Engineering & Support

Asset Integrity Management Department

[Vacuum Distillation] Section
Final TCS Report – October 2015
[R210-D-0001] / [Feed Surge Drum]

I. INSPECTION CHECKLIST FOR PROCESS EQUIPMENT - VESSEL

Report No.: Date prepared: October 24, 2015
Equipment No. & Service: R210-D-0001 HYDROCARBON Location/ Area: REF/VDS Plant No.: R210

Reason for Inspection: TCS 2015 Date Inspected: 10/24/2015

Reviewed By: Robert Lunt
P&E Inspector: Field insp. Supervisor: WASEEM
Unit Supervisor :
Equipment data:
Shell Material: SA-516 GR.70 Design Pressure, Kg/ cm²g or psig: 4.45 Kg/cm² (g)
Shell thickness (mm or in): 20mm Design Temp. °C or °F: 175°C

Cladding/ Lining: NO Corrosion Allowance (mm or in): 1.5mm

A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected
# ITEM A U NA NI COMMENTS
1.0 Top Head and Nozzles
Internal Corrosion (scales, pits, buildup)/Cracking A
1.1
Describe location, appearance and depth.
1.2 Excessive scale presence. Describe NA
1.3 Weld condition/corrosion, perform WFMPT for cracks. A
1.4 Condition of manway gasket surface A
1.5 UT measurement- Top head & Nozzles including Manway A
Internal and external cracks, erosion/corrosion, foreign A
1.6
deposit
1.7 Insulation condition A
Condition of attachment welds (Includes Lift lugs, pipe A
1.8
supports etc.)
1.9 External and Internal coating/painting A
2.0 Shell: Cylindrical and Conical
Internal Corrosion (scales, pits, buildup)/Cracking A
2.1
Describe location, appearance and depth
2.2 Excessive scale presence. Describe NA
2.3 Weld condition/corrosion, perform WFMPT for cracks. A
2.4 UT measurements-shell, cone section and heads A
Inspect distributors (channel and pipe with holes) for NA
2.5
corrosion, erosion, fouling and blockage
Inspect the inlet outlet and draw off nozzles for corrosion, A
2.6
erosion and thinning
2.7 Condition of Internal coating, External paint, Insulation A
3.0 Demister Pad (DP)
3.1 Check if demister pad is not disturbed A
Get DP removed and inspect vessel wall above and below A
3.2
including the attachments
Inspect DP for fouling, damage and if compressed and A
3.3
assess if can be reused for another cycle
Inspect DP fit up and attachment wires (size and material) A
3.4
on completion of DP fit up

Packing, Packing Beds, Shell and

4.0
Distribut.

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 Engineering & Support
Asset Integrity Management Department
[Vacuum Distillation] Section
Final TCS Report – October 2015
[R210-D-0001] / [Feed Surge Drum]

4.1 Check the packing and beds for loss and disturbances. NA

Check the packing and support beds and attachments for NA

4.2
corrosion, mechanical damage and looseness
Inspect the shell wall under the packing bed for corrosion, NA
4.3
grooving and pitting
Based on the finding (item 3.7) recommend complete NA
4.4
removal of packing for shell wall inspection

5.0 Trays
5.1 Check both top and bottom of trays for fouling NA
5.2 Check the tray floor for bulge/ level and corrosion NA
Check the valves on trays for corrosion, looseness and NA
5.3
mechanical damage
Check the tray support ring condition and welds for NA
5.4
corrosion/erosion
5.5 Carry out dimensional check on trays and fittings. NA
6.0 Clad/Lining
6.1 Check if the lining clad or strip lining NA
6.2 Check if the vessel section or fully lined NA
6.3 Check the lining for disbanding and inspect all welds NA
6.4 Check for cracks or damage if lined with cement NA
6.5 Perform PT on welds NA

7.0 Bottom Head

Internal Corrosion (scales, pits, buildup)/Cracking A
7.1
Describe location, appearance and depth.
7.2 Excessive scale presence. Describe A
7.3 Weld condition/corrosion, perform WFMPT for cracks. A
7.4 Condition of man way gasket surface A
UT measurement- Top head and Nozzles including A
7.5
Manway
Internal and external cracks, erosion/corrosion, foreign NA
7.6
deposit
7.7 Insulation condition A
Condition of attachment welds (Includes Lift lugs, pipe A
7.8
supports etc.)
Check the Vortex breaker for weld cracks, corrosion or NA
7.9
mechanical damage
7.10 Check internal and external coating/painting NA

8.0 Foundation/Supports
8.1 Condition of skirt and fire proofing NA
8.2 Condition of support bolts A
8.3 Condition of foundation A

NOTES :

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 Engineering & Support
Asset Integrity Management Department
[Vacuum Distillation] Section
Final TCS Report – October 2015
[R210-D-0001] / [Feed Surge Drum]

II. INTERNAL PICTURES

View of Vortex Breaker View of internal piping and support

View of internal before cleaning View of internal before cleaning

III. HISTORY:
As per available record this is the 2nd internal inspection of the vessel since its commissioning. Previous inspection was
carried out in 2011.

IV. NDT:
UT: UT Thickness was performed at the CML locations and there was no appreciable wall loss.
MPI: MPI was performed on the circumferential shell welds. No significant indications observed.
DPT: DPT was performed on required shell and nozzle welds. No significant indications observed.

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 Engineering & Support
Asset Integrity Management Department
[Vacuum Distillation] Section
Final TCS Report – October 2015
[R210-D-0001] / [Feed Surge Drum]

V. FINDINGS:
Initial visual inspection performed and found generally in good condition. Nozzles were free of fouling and nozzle welds visually
found to be in good condition. The vortex breaker and internal piping were found secure. The gasket surface was in good
serviceable condition. Based upon Visual Inspection, and NDE (UTT, MPI, and DPT) this shell was deemed Fit for Service.

The inspection and evaluation of the shell, heads, and welds was performed in accordance with the following codes, standards,
and specifications.
- API 510 Pressure Vessel Inspection Code, Tenth Edition 2014
- API 572 Inspection of Pressure Vessels, RP Third Edition 2009

VI. RECOMMENDATION:
Offer this equipment for internal inspection as per next EIS.

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