Noc Ges I 04

NATIONAL OIL CORPORATION
GENERAL ENGINEERING SPECIFICATION
GES I.04
BASE LINE NDT SURVEY OF

VESSELS, HEAT EXCHANGERS AND PIPING SYSTEMS
Rev Date Description Checked Approved

0 1999 Issued for Implementation DL
Compiled by Teknica (UK) Ltd

GENERAL ENGINEERING SPECIFICATION GES I.04
BASE LINE NDT SURVEY OF VESSELS, HEAT Page 2 of 17
EXCHANGERS AND PIPING SYSTEMS Rev 0 1999
INDEX
SEC TITLE PAGE
1.0 SCOPE OF SPECIFICATION 3
1.1 Introduction 3
1.2 Other NOC Specifications 3
2.0 DEFINITIONS 3
2.1 Technical 3
2.2 Contractual 4
3.0 DESIGN 5
3.1 Codes and Standards 5
4.0 PREPARATION FOR THE BASELINE SURVEY 5
4.1 Process Flow Diagram Evaluation 5

4.2 Classification Guideline 6
4.3 Setting the Baseline Inspection Points 7
4.4 Determination of the Equipment to be used 7
4.5 Determination of the Extent of Initial Baseline Inspection 7
5.0 INSPECTION SPECIFICS 8
5.1 Requirements for Inspectors 8

5.2 Piping Inspection Specifics 9
5.3 Determination of Future Inspection Frequencies 10
for Piping Systems
5.4 Extent of Inspections on Pipework Systems 11
5.5 Pressure Vessels/Heat Exchangers Inspection Specifics 11
5.6 Determination of Future Inspection Frequencies for 12
Vessels/Exchangers
5.7 Storage Tanks Inspection Specifics 12
5.8 Frequencies of Inspection of Storage Tanks 14
5.9 Relief and Vent Systems and Devices Inspection Specifics 14
5.10 Frequency of Inspection 15
6.0 REPORTING AND RECORDS 15

1.0 SCOPE OF SPECIFICATION
1.1 Introduction
1.1.1 This specification is applicable to all types of process plants and facilities where components such as
vessels, heat exchangers, storage tanks, pieces of piping sections or whole of the system have not
previously been subjected to a comprehensive NDT survey to establish imperfections or defects.
1.1.2 This survey need not be for a new plant, equipment or piping and applies equally to new, modified, or
existing plant.
1.1.3 The results from this examination shall be systematically recorded and shall form the basis of an ongoing
inspection and monitoring programme.
1.1.4 The inspection carried out to this specification may be done during a shutdown or whilst the plant is in
service. The inspection and NDT of equipment in operation is covered by GES I.02.
1.2 Other NOC Specifications
1.2.1 Where indicated in this specification the following additional NOC specifications shall apply:
GES I.02 Inspection and NDT of Equipment in Operation
GES I.05 Acceptance Criteria for Non-Destruction Examination
GES I.06 Equipment and Tools for NDT
GES W.07 Non-Destruction testing
2.0 DEFINITIONS
2.1 Technical
The technical terms used in this specification are defined as follows:
On-Stream Inspection
This inspection is used to establish the suitability of a pressure vessel, heat exchanger, pipeline system or
other pressure containing items, for continued operation. Nondestructive examination procedures are
used to establish their suitability while the plant is in normal operation. Because the plant is normally in
operation while inspection is being carried out, an on-stream inspection means essentially that internal
inspection will not be carried out.
Baseline Survey
The first systematic NDT survey of a plant or part of a plant which will form the basis of an ongoing
inspection and monitoring program. The plant need not be new for the survey.
Hydrogen Induced Cracking(HIC)
HIC is the term used for cracking associated with the presence of hydrogen and inclusions or
metallurgical imperfections that have an affinity for hydrogen. It is frequently found in systems in sour
service, where cracking occurs regardless of the presence of stress.
Imperfection
A flaw, inclusion, or other discontinuity that is subject to evaluation for its significance, either singly or
grouped, against defined acceptance criteria in design codes and standards. The code establishes their
acceptability or re-classification as defects.
Inclusion
Foreign matter entrapped within the metal during manufacture or welding.
Lamination
An internal physical separation of materials, creating imperfections that lay parallel to the surface and
which produces partial or total loss of back wall echo from an ultrasonic beam dependant upon the extent
of area they cover and the tightness of the laminations surface
Non-Destructive Testing
It is a general term covering methods of examination of installed plant, equipment and materials, without
subjecting them to any forces that will in some way damage or destroy their properties.
Pitting
A reduction in wall thickness of at least 0.5mm where the boundary edge between the wasted area and the
material surface is discrete and can be clearly defined. This would normally apply to internal and external
corrosion but mechanical or manufacturing imperfections should also be included as they have the same
effect on the integrity of the material.
Stepwise Cracking (SWC)
This is a type of cracking, typically associated with, but not confined to equipment in sour service
conditions, and occurs when hydrogen causes laminar type imperfections inclusions to rupture. Where
inclusions are in the same area, but vary in depth through the thickness, the individual ruptures may join
up in a step-like fashion.
Sulphide Stress Corrosion Cracking(SSCC)
SSCC is found in sour service associated with areas of residual stress, particularly near welds. Cracking
can occur associated with hardened microstructure which are highly strained.
Weld Hydrogen Cracking/ Cold Cracking
Cracking associated with a weld, caused by hydrogen ingress during welding, which may appear in the
weldmetal or heat affected zone. Cracking may be parallel or transverse to the weld.
2.2 Contractual
The commercial terms used in this specification are defined as follows:
Owner
The oil or gas company, an associate or subsidiary, who is the end user of the equipment and facilities.
Vendor
The company supplying the equipment and material.
Contractor
The main contractor for a defined piece of work.
Sub-Contractor
A company awarded a contract by a Contractor to do part of the work awarded to the Contractor.
Inspection Authority
The organisation representing the Owner or Vendor/Contractor that verifies that the equipment and
facilities have been designed, constructed, inspected and tested in accordance with the requirements of
this specification and the Purchase Order/Contract.
Inspector
A qualified individual representing the Owner, Vendor/Contractor or the assigned Inspection Authority,
who verifies that the equipment and facilities have been designed, constructed, inspected and tested in
accordance with the requirements of this specification and the Purchase Order/Contract.
3.0 DESIGN
3.1 Codes and Standards
3.1.1 The following Codes and Standards are referenced in this specification. Unless specified otherwise, the
current editions of the Codes and Standards should be used.
American Petroleum Institute (API)
API 510 Pressure Vessel Inspection Code - Maintenance Inspection, Rating, Repair, and
Alteration
API RP 572 Inspection of Pressure Vessels
API 570 Piping Inspection Code - Inspection, Repair, Alteration and Rerating of In-Service
Piping System
API RP 574 Inspection of Piping, Tubing, Valves and Fittings
API 653 Tank Inspection, Repair, Alteration and Reconstruction
4.0 PREPARATION FOR THE BASELINE SURVEY
4.1 Process Flow Diagram Evaluation.
4.1.1 In order to ensure that the baseline survey is cost effective and focused on the important areas of the
plant, an initial study of the plant shall be undertaken. The study shall include all elements within a
specific process area and define the boundaries of the process on the process flow diagrams (PFDs).
4.1.2 Each process area on the PFD shall be further evaluated by the process and the corrosion engineers and
operations personnel. This review shall be conducted step-by-step in a similar manner to a HAZOP study.
At each step it shall be established what are the likely problems to be anticipated with the future operation
of the plant. Typical key items which shall be considered are:
External corrosion under insulation

