Inspection

Training Services
Inspection Training Course

Refinery NDE
2003 ENGINEERING DESIGN SEMINAR – LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Refinery NDE Topics
n The Role of NDE in the Refinery

n Classification of NDE Methods
n NDE Definitions
n Inspection vs. Examination
n NDE Selection
n NDE Steps and Actions
n In-Process NDE
n NDE Demonstrations
n NDE Codes and Standards
n NDE Results
Role of NDE in the Refinery
n Quality Control During Fabrication
n Mechanical Integrity Programs
n Fitness-For-Service Evaluations
Classification of NDE Methods
Refinery NDE
Standard NDE Methods Advanced NDE Methods
NDE Definitions
n Nondestructive Examination
n Indication (Types)
n Interpretation
n Evaluation
n Discontinuity
NDE Definitions
(continued)
n Defect
n NDE Technique
n NDE Procedure
Inspection vs. Examination
n Duties of the Authorized Inspector
NDE Selection
?????
NDE To
ol B ox
NDE Selection
(continued)
What is the extent

What are we trying and coverage?
to detect?
What acceptance standards
are to be used?
What is the material type
and thickness?
Is access limited?
What are the

limitations of the What preparations
method or are needed?
technique?
Economics?
NDE Selection
(continued)
What is the extent

What are we trying and coverage?
to detect?
What acceptance standards
are to be used?
What is the material type
and thickness?
Is access limited?
What are the

limitations of the What preparations
method or are needed?
technique?
Economics?
NDE Steps and Actions
NDE Technique Nonrelevant/False Nonrecordable
Indication Interpretation Relevant
Evaluation To
Discontinuity Acceptance Recordable
Standard
Acceptance Defect Rejected
In-Process NDE
n Hold Point Inspection
n Witnessing NDE
NDE Demonstrations
n Procedure Demonstration
n Advance NDE Methods
Codes and Standards
SNT-TC-1A
n Written Practice
Codes and Standards
SNT-TC-1A
n Trainee
n Levels of Certification
– Level I
– Level II
– Level III
Codes and Standards
ASME Boiler and Pressure Vessel Code
n Section V, Nondestructive Examination

– Methods Covered
– Subsection A
– Subsection B
Standards and Codes
ASME Boiler and Pressure Vessel Code
Section VIII, Division 1, Pressure Vessels
NDE Requirements For Welds

Written Acceptance Personnel Eye
Method Procedure Criteria Certification Examination
RT No Part UW By employer1 Not Covered
UT Yes Appendix 12 By employer1 Not Covered
PT Yes Appendix 8 By employer Yes
MT Yes Appendix 6 By employer Yes
VT Yes See Code By employer Not Covered
1
SNT-TC-1A used as guideline.
Standards and Codes
ASME B31.3 Chemical Plant
and Petroleum Refinery Piping
NDE Requirements For Welds

Written Acceptance Personnel Eye
Method Procedure Criteria Certification Examination
RT Yes B31.3 By employer1 Not Covered
UT Yes B31.3 By employer1 Not Covered
PT Yes B31.3 By employer1 Not Covered
MT Yes B31.3 By employer1 Not Covered
VT Yes B31.3 By employer1 Not Covered
1
SNT-TC-1A used as guideline.
Codes and Standards
API-510 Pressure Vessel Inspection Code
n NDE Supplements Visual Inspection

n NDE Certification Is Not Required
n Examiner Is Not Qualified Under API-510
n NDE Procedures
Codes and Standards
API-570 Piping Inspection Code
n Examiner Assists Inspector

n Examiner Not Qualified Under API-570
n NDE Certification Required
n Certification Records
n SNT-TC-1A
n American Welding Society
Codes and Standards
National Board Inspection Code
n NDE Requirements
n NDE of Repairs and Alterations by Welding
n Alternative Methods
Codes and Standards
Company Standards
n Requirements
NDE Results
n Validating Results
n Follow-Up Actions
NDE Results
(continued)
n Validating Results
n Follow-Up Actions
Training Services
Refinery Pressure
Equipment
2003 ENGINEERING DESIGN SEMINAR – LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential EDS 2003/INSP-1
Topics
n Mechanical Integrity Program

