VESSELS

SL CONTENTS
1.0 Purpose

2.0 Scope

3.0 Definitions

4.0 References

5.0 Types of pressure vessels

6.0 Need for inspection

7.0 Frequency of Inspection

8.0 Inspection procedure

9.0 Inspection during maintenance

10.0 Hydrostatic testing

11.0 Pneumatic testing

12.0 Corrosion coupons / Probes

13.0 Inspection report

14.0 Documentation

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 VESSELS

1.0 PURPOSE

This document shall deal with the various types of inspection and tests carried
out to know the condition of unfired pressure vessels for timely forecasting of
repair / replacement jobs.

2.0 SCOPE

The scope covers the inspection method followed in Gujarat Refinery for
unfired pressure vessels in hydrocarbon, steam, air and gas services.

3.0 DEFINITION

A pressure vessel is usually defined as a vessel designed to safely withstand

an internal pressure in excess of 15 psi (g). Some vessels in the refinery may
be subjected to an internal vacuum or by fluid between an outer jacket and
vessel wall. Such vessels are usually inspected in the same way as vessels
with internal pressure.

4.0 REFERENCES

The following codes, standards and publications have been referred in

preparation of this manual.

4.1 API Guide for Inspection of Refinery Equipment – Chapter VI – Unfired

Pressure Vessels.

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4.2 API Guide for Inspection Refinery Equipment – Chapter V – Preparation of
equipment for safe entry and work.
4.3 ASME – Pressure Vessel Code, Section VIII Div I & II.
4.4 Indian Standard for Unfired Pressure Vessels – IS-2825
4.5 BS-5500-Specification for Unfired Fusion Welded Pressure Vessels
4.6 API-510-Pressure Vessels, Inspection code – Maintenance, Inspection,
Rating, Repair and Alteration.
4.7 IS-9964 Part-I, Code of practices for lining of vessels and equipment for
chemical processes – Rubber lining
4.8 Pressure Vessel Inspection Safety Code – Part 12, Institute of Petroleum
4.9 OISD-128 – Inspection of Unfired Pressure Vessel.

5.0 TYPE OF PRESSURE VESSELS

5.1 PRESSURE VESSEL CLASSIFICATION AS PER SHAPE

5.1.1 Cylindrical vessels with flat, conical, tori-conical, tori-spherical, semi-ellipsoidal

or hemispherical heads.
5.1.2 Spheroids
5.1.3 Spherical

5.2 PRESSURE VESSEL CLASSIFICATION AS PER CONSTRUCTION

5.2.1 Unlined vessels

5.2.2 Vessels with internals such as demister pads
5.2.3 Vessels with internal corrosion protection lining – FRE, FRP, Rubber, Cement
lining
5.2.4 Vessels with internal painting for corrosion protection.
5.2.5 Vessels internally lined with refractory
5.2.6 Jacketed vessels

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6.0 NEED FOR INSPECTION

The reasons for inspection of pressure vessel are to determine the physical
condition of vessels. Systematic and regular inspection will also reveal the
following;

6.1. Cause of deterioration and taking remedial measures

6.2. Corrosion rate and remaining corrosion allowance
6.3. Plan future repair and maintenance
6.4. Increase in run length and minimizing in-service failures

The following types of pressure vessels are requiring inspection as per

statutory norms;

6.5. Vessels handling steam – As per statutory rules of Indian Boiler Regulation
Act
6.6. Vessels handling LPG, N2, H2 and compressed gases – As per statutory rules
of Static and Mobile Pressure Vessels Act, 1981
6.7. Pressure vessels – As per statutory rules of Factories Act, 1923

7.0 FREQUENCY OF INSPECTION

7.1 INTERNAL INSPECTION

7.1.1 Vessels connected with process units –M&I of the unit, which is 4-5 years for
primary units and 3-4 years for secondary units.
7.1.2 Vessels covered under statutory rules – As per statutory rules given below;

7.1.2.1 IBR Rules (Unfired) – Every two years

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7.1.2.2 SMPV rules – Every five years
7.1.2.3 Factories Act – Every two years or if vessel is part of continuous process,
every four years, where hydro-test is also done if possible. If internal
inspection is not possible, ultrasonic thickness measurement is done as per
the act.

