Inspection Practices for Pressure Vessels

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Fion Zhang/ Charlie Chong
If carbon steel would not resist the corrosion or erosion expected or would cause contamination of the product, vessels may be lined with other metals or nonmetals. A lined vessel is usually more economical than one built of a solid corrosionresistant material. However, when the pressure vessel will operate at a high temperature, a high pressure, or both, solid alloy steels may be both necessary and economical. Metallic liners are installed in various ways. They may be an integral part of the plate material (1.) rolled or (2.) explosion bonded be<strong>for</strong>e fabrication of the vessel. They may instead be (3.) separate sheets of metal fastened to the vessel by welding. Corrosion-resistant metal can also be applied to the vessel surfaces by various weld (4.) overlay processes. Metallic liners may be made of a ferritic alloy, Alloy 400, nickel, lead, or any other metal resistant to the corrosive agent. Figure 1 through Figure 4 show various methods of applying metallic linings. Figure 5 and Figure 6 show the Hex mesh installation to support the refractory lining and the rein<strong>for</strong>ced refractory lining. (1.) Rolled, (2.) Explosive bonded, (3.) Fasten, (4.) Weld overlay. Fion Zhang/ Charlie Chong
Page 1 and 2: Inspection Practices for Pressure V
Page 3 and 4: Fion Zhang/ Charlie Chong
Page 5 and 6: Contents 1 Scope. 2 Normative Refer
Page 7 and 8: 10 Condition Assessment and Repair.
Page 9 and 10: 2 Normative References The followin
Page 11 and 12: 3 Terms and Definitions 3.1 Definit
Page 13 and 14: 3.1.8 design temperature The temper
Page 15 and 16: 3.1.18 maximum allowable working pr
Page 17 and 18: 3.1.24 pressure vessel engineer One
Page 19 and 20: 3.1.30 testing Within this document
Page 21 and 22: 4 Introduction to Pressure Vessels
Page 23 and 24: 4.1 General 4.2 Methods of Construc
Page 25 and 26: Columns, towers, drums, reactors, h
Page 27 and 28: Pressure vessels are designed in va
Page 31 and 32: 4.2 Methods of Construction Prior t
Page 33 and 34: Fion Zhang/ Charlie Chong The cylin
Page 35 and 36: Fion Zhang/ Charlie Chong Hydrocrac
Page 37 and 38: 4.3 Materials of Construction Carbo
Page 39 and 40: Tubesheets for exchanger bundles ar
Page 41: Fion Zhang/ Charlie Chong
Page 45 and 46: Strip-lined Vessel Fion Zhang/ Char
Page 47 and 48: Fion Zhang/ Charlie Chong Overlay p
Page 53 and 54: Some pressure vessels have heat exc
Page 55 and 56: 1. stationary head—channel cover
Page 63 and 64: Thermal / catalytic reactor Fion Zh
Page 65 and 66: Separator to separate gases Fion Zh
Page 67 and 68: Chemical treating unit Fion Zhang/
Page 69 and 70: Fion Zhang/ Charlie Chong Regenerat
Page 71 and 72: Figure 7—Vertical Heat Exchanger
Page 73 and 74: Figure 12—Exchangers Figure 10—
Page 79 and 80: 4.6 Design and Construction Standar
Page 83 and 84: The ASME BPVC lists materials that
Page 85 and 86: A pressure vessel should be maintai
Page 91 and 92: Reasons for Inspection 5.1 General
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5.2 Safety One of the primary reaso
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Internal company procedures regardi
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Inspection Plans 6.1 General 6.2 In
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f. Safe accessibility of equipment
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6.2 Inspection for Specific Types o
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Understanding factors and condition
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Visual checks of the external parts
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Non- E&P Vessel External Inspection
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7 Frequency and Extent of Inspectio
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7.1 General The frequency with whic
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7.2 Opportunities for Inspection. T
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d) An occasional check of the opera
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8 Safety Precautions and Preparator
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8.1 Safety Precautions Safety preca
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8.1.1 Precautions Regarding the Use
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n) tube gauges (inside diameter); o
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p) thermocouples; q) metal sample-c
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9 Inspection Methods and Limitation
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9.1 General Before starting the ins
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Where operating deposits such as co
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API 510 allows a statistical treatm
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When on-stream inspection to be con
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API 510 permits an on-stream inspec
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9.2.2 Limits of Thickness The limit
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Most vessels are built with greater
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In the case of exchangers, minimum
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9.3 External Inspection 9.3.1 Gener
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9.3.3 Foundations and Supports Foun
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Fion Zhang/ Charlie Chong Excessive
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Some settling is expected in any fo
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9.3.5 Concrete Supports Inspection
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9.3.6 Steel Supports Steel supports
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If supporting skirts are insulated,
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9.3.7 Rivets Although uncommon, riv
