00 Saip 80

Inspection Procedure
00-SAIP-80 17 February 2020

Guidelines for Process Equipment Inspection
Document Responsibility: Inspection Engineering Standards Committee
Contents
1 Scope ................................................................ 2
2 Purpose............................................................. 2
3 Safety ................................................................ 2
4 References........................................................ 2
5 Terminology ...................................................... 4
6 Inspection Guidelines ........................................ 7
6.1 Vessels ....................................................... 7
6.2 Reactor Vessels ......................................... 8
6.3 Platformer Reactor Vessel ........................ 10
6.4 Heat Exchangers ...................................... 11
6.5 Reactor Effluent Heat Exchangers ........... 14
6.6 Fin Fan Cooler .......................................... 16
6.7 Process Heaters ....................................... 16
6.8 Reformer Heater ....................................... 18
6.9 Industrial Boilers ....................................... 21
6.10 Tanks ....................................................... 23
Attachment 1 - Flowchart-Process Equipment
External and Internal Inspection
per Typical Inspection Plan (TIP)........... 25
Attachment 2 - Typical Inspection Plan (TIP)
for Static Process Equipment - .............. 26
Attachment 3 - Inspection Checklist
for Process Equipment - ........................ 33
Attachment 4 - Nomenclature and Types
of Heat Exchangers ............................... 64
Revision History ..................................................... 75
Previous Issue: 26 November 2007 Next Revision: TBD

Contact: lodhizf Page 1 of 75
©Saudi Aramco 2020. All rights reserved.
Saudi Aramco: Company General Use

Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-80
Publish Date: 17 February 2020
Next Revision: TBD Guidelines for Process Equipment Inspection
1 Scope
This Saudi Aramco Inspection Procedure (SAIP) establishes guidelines for inspecting
pressurized static process equipment that have been placed in service. This procedure
supplements SAEP-325.
2 Purpose
This SAIP is intended to assist the Plant and Equipment (P&E) Inspectors of Plant
Inspection Units in their selection by providing Typical Plans and inspection checklist
for all types of existing plant equipment, on stream evaluation, and tracking of existing
equipment condition.
3 Safety
3.1 Radiographic examination personnel safety should be per SAEP-1143 paragraph 3 and
GI-0150.003.
3.2 All pressure testing should be in compliance with GI-0002.102, “Pressure Testing
Safely.”
3.3 Use of personnel protection equipment and safe entry for inspection is the responsibility
of the inspector/Inspection Engineer.
4 References
The following standards were used in the preparation of these inspection guidelines and
should be carefully reviewed by the inspectors/inspection engineers prior to performing
inspection. All references should be the latest issued revision or edition.
4.1 Saudi Aramco References
Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedule
SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering Requirement
SAEP-325 Inspection Requirements for Pressurized Equipment
SAEP-1140 Qualification and Certification of Saudi Aramco NDT Personnel
SAEP-1141 Industrial Radiation Safety
SAEP-1142 Qualification and Certification of Non-Saudi Aramco NDT Personnel
SAEP-1143 Radiographic Examination
©Saudi Aramco 2020. All rights reserved. Page 2 of 75

SAEP-1144 Magnetic Particle Examination of Welds and Components

SAEP-1145 Liquid Penetrant Examination of Welds and Components
Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-A-206 Positive Material Identification
SAES-D-008 Repairs, Alteration, and Re-rating of Process Equipment
SAES-W-010 Welding Requirements for Pressure Vessels
SAES-W-011 Welding Requirements for On-plot Piping
SAES-W-012 Welding Requirements for Pipelines
SAES-W-014 Weld Overlays and Welding of Clad Materials
SAES-W-015 Strip Lining Application
SAES-W-016 Weld of Special Corrosion-Resistance Materials
SAES-W-017 Welding Requirement for API Tanks
Saudi Aramco General Instructions

GI-0002.102 Pressure Testing Safely
GI-0150.003 Radiation Safety
Saudi Aramco Inspection Procedures

00-SAIP-07 Positive Material Identification Requirements
00-SAIP-74 Inspection of Corrosion under Insulation and Fireproofing
00-SAIP-75 External Visual Inspection Procedure
01-SAIP-01 Small Nipple Inspection Program
01-SAIP-02 Retirement Thickness of In-plant Piping
01-SAIP-04 Injection Point Inspection Program
32-SAIP-11 Inspection of Air-Cooled Exchangers
4.2 Industry Codes and Standards

American Petroleum Institute
API STD 510 Pressure Vessel Inspection Code
API RP 571 Damage Mechanism Affecting fixed Equipment
API RP 572 Inspection of Pressure Vessels
API RP 573 Inspection of Boilers and Heaters

API RP 580 Risk Based Inspection

API RP 578 Material Verification
API STD 620 Design and construction of Large, Welded, Low Pressure Storage
Tanks
API STD 650 Welded Steel Tanks for Storage
API STD 660 Shell and Tube Heat Exchangers
API STD 661 Air Fin-Coolers
API RP 932-B Insp. Guideline for Effluent Air Coolers
American Society of Mechanical Engineers

ASME SEC V Nondestructive Examination
ASME SEC VIII Boiler and Pressure Vessel Code
ASME B 31.1 Power Piping
ASME B 31.3 Chemical Plants and Petroleum Refinery Piping
NBIC, National Board Inspection Code
5 Terminology
5.1 Abbreviations
ADIP Amino-Di-Iso-Propanol
DEA Di Ethanol Amine
DGA Di Glycol Amine
HAZ Heat Affected Zone
HC Hydrocarbon
MEA Mono Ethanol Amine
MSAER Mandatory SA Engineering Requirements
MT Magnetic Particle Testing
NDT Non Destructive Testing
P&ID Piping and Instrumentation Drawings
PFD Process Flow Diagram
PMI Positive Material Identification
PT Penetrant Testing
PWHT Post Weld Heat Treatment
RT Radiography Testing
RTFI Radiographic Film Interpretation

TEG Tri Ethylene Glycol

UT Ultrasonic Testing
VT Visual Testing
PV Pressure Vessel
TIP Typical Inspection Plan
5.2 Definitions
Pressure Vessels: Is a container designed to withstand internal or external pressure.

The vessels are constructed in accordance to ASME Boiler and Pressure Vessel Code,
Section VIII. These vessels are subjected to internal or external operating pressure
greater than 15 lbs/in2. Drums, Towers, Columns and Reactors, heat exchangers,
condensers, air coolers, bullets, spheres and accumulators are common types of pressure
vessels.
Tanks: Tanks are built to API STD 650 covers, fixed roof, floating roof, floating and
fixed roof tanks. The scope is limited to the tank foundation, bottom, shell, structure,
roof, attached appurtenance, and nozzles.
Heaters: There are a variety of designs for fired tubular heaters. Some of the
commonly used designs are the box, cylindrical, and cabin types. The tubes in the
radiant are called radiant tubes. The heat transfer in these tubes is mainly through the
radiation from the heating flame and incandescent refractory. The shock or shield tubes
are located at the entrance to the convection section and they receive more heat flux.
Convection tubes are on top of the heater, heated by the outgoing flue gas from the
radiant section.
Boilers: Fired boilers are boilers in which fuel is burned in the combustion chamber
associated with the boiler. The heat of the combustion is absorbed by the boiler to heat
the water and convert it to steam. Boilers are mainly of two types, water tube and fire
tube boilers, where water is in the tube is called water tube boiler and fire in the tube is
called the fire tube boiler.
Alloy Material: Any metallic material (including welding filler materials) that contains
alloying elements such as chromium, nickel, or molybdenum, which are added to
enhance mechanical or physical properties and/or corrosion resistance.
Fabrication: The preparation of piping and small connection for assembly, including
cutting, threading, grooving, forming, bending, and joining of components into
sub-assemblies.
Face of the Weld: The exposed surface of a weld on the side from which the welding
was done.
Filler Material: The material to be added in making metallic or nonmetallic joints.

Fillet Weld: A weld of approximately triangular cross section joining two surfaces
approximately at right angles to each other in a lap joint, tee joint, or corner joint.
Crack: A fracture type discontinuity characterized by a sharp tip and high ratio of
length to width to opening displacement.
Lack of Fusion: A weld discontinuity in which fusion did not occur between weld
metal and base metal or adjoining weld beads.
Incomplete Penetration: The weld beads unable to fill the weld bevel groove.
Porosity: Cavity type discontinuities formed by gas entrapment during solidification of

the weld metal.
Rounded Indications: Indication’s with a maximum length of three times the width or
less on the radiograph.
Aligned Indications: A sequence of four (4) or more rounded indications should be

considered aligned.
Leg Length: is the thickness of a fillet weld, excluding any allowable reinforcement
measured through the leg.
tm: Minimum thickness required (t) is equal to the design thickness as calculated by the
applicable ASME SEC VIII D1, ASME B31.3 (Barlow’s/Hoop’s) formula.
Hydrocarbon Services: Process streams of liquid or gaseous hydrocarbon (HC)

materials, or HC streams that may contain phenols, carbon dioxide, and ammonia.
Category “D” Fluid Service: A fluid service in which all the following apply:
1) The fluid handled is nonflammable, non-toxic, and not damaging to human tissues
as defined in ASME B31.3 paragraph 300.2.
2) The design gage pressure does not exceed 150 psi (1030 kpa)
3) The design temperature is from -20°F (-29°C) through 366°F (180°C)
Category “M” Fluid Service: A fluid service in which the potential for personnel
exposure is judged to be significant and in which a single exposure to a very small
quantity of a toxic fluid, caused by leakage, can produce serious irreversible harm to
persons on breathing or bodily contact, even if prompt restorative measures are taken.
High Pressure Fluid Service: A fluid service for which the owner specifies the use of
high pressure piping.
Normal Fluid Service: A fluid service pertaining to most piping covered by the code
(ASME 31.3), that is, not subjected to the rules for Category D, Category M, or High

Pressure Service.
Low-Chrome Alloy Steels: Alloy materials with nominal chromium contents of 1% to

12% chrome.
Repair: The work necessary to restore the condition of the equipment suitable for safe
operation at the design conditions, without any deviation from the original configuration.
6 Inspection Guidelines
These guidelines are intended for inspectors and inspection engineers. Generally, the steps
for static process equipment inspection are shown in the Flowchart in Attachment 1.
Equipment shall be inspected per Typical Inspection Plan (TIP) and Checklist shown in
Attachment 2 and DI-DXI respectively.
6.1 Vessels
6.1.1 Check the vessel drawing, construction code, material of construction, internal
parts, PWHT, and dimensions (diameter, height, and thickness)
6.1.2 Read the vessel file and note history of corrosion, repairs or replacement if any.
6.1.3 Carry out joint inspection for vessel entry permit (confirm if ventilation, blinds,
scaffolds and lighting are provided) to ensure the vessel is safe and adequately
ventilated for vessel entry and obtain vessel entry permit. At the time of entry
arrange a man watch at the man way of the vessel for your safety.
6.1.4 Primarily carry out external inspection for external leaks, external damage,
insulation or paint damage and external corrosion.
6.1.5 Gas tests the vessel internally before entry to the vessel for internal inspection.
Check the vessel has adequate venting and free from any foul smell/toxic gas
release while scales or deposit are disturbed. Check for adequate lighting and
scaffold as required for inspection. Also, at the time of vessel entry ensure a
man stand by is available, for your safety and company loss prevention.
6.1.6 Start preliminary internal inspection at all man ways (man way inspection)
going from bottom (If a column or tower) to the top or vice versa. Record the
observations at each level on a note pad. Start entering the vessel from the top
man way and assess the conditions of nozzles, vessel head, vessel wall, vessel
internal hardware’s (Trays, bubble caps seal pan, support rings, demister pad,
Glitch, etc.). Identify each item and note the observations for your evaluation.
Request demister pad, packing removal and cleaning including packing beds if
required for detailed inspection. Focus on flash zones, inlet areas, vapor
phases, welds, etc.

