable project number. Parking and tollway expenses are
overnight, shall be reimbursed
reimbursed at cost. Parking and toll road charges will be
$30/day for meals. The $30 is
reimbursed without a receipt for amounts up to $1.00. Original
broken down according to the
receipts shall be provided for parking and toll expenses greater
following meal allocation:
than $1.00. If an employee expects to be out of town for more
Breakfast $5.00
than one week, it is suggested that the employee use a taxi
Lunch $10.00
service instead of airport parking. If you do use airport parking
Dinner $15.00
and will be gone for more than three days, remote parking
must be used.
B
r
e
a
k
f
Issue Date: 8/9/04, 2004 Rev. Copyright © 1996-2004
a by Capstone Engineering Services, Inc. Page 34
s
t
5
.
0
0
C H A P T E R 3 – S T A R T I N G LA N D O R G A N I Z I N G T H E P R O J E C T
D E F I N I N G T H E P R O J E C T uS C O P E
n
c
h
Enter the sum
of all
reimbursable
expenses in
each column.
1
0
.
0
0
Dinner 15.00
B
r
e
a
k
f
a
s
t
5
Record an . Record the total
explanation for 0 amount of
all expenses 0 expenses for
listed in the L the week.
“Other” column. u
n
c
Record any expense
h
advance or other expense
items pre-paid by
Capstone for the week
(e.g., hotel that is pre-paid
by Capstone).
Record total 1expenses due the employee.

This entry should
0 be the total expenses
less expenses. paid by Capstone, when
total expenses
0 are greater than expenses
paid by Capstone.
0
D
i
n by Capstone are greater than total
If expenses paid
n
expenses, record the difference in the “Expenses
Due Company” e box. Attach a check for the
r Time & Expense Report.
difference to the
1
5 The employee
. signs and dates
0 the expense
0 report here.
Filling out a Daily Log
Each on-site Capstone employee is responsible for accurately completing a daily log for each
project worked on for each work week. The Daily Log form is filled out as follows:
Enter the total number Enter the total number of items that were actually
of hours you worked on completed for each task. Only enter quantities
each particular task that are 100% complete. If no quantities are
each day. completed enter “0”. Example: If you complete 1/2
Same as time of a pressure vessel data sheet on Monday and the
report other 1/2 of the data sheet on Tuesday, enter “0” in
the quantities complete column for Monday, and “1”
in the quantities complete column on Tuesday.
Enter the Task Code for the activity being

Enter the appropriate performed.
work code for the work
Enter the task type relating to the specific job you are performing. If
being performed. It
the work is added scope, enter “ADD” as the task type. If the job
should be the same value
you are performing is not related to a specific task type, enter 0.
as that on the time report.
Task types are included in the table below:
Task Type
PVSL
TANK
PIPE
INST
Provide a brief ROT
description of RELIEF
the work ELEC
performed FIRE
during each day CRANE
for each task.
ADMN
ADD
Enter the plant unit number PROC
applicable to the work being TRAIN
performed. If the work being QAQC
performed does not apply to a CRIT
specific unit, enter 0. FILE
PREVAL
FAIL
MATCONDescription
Pressure Vessel
Storage Tank
Piping/Piping Component
Instrumentation/Control
Rotating Equipment
Relief/Vent Device
Electrical System
Issue Date: 8/9/04, 2004 Rev. Copyright © 1996-2004 by Capstone Engineering Services, Inc. Systems
Fire Protection Page 36
Cranes and Lifting Devices
Project Management/Administration
Training
Quality Assurance/Control
Criticality Ranking
File Maintenance/Setup
CHAPTER 3 – STARTING AND ORGANIZING TH Program
E PR Evaluation
OJECT
Failure Analysis
Materials Consulting
Enter the total number of

Enter the total number of hours worked for the hours worked for the
week that was assigned the “PIPE” task type. This week that were assigned
value is used by the Site Coordinator to calculate the “ADMN” task type.
monthly cost summaries. This value is used by the
Site Coordinator to
calculate monthly cost
summaries.
Enter the total number of hours worked for the week
that was assigned the “PVSL” task type. This value is
used by the Site Coordinator to calculate monthly cost
summaries.
Same as
time report
Enter the total number

of hours worked for the
week that was assigned
the “ADD” task type.
This value is used by
the Site Coordinator to
calculate monthly cost
summaries.
Enter the total hours worked during the

week for each task. This is a summation
of all hours worked, from Monday through
Sunday, for each task.
Record the total quantities that are 100%

complete for each task. This is a
summation of all quantities complete
(Monday through Sunday) for each task. If Record any comments or
no quantities were completed entirely, enter concerns regarding work
0. performed for each
applicable task.
Reviewing and Transmitting Time and Expense Reports
Each Capstone employee is responsible for accurately completing a time report (timesheet) for
each work week.
Site Coordinators are responsible for reviewing and approving time and expense (T&E) reports
each week. A faxed copy is due at the Capstone office every Monday at NOON (not just
payroll weeks!) and the signed originals with original receipts are due at the office by the end of
day Tuesday. E-mailed timesheets do not include the employee’s signature so are inferior to
fax copies. The originals are legal documents and necessary to provide backup for payroll,
expense reimbursements and invoicing. Copies of all T&E reports for a project shall be
retained in the project files (see Project Files).
Some errors on invoices are because of errors on the T&E Summary and many of these errors
are because the T&E sheets were not reviewed prior to approval. When the Site Coordinator
signs a time sheet they are assuring the office that there are no errors and therefore no
changes will be necessary when the invoice is issued. A common error on time reports is
hours billed to the wrong project number.
Reviewing and Transmitting Time and Expense Summaries

The office staff will issue a draft T&E Summary within 3 days after receiving all timesheets that
could contain billable time for each project. The T&E Summary may be delayed even if all site
T&E sheets have been properly submitted because the office is waiting on late timesheets
from offsite personnel that may have worked on your project. The office staff will also provide
the total Expense and Labor costs that match the amounts recorded in our accounting
software, which must match the T&E Summary entries, which must match T&E sheets. That is
why getting T&E sheets correct the first time is so important! The Site Coordinator should then
verify the Expense and Labor cost totals as a final check for errors in the whole process.
On fixed fee projects, the Site Coordinator must also provide the percent complete at the end
of each month to determine the proper amount to bill the client. In addition, the Site
Coordinator must clearly communicate when project time is no longer billable if the fixed fee
amount has been reached. When T&E sheets include billable time, the office staff can only
assume the Site Coordinator or Project Manager has obtained a contract extension and the
billable hours are truly billable. Because the office staff provides the total Expense and Labor
costs, the Site Coordinator will know each week how close they are to the budget.
The Site Coordinator must review the T&E Summary within 2 days of receiving it from the
office. The following key items should be verified on every T&E Summary:
 Project number at the top of the page is correct

 All personnel that worked on the project are included; both on-site and off-site
(specifically ask if off-site resources had any time charged to your client but may have
used the wrong project number)
 Resource codes are correct (these define the billing rate)
Note: The Project Manager assigns the resource code for each person at the
start of the project. If personnel are moved to new positions during a project
(e.g. VISR to API because they earned their first certification), the resource code
is not changed until the client has approved the new corresponding billing rate.
 On-site, off-site and travel hours are correct (travel code 40 means travel is billed at half
rate)
 Overtime is properly recorded (must match T&E sheet that indicates work code is 11 or
21 which indicates bill at time-and-a-half, if overtime is billed at double-time then work
codes are 12 or 22)
 Expenses are complete and include any markup (e.g. cost +10%)
 Fixed project expenses (printers, computers, NDE equipment, etc.) are included as
appropriate and are accurate.
The Site Coordinator should then sign the T&E Summary indicating all information is correct
and obtain client approval; preferably the same day. Then the T&E Summary should be faxed
to the office and the signed original mailed. A copy of the signed T&E Summary shall be
retained in the project files (see Project Files).
Invoicing
Invoices are the means by which Capstone gets paid for the work that Capstone employees
perform on a project. The Site Coordinator is responsible for reviewing the draft invoices
generated by Capstone office staff and ensuring that invoices are routed to the appropriate
client personnel for timely payment. Effective invoicing involves four things:
1. Schedule – The Site Coordinator should insure that invoices are generated at the intervals
agreed to in the project contract and/or at the Project Kickoff Meeting. Invoices are
typically generated for a project every two to four weeks. The Site Coordinator is
responsible for requesting that office staff generate an invoice at the appropriate time.
2. Accuracy – The Site Coordinator will review the draft invoice by comparing them to the
client-approved T&E Summaries for that invoicing period. Any errors need to be corrected
prior to issuing the invoice. The following items should be checked on the invoice:
a. Personnel hours - Check that invoiced hours on the invoice for all personnel
match those shown on the weekly time and expense summaries.
b. Expenses - Verify that expenses on the invoice match those on the weekly time
and expense summaries. Also ensure that expenses shown on the invoice are
billable in accordance with the contract for that customer. (For example, some
expenses may be passed on the customer “at cost”, while others may be at “cost +
5%”)
c. Personnel on project - Check that personnel billed on the invoice were authorized
to work on the project.
d. Billable rates - Ensure that the billing rates for personnel on the invoice match the
resource codes and rate schedule for that project.
3. What – The Site Coordinator will ensure that the invoice includes all information required
by the client for timely payment. This can include purchase order/reference numbers,
back-up documents (receipts, timesheets, T&E summaries, etc.). The invoicing
requirements are typically agreed to at the Project Kickoff Meeting.
4. Who – To ensure timely payment, the Site Coordinator will ensure that the invoice is routed
to the appropriate client personnel for approval and payment. In some cases, the invoice
may be mailed directly to the client’s accounts payable department. Other projects require
the project client contact to review and approve the invoice before it is forwarded to
accounts payable. The invoice routing method is typically defined at the Project Kickoff
Meeting or by confirming it with the project client contact.
Project Reporting
Progress and project status are communicated to the client and Capstone management on a
weekly and monthly basis.
Weekly Reports
The site coordinator develops the weekly reports for each active project and issues them to the
client and Capstone project manager by the second workday following the week addressed in
the report. The weekly report can be documented using the Weekly Progress Report form.
The following sections shall be addressed in the weekly report:
Section Description/Explanation Source of Data/Location
Safety Summarize the safety meeting  Safety Meeting Records

topics, identify the date of the next
scheduled safety meeting, and  Time and Expense
summarize the hours to date on the Summaries or Monthly
project without an OSHA recordable reports (for hours worked
incident. safely)
Personnel List the names of personnel Time and Expense Summary

including subcontractors and visitors
working on site and offsite along with
their titles for the specific project.
(For example: John Doe – API
Inspector)
Meetings Held List meetings held which involved Meeting minutes

Capstone and client personnel, who
attended the meetings, and the
subject of the meetings.
Meetings List meetings planned for the ---

Scheduled upcoming week.
Work Completed List tasks completed or progress Tracking Lists

made during the week. On multiple
unit projects this information shall be
organized by unit. Focus on
deliverables (data collection, visual
inspections, NDE inspections, etc.)
and not on administrative or minor
tasks (organizing files, copying, etc.).
For example: “Completed 21fixed
equipment visual inspections (45 of
111)”
Work Planned List tasks or progress planned for Project plan/Gantt chart
the upcoming week. For example:
“Will complete 30 fixed equipment
visual inspections in fractionation
unit.”
Issues and List all issues that need to be ---

Concerns addressed. Examples are “Missing
required U1 forms from engineering
department”, “decision needed
whether utilities should be included
in the RBMI project scope”, etc.
Added Scope List all added scope work items that ---
the client has agreed to. For each
added scope item include the
following:
 Task Description
 Anticipated Start Date
 Anticipated Completion Date
 Estimated Costs – Labor,

Expenses, Total
Monthly Reports
The monthly reports are also prepared by the site coordinator and are transmitted to the client
and Capstone project manager by the second workday following the end of the month. The
invoice when given to the client typically accompanies the monthly report.
The first eight sections of the monthly report are identical to the weekly report except they
summarize the month versus individual weeks. An additional Project Status section is added
to the monthly report and is described in the table below. The monthly report can be generated
using the Monthly Progress Report form and the Project Status Worksheet (for the project
status section).
Project Status The project status section is used to  Proposals

communicate the “numbers” or
quantitative progress of the project.  Scope Changes
Project status values for a project can
be maintained and reported using the  T&E Summaries
Project Status Worksheet.
 Tracking Lists
Project status reporting includes:
 Project budget (project

summary tab)
 Project costs to date (project

summary tab)
 Percent of project completed

(project summary tab)
 Percent of project expended

(project summary tab)
 Status of Deliverables
(deliverables tabs)
 Project Schedule (schedule and

Gantt chart tabs)
 Time and Expense Summaries

(Summary T&E tab)
Scope Changes
Scope changes are common in RBMISM implementation projects. Scope changes are a great
opportunity for Capstone personnel to perform more work for a client. However, it is important
that scope changes be effectively managed to prevent them from negatively affecting the
budget and schedule of the original project(s). All scope changes should have their own
approved budget and schedule. The Site Coordinator is responsible for estimating and
managing scope changes. Scope changes typically arise from the following two situations:
1. Additional Equipment – At the beginning of the project, while defining the project
scope, additional equipment items are identified (greater than the number identified in
the proposal and contract) that the client would like to include in the RBMI SM project.
Another typical situation requiring a scope change is when, during the course of the
project, the client requests several equipment items be added to the project scope.
2. Additional Tasks – The client requests that Capstone perform work not originally
defined in the project scope. For example, a client agreed to pay for pressure vessel
data collection in a unit, but not field verification. Capstone personnel begin data
collection and find numerous discrepancies in design data. After the Site Coordinator
communicates these discrepancies to the project client contact, the client contact
requests that Capstone personnel field verify nameplate information for all pressure
vessels in the unit.
Scope changes are managed as follows:
1. Requesting the change - Even though the Site Coordinator may have recommended
the added work, the client must initiate the scope change by requesting that the
additional work be performed.
2. Estimate the scope change – The Site Coordinator (SC) communicates to the
Capstone Project Manager (PM) the details of the scope change. The SC and PM work
together to determine:
a. The estimated cost, schedule, and personnel requirements of the additional

work. The Cost Estimating worksheet can be used to develop the estimate.
b. How the added scope will impact the original project schedule.
3. Submit a Notification of Scope Change– The Site Coordinator or Project Manager

will develop and submit a notification of scope change to the project client contact for
approval. The Scope Change form can be used for this purpose.
4. Approve the scope change – The project client contact approves the scope change
by signing the Scope Change form and returning it to the Site Coordinator. In addition
to the approved scope change, the Site Coordinator must receive an approved
purchase order or purchase order modification for the additional work. The scope
change form and purchase order for the change shall be retained in the project files.
5. Manage the scope change – Once the additional work commences, the Site
Coordinator is responsible for including and tracking the added tasks in T&E reports,
T&E summaries, invoices; and weekly and monthly project reports.
Project Summary
Project Summary reports are developed and issued to the client at the completion of
implementation of an RBMI program (project closeout). Project Summary reports are typically
issued for each unit in which implementation work is performed.
Project Summary reports are provided to the client to summarize work completed and findings
from the Reliability Based Mechanical IntegritySM(RBMISM) implementation projects.
The Site Coordinator generates the Project Summary report and compiles it into a binder. The
sections of the report binder (divided by tabs) are as follows:
 Project Summary – typically includes:
Project Summary Section Information Source
Title Page ---

Table of Contents ---

Executive Summary - a one-page discussion of the project scope,  Criticality Summaries
the work performed, the results, and recommendations. A combined
criticality risk distribution matrix is typically included on this page as  IWP Summaries
well.  NDE Summaries
 Cost Comparisons
Introduction - provides general information about Criticality and the ---
RBMISM implementation process
Criticality Summary - includes: Criticality Summaries
 Discussion of how criticality values were calculated and why
items had “High” criticality values.
 Table detailing the distribution of criticality ratings by equipment
type
 Figures detailing the combined criticality distribution for each
identified potential damage mechanism
 Discussion of the probability of failure analysis including all
mechanisms identified
 Figures graphing the overall probability of failure distribution (1 to
5) and probability of failure by damage mechanism (1 to 5)
 Discussion of consequence of failure analysis including how
consequence was modeled for the different equipment types and
what fluids were modeled
 Figure graphing the consequence of failure distribution (A to E)
Inspection Planning - discussion of how the inspection plans for the IWP Summaries
equipment items were developed
Cost Comparison - discussion of potential cost savings due to Cost Comparisons
reduced inspection requirements over the next 10 years and due to
risk reduction in the unit. This section summarizes the calculated
savings from the cost comparison MS Excel worksheets.
Inspection Recommendations - discussion of recommended  Criticality Summaries
inspection activities including a table identifying the reasons why
equipment items are “High” criticality and what inspections should be  IWP Summaries
performed to manage those items.
 Criticality Summaries – MS Excel Worksheet that lists design/operation information,

damage mechanisms, and criticality information for each equipment component in the
project scope. Summaries are typically developed for each equipment type (fixed
equipment, piping, PRDs). Select this link to view an example of a Criticality Summary
in MS Excel.
Note: In order to prevent confusion for the client, always hide the Wall Ratio and
Remaining Life fields when preparing a Criticality Summary for the Project Summary
(final report).
Criticality Summaries are generated in the RBMI software and exported to MS Excel
as follows:
From the main screen select Reports, then Criticality, then Criticality Report
Specify the selection criteria (unit name, equipment type), then press
Specify
selection
criteria
here
Press to export the report to MS Excel.
Select the export format and press
Set the export format options and press
Choose a path and file name for the MS Excel worksheet, then press
 Inspection Work Plan (IWP) Summaries – MS Excel Worksheet that lists the
recommended inspection tasks with associated potential damage mechanisms and
inspection priorities for each equipment item. The extent of inspection, availability, last
inspection date, date due, and recommended frequency of inspection is also identified.
These summaries are useful to the client in planning shutdowns and prioritizing
inspection work.
The IWP summaries should be developed for each equipment type in the project scope
of work (fixed equipment, piping, PRDs) and should be sorted by both Equipment ID
and by Due Date. Select this link to view an example of an IWP Summary in MS Excel.
IWP Summaries are generated in the RBMI software and exported to MS Excel as
follows:
From the main screen select Reports, then Inspection Planning, then Inspections
Due
Specify the plant, unit, and selection criteria (unit name, equipment type), then press
Specify
selection
criteria here
Follow the same process used for the Criticality Summary to export a report to MS
Excel.
 Cost Comparisons – MS Excel Worksheet that calculates costs for a ten-year

inspection program using RBMI versus using a standard API approach. The cost
comparison worksheets differ depending on the equipment type (vessels, piping, or
PRDs).
Vessel Cost Comparison
The Vessel Cost Comparison worksheet can be used to compare the costs of the RBMI
vs. API inspection program for the vessels in the unit. Note: the “gray” fields in the
worksheet are calculated fields and do not require entry. The worksheet is filled out as
follows:
Enter the
equipment ID for all Enter the number of recommended TMLs from
vessels in the unit the Inspection Plan in the RBMI software
or project scope
including pressure
vessels, heat Enter the recommended UT/RT inspection
exchangers, and interval from the Inspection Plan in the
storage tanks RBMI software
Enter 10 or ½ of the
remaining life;
whichever is less. Enter the VI-Ext. recommended Enter 5 or ½ of
inspection frequency from the the remaining
Inspection Plan in the RBMI life; whichever
software is less.
Enter the VI-Int.

recommended inspection
frequency from the Enter 10 or ½ of
Enter S, M, or L for the
Inspection Plan in the RBMI the remaining life;
vessel length:
software whichever is less.
S = less than 20 ft
M = between 20 and 75 ft
L = greater than 75 ft
Piping Cost Comparison
The Piping Cost Comparison worksheet can be used to compare the costs of the RBMI
vs. API inspection program for the piping circuits in the unit. Note: the “gray” fields in
the worksheet are calculated fields and do not require entry. The worksheet is filled out
as follows:
Enter the number of
TMLS for each
circuit as identified
Enter the piping on the Inspection
circuit IDs for all Plan in the RBMI Enter the UT/RT inspection
circuits in the Software frequency from the
project scope of
Inspection Plan in the RBMI
work
Software
Enter the VI-Ext. Enter the API

inspection frequency class for the
from the Inspection Plan piping circuit
in the RBMI software
Pressure Relief Device Cost Comparison
The Pressure Relief Devices cost comparison worksheet can be used to compare the
costs of the RBMI vs. API inspection program for the relief devices in the unit. Note: the
“gray” fields in the worksheet are calculated fields and do not require entry. The
worksheet is filled out as follows:
Enter the usual
Enter the relief test relief test
Enter the name of
frequency from the frequency
all relief devices in
Inspection Plan in followed by the
the project scope of
the RBMI software client.
work
Project Meetings
Project meetings are held between Capstone and client personnel to discuss project-related
issues. Regularly scheduled meetings typically occur weekly or monthly between the Site
Coordinator and the client project coordinator to report project status and correlate with
delivering weekly or monthly reports. Capstone or client personnel, to resolve other issues,
may initiate other meetings as needed.
Planning the meeting

When the Site Coordinator and/or Project Manager determine that a meeting is required, the
following preparations should be performed:
 Develop an agenda/purpose for the meeting – determine the topics to be discussed

and prepare supporting documents and/or presentation materials.
 Schedule the meeting and notify attendees – work with the client project contact to
determine an acceptable time and place for the meeting, then notify the attendees.
Give as much advance notice as possible (at least one week, if possible), to
accommodate the individual schedules of the project contact and other client personnel.
Documenting the meeting

Site Coordinators and/or Project Managers must keep an accurate an account of the meetings
conducted. Meeting information that shall be documented includes:
 Purpose/Agenda – What topics were discussed
 Attendees – Who attended the meeting
 Date/Time – The date, time, and duration of the meeting
 Decisions Made/Action Items – what decisions and action items were agreed to. For
each action item, document who is responsible for the task and when the task is to be
completed by.
 Documents/Materials – copies of any written materials or presentation materials used

and/or transmitted during the meeting should be attached to the meeting notes.
The Meeting Notes form can be used to document meetings. The Site Coordinator shall retain
copies of meeting notes (along with any attachments) in the project files.
Project Quality Assurance and Quality Control (QA/QC)

In order to have quality on a project, the project deliverables must be accurate and meet (or
exceed) the expectations of the client. These expectations are documented in the project
proposal and contract; and communicated and agreed to in the project kickoff meeting. Project
quality assurance is required to promote consistency throughout the project and reduce the
possibility of costly errors in documentation and reporting practices.
All MI Project Team personnel are responsible for the quality of their work/deliverables and the
Site Coordinator is responsible for ensuring that task training and quality checks of deliverables
are performed. The Project Manager is responsible for auditing or assigning an auditor for the
project to verify that established standards are being met.
Project quality assurance and quality control are achieved through the following:
 Task Training – familiarizing Capstone on-site personnel with the proper methods of
performing and documenting project tasks including data collection, inspection, and
inspection planning. This also includes providing continuing education for existing
employees on new elements of the RBMI process or for elements that have been
changed and/or improved.
 Reviewing Deliverables – verifying the accuracy and quality of project deliverables

including data collection forms, inspection forms, and inspection plans. Verification of
quality involves comparing deliverables to the standards and requirements defined in
this manual. Verification of quality includes checking values on data collection and
inspection forms for accuracy; and field-checking inspections and sketches.
 Project Audits – a quarterly quality check of a RBMI project looking at: organization,
training of new employees to the project, continuing education of existing employees,
quality control process’s of project tasks, and meeting client expectations.
Task Training
The Site Coordinator will ensure that all project personnel have received training before
performing each major project task (i.e. collect data, summarize histories, sketching, visual
inspection, data entry, and preparing the final report). All project personnel require training for
all project tasks that they will be performing, even if they may have been previously qualified on
the task at another project site.
Separate task training should be performed for the following project tasks (as applicable):
 Time/Expense Reports and Daily Logs  Reviewing Inspection / Maintenance  Internal Visual Inspection: Storage
Histories Tanks
 Defining Piping Systems and Circuits  Inspection Drawings: Piping  Inspection Planning: Pressure Vessels
Circuits, Vessels, Heat Exchangers, and Heat Exchangers
and Storage Tanks
 Data Collection: Pressure Vessels,  External Visual Inspection: Pressure  Inspection Planning: Storage Tanks
Columns, Heat Exchangers, and Air Vessels and Heat Exchangers
Coolers
 Data Collection: Piping Circuits  External Visual Inspection: Piping  Inspection Planning: Piping Circuits
Circuits
 Data Collection: Storage Tanks  External Visual Inspection: Storage  Inspection Planning: Relief Devices
Tanks
 Data Collection: Relief Devices  External Visual Inspection: Relief  Performing and Evaluating NDE
Devices Inspections
 Data Discrepancies and Redlines  Internal Visual Inspection: Pressure  Evaluating and Reporting
Vessels and Heat Exchangers Nonconformances
Initial task training shall include the following:
1. Trainer and trainee(s) review written task instructions and documentation
2. Trainer instructs trainee(s) on how to perform the task
3. Trainee(s) successfully demonstrates execution and completion of the task while being
observed (without assistance) by the trainer.
4. The Trainer documents the training including: project task, employee name, training date,
and the name of the trainer. The Project Task Training Log can be used to document task
training.
An example of training would be:
1. The Site Coordinator (trainer) makes copies of the written instructions and forms for
piping circuit data collection and gives them to the two Capstone inspectors (trainees)
who are going to be performing piping data collection for this project. The Site
Coordinator explains the written instructions including the fields on the datasheet,
required fields, valid values, and proper data sources (from the Unit Overview).
2. The Site Coordinator works through an example datasheet with the two inspectors,
answering any questions and providing help when needed.
3. The inspectors each complete a datasheet on their own which the Site Coordinator
reviews for completeness and accuracy. If the datasheets are satisfactory, the Site
Coordinator then documents the completed training using the Project Task Training Log.
If the work is unsatisfactory, then training shall be repeated.
Note: The trainer can be the Project Manager, Site Coordinator, or any other Capstone
personnel that has successfully completed the training for that task. However, the Site
Coordinator shall verify that all training has been properly performed.
Refresher training shall occur when a change is made to how a task is performed. For
example, if a new method of drawing inspection sketches is implemented during the course of
a project, the Site Coordinator will document the new method and then communicate the
changes to affected Capstone project personnel. Refresher training can be documented using
the Project Task Training Log .
Reviewing Deliverables
In order to ensure the project quality, the Site Coordinator will establish a filing system that
enables tracking of the quality process for project deliverables. One example is the three-bin
system. This system contains the following files or bins:
 Review: All project deliverables (datasheets, inspection reports, etc.) that
are complete are placed in this bin for review.
 Enter: All project deliverables, which have been reviewed and require data
entry are placed in this bin.
 File: All project deliverables that have been reviewed and/or entered are
placed in this bin to be filed in the Equipment Files.
This filing system will be used for the following deliverables:
 Field Verification forms

 Data Collection forms
 Inspection Drawings/Field Sketches
 Visual Inspection Reports
 NDE Reports
 Inspection Work Plans
 Nonconformance Reports (NCRs)
All deliverables of an RBMISM project require review in order to ensure that information
collected and reported will be as accurate as possible. Because sketching and inspections
involve fieldwork, field checks will be performed on a percentage of those deliverables to verify
their accuracy. Each deliverable, along with its hold point and the minimum requirements of
quality control are listed below. Hold Points establish when a deliverable should be reviewed,
and Minimum Requirements define how it should be reviewed.
Deliverable Hold Point Minimum Requirements
Systemizing and At the completion of  Review systemized P&IDs to ensure that

Circuitizing Piping visual inspections or all processes defined in the scope of
at the completion of work have been included.
data collection (if  Review circuitized P&IDs during data
visuals are not collection and visual inspection to verify
performed) accuracy of circuits, looking for things
like changes in materials of construction,
injection points, missing/additional
piping, etc.
Field Verification Before completing Ensure that all required fields (shaded) are
Datasheet Data Collection forms filled out. If design information is not listed
on the form, ensure that the nameplate is
marked “missing”.
Data Collection forms Before data entry  Ensure completeness by verifying that
all required fields are filled out and are in
the proper format as indicated by the
written instructions. Pay special
attention to the units assigned to values
(For example, shell diameter should be
in decimal inches and not feet).
 Review 10% (minimum) of the forms for
accuracy by comparing the values in the
required fields to the corresponding
values from the proper data sources (ex.
U-1s, P&IDs, client-provided process/op.
conditions, etc.)
Criticality Before baseline  Review criticality report for missing fields
inspection planning and wall ratios that are less than 1.
Inspection Before baseline  Ensure that all title block information is

Drawings/Sketches inspection planning on the sketch and that all required
drawing elements are present.
 Field verify 10% of the sketches
checking for accuracy of components,
orientation, and dimensions.
Note 1: It is usually more efficient to review
the sketches at the same time as the visual
inspection report
Note 2: All personnel performing this task
should be QC’d regardless of experience.
Visual Inspection Before data entry and  Check that all fields have been
Reports before baseline completed on the report. No fields can
inspection planning be left blank.
 Ensure that all VI indications noted on
the report are present on the attached
sketch and that none are duplicated.
 Read the comments for all indications.
They should be clear and make sense.
Also, any indication marked “Yes”, “Fair”,
or “Poor” must have a comment.
 Field verification should be performed on
at least 10% of the VI reports as a
minimum. Higher percentages of field
verification may be required for less
experienced personnel or in cases
where previous mistakes have been
found.
Note: All personnel performing this task
should be QC’d regardless of experience.
Baseline Inspection Before Baseline NDE  Review equipment groupings to ensure

Planning inspections that grouping criteria are properly met.
 Review equipment items selected for
inspection to ensure that minimum
percentage criteria (by inspection priority
categories) have been met for each
damage mechanism.
 Ensure that equipment not being
inspected with NDE or VI-Internals have
been properly represented.
NDE Reports Before data entry and  Check that all required fields have been
before updating completed
criticality  Check the validity of thickness readings:
those that are 25% greater than the
nominal or previous reading will need to
be rechecked.
 Readings at or below minimum
thickness require rechecks
 Rechecks involve two steps:
1. Verify the accuracy of the nominal,
previous, and minimum thickness
recorded on the NDE report.
2. Recheck the reading.
 Rechecks will be performed by someone
other than the original inspector and will
occur within 7 days of the original
inspection.
 Above-nominal rechecks can be
performed by the company performing
the NDE (Capstone or other). Rechecks
due to being at or below min. thickness
should be performed by Capstone
personnel only (in the case of another
company performing the NDE)
 Field verify 5% of thickness readings
when subcontractors are used. Field
verification should also be performed
when errors are suspected.
Nonconformance Before transmitting to 

Review NCRs to ensure that all required
Reports (NCRs) the client fields are completed.
 Check the NCR rank to ensure that it is
appropriate for the problem being
reported.
 Verify that a drawing is attached (when
necessary) and that the locations on the
drawing are identified and match those
on the NCR.
Inspection Work Before project  Ensure that each asset has a work plan,
Plans closeout that each work plan has correct criticality
information and the proper intervals are
assigned for each inspection. Each
work plan should have at least a visual
inspection entered on it.
Data Entry  Data collection  Review the criticality report for the unit
forms: before for errors and omissions to check entry
inspection of data collection forms
planning  Review the MS Excel view reports:
“vwAllInspectionData” and
 Visual, Other “vwAllNDEData” for missing data in
Inspection, and required fields. Check 10% of required
NDE reports: values for accuracy by comparing the
before project view report to the original inspection
closeout forms. (See Using Views to Export Data
to MS Excel.)
 Nonconformance  Print out the individual NCRs or the MS
reports: before Excel view report
transmitting to “vwAllNonConformanceData” (for
client multiple NCRs) and check for missing
data in the required fields. Check 10%
of required values for accuracy by
comparing the printed copies to the
original NCRs.
Project Summary  Prior to project  Compare the NDE Summary to the IWP
(Final Report) closeout meeting Summary by checking tasks and
intervals
 Compare the NCR Summary to the NDE
Summary by verifying that all minimum
thickness issues are addressed with
NCRs.
Note: The Project Manager shall verify the
quality of the Project Summary report.
The proposed review requirements are minimum criteria and, when appropriate, should be
increased in order to promote the quality of the project. All Personnel performing tasks on an
RBMISM project will have their work checked for quality, if errors found become repetitive, then
follow-up checks will be performed until the extent of the errors are resolved.
Any Capstone project personnel that have successfully completed the task training for the
deliverables being reviewed can perform the quality checks.
Quality Audits
Project Quality will be audited quarterly by the Project Manager (or designee). Audit results
should be a direct reflection of how well the project is organized, training of new employees to
the project, continuing education of existing employees, quality control process’s of project
tasks, and meeting client expectations. Audit scores are also used to determine if Capstone
project personnel are to receive incentive benefits. In addition to quality, the following criteria
are also assessed during the project audit:
 Safety: Project Safety will be included as part of the quarterly audit and will be subjectively
measured as Passing or Failing in meeting Capstone Engineering Services, Inc. requirements
and Client requirements for performing and documenting regularly scheduled safety meetings
along with complying with personnel protection requirement and inspection safety related
devices.
 Profitability for Capstone Engineering Services, Inc.: The incentive program will provide
for a means to judge profitability for Capstone based on properly documenting changes to the
original scope the project which was defined in Capstone Engineering Services, Inc. Proposal,
identifying and documenting scope changes are a vital part in supporting increases in project
cost and schedule overruns. Profitability will also take into account information obtained from
the office that reflects on project personnel absenteeism and tardiness, quantity of timesheet
errors, achieving timesheet deadlines, and invoice errors along with invoicing delays.
 Client Profitability: should be directly correlated with a projects ability to meet or exceed
schedule constraints while performing project tasks efficiently resulting in meeting or
exceeding budget expectations, communicating project progress on a regularly scheduled
basis and providing documented training of client personnel that will be in charge of resuming
the responsibility of the program after the project has been completed.
 Environmental Impact: will be an objective approach in determining whether or not project

personnel are complying with Capstone Engineering Services, Inc. procedures along with
Client procedures for reporting Non-conformances that reflect a direct concern on releasing or
have the potential to release a process stream into the environment.
Project audit results are documented by the Project Manager on the Project Audit form and
distributed to the Site Coordinator and the MI Department Manager for review and comments.
Subcontractors
Although it does not commonly occur, the Site Coordinator may be required to hire contractors
to perform tasks such as NDE inspection, data entry, and CAD drafting. Capstone only gets
involved in hiring subcontractors when the tasks to be subcontracted are included in the RBMI
project budget. Otherwise, it is the responsibility of the client to select contractors.
As Capstone is responsible for all work performed by subcontractors, it is important that the
Site Coordinator selects the right subcontractors, ensures that the subcontractors work safely,
and ensures that the quality of their work is acceptable.
Selecting Contractors
The best source of information when hiring subcontractors is the client. The client has most
likely already worked with local contractors and can make recommendations as to which ones
are suitable. Also, it is important to confirm with the client that a contractor that you have
selected is acceptable to them.
The Site Coordinator will work with the Project Manager to select subcontractors. The
following areas should be considered and evaluated when selecting a subcontractor:
 Safety – Obtain a copy of the prospective subcontractor’s safety policy and manual.
Verify that all personnel working on site have had the required safety training and site-
specific orientations for that facility. Retain copies of this information in the project files.
 Certifications – (for NDE subcontractors) obtain copies of applicable certifications for

all personnel performing work. Verify that the subcontractor personnel have
certifications for the work to be performed. For example, a person taking UT thickness
readings should have a current certification for UT level II thickness. Verify that all
inspection equipment used by the NDE subcontractor has current calibrations. Retain
copies of certification and calibration information in the project files.
 NDE Procedures – (for NDE subcontractors) Obtain copies of NDE procedures from
the subcontractor for all inspections to be performed and retain this information in the
project files.
 Quality Program – (for NDE subcontractors) Obtain a copy of the NDE subcontractor’s
quality program/manual and retain this information in the project files.
Once a subcontractor has been selected, the Site Coordinator or Project Manager contacts
Capstone office personnel so that they can develop a contract agreement between Capstone
and the subcontractor.
Managing Subcontractors
To ensure successful performance of the subcontractors, the Site Coordinator should manage
the subcontractors as follows:
 Safety – While working on-site, the subcontractors will be included in all Capstone
safety processes including safety meetings and audits.
 Quality – Capstone personnel will verify the quality of the subcontractor’s deliverables
using the guidelines established in this manual (see Reviewing Deliverables). The Site
Coordinator will communicate quality problems to the subcontractor and the Capstone
Project Manager. Quality problems should be resolved by either changing subcontractor
work practices or replacing subcontractor on-site personnel.
5
6
Chapter
 Budget/Schedule – The Site Coordinator will monitor the subcontractor work to ensure
that productivity goals are met. Reviewing completed work on a daily basis and clearly
communicating productivity expectations with the subcontractor before the work begins
can verify this.
The Site Coordinator will also ensure that subcontractor costs are maintained at agreed
upon levels by reviewing subcontractor’s daily and/or weekly time and expense
summaries. These summaries can be verified by confirming the actual hours worked
by the on-site subcontractor personnel, and by comparing rates and expenses on the
summaries to those in the subcontractor’s rate sheets. Copies of subcontractor
time/expense summaries and invoices should be retained in the project files.
Chapter 5 – Using the RBMI

Software
Removed
Please refer to the Software Manual for the operation and latest updates of the Software.
Chapter 6 – Collecting Equipment

Data
Data Collection
Data is collected for equipment items for three reasons:
1. To calculate criticality.
2. Determine the inspection plan.

