Visual Inspection -sample Report For Spherical Vessel 1j1p2b

NDT Inspection and Integrity Assessment of Ammonia Spherical Vessel

INSPECTEST REPORT NO.

SUBJECT GROUP II DIVISION

Report : Date: XYX Rev:00

DATE XYZ

TITLE OF REPORT NDT Inspection and Integrity Assessment of Ammonia Spherical Vessel at XYZ

DEPARTMENT INDUSTRIAL INSPECTION

PROJECT NO.

APPROVED BY INSPECTEST

CLIENT / SPONSOR OF PROJECT / ADDRESS XYZ PAKISTAN ATTN: MR. ABC MAINTENANCE MANAGER

CHECKED BY

WORK CARRIED OUT BY REPORTED BY

DISTRIBUTION STATEMENT: NO DISTRIBUTION WITHOUT LOCATION XYZ

SUBMISSION DATE OF REV. NO. 0

X

PERMISSION FROM RESPONSIBLE DEPARTMENT

THE

LIMITED DISTRIBUTION WITHIN INSPECTEST FREE DISTRIBUTION NUMBER OF PAGES

8

The item/s described above was/were examined in prescribed manner. The information contains hereon reflects the company’s finding at time of inspection only and within client’s instructions & premises. Inspection and certification becomes null and void if any changes made in equipment that alters safety features of above described equipment. This inspection report does not relieve the contractor/ from his obligations to keep the equipment maintained and used safely. Any unsanctioned alteration, forgery or falsification of the content or appearance of document is unlawful and delinquents may be prosecuted to the completest extent of law. Inspectest (Pvt.) Limited 18 km, Ferozepur Road, Lahore, Pakistan  T: + 92 42 3540 2053 ‐58 UAN: III‐INSPEC I F: + 92 42 3540 2050 E: [email protected]                                                                                               1 | P a g e

NDT Inspection and Integrity Assessment of Ammonia Spherical Vessel

Report : Date: XYZ Rev:00

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TABLE OF CONTENTS 1 

Executive Summary ................................................................................................ 3 

2 

Abbreviations ............................................................................................................ 3 

3 

Objective ...................................................................................................................... 3 

4 

Scope of Work ........................................................................................................... 4 

5 

Reference documents ............................................................................................. 4 

6 

Deliverables ............................................................................................................... 4 

7 

Equipment Details ................................................................................................... 4  7.1 

Design Detail ................................................................................................................. 4 

7.2 

Previous Inspection Detail ........................................................................................ 5 

8 

Inspection Equipment/Tools ................................................................................ 5 

9 

Visual Inspection ..................................................................................................... 5  9.1 

External Visual Inspection........................................................................................ 5 

9.2 

Internal Visual Inspection ........................................................................................ 6 

10  Non-Destructive Testing ........................................................................................ 6  10.1 

Ultrasonic thickness gauging ............................................................................... 6 

10.2 

Magnetic Particle Inspection ............................................................................... 6 

11  Integrity Calculations ............................................................................................ 6  11.1 

Calculation of Minimum Required Thickness ................................................ 6 

11.2 

Calculation of Corrosion Rate ............................................................................. 7 

11.3 

Calculation of Remaining Life ............................................................................. 7 

11.4 

Calculation of Next Inspection Interval ........................................................... 8 

12  Conclusion .................................................................................................................. 8  13  Attachments .............................................................................................................. 8 

    The item/s described above was/were examined in prescribed manner. The information contains hereon reflects the company’s finding at time of inspection only and within client’s instructions & premises. Inspection and certification becomes null and void if any changes made in equipment that alters safety features of above described equipment. This inspection report does not relieve the contractor/ from his obligations to keep the equipment maintained and used safely. Any unsanctioned alteration, forgery or falsification of the content or appearance of document is unlawful and delinquents may be prosecuted to the completest extent of law. Inspectest (Pvt.) Limited 18 km, Ferozepur Road, Lahore, Pakistan  T: + 92 42 3540 2053 ‐58 UAN: III‐INSPEC I F: + 92 42 3540 2050 E: [email protected]                                                                                               2 | P a g e

