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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

TABLE OF CONTENTS

SECTION TITLE PAGE

1.0 PURPOSE 2

2.0 SCOPE 2

3.0 DEFINITIONS 2

4.0 RESPONSIBILITIES 2

5.0 PROCEDURE 3

6.0 RELATED DOCUMENTS 13

7.0 RECORDS 13

APPENDIX-A PRESSURE VESSELS INSPECTION CHECKLIST 14

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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

1.0 PURPOSE
1.1 The purpose of this standard operating procedure is to provide an approach for the
inspection of pressure vessels installed at the facilities of JO to ensure their
continued safe & efficient service.

2.0 SCOPE
2.1 Scope of this procedure is to provide instructions and establish techniques for the
maintenance inspection of all kind of pressure vessels in accordance with
requirements of the referenced codes or standards.
This procedure establishes and defines the standard requirement for inspection.
However, final Inspection methodology depends on the discretion of the
inspector.

3.0 DEFINITIONS
3.1 Alteration: A physical change in any component that has design implications that
affect the pressure containing capability of a pressure vessel.
3.2 Authorized Pressure Vessel Inspector: An employee of an authorized inspection
agency who is qualified and certified to perform inspection under the inspection
code.
3.3 Maximum Allowable Working Pressure: The maximum gauge pressure permitted
at the top of a pressure vessel in its operating position for a designated
temperature.
3.4 Minimum Allowable Shell Thickness: The thickness required for each element of
a vessel. The minimum allowable shell thickness is based on calculations that
consider temperature, pressure and all loadings.
3.5 Pressure Vessel: A container designed to withstand internal or external pressure.
3.6 Pressure Vessel Engineer: Shall be one or more persons, acceptable to the owner
user, who is knowledgeable and experienced in the engineering disciplines
associated with evaluating mechanical and material characteristics, which affect
the integrity and reliability of pressure vessels.
3.7 Repair: The work necessary to restore a vessel to a condition suitable for safe
operation at the design conditions.
3.8 Re-rating: A change in either the temperature ratings or the maximum allowable
working pressure rating of a vessel, or a change in both.

4.0 RESPONSIBILITIES
4.1 Overall responsibility for implementation of this SOP shall be with the concerned
INTREX Senior Engineer/Engineer.
4.2 Inspection activities and supervision of NDT/NDE shall be performed by the
approved INTREX personnel (Engineer/Senior Technician/Technician) or the JO
B authorized Contractor Personnel, who have appropriate qualification, skills,
experience and knowledge of relevant codes, standards and work practices.
4.3 NDT shall be performed by the INTREX Senior Technician/Technician who have
minimum ASNT Level-2 in accordance with “ASNT SNT-TC-1A” or as
approved by JO.
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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

4.4 List of inspection personnel (INTREX/Contractor) authorized to perform a

specific inspection activity based on the above and similar criteria shall be
approved by the AIDs Senior Engineer and maintained by the AIDs Engineer.

5.0 PROCEDURE
5.1 Preparation Work & Other Requirements:
5.1.1 Review the vessel records and history of repairs, pressure relief protection,
etc. Upon receipt of equipment readiness information from the campaign
crew Plant Inspector shall study the inspection history files of the pressure
vessel thorough in order to know the previous thickness measurements
taken and find out the details of any major repairs carried out before and
any pending integrity issues from previous inspections. The inspector
shall make himself familiar with the operating conditions of the vessel
with the causes and characteristics of potential defects and deterioration
mechanisms.
5.1.2 The mandatory requirements for meaningful visual examination of the
vessel are a clean surface and good illumination of the vessel and the
working area. Adequate lighting shall be available in addition to hand held
flashlights. Surface preparation such as wire brushing, grit blast cleaning,
chipping, grinding or a combination of these preparations may be required.
5.1.3 External and internal coverings such as insulation, refractory, protective
linings, and corrosion resistant linings shall be examined to determine if
they are in good condition. Unless otherwise noted, small portions of the
coverings (insulation) may be removed to investigate their condition and
the condition of the metal underneath them. In case of internal
lining/coating, refractory etc., if it observed to be in good condition
satisfactory for further service till next inspection schedule, then its
removal is not required.