3. To create an electronic reference for equipment information that would otherwise only be
accessible in paper equipment files.
Assets and Components

Data is collected for both assets and components. Assets correlate to an equipment item or
piping circuit on the equipment lists (for example, a heat exchanger, a piping circuit, a storage
tank). A component is a part of an asset (for example, tubes, channel, and shell are all
components of a heat exchanger).
The types of assets and components available in RBMISM are:

Asset Type Component Type
Pressure Vessels Pressure Vessel
Columns  Top
 Middle
 Bottom
Air Cooled Exchangers  Header
 Tubes
Shell and Tube Exchangers  Shell
 Channel
 Tube Bundle
Piping Pipe
Storage Tanks  Shell
 Bottom
Relief Devices  Location
 Device
The Data Collection Process

The general data collection process is common for all assets and components and is as
follows:
1. Get Equipment List – Make a copy of the equipment or tracking list for the specific
type of equipment that data is to be collected for (see Developing Tracking Lists).
2. Field Verify Equipment – Perform a field verification of the equipment on the

equipment list to ensure that the equipment does exist in the unit, that it is in-service,
and collect all basic information about the equipment (insulated, coated, nameplate
info., etc). Verifying the equipment prior to completing datasheets will save the effort of
collecting information on equipment that may no longer located in the unit or is out of
service. Typical field verification information collected is identified for each equipment
type later in this chapter.
Note: Confirm that field verification is part of the project scope before starting. Some
clients will not pay for or do not want Capstone personnel to perform field verification of
the equipment. After field verification is completed, have client sign equipment list.
3. Gather Data Sources – Collect the information sources needed to fill out the
datasheet. The primary sources of information used should be those agreed to in the
Project Kickoff Meeting. Other sources may be used if the needed information is not
found in the primary ones. Typical data sources will vary depending on the equipment
type and the process facility. Typical data sources are identified for each equipment
type later in this chapter.
4. Complete Datasheets – Make copies of the datasheets for the appropriate equipment
type.
Note 1: Only collect Capstone defined required fields unless otherwise instructed by
client in the kickoff meeting.
Note 2: Level three CUI analysis involves collecting additional data and re-running risk.
Additional fields collected are: For vessels, exchangers, tanks: Insulation type and
condition. For piping: Insulation type and condition, number of penetrations,
terminations, vertical runs, and total piping length.
Note 3: Filling out fields that will be common for all datasheets prior to making copies
will save considerable time when data collecting. For example, the data collectors
name, the unit name, and fields identified from the unit overview (humidity, date in
service, etc.)
Note 4: Datasheets and Software doesn’t consider vessels built to Div. 2. This will
have to be entered manually with the correct stress value from part D.
Fill out the data sheet ensuring that the fields required for criticality and inspection
planning are complete. Required fields are identified for each equipment type later in
this chapter. Ensure that data is collected for all components included in the scope of
work. For example, a column may require data collection for the top, middle, and
bottom.
Completed datasheets should be “logged” on the appropriate tracking list by entering

the date completed and the data collector’s name/initials. The data sheet should then
be submitted for review.
5. Data Discrepancies - If differences are found during data collection between two or
more sources of data, the data should be verified with the client to determine the correct
value and the discrepancy should be documented (see Documenting Data
Discrepancies and Redlines). An example would be if the U-1 for a vessel has a design
pressure that is different from the design pressure identified on the P&ID.
Note: In cases where the client doesn’t determine the correct value, the U1 will be the
overriding factor. This shall be documented and approved by the Site Coordinator.
6. Check Datasheets – All datasheets should be reviewed for completeness and

accuracy prior to data entry (See Reviewing Deliverables).
Note: Attach completed Field Verification Datasheet to the equipment datasheet to
assist in QC effort.
7. Enter Datasheets –There are two different methods of entering datasheet information:
a. RBMI Fixed Equipment Data Import Workbook– There is a MS Excel

Workbook that equipment component data can be entered into and directly
imported into the RBMI software. The workbook contains worksheets for each of
the equipment types (pressure vessels, columns, piping circuits, etc). The file
name for the MS Excel file is RBMI Fixed Equipment Data Import.xls.
Note: In order to maximize efficiency and accuracy, the workbook should not be
imported into the database until all information required for Criticality has been
entered. This includes information from Data Collection, the History Review, the
Corrosion Study, and the Process Review.
Note: if the Data Import Workbook is used to enter the datasheets, the following
items will not be imported:
 Comment Fields
 Line Lists (piping circuits)
 Component Lists (vessels, exchangers, etc.)
 Corrosion Study Data
b. Direct entry into RBMI software – Information from datasheets can be directly
entered into the RBMI software (see Software Manual).
Note: Data entry is performed by a dedicated data entry resource only, not by the Site
Coordinator or Capstone inspection personnel. The Site Coordinator should check with
the Client Project Contact and the Project Manager when a data entry resource is
needed. Data entry is typically included in the project scope of work.
Pressure Vessels
Prior to completing pressure vessel datasheets, field verify the following:
 That the equipment exists
 Nameplate Data
 Material of Construction (C.S. or S.S.)
 That it is in service (not blinded or disconnected)
 Insulated (Y/N) and extent of insulation (if partially insulated)
 External Wetting (Y/N)
The field verification can be documented on the Field Verification Datasheet.
Typical data sources for pressure vessel data collection include:

1. U-1s – can provide design and construction data (typically located in the equipment
files)
2. Specification Sheets– can provide design and construction data (typically located in
the equipment files or job books)
3. Construction Drawings – can provide design and construction data
4. P&IDs – can indicate insulated, insulation type, and design information
The following tables describe the fields of the Pressure Vessel Data Collection Form:
Background Data
Field Name Description Data Source Required Valid Values Example
Date Data collection completion date ---- No Month, day, and year 7/1/2002
in any format
Performed by The name of the person --- No Full name or initials M. Mouse
completing the datasheet
QC The name of the person --- No Full name or initials D. Duck / 7/1/2002
reviewing the datasheet and the and date (month,
date it was reviewed day, and year in any
format)
Equipment ID The identifier assigned to the Pressure Vessel Yes Alphanumeric R-1001A
vessel Tracking List
Operating Unit The process unit the vessel is --- Yes Alphanumeric FCCU
located in
Reliability System The process system the vessel Defined piping Yes Alphanumeric 1301
is assigned to systems
Vessel Type --- --- No Picklist: Reactor
Accumulator
Drum
Filter
Reactor
Receiver
Sphere
Manufacturer Serial ---  U1 No Alphanumeric AF432171

Number
 Spec. Sheet
National Board --- U1 No Numeric 1745
Number
Orientation The position of the equipment  Construction No Picklist: Vertical
as it sits in the field Drawings Horizontal
geometrically. Vertical
 P&ID
 Field Verification
Drawing Number The inspection or construction Drawing files (paper No Alphanumeric DR0001001A
drawing number for the vessel or electronic)
PFD The process flow diagram PFDs No Alphanumeric F009877001
number(s) which contain the
vessel
P&ID The P&ID number(s) that P&IDs No Alphanumeric P0000764005B
contain the vessel
Asset Number ----  Maint. Mgmt. No Alphanumeric 11008743
system
 Equipment list
U1 available Indicates whether or not a Equipment Files Yes Y/N N
ASME U-1 Data Sheet is
available
Description ---  P&IDs Yes, for Alphanumeric 1st stage reactor
clarificatio
 Equipment list n
purposes
Manufacturer --- U1 No User-defined list Nooter Corporation
Design/Construction Data
Field Name Description Data Source(s) Required Valid Values/Units Example
Construction Code The code used for design or  U1 Yes ASME Sect. VIII Div. ASME Sect. VIII Div. 1
construction of the vessel  Spec. Sheet 1
Code Date The edition date of the  U1 No Numeric (yyyy) 1995
construction code  Spec. Sheet
Year Built The year the vessel was  U1 Yes Numeric (yyyy) 1998
constructed  Spec. Sheet
Length Length of equipment in feet  U1 Yes, for Numeric / feet 85
 Spec. Sheet cost
comparis
on
Test Pressure Hydrostatic test pressure  U1 No Numeric / psig 500
 Spec. Sheet
 Nameplate
Gasket Material Material used for flange gaskets  Construction No User-defined list Spiral Wound
Drawings
 Spec. Sheet
Bolting Material Material used in flange bolts  Construction No User-defined list SA 193 B7
Drawings
 Spec. Sheet
Relief Set Pressure The set pressure of the relieving P&IDs No Numeric/ psig 175
device
Relief Valve Number The unique identifier assigned P&IDs No Alphanumeric 1300PSV-001B
to the relief device location
Jacket Type ----  U1 Yes User-defined list Dimple
 Spec. Sheet
 Construction
Drawings
Number of Shell Enter the number of shell  U1 Yes Numeric 4
Courses/Bands courses for the vessels. Note:  Spec. Sheet
Because this value is used in  Construction
the RBMI inspection planning Drawings
module, the number of bands

(every 20’) may be used in this
field instead of courses. Be
sure to include liquid boot shells
if present
Number of Enter the number of heads on  U1 Yes Numeric 2
Heads/Covers the equipment. Be sure to  Spec. Sheet
include liquid boot heads if  Construction
present Drawings
Number of Nozzles Enter the number of nozzles on  U1 Yes Numeric 22
the equipment. Note: This is  Spec. Sheet
where a UT is repeatable. Do  Construction
not count Thermowelds or Drawings
Studded Outlet / Studded Pad.
Internal Entry Whether or not the asset can be  U1 Yes User-defined Picklist: No manway
Possible entered by inspection personnel  Construction Yes
Drawings No
Material Spec. Note: Select SA-283 if material  U1 Yes Pick list: SA-106
spec. isn’t known.  Spec. Sheet See Pressure
 Construction Vessel Material
Drawings Specs. and Grades
Material Grade Note: Select C if material grade  U1 Yes Pick list: B
isn’t known.  Spec. Sheet See Pressure
Design Temperature Note: If the design  U1 Yes Numeric/Degrees F 600
temperature isn’t known, add  Spec. Sheet
100 degrees F to the
operating temperature and
then round up to the nearest
100 degrees.
Design Pressure Note: If the design pressure  U1 Yes Numeric value 250
isn’t known, use the relief set  Spec. Sheet greater than 0 / psig
pressure or 20% above
operation pressure.
Diameter ID of vessel shell  U1 Yes Numeric value 78
 Spec. Sheet greater than zero /
inches
MDMT Minimum design metal  U1 Consult Numeric/Degrees F -20
temperature  Spec. Sheet w/ Site
Coordinat
or
PWHT Indicates whether or not the  U1 Yes Y/N N
vessel material has been post  Spec. Sheet
weld heat treated
PWHT Temperature The heat treat temperature  U1 Yes, if Numeric/Degrees F 750
 Spec. Sheet PWHT
Joint Efficiency Note: Select 0.85 if the joint  U1 Yes Picklist: 1.00
efficiency isn’t known.  Spec. Sheet 1.00
0.90
0.85
0.80
0.70
0.65
0.60
0.55
0.50
0.45
Nominal thickness The nominal thickness of the  U1 Yes Numeric/inches 0.500

shell. Note: If nominal isn’t  Spec. Sheet
known, take reading plus
internal expected corrosion rate
times number of years in
service.
Corrosion Allowance ---  U1 No Numeric/inches 0.0625
 Spec. Sheet
Flange Rating Enter the flange rating for the  U1 No Numeric 300
equipment. If more than one  Spec. Sheet
flange rating exists for the  Construction
equipment, record the smallest. drawings
Insulated ----  Field Verification Yes Y/N N
 Construction
drawings
 P&IDs
Insulation Type ----  Unit Overview No, Picklist: Asbestos
 Construction unless  Asbestos
drawings Level 3  Calcium Silicate
 P&IDs Eval. (CI Free)
 Calcium Silicate
(Not CI Free)
 Foam/Cellular
Glass
 Mineral
Wool/Fiber Glass
Date in Service --- Unit Overview Yes (MM,DD,YYYY) 11/01/1978
Components – (used to run criticality on individual components of vessels)

Column Name Description Data Source(s) Required Valid Values/Units Example
Location A unique identifier for a --- No Alphanumeric 4” inlet nozzle

component of a vessel
Description ---- --- No Alphanumeric C
Material Specification ----  U1 No Alphanumeric A
 Spec. Sheet
 Construction
drawings
Grade ----  U1 No Alphanumeric 40
 Spec. Sheet
 Construction
drawings
Size The nominal size of the  U1 No Numeric value 12
component in inches.  Spec. Sheet greater than zero
 Construction /inches
drawings
Nominal Thickness The nominal thickness of the  U1 No Numeric value 0.125
componet. Note: If nominal  Spec. Sheet greater than zero /
isn’t known, take reading plus  Construction inches
internal expected corrosion rate drawings
service.
Minimum Thickness Minimum required thickness of  U1 No Numeric value .063
the component  Spec. Sheet greater than zero /
 Construction inches
drawings
Date in Service ---- Unit Overview No Numeric / 11/01/1978
(mm/dd/yyyy)
Process Data
Representative Fluid The process fluid contained in Process Review Yes Picklist: C6
the vessel See RBMI Typical
Representative
Fluids
Fluid Phase The phase of the fluid in the Process Review Yes Liquid/Gas Gas
vessel. For mixed phases,
select liquid.
Operating Pressure --- Process Review Yes Numeric value 150
greater than zero /
psig
Operating --- Process Review Yes Numeric value 275

Temperature greater than –459.66
/ degrees F
Toxic Fluid --- Process Review Yes Picklist: H2S
ACR (Acrolein)
AN (Acrylonitrile)
BF3
Chlorine
CO
EO
H2S
HCHO
HCL
HCN
HF
Hydrazine
Methyl Mercaptan
NH3
Perchloromethylme
rcaptan
Phosgene
Propionitrile
Propylene Oxide
Sulfur Trioxide
VAM
Toxic Percentage The percentage of toxic in the Process Review Yes Numeric value 5.5
representative process stream between 0 and 100.
Process Service The type of fluid contained in --- No User-defined list Light Hydrocarbon
the vessel
Process System ? ? ? ? ?
Corrosion Study Data

Impact Test Indicates whether or not the  Spec. Sheet No Y/N and Y/?
(checkbox) vessel had impact tests  Equipment File alphanumeric
performed and the results of the
impact tests
Impact Test Value The results of impact tests  Spec. Sheet No Alphanumeric ?
 Equipment File
Stabilized Indicates whether or not the  Spec. Sheet No Y/N N
steel is stabilized  Equipment File
Annealed Indicates whether or not the  Spec. Sheet No Y/N N

steel is annealed  Equipment File
Stable Scale Indicates whether or not the  Spec. Sheet No Y/N Y

HIC Steel Indicates whether or not the  Spec. Sheet No Y/N Y

steel is HIC  Equipment File
Sensitized Indicates whether or not the  Spec. Sheet No Y/N Y

steel is sensitized  Equipment File
Contaminant 1 and 2 The name of a contaminant Vessel Process No Alphanumeric ?

present in the process service Conditions
Concentration 1 and Percentage of a contaminant in Vessel Process No Numeric value 10
2 the process service. Conditions greater than zero up
to 100.
Expected Internal ---- Corrosion Study Ye Numeric value 0.001
Corrosion Rate greater than zero /
inches per year
Internal Corrosion The expected corrosion type for  Corrosion Study Yes Select from list Pitting
Type the component (General, Localized,
 Inspection History Pitting)
Pitting Potential The likelihood for pitting Corrosion Study Yes, if call Select from list (Low, Medium
damage to occur to the out in Medium, High)
component Corrosion
Study
Lining/Coating The lining or coating type  Spec. Sheet Yes, if call Alphanumeric Teflon
out in
 Construction Corrosion
drawings Study
Corrosion Loop The corrosion loop number from Corrosion Study No Alphanumeric 012
Number the corrosion loop diagram that
contains the vessel.
Corrosion The potential source or cause of Corrosion Study No User-defined list Amine
Mechanism the internal corrosion.
Corrosion Loop ---- Corrosion Study No Alphanumeric Lean amine feed
Description
Predictable Whether or not the potential Corrosion Study Yes, if Y/N and Y / Dead legs
Locations locations for internal corrosion isolated Alphanumeric
can be predicted and corrosion
description of the locations exist.
Operating The process temperature at the  Process Review No Numeric / degrees F 250
Temperature –In inlet of the vessel
 Temperature
gauges
Temperature – Out outlet of the vessel
 Temperature
gauges
Water Present Is there a presence of water in Vessel Process No Y/N and numeric Y / 12
(checkbox) process service and what Conditions value between 0 and
percentage 100
PH The pH level of the process Vessel Process No Numeric value from 11.5
service Conditions 0 to 14
Coating Type The type of coating applied  Unit Overview Yes Select from list Average
under the insulation – Select (none, average or
none for no coating applied or if  Field Verification best)
only a primer is applied; Select  Spec. Sheet
average for standard coatings
 Equipment File
such as epoxy; Select best for
immersion grade coatings.  Construction
drawings
Area Humidity ---- Unit Overview Yes Select from list (low, Medium
medium, high)
External Wetting Is there an external source for Field Verification Yes Y/N N
the vessel to become wet or
saturated? Note: Cooling
water spray should be
considered based on if it’s a
constant wetting throughout the
year.
Intermittent Service Whether or not the component Vessel Process Yes Yes/No Y
is not in continuous service. Conditions
Traced ----  P&IDs No Select from list Steam
(steam or electric)
Expected External ---- Corrosion Study No Numeric/inches per 0.003
Corrosion Rate year
Other Damage ---- Corrosion Study Yes User-defined list Creep

Mechanism
Other Damage The potential for other damage Corrosion Study Yes Select from list (high, High
Mechanism Potential mechanisms medium, low)
Other Damage The probability for other Corrosion Study Yes Picklist: 2
Mechanism damage mechanisms
Probability 1, 2, 3, 4, 5, N/A
Corrosion Study Name of person noting Corrosion Study No Alphanumeric Y. Sam

Comments Name corrosion study comment
Corrosion Study Date of corrosion study Corrosion Study No Numeric / 12/10/1938
Comments Date comment (MM/DD/YYYY)
Corrosion Study Comments from corrosion study Corrosion Study No Alphanumeric Thermal fatigue
Comments cracking has been
documented at the last
two inspections.
Environmental Cracking Study

Environmental ---- Corrosion Study Yes Picklist: Polythionic Acid SCC

Cracking Mechanism (PTA)
Amine Cracking
(ASCC)
Carbonate
Cracking
Caustic Cracking
Chloride Stress
Corrosion Cracking
(Cl SCC)
Hydrofluoric Acid
(SOHIC, HIC,
HSC)
Polythionic Acid
SCC (PTA)
Wet H2S
(Blistering, SOHIC,
HIC, SSC)
Environmental ---- Corrosion Study Yes Picklist: High

Cracking Initial
Potential High, Medium, Low
Initial Potential Not required --- No --- ---
Description
Environmental The name of the potential Corrosion Study No Alphanumeric ?
Cracking Agent 1 cracking agent
and 2
Environmental Percent concentration of the Corrosion Study No Numeric value 22.5
Cracking Agent cracking agent greater than zero up
Concentration 1 and to 100.
2
Steam Out Indicates whether or not a Corrosion Study No Yes/No Y
(checkbox) steam out is used on the vessel
Environmental Name of person noting Corrosion Study No Alphanumeric B. Bunny
Cracking Study environmental cracking study
Comments Name comment
Environmental Date of environmental cracking Corrosion Study No Numeric / 10/20/1940

Cracking Study study comment (MM/DD/YYYY)
Comments Date
Environmental Comments from environmental Corrosion Study No Alphanumeric No cracking found at PT
Cracking Study cracking study inspection of welds
Comments during last T/A.
Columns
Prior to completing column datasheets, field verify the following:
 Nameplate Data
 Material of Construction (C.S. or S.S.)
 Insulated (Y/N) and extent of insulation (if partially insulated)
Typical data sources for column data collection include:

files)
The following tables describe the fields of the Column Data Collection Form:
Note: Only collect middle data if there is a process or material change.
Background Data
in any format
format)
Equipment ID The identifier assigned to the Tracking List Yes Alphanumeric T-1001A
column
Operating Unit The process unit the column is --- Yes Alphanumeric FCCU
located in
System The process system the column Defined piping Yes Alphanumeric 1301
is assigned to systems
Column Type Classification of the column --- No User-defined picklist: Trayed
Packed
Trayed
Manufacturer Serial ---  U1 No Alphanumeric AF432171
Number
 Spec. Sheet
Number
drawing number for the column or electronic)
column
contain the column
system
 Equipment list
available
Description ---  P&IDs Yes, for Alphanumeric Fractionation Tower
clarificatio
purposes
Design/Construction Data – Column

construction of the column  Spec. Sheet 1
Year Built The year the column was  U1 Yes Numeric / (YYYY) 1998
Height Height of the column in feet  U1 Yes, for Numeric / feet 85
comparis
on
Test Pressure Hydrostatic or pneumatic test  U1 No Numeric / psig 500
pressure  Spec. Sheet
 Nameplate
Drawings
 Spec. Sheet
Drawings
 Spec. Sheet
device
Internal Entry Whether or not the asset can be  U1 Yes User-defined Picklist: No manway
Possible entered by inspection personnel  Construction Yes
Drawings No
Courses/Bands courses for the column. Note:  Spec. Sheet
Because this value is used in  Construction
the RBMI inspection planning Drawings
module, the number of bands
may be used in this field instead
of courses.
Number of ---  U1 Yes Numeric 2
Heads/Covers  Spec. Sheet
 Construction
Drawings
Number of trays ---  Construction No Numeric 16
Drawings
 Spec. Sheet
Design/Construction Data – Top, Middle, Bottom

Design Temperature Note: If the design temperature  U1 Yes Numeric/Degrees F 600
isn’t known, add 100 degrees F  Spec. Sheet
to the operating temperature
and then round up to the
nearest 100 degrees.
operation pressure.
Diameter ID of column shell  U1 Yes Numeric value 78
inches
Coordinat
or
column material has been post  Spec. Sheet
weld heat treated
0.90
0.85
0.80
0.70
0.65
0.60
0.55
0.50
0.45
Nominal thickness Nominal thickness of the shell  U1 Yes Numeric/inches 0.500

Note 1: Use the thinnest  Spec. Sheet
thickness if different thicknesses
for each shell / component.
Note 2: If nominal isn’t known,
take reading plus internal
expected corrosion rate times
number of years in service.
 Spec. Sheet
 Construction
drawings
 P&IDs
(Not CI Free)
 Foam/Cellular
Glass
 Mineral
Wool/Fiber Glass
Components - Top, Middle, Bottom– used to run criticality on individual components of

columns

component of a column
 Spec. Sheet
 Construction
drawings
 Spec. Sheet
 Construction
drawings
drawings
Nominal Thickness Nominal thickness of the  U1 No Numeric value 0.125
component. Note 1: Use the  Spec. Sheet greater than zero /
thinnest thickness if different  Construction inches
thicknesses for each shell / drawings
componet. Note 2: If nominal
isn’t known, take reading plus
service.
drawings
(mm/dd/yyyy)
Process Data – Top, Middle, Bottom

the column section.
See RBMI Typical
Representative
Fluids
column section. For mixed
phases, select liquid.
greater than zero /
psig
/ degrees F
ACR (Acrolein)
AN (Acrylonitrile)
BF3
Chlorine
CO
EO
H2S
HCHO
HCL
HCN
HF
Hydrazine
Methyl Mercaptan
NH3
Perchloromethylme
rcaptan
Phosgene
Propionitrile
Propylene Oxide
Sulfur Trioxide
VAM
the column section

(checkbox) column had impact tests  Equipment File alphanumeric
impact tests
 Equipment File





to 100.
Expected Internal ---- Corrosion Study No Numeric value 0.001
inches per year

component Corrosion
Study
Lining/Coating The lining or coating type  Spec. Sheet No Alphanumeric Teflon
 Construction
drawings
contains the column.
Description
Predictable Whether or not the potential Corrosion Study No Y/N and Y / Dead legs
Locations locations for internal corrosion Alphanumeric
can be predicted and
description of the locations
Temperature –In inlet of the column
 Temperature
gauges
Temperature – Out outlet of the column
 Temperature
gauges
Water Present Is there a presence of water in Process Review No Y/N and numeric Y / 12
(checkbox) process service and what value between 0 and
percentage 100
PH The pH level of the process Process Review No Numeric value from 11.5
service 0 to 14
 Equipment File
drawings
medium, high)
the column to become wet or
year.
Intermittent Service Whether or not the component Vessel Process No Yes/No Y
(steam or electric)
Corrosion Rate year
Mechanism

two inspections.


Amine Cracking
(ASCC)
Carbonate
Cracking
Caustic Cracking
Chloride Stress
Corrosion Cracking
(Cl SCC)
Hydrofluoric Acid
(SOHIC, HIC,
HSC)
Polythionic Acid
SCC (PTA)
Wet H2S
(Blistering, SOHIC,
HIC, SSC)

Cracking Initial
Description
and 2
2
Comments Date
Cracking Study inspection of welds
Comments cracking study during last T/A.
Air Cooled Exchangers

Prior to completing air cooled exchanger datasheets, field verify the following:
 Nameplate data
 Material of construction (CS or SS)
Typical data sources for air cooler data collection include:

files)
4. P&IDs – can indicate design information
The following tables describe the fields of the Air Cooled Exchanger Data Collection Form:
Background Data
in any format
format)
Equipment ID The identifier assigned to the air Tracking List Yes Alphanumeric AC1001A
cooler
Operating Unit The process unit the air cooler --- Yes Alphanumeric FCCU
is located in
System The process system the air Defined piping Yes Alphanumeric 1301
cooler is assigned to systems
Manufacturer Serial ---  U1 No Alphanumeric AC432171
Number
 Spec. Sheet
Number
Orientation The position of the equipment  Construction No Picklist: Horizontal
as it sits in the field drawings
geometrically. Horizontal
Vertical
drawing number for the air or electronic)
cooler
number(s) which contain the air

cooler
contain the air cooler
Asset Number ----  Maint. Mgmt. Yes, for Alphanumeric 11008743
system clarificatio
n
 Equipment list purposes
available
Description ---  P&IDs No Alphanumeric Number 1 overhead
cooler
 Equipment list
Design/Construction Data – Header

construction of the air cooler  Spec. Sheet 1
Year Built The year the air cooler was  U1 Yes Numeric / (YYYY) 1998
Draft Indicate if the air cooler has fans  U1 No Picklist: Forced
(forced) or relies on natural air  Spec. Sheet Natural
movement (natural) Forced
Drawings
 Spec. Sheet
Drawings
 Spec. Sheet
Partial Internal Visual Whether or not visual access is  U1 Yes Y/N Y
Possible available to the ID of the header  Construction
box and tubes Drawings
Number of Fans ---  U1 No Numeric 2
 Spec. Sheet
 Construction
Drawings
Number of Headers ---  U1 Yes Numeric 2
 Spec. Sheet
 Construction
Drawings
operation pressure.
Diameter The calculated equivalent  U1 Yes Numeric value 11.5
diameter of the header box  Spec. Sheet greater than zero /
using the following formula(all inches
units in inches):
D = (W+H) 2 divided by 3.14
D = equivalent diameter
W = header box width
(plugsheet to tubesheet)
H = height of header box
Coordinat
or
header box material has been  Spec. Sheet
post weld heat treated
0.90
0.85
0.80
0.70
0.65
0.60
0.55
0.50
0.45

header box. Note: If nominal  Spec. Sheet
isn’t known, take reading plus
internal expected corrosion
rate times number of years in
service or compare to similar
coolers or consult Risk
Engineer.

 Spec. Sheet
Header Type Whether or not the header has  U1 Yes Picklist: Box & Plug
a plug sheet or is welded  Construction Box & Plug
drawings Welded
 Spec. Sheet
device
Test Pressure The hydrostatic or pneumatic  U1 No Numeric/ psig 250
pressure the air cooler was  Spec. Sheet
tested to
Plug Type ---  U1 No Alphanumeric ?
 Construction
drawings
 Spec. Sheet
Plug Material ---  U1 No Alphanumeric ?
 Construction
drawings
 Spec. Sheet
Components – Header, Tubes – used to run criticality on individual components of air coolers

component of an air cooler
 Spec. Sheet
 Construction
drawings
 Spec. Sheet
 Construction
drawings
drawings
component. Note: If nominal  Spec. Sheet greater than zero /
Engineer.
drawings
(mm/dd/yyyy)
Process Data
the air cooler. See RBMI Typical
Representative
Fluids
Fluid Phase The phase of the fluid in the air Process Review Yes Liquid/Gas Gas
cooler. For mixed phases,
select liquid.
greater than zero /
psig
/ degrees F
ACR (Acrolein)
AN (Acrylonitrile)
BF3
Chlorine
CO
EO
H2S
HCHO
HCL
HCN
HF
Hydrazine
Methyl Mercaptan
NH3
Perchloromethylme
rcaptan
Phosgene
Propionitrile
Propylene Oxide
Sulfur Trioxide
VAM
the air cooler
Design/Construction Data – Tubes

tested to
Number of Tubes ---  U1 No Numeric 300
 Spec. Sheet
 Construction
Drawings
Number of Rows ---  U1 No Numeric 8
 Spec. Sheet
 Construction
Drawings
Tube-Tubes Sheet ---  U1 No Picklist: Rolled
Joint  Spec. Sheet Rolled
 Construction Welded
Drawings Rolled & Welded
Welded or Seamless --  U1 No Welded or Seamless Seamless
Tubes  Spec. Sheet
 Construction
Drawings
operation pressure.
device
Material Spec. Note: If material specs aren’t  U1 Yes Pick list: SA-106
known, select SA-214 or carbon  Spec. Sheet See Pressure
steel and SA-249 if stainless  Construction Vessel Material
steel. Drawings Specs. and Grades
Material Grade Note: If material grades aren’t  U1 Yes Pick list: B
known, select Wld Tube for  Spec. Sheet See Pressure
carbon steel and 316L if  Construction Vessel Material
stainless steel. Drawings Specs. and Grades
MDMT Minimum design metal  U1 No Numeric/Degrees F -20
temperature  Spec. Sheet
 Spec. Sheet
tubes. Note: If nominal isn’t  Spec. Sheet
Engineer.
Diameter The OD of the tubes  U1 Yes Numeric value 1.00

inches
Fin Type ---  U1 No Alphanumeric ?
 Construction
drawings
 Spec. Sheet
Fin Material ---  U1 No Alphanumeric ?
 Construction
drawings
 Spec. Sheet

Impact Test Indicates whether or not the air  Spec. Sheet No Y/N and Y/?
(checkbox) cooler had impact tests  Equipment File alphanumeric
impact tests
 Equipment File





to 100.
inches per year
component Corrosion
Study
 Construction
drawings

contains the air cooler.
Description
Predictable Whether or not the potential Corrosion Study No Y/N and Y / Stagnant areas in
Locations locations for internal corrosion Alphanumeric header box
Temperature –In inlet of the air cooler
 Temperature
gauges
Temperature – Out outlet of the air cooler
 Temperature
gauges
percentage 100
 Equipment File
drawings
medium, high)
the air cooler to become wet or
year.
(steam or electric)
Corrosion Rate year
Mechanism


two inspections.


Amine Cracking
(ASCC)
Carbonate
Cracking
Caustic Cracking
Chloride Stress
Corrosion Cracking
(Cl SCC)
Hydrofluoric Acid
(SOHIC, HIC,
HSC)
Polythionic Acid
SCC (PTA)
Wet H2S
(Blistering, SOHIC,
HIC, SSC)

Cracking Initial
Description
and 2
2
Comments Date
Shell and Tube Heat Exchangers

Prior to completing shell and tube exchanger datasheets, field verify the following:
 Nameplate data
 Material of construction (C.S. or S.S.)
 Insulated (Y/N) and to what extent- (Example: channel not insulated)
Typical data sources for shell and tube exchanger data collection include:
files)
The following tables describe the fields of the Shell and Tube Heat Exchanger Data Collection
Form:
Background Data
in any format
format)
Equipment ID The identifier assigned to the Tracking List Yes Alphanumeric E-1001A
heat exchanger
Operating Unit The process unit the heat --- Yes Alphanumeric FCCU
exchanger is located in
Reliability System The process system the heat Defined piping Yes Alphanumeric 1301
exchanger shell is assigned to systems
Exchanger Type ---  Spec. Sheet No User-defined picklist: Shell & Tube
Core
 Construction
Double Pipe
Drawings
Kettle
Plate & Frame
Shell & Tube
Spiral Tube
Steam Drum
Manufacturer Serial ---  U1 No Alphanumeric AC432171

Number
 Spec. Sheet
Number
Orientation The position of the vessel as it  Construction No Picklist: Horizontal
sits in the field geometrically. drawings
Horizontal
Vertical
drawing number for the heat or electronic)
exchanger
heat exchanger
contain the heat exchanger
system
 Equipment list
available
Description ---  P&IDs Yes, for Alphanumeric 2nd stage condenser
clarificatio
purposes
Design/Construction Data – Shell

construction of the heat  Spec. Sheet 1
exchanger
Year Built The year the heat exchanger  U1 Yes Numeric / (YYYY) 1998
was constructed  Spec. Sheet
TEMA Type A three-letter designation that  U1 No Alphanumeric BEM
defines the shell and closure  Spec. Sheet
configurations. (see API 572,  Construction
figure 7) drawings
Length Length of equipment in feet  U1 Yes, for Numeric / feet 22
comparis
on
Drawings
 Spec. Sheet
Drawings
 Spec. Sheet
Internal Entry Whether or not inspection  U1 Yes User-defined Picklist: No manway
Possible personnel can access the ID of  Construction Yes
the exchanger Note: Select No Drawings No
if fixed tubesheet.
Courses courses. Be sure to include  Spec. Sheet
bonnet cover shells and boot  Construction
shells if present Drawings
Number of Enter the number of  U1 Yes Numeric 2
Heads/Covers heads/covers. Be sure to  Spec. Sheet
include liquid boot heads if  Construction
present. Drawings
operation pressure.
Diameter ID of exchanger shell  U1 Yes Numeric value 78
inches
Coordinat
or
shell material has been post  Spec. Sheet
weld heat treated
0.90
0.85
0.80
0.70
0.65
0.60
0.55
0.50
0.45

shell. Note: If nominal isn’t  Spec. Sheet
shell and tube exchangers or
consult Risk Engineer.

 Spec. Sheet
 Construction
drawings
 P&IDs
(Not CI Free)
 Foam/Cellular
Glass
 Mineral
Wool/Fiber Glass
device
pressure the heat exchanger  Spec. Sheet
shell was tested to
Components – Shell, Channel, Tube Bundle – used to run criticality on individual

components of shell and tube exchangers

component of a shell and tube
exchanger
 Spec. Sheet
 Construction
drawings
 Spec. Sheet
 Construction
drawings
drawings
component . Note: If nominal  Spec. Sheet greater than zero /
drawings
(mm/dd/yyyy)
Process Data – Shell, Channel

the exchanger component. See RBMI Typical
Representative
Fluids
exchanger component. For
mixed phases, select liquid.

greater than zero /
psig
/ degrees F
ACR (Acrolein)
AN (Acrylonitrile)
BF3
Chlorine
CO
EO
H2S
HCHO
HCL
HCN
HF
Hydrazine
Methyl Mercaptan
NH3
Perchloromethylme
rcaptan
Phosgene
Propionitrile
Propylene Oxide
Sulfur Trioxide
VAM
the exchanger component
Design/Construction Data – Channel

operation pressure.
Diameter ID of exchanger channel  U1 Yes Numeric value 55
inches
MDMT Minimum design metal  U1 No Numeric/Degrees F -20
temperature  Spec. Sheet
channel material has been post  Spec. Sheet
weld heat treated
PWHT Temperature The heat treat temperature  U1 No Numeric/Degrees F 1000
 Spec. Sheet
0.90
0.85
0.80
0.70
0.65
0.60
0.55
0.50
0.45

channel. Note: If nominal isn’t  Spec. Sheet
 Spec. Sheet
 Construction
drawings
 P&IDs
Insulation Type ----  Unit Overview Yes Picklist: Asbestos
 Construction  Asbestos
drawings  Calcium Silicate
 P&IDs (CI Free)
(Not CI Free)
 Foam/Cellular
Glass
 Mineral
Wool/Fiber Glass
device
pressure the heat exchanger  Spec. Sheet
channel was tested to
Design/Construction Data – Tube Bundle

Bundle Type ---  U1 No Picklist: U-Tube
 Spec. Sheet Straight
U-Tube
Number of Tubes ---  U1 No Numeric 300
 Spec. Sheet
 Construction
Drawings
Welded or Seamless --  U1 No Welded or Seamless Seamless
Tubes  Spec. Sheet
 Construction
Drawings
Tube-Tubes Sheet ---  U1 No Picklist: Rolled
Joint  Spec. Sheet Rolled
 Construction Welded
Drawings Rolled & Welded
tubes have been post weld heat  Spec. Sheet
treated
PWHT Temperature The heat treat temperature  U1 No Numeric/Degrees F 750
 Spec. Sheet
operation pressure.
tested to
Material Spec. Note: If material specs aren’t  U1 Yes Pick list: SA-106
known, select SA-214 or carbon  Spec. Sheet See Pressure
steel and SA-249 if stainless  Construction Vessel Material
steel. Drawings Specs. and Grades
Material Grade Note: If material grades aren’t  U1 Yes Pick list: B
known, select Wld Tube for  Spec. Sheet See Pressure
carbon steel and 316L if  Construction Vessel Material
stainless steel. Drawings Specs. and Grades
Coordinat
or
Tube Nominal The nominal thickness of the  U1 Yes Numeric/inches 0.109
thickness tubes. Note: If nominal isn’t  Spec. Sheet
Tube Diameter The OD of the tubes  U1 Yes Numeric value 1.00
inches
 Spec. Sheet
Corrosion Study Data – Shell, Channel, Tube Bundle

(checkbox) exchanger component had  Equipment File alphanumeric
impact tests performed and the
results of the impact tests
 Equipment File





to 100.
Expected Internal ---- Corrosion Study Yes Numeric value 0.001
inches per year
Pitting Potential The likelihood for pitting Corrosion Study No Select from list (Low, Medium
damage to occur to the Medium, High)
component
 Construction
drawings
contains the exchanger
component.
Description
Predictable Whether or not the potential Corrosion Study No Y/N and Y / Stagnant areas in
Locations locations for internal corrosion Alphanumeric header box
Temperature –In inlet of the exchanger
component  Temperature
gauges
Temperature – Out outlet of the exchanger
component  Temperature
gauges
percentage 100
 Equipment File
drawings
medium, high)
the exchanger component to
become wet or saturated?
Note: Cooling water spray
should be considered based on
if it’s a constant wetting
throughout the year.
 Field Verification (steam or electric)

Corrosion Rate year
Mechanism

two inspections.
Environmental Cracking Study – Shell, Channel, Tube Bundle


Amine Cracking
(ASCC)
Carbonate
Cracking
Caustic Cracking
Chloride Stress
Corrosion Cracking
(Cl SCC)
Hydrofluoric Acid
(SOHIC, HIC,
HSC)
Polythionic Acid
SCC (PTA)
Wet H2S
(Blistering, SOHIC,
HIC, SSC)

Cracking Initial
Description
and 2
2
(checkbox) steam out is used on the
exchanger component

Comments Date
Piping Circuits
Prior to completing piping circuit datasheets, field verify the following:
 That the circuit exists
 Insulated (Y/N)
 Soil-Air Interface (Y/N)
 Injection Point Circuit (Y/N)
 Representative pipe size
 Tracing (Y/N) and Tracing type (electric or steam)
 Estimated length
Typical data sources for piping circuit data collection include:

1. “Circuitized” P&IDs – can provide information including line size, insulated (Y/N),
insulation type, line specification, and location of injection points.
2. Piping Specifications – provide information including design conditions, schedules,
material of construction
3. Line Lists – (from the project books) can provide information including design
conditions, insulated (Y/N) and insulation type
The following tables describe the fields of the Piping Data Collection Form:
Background Data
in any format
format)
Circuit ID The identifier assigned to the  Piping Yes Alphanumeric 1301A
piping circuit System/Circuit ID
Log or,
 Circuit Tracking
List
Operating Unit The process unit the circuit is ‘--- Yes Alphanumeric FCCU
located in
Reliability System The piping system the circuit is Piping Yes Alphanumeric 1301
assigned to System/Circuit ID
Log
Drawing Number The isometric inspection or  Line list No Alphanumeric ISO1301A

construction drawing number
for the circuit  Drawing files
(paper or
electronic)
Soil-Air Interface Indicates whether or not the  Field verification Yes Y/N Y
circuit has soil-air interface(s) or,
 P&IDs
Injection Point Circuit Indicates whether or not the  Field verification Yes Y/N N
circuit contains injection point(s) or,
 P&IDs
Chemical Injected The name of the chemical being  PFDs No Alphanumeric Methanol
injected
 P&IDs
piping circuit
P&ID The P&ID number(s) that Circuitized P&IDs No Alphanumeric P0000764005B
contain the piping circuit
Circuit Description Description of where the piping Circuitized P&IDs Yes Alphanumeric R1001A 1st Stage
From circuit starts Reactor
Circuit Description To Description of where the piping Circuitized P&IDs Yes Alphanumeric E1005A Interstage
circuit ends Cooler
Line List – (the lines that are included in the defined piping circuit)
Line Number The line identifier for each line in Circuitized P&IDs No Alphanumeric 1181C-6”-A
the defined piping circuit
Pipe Specification The piping specification number Circuitized P&IDs No Alphanumeric C
for the line
Nominal Size The nominal line size (in inches) Circuitized P&IDs No Numeric/Inches 6
for the line
Pipe Schedule --- Piping Specifications No Alphanumeric 40
Flange Rating Enter the flange rating for the Piping Specifications No Numeric 150
equipment. If more than one
flange rating exists for the
equipment, record the smallest.
Insulation Type ---  Line list No, Alphanumeric Asbestos
unless
 Piping Level 3
Specifications Eval.
Tracing Type The type of heat tracing on the  Field Verification No Alphanumeric Steam
line
 Circuitized P&IDs
Construction Code The code used for design or  Line list Yes ASME B31.3 ASME B31.3
construction of the piping circuit
 Piping
Specifications
Code Date The edition date of the  Line list No Numeric (yyyy) 1995
construction code
 Piping
Specifications
Year Built --- Unit Overview Yes Numeric (yyyy) 1978
Relief Set Pressure The set pressure of the relieving Circuitized P&IDs No Numeric/ psig 175
device
Relief Valve Number The unique identifier assigned Circuitized P&IDs No Alphanumeric 1300PSV-001B
Gasket Material Material used for flange gaskets Piping Specifications No User-defined list Spiral Wound
Bolting Material Material used in flange bolts Piping Specifications No User-defined list SA 193 B7
Jacket Type ----  Circuitized P&IDs No User-defined list ?
 Piping
Specifications
Partial Internal Visual Whether or not the asset can be ? ? Y/N Y
Possible entered by inspection personnel
Material Spec. Note: Select SA-283 if material Piping Specifications Yes Pick list: SA-105
spec. isn’t known. API-5L
SA-105
SA-106
SA-182
SA-202
SA-203
SA-204
SA-216
SA-234
SA-240
SA-283
SA-285
SA-312
SA-333
SA-335
SA-350
SA-36
SA-387
SA-515
SA-516
SA-53
SB-337
Material Grade Note: Select C if material grade Pipe Specifications Yes Picklist: B
isn’t known. 1, 11, 2, 3, 304,
304L, 316, 316L,
321, 347, 405, 410,
55, 6, 60, 65, 70, A,
B, C, D, E, F1,
F304, F304L,
F316, F316L,
F321, LF-2, P1,
P11, P12, P9,
TP304, TP304L,
TP316, TP316L,
TP321, TP347,
WPB
Design Temperature Note: If the design temperature  Line List Yes Numeric/Degrees F 600
isn’t known, add 100 degrees F
to the operating temperature  Piping
and then round up to the Specifications
Design Pressure Note: If the design pressure  Line List Yes Numeric value 250
isn’t known, use the relief set greater than 0 / psig
pressure or 20% above  Piping
operation pressure. Specifications
MDMT Minimum design metal Piping Specifications Consult Numeric/Degrees F -20

temperature w/ Site
Coordinat
or
PWHT Indicates whether or not the Piping Specifications Yes Y/N N
piping material has been post
weld heat treated
PWHT Temperature The heat treat temperature Piping Specifications Yes, if Numeric/Degrees F 750
PWHT
Joint Efficiency Note: Select 0.85 if the joint Piping Specifications Yes Picklist: 1.00
efficiency isn’t known. Select 1.00
1.0 if seamless pipe. 0.90
0.85
0.80
0.70
0.65
0.60
0.55
0.50
0.45
Representative The nominal thickness of the Piping Specifications Yes Numeric/inches 0.125
Thickness representative line size for the
piping circuit
Corrosion Allowance --- Piping Specifications No Numeric/inches 0.0625
 Line List
 Circuitized P&IDs
 Piping  Asbestos
Specifications  Calcium Silicate
(CI Free)
 Line List  Calcium Silicate
(Not CI Free)
 Circuitized P&IDs  Foam/Cellular
Glass
 Mineral
Wool/Fiber Glass
Estimated length The estimated total length of the  Field Verification No Numeric/feet 129
piping circuit
 Inspection
Drawings/Isos
Representative Size The largest nominal size of the  Field Verification Yes Picklist: 6” pipe
representative line for the piping ¾” Pipe
circuit. Note: In some cases it  Circuitized P&IDs Note: Do not show the
1” Pipe inch marks or pipe when
may not be the larger size due 1.5” Pipe
to footage of piping involved. using the import spread
2” Pipe sheet.
Refer to Site Coordinator for 2.5” Pipe
such instances. 3” Pipe
4” Pipe
5” Pipe
5” Pipe
8” Pipe
10” Pipe
12” Pipe
14” Pipe
16” Pipe
18” Pipe
20” Pipe
24” Pipe
30” Pipe
36” Pipe
40” Pipe
42” Pipe
48” Pipe
54” Pipe
60” Pipe
>60” Pipe
Representative Pipe The pipe specification of the Circuitized P&IDs No Alphanumeric B
Spec. representative line for the piping
circuit
Representative The schedule of the Piping Specifications No Alphanumeric 40
Schedule representative line size for the
piping circuit
Components – (used to run criticality on individual components of piping circuits)

Location A unique identifier for a --- No Alphanumeric 1185C-12”-A

component of a piping circuit
Material Specification ---- Piping Specifications No Alphanumeric A
Grade ---- Piping Specifications No Alphanumeric 40
Size The nominal size of the  Field Verification No Numeric value 12
component in inches. greater than zero
 Circuitized P&IDs /inches
Nominal Thickness Nominal thickness of the Piping Specifications No Numeric value 0.125
component. Note: If nominal greater than zero /
isn’t known, take reading plus inches
service.
Minimum Thickness Minimum required thickness of Unit Overview No Numeric value .063
the component greater than zero /
inches
(mm/dd/yyyy)
Process Data
the circuit. See RBMI Typical
Representative
Fluids
circuit. For mixed phases select
liquid.
greater than zero /
psig
/ degrees F

ACR (Acrolein)
AN (Acrylonitrile)
BF3
Chlorine
CO
EO
H2S
HCHO
HCL
HCN
HF
Hydrazine
Methyl Mercaptan
NH3
Perchloromethylme
rcaptan
Phosgene
Propionitrile
Propylene Oxide
Sulfur Trioxide
VAM
the circuit

Impact Test Indicates whether or not the Piping Specifications No Y/N and Y/?
(checkbox) piping circuit had impact tests alphanumeric
impact tests
Impact Test Value The results of impact tests Piping Specifications No Alphanumeric ?
Stabilized Indicates whether or not the Piping Specifications No Y/N N
steel is stabilized
Annealed Indicates whether or not the Piping Specifications No Y/N N
steel is annealed
Stable Scale Indicates whether or not the Piping Specifications No Y/N Y
steel is stabilized
HIC Steel Indicates whether or not the Piping Specifications No Y/N Y
steel is HIC
Sensitized Indicates whether or not the Piping Specifications No Y/N Y
steel is sensitized
to 100.
Expected Internal ---- Corrosion Study Yes Numeric value 0.001
inches per year
component
Lining/Coating The lining or coating type Piping Specifications No Alphanumeric Teflon
contains the piping circuit.
Description
Temperature –In inlet of the circuit
 Temperature
gauges
Operating The process temperature ate  Process Review No Numeric / degrees F 400
Temperature – Out the outlet of the circuit
 Temperature
gauges
percentage 100
only a primer is applied; Select
 Construction
drawings
immersion grade coatings.
medium, high)
the vessel to become wet or
year.
Tracing ----  Circuitized P&IDs No Select from list Steam
(steam or electric)
Corrosion Rate year
Mechanism


Corrosion Study Comments from corrosion study Corrosion Study No Alphanumeric This circuit has
Comments experienced creep
damage in the past 10
years.


