Onshore Regeneration Gas Subcooler Internal Inspection Procedure

‫تراست الدولية للخدمات الصناعية‬
Trust International for Industrial and

Petroleum Services- Limited ‫ ذات مسئولية محدودة‬-‫والبترولية‬
ONSHORE
REGENERATION GAS SUBCOOLER
E-2521
REF NO DATE
S/N SUBJECT 0 1 2 3
SCOPE
1 
REFERENCES
2 
3 DEFINITIONS 
‫ سموحة – األسكندرية – جمهورية مصر العربية‬،‫ برج البانسيه‬،‫ ميدان علي بن أبي طالب‬،‫ِ ابراج السرايا‬
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
ِAl Saraya Towers, Ali Bin Abi-Talib Square, Alpansi Tower, 2nd Floor, Smouha, Alexandria, Egypt
Tel: 002 03 4256262 - Fax: 002 03 4256162 - www.trusteg.com - Email: trust@trusteg.com
ITEM
4 DESCRIPTION 
PREINSPECTION
5 REQUIREMENTS 
TYPES OF
6 INSPECTION 
INSPECTION
7 PROCEDURE 
REPORTING
8 
ATTACHMENTS
9 
1- SCOPE
This procedure delineates the internal inspection of the onshore regeration gas sub cooler E -2521
during the scheduled shutdown to determine the status of internal surfaces of the vessel, and the
need for repair or re rating according to the code requirements.
2- REFERENCES;
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
2.1 API STD 510 Pressure vessel inspection code : maintenance inspection, re
rating , repair and alteration.
2.2 API RP 572 Inspection of pressure vessels
2.3 ANSI/NB-23 National board inspection code
2-4 R7126 guidance notes and supporting information for rashpetco

(Egypt) written schemes of examination managed by the
pressure system data base.
2-5 vessel drawings and