Corrosion at soil to air interfaces
External erosion
Internal erosion
Internal corrosion beneath deposits and linings
Fatigue cracking
Creep cracking
Brittle fracture
HIC
SSCC
4.1.3 For each process area on the PFD, conclusion must be drawn on the expected problems and on the
potential influencing factors, e.g. areas where water, dissolved solids, hydrogen sulphide etc. are present,
atmospheric influences, abrasive service, temperature pressures and ranges.
4.1.4 For each process area on the PFD, the areas will also be marked where internal corrosion of components
will take place that cannot be readily detected by standard thickness measurements. Typically, trayed
columns, vessels with vortex breakers and complex internals, exchanger tube bundles and reactors with
internals wall all suffer erosion and corrosion however, the full extent of this can only be determined by a
full internal examination.
4.1.5 For each process area on the PFD, items will also be marked that must be examined internally as the only
means of evaluating their internal condition. As an example, it may be determined that a particular heat
exchanger may not be subject to any serious erosion or corrosion of the exchanger shell, but will be
subject to heavy corrosion of the tube bundle.
4.1.6 At the discretion of the corrosion engineer process areas of the PFD may be split up into zones, e.g. light,
normal, heavy corrosion in order to provide a priority weighting on the examination schedule. For
example, equipment immediately down stream of the inlet manifold of a crude production facility of a
reactor would receive a higher rating than the upstream areas.
4.2 Classification Guideline
4.2.1 In addition to the corrosion zones outlined in Section 4.1.6, all plant equipment shall be identified and
classified into a minimum of the following two classes:
Class 1 equipment is that which contains highly hazardous chemicals (HHC) i.e, those materials where a
release would cause an emergency in itself, or would create an emergency situation in contact with other
materials and/or danger to life or the process plant itself.
Class 2 equipment shall identify safety, health, or environmentally sensitive areas which are subject to the
full extent of inspection but does not contain highly hazardous materials.
Additional classes may be established at the option of site management.
4.2.2 All plant equipment classified as Class 1 shall be listed as Critical Equipment under the inspection and
monitoring programme and it will be mandatory to comply with the requirements of this specification.
4.3 Setting the Baseline Inspection Points
4.3.1 Once the PFDs have been classified, the extent of the inspection to be undertaken, and the method of
inspection to be employed, can be determined.
4.3.2 A folder shall be set up with a copy of the relevant PFD for the part of the plant to be surveyed, marked
up showing the extent of the survey i.e. the starting and finishing points. The associated P&ID's for the
part of the plant under evaluation shall be obtained, together with relevant piping isometrics and
equipment main assembly drawings.
4.3.3 Using the details provided by the corrosion engineer, each P&ID, piping isometric, vessel, exchanger,
storage tank etc., drawings will be marked up with the approximate points where checks will be made.
Where no drawing exists or is illegible, then a detailed sketch will be produced to the extent that
information on corrosion, mechanical damage such as dents, gouges and distortion, and other significant
imperfections can be recorded in order that they can be relocated and confirmed at a later date. A decision
will be taken by the Inspection team leader on the best method to be employed for the detection of the
type of problem anticipated by the PFD study team.
4.3.4 The marked up details are to be included into the folder and presented to the PFD study team for review
and comment. When all comments have been resolved, the inspection team shall physically walk the area
covered by the folder and determine if all of the points identified on the drawings can be readily accessed.
It will also determine if the desired location is in fact, the most suitable location. Modifications to the
plans will be made as necessary and all details shall be finalised before starting the physical evaluation.
4.3.5 When it is found that the 'as built' sections of the plant are not the same as defined on the drawings, the
drawings shall be marked up with the differences and, where changes are major in nature, these shall be
submitted to the engineering department for revision.
4.4 Determination of the Equipment to be used
4.4.1 Where necessary, details of any special scaffolding requirements is added to the PFD, e.g,
SCAFFOLDING REQUIRED, or MOBILE PLATFORM REQUIRED. This form of statement ensures
the correct equipment is available when the inspection takes place
4.4.2 Having established the types of inspection to be carried out, the necessary equipment shall be selected in
accordance with GES I.06.
4.5 Determination of the Extent of Initial Base Line Inspection
4.5.1 In setting the baseline survey inspection requirements, it is essential to determine the extent of each
examination that will carried out. In the first evaluation of new equipment the only requirement is to set
the base criteria in respect to thicknesses as corrosion will not have taken place and the equipment will
have been constructed and inspected to code requirements.
4.5.2 At each designated inspection area the number and location of any thickness checks to be undertaken
shall be established. Where practical, a circle will be painted on the area to be examined in order that each
successive reading is taken in the same area. These areas shall be marked "INSPECTION POINT" or
some other pre-determined identifier.
4.5.3 If a full weld survey, or a full thickness survey is required on an existing item of equipment this shall be
specified. Full surveys will normally be conducted on any item where the integrity is in any way suspect
or where previous routine monitoring shows a significant deterioration from the expected condition. This
is applicable in respect to this specification when establishing the base line data on old existing plant and
if the original specified testing, that was defined as part of the PFD review, reveals worse than expected
values when actually carried out.
4.5.4 Full surveys can be instigated at any time an item of equipment is being considered for a new service and
shall always be carried out if the equipment is being transferred from a class 2 service to class 1. Note:
The equipment shall also have been designed as suitable for class 1 service, or subjected to a full design
re-appraisal before the change of service can take place. A full survey can also be requested on any item
irrespective of use at the option of the plant personnel if there is doubt on the integrity of the item.
4.5.5 Where inspection is required to take place on insulated or coated, vessels, exchangers and pipework, there
shall be a defined method in place for ensuring the insulation or coating is restored to its original
condition. For insulated items a plug is to be trepanned out of the insulation and retained to be re-inserted
after each inspection. The plug is to be painted red or orange or other designated colour, to readily
identify it as the inspection point. On coated items, the coating is to be removed without damaging the
wall of the item and after inspection re-coating shall be carried out as per GES X.01, X.02 and X.03. The
location is to be identified as the INSPECTION POINT for future checks.
4.5.6 The design service conditions shall be determined for each item in order that this can be verified during
the inspection. This information shall be checked to confirm that the equipment or system is operating