Amine Cracking
(ASCC)
Carbonate
Cracking
Caustic Cracking
Chloride Stress
Corrosion Cracking
(Cl SCC)
Hydrofluoric Acid
(SOHIC, HIC,
HSC)
Polythionic Acid
SCC (PTA)
Wet H2S
(Blistering, SOHIC,
HIC, SSC)

Cracking Initial
Description
and 2
2
(checkbox) steam out is used on the circuit
Comments Date
Storage Tanks
Prior to completing storage tank datasheets, field verify the following:
 Nameplate data
 Dike area in feet
 Foundation Type
 Bottom Support Type
 Operating Level
 Insulated (Y/N)
Typical data sources for storage data collection include:

The following tables describe the fields of the Storage Tank Data Collection Form:
Background Data
in any format
format)
Equipment ID The identifier assigned to the Storage Tank Yes Alphanumeric TK1001A
storage tank Tracking List
Operating Unit The process unit the storage --- Yes Alphanumeric FCCU
tank is located in
Reliability System The process system the storage Defined piping Yes Alphanumeric 1301
tank is assigned to systems
Manufacturer Serial ---  Field Verification No Alphanumeric AF432171
Number
 Spec. Sheet
 Construction
Drawing
drawing number for the storage or electronic)
tank
storage tank
contain the storage tank
system
 Equipment list
Description ---  P&IDs Yes, for Alphanumeric Light Feed Day Tank
clarificatio
purposes
Manufacturer --- U1 No User-defined list Monticello Tank
Roof Data
Roof Type ---  Spec. Sheet No Picklist: Cone

Cone
 Construction
Floating
Drawings
Pan
Roof Plate Thickness Nominal thickness of roof  Spec. Sheet No Numeric value 0.75
plates. Note: If nominal isn’t greater than 0 /
known, take reading plus  Construction inches
internal expected corrosion rate Drawings
service.
Roof Material Spec. Note: Select A-36 if material  Spec. Sheet No Pick list: A285
spec. isn’t known.  Construction A131
Drawings A283
A285
A36
A442
A516
A537
A573
A633
A662
A678
A737
Roof Material Grade Note: Select C if material grade  Spec. Sheet No Pick list: B
isn’t known.  Construction 1
Drawings 2
55
58
60
65
70
A
B
C
CS
D
EH 36
Internal Support ---  Spec. Sheet No Picklist: Columns
Type  Construction None
Drawings Columns
Rafters
Girders
Internal Support ---  Spec. Sheet No Alphanumeric A53-B
Material  Construction
Drawings
Design/Construction Data - Shell

Construction Code The code used for design or  Spec. Sheet Yes API 650 API 650
construction of the storage tank  Construction
drawings
Code Date The edition date of the  Spec. Sheet No Numeric (yyyy) 1995
construction code  Construction
drawings
Year Built The year the tank was  Spec. Sheet Yes Numeric (yyyy) 1998
constructed  Construction
drawings
Diameter Tank diameter in feet  Spec. Sheet Yes Numeric greater 55.0
 Construction than 0 / feet
drawings
Height Tank height in feet  Spec. Sheet No Numeric / feet 25.0
 Construction
drawings
Design Temperature Note: If the design temperature  Spec. Sheet Yes Numeric/Degrees F 300
isn’t known, add 100 degrees F  Construction
to the operating temperature drawings
and then round up to the  Field verification
Design Specific ---  Spec. Sheet No Numeric 1.2
Gravity  Construction
drawings
PWHT Indicates whether or not the  Spec. Sheet Yes Y/N N
shell material has been post  Construction
weld heat treated drawings
PWHT Temperature The heat treat temperature  Spec. Sheet Yes, if Numeric/Degrees F 750
 Construction PWHT
drawings
MDMT Minimum design metal  Spec. Sheet Consult Numeric/Degrees F -20
temperature  Construction w/ Site
drawings Coordinat
or
Int. Cathodic If the tank has internal cathodic  Spec. Sheet No Picklist: Anodic
Protection protection indicate which type  Construction None
drawings Anodic
Cathodic
Fire Protection Type ---  Unit Overview No User-defined picklist: Water
 Construction Deluge
drawings Foam
 P&IDs Gas Detector
Water
Flame Arrestor Type ---  Unit Overview No User-defined picklist: Inline
 Construction Detonation
drawings Preventor
Free Venting
Inline
Integral w/ Relief
Drawings
 Spec. Sheet
Drawings
 Spec. Sheet
Diked Whether or not the tank has a  Plot Plan Yes Y/N Y
containment wall around it  Unit Overview
Diked Area The area of containment in  Plot Plan Yes Numeric greater 1200
square feet  Field Verification than 0 / square feet
Internal Entry Whether or not the asset can be Construction Yes User-defined Picklist: No manway
Possible entered by inspection personnel Drawings Yes
No
Overfill Protection Examples include overflow  P&IDs No Y/N N
pipes and valves controlled by  Field Verification
high level indicators
Double Wall ---  Construction No Y/N N
Drawings
 Spec. Sheet
Shell Material Spec. Note: Select A-36 if material  Spec. Sheet Yes Pick list: A285
spec. isn’t known.  Construction A131
Drawings A283
A285
A36
A442
A516
A537
A573
A633
A662
A678
A737
Shell Material Grade Note: Select C if material grade  Spec. Sheet Yes Pick list: B
isn’t known.  Construction 1
Drawings 2
55
58
60
65
70
A
B
C
CS
D
EH 36
 Construction
drawings
 P&IDs
 Construction  Asbestos
drawings  Calcium Silicate
 P&IDs (CI Free)
(Not CI Free)
 Foam/Cellular
Glass
 Mineral
Wool/Fiber Glass
Maximum Liquid --- Process Review Yes Numeric / feet 18
Level
Relief Set Pressure The set pressure of the relieving P&IDs No Numeric / inches of 10
device H2O
Design Capacity Identify the design capacity and  Spec. Sheet No Numeric and picklist 50000 gal
whether it is measured in  Construction for units:
barrels or gallons Drawings bbl
 Field Verification gal
Number of Shell ---  Spec. Sheet Yes Numeric 4
Courses  Construction
Drawings
Number of Nozzles ---  Spec. Sheet Yes Numeric 22
 Construction
Drawings
Corrosion Allowance ---  Spec. Sheet No Numeric/inches 0.125
 Construction
Drawings
Joint Type ---  Spec. Sheet No Picklist: Welded
 Construction Bolted
Drawings
Welded
Riveted
Joint Efficiency Note: Select 0.85 if the joint  Spec. Sheet Yes Picklist: 1.00
efficiency isn’t known.  Construction 1.00
Drawings 0.90
0.85
0.80
0.70
0.65
0.60
0.55
0.50
0.45
Nominal thickness The nominal thickness of the  Spec. Sheet Yes Numeric/inches 0.500
shell. Note: If nominal isn’t  Construction
known, take reading plus Drawings
service.
Components – (used to run criticality on individual components of storage tanks)


component of a storage tank
Material Specification ----  Spec. Sheet No Alphanumeric A
 Construction
drawings
Grade ----  Spec. Sheet No Alphanumeric 40
 Construction
drawings
Size The nominal size of the  Spec. Sheet No Numeric value 12
component in inches.  Construction greater than zero
drawings /inches
Nominal Thickness Nominal thickness of the  Spec. Sheet No Numeric value 0.125
component . Note: If nominal  Construction greater than zero /
isn’t known, take reading plus drawings inches
service.
Minimum Thickness Minimum required thickness of  Spec. Sheet No Numeric value .063
the component  Construction greater than zero /
drawings inches
(mm/dd/yyyy)
Process Data
the storage tank See RBMI Typical
Representative
Fluids
storage tank. For mixed
phases, select liquid.
ACR (Acrolein)
AN (Acrylonitrile)
BF3
Chlorine
CO
EO
H2S
HCHO
HCL
HCN
HF
Hydrazine
Methyl Mercaptan
NH3
Perchloromethylme
rcaptan
Phosgene
Propionitrile
Propylene Oxide
Sulfur Trioxide
VAM
the storage tank
/ degrees F
Density --- Process Review No Numeric / lbs per 57.2
cubic foot
Design/Construction Data - Bottom

Leak Detection Indicate whether or not there is Unit Overview No Y/N N
leak detection system on tank
Leak Detection Area ? ? No ? ?
Foundation Type ---  Spec. Sheet Yes Picklist: Concrete
 Construction Clay
drawings Concrete
Double Floor
Gravel
Sand
Silt
Bottom Support Indicate whether or not there is  Spec. Sheet No Y/N Y
a tank bottom support system  Construction
drawings
Bottom Support Type ---  Spec. Sheet No User-defined picklist Clay
 Construction Clay
drawings Ring Wall
Double Floor
Gravel
Piers
Sand
Silt
Concrete Slab
Structural Steel
Cathodic Protection Whether or not the tank bottom  Unit Overview No Y/N Y
has a cathodic protection  Spec. Sheet
system  Construction
drawings
 Field verification
Soil Composition ---  Unit Overview No User-defined picklist Silt
 Field Verification Clay
Gravel
Sand
Silt
Lining/Coating Whether or not the tank bottom  Insp./Maint. No Y/N N

has a lining or coating History
 Spec. Sheet
 Construction
drawings
Lining/Coating Type ---  Insp./Maint. No Alphanumeric ?
History
 Spec. Sheet
 Construction
drawings
PWHT Indicates whether or not the  Spec. Sheet Yes Y/N N
bottom material has been post  Construction
weld heat treated drawings
PWHT Temperature The heat treat temperature  Spec. Sheet No Numeric/Degrees F 750
 Construction
drawings
MDMT Minimum design metal  Spec. Sheet Consult Numeric/Degrees F -20
temperature  Construction w/ Site
drawings Coordinat
or
Joint Type ---  Spec. Sheet No Picklist: Welded
 Construction Bolted
Drawings
Welded
Riveted
Design Temperature Note: If the design temperature  Spec. Sheet Yes Numeric/Degrees F 300
isn’t known, add 100 degrees F  Construction
to the operating temperature drawings
and then round up to the  Field verification
Tank Bottom Material Note: Select A-36 if material  Spec. Sheet Yes Pick list: A285
Spec. spec. isn’t known.  Construction A131
Drawings A283
A285
A36
A442
A516
A537
A573
A633
A662
A678
A737
Tank Bottom Material Note: Select C if material grade  Spec. Sheet Yes Pick list: B
Grade isn’t known.  Construction 1
Drawings 2
55
58
60
65
70
A
B
C
CS
D
EH 36
Nominal thickness The nominal thickness of the  Spec. Sheet Yes Numeric/inches 0.125
tank bottom. Note: If nominal  Construction
isn’t known, take reading plus Drawings
service.
Corrosion Allowance ---  Spec. Sheet No Numeric/inches 0.125
 Construction
Drawings
Minimum thickness The minimum required Unit Overview No Numeric/inches 0.125
thickness of the tank bottom

(checkbox) storage tank had impact tests  Equipment File alphanumeric
impact tests
 Equipment File




Contaminant 1 and 2 The name of a contaminant Process Review No Alphanumeric ?

present in the process service
Concentration 1 and Percentage of a contaminant in Process Review No Numeric value 10
2 the process service. greater than zero up
to 100.
inches per year
component
 Construction
drawings
contains the storage tank.
Description
Temperature –In inlet of the storage tank
 Temperature
gauges
Temperature – Out outlet of the storage tank
 Temperature
gauges
Water Present Is there a presence of water in Process Review No Y/N and numeric Y / 12
(checkbox) process service and what value between 0 and
percentage 100
PH The pH level of the process Process Review No Numeric value from 11.5
service 0 to 14
 Equipment File
drawings
medium, high)
the storage tank to become wet
or saturated? Note: Cooling
year.
Intermittent Service Whether or not the component Process Review No Yes/No Y
is not in continuous service.
(steam or electric)
Corrosion Rate year
Mechanism

two inspections.


Amine Cracking
(ASCC)
Carbonate
Cracking
Caustic Cracking
Chloride Stress
Corrosion Cracking
(Cl SCC)
Hydrofluoric Acid
(SOHIC, HIC,
HSC)
Polythionic Acid
SCC (PTA)
Wet H2S
(Blistering, SOHIC,
HIC, SSC)

Cracking Initial
Description
and 2
2
(checkbox) steam out is used on the
storage tank
Comments Date
Relief Devices
Data collection for relief devices differs from other equipment types because the typical data
sources for the relief device locations are usually different that those for the relief devices
installed in those locations.
Typical data sources for relief device locations include:

1. P&IDs – can identify location IDs, set pressures, sizes, and device types, redundant
relief devices, rupture disk information, etc.
2. Sizing Calculations– can provide sizes, required capacities, design basis, etc.
3. Electronic/Paper Records – plants may have location data including operating,
design, set pressures, inspection/test records etc.
Typical data sources for relief devices (including rupture disks) include:
1. Electronic/Paper Records – plants may have device information including design,
manufacturer, sizes, nameplate info., etc.
2. Field Verification– can provide size, manufacturer, orientation, set pressure, and other
nameplate information
Due to the transient nature of relief devices (moving from location to location), in most cases
field verification will be required to verify the specific relief device ID assigned to each relief
device location. In order to save time, the field verification should be performed at the same
time as the visual inspection. This can be accomplished by taking the Relief Device Data
Collection Form along with the relief device visual inspection form when performing the
inspection. Information that typically requires field verification includes the following:
 That the relief device location ID exists
 That a relief device is installed at that location and is the assigned device
 Type of device
 Nameplate information for the relief device including manufacturer, design info, set
pressures, date of last test, etc.
 Physical information about the relief device including bolt/nut materials, flange ratings,
orientation, gasket types, relieves to, etc.
 Whether or not the is protected by a rupture disk
The following tables describe the fields of the Relief Device Data Collection Form:
Location - Background Data

in any format

format)
Location ID ID for location of PRD, usually  Relief Device Yes Alphanumeric PSV-001A
taken from the P&ID tag Tracking list
number for the device's location
 P&IDs
Operating Unit The process unit for the relief --- Yes Alphanumeric FCCU
device location
System The process system the relief Defined piping Yes Alphanumeric 1301
device location is assigned to. It systems
should be the same system as
the protected equipment assets.
P&ID --- P&IDs Yes Alphanumeric ANP00199002A
Orientation The position of the equipment Field Verification No Picklist: Horizontal
as it sits in the field Horizontal
geometrically.
Vertical
In-Place Relief Tests Whether or not local jurisdiction Unit Overview No Y/N Y
Allowed allows in-place testing of relief
devices instead of shop testing.
Redundant Relief "Y" if the valve can be Process Review Yes Y/N N
Devices completely taken out of the
process, and the unit still has
full relief capabilities, otherwise
"N". This may require input
from the Operations Engineer.
If unsure, use "N".
Protected by Rupture Whether or not the relief device  P&IDs Yes Y/N N
Disk is protected by a rupture disk
Rupture Disk ID The unique location ID for the P&IDs Yes, If Alphanumeric RD0001A
rupture disk that is protecting Rupture
the relief device. Disk
exists
Location Comment The brief description of where Field Verification No Alphanumeric Top of V-100, or 2nd level
(This is enter under PRD is located in the field. of pipe rack east of
the general control room.
comments field)
Location – Protected Equipment

Column Name Description Data Source Required Valid Values/Units Example
Protected Equipment The equipment item(s) that are P&IDs Yes Alphanumeric R-1001A
ID protected by the relief device.
Equipment Type The equipment type of the item RBMI database Yes Picklist: Pressure Vessel
protected by the relief device
Pipe
Pressure Vessel
Column
Shell and Tube
Exchanger
Air Cooled
Exchanger
Storage Tank
Component Type The component type for the RBMI database Yes Picklist: Pressure Vessel
protected equipment item
Top (column)
Middle (column)
Bottom (column and
Column Name Description Data Source Required Valid Values/Units Example
storage tank)
Header (air cooler)
Tubes (air cooler)
Shell (exchanger
and storage tank)
Channel
(exchanger)
Tube bundle
(exchanger)
Pressure Vessel
Consequence Combined Consequence for RBMI database Yes A-E B

Protected Equipment
Design Pressure The design pressure of the RBMI database Yes Numeric value 175
protected component greater than 0 / psig
Unit The process unit that the RBMI database Yes Alphanumeric FCCU
protected equipment
component is located in
Location – Process Data

Field Name Description Data Source Required Valid Values/Units Example
Representative The representative fluid name RBMI database Yes Picklist: C1

Fluid Name from the protected See RBMI Typical
component with the highest Representative
consequence from the driving Fluids
risk
Representative The representative fluid RBMI database Yes liquid or gas gas
Fluid Phase phase from the protected
component with the highest
consequence from the driving
risk
Process Service The process service from the RBMI database No User defined Light Hydrocarbon
protected component with the picklist
highest consequence from
the driving risk
Process System The process system of the RBMI database No Alphanumeric ?
protected equipment ID with
the highest combined
consequence
Operating Pressure The operating pressure from RBMI database Yes Numeric value 150
the protected component with greater than zero /
the highest consequence psig
from the driving risk
Operating The operating temperature RBMI database No Numeric value 350
Temperature from the protected greater than –
component with the highest 459.66 / degrees F
risk
Protected The internal corrosion rate RBMI database Yes numeric value 0.005
Equipment used for calculating driving greater than zero /
Corrosion Rate risk from the protected inches per year
component with the highest
risk
Specific Gravity ---  Process Review No Numeric 1.2
 Sizing
Calculations
Design Basis --- Sizing Calculations No User-defined picklist: Fire
Contents Vapor
Pressure
Exothermic Reaction
Fire
Overpress by a
mech. Device
Thermal Expansion
Potential for This input is HIGHLY critical. Process Review Yes Picklist: Medium
Fouling A process engineer should
provide this input. Can be Low
based on similar service. If a Medium
rupture disk protects the High
device, input is based on
fouling found on the RD, but Very High
give credit for the RD in
another field, not here. Here
are some suggestions on how
to interpret the inputs:
LOW - fouling almost never
occurs at this location
MEDIUM - some fouling
found if valve is in service at
location for 2-3 years or more
HIGH - Relief device fouls to
the point of degraded
capacity within 1-2 years
VERY HIGH - Relief device
fouls to the point of degraded
capacity in less than 1 year
Estimated A Process Engineer based on Kickoff meeting Yes, if Units Picklist: more than once every 6
Challenge Rate his/her experience with the using months
(Required if number of lifts a year (or more than once
Experienc every 6 months
“Challenge Rate years between lifts) that have e method.
Used” is “E”) been experience for the relief once every 6 months
device at the location. to 2 years
once every 2 to 5
years
once every 5 to 10
years
less than once in 10
years.
Location – Process Data (Pressure Vacuum Vents only)

Maximum Pressure Identify the flow capacity Sizing Calculations No Units Picklist: 2100 lbs/hr
Flow Capacity required and the units of Lbs/hr
Required measurement
Gpm
Scfm
In/water
(and numeric
value for capacity)
Maximum Vacuum Identify the flow capacity Sizing Calculations No Units Picklist: 100 gpm
Flow Capacity required and the units of Lbs/hr
Required measurement
Gpm
Scfm
In/water
(and numeric
value for capacity)
Flashpoint ---  Process Review No Numeric / degrees 375

F
 MSDSs
Pump pressure in ---  Process Review No Numeric / psig 30
 PFDs
Pump pressure out ---  Process Review No Numeric / psig 20
 PFDs
Location – Process Data (Pressure Relief Valves and Rupture Disks)

Required Capacity Identify the required capacity Sizing Calculations No Units Picklist: 2100 lbs/hr
and the units of measurement Lbs/hr
Gpm
Scfm
In/water
(and numeric
value for capacity)
Back Pressure --- Sizing Calculations No Numeric / psig 20
Differential Set ---  Field Verification No Numeric / psig 32.5

Pressure
 P&IDs
Allowable --- Sizing Calculations No Numeric / % 15
Overpressure
Relieves to: Whether or not the relief  P&IDs Yes Picklist: Flare
device releases to the Atmosphere
atmosphere, flare header, or  Field Verification
other location Flare
Other (specify)
Relief Device – Background Data

Device Type The type of relief device  P&IDs Yes Picklist: Pressure Relief Valve
installed at a specific location Pressure Relief
 Field Verification Valve
 Tracking List Pressure Vacuum
Vent
Manufacturer ---  Field Verification No User defined Mc Junkin

picklist
 Electronic/Paper
Records
Serial Number ---  Field Verification Yes Alphanumeric 044-T-999A1
Records
Model Number ---  Field Verification No Alphanumeric M33101
Records
Pressure Set Point The units and value of the  Field Verification Yes Units picklist: 12 psig
(Pressure Vacuum pressure set point for the Oz
Vent (PV) Vent pressure vacuum vent  Electronic/Paper
only) Psig
Records
(and numeric value
for set point)
Vacuum Set Point The units and value of the  Field Verification Yes Units picklist: 10 oz
(PV Vent only) vacuum set point for the Oz
pressure vacuum vent  Electronic/Paper
Psig
Records
(and numeric value
for set point)

Pressure Flow The units and value of the  Field Verification No Units Picklist: 2000 scfm
Capacity pressure flow capacity Lbs/hr
(PV Vent only)  Electronic/Paper
Gpm
Records
Scfm
In/water
(and numeric
value for capacity)
Vacuum Flow The units and value of the  Field Verification No Units Picklist: 120 gpm
Capacity vacuum flow capacity Lbs/hr
(PV Vent only)  Electronic/Paper
Gpm
Records
Scfm
In/water
(and numeric
value for capacity)
Nameplate ---  Field Verification No Units Picklist: 175 gpm

Capacity Lbs/hr
(Pressure Relief  Electronic/Paper
Valve (PRV) only) Gpm
Records
Scfm
In/water
(and numeric
value for capacity)
Relief Set Pressure ---  Field Verification Yes numeric/ psig 250
(PRV only)
Records
Relief Temperature --- ? No Numeric/ degrees 200
(PRV only) F
Relief Device – Design/Construction Data

Construction Code ---  Field Verification No Picklist: API 650

ASME B 31.1
ASME B 31.3
Records
ASME Sec. VIII
API 2000
API 650
Bolts/Nuts ---  Piping No User-defined list SA 193 B7

Specifications
Inlet Size Size of valve inlet  Field Verification No Numeric / inches 3
Records
Inlet Flange Facing ---  Electronic/Paper No Picklist: Flat
Type Records Flat
RF
 Piping RTJ
Specifications
Inlet Flange Rating ---  Electronic/Paper No Numeric 300
Records
 Piping
Specifications
Date in this Service This is either (1) the date it  Electronic/Paper Yes MM/DD/YYYY 11/28/1998
was last inspected (assuming Records
valve pop-tested OK) or date
installed, whichever is  Field Verification
LATER.
Sizing Calculations --- Electronic/Paper No Y/N Y
on File Records
Threaded Whether or not the valve is of  Electronic/Paper No Y/N N
a threaded design Records
 Piping
Specifications
Gasket Type ---  Field Verification No User-defined picklist Rubber
(PRV only)
 Piping
Specifications
Operation Type The type of relief valve based  Electronic/Paper No User-defined picklist: Pilot Operated
(PRV only) on function Records Pilot Operated
Relief
 Field Verification Safety
Safety Relief
Design Type The type of relief valve based  Electronic/Paper Yes Picklist: Conventional
(PRV only) on activation Records Conventional
Bellows
 Field Verification Pilot Operated
Orifice Size The area of the orifice Electronic/Paper No Numeric/ square 3.75
(PRV only) opening Records inches
Outlet Size ---  Electronic/Paper No Numeric/ inches 6
(PRV only) Records
 P&IDs
Outlet Flange ---  Electronic/Paper No Picklist: Flat
Facing Type Records Flat
(PRV only) RF
 Piping RTJ
Specifications
Outlet Flange ---  Electronic/Paper No Numeric 300
Rating Records
(PRV only)
 Piping
Specifications
Spring Size --- Electronic/Paper No ? ?
(PRV only) Records
Spring Number --- Electronic/Paper No ? ?
(PRV only) Records
Spring Type --- Electronic/Paper No User-defined picklist: Spring
(PRV only) Records Spiral
Spring
Maximum Back The maximum allowable  Electronic/Paper No Numeric/ psig 25
Pressure backpressure for the valve. Records
(PRV only)
Higher Alloy Whether or not higher alloy Electronic/Paper Yes Y/N N
Materials on materials are used for internal Records
Internal Parts parts on the relief device
(PRV only) indicating less of a potential

for internal corrosion
Size ---  Electronic/Paper No ? ?
(PV Vent only) Records
All Weather ---  Electronic/Paper No Y/N N
Construction Records
(PV Vent only)
Rupture Disk Data

Rupture Disk ID The unique location ID for the P&IDs No Alphanumeric RD0001A
rupture disk that is protecting
the relief device.
Rupture Disk Type ---  Electronic/Paper No User-defined picklist: Pre-scored Reverse
Records Composite
 Field Verification Conventional
DV
Emergency
Graphite
MB
Mono
Pre-scored Reverse
Disk Material --- Electronic/Paper No User-defined picklist: SS
Records 316 SS
SS
Stainless Steel
Carbon
CS
Hastelloy
Monel
PTFE – coated SS
Coating Material --- Electronic/Paper No Alphanumeric None
Records
Side to Pressure The side of the rupture disk Field Verification No Picklist: Flat
exposed to the process Convex
pressure
Concave
Flat
Manufacturer --- Electronic/Paper No User-defined picklist Zook
Records
Gasket Material ---  Electronic/Paper No User-defined picklist PTFE
Records
 Piping
Specifications
Seal Material --- Electronic/Paper No User-defined picklist Teflon
Records
Date in this Service The date that the disk was Electronic/Paper No MM/DD/YYYY 12/10/1998
installed at the current location Records
Number of Rupture The number of times rupture Electronic/Paper No Numeric 12
Disk Replacements disks have been replaced at the Records
current location.
Sizing Calculations --- Electronic/Paper No Y/N Y
on File Records
Lot Test Certificate --- Electronic/Paper No Y/N Y
Records
Fragmentation --- Sizing Calculations No Y/N N
Allowed
Leak Through Whether or not there is a  Field Verification No Y/N Y
Indicator pressure gage or other indicator
between the rupture disk and  P&IDs
the relief device (valve) to
indicate leakage or a failure of
the rupture disk.
Rupture Disk Nameplate Data

Burst Pressure The pressure at which the Field Verification No Numeric / psig 205
rupture disk is designed to open
Burst Temperature --- Field Verification No Numeric / degrees F 375
Lot/ID Number --- Field Verification Alphanumeric 2001-47A
Size --- Field Verification No Numeric / inches 4
Kr ? Field Verification No ? ?
MNFA ? Field Verification No ? ?
Nameplate Capacity --- Field Verification No Units Picklist: 1245 scfm
Lbs/hr
Gpm
Scfm
In/water
(and numeric
value for capacity)
Rupture Disk Holder Data

Rupture Disk Holder ---  Electronic/Paper No Y/N Y

Records
Holder Model ---  Electronic/Paper No Alphanumeric H2700B
Number Records
Holder Flange Rating ---  Electronic/Paper No Numeric 900
Records
 Piping
Specifications
Holder Manufacturer ---  Electronic/Paper No User-defined picklist BS&B
Records
Holder Material --- Field Verification No User-defined picklist: SS
316 SS
SS
Stainless Steel
Carbon
CS
Hastelloy
Monel
PTFE – coated SS
Documenting Data Discrepancies and Redlines

Data discrepancies are differences between two sources of information when the correct value
is uncertain. For example, Data discrepancies are typically discovered during:
1. Data Collection – example: a P&ID indicates a design pressure of 100 psig for a drum,
but the U1 form indicates 175 psig
2. Field Verification/Inspection – example: piping specification and P&ID indicate that a

piping circuit is insulated; field verification reveals that it is not.
Data discrepancies are reported to the client so that correct values for information can be
determined to update client information sources (engineering records, maintenance records,
U1’s, etc.). Data discrepancies are documented in two ways:
1. “Redlined” P&IDs – Maintain a set of P&IDs for each unit in which RBMI is being
implemented on which any changes or modifications that are found can be
documented. Examples include added/deleted equipment and piping, changes in
equipment IDs, incorrect sizes of equipment and piping, etc. These changes should be
marked clearly and accurately so that client’s drafting personnel can use the “redlines”
to update their master P&IDs.
Note: A Scope Change should be considered if redlining is complex or where P&IDs

are in poor condition.
2. Data Discrepancies - Data discrepancies that cannot be resolved by “red-lining”

P&IDs should be documented on the Data Collection Discrepancy Log. This log should
be posted or located so that Capstone personnel performing data collection, field
verification, and inspections can easily access it. Discovering a different national board
number on a U1 than that found on the vessel nameplate during field verification would
be an example of a data discrepancy.
Note: The client will make the determination as to which data source is the most
accurate and should be used in RBMI. The client may also choose to make the most
conservative of sources his default to be used in all such cases.
Data discrepancy logs and “Redline” P&IDs are typically transmitted to the client at the unit or
project closeout meeting.
7
Chapter
Chapter 7 – Calculating Criticality
Reviewing Inspection and Maintenance History

The inspection and maintenance records for the equipment assets in the project scope must
be reviewed to provide information needed for Data Collection, the Corrosion Study, Criticality,
and Inspection Planning. The history review should be performed prior to the completion of
data collection. Maintenance and inspection information collected includes:
History Data Collected: Used For:

Maintenance Descriptions (Repairs/Replacements):  Data Collection (year built,
 Year Built date in service, changes in
 Date materials, etc.)
 Extent  Corrosion Study
 Method  Inspection Planning (date of
 Description previous inspection)
Inspection Descriptions:  Corrosion Study

 Date  Calculating Criticality
 Method
 Extent
 Summary of Results
Sources of history information that should be reviewed are defined and documented in the
Project Kickoff Meeting. Typical sources of history information include:
 Inspection files (paper and/or electronic)
 Maintenance work orders (for repairs and replacements)
 Turnaround Reports
Qualified Data Collectors and Inspectors collect history data for all assets and components in
the project scope of work and document it on the Inspection History Summary form. This form
is filled out as follows:
Histories are typically performed/grouped
Make a new entry for each by equipment type:
inspection or maintenance Pressure Vessels
action performed Columns
Shell and Tube ExchangersAir Cooled
Exchangers
Piping
Storage Tanks
Relief Devices
The The type of Summarize the extent (areas

component(s) action and/or % coverage), results,
covered by performed and any repairs/replacements
this inspection made(note whether repairs
or were post-weld heat treated
maintenance (PWHT). Note: Corrosion
action. depths noted in internal
inspections must be
Verify year documented so that
built in localized/pitting corrosion rates
history can be determined.
records vs
year built in
data/
construction
records
Note: Any records of CUI damage and/or CUI inspections shall be documented on the History
Summaries.
The completed History Summaries are retained in the Equipment Files.
Process Review
The process review is performed prior to the Corrosion Study to collect process and operating
information required to perform the consequence calculations in Calculating Criticality. The
client provides the process data for the process review because it is not typically included in
the project scope. However, at the client’s request, the Capstone Chemical Engineer can
perform the process review as added scope (see Scope Changes).
The Process Review is performed as follows:
1. Prepare the Process Review Worksheet – The Site Coordinator creates a Process
Review Worksheet in MS Excel by inserting the Equipment IDs and Descriptions of all
fixed equipment assets (vessels, exchangers, columns, storage tanks) in the
appropriate sections:
Enter ID and
Description of
Asset.
2. Transmit the Process Review Worksheet – The Site Coordinator transmits the
Process Review Worksheet to the Client Project Coordinator (see Project
Correspondence).
Note: The Site Coordinator should provide the worksheet to the client as soon as the
scope of work is finalized (i.e. after field verification) so that the process review is
completed prior to the Corrosion Study.
3. Perform the Process Review – The Client Project Coordinator is responsible for
ensuring that all applicable fields on the Process Review Worksheet are completed:
These two fields are picklists
so that only values that match
the RBMI software can be
selected.
Note: Fouling Potential is required only if relief devices are included in the project
scope.
LOW - fouling almost never occurs at this location
MEDIUM - some fouling found if valve is in service at location for 2-3 years or more
HIGH - Relief device fouls to the point of degraded capacity within 1-2 years
VERY HIGH - Relief device fouls to the point of degraded capacity in less than 1 year
Note 1: Guidelines for Assigning Operating Temperatures and Pressures -

In General, we want “Normal” operating pressures and temperatures. The general
rule for operating pressures would be within 10%, estimating on the high side is
best. Hydrogen partial pressure (in psia) should be given to represent the highest
operating pressure.
The Capstone CUI calculator uses an operating temperature range of 0 to 300 oF.
The highest probability of CUI is between 150 and 200 oF. We try to stay on the
conservative side for CUI. If a vessel operates in a range of temperature and
sometimes that range is between 0 and 300 oF (especially 150 to 200), assign the
operating temperature to fit in the CUI temperature range. If a vessel operates in
intermittent service, sometimes above 300 oF and sometimes not, assign the
operating temperature to fit with in the CUI range.
Concerning higher temperature equipment, 400 oF is a key temperature. Typically
this is the start of high temperature sulfidation, high temperature hydrogen attack,
and creep. Therefore, for a conservative first pass, we would like the highest
‘normal’ temperature, such as end of run or similar regular events. Sometimes, as
little as 100 cumulative hours is all that is needed to cause a failure.
For vessels that normally operate above 300 oF, an accuracy within 25 oF is
requested, estimating on the high side is best for the first pass. If it is found that the
estimated values give a high risk assessment, only the specific equipment affected
will need to be re-evaluated to input more precise values to fine tune the risk
ranking.
Note 2: Relief Devices - If relief devices are included in the project scope of work,
the Site Coordinator should also submit a list of in-scope PRDs to the Client Project
Coordinator to identify whether or not they are in redundant service (the valve can
be completely taken out of the process, and the unit still has full relief capabilities).
4. Review Process Data – The Site Coordinator reviews the completed Process
Review Worksheet by verifying that applicable fields have been filled in for all
equipment components in the project scope. For example, an exchanger should
have data for both the shell and channel.
The Site Coordinator shall then submit the Process Review Worksheet to the
Capstone Chemical Engineer for technical review and approval of the client-
provided process data.
5. Transfer Process Data – The Site Coordinator or qualified Capstone employee
records the process information from the approved Process Review Worksheet next
to each equipment asset on the Systemized P&IDs.
The approved Process Review Worksheet is retained in the Project Files.
Corrosion Study
A corrosion study is a review of a unit’s process, design, materials, and history to determine
potential damage mechanisms, corrosion types, and corrosion rates to be used in Calculating
Criticality and Inspection Planning. A Capstone Corrosion Engineer, utilizing information
collected by Capstone on-site project personnel, performs this study. The four basic steps of a
corrosion study are reviewing corrosion rates, preparing documents for the on-site review,
performing the on-site review, and documenting the corrosion study.
Review Measured Corrosion Rates

Measured internal corrosion rates are calculated and documented on the Corrosion and
Materials Diagrams (CMD) for review by the Capstone Corrosion Engineer. Measured external
corrosion rates due to CUI are calculated and entered on the Fixed Equipment Data Import
Workbook.
Internal Corrosion
The Site Coordinator or Qualified Capstone Inspector will review thickness inspection records
and Inspection History Summaries to determine the following for each component in the
project scope of work:
 Short Term Average Corrosion Rates – the corrosion rates (inches per year) calculated
using the most current and the previous thickness data. The short term average corrosion
rate is calculated as follows:
1. Subtract the current thickness reading (in inches) from the previous reading for each
inspection location on the component.
2. Divide these values by the number of years between inspections. The result will be
the short-term corrosion rates for the inspection locations on the component.
3. Sum the short-term corrosion rates calculated in step 2 and divide the total by the
total number of inspection locations on the component. The result is the short-term
average corrosion rate for the component.
 Long Term Average Corrosion Rates – the corrosion rates (inches per year) calculated
using the most current and the baseline (or nominal if no baseline exists) thickness data.
The long-term average corrosion rates for each component are calculated in a similar
manner to the one described above for short-term average corrosion rates.
 Maximum Corrosion Rates – the highest corrosion rate measured on the component.
The maximum corrosion rate is determined by selecting the highest value from the
following:
 Maximum short-term corrosion rate – the highest short-term corrosion rate

calculated at an inspection location on the component
 Maximum long-term corrosion rate – the highest long term corrosion rate calculated
at an inspection location on the component
 Maximum calculated corrosion rate due to wall losses documented during VI-
Internal inspections or due to through-wall failures/equipment replacements– This is
determined by reviewing the completed Inspection History Summaries.
Example 1: Internal pitting to a maximum depth of 0.15 inches was found in an

exchanger shell that had been in service 10 years at the time of inspection. The
maximum corrosion rate due to pitting would be 0.015 inches per year (0.15 divided
by 10).
Example 2: An air cooler tube leak due to through wall corrosion was found during
an external visual inspection after 5 years of service. The tube nominal thickness
was 0.109 inches. The maximum corrosion rate would be 0.022 ipy (0.109 divided
by 5).
The short-term average, long-term average, and maximum corrosion rates are documented for
each component by writing these values next to the equipment item on the Corrosion and
Materials Diagram (CMD).
Note: A description of the location and nature of the maximum corrosion rate shall also be
noted on the CMD. For example: “max. corr. rate = 0.015 ipy due to pitting found in lower half
of shell in 1995.”
External Corrosion (CUI)

Review the Inspection History Summaries for documented CUI inspections. If external wall
loss values are found, then an external corrosion rate can be calculated for that equipment
component as follows: Divide the measured external corrosion depth (inches) by the external
years in service. (External years is service = years in service for the equipment asset – 1)
Record any measured external corrosion rates in the Measured External Corrosion Rate
field on the appropriate equipment tab in the Fixed Equipment Data Import Workbook.
Prepare Documents for the On-site Review

In order to expedite the on-site corrosion review, the Site Coordinator, or other qualified
Capstone on-site personnel prepares a package of information for the Capstone Corrosion
Engineer. This information package should be compiled prior to the on-site corrosion review.
This package of information should include the following:
 Process Description – this can be found in the unit operating manual, unit training
manual, construction job books, PHAs, etc.
 Process Review – the documented process review prepared by the Capstone Process
Engineer or provided by the client.
 Process Flow Diagrams (PFDs) – any equipment items in the unit scope of work not
shown on the PFDs should be drawn in the appropriate location in the process flow.
 Corrosion and Materials Diagrams (CMDs) – existing unit CMDs can be utilized or
create CMD sketches as follows:
1. After a unit has been systemized (see Defining Piping Systems), look at each system
independently on the systemized P&IDs and note every vessel that the system ties into
directly.
2. Once all equipment within a system has been identified, sketch the equipment assets
on whatever size paper needed to allow you to clearly label each piece of equipment
and write in any other information needed for corrosion reviews and have the drawing
remain legible.
3. Once all equipment has been sketched, find the beginning of your system and sketch in
your piping. Only draw the primary process lines leaving out any small branch
connections to sewer for example.
4. Any piping that does not end at a piece of equipment such as a Furnace, Reactor or
Column, must be referenced to the connecting system or unit.
5. All equipment associated with more than one system shall be labeled accordingly. For
example, a column where you have sketched the feed should show what systems
make up the overhead and bottoms, or an exchanger where you have sketched the
shell side process should reference what system makes up the tube/channel side.
The following should be included on the CMDs for each equipment component and for
piping in the unit scope of work:
 Equipment Location – any equipment items in the unit scope of work not shown on
the CMDs should be drawn in the appropriate location in the process flow.
 PWHT – Whether or not the component is post weld heat treated
 Material of Construction
 Age – the date in service of each equipment component
 Lining/Cladding – the type and material of any internal lining/cladding/coating.
 Repairs/Replacements – note any repairs (and if they were post weld heat treated)
or replacements
 Measured Corrosion Rates – short-term average, long-term average, and

maximum internal corrosion rates as determined during the Measured Corrosion
Rates Review.
 Process information – representative fluid/phase, operating temperature,

operating pressure, toxics and toxic percentages.
The on-site corrosion review documents shall be copied for the Capstone Corrosion Engineer
and the originals retained in the Equipment Files.
Perform the On-site Review

The on-site corrosion review is performed to generate inputs for Calculating Criticality for each
equipment component. The Capstone Corrosion Engineer completes the on-site corrosion
review using the documents described above and by collaborating/meeting with key client
personnel that may include the Unit Process Engineer, the Corrosion/Materials Engineer(s),
and inspection staff. The Corrosion Review Questionnaire identifies typical questions that
should be answered during the on-site corrosion review.
The Site Coordinator should schedule these meetings in advance of the Capstone Corrosion
Engineer’s visit so as to minimize delays and on-site time. The Site Coordinator should attend
and document (see Documenting Meetings) all corrosion review meetings with the Capstone
Corrosion Engineer.
Note: The Capstone Corrosion Engineer may request that Screening NDE inspections be
performed in cases where no inspection history exists for environmental cracking or internal
corrosion.
Document the Corrosion Study

The Capstone Corrosion Engineer will document the corrosion review by identifying the
following on a copy of the unit CMDs:
 Internal Corrosion Type – if the IC type is defined as “Localized” or “Pitting”, specific

locations of damage should be identified (top head, OD of tube bundle, etc.)
 Expected Internal Corrosion Rate – identify the expected rate and which rate should be
used (expected, short-term average, long-term average, or maximum)
 Environmental Cracking Type - Amine Cracking (ASCC), Carbonate Cracking, Caustic

Cracking, Chloride Stress Corrosion Cracking (Cl SCC), Hydrofluoric Acid (SOHIC, HIC,
HSC), Polythionic Acid SCC (PTA), or Wet H2S (Blistering, SOHIC, HIC, SSC)
 Environmental Cracking Initial Potential – High, Medium, or Low
 Other Damage Mechanisms – Identify potential damage mechanisms other than internal
corrosion or environmental cracking.
 Likelihood of Other Mechanisms – (1, 2, 3, 4, or 5). For an “Other Mechanisms”

assigned during the corrosion study, the likelihood of failure must be assigned in order for
criticality to be calculated.
 Potential Damage Locations – For any mechanism other than Internal General
Corrosion, the specific potential location(s) of the damage must be defined in order to
generate an effective baseline and/or Inspection Work Plan (IWP). For example, if
environmental cracking is identified as a potential damage mechanism on an exchanger
shell, the Corrosion Engineer might identify “the weld seams and HAZs in the lower half” as
the potential damage location.
The Capstone Corrosion Engineer will also provide to the Site Coordinator a brief written
summary (i.e.: “Hot Spot” summary) that identifies the major potential damage mechanisms in
the unit and their locations.
The corrosion study CMDs and written corrosion summary will be retained in the Equipment
Files.
Screening NDE Inspections

Screening NDE inspections are inspections performed in conjunction with the Corrosion Study
to confirm the existence and extent of either internal corrosion or environmental cracking in the
following cases:
 No inspection data or history is available to confirm the presence of a damage mechanism

that the Capstone Corrosion Engineer suspects may be present.
 Only a small amount of equipment components are affected by the damage mechanism
Screening NDE inspections allow the Corrosion Study to be improved so that Criticality and
subsequent baseline inspection plans are not overly conservative.
The Screening NDE inspection process is as follows:
1. Identify the Equipment to be Inspected - The Capstone Corrosion Engineer identifies

the equipment components to be inspected, potential damage mechanism (either
internal corrosion and/or environmental cracking), inspection locations, and inspection
method(s) to be used.
2. Prepare the NDE Inspection Forms - The Site Coordinator or qualified Capstone
employee prepares NDE inspection forms and inspection drawings for the inspections.
3. Perform the Inspections - (see UT, RT, MT, PT, CUI Visual)
4. Review the inspection results - Once inspections are completed, a qualified

Capstone employee reviews the inspection results for:
 Report and Data quality (see Reviewing Deliverables)
 Non-conformances (see Evaluating and Reporting Non-conformances)
5. Report Inspection Results – The Site Coordinator provides copies of the completed
inspection reports to Capstone Corrosion Engineer so that the Corrosion Study can be
completed.
6. Enter and File the Inspection - Completed and reviewed NDE reports are entered into
the RBMI database (see Finding, Entering, and Evaluating NDE Reports) and retained
in the Equipment Files.
Note: Funding for screening NDE inspections typically comes from the baseline inspection
budget and is not considered a scope change.
Calculating Criticality
Initial Criticality values are calculated for all equipment items in the project scope so that
Inspections can be planned and prioritized according to defined RBMI inspection strategies
(see Inspection Planning).
Assign Inspection History Information

The Site Coordinator or qualified Capstone Inspector will assign values for Inspection
Confidence, Date of Last Inspection, and Number of Inspections for all components in the
project scope by reviewing the Inspection History Summaries. These values are required to
calculate the likelihood of failure for Internal Corrosion, External Corrosion (CUI), and
Environmental Cracking.
These values are assigned according to the following guidelines:
Internal Corrosion
 Number of Inspections – the total number of NDE thickness inspections and

visual internal inspections (unless both inspections occurred at the same time, in
which case, they only count as one inspection).
 Inspection Confidence - the average confidence of the most recent six
inspections that have been performed on the equipment component. The
confidence of each inspection is determined by reviewing the Internal Corrosion
Inspection Strategies for that inspection method.
Example: 4 VI-Internals have been performed at 10-year intervals and
coverage was 100%. Reviewing the VI-Internal Strategy yields an inspection
confidence for these inspections “Very High”.
2 UT Inspections were also performed (not concurrently with VI-Internals) at 10-

year intervals. The extent of the inspections was equivalent to the requirements
for a “Medium-High” IC priority for general corrosion. Reviewing the UT w/o
Internal Visual Strategy yields an inspection confidence of “Medium”.
If 4 VI-Internals with a “Very High” confidence and 2 UT inspections with a

“Medium” confidence have been performed, the average assigned confidence
would be calculated as follows:
Avg. Confidence VH H M L
Assigned Value 4 3 2 1
From the table above, each VH inspection has an assigned value of 4, so 4
inspections is 4 x 4 = 16. Each M inspection is assigned a 2, so 4 inspections is
2 x 2 = 4. Summing the two values 16 plus 4 equals 20. Divide the total (20) by
6 inspections equals 3.3. Rounding the average assigned value to 3, the
equivalent average assigned confidence from the table is “High”.
 Date of Last Inspection – the most recent date of an internal visual inspection
or NDE inspection looking for internal corrosion.
Note: The Inspection Confidence should be factored for time since the last inspection. If
the Date of Last Inspection for internal corrosion (Thickness, VI-Internal, or otherwise) was
more than 10 years ago but less than or equal to15 years, the Inspection Confidence
should be reduced by one category (example: High to Medium). If the Date of Last
Inspection for internal corrosion was more than 15 years ago, the Inspection Confidence
should be “Low”.

