SGS Pakistan (Pvt.) Ltd.

H-3/3, Sector - 5
Korangi Industrial Area,
Repair Works of Karachi - PAKISTAN.

Jagir Separator V-5100 Tel: +92 21 35121388

Fax: +92 21 5121325 / 5121386
Web Site: www.sgs.com
(UEPL)

Inspection Report

Client : United Energy Pakistan Limited

Client Ref : 246958

Client Contact Person : Mr. Rafey Anwar

SGS Ref. No. : 5005214

Inspected by : Ali Dad Khan – Sr Inspection Engineer

Site : Metcraft Engineers Yard National Hi-way Karachi

Equipment
: Separator V-5100
Identification

Survey Date : August 18, 2018

Prepared by Reviewed / Approved by

Ali Dad Khan

Ghulam Muhammad for
Sr. Inspection Engineer
Deputy Manager

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability,
indemnification and jurisdiction issues defined therein.
Any other holder of this document is advised that information contained hereon reflects the Company’s findings at the time of its intervention only and within the limits of Client’s instructions, if
any. The Company’s sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction
documents.
Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law.
Title Page of Report - Ref: IND-QMS-FOR-123 Rev: 00
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INDUSTRIAL SERVICES
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Inspection Summary
Date: 18-08-2018

Introduction:

Project Title: TPI during Repair works of Jagir Separator V-5100

Client: United Energy Pakistan Limited
Contract Ref No: PO # xxxxxx
Location: Metcraft Engineers Karachi.
Inspection Date: August 18, 2018

Scope of Work:

API (510) certified inspector visited Metcraft workshop to inspect the repair works of Jagir Separator
V-5100 in accordance with the SOW, sketches and other reference documents to ensure the
reliable, safe and continue storage capability of subject tank. Scope and inspection finding of API
inspector for visit 1 are as under,

Reference Documents:

• API 510.
• ASME SEC VIII Div. 1 (Boiler and Pressure Vessel Code).
• ASME PCC-2.
• ASME PCC-1.
• ASME Sec IX (Welding, Brazing and Fusing Qualification.
• ASME Sec V (Non Destructive Examination)
• ASME Sec II Part A.
• Approved Scope of Work.
• GA drawing.

Inspection Activities:

3.1 Visual inspection.

3.2 Dimension Verification.

Visual Inspection: -

Subject Vessel was inspected externally and internally to verify SOW recommendations in the
scenario of API-510 to ensure the continued safe and reliable operation,
During physical verification of scope, SGS Inspector has been made some changes in SOW as per
actual condition of vessel. Detailed of changes and its corrective actions are as under.

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and
jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Company’s findings at the time of its intervention only and within the limits of Client’s
instructions, if any.
The Company’s sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents.
Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law.

Inspection Summary Report - Ref: IND-QMS-FOR- 121 Rev: 00

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S.No Observations Recommendations

Shell (External and Internal)

External:

a) External inspection of vessel was

performed and no corrosion, pitting, bulging
and other imperfection was noted on the
vessel shell surface.

b) Longitudinal and circumferential welds Recommendation follows as per SOW.

01 were inspected visually, found satisfactory.

c) Supporting legs of vessel were inspected

and found satisfactory.

d) Magnetic Particle Inspection was

performed on Tee section welds, no linear
indication was observed.

Internal:

a) Sever pitting in the form of uniform Recommendation follows as per SOW.

Grooves, Gullies & waves was observed on However, insert plate sizes must be as
shell course 1 and 2 at 5 ~7 O’clock mentioned below due to weld spacing and
position. See defect ID Sketch and current condition of vessel.
photographic presentation for more details. For course # 01,
Approximate length and width of corroded 1650 mm in length, 1300 mm in
or pitted area in shell course 1 was 1550 circumferentially, Thickness is 16 mm.
mm and 1050 mm respectively. Depth of
deepest pit was recorded with pit gauge Insert plate for course # 01 having rounded
02
and it was 11 mm so remaining thickness of corner at least 75 mm from dish-B side only.
shell under deepest pit is 5.50 mm against
design thickness of 16.50 mm. Same was For Course # 02
verified by UT A-scanning from external 2285 mm in length, 1300 mm in
side. Approximate length and width of circumferentially, Thickness is 16 mm.
corroded or pitted area in shell course 2
was 2285 mm and 1220 mm respectively.
As pitting was in the form of uniform
Grooves, Gullies & waves so pit depth
measurement was not possible with depth
This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and
jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Company’s findings at the time of its intervention only and within the limits of Client’s
instructions, if any.
The Company’s sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents.
Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law.

Inspection Summary Report - Ref: IND-QMS-FOR- 121 Rev: 00

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gauge so UT A-scanning was performed

from external side to locate the extent
of pitting. Minimum observed thickness of
shell course 2 was 6.00 mm against design
thickness of 16.50 mm so metal loss due to
pitting is 10.50 mm approximately.

b) Circumferential weld CS-2 was found

corroded due to pitting at 5 ~ 7 O’clock
position. Other welds (circumferential and
longitudinal) were found satisfactory.

Repair of Internal Attachments

Baffle Plates:
Two baffle plates already installed inside the
Pitting was observed on internal baffles vessel and pitting was observed on their
plate surface. For thorough internal visual surfaces.
inspection, these plates were cut by Both plates shall be removed for insertion
new plate (bottom section of shell) by cutting,
Metcraft Engineers.
and the diameter of both plate would be
03 Approximate cut size of these plates reduced than required diameter due to
was 32” x 19”. cutting.

Therefore, it is recommended that, both baffle

plate shall be replaced with new one with
same design as existing.

Weir Plate:
Weir plate shall also be removed for insertion
Visual appearance condition of weir plate of new plate (bottom section of shell) by
and its fillet weld with shell was found cutting, and the diameter of weir plate would
satisfactory, however window has been be reduced than required diameter due to
04 cutting.
made by Metcraft Engineers for inspection
purpose. Therefore, it is recommended that, weir plate
shall be replaced with new one with same
design as existing.

Nozzles & Manway

Nozzle N-7 (2” LNW, RF#150): All Nozzles & Manway has integral flanged
with nozzle neck, so only flange could not be
As per SOW, Pitting was observed on flange
replaced with new RF#150 Class flange.
serrations which may cause leakage/seepage in
near future.
This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and
jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Company’s findings at the time of its intervention only and within the limits of Client’s
instructions, if any.
The Company’s sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents.
Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law.

Inspection Summary Report - Ref: IND-QMS-FOR- 121 Rev: 00

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Nozzle N-8 (2” LNW, RF#150): Therefore, Metcraft Engineers is advised,

nozzle shall be removed from vessel by gas
As per SOW, Pitting was observed on flange cutting and after removal of nozzle shall be
serrations which may cause leakage/seepage in
repaired by approved repairing method by
near future.
inspector.
Nozzle N-5 (3” LNW, RF#150):
After satisfactorily repaired, nozzle shall be
As per SOW, Pitting was observed on flange re-install its respective location as per existing
serrations which may cause leakage/seepage in design and dimensions.
near future.

Manway M-1 (20” LNW, RF#150):

As per SOW, Pitting was observed on flange

serrations which may cause leakage/seepage in
near future.

Manway Cover (20” Blind Flange, RF#150) Recommendation follows as per SOW

Dimension Verification: -

Before cutting nozzles, internal attachment and man way, all dimension orientation has
been noted by Metcraft QA/QC in-charge in the presence of API inspector. All noted
dimension and design detail shall be used in rehabilitation works of Jagir separator V-5100
and incorporated in As-built drawing.

Metcraft was permitted to initiate repairing works, and shall be submitted all relevant
documents such as Repairing Methodology, Quality Inspection Plan, Hydro Test
Procedure, painting & Coating procedure, Welding procedure specification, welder
performance record, and construction related procedures as per repair requirements.

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and
jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Company’s findings at the time of its intervention only and within the limits of Client’s
instructions, if any.
The Company’s sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents.
Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law.

Inspection Summary Report - Ref: IND-QMS-FOR- 121 Rev: 00

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Photographic Presentation:

Image # 01, Image # 02,

Internal pitted areas. Cutting line 4” beyond the weir plate.

Image # 03, Image # 04,

Weir plate Baffle plates

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and
jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Company’s findings at the time of its intervention only and within the limits of Client’s
instructions, if any.
The Company’s sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents.
Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law.

Inspection Summary Report - Ref: IND-QMS-FOR- 121 Rev: 00

 SGS Ref No: 5005314
INDUSTRIAL SERVICES
Rev: 00
Page: 6 of 6
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Date: 18-08-2018

Image # 05, Image # 06,

Nozzle N-5 flange serrations damaged. Internal manway neck pitting.

Image # 07 & 08,

Dimension verification for As-built and rehabilitation.

Particulars Prepared By Reviewed By

Signature:
for

Name: Ali Dad Khan Ghulam Muhammad

Date: 18-08-2018 18-08-2018

This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and
jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Company’s findings at the time of its intervention only and within the limits of Client’s
instructions, if any.
The Company’s sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents.
Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law.

Inspection Summary Report - Ref: IND-QMS-FOR- 121 Rev: 00