INSPECTION,INSPECTION,

NON-DESTRUCTIVE TESTINGNON-DESTRUCTIVE TESTING

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STATUTORY REQUIREMENTS STATUTORY REQUIREMENTS E&M, Inspection &CorrosionE&M, Inspection &Corrosion

What is Inspection?Inspection involves the scrutiny of an item and its classification into" conforming" or "non-conforming" (or "defective").

There are two common routes to this:• Measure some physical parameter and compare with a standard

specification limit • Scrutinize the item and subjectively compare it against a standard. The standard can be in the form of a description with or without

visual aid (VA).

There are two critical questions to ask about any inspection process:

1. Are we measuring/ scrutinizing the right characteristic? 2. Have we set the boundary between conforming and non-

conforming in the right place?

INSPECTIONINSPECTION

INSPECTIONINSPECTION

WHY INSPECT?

• Static equipment in 99% of the cases are single line equipment and any leak, corrosion, damage needing immediate repairs will require stopping of operation of the unit, in turn affecting the business of the unit.

• Static equipment inspection ensures that the Company’s assets remain in a satisfactory condition i.e. fit for purpose.

• The basic reasons for inspection are to determine the physical The basic reasons for inspection are to determine the physical condition of the vessel and to determine the type, rate, and causes condition of the vessel and to determine the type, rate, and causes of deterioration.of deterioration.

• This information is carefully documented after each inspection. With this data, safety can be maintained, the period of operation without a shutdown can be extended, the rate of deterioration can sometimes be reduced, and future repair and replacement requirements can be estimated.

Design

Materials

Fabrication

Inspection

Product

FAILURE AVOIDANCE MODEL

OBJECTIVESOBJECTIVES

OBJECTIVES• Proactive inspection programmes based on statutory requirements,

Company policies

• Effective inspection history and inspection record system

• Monitor the equipment; report deviations to management, advise on consequences of the duration and on possible remedial action.

• Advise on new equipment design; repairs and modifications on existing equipment as per statutory and company requirements

• Advise on correct selection and application of materials and design cases to ensure safety and integrity of existing and new assets.

• Maintain professional working relationships with the statutory authorities

To achieve these objectives, following system is adopted:

• Step1: Recording information about physical condition of the process unit.

• Step2: Analysis of the recorded information and recommending actions

• Step3: Verification that adequate action is being/has been taken consistent with recommended actions and according to relevant standards, codes and quality control requirements.

• Step4: Updating of plant records following inspection repairs/renewal to re-establish current condition and recommend next inspection date.

TYPES OF INSPECTIONTYPES OF INSPECTION

SHOP INSPECTION (Vendor works)• Dimensional tolerances• Positive Material Identification• Review of MTCs, Heat treatment charts, WPS etc.• Witnessing hydrotest.

FIELD INSPECTION (On/Off stream inspections)• Ladder, platforms, foundations, supports, Anchor bolts, • Insulation and protective coatings• Nozzles• External surface, Bulges or distortions• Weld seams• Lined and/or unlined areas

INSPECTION TECHNIQUESINSPECTION TECHNIQUES

• 1. VISUAL - Direct Visual Inspection

- Remote Visual Inspection

• 2. NON DESTRUCTIVE TESTING (NDT)– DPT (Dye Penetrant Test)– MPT (Magnetic Particle Test)– RT (Radiography Test)– UT (Ultrasonic Test)

- Eddy current Testing (ET Test)

• 3. PRESSURE TESTING– Hydraulic testing– Pneumatic testing

VISUAL TESTVISUAL TEST

“Mother” of inspection; used to detect and examine surface flaws.

Application• Anything which needs to be inspected viz. Corrosion, deposits, cracks,

surface finish, dead legs, piping supports, piping hangers, insulation, bolting, leaks, injection points etc.

• Visual inspection can be aided by magnifications and/or light viz. Magnifying lens, Rotating mirrors, Borescopes, Fibroscope etc.

• In-situ metallography vide replica method provides information of metallurgical structure and also the topography of the examining surface.