5.2 NDT/DT Techniques Recommended

The following inspection techniques are recommended to supplement the visual

inspection but not limited to:
5.2.1 Visual Inspection with all kind of aids including video probes for non
accessible areas.
5.2.2 Hammer test
5.2.3 Magnetic Particle Inspection for all support/ attachment welding and areas
where cracks are suspected.
5.2.4 Eddy current inspection
5.2.5 Liquid Penetrant Inspection
5.2.6 Ultrasonic Inspection
5.2.7 Adhesion test to check the integrity of coating as applicable.
5.2.8 Holiday detection to find out the general condition of coating.
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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

5.3 Visual Examination Method:

5.3.1 The vessel shall be examined visually for deposits, sludge & their type
(solid, semi solid, liquid etc), color etc., so as to assess the type of
corrosion mechanism. If required the deposits may be sent for laboratory
testing for chemical composition.
5.3.2 The vessel shall be examined for visual indications for distortion,
corrosion, erosion, missing components, breakage etc.
5.3.3 Vessel internals like trays, demisters, support structure etc. shall also be
inspected for cleanliness, weld cracks, thinning, tightness and overall
integrity of the system.
5.3.4 Visual check for internal and external coating condition.

5.4 Vessel Foundation

5.4.1 Vessel foundation shall be inspected for deterioration such as spalling,
cracking, and settling.
5.4.1 The crevice formed between an exchanger shell or a horizontal vessel and a
cradle support shall be carefully checked.
5.4.2 The cradle is sealed with a mastic compound, this seal shall be checked by
judiciously picking at the mastic with a scraper to make sure that it is intact
5.4.3 A rough check for uneven settling to be made
5.4.4 The nuts on anchor bolts shall be inspected to determine whether they are
properly tightened.

5.5 Vessel Shells

5.5.1 The metal surfaces of a vessel to be inspected visually by picking,
scraping, and limited hammering to locate corroded areas.
5.5.2 Evidence of corrosion should be investigated and the depth and extent of
the corrosion should be determined.
5.5.3 Ultrasonic thickness measurement shall be carried out to establish the
effective thickness of vessel walls, heads.
5.5.4 Depth of all pittings shall be measured and recorded. Special attention shall
be given to the areas of standing water at the bottom of the shell.
5.5.5 All welds shall be inspected for corrosion and repairs shall be marked and
recorded.
5.5.6 Thickness measurements may be carried out at shell plate areas around the
nozzles and other locations which tend to trap moisture or allow moisture
ingress and not accessible from outside due to the reinforcement pad.
5.5.7 The minimum acceptable shell plate thickness shall be calculated as per
API 510 clause 7.1,7.2 & 7.3
5.5.8 Drain holes shall be checked for its location and the attachment welds for
corrosion.

5.6 Vessel Nozzles

5.6.1 Nozzles and adjacent shell areas shall be inspected for distortion and
cracking.
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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

5.6.2 Flange faces to be checked for distortion.

5.6.3 When accessible, nozzles shall be internally inspected for corrosion,
cracking, and distortion.
5.6.4 Exposed gasket surfaces shall be checked for scoring and corrosion.
5.6.5 The grooves of ring joint flanges shall be checked for cracks due to
excessive bolt tightening. Also, stainless steel ring joint grooves shall be
checked for stress-corrosion cracking.
5.6.6 Lap joint flanges or slip on flanges such as Van Stone flanges shall be
checked for corrosion between the flanges and the pipe.
5.6.7 Wall thickness of nozzles shall be measured.

5.7 Vessel Auxiliary Equipment

5.7.1 Auxiliary equipment, such as gauge connections, float wells, sight
glasses,and safety valves, may be visually inspected while the unit is in
service.
5.7.2 Undue vibration of these parts should be noted.
5.7.3 Check for proper construction of auxiliary equipment and connecting
piping beyond vessel blockvalves.
5.7.4 Sacrificial Anode Inspection – Sacrificial Anodes are highly active metals
that are used to prevent a less active material surface from
corroding.Various Inspection checks are required for the consumption of
anode. The checks are describes as below:
5.7.4.1 Visual Check – The check is done to confirm if the anode is consumed or
B
not visually by the INTREX personnel.
5.7.4.2 Electrical Conductivity Check – The check is done by confirming the
parameters of Electrical Conductivity of the sacrificial Anode.
5.7.4.3 Additional Checks – Additional checks are to performed on the discreation
of the API or Cathodic Protection Inspector as per the requirement.

5.8 Protective Coatings and Insulation

5.8.1 The condition of the protective coating or insulation shall be determined.
5.8.2 The supporting clips, angles, bands, and wires shall be examined visually
for corrosion and breakage.
5.8.3 Corrosion under insulation (CUI) shall be considered for externally
insulated vessels.
5.8.4 Painting/coating shall be inspected for damages like disbondment, pinholes
etc. A decision to remove the painting/ coating shall be made based on the
number of years it served against the manufacturers design life expectancy
for the system and current condition of the system as observed through
adhesion test and holiday tests. All the damages to coating shall be
repaired and a holiday test shall be carried out before clearing the
equipment for final closure.
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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

5.9 Non-Destructive Examination Method (General):

5.9.1 Non-destructive examination methods are required to supplement vessel
visual examination and confirm material defects and deterioration.
5.9.2 The implementation of non-destructive examination techniques results
for structural integrity and safety assessment involves a detailed
consideration of two separate but interrelated factors:
5.9.2.1 Detecting the discontinuity.
5.9.2.2 Identifying the nature of the discontinuity, determining its size,
location and orientation.
5.9.3 Depending upon metallurgy of the pressure vessel, the type of NDT
technique to be deployed shall be decided. One or more NDT techniques
may be deployed depending upon the pressure vessel service, operating
parameters, history etc.
5.9.4 Generally initial inspection of pressure vessel is carried out by using
magnetic particle testing (wet fluorescent or normal dry or wet method) for
carbon steel vessels and by using dye penetrant testing (normal or
fluorescent) for stainless steel clad or solid stainless steel vessels.
5.9.5 Preliminary examination is carried out for approximately 10% weld joints
and all T junctions and 3” on both sides of the joint. Depending upon the
result of this preliminary examination, further inspection may be deployed
and extended up to 100% examination. If required the vessel parent metal
area shall also be inspected.
5.9.6 Sample radiography of weld joints for highly critical vessels is also carried
out for ascertaining that the weld joints are free of any detrimental internal
defects.
5.9.7 Ultrasonic scanning of sample area on the pressure vessel surface is
carried out for detection of any service induced defects. Depending upon
requirement normal beam, angle beam or any other technique will be
deployed.
5.9.8 Thickness measurement of all the major components (like shell plates, dish
ends, nozzles, manholes etc.) of a pressure vessel is measured, recorded
and compared with previous and original/design thickness readings. Long
term and short term corrosion rates are accordingly determined.
5.9.8.1 Vessel is fit for service (for thickness criteria) if the thickness of
individual component is not reduced below the design thickness
measurement.
5.9.8.2 Otherwise the vessel is recommended for repair, replacement or
re-rating.

5.10 Non-Destructive Examination Method (Magnetic Particle Examination):

5.10.1 The principle of magnetic particle examination depends on the fact that
discontinuities in or near the surface (sub-surface) change the magnetic
flux lines induced into a ferromagnetic material by magnetization.
5.10.2 Magnetic particle examination may be used for examination of cracks and
other elongated discontinuities in magnetic vessel materials.
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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

5.10.3 Wet fluorescent magnetic particle inspection (WFMPI) or dry method may
be deployed for inspection depending upon the sensitivity desired and site
conditions.

5.11 Non-Destructive Examination Method (Dye Penetrant Examination):

5.11.1 Principle of fluorescent or normal dye penetrant examination depends on
allowing a specially formulated liquid (penetrant) to seep into an open
discontinuity and then detecting the entrapped liquid by a developing
agent.
5.11.2 It is essential that the examined discontinuity must be open, clean and
undisturbed surface.
5.11.3 Fluorescent or dye penetrant examination can be used for disclosing
cracks, porosity or pin holes that extend to the surface of the material and
for outlining other surface imperfections.

5.12 Non-Destructive Examination Method (Radiographic Examination):

5.12.1 The basic principle of radiographic examination of vessel metallic parts is
that the holes, voids and discontinuities decrease the attenuation of the X-
ray and produce greater exposure on the film (darker areas on the negative
film).
5.12.2 This method depends on density differences; cracks with tightly closed
surfaces are much more difficult to detect than open voids. Also, defects
located in areas of a dimensional change are difficult to detect due to the
superimposed density difference.
5.12.3 Special safety precautions shall be considered while using this method.
Since ionizing radiation is involved, field application requires careful
implementation to prevent health hazards. Only certified personnel shall
carry out the implementation of this technique.

5.13 Non-Destructive Examination Method (Ultrasonic Examination):

5.13.1 The principle of ultrasonic examination of metallic materials is based on
using electromagnetic and acoustic waves for detection of discontinuities.
The signal pulses are induced into the material and waves reflected back
from discontinuities are detected.
5.13.2 Ultrasonic techniques are used for the detection and measurement of
general material loss such as by corrosion and erosion. Wave velocity is
constant for a specific material. This method is used for thickness
measurement and flaw detection.

5.14 Non-Destructive Examination Method (Pressure Test):

5.14.1 A hydrostatic pressure test is required to be carried out if major repairs are
carried out in the pressure vessel which may have seriously affected its
integrity like; cutting a window and rewelding, introduction of a manway
or nozzle, excessive grinding for removal of detrimental defects and
welding thereafter, modification in vessel etc.
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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

5.14.2 The pressure test shall be conducted at a pressure in accordance with the
construction code used for determining the maximum allowable working
pressure.
5.14.3 Pneumatic testing may be used when hydrostatic testing is impracticable.
Pneumatic testing shall be considered as “leak test” and should be made at
low pressure.
5.13.4 When a pressure test is to be conducted in which the test pressure will
exceed the set pressure of the safety relief valve with the lowest setting,
then the safety valve shall be removed. Other appurtenances, such as
gauge glasses, pressure gauges and rupture disks should be removed or
blanked off. When the pressure test has been completed, pressure relief
devices of the proper settings and other appurtenances shall be reinstalled
or reactivated.

5.15 Assessment Of Inspection Findings:

5.15.1 Pressure containing components found to have degradation that could
affect their operating load carrying capability shall be evaluated for
continued service. Fitness for service techniques shall be used for this
evaluation. The fitness for service techniques must be applicable to the
specific degradation observed. As a minimum, the following evaluation
items shall be included:
5.15.1.1 Metal loss, including local and pitting corrosion.
5.15.1.2 Blisters and laminations.
5.15.1.3 Weld misalignment and shell distortion.
5.15.1.4 Crack-like flaws.
5.15.1.5 Effects of fire damage.
5.15.1.6 Potential of brittle fracture.
5.15.1.7 Creep damage if component operates at high temperature.
5.15.1.8 Information obtained during inspections and related results.
5.15.2 Information obtained during inspections and related results shall assist in
the safety assessment and as a minimum shall include the following items:
5.15.2.1 Inspection performed, type, extent and date.
5.15.2.2 Examination methods.
5.15.2.3 Preparation of surfaces and welds.
5.15.2.4 Techniques used, visual, magnetic particle, penetrant test,
radiography or ultrasonic.
5.15.2.5 Qualifications of inspection and supervisory personnel.
5.15.2.6 Inspection results and reports.
5.15.2.7 Summary of type and extent of damage or cracking.
5.15.2.8 Disposition, no action, delayed action or repair.
5.15.3 Corrosion & Minimum Thickness Evaluation: Corrosion may cause a
uniform loss of the vessel’s surface area, a local loss of surface or may
cause pitting of the surface:
5.15.3.1 Uniform corrosion may be difficult to be detected visually and
thickness readings is necessary to determine its extent.
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5.15.3.2 Locally corroded or pitted surfaces may be thinner than they

appear visually and when there is uncertainty about the original
surface location, thickness determinations may also be necessary.
5.15.3.3 The minimum actual thickness and maximum corrosion rate for
any part of the vessel may be assessed during inspection. Retiring
wall thickness shall be calculated as per the applicable pressure
vessel code. When the thickness of a pressure vessel has been
reduced to the minimum design thickness required to contain the
contents at its design pressure and temperature, then the vessel is
said to have reached its retiring thickness.
5.15.3.4 The corrosion rate is estimated by the following methods:
5.15.3.4.1 Using data collected on vessels in the same or similar
service.
5.15.3.4.2 Using the inspector’s knowledge and experience with
vessels in similar service.
5.15.3.5 Widely scattered pits may be ignored as long as the following is
true:
5.15.3.5.1 No pit depth is greater than one half the vessel wall
thicknesses exclusive of the corrosion allowance.
5.15.3.5.2 The total area of the pits does not exceed 45 cm2
within any 20 cm diameter circle.
5.15.3.5.3 The sum of their dimensions along any straight line
within the circle does not exceed 5 cm.
5.15.3.6 Any vessel component with thinning of walls due to corrosion
etc., which is below the minimum required wall thickness, must
be evaluated to determine if it is adequate for continued service.

5.16 Inspection Results & Conclusions:

5.16.1 After completion of inspection, assessment is conducted and the results
shall be used to establish and define the following:
5.16.1.1 Confirm that appropriate inspection methods, scope, tools and
techniques were utilized based on the inspected forms of
degradation.
5.16.1.2 Confirm and establish the appropriate frequency for internal,
external, and on-stream inspection.
5.16.1.3 The need for pressure testing after damage has been incurred, or
after repairs or modifications have been completed.
5.16.1.4 Establish prevention and mitigation steps to reduce the likelihood
and consequence of a vessel failure. If necessary, recommend
future monitoring or replacement.

5.17 External Inspection & Intervals:

5.17.1 Each aboveground vessel shall be given visual external inspection each
year and preferably while the vessel is in operation.
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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

5.17.2 The inspection shall determine the condition of the exterior surface, the
condition of the supports, the allowance for the expansion and the general
alignment of the vessel on its supports. The pressure temperature and level
gauges shall also be visually inspected and any malfunction or damage
reported.
5.17.3 Any signs of leakage should be investigated so that the sources can be
established.
5.17.4 Inspection for corrosion under insulation shall be considered and this may
require removal of some insulation. Jacketing shall be inspected during the
major surveys. Portions of the insulation shall be removed for inspecting
the metal substrate underneath. Select locations where condensation could
be expected or water from other sources could seep into the insulation.
5.17.5 Buried sections of vessels shall be monitored to determine their external
condition.

5.18 On-Stream Inspection & Intervals:

5.18.1 On-stream inspection is performed from the outside of a pressure vessel
using non-destructive examination procedures to establish the suitability of
the vessel for continued operation. The vessel may or may not be in
operation while the inspection is carried out.
5.18.2 On-stream inspection may be substituted for internal inspection in the
following situations:
5.18.2.1 When size, configuration or lack of access makes vessel entry for
internal inspection physically impossible.
5.18.2.2 When the general corrosion rate of a vessel is known to be less
than 0.125 mm per year and the estimated remaining life is
greater than 10 years.
5.18.3 When an on-stream inspection is conducted in lieu of an internal
inspection, then a thorough examination shall be performed using
ultrasonic thickness measurements, radiography or other means of NDE to
measure metal thickness and assess the integrity of the welds.
5.18.4 Either an on-stream or an internal inspection may be used interchangeably
to satisfy inspection requirements. However, an internal inspection is
required when the vessel integrity cannot be established with an on-stream
inspection.
5.18.5 Measure and record any corrosion and pitting depth using appropriate tools
(pit gauges, welding gauges etc). Compare readings with previous results
and calculate the corrosion rate, if any.
5.18.6 JO pressure vessels may have coal tar epoxy, phenol epoxy, gunnite lining,
or belzona compounds protection system. Accordingly, for internally
protected vessels, inspect the coating systems using appropriate tools and
instruments. Consult INTREX Corrosion Engineer to perform detailed
examination and request him to provide full report on the finding.
5.18.7 Old vessels fabricated by old generation carbon steel plates are susceptible
to Hydrogen Induced Cracking (HIC) in wet H2S service. Both normal
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beam and angle beam technique to be used to determine HIC type

indication.
5.18.8 Examine accessible flange faces for distortion and determine the condition
of gasket seating surfaces. If evidence of distortion is found, it may be
necessary to make a detailed check of the actual contours and dimensions
compared with the original design details.

