Method Statement

Inspection and Testing of

CO2 Cryogenic Storage Tanks

Client : MaSa Services Company

Contractor : Al-Riyadha Al Oula Valve
Services Company. (RAVSCO)
Location : SWRO Plant, Dammam, KSA

Company Name Date Signature

Prepared by 3A Cryogenic FZE 23.08.2023

Approved by Client Rep.

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 Table of Contents
SECTION DESCRIPTION PAGE NO
1.0 Purpose 3

2.0 Scope 3

3.0 Definitions 3

4.0 Inspection & Testing Activities Requirements 4

4.1 - General Requirements

4.2 - Safety Requirements

5.0 Inspection & Testing of Cryogenic vessel 5

5.1 Vacuum Integrity Check 5

5.2 External Visual Inspection Of The Cryogenic Vessel 6

5.3 Pressure & Level Gauge Inspection & Testing 7

5.4 Safety Relief Valve Inspection & Testing 7
5.5 Pneumatic Pressure Testing Under Operating 8
Conditions
5.6 Visual Inspection & Functional Check Of Isolation & 8
Check Valves
6.0 Final Report And Documentation 9

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1.0 PURPOSE

To ensure safety, reliability and integrity of CO2 cryogenic storage tanks for continue safe
service through perform inspection in accordance with this procedure in line with inspection
standards EN-13458 Part-1, 2 & 3 meets all the In service Inspection Requirements for this
Cryogenic Tanks.

This document considers the influence of periodic inspection and testing of static vacuum
insulated cryogenic pressure vessels on the continuing safety of these vessels, as the underlying
concern of the industrial gases industry is the safe operation of all its equipment.

2.0 SCOPE

This work procedure describes the inspection & testing activities and the in service inspection
requirements applicable to static vacuum insulated cryogenic pressure vessels used in the
storage of CO2 as per applicable code and standard requirements.
It does not consider the vessels/equipment directly used in the production of these products or
those used for transport, which are covered by the Transport Pressure Equipment Directive
(TPED) or transport of dangerous goods regulations.

3.0 Definitions

Static Vacuum Insulated Cryogenic Pressure Vessels. - As detailed in EN 13458.1

3.1 ABBREVIATIONS

The following abbreviations and acronyms are used throughout this manual:

BAR Pressure (Metric)

CBM Center Back Mount Gauge
CO2 Carbon Dioxide
FPT Female Pipe Thread
MPT Male Pipe Thread
NPT National Pipe Thread
PSV Pressure Safety Valve
TRV Temperature Relief Valve
PSI Pounds per Square Inch
PSIG Pounds per Square Inch (Gauge)
SCM Standard Cubic Meters
PB Pressure Builder
Nm3 Normal Cubic Meters

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4.0 Inspection & Testing Activities Requirements:

4.1 General Requirements:

 Tank specification, drawings, location details and history of previous inspection data verified
by the tank inspector personnel in prior to the execution of the task.
 The inspector to know the present condition of the tank shall refer inspection history along
with its examination and testing reports.
 The tank inspection personnel’s should be familiar with the conditions and potential hazard
present in the area.

4.2 Safety Requirements:

In all inspection & testing of cryogenic vessel following safety considerations shall be taken
into account:

 Small amounts of cryogenic fluids will produce large volumes of vaporized gas. Spillage of
cryogenic fluids can result in an oxygen deficient atmosphere, or in the case of vaporizing
oxygen, in an oxygen enriched atmosphere. Provision is to be made for appropriate
measures for this, e.g. ventilation.

 Due to the possibility of cold embrittlement, cryogenic fluids shall not come in contact with
materials (metals or plastics) which are not suitable for low temperatures.

 Because of their extremely low temperatures, cryogenic fluids will produce cold burns when
coming in contact with the skin. Cold burns can also be produced from contact with
uninsulated equipment and pipe.

 Oxygen enrichment due to liquefaction of ambient air can occur on the cold surfaces of
uninsulated equipment which contain fluids with a boiling point lower than oxygen.

