NON-DESTRUTIVE

TESTING GROUP

Typical Mechanical Integrity Implementation:

1. Identification and list of all process piping circuits (Process Engineer or

Corrosion specialist)
2. Systemizing & Circuiting of piping according to process streams
3. Field verified & redline P&ID’s
4. Provide accurate isometric drawings of process piping
5. Document NDE Inspection & test plans
6. Visual inspection identifying non-conformances and discrepancies
7. Recommendations are made to correct the identifying discrepancies
8. Document visual inspections

#2- Systemizing & Circuiting of piping according to process streams

Pipe - A pressure-tight cylinder used to convey a fluid or to transmit a fluid

Piping Circuit - A section of piping that has all points exposed to an environment of
similar corrosivity and that is of similar design conditions and construction material.
Complex process units or piping systems are divided into piping circuits to manage
the necessary inspections, calculations, and record keeping.
Piping System - An assembly of interconnected piping that is subject to the same
set or sets of design conditions and is used to convey or otherwise affect fluid flows.
Piping systems also include pipe-supporting elements but not support structures.

SYSTEM CIRCUIT EX-2D

-- 00- 010H
SAME TEMP. ANY CHANGE IN FLOW
SAME PRESS. SUCH AS A FILTER START NEW SYSTEM
SAME MATERIAL PUMP, CV, HEADERS At Next EQUIPMENT
GENERALY FROM ONE AND DIRECTION BUT AT
EQUIPMENT TO ANOTHER AT VALVE
FROM THERE E- 20A
SYSYEM- BROKE
- -
EX-2D-00-010G
UP INTO CIRCUITS

EX-2D-00-010C EX-2D-00-010D

2D-00 CV
EX-2D-00-010F

EX-2D-00 010A EX-2D-00-010B

EX-2D-00-010E
2S-00 2G-00
EXAMPLE SYSEM EX-2D-00-010A-H
 #3- Field verified & redlines P&ID’s

A. Delete redlined P&ID to next P&ID by marking with Green marker and
labeled delete.
B. A new line should be marked in red to next P&ID.
C. Create a folder for red lined P&ID’s.

DELETED

2D-00 CV

2S-00 2G-00
NEW
REDLINE TO
NEXT P&ID
 #4- Provide accurate isometric drawings of process piping

A. ISO drawn from circuit located on P&ID.

B. Equipment labeled with appropriate identification number.
C. All continuations labeled to where or from.
D. Flow arrow & line number.
E. Line sizes.

4” SEE P-822-6”-A1
BD-325
PS. Jump over
4”
To B1 line
PS.
PS. 6”
1” PS.
SEE PS.
RAF-037
PS. PS.
PS.
6”
PS. PS.
PS.
1” PS.
PS. 850
PS. Line
2” Rack
6”
SEE
BD-331 6”
SK 1
SEE
BD-322
SK 2 SEE
RAF-037
 #5- Test plan

A. Set location points A1, A2 exedra.

B. Mark UT readings at location points
C. Document NDE Inspection

.297

A3

4” SEE P-822-6”-A1
.321 BD-325
PS. Jump over
4”
To B1 line
A1 PS.
6”
1” PS. PS.
SEE PS.
RAF-037
PS. PS.
PS.
6”
PS. PS.
PS.
1” PS.
PS.
PS.
.300 A4 850
Line
2” Rack
6” A2 SEE
BD-331 6”
.311
SK 1
SEE
BD-322
SK 2 SEE
RAF-037
 #5- Document NDE Inspections

Page 1 of 2
Client: TPC
Location: Houston
Inspector: Name Level: II
Tech Corr Job: 509150138 Date:
ULTRASONIC THICKNESS INSPECTION REPORT
Examination Item: 2F-0017 Noz. Drawing #: P & ID: 200-M-616

Acceptance Standard: API-510 Procedure: TEC-1300

Material: C/S Surface Type: painted Surface Cond.: satisfactory Temp.: 80 F

CALIBRATION
Instrument: Manuf.: Panametrics Model: 37 DL Plus Serial#:
Velocity: 0.226 041183906/051328311/ 051328411
Range: .100" - .500"
Ref. (dB): 56

Cal. Block: Type: C/S Serial#: A21062/A21581/A21582

Transducer: Manuf.: Panametrics Serial#: Size: D790SM
Frequency: 5 MHZ Couplant:

EXAMINATION DETAILS
S=Straight, H=Horizontal, V=Verticle, T=T-Section, 90=90° Elbow, 45=45° Elbow, SH=Shell, HD=Head, N=Nozzle…0° is Top or North…90° is clockwise or Right looking downstream.