data sheets
3. DEFINITIONS:
3.1 API The American Petroleum Institute
3.2 ANSI The American National Standards institute
3.3 ASME The American Society for Mechanical Engineers
3.4 MAWP Maximum allowance working pressure
3.5 MDMT minimum design metal temperature
3.6 NB ASME national board
3.7 WSOE Written scheme of examination
4. ITEM DESCRIPTION:
The onshore regeration gas subcooler E-2521, located horizontally at roseta gas field,
was fabricated by JOY INDUSTRIES , under manufacturer's number 1101 at 1999 from
stainless steel in accordance with ASME code sec. VIII Div. 1,1998 edition, and stamped by "U"
stamp. The medium inside the vessel is HS gas shell side / HC gas tube side.
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
SHELL:
The shell is constructed from two courses of "SA-240-316. with dimensions of 660.4 ID * 25.4
mm thick and length of shell is 5870 mm, the corrosion allowance is 0.0 mm.
HAEDS :
The heads are constructed from one piece of SA-240-316 formed to be elliptical 2:1 with
dimensions of 660.4 ID * 25.4 mm thick, the corrosion allowance is 0.0 mm.
NOZZELS :
The nozzles are fabricated from SA-213-316, total number of tubes are 321 in one pass, tube
outside diameter is 25.4 with 2.1 mm thickness and 6096 mm length.
BOLTS :
Stud bolts / nuts are constructed from SA -193-B7/SA-194-2H
COATING :
No cating exists on internal or external surfaces.
NAMEPLATE :
The name plate is fabricated from stinless steel material and includes the following information:
Manufacturer :
Manufacturer's S/N :
Tag number :
Year built :
MAWP shell side :
MDMT shell side :
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
MAWP shell side :
MDMT shell side :
MAWP tube side :
MDMT tube side :
Test pressure :
Construction code :
Code stamp :
ACCESS :
No access is available to inside the vessel, however inspector shall use 8"N3,N4 and other
available nozzles to inspect the internal surface of the shell.
5. PREINSPECTION REQUIREMENTS:
5.1 Operation and inspection history of the tank shall be available for review by the
inspector. For example: operating conditions, including process upsets that may affect
mechanical integrity, inspection reports, and data for each type of inspection
conducted (for example, internal, external, thickness measurements), and inspection
recommendations for repair.
5.2 For an internal inspection, the tank shall be isolated by blinds or other positive
methods from all sources of liquids, gases, and / or vapors. The vessel shall be drained,
purged, cleaned, ventilated, and gas tested. Where required , protective equipment
shall be worn that will protect the eyes, lungs, and other parts of the body from
specific hazards that may exists in the vessel.
5.3 No access is available to inside the vessel , however inspector shall use 8" N3,N4 and
other available nozzles to inspect the internal surfaces of the shell using fiberscope
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
and/or the inspection mirror as access permits.
5.4 Nozzles shall be opened as required by inspector, isolation kits ( if required ),shall be
available at site during the S/D to enable of the nozzles.
5.5 Electrical line source terminal of 220 V shall be available near to vessel.
5.6 Powerful light source shall be available to inspect the inside surface of the vessel.
5.7 The vessel shall be prepared for hydraulic pressure testing of both the shell and the
tube side at 127 barg using tap water as a test medium and hold for 1 hour. The
required pump, calibrated pressure gauges and blind flanges/ spades shall be available
for hydraulic pressure testing . the inspector shall witness the hydraulic pressure
testing. ( use guidelines for hydraulic pressure testing PT/01)
5.8 NDT and other inspection equipment shall be available for inspector to conduct the
internal inspection (required inspection equipment are attached).
6. TYPES OF INSPECTION:
The internal inspection of the tank included, visual inspection, dye penetration and UT wall
thickness measurements and supplements with NDT as required per examination specification
RPCO-05, issue 1 ( WSOE ), and hydrostatic testing for both the shell and tube side at 127 barg for
1 hour hold.
7. INSPECTION PROCEDURE:
7.1 Check the tank tag number and name plate.
7.2 Obtain the safe entry permit from the appropriate HSE personnel.
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
7.3 Check that cleaning of the vessel is adequate and the internal surface of the shell,
heads, and nozzles are clearly visible.
7.4 Check that inspection and NDT equipment that shall be used during the inspection are
available and valid.
7.5 Check that the light source that shall be used is operating and powerful and check for
the availability of electrical line source terminal that be used to operate the NDT
equipment.
7.6
If the vessel is not properly prepared for internal inspection, the inspector shall
decline to make the inspection until the tank is ready for that inspection. inspection.
7.7 Examine the internal surfaces of shell and heads carefully, as access permits, for
possible cracks, general corrosion , pitting , and other signs of deterioration. If there is a
suspect indication, use Dye penetrates according to approved NDT procedures; to
verify the indication. Ultrasonic testing may be used for determining the depth of
indication. Pit depth shall be measured by depth gauge or venire caliber
7.8 If evidence of distortion is found, it may be necessary to make a detailed check of the
actual contours or principal dimensions of the vessel and to compare those contours
and dimensions with the original design details.
7.9 Examine welded joints and the adjacent heat-affected zones for service-induced cracks
or other defects.
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
7.10 Carry out PT on 10% of all seam and girth welds on the shell, plus all "T" weld
inspections, to distance of 300 mm from inspection of weld looking for signs of cracking
and other weld defects ( including transverse cracking where appropriate ).
7.11 Carry out PT on nozzles.
7.12
Examine the surfaces of. Nozzles and other openings for distortion, crack, and other
defects, using a mirror as necessary, paying particular attention to the welding used to
attach the parts and their reinforcements.
7.13 Examine accessible flange faces for distortion and determine the condition of gasket-
seating surfaces.
7.14
Examine the tubing and tube sheets externally for possible cracks and other signs of
deterioration.
7.15 Examine the earthing conditions, and describe the status in the final inspection report.
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
7.16 Measure the wall thichness of the shell at 500 mm intervals ( as access permits ) from
the datum points ( shell-to-front head weld seam ) till the shell-to-rear head weld
seam. The readings will be taken in four directions (3,6,9,12 o'clock ). Readings also will
be taken on heads and nozzles and shall be included in the report.
7.17 Clearly mark all defects found with a permanent marker on place. Sketch the size and
location of defects and document the findings on the final inspection report.
7.18 Witness the hydraulic pressure test at 127 barg for both shell and tube side using tap
water as a test medium and hold for 1 hour . ( use guidelines for hydraulic pressure
testing ( PT/01)
7.19 Sate areas not accessible and reasons why.
8. REPORTING:
8.1 All findings shall be reported in the attached final inspection report form.
9. ATTACHEMENTS:
9.1 Sketch for onshore registration gas subcooler E-2521
9.2 List of required inspection equipment.
9.3 Inspection check list.
9.4 final inspection report.
9.1 LIST OF REQUIRED INSPECTION EQUIPMENT
S/N DESCRIPTION QTY RECOMMENDED TYPE