within the specified conditions and that any safety devices are rated correctly. Where it is found during
the PFD reviews that a process has been changed from that recorded for the plant, then details shall be
passed to the engineering department for verification that the equipment is still capable of operating
within the new range on a constant basis and that the records can be amended to show actual confirmed
conditions.
4.5.7 Prior to any inspection work taking place, the service conditions shall be available. If necessary, the
engineering department may request a full survey or a hydrostatic test upon shut down of the unit in order
to determine design integrity. Normally newly constructed plant will not be operating outside design
limits, but the evaluation team shall verify this fact as part of their preparations for inspection.
5.0 INSPECTION SPECIFICS
5.1 Requirements for Inspectors
5.1.1 All inspectors who will be engaged for the establishment of the base line data shall be fully experienced
in process plant inspections and hold formal qualifications in each method of inspection for which they
will be responsible for. The personnel will determine the minimum qualification levels necessary and if
ASNT, CSWIP or other equivalent qualifications can be accepted.
5.1.2 Inspection techniques are defined in API 510, API 570 and API 653 standards. The inspection team shall
be fully familiar with the requirements of these standards and the recommended practices contained in
API RP 572 and API RP 574 as these will form the basis of the techniques used during actual inspection.
5.1.3 The inspection team shall prepare special procedures for any item of equipment where there is inadequate
guidance in the API standards to cover complex configurations, e.g, Node sections and manifolds on
pipework. For all standard inspections, the requirements of the codes supported by standard procedures
as per GES I.02 is adequate.
5.1.4 The inspection team shall be fully aware of the safe working practices for the plant and abide by all of the
safety rules at all times. Where sub-contract inspection teams are employed the plant personnel may
request that the sub-contractor submits inspection procedures for approval prior to the commencement of
any work.
5.1.5 The inspection team shall review the contents of each file to ensure that all of the details set up during the
PFD reviews are available and adequate information is available for the team to commence the work. If
there is any doubt about the equipment required, access, inspection coverage or any other item essential
to commence the work, then it shall be obtained. If necessary the portion of the plant under inspection
shall be visited to verify the actual situation.
5.1.6 All safe working permits and entry permits shall be approved by the Owner before commencing any
work.
5.2 Piping Inspection Specifics
5.2.1 Identify and confirm all facility Class 1 piping and piping systems which meet the criteria. Ensure the
accuracy of P&IDs, basic piping design and fabrication data as part of the documentation verification.
Establish if there are any interfaces with other piping systems that have not been classified as Class 1 and
determine if there is adequate separation between them to justify the rating. As an example, a sample line
may not have been considered as a Class 1 line and is effectively isolated from the main process stream
by an isolating valve. This line may be excluded from the inspection other than the verification of the
condition of the isolating valve. In contrast, if there is a sample line that has a side stream continuously
passing through a sampling loop, then this should be included in the inspection as failure will create a
release of highly hazardous materials.
5.2.2 All by-pass piping shall have base line data established even if its usage is infrequent. The re-inspection
frequency can be at far greater intervals than the main stream pipework but it shall still be included in the
base line survey.
5.2.3 Perform initial inspections as necessary to properly document the current condition of all regulated piping
and piping systems, utilizing inspectors qualified for the technique used and following the requirements
of API 570 and recommended practices in API 574.
5.2.4 The API standards and recommended practices do not cover all eventualities or configurations of
pipework. The Inspection team in conjunction with the corrosion engineer shall determine for themselves
the most likely areas where thinning or problems will occur. The configuration of a pipe manifold is often
complex with many branch connections, and is usually exposed to a very high level of stress. In
examining any pipework with multiple branches it is not adequate to take one or two thickness
measurements. When this specification is applied to existing pipework, there shall be an examination of
the welds as well as thickness measurements. This may be carried out by radiography or ultrasonics,
depending upon the actual joint configuration, or a combination of both.
5.2.5 The surfaces on tees and fabricated manifolds directly opposite to the incoming branch lines shall be
thickness checked and the details recorded for future reference. The backs of elbows shall be measured.
All branch connections shall be checked for signs of stress cracking, in particular small bore attachments
that are not cross braced against vibration. These may be checked by dye penetrant, magnetic particle or
ultasonics at the option of the corrosion engineer. Thickness measurements shall be carried out on faces
opposite the connections, where erosion is most likely to occur.
5.2.6 Thickness data points shall be established in areas near to mechanical equipment and control valves as the
vortexes created by the equipment may cause erosion, in particular on heavy duty pump discharge piping.
5.2.7 Where pipework is located underground the establishment of data is more complicated. On new piping
the measurement of soil potentials can be determined as part of the cathodic protection system and then
this data is used to determine the rates of corrosion on subsequent inspections. The soil to air interface
thicknesses shall be established as part of the base line data. A check can also be made of the soil
resitivity at different distances along its length as part of the base data in order to pinpoint areas where
corrosion is most likely to occur.
5.2.8 On existing buried pipework the methods available are limited, especially if there has been no previous
corrosion protection system in place and the line has not been designed to accept an intelligent pig. A soil
survey may carried out to determine the areas most at risk from corrosion and a holiday survey can be
done to check the integrity of the coating. This will provide a crude indication of a problem, which can
then be followed by a local excavation to conduct a formal thickness check. This does not cover internal
corrosion and thinning particularly at bends and low points. Ideally intelligent pigging is required to
establish the base survey data but where this is impractical the line will need to be shut down and
subjected to pressure testing at the original design test pressure. At the option of the engineer this may be
reduced to one and a half times maximum working pressure providing the line is formally downgraded in
the records Where a hydrostatic test cannot be performed, a pneumatic leak test using a tracer gas may be
carried out with the prior consent of the plant personnel and the engineer. All safe working practices in
respect to pneumatic and hydraulic testing shall be observed.
5.2.9 Based on the analysis of the inspection findings and current condition of the piping and piping system
and its operating parameters, inspection frequencies and methodology shall be as defined below.
5.3 Determination of Future Inspection Frequencies for Piping Systems