TML Disc. Dia. T-Min 0° 90° 180° 270° Access Method Comments
1 A1 6" .100" .321" acc. N/A
2 A2 6" .100" .311" acc. N/A
3 A3 6" .100" .297" acc. N/A
4 A4 6" .100" .300" acc. N/A
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
#6- Visual inspection points identifying non-conformances and discrepancies

This Piping Inspection Procedure outlines the requirements for the inspection,
testing, and maintenance of piping system components as established by
recognized and generally accepted good engineering practices. It provides
directions to determine the physical condition of the pipe in a piping circuit
and to identify signs of deterioration.

Typical Visual Report

 #7- Recommendations are made to correct the identifying discepancies

Nonconformance Report - The report, which identifies inspection activity

results, which do not meet the acceptance criteria or have deviated from the
prior activity. These nonconformances require evaluation. This report is
initiated by the Inspector(s) who discovered the issue. The Mechanical
Integrity Program Site Supervisor reviews the report and issues it to the Host
Company Representative for evaluation.

VI-2 Heavy corrosion

Sandblast
4” SEE
1” BD-325 Uts
Jump over .295 to .302
4” To B1 line Pitting
PS. .090
PS. 6”
1”
PS.
SEE PS.
RAF-037 Uts
PS.
PS. .530
VI-2 Heavy corrosion PS.
Sandblast Uts 6”
PS. PS. .153
PS. PS. VI-3 Heavy corrosion Uts
1”
Pitting Sandblast .171 to .188
SEE PS.
Pitting 850
RAF-037 PS. Nominal thickness 6” .280 .060 Line
Actual thickness from UT .153 Rack
6” Pitting -.090 2”
SEE = .063
6” BD-322 Recommended t-min - .100 SEE
6” SK1 Replace BD-331 6”
SK 1

8” SEE
RAF-037
1”

1”

3”
6G-851
 #8- Document visual inspections Visual inspection

Typical Inspection Form

TEXAS PETROCHEMICALS LP
ATTACHMENT A
EXTERNAL INSPECTION CHECKLIST FOR PROCESS PIPING

PROJECT: BUTADIENE DATE: 11-20-06

AREA: 600 TANK FARM INSPECTED BY: Eddie Payne
CIRCUIT: BD-1-A1-600-281

LEAKS MISALIGNMENT
YES NO YES NO
PROCESS/SERVICE X RESTRICTED MOVEMENT X
STEAM TRACING X EXPANSION JOINT X
COMMENTS: COMMENTS:

CORROSION CONDITIONS OF SUPPORTS

None Surface Heavy N/A GOOD FAIR POOR
BOLTS & SUPRT CLAMPS SUPPORTS X
COAT/PAINT X X HANGERS X
SOIL/AIR INTERFACE SPRINGS X
C.U.I. BRACES X
SUPPORT CORROSION BRACKETS X
PITTING X SLIDE PLATES/ROLLERS X
1. PIT DEPTH .060” COUNTER BAL. COND. X
2. REMAINING WALL .171”
3. EXTENT .111” Remaining Wall COMMENTS: Supports good condition
COMMENTS: VI-1- Heavy to Lt. Paint failure
VI-2- Heavy Cor. VI-3- Heavy Cor./ Pitting
DEAD LEGS INSULATION
N/A CHECK
VENTS X TYPE OF INSULATION
BLEEDERS X FOAM GLASS
LEVEL BRIDLES X CAL. SILICATE
SAMPLE POINTS X OTHER: X
DRAINS X TYPE OF JACKET: MASTIC CS SS AL OTHER
INSTRUMENT CONNECTIONS X YES NO
CONTROL VALVE BYPASS PIPING X DAMAGE/PENETRATION
PUMP BYPASS PIPING X MISSING INSULATION JACKET
RELIEF VALVE IN/OUTLET PIPING X SEALING DETERIORATION
PRESSURIZED DUMMY SUP. LEGS X BANDING (BROKEN/MISSING)
COMMENTS:Dead legs good condition COMMENTS: N/A

VIBRATION VERIFICATION OF LINE SIZES & SPECIFICATIONS

OF INSPECTION ISO’s
YES NO N/A COMMENTS:
EXCESSIVE OVERHUNG WEIGHT X VI-1 Clean & Paint
INADEQUATE SUPPORT X VI-2 Blast for more Inspection
THIN, SMALL BORE, OR ALLOY X VI-3 Blast & Paint to stop active corrosion.
THREADED CONNECTIONS X
LOOSE SUP CAUSING WEAR X