DYE PENETRANT TESTDYE PENETRANT TEST

Principle • Surface tension, capillary action of the penetrant (dye)

Steps • Cleaning, Dye/penetrant application, Dwell time (5-8 mins), Cleaning,

Developing, Dwell time (5-8 mins), Inspect

Application • To detect surface discontinuities viz. cracks, open porosities etc. for both

ferrous and non-ferrous materials.

Types• Normal and Fluorescent (for detecting tight cracks)

Procedure• ASME Sec V

Acceptance• ASME Sec VIII Div I

DYE PENETRANT TESTDYE PENETRANT TEST

Cleaning

Dye application

Crack plane

Cleaning and Developing

Inspection of

indication

MAGNETIC PARTICLE TESTMAGNETIC PARTICLE TEST

Principle • Magnetic flux leakage due to discontinuities

Steps • Cleaning, Induce magnetism vide prods, sprinkle Fe powder, Inspect

Application • To detect surface/sub-surface discontinuities viz. cracks, porosities etc.

for magnetic materials.

Types • Normal: Wet/Dry; Fluorescent: Wet/Dry

Procedure • As per ASME Sec V

Acceptance • ASME Sec VIII Div I

MAGNETIC PARTICLE MAGNETIC PARTICLE EXAMINATIONEXAMINATION

Magnetic field linesDefect

Flux leakage (Fe powder accumulation)

Magnetic field

Job

Magnetizing

currentMagnetic field

ULTRASONIC TESTULTRASONIC TEST

Principle• Reflection of sound waves at interfaces of different media. 1-10 MHz

frequency generated by piezo-electric effect.

Steps• Cleaning, Couplant application, Inspect using UT probe

Application• Thk measurement, corrosion, laminations, cracks etc discontinuities.

Types• Normal beam, Angle beam

Procedure• As per ASME Sec V

Acceptance• ASME Sec VIII Div I

ULTRASONIC TESTING ULTRASONIC TESTING (Normal beam) (Normal beam)

Thickness = Velocity of sound in steel x time/2

ULTRASONIC TESTINGULTRASONIC TESTING(Angle beam)(Angle beam)

RADIOGRAPHY TESTRADIOGRAPHY TEST

Principle • Differential absorption of radiation due difference in densities

Steps • Place radiographic film, Expose to radiation (exposure time), Develop the film

(developing time). Interpretation

Application • Voluminous defects viz. porosities, slag, lack of fusion/penetration etc.

Types• Single wall single image, Double wall single image, Double wall double image

Procedure• As per ASME Sec V

Acceptance• ASME Sec VIII Div I

FILM

WELD

RADIOGRAPHY TESTINGRADIOGRAPHY TESTINGSOURCE

EDDY CURRENT TESTINGEDDY CURRENT TESTING

Principle• An electromagnetic nondestructive testing method in which eddy

current flow is induced in the object. Changes in the flow caused by variations in the object are reflected into a nearby coil or coils where they are detected and measured by suitable instrumentation.

Steps• Cleaning, Surface finish, Inspect using ET probe

Application• Thk measurement, corrosion, cracks etc discontinuities.

Procedure• As per ASME Sec V

Acceptance• ASME Sec VIII Div I

EDDY CURRENT TESTING

THERMAL TESTTHERMAL TEST

Principle

• Temperature differences detected by IR detectors

Steps

• IR detection systems viz. Thermography camera/IR gun

Application

• Hot spots, leak detection

Types

• Normal temperature, High temperature (using filters)

Other Inspection Instruments used

• Infra Red Thermography

• Video scopy

• Automated Ultrasonic Scanning of reformer tubes (H-Scan)

• Laser beam inspection of Coke drums

• Acoustic Emission (AE) Testing.

• Low frequency electromagnetic Technique (LFET) for tank bottom inspection.

• Alternating current field measurement technique (ACFM) for Marine structures.

HYDROTEST

Hydrotest is done for two reasons

Check integrity

Check for leaks.