 Number of Inspections – the total number of CUI NDE inspections and Visual
External Inspections.
 Inspection Confidence - the average confidence of the most recent six CUI
inspections performed according to the CUI Inspection Strategies (see internal
corrosion example above).
 Date of Last Inspection – the date of the most recent CUI visual inspection or NDE
inspection looking for CUI.
Note 1: Inspection Confidence should be factored for time since the last inspection (see
internal corrosion example above).
Note 2: If the Inspection History Summaries indicate that an equipment component has
been stripped of insulation, coated, and reinsulated, then the External Service Date field
in the Fixed Equipment Data Import Workbook shall be set to the date the component was
re-coated and reinsulated.
Environmental Cracking
 Number of Inspections – the total number of NDE inspections for environmental

cracking (typically includes MT, PT, and Shear Wave UT)
 Inspection Confidence – the average confidence of the most recent six
environmental cracking inspections performed according to the Environmental
Cracking Inspection Strategies (see internal corrosion example above).
 Date of Last Inspection - the date of the most recent environmental cracking
inspection.
Note: Inspection Confidence should be factored for time since the last inspection (see
internal corrosion example above).
These three values for internal corrosion, external corrosion, and environmental cracking are
entered in the RBMI Fixed Equipment Data Import Workbook on different worksheets based on
equipment type. The file name for the MS Excel file is RBMI Fixed Equipment Data Import.xls.
Enter Process and Corrosion Information

The following fields are entered into the RBMI Fixed Equipment Data Import Workbook (RBMI
Fixed Equipment Data Import.xls) on different worksheets based on equipment type:
From the Process Review: From the Corrosion Study:

 Operating Temperature  Internal Expected Corrosion Rate
 Operating Pressure  Internal Corrosion Type
 Representative Fluid  Predictable locations for IC (Yes or No plus
location description)
 Representative Fluid Phase  Other Damage Mechanism(s)
 Toxic Fluid  Other Damage Mechanism Likelihood(s)
 Percent Toxic  Environmental Cracking Mechanism
 Environmental Cracking Initial Potential
Coordinator or Capstone inspection personnel. The Site Coordinator should check with the
Client Project Contact and the Project Manager when a data entry resource is needed. Data
entry is typically included in the project scope of work.
Calculate Criticality
Once all required data has been entered into the RBMI Fixed Equipment Data Import
Workbook, the Site Coordinator sends the file to the Risk Engineer for review.
The Risk Engineer reviews the RBMI Fixed Equipment Data Import Workbook for omissions
and formatting errors before the data is imported into the database using the following
guidelines:
 Check required fields for blanks

 Look for unrealistic data (decimal point errors)
 Compare operating temp/pressure to design
 Operating pressure must be a positive number and not less than 1
 Check year built vs. internal date in service vs. external date in service & inspection dates
 Make sure materials & grades are on the list:
o Add new materials to the list or Input Material allowable stress override
o Confirm “Susceptible to CUI field
 Make sure fluids are on the list or model if necessary
 Check Fluid phase – does it seem unlikely? (i.e.: H2 or C1- Liquid)
 Do systems contain more than one fluid??
 Make sure toxic fluids have % associated with them.
 Verify that toxic is given in % and not decimal

 Make sure inventory isn’t left blank
o Defaults used other than Storage Tanks
 40,000 Liquid
 10,000 Gas
 Make sure mitigation isn’t left blank
o Defaults used
 Detection Time 5 minutes
 Isolation Time 5 minutes
 Make sure numeric fields are numeric (i.e.: No “psi”)
 Common Data Mistakes:
o H20 not H2O
o Susceptible to CUI not checked
o 304/316 (have to choose one)
o 316SS – (No “SS” permitted)
After any data problems are resolved, the Risk Engineer has Capstone Software Systems
import the workbook data into the database.
Mass Criticality
The Site Coordinator, Project Manager, or the Risk Engineer should perform the baseline
criticality calculations. The most efficient method of performing baseline criticality calculations
on multiple equipment items is using Mass Criticality.
The Mass Criticality module is tightly integrated with the Work Flow Steps process, which
allows the user to work on multiple assets. The Filtering process allows the user to drill down
to any group of assets to perform Mass Criticality.
1. There are two methods to select Work Flow Steps. One, by clicking the “Work Flow
Steps” button on the toolbar, or by right-clicking in the open area to get the short cut
menu to appear:
2. Select the type of equipment to perform Mass Criticality on and select Query.
3. Once you have filtered to the appropriate equipment items, or selected the appropriate
equipment items as in the example above, use the Go To button (or Right-Click) to display the
available Work Flow Steps. Choose Criticality.
4. On the toolbar click the Mass button:
5. The Mass Criticality screen appears. It is important to note that any changes
applied on the first tab will be applied to all assets displayed in the tree to the right.
The only fields that will be updated will be determined by the check box to the left of
each field. If the check box is not checked, then the field will not be updated. Note:
For the baseline or initial Criticality run, no check boxes should be checked.
6. Once the appropriate changes have been made on the first tab, click the “Run”
button. When the run is completed two grids will appear, the old and new results.
This will allow the user to compare previous results to the new results.
There are some additional features available that will allow the user to perform
further analysis. These features include side-by-side grid placement, displaying the
risk colors, displaying the Delta’s (or differences), as well as placing splits in the
each grid.
7. The third tab, the “Matrix” tab, is a further analysis tool that will allow the user to
further break down the previous and the new results from the Criticality calculations.
The user has control of what Probability and Consequence category they would like
to view.
8. To save the results a Signature and a Comment is required on the first tab. Note: By
default, it will be saved as a “What if” criticality. Be sure to click the “Driving Risk”
radio button if you want to set the new Criticality runs as a “Driving Risk.”
Relief Devices
Calculating baseline criticality for relief devices differs from the other equipment types in
several ways:
 Initial criticality calculations for relief devices should not be performed until after other fixed
equipment criticalities have been updated (i.e. after baseline/follow-up NDE inspections) to
accommodate for potential changes in the protected equipment corrosion rates.
 The Process Review for relief devices involves determining only two things:
1. What is the fouling potential for the relief device location?
2. Does the relief device location have redundancy?
 There is not currently a “Mass Criticality” function for calculating baseline criticality for relief
devices. Criticality must be calculated individually for each location/device.
The process for calculating criticality for relief devices is as follows:
1. Use the Equipment Browser to select the location/device:
2. Press the New button on the toolbar to create a criticality for the relief location/device:
3. Fill in the appropriate fields as required and press :
Select
Driving Risk
Enter a
description
of the risk
calculation
Enter the
name of who
performed
the
calculation.
Modify and/or input Probability and
Consequence values as appropriate.
4. Press on the toolbar to save the criticality run.
Review Baseline Criticality
The Site Coordinator should generate a Criticality Summary and review the baseline criticality
results to ensure that criticality values were generated for all assets and components in the
project scope of work.
Approval of the initial criticality is an official project hold point with signed review/approvals
required from: Capstone Risk Engineer, Capstone Corrosion Engineer, and the client project
representative.
Note: Baseline inspection planning cannot be performed until these approvals are obtained.
The Site Coordinator distributes copies of the Criticality Summary to these three individuals for
review and makes revisions as directed by them. The documented approvals can be an email
message, a memo, or a signed paper copy of the Criticality Summary.
A copy of the approved Criticality Summary will be retained in the Equipment Files, and the
three approvals will be retained as project correspondence in the Project Files.
Here are the guidelines the Capstone Risk Engineer uses to review the Criticality Summary:
 Look at wall ratio (If less than 1, need to understand why)

o (If less than 1, check required wall vs. new wall)
 Wall thickness
 Diameter
 Design pressure
 Material
 Compare operating temp/pressure to design
 Remaining Life ( If less that 0, need to understand why)
 Are the other mechanisms applied properly?
 Check Distribution of Risk Categories – Does it seem reasonable for the unit??
 Spot check Number/Confidence and last date of inspections
 Equipment
o Are double pipe exchangers modeled as Pipe
o Fin Fan Tubes – Adjust Minimum required wall if necessary
o Spheres – Divide calculated required wall thickness by 2
o Check if Susceptible to CUI
 Fluids
o Choosing Fluid – HC mixed streams
 Molecular weight/density
 Boiling Point
 Lightest (C5 vs. C6)
o Toxic Mixtures – Use % of total stream by weight
o Multiple Toxics – Evaluate both and use worst case
o Two Phase – Use Liquid
 General
o Intermittent service
 Corrosion Rate
 Process Conditions
 Fluid
 Temperature
o Change in service/used equipment
o Credit for repairs (Note: Consult with Corrosion Engineer)
o Credit for inspection
o Short term vs. long term corrosion rates
o CUI – Is the measured external corrosion rate greater than the calculated
external corrosion rate?
Updating Criticality
During an RBMI implementation project, criticality values require updating when:
 A new inspection has been performed – For example: at the completion of Baseline
NDE Inspections.
 Asset/component data affecting criticality has been changed – Examples include: an

equipment component was replaced or operating/process information has changed.
Fixed Equipment and Piping

The Site Coordinator will update criticality values for all equipment items when baseline
inspections are completed and NDE data has been evaluated. Due to the variability in
baseline inspection performed and their confidences, the mass criticality feature typically
cannot be used and the updates for each asset and component will have to be performed
individually.
The criticality updating process is as follows:
1. Use Work Flow Steps to work on the Criticality task and select the equipment asset to be
updated:
2. Press the New button on the toolbar and select the component that you want to create an
updated criticality for:
Note: In order to establish a criticality history for the

component, always create a new criticality run for
updates (don’t edit an existing one).
3. On the Criticality tab (first tab), update the following:
Select
Driving Risk
Enter a
description
of why risk is
being
updated.
Enter the name

of who
performed the
update.
4. If inspection(s) for internal corrosion were performed, update the following on the Internal
Corrosion tab:
Update the number of
inspections, Confidence,
and Date of Last
Inspection.
Note: An asset/component
that did not receive an
“actual” inspection, but was
represented by inspection
of another
asset/component still
requires updates in these
fields (see Inspection
Strategies)
Press this button to update

the ST and LT average
corrosion rates if NDE was
performed and entered into
the database.
Note: In order for these Once the corrosion rates have been updated, select the higher of the ST
values to update, the or LT average if you have 2 or more sets of readings on General
button must have been Corrosion. Consult Corrosion Engineer for Localized or Pitting.
previously pressed on the Exception: If the ST or LT average is 1/2 or less of the expected rate,
Evaluations tab in the reduce the expected rate by ½ and select the expected rate. For
NDE module for this asset. example, if the expected rate is 0.002 ipy and the ST and LT averages
are 0.0005 ipy, then the expected rate should be changed to 0.001 ipy
and it should be selected for this criticality update run.
5. If inspection(s) for external corrosion (CUI) were performed, update the following on the
External Corrosion tab:
Update the number of

inspections,
Confidence, and Date
of Last Inspection.
Note: An
asset/component that
did not receive an
“actual” inspection, but
was represented by
inspection of another
asset/component still
requires updates in
these fields (see
Inspection Strategies)
6. Although cracking inspections (MT, PT, Shearwave) are not typically performed as part of
RBMI project baseline inspections, criticality can be updated based on their results. If a
cracking inspection is performed, update the following on the Environmental Cracking
tab:
Update the
number of
inspections,
Confidence,
and Date of
Last
Inspection.
Also indicate
whether or not
damage was
found during
the inspection.
7. Press on the toolbar to save the updated criticality run.
8. Once criticality updates are complete for all assets/components in the project scope of
work, the Site Coordinator generates an updated Criticality Summary and transmits it to the
Risk Engineer for review and approval.
A copy of the approved updated Criticality Summary will be retained in the Equipment Files,
and the approval documentation will be retained as project correspondence in the Project
Files.
Relief Devices
Criticality values for relief devices are not typically updated as a result of baseline NDE
inspections. However, they are updated when the following occur:
 The relief device is replaced
 A relief test on the device is performed
 The corrosion rate for the protected equipment or the expected corrosion rate
changes
 The protected equipment components change
 The consequence values of the protected equipment components change
The criticality updating process for relief devices is as follows:
5. Use the Equipment Browser to select the equipment asset to be updated:
6. Press the New button on the toolbar to create an updated criticality for the relief device:
Note: In order to
establish a
criticality history
for the relief
device, always
create a new
criticality run for
updates (don’t edit
an existing one).
7. Modify the appropriate fields as required and press :
Select
Driving Risk
Enter a
description
of why risk is
being
updated.
Enter the
name of who
performed
the update.
Update Probability and Consequence values

as appropriate.
8. Press on the toolbar to save the updated criticality run.
Chapter 8 – Visual Inspections
8
Chapter
Inspection Drawings
Inspection drawings are used for three things:
1. Documenting the location of indications found during Visual and other NDE inspections
so that they can be accurately reported and/or resolved.
2. To aid and expedite location selection during Baseline Inspection Planning.
3. Documenting NDE inspection locations to ensure repeatability of readings taken
Inspection drawings are developed for every fixed equipment asset (excluding relief devices) in
the project scope of work. In some cases, inspection drawings may already exist. Existing
inspection drawings should be used, if possible, to minimize drawing time. However, these
drawings should be reviewed and enhanced if they do not meet the minimum requirements
described in this chapter.
Inspection drawings are prepared by qualified Capstone on-site personnel prior to performing
Visual Inspections so that they may be field verified during the inspection and be used to
document the inspection.
The General Drawing Process

Specific requirements for each equipment type will be described later in this chapter. The
general process for developing inspection drawings is as follows:
1. Locate Existing Inspection Drawings – existing inspection drawings may be found in

the client’s paper/electronic inspection files. If inspection drawings do not exist,
construction drawings for pressure vessels and storage tanks may be utilized.
Construction drawings are usually found in project books or equipment files.
Depending on their layout, construction isometric drawings can sometimes be used to

create inspection drawings for piping circuits. For example, if the piping sections
displayed on one construction isometric are so short that it requires four or more
construction isometrics to represent the same amount of piping that would have been
hand drawn on one sketch, then the construction isometrics should most likely not be
utilized.
Make copies of the existing drawings found so that they can be used to create
inspection drawings for the RBMI program.
2. Gather Drawing Materials – Make a copy of the unit plot plan. This can be used to
locate equipment items in the unit. For piping circuits, in addition to the plot plan, the
circuitized P&IDs should be used to locate the circuits in the process unit. Use 8 ½ x 11
graph or engineering paper for drawing pressure vessels and storage tanks. Use 8 ½ x
11 isometric paper for piping circuits. If existing drawings were found, use these to
develop the inspection drawings. A straight-edge (ruler) and circle template may also
be helpful when creating the drawings.
3. Select Equipment Items – Check the tracking list to select equipment items to be
drawn.
4. Locate Equipment in the Process Unit – Use the plot plan or information from plant
personnel to locate the equipment item(s) in the process unit.
5. Field Sketch the Equipment – Using blank drawing paper or an existing

inspection/construction drawing (if one was found), sketch the equipment item. Ensure
that the minimum requirements for information and level of detail are met (see sections
below for specific requirements for each equipment type).
6. Report Discrepancies – any differences found with the P&IDs, plot plans, etc. as
compared to field observations while sketching should be reported (see Documenting
Data Discrepancies and Redlines). Examples of P&ID discrepancies include incorrect
equipment numbers, incorrect line sizes, and missing equipment.
7. Submit the Inspection Drawing for Review – all completed inspection drawings are
logged on the appropriate equipment Tracking Lists and submitted for review (see
Reviewing Deliverables).
Piping Circuits
Piping circuit isometric drawings shall include the following details:
 North arrow (pointing towards upper right corner of page)

 Identify all connected piping systems
 Line numbers (from P&ID’s). If no line number is available, then identify the line size
(ex: 2”)
 Referenced equipment and equipment numbers (show where and how line connects)
 Indicate what part of the lines are insulated
 Dead legs
 Valve locations will be shown using the basic gate valve symbol (pressure relief,
check, and control valves are shown with standard symbols)
 Valve sizes
 Flange and reducer locations and sizes
 Thread-o-lets and weld-o-lets
 Estimated length of each line section / iso / circuit
 Flow directions if known (from P&ID or check valves)
 Pipe hanger and support locations

 Threaded or welded process connections (if visible and uninsulated)
The title block for the isometric drawing will be located in the lower right corner of the page and
will include the following:
 System ID
 Circuit ID
 P&ID number(s)
 First Initial and last name of sketcher
 Unit Name
 Date
 Total length of piping circuit (Ft.)
Vessels and Heat Exchangers
Vessel and exchanger inspection drawings shall include the following:
 View in which the equipment is sketched - the view in which the field sketch is drawn
is dependent on the orientation of the equipment:
o Horizontal equipment: Draw the sketch in one of the following orientations which
will show the most detail: “south view looking north”, “north view looking south”,
“east view looking west”, or “west view looking east”
o Vertical equipment: “South view looking north”
 Location of all manways and nozzles (use “NS” for near side and “FS” for far side)
 Saddle and support locations
 Indicate insulated parts and type of insulation (if known)
 Weld locations and dimensions (circ. and long. seams)
 Flow directions at nozzles (get from P&IDs)
 Nozzle orientations in separate view (if not clear in primary field sketch view)
 Equipment length (ft.)
 Equipment diameter (ft.)
 Locations of stiffener rings or insulation support rings
 Level bridle details
The title block shall include:
 Equipment identification number
 Unit name
 P&ID number
 First initial and last name of the sketcher
 Date
Storage Tanks
Inspection drawings for storage tanks should include the following minimum information and
level of detail:
 View in which the equipment is sketched - the drawing should be sketched in an
“Externally Rolled-Out” format indicating compass directions. A roof orientation
component should also be shown.
 Location of all manways and nozzles (use “NS” for near side and “FS” for far side)
 Saddle and support locations
 Indicate insulated parts and type of insulation (if known)
 Weld locations and dimensions (circ., long seams and repair welds)
 Flow directions at nozzles (get from P&ID’s)
 Nozzle orientations in separate view (if not clear in primary field sketch view)
 Equipment height (ft.)
 Equipment diameter (ft.)
 Locations of stiffener rings or insulation support rings
 Level bridle details
The title block shall include:
 Equipment identification number
 Unit name
 P&ID number
 First initial and last name of the sketcher
 Date
External Visual Inspections

External visual inspections are performed on all equipment assets in the project scope of work.
These inspections can be performed once the project scope has been defined.
The purpose of visual inspections for fixed equipment assets is to assess the integrity of the
equipment assets and to provide a count of potential inspection location categories. The count
of inspection location categories will be used as part of the RBMISM program to determine the
number of actual locations for Inspection Planning.
Qualified Capstone on-site inspection personnel perform visual inspections.
The External Visual Inspection Process

The visual inspection process for fixed equipment (excluding relief devices) is as follows:
1. Review Inspection History - review previous visual inspection reports and any other
inspection method reports to determine if there are indications or previous
recommendations that need to be followed up (see Reviewing Inspection and
Maintenance History).
2. Gather Materials –
a. Review the tracking lists to determine which assets need to be visually
inspected.
b. Make a copy of the unmarked original inspection drawing of the asset from the
equipment files.
c. Get a clean copy of the external visual inspection form for the equipment type
being inspected and fill out the header information.
d. Make a copy of the plot plan that can be used to locate equipment assets in the
process unit
e. Have the following inspection tools available while performing the external visual
inspection:
o Pit depth gage
o Scraper
o Wire brush
o Flashlight
o Magnet
o Flange rating chart
o Digital thickness meter (for verifying component thicknesses if necessary)
3. Field Verify Inspection Drawings/Equipment Data – field verify the inspection
drawing to determine if any equipment changes/modifications have occurred since the
last inspection. If differences are found, the inspector shall make corrections to original
inspection drawing in the equipment files.
The presence of differences in the inspection drawing requires that the equipment data
collection form (datasheet) be verified as well. Any changes affecting the datasheets
shall be reported to the Site Coordinator so that the RBMI database can be updated.
Data values to verify in particular include:
o Insulated (Y/N)
o Flange Ratings – compare to piping, construction, and or equipment design
specifications
o Material of Construction – whether carbon or stainless steel
o Nameplate Data – (Vessels and Tanks only) check the accuracy of information
recorded on the Field Verification Datasheet.
o Relief Device Settings – Vessels and Tanks only
4. Perform and Document the Visual Inspection - see sections below for details for
each equipment type.
5. Report Discrepancies and Redlines - any differences found with the P&IDs, plot
plans, etc. as compared to field observations during the visual inspection process
should be reported (see Documenting Data Discrepancies and Redlines). Examples of
P&ID discrepancies include incorrect equipment numbers, incorrect line sizes, and
missing equipment.
6. Report Nonconformances – report Rank 1 and Rank 2 nonconformances identified

during the visual inspection (see Evaluating and Reporting Non-conformances).
7. Submit the Inspection Report for Review - all completed inspections are logged on
the appropriate equipment Tracking Lists and submitted for review (see Reviewing
Deliverables).
8. Enter the Inspection Report – once reviewed, visual inspection reports are entered
into the RBMI database (see Finding and Entering Visual Inspections) and the original
reports are retained in the Equipment Files.
Piping Circuits
Using the Piping Visual Inspection Report form as a guide, inspect all items on the checklist as
well as any other items that need to be inspected based on good judgment. Here is a
description of the sections on the form:
Enter:
Circuit ID
Insulated (Yes or
No)
Whether or not
the pipe or
insulation jacket
is “sweating”.
Count the potential

Internal and
External (CUI)
inspection
locations (used for
inspection
planning)
Inspect for and

complete all
checklist items.
Enter details of
any checklist item
designated as
“Fair” or “Poor”.
The
Additional Comme
nts Form
can be used if
more entries are
needed for the
inspection.
Enter the
Inspector’s Name,
Company,
inspection date
and API 570
Certification
Number Initials and Dates are entered for
the persons checking and entering
the report
Note: During the performance of piping visual inspections, additional circuits may be identified
and others may be eliminated. The Inspector should report these changes to the Site
Coordinator so that changes can be made to the project scope and tracking lists (see Scope
Changes).
The following tables describe the fields of the Piping Visual Inspection Report:
External Location Categories – count the number of each external category observed for the
piping circuit. All categories apply to insulated circuits only except Soil-Air Interface. Note: 1
Don’t count items twice. 2 Not to be confused with recommended selection count in the
inspection strategies.
Field Name Description Examples
Barrier Penetrations Any place something protrudes from/into the insulation jacket.  Pipe hangars
 Pipe supports
 Valve stems
 Heat tracing
Things like flanged connections that are not
insulated are counted as Insulation Termination
because the entire circumference of the pipe is
exposed.
Damaged Insulation Any place there is an unexpected break in the insulation This number should equal the number of
jacket that exposes the insulation or pipe to the observations in “P42”. Note: Number of
atmosphere. observations and not VI numbers. VI numbers
may be grouped and you may have similar
observations grouped under one VI number.
Insulation Termination Any place where the insulation is designed to start or stop and  Uninsulated flanged connections (each side of
exposes the entire circumference of the pipe to the flange counts as 1)
atmosphere.
 Connection to uninsulated fixed equipment.
Vertical Runs Any place that insulated pipe is oriented vertically for more than  Lines down the sides of vertical vessels
six feet.
 Control loops
Horizontal Low Points Where a horizontal section of insulated pipe is lower than Examples are long runs that sag between supports.
the surrounding pipe. The bottoms of control loops will be counted as a
Vertical Run.
Soil-Air Interface Where the piping goes underground through soil, concrete, ---
or asphalt, pipe is partially buried, or the pipe is resting on
the ground.
Internal Location Categories – count the number of each internal category observed for the
piping circuit. Note: 1 Don’t count items twice. 2 Not to be confused with recommended
selection count in the inspection strategies.
Dead Legs A length of pipe where the flow is normally stagnant.  Vents
 Drains
 Bypass lines
 Pipe on the other side of a normally closed
valve
 Orifice flange piping
 Sections of pipe connected to the process but
not in service
Long Horizontal Runs Any place the pipe is oriented horizontally for more than 50 50’ – 99’ = 1, 100’ -149’ = 2, 150’ – 199’ = 3
ft. Note: Count 1 for ever 50 feet of pipe.
Erosion Zones Any place where the process flows at increased flow rates Downstream of the following:
carries solids or liquids, or where the flow is turbulent.
 Compressors
Note: This count covers erosion areas that aren’t covered
under elbows, reducers, and tees. This would be piping  Pumps
downstream of examples listed. This may also be additional
 Control valves
areas that may have been called out in the Corrosion Study.
 Orifices
Do not count Elbows, Reducers, Tees, or
thermowells as erosion zones.
Elbows Any place where the process flow changes direction. Examples are manufactured or mitered elbows
ranging from 22 1/2 to 180 as well as reducing
elbows. Not included are long radius bends.
Tees A three-way intersection of pipe.  Tees
 Stub-ins
Reducers Any place the pipe changes diameter, but not flow ---
direction.
Observations – As a minimum, inspect for all items on the checklist. Mark each observation
item with a check in one of the following columns:
 “Good/No” – The condition is good or the problem does not exist
 “NA” – The observation item is not applicable to the circuit being inspected
 “See Below” – The condition for the observation item is “Fair” or “Poor”. “Fair”
means an indication was observed, but does not require follow-up action or attention.
“Poor” means an indication requires attention and may need a Nonconformance
Report (NCR). Each indication with a condition of “Fair” or “Poor” must have an entry
made into the Additional Comments section.
Category Observation Description Examples NCR/Rank
Item
General P01 – Other Use this field to capture any GENERAL  Gouges Rank 2:
Piping (Please Explain) observations that cannot be included with the
other general items.  Grooves  Weld defects
 Dents  Distorted/bent piping
 Weld defects  Significant

dents/gouges
 Not in service
at time of  Temporary patch on
inspection. piping
Item
General P02 - Corrosion Look for corrosion of the pipe, supports, and External scattered Rank 2:
Piping connections. Mark FAIR if minor corrosion pitting to 0.15” noted
observed but no visible wall loss. Mark POOR in 3 ft section of  UT reading minus
if visible wall loss is observed. If no corrosion piping. external corrosion
observed, circle NO. depth measurement
results in remaining
For corroded pipe, use a pit depth gage to wall at or below
measure the maximum corrosion depth or minimum thickness
provide an estimate of the depth and also
record the linear length of each corroded area.  Severe corrosion
Record the fitting type where the corrosion is affecting the
observed in the comments column. serviceability of valves,
For corroded supports, do not need to supports, bolting, or
measure wall loss and do not need to indicate flanges
the extent of corrosion.
(The visual inspection is not intended to
capture all information needed for a full
evaluation, but does record enough
information to determine where additional
NDE is required.)
Note: All corrosion should be documented
in “P02” regardless of what piping
component the corrosion is on.
General P03 – Leaks Look for any leaks (e.g. liquid dripping, vapor  Process Leaks Rank 1: Process Leaks
Piping mist) or signs of leaks (e.g. stains, product
buildup) particularly around flanged  Product Rank 2: Evidence of Leaks
connections, packing glands, valve bonnets, residue on
and expansion joints. If process material is flanges
leaking notify an operator immediately. Signs
of leaks do not need to be reported
immediately, but should be noted on the
inspection report.
General P04 – Vibration Look for visually observable vibrating or  Excessive Rank 2:
Piping swaying lines especially large weights vibration
supported by a thin line (like a valve on a  Excessive movement
small diameter line), or branch connections.  Fretting or vibration
Also look for signs of vibration like abrasion on (rubbing)
 Fretting/rubbing with
supports, fretting, and metal wear. If line
wall loss (piping at or
movement is observed, look where the line is
below minimum
restrained for cracking. Identify the area of
thickness)
line movement and the restrained areas on
the inspection isometric. Provide an estimate Rank 3: Fretting/rubbing (no
of maximum line displacement and the significant wall loss)
potential cause of displacement (Sample
entry: +-0.25”). Vibration can cause fatigue
especially where the pipe is restrained from
both low cycle movement as well as high
cycle. Normal vibration because the unit is
running is not considered unacceptable
“vibration”. [API 570, paragraph 3.3.4]
General P05 – Look for long runs that are not straight, Pipe section May require an NCR
Piping Misalignment connections that are not square, and deflected down depending on the severity of
deformed vessel wall where the pipe approximately 8 the specific indication found.
connects. Misalignment can cause severe inches.
stresses in both the piping and the attached
equipment.
Note: misaligned flanges are documented
under P38 – Flanges.
Item
General P06 – Soil-Air Look for where the piping goes underground Wrap/Coating cut at None
Piping Interface through soil, concrete, or asphalt, pipe is grade
partially buried, or the pipe is resting on the
ground. For soil-air interface, determine if
there is evidence of corrosion or loss of
protective coating just below the surface by
digging away several inches of soil. If
corrosion is observed, document under P02 -
Corrosion.
For concrete or asphalt interfaces look for
signs of corrosion and note whether the seal
or caulking is intact. If the seal or caulking is
missing and the line is more than 10 years
old, it may be necessary to inspect beneath
the surface.
General P07 – Painted Look for external corrosion that is no longer Inactive pitting to Rank 2: Inactive pitting
Piping Inactive active and has been painted over. If the 0.05” depth in 6 x 8 resulting in remaining wall at
Corrosion corrosion appears active, document on item inch area or below minimum thickness
P02 – Corrosion. If there is visible wall loss,
measure the corrosion the same way as
explained in P02. Example is pitting that’s
been painted over. If the painting is bubbled
then there’s probably active corrosion that
should be documented with item P02.
General P08 – Coating/ Look for protective coating or painting failures  Scattered None
Piping Painting indicated by chalking, flaking, or chips. Also Coating Failure
note any pipe that is not painted. If corrosion
is observed, document it with item P02.  Uncoated
piping
Supports P21 - Other Use this field to capture any SUPPORT  Sagging Piping Rank 3:
(Please explain) observations that cannot be included with the
other support items.  Unsupported  Inadequate Support
Tubing
 Unsupported Tubing
Supports P22 – Support Look for shoes that are off their supports,  Missing shoe Rank 3 for all indications
Shoes bent, or missing.
 Gap between
shoe and
support beam
Supports P23 – Support Support members include pipe racks,  Inadequate Rank 3 for all indications
Members structural beams, dummy legs, and vertical Support
braces. Look for damaged, inadequate
support, or missing support members.  Missing
Dummy legs should not be filled with water or support or U-
be oriented such that they could fill with water. bolt
 Broken or bent
pipe support
 Loose or
missing U-bolt
 Support has
missing, loose
or short bolts
on supports
Supports P24 – Look for pipe hangers, brackets, or U-bolts  Hangar Rank 3 for all indications
Hangars/Bracket that do not support the pipe. Also look for disconnected,
s spring hangers that are “bottomed out” or loose, or
bent. broken
 Bolting/nuts on
hangar are
loose, missing,
or short bolted
Item
Connections P31 – Other Use this field to capture any CONNECTION or  ??? May require an NCR
and (Please explain) COMPONENT observations that cannot be depending on the severity of
Components included with the other connection items. the specific indication found.
Connections P32 – Expansion Look for unusual deformations, misalignment, External cracks May require an NCR
and Joint or displacements that may exceed design. observed on depending on the severity of
Components expansion joint the specific indication found.
Connections P33 – Small Specifically look at small branch connections  Missing plugs Rank 3:
and Branches (vents, drains, tubing, etc.), small bore piping
 Broken gauges  Missing cap/plug
Components and tubing because of the higher potential for
leaks. Small-bore piping is NPS 2 or less.  Small bore piping or
Look for broken pressure or temperature tubing is bent, crimped
gauges. Note whether vents and drains are or cracked
plugged. Note pipe line sizes of all
observations.  Small bore piping or
tubing fittings are loose
or missing
Connections P34 – “Short Bolting” - Look for adequate thread  Short bolting Rank 3 for all indications
and Inadequate engagement (no more than one thread on flange
Components Thread showing on inside of nut).
Engagement
Connections P35 - Bolting Look for missing bolts, loose bolts, damaged  Missing bolts Rank 3 for all indications
and threads, bent bolts, and whether the correct
 Bolts wrong
Components bolts were used. Compare the bolting in the
specification
field with the piping specification. If bolts are
missing, mark POOR on the report form. If  Loose bolts
corrosion is observed, document under P02 -
Corrosion.  Wrong size
bolts
Connections P36 – Socket A socket weld is where the pipe slips inside a Cracked fittings May require an NCR
and Welds fitting and is fillet welded around the pipe to depending on the severity of
Components the fitting. A threaded connection that is back the specific indication found.
welded will not look any different if there are
no threads showing. Look for cracks or
porosity in the welds that may allow a leak.
Connections P37 – Threaded Look for cross-threaded, stripped threads, Cross-threaded Rank 3 for all indications
and Connections and mechanical damage. fittings
Components
Connections P38 - Flanges Look for warped flanges, misaligned flanges,  Missing blind Rank 2:
and dissimilar flange ratings, and flanges with a flange
Components lower rating than specified in the piping  Cracked Flange
specification. Dissimilar flange rating exists  Cracked  Dissimilar flange
when a pair of mated flanges has different Flange ratings
pressure ratings. If dissimilar flange rating is
observed, measure the thickness of both  Dissimilar
mated flanges. If a blind flange is missing, flange ratings
mark POOR on the report form. Also ensure
that gasket is the proper size, if known. Rank 3: Missing Blind
Flange
Connections P39 - Valves Look for condition of bolts and condition of the  Missing May require an NCR
and stem. If missing hand wheel on valve (i.e. handweel depending on the severity of
Components cannot operate valve with valve wrench), mark the specific indication found.
FAIR on the report form.  Operability of
valve
Connections P40 – Leak Document the presence and location of leak  Leak clamp Rank 3 for all indications
and Clamps clamps. Leak clamps are considered present
Components temporary repairs and should be reported.
Item
Insulation P41 - Other Use this field to capture any INSULATION  Product stains None
observations that cannot be included with the on jacket
other insulation items.
 Moisture on
insulation
jacket
Insulation P42 - Damage Damage like tears and rips are defined as  Exposed Rank 1: Exposed asbestos
any unexpected break in the insulation jacket insulation insulation
that exposes the insulation or pipe to the Rank 2: Evidence of CUI
atmosphere. Look for evidence of corrosion  Missing
(requires follow-up)
under insulation like rust scale, bulging of the sections of
jacket, or rust streaks on the surface of the insulation
jacket. Note in Comments whether CUI is
suspected.  Torn insulation
Insulation P43 - Penetrations are defined as any place  Jacket bulging Rank 2: Evidence of CUI
Penetrations something protrudes from the insulation jacket (requires follow-up)
like pipe hangers and pipe supports. Look for
evidence of corrosion under insulation like rust
scale, bulging of the jacket, or rust streaks on
the surface of the jacket.
Insulation P44 -Jacket Look for missing or improperly connected  Missing jacket Rank 1: Exposed asbestos
insulation jacket. Any openings in the jacket insulation
for asbestos insulation should be reported to  Dented jacket
maintenance. (Example: dented jacket) If any
exposed insulation, document under P42
Damage.
Insulation P45 – Banding Banding - Look for broken or missing banding  Missing None
that may allow insulation jacket to loose its banding
seal and allow water in or loss of process
temperature.  Loose banding
Insulation P46 – Seals/Joints/Caulking - Look for cracked,  Missing Seals Rank 1: Exposed asbestos
Seals/Joints/ hard, or missing caulking or seals around insulation
Caulking insulation joints. Seals and joints can be  Cracked Seals
found at the end/edge of each jacket sheet,
where the pipe changes direction, at
intersections of pipe with other pipe or other
types of equipment, and at insulation
terminations.
Additional Comments – Make an entry for each unique indication type identified in the
Observations checklist. Here’s an example:
Every item
in the
checklist
must be
marked
Items marked “See

Below” must have
Note that the an entry in the
same Additional
indication ID Comments section
can be used
more than
once when
several
different
types of
indications
exist for one
ID
Enter the rank (1,2, or 3) in
Note that an the NCR column when the
The indication type indication found requires
reporting.
indication can have more
item ID from than one location
the checklist on the piping Provide any comments about
circuit. Note: A any indications observed or
Unique location location number whether there were problems in
numbers are may be used for making a complete inspection.
sequentially assigned several ID
to indication locations. numbers.
Every location on this
report should also be
identified on the
inspection drawing.