NDT Inspection and Integrity Assessment of Ammonia Spherical Vessel

Report : Date: XYZ Rev:00

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1 Executive Summary In compliance with the instruction from M/s XYZ Company Limited, we attended their Plant at above mentioned date and place.Our purpose of visit was to assess the mechanical integrity of ammonia spherical vessel to establish the suitability of the pressure boundary for continued operation. We have conducted visual external and internal Inspection, Flouroscent Magnetic Particle Testing, Ultrasonic Thickness gauging of differnet components of Sphere. Our findings are as under which were also communicated with client representative via preliminary inspection reports. Inspection team comprised of the following personnel:  01 API 510 Authorized Vessel Inspector  01 Inspection Engineer  05 ASNT Level 2 Examiner

2 Abbreviations API ASNT ASME ASNI AC DPT FFS IPL ID MPI MFL NDT NBIC NPS SCC RP RT UT UTG VT

: : : : : : : : : : : : : : : : : : : :

American Petroleum Institute American Society for Non-Destructive Testing American Society for Mechanical Engineer American Standards National Institute Alternating Current Dye Penetrant Testing Fitness for Service Analysis Inspectest Private Limited Internal Diameter Magnetic Particle Inspection Magnetic Flux Leakage Non-Destructive Testing National Boiler Inspection Code Nominal Pipe Size Stress Corrosion Cracking Recommended Practice Radiography Testing Ultrasonic Testing Ultrasonic Thickness Gauging Visual Testing

3 Objective For integrity assessment of vessel, external and internal visual inspection was perfomed as per API-510 (In Service Pressure Vessel Inspection Code) to to find conditions that could impact the vessel’s ability to maintain pressure integrity or     The item/s described above was/were examined in prescribed manner. The information contains hereon reflects the company’s finding at time of inspection only and within client’s instructions & premises. Inspection and certification becomes null and void if any changes made in equipment that alters safety features of above described equipment. This inspection report does not relieve the contractor/ from his obligations to keep the equipment maintained and used safely. Any unsanctioned alteration, forgery or falsification of the content or appearance of document is unlawful and delinquents may be prosecuted to the completest extent of law. Inspectest (Pvt.) Limited 18 km, Ferozepur Road, Lahore, Pakistan  T: + 92 42 3540 2053 ‐58 UAN: III‐INSPEC I F: + 92 42 3540 2050 E: [email protected]                                                                                               3 | P a g e

NDT Inspection and Integrity Assessment of Ammonia Spherical Vessel

Report : Date: XYZ Rev:00

` conditions. Ultrasonic thickness gauging was conducted in accordance with SE797 of ASME Section V and as per approved procedure. Magnetic Particle testing was carried out as per ASME Section V article 7.

4 Scope of Work Following Inspection and NDT techniques were used for assessment and evaluation of different parts of pressure vessel.    

To perform external and internal visual inspection by API 510 certified inspector to locate any visible imperfection / discontinuity. To perform flouroscent MPI on longitudinal and circumferential welds to locate any surface opening discontinuities. To perform UTG on shell plates, nozzles and man hole to locate any thinning due to corrosion/erosion. To furnish detailed inspection report along with repair recommendation (if any) in case of unacceptable condition such as low thickness, deep and isolated pitting or cracks etc.

5 Reference documents Following international codes and standards were followed during inspection.       

API 510 API RP 572 ASME Section VII,Div 2 API RP 571 API RP 577 ASME Section V NBIC 23 Part 2

`

Pressure Vessel Inspection Code Inspection Practices for Pressure Vessels Rules for construction of pressure vessel Damage Mechanisms Welding Inspection & Metallurgy Nondestructive Examination National Boiler Inspection Code

6 Deliverables The deliverables of the work assigned as per contract were follows:   1. A comprehensive report from API authorized inspector in hard form. 2. Soft copy of report in pdf format.