7.2 EXTERNAL INSPECTION

7.2.1 For vessels connected with process plants – At a frequency of 3 years or 6

months before unit shutdown whichever is earlier.
7.2.2 For vessels covered under statutory rules – As per rules given below;

7.2.2.1 As per Factories Act – Every six months or every two years depending on
classification.

8.0 INSPECTION PROCEDURES

Prior to carrying out inspection of a pressure vessel, the inspector reviews the
complete previous history of the vessel, design parameters, service, original
thickness, corrosion allowance, corrosion rate and vulnerable locations of
corrosion.

8.1 TOOLS REQUIRED FOR INSPECTION

Tools required for inspection are as below;

8.1.1 Safety Torch.

8.1.2 Yellow Crayon Chalk / Permanent Marker.
8.1.3 Digital Camera.
8.1.4 Magnifying Glass.

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8.1.5 Inspector's Hammer & Magnet
8.1.6 Inspection Mirror.
8.1.7 Pit Depth Gauge.
8.1.8 Measuring Tape.
8.1.9 Plumb and Bob.
8.1.10 Straight Edge.
8.1.11 Ultrasonic Thickness Gauge.
8.1.12 Shore Hardness tester.
8.1.13 Paint Thickness Gauge
8.1.14 Dye Penetrant Kit.
8.1.15 WFMPI Testing Kit - Wet Fluorescent Magnetic Particle Inspection.
8.1.16 Infra-red Scanner for Thermography.
8.1.17 Ultrasonic Flaw Detector.
8.1.18 Radiography Equipment.
8.1.19 Metallographic Equipment.

8.2 EXTERNAL INSPECTION

Most of the external inspection is done while the pressure vessel is in

operation. The following shall be checked during the external inspection;

8.2.1 Visual inspection is done every six months for checking corrosion/damage in
foundation, supports, anchor bolts, ladders / stairways, platforms, structural,
Insulation and protective coating, ground connections, nozzles &
reinforcement pad tell-tale holes.

8.2.2 The metal surface is visually checked for hot spots on internally lined vessels.
Thermography is done to know if the refractory is damaged and shell
temperature exceeds the design temperature of the vessel. Under such

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 situation, a report is issued to ‘Production’ for making suitable arrangement for
keeping the metal surface cool till the vessel is isolated for carrying out
repairs.

8.3 INTERNAL INSPECTION

Pressure vessels entry shall be made only with an applicable work permit as
detailed in OISD-STD-105 on work permit systems. Internal inspection can be
divided into two parts.

8.3.1 Preliminary inspection

8.3.1.1 Preliminary internal inspection is done before internal cleaning. Samples of

deposit are collected for analysis if significant corrosion is observed.

8.3.1.2 Preliminary inspection will also reveal the areas having deposits, scales etc.
requiring thorough cleaning to detect metal wastage underneath the deposits
during detailed inspection.

8.3.1.3 After preliminary inspection, clearance for cleaning may be given.

8.3.2 Detailed inspection

8.3.2.1 Visual inspection of domes, shell, boot, internals and weld joints are done to
know corrosion, erosion, cracking, lamination etc. If pits are noticed, depth is
measured with pit gauge. Shell below the inlet nozzle is inspected for any
possible grooving. If the vessel handles hydrogen, inspection is done to find
out possible hydrogen blistering. Hydrogen blisters can be detected by visual
inspection. All the internal piping, distributor pipes etc. are also checked for
corrosion, chokage etc. The observations are noted in the checklist.

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8.3.2.2 Thickness of shell and domes near welding is taken in four directions.
Thickness of the dome around the nozzle is also taken. In case of insulated
vessels, insulation around nozzles is removed to facilitate thickness survey. All
the nozzles including the manhole nozzles are thickness surveyed. Sample
thickness of internals like distributor pipe/ baffles etc. is also taken. Thickness
scanning is done to know the metal loss at corroded locations of shell/dome.

8.3.2.3 Out of roundness or bulging may be evaluated by measuring the inside

diameter of the vessel at the cross section of maximum deformation and
comparing it with the original inside diameter. If the bulging is at intervals, the
measurements can be done by a straight edge or dropping a plumb line and
taking the measurements at selected intervals. This will also reveal the
contour of the shell.

8.3.2.4 The vessels in wet H2S service are examined with Wet Fluorescent Magnetic
Particle Inspection for cracks in weld joints/HAZ due to stress corrosion
cracking.

8.3.2.5 The weld joints of high-pressure vessels are subjected to ultrasonic

examination.