5.3.1 As a minimum, piping and piping systems shall be inspected per the following practices (listed in order of
preference):
1) The applicable codes or established historical practice of the site at industry if these
practices are recognized and accepted as being good engineering practices.
2) In the absence of the above and if the remaining life is known (from prior inspections):
Maximum interval is one-half (1/2) of the remaining life or five (5) years,
whichever is less
3) If the remaining life is not known (for new or existing pipe or piping systems):
Maximum interval of five (5) years after commissioning a new piping system or at
five (5) year intervals for existing pipe or piping systems (in new or changed
service)
4) Alternately, if the corrosion rate is known, the following frequencies apply:
Fluid Corrosity Corrosion Rate External NDT Inspection

Highly Corrosive >10 MPY Annual
Mildly Corrosive 2 - 10 MPY 3 Year
Non-Corrosive < 2 MPY 5 Year
Note: MPY - Mils per year.
5.3.2 Deviations from the above shall be fully documented based on recognized and generally accepted good
engineering practices.
5.4 Extent of Inspections on Pipework Systems
5.4.1 The extent of examination for pipework that is already in service and for which no base line survey has
been completed previously, or is no longer valid due to inadequate routine inspections, will comply with
the following minimum requirement.
(a) Butt Welds: Circumferential scans over 100% of the area for 4" (100mm) each side of the weld
(b) Bottom Quadrants:10% of the total length of each line for 100% of the area. The areas scanned shall
be regularly spaced over the length
(c) Elbows: 100% of the outer radius shall be scanned from butt weld to butt weld covering the outer
quadrant
(d) Tee Pieces: 100% of the impingement zone
(e) Vertical Pipework: A 24" (600mm) band or full length of pipework, whichever is smaller, shall be
scanned around the entire line circumference over 100% of its area. This band shall be above and
immediately adjacent to any existing valves.
(f) Dead Ends: 25% of the area of dead ends shall be examined using 100% scanning over the full
circumference
(h) Low Points: 100% scan around the full circumference inspection.
5.5 Pressure Vessels/Heat Exchangers Inspection Specifics