 All tools, equipment, and personal protective equipment used during vessel work (inspection,
and testing, repairs, and alterations) should be checked prior to use. During all inspection
and testing activities the owner/user’s safety requirements shall meet. Other equipment
that might be needed for the vessel work, such as planking, scaffolding, and portable
ladders, should be checked before being used. Personal protective equipment shall be worn
when required either by regulations, the owner/user, or the repair organization.

 Before starting the inspection and maintenance activities personnel’s should obtain
permission to work in the vicinity from operating personnel responsible for that area.

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 5.0 Inspection & Testing of Cryogenic vessel:

Inspection and testing activities for CO2 cryogenic vessel performed as per the applicable
standard EN-13458 Part-03 clause 7.2 for periodic inspection. Below are the periodic inspection
and testing requirements for any cryogenic vessel mentioned below as per applicable standard
EN-13458 part-1, 02 & 03.

The periodic inspection of a cryogenic vessel shall consist of below inspection and testing
activities.

5.1 Vacuum Integrity Check

1. The standard Chart probe (VR-1) is the Hastings DV-6R probe. Select a compatible instrument
to match this type of probe.

2. Remove the rubber cap on the probe outlet to expose the contacts. Note that the probe
housing need not be removed for this step.

3. Plug the instrument to the probe and calibrate the instrument.

4. Open the vacuum probe isolation valve (HCV-5). Wait for 5 minutes and take and record a
vacuum reading. Note that the valve handle protrudes through the protective housing and
can be turned without opening the housing.

5. Close the isolation valve (HCV-5) and take a second reading. Monitor the rate of vacuum
pressure rise in the vacuum probe with the isolation valve closed. If the vacuum continues to
rise at a constant rate, it is possible that probe assembly is leaking. Consult the factory.

6. Verify that the isolation valve (HCV-5) is closed.

7. Replace rubber cap on probe.

8. Review the vacuum reading you recorded.

a. If the first vacuum reading is above 40 microns, Vaccum repair is required. Otherwise tank
vaccum reading is okay.

b. If your last vacuum reading shows a steady increase from the first, Vaccum repair is
required.

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 5.2 External Visual Inspection Of The Cryogenic Vessel:

An external inspection of the inner vessel is not usually required due to the presence of the
insulation and vacuum in the interspace. Any interference could adversely affect the thermal
properties of the insulation by destroying the vacuum, which could prove difficult to reinstate
on site. Visual internal inspection of the vessels is also not practical due to the elimination of
bolted manholes and connections, and the difficulty of ensuring a gas tight seal at the low
temperatures involved.

For external visual check of the condition of the outer jacket, special attention shall
be given to any signs frosting observed at any level of vessel outer jacket, its evidence of the
interface vacuum loss. any deterioration or loss of vacuum will be apparent by cold spots, frost,
or condensation on the outside of the tank or evidenced by abnormally rapid pressure buildup.
Unless one of these conditions is evidenced, the vacuum level should not be suspect.

Moreover during external visual inspection performed for support structure, exposed pipework
and controls should be carried out. Vessel lifting lugs should be inspected for absence of
corrosion. External visual inspections are performed to check the condition of the outside
surface of the outer jacket, coating condition, associated structure, and general alignment of
the vessel on its supports. Particular attention given to welds used to attach components (e.g.
reinforcement plates and clips) for cracking or other defects. Vessels shall be examined for
visual indications of bulging,out-of-roundness, sagging, and distortion.

Below are the damage mechanism shall be consider during inspecting the vessel outer jacket.

• Ice formation on the external tank

• Excessive underside corrosion of annular/bottom plate
• Corrosion
• Paint damage
• Cracks
• Leaks
• Anchors degradation
In case of any sign of the above degradation, damage mechanism shall be evaluated and based
on finding appropriate recommendation will raised to arrest the damage mechanism.

Other Major Checks on Outer vessel:

1. Perlite nozzle inspection checks (dislocation from its original position)

2. Condition of vacuum ports (including seals, any rusting/scaling in the cir-clips).

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5.3 Pressure & Level Gauge Inspection & Testing:

• Pressure & Level gauges shall be inspected and calibration performed as per code and standard
requirements. Below are the procedure to inspect and testing the gauges.

• Check the gauge for any physical damage or signs of wear and tear, such as scratches or cracks
on the gauge lens or case.

• Verify that the gauge is properly connected and secured to the system or Equipment it is
monitoring.

The major cause of gauge malfunction is a leakage in the gauge line. Therefore as a first check,
make certain that gauge lines are leak tight. Other gauge checks include:

 Checking the gauge lines for obstructions.

 Checking for a leak at the liquid phase valve (HCV-10) and at the gas phase valve (HCV-8).

Verifying that the liquid level gauge is properly zeroed. The liquid level gauge is a differential
pressure gauge used to indicate the amount of liquid in the tank. To check and/or adjust the zero
setting of this gauge, close the low pressure and high pressure valves (HCV-8 & HCV-10). With
these valves closed, open the equalization valve (HCV-9). The gauge pointer should indicate zero.
If the gauge pointer does not indicate zero, adjust the gauge until the zero setting is reached. After
adjustment, close the equalizer valve (HCV-9) and slowly open the gauge valves (HCV-8 & HCV-
10).

If these checks and adjustments is not within an acceptable range, the gauge may need
calibration.

• Perform calibration by adjusting the gauge to match the reference pressure. Calibration can be
done using a calibration pump or a deadweight tester. (By Affiliated Calibration Company)

• After calibration, perform a final check to verify that the gauge is reading Accurately.

• In Case readings are again not within an acceptable range, gauges need to be replaced.

5.4 Safety Relief Valve Inspection & Testing:

Pressure & Temperature safety relieve (PSV & TRV) valve should visually inspected and tested as
per below steps:

• Visual Inspection -- During visual inspection below are the points followed:

- Checking the general condition of valve.

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- Checking the current installation/orientation of valve.

- Verify the leak tightness.

- Checking the vent location.

- Inspected for any unobstructed discharge piping.

- When a relief valve protecting cryogenic equipment is leaking, it is easily seen as the valve outlet
will be covered by ice due to the condensation and freezing of water vapor from the surrounding
air. The presence of ice can impair the safe functioning of the valve, and any defect must be
remedied.

• Performance Test & Calibration -- Following parameters should be checked:

- Set pressure test.

- Lift/stroke test.

- Leak tightness test.

The above mentioned performance test and appropriate calibration should be done by Affiliated
Calibration Company. The results of the tests shall be recorded and kept at least until the next
inspection.

5.5 Pneumatic Pressure Testing Under Operating Conditions.

As per applicable standard Pneumatic Pressure test under operating condition shall perform for
inner vessel as a part of periodic inspection requirements.

All Gauges,PSV & TRV Should be tested and calibrated before this pressure testing. During leak
test all pressure safety valves installed after calibration and pressure gauges need to be check
visually under operating condition. And find any sign of leak. Need to hold this pressure till 1 hour
and observed any pressure drop in PI gauge. No pressure drop in inner vessel proves that no any
leak or through wall defect found in inner vessel and connecting pipelines.

Other Major Checks During Pressure Test:

 Regulator leakage and functionality check

 PBU leakage and functional check.
 Isolation vales leakage and functional check.
 External visible piping leakage inspection under operating condition.

5.6 Visual Inspection & Functional Check Of Isolation & Check Valves.

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Isolation valve shall be check manually to confirm it’s operate safely and no any sign of leak. Valve
handle check for any abnormal like (broken, damage) condition. Check that the valve is in the
correct position, i.e. fully closed or fully open, as required. Test the valve to ensure it opens and
closes smoothly and without any obstruction.

Ensure the valve handle turns smoothly and that it is securely attached. Inspect the valve body for
any signs of damage, such as cracks or corrosion. Check the valve bolting to ensure it is tight and
secure. Look for any signs of corrosion or damage. Suspect the valve flanges for any signs of
damage or wear. Ensure that the bolts are tight and that there is no leakage between the flanges.

6.0 Final Report And Documentation:

After the completion of detailed external inspection & testing of equipment’s inspector shall share
the final inspection reports which includes details inspection summary, and all minor and major
inspection findings, recommendation shall be share based on finding to restore the condition of
equipment’s for continue safe service. In addition all test & calibration certificates of Safety Valves
and Gauges shared to client for their record.

Moreover, based on equipment condition describe the next inspection interval of equipment’s
based on current equipment condition and corrosion and remaining life calculation.