n Inspection Plans
n Audits
n Corrosion and Other Forms of
Deterioration
n Equipment Inspections
– Pressure vessels
– Heaters
– Piping
– Reportables and actions
Mechanical Integrity Program
Mechanical Integrity Programs
• Pressure Vessels
• Piping Systems
• Process Heaters
• Above Ground Storage Tanks
• Pressure Relief Devices
• Rotating Equipment
• Process Controls and Instrumentation
• Emergency Shutdown Controls
Inspection
Maintenance Operations
Engineering
(continued)
n Process Safety Management Documents

− OSHA 29 CFR 1910.119 Process Safety
Management of Highly Hazardous Chemicals,
Section (j)1910
− API RP-750 Management of Process Hazards,
Section 8
− Chemical Manufactures Association’s
Responsible Care Process, Safety Code of
Management
(continued)
n Recognized and Generally Accepted Good Engineering

Practices
– API-510 Pressure Vessel Code or NBIC
– API-570 Piping Inspection Code
– API-RP 573 Inspection of Fired Boilers and Heaters
– API-576 Inspection of Pressure Relief Devices
– API-653 Aboveground Storage Tanks
– API-RP 2201, Procedures for Welding or Hot Tapping
on Equipment in Service
– SNT-TC-1A Recommended Practice For NDE Personnel
– Other Codes or Standards
(continued)
Inspection
Library Inspection
Inspection Procedures
Standards
Recognized and Generally

Accepted Good
Engineering Practices
Train personnel and

document training
Benefits of a Mechanical
Integrity Program
n Reduced risk of a catastrophic release

n Shows compliance with industry standards
n Optimizes inspection efforts
n Helps control and project maintenance and
inspection costs
n Set-up cost usually less than noncompliance fines
Inspection Plan
Identifies equipment to be inspected
Identifies what and when inspections shall be made
Identifies NDE requirements
Identifies procedures to be used
Preparation requirements for inspection
Training tool
Inspection Plan - Life Cycle
Operational Occurrences
Engineering Revamps
Capital Project Work File
Design Information
Plan Update
Final
Potential Forms of
Data Acquisition
Reports
Deterioration Inspection Plan
Historical Data
Inspection Standards
Inspection Procedures
NDE Procedures Repairs
Plan Execution
Pre T/A or T/A
Repair
UOP Experience
Inspection
Data Assessment
Auditing an Inspection Plan
n Auditors take the

show me approach
n They look for paper

trails
n They drilling down
Auditing an Inspection Program
(continued)
What do external auditors want to know?

− What was inspected
− When was it inspected
− What inspections were performed
− The result of each inspection
− What corrective actions were take to correct deficiencies
− Who did the inspection
Auditing an Inspection Program
(continued)
Compliance
No Action Required
Inspection
Program Partial
vs. Compliance
Industry
Standards Corrective Action
Required
Non-Compliance

Inspection

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Training Services

Inspection Training Course

n The Role of NDE in the Refinery

n Quality Control During Fabrication

n Mechanical Integrity Programs

Standard NDE Methods Advanced NDE Methods

n Duties of the Authorized Inspector

What is the extent

What are the

What is the extent

What are the

NDE Technique Nonrelevant/False Nonrecordable

Indication Interpretation Relevant

Acceptance Defect Rejected

n Hold Point Inspection

n Advance NDE Methods

n Section V, Nondestructive Examination

NDE Requirements For Welds

NDE Requirements For Welds

n NDE Supplements Visual Inspection

n Examiner Assists Inspector

n NDE of Repairs and Alterations by Welding

n Mechanical Integrity Program

n Process Safety Management Documents

n Recognized and Generally Accepted Good Engineering

Recognized and Generally

Train personnel and

n Reduced risk of a catastrophic release

Identifies equipment to be inspected

Identifies what and when inspections shall be made

Identifies NDE requirements

Identifies procedures to be used

Preparation requirements for inspection

n Auditors take the

n They look for paper

n They drilling down

What do external auditors want to know?

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