5.5.1 Perform first and/or subsequent inspections per API 510 and API RP 572 requirements and establish the
base line inspection point measurements. On new vessels or exchangers this is basically a confirmation
of the original design data and verification of the actual thickness available as a future reference.
5.5.2 For existing systems that have no base line survey data or no valid data, the inspection points shall be
established for future reference. An essential requirement is to have an understanding of the service the
vessel or exchanger has been subjected to in order to establish a base survey pattern. As guidance
thickness checks shall be taken around nozzles, lower half of the shell and areas of impingement. If there
is a defined normal liquid level in separators that can be determined from the process operation then this
is a key area to examine as the liquid/gas interface tends to suffer erosion. This can only be established
where vessel is operated with pre-determined level controls or internal weirs.
5.5.3 Where the equipment is available, an infra red thermal survey is an ideal method for establishing the most
critical areas for thickness checking and existing operating plant. From the thermal scan areas of
potential thinning can be determined.
5.5.4 Where thermal imaging is not practical or available, then the process engineer and corrosion engineer
shall study the construction to determine the areas most susceptible to corrosion, erosion or cracking.
5.5.5 When a conclusive determination of potential problem areas cannot be defined then a full survey will be
necessary to establish the base line data.
5.5.6 The extent of the initial survey is also very dependent upon the age of the plant. A new or recently
constructed plant will normally not have suffered significant erosion and corrosion or process influenced
metallurgical defects, such as HIC, SSCC, blistering etc. The base line survey can therefore be conducted
whilst the plant is in full or reduced service.
5.5.7 When the plant is old and the initial evaluation of the process and corrosion engineers indicate there is a
strong possibility of serious thinning and metallurgical defects, then the plant shall be either shut down or
service reduced to a point where a full survey can take place. All insulation materials will need to be
removed and both the shell and welds will have to be formally examined to determine the state of the
equipment to establish the base line data.
5.5.8 Any vessel or exchanger that has been repaired, and does not have a recorded base line survey, shall be
subjected to a full survey as recommended in the API standards on recommended practices.
5.6 Determination Of Future Inspection Frequencies For Vessels/Exchangers
5.6.1 Develop a site-specific inspection plan (including inspection frequencies, nondestructive testing needs,
etc.) for each pressure vessel/exchanger based on the referenced inspection codes and the data gathered
under paragraphs above.
5.6.2 Frequencies of Inspection
As a minimum, pressure vessels/exchangers shall be inspected per one of the following practices (listed in
order of preference):
1) The applicable codes or established historical practices of the site or industry if these practices are
recognized and accepted as being good engineering practices.
2) In the absence of the above.
Service Corrosion External Internal Inspection