6.1.7 While performing detailed inspection look for pitting corrosion,

erosion/corrosion, channeling, weld erosion/corrosion and cracks, mechanical
damages while opening and fixing, environmental cracking, bulging and
blistering and the like are some to look for with in the vessel. A good cleaning
and careful evaluation will help make a good decision. If Fitness for Service
(FFS) assessment is required, a full evaluation will have to be done from
design, operation, and history of operation to assess the possibility of
extending the service life of the vessel.
6.1.8 After completion of the full inspection, request any additional cleaning or
removal of internals for detailed inspection or repairs if any, repair procedure
shall be issued by API certified or experienced senior inspector in consultation
with PV engineer. Reference the applicable standards and codes in your
recommendation.
6.1.9 Follow up the recommendations and the related repairs per Saudi Aramco
standards, the codes, ASME, and API.
6.1.10 Carry out the final inspection on completion of the repairs and cleaning as
applicable. Assess the vessel condition for operation until the next T&I date.
If FFS assessment is done and the vessel can go through minimally the EIS
period, then request for change of EIS schedule. Request a new vessel on
hand for replacement.
6.1.11 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325, SAES-D-008,

SAES-W-010, SAES-W-015, ASME SEC VIII D1 and API STD 510.
Any repair to the main vessel will be hydrostatically tested per SAES-A-004
and SAES-D-008. Test procedure shall be provided by operation engineer of
the unit or waivers shall be per SAEP-20 in advance. The test or waiver
documents shall be filed for reference.
6.2 Reactor Vessels
6.2.1 Check the reactor vessel drawing, construction code, material of construction,
internal lining, attachment parts, PWHT and dimensions (diameter, height, and
thickness).
6.2.2 Refer to the vessel file and read the history, if any cracking (welds, vessel wall
or lining), corrosion, disbonding of clad, ring joint gasket and grooves, repairs,
or replacement if any.
6.2.3 On dumping the catalyst carry out joint inspection (confirm ventilation, blinds,
scaffolds and lighting are provided) to ensure the vessel is safe for entry and
then obtain vessel entry permit. Arrange a man watch at the man way of the
vessel at the time of entry to the vessel for your safety. Do not enter the vessel
if the temperature is above 90ºF approximately.

6.2.4 Primarily carry out external inspection of the vessel for signs of external leaks,
external damage, insulation damage, external corrosion, and cracks in external
attachment welds which can be detected by MT and sized by UT, (common
occurrence).
Check the vessel has adequate venting and free from any foul smell/toxic gas
6.2.6 Start preliminary inspection at manway (manway inspection) going from top
to the bottom dished head internally. Record the observations on a note pad at
each level. Start entering the vessel from the top manway and assess the
conditions of nozzles, vessel head, vessel wall, vessel internal lining and
hardware’s (Trays, Valve caps, support rings, Liners, etc.). Identify each item
and note the observations for your evaluation. Request catalyst screen to be
removed if required for detailed inspection. Focus on inlet/outlet areas, vapor
phases, welds, clad, attachments and WFMPT test all welds or minimum 10%
of the welds externally, PT test clad welds internal, and all ring joint flanges
for crack initiation.
6.2.7 While making a detailed inspection, look for pitting corrosion,

blistering and the like are some that will be noted with in the vessel. A good
cleaning for careful evaluation of the defect will help to make a good decision.
If Fitness for Service (FFS) assessment is required, a full evaluation will have
to be done from design, operation, and history of operation to assess the
possibility of extending the service life of the vessel. This can be done sizing
the defects by UT and assessing the results.
All the ring joints must be PT checked for cracks including the ring gasket.
Cracks on them are very common due to the corners of the ring groove which
are considers high stress raising points.
recommendation.

applicable. Assess the reactor vessel condition for operation until the next
T&I date. If FFS assessment is done and the vessel can go through minimally
the EIS period, then request for change of EIS schedule. Request a new vessel
on hand for replacement. This is not applicable to rector vessels, unless the
reactor vessel experienced extreme temperature runaway causing severe
metallurgical damage.
6.2.11 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325, SAES-W-010,

SAES-W-015, SAES-D-008, SAES-A-004, ASME SEC VIII D1, and
API STD 510. Any repair to the main vessel will be hydrostatically tested.
Test procedure shall be provided by operation engineer of the unit or waivers
shall be submitted per SAEP-20 in advance. The test or waiver documents
shall be filed for reference.
6.3 Platformer Reactor Vessel
6.3.1 Check the reactor vessel drawing, construction code, internal parts, material of
construction, PWHT, and dimensions (diameter, height, and thickness).
6.3.2 Refer to the vessel file, read file and note history of corrosion, replacement of
internal parts, and repairs or replacement if any.
6.3.3 On dumping the catalyst carry out joint inspection (confirm ventilation, blinds,
scaffolds and lighting are provided) to ensure the vessel is safe for entry and
then obtain vessel entry permit. Arrange a man watch at the man way of the
vessel at the time of entry to the vessel for your safety. Do not enter the vessel
if the temperature is above 90°F approximately.
insulation damage, external corrosion and cracks in external attachment welds
which can be detected by MT and sized by UT, (common occurrence).
Check the vessel has adequate venting and free from any foul smell/toxic
gases are released while scales or deposit are disturbed. Check for adequate
lighting and scaffold as required for inspection. Also, at the time of vessel
entry ensure a man stand by is available, for your safety and company loss
prevention.
6.3.6 Start preliminary inspection at manway (manway inspection) at the top dished
head internally; ensure proper ladder is fixed to go down the vessel. Record the
observations on a note pad at each level. Start entering the vessel from the top
man way and assess the conditions of nozzles, vessel head, vessel wall, vessel
internal such as the deflectors, scallops, scallops keeper bar gap, scallop
position, seats & seat tack welds, heat damage and perforation to scallops and

center pipe, dents, seat rings and other hardware’s. Identify each item and note
the observations for your evaluation. Request scallops and center pipe removal
for detailed inspection if required. Focus on inlet/outlet areas, vapor phases,
welds, clad, attachments and WFMPT test all welds or minimum 10% of the
welds internally and externally for crack initiation.
6.3.7 While performing detailed inspection, look for pitting corrosion,

erosion/corrosion, channeling, weld erosion/corrosion & cracks, mechanical
blistering and the like are some that will be noted with in the vessel. A good
cleaning and careful evaluation will help make a good decision.
If Fitness for Service (FFS) assessment is required, a full evaluation will have
possibility of extending the service life of the vessel. This can be done sizing
If deep channeling or pits are noted, do not attempt weld build up but patch the
location.
recommendation.
applicable. Assess the reactor vessel condition for operation until the next EIS
period. If FFS assessment is done and the vessel can go through minimally the
T&I date, then request for change of EIS schedule. Request a new vessel on
hand for replacement. This is not applicable to rector vessels, unless the
reactor vessel experienced extreme temperature runaway causing severe
metallurgical damage.
6.3.11 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325, SAES-W-010,

SAES-W-015, SAES-A-004, SAES-D-008, ASME SEC VIII D1, and
API STD 510. Any repair to the main vessel will be hydrostatically tested.
6.4 Heat Exchangers

6.4.1 Check the Exchanger drawing, construction codes, material of shell, tubes,
tube sheet, baffles, heads, and dimensions (diameter, length and thickness).
6.4.2 Read the Exchanger file and note history of corrosion, tube failures, re-tubing
frequency, other repairs, replacement, and outstanding recommendations if any.
6.4.3 Carry out joint inspection (check includes ventilation, blinds, scaffolds and
lighting) to ensure the exchanger shell is safe for entry. Obtain exchanger
work permit (including shell entry). At the time of shell entry keep a man
watch outside the shell for your safety.
insulation or paint damage, external corrosion to the shell.
6.4.5 Gas tests the exchanger internally before entry to the exchanger for internal
inspection. Check the exchanger has adequate venting and free from any foul
smell/toxic gas release while scales or deposit are disturbed. Check for
adequate lighting and scaffold as required for inspection. Also, at the time of
vessel entry ensure a man stand by is available, for your safety and company
loss prevention.
6.4.6 Start preliminary inspection after removal of the channel head cover and
floating head cover. Note the fouling condition. Do the same when the tube
bundle is pulled out. Inspect the extent of fouling. Collect samples of fouling
both from the shell and tube side for laboratory analysis. Request adequate
cleaning of the shell, heads, covers and the tube bundle for full inspection.
6.4.7 Inspect the exchanger if adequately cleaned for inspection. If cleaning is not
adequate to perform inspection, request for further cleaning. After adequate
cleaning for inspection inspect as follows:
6.4.7.1 Check gasket faces of all parts (shell, heads, covers and tube sheets).
6.4.7.2 Inspect the channel, floating heads and covers for coating and anode
failure if any, corrosion/erosion, any mechanical damage. Check the
thickness to ensure no signs of uniform corrosion.
6.4.7.3 Inspect the shell for corrosion/erosion of shell and seam welds, any
mechanical damage. Check the thickness to ensure no signs of
uniform corrosion.
6.4.7.4 Check all nozzle condition to ensure they are free of

corrosion/erosion and check the thickness is with in the allowable
condition.
6.4.8 Tube bundle has to be thoroughly inspected as follows:

6.4.8.1 Inspect the tube sheets for corrosion/erosion, tube end thinning
(assess severity of Grooving at tube to tube sheet contact. PT tests if
tube to tube sheet seal welded, for cracks or deep pits).
6.4.8.2 Go along the tube external surface, note for corrosion thinning of
tubes and impingement plates, pitting corrosion, dents and the like.
Take OD and ID measurement and compare to the original for
discrepancy. Check for enlarged baffle holes and grooving to tubes.
Take thickness measure of the baffles to evaluate corrosion thinning.
See if scales remains between tube rows and if severe request re-cleaning.
6.4.8.3 Inspect tube ID for un-removed scales. Check for pits with in the
tubes and measure the depth and compare it to the original thickness.
Measure tube end thickness and compare to the original thickness.
Use a boroscope, eddy current or MFL as applicable to ensure the
condition for further service.
6.4.9 While performing detailed inspection of the shell, look for pitting corrosion,
erosion/corrosion, channeling, weld erosion/corrosion & cracks, mechanical
blistering and the like are some damages that will be noted with in the shell
wall. A good cleaning and careful evaluation will help make a good decision.
6.4.10 If Fitness for Service (FFS) assessment is required, a full evaluation will have
possibility of extending the service life of the shell. This can be done sizing
6.4.11 After completion of the full inspection, request any other needs for cleaning,
repair or re-tubing, renewal of anodes if any as required.
standards SAEP-317, the codes, TEMA, ASME, and API STD 660.
6.4.13 Carry out the final inspection on completion of the repairs if any and cleaning
as applicable. Assess the exchanger condition for operation until the next EIS
period. If FFS assessment is done and the exchanger can go through
minimally the T&I date, then request for change of EIS schedule. Request a
new exchanger on hand for replacement or tube bundle as applicable.
6.4.14 On completion of inspection and repairs if any, hydrostatically test the

exchanger both from the shell and tube side at its test pressure (Design
pressure x 1.5 for exchangers built before 1999 and design x 1.3 after 1999).
Note: The reactor effluent and some exchangers with bellow design will
require to be tested at differential test pressure only.