8.3.2.6 Internally painted/FRP lined vessels is visually inspected for damage in the
form of loosening, blistering, bulging, cracks etc. The bare surface due to
above damage is checked for corrosion/pitting/grooving. Dry Film Thickness
(DFT) is measured with paint thickness gauge and the same is compared with
original DFT of painting system.

8.3.2.7 Concrete, gunite and refractory linings inside a pressure vessel are visually
checked for mechanical damage such as spalling and cracks. Particular
attention is given at locations where hot spots are noticed during operation.
Light scrapping is done to reveal minor cracks and areas of porosity. Bulging,

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 which can be located visually, is usually accompanied by cracking in most
cases. If corrosion occurs behind a concrete lining, the lining will lose its bond
with steel. The sound and feel of light hammer tapping is usually done to
make such looseness evident. If corrosion behind a lining is suspected small
section of the linings is removed for shell inspection. This will also permit a
cross sectional examination of the lining. In cases where bare metal has been
exposed because of lining failure, visual inspection shall be made of the
exposed metal.

8.3.2.8 Some pressure vessels are rubber lined from inside for protection against
corrosion. The rubber lining is inspected for mechanical damages, holes,
cracking, blistering, loose bonding etc. A holiday detector is used to thoroughly
check the lining for leaks and holidays. For inspecting rubber lined vessels, IS-
4682-Part-I is referred.

8.3.3 Special considerations as per service

8.3.3.1 Pressure vessels, which cannot be internally inspected due to mechanical

restrictions, is inspected using ultrasonic equipment. In addition, they are
pressure tested as per statutory requirements.

8.3.3.2 All weld joints in Ammonia and LPG storage vessels are checked internally by
wet fluorescent magnetic particle examination to detect cracks due to stress
corrosion cracking once in five years as per statutory rules of SMPV. In
addition, 25% of weld joints are subjected to ultrasonic examination, besides
the normal NDT/inspection activities.

8.3.3.3 For vessels in DEA/MEA service, spot-checking of T-weld joints shall be

carried out by radiography / ultrasonic testing. If defects or cracks are
detected, 100% weld joints are checked by radiography / ultrasonic testing.

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9.0 INSPECTION DURING MAINTENANCE

9.1 WELD BUILD UP

9.1.1 Weld filling may be required to build up the thickness due to localised thinning
exceeding the corrosion allowance. The area to be repaired is marked at site
and cleaned thoroughly. Weld filling is done in a staggered manner to avoid
warping using suitable electrodes. After weld build up, the area is visually
inspected and DP tested for cracks and defects. Thickness is taken at the
built up area to check whether requisite thickness has been obtained.
Preheating and post weld heat treatment wherever required are carried out as
per the code.

9.2 NOZZLES REPLACEMENT

9.2.1 Thinned and deteriorated nozzles are replaced. Rejected nozzle is removed
by gouging the welding. New nozzles fabricated out of piping having
thickness equivalent to original nozzles are installed. Welding is carried out
from inside as well as outside with suitable electrodes matching with base
metal and nozzle material. Root run and back chip DP test is carried out.
Preheating and post weld heat treatment of the welding is carried out as per
the relevant code. The weld joints is checked visually and also by DP test.
Pneumatic test through reinforcement pad tell-tale holes is carried out at 1.03
kg/cm2 to check the weld joints. Pressurising the entire column to check the
nozzle weld joints should be avoided. In some cases where the area is
accessible from inside, a box is provided around the nozzle. The box is
pressurised with water to the test pressure calculated by applicable code. The
weld joints and HAZ are checked for possible leaks. If any defect is found in
the weld joints, these are gouged, re-welded and re-tested.

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9.3 PARTIAL REPLACEMENT OF SHELL PLATES AND DOMES

9.3.1 Some portion of shell and domes may get thinned due to corrosion or erosion
and the thickness of the affected area may reach the retiring thickness. In
such cases, partial replacement of shell or dome is carried out, as weld repair
of the big area is not practically possible. The affected portion is cut and
removed. The new plates matching with the metallurgy and thickness of the
original plate is made available.

9.3.2 The edge preparation is done by grinding as per the code requirement. The
prepared edges are checked for cracks, flaws and defects with magnifying
glass or DP test. Welding procedure is developed for welding the old and new
piece as per the relevant code.