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The cable should be inspected for c
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Wall thickness of nozzles should be
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Test the system to see that the res
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9.3.12 Protective Coatings and Insu
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Inspection for CUI should be consid
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Fion Zhang/ Charlie Chong Neutron b
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9.3.13 External Metal Surfaces The
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9.3.14 External Evidence of Corrosi
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Vessels that are partially or compl
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Buckles and bulges will normally be
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API510 3.59 temper embrittlement: T
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API571 SECTION 4.0 GENERAL DAMAGE M
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Brittle Fracture Below DTBTT C, C-
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9.4 Internal Inspection 9.4.1 Gener
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9.4.2 Surface Preparation The degre
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9.4.3 Preliminary Visual Inspection
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Fractionation and distillation towe
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Figure 16—Corrosion in Channel Fi
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9.4.4 Inspection of Degradation 9.4
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9.4.4.1 Thinning and Pitting Thickn
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Fion Zhang/ Charlie Chong 9.4.4.2 C
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Vessels containing amines (absorber
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9.4.4.3 Erosion Erosion usually dif
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9.4.4.4 Blistering Areas directly a
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Figure 19 - Self-vented Hydrogen Bl
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9.4.5 Inspection of Components 9.4.
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9.4.5.2 Trays The general condition
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Fion Zhang/ Charlie Chong Figure 21
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9.4.5.5 Linings Heavy-wall hydropro
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9.4.6 Inspection of Nozzles When ac
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Small 1 in. × 2 in. (2.5 cm × 5.0
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Bulges and buckling often occur in
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Where a lining leaks, it should be
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9.4.8 Inspection of Nonmetallic Lin
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Considerable care should be exercis
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Some refractory-tile linings are hu
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Refractory linings may spall or cra
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9.5 Special Methods of Detecting Me
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Etching of small areas may sometime
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Fion Zhang/ Charlie Chong Sensitize
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9.7 Testing Fion Zhang/ Charlie Cho
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9.7.2 Pressure and Vacuum Testing W
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Pressure testing consists of fillin
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When testing pneumatically, a UT le
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When conducting hydrostatic or pneu
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10ºF / 30ºF / 120ºF Fion Zhang/
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This test will not normally disting
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• Stationary Heat Exchanger with
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• AKT Type Heat Exchanger • Hor
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Frequently, a bundle will be tested
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When water is used to conduct a pre
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10 Condition Assessment and Repair
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10.2 Visual Inspection A visual ins
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Degradation may be determined to be
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10.4 Remaining Life Once the vessel
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10.5 Methods of Repair Although rep
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The defects requiring repair and th
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10.5.1 Welding Repairs 10.5.1.1 Gen
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If the remaining metal, after defec
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10.6 Repair of Supporting Vessel Eq
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11 Records and Reports 11.1 Records
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Field notes consist of notes and me
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These reports should include; • t
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Annex B (informative) Towers Fion Z
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Fractionating column Fion Zhang/ Ch
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Sieve trays Sieve trays are made fr
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One piece valve; This is the most c
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Fion Zhang/ Charlie Chong One piece
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http://seperationtechnology.com/dis
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