6.4.15 Applicable standards and codes: SAEP-20, SAEP-317, SAES-W-010,

ASME SEC VIII D1, API STD 660, TEMA and API STD 510. Any repair to
the main exchanger or otherwise, will be hydrostatically tested. Test procedure
shall be provided by operation engineer of the unit or waivers shall be submitted
per SAEP-20 in advance. The test or waiver documents shall be filed for
reference.
6.5 Reactor Effluent Heat Exchangers
6.5.1 Check the Exchanger drawing, construction codes, material of shell, tubes,
tube sheet, baffles, heads, lining material, and dimensions (diameter, length,
and thickness).
6.5.2 Read the Exchanger file and note history of corrosion, tube failures, re-tubing
frequency, lining failures, and other repairs or replacement if any.
6.5.3 Carry out joint inspection (check includes ventilation, blinds, scaffolds and
lighting) to ensure the exchanger shell is safe for entry. Obtain exchanger
work permit (including shell entry). At the time of shell entry keep a man
watch outside the shell for your safety.
insulation or paint damage, external corrosion to the shell nozzles and the heads.
6.5.5 Gas tests the exchanger internally before entry to the exchanger for internal
inspection. Check the exchanger has adequate venting and free from any foul
smell/toxic gas release while scales or deposit are disturbed. Check for
adequate lighting and scaffold as required for inspection. Also, at the time of
vessel entry ensure a man stand by is available, for your safety and company
loss prevention.
6.5.6 Start preliminary inspection after removal of the channel head cover and
floating head cover. Note the fouling condition. Do the same when the tube
bundle is pulled out. Inspect extend of fouling and collect fouling samples
both from the shell and tube side for laboratory analysis. Request adequate
cleaning of the shell, heads, covers and the tube bundle for full inspection.
6.5.7 Inspect the exchanger if adequately cleaned for inspection. If cleaning is not
adequate to perform inspection, request for further cleaning. After adequate
cleaning for inspection:
6.5.7.1 Check gasket faces of all parts (shell, nozzles, heads, covers, and
tube sheets).

6.5.7.2 Inspect the channel heads and covers for corrosion/erosion, any
mechanical damage. Check the thickness to ensure no signs of
uniform or localized corrosion exists.
6.5.7.3 Inspect the shell for corrosion/erosion at seam welds, shell plate and
any mechanical damage. Check the thickness to ensure no signs of
uniform or localized corrosion exists. Carry out PT test at random
locations for cracks on shell clad or lining (if any), and all ring
joints.
6.5.7.4 Check all nozzle condition to ensure they are free of

corrosion/erosion and check the thickness is within the allowable
condition and gasket faces free from damages.
6.5.8 Tube bundle has to be thoroughly inspected as follows:
6.5.8.1 Inspect the tube sheets for corrosion/erosion, tube end thinning
(assess severity of grooving at tube to tube sheet contact. PT tests if
tube to tube sheet, seal welded for cracks or deep pits).
6.5.8.2 Go along the tube external surface, note for corrosion thinning of
tubes & impingement plates, baffle plates & tie rods, pitting
corrosion, dents and the like. Take OD and ID measurement and
compare to the original for discrepancy. Check for enlarged baffle
holes and grooving to tubes. Take thickness measure of the baffles
to evaluate corrosion thinning. See if scales remains between tube
rows and if severe request re-cleaning.
6.5.8.3 Inspect the tube ID for un-removed scales. Check for pits with in the
tubes and measure the depth and compare it to the original thickness.
Measure tube end thickness and compare to the original thickness.
Use boroscope, eddy current or MFL as applicable to ensure the
condition of the tubes for further service.
6.5.9 While performing detailed inspection of the shell, look for pitting corrosion,
blistering, and the like are some damages that will be noted with in the shell
wall. A good cleaning and careful evaluation will help make a good decision.
6.5.10 If Fitness for Service (FFS) assessment is required, a full evaluation will have
possibility of extending the service life of the shell. This can be done sizing

repair or re-tubing, renewal of tubes or tube bundle.
standards, the codes, TEMA, ASME, and API STD 660.
6.5.13 Carry out the final inspection on completion of the repairs if any and cleaning
as applicable. Assess the exchanger condition for operation until the next EIS
period. If FFS assessment is done and the exchanger can go through the T&I
date, then request for change of EIS schedule. Request a new exchanger on
hand for replacement or tube bundle as applicable.
6.5.14 On completion of inspection and repairs if any, the exchanger will be tested
both from the shell and tube side at its test pressure (Design differential
pressure x 1.5 for equipment built before 1999 and 1.3 x for equipment after
1999).
Note: The reactor effluent and some exchangers with bellow design will
require to be tested at differential test pressure only.
6.5.15 Applicable standards and codes: SAEP-20, SAEP-317, SAES-W-010,

ASME SEC VIII D1, API STD 660, TEMA, and API STD 510. Any repair to
the main exchanger or otherwise, will be hydrostatically tested. Test procedure
shall be provided by operation engineer of the unit or waivers shall be submitted
per SAEP-20 in advance. The test or waiver documents shall be filed for
reference.
6.6 Fin Fan Cooler
Refer to 32-SAIP-11 for inspection of Fin fan coolers.
6.7 Process Heaters
6.7.1 Check the heater drawing, construction code, material of radiant & convection
tubes, tube support & tube guide, refractory, Skin Thermocouple and or
Thermowell, Damper and Baffle plates and dimensions of individual items
(diameter, length/height and thickness) as applicable to the heater type
(Cylindrical or horizontal). Check the burner assembly and orientation of
burner tip and material.
6.7.2 Read the heater file and note history of corrosion, tube failures, history of
overheating, failures, and re-tubing frequency, if any and other replacement or
repairs.
6.7.3 Carry out joint inspection (verify if, blinds and ventilation, lighting,
scaffolding provided) and obtain entry permit to ensure the heater is safe to
enter and inspect. At the time of inspection keep a man watch for your safety.

6.7.4 Primarily carry out external inspection for external flue gas leaks, external
damage to heater casing, and structure’s, Burner blocks and fuel leaks. It is
suggested an infrared survey is done prior to shutdown of the heater to identify
hotspots and hot tubes and any refractory damage to heater casing.
6.7.5 Gas tests the heater internally before entry to the heater for internal inspection.
Check the heater has adequate venting and free from any foul smell/toxic gas
6.7.6 Start preliminary visual inspection of the heater internally, pay attention to the
heater floor, burner assembly, burners and snuffing steam connections, the
refractory walls, bottom, mid and top tube guides and the seat as applicable
and accessible.
Inspect tubes, elbows/U-bends, and skin thermocouples for significant

overheating, bulging, bowing /distortion, and scaling of tubes and recommend
cleaning for detailed inspection.
6.7.7 Evaluate if the heater tubes are adequately cleaned for inspection. If cleaning
is not adequate to carry out inspection, request for further cleaning.
Inspection after adequate cleaning:
6.7.7.1 Check tube surfaces externally for any significant corrosion,

mechanical damage, bulge, tube distortion or bowing.
6.7.7.2 Request for UT check on full length of tubes including elbows at top
and bottom, random hardness at the most overheated area/flame
impinged area. RT the inlet and outlet tubes including U bends (for
metal loss, coking, cracking, etc.). Also, concentrate on the shock
and hip tubes if any. Compare and evaluate results well in advance
to predict problem areas.
6.7.7.3 Get Thermo-wells removed and skin thermocouple cleaned for visual
and DP test and evaluates results. Request Thermowell continuity
test for acceptance.
6.7.7.4 Check snuffing steam nozzles/connection for plugging and corrosion.
6.7.7.5 Check the floor bricks or refractory and wall refractory for any
significant damage and request repairs as applicable.
6.7.7.6 Inspect the bottom U-bend and attachment tube guide for corrosion
damage externally.

6.7.7.7 Inspect closely the interim tube guides, top tube guides and tube
supports for damaged bolts, erosion/corrosion and damage to tube
contact.
repair or re-tubing if any. Hydrostatic test will be required if major repairs
are executed for acceptance.
applicable. Assess the heater condition for operation during the next EIS
period. If heater inspection reveals the heater do not comply with the
inspection finding for further service, then FFS assessment has to be done and
the heater can go through minimally the EIS period, then request for change of
EIS schedule. Request a partial or full re-tubing of the heater next time with
spare tubes on hand for replacement.
6.7.11 On completion of inspection and repairs if any, the heater will be tested from
the tube side at its test pressure (Design pressure x 1.5 for heater built before
1999 and 1.3 x design for those built after 1999) only if repairs are performed.
Refer to the name plate for the test pressure in addition to the SIS for the test
pressure. Tube leaks at hydrostatic test should be renewed partially or in full
as deemed and retested.
6.7.12 Applicable standards and codes: SAEP-20, SAES-W-010, SAES-A-004,

ASME SEC VIII D1, API STD 530, and API STD 510. Any repair to the heater
will be hydrostatically tested per SAES-A-004 and ASME SEC VIII D1.
6.8 Reformer Heater
6.8.1 Check the heater drawing, material of radiant and convection tubes, tube
support/tube guide, refractory, Thermowell, Damper plates, and dimensions of
individual items (diameter, length and thickness) as applicable to the heater
(horizontal). Check the burner assembly and orientation of burner tip and
material.
6.8.2 Read the heater file and note history of corrosion, tube failures, history of
overheating, failures and re-tubing frequency, if any and other replacement or
repairs.

6.8.4 Primarily carry out external inspection for external flue gas leaks, external
damage to heater casing, and structure’s, Burner blocks and fuel leaks. It is
suggested an infrared survey is done prior to shutdown of the heater to identify
hotspots and hot tubes and any refractory damage to heater casing.
6.8.5 Gas tests the heater internally before entry to the heater for internal inspection.
Check the heater has adequate venting and free from any foul smell/toxic gas
6.8.6 Start preliminary visual inspection of the heater internally, pay attention to the
heater floor, burner assembly, burners, snuffing steam connections, and the
refractory walls.
6.8.6.1 Number the tubes per cell starting from north to south or west to east
vice versa.
6.8.6.2 Inspect individual tube, for overheating, bulging, bowing, surface

discontinuities, such as micro fissuring, cracks and the like.
Attention to be paid in locations opposite to the burner or flame area.
6.8.6.3 Carry out creep measurement on all tubes; compare the results with
the previous creep measurement results. Evaluate the creep
behavior. Recommend all tubes with creep above 3.5% for renewal.
Arrange Magnetize, LOTIS, or H-scan to carry out creep
measurement and evaluate the results aided by computer, which will
give the tube renewal criteria based on creep and crack initiation in
the tube. Crack indication above 30% should be considered for
renewal if not sooner.
6.8.7 Evaluate if the heater tubes are adequately cleaned for inspection. If cleaning
is not adequate to carry out inspection, request for adequate cleaning.
Inspection after adequate cleaning:
6.8.7.1 Check tube surfaces externally for any significant corrosion,

mechanical damage, bulge, tube distortion or bowing and fissuring.
6.8.7.2 Get Thermo-wells removed and cleaned for visual and DP test and
evaluate results. Request Thermowell continuity test for acceptance.

