An inspection & evaluation perspective International Inspection Services Ltd.

Main components: 1. Pressure vessels e.g. Atmospheric Distillation Unit, Vacuum Distillation Unit, Stripping Column, desalters, FCC, Reflux drum etc. 2. Connecting piping: Piping and by pass pipe lines carrying various stages of process fluids and interconnecting the process units. 3. Re-boilers: For intermediate heating of process fluids. 4. Air-coolers: For cooling and condensation of process fluids. 5. Valves: Various valves connected to inlets and outlets e. g. stop valves, gate valves, NRVs, and relief valves. 6. Rotating equipments like feed pumps, compressors, turbines etc. 7. Bearings e.g. Rolling element or sliding bearings.

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When inspection for assessment of component integrity is required? During fabrication stage for a new equipment to ensure and evaluate the integrity of the fabricated component in accordance with established International Codes and Standards e. g. ASME Sec VIII Div 1 & 2; ASME B 31.3 etc. After a length of service i.e. after 5 to 10 years of service. During service, the components are subjected to various service conditions including high temperatures, pressures, chemical reactions and high velocity flow of liquids and gases any or all of which may cause service induced damages to the components. The extent of these damages are required to be evaluated by using proper NDE techniques and engineering assessment to ensure the fitness of the component for the intended service. Established codes and standards for this activity are API 570; API 510; API 579; 580 etc.

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During Fabrication Stage for new installation: (ASME Sec VIII Div 1 & 2)
Pressure Vessels:

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Category A & B: Radiography or Ultrasonic Testing; Magnetic particle or Liquid Penetrant testing plus Visual testing of all welds. Category C & D: Ultrasonic Testing; Magnetic particle or Liquid Penetrant testing plus Visual testing of all welds.

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Pressure Piping: (ASME B 31.3 & 31.4; 31.8) API 1104 1. High pressure piping 2. Category M fluid service 3. Category D fluid service 4. Normal Fluid service 5. Severe cyclic conditions Depending on the fluid service requirements (Toxic, Flammable, high pressure, fluctuating loads etc.), the extent of NDT will vary; however all the conventional NDT are required e.g. radiography, Ultrasonic, MPI, PT and Visual testing.

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Inspection after a period of services (Inservice inspection applicable to Piping and vessels)
Understanding the damage mechanism that may be expected during the service based on service environment Knowledge of the specific NDT method that will be useful to detect those damages and their extent. Application of the NDT method and detection as well as extent of the damages. Apply basic rules for evaluation of damages (API 570/API 510/API 653) Apply advanced assessment/formulae for estimating the extent and type of damage (API 579-1/ASME FFS-1). Apply Risk Based Inspection Technology (API 580; API 581). Determination of remaining life of each component based on above (refer 2.4; 2.5 & 2.6).

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2.2 2.3 2.4 2.5 2.6 2.7

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3.1 3.2 3.3 3.4

In-service inspection of Rotating equipment:

Mainly include: Pumps, turbines, bearing and supports, motors etc. Predominant damage mechanisms: Vibrations, wear, fatigue, erosion, erosion corrosion etc. Suitable NDT method: Vibration analysis, thermography Conventional NDT are also applicable: UT, MT,PT & VT mainly.