TUV INDIA – EXPERTISE FOR YOUR SUCCESS

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 Pressure Vessel Inspection
To ensure safe and reliable operation

Working of pressure vessel

deaerator working video

Horizontal separator

Vertical Konckout drum

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 Inspection

External Inspection

- Obtain valid work permit.

 vessel mounting base condition check.

 Check for studs/bolts intactness

 structural attachments like legs, supports are checked for distortion

or cracks at welds.

 external surface to be checked for blisters, cracks.

 Skirt inspection to be carried out for bottom dish end corrosion.

 CUI checked if insulation damage observed.

 CUI checked at nozzle location.

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 RF pad and weep hole to be checked for any leak.
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Internal Inspection.
Internal inspection video
Pre cleaning inspection:
Internal inspection video 2
-Obtain valid work permit
 Check for deposits, collect sample if required.
 Take photographs.
 Note down the area of heavy deposits its appearance and color. Check carefully this area after cleaning.
Post cleaning inspection:
Obtain valid work permit

 ensure standby person outside of manway. Proper communication to outside to be ensured.

 Welded seams and nozzles and areas adjacent to welds are often subjected to accelerated corrosion.
 Pitting to be checked at shell opposite to feed inlet nozzle.
 All parts of the vessel to be inspected for corrosion, erosion, blistering, deformation, cracking and lamination.
 WFMPI of dish ends weld joints to be done as required by MOC and process (sour service)
 Conduct thickness survey of entire vessel.
 In case of any weld repair proper NDT method to be used to check integrity of weld following hydro test.

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 Post cleaning inspection:

Check condition of following parts for any sign of abnormality.

 Shell,
 Dish ends,
 Nozzles,
 Vortex breaker,
 Impingement plate,
 Demister if any,
 Inlet/outlet nozzle weld joints,
 Boot leg

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Vessel for inspection
 Demister in pressure vessel

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12 Internal inspection of vessel
 Vortex breaker Flare knockout drum

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 CUI on nozzle
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 Crack detected in shell by MPI

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 Crack detected near weld by MPI

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 How to repair crack ?

Cracks to repaired by a four steps procedure:

1. Mechanical removal of cracks by grinding. Drilling holes is necessary only if hardness is high. Start grinding

without drilling. If crack continues to expand, perform drilling before grinding, otherwise, do not.

2. Perform MT for 100% of removal area to confirm cracks are removed and the area is completely sound.

3. Perform welding of in removal area in accordance to qualified Welding Procedure Specification (WPS).

4. Perform MT and UT for 100% welding of removal area.

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 Corrosion rate and remaining life calculation

LT – long term
ST- short term

Remaining life

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 Hydro test of vessel:

 Pressure testing is not normally part of a periodic pressure vessel inspection.

 A pressure test may also be necessary after certain repairs and alterations have been made to the pressure

vessel.

 Hydro test procedure to be followed as per ASME SEC V article 10.

 Two PG required for test. One top and one bottom. Test pressure to be maintained at top PG.

Repair and NDT :

 Any repair should be done with approved procedure and in accordance with code and standards (API 510,

API RP 571, ASME SEC VIII DIV-1, ASME SEC IX)

In case of repair or alteration following suitable NDT to be used :

 Ultrasonic thickness: calibration to be checked before job done.

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 Repair and NDT :

 DPT as per ASME SEC V article 6, ASME sec VIII div-1, App-8

 Wet fluorescent magnetic particle inspection (WFMPI)/MPI as per ASME SEC V article 7, ASME

sec VIII div-1, App-6

 Radiography as per ASME SEC V, article 2. ASME SEC VIII DIV-1

 UT as per ASME SEC V article 6, ASME sec VIII div-1, App-12

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 Corrosion types for vessel: refer API 510 and API RP 571

Pitting: Isolated or scattered pitting over a small area

Line corrosion: Pits are connected to nearby pits in narrow or in line.

General corrosion: It covers a considerable area of vessel

Grooving: Metal deterioration caused by localized corrosion. Generally found at welds, lap joints, and flange

surfaces.

Galvanic corrosion: between two dissimilar metals

Fatigue: locations where metals having different thermal coefficient of expansion are joined by welding may

be subject to thermal fatigue.

Creep: it occurs if equipment is subject to temperature above those for which the equipment is designed.

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 Inspection record :
 Observations in brief,

 Thickness and gauging record of all components including data readings prior to commissioning.

 NDT reports if any.

 In case of any repair / replacement jobs to be carried out,

 ITP/WPS/PQR
 Radiographic and other NDE results
 Procedure for stress relieving
 Electrode / filler wire specifications
 Material specification
 Stages of NDT required.
 Pressure test records.
 Record of material replacement
 PMI record if any
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 Document record :
The data report should include the following information:

 Manufacturers Serial Number

 GA drawing

 Owner-Users Identification Number

 Pressure vessel dimensional data (width, height, diameter, etc.)

 Material of construction

 Original wall thickness data for pressure vessel and dished heads

 Original code of construction including NDE method

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