6.8.7.3 Check snuffing steam nozzles/connection for plugging and corrosion.
6.8.7.4 Check the floor bricks, refractory and wall refractory for bulge or any
significant damage. Request repairs if required as applicable.
6.8.7.5 Inspect the bottom transfer/pigtail pipe overheating and for crack
damage externally. Carry out PT test on all weld joints for cracks.
6.8.7.6 Inspect the inlet pigtail pipe for crack damage at the weld joints at
inlet header and catalyst tube. Open the blind nozzle flanges on the
inlet header, check for fouling. If required get it cleaned free of the
foulant.
6.8.7.7 Inspect the steam generator, economizer and super heater coils
visually and by UT gauging.
6.8.7.8 Check the dampers and their operability.
6.8.7.9 Inspect the stack where accessible for cleanliness and refractory
damage.
repair or re-tubing if any as required.
applicable. Assess the heater condition for operation during the next EIS
the heater can go through minimally the EIS period; then, request for change
of EIS schedule. Request a partial or full re-tubing of the heater next time
with spare tubes on hand for replacement.
6.8.11 On completion of inspection and repairs if any, the heater will be tested from
the tube side at its test pressure (Design pressure x 1.5 for heaters built before
1999 and 1.3 x after 1999). Refer to the name plate for the test pressure in
addition to the SIS for the test pressure. Tube leaks at hydrostatic test should
be renewed as deemed and retested. Hydrostatic test in the case of this
heater shall not be practical due to the catalyst and the refractory.
Therefore, the heater shall be tested pneumatically with prior approval or
leak tested with a waiver in lieu of hydrostatic test.
6.8.12 Applicable standards and codes: SAEP-20, SAES-W-010, ASME SEC VIII D1,
API STD 530 and API STD 510. Any repair to the heater will be

hydrostatically tested per SAES-A-004 and ASME SEC VIII D1 if not a

waiver shall be processed and leak test shall be performed at the available
plant nitrogen pressure. Test procedure shall be provided by operation
engineer of the unit or waivers shall be submitted per SAEP-20 in advance.
The test or waiver documents shall be filed for reference.
6.9 Industrial Boilers
6.9.1 Check the boiler drawing, material, size of tubes, fire bricks and refractory,
Steam drum internals, Baffle plates and dimensions of individual items
(diameter, length and thickness) as applicable to the boiler. Check the burner
assembly, orientation of burner tip and material.
6.9.2 Read the boiler file and note history of corrosion, tube failures, history of
overheating, boiler failures and re-tubing frequency, and other forms of repairs
or replacement if any.
6.9.4 Carry out preliminary external inspection for external flue gas leaks, external
damage to boiler casing and structure’s, Burner assembly and fuel leaks.
6.9.5 Gas tests the boiler internally before entry to the boiler for internal inspection.
Check the boiler has adequate venting and free from any foul smell/toxic gas
6.9.6 Start preliminary visual inspection of the boiler internally, (furnace or fire box,
bank and super heater section, flues gas duct, steam and mud drums, economizer
if available) pay attention to the boiler floor, bank tubes, burner assembly,
burners, the refractory to the walls and roof, flue gas duct, and stack.
6.9.7 Inspect tubes, bends, significant overheating of target wall tubes, bulging,
bowing /distortion and scaling of tubes. Recommend tube external and
internal cleaning for detail inspection.
6.9.8 Evaluate if the boiler tubes are adequately cleaned for inspection. If cleaning
is not adequate to carry out inspection, request for further cleaning. Inspection
after adequate cleaning:
6.9.8.1 Check tube surfaces externally for any significant corrosion or

mechanical damage, bulge, tube distortion or bowing. Concentrate
on the target wall and roof tubes for possible flame impingement and

tube surface bulge.
6.9.8.2 Request UT for full length of tubes including bends, Hardness at

random locations most affected by flame. Compare and Evaluate
results well in advance to predict problem areas.
6.9.8.3 Inspect the steam drum and internals for cracks, corrosion and other
damages. Inspect all tubes internally using boroscope to assess the
tube ID condition. Evaluate if chemical cleaning is to be performed.
Also, mark a meter length tube for scale measurement if tube ID’s
are heavily scaled or every other T&I.
6.9.8.4 Inspect the mud drum for corrosion accumulated deposit. Tube ends
and tube end thinning and the like.
6.9.8.5 Inspect the flue gas duct, stack for accumulated ash, clean and
inspect for cracks, and damage to the refractory that may eventually
result in flue gas leaks while in operation.
repair or re-tubing if any as required.
applicable. Assess the boiler condition for operation during the next EIS
the heater can go through minimally the EIS period, then request for change of
EIS schedule. Request a partial or full re-tubing of the heater next time with
spare tubes on hand for replacement.
6.9.12 On completion of inspection and repairs if any, the boiler shall be pressure
tested at its test pressure (Design pressure x 1.5). Refer to the name plate for
the test pressure in addition to the SIS for the test pressure. Tube leaks at
hydrostatic test should be renewed partially or in full as deemed and retested.
6.9.13 Applicable standards and codes: SAEP-20, SAES-W-010, ASME SEC VIII D1,
API STD 530 and API STD 510. Any repair to the heater will be
hydrostatically tested per SAES-A-004 and ASME SEC VIII D1.

6.9.14 After the commissioning the boiler, the safety valves should be floated prior to
full operation. An in-place test procedure should be followed strictly in
performing the test.
6.10 Tanks
6.10.1 Check the tank drawing, construction codes, and material of construction,
internal parts, and dimensions (diameter, height and thickness).
6.10.2 Read the tank file and note history of corrosion, repairs and replacement if
any.
6.10.3 Carry out joint inspection (check includes ventilation, blinds, scaffolds, and
lighting) and obtain entry permit to ensure the Tank is safe to enter and
inspect. At the time of inspection keep a man watch for your safety.
insulation or paint damage, and external corrosion.
6.10.5 Ensure the tank is isolated with proper blinds. Obtain entry permit from
operation. Prior to internal inspection entry gas test to make sure no toxic
gases are released. While entry to the tank, have a man stand by at the
manway for your safety and company loss prevention.
6.10.6 Start preliminary inspection at all manways (manway inspection) going from
bottom (all around) to the top. Record the observations on a note pad at each
level. Start entering the tank from the bottom man way and assess the
conditions of nozzles, tank bottom plates, tank shell plates, tank internal
hardware’s (Columns, float, supports/legs, sumps, etc.). Identify each item
and note the observations for your inspection evaluation.
6.10.7 While performing detail inspection look for pitting corrosion,

damages while opening and closing, environmental cracking, bulging and
blistering and the like are some that will be noted with in the tanks. Coating
conditions, if coated. A good cleaning and careful evaluation will help make a
good decision. Sometime Fitness for Service inspection (FFS) assessment will
be required and full evaluation will have to be done from design, operation,
and history of operation to increase the service life of the tank.
6.10.8 After completion of the full inspection, request any other needs for cleaning or
removal and cleaning of internals for detail inspection and repairs or renewal
if any.

Carry out the final inspection on completion of the repairs and cleaning as
applicable. Assess the tank condition for operation during the next EIS period.
If FFS assessment is done and the tank can go through minimally the EIS
period, then request for change of EIS schedule. Request replacement of the
tank plates.
6.10.10 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-326, SAES-D-008,

SAES-W-010, SAES-W-015, ASME SEC VIII D1, API STD 510, and
API STD 653. Any repair to the tank will be hydrostatically tested per
SAES-A-004. Test procedure shall be provided by operation engineer of the
unit or waivers shall be submitted per SAEP-20 in advance. The test or waiver
documents shall be filed for reference.

Attachment 1 - Flowchart-Process Equipment External and Internal Inspection

per Typical Inspection Plan (TIP)

Attachment 2(A) - Typical Inspection Plan (TIP) for Static Process Equipment - Vessels
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT - VESSELS

Inspection Phase Reference
1 Reference and Records: Review the following: Project Data Books.

 Operation Procedure
 SIS sheet information Equipment file
 EIS periods, revision and deviations
 Equipment as built drawing
 Design data
1. Material
2. Dimensions and Thickness
3. Pressure/Temperature
4. PWHT
 OSI drawings and TML points
2 Equipment File Information: Review the following: Equipment file

 Historical T&I’s information
 OSI information SAIF
 Corrosion information
 Repairs and frequency
 Recommendation
3 Work permit (WP) and personnel safety: GI-0002.1 & self

 Ensure your WP is valid.
 Make sure what process products in the equipment
 Have a joint inspection before accepting the permit
 Have your own assessment before entry
4 External inspection: Inspect the following: 00-SAIP-75

 Insulation and painting
 Foundation, skirts, fire proof and support bolts and nuts
 Nozzles including the manway
 Flange Leaks
 Any other leaks from the equipment
 Enter findings in Operation/Inspection Log Book
5 Internal inspection: Inspect the following: SAEP-20, SAEP-325, SAES-D-008,

 Fouling and cleanliness SAES-A-004, API STD 510, API STD 572.
 Top Head and Nozzles including manway Checklist-DI, DII, DIII
 Demister Pad
 Trays, scallops, catalyst, packing, support and support rings
 Shell wall , clad, epoxy, in/out nozzles and manway
 Bottom head and nozzles
 Corrosion, Erosion, mechanical damage, etc., on internal
6 Worksheets and Tracking:
 Issue worksheets on major findings
 Follow up worksheet implementation and closure.
7 Final Inspection:
 Carry out final inspection on completion of maintenance
activities and issue box up report.

Attachment 2(B) - Typical Inspection Plan (TIP) for Static Process Equipment - Heat Exchangers
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT - HEAT EXCHANGERS
1 Reference and Records: Review the following:
 Operation Procedure Project Data Books.
 SIS sheet information
 EIS periods, revision and deviations Equipment file
 Design data
1. Material
4. PWHT
2 Equipment File Information: Review the following:
 Historical T&I’s information Equipment file
 OSI information
 Corrosion information SAIF
 Recommendation
3 Work permit (WP) and personnel safety:
 Ensure your WP is valid. GI-0002.1 & self
4 External inspection: Inspect the following:
 Insulation and painting 00-SAIP-75
 Flange or any other leaks from the equipment
5 Internal Inspection: Inspect the following:
 Fouling and cleanliness of heads, shell and tube bundle. SAES-A-004, SAEP-325, SAES-D-008, SAEP-317,
 Anodes and Epoxy if any. API STD 510, API STD 660, API RP 572, Checklist-
 Stationary Head welds, Pass Partician plates for weld damages DIV, DV, DX.
and corrosion
 Shell head and Floating Head welds for damages and corrosion
 Nozzles, flange gasket faces
 Shell, shell welds, nozzles and faces
 Tube bundle
 Tube sheets for damages and corrosion
 Tubes inside and outside for corrosion thinning
 Dimensional check of tubes, baffles
 Tie rods and fasteners
 Shell and Tube side hydro test
7 Final Inspection:
activities and issue box up report

Attachment 2(C) - Typical Inspection Plan (TIP) for Static Process Equipment - Air Fin Coolers
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT - AIR FIN COOLERS
1 Reference and Records: Review the following Project Data Books.