Using the Pressure Vessel External Visual Inspection Report form as a guide, inspect all items
on the checklist as well as any other items that need to be inspected based on good judgment.
Here is a description of the sections on the form:
Enter:
Equipment ID
Unit Name
Insulated (Yes or
No)
Count the potential

External (CUI)
inspection
locations (used for
inspection
planning)
Inspect for and

complete all
checklist items.
Enter details of
any checklist item
designated as
The
Additional Comme
nts Form
can be used if
more entries are
needed for the
inspection.
Enter the
Inspector’s Name,
Company,
inspection date
and API 510 Initials and Dates are entered for
Certification the persons checking and entering
Number the report
The following tables describe the fields of the Pressure Vessel External Visual Inspection
Report:
piping circuit. All categories apply to insulated or vessels only.
Barrier Penetrations Any place something protrudes from/into the insulation jacket  Nozzles
 Manways
 Pipe supports
 Insulated Level Bridles – Note: Count all

insulated level bridles as barrier penetrations
jacket that exposes the insulation or vessel to the observations in “V42”. Note: Number of
atmosphere. observations and not VI numbers. VI numbers
may be grouped and you may have similar
observations grouped under one VI number.
Vessel Supports The number of vessel supports observed during the external  Saddles
visual inspection.
 Support Legs
Insulation Rings The number of insulation support rings and stiffening rings on  Insulation support rings
the vessel or exchanger
 Stiffening rings
 “NA” – The observation item is not applicable to the equipment being inspected.
“Poor” means an indication requires attention and may need Nonconformance Report
(NCR). Each indication with a condition of “Fair” or “Poor” must have an entry made
into the Additional Comments section.
Item
General V01 – Other Use this field to capture any GENERAL  Gouges Rank 2:
(Please Explain) observations that have not been included with
the other GENERAL items. Examples  Air cooler  Weld defects
machine gouges, problems with air cooler components –
fan motors,  Significant gouges
louvers, motors, and fan blades.
louvers, fan Rank 3: air cooler
blades components – broken
louvers, fan blades, etc.
 Weld defects
 Not in service
at time of
inspection.
Item
General V02 - Corrosion Look for corrosion of the pressure vessel wall, External scattered Rank 2:
nozzles, and supports. Mark FAIR if minor pitting to 0.15” noted
corrosion observed but no visible wall loss. in 3 ft section around  UT reading minus
Mark POOR if visible wall loss is observed. If the lower manway external corrosion
no corrosion observed, circle NO. depth measurement
For visible wall loss, use a pit depth gage to wall at or below
record the size of each corroded area.  Severe corrosion
(The visual inspection is not intended to affecting the
capture all information needed for a full serviceability of valves,
evaluation, but does record enough supports, platforms,
information to determine where additional ladders, bolting, or
NDE is required.) flanges
Note: All indications of corrosion should be

documented under “V2”.
General V03 – Leaks Leaks - Look for any leaks (e.g. liquid  Process Leaks Rank 1: Process Leaks
dripping, vapor mist) or signs of leaks (e.g.
stains, product buildup) particularly around  Product Rank 2: Evidence of Leaks
flanged connections and expansion joints. If residue on
process material is leaking, notify an operator flanges
immediately. Signs of leaks do not need to be
reported immediately, but should be noted on
the inspection report.
General V04 – Vibration Vibration - Look for visually observable  Excessive Rank 2:
vibrating or swaying lines connected to the vibration
pressure vessel. If line movement is  Excessive movement
observed, look for distortion of the nozzles  Fretting or vibration
where the lines attach. Identify where the (rubbing)
lines attach on the pressure vessel sketch and
wall loss (piping at or
estimate the maximum displacement.
below minimum
thickness)
Rank 3: Fretting/rubbing (no
significant wall loss)
General V05 – Dissimilar Look for mated flanges that do not have the Dissimilar flange Rank 2 for all indications
Flange Rating same pressure rating. If dissimilar flanges, ratings
measure the thickness of each flange.
General V06 – Look for corroded or broken parts, cracks, and  Bent/ loose/ May require an NCR
Ladder/Stairway loose bolts. Bolts may need to be hammer missing rungs depending on the severity of
tested to ensure that they are not corroded the specific indication found.
just below the nut.  Loose/ bent/ or (For example, an unstable
missing ladder ladder may be considered a
Note: Use extreme caution when working
cage safety issue and therefore
with glass lined equipment; small bore piping
and corroded material. would be reported as a
Rank 1)
General V07 – Platform Look for corroded floor plates, damaged  Loose/ warped/ May require an NCR
handrails, and corroded or damaged support unbolted/ depending on the severity of
members. missing grating the specific indication found.
(For example, a missing
 Loose or section of grating may be
missing considered a safety issue
handrails and therefore would be
reported as a Rank 1)
General V08 – Guy Wires Look for loose wires, broken strands, corroded  Loose guy Rank 3 for all indications
wire and integrity of the connections to the wires
pressure vessel and ground anchor. Also look
at the wire rope clips at each end of the cable  Improperly
(refer to API 572, paragraph 8.3.7). installed saddle
clamps
Item
General V09 – Electrical Look for loose, broken, or corroded ground  Disconnected Rank 3: Ground wire
Ground cables and ground connections. Mark “poor” or frayed wire broken, cut, or loose
if the ground is broken, loose, or cut. Mark
“fair” if there is no ground.  Loose/broken
or missing
clamp
 Missing ground
wire
General V10 – Painted Look for external corrosion that is no longer Painted over pitting Rank 2: Painted inactive
Inactive active and has been painted over. If the corrosion/pitting with
Corrosion corrosion appears active, document on item measurable wall loss (at or
V2. If there is visible wall loss, measure the below minimum thickness)
corrosion the same way as explained in V2.
Example is pitting that’s been painted over. If
the paint is bubbled then there’s probably
active corrosion, which should be
documented, with item V2.
General V11 – Coating / Look for protective coating or painting failures  Coating failure None
Painting indicated by chalking, flaking, or chips. Also
note if the pressure vessel has not been  Uncoated
painted. If corrosion is observed, document it components
with item V2.
General V12 – Expansion Look for unusual deformations, misalignment,  Expansion joint May require an NCR
Joint or Bellows or displacements that may exceed design. misaligned depending on the severity of
the specific indication found.
 External cracks
on expansion
joint
General V13 – Gauge/Site Look for broken pressure or temperature  Broken gauge Rank 3 for all indications
Glass gauges, cracked site glass, and corrosion.
For insulated gauge/site glass, look for CUI  Missing gauge
especially where carbon steel or low alloy is
connected to high alloy materials.
General V14 - Shell Look for distortion, out of plumb, blisters, etc.  Buckling Rank 2:
Document corrosion in V2.
 Bulging  Shell is dented or
distorted
 Temporary
patch on shell  Temporary patch on
shell
 Dents
Supports V21 – Other Use this field to capture any SUPPORT  Inadequate Rank 3:
(Please explain) observations that cannot be included with the supports  Inadequate support
other SUPPORT items. (example:
wood block)  Loose or bent support
 Loose or bent
support
 Missing shims
Supports V22- Look for cracked or spalling concrete and  Cracking or Rank 3: Concrete cracked
Foundation settling of the foundation. Damaged concrete spalling of or missing
may be caused by excessive heat, foundation or
mechanical shock, corrosion of the concrete pedestal
reinforcing steel, or freeze damage.
 Ground
settling
 Exposed rebar
Item
Supports V23 – Anchor Look for corroded or missing bolts. Also look  Missing, Rank 3: Anchor bolts/nuts
Bolts for anchor bolts that are loose but not broken, bent, loose, missing, or short
designed to be loose. or wrong size bolted
anchor nuts
 Missing nuts
Supports V24 – Saddle/ On horizontal vessels look for crevice  Buckling of Rank 2: Buckling of skirt
Skirt corrosion, general condition of the saddle, and skirt
whether an improper material (like wood) was Rank 3: All other indications
used to support the pressure vessel. On  Gap between
vertical vessels looks for distortions in the vessel and
skirt, corrosion, and general condition of the saddle
skirt. Use flashlight and mirror to inspect
 Shifted saddle
inside all vessel skirts.
 Plugged or
missing weep
holes on
welded
saddles
 Broken saddle
attachment
welds
Supports V25 – Davit Look for crevice corrosion and signs of  Bent or None
excessive mechanical loading. disconnected
davit
 Hinge appears
inoperable
Supports V26 - Look for cracking or spalling that may have  Cracking or None
Fireproofing caused corrosion under the fireproofing. spalling of
fireproofing
 Missing/ loose/
or blistering
fireproofing
Connections V31 – Other Use this field to capture any CONNECTION ? May require an NCR
(Please explain) observations that cannot be included with the depending on the severity of
other CONNECTION items. the specific indication found.
Connections V32 – Small Specifically look at small branch connections  Missing plugs Rank 3 for all indications
Branches (vents, drains, etc.), small bore piping and
tubing because of the higher potential for  Unsupported
leaks. Small-bore piping is NPS 2 or less. piping or tubing
Look for cracked welds, vibration,
misalignment, improper support, and  Bent piping
restrained areas. Note whether vents and  Crossthreaded
drains are plugged. fittings
Connections V33 - Nozzles Look for signs of excessive external loading,  Bent or Rank 2: Nozzle dented,
distortion, corrosion, and whether flanges deflected cracked, or bent
have proper bolting (document bolting nozzles
problems in field # V37). Look at welds for
excessive undercut or lack of fusion.  Weld defects
on nozzles
Connections V34 - Manways Look for signs of excessive external loading,  Weld Defects May require an NCR
corrosion, and whether flanges have proper depending on the severity of
bolting (document bolting problems in field the specific indication found.
#V37). Look at welds for excessive undercut
or lack of fusion.
Item
Connections V35 – Look for plugged weep holes, signs of the  Missing weep Rank 2: No weep hole on
Reinforcing process leaking, and cracked welds. holes reinforcing pad
Pads Rank 3: Plugged weep hole
 Weep holes
obstructed
Connections V36 – Look for adequate thread engagement (no Short bolted Rank 3 for all indications
Inadequate more than one thread inside nut). If yes, this
Thread is a code violation.
Engagement
Connections V37 - Bolting Look for missing bolts, damaged threads, bent  Missing bolts Rank 3 for all indications
bolts, and whether the correct bolts were
 Bolts wrong
used. Compare the bolting in the field with the
specification
bolting defined by the pressure vessel design
and piping specifications. If bolts are missing,  Loose bolts
mark POOR on the report form. If corrosion is
observed, document under P02 - Corrosion.  Wrong size
bolts
Connections V38 - Flanges Look for warped or misaligned flanges. If  Missing blind Rank 2:
blind flange is missing, mark POOR on the flange
report form.  Cracked Flange
 Cracked  Dissimilar flange
Flange ratings
 Dissimilar
flange ratings Rank 3: Missing Blind
Flange
Connections V39 – Leak Document the presence and location of leak  Leak clamp Rank 3 for all indications
Clamps clamps. Leak clamps are considered present
temporary repairs and should be reported.
Insulation V41 - Other Use this field to capture any INSULATION  Product stains None
(Please explain) observations that cannot be included with the on jacket
other INSULATION items.
 Moisture on
insulation
jacket
Insulation V42 - Damage Damage, like tears and rips, is defined as any  Exposed Rank 1: Exposed asbestos
unexpected break in the insulation jacket that insulation insulation
exposes the insulation or pressure vessel to
the atmosphere. Look for evidence of  Missing Rank 2: Evidence of CUI
corrosion under insulation like rust scale, sections of (requires follow-up)
bulging of the jacket, or rust streaks on the insulation
surface of the jacket. Note in Comments
whether CUI is suspected.  Torn insulation
Insulation V43 - Penetrations are defined as any place  Jacket bulging Rank 2: Evidence of CUI
Insulation V44 -Jacket Look for missing or improperly connected  Missing jacket Rank 1: Exposed asbestos
maintenance. If any exposed insulation,
document under V42 Damage.
Insulation V45 – Banding Look for broken or missing banding that may  Missing None
allow insulation jacket to loose its seal and banding
allow water in or loss of process temperature.
 Loose banding
Item
Insulation V46 – Look for cracked, hard, or missing caulking or  Missing Seals Rank 1: Exposed asbestos
Seals/Joints/ seals around insulation joints. Seals and insulation
Caulking joints can be found at the end/edge of each  Cracked Seals
jacket sheet, at intersections with pipe, and at
insulation terminations.
Relief Device V51 – Other Use this field to capture any RELIEF DEVICE ? ?
other RELIEF DEVICE items. This would
include observations on piping up to the PSV.
Relief Device V52 - Corrosion Same as V2, but record relief device corrosion  Light surface Rank 3: Corrosion
here. corrosion on appears to affect the
valve operability of the valve
 Severe
corrosion
appearing to
affect valve
operability
Relief Device V53 - Leaks Same as V3, but record relief device leaks  Process leaks Rank 1: process leak
here. relieving to atmosphere
 Evidence of
leaks Rank 2:
 Process leak through
device to
flare/blowdown
system
 Evidence of leaks
Relief Device V54 – Look for block valves upstream or  Block valve Rank 1: block valve closed
Restricted downstream of the pressure-relieving device chained
Inlet/Outlet that are a smaller diameter than the maximum closed Rank 3:
diameter of the relief device. Also make sure
 No car seal  No car seal
that block valves are open. Note whether any
block valves are not chained and locked in the  Restricted inlet/outlet
open position.  Restricted
outlet (ex:
reducer on
PSV outlet
piping)
Relief Device V55 – Manual Manual Operation Lever - Look for bent or Missing handle Rank 3 for all indications
Operation corroded lever and connecting pins.
Lever
Relief Device V56 – Tag Record the actual information on the most --- None
Information recent Test Tag, P&ID, and the Valve ID Tag.
Valve ID is the unique number shown on the
Test Tag assigned to the valve. Location ID is
the P&ID location number shown on the P&ID.
The Location ID and Valve ID may or may not
be the same number. Set Pressure is the
most recent set pressure shown on the Test
Tag. Test Date is the most recent test date
shown on the Test Tag. Size is the valve size
shown on the Valve ID Tag. Serial Number is
the serial number shown on the Valve ID Tag.
Model Number is the model number shown on
the Valve ID Tag. For any items not defined
on the test tag or ID tag, put NA for Not
Applicable.
Every item
in the
checklist
must be
marked
Items marked
“See Below”
must have an
entry in the
Additional
Comments
section
Note that the

same
indication ID
can be used
more than
once when
several
different
types of
indications
exist for one
ID
Enter the rank (1,2, or
Note that an 3) in the NCR column
The
indication type when the indication
indication found requires
can have more
item ID from reporting.
than one location
the checklist
on the vessel.
Note: A location Provide any comments about
Unique location number may be any indications observed or
numbers are used for several whether there were problems in
sequentially assigned ID numbers. making a complete inspection.
to indication locations.
identified on the
inspection drawing.
Storage Tanks
Using the Storage Tank External Visual Inspection form as a guide, inspect all items the
checklist as well as any other items that need to be inspected based on good judgment. Here
is a description of the sections on the form:
Enter:
Equipment ID
Unit Name
Insulated (Yes or
No)
Count the potential

External (CUI)
inspection
locations (used for
inspection
planning)
Inspect for and

complete all
checklist items.
Enter details of
any checklist item
designated as
The
Additional Comme
nts Form
can be used if
more entries are
needed for the
inspection.
Enter the
Inspector’s Name,
Company,
inspection date
and API 653
Certification Initials and Dates are entered for
Number the persons checking and entering
the report
The following tables describe the fields of the Storage Tank External Visual Inspection Report:
piping circuit. All categories apply to insulated vessels only.
Barrier Penetrations Any place something protrudes from/into the insulation jacket  Nozzles
 Manways
 Pipe supports
 Insulated Level Bridles – Note: Count all

insulated level bridles as barrier penetrations
jacket that exposes the insulation or tank to the observations in “V42”.
atmosphere.
Insulation Rings The number of insulation support rings on the storage tank Insulation support rings
“Poor” means an indication requires attention and a Nonconformance Report (NCR).
Each indication with a condition of “Fair” or “Poor” must have an entry made into the
Additional Comments section.
Item
General T01 – Other Use this field to capture any GENERAL ? ?

(Please observations that have not been included with
Explain) the other GENERAL items.
General T02 - Corrosion Look for corrosion of the storage tank wall, Scattered pitting to Rank 2:
nozzles, and supports. Mark FAIR if minor 0.1” in a 6 x 6” area
corrosion observed but no visible wall loss.  UT reading minus
Mark POOR if visible wall loss is observed. If external corrosion
no corrosion observed, circle NO. depth measurement
For visible wall loss, use a pit depth gage to wall at or below
record the size of each corroded area.  Severe corrosion
affecting the
(The visual inspection is not intended to serviceability of
capture all information needed for a full valves, supports,
evaluation, but does record enough platforms, ladders,
information to determine where additional bolting, or flanges
NDE is required.)
Item
General T03 – Leaks Look for any leaks (e.g. liquid dripping, vapor  Process Rank 1: Process Leaks
mist) or signs of leaks (e.g. stains, product Leaks
buildup) particularly around flanged Rank 2: Evidence of Leaks
connections and expansion joints. If process  Product
material is leaking, notify an operator residue on
immediately. Signs of leaks do not need to be flanges
reported immediately, but should be noted on
General T04 – Vibration Look for visually observable vibrating or  Excessive Rank 2:
swaying lines connected to the storage tank. vibration
If line movement is observed, look for  Excessive movement
distortion of the nozzles where the lines  Fretting or vibration
attach. Identify where the lines attach on the (rubbing)
storage tank sketch and estimate the wall loss (piping at or
maximum displacement. below minimum
thickness)
Rank 3: Fretting/rubbing (no
significant wall loss)
General T05 – Dissimilar Look for mated flanges that do not have the Dissimilar flange Rank 2 for all indications
Flange Rating same pressure rating. If dissimilar flanges, ratings
measure the thickness of each flange.
General T06 – Ladder/ Ladder/Stairway - Look for corroded or  Bent/ loose/ May require an NCR
Stairway broken parts, cracks, and loose bolts. Bolts missing rungs depending on the severity of
may need to be hammer tested to ensure that the specific indication found.
they are not corroded just below the nut.  Loose/ bent/ or (For example, an unstable
missing ladder ladder may be considered a
Note: Use extreme caution when working cage safety issue and therefore
with glass lined equipment; small bore piping
would be reported as a
and corroded material.
Rank 1)
General T07 – Platform Platform - Look for corroded floor plates,  Loose/ warped/ May require an NCR
damaged handrails, and corroded or damaged unbolted/ depending on the severity of
support members. missing grating the specific indication found.
(For example, a missing
 Loose or section of grating may be
missing considered a safety issue
handrails and therefore would be
reported as a Rank 1)
General T08 – Electrical Electrical Ground - Look for loose, broken, or  Disconnected Rank 3: Ground wire
Ground corroded ground cables and ground or frayed wire broken, cut, or loose
connections. Mark “poor” if the ground is
broken, loose, or cut. Mark “fair” if there is no  Loose/broken
ground. or missing
clamp
 Missing ground
wire
General T09 – Cathodic For impressed current systems, checks ? ?
Protection functionality of the system including the
condition of rectifier and also verify for proper
amps readings. For buried anode systems,
check condition of wiring and also verify
proper amps readings.
General T10 – Painted Look for external corrosion that is no longer Painted over pitting Rank 2: Painted inactive
Inactive active and has been painted over. If the corrosion/pitting with
Corrosion corrosion appears active, document on item measurable wall loss (at or
T2. If there is visible wall loss, measure the below minimum thickness)
corrosion the same way as explained in T2.
Example is pitting that’s been painted over. If
the paint is bubbled then there’s probably
active corrosion that should be documented
with item T2.
Item
General T11 – Coating / Look for protective coating or painting failures  Coating failure None
Painting indicated by chalking, flaking, or chips. Also
note if the storage tank has not been painted.  Uncoated
If corrosion is observed, document it with item components
T2.
General T12 – Level Look for cracked sight glass and missing or  Broken gauge Rank 3 for all indications
Gauge damaged sight glass protector. For insulated
gauge/site glass, look for CUI especially  Loose gauge
where carbon steel or low alloy is connected
 Missing gauge
to high alloy materials. If corrosion is
observed, document it with item T2.
General T13 – Bottom Look at base for evidence of leaks, settling or Bottom distorted, Rank 2 for all indications
distortion. If corrosion is observed, document cracked or buckled
it with item T2.
General T14 – Secondary Check the integrity of the retaining wall ? ?

Containment surrounding the storage tank. If the retaining
wall is concrete, check for cracks, obstructed
drains, etc.
General T15 - Shell Look for distortion including out-of-roundness,  Buckling Rank 2:
buckling, flat spots, and peaking banding at
weld locations. Also check for cracks and  Bulging  Shell is dented or
laminations. If corrosion is observed, distorted
 Temporary
document it with item T2.
patch on shell  Temporary patch on
shell
 Dents
General T16 - Roof Look for cracks or punctures in roof plates. Roof dented, May require an NCR
For floating roofs, examine pontoons and cracked, distorted, depending on the severity of
seals. buckled, or bulging the specific indication found.
General T17 – Check fan blades, rotation speed, look for ? ?
Agitator/Mixer erosion on blades, condition of catwalk to
center , excessive vibration, and overfilling of
tanks.
Supports T31 – Other Use this field to capture any SUPPORT  Inadequate Rank 3:
(Please explain) observations that cannot be included with the supports  Inadequate support
other SUPPORT items. (example:
wood block)  Loose or bent support
 Loose or bent
support
 Missing shims
Supports T32- Look for cracked or spalling concrete and  Cracking or Rank 3: Concrete cracked
Foundation settling of the foundation. Damaged concrete spalling of or missing
may be caused by excessive heat, foundation or
mechanical shock, corrosion of the concrete pedestal
reinforcing steel, or freeze damage.
 Ground
settling
 Exposed rebar
Supports T33 – Anchor Look for corroded or missing bolts. Also look  Missing, Rank 3: Anchor bolts/nuts
Bolts for anchor bolts that are loose but not broken, bent, loose, missing, or short
designed to be loose. or wrong size bolted
anchor nuts
 Missing nuts
Supports T34 - Look for corrosion on shell stiffeners and ? ?

Windgirders windgirders. Also look for corrosion and
cracking on attachment welds for these
components.
Item
Connections T41 – Other Use this field to capture any CONNECTION ? May require an NCR
other CONNECTION items. the specific indication found.
Connections T42 – Small Specifically look at small branch connections  Missing plugs Rank 3 for all indications
Branches (vents, drains, etc.), small bore piping and
tubing because of the higher potential for  Unsupported
leaks. Small-bore piping is NPS 2 or less. piping or tubing
Look for cracked welds, vibration,
misalignment, improper support, and  Bent piping
restrained areas. Note whether vents and  Crossthreaded
drains are plugged. fittings
Connections T43 - Nozzles Nozzles - Look for signs of excessive external  Bent or Rank 2: Nozzle dented,
loading, distortion, corrosion, and whether deflected cracked, or bent
flanges have proper bolting (document bolting nozzles
problems in field # T49). Look at welds for
excessive undercut or lack of fusion.  Weld defects
on nozzles
Connections T44 – Pipe Look for misalignment and lack of support on ? ?

Manifolds piping. Also check the valves and gauges on
the manifold.
Connections T45 – Swing Look for lack of support and cracks in flexible ? ?
Lines joints. Also check the condition of the support
cable.
Connections T46 – Manways/ Look for signs of excessive external loading,  Weld Defects May require an NCR
Hatches misalignment, corrosion, and whether flanges depending on the severity of
have proper bolting (document bolting the specific indication found.
problems in field #T49). Look at welds for
cracking, excessive undercut or lack of fusion.
Also check the condition of hinges and davits.
Connections T47 – Look for plugged weep holes, signs of the  Missing weep Rank 2: No weep hole on
Reinforcing process leaking, and cracked welds. holes reinforcing pad
Pads Rank 3: Plugged weep hole
 Weep holes
obstructed
Connections T48 – Look for adequate thread engagement (no Short bolted Rank 3 for all indications
Inadequate more than one thread inside nut). If yes, this
Thread is a code violation.
Engagement
Connections T49 - Bolting Look for missing bolts, damaged threads, bent  Missing bolts Rank 3 for all indications
 Bolts wrong
used. Also look for corrosion particularly on
specification
insulated storage tanks where carbon steel or
low alloy bolts were used in high alloy  Loose bolts
components. Compare the bolting in the field
with the bolting defined by the tank design and  Wrong size
piping specifications. If bolts are missing, bolts
mark POOR on the report form.
Connections T50 - Flanges Look for warped or misaligned flanges. If  Missing blind Rank 2:
blind flange is missing, mark POOR on the flange
report form.  Cracked Flange
 Cracked  Dissimilar flange
Flange ratings
 Dissimilar
flange ratings Rank 3: Missing Blind
Flange
Connections T51 – Leak Document the presence and location of leak  Leak clamp Rank 3 for all indications
Clamps clamps. Leak clamps are considered present
temporary repairs and should be reported.
Item
Insulation T61 - Other Use this field to capture any INSULATION  Product stains None
(Please explain) observations that cannot be included with the on jacket
other INSULATION items.
 Moisture on
insulation
jacket
Insulation T62 - Damage Damage, like tears and rips, is defined as any  Exposed Rank 1: Exposed asbestos
unexpected break in the insulation jacket that insulation insulation
exposes the insulation or pressure vessel to
the atmosphere. Look for evidence of  Missing Rank 2: Evidence of CUI
corrosion under insulation like rust scale, sections of (requires follow-up)
bulging of the jacket, or rust streaks on the insulation
surface of the jacket. Note in Comments
whether CUI is suspected.  Torn insulation
Insulation T63 - Penetrations are defined as any place  Jacket bulging Rank 2: Evidence of CUI
Insulation T64 -Jacket Look for missing or improperly connected  Missing jacket Rank 1: Exposed asbestos
maintenance.
Insulation T65 – Banding Look for broken or missing banding that may  Missing None
allow insulation jacket to loose its seal and banding
allow water in or loss of process temperature.
 Loose banding
Insulation T66 – Look for cracked, hard, or missing caulking or  Missing Seals Rank 1: Exposed asbestos
Seals/Joints/ seals around insulation joints. Seals and insulation
Caulking joints can be found at the end/edge of each  Cracked Seals
jacket sheet, at intersections with pipe, and at
insulation terminations.
Relief Device T71 – Other Use this field to capture any RELIEF DEVICE ? ?
other RELIEF DEVICE items. This would
include observations on piping up to the PSV
or Vacuum Vent.
Relief Device T72 - Corrosion Same as T2, but record relief device corrosion  Light surface Rank 3: Corrosion
here. corrosion on appears to affect the
valve operability of the valve
 Severe
corrosion
appearing to
affect valve
operability
Relief Device T73 - Leaks Same as T3, but record relief device leaks  Process leaks Rank 1: process leak
here. relieving to atmosphere
 Evidence of
leaks Rank 2:
device to
flare/blowdown
system
Item
Relief Device T74 – Look for block valves upstream or  Block valve Rank 1: block valve closed
Restricted downstream of the pressure-relieving device chained
Inlet/Outlet that are a smaller diameter than the maximum closed Rank 3:
diameter of the relief device. Also make sure
 No car seal  No car seal
that block valves are open. Note whether any
block valves are not chained and locked in the  Restricted inlet/outlet
open position.  Restricted
outlet (ex:
reducer on
PSV outlet
piping)
Relief Device T75 – Manual Manual Operation Lever - Look for bent or Missing handle Rank 3 for all indications
Operation corroded lever and connecting pins.
Lever
Relief Device T76 – Tag Record the actual information on the most --- None
Information recent Test Tag, P&ID, and the Valve ID Tag.
Valve ID is the unique number shown on the
Test Tag assigned to the valve. Location ID is
the P&ID location number shown on the P&ID.
The Location ID and Valve ID may or may not
be the same number. Set Pressure is the
most recent set pressure shown on the Test
Tag. Test Date is the most recent test date
shown on the Test Tag. Size is the valve size
shown on the Valve ID Tag. Serial Number is
the serial number shown on the Valve ID Tag.
Model Number is the model number shown on
the Valve ID Tag. For any items not defined
on the test tag or ID tag, put NA for Not
Applicable.
Every item
in the
checklist
must be
marked
Items marked
“See Below”
must have an
entry in the
Additional
Comments
section
Note that the

same
indication ID
can be used
more than
once when
several
different
types of
indications
exist for one
ID
Enter the rank (1,2, or 3)
Note that an in the NCR column when
indication type the indication found
The can have more requires reporting.
indication than one
item ID from location on the
the checklist storage tank. Provide any comments about
any indications observed or
Unique location whether there were problems in
numbers are making a complete inspection.
sequentially assigned
identified on the
inspection drawing.
Relief Devices
In-service external visual inspections are performed on all relief devices in the project scope of
work to identify conditions or situations that could impede the proper functioning of the devices.
The visual inspection process for relief devices differs from the other equipment types because
the visual inspection and field data collection are performed at the same time (see Relief
Devices data collection). Also, those relief devices that are protected by rupture disks require
an additional visual inspection be performed on the rupture disk.
The relief device visual inspection process is as follows:
a. Review the tracking lists to determine which device location IDs need to be
visually inspected.
b. Get clean copies of the appropriate inspection report forms. The report form
utilized for the visual inspections depends on the type of relief device installed at
each location. Review the location IDs on the P&IDs to determine if the device
type is a relief valve or a vacuum vent.
Vacuum vents are typically installed on storage tanks and are externally
inspected as part of the Storage Tank External Visual Inspection. Pressure
relief valves are installed on pressure vessels/exchangers and process piping.
For pressure relief valves, use the Pressure Relief Valve Visual Inspection
Report form and the Rupture Disk Visual Inspection Report form (if the valve is
protected by a rupture disk).
Use the unit P&IDs or relief device datasheets to help determine the location of
relief devices by identifying which equipment assets they are protecting. Then
make a copy of the plot plan that can be used to locate relief devices (by the
equipment they are connected to) in the process unit.
3. Field Verify P&IDs/Equipment Data – field verify the P&IDs to determine if any
equipment changes/modifications have occurred since the last inspection.
The presence of differences on the P&IDs requires that the relief device data collection
form (datasheet) be verified as well. Any changes affecting the datasheets shall be
reported to the Site Coordinator so that the RBMI database can be updated.
Data values to verify in particular include:

o Relief Set Pressure
o Serial Number
4. Collect Relief Device Data – using the Relief Device Data Collection form (see Relief
Device data collection).
5. Perform and Document the Visual Inspection – see section below for performing
relief valve and rupture disk visual inspections. Note: These inspections should be
performed at the same time if a rupture disk protects the relief valve.
P&ID discrepancies include incorrect relief device location numbers, valve sizes, and
set pressures.
7. Report Non-conformances – report Rank 1 and Rank 2 non-conformances identified

during the visual inspection (see Evaluating and Reporting Non-conformances).
8. Submit the Inspection Report for Review - all completed inspection reports are
logged on the relief device Tracking Lists and submitted for review (see Reviewing
Deliverables).
into the RBMI database (see Finding and Entering Visual Inspections)
Documenting Pressure Relief Valve Visual Inspections
Using the Pressure Relief Valve Visual Inspection Report form as a guide, inspect all items on
the checklist as well as any other items that need to be inspected based on good judgment.
Enter the header

information for the
location and device.
Enter Background
information:
Whether or not the
valve is insulated
The set pressure
shown on the valve tag
The last inspection
date shown on the
valve tag
The serial number on
the valve tag
Enter the
Inspector’s
Name, and
Company
Inspect for and

complete all
checklist items.
Summarize the
indications found
during the
inspection.
Enter a
Initials and Dates are entered location
for the persons checking and Enter the rank (1,2, or 3) description and
entering the report in the NCR column when a comment for
the indication found any indication
requires reporting. found.
Observations - As a minimum, inspect for all items on the checklist. Mark each observation
 “Good” or “NA” – The condition is good, the problem does not exist, or the observation
item is not applicable to the valve being inspected.
 “Yes” – The condition being inspected for exists. Note: This may or may not require a
location and comment. For example: if “Vibration” is marked “Yes”, a location and
comment are required. However, if “Block Valves Sealed Open” is marked “Yes”, then
no comments are required because this is the desired condition for the valve. Any item
marked “Yes” that requires attention should have a Nonconformance Report (NCR)
generated.
 “No” – The condition being inspected for does not exist. Note: This may or may not
require a location and comment. For example, if “Block Valves Sealed Open” is
marked “No”, a location and comment are required. If “Vibration” is marked “No”, then
no comments are required because this is the desired condition for the valve. Any item
marked “No” that requires attention should have a Nonconformance Report (NCR)
generated.
 “Poor” means an indication requires attention and a Nonconformance Report (NCR).
The following table describes the fields of the Inspection Comments section of the Pressure
Relief Valve Visual Inspection Report.
Item
General R01 – Other Use this field to capture any GENERAL  Missing Tag Rank 1: Incorrect relief set
(Please Explain) observations that have not been included with pressure (higher than vessel
other items.  Icing design)
 Incorrect Set
Rank 2:
Pressure
 Valve Tag missing
 Incorrect relief set

pressure (lower than
vessel design)
General R02 - Corrosion Look for corrosion of the valve body, bolting, External scattered May require an NCR
flanges, supports, and vent piping. Mark FAIR pitting to 0.15” noted depending on the severity of
if minor corrosion observed but no visible wall on valve body the specific indication found.
loss. Mark POOR if visible wall loss is
observed. If no corrosion observed, circle
NO.
For visible wall loss, use a pit depth gage to
measure the maximum corrosion depth or
record the size of each corroded area.
(The visual inspection is not intended to
capture all information needed for a full
evaluation, but does record enough
information to determine where additional
NDE is required.
Note: All indications of corrosion should be
documented under “R02”.
Item
General R03 – Leaks Look for any leaks (e.g. liquid dripping, vapor  Process Leaks Rank 1: Process Leaks
mist) or signs of leaks (e.g. stains, product
buildup) particularly around flanged  Product Rank 2: Evidence of Leaks
connections.. If process material is leaking, residue on
notify an operator immediately. Signs of leaks flanges
do not need to be reported immediately, but
should be noted on the inspection report.
General R04 – Device Look for leakage or evidence of leakage  Burst rupture Rank 1:
Leak Through through the relief device by observing for fluid disk
or vapors at the vent piping outlet, vent piping  Process leak
drains, or flow noises through the valve.  Vapors at vent relieving to
outlet atmosphere
 Burst rupture disk
Rank 2:
device to
flare/blowdown
system
General R05 – Vibration Look for visually observable vibrating or  Valve rubbing Rank 2: Excessive
swaying equipment and lines connected to the against railing movement or vibration
relief valve. Also look for signs of vibration
like abrasion on supports, fretting, and metal  Valve vibrating Rank 3: Fretting/rubbing (no
wear. If movement is observed, look for with significant wall loss)
distortion of the flanges and nozzles where displacement
the lines or equipment attach. Describe where of +- 2 inches
the vibration is observed and estimate the
maximum displacement in inches.
General R06 – Look for connections that are not square and Relief outlet piping is May require an NCR
Misalignment deformation of the piping and/or equipment deflected up depending on the severity of
that the relief valve is connected to. approximately 1 foot. the specific indication found.
General R07 – Piping Look for plugged vent piping, blinds,  Plugged vent Rank 1: Blocked flow to or
Obstruction dented/deformed piping or any other condition piping from relief valve
that may obstruct flow to and from the relief
valve.  Closed block Rank 2: Restricted flow to or
valves (vessel from relief valve
in service)
General R08 – Block Ensure that all block valves to and from the Valve not car sealed Rank 3 for all indications
Valves Sealed relief valve are car-sealed open.
Open
General R09 – Spring Check that seal on the spring is present and Spring seal missing None
Tamper Seal in-place.
Intact
General R10 – Rupture Look at the flow arrow or other indicator on Rupture disk Rank 2 for all indications
Disk Orientation the rupture disk holder to verify that it is installed upside
Correct installed with the correct side to pressure. down
Supports R11 – Insulation Note damaged or missing insulation on the  Exposed Rank 1: Exposed asbestos
relief valve. Look for evidence of corrosion insulation insulation
under insulation like rust scale, bulging of the
jacket, or rust streaks on the surface of the  Missing Rank 2: Evidence of CUI
jacket. Note in Comments whether CUI is sections of (requires follow-up)
suspected. insulation
 Torn insulation
Supports R21 – Other Use this field to capture any SUPPORT Unsupported Tubing Rank 3: Unsupported
(Please explain) observations that cannot be included with the Tubing
other SUPPORT items.
Item
Supports R22 – Discharge Look for damaged, inadequate support, or  Inadequate Rank 3 for all indications
Supports missing support members on the relief valve Support
and vent piping.
 Missing
support or U-
bolt
 Broken or bent
pipe support
 Loose or
missing U-bolt
 Support has
missing, loose
or short bolts
on supports
Connections R31 – Other Use this field to capture any CONNECTION ? ?
other CONNECTION items.
Connections R32 – Bellows Verify that the bellows vent is open and clear, ? Rank 2: Bellows vent
Vent and routed to a safe location. missing, plugged, or
removed
Connections R33 – Vent Look for missing, damaged, or vent piping ? May require an NCR
Piping installed incorrectly. depending on the severity of
Connections R34 – Drains Ensure that body and vent piping drains are ? May require an NCR
Open open. depending on the severity of
Connections R35 – Look for adequate thread engagement (no Short bolting on Rank 3 for all indications
Inadequate more than one thread inside nut). flange
Thread
Engagement
Connections R36 - Bolting Look for missing bolts, damaged threads, bent  Missing bolts Rank 3 for all indications
 Bolts wrong
used. Compare the bolting in the field with the
specification
bolting defined by the pressure vessel design
and piping specifications. If bolts are missing,  Loose bolts
mark POOR on the report form.
 Wrong size
bolts
Connections R37 - Flanges Look for warped or misaligned flanges. Note  Cracked Rank 2:
dissimilar flange ratings and verify that the Flange
flange ratings are correct for the process  Cracked Flange
service.  Dissimilar  Dissimilar flange
flange ratings ratings
Connections R38 – Threaded Look for cross-threaded, stripped threads, and Cross-threaded Rank 3 for all indications
Connections mechanical damage. fittings
Connections R39 - Gauges Look for broken or missing pressure or  Broken gauge Rank 3 for all indications
temperature gauges.
 Missing gauge
Connections R40 – Manual Ensure that the lever is properly positioned Missing handle Rank 3 for all indications
Operation and appears operable.
Lever
Documenting Rupture Disk Visual Inspections
Using the Rupture Disk Visual Inspection Report form as a guide, inspect all items on the
Enter the header

information for the location
and device. (same as the
header on the
Pressure Relief Valve Visual
Inspection Report
Enter Background
information:
The serial number
on the rupture disk
tag
The burst pressure
shown on the tag
Enter the
Inspector’s
Name, and
Company
Inspect for and

complete all
checklist items.
Summarize the
indications found
during the
inspection.
Initials and Dates are entered Enter the rank (1,2, or 3) in the
Enter a
NCR column when the
for the persons checking and location
indication found requires
entering the report reporting. description and
a comment for
any indication
found.
Observations - As a minimum, inspect for all items on the checklist. Mark each observation
 “Good” or “NA” – The condition is good, the problem does not exist, or the observation
item is not applicable to the valve being inspected.
 “Yes” – The condition being inspected for exists. Note: This may or may not require a
location and comment. For example: if “Disk leak through” is marked “Yes”, a location
and comment are required. However, if “Correct disk installed” is marked “Yes”, then
no comments are required because this is the desired condition for the rupture disk.
Any item marked “Yes” that requires attention should have a Nonconformance Report
(NCR) generated.
 “No” – The condition being inspected for does not exist. Note: This may or may not
require a location and comment. For example, if “Correct disk installed” is marked
“No”, a location and comment are required. If “Disk leak through” is marked “No”, then
no comments are required because this is the desired condition for the rupture disk.
Any item marked “No” that requires attention should have a Nonconformance Report
(NCR) generated.
 “Poor” means an indication requires attention and a Nonconformance Report (NCR).
The following table describes the fields of the Inspection Comments section of the Rupture
Disk Visual Inspection Report:
Item
General R01 – Other Use this field to capture any GENERAL Missing Tag Rank 2: Missing tag
(Please Explain) observations that have not been included with
other items.
General R02 – Correct Compare the disk identification and the Rupture disk has Rank 2: Incorrect disk
Disk Installed location tag to verify that the correct rupture wrong burst installed (does not meets
disk is installed. pressure rating design requirements)
(compared to
design) Rank 3: Incorrect disk
installed (meets design
requirements)
General R03 – Verify that the rupture disk has a nameplate Missing nameplate Rank 2 for all indications
Nameplate and that the information is legible.
information
legibility
General R04 – Piping Look for plugged vent piping, blinds,  Plugged vent Rank 1: Blocked flow to or
Obstruction dented/deformed piping or any other condition piping from rupture disk
that may obstruct flow to and from the rupture
disk and relief valve.  Closed block Rank 2: Restricted flow to or
valves (vessel from rupture disk
in service)
General R05 – Correct Correct orientation in piping – Look at the Rupture disk Rank 2 for all indications
orientation in flow arrow or other indicator on the rupture installed upside
piping disk holder to verify that it is installed with the down
correct side to pressure.
Item
General R06 – Verify that the rupture disk and mating flanges  Short bolted Rank 3:
Connection are the same size, the flanges are square with
joint makeup each other, the gasket is centered, and the  Misaligned  Short bolted
correct bolt thread engagement is attained. flanges
 Dissimilar flange
 Dissimilar ratings
flange ratings
General R07 – Device Look for leakage or evidence of leakage Vent or gage Rank 2 for all indications.
leak through through the rupture disk. If the rupture disk is indicates rupture
installed to protect another relief device, check disk has failed or
the tell-tale vent or pressure gage to verify burst.
that the disk has not ruptured. Note in
“Comments” if the pressure gage appears to
be defective.
General R08 – Block Ensure that all block valves to and from the Valve not car sealed Rank 3 for all indications
Valves Sealed rupture disk and relief valve are car-sealed
Open open.
General R09 – Check that vent stacks, discharge piping, and  Inadequate Rank 3 for all indications
Discharge pipe small nipples are properly supported to avoid Support
or vent breakage or leakage.
supports  Missing
support or U-
bolt
 Broken or bent
pipe support
 Loose or
missing U-bolt
 Support has
missing, loose
or short bolts
on supports
Every item
in the
checklist
must be
marked
Items marked “See

Below” must have
same Additional
can be used
more than
once when
several
different
types of
indications
exist for one
ID
Check the NCR
Note that an column when the
The indication type indication found
requires reporting
indication can have more
the checklist on the piping Provide any comments about
circuit. any indications observed or
identified on the
inspection drawing.
Internal Visual Inspections

Plant inspection personnel or inspection contractors typically perform internal visual inspections
on pressure vessels, heat exchangers, and storage tanks during equipment and unit
shutdowns. However, in cases where these resources are not available, Capstone on-site
inspection personnel may be called upon to perform the work.
Regardless of who performs the work, these guidelines for performing internals should be
followed for two reasons:
1. Consistency – because different inspectors and different companies typically perform

internal inspections each time, the defined checklist format for performing and
documenting VI-Internal inspections helps improve consistency and assure a more
comprehensive inspection.
2. Compatibility – the checklist format is compatible with the RBMI database.
Internal visual inspections are not usually performed during baseline inspections. However,
they are commonly called for on inspection plans. Before Capstone personnel perform internal
visuals, the Site Coordinator should ensure that the inspections are included in the project
scope or get a scope change approved for the work (see Scope Changes).
The Internal Visual Inspection Process

The general internal visual inspection process is as follows:
2. Determine/Review Safety Requirements – The Site Coordinator will review the plant
and regulatory safety requirements for making entry into the equipment. The Site
Coordinator will verify that all preparations have been performed and safety equipment
has been made available to ensure safe entry by Capstone personnel.
Safety Considerations include:
 Equipment isolation (lockout/tag out)
 Equipment cleaning/purging
 Equipment ventilation
 Safety equipment - respiratory protection, harnesses, tag lines, communication
equipment, rescue equipment
 Hole watch – who will provide? (Client or Capstone)
 Safety Training – Have Capstone personnel had the proper training for
performing entry, hole watch, and respirators?
 Permitting – Confined Space
 Safety equipment – may include safety harnesses, tag lines, respirators, radios,
horns, etc.
 Make a copy of the unmarked original inspection drawing of the asset from the
equipment files.
 Get a clean copy of the internal visual inspection form for the equipment type
being inspected and fill out the header information.
 Have the following inspection tools available while performing the internal visual
inspection:
o Pit depth gage
o Scraper
o Wire brush
o Flashlight
o Magnet
o Flange rating chart
o Digital thickness meter (for verifying component thicknesses if necessary)
o Marker (soap stone, paint pen, chalk, mean streak)
4. Perform and Document the Visual Inspection - see sections below for details for
each equipment type.
P&ID discrepancies include incorrect equipment numbers, incorrect line sizes, and
missing equipment.
6. Report Non-conformances – due to the time-sensitivity of internal inspections, report

all non-conformances (Rank 1, 2, or 3) as soon as possible and before the equipment
is closed and returned to service. For an explanation of non-conformances, see
Evaluating and Reporting Non-conformances.
7. Submit the Inspection Report for Review – submit the completed inspection for
review (see Reviewing Deliverables).
into the RBMI database (see Finding and Entering Visual Inspections) and the original
reports are retained in the Equipment Files.

Using the Pressure Vessel Internal Visual Inspection form as a guide, inspect all items on the
Enter:
Equipment ID
Unit Name
Insulated (Yes or
No)
Inspect for and

complete all
checklist items.
Enter details of
any checklist item
designated as
The
Additional Comme
nts Form
can be used if
more entries are
needed for the
inspection.
Enter the
Inspector’s Name,
Company,
inspection date
and API 510
Certification
Number
Initials and Dates are entered for

the report
The following table describes the fields of the Pressure Vessel Internal Visual Inspection
Report form.
Note: Document all indications found, regardless of significance.