REQ.
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
Ultrasonic thickness meter.

1 1 ANY
Inspection mirror with telescopic

hand, the mirror size shall fit into 2"
2 pipe at least. 1 Any
Pocket size flash light

3 1 Any
Measuring tape 5 m.
4 1 Any
Flexible fiberscope with light source

5 1 Olympus or equivalent
and forward & side tip.
Dye penetration material kit ( From only one family product

6 1
penetrant-remover-developer ) e.g. Ely , or magnaflux etc.
Ultrasonic instrument for crack

detection with cables and 0, 45, 60, 70
degree angle probes, with IIW-V2 KRAUTKRAMER OR
7 1
block. EQUIVALENT
Still photos digital camera.

8 1 Sony or equivalent
Depth gauge or vernier caliber.

9 1 Any
Magnifier lens 2, 5, or 8X
10 1 Any
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
Permanent markers (Yellow/red

11 1 Any
color).
12
9.2 INSPECTION CHECK LIST
S/N ITEM CODITION ACCEPTANCE REMARKS
Shell internal / external

1
surface
Head internal / external

2
surface
Shell-to-shell circumferential
3
weld seam
Shell-to shell longitudinal weld

4
seam
Shell-to-head circumferential
5
weld seam
6 N1 16" -900# tube inlet
7 N1 16" -900# tube outet
8 N3 8"-900# shell inlet
9 N4 8"-900# shell oulet
10 N1A 2"-900#P1 connection
11 N2A2"-900#P1 connection
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
14 N1B2"-900#T1 connection
18 Earthing
19 External bolts & nuts
Opened flange faces and

20
gaskets
State areas not accessible and

21
reasons why
9.4 FINAL INSPECTION REPORT
PRESSURE VESSEL
EXAMINATION REPORT
PART 1: VESSEL DESCRIPTION
Pressure System Name Vessel serial number
Tag number
Installation Area Examination Specification Number
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
Data of examination Data of last examination Vessel Drawing Number
Data of manufacture Manufacturer Design Code
PART 2: VESSEL DATA
Shell Tube side
Contents
Max/min design pressure (bar)
Max/min design temperature

(C degree)
Material
Thickness (mm)
Corrosion allowance (mm)
Material (lining)
Insulation
PART 3: EXETENT AND METHOD OF EXAMINATION
Examination and/or tests carried out, plus no of attached sheets.
Parts not examined with reasons
PART 4: CONDITION OF VESSEL (SUMMARY)
EXTELNAL
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
Element Condition Comments
Access ladders/platforms
Man ways
Heads
Shell
Nozzles
Protective coatings
insulation
Bolted attachments
Welded attachments
Supports/ skirt/ mounts
Ear thing
Nameplate
Internal
Element Condition Comments
Access ladders/platforms
Man ways
Heads
Shell
Nozzles
Protective coatings
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
Tubes
Tube plates
Welded attachments /
supports
Bolted attachments / trays
Strainers /filters/demisters
Definition of vessel Condition
C-Nothing to report B-Less significant Fault A2-significant and A1-Imminent Danger