 Design data
1. Material
4. PWHT

 Recommendation


 Enter findings in the log book
5 Internal Inspection: Inspect the following: SAES-A-004, SAES-D-008, SAEP-317,

 Headers: Inspect header plugs, headers and plug sheets and API STD 510, API STD 661, API RP
gaskets 572,Checklist-DVI
 Tubes ID and OD for corrosion and damages
 Nozzles, vents and drains
 Tube fins, Shroud and hood, structure, fan assembly, ladders
and platform
 Hydro test
7 Final Inspection:
 Carry out final inspection on completion of
maintenance activities and issue box up report

Attachment 2(D) - Typical Inspection Plan (TIP) for Static Process Equipment - Heaters
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT -HEATERS

1 Reference and Records: Project Data Books.

Review the following:
 Operation Procedure Equipment file
 Design data
1. Material
4. PWHT
2 Equipment File Information: Equipment file

Review the following:
 Historical T&I’s information SAIF
 OSI information
 Recommendation
3 Work permit (WP) and personnel safety:

 Ensure your WP is valid. GI-0002.1 & self

5 Internal inspection: Inspect the following: SAES-A-004, SAES-D-008, SAEP-325,

 Heater casing and painting API STD 510, API STD 530, API STD 560,
 Burners and burner tips API RP 573, Checklist-DVII
 Heater floor and fire bricks/refractory
 Wall and roof refractory
 Radiant tubes
 Tube guides-bottom, mid and top
 Convection tubes and tube guides
 Repairs and hydro test
7 Final Inspection:

Attachment 2(E) - Typical Inspection Plan (TIP) for Static Process Equipment - Boilers
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT - BOILERS

1 Reference and Records: Review the following: Project Data Books.

 Design data
1. Material
4. PWHT

 Recommendation


5 Internal inspection: Inspect the following: SAES-A-004, SAES-D-008, SAEP-325,

 External inspection of casing, foundations and stacks. API STD 510, API RP 573, Checklist-DIX
 Furnace, burners, floor bricks and refractory
 Furnace tubes, super heater tubes, bank tubes and economizer
tubes
 Inlet and outlet ducts
 Steam drum and internals
 Mud drum and internal
 UT, RT, MPI, boroscoping boiler tubes and drums
 Gauge glass, side glass, man ways
 Soot blower elements
 Stack and internal refractory
7 Final Inspection:

Attachment 2(F) - Typical Inspection Plan (TIP) for Static Process Equipment - Tanks
TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT -TANKS
Reference and Records: Review the following:
1  Operation Procedure Project Data Books.
 EIS periods, revision and deviations Equipment file
 Design data
1. Material
4. PWHT
Equipment File Information: Review the following:
2  Historical T&I’s information Equipment file
 OSI information
 Corrosion information SAIF
 Recommendation
Work permit (WP) and personnel safety:
3  Ensure your WP is valid. GI-0002.1 & self
External inspection: Inspect the following:
4  Insulation and painting 00-SAIP-75
Internal Inspection: Inspect the following:
5  Overview API STD 620, API STD 650, API STD 653, Checklist-
 Tank External XI, SAES-A-004
 Bottom Interior service
 Shell seams and Plates
 Roof Interior surface
 Fixed Roof Supports
 Fixed roof appurtenance
 Breathers and vents
 Emergency P/V Hatches
 Floating roof
 Floating roof pontoons
 Floating roof supports
 Primary shoe and toroidal assembly
 Rim mounted secondary’s
 Floating roof appurtenances
1. Roof manways,
2. Rim vents,
3. Vacuum breakers
4. Roof drains, open & closed,
5. Autogauge systems & alarms
 Common Tank Appurtenances
 Shell Nozzles
 Diffusers and rolling systems
 Swing lines
 Accesses structures
 Platform Frames
 Deck plates and gratings
 Rolling ladder

TYPICAL INSPECTION PLAN (TIP) FOR STATIC PROCESS EQUIPMENT -TANKS

7 Final Inspection:

Attachment 3(A) - Inspection Checklist for Process Equipment - Vessel
Report No.: Date prepared:

Equipment No. & Service Location/ Area: Plant No.:
Reason for Inspection: Date Inspected
P&E Inspector: Field insp. Supervisor: Unit Supervisor :
Equipment data:
Shell Material Design Pressure, Kg/ cm²g or psig:
Shell thickness (mm or in) Design Temp. °C or °F:
Cladding/ Lining Corrosion Allowance (mm or in)
A=Acceptable, U=Un-acceptable, NA=Not Applicable, NI=Not Inspected
# ITEM A U NA NI COMMENTS
1.0 Top Head and Nozzles
Internal Corrosion (scales, pits, buildup)/Cracking
1.1
Describe location, appearance and depth.
1.2 Excessive scale presence. Describe
1.3 Weld condition/corrosion, perform WFMPT for cracks.
1.4 Condition of manway gasket surface
1.5 UT measurement- Top head & Nozzles including Manway
Internal and external cracks, erosion/corrosion, foreign
1.6
deposit
1.7 Insulation condition
Condition of attachment welds (Includes Lift lugs, pipe
1.8
supports, etc.)
1.9 External and Internal coating/painting
2.0 Shell: Cylindrical and Conical

2.1
Describe location, appearance and depth
2.4 UT measurements-shell, cone section and heads
Inspect distributors (channel and pipe with holes) for
2.5
corrosion, erosion, fouling and blockage
Inspect the inlet outlet and draw off nozzles for corrosion,
2.6
erosion and thinning
2.7 Condition of Internal coating, External paint, Insulation
3.0 Demister Pad (DP)

3.1 Check if demister pad is not disturbed
Get DP removed and inspect vessel wall above and below
3.2
including the attachments
Inspect DP for fouling, damage and if compressed and
3.3
assess if can be reused for another cycle
Inspect DP fit up and attachment wires (size and material)
3.4
on completion of DP fit up
4.0 Packing, Packing Beds, Shell and Distribut.

4.1 Check the packing and beds for loss and disturbances.
Check the packing and support beds and attachments for
4.2
corrosion, mechanical damage and looseness
Inspect the shell wall under the packing bed for corrosion,
4.3
grooving and pitting
Based on the finding (item 3.7) recommend complete
4.4
removal of packing for shell wall inspection

Attachment 3(A) - Inspection Checklist for Process Equipment - Vessel (cont'd)

Equipment No. & Service Location/ Area: Plant No.:
Reason for Inspection: Date Inspected
Equipment data:
Shell Material Design Pressure, Kg/ cm²g or psig:
Shell thickness (mm or in) Design Temp. °C or °F:
Cladding/ Lining Corrosion Allowance (mm or in)
5.0 Trays
5.1 Check both top and bottom of trays for fouling
5.2 Check the tray floor for bulge/ level and corrosion
Check the valves on trays for corrosion, looseness and
5.3
mechanical damage
Check the tray support ring condition and welds for
5.4
corrosion/erosion
5.5 Carry out dimensional check on trays and fittings.
6.0 Clad/Lining
6.1 Check if the lining clad or strip lining
6.2 Check if the vessel section or fully lined
6.3 Check the lining for disbanding and inspect all welds
6.4 Check for cracks or damage if lined with cement
6.5 Perform PT on welds
7.0 Bottom Head

7.1
7.4 Condition of man way gasket surface
UT measurement- Top head and Nozzles including
7.5
Manway
7.6
deposit
Condition of attachment welds (Includes Lift lugs, pipe
7.8
supports, etc.)
Check the Vortex breaker for weld cracks, corrosion or
7.9
mechanical damage
7.10 Check internal and external coating/painting
8.0 Foundation/Supports
8.1 Condition of skirt and fire proofing
8.2 Condition of support bolts
8.3 Condition of foundation
Notes:

Attachment 3(B) - Inspection Checklist for Process Equipment - Reactor Vessel

Equipment No. & Service: Location/ Area: Plant No.:
Reason for Inspection: Date Inspected:
P&E Inspector: Field Insp. Supervisor: Unit Supervisor:
Equipment data:
Material Design Press. Kg/ cm²: PSIG:
Size/ Thick. Mm/in Design Temp. °C: OF:
Cladding / Lining Corrosion Allowance mm: In:

1.0 Inlet Elbow
1.1 Check inlet elbow for scaling, Mechanical damage
Check both flanges, gasket faces and gasket for
1.2
damage
1.3 DP test the ring gasket and the flange groove for cracks
2.0 Manway Nozzles and Top Head

Internal Erosion/Corrosion (scales, pits,
2.1 buildup)/Cracking
2.4 Condition of manway gasket and groove
2.5 UT measurement- Top head and Manway
Inspect the internal clad for bulge, cracks, disbanding,
2.6
etc.
Check the condition of attachment and reinforcement
2.7 pad welds (Includes Lift lugs, pipe supports, etc.) for
cracks
2.8 Check the condition of insulation
2.9 Check the inlet distributor for damages
3.0 Shell and Internals:

Check the shell and top head clad for cracks, bulge
3.1
channeling, disbanding, etc.
3.2 DP check the clad welds for cracks
Check distributor tray and support ring for any
3.3
abnormality
4.0 Bottom Head

Check the outlet grid and screen and grid support beam,
4.1
attachment welds for any abnormalities
Inspect the bottom head, outlet nozzle and catalyst
4.2
dumping nozzle
4.3 PT check all welds including the clad
5.0 External
MPI and UT shear wave test all nozzle and attachment
5.1
welds for cracking
Test all vertical and circumferential seam welds by MPI
5.2
and UT shear wave Technique

Attachment 3(B) - Inspection Checklist for Process Equipment - Reactor Vessel (cont'd)


Equipment data:
Size/ Thick. Mm/in Design Temp. °C: OF:
Cladding / Lining Corrosion Allowance mm: In:

Remove all Thermowells and DP test Flanges, barrel for
5.3
cracks and continuity test
Check all bolts used for closure are in good condition
5.4
(Sample one bolt for tensile test)
5.5 Check all gaskets are renewed in kind
5.6 Check the external insulation condition finally
6.1 Check condition of skirt and fire proofing
6.2 Check condition of foundation and support bolts
Notes:

Attachment 3(C) - Inspection Checklist for Process Equipment - Platformer Reactor Vessel

Equipment data:
Size/ Thick. Mm/in Design Temp. °C: °F
Cladding / Lining Corrosion Allowance mm: in
1.0 Inlet Elbow
Check inlet elbow for excessive scaling, Mechanical
1.1
damage
1.2 Check both flanges and gasket faces
2.0 Top Head and Manway Nozzles

Internal Erosion/Corrosion (scales, pits,
2.1 buildup)/Cracking
2.3 Weld condition/corrosion
2.4 Condition of man way gasket face
2.5 UT measurement- Top head and Manway
Inspect the internal deflection plates, Scallop keeper
2.6 bars (for bending), breaking, missing or loose bolts and
weld defects
Check the condition of attachment and welds (Includes
2.7
Lift lugs, pipe supports, etc.) for cracks
2.8 Check the condition of insulation
3.0 Internal, Scallops & Support Rings

Center pipe: Inspect for any damage caused( perforation
3.1
burnt or holed )
Scallops: Inspect individually all for mechanical, heat
3.2
damage and fouling or blocked ports
3.3 Check all support rings for twisting and cracking
Check the scallop support ring at the bottom of the
3.4
reactor for mechanical, weld and seat damage
4.0 Shell
Check the shell wall for corrosion, pits, channeling,
4.1
cracking, bulge and mechanical damage
4.2 UT measurements-shell and attachments
DP or WFMPI test the seam, nozzle and attachment
4.3
welds for cracks
5.0 Bottom Head

5.1 Inspect the bottom head for pitting gouging and cracking
Inspect the packing condition of the center pipe with the
5.2
bottom head for tightness

Attachment 3(C) - Inspection Checklist for Process Equipment - Platformer Reactor Vessel (contd)

Equipment data:
Size/ Thick. Mm/in Design Temp. °C: °F
Cladding / Lining Corrosion Allowance mm: in
5.3 UT measurement- Bottom head and Nozzles
6.0 Internal Assembly

6.1 Check all internals are assembled correctly.
Check clearance between internals are with in allowable
6.2
limits
Ensure the excess clearance are compensated by KAO
6.3
wool packing if required
7.0 External
MPI test all seam, nozzle and attachment welds for
7.1
cracking
7.2 Check the external insulation is in good condition
Check all bolts used for closure are in good condition

8.0
(Sample one bolt for tensile test)
9.0 Check all gaskets are renewed in kind
10.1 Check condition of skirt and fire proofing
10.2 Check condition of foundation and support bolts
Notes:

Attachment 3(D) - Inspection Checklist for Process Equipment - Heat Exchanger


Equipment data:
DESCRIPTION Shell TUBES DESCRIPTION SHELL TUBES
Material Design Pressure Kg/cm²g/psig
Thick. mm/in Design Temperature °C / °F
Corrosion Allowance mm /in Hydro Test Pressure Kg/cm²g/psig
1.0 Channel Head, Cover and Nozzles
1.1
Weld condition/corrosion & condition of Pass partition
1.3
plate
1.4 Condition of gasket surfaces
1.5 UT measurement- Channel and Nozzles
1.6
deposit
1.8 Condition of attachment welds (Includes Lift lugs, etc.)
1.9 Channel cover
1.10 Check instrument connection for corrosion damage
1.11 Internal/External coating/painting
2.0 Shell: Cylindrical and Conical