7 Equipment Details 7.1 Design Detail Following detail of Sphere was taken from available Inspection dossier and Client; Equipment Name : Ammonia Spherical Vessel     The item/s described above was/were examined in prescribed manner. The information contains hereon reflects the company’s finding at time of inspection only and within client’s instructions & premises. Inspection and certification becomes null and void if any changes made in equipment that alters safety features of above described equipment. This inspection report does not relieve the contractor/ from his obligations to keep the equipment maintained and used safely. Any unsanctioned alteration, forgery or falsification of the content or appearance of document is unlawful and delinquents may be prosecuted to the completest extent of law. Inspectest (Pvt.) Limited 18 km, Ferozepur Road, Lahore, Pakistan  T: + 92 42 3540 2053 ‐58 UAN: III‐INSPEC I F: + 92 42 3540 2050 E: [email protected]                                                                                               4 | P a g e

NDT Inspection and Integrity Assessment of Ammonia Spherical Vessel

Report : Date: XYZ Rev:00

` Manufacturer ID Material of construction Corrosion Allowance Manufacturer Code Design Pressure Operating Pressure Hydrotest Pressure Design Temperature Operating Temperature Extent of Radiography t Efficiency Manufacture Year

: : : : : : : : : : : : :

Mitsubishi Corporation 19500 mm A-537 CL2 2 mm ASME Section VIII,Div 2 9 Bar 5.5 Bar 11.3 Bar 60 0C 0-40 0C Full 1 1999

7.2 Previous Inspection Detail Previous inspection of vessel was carried out in January, 2011. Measured thickness of shell in 2011 was 12.10 mm. MPI was also performed, no significant crack like flaws was observed in this inspection tenure.

8 Inspection Equipment/Tools Following equipments were used for inspection;        

Complete visual inspection kit DMS-Go (Ultrasonic Thickness Meter) MPI consumables AC hand yoke Cam gauge Pit depth gauge Meter Tape Vernier Calliper

9 Visual Inspection Vessel was properly purged and vented for entry and all the pre-requisites of internal and external inspection were fulfilled. Platform was provide outside the vessel for external visual inspection and lighting and scafolding was provided inside the vessel for internal visual inspection.

9.1 External Visual Inspection Vessel was insulated externally at the time of inspection. External visual inspection of isulation was carried out for assessment of insulation mechanical and operational integrity specially attention was meted out to the areas where     The item/s described above was/were examined in prescribed manner. The information contains hereon reflects the company’s finding at time of inspection only and within client’s instructions & premises. Inspection and certification becomes null and void if any changes made in equipment that alters safety features of above described equipment. This inspection report does not relieve the contractor/ from his obligations to keep the equipment maintained and used safely. Any unsanctioned alteration, forgery or falsification of the content or appearance of document is unlawful and delinquents may be prosecuted to the completest extent of law. Inspectest (Pvt.) Limited 18 km, Ferozepur Road, Lahore, Pakistan  T: + 92 42 3540 2053 ‐58 UAN: III‐INSPEC I F: + 92 42 3540 2050 E: [email protected]                                                                                               5 | P a g e

NDT Inspection and Integrity Assessment of Ammonia Spherical Vessel

Report : Date: XYZ Rev:00

` isulation t ends meet and any susceptibility of protusion of water or other external environmental fluid or debri etc was analysised visually and by available drawings. No major discrepancy was observed during inspection and overall condition of insulation was decalred to be satisfactory.

9.2 Internal Visual Inspection Internal visual inspection of vessel was performed to locate any visible imperfection / discontinuity. No signs of corrosion, pitting and buging was observed at the time of inspection. Longitudinal and circumferential welds were visually inspected, No signs of visible deterioration was observed.Vessel opportenances were also inspected, found satisfactory. Special attention was given to the areas inside vessel where localized stresses were supposed to be act on further where internal or other structure which can act as stress raisers for susceptibility of Ammonia Stress Corrosion Cracking (SCC), no such anomaly was observed visually.

10 Non-Destructive Testing NDT inspection of Vessel was done as deemed appropriate for suitability for service analysis. Following is the details of NDT inspection.

10.1 Ultrasonic thickness gauging Ultrasonic thickness gauging of Tank Shell plates, openings and other appurtenances was done. Calibrated thickness meter was used for UTG. UTG was perfomed by taking five point on each plate. No major variation was observed in the thickness readings. Minimum observed thickness reading was 11.81 mm. See attached report for reference.

10.2 Magnetic Particle Inspection Flourscent MPI of longitudinal and circumferential welds from internal side for assessments of any cracks surface or subsurface in weld ts was done. Calibrated AC hand yoke was used for magnetization of welds. No crack like flaw was observed at the time of inspection. Details are to be found in Appendix-D.

11 Integrity Calculations 11.1 Calculation of Minimum Required Thickness Minimum required thickness can be calculated by using the following formula:

    The item/s described above was/were examined in prescribed manner. The information contains hereon reflects the company’s finding at time of inspection only and within client’s instructions & premises. Inspection and certification becomes null and void if any changes made in equipment that alters safety features of above described equipment. This inspection report does not relieve the contractor/ from his obligations to keep the equipment maintained and used safely. Any unsanctioned alteration, forgery or falsification of the content or appearance of document is unlawful and delinquents may be prosecuted to the completest extent of law. Inspectest (Pvt.) Limited 18 km, Ferozepur Road, Lahore, Pakistan  T: + 92 42 3540 2053 ‐58 UAN: III‐INSPEC I F: + 92 42 3540 2050 E: [email protected]                                                                                               6 | P a g e

NDT Inspection and Integrity Assessment of Ammonia Spherical Vessel

Report : Date: XYZ Rev:00

` Where t = Minimum required thickness P = Internal Design Pressure D = Internal Diameter S = Maximum Allowable Stress E = t Efficiency P = 130.54 Psi, D= 19500 mm, S= 70000 Psig (From ASME Section II Part D), E= 1 (As mentioned on drawing and on the basis of full RT) t = 9.09 mm

11.2 Calculation of Corrosion Rate Corrosion rate can be calculated by using the following formulae as per API 510 clause 7.1.1.1:

Where tprevious tactual

= Measured thickness in 2011 = 12.10 mm = Measured thickness in 2016 = 11.81 mm

The corrosion rate as per above given formula was calculated as 0.058 mm/year.

11.3 Calculation of Remaining Life Remaining life of vessel can be calculated by using the following formulkae as per API 510 clause 7.2.1.

Where tactual = Measured thickness in 2016 = 11.81 mm trequired = Minimum required thickness = 9.09 mm Corrosion Rate = 0.058 mm/year     The item/s described above was/were examined in prescribed manner. The information contains hereon reflects the company’s finding at time of inspection only and within client’s instructions & premises. Inspection and certification becomes null and void if any changes made in equipment that alters safety features of above described equipment. This inspection report does not relieve the contractor/ from his obligations to keep the equipment maintained and used safely. Any unsanctioned alteration, forgery or falsification of the content or appearance of document is unlawful and delinquents may be prosecuted to the completest extent of law. Inspectest (Pvt.) Limited 18 km, Ferozepur Road, Lahore, Pakistan  T: + 92 42 3540 2053 ‐58 UAN: III‐INSPEC I F: + 92 42 3540 2050 E: [email protected]                                                                                               7 | P a g e

NDT Inspection and Integrity Assessment of Ammonia Spherical Vessel

Report : Date: XYZ Rev:00

` The remaining life as per above given formula was calculated as 47 year.

11.4 Calculation of Next Inspection Interval Next inspection interval as per above calculation and on the basis of API 510 is 05 year for external Visual and ultrasonic inspection and 10 years for internal thourough inspection.

12 Conclusion In light of our inspection and NDT techniques applied, vessel is fit for service. Vessel shell thickness as measured during inspection satisfies the requirement of ASME Section VIII, Div 2 determined in section 11.1 of this report. Measured minimum value of shell is greater than minimum required thickness.

13 Attachments Appendix-A Appendix-B Appendix-C Appendix-D

Ultrasonic Thickness Measurement Reports Photographic Presentation Conceptual Sketches Magnetic Particle Inspection Reports

    The item/s described above was/were examined in prescribed manner. The information contains hereon reflects the company’s finding at time of inspection only and within client’s instructions & premises. Inspection and certification becomes null and void if any changes made in equipment that alters safety features of above described equipment. This inspection report does not relieve the contractor/ from his obligations to keep the equipment maintained and used safely. Any unsanctioned alteration, forgery or falsification of the content or appearance of document is unlawful and delinquents may be prosecuted to the completest extent of law. Inspectest (Pvt.) Limited 18 km, Ferozepur Road, Lahore, Pakistan  T: + 92 42 3540 2053 ‐58 UAN: III‐INSPEC I F: + 92 42 3540 2050 E: [email protected]                                                                                               8 | P a g e