5.19 Inspection Intervals:

5.19.1 Based on experience, the hydrocarbon handling pressure vessels of Joint
Operation are required internal inspection in every 4 years.
5.19.2 Stationary air receivers shall be inspected at least every 2 years.
5.19.3 Lower risk vessels shall be inspected as follows:
5.19.3.1 Inspection on a representative sample of vessels in that class or all
vessels in that class may be performed.
5.19.3.2 External inspection shall be performed when an on-stream or
internal inspection is performed or at shorter intervals.
5.19.3.3 Any signs of leakage or deterioration detected in the interval
between inspections shall require an on-stream or internal
inspection of the vessel and re-evaluation of the inspection
interval for the vessel class.
5.19.4 Higher risk vessels shall be inspected as follows:
5.19.4.1 External inspection shall be performed when an on-stream or
internal inspection is performed or at shorter intervals.
5.19.4.2 In the case where remaining life is estimated to be less than 4
years, the inspection interval may be the full remaining life up to
a maximum of 2 years.
5.19.4.3 Any signs of leakage or deterioration detected in the interval
between inspections shall require an on-stream or internal
inspection of the vessel and re-evaluation of the inspection
interval for the vessel class.
5.19.5 The internally coated/lined vessels shall be inspected internally within 4
years after the installation of internal lining and every 4 years thereafter.
The lining shall be checked and/or repaired in accordance with the original
manufactures specifications.
5.19.6 The cycle of planned inspection for JO (sweet service duties) shall be as
follows:
5.19.6.1 Minor surveys every 2 years.
5.19.6.2 Intermediate surveys every 4 years.
5.19.6.3 Major surveys every 8 years for gathering centers and every 4
years for booster stations.

5.20 Inspection Requirements For Out-Of-Service Equipment:

5.20.1 Existing pressure vessels scheduled for re-commissioning shall be
inspected as follows:
5.20.1.1 Check for signs of wall thinning.
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5.20.1.2 Check for mechanical damage to the shell.

5.20.1.3 Check for leakage gaskets and seals and other evidence of poor
maintenance.
5.20.1.4 Inspect protective coatings and linings.
5.20.1.5 Inspect the soundness of foundations and supports.
5.20.1.6 Check pressure relief devices for proper functionality.
5.20.1.7 Review and check previous inspection servicing and maintenance
records.
5.20.1.8 Check for corrosion under insulation.

5.21 Pressure Vessels Permanent & Progressive Records:

5.21.1 Permanent records shall be maintained throughout the service life of each
vessel. Progressive records shall be regularly updated to include new
information pertinent to the operation, inspection and maintenance history
of the vessel. The preferred method of record keeping is to maintain data
by individual vessel. Pressure vessel records shall contain the following
information pertinent to mechanical integrity:
5.21.1.1 Construction and design information that will identify the code or
standard used for the design and construction of the vessel, and
will include the following:
5.21.1.1.1 ASME, API or any other applicable code.
5.21.1.1.2 Type of construction, shop or field fabrication, as
built drawings.
5.21.1.1.3 Maximum design, allowable and test pressure and
temperature.
5.21.1.1.4 Vessel materials, ASME or ASTM specifications.
5.21.1.1.5 Design corrosion allowance, thickness, etc.
5.21.1.1.6 Equipment serial number or other identifier.
5.21.1.2 Inspection history information:
5.21.1.2.1 Vessel conditions.
5.21.1.2.2 Previous inspection reports and data.
5.21.1.2.3 Previous inspection recommendations for repair.
5.21.1.2.4 Results of the inspection and/or test.
5.21.1.2.5 Thickness surveys.
5.21.1.3 Repair, alteration and re-rating history:
5.21.1.3.1 Repair, re-rating and alteration information.
5.21.1.3.2 Dates of changes or repairs.
5.21.1.3.3 Reports indicating that equipment is still in-service
with identified deficiencies or recommendations for
repair are suitable for continued service until repairs
can be completed.
5.21.1.4 Previous fitness for service assessment documentation and
information, if any.
5.21.1.5 Service history, information on conditions of operating history of
the vessel, such as:
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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

5.21.1.5.1 Fluids handled, type, composition, temperature and

pressure.
5.21.1.5.2 Type of service whether it is continuous, intermittent
or irregular.
5.21.1.5.3 Significant changes in service conditions, pressure,
temperatures and fluid compositions and the dates of
the changes.