2.1
Weld condition/corrosion (both longitudinal and
2.3
circumferential)
2.4 UT measurements-shell, cone and nozzles
Inspect lining and distributors if provided for corrosion,
2.5
erosion, fouling and blockage
Inspect the inlet, outlet nozzles for corrosion, erosion
2.6
and thinning
2.7 Inspect gasket faces
2.8 Condition of external paint, insulation
3.0 Demister Pad (DP)

3.1 Check if demister pad is not disturbed
Get DP removed and inspect shell wall above and
3.2
below including the attachments
Inspect DP for fouling, damage and if compressed and
3.3
assess if can be reused for another cycle
Inspect DP fit up and attachment wires (size and
3.4
material ) on completion of DP fit up

Attachment 3(D) - Inspection Checklist for Process Equipment - Heat Exchanger (contd)


Equipment data:
4.0 Tube Bundle
Check tube ID & OD fouling. Describe the extend of
4.1
fouling and locations
Measure ID and OD and compare to the original for
4.2
metal loss
Visually inspect ID and OD for pits measure the depth
4.3
of pit
4.4 Inspect tube ends for corrosion thinning.
If tube to tube-sheet welded, then perform DP test to
4.5
ensure no crack
Check the tube sheet for corrosion, erosion and any
4.6
mechanical damage
Notes:
Eddy current testing and evaluation of the tube

4.7
condition
Mark defective tubes for plugging or re-tubing as
4.8
required
Check baffle plates for corrosion, thinning and enlarged
4.9
tube holes
4.10 Check tie-rods for corrosion & damage

Attachment 3(D) - Inspection Checklist for Process Equipment - Heat Exchanger (contd)


Equipment data:
5.0 Floating Head Cover
5.1 Check for corrosion, erosion & pits
Check gasket face for corrosion, erosion, pit or
5.2
mechanical damage
6.0 Shell Cover

6.1 Check for corrosion, erosion & pits
Check gasket face for corrosion, erosion, pit or
6.2
mechanical damage
6.3 UT check
Check vent and drain for blockage and corrosion
6.4
thinning
7.1 Condition of support saddle and fire proofing
8.0 Hydrostatic Test

Test from shell side # Design x 1.5 (Built before1999
8.1
and 1.3 after 1999)
Test from Tube side # Design x 1.5 (Built before1999
8.2
and 1.3 after 1999)
Final Test from shell side # Design x 1.5 (Built
8.3
before1999 and 1.3 after 1999)
Notes:

Attachment 3(E) - Inspection Checklist for Process Equipment - Vertical Heat Exchanger

Equipment data:
DESCRIPTION Shell TUBE DESCRIPTION Shell Tube
Thick. mm/in Design Temperature Deg °C /°F
Corrosion Allowance mm/in Hydro Test Pressure Kg/cm²g/psig
1.0 Channel Head, Cover and Nozzles
1.1
1.4 Condition of gasket surfaces
1.5 UT measurement- Channel and Nozzles
1.6 Internal and external cracks, erosion/corrosion, foreign deposit
1.8 Condition of attachment welds (Includes Lift lugs, etc.)
1.9 Channel cover
1.11 External coating/painting
2.0 Shell
2.1
2.3 Weld condition/corrosion (both longitudinal and circumferential)
2.4 UT measurements-shell, cone and nozzles
Inspect lining if provided. Check for corrosion/erosion, disbanding and
2.5
bulges
2.6 Inspect the inlet, outlet nozzles for corrosion, erosion and thinning
2.7 Inspect gasket faces
2.8 Condition of external paint, insulation
3.0 Bellow
3.1 Check if bellow is dimensionally not disturbed
3.2 PT check the bellow for cracks
Request and Witness the Pressure test of the bellow at 1.5 x design
3.3
differential pressure
4.0 Tube Bundle

Check tube ID and OD fouling. Describe the extend of fouling and
4.1
locations
4.2 Measure ID and OD and compare to the original for metal loss
4.3 Visually inspect ID and OD for pits, measure the depth of pit and record
4.4 Inspect tube ends for corrosion thinning/weld erosion/cracks.

Attachment 3(E) - Inspection Checklist for Process Equipment - Vertical Heat Exchanger (contd)

Equipment data:
4.5 If tube to tube-sheet welded, then perform PT test to ensure no crack
4.6 Check the tube sheet for corrosion, erosion and any mechanical damage
4.7 Eddy current testing and evaluate tube condition
4.8 Mark defective tubes for plugging or re-tubing as required
4.9 Check baffle plates for corrosion, thinning and enlarged tube holes
4.10 Check tie-rods for corrosion and damage
Notes:
5.0 Floating Head (cone type)

5.1 Check for corrosion, erosion and pits
5.2 Check gasket face for corrosion, erosion, pit or mechanical damage
6.0 Shell Cover

6.1 Check for corrosion, erosion and pits
6.2 Check gasket face for corrosion, erosion, pit or mechanical damage
6.3 UT check
6.4 Check vent and drain for blockage and corrosion thinning
7.1 Condition of support saddle and fire proofing

Attachment 3(E) - Inspection Checklist for Process Equipment - Vertical Heat Exchanger (contd)

Equipment data:
Hydro test shell and tube side at 1.5 x differential pressure-Test from
8.1
shell side # Design x 1.5 (Built before1999 and 1.3 after 1999)
8.2 Test from Tube side # Design x 1.5 (Built before1999 and 1.3 after 1999)
Final Test from shell side # Design x 1.5 (Built before1999 and 1.3 after
8.3
1999)
Notes:

Attachment 3(F) - Inspection Checklist for Process Equipment - Fin Fan Cooler

Equipment data:
DESCRIPTION HEADERS TUBES DESCRIPTION
Material Design Press.: Kg/cm²g/psig
Shell Thick: mm/ in Design Temp.: oC/oF
Corrosion Allowance: mm/ in Corrosion allowance: mm/in
1.0 Inlet Header and Nozzles
1.1
Describe location, appearance and depth if accessible.
1.3 Weld condition/corrosion and condition of Pass partition plate
1.4 Condition of all plug gasket surfaces and threads
1.5 UT measurement- Header box plates and Nozzles
1.6 Internal and external cracks, erosion/corrosion, deposit
1.7 Condition of attachment welds (Includes lift lugs, etc.)
1.8 Header plug seat/gasket face and threads
1.10 Check the vent and drain for plugging and corrosion
2.0 Outlet Header and Nozzles

2.1
Describe location, appearance and depth if accessible.
2.3 condition of Pass partition plate and Weld/ corrosion
2.4 Condition of all plug gasket surfaces and threads
2.5 UT measurement- Header box plates and Nozzles
2.6 Internal and external cracks, erosion/corrosion, foreign deposit
2.7 Condition of attachment welds (Includes lift lugs, etc.)
2.8 Header plug seat/gasket face and threads
3.0 Tubes
Visually see through the plug holes for tube end thinning and fouling at both
3.1
headers
3.2 Check tube leak marks behind the tube sheet
Get random RT taken on accessible tubes, around headers and at mid section
3.3
and evaluate corrosion
3.4 Check if tubes are sagged/bowed

Attachment 3(F) - Inspection Checklist for Process Equipment - Fin Fan Cooler (contd)
Equipment data:
DESCRIPTION HEADERS TUBES DESCRIPTION
Material Design Press.: Kg/cm²g/psig
Shell Thick: mm/ in Design Temp.: oC/oF
Corrosion Allowance: mm/ in Corrosion allowance: mm/in
3.5 Check condition of tube fins for damage or flattening
3.6 Inspect tube ends for thinning at both headers
Carry out MFL test or any equivalent test based on RBI assessment
3.7
inspection plan
3.8 Unacceptable tubes for plugging to be marked on site
3.9 Check the side frames for any possible damage
Check the condition of stiffeners, tube spacers, tube keepers and tube support
3.10
cross members
4.1 Condition of supporting columns/ beams and fire proofing
5.0 General
5.1 Check the fan blades for cleanliness
5.2 Check the Plenum, fan ring, fan deck
5.3 Check the drive assembly for any abnormality
5.4 Check ladder and platforms if they are intact
NOTES:

Attachment 3(F) - Inspection Checklist for Process Equipment - Fin Fan Cooler (contd)
Equipment data:
DESCRIPTION HEADERS TUBES DESCRIPTION Details
2
Material Design Pressure Kg/cm , psig
Shell Thick: mm/ in Design Temperature Deg °C / °F
Corrosion Allowance: mm/ in Hydro Test Pressure in Kg/cm2 , psig
Notes:

6.1 Test from Tube side # Design x 1.5 (Built before1999 and 1.3 after 1999)
Notes:

Attachment 3(G) - Inspection Checklist for Process Equipment - Heater

Equipment data:
Description Tubes Description
Tube Material Design Press.: Kg/cm²g/psig
Size/ Thick.: mm/in Design Temp.: oC/oF
Thickness: mm/in Corrosion allowance: mm/in
1.0 Tubes - Radiant
1.1 External scale
External corrosion-describe location appearance and
1.2
depth
1.3 Sagging/bulges/blisters
1.4 Tube OD measurement
1.5 Externally cleaned
1.6 Internally cleaned
1.7 UT measurement- Tubes and bends
1.8 Hardness measurement
1.9 Radiographic Inspection
1.10 Internal cracks, erosion/corrosion, foreign deposit
1.11 Tube supports and hardware
1.12 Weld condition
2.0 Tubes - Convection

2.1 External scales/debris
2.2 Tube fin condition
2.3 Tube supports and hardware’s
2.4 UT measurements, accessible locations
2.5 Tube distortion and bulges
3.0 Fittings
3.1 Corrosion-describe location appearance and depth
3.2 Distortion
3.3 Condition of tube rolls, plugs and threads
3.4 UT measurement
4.0 Casing and Internals

4.1 Insulation/Refractory
4.2 Insulation clips
4.3 Fire bricks
4.4 Inspection doors/ burner view port
4.5 Convection section

Attachment 3(G) - Inspection Checklist for Process Equipment - Heater (contd)


Equipment data:
4.6 Thermowells
4.7 Explosion door condition
4.8 Casing condition
4.9 Condition of external coating
4.10 Condition of access doors
5.0 Burner Assembly

5.1 Corrosion, deterioration of burner tips, coking
5.2 Condition of pilot burner
5.3 Thermocouple condition
5.4 Burner tiles condition
6.0 Heater Stack

6.1 External condition
6.2 Condition of support bolts and guy wire
6.3 Internal refractory
6.4 External insulation and coating
6.5 Condition of damper
6.6 Check if the damper blade is scaled or overheated
7.1 Condition of concrete support
7.2 Condition of steel support
7.3 Condition of fireproofing

8.1 Witness pressure test
8.2 Look for flange, and tube leaks.
Notes:

Attachment 3(H) - Inspection Checklist for Process Equipment - Reformer Heater

Equipment data:
1.0 Tubes - Radiant
1.1 External scale
External corrosion-describe location appearance and
1.2
depth
1.3 Sagging/bulges/blisters
Tube OD measurement, Manual, eddy current or
1.4
Lotis, H Scan
1.5 Externally cleaned
1.6 Internally cleaned
1.7 UT measurement- Tubes and bends
1.8 Hardness measurement
1.9 Radiographic Inspection
Internal or external cracks, erosion/corrosion, foreign
1.10
deposit
1.11 Tube supports & hardware and lugs
Condition of Counter weight, connecting cable and
1.12
obstruction to movements
1.12 Tube weld condition
2.0 Tubes - Convection