Item
General V01 – Other Other (Please Explain) - Use this field to Partial inspection May require an NCR
(Please capture any GENERAL observations that due to packing in depending on the severity of
Explain) have not been included with the other lower 1/3 of vessel the specific indication found.
GENERAL items.
General V02 - Corrosion Corrosion (depth, length, width) - Look for Scattered pitting to Rank 2:
corrosion of the pressure vessel wall, nozzles, 0.15” noted in 3 ft
and supports. If visible wall loss is observed, section near 8”  UT reading minus
the remaining wall thickness must be drain. corrosion depth
measured using either a direct UT reading or measurement results
a direct pit depth measurement and an in remaining wall at
indirect UT reading. Indicate Yes for any or below minimum
corrosion observed. Indicate in the thickness
Comments column whether visible wall loss
 Severe corrosion
was observed.
affecting the
If localized or random corrosion is observed, serviceability of
define the exact location of the corrosion and vessel: gasket
record the depth, length and width (may need surfaces, internals,
a separate detailed sketch to show the exact tubesheets, etc.
location and recorded measurements).
General V03 – Erosion Look for any service-related erosion. If Erosion in inlet Rank 2:
visible wall loss is observed, document the nozzle to 0.18”.
location and dimensions (length, width, and  UT reading minus
depth). erosion depth
measurement results
in remaining wall at
or below minimum
thickness
 Severe erosion
affecting the
serviceability of
vessel: gasket
surfaces, internals,
tubesheets, etc.
General V04 – Distortion Look for visually observable bulging, buckling,  Buckling Rank 2 for all indications
denting, or other visible signs of distortion.
Any significant distortion will require checking  Bulging
dimensions of the vessel so that the distortion
can be evaluated.
Item
General V05 – Blisters Look for blistering in shell, head, and nozzles. Three 0.25” diameter Rank 2 for all indications
Record location and dimensions (length, by 0.25” high blisters
width, height) found in the top
head.
General V06 – Deposits Look for product build up such as fouled tubes  Fouled tubes Rank 3 if indication prevents
and clogged nozzles. the proper operation of the
 Heavy product vessel.
scale
General V07 – Heads Look for cracking in head material and heat Visible cracks in May require an NCR
affected zone (HAZ). Also look for gouges HAZ of head to shell depending on the severity of
and mechanical damage. weld the specific indication found.
General V08 – Welds Look for cracking, weld defects, and  Lack of Rank 2 for all indications
inadequate weld reinforcement. penetration on
weld
 Cracks in weld
seam
General V09 – Nozzles Look for bending, cracking, and distortion in  Bent nozzle May require an NCR
the nozzles. depending on the severity of
 Nozzle cracked the specific indication found.
at flange
General V10 – Shell Look for gouges, mechanical damage, and  Grooves in May require an NCR
cracking of shell plates. shell from depending on the severity of
bundle removal the specific indication found.
 Several deep
gouges to 0.9”
due to arc
strikes
Internals V21 – Other Use this field to capture any INTERNALS Supports for May require an NCR
(Please explain) observations that cannot be included with the internal piping are depending on the severity of
other INTERNALS items. loose the specific indication found.
Internals V22- Demister Look for plugged, missing, loose or separated ? May require an NCR
demister pads. Also look at the tie downs for depending on the severity of
the demister pads to ensure they are intact. the specific indication found.
Internals V23 – Baffle/ Check for erosion and the condition of the  Missing bolts May require an NCR
Weir attachment welds on baffle/weir plates. If the on weir plate depending on the severity of
baffle/weir plate is bolted to the shell, check the specific indication found.
the condition of the bolting.  Weir plate
attachment
welds cracked
in two
locations.
Internals V24 – Sparger Ensure that the sparger is intact and in place. ? ?
Also look for corrosion/erosion of outlet holes
in sparger.
Internals V25 – Look for bent or broken thermowells.  Bent Rank 3 for broken
Thermowells thermowell thermowells
 Broken
thermowell
Internals V26 – Metallic Look for holidays/gaps, cracking, separation,  Small cracks Rank 2 for all indications
Lining buckling, and bulging of the liner. in lining near
bottom outlet
nozzle
 Liner has
separated from
the shell
Item
Internals V27 – Look for cracks, separation from the shell, and  Small cracks Rank 2 for all indications
Nonmetallic bulging of the liner. in lining near
Lining bottom outlet
nozzle
 Liner has
separated from
the shell
Internals V28 - Trays Look for stuck or missing bubble caps. Also  Tray has fallen May require an NCR
look for trays that are corroded through or depending on the severity of
have erosion at hole locations.  Tray missing the specific indication found.
20 caps
Internals V29 – Tray Check that trays are properly seated on the  Tray support is May require an NCR
Rings tray supports. Also check the condition of the cracked depending on the severity of
attachment welds of the tray rings to the the specific indication found.
vessel shell.  Tray ring is
warped
Internals V30 – Other Note the condition of any other weld ? ?

Welded attachments found in the shell of the vessel.
Attachments
Internals V31 – Tubes Look for plugged, bent, fouled, leaking or  6 plugged May require an NCR
broken tubes. Also look at the tube bundle tubes found on depending on the severity of
spacers and supports. the bundle the specific indication found.
 Ends of 5 tubes
found cracked
at tubesheet
Internals V32 - Tubesheet Look for cracks and leaks on the tubesheet.  12 roll leaks May require an NCR
Any gasket surface observations should be found on depending on the severity of
documented under “V11” tubesheet the specific indication found.
 Tubesheet has
numerous
surface cracks
between the
second and
third rows of
tubes
Every item
in the
checklist
must be
marked
Items marked “See
Below” must have
same Additional
can be used
more than
once when
several
different
types of
indications
exist for one
ID
Enter the rank (1,2, or 3) in the

Note that an NCR column when the
The indication type indication found requires
indication can have more reporting.
the checklist on the vessel Provide any comments about
any indications observed or
identified on the
inspection drawing.
Storage Tanks
Using the Storage Tank Internal Visual Inspection Report form as a guide, inspect all items on
the checklist as well as any other items that need to be inspected based on good judgment.
Enter:
Equipment ID
Unit Name
Internal Lining
(Yes or No)
Inspect for and

complete all
checklist items.
Enter details of
any checklist item
designated as
The
Additional Comme
nts Form
can be used if
more entries are
needed for the
inspection.
Enter the
Inspector’s Name,
Company,
inspection date
and API 653
Certification
Number
Initials and Dates are entered for

the report
The following table describes the fields of the Storage Tank Internal Visual Inspection Report
form:
Note: Document all indications found, regardless of significance.

Item
General T01 – Other Other (Please Explain) - Use this field to  Partial inspection May require an NCR
(Please capture any GENERAL observations that due to packing in depending on the severity of
Explain) have not been included with the other lower 1/3 of the specific indication found.
GENERAL items. vessel
 Plugged vacuum
vent
General T02 - Corrosion Corrosion (depth, length, width) - Look for Scattered pitting to Rank 2:
corrosion of the tank wall, floor, roof, nozzles, 0.15” noted in 3 ft
and supports. Pay special attention to section on first  UT reading minus
corrosion in the vapor space of the tank, course of shell near corrosion depth
sumps and at the annular ring welds. If visible manway measurement results
wall loss is observed, the remaining wall in remaining wall at
thickness must be measured using either a or below minimum
direct UT reading or a direct pit depth thickness
measurement and an indirect UT reading.
 Severe corrosion on
Indicate Yes for any corrosion observed.
roof supports
Indicate in the Comments column whether
visible wall loss was observed.
If localized or random corrosion is observed,
define the exact location of the corrosion and
record the depth, length and width (may need
a separate detailed sketch to show the exact
location and recorded measurements).
General T03 – Erosion Look for any service-related erosion. If Erosion in inlet Rank 2: UT reading minus
visible wall loss is observed, document the nozzle to 0.18”. erosion depth
location and dimensions (length, width, and measurement results in
depth). remaining wall at or below
minimum thickness
General T04 – Distortion Look for visually observable bulging, buckling,  Buckling Rank 2 for all indications
denting, or other visible signs of distortion of
shell, floor, or roof. Any significant distortion  Bulging
will require checking dimensions of the vessel
so that the distortion can be evaluated.
General T05 – Blisters Look for blistering in shell, head, and nozzles. Three 0.25” diameter Rank 2 for all indications
Record location and dimensions (length, by 0.25” high blisters
width, height) found in the floor
plates
Item
General T06 – Deposits Look for product build up such as sludge in  Sludge in sump Rank 3 if indication prevents
the sump and clogged nozzles. the proper operation of the
 Plugged vessel.
nozzles
General T07 – Welds Look for cracking, weld defects, and  Lack of Rank 2 for all indications
inadequate weld reinforcement. penetration on
weld
 Cracks in weld
seam
General T08 – Nozzles Look for bending, cracking, and distortion in  Bent nozzle May require an NCR
the nozzles. depending on the severity of
 Nozzle cracked the specific indication found.
at flange
General T09 – Shell Look for gouges, mechanical damage, and  Cracking on May require an NCR
cracking of shell plates. shell plate on depending on the severity of
3rd course the specific indication found.
 Several deep
gouges to 0.9”
due to arc
strikes
General T10 – Roof Fixed Roofs: Look for mechanical damage to  Roof seal torn May require an NCR
roof, and loose or twisted rafters, Floating depending on the severity of
Roofs: Check for seals that are damaged,  Floating roof the specific indication found.
missing, or out of position. Verify that the roof displaced from
is properly positioned in the guides. Verify that guides
the roof stop and hatch are in good working
condition.
General T11 - Floor Look for cracking and distortion due to Cracks in floor May require an NCR
settlement. plates depending on the severity of
Internals T21 – Other Use this field to capture any INTERNALS ? May require an NCR
other INTERNALS items. the specific indication found.
Internals T22- Annular Look for cracking due to settlement or the Cracks on annular Rank 2 for all indications
Ring process. ring near manway
Internals T23 – Sump Look for cracking and foreign objects (trash,  Missing May require an NCR
tools, parts, etc.) in sump. Verify that the screen depending on the severity of
screen is in place and in good condition. the specific indication found.
 Numerous
cracks in base
material of
sump
Internals T24 - Roof Look for mechanically damaged, loose, or  Roof support May require an NCR
Supports twisted roof supports. Make sure center is bent depending on the severity of
support pole has weep holes for the specific indication found.
product/moisture drainage.  No weep hole
in center
support pole
Internals T25 – Look for bent or broken thermowells.  Bent Rank 3 for broken
Thermowells thermowell thermowells
 Broken
thermowell
Internals T26 – Metallic Look for holidays/gaps, cracking, separation,  Small cracks Rank 2 for all indications
Lining buckling, and bulging of the liner. in lining near
bottom outlet
nozzle
 Liner has
separated from
the shell
Item
Internals T27 – Look for cracks, separation from the  Small cracks Rank 2 for all indications
Nonmetallic shell/floor, and bulging of the liner. in lining near
Lining outlet nozzle
 Liner has
separated from
the shell
Internals T28 – Internal Look for cracking and leaks on piping. Check  Missing May require an NCR
Steam Coil or the condition of piping supports. supports on depending on the severity of
Other Piping steam coil the specific indication found.
 Steam coil
cracked
Internals T29 – Level Check that the level cable is connected and  Float is leaking Rank 3 for all indications
Gauge the float is not leaking.
 Gauge cable is
disconnected
Internals T30 – Other Note the condition of any other internal weld ? ?
Welded attachments found on the floor, shell or roof of
Attachments the tank.
Every item
in the
checklist
must be
marked
Items marked “See
Below” must have
same Additional
can be used
more than
once when
several
different
types of
indications
exist for one
ID
Note that an Enter the rank (1,2, or 3) in the

The NCR column when the
indication type indication found requires
indication can have more reporting.
the checklist on the storage Provide any comments about
tank any indications observed or
identified on the
inspection drawing.
Finding and Entering Visual Inspections

Internal and External Visual Inspections are entered into the RBMI database and can be
viewed and printed as needed.
Finding Visual Inspections

Existing visual inspection reports in the database can be found two ways:
Finding Visual Inspections for a Single Equipment Asset

1. From the equipment asset browser, select the equipment item for which you want to find a
visual inspection:
2. Select Visual Inspection on the RBMI module tree:
3. Select an existing internal or external visual inspection from the list:
The number of
existing visual
inspections
4. The visual inspection is displayed: Attach electronic “photos” or images to the

inspection report (see
Edit the Adding an Image to a Visual Inspection).
inspection
report
Print or export the inspection report
Select the
appropriate tab or
folder for Internal
or External Visual
inspections
Finding Visual Inspections for Multiple Equipment Assets
1. Select Work Flow Steps by either of two methods: One, by clicking the “Work Flow Steps”
button on the toolbar, or by right clicking in the open area to get the short cut menu to
appear:
2. Select the desired equipment type(s) and then press
3. Select Visual Inspection on the Go To picklist:
4. The list of all existing visual inspections for the selected equipment is displayed:
Change the list to display:
The last inspection for each asset
All inspections for each asset
Inspection details from all inspections
Non-Conformances from all inspections
Print the
currently
displayed list
5. Find the asset you want to view visual inspections for by using the tree and then select the
specific inspection:
Entering Visual Inspections

1. Find the asset that you want to enter a visual inspection for (see Finding Visual
Inspections).
2. Press on the toolbar to enter the visual inspection information (see figure below).
3. Press on the toolbar to save the visual inspection (see figure below).
Attach electronic
Cancel the added “photos” or images to
inspection or any the inspection report
changes made while (see
editing Adding an Image to a Vi
sual Inspection
).
Evaluating and Reporting Non-conformances

A non-conformance is an indication found during an inspection that is outside of acceptance
criteria and requires correction. Typical non-conformances include corrosion/thinning
problems, missing bolting, cracking, etc. Non-conformances are ranked 1, 2, 3, or 4 based on
the severity of the problem found. Non-conformances are reported to the client so that they
can be resolved. Non-conformance reports are documented/tracked in the RBMI database.
Identifying Non-conformances
Non-conformances are identified during inspections as follows:
 Visual Inspections – During the visual inspection, the Capstone inspector identifies
indication(s) as non-conformances by entering an rank number in the NCR (Non-
conformance Report) column on the Visual Inspection Report Form:
Note: Only rank 1, 2, or 3 non-conformances are identified in the NCR column on the
form.
The Inspector can use the observation item description tables to determine what
indications should be identified as non-conformances and what rank should be assigned
to those indications. Here is an example from the observation item description table for
piping circuit external visual inspections: Indications
Typical requiring NCRs
Indications and their rank
 NDE Inspections – Non-conformances from NDE inspections include thickness

readings at or below minimum thickness and observed CUI damage (RT Profile or
visually during UT inspection). Capstone personnel while reviewing the NDE inspection
reports identify these non-conformances.
 Other Inspections – Non-conformances that result from other inspections like

Penetrant Testing (PT), Magnetic Particle Testing (MT), and CUI-Visuals include any
indications that require attention. For example, cracking observed during a PT
inspection would be reported as a non-conformance. Like visual inspections, the
Capstone inspector identifies indication(s) as non-conformances by entering an rank
number in the NCR (Non-conformance Report) column on the Other Inspection Report
Form:
Ranking Non-conformances
Once a non-conformance has been identified, it then must be ranked to prioritize its reporting
to the client and to help the client prioritize its resolution. In the case of visual or “other”
inspections, the inspector will rank the non-conformances on the inspection report form. In the
case of NDE thickness inspections (UT and RT), the non-conformances are ranked by the
Inspector reviewing/evaluating the inspection report.
The non-conformance ranking system goes from 1 (most critical) to 4 (least critical). The
following table describes the ranking system and reporting requirements at a minimum. This
table shall be covered in the kickoff meeting to dicuss any modifications based on the client’s
priorities.
NC Reporting Review Tracking Contents of NC Comments/

Rank Requirements Req’d? Required? Transmittal Examples
1 Immediately notify Yes - Yes  Detailed NC Report per Fixed Equipment:
responsible plant Engineer or individual situation  Process leaks
personnel of situation - Subject
 Drawings/Sketches  Immediate hazard to
then complete/submit a Matter
detailed NC Report Expert  Calculations, etc. personnel
(within the same shift)  RV set pressure greater
than design pressure
2 Complete Detailed NC Yes - Yes  Detailed NC Report per  Actual thickness less
Report with possible Engineer or individual situation than required thickness
corrective Subject
 Drawings/Sketches  Operating
recommendations - Matter
 Calculations, etc. temperature/pressure
Transmit to plant at Expert
greater than design
intervals established in
temperature/pressure
the Project Kickoff
Meeting.  Evidence of leaks
3 Complete Detailed NC No Yes  Detailed NC Report per  Missing bolts
Report with possible type of indication  Inadequate thread
corrective
 summary list of equip. / engagement
recommendations
locations  Pipe supports
-Transmit to plant at
unit/project closeout.  Drawings/sketches  Broken gages
 Missing plugs
 Fretting
 Missing blind flange
4 Summarize at No No  Summary Report per type  Insulation damage
completion of Unit or of indication  Coating failure
Project. Note: These
 Summary list of equip. /  Visual indications of
are only reported at the
locations “poor”
client’s request
 Drawings/sketch
The inspector can use the observation item description tables to determine what rank
should be assigned to typical visual non-conformances. The following are links to the
observation item description tables for each inspection type:
External Visual Inspections:
 Piping Circuits
 Pressure Vessels and Exchangers
 Storage Tanks
 Relief Devices
Internal Visual Inspections:
 Pressure Vessels and Exchangers
 Storage Tanks
The Inspector should consult with the Site Coordinator if unsure about what rank to assign to a
non-conformance.
Reporting and Tracking Non-conformances

Rank 1 and 2 non-conformances are documented upon completion of the inspection in which
they were identified by filling out a Non-Conformance Report form (NCR). These reports are
filled out by the inspector for visual and “other” inspections (MT, PT, or CUI-Visuals) and by the
person evaluating the inspection results for NDE thickness inspections (UT or RT).
Rank 3 and 4 non-conformances are documented on the same form, but are grouped by
indication type. For example, one NCR can be written for missing bolts on numerous
equipment items.
Here is a description of the sections of the Non-Conformance Report form:

The inspection location number where
the non-conformance was found.
Enter a unique NC number. This is typically an
Attach a copy of the inspection
assigned sequential number for the project or unit.
drawing showing the NC location.
Fill out the

background
information when
initiating the non-
conformance report
(NCR).
The inspector or
person
evaluating NDE The Site Coordinator
inspections fills reviews the NCR before
out this section to it is transmitted to the
initiate the NCR. client.
The client fills

out the
correction
section when
the NC is
addressed or
resolved.
The following table describes the fields of the Non-Conformance Report form:
Initiation
Field Name Description Source Valid Values Example

Non-Conformance A unique number assigned for Review the NCR Alphanumeric FCCU - 0012
Number tracking of the NCR. module in the RBMI
database to see what
the last NCR number
was used and add 1.
Non-Conformance A user-assigned priority for the See Ranking Non- Numeric value from 1 to 4 2
Rank NCR. (1 is high priority, 4 is low conformances
priority)
Initiated by The name of the individual --- Alphanumeric Daffy Duck
filling out the NCR.
Date Initiated The date the NCR is filled out --- Date (mm/dd/yyyy) 05/06/2003
Company No data entry required – --- Alphanumeric Capstone Engineering
Displays value of company Services
associated with the name
entered in the “Initiated by”
field.
P&ID The P&ID the asset is located Inspection Drawing Select from List P0449-003A
on
Status Displays “Open” if the non- --- Open or Closed Open
conformance has not been
corrected and displays “Closed”
if it has.
NC Identified by The type of inspection or Inspection Report User-defined list: NDE
activity being performed when
the non-conformance was  NDE
discovered  Other Inspection
 VI-Int.
 VI-Ext.
Date Identified The date of the inspection in Inspection Report Date (mm/dd/yyyy) 05/06/2003
which the NC was identified
Location The indication location as it is Inspection Report Alphanumeric 5
referenced on the inspection
report/drawing that identified
the non-conformance
Applicable The standard that defines the ---- User-defined list: API - 510
Code/Standard acceptance criteria which has
been exceeded.  API-510
 API-570
 API-653
 API-650
 ASME B31.3
 ASME Section VIII -
Div 1
Description Description of what section of --- Alphanumeric API-510 6.3 Calculating
the code/standard applies to remaining life
the non-conformance
Details of Non- Required field – Description of --- Alphanumeric UT thickness inspection
conformance the non-conformance revealed one reading
below minimum thickness
at location 5. Nominal =
0.500”, minimum = 0.375”,
UT reading = 0.360”
Field Name Description Source Valid Values Example
Recommendations List of possible solutions or --- Alphanumeric Calculate actual required
recommendations for the minimum thickness and/or
nonconformance. repair corroded area as
required.
Correction (typically completed by the client)

Field Name Comments/Description Valid Values Example
Correction Due A estimated date for which the NC may be Date (mm/dd/yyyy) 05/17/2003
Date completed
Correction The name of the person responsible for Alphanumeric Bugs Bunny
Completed by correcting the NC.
Date to be The date the temporary safeguards are to be Date (mm/dd/yyyy) 04/03/2005
Implemented by installed
Date to be The date the temporary safeguards are to be Date (mm/dd/yyyy) 04/17/2005
Removed removed
Code or Standards Code or Standards Used for temporary Alphanumeric API-579
Used operation with Safeguards
Tracking Required ---- Yes/No Yes
(checkbox)
Management of ---- Yes/No No
Change Required
(checkbox)
Management of ---- Yes/No No
Change Approved
(checkbox)
Management of ---- Alphanumeric MOC-11045
Change Number
Work Order The work order number for the correction work Alphanumeric FX-0043954
Number
Correction Date The actual completion date of the correction Date (mm/dd/yyyy) 05/25/2003
work
Responsible ---- Alphanumeric ????
Permanent The method by which the non-conformance Select from list Redefine Acceptance Criteria
Correction by was corrected
(radio box)
Details of A description of the temporary operation / Alphanumeric Fitness for service calculations
Temporary Correction work that was performed. performed. Calculated shell
Operation/ minimum thickness = 0.300”.
Correction Minimum thickness values reset
for shell UT locations in the NDE
module.
Note: All NCRs will have drawings attached indicating the locations of the non-conformance.
Transmitting and Tracking Non-conformance Reports
The Site Coordinator reviews the completed NCR for completeness and accuracy. Once
reviewed, the transmittal and tracking process is as follows:
1. Log the NCR – The Site Coordinator or qualified Capstone employee logs the Non-
conformance Report (NCR) on the Non-Conformance Tracking Log. This log is used to
track the reporting of non-conformances. It is typically kept in a binder and is part of the
Project Files. All NCRs reported to the client shall be entered on this log.
The initials of
The name of the client the Capstone
representative that the employee that
NCR was transmitted transmitted the
to. NCR
A unique, The date the NCR was

sequential number transmitted to the client
assigned to each
NCR
2. Transmit the NCR – The Site Coordinator or qualified Capstone employee makes a
copy of the NCR (with accompanying drawing(s)) and forwards it to the appropriate
client representative using Documents Transmitted/Received logs (see Project
Correspondence). Note: A client signature on the Documents Transmitted/Received
log is required for documentation of receipt of the NCR.
Deadlines for reporting NCRs are as follows:
 Rank 1 – immediately report the problem to responsible plant personnel and

transmit the NCR to the client within the same work shift.
 Rank 2 – transmit NCRs to the client at intervals agreed to during the Project
Kickoff Meeting.
 Rank 3 – transmit NCRs to the client at project/unit closeout.
 Rank 4 – only report NCRs at the client’s request.

3. Enter the NCR into the RBMI database – the data entry resource enters the NCR into
the RBMI database (see Finding and Entering Non-conformance Reports below).
4. File NCR documentation – The original NCR is filed in the Equipment Files and the
Documents Transmitted/Received log for the NCR is retained in the Project Files.
Finding and Entering Non-conformance Reports

The non-conformance module is used to report equipment conditions that do not meet
acceptance criteria and to document the correction of those non-conformances.
In addition to the originals filed in the Equipment Files, NCRs are entered into the RBMI
database and can be viewed and printed as needed.
Finding NCRs
Existing non-conformance reports in the database can be found two ways:
Finding NCRs for a Single Equipment Asset
1. From the equipment asset browser, select the equipment item for which you want to
find a non-conformance report:
2. Select Non-Conformance on the RBMI module tree:
List of all NCRs for

this equipment
asset.
3. Select an existing non-conformance report from the list:
Edit the Print or export the NCR

NCR
Select the appropriate tab to view

Initiation or Correction
information for the NCR.
Select the
Issue Date: 8/9/04,
appropriate tab or 2004 Rev. Copyright © 1996-2004 by Capstone Engineering Services, Inc. Page 226
folder for Internal
or External Visual
inspections
Finding Non-conformance Reports for Multiple Equipment Assets
1. Select Work Flow Steps by either of two methods: One, by clicking the “Work Flow Steps”
button on the toolbar, or by right clicking in the open area to get the short cut menu to
appear:
2. Select the desired equipment type(s) and then press
3. Select Non-Conformance on the Go To picklist:
4. The list of all existing non-conformance reports for the selected equipment is displayed:
Print the
currently
displayed list
5. Find the asset you want to view NCRs for by using the tree and then select the specific
NCR:
Entering NCRs
1. Find the asset that you want to enter a non-conformance report for (see Finding NCRs).
2. Press on the toolbar to enter the NCR information (see figure below).
3. Press on the toolbar to save the NCR (see figure below).
Cancel the added

NCR or any changes
made while editing
Note: Typically the only data entry completed by Capstone is the Initiation section
(Correction information is usually completed by the client).
Chapter 9 – Baseline Inspection

Planning
9
Chapter
Baseline Inspection Planning

Planning for baseline inspections occurs the first time a Criticality run has been calculated for
the equipment in the project scope of work. The purpose of these baseline NDE inspections is
to confirm the existence and extent of the damage mechanisms assigned during the corrosion
study and initial Criticality run.
The qualified Capstone employee generates the baseline NDE inspections to be performed for
the equipment in the project scope of work using the following:
 Initial Criticality Run – identifies the inspection priority categories and damage
mechanisms for each equipment item.
 External Visual Inspections – identify the potential inspection locations for Internal
and External Corrosion
 Inspection Drawings – baseline inspection locations are marked on copies of the

inspection drawings
 Existing NDE thickness data/reports – existing thickness data should be utilized if

possible to minimize or eliminate current baseline NDE requirements. Also, inspection
at existing NDE thickness locations should be repeated to increase the quality of
measured corrosion rates.
Note: If inspection is repeated at existing NDE thickness locations, these previous

readings should be entered as inspections into the RBMI software (see Finding,
Entering, and Evaluating NDE Inspections).
 Inspection Strategies – define how many equipment items, the inspection methods,
and extent of inspections to be performed for each damage mechanism
Note: Baseline inspection planning can only be performed after visual inspections and
baseline Criticality calculations have been reviewed/approved for all equipment items in the
unit.
Piping Circuits
One of the biggest advantages of implementing a risk-based mechanical integrity program for
piping is that the NDE inspection requirements can be optimized using grouping and by
minimizing inspection requirements for lower risk circuits.
Piping circuits are already grouped by similar processes (i.e.: piping systems); therefore NDE
performed on one circuit can “represent” other circuits not inspected in that piping system. The
inspection strategies for piping circuits provide guidelines for selecting circuits and inspection
locations for each damage mechanism.
Here are the steps for piping circuit baseline inspection planning:
1. Generate a Criticality Summary – for all piping circuits in the unit (see Criticality
Summary).
2. Add Columns to Criticality Summary – For each applicable damage mechanism

identified on the criticality summary, add and label a column at the far right side of the
worksheet. Damage mechanisms can include (but are not limited to): External Corrosion
(CUI), Internal General Corrosion, Internal Localized Corrosion, Environmental Cracking,
and Fatigue. Also, add columns for “System Inspection” and “Injection Point Circuit”:
Add columns here
3. Select Piping Circuits – For each damage mechanism, select circuits to be inspected.
Use the approved piping inspection strategies for each damage mechanism to determine
which circuits to select. The “AutoFilter” can be used in MS Excel to help in the selection
process. Circuit selection should be performed independently for each damage
mechanism in the following order:
First, narrow down the list of circuits that are susceptible to CUI by applying appropriate
filters to the worksheet:
Turn on the AutoFilter by selecting it from the Data menu on the toolbar.
Select “Y” for the Insulated column.
Select the temperature range from 0 to 300 degrees F in the Operating Temperature
column:
Deselect circuits constructed of materials not susceptible to CUI in the Material

Specification column:
The resulting list should include all piping circuits that are susceptible to CUI.
Next, select values from 1 to 5 in the External Corrosion Inspection Priority Category
column:
The result will be the high criticality piping circuits for CUI:
When selecting circuits, select the ones Select the circuits to be

with the lowest Inspection Priority inspected by placing a “Y” in
Category number (These have a the CUI Inspection column.
higher risk associated with this The percentage of baseline
mechanism). circuits selected for each
In this example, the circuits with an criticality category for CUI is
inspection priority number of 2 should defined in the piping
be selected before the ones with and inspection strategies.
inspection priority number of 4.
For CUI, selected circuits should be

evenly distributed among the following
four temperature ranges in degrees
F(listed in order from highest to lowest
concern):
150 –200
200 – 300
75 – 150
0 - 75
Repeat the same process for Medium-High and Medium CUI Piping circuits by first
modifying the custom filter on the External Corrosion Inspection Priority Category
column:
Selection criteria
Selection criteria for for Medium
Medium-High circuits circuits
Then select the appropriate number of piping circuits for that Criticality category by using
the same guidelines shown above (for High CUI circuits) and using the percentages
defined for Medium-High and Medium circuits from the piping CUI inspection strategy.
Note 1: Once circuit selection for CUI based on Criticality is complete, review the
inspection history summaries and visual inspections looking for piping circuits that have
documented CUI. Ensure that these circuits are either among those already selected or
added to the list of those selected for baseline CUI inspections.
Note 2: Piping circuits that have low criticality for CUI (EC Insp. Priority = 20 to 25) are
not inspected for CUI unless problems have been documented.
Internal Localized Corrosion
Remove any existing filters from the piping criticality summary worksheet. Then apply the
following filter to display only circuits with localized internal corrosion:
Then apply a custom filter to the Internal Corrosion Inspection Priority Category column
to view piping circuits with High criticality for localized internal corrosion:
Here is the resulting list of piping circuits with High criticality for localized internal corrosion:
A circuit is selected by placing a “Y” in the

column for that damage mechanism
Select circuits in each Criticality Category, working from lower to higher numbers within a
category, based on the Internal Corrosion Inspection Priority Category, until the minimum
required percentage of circuits per Criticality Category have been selected as defined in the
piping inspection strategy for this damage mechanism.
Note: To help optimize the baseline inspections, where practical, select circuits that have
also been selected for CUI inspection.
The following filter criteria can be used to limit the list to those with Medium-High, Medium,
and Low Criticality for internal localized corrosion:
Selection criteria
Selection criteria for for Medium
Medium-High circuits circuits
Selection
criteria for Low
circuits
Internal General Corrosion
Follow the same process (see Internal Localized Corrosion above) to select piping circuits
for inspection for internal general corrosion by applying a “General” filter in the Internal
Corrosion Type column, then applying custom filters in the Internal Corrosion
Inspection Priority Category column to select circuits from each criticality category for
Internal General Corrosion. Mark all selected circuits with a “Y” in the IC General
Inspection column.
Injection Point Circuits, Environmental Cracking, and Other Mechanisms
Select for inspection any piping circuits identified as being injection point circuits, as having
cracking or any other damage mechanisms by putting a “Y” in the appropriate inspection
column.
Piping System Inspections
After circuit selection has been completed based upon potential damage mechanisms and
injection points, review the piping criticality summary worksheet to ensure that a circuit has
been selected from every piping system and that every material of construction and IC
corrosion type in that system has been selected for an internal corrosion inspection.
In this example, none of the four circuits in piping system 001 have
been selected for inspection; so select a circuit that has the lowest
Internal Corrosion Inspection Priority Category number by placing a
“Y” in the System Inspection column
In this example, none of the nine circuits in piping system 003 have been selected for an
internal corrosion inspection; so select one for general and one for localized.
In this piping system, the stainless steel circuit (SA-240) cannot be represented by inspection of the
carbon steel ones (SA-53); so select this circuit for an internal corrosion inspection.
Wall Ratio Inspections
Wall ratio inspections are performed on piping circuits that have internal wall ratios less
than or equal to 1.0 and do not have any previous NDE thickness data. These circuits are
selected as follows:
Select “(Blanks)” on the filter pick lists for the following
columns:
Internal General Corrosion
Internal Localized Corrosion
System Inspection
Then filter the Internal Wall Ratio column for values less than or equal to 1:
Review the inspection history summaries for the piping circuits on the resulting list. If they
have no existing/previous thickness data, then add a Wall Ratio Inspection column to the
piping criticality summary worksheet and put a “Y” in that column to select that circuit for
inspection:
4. Save and Print the Circuit List – Save the piping criticality summary worksheet as the
baseline inspection circuit selection list for the unit. Print out the worksheet so it can be
used to create the inspection reports.
5. Gather Materials – Collect the following documents/materials to perform the baseline

inspection planning:
 Baseline inspection circuit selection list worksheet
 Visual inspection reports for all circuits selected for inspection
 Clean, unmarked copies of inspection drawings for all circuits selected for inspection
 Blank copies of inspection forms as required (UT, RT, etc.)
 Previous NDE thickness inspection reports/records for circuits selected for inspection
 Piping inspection strategies for all potential damage mechanisms
6. Select Inspection Methods and Locations – Starting with the first selected circuit on the
baseline inspection circuit selection list, prepare a baseline inspection plan by filling out
inspection report(s) for the selected damage mechanism(s) for all selected circuits.
For example, the first selected circuit (735001B) requires a “system inspection” for internal
general corrosion and the internal corrosion inspection priority category is 22.
Review the inspection strategy for general internal corrosion to determine the inspection
method and extent:
Need to select
greater of 2 or
5% of potential
inspection
locations for this
circuit.
Review the visual inspection for the circuit to determine the total number of potential
internal inspection locations:
Choose a
minimum of 2 or
5% of each of
these
categories.
Based on the strategy and the visual inspection, select and document the following
locations on an Ultrasonic (UT) Thickness Report or a Profile Radiographic Testing (RT)
Report (as applicable) and on an attached inspection drawing:
Fill out background Use the piping Enter the minimum thickness. Use the largest
information about the specifications or value of the following:
circuit and select previous inspection Client-provided minimum thicknesses
“Baseline” as the data to fill out the Calculated minimums based on design pressure
inspection type. nominal values. Structural minimums: up to 2” dia. = 0.063”; 2 to
8” dia. = 0.094”; 10”+ dia. = 0.125”
Enter “Pipe” for

all inspection
locations
The internal or external location category (or both) from the external visual
inspection abbreviated as follows:
Enter a Internal:External:LHR = Long Horizontal RunsHLP = Horizontal Low
unique
number for PointsEL = ElbowsIT = Insulation TerminationRed = ReducersDI = Damaged
each InsulationDL = Dead LegsVR = Vertical RunsEZ = Erosion ZonesSAI = Soil-
thickness
location Air InterfaceTee = TeesBP = Barrier Penetrations
In this example, we need the Additional UT Thickness Report form to define additional
thickness inspection locations:
Note: Inspection Strategies only define inspection methods and extent of inspection (along
with potential inspection locations from the visual inspections) for:
 Internal Corrosion – General and Localized
 External Corrosion – CUI
 Environmental Cracking
 Injection Points
 Erosion
For piping circuits with Other Mechanisms (fatigue, pitting, HTHA, etc.), consult with the
Capstone Corrosion Engineer for guidance in determining what inspection methods and
extent should be performed.
Note: Inspections which require the equipment to be entered and/or shutdown are not
typically included as part of baseline inspections. Instead, these inspections are scheduled
when the Inspection Work Plans are developed.
For Wall Ratio Inspections (circuits with no previous thickness data and wall ratios less
than or equal to 1.0), prepare an Ultrasonic (UT) Thickness Report form using the following
guidelines to select locations:
Internal Corrosion Type Extent of Inspection

General Internal Corrosion 2 thickness readings per circuit
Localized Internal Corrosion (predictable 2 locations per Internal Location Category
locations) (from the external visual inspection)
Localized Internal Corrosion (unpredictable ????
locations) or Pitting
7. Fill out the Inspection Tracking Log – Once inspection forms have been prepared for all
selected circuits (and selected damage mechanisms/inspections), the qualified Capstone
employee will enter all inspections to be performed on the Inspection Tracking Log (see
Tracking Baseline/Follow-up Inspection Locations). The Site Coordinator uses the
Inspection Tracking Log to track completion of preparations (insulation removal, scaffolding,
etc.), baseline, and follow-up NDE inspections.
8. Perform Baseline Inspections – Typically, contractors perform the inspections using the
prepared baseline NDE inspection forms (see NDE Inspections).
9. Evaluate Inspection Results – A qualified Capstone employee reviews the inspection

results for:
 Follow-up Inspections (see Follow-up Inspection Planning)

Unlike piping circuits, all vessels and exchangers receive some level of NDE thickness
inspections during baseline inspections. Similar vessels and exchangers may be grouped so
that only representative ones require internal visual inspections. Also, insulated vessels and
exchangers are grouped in a similar manner to piping circuits for the purposes of performing
External Corrosion (CUI) inspections. The inspection strategies for vessels and exchangers
provide guidelines for selecting inspection methods and inspection locations for each damage
mechanism.
Here are the steps for vessel and exchanger baseline inspection planning:
1. Generate a Criticality Summary – for all vessels and exchangers in the unit (see
Criticality Summary). Note: This summary should include pressure vessels, exchangers,
air coolers, and columns.
2. Add Columns to Criticality Summary – Add columns for Internal Corrosion Group, VI-
Internal Inspection, and CUI Inspection to the right side of the worksheet:
Add columns here
3. Group Equipment for Internal Corrosion – Review the summary worksheet to create
groups of similar vessels/exchangers so that only representative ones require internal
visual inspections. Vessels/exchangers can be grouped if they:
 Have the same process service (and process conditions do not exceed key variables)
 Do not have a High criticality rating
 Have the same corrosion type – either general internal corrosion or localized internal
corrosion with predictable locations
 The internal corrosion rate is less than 0.005 inches per year (ipy).
Note: Some clients may not allow grouping of vessels/exchangers to eliminate internal
visual inspections (see Approve Inspection Strategies).
Use a number or other code to identify

vessels/exchangers that are grouped together in the
Internal Corrosion Group column.
4. Select which Vessels/Exchangers need Internal Inspections – Using the criteria in the
internal corrosion inspection strategies, the inspection history summaries, and the internal
corrosion groupings from step 3, select the vessels/exchangers that require internal visual
inspections.
Mark the selected vessels/exchangers with a “Y” in the VI-Internal
Inspection Required column.
Note 1: Internal visual inspections are not typically included as part of baseline inspections.
However, it is important to know which vessels/exchangers require internal inspections so
that the extent of NDE thickness inspections can be determined.
Note 2: Review drawings/inspection records to confirm that internal entry is possible. Due
to equipment size or configuration, internal visual inspections may not be possible (small
pulsation bottles and the shells of fixed tube heat exchangers are examples).
5. Select Vessels/Exchangers for CUI Inspections
First, narrow down the list of vessels/exchangers that are susceptible to CUI by applying
appropriate filters to the worksheet:
Turn on the AutoFilter by selecting it from the Data menu on the toolbar.
Select “Y” for the Insulated column.
Select the temperature range from 0 to 300 degrees F in the Operating Temperature
column:
Deselect vessel/exchanger components constructed of materials not susceptible to CUI in

the Material Specification column:
The resulting list should include all vessel/exchanger components that are susceptible to
CUI.
Next, select values from 1 to 5 in the External Corrosion Inspection Priority Category
column:
The result will be the high criticality vessel/exchanger components for CUI:
When selecting vessel/exchanger Select the components to be

components, select the ones with the lowest inspected by placing a “Y” in the
Inspection Priority Category number CUI Inspection column. The
(These have a higher risk associated with percentage of baseline
this mechanism). components selected for each
In this example, the components with an criticality category for CUI is
inspection priority number of 1 should be defined in the vessel/exchanger
selected before the ones with and inspection inspection strategies.
priority number of 2.
For CUI, selected vessels should be evenly

distributed among the following four
temperature ranges in degrees F (listed in
order from highest to lowest concern):
150 –200
200 – 300
75 – 150
0 - 75
Repeat the same process for Medium-High and Medium CUI components by first modifying
the custom filter on the External Corrosion Inspection Priority Category column:
Selection criteria for Selection criteria for
Medium-High components Medium components
Then select the appropriate number of components for that Criticality category by using the
same guidelines shown above (for High CUI vessel/exchanger components) and using the
percentages defined for Medium-High and Medium from the vessel/exchanger CUI
inspection strategy.
Note 1: Once equipment selection for CUI based on Criticality is complete, review the
inspection history summaries and visual inspections looking for vessels/exchangers that
have documented CUI. Ensure that these vessels/exchangers are either among those
already selected or added to the list of those selected for baseline CUI inspections.
Note 2: Vessels/exchangers that have low criticality for CUI (EC Insp. Priority = 20 to 25)
are not inspected for CUI unless problems have been documented.
6. Save and Print the Equipment List – Save the vessel and exchanger criticality summary
worksheet as the baseline inspection vessel and exchanger selection list for the unit. Print
out the worksheet so it can be used to create the inspection reports.
7. Gather Materials – Collect the following documents/materials to perform the baseline

inspection planning:
 Baseline inspection vessel and exchanger selection list worksheet
 Visual inspection reports for all vessels and exchangers in the project scope of work
 Clean, unmarked copies of inspection drawings for all vessels and exchangers in the
project scope of work
 Blank copies of inspection forms as required (UT, RT, Other Inspection, etc.)
 Previous NDE thickness inspection reports/records for all vessels and exchangers in
the project scope of work
 Vessel and exchanger inspection strategies for all potential damage mechanisms
8. Select Inspection Methods and Locations – Starting with the first equipment item on the
baseline inspection selection list, prepare a baseline inspection plan by filling out inspection
report(s) for all damage mechanism(s) identified for that vessel/exchanger.
All vessels and exchangers will be inspected for internal corrosion according to the
inspection strategies, however; only the ones marked with a “Y” in the VI-Internal Inspection
Required column will require an internal inspection. The rest will be inspected using the
external inspection strategy for internal corrosion (typically using UT).
For example, the first equipment item (D0001A) requires an inspection for internal general
corrosion, a CUI inspection and it has been marked as requiring a visual internal inspection.
The internal corrosion inspection priority category equals 18 and the external corrosion
inspection priority category equals 14.
First, plan for the CUI by reviewing the inspection strategy for CUI to determine the method
and extent that should be performed:
The extent is 10%
of potential
inspection
locations from the
external visual
inspection
The method in
this strategy is
to cut windows
in the insulation
and visually
inspect the
vessel surface.
The size of the
stripped area
depends on the
equipment size.
Minimum size
is 12” x 12”.
Review the visual inspection for the circuit to determine the total number of potential
external inspection locations:
Choose a
minimum of 2 or
10% of each of
these
categories.
Fill out an Other Inspection Report form with the CUI inspection locations and attach a copy
of the inspection drawing with the six locations marked:
After CUI planning is completed for this example, plan the inspection for internal corrosion.
Review the inspection strategy for internal corrosion (complimenting an internal visual) to
determine the inspection method and extent:
This is the minimum

extent of UT
thickness inspection
for a “Medium”
component with
general internal
corrosion and that
will receive a full
internal visual
inspection
Review the inspection drawing, data collection form, or visual inspection for the vessel to
determine the total number of heads, shell courses and nozzles.
Based on the strategy and the visual inspection, select and document the following locations
on an Ultrasonic (UT) Thickness Report and on an attached inspection drawing:
Enter the minimum thickness. Use the largest
Use the U-1 or value of the following:
previous inspection Client-provided minimum thicknesses
data to fill out the Nominal minus Corrosion Allowance
nominal values.
Enter the component that the

Enter a The external location category (for
inspection location is located
unique CUI inspections) from the external visual
on:
number for inspection abbreviated as follows:
Pressure Vessel
each BP – Barrier Penetrations
Column:
thickness DI – Damaged Insulation
Top
location VS – Vessel Supports
Middle
IR – Insulation Rings
Bottom
Shell and Tube Exchangers:
Shell
Channel
Tube Bundle
Air Cooled Exchangers:
Header
Tubes
 Environmental Cracking
 Erosion
 Lining Deterioration
For vessels/exchangers with Other Mechanisms (fatigue, pitting, HTHA, etc.), consult with
the Capstone Corrosion Engineer for guidance in determining what inspection methods and
extent should be performed.
9. Fill out the Inspection Tracking Log – Once inspection forms have been prepared for all
vessels/exchangers, the qualified Capstone employee will enter all inspections to be
performed on the Inspection Tracking Log (see Tracking Baseline/Follow-up Inspection
Locations). The Site Coordinator uses the Inspection Tracking Log to track completion of
preparations (insulation removal, scaffolding, etc.), baseline, and follow-up NDE
inspections.
10. Perform Baseline Inspections – Typically, contractors perform the inspections using the
prepared baseline NDE inspection forms (see NDE Inspections).
results for:
Storage Tanks
Baseline inspection planning for storage tanks follows the same steps as for pressure vessels
and exchangers (see vessel and exchanger baseline inspection planning), but is performed
separately so that tanks are not grouped with vessels for the purposes of selecting equipment
for CUI inspections.
Just like vessels and exchangers, storage tanks may be grouped so that only representative
ones require internal visual inspections.
 Erosion
 Tank Bottom Corrosion
 Tank Bottom Weld Leaks
For tanks with Other Mechanisms consult with the Capstone Corrosion Engineer for guidance
in determining what inspection methods and extent should be performed.
Note: Inspections which require the equipment to be entered and/or shutdown are not typically
included as part of baseline inspections. Instead, these inspections are scheduled when the
Inspection Work Plans are developed.
Relief Devices
Baseline inspection planning is not performed for relief devices because beyond the external
visual inspections required for all devices, there are typically no in-service NDE inspections that
can be performed (Relief tests are usually occur when the protected equipment is shutdown
and the relief device is removed).
Follow-up Inspection Planning

If baseline NDE inspections confirm the presence of a damage mechanism, additional
inspections may be required to determine the extent of damage on that equipment component
and/or other similar components in the unit. These follow-up NDE inspections are planned
using the guidelines in the inspection strategies. Follow-up inspections are an iterative
process: they continue until either the damage mechanism is no longer found or maximum
percentages of potential inspection locations have been inspected (whichever comes first).
Determine if Follow-up Inspections are Required

After baseline NDE inspections are complete, a qualified Capstone employee reviews the
results to determine if follow-up inspections are required. Follow-up inspections are required if
any baseline NDE inspection results have the following characteristics:
Damage Mechanism Follow-up inspections Example

required if:
Internal Corrosion – 1. Measured corrosion UT inspection resulted in a

General or Localized with rate is 0.005 inches per measured corrosion rate of
predictable locations year (ipy) or greater 0.008 ipy on the head of a
vessel.
Or
2. Remaining wall
thickness is at or below
minimum thickness.
External Corrosion (CUI) Measured corrosion rate is A piping circuit CUI

0.005 inches per year (ipy) inspection using RT profile
or greater reveals measured external
wall loss of 0.010 ipy at 2
elbows.
Any Other Mechanisms The presence of the Several cracks found during
damage mechanism being a PT inspection for fatigue
inspected for has been on a vessel nozzle.
confirmed
Plan and Perform Local Follow-up Inspections

Local follow-up inspection involves performing NDE inspections at additional locations on the
same equipment item to confirm that the damage either:
1. Is limited to the location at which it was found during the baseline inspection
or
2. Is present at other similar locations on the equipment component.

The process for planning/performing local follow-up NDE inspections is as follows:
1. Review the inspection strategy for the equipment type and damage mechanism of the
equipment component requiring follow-up inspection to determine how many additional
inspection locations should be looked at as follow-up.
For example, evaluating the RT baseline inspection for piping circuit 735002L indicates
that one elbow has a corrosion rate that exceeds the action level of 0.005 ipy:
We get the internal corrosion mechanism (Localized) and the Internal Inspection Priority
Category Number (13) from the Baseline Inspection Circuit Selection List:
2. Determine the number of follow-up locations required by reviewing the appropriate
inspection strategy. In this example, review the localized internal inspection strategy for
piping circuits:
Select an additional 25%

of potential inspection
locations for the follow –
up inspection for a total of
50% (25% baseline + 25%
follow-up)
3. Review the visual inspection to determine the number of inspection locations to add:
Following the strategy, the

baseline inspection included:
2 Dead Legs
2 Long Horizontal Runs
2 Erosion Zones
2 Elbows
2 Tees
2 Reducers
The follow –up inspection
should include:
2 Dead Legs
1 Long Horizontal Run
2 Elbows
2 Tees
1 Reducer
4. Select and document the following locations on an Ultrasonic (UT) Thickness Report or a
Profile Radiographic Testing (RT) Report (as applicable) and on an attached inspection
drawing:
Identify the Inspection Type as “Follow-up”
5. Add follow-up inspections to the Inspection Tracking Log – Once the inspection form
has been prepared for the follow-up inspection locations, the qualified Capstone employee
will enter the locations on the Inspection Tracking Log (see Tracking Baseline/Follow-up
Inspection Locations). The Site Coordinator uses the Inspection Tracking Log to track
completion of preparations (insulation removal, scaffolding, etc.), baseline, and follow-up
NDE inspections.
6. Perform Follow-up Inspections – Typically, contractors perform the inspections using the
prepared NDE inspection forms (see NDE Inspections).

results for:
 General Follow-up Inspections (see General Follow-up Inspections)
Plan and Perform General Follow-up Inspections

General follow-up NDE inspections are required on similar uninspected equipment items when
damage has been confirmed on one equipment component.
Review local follow-up NDE inspection results to confirm whether or not the damage found in
the baseline inspection is present in other location(s) on the equipment component. Damage
found must be meet the action levels defined in Plan and Perform Local Follow-up Inspections.
If no additional damage was found during the follow-up inspections, no further inspection is
required. However, if damage was found during the follow-up inspection, general follow-up
inspection may be required.
Note: General follow-up inspection only applies to equipment components that are grouped
for inspection purposes.
Here are the steps for planning/performing general follow-up NDE inspections:
8. Add a column to the baseline inspection selection list worksheet for the
damage mechanism requiring follow-up. - Using the piping circuit 735002L
example from above, add a column to the baseline inspection circuit selection list for
internal localized follow-up “IC-Loc. Follow-up”:
9. Determine the number of equipment components to be added – by reviewing

the inspection strategy. Continuing this example:
Select additional
circuits in the same
system until 50% of
all IC-Localized
circuits have been
chosen. (select those
with lowest inspection
priority number for
that mechanism first)
10. Select follow-up equipment components – Mark the selected components with a
“Y” in the follow-up column. For this example:
Selecting this item results in 50% of the IC-Localized
circuits in this system being inspected (3 of 6).
11. Select inspection methods and locations – Prepare inspection forms for the
added equipment components in the same manner as for baseline inspections (see
Baseline Inspection Planning).
12. Add follow-up inspections to the Inspection Tracking Log – Once inspection
forms have been prepared for all follow-up equipment components, the qualified
Capstone employee will enter all inspections to be performed on the Inspection
Tracking Log (see Tracking Baseline/Follow-up Inspection Locations). The Site
Coordinator uses the Inspection Tracking Log to track completion of preparations
(insulation removal, scaffolding, etc.), baseline, and follow-up NDE inspections.
13. Perform Follow-up Inspections – Typically, contractors perform the inspections

using the prepared NDE inspection forms (see NDE Inspections).
14. Evaluate Inspection Results – A qualified Capstone employee reviews the

inspection results for:
Tracking Baseline/Follow-up Inspection Locations

The Site Coordinator uses the Inspection Tracking Log to track completion of preparations
(insulation removal, scaffolding, etc.), baseline, and follow-up NDE inspections. The qualified
Capstone employee initially fills out the Inspection Tracking Log during Baseline Inspection
Planning as a list of inspections and preparations that need to be performed. Each line of the
tracking log represents a NDE inspection. The log is filled out as follows:
Indicate if the Describe the Enter the
inspection is preparation completion
Baseline or required. date for the
Follow-up inspection.
Indicate
whether or not Enter the date
the equipment the preparation Enter comments about the
component is is completed. inspection performed.
insulated. (Once Comments can include:
completed, the Maximum measured corrosion
inspection can rate
Enter whether or not inspection Description of damage found
preparation is required prior to be performed.)
Whether or not follow-up
the inspection. Preparation inspection is required
can include:
Insulation removal
Insulation plug installation
Scaffolding
Man lift/Crane Access
Inspection Tracking Logs are updated as preparations and inspections are completed. These
logs are maintained until completion of all baseline and follow-up NDE inspections. Inspection
Tracking Logs are retained in the Equipment Files.
10
Chapter
Chapter 10 – NDE Inspections

NDE inspections are performed as part of screening, baseline, and follow-up inspections.
Client or contract inspection personnel typically perform these inspections, however, Capstone
personnel are responsible for their quality and for reviewing/evaluating the inspection results.
The steps for performing NDE inspections are as follows:
1. Complete inspection forms - NDE inspection forms are filled out prior to inspections
being performed during inspection planning and shall have an inspection drawing attached
detailing the inspection locations.
2. Review history – The inspector reviews inspection records and history to determine what
indications have been reported in the past.
3. Perform the inspection - (see UT, RT, MT, PT, CUI Visual)
4. Review the inspection results - Once inspections are completed, a qualified Capstone
employee reviews the inspection results for:
5. Enter and File the Inspection - Completed and reviewed NDE reports are entered into the
RBMI database (see Finding, Entering, and Evaluating NDE Reports) and retained in the
Equipment Files.
(UT) Ultrasonic Thickness Testing

UT thickness measurements are documented on the Ultrasonic Thickness Report. Here
are the sections of the form:
Select the inspection type:
Baseline – inspections planned during
baseline inspection planning or
inspections from the
Enter background inspection work plan (IWP)
information about Follow-up – inspections planned
the equipment during follow-up inspection planning
being inspected.
Enter
information
about the UT
Meter,
transducer and
calibration
block.
Enter
information
about each
inspection
location.
Summarize the
results of the
inspection
performed.
Enter the inspector’s name(s), company, and

inspection date. Also, the initials and dates for the
individuals checking and entering the inspection
report.
The Additional UT Thickness Report form can be used to define additional thickness inspection
locations.
The following tables describe the fields of the Ultrasonic Thickness Report:
Background Information – data about the UT meter, transducer, calibration block and
technique used.
Test Unit The type of test unit. Either “digital” or “scope”. Digital
UT Meter Cal Due Enter the calibration due date for the UT meter. 03/12/04
Date
UT Meter Enter the manufacturer of the UT meter. Krautkramer
Manufacturer
UT Meter Model The model number of the UT meter. DM-2 LED

Number
UT Meter Serial Enter the serial number of the UT meter. 690804

Number
Transducer Enter the model or type of transducer used for the KBA-560
inspection.
Frequency Enter the frequency in (MHz) of the transducer. 5
Transducer Serial Enter the serial number of the transducer. 796560
Number
Diameter Enter the diameter of the transducer. .312

Calibration Block Enter the type of calibration block used. Typically, this will Stepwedge
be a “stepwedge”. It could also be an actual material
sample block for the equipment being tested
Calibration Serial Enter the serial number of the calibration block. A12415
Number
Thickness Enter the thickness range of the calibration block. .100 - .500
Material Enter the material of the calibration block 1018 Steel
Echo to Echo Enter Yes if technique used was echo to echo. Yes / No
Through Coating Enter Yes if reading was taken through coating. Yes / No
Chipped Paint Enter Yes if paint was removed to take reading. Yes / No
Other Enter Yes if other technique was used and brief Yes / No,
description.
Observations/Measurements – information about the thickness measurement locations
Inspection Location A unique, sequential number assigned to inspection location. This number shall 1
also be used to identify the inspection location on the inspection drawing
accompanying the inspection report.
Location Category The internal or external location category (or both) from the external visual LHR
For Piping Circuits:
Internal: External:
 LHR = Long Horizontal Runs  HLP = Horizontal Low

Points
 EL = Elbows  IT = Insulation Termination
 Red = Reducers  DI = Damaged Insulation
 DL = Dead Legs  VR = Vertical Runs
 EZ = Erosion Zones  SAI = Soil-Air Interface
 Tee = Tees  BP = Barrier Penetrations
For Vessels, Exchangers, and Storage Tanks:

External:
 BP – Barrier Penetrations
 DI – Damaged Insulation
 IR – Insulation Rings
 VS – Vessel Supports (vessels and exchangers only)
Component Enter the component type that each inspection point is Shell
located on. The component type correlates with those

defined in the RBMI database:
Columns  Top
 Middle
 Bottom
 Tubes
 Channel
 Tube Bundle
Piping Pipe
 Bottom
Note: An inspection report may include more than one component type. For
example, a column inspection may include points on the “Top”, “Middle”, and
“Bottom”.
Location Description A physical description of the thickness measurement point. For piping: include the Top Head - North
type and orientation of the component. (Ex.: elbow - outside radius) For vessels:
include the type of component and orientation. (Ex.: top head - north) Avoid
abbreviations that aren’t obvious.
Size Enter the nominal size of pipe, reducer, tee, deadleg, nozzle, and etc. 6”
Date Installed Enter the date in which the component was installed. 1/1/2000
Matl Enter the material spec. SA-105
Grade Enter the material grade B
Nominal Thickness The nominal thickness to three decimal places at the inspection location in inches. 0.237
For piping, refer to the piping specifications to determine nominals. For vessels
and tanks, refer to U-1 forms, construction drawings, or specification sheets for
nominal values.
Note: Verify nominals for long weld neck flanges on vessels because they can be
much thicker than standard nozzles.
Previous Reading The thickness value to three decimal places in inches from the most recent 0.240
inspection.
Current Reading The thickness reading to three decimal places in inches measured at the inspection 0.220
location for this inspection point.
Temp Enter the temperature reading at where the reading was taken. 76
Minimum Thickness The minimum thickness in inches at the inspection location. This is the thickness 0.094
at which the client should be alerted so that an engineering evaluation can be
performed.
For piping use the largest value of the following:
 Client-provided minimum thicknesses
 Calculated minimums based on design pressure
 Structural minimums: up to 2” dia. = 0.063”; 2 to 8” dia. = 0.094”; 10”+ dia. =
0.125”
For vessels, exchangers, and storage tanks use the largest value of the
following:
 Nominal minus Corrosion Allowance
Comments Note any observations at the inspection point. Examples would include pitting or Pitting in inspection port
CUI. If external corrosion is observed, record the location and depth. (Ex: Pitting in to 0.01 inches. Or
3 x 2” area to 0.05”) Note if minimum thickness used is other than client provided Calculated minimum
minimum thicknesses. thickness based on
design pressure.
Note: This can also be entered in the inspection summary if more room is needed.
Inspection Summary Summarize the results of the inspection performed and/or capture any additional All readings above
comments. minimum thickness.
(RT) Profile Radiographic Testing

Profile Radiography inspection is typically used to inspect piping for localized internal
corrosion, pitting, and CUI. RT thickness measurements are documented on the Profile
Radiographic Testing Report. Here are the sections of the form:
Select the inspection type:

Baseline – inspections planned during
baseline inspection planning or
inspections from the
Enter background inspection work plan (IWP)
information about Follow-up – inspections planned
the equipment during follow-up inspection planning
being inspected.
Enter
information
about the RT
source and film
Enter
information
about each
inspection
location.
Summarize the
results of the
inspection
performed.
Enter the inspector’s name(s), company, and

inspection date. Also, the initials and dates for the
individuals checking and entering the inspection
report.
The Additional RT Report form can be used to define additional thickness inspection locations.
The following tables describe the fields of the Profile Radiographic Testing Report:
Background Information – data about the radiographic source and film

Source Type The type of source used. Iridium - 192
Source Strength The strength of the source in curies. 55
Film Type The manufacturer and film type used in the inspections. AGFA D-5
Film Size The length and width of the film in inches. 17” x 14”
Observations/Measurements – information about the thickness measurement locations

Inspection Location A unique, sequential number assigned to inspection location. This number shall 1
also be used to identify the inspection location on the inspection drawing
accompanying the inspection report.
Location Category The internal or external location category (or both) from the external visual LHR/DI
For Piping Circuits:
Internal: External:
 LHR = Long Horizontal Runs  HLP = Horizontal Low

Points
 EL = Elbows  IT = Insulation Termination
 Red = Reducers  DI = Damaged Insulation
 DL = Dead Legs  VR = Vertical Runs
 EZ = Erosion Zones  SAI = Soil-Air Interface
 Tee = Tees  BP = Barrier Penetrations
For Vessels, Exchangers, and Storage Tanks:

External:
 BP – Barrier Penetrations
 DI – Damaged Insulation
 IR – Insulation Rings
 VS – Vessel Supports (vessels and exchangers only)
Component Enter the component type that each inspection point is Shell
located on. The component type correlates with those

defined in the RBMI database:
Columns  Top
 Middle
 Bottom
 Tubes
 Channel
 Tube Bundle
Piping Pipe
 Bottom
Note: An inspection report may include more than one component type. For
example, a column inspection may include points on the “Top”, “Middle”, and
“Bottom”.
Location Description A physical description of the thickness measurement point. For piping: include the Top Head - North
size, type and orientation of the component. (Ex.: 2” elbow - outside radius) For
vessels: include the type of component and orientation. (Ex.: top head - north)
Avoid abbreviations that aren’t obvious.
Size Enter the nominal size of pipe, reducer, tee, deadleg, nozzle, and etc. 6”
Date Installed Enter the date in which the component was installed. 1/1/2000
Matl Enter the material spec. SA-105
Grade Enter the material grade B
Nominal Thickness The nominal thickness to three decimal places at the inspection location in inches. 0.237
For piping, refer to the piping specifications to determine nominals. For vessels
and tanks, refer to U-1 forms, construction drawings, or specification sheets for
nominal values.
Note: Verify nominals for long weld neck flanges on vessels because they can be
much thicker than standard nozzles.
Previous Reading The thickness value to three decimal places in inches from the most recent 0.240
inspection.
Current Reading The thickness reading to three decimal places in inches measured at the inspection 0.220
location for this inspection point.
Minimum Thickness The minimum thickness in inches at the inspection location. This is the thickness 0.094
at which the client should be alerted so that an engineering evaluation can be
performed.
For piping use the largest value of the following:
 Calculated minimums based on design pressure
 Structural minimums: up to 2” dia. = 0.063”; 2 to 8” dia. = 0.094”; 10”+ dia. =
0.125”
For vessels, exchangers, and storage tanks use the largest value of the
following:
 Nominal minus Corrosion Allowance
Center to Film The distance from the center of the equipment to the film in decimal inches. 3.5
Source to Film The distance from the radiographic source to the film in decimal inches. 22.0
Exposure Time The length of exposure time in decimal minutes. 4.5
Comments Note any observations at the inspection point. Examples would include pitting or Internal pitting to 0.05”
CUI. If external corrosion is observed, record the location and depth. (Ex: Pitting in measured on film. Or
3 x 2” area to 0.05”) Note if minimum thickness used is other than client provided Calculated minimum
minimum thicknesses. thickness based on
design pressure.
Note: This can also be entered in the inspection summary if more room is needed.
Inspection Summary Summarize the results of the inspection performed and/or capture any additional All readings above
comments. minimum thickness.
(PT) Liquid Penetrant Testing

The components of Capstone Engineering Services Penetrant Testing Procedures are defined
in the Penetrant Testing Procedures NDE-403. The project manager or site coordinator will
ensure that a copy is made available on-site to Capstone employees performing Penetrant
Testing.
Fill out the Other Inspection Report form for the PT Inspection as follows:
Enter the
penetrant
manufacturer
and penetrant
model/type Describe the Describe any predefined
indication acceptance criteria for any
found. indications found.
Briefly describe
all surfaces and
areas
inspected.
Enter a unique
number for Check the NCR column Provide any comments
each indication when the indication found about any indications
found. Identify requires reporting. observed or whether there
the location of were problems in making a
this indication complete inspection.
on an attached
drawing.
Summarize the
inspection results and
record the following
required information:
Material used for
removing excess
penetrant
Developer used
Penetrant dwell time
Surface Temperature
The initials and dates of the

person s reviewing and entering
Enter the Inspector’s name,
company, inspection date, and
API certification (as applicable).
(MT) Magnetic Particle Testing

The components of Capstone Engineering Services Magnetic Particle Inspection Procedures
are defined in the Magnetic Particle Inspection Procedures NDE-404. The project manager or
site coordinator will ensure that a copy is made available on-site to Capstone employees
performing Magnetic Particle Testing.
Fill out the Other Inspection Report form for the MT Inspection as follows:
Select Wet Mag Particle

Testing or Dry Mag Particle
Testing
Enter the yoke

manufacturer
and yoke
model.
Describe the Describe any predefined
indication acceptance criteria for any
found. indications found.
Briefly describe
all surfaces and
areas
inspected.
Enter a unique
number for Check the NCR column Provide any comments
each indication when the indication found about any indications
found. Identify requires reporting. observed or whether there
the location of were problems in making a
this indication complete inspection.
on an attached
drawing.
Summarize the
inspection results and
record the following
required information:
Yoke energizing style:
AC or DC
Particle type: Dry, Wet
Visible, or Wet
Fluorescent
Particle Manufacturer /
Model
The initials and dates of the

person s reviewing and entering
Enter the Inspector’s name,
company, inspection date, and
API certification (as applicable).
CUI Visual Inspection

CUI visual inspections are performed as part of baseline and follow-up NDE inspections to look
for Corrosion-Under-Insulation (CUI) damage on equipment components. These inspections
are typically performed by Capstone Inspectors. However, client or contractor personnel
perform insulation removal. The CUI visual inspection involves removing insulation from areas
of potential CUI and then visually observing the condition of the equipment external surface.
NOTE: Have a qualified person confirm if insulation is asbestos free before insulation is
removed. If asbestos insulation, asbestos abatement will have to be performed by a
client approved vendor.
The CUI visual inspection steps are:
1. Remove Insulation – Client or contractor personnel remove insulation in the areas

identified on the Other Inspection Report form for CUI and attached Inspection Drawing.
2. Inspect Areas – The inspector documents corrosion damage on the Other Inspection
Report form.
If wall loss is noted, use a pit gauge to measure the maximum depth and take a UT
thickness measurement of component at that location. Subtract the max corrosion depth
reading from the UT measurement to determine the remaining wall.
Record the following on the Other Inspection Report form:
 Description of the damage found
 Measured maximum corrosion depth (use pit gauge)
 Measured component thickness (use UT meter)
 Remaining wall thickness
Fill out the Other Inspection Report form for CUI visual inspections as follows:
Select CUI Visual/Profile RT
Describe the
indication found.
If external
corrosion is
found, include
the max. depth
(use pit gauge).
Describe any predefined

acceptance criteria for any
Briefly describe indications found.
all areas
inspected.
Enter a unique
number for
each indication
found. Identify
the location of
this indication
on an attached
drawing.
Summarize the
inspection results
Enter the Inspector’s

name, company,
inspection date, and
API certification (as
applicable).
The initials and dates of the Check the NCR Describe location and any
person s reviewing and entering column when the comments about any indications
the inspection report. indication found observed or whether there were
requires reporting. problems in making a complete
inspection. If CUI is found,
include the following:
Wall Thickness (from UT reading)
Calculated external corrosion rate
Remaining wall thickness
Finding, Entering, and Evaluating NDE Inspections

Although there are numerous types of NDE inspections, the RBMI database accommodates
storage of these results using only two modules:
 NDE – UT or RT thickness inspection data
 Other Inspection – all other NDE inspections including MT, PT, CUI Visuals, etc.
NDE Inspection
The NDE Inspection module is used to store and evaluate thickness measurement data from
Ultrasonic (UT) and Radiographic Profile (RT) inspection methods.
This module has four sections:
1. Inspection Locations – This section is used to define thickness inspection locations

needed for corrosion rate and remaining life evaluations.
Note: Thickness inspection locations must be defined before inspection results (data) can
be entered into the database.
2. Inspection Data – This section is used to enter, edit, and save thickness inspection results
3. Evaluations – This section is used to calculate short term and long-term corrosion rates
and remaining life for each active inspection location. Also, average corrosion rates,
remaining life, and inspection intervals are calculated for the equipment asset and its
components.
Note: In order for the corrosion rate values to be updated, the button must be
pressed.
4. History – Allows the user to review all historical thickness data, corrosion rates, and
comments for any active or inactive inspection location
Accessing the NDE Inspection Module
Click on NDE Inspection node on the module tree to access the NDE data for the asset:
Access the four sections of the NDE Inspection

module by clicking on one of the tabs. Or, select one
of the NDE Inspection sub-nodes on the module tree.
Defining Inspection Locations

Inspection locations must be defined prior to entering thickness inspection results/data. The
fields “Status”, “Location”, “Component Type”, and “Minimum Thickness” are required for each
inspection location defined.
1. Select the Inspection Locations tab/form.
2. Press to enter or change inspection location information:
Here is a description of the fields on the Inspection Location form:
Field Name Valid Values Comments/Description
Status Select from List (Active, Required field – Whether or not the inspection location should be
Inactive) included in the evaluation of corrosion rates, remaining life, and
inspection intervals for the asset components. (Select “Active” to
include it, “Inactive” to exclude it)
Inspection Location Alphanumeric Required field – A unique identifier for the inspection location
Location Description Alphanumeric ----
Component Select from List Required field
Size Alphanumeric The diameter of the component or item that the inspection location is
located on
Date Installed Date (mm/dd/yyyy) The installation date of the component at the inspection location.
Material Specification Alphanumeric ----
Material Grade Alphanumeric ----
Nominal Thickness Numeric value greater than Inches
zero
Minimum Thickness Numeric value greater than Required field - The minimum required thickness in inches of the
zero component or item at the inspection location
Calculated Minimum Thickness Yes/No Whether or not the minimum thickness value for the inspection location
(checkbox) is a calculated value.
3. Press to save the inspection locations.
Removing Inspection Locations

Inspection locations may no longer require monitoring if the history indicates that consistently
no wall loss is found, the component the inspection location was on has been removed, or the
NDE location is being replaced by another NDE location at a different point on the component.
The best way to handle this situation is to:
1. Select the Inspection Locations tab/form in the NDE module.
2. Press to enter or change inspection location information:
3. Change the status from “Active” to “Inactive” for the NDE location that is no longer to be
monitored.
4. Press to save the change.
By making the location “Inactive”, its data will no longer be used to calculate average corrosion
rates that are used by the Criticality and Inspection Planning modules.
Replacing an NDE location
An NDE location may be replaced when a component or fitting that it was on is repaired
and/or replaced (a piping spool piece, for example). Because the inspection history and
data from the old component’s NDE location will not be valid for the new component, this
situation should be handled as follows:
1. Select the Inspection Locations tab/form in the NDE module.
2. Press to enter or change inspection location information.
3. Change the status from “Active” to “Inactive” for the NDE location that was on the
replaced item/component.
4. Define a new location for the new or renewed item/component. Set the new location to
“Active”. (Note: The “Date Installed” should match the installation date for the new or
renewed item and will be different from the “Date Installed” for the asset)
5. Press to save the changes.
Entering Inspection Data
Thickness data is entered on the inspection data tab.
1. Select the Inspection Data tab/form.
2. Press to create a new thickness inspection record. Individual inspection

readings are entered as rows in the table:
Select existing
Edit an existing inspections for Print the currently
NDE inspection viewing/editing displayed inspection
report.
Here is a description of the fields on the Inspection Data form:

Inspector User-defined list Required field – Enter the name of the inspector performing the
inspection
Company Alphanumeric No entry required – field is populated by Company name associated
with the Inspector name.
Inspection Method Select from List (UT or RT) Required field – Enter UT or RT.
Inspection Date Date (mm/dd/yyyy) Required field – Enter the date of the inspection
Inspection Location Select from list Required field – Enter the inspection location at which the thickness
reading was taken.
 Component ---- No data entry required – Displays value from inspection location tab
 Location Description
 Nominal Thickness
 Minimum Thickness
Previous Reading Numeric value No data entry required – Displays value from most recent previous
inspection record
Current Reading Numeric value greater than Required field – Enter the thickness measurement in inches
zero
Comments Alphanumeric ----
Inspection Summary Alphanumeric Summarize the inspection results.
3. Press to save the inspection record.
Finding/Editing Inspection Data

Thickness data is entered on the inspection data tab.
1. Select the inspection record to edit in the “Previous Inspections Performed” field.
2. Press to modify the inspection record data.
Evaluating Inspection Data

The Evaluation section will calculate corrosion rates and remaining life for each active
inspection location. This section will also calculate average corrosion rates, remaining life, and
inspection interval for the asset and its components.
Note: If only one set of NDE data exists for an asset, create an NDE report with nominal
values and date in service as the original baseline readings so that corrosion rates can be
established.
NDE Thickness Inspections are evaluated as follows:
1. Select the Evaluation tab/form.
2. Select the inspection date in the field “Calculate corrosion rates as of”. This will be the date
that the evaluation will be based on. (Note: If no date is selected, the default is the most
recent inspection date)
3. Press to evaluate the inspection data. Note: In order for corrosion rates to be
updated, the button must be pressed each time thickness data is added to the
database.
Here is a description of the fields on the Evaluations form:

Locations Evaluation
Calculation Corrosion Rates as of Select from list The inspection date the evaluation should be based on. The default is
the most current inspection record date
 Inspection Location ---- No data entry required – Displays value from inspection location tab
 Nominal Thickness
 Previous Reading ---- No data entry required – Displays value from the previous inspection
record
 Previous Reading Date
Current Reading ---- No data entry required – Displays value from the most recent
inspection record
ST Corrosion Rate Numeric value in inches per No data entry required – Calculated short term corrosion rate=
year (Current Reading – Previous Reading)/ Years between readings
LT Corrosion Rate Numeric value in inches per No data entry required – Calculated short term corrosion rate=
year (Current Reading – Oldest Reading)/ Years between readings
Remaining Life Numeric value in years No data entry required – Calculated remaining life= (Current Reading
– minimum thickness)/ (greater of LT or ST corrosion rate)
Remarks Alphanumeric No data entry required – Displays:
 “Thickness below T-min” if the current thickness is less than the
defined minimum thickness.
 “Reading indicates growth” if the current thickness is greater than
the previous thickness.
Component Evaluation
Component ---- Displays the components that are a part of the asset
ST Average Corrosion Rate Numeric value in inches per No data entry required – Calculated short term average corrosion rate
year = Average of all ST corrosion rates for all active inspection locations on
that component
LT Average Corrosion Rate Numeric value in inches per No data entry required – Calculated long term average corrosion rate
year = Average of all LT corrosion rates for all active inspection locations on
that component
Remaining Life Numeric value in years No data entry required – Displays the smallest remaining life value
from all active inspection locations on that component.
Half life Inspection Interval Numeric value in years No data entry required – Displays ½ of the shortest remaining life
value from all active inspection locations for the asset.
Reviewing Inspection History

The History section is used to review the historical inspection and evaluation data for a
selected thickness inspection location. The history of active and inactive inspection locations
can be reviewed. Select the inspection location to review its history:
Here is a description of the fields on the History form:
Inspection Location Select from list The inspection location the history review should be based on.
 Status ---- No data entry required – Displays value from inspection location tab
 Minimum Thickness
 Inspection Date ---- No data entry required – Displays value from the inspection record
 Reading
 Method
 ST Corrosion Rate ---- No data entry required – Displays value from the inspection evaluation
record
 LT Corrosion Rate
 Remarks
Other Inspections
The Other Inspection module is used to store and review results for MT, PT, CUI-Visual, Tube
inspections or any other user-defined inspection types.
Adding an Other Inspection Record

1. Select the Other Inspection node on the module tree:
View or edit
Edit an existing Print the displayed
previous
inspection inspection report
inspections.
report.
Select the other inspection type “General” or “Tube” using

the tab in the lower left corner of the Other Inspection form.
(Note: “Tube” inspections are only available for shell and
tube and air cooled exchangers).
2. Press to create a new inspection report.
Here is a description of the fields on the General Other Inspection form:

Test Equipment Mfg User-defined list ----
Model Alphanumeric ----
Inspector User-defined list Required field
Inspection Company Alphanumeric No entry required – field is populated by Company name associated with the
Inspector name.
Other Inspection Method User-defined list The inspection type that is being documented
Date Inspected Date (mm/dd/yyyy) Required Field
Scope of Inspection Alphanumeric Descriptions of what components were inspected and the inspection techniques
used.
Location Alphanumeric Required Field – The location identifier of the observation or measurement
Observation/Measurement Alphanumeric Required Field
Acceptance Criteria Alphanumeric Required Field – The acceptable limits for the observation or measurement
NCR (checkbox) Yes/No Whether or not a nonconformance report(NCR) should be generated for the
indication. Note: If checked “yes”, a task to create a NCR on the task manager.
Comments Alphanumeric Provide any comments about any indications observed or whether there were
problems in making a complete inspection.
Inspection Summary Alphanumeric Any general comments about the equipment inspection that cannot be covered
in the individual comment fields.
The Tube Inspection form is used to document tube inspections on shell and tube and air-
cooled exchangers:
Here is a description of the fields on the Tube Inspection form:

Test Equipment Mfg User-defined list ----
Model Alphanumeric ----
Inspector User-defined list Required field
Inspection Company Alphanumeric No entry required – field is populated by Company name associated with the
Inspector name.
Date Inspected Date (mm/dd/yyyy) Required Field
Tube Inspection Method User-defined list The inspection type being documented
Tube Diameter ---- No data entry required – Displays values from driving risk for exchanger tubes
 Tube Nominal Thickness
 Tube Minimum Thickness

11
Material Specification
 Material Grade
Scope of Inspection Alphanumeric
Chapter
Descriptions of what tubes were inspected and the inspection techniques used.
Tube number Alphanumeric Required field
Flaw Type Alphanumeric A description of any flaws discovered during inspection
Flaw Length Alphanumeric Required field -the dimensions of any indications found in the process of
inspection
Location Along Tube Alphanumeric Required field - the location on the tube where flaw indications were identified
from inspection
Wall Loss Alphanumeric Required field - the amount of tube wall loss revealed from the inspection
NCR (checkbox) Yes/No Whether or not a nonconformance report (NCR) should be generated for the
indication. Note: If checked “yes”, a task to create a NCR on the task manager.
Comments Alphanumeric Provide any comments about any indications observed or whether there were
problems in making a complete inspection.
Inspection Summary Alphanumeric Any general comments about the equipment inspection that cannot be covered
in the individual comment fields.
Editing an Other Inspection

1. Select an existing Other inspection record in the “Previous Inspection” field:
2. Press to modify information in the inspection record.
3. Press to save the changes.
Chapter 11 – Inspection Work Plans

Inspection Work Plans (IWPs) document the reason for inspection, lists selected NDE
methods, defines locations, identifies inspection dates/intervals and lists basic preparations
required to perform the inspection. IWPs list the inspection tasks that are performed to ensure
the ongoing mechanical integrity of each equipment item in the project scope of work.
A qualified Capstone employee develops IWPs in the RBMI database after baseline and
follow-up inspections have been performed and after criticality calculations have been updated
(see Updating Criticality).
Developing Inspection Work Plans

Each equipment item in the RBMI project scope of work will require an Inspection Work Plan.
A qualified Capstone employee develops IWPs by following these steps:
1. Gather Materials – Print out copies of:
 Baseline inspection selection worksheets – lists all baseline/follow-up inspections

performed and representative inspection groupings
 Inspection history summaries – list all previous inspections performed
 Inspection tracking logs – list all completed baseline/follow-up inspections
2. Open Inspection Planning module:
Using Work Flow Steps, open the Inspection Planning module for the equipment type(s)
you are working on:
“Right click” on
the mouse to
display this
menu.
Select the equipment

type(s) that you want
to create IWPs for and
then press
Select Inspection Planning
3. Prepare an IWP – For each equipment asset listed on the baseline inspection selection list
worksheet, create an IWP :
Review the baseline inspection selection list worksheet to determine which inspections that this
equipment asset was selected for: Prepare an inspection plan that includes inspection tasks that
address each mechanism / inspection column marked with a “Y”.
This circuit only requires an external visual

inspection. (All assets require a VI-External
inspection on the IWP and no columns are
marked with a “Y”).
Select the equipment asset, press , and then press :
D E F I N I N G T H E P R O J E C T
Cancels Save notes S C O P E Recommended tasks can be selected and
changes made about the IWP “dragged” down onto the Inspection Plan or
moved to the Inspection Plan by pressing
Saves the IWP
Each row represents a planned inspection task.

Note: Defining each inspection point is not required on the plan.
This circuit represented by 735001B (see Baseline Inspection Circuit Selection List above)
The Inspection Work Plan fields are as follows: (Note: All fields on the IWP are
required.)

Damage Mechanism Alphanumeric The damage mechanism that is being inspected for by this task
Inspection Priority Alphanumeric The inspection priority category associated with the damage mechanism
Location Alphanumeric List the components being inspected (shell, channel, top, etc.) or enter “Entire” or
“All” if the inspection is for the entire equipment asset.
Method Alphanumeric The inspection method used to perform the task
Extent Alphanumeric The parts of the asset being inspected by the task
Availability Select from list (Online, The operational status of the equipment that is required to perform the inspection.
Offline, Shutdown) The three options are:
 Online- any inspection that can be performed with the equipment
running (example: VI-External inspection)
 Offline- any inspection that requires the equipment to be not
operating, but does not require the equipment to be opened (example:
A UT inspection performed on a high temperature exchanger shell)
 Shutdown – any inspection requiring equipment to be opened
(example: VI-Internal Inspection)
Last Inspection Date Date(mm/dd/yyyy) This field is automatically filled in from the database except for “Other
Inspections”. Fill in the date of last inspection from the Inspection Tracking Logs
or Inspection History Summaries.
Due Date Date(mm/dd/yyyy) This field is automatically filled in from the database except for “Other
Inspections”. Fill in the date based on the recommended frequency and Last
Inspection Date.
Frequency Numeric The recommended task interval in years
Preparation Alphanumeric Enter the preparation required to perform the inspection task (example:
“scaffolding”)
Planned By Alphanumeric The name of the person that created the inspection plan
Planning Date Date (mm/dd/yyyy) The date the inspection plan was created or updated
NDE represented by Alphanumeric If no NDE is being performed on this asset, enter the equipment ID number of the
asset that has representative NDE data.
4. Press to save the Inspection Work Plan.
Here is another example of creating an IWP (for piping circuit 735002C):
Review the baseline inspection selection list worksheet to determine which inspections that this
equipment asset was selected for:
This circuit requires an external visual inspection, and

tasks for localized internal corrosion and CUI on the IWP.
Always enter specific recommendations on the IWP. Any inspections “Due Now” or overdue should
Obtain them from the Capstone Corrosion Engineer. be scheduled for 6 months from project
“Consult with Materials Engineer” is not a valid closeout (for online tasks) and at the first
inspection method or inspection scope. available turnaround (for offline/shutdown
tasks).
Note: Accommodate unit/plant turnaround schedules when defining due dates for
offline/shutdown inspection tasks. Obtain the turnaround schedule for the next ten years
and modify offline/shutdown inspection due dates to correlate with unit downtimes.
5. Review Inspection Work Plans – After IWPs have been developed for all equipment assets
in the project scope, the Site Coordinator generates an “Inspections Due” report for the unit
(see Running a Report) and verifies the quality and accuracy of the plans (see Reviewing
Deliverables).
Updating Inspection Work Plans

After development of the initial IWPs is completed, an IWP for an equipment asset may require
updating/modification in the following situations:
 Criticality values for an asset have changed
 An inspection has been performed (and subsequently the criticality has been updated,
see Updating Criticality)
Note: The RBMI software

Task Manager will inform
you when an Inspection
Work Plan needs to be
updated.
A qualified Capstone employee updates an IWP as follows:
1. Using Work Flow Steps or the appropriate Equipment Browser, open the inspection plan
that you want to modify and press :
2. Press to update the recommended tasks:
Compare the
Recommended
Inspection Tasks
to the planned
tasks on the
Inspection Plan.
(Note: In this
example, the
recommendation
for Internal
Corrosion differs
from the planned
task)
3. Modify the Inspection Work Plan based on changes in the recommended tasks
and press :
The Internal
Corrosion
inspection task
was modified to
match the
recommended
one.
1
Appendix
Appendix 1 – Forms
Safety Meeting Record
Project Location/Number:
Date:
Meeting Type:
Scheduled Topics:
Additional Safety Issues/Concerns:

1.
2.
3.
4.
5.
Safety Equipment
Equip. and PPE Checked? Needs/Comments
Yes No
Attendance:
Piping System/Circuit Identification Log

Unit Name: _________________________
Date: ______________________________
Unique System Circuit System

Identifier ID ID P&ID Description
Piping Data Collection Form

Date __________________ Performed by ________________________ QC ___________________________
BACKGROUND DATA
Circuit ID : Drawing Number: Chemical Injected:
Operating Unit: Soil-Air Interface (Y/N): PFD:
Reliability System: Injection Point Circuit (Y/N) : P&ID:
Circuit Description From:
Circuit Description To:
LINE LIST
Line Pipe Nom. Pipe Flange Insulation Tracing
Number Spec Size Sched. Rating Type Type
DESIGN/CONSTRUCTION DATA
Construction Code: Gasket Material:
Code Date: Bolting Material:
Year Built: Jacket Type (If any):
Relief Set Pressure: Partial Internal Visual Possible (Y/N):
Relief Valve Number:
Material Spec: MDMT (F): Insulated (Y/N): Type:
Material Grade: PWHT (Y/N): Temperature: Estimated Length (ft):
Design Temperature: Joint Efficiency: Representative Size (in):
Design Pressure: Representative Thickness: Representative Pipe Spec.:
Date In Service: Corrosion Allowance (in): Representative Schedule:
COMPONENTS
Location Description Matl Spec Grade Size Nominal Minimum Date In service
Thickness Thickness
PROCESS DATA
Representative Fluid: Operating Pressure (psi):
Fluid Phase: Operating Temp (F):

Liquid Gas
Toxic Fluid: Toxic Fluid Percentage:
Process Service: Process System:
Material Data Internal Corrosion
Impact Test: Contaminant 1: Concentration 1:
Stabilized: Contaminant 2: Concentration 2:
Annealed: Expected Corrosion Rate (ipy): Pitting Potential (L, M, H):
Stable Scale: Corrosion Type: Lining \ Coating:

General, Localized, Pitting
HIC Steel: Corrosion Loop Number: Corrosion Mechanism:
Sensitized: Corrosion Loop Description:
Predictable Locations:
Process Data External Corrosion Other Mechanisms

Operating Temp – In (F): Coating: Mechanism:
None, Avg., Best
Operating Temp – Out (F): Area Humidity: Potential (H, M, L):
High, Medium, Low
Water Present (%) if any: External Wetting (Y\N): Probability Category:
pH: Intermittent Service (Y\N):
Traced:
Steam Electric
Expected Ext. Corrosion Rate (ipy):
Name: Date: Comments:

Initial Potential for Environmental Cracking
Mechanism:
Initial Potential (L, M, H):
Initial Potential Description:
Cracking Agent 1: Concentration 1:
Steam Out (Y\N):
Name: Date: Comment:
Line List (cont.)

Line Pipe Nom. Pipe Flange Insulation Tracing
Number Spec Size Sched. Rating Type Type
Field Verification Datasheet

Name Plate Legible: Y N Missing Equip ID No.:
Vessel Insulated: Y N Partial Unit Name:
Which Components:
External Wetting: Y N System:
Coating: Best Average None General Location:
Internal Entry Possible: Y N
Equipment Name:
Equipment Type:
Name Plate Stamps:
Serial No.:
National Board No.:
Manufacturer:
Year Built:
Code Built to:
Model:
No. of Heads:
No. of Nozzles:
No. of Shell Courses:
Diameter:
Length:
Material of Construction: shell- channel-
Thickness: shell- channel-
Corrosion Allowance: shell- channel-
Design Pressure @ shell- channel-
Design Temp.
Hydro Test: S/S PSI@ F T/S PSI@ F
MDMT: S/S PSI@ F T/S PSI@ F
Post Weld Heat Treated:
RT Circle One 1 2 3 4 N/A
Joint Efficiency:
Radiographic Tested:
Operating Conditions S/S PSI@ F T/S PSI@ F
Storage Tanks
Diked Area: Yes / No Square Footage
Foundation Type: Clay Sand Double Floor Gravel Silt Concrete
Soil Composition: Clay Sand Gravel Silt
Maximum Liquid Level:
Other Comments:
Verified By: Company: Date Field Verified:
Pressure Vessel Data Collection Form

Date ________________________ Performed by _____________________ QC _________________________
Background Data
Equipment ID: Manufacturer Serial No.: PFD:
Operating Unit: National Board Number: P&ID:
Reliability System: Orientation: Asset Number:

Horizontal Vertical
Vessel Type: Drawing Number: U-1 Available (Y/N):
Description:
Manufacturer:
Construction Code: Gasket Material: Number of Shell Courses/Bands:
ASME Sect. VIII Div. 1
Code Date : Bolting Material: Number of Heads/Covers:
Year Built: Relief Set Pressure (psi): Number of Nozzles:
Length (ft): Relief Valve Number: Internal Entry Possible :
Test Pressure (psi): Jacket Type (If any):

Dimple/ Fin-tube/ Half Pipe/ Full
Material Spec: MDMT (F): Insulated (Y/N):
Material Grade: PWHT (Y/N): Temperature: Insulation Type:
Design Temperature: Joint Efficiency:
Nominal Thickness (in):
Design Pressure: Corrosion Allowance (in):
Diameter (in.): Flange Rating: Date In Service: (xx/xx/xxxx)
COMPONENTS
Item Description Matl Spec Grade Size Nominal Minimum Date In service
Thickness Thickness
PROCESS DATA

Liquid Gas



None, Avg., Best
High, Medium, Low
Traced:
Steam Electric

Mechanism:
Steam Out (Y\N):
Column Data Collection Form

Performed by __________________ Date____________ QC_______________________
Background Data
System: Drawing Number: Asset Number:
Column Type: U-1 Available (Y or N):

Trayed Packed
Description:
Manufacturer:
Construction Code: Gasket Material: Number of Shell Courses/Bands:
Code Date : Bolting Material: Number of Heads/Covers:
Year Built: Relief Valve Number: Number of Nozzles:
Height (ft): Relief Set Pressure (psi): Number of Trays:
Test Pressure (psi): Internal Entry Possible :
Design/Construction Data (Top)

Material Spec: MDMT (F): Flange Rating:
Material Grade: PWHT (Y or N): Temperature: Insulated (Y or N):
Design Temperature: Joint Efficiency: Insulation Type:
Design Pressure: Nominal Thickness (in):
Diameter (in.): Corrosion Allowance (in): Date in Service:
COMPONENTS(TOP)
Thickness Thickness
PROCESS DATA (TOP)


Liquid Gas
Design/Construction Data (Middle)
COMPONENTS (MIDDLE)
Thickness Thickness
PROCESS DATA (MIDDLE)


Liquid Gas
DESIGN/CONSTRUCTION DATA (BOTTOM)

COMPONENTS (BOTTOM)
Thickness Thickness
PROCESS DATA (BOTTOM)


Liquid Gas



None, Avg., Best
High, Medium, Low
Traced:
Steam Electric

Mechanism:
Steam Out (Y\N):
Air Cooled Exchanger Data Collection Form

Date _________________________ Performed by _____________________ QC ____________________________
Background Data
System: Orientation: Asset Number:

Horizontal Vertical
Drawing Number: U-1 Available (Y/N):
Description:
Manufacturer:
Design/Construction Data - Header

Construction Code: Gasket Material: Number of Fans:
Code Date : Bolting Material: Number of Headers:
Year Built: Partial Internal Visual Possible (Y/N): Number of Nozzles:
Draft:
Material Spec: MDMT (F): Header Type:
Material Grade: PWHT (Y/N): Temperature: Relief Set Pressure (psi):
Design Temperature (F): Joint Efficiency: Test Pressure (psi):
Nominal Thickness (in): Relief Valve Number:
Design Pressure (psi): Corrosion Allowance (in): Plug Type:
Diameter (in.): Flange Rating: Plug Material:
COMPONENTS - HEADER
Thickness Thickness
PROCESS DATA – HEADER

Process Service:
DESIGN/CONSTRUCTION DATA - TUBE

Test Pressure (psi): Design Pressure (psi): MDMT (F):
Number of Tubes: Design Temperature (F): Corrosion Allowance (in.):
Number of Rows: Relief Set Pressure (psi): Nominal Thickness (in.):
Tube-Tube Sheet Joint: Material Spec: Diameter (in.):
Material Grade: Fin Type :
Welded Tube Seamless Fin Material :

Tube
COMPONENTS - TUBE
Thickness Thickness

Stable Scale: Corrosion Type (General, Localized, Lining \ Coating:

Pitting):

Operating Temp – In (F): Coating (None, Avg., Best): Mechanism:
Operating Temp – Out (F): Area Humidity (High, Medium, Low): Potential (H, M, L):
Traced (Steam\Electric):

Mechanism:
Steam Out (Y\N):
Shell and Tube Heat Exchanger Data Collection Form

Date _________________________ Performed by ____________________ QC __________________________
Background Data
Reliability System: Orientation: Asset Number:

Horizontal Vertical
Exchanger Type: Shell & Tube Drawing Number: U-1 Available (Y or N):
Core Plate & Fin Spiral Tube
Description:
Manufacturer:

Construction Code: Length (ft): Number of Shell Courses:
ASME Sect. VIII Div. 1
Code Date : Gasket Material: Number of Heads/Covers:
Year Built: Bolting Material: Number of Nozzles:
TEMA Type: Internal Entry Possible:
Design Temperature: Joint Efficiency: Test Pressure (psi):
Diameter (in.): Flange Rating: Date In Service: (xx/xx/xxxx)
COMPONENTS - SHELL
Thickness Thickness
PROCESS DATA - SHELL


Liquid Gas
DESIGN/CONSTRUCTION DATA - CHANNEL
Design Temperature: Joint Efficiency: Test Pressure (psi):
Diameter (in.): Flange Rating: Date In Service:
COMPONENTS - CHANNEL
Thickness Thickness
PROCESS DATA - CHANNEL


Liquid Gas
DESIGN/CONSTRUCTION DATA - BUNDLE

Bundle Type: Design Pressure:
Straight U-Tube
Number of Tubes: Design Temperature: Date In Service:
Welded Seamless Test Pressure (psi): Tube Nom. Thickness (in):
Tube-Tube Sheet Joint: Material Spec: Tube Diameter (in):
PWHT (Y/N): Temperature: Material Grade: Corrosion Allowance (in):
COMPONENTS - BUNDLE
Thickness Thickness
Corrosion Study Data SHELL



None, Avg., Best
High, Medium, Low
Traced:
Steam Electric

Mechanism:
Steam Out (Y\N):
Corrosion Study Data CHANNEL



None, Avg., Best
High, Medium, Low
Traced:
Steam Electric

Mechanism:
Steam Out (Y\N):
Corrosion Study Data BUNDLE


Internal: External:

None, Avg., Best
High, Medium, Low
Traced:
Steam Electric

Mechanism:
Steam Out (Y\N):
Storage Tank Data Collection Form

Date _________________________ Performed by _____________________ QC ____________________________
Background Data Roof Data

Equipment ID: Drawing Number: Roof Type:
Cone Floating Pan
Operating Unit: PFD: Plate Thickness:
Reliability System: P&ID: Material Specification:
Manufacturer Serial No.: Asset Number: Material Grade:
Internal Support Type:
Description: Internal Support Material:
Manufacturer:

Construction Code : Fire Protection Type : Insulation Type :
Deluge Foam Gas Detector Water
Code Date : Flame Arrestor Type: Detonation Preventor Maximum Liquid Level (ft) :
Free Venting Inline Intergal with Relief
Year Built: Gasket Material: Relief Valve No.:
Diameter (ft): Bolting Material: Relief Set Pressure (in. H2O):
Height (ft): Diked (Y/N): Area (sq ft): Design Capacity (BBL or Gals):
Design Temperature (F): Internal Entry Possible: Number of shell courses:
Design Specific Gravity: Overfill Protection (Y/N): Number of Nozzles:
PWHT (Y/N) Temperature Double Wall (Y/N): Corrosion Allowance (in):
MDMT (F): Material Spec: Joint Type:

Bolted Welded Riveted
Int. Cathodic Protection: Material Grade: Joint Efficiency:
Date In Service: Insulated (Y/N): Nominal Thickness (in):
COMPONENTS - SHELL
Thickness Thickness
PROCESS DATA – SHELL

Representative Fluid: Operating Temp (F):
Fluid Phase: Toxic Fluid Percentage:

Liquid Gas
Toxic Fluid: Density (lb/ft^3):
Design/Construction Data - Bottom
Leak Detection (Y/N): Soil Composition: Material Spec:
Clay Gravel Sand Silt
Leak Detection Area: Lining/Coating (Y/N): Type: Material Grade:
Foundation Type: Clay Sand PWHT (Y/N): Temperature: Nominal Thickness (in):
Double Floor Gravel Silt Concrete
Bottom Support Type: MDMT (F): Corrosion Allowance (in):
(Y/N):
Joint Type: Minimum Thickness (in):
Cathodic Protection( Y/N): Design Temperature (F): Date In Service: (xx/xx/xxxx)
COMPONENTS - BOTTOM
Thickness Thickness



None, Avg., Best
High, Medium, Low
Traced:
Steam Electric

Mechanism:
Steam Out (Y\N):
RELIEF DEVICE DATA COLLECTION FORM

Date ________________________ Performed by _____________________ QC _________________________
Location - Background Data:
Location ID: Operation Unit:
System: P&ID:
Orientation: Horizontal Vertical In-Place Relief Test Allowed (Y/N):
Redundant Relief Devices (Y/N): Protected by Rupture Disk (Y/N):

Rupture Disk ID:
Location Comment:
Location – Protected Equipment:

Protected Equipment ID: Equipment Type:
Component Type: Consequence (A B C D E):
Design Pressure: Unit:
Location – Process Data:

Representative Fluid Name: Representative Fluid Phase (Liquid Gas):
Operating Pressure: Operating Temperature:
Protected Equipment Corrosion Rate: Specific Gravity:
Design Basis: Potential for Fouling (Low / Medium / High / Very High):
Estimated Challenge Rate (Only required if challenge rate

used is E):
Location – Process Data (Pressure Vacuum Vent only):
Maximum Pressure Flow Capacity Required: Maximum Vacuum Flow Capacity Required:
Flashpoint: Pump pressure in:
Pump pressure out:
Location – Process Data (Pressure Relief Valves and Rupture Disks):

Required Capacity: Back Pressure:
Differential Set Pressure: Allowable Overpressure:
Relieves to (Atmosphere, Flare, Other):
Relief Device – Background Data / Name Plate Data:

Device ID: Device Type:
Manufacturer: Serial Number:
Model Number: Pressure Set Point (Pressure Vacuum Vent (PV) Vent only):
Vacuum Set Point (PV Vent only): Pressure Flow Capacity (PV Vent only):
Vacuum Flow Capacity (PV Vent only): Nameplate Capacity (Pressure Relief Valve (PRV) only):
Relief Set Pressure (PRV only): Relief Temperature (PRV only):
Relief Device – Design / Construction Data:

Construction Code: Bolts / Nuts:
Inlet Size: Inlet Flange Facing Type:
Inlet Flange Rating: Date in this Service:
Sizing Calculations on File (Y/N): Threaded (Y/N):
Gasket Type (PRV only): Operation Type (PRV only):
Design Type (PRV only) (Conventional Bellows Pilot Orifice Size (PRV only):
Operated):
Outlet Size (PRV only): Outlet Flange Facing Type (PRV only):
Outlet Flange Rating (PRV only): Spring Size (PRV only):
Spring Number (PRV only): Spring Type (PRV only):
Maximum Back Pressure (PRV only): Higher Alloy Materials on Internal Parts (PRV only) (Y/N):
Size (PV Vent only): All Weather Construction (PV Vent only) (Y/N):
Rupture Disk Data:

Rupture Disk ID: Rupture Disk Type:
Disk Material: Coating Material:
Side to Pressure: Convex Concave Flat Manufacturer:

Gasket Material: Seal Material:
Date in this Service: Number of Rupture Disk Replacements:
Sizing Calculations on File (Y/N): Lot Test Certificate (Y/N):
Fragmentation Allowed (Y/N): Leak Through Indicator (Y/N):
Rupture Disk Nameplate Data:

Burst Pressure: Burst Temperature:
Lot/ID Number: Size:
Kr: MNFA:
Nameplate Capacity:
Rupture Disk Holder Data:

Rupture Disk Holder (Y/N): Holder Model Number:
Holder Flange Rating: Holder Manufacturer:
Holder Material:
Data Collection Discrepancy Log
Documents Transmitted/Received
Date: _______________
From: ________________________________________
To: __________________________________________
The following is being transmitted/received for:
Approval Information Review Action ____________________________
Required by: ______________________
Signature/Date: ____________________
Number Description Pages
Inspection History Summary

Project No.: Equip. Type:
Unit: Date:
Equipment Component Year Inspection Insp. Comments
ID Built Type Date
Page ____ of ____
Piping Visual Inspection Report

Background Information
Circuit ID: Insulated (Y, N): Metal Temp. < Dew Point (Y or N):
External Location Categories

Barrier Damaged Insulation Vertical Horizontal Soil-Air
Penetrations: Insulation: Termination: Runs: Low Points: Interface:
Internal Location Categories

Dead Long Erosion Elbows: Tees: Reducers:
Legs: Horizontal Runs: Zones:
Observations
ID Item Good NA See ID Item Good NA See Below ID Item Good NA See Below
Below
GENERAL PIPING CONNECTIONS & INSULATION
COMPONENTS
P1 Other (Please Explain) P31 Other (Please explain) P41 Other (Please explain)
P2 Corrosion No P32 Expansion Joint P42 Damage No
P3 Leaks No P33 Small Branches P43 Penetrations
P4 Vibration No P34 Inadequate Thread Engagement No P44 Jacket
P5 Misalignment No P35 Bolting P45 Banding
P6 Soil-Air Interface P36 Socket Welds P46 Seals/Joints/Caulking
P7 Painted Inactive Corrosion P37 Threaded Connections

P8 Coating/Painting P38 Flanges
SUPPORTS P39 Valves
P21 Other (Please explain) P40 Leak Clamps No
P22 Support Shoes

P23 Support Members
P24 Hanger/Brackets
Additional Comments
ID Fair Poor Location Comments NCR
Inspected by Company Date Cert. #
Enter _________ QC _________

Initial/Date Initial/Date
Pressure Vessel External Visual Inspection Report

Equipment ID: Unit Name: Insulated (Y, N,):
External Location Categories for Insulated Vessels

Barrier Penetrations: Damaged Insulation: Vessel Supports: Insulation Rings:
Observations
Item Good NA See Below ID Item Good NA See Below ID Item Good NA See
Below
GENERAL SUPPORTS INSULATION

V1 Other (Please Explain) V21 Other (Please explain) V41 Other (Please explain)
V2 Corrosion No V22 Foundation V42 Damage No
V3 Leaks No V23 Anchor Bolts V43 Penetrations
V4 Vibration No V24 Saddle/Skirt V44 Jacket
V5 Dissimilar Flange Rating No V25 Davit V45 Banding
V6 Ladder/Stairway V26 Fireproofing V46 Seals/Joints
V7 Platform CONNECTIONS RELIEF DEVICE
V8 Guy Wires V31 Other (Please explain) V51 Other (Please explain)
V9 Electrical Ground V32 Small Branches V52 Corrosion No
V10 Painted Inactive Corrosion V33 Nozzles V53 Leaks No
V11 Coating/Painting V34 Manways V54 Restricted Inlet/Outlet No
V12 Expansion Joint or Bellows V35 Reinforcing Pads V55 Manual Operation Lever
V13 Gauge/Site Glass V36 Inadequate Thread Engagement No
V14 Shell V37 Bolting
V38 Flanges
V39 Leak Clamps No
V56 Tag Information:: Unit = Valve ID= Location ID=

Set Pressure= Test Date=
Size= Serial Number= Model Number=
Additional Comments

Enter ________ QC __________
Storage Tank External Visual Inspection Report

Equipment ID: Unit Name: Insulated (Y, N):
External Location Categories for Insulated Vessels

Barrier Penetrations: Damaged Insulation: Insulation Rings:
Observations
Item Good NA See Below ID Item Good NA See Below ID Item Good NA See
Below
GENERAL SUPPORTS INSULATION

T1 Other (Please Explain) T31 Other (Please Explain) T61 Other (Please explain)
T2 Corrosion No T32 Foundation T62 Damage No
T3 Leaks No T33 Anchor Bolts T63 Penetrations
T4 Vibration No T34 Windgirders T64 Jacket
T5 Dissimilar Flange Rating No CONNECTIONS T65 Banding
T6 Ladder/Stairway T41 Other (Please explain) T66 Seals/Joints
T7 Platform T42 Small Branches
T8 Electrical Ground T43 Nozzles RELIEF DEVICE
T9 Cathodic Protection T44 Pipe Manifolds T71 Other (Please explain)
T10 Painted Inactive Corrosion T45 Swing Lines T72 Corrosion No
T11 Coating/Painting T46 Manways/Hatches T73 Leaks No
T12 Level Gauge T47 Reinforcing Pads T74 Restricted Inlet/Outlet No
T13 Bottom T48 Inadequate Thread Engagement No T75 Manual Operation Lever
T14 Secondary Containment T49 Bolting
T15 Shell T50 Flanges
T16 Roof T51 Leak Clamps No
T17 Agitator/ Mixer
T76 Tag Information:: Unit = Valve ID= Location ID=

Set Pressure= Test Date=
Size= Serial Number= Model Number=
Additional Comments
Enter ________ QC __________
Pressure Relief Valve Visual Inspection Report

Organization: Inspection Date:
Plant: Location ID:
Operating Unit: Relief Device ID:
System:
Background
Insulated (Y/N): Relief Set Pressure (PSIG): Last Inspection Date: Serial Number:
Inspector
Inspector: Company:
Inspection Comments
Condition (Check one)
Description Good Fair Poor NA Location NCR Comments
ID GENERAL
R01 Other (Please Explain)
R02 Corrosion No
R03 Leaks No Yes
R04 Device Leak Through No Yes
R05 Vibration No Yes
R06 Misalignment No Yes
R07 Piping Obstruction No Yes
R08 Block Valves Sealed Open No Yes
R09 Spring Tamper Seal Intact No Yes
R10 Rupture Disk Orientation No Yes
Correct
R11 Insulation
SUPPORTS
R21 Other (Please explain)
R22 Discharge Supports
CONNECTIONS
R31 Other (Please explain)
R32 Bellows Vent
R33 Vent Piping
R34 Drains Open No Yes
R35 Inadequate Thread No Yes
Engagement
R36 Bolting
R37 Flanges
R38 Threaded Connections
R39 Gauges
R40 Manual Operation Lever
Inspection Summary
Enter: _____________ QC: ____________
Rupture Disk Visual Inspection Report

Organization: Inspection Date:
Plant: Location ID:
Operating Unit: Relief Device ID:
System:
Background
Lot/ID Number: Burst Pressure (PSIG):
Inspector
Inspector: Company:
Inspection Comments
Condition (Check one)
Description Good Fair Poor NA Location NCR Comments
ID GENERAL
R01 Other (Please Explain)
R02 Correct disk installed No Yes
R03 Nameplate information
legibility
R04 Piping Obstruction No Yes
R05 Correct orientation in No Yes
piping
R06 Connection joint makeup
R07 Disk leak through No Yes
R08 Block valves sealed open No Yes
R09 Discharge pipe or vent
supports
Comments
Enter: ___________ QC: ____________
Pressure Vessel Internal Visual Inspection Report

Equipment ID: Unit Name: Internal Lining (Y/N):
Observations
Item Good NA See Below Item Good NA See Below
ID GENERAL ID INTERNALS
V1 Other (Please Explain) V21 Other (Please explain)
V2 Corrosion (depth, length, width) No V22 Demister
V3 Erosion No V23 Baffle/Wier
V4 Distortion No V24 Sparger
V5 Blisters No V25 Thermowells
V6 Deposits No V26 Metallic Linings
V7 Heads V27 Nonmetallic Linings
V8 Welds V28 Trays

V9 Nozzles V29 Tray Rings
V10 Shell V30 Other Welded Attachments
V11 Gasket Surfaces V31 Tubes
V32 Tubesheets
Additional Comments
Enter ________ QC __________

Storage Tank Internal Visual Inspection Report

Equipment ID: Unit Name: Internal Lining (Y/N):
Observations
Item Good NA See Below Item Good NA See Below
ID GENERAL ID INTERNALS
T1 Other (Please Explain) T21 Other (Please explain)
T2 Corrosion (depth, length, width) No T22 Annular Ring
T3 Erosion No T23 Sump
T4 Distortion No T24 Roof Supports
T5 Blisters No T25 Thermowells
T6 Deposits No T26 Metallic Linings
T7 Welds T27 Nonmetallic Linings
T8 Nozzles T28 Internal steam coil or other

piping
T9 Shell T29 Level gauge
T10 Roof T30 Other Welded Attachments
T11 Floor
Additional Comments
Enter ________ QC __________

Other Inspection Report

Equipment ID: Unit Name: Inspection Method:
Other Inspection Data

Test Equipment Manufacturer: Test Equipment Model:
Scope of Inspection
Observations/Measurements
Location Observation/Measurement Acceptance Criteria NCR Comments
Inspection Summary

Enter ________ QC __________
Non-conformance Report
BACKGROUND INFORMATION
Operating Unit: Non-conformance Number:
Equipment ID: Location:
Applicable Code / Standard:
Initiation
Non-conformance Rank: P&ID: Status:
Initiated By: NC Identified By: Reviewed by:
Date Initiated: Date Identified: Date Reviewed:
Company:
Description of Code Reference
Details of Non-conformance
Recommendations
Correction
Temporary Operation with Safeguards
Date to be Implemented by: Tracking Required:
Yes No
Date to be Removed: Management of Change Required:
Yes No
Code or Standards Used: Management of Change Approved:
Yes No
Management of Change Number: Permanent Corrections By:
[ ] Rerate [ ] Repair [ ] Replacement [ ] Redefine Acceptance Criteria
[ ] Other:
Details of Temporary Operation / Correction
Correction Due Date: Work Order Number:
Correction Completed by: Correction Date:
Responsible:
Additional Comments
Equipment ID:
Additional Comments
Enter _________ QC ________

Non-Conformance Tracking Log

Project Number:
Client:
Unit:
NC Equipment NC Description of Problem Date

Date NC Reported To Initials
Number ID Rank Reported
Page _____ of ______
Ultrasonic Thickness Report

Background Information Page _____ of _____
Equipment ID: Unit Name: P&ID: Insp. Type: Baseline Follow-up Plant System No:
Test Unit: Cal Due Date: Manufacturer: Model Number:

UT Meter: Serial Number:
Transducer: Frequency (MHz): Serial Number: Diameter:

UT Transducer:
Calibration Block: Serial Number: Thickness: Material:
UT Calibration Block:
Echo to Echo: Y/N Through Coating: Y/N Chipped Paint: Y/N Other: Y/N
Technique:
Location Information Thickness Information
Comments
Insp. Loc. Comp. Loc. Size Date Matl. Grade Nominal Previous Current Temp Min.
Thickness Reading Reading Thick.
Loc. Cat. Descr. Installed
Inspection Summary
Inspector(s) Company Date Enter (Initial/Date) QC (Initial/Date)
Additional UT Thickness Report

Equipment ID: ___________________
Observations/Measurements Page _____ of _____
Location Information Thickness Information

Comments
Insp. Loc. Comp. Loc. Size Date Matl. Grade Nominal Previous Current Temp Min.
Thickness Reading Reading Thick.
Loc. Cat. Descr. Installed
Profile Radiographic Testing Report

Page _____ of ______
Equipment ID: Unit Name: P&ID: Inspection Type: Plant System No:
Source Type: Source Strength (curies): Film Type: Film Size:

Test Equipment:
Location Information Thickness Information Set Up Information
Comments
Insp. Loc. Comp. Loc. Size Date Matl. Grade Nom. Previous Current Min. Center Source Exp.
Reading Reading Thick. to Film to Film
Loc. Cat. Descr. Installed Thick. Time
Inspection Summary
Inspector(s) Company Date Enter (Initial/Date) QC (Initial/Date)
Additional RT Report
Equipment ID: ___________________
Observations/Measurements Page _____ of _____
Location Information Thickness Information Set Up Information

Comments
Insp. Loc. Comp. Loc. Size Date Matl. Grade Nom. Previous Current Min. Center Source Exp.
Reading Reading Thick. to Film to Film
Loc. Cat. Descr. Installed Thick. Time
Inspection Tracking Log

Client: Location: Unit:
Page _____ of ______
Inspection Preparation
Type Insulated Required
Equipment NDE Preparation Inspection
ID Method (B / F) (Y / N) (Y / N) Preparation Description Complete Complete Comments/Results
2
Appendix
Appendix 2 – References
Pressure Vessel Material Specs. and Grades

MatlSpec MatlGrd
CS
CS A214
SA-106 A
SA-106 B
SA-106 C
SA-179 Smls. tube
SA-181 60
SA-181 70
SA-182 F1
SA-182 F11-CL1
SA-182 F11-CL2
SA-182 F12-CL1
SA-182 F12-CL2
SA-182 F2
SA-182 F21
SA-182 F22-CL1
SA-182 F22-CL3
SA-182 F304
SA-182 F304H
SA-182 F304L
SA-182 F310
SA-182 F316
SA-182 F316H
SA-182 F316L
SA-182 F317
SA-182 F317L
SA-182 F321
SA-182 F321H
SA-182 F347
MatlSpec MatlGrd
SA-182 F347H
SA-182 F348
SA-182 F348H
SA-182 F3V
SA-182 F44
SA-182 F45
SA-182 F5
SA-182 F51
SA-182 F5a
SA-182 F6a-CL1
SA-182 F6a-CL2
SA-182 F9
SA-182 F91
SA-182 FR
SA-182 FXM-11
SA-182 FXM-19
SA-182 FXM-27Cb
SA-199 T11
SA-199 T21
SA-199 T22
SA-199 T5
SA-199 T9
SA-203 D
SA-203 E
SA-203 F
SA-209 T1
SA-209 T1a
SA-209 T1b
SA-210 A1
SA-212 B-FB
SA-212 B-FBX
SA-213 T12
SA-213 T17
SA-213 T2
SA-213 T5b
SA-213 T5c
SA-213 T91
SA-213 TP304
SA-213 TP304H
SA-213 TP304L
SA-213 TP304N
SA-213 TP309Cb
SA-213 TP309H
SA-213 TP309S
SA-213 TP310Cb
MatlSpec MatlGrd
SA-213 TP310H
SA-213 TP310MoLN
SA-213 TP310S
SA-213 TP316
SA-213 TP316H
SA-213 TP316L
SA-213 TP316N
SA-213 TP321
SA-213 TP321H
SA-213 TP347
SA-213 TP347H
SA-213 TP348
SA-213 TP348H
SA-213 XM-15
SA-213 XM-19
SA-214 Wld. Tube
SA-216 WCA
SA-216 WCB
SA-216 WCC
SA-217 C12
SA-217 C5
SA-217 CA15
SA-217 WC1
SA-217 WC4
SA-217 WC5
SA-217 WC6
SA-217 WC9
SA-234 WP1
SA-234 WP11
SA-234 WP12
SA-234 WP22
SA-234 WP5
SA-234 WP9
SA-234 WPB
SA-234 WPC
SA-234 WPR
SA-240 201-1
SA-240 201-2
SA-240 204
SA-240 26-3-3
SA-240 302
SA-240 304
SA-240 304H
SA-240 304L
SA-240 TP-304L
MatlSpec MatlGrd
SA-240 304N
SA-240 309Cb
SA-240 309H
SA-240 309S
SA-240 310Cb
SA-240 310H
SA-240 310MoLN
SA-240 310S
SA-240 316
SA-240 316Cb
SA-240 316-ELC
SA-240 316H
SA-240 316L
SA-240 316Ti
SA-240 317L
SA-240 321
SA-240 329
SA-240 347
SA-240 347H
SA-240 348
SA-240 405
SA-240 410
SA-240 410S
SA-240 429
SA-240 430
SA-240 TP409
SA-240 XM-27
SA-240 XM-29
SA-240 XM-33
SA-249 TP317
SA-249 TP317L
SA-249 TPXM-15
SA-249 TPXM-19
SA-266 1
SA-266 2
SA-266 3
SA-266 4
SA-268 29-4
SA-268 29-4-2
SA-268 TP405
SA-268 TP410
SA-268 TP429
SA-268 TP430
SA-268 TP439
MatlSpec MatlGrd
SA-268 TP446-1
SA-268 TPXM-27
SA-268 TPXM-33
SA-278 40
SA-285 CFB
SA-285 C-FQ
SA-312 TP304 Smls. Pipe
SA-312 TP304 Wld. Pipe
SA-312 TP304H Smls. Pipe
SA-312 TP304H Wld. Pipe
SA-312 TP304L Smls. Pipe
SA-312 TP304L Wld. Pipe
SA-312 TP304N Smls. Pipe
SA-312 TP304N Wld. Pipe
SA-312 TP309S Smls. Pipe
SA-312 TP309S Wld. Pipe
SA-312 TP310Cb Smls. Pipe
SA-312 TP310Cb Wld. Pipe
SA-312 TP310S Smls. Pipe
SA-312 TP310S Wld. Pipe
SA-312 TP316N Smls. Pipe
SA-312 TP316N Wld. Pipe
SA-312 TP317L Wld. Pipe
MatlSpec MatlGrd
SA-312 TPXM-11 Smls. Pipe
SA-312 TPXM-11 Wld. Pipe
SA-312 TPXM-19 Smls. Pipe
SA-312 TPXM-19 Wld. Pipe
SA-333 6
SA-334 1 Wld. & smls. Tube
SA-334 1 Wld. Tube
SA-334 3 Tube
SA-334 3 Wld. Tube
SA-334 6 Wld. & smls. Tube
SA-334 6 Wld. Tube
SA-334 8 Smls. Tube
SA-334 8 Wld. Tube
SA-334 9
SA-335 P1
SA-335 P11
SA-335 P12
SA-335 P15
SA-335 P2
SA-335 P21
SA-335 P22
SA-335 P5
SA-335 P5b
SA-335 P5c
SA-335 P9
SA-335 P91
SA-336 F11-CL3
SA-336 F12
SA-336 F21-CL1
SA-336 F21-CL3
SA-336 F304N
SA-336 F316N
SA-350 LF1
SA-350 LF2
SA-350 LF3
SA-350 LF5-CL1
SA-350 LF5-CL2
SA-350 LF9
SA-351 CE8MN
SA-351 CF10
SA-351 CF10M
SA-351 CF3
MatlSpec MatlGrd
SA-351 CF3A
SA-351 CF3M
SA-351 CF8
SA-351 CF8A
SA-351 CF8C
SA-351 CF8M
SA-351 CG6MMN
SA-351 CG8M
SA-351 CH20
SA-351 CH8
SA-351 CK20
SA-351 CK3MCuN
SA-351 CN-3MN
SA-351 CT15C
SA-352 LC1
SA-352 LC2
SA-352 LC3
SA-352 LCB
SA-369 FP1
SA-369 FP11
SA-369 FP12
SA-369 FP2
SA-369 FP21
SA-369 FP22
SA-369 FP5
SA-369 FP9
SA-372 G
SA-372 H
SA-372 J-110
SA-372 J-70
SA-387 11 CL.1
SA-387 11 CL.2
SA-387 11-CL1
SA-387 11-CL2
SA-387 12-CL1
SA-387 12-CL2
SA-387 2 CL.1
SA-387 2-CL1
SA-387 2-CL2
SA-387 21-CL1
SA-387 21-CL2
SA-387 22-CL1
SA-387 22-CL2
SA-387 5-CL1
SA-387 5-CL2
MatlSpec MatlGrd
SA-387 91-CL2
SA-403 309
SA-403 310
SA-403 316N
SA-403 317
SA-403 317L-CR
SA-403 317L-WP-S
SA-403 317L-WP-W
SA-403 317L-WP-WU
SA-403 317L-WP-WX
SA-403 321H
SA-403 348H
SA-420 WPL3
SA-420 WPL6
SA-420 WPL8
SA-420 WPL9
SA-430 FP304
SA-430 FP304H
SA-430 FP304N
SA-430 FP316
SA-430 FP316H
SA-430 FP316N
SA-430 FP321
SA-430 FP321H
SA-430 FP347
SA-430 FP347H
SA-479 439
SA-487 1-A
SA-487 1-B
SA-487 2-A
SA-487 2-B
SA-487 4-A
SA-487 4-B
SA-487 4-E
SA-487 8
SA-487 CA6NM
SA-494 CW-12MW/C
SA-494 CX2MW
SA-494 N-12MV/B
SA-508 1A
SA-508 3V
SA-508 4N-CL1
SA-508 4N-CL2
SA-508 4N-CL3
MatlSpec MatlGrd
SA-515 65
SA-516 55
SA-517 J
SA-517 P
SA-522 I
SA-524 II
SA-53 E/A
SA-53 E/B
SA-53 S/A
SA-53 S/B
SA-533 A-CL1
SA-533 A-CL2
SA-533 B-CL1
SA-533 B-CL2
SA-533 B-CL3
SA-533 C-CL1
SA-533 C-CL2
SA-533 D-CL2
SA-533 D-CL3
SA-537 CL1
SA-537 CL2
SA-537 CL3
SA-543 C-CL3
SA-556 A2
SA-556 B2
SA-556 C2
SA-564 630-H1100
SA-564 630-H1150
SA-666 XM-11
SA-675 45
SA-675 50
SA-688 TPXM-29
SA-695 B/35
SA-695 B/40
SA-739 B11
SA-739 B22
SA-747 CB7Cu-1
SA-765 III
SA-812 80
SA/CSA-G40 38W
SB-108 T4
SB-108 T6
SB-111 H55
MatlSpec MatlGrd
H80 Smls. cond.
SB-111 Tube
SB-111 H80 Smls. Tube
SB-111 O61 Bar
O61 Smls. cond.
SB-111 Tube
SB-111 O61 Smls. Tube
SB-127 Annealed
SB-127 As rolled
SB-135 O60
SB-148 M01
SB-152 O25 Plate, sheet, st
SB-160 Hot rolled
SB-160 Hot rolled/ann.
SB-163 Ann./sol. treat.
SB-163 Stress rel.
SB-164 Annealed Bar
SB-164 Hot worked Bar
SB-164 Hot worked Bar, rod
SB-166 Annealed Rod, bar
SB-166 Hot fin.
SB-167 Cold drawn/ann. Pipe
Cold drawn/ann.
SB-167 Smls
SB-167 Hot fin./ann.
SB-169 O25 or O60
SB-171 O61
SB-171 O61 Plate
SB-171 O61 Plate, sheet
SB-187 O60 Rod
SB-187 O60 Rod, bar
SB-209 5052-H34
SB-209 H112
SB-209 H116
SB-209 H14
SB-209 H32
SB-209 H321
SB-209 H34
SB-209 O
SB-209 T4 wld.
SB-209 T451
SB-209 T451 wld.
SB-209 T6 wld.
SB-209 T651
SB-209 T651 wld.
MatlSpec MatlGrd
SB-210 0
SB-210 H113
SB-210 H12
SB-210 H18
SB-221 H111
SB-221 T3
SB-221 T5 wld.
SB-234 H25
SB-241 T6 Smls. extr. Tube
SB-241 T6 Smls. Pipe
SB-241 T6 wld. Smls. extr.
SB-241 T6 wld. Smls. Pipe
SB-247 H111 wld.
SB-247 H112 Die & hand forg
SB-247 H112 Die forgings
SB-247 H112 wld. Die & hand
SB-247 H112 wld. Die forgin
SB-247 T6 Die forgings
SB-247 T6 Hand forgings
SB-26 T71
SB-265 11
SB-265 12
SB-265 16
SB-265 7
SB-271 M02
SB-283 M10 Forgings
SB-283 M10 Forgings, brass
SB-333 Solution ann.
SB-337 1 Smls. Pipe
SB-337 1 Wld. Pipe
SB-337 12 Smls. Pipe
SB-337 12 Wld. Pipe
SB-337 2 Smls. Pipe
SB-337 2 Wld. Pipe
SB-337 3 Smls. Pipe
SB-337 3 Wld. Pipe
SB-337 7 Smls. Pipe
SB-337 7 Wld. Pipe
SB-337 9 Smls. Pipe
SB-337 9 Wld. Pipe
SB-338 1 Smls. Tube
SB-338 12 Smls. Tube
SB-338 12 Wld. Tube
MatlSpec MatlGrd
SB-338 16 Smls. Tube
SB-338 2 Smls. Tube
SB-338 2 Wld. Tube
SB-338 3 Smls. Tube
SB-338 7 Smls. Tube
SB-338 7 Wld. Tube
SB-338 9 Smls. Tube
SB-338 9 Wld. Tube
SB-363 WPT1
SB-363 WPT12
SB-363 WPT12W
SB-363 WPT2
SB-363 WPT3
SB-363 WPT7
SB-363 WPT7W
SB-366 CR5923
SB-366 WP5923
SB-366 WP5923W
SB-366 WP5923WX
SB-367 C-2
SB-367 C-3
SB-381 F3
SB-381 F7
SB-395 HR58
O61 Smls. U-bend
SB-395 tub
SB-407 Ann./hot fin.
SB-42 H80
SB-423 Cold worked/ann.
SB-435 Annealed Plate
SB-435 Annealed Plate, shee
SB-435 Annealed Sheet
SB-435 Solution ann. Sheet
SB-464 Wld.-ann.
SB-467 Wld. fr. cold rld. s
SB-467 WO61
SB-517 Cold drawn/ann.
SB-543 Light cold worked Wl
SB-550 Bar
SB-551 Plate
SB-574 Solution ann. Rod
SB-575 Solution ann. Plate,
SB-622 Solution ann. Smls.
MatlSpec MatlGrd
SB-622 Solution ann. Wld. p
SB-675 Sol. treat.
SB-75 O50
SB-98 H02
RBMI Typical Representative Fluids

Representative Fluids
15% H2
2-Methoxyethanol
Acetic Acid
Acetic Anhydride
Acetone
Acetonitrile
ACR (Acrolein)
AIR
Amine
AN (Acrylonitrile)
Asphalt
Benzene
BF3
C1
C10 (Diesel)
C11
C12
C13-16 (Kerosene)
C17-25 (Gas Oil)
C2
C25+ (Resid)
C3
C4
C5
C6
C7
C8
C9
Calcium Acetate
Calcium Chloride
Caustic (20%)
CCL4
Chlorine
CO
CO2
DMDS (Di-methyl disulfide)
DMDS (Dimethyl Disulfide)
DMF (Dimethyl Floride)
DMS (Dimethyl Sulfide)
EDA (Ethylenediamine)
Eliminox
EO
ETOH (Ethanol)
Freon 22
Furfural
Glycol
H2
H2O
H2S
H2SO4
HCHO
HCL
HCN
HF
Hydrazine
Hydroquinone
IPAC (Isopropyl Alcohol)
Ketene
KOH
MDEA
MEHQ
MEK (Methylethyl Ketone)
MEO (Methyl Ethyl Oleate)
MEOH (Methanol)
Methanol Brine
Methyl Mercaptan
Methylene Chloride
MTBE
N2
Na2SO3
NAOH
NH3
Oleum
Perchloroethylene
Perchloromethylmercaptan
Peroxide
Phosgene
Phosphoric Acid
Propanol
Propionitrile
Propylene Oxide
Steam
Sulfur
Sulfur dioxide
Sulfur Trioxide
TBA (Tert-Butyl Alcohol)
Toluene
TSP (Trisodium Phosphate)
VAM
Xylene
Resource Codes
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Task Codes
General Project Tasks (ADMN) Project Implementation Tasks (cont.)
0010 Project Setup 1430 QC Equipment Work Plans
0100 Project Startup 1500 Standby / Delay Time
0200 Project Management 1600** Perform Activity Preparation
0210 Meetings 1700 Activity Holewatch / Helper
0220 Progress Reporting 1800 Activity Implementation
0230 Mgmt of Subcontractors 1810 Visual External
0240 Training 1811** Perform
0250 Planning/Scheduling 1812 QC
0260 Project Tracking 1820 Visual Internal
0270 Invoicing 1821** Perform
0300 Project Administration 1822 QC
0400 Comp. Apps/Software 1830 UT
Project Implementation Tasks 1831** Perform
0500 Plant Eq./Sys. Overview 1832 QC
0600 Identify Scope of Work 1840 RT - Real Time
0610 ID Processes/Equipment 1841** Perform
0620** ID Piping Systems 1842 QC
0630** ID Piping Circuits 1850 RT - Profile
0640 Gather Information 1851** Perform
1852 QC
0700 Equipment Files 1860 Liquid Penetrant
0710** Set up Equipment Files 1861** Perform
0720 QC Equipment Files 1862 QC
0800 Data Entry 1870 Magnetic Particle
0810 Data Entry 1871** Perform
0820 QC Data Entry 1872 QC
0900 Discrepancies 1880 UT Angle Beam
1000 Data Collection 1881** Perform
1010** Collect Data 1882 QC
1020 Field Verify Equipment 1890** Other Inspection Activity
1030 QC Data and History 1900 Activity Evaluation
1100 Criticality 1910** Evaluate Results
1200 General Drafting 1920** Report Deficiencies
1210** Field Sketching 2000 Project Closeout/Completion
1220 QC Field Sketching
1230** CAD Drafting
1240 QC Cad Drafting
1300 P&ID’s
1400 Equipment Work Plans
1405** Define Insp. Locations
1410** Develop
1420** Revise
** Asterisk indicates that quantities must be entered on the Daily Log next to the
corresponding hours.

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CAPSTONE ENGINEERING SERVICES, INC.

RBMISM SITE COORDINATOR’S MANUAL

RBMI Site Coordinator’s Manual

 Capstone Engineering Services, Inc.

Purpose of Site Coordinator’s Manual 1

Using this Manual 2

The RBMI Process 3

CHAPTER 2 – PROJECT SAFETY 5

CHAPTER 3 – STARTING AND ORGANIZING THE PROJECT 6

Project Kickoff Meeting 7

Preparation for the meeting 7

Scheduling the meeting 7

The meeting agenda 7

Documenting the meeting 14

Prepare Site Offices 14

Defining the Project Scope 15

Defining Piping Systems 16

Defining Piping Circuits 18

Developing Tracking Lists 20

Approve Inspection Strategies 25

CHAPTER 4 – MANAGING THE PROJECT 26

Time and Expense Reporting 28

Filling out a Time Report 28

Filling out an Expense Report 32

Filling out an Expense Report 33

Filling out a Daily Log 36

Reviewing and Transmitting Time and Expense Reports 37

Reviewing and Transmitting Time and Expense Reports 38

Reviewing and Transmitting Time and Expense Summaries 38

Vessel Cost Comparison 51

Piping Cost Comparison 53

Pressure Relief Device Cost Comparison 54

Planning the meeting 55

Documenting the meeting 55

Project Quality Assurance and Quality Control (QA/QC)56

CHAPTER 5 – USING THE RBMI SOFTWARE 65

CHAPTER 6 – COLLECTING EQUIPMENT DATA 66

Assets and Components 66

The Data Collection Process 67

Air Cooled Exchangers 86

Shell and Tube Heat Exchangers 94

Piping Circuits 104

Storage Tanks 112

Relief Devices 123

Documenting Data Discrepancies and Redlines 133

CHAPTER 7 – CALCULATING CRITICALITY 134

Reviewing Inspection and Maintenance History 134

Process Review 136

Corrosion Study 139

Review Measured Corrosion Rates 139

Internal Corrosion 139

External Corrosion (CUI) 140

Prepare Documents for the On-site Review 140

Document the Corrosion Study 142

Screening NDE Inspections 143

Calculating Criticality 144

Assign Inspection History Information 144

Internal Corrosion 144

External Corrosion (CUI) 146

Environmental Cracking 146

Enter Process and Corrosion Information 147

Calculate Criticality 147

Mass Criticality 148

Relief Devices 153