Condition Rate Inspection and Pressure Test
(In-Service)
Highly Corrosive > 10 MPY 1 year 2 years
in Sour Service
Mildly Corrosive > 2-10 MPY 3 years 5 years
Non-Corrosive < 2 MPY 5 years 10 years
Notes: 1. Frequency may be reduced dependent upon the base line survey results.
2. For certain cryogenic and non-corrosive services, integrity of the vessel is determined by service
history and external, nondestructive testing. Internal inspections or pressure tests are avoided to
eliminate complications caused by entry of moisture or other process contaminant. See Section
4.2 of API 510.
3. Adapted from API 510 recommendations.
4. Hydrostatic test (if repairs or modifications were made affecting the pressure envelope),
pneumatic, or service (leak) test.
Deviations from the above frequencies are to be fully documented and shall adhere to recognized and
generally accepted good engineering practices.
5.7 Storage Tanks Inspection Specifics
5.7.1 Perform first and/or subsequent inspections per API STD 653 requirements and establish facility standards
using qualified inspectors.
5.7.2 Based on findings and analysis of data, establish inspection frequencies as defined in applicable API standards
but will be a minimum of a ten year cycles.
5.7.3 Develop a site-specific inspection (including inspection frequencies, nondestructive testing needs, etc.) for
each storage tank based on analysis of data gathered.
5.7.4 Where a tank is new the points for examination are to be determined in a similar manner to those for pressure
vessels, exchangers and piping systems. Each location for inspection is to be clearly identified as an
“INSPECTION POINT” and recorded on the drawings in order to ensure these points are rechecked at each
inspection.
5.7.5 For tanks which are in service the following areas shall be checked and reported upon as well as the thickness
measurements identified.
Insulation
Protective coatings
Fireproofing
Structural members such as ladders, platforms, ground cables
Foundation (elevation, cracks, sealant/caulking, housekeeping)
Roof (deck plate condition, drainage, insulation, sample hatch, gagewell, etc) Dikes
Presence of:
Unusual vibration or noises.
Bending, bowing, weld defects, atmospheric, corrosion, leaks at nozzles, shell, seams.
5.7.6 When a storage tank or vessel is in service, which has no valid base line survey data and has been shut down
and brought to a safe condition for entry, an internal inspection shall also be performed to include the
following:
Condition of:
Internal heater or exchanger
Internal surfaces
Floor and Tank walls
False bottom (check “tell-tale” drains)
Floating roof (support legs, levelness, hardware, seals etc)
Welds (perform non-destructive testing if deemed necessary)
Gasket areas (if accessible)
Lining (conduct spark test)
Any sacrificial anodes
Presence of:
Deposits
Erosion, corrosion, fatigue, cracking
Metallurgical or physical changes
Pitting, bulging, bending, blisters
5.7.7 Measure and document wall, bottom and roof thickness at points where corrosion may be of concern. All
internal inspection points established shall be clearly identified on drawings as this is the only method of being
able to return to the same inspection point. Locations should all be referenced back to one datum point
wherever possible.
5.7.8 For underground storage tanks the methods available are limited especially if the tank is old and no previous
corrosion protection data is available. On new tanks the base line survey shall ensure all corrosion coupons
and sacrificial anodes are checked and their “as built” status established. Resistivity values shall be established
where applicable for future comparisons.
If the tanks are old and without previous baseline survey, soil surveys may be done to determine if there are
areas indicating problems. Where there is any doubt over the tanks integrity a full hydrostatic test or
pneumatic leak test shall be performed.
5.8 Frequencies of Inspection for Storage Tanks
5.8.1 As a minimum, storage tanks shall be inspected per the following practices (listed in the order of preference):
1) The applicable codes or established historical practices of the site or industry if these procedures are
recognized and accepted as being good engineering practices
2) In the absence of the above, and if the remaining life is known (from prior inspections): Maximum
interval shall be the smaller of RCA/2N years (where RCA is the Remaining Corrosion Allowance in
mils and N is the shell corrosion rate in mils per year) or 10 years.
3) If the remaining life is not known (for new or existing tanks):
Ten (10) years after commissioning a new tank or at ten (10) year intervals for existing tanks (in new
or changed services).
5.8.2 Deviations from the above are to be fully documented based on recognized and generally accepted good
engineering practices.
5.9 Relief And Vent Systems And Devices Inspection Specifics
5.9.1 A written site inspection plan shall be developed for each relief and vent system device. These will need to be
incorporated into appropriate preventive maintenance schedules and procedures once the base line survey has
been completed.
5.9.2 For all units in service, and on new units where applicable, the following inspections shall be performed to
confirm that:
Tag attached for proper device identification.