2.1 External scales/debris
2.2 Tube fin condition
2.4 UT measurements, accessible locations
3.0 Fittings
3.1 Corrosion-describe location appearance and depth
3.2 Distortion
3.3 Condition of tube rolls, plugs and threads
3.4 UT measurement
4.0 Casing and Internals

4.1 Insulation/Refractory
4.2 Insulation clips
4.3 Fire bricks

Attachment 3(H) - Inspection Checklist for Process Equipment - Reformer Heater (contd)

Equipment data:
4.4 Inspection doors/ burner view port
Convection section
4.5 Condition of tubes, elbows/bends and refractory
4.6 Thermowells
4.7 Explosion door condition
4.8 Heater casing condition
5.0 Burner Assembly

6.0 Heater Stack

6.5 Condition of damper
7.1 Condition of support and fire proofing
7.3 Condition of fireproofing
8.0 Pneumatic or Hydrostatic test

8.2 Look for flange, roll and tube leaks.
Notes:

Attachment 3(I) - Inspection Checklist for Process Equipment - Boiler

Reason for Inspection: T&I P&E Inspector: Date Inspected:
Equipment data:
Boiler Type:
Manufacturer: Design Pressure,
Model: Design Temperature,
Design Code Hydrotest pressure
Equipment Data:
Data: Steam Drum Water Drum Furnace tubes Super heater tubes Bank tubes Wall headers
Material
OD or ID
Thickness
1.0 Tubes, Drums-Waterside
Corrosion (scales, pits, buildup)/Cracking
1.1
1.3 Tubes free of blockage, scales
1.5 UT measurement- Drums
1.6 Condition of man way gasket surface
1.7 Tube boroscope inspection
1.8 Internal cracks, erosion/corrosion, foreign deposit
2.0 Tubes, Drums-Fireside

External tube corrosion, erosion, pitting (describe
2.1
location and size)
External drum corrosion, scales & deposits and
2.2
insulation loss.
2.4 UT measurements
2.6 External signs of roll leaks
2.7 Evidence of erosion from soot blowers
2.8 Condition of soot blowers
3.0 Headers
3.1 Internal scale and corrosion
3.2 Condition of hand hole plugs
3.3 External corrosion, erosion, deposits, scales
4.0 Water Column

4.1 Gage glass condition
4.2 Illuminators, reflectors, view glasses
4.3 Gage cocks and valves

Attachment 3(I) - Inspection Checklist for Process Equipment - Boiler (contd)

Reason for Inspection: P&E Inspector: Date Inspected:
Equipment data:
Boiler Type:
Manufacturer: Design Pressure,
Model: Design Temperature,
Design Code Hydrotest pressure
Equipment Data:
Data: Steam Drum Water Drum Furnace tubes Super heater tubes Bank tubes Wall headers
Material
OD or ID
Thickness
4.4 Condition high and low water alarms
5.0 Casing
5.1 Condition of insulation/refractory
5.2 Condition of casing structures
5.3 Casing distorted, cracked, corroded or burnt
5.4 Any obstruction to thermal expansion
5.5 Condition all baffle tiles and caulking
5.7 Condition of external paint
6.0 Burner Assembly

8.0 Boiler Stack


Pressure tested # Design x 1.5 for boilers built before
9.2
1999 and Design x 1.3 after 1999
Notes:

Attachment 3(J) - Inspection Checklist for Process Equipment - Unfired Boiler

Equipment data:
DESCRIPTION Shell Tube DESCRIPTION Shell Tube
Material Design Pressure Kg/psig
Thick.: mm/ in Design Temperature Deg °C/ °F
Corrosion Allowance :mm / in -- Hydro Test Pressure in Kg/psig
1.0 Tube-Waterside
Corrosion (scales, pits, buildup)/Cracking
1.1
1.3 UT measurement
1.4 Tube Distortion
1.5 Boroscope inspection
2.0 Tube/ Fireside

corrosion, erosion, pitting (describe location,
2.1
appearance and size)
2.2 Tubes blockage, scales, deposits
2.3 UT measurements
2.4 Tube boroscope inspection
2.5 Signs of tube roll leaks
2.6 Evidence of Tubesheet cracks
2.7 Refractory cracking and spalling
2.8 Ferrule conditions
3.0 Shell
3.1 Internal scale and corrosion
3.2 UT measurement
4.0 Gas Inlet/Outlet

4.1 Condition of insulation/refractory

Notes:

Attachment 3(K) - Inspection Checklist for Process Equipment - Tank

Reason for Inspection: Date of Commissioning: Date Inspected:
Equipment data:
Shell Material Design Pressure, Kg/ psig:
Shell thickness: mm/in Max. Operating level meters /ft:
CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected Checklist Per API 653
# ITEM CA NC NI COMMENTS
1.0 Overview
1.1 Check the tank is cleaned, gas free and safe for entry
1.2 Check the tank is completely isolated from service.
Check the roof is adequately supported including
1.3
fixed roof structures and floating roof legs
Check for presence of falling objects hazards, such as
1.4
corroded roof items and appurtenance, etc.
1.5 Inspect slipping hazards on the tank floor and roof.
1.6 Check structural welds on the accessways and clips
Check surfaces required for inspection is free from
debris and oily surfaces where welding is to be
1.7
performed. Note areas requiring more cleaning or
sand blasting
2.0 Tank External

Inspect appurtenances opened during cleaning such
2.1 as lower floating swing sheave assemblies, nozzle
interior after removal of valves.
2.2 Hammer test or UT check the roof
2.3 Enter and inspect floating roof pontoon compartments
3.0 Bottom Interior Surface

Use flash light parallel to the bottom plates and
3.1 inspect the plates, welds and hammer test the entire
bottom.
Measure the depth of pitting and describe the
3.2
appearance ( sharp, lake like, dense scattered, etc.
3.3 Mark areas for further inspection or patching
3.4 Mark areas for coupon sampling for inspection.
Inspect all welds for corrosion and leaks, particularly
3.5
the shell to bottom plate weld.
3.6 Inspect sketch plate for corrosion
Check the internal sump. If liquid found, recommend
3.7
for removal and inspect the welds and for corrosion.
3.8 Locate and mark voids under the bottom plates
Record bottom data on a lay out bottom drawing and
3.9
list the number of plates to renew or patches required
3.10 Vacuum test the bottom plate lap welds.
Inspect closely any discolored or wet areas by
3.11
hammer or UT scan.
3.12 Check all reinforcement pads, supports and clips
3.13 Inspect floating roof leg pads for pits, cuts, etc.
Inspect column bases of fixed roof support pads for
3.14
adequacy
Check the area beneath the swing line cable for
3.15
indication of cable cutting or damage

Attachment 3(K) - Inspection Checklist for Process Equipment - Tank (cont'd)


Equipment data:
CA=Completed & acceptable, NC=Not Completed, NI=Not Inspected Checklist per API 653
Identify and report low areas on the bottom that does
3.16
not drain adequately.
Inspect coating for discoloration, blisters, holes and
3.17
disbonding.
4.0 Shell Seams and Plates

Check the bottom 2” to 4” for corrosion /erosion due
4.1
to water accumulation.
Inspect and measure the depth of pits on each course
4.2
plate and measure the amount of metal loss.
4.3 Inspect shell to bottom plate weld
Inspect grooving damage from seal assembly
4.4
protrusion.
Inspect the existing coating for damage deterioration
4.5
and disbanding.
4.6 Check for seal rubbing
Visually check the shell plates for indication leaks and
4.7
leak marks
4.8 Survey the tank for roundness or bulges.
4.9 Check tank overflow nozzle internally & externally
5.0 Roof Interior Surface

5.1.0 General
Visually inspect the underside surface of the tank roof
5.1.1
plates for scaling/deposit buildup, pitting, and holes.
Hammer test or thickness gage for corrosion thinning
5.1.2 particularly in vapor space of floating roof and at the
edge of cone roof.
Check all clips, attachments to roof plates, welds for
5.1.3
cracks and damage.
5.1.4 Inspect the protective coating for any damage.
5.2 Fixed Roof Support
5.2.1 Inspect the support columns for thinning
Check the reinforcing pad on the bottom is seal
5.2.2 welded to the tank bottom plate with horizontal
movement clips welded to the pads
Determine if the pipe column supports are concrete
5.2.3
filled, if not they are provided with a drain hole.
Inspect the drafters for corrosion, particularly near the
5.2.4
center of the roof
5.2.5 Check for loose or twisted drafters
5.2.6 Inspect girders for corrosion and fixed properly


Equipment data:
5.3 Fixed roof Appurtenances
5.3.1 Inspection and light hatches
Inspect the hatches for corrosion, paint and coating
5.3.1.1
damages, holes and cover sealing
On loose covers check if the safety chain in good
5.3.1.2
condition
5.3.1.3 On light hatches check for safety rods
5.3.1.4 Check the gasket face on the hatch covers
5.4 Breathers and Vents

5.4.1 Inspect the breathers if they are functional
5.4.2 Inspect screens on vents and breathers.
5.5 Emergency P/V Hatches

5.5.1 Inspect the pressure/vacuum hatches
5.5.2 Inspect the liquid seal hatches for corrosion
5.6 Floating Roof

5.6.1 Roof Deck
5.6.1.1 Hammer test the area between the roof rim and shell
5.6.1.2 Check the roof drain for plugging.
5.6.1.3 In sour service check all welds for cracks
5.6.2 Floating roof pontoons

5.6.2.1 Visually check all the pontoons for leaks
Check each pontoon for vapor tight, liquid tight and
5.6.2.2
acceptable.
Inspect the lockdown hatches each cover and the
5.6.2.3
opening
5.6.3 Floating Roof Cutouts

5.6.3.1 Inspect under side of cutouts for mechanical damage
5.6.3.2 Inspect welds for cracks
5.6.3.3 Inspect plates for thinning, pits and erosion
5.6.3.4 Measure mixer cutout and plate thickness
5.6.4 Floating Roof Supports

Inspect fixed low and removable high floating roof
5.6.4.1
legs for thinning
5.6.4.2 Inspect notching at bottom of legs for drainage
5.6.4.3 Inspect for leg buckling or fall off at the bottom
5.6.4.4 Inspect pin hole in roof guide for tears


Equipment data:
5.6.4.5 Check plum of all legs
Inspect for adequate reinforcing gussets on all legs
5.6.4.6
through a single portion of the roof
5.6.4.7 Inspect the roof area for cracks, etc.
5.6.4.8 Inspect the sealing system and the vapor plugs
On shell mounted roof support, check for adequate
clearance based on the maximum floating roof
5.6.4.9 movement as determined by the position of the roof
relative to the gauge well and or counter rotational
device
6.0 Floating Roof Seal Assemblies

6.1 Primary shoe assembly
Remove four sections of foam log ( foam filled seals)
6.1.1
for inspection on 90O locations
Inspect hanger attachment to roof rim for thinning,
6.1.2
bending, weld damage, etc.
6.1.3 Inspect clips welded to roof rim for thinning
6.1.4 Shoes-inspect for thinning and holes in shoe
6.1.5 Inspect for bit-metal bolts, clips and attachment
Seal Fabrics-Inspect for deterioration, stiffening, holes
6.1.6
and tears in fabrics
Measure length of fabric from top of shoe to roof rim,
6.1.7 and check the maximum annular space allowed for
roof movement
Inspect any modification of shoe over shell nozzles,
6.1.8
mixers, etc., for clearance
Inspect shoes for damage caused by striking shell
6.1.9
nozzles, mixers, etc.
6.2 Primary Toroidal Assembly

Inspect seal fabrics for wear, deterioration, holes and
6.2.1
tear
6.2.2 Inspect foam for liquid absorption and deterioration
6.3 Rim-Mounted Secondary’s

Inspect the rim-mounted bolting bar for corrosion and
6.3.1
weld defects
6.3.2 Measure and chart seal to shell gaps
Visually inspect from under side for holes as evident
6.3.3
by light
6.3.4 Inspect fabrics for deterioration
6.3.5 Inspect for contacts and deterioration
6.3.6 Inspect for mechanical damage, corrosion, etc.


