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An inspection & evaluation perspective

International Inspection Services Ltd.

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Main components:1. Pressure vessels e.g. Atmospheric Distillation Unit,

Vacuum Distillation Unit, Stripping Column, de-salters, FCC, Reflux drum etc.

2. Connecting piping: Piping and by pass pipe linescarrying various stages of process fluids andinterconnecting the process units.

3. Re-boilers: For intermediate heating of process fluids.4. Air-coolers: For cooling and condensation of process

fluids.5. Valves: Various valves connected to inlets and outlets e.

g. stop valves, gate valves, NRVs, and relief valves.6. Rotating equipments like feed pumps, compressors,

turbines etc.7. Bearings e.g. Rolling element or sliding bearings.

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When inspection for assessment of component integrity is

required?1. During fabrication stage for a new equipment to ensure and

evaluate the integrity of the fabricated component in accordancewith established International Codes and Standards e. g. ASMESec VIII Div 1 & 2; ASME B 31.3 etc.

2. After a length of service i.e. after 5 to 10 years of service. Duringservice, the components are subjected to various serviceconditions including high temperatures, pressures, chemicalreactions and high velocity flow of liquids and gases any or all ofwhich may cause service induced damages to the components.

The extent of these damages are required to be evaluated by usingproper NDE techniques and engineering assessment to ensure thefitness of the component for the intended service. Establishedcodes and standards for this activity are API 570; API 510; API579; 580 etc.

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1. During Fabrication Stage for new installation: (ASME Sec VIIIDiv 1 & 2)

1.1 Pressure Vessels:

Category A & B: Radiography or Ultrasonic Testing; Magnetic particle orLiquid Penetrant testing plus Visual testing of all welds.

Category C & D: Ultrasonic Testing; Magnetic particle or Liquid Penetranttesting plus Visual testing of all welds.

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1.2 Pressure Piping: (ASME B 31.3 & 31.4; 31.8) API

11041. High pressure piping

2. Category M fluid service

3. Category D fluid service

4. Normal Fluid service

5. Severe cyclic conditions

Depending on the fluid service requirements (Toxic,

Flammable, high pressure, fluctuating loads etc.), theextent of NDT will vary; however all the conventionalNDT are required e.g. radiography, Ultrasonic, MPI,PT and Visual testing.

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2. Inspection after a period of services (In-

service inspection applicable to Piping andvessels)2.1 Understanding the damage mechanism that may be expected during

the service based on service environment

2.2 Knowledge of the specific NDT method that will be useful to detect

those damages and their extent.2.3 Application of the NDT method and detection as well as extent of the

damages.

2.4 Apply basic rules for evaluation of damages (API 570/API 510/API653)

2.5 Apply advanced assessment/formulae for estimating the extent andtype of damage (API 579-1/ASME FFS-1).

2.6 Apply Risk Based Inspection Technology (API 580; API 581).

2.7 Determination of remaining life of each component based on above(refer 2.4; 2.5 & 2.6).

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3. In-service inspection of Rotating equipment:

3.1  Mainly include: Pumps, turbines, bearing and supports, motors etc.

3.2 Predominant damage mechanisms: Vibrations, wear, fatigue, erosion,erosion corrosion etc.

3.3 Suitable NDT method: Vibration analysis, thermography

3.4 Conventional NDT are also applicable: UT, MT,PT & VT mainly.