Nameplate data is legible and reflects correct set pressure, burst pressure, temperature, vacuum setting,
capacity, proper ASME “V” or “UV” stamping (as applicable)
Pressure adjustment sealing device in place and undamaged.
Device is free of external corrosion.
Bolted, threaded, and welded connections free of defects.
Block valves car-sealed or chained/locked in the proper position.
Tell-tale indicator on space between pressure relief devices and rupture disks, or breaking pins, are free of
defects.
Inlet and outlet piping free of defects (may be part of piping inspection program)
Drain holes on pressure relief valve discharge piping (when provided) are unobstructed.
Piping supports for relieving reaction forces are free of defects.
Leak through into discharge piping systems is not apparent or is within design tolerance.
5.9.3 In-service testing of existing pressure relief devices may be performed in some instances. However, shop
inspections shall still be performed in order to verify that the device is in safe working condition. Specifically
for manual testing of steam safety valves, ASME Section VII subsection C4-220 provides recommendations
for frequency of testing.
5.10 Frequencies of Inspection
5.10.1 As a minimum, relief and vent systems, and devices shall be inspected per the following table which specifies
recommended frequency of inspection as a function of the service conditions under normal operations:
FREQUENCY OF INSPECTION IN YEARS

SERVICE
TYPE 1 2 3 4 5 6 7 8 9 10
A
B
C
D
E
Definitions:
Service Type
A. 0-2 year
- All fouling services (i.e. gas or liquid containing solids or capable of producing solids) and
new types of devices of unknown performance or devices installed in new processes with
unknown characteristics.
B. 2-3 years
- Steam service or compressed air before drying. (Water may condense on internal parts and
result in some corrosion).
- Ammonia service. (To coincide with the periodical maintenance of the refrigeration
systems.)
C. 3-5 years
- Refrigerated water, jacket water, and cooling water.
- Gas or liquid services which are clean, non- corrosive, and discharge to the atmosphere.
D. 4-6 years
- Gas or liquid services which are clean, non- corrosive, and discharge to the flare system.
5.10.2 No extensions are allowed beyond established current frequency without supporting history and
documentation (operation, inspection, shop experience).
5.10.3 No extensions are allowed beyond maximum allowable frequency (per service) indicated in the table above.
5.10.4 The frequency of inspection can be adjusted within the frequency ranges based on service conditions and
sufficient inspection and repair history.
6.0 REPORTING AND RECORDS
6.1 Each inspection and test shall be documented, whether performed by the Owner or Contractor personnel. The
documentation shall have:
- the date of the inspection or test

- the name of the person who performed the inspection or test,
- the serial number, tag number, or other identifier of the equipment on which the inspection or test was
performed
- a description of the inspection or test performed, and the results of the inspection or test.
6.2 Each facility shall keep a folder for each P&ID, or Isometric, Pressure Vessel, Exchanger, Storage Tank,
Pressure containing equipment item, Safety device and ESD system. Each file is to contain all of the data used
in setting up the base line survey as a reference.
- Qualified welding procedures and procedure qualifications per applicable code

- U-1 form (ASME) for new fabrications; R-1 form for ASME or example form from API 510 for
repairs or alterations (include design calculations), in pressure vessels and exchangers.
- Certified forms (API) for new fabrications, repairs, alterations, or reconstructions, and design
calculations for storage tanks.
- Welder qualification records
- Non-conformance reports on mill defects, workmanship, and shipping methods / damage
- Mill test reports / independent alloy verification
- Dimensional checks
- Heat treatment procedures
- Leak testing reports
- Lining testing reports
- Nameplate data
- Condition of all internal components such as trays, baffles, tubes & tube sheets, demisters etc for
vessels, exchangers and heaters supports, piping floating roofs, gauging devices etc. for tanks.
- Gasket surface conditions
- As-built" wall thickness measurements ("baseline" readings)
- Field erection procedures
- Drawings of supports, foundations, ladders, etc.
- Location of ground cables
- Hard copy of specifications, design data sheets and any revisions
- Weld maps
- Any other documents required by the local jurisdictional authority and facility policies.
For in-service/on-stream inspection at the assigned frequency, the following needs to be documented as a
minimum:
- Wall thickness at "baseline" points taken during fabrication, repairs, alterations, and/or previous
inspections and any new ones established as a result of the inspection.
- Temperature, pressure, composition-verify that current operations are within the original design
criteria or that no significant process excursions or composition changes have occurred which may
indicate a need for special emphasis on any specific mechanical condition.
Condition of:
Pressure or vacuum relief devices
Insulation
Protective coating
Fireproofing
Structural members such as ladders, platforms, foundations, ground cables.
Presence of:
Unusual vibration or noises.
Bending, bowing, weld defects, atmospheric corrosion, leaks at nozzles, shells, seams.
- Cathodic protection output (if applicable)
Presence of:
Deposits, erosion, corrosion, fatigue, cracking, pitting, bulging, bending, blisters
- Witness pressure test (if any) examine pressure retaining parts.
6.3 In addition, each facility should keep the following records for each relief and vent system or device:
- Device specification
- Location of device and equipment / system being protected
- Manufacturer, model number and size
- Basic design information / applicable engineering calculations / service condition data
- Materials of construction
- In-service inspection
- Flame arrestor associated with the relief device (if applicable) is free of defects
- Shop inspection
- Documentation of devices inspected and tested in shop facilities should, as a minimum, verify that the
valve relieved (“popped”) and reseated in accordance with the basic design criteria (i.e. “prepop” test)
- Records of pressure test (“pop” test and leak test) results including test media, set pressure, cold set
pressure, back pressure, net set pressure, nozzle ring, and guide ring setting (if applicable), date of
test and person conducting test.
- For rupture disks, record as found condition and disposition (reused or replaced).
6.4 For new or replaced ESD & CSD equipment, the following documentation is required to confirm installation
in accordance with design specifications, manufacturers' instructions, and safe operating limits:
Initial calibration or test documentation:

