Inspection Practices for Pressure Vessels

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Inspection Practices for Pressure Vessels 1 Scope This recommended practice (RP) covers the inspection of pressure vessels. It includes a description of the various types of pressure vessels. (including pressure vessels with a design pressure below 15 psig) and the standards for their construction and maintenance. This RP also includes reasons for inspection, causes of deterioration, frequency and methods of inspection, methods of repair, and preparation of records and reports. Safe operation is emphasized Fion Zhang/ Charlie Chong
2 Normative References The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. • API 510, Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair, and Alteration • API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry • API Recommended Practice 574, Inspection Practices for Piping System Components • API Recommended Practice 575,Guidelines and Methods for Inspection of Existing Atmospheric and Low-pressure Storage Tanks • API Recommended Practice 576, Inspection of Pressure-Relieving Devices • API Recommended Practice 577, Welding Inspection and Metallurgy • API 579-1/ASME FFS-1 1, Fitness-For-Service • API Standard 660, Shell-and-Tube Heat Exchangers • API Standard 661, Air-Cooled Heat Exchangers for General Refinery Service • API Recommended Practice 945, Avoiding Environmental Cracking in Amine Units • API Publication 2214, Spark Ignition Properties of Hand Tools • API Publication 2217A, Guidelines for Safe Work in Inert Confined Spaces in the Petroleum and Petrochemical • Industries 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: 10 Condition Assessment and Repair.
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 43 and 44: If carbon steel would not resist th
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
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Fion Zhang/ Charlie Chong
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Thermal / catalytic reactor Fion Zh
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Separator to separate gases Fion Zh
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Chemical treating unit Fion Zhang/
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Fion Zhang/ Charlie Chong Regenerat
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Figure 7—Vertical Heat Exchanger
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Figure 12—Exchangers Figure 10—
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4.6 Design and Construction Standar
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The ASME BPVC lists materials that
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A pressure vessel should be maintai
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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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