9.3.3 Welding is performed either from inside or outside. The root run is thoroughly
inspected for cracks/flaws. After completing the welding from one side, the
other side is chipped and ground. Before welding again, the groove is
checked for cracks and defects by DP test. Welding is then completed from
the other side. Complete welding is visually checked radiographed as per the
applicable code.

9.3.4 Preheat and post weld heat treatment (PWHT) is carried out as per the
relevant code. In order to check whether PWHT has been carried out
properly, hardness readings on the weldment and HAZ is taken after PWHT. If
hardness values are more than the specified limit, the weld joints are again
subjected to PWHT. If PWHT is required, radiography before and after PWHT
is taken. The weld defects as per radiography report are repaired by gouging
and re-welding. In lieu of radiography, ultrasonic inspection of weld joints may
be carried out.

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9.4 REPAIR OF PAINTED AND RUBBER LINED AREA

9.4.1 If the painting in a small area of a vessel has peeled off or damaged, patch
repair is done. The damaged area is painted with original painting system.

9.4.2 If the area of damage is large, the area is sand/shot blasted to Swedish
standard Sa 2 ½ to clean the surface and original painting system is applied
with proper curing time. DFT is measured with paint thickness gauge.

9.4.3 If internal rubber lining of a vessel has bulged or cracked in a small area, the
deteriorated lining is removed and fresh rubber lining is put in that small area.
New lining is checked for holes and flaws with Holiday detector. Local curing
is done to achieve hardness of 65+5 (shore hardness-A).

9.4.4 When a large area of the rubber lining has cracked and bulged, the damaged
lining is removed. Bare metal is cleaned by shot blasting and new rubber lining
is provided. Curing is done to achieve 65+5 (shore hardness A). The lining is
checked for cracks, holiday and bulging with Holiday detector. For inspecting
the rubber lining IS-4682-Part-I is referred.

10.0 HYDROSTATIC TESTING

10.1 After satisfactory inspection and radiography, the vessel is hydro-statically

tested at a pressure calculated by applicable code. The pressure is held for a
minimum of 30 minutes. Prior to subjecting the vessels to hydrostatic test, the
foundation / supporting structures of the pressure vessels should be checked
for water load.

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10.2 Two freshly calibrated pressure gauges are used for testing, one is installed at
the highest point and the other is installed with the testing pump. The range of
the pressure gauge should be 30% more than test pressure.

10.3 The area, which has been repaired, is thoroughly checked for leaks and signs
of deformation. The pressure drop is also noted.

10.4 Austenitic SS pressure vessels are pressure tested using DM water or

passivating solution.

11.0 PNEUMATIC TESTING

11.1 Hydrostatic test is substituted by pneumatic test of vessels where there is a

problem of process contamination, risk in damage of internals or foundation
etc. by water.

11.2 The soap solution is brushed over the seams and joints on the vessel. The
vessel is then examined for evidence of bubbles as an indication of leaks.

11.3 It is suggested that pneumatic testing should be avoided as far possible and if
at all is to be carried out, it should be done in accordance with relevant code.

12.0 CORROSION COUPONS / PROBES

12.1 Corrosion coupons are installed in the pressure vessels to evaluate accurately
the corrosion rate or to evaluate a new material in the existing environment.

12.2 During internal inspection, the corrosion coupons are taken out and nature of
corrosion attack on the coupons is studied.

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12.3 The coupons are then thoroughly cleaned and weight loss in a specified length
of time is calculated for determining corrosion rate.

12.4 Cleaned coupons are again installed for future evaluation.

12.5 Corrosion probes may be installed at vulnerable locations on the pressure

vessels for on-stream monitoring of corrosion rates. Coupons and probes can
be either fixed or accurate type.

13.0 INSPECTION REPORT

Inspection report is issued based on inspection findings. The report includes

observations in brief, jobs to be carried out, material specifications,
electrode/filler wire/welding process to be used, procedure for PWHT and
stage inspection to be carried out. The report is supplemented with
sketches/photographs.

14.0 DOCUMENTATION

Observations of each inspection are properly recorded. Repair and

replacement of a pressure vessel can be planned after determining the
corrosion rate and remaining corrosion allowance. The following cards are
used for proper documentation of the Inspection findings;

14.1 Data card

14.2 History card
14.3 Data Record card
14.4 Development Sketch
14.5 Inspection Checklist
14.6 Form 11

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