- Data short information for each device, where applicable
- Manufacturer, tag, and model number
- Size and connections
- Materials of construction (for parts exposed to process)
- Device setpoint, range calibration
- Special features or accessories
- Fail-safe mode or specific action
Verification that applicable inspections and tests were performed:

- Equipment installed and connected as shown on the documentation and in accordance with job
construction specification
- Devices visually checked after installation to verify nameplate data and proper orientation
- Equipment meets vendor's published specifications
- Wire and cable tested electrically for continuity and insulation (grounds)
- Installation inspected for proper craftsmanship, good connections, and the use of appropriate
connectors, sealants, wire gauge, fuses, etc.
- Software loaded and functioning as intended
- All devices function properly, individually and/or together, as a system
- Connected process equipment or piping flushed of construction debris in a manner to protect the
integrity of the device(s)
Test equipment used in the testing and repairs or recalibration of ESD devices and CSDs should be calibrated
in accordance with the manufacturers' recommendations and shall be certified and traceable to the National
Standards.
S:\NOC9077\ADMIN\SPECIFICATIONS\I-SERIES\I-04\GESI04RF

Noc Ges I 04

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Noc Ges I 04

Uploaded by

Copyright:

Available Formats

NATIONAL OIL CORPORATION

GENERAL ENGINEERING SPECIFICATION

BASE LINE NDT SURVEY OF

Rev Date Description Checked Approved

Compiled by Teknica (UK) Ltd

SEC TITLE PAGE

1.0 SCOPE OF SPECIFICATION 3

3.1 Codes and Standards 5

4.0 PREPARATION FOR THE BASELINE SURVEY 5

4.1 Process Flow Diagram Evaluation 5

5.0 INSPECTION SPECIFICS 8

5.1 Requirements for Inspectors 8

6.0 REPORTING AND RECORDS 15

1.2 Other NOC Specifications

GES I.02 Inspection and NDT of Equipment in Operation

GES I.05 Acceptance Criteria for Non-Destruction Examination

GES I.06 Equipment and Tools for NDT

GES W.07 Non-Destruction testing

The technical terms used in this specification are defined as follows:

Hydrogen Induced Cracking(HIC)

Foreign matter entrapped within the metal during manufacture or welding.

Stepwise Cracking (SWC)

Sulphide Stress Corrosion Cracking(SSCC)

Weld Hydrogen Cracking/ Cold Cracking

The commercial terms used in this specification are defined as follows:

The company supplying the equipment and material.

3.1 Codes and Standards

American Petroleum Institute (API)

API RP 572 Inspection of Pressure Vessels

API RP 574 Inspection of Piping, Tubing, Valves and Fittings

API 653 Tank Inspection, Repair, Alteration and Reconstruction

4.0 PREPARATION FOR THE BASELINE SURVEY

4.1 Process Flow Diagram Evaluation.

External corrosion under insulation

4.2 Classification Guideline

Additional classes may be established at the option of site management.

4.3 Setting the Baseline Inspection Points

4.4 Determination of the Equipment to be used

4.5 Determination of the Extent of Initial Base Line Inspection

5.0 INSPECTION SPECIFICS

5.1 Requirements for Inspectors

5.2 Piping Inspection Specifics

5.3 Determination of Future Inspection Frequencies for Piping Systems

4) Alternately, if the corrosion rate is known, the following frequencies apply:

Fluid Corrosity Corrosion Rate External NDT Inspection

Note: MPY - Mils per year.

5.4 Extent of Inspections on Pipework Systems

(d) Tee Pieces: 100% of the impingement zone

5.5 Pressure Vessels/Heat Exchangers Inspection Specifics

5.6 Determination Of Future Inspection Frequencies For Vessels/Exchangers

5.6.2 Frequencies of Inspection

2) In the absence of the above.

Service Corrosion External Internal Inspection

3. Adapted from API 510 recommendations.

5.7 Storage Tanks Inspection Specifics

5.8 Frequencies of Inspection for Storage Tanks

5.9 Relief And Vent Systems And Devices Inspection Specifics

Tag attached for proper device identification.

5.10 Frequencies of Inspection

FREQUENCY OF INSPECTION IN YEARS

6.0 REPORTING AND RECORDS

- the date of the inspection or test

- Qualified welding procedures and procedure qualifications per applicable code