6.0 RELATED DOCUMENTS

6.1 Control Of Non-Conformity Procedure.
6.2 Plant & Equipment Inspection Section.
6.3 General Plant Inspection.
6.4 Boiler & Pressure Vessel Code-Pressure Vessels, ASME VIII, Division 1&2.
6.5 Pressure Vessel Inspection Code-Maintenance Inspection, Rating, Repair &
Alteration, API 510.
6.6 Inspection of Pressure Vessels, Heat Exchangers, Condensers & Coolers, API RP
572.
6.7 Fitness For Service, API RP 579.
6.8 Standard for Qualification & Certification of Non-Destructive Testing Personnel,
ASNT SNT-TC-1A.
6.9 Pressure Equipment Directive.
6.10 Unfired Pressure Vessels, BSEN 13445-5.
6.11 Requirements for the Certification of Plant Inspectors.
6.12 ASME PCC-1 1, Guidelines for Pressure Boundary Bolted Flange Joint Assembly
6.13 ASME PCC-2, Repair of Pressure Equipment and Piping
6.14 ASME boiler and Pressure Vessel Code, Section V: Non-Destructive Examination
B
6.15 ASME Boiler and Pressure Vessel Code, Section IX: Welding and Brazing
Qualifications
6.16 National Board NB-23 4, National Board Inspection Code

7.0 RECORDS
7.1 Pressure Vessels Inspection Checklist – Appendix A.
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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

Appendix A

Pressure Vessels Inspection Checklist

Description Check Findings
Before Inspection-General
1 Study the Vessel History Files
PTW including the confined space entry permit/Job
2
hazard Analysis
Check the PPEs including H2S monitor and Escape
3
Hood/ SCBA.
Find out operating parameters, product/service
4 details and any items found malfunctioning from the
station operator.
Check the Vessel is cleaned and degassed properly
5
and ventilation is proper
Check isolation of product lines and electrical
6
power etc.
7 Check the area for slipping/tripping hazards.
8 Identify areas required more cleaning.
Vessel Foundation `
1 Check the condition of the Concrete Foundations
Condition of seal between the Vessel bottom and
2
foundation.
3 Check the ground earthing is proper.
Check the area for general housekeeping/ No
4
flammable material storage nearby.
Vessel Shell
1 Painting/coating failures inside & Outside
2 Visual inspection against pitting/corrosion.
Ultrasonic thickness measurements on shell plates
3
and nozzles.
Inspect visually the welds for any serious
4
corrosion/cracks.
Check all nozzles, Manways, reinforcing plates
5 including the flange faces for corrosion, Leaks,
paint failure etc.
Check the Ladder and hand rails for corrosion
6
broken welds etc.
7 Inspect for flange leaks and leaks through bolting
8 Check shell plate dimpling around nozzles
Check for metal loss at bottom shell area of
9
standing water
10 Measure the depth of pitting
Check the protective coatings for damages,
11
deterioration and disbonding
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PRESSURE VESSEL INSPECTION PROCEDURE Doc. No. IIC/PVI/34/JO/SC430/AI17, Rev.B

12 Check for any bulges

Visually inspect the shell plate and all welding for
13
preferential corrosion and leaks.
Inspect coating for holes, disbonding, deterioration,
14
and discoloration.

Shell nozzles
1 Inspect shell nozzles for thinning and pitting.
2 Inspect hot tap nozzles for trimming of holes.
3 Identify type of shell nozzles.
Identify and describe internal piping, including
4
elbow up and elbow down types.

Drain Systems
1 Inspect for thinning and pitting.
2 Inspect protective coating
3 Inspect for damage to exterior of pipe.
4 Check for obstructions that pipe could catch on.