fault
Vessel in excellent Surface rust, light Corrosion greater Heavy corrosion

condition no signs of scale or corrosion not than 0.5mm possible and/or deep pitting or
damage or corrosion- exceeding 0.5mm and cracking adjacent to cracking of any
nothing to report within the corrosion welds-more description; vessel
allowance-damage significant damage operating above SOL-
judged not to be than B but no significant damage
dangerous immediate of failure with risk of imminent
danger
PART5: Anomalies and defects
PART6: Statement by Inspector
I declare that the above equipment has been inspected according to the examination described in part 3
and that this document is a true report of the inspection carried out
Inspectors name signature data
PART 7: Statement by competent person
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬
The vessel is suitable for its design specified in part 2 subject to the relief system remaining in order:
YES/NO
The written scheme of examination require amending as result of this examination : yes / no
Description of amendments required
The above equipment may be used within the duty specified in part 2, subject to the following conditions
Next thorough examination due before
Name signature
002 03 4256162 : ‫ فاكس‬- 002 03 4256262 : ‫تليفون‬

Onshore Regeneration Gas Subcooler Internal Inspection Procedure

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‫تراست الدولية للخدمات الصناعية‬

Trust International for Industrial and

REGENERATION GAS SUBCOOLER

2.2 API RP 572 Inspection of pressure vessels

2.3 ANSI/NB-23 National board inspection code

2-4 R7126 guidance notes and supporting information for rashpetco

2-5 vessel drawings and

3.1 API The American Petroleum Institute

3.2 ANSI The American National Standards institute

3.3 ASME The American Society for Mechanical Engineers

3.4 MAWP Maximum allowance working pressure

3.5 MDMT minimum design metal temperature

3.6 NB ASME national board

3.7 WSOE Written scheme of examination

Stud bolts / nuts are constructed from SA -193-B7/SA-194-2H

No cating exists on internal or external surfaces.

MAWP shell side :

MDMT shell side :

MAWP shell side :

MDMT shell side :

MAWP tube side :

MDMT tube side :

and/or the inspection mirror as access permits.

7.1 Check the tank tag number and name plate.

7.11 Carry out PT on nozzles.

7.19 Sate areas not accessible and reasons why.

9.1 Sketch for onshore registration gas subcooler E-2521

9.2 List of required inspection equipment.

9.3 Inspection check list.

9.4 final inspection report.

9.1 LIST OF REQUIRED INSPECTION EQUIPMENT

S/N DESCRIPTION QTY RECOMMENDED TYPE

Ultrasonic thickness meter.

Inspection mirror with telescopic

Pocket size flash light

Flexible fiberscope with light source

Dye penetration material kit ( From only one family product

Ultrasonic instrument for crack

Still photos digital camera.

Depth gauge or vernier caliber.

Permanent markers (Yellow/red

9.2 INSPECTION CHECK LIST

S/N ITEM CODITION ACCEPTANCE REMARKS

Shell internal / external

Head internal / external

Shell-to shell longitudinal weld

6 N1 16" -900# tube inlet

7 N1 16" -900# tube outet

8 N3 8"-900# shell inlet

9 N4 8"-900# shell oulet

10 N1A 2"-900#P1 connection

19 External bolts & nuts

Opened flange faces and

State areas not accessible and

9.4 FINAL INSPECTION REPORT

PART 1: VESSEL DESCRIPTION

Pressure System Name Vessel serial number

Installation Area Examination Specification Number

Data of examination Data of last examination Vessel Drawing Number

Data of manufacture Manufacturer Design Code

PART 2: VESSEL DATA

Shell Tube side

Max/min design pressure (bar)