Equipment data:
7.0 Floating Roof Appurtenances
7.1 Roof Manway
7.1.1 Inspect manway wall for pitting and thinning
7.1.2 Inspect manway cover, gasket face and bolts
7.2 Rim Vent
7.2.1 Check Rim Vent for pitting and holes
7.2.2 Check the condition of vent screen
On floating roof check the vent pipe to rim joint for
7.2.3
corrosion
7.3 Vacuum Breaker, Breather Type

7.3.1 Check breather valve operations
Check the nozzle pipe projection is ½” below roof
7.3.2
deck
Inspect stem for thinning and measure how far the
7.3.3 vacuum breather cover is when raised off the pipe
when roof is resting high ,low
Roof Drains: Open System including

7.4
Emergency Drains
Check liquid level inside open roof drains for
7.4.1 adequate free board. Report if there is insufficient
distance between liquid level and top of drain
If tank comes under Air Quality Monitoring District
7.4.2
rules, inspect the roof drain vapor plug
If emergency drain is not at the center of the roof,
7.4.3
check at least there are three emergency drains
7.5 Closed Drain Systems: Drain Basins

7.5.1 Inspect for thinning and corrosion
7.5.2 Inspect protective coating
7.5.3 Inspect basin cover or screen for corrosion
7.5.4 Test operation of check valve
Check for the presence of check valve where bottom
7.5.5
of basin is below product level
Inspect drain basin(s) to roof deck welds for cracking
7.5.6
including reinforcement pad
Closed Drain System: Fixed Drain Line on

7.6
Tank Bottom
7.6.1 Hammer test the drain line for thinning and plugging
Inspect supports & reinforcing pads for weld failures
7.6.2
and corrosion


Equipment data:
Check that pipe is guided, not rigidly locked to
7.6.3
support, to avoid tearing of bottom plate
7.7 Closed Drain System: Flexible pipe system

7.7.1 Inspect any external damage to pipe
7.7.2 Check for obstruction that pipe could catch
7.7.3 Inspect shield to protect pipe from snagging
Closed Drain System: Articulated joint

7.8
drain
Hammer test the rigid pipe in flexible joint system for
7.8.1
corrosion
7.8.2 Inspect system for bending or strain
7.8.3 Inspect landing legs and pads
7.9 Autogauge System and Alarms

Check free movement of tape through autogauge
7.9.1
tape guide
7.9.2 Inspect sheaves for free movement
7.9.3 Check operation checker
7.9.4 Inspect tape and tape cable for twist and fraying
Test tape’s free movement through the guide sheaves
7.9.5
and guide pipes
7.9.6 Check float for leakage
Test float guide wire anchors for spring action by
7.9.7
pulling on wire and releasing
Inspect float wells in floating roofs for thinning and
7.9.8
corrosion, just above the liquid level
Check the autogauge wire is firmly attached to the
7.9.9
float
Inspect the tape cable and float guide wire fabric
7.9.10
seals through the float well cover
8.0 Common Tank Appurtenances

8.1 Gauge Well
Inspect gauge well pipe for thinning: check for
8.1.1
thinning at the edge of the slots
8.1.2 Check for corrosion on the pipe joint:
8.1.3 Check for cone at the bottom end of pipe

Check the condition of well washer pipe and its flared
8.1.4
end point towards the hold off pad
Check that the support for gauge well welded to pad
8.1.5
or shell and not directly to the pad


Equipment data:
8.1.6 Check operation of the gauge well cover
Check the hold off distance in well pipe and record
8.1.7
the mark.
Identify and report pipe size & schedule, whether solid
8.1.8
or slotted
Check the hold off plate is seal welded to the bottom
8.1.9
indirectly
8.1.10 Inspect the vapor control float and cable
8.1.11 Check for the presence of gauge well washer
Inspect gauge well guide in floating roof for corrosion
8.1.12
or thinning
Inspect guide rollers and sliding plates for free
8.1.13
movement
8.1.14 Inspect the seal system of the gauge well
Visually inspect inside of the pipe for weld protrusion,
8.1.15
which may catch the float.
8.2 Sampling system: Roof Sample Hatches

Inspect roof mounted sample hatches for reinforcing
8.2.1
pad and cracking
8.2.2 Inspect cover for operation
8.2.3 Inspect sample hatch covers for proper sealing
Check alignment of internal float roof sample hatch
8.2.4
under fixed roof hatches
Inspect the sealing system on the internal floating roof
8.2.5
sample hatch cover
Inspect floating roof sample hatch cover recoil reel
8.2.6
and rope
8.3 Shell Nozzles

8.3.1 Inspect shell nozzles for pitting and thinning
8.3.2 Inspect hot tap nozzles for trimming of holes
8.3.3 Identify types of shell nozzles
Identify and describe internal piping including elbow
8.3.4
up and elbow down types
8.4 For Nozzles Extended into the Tank

8.4.1 Inspect the pipe pads welded to the tank bottom
8.4.2 Inspect pipe is free to move with out strain
8.4.3 Inspect nozzle valves for leaks
8.4.4 Check which nozzle is fitted with thermal relief valve
8.4.5 Inspect wear plate on the down fill nozzle
Inspect impact of erosion in elbow up-fill in floating
8.4.6
roof


Equipment data:
8.5 Diffusers and Air Rolling System
8.5.1 Inspect diffuser pipe for erosion /thinning
8.5.2 Check holes in the diffuser for wear and enlargement
8.5.3 Inspect diffuser supports for corrosion and damage
Check that diffuser supports restrain and not
8.5.4
anchored
Inspect air spiders on bottom of the lube oil tanks for
8.5.5
plugging, damage or breaking
8.6 Swing Lines

8.6.1 Inspect flexible joints for cracks and leaks
8.6.2 Inspect moving faces between swing lines
8.6.3 Check flexible joints over 6” are supported
8.6.4 Inspect swing pipes for pits and weld corrosion
8.6.5 Check for pits & leaking pontoons
8.6.6 Inspect the pull-down cables for damages
Inspect bottom mounted supports and safety hold
8.6.7
chain for integrity
9.0 Access Structure

9.1 Handrails
9.1.1 Identify and record the type of handrail
9.1.2 Inspect attachment
9.1.3 Inspect pitting, holes and paints
9.1.4 Inspect sharp edges
9.1.5 Inspect the hand rails between rollers
9.2 Platform Frames

9.2.1 Inspect platform for corrosion and paint loss
9.2.2 Inspect all attachment
9.2.3 Check the grating for damages
9.3 Deck Plate and Grating

Inspect the deck plate for corrosion, holes, and paint
9.3.1
failure
9.3.2 Inspect plate to frame welds
9.3.3 Inspect grating for breakage, damage
9.4 Stairway Stringers

Inspect spiral stairway stringers for corrosion, paint
9.4.1
and weld failure
9.4.2 Inspect stairway welds to shell



Equipment data:
Inspect steel support attachment to concrete base for
9.4.3
corrosion
9.5 Rolling Ladder

9.5.1 Inspect rolling ladder stringers for corrosion
Identify and inspect ladder fixed rungs for weld
9.5.2
attachment to stringers and corrosion
Inspect steel support attachment to concrete base for
9.4.3
corrosion
Check for wear and corrosion where rolling ladder
9.5.3
attaches to gaging platform
9.5.4 Inspect pivot for wear and secureness
9.5.5 Inspect corrosion of moving parts
9.5.6 Inspect operation of self-leveling stairway treads
9.5.7 Inspect rolling ladder wheels for free movement
9.5.8 Inspect rolling ladder alignment with roof rack
9.5.9 Inspect rolling ladder welds for corrosion
Notes:

Attachment 4 - Nomenclature and Types of Heat Exchangers

Different Types of Heat Exchangers



Vessel

Typical Heater Arrangement

Fin Fan Cooler

CRUDE HEATER

ISOMAX REACTOR PLATFORMER REACTOR

CRUDE COLUMN VACUUM COLUMN

TYPICAL CONCRETE LINED AND TRAYED VESSEL

Revision History
17 February 2020 Minor revision.
26 November 2007 New Saudi Aramco Inspection Procedure.

00 Saip 80

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

00 Saip 80

Uploaded by

Copyright:

Available Formats

Inspection Procedure

00-SAIP-80 17 February 2020

Previous Issue: 26 November 2007 Next Revision: TBD

Saudi Aramco: Company General Use

4.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

©Saudi Aramco 2020. All rights reserved. Page 2 of 75

Saudi Aramco: Company General Use

SAEP-1144 Magnetic Particle Examination of Welds and Components

Saudi Aramco Engineering Standards

Saudi Aramco General Instructions

Saudi Aramco Inspection Procedures

4.2 Industry Codes and Standards

©Saudi Aramco 2020. All rights reserved. Page 3 of 75

Saudi Aramco: Company General Use

API RP 580 Risk Based Inspection

American Society of Mechanical Engineers

NBIC, National Board Inspection Code

©Saudi Aramco 2020. All rights reserved. Page 4 of 75

Saudi Aramco: Company General Use

TEG Tri Ethylene Glycol

Pressure Vessels: Is a container designed to withstand internal or external pressure.

Filler Material: The material to be added in making metallic or nonmetallic joints.

©Saudi Aramco 2020. All rights reserved. Page 5 of 75

Saudi Aramco: Company General Use

Porosity: Cavity type discontinuities formed by gas entrapment during solidification of

Aligned Indications: A sequence of four (4) or more rounded indications should be

Hydrocarbon Services: Process streams of liquid or gaseous hydrocarbon (HC)

©Saudi Aramco 2020. All rights reserved. Page 6 of 75

Saudi Aramco: Company General Use

Low-Chrome Alloy Steels: Alloy materials with nominal chromium contents of 1% to

©Saudi Aramco 2020. All rights reserved. Page 7 of 75

Saudi Aramco: Company General Use

6.1.7 While performing detailed inspection look for pitting corrosion,

6.1.11 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325, SAES-D-008,

6.2 Reactor Vessels

©Saudi Aramco 2020. All rights reserved. Page 8 of 75

Saudi Aramco: Company General Use

6.2.7 While making a detailed inspection, look for pitting corrosion,

©Saudi Aramco 2020. All rights reserved. Page 9 of 75

Saudi Aramco: Company General Use

6.2.11 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325, SAES-W-010,

6.3 Platformer Reactor Vessel

©Saudi Aramco 2020. All rights reserved. Page 10 of 75

Saudi Aramco: Company General Use

6.3.7 While performing detailed inspection, look for pitting corrosion,

6.3.11 Applicable standards and codes: SAEP-20, SAEP-302, SAEP-325, SAES-W-010,

6.4 Heat Exchangers

©Saudi Aramco 2020. All rights reserved. Page 11 of 75

Saudi Aramco: Company General Use

6.4.7.4 Check all nozzle condition to ensure they are free of

6.4.8 Tube bundle has to be thoroughly inspected as follows:

©Saudi Aramco 2020. All rights reserved. Page 12 of 75

Saudi Aramco: Company General Use

6.4.14 On completion of inspection and repairs if any, hydrostatically test the

©Saudi Aramco 2020. All rights reserved. Page 13 of 75

Saudi Aramco: Company General Use

6.4.15 Applicable standards and codes: SAEP-20, SAEP-317, SAES-W-010,

6.5 Reactor Effluent Heat Exchangers

©Saudi Aramco 2020. All rights reserved. Page 14 of 75

Saudi Aramco: Company General Use

6.5.7.4 Check all nozzle condition to ensure they are free of

6.5.8 Tube bundle has to be thoroughly inspected as follows: