Contractor: Tic Libyan branch. Bp 2755.

HassounaPacha, AV 24 December -Tripoli -Libya

Date 27-11-2021 N° of day(s) :
Work on (component/unit/sector) SECOND STAGE SEPARATOR S2.2
 Nozzle G : Localized corrosion in the internal side of
the neck .Defects were recorded on the internal weld.
 Nozzle M : Internal localized metal loss has been
observed and confirmed by UT. Severe reduction in
thickness has been recorded.
 Many nozzles still need internal cleaning.
 Upper Manway “V” : The weld of the neck to the
flange revealed multiple defects in the internal side of
the manway. PT has been performed after surface
preparation and revealed unacceptable defects. This
weld shall be repaired.
 Nozzle “O” : Internal localized corrosion has been
observed and measured. The nozzle shall be repaired
by build up or otherwise replaced.
 Multiple paint defects and pits were observed near
the built-in access platform. Pits were measured to be
under 1 mm.
Daily tasks  An indication at 12 Oclock, internally, is currently
inaccessible.
 A total of 10 patches were found thourouly holed due
to severe localized corrosion. Further investigation
confirmed the existence of liquid (water/product)
beneath many patch plates.
 Multiple pits were reported in the bottom of the
vessel.
 After cleaning, a through hole was observed in the
intersection of patch plates number 5,6,7 and 8.
 Note that no scaffolding has been erected inside the
vessel.
 Visual inspection is in progress.
 UT is in progress.
 Note that not all the face flanges are accessible. Face
flanges shall be accessible for inspection.
 Many face flanges should be cleaned for inspection.

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 Kindly arrange to provide the following:
 Nozzle G to be repaired or otherwise replaced.
 Nozzle M shall be cut and replaced.
 Based on data from actual visual and non destructive
examinations, we cannot confirm the integrity of the
existing fillet welded patch plates. Thus, we
recommend cutting the existing patches for further
inspection/investigation on the pressure boundaries
beneath it.
 Nozzle O and Manway V shall be repaired.
 Arrange to clean the vessel internally from dust.
 Arrange to repair the foam breaker.
 Arrange to repair the ladder inside the vessel.
 The missing anchoring bolts shall be mounted. All anchor
Daily Recommendations bolts shall be tightened as required by the manufacturer
specifications.
 Arrange to make the rest of face flanges accessible.
 Some areas of the vessel still need cleaning from product
deposit.
 Face flanges and internal surfaces of the nozzles still need
cleaning.
 To erect scaffolding or any mean of access to the 3, 9 and
12 O’clock positions inside the vessel .
 Arrange to provide sufficient lighting inside the vessel.
 Arrange to measure the earthling resistance. Inspector
should witness the measurement.
 Arrange to repair the defected concrete foundation.
 Make all pressure boundaries accessible to the inspector
 To perform the rest of the requirements as detailed in the
scope of work.

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Internal severe defects and Metal loss in nozzle G INternal localized metal loss in nozzle M

Severe metal loss in nozzle M confirmed by UT

Close photo of the internal nozzle neck to flange Dye pen has been applied after surface preparation
weld – Nozzle V

View of the Dye Pen result on the internal weld of View of the Dye Pen result on the internal weld of
nozzle neck to flange – Nozzle V nozzle neck to flange – Nozzle V

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Nozzle O : Deep internal localized corrosion Non accessible indication at 12 Oclock inside
the vessel

Cracked weld and through hole between FW Existence of liquid beneath the patch plate
patches #11 and 12 #11 and 12 is confirmed

Through hole between FW patches number 5,6,7 and 8 . Existence of liquid beneath it is
confirmed

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Visual inspection is in progress Multiple pits were reported in the bottom of
the vessel

MT on weld joints MT on weld joints

MT on weld joints

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 Non accessible face flanges

Broken step (first step) in the upper ladder The upper ladder is broken from its bottom
end.

Deformation in the upper ladder Missing stair in the access ladder

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 Missing bolts and nuts Boken plate in the foam breaker

Missing anchor bolts Untightened anchor bolt

View of the internal surface of one nozzle , View of the deformed steam coil pipes
cleaning is still required

Prepared by
Amjed BENRHAIEM Hassan ALBAWANDI Ismael AL-ASWAD
TIC Libyan
(API 510 Authorized Inspector) (Plant Inspector) (Inspection Supervisor)
branch

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