Integrity check is at

(1.5 x design pressure x temperature correction)

New equipment : 30 mins to 1 hour. Old equipment : 5 to 20 minutes

Leak test is at 2/3 hydrotest pressure. No time limit.

BEWARE OF DIFFERENTIAL PRESSURE TEST IN

EXCHANGERS

PRESSUREPRESSURE TESTING TESTING

HYDROTEST PRECAUTIONS

Know the correct pressure.

Lock expansion bellows

Vent properly.

Use calibrated pressure gages.

Gage range shall be 1.5 to 4 times the pressure to be maintained.

Use two pressure gages.

Pressurize in steps especially if hydrotest pressure is more than 40 barg.

If in delay of arrival of inspector, reduce pressure to less than design pressure.

Do not leave pressurized equipment unattended especially in summer.

Open vent to depressurize.

Drain only with vent in open condition.

PNEUMATIC TESTING

Pneumatic test is dangerous because of the high amount of energy stored in a compressed gas.

Other precautions indicated for hydrotest is applicable for pneumatic test also.

STATUTORY REQUIREMENTSSTATUTORY REQUIREMENTS

• Indian Boiler Regulations (IBR)

• Gujarat Factories Act (GFA)

• Static and Mobile Pressure Vessels (SMPV)

IBR (INDIAN BOILER REGULATION)

• “Boiler” means any closed vessel exceeding 22.75 liters in capacity used expressly for generating steam under pressure.

• “Steam pipe” any pipe through which steam passes at pressures greater than 3 bars or having dia. greater than 10”.

• All steam generators shall be inspected by the competent persons appointed by IBR once in 12 months.

• In case of process unfired boilers (waster heat boilers) exemption may be granted for inspection of the boilers by the competent persons once in 24 months.

• Visual inspection and Hydrotest

SMPV (STATIC AND MOBILE PRESSURE VESSELS)

• Applicable in our case to Spheres, Nitrogen storage vessels and the relief devices installed on the same.

• Inspection of spheres and Nitrogen vessels : Frequency 05 years

• Visual inspection, Magnetic Particle examination of all welds, Ultrasonic examination of TEE joints, Hydrotest.

• Inspection of Relief devices : Frequency 01 year

GUJARAT FACTORIES ACT

• Inspect equipment externally once in 6 months

• Carry out internal examination every year

• If this is not possible then carry out hydrotest once every 2 years.

• Due to continuous nature of operation or unit carry out detailed ultrasonic test once every 4 years

OISD (OIL INDUSTRY SAFETY DIRECTORATE)

• There is no statutory code that specifies an inspection frequency for storage tanks. OISD guidelines are used for fixing inspection frequency. Range 5 - 10 years

Inspection Management GuidelinesInspection Management Guidelines1. MISSION

To ensure that the Static Equipments remain in a satisfactory condition i.e. fit for purpose, for continued operation consistent with requirements of safety, compliance with statutory and RPL requirements and economic operation.

2. VISION

RIL shall apply a philosophy of mix of on-line and off-line inspection. Inspection shall be carried out by qualified and competent personnel working to a structured, overall cost-effective, inspection programme. The inspection function will work to support the business objectives of RPL whilst ensuring that the safety and integrity of the assets are not compromised.

3. OBJECTIVES

Based on an overall integrity assurance management plan, the main objectives of the Inspection function are to: 1. Prepare and implement pro-active inspection programs which are

based on statutory requirements and Company policies and guidelines. 2. Set up and maintain an effective equipment inspection history and

Inspection record system. 3. Monitor that equipment is being operated within design parameters

and highlight to the management cases of deviation. 4. Advice on the design of new equipment and on repairs and

modifications of existing equipment and ensure that these are executed to statutory and Company requirements.

5. Advice on the correct selection and application of materials and design cases to ensure the safety and integrity of existing and new assets.

6. Maintain professional working relationships with the Statutory Authorities to facilitate the effective and safe operation of the Company’s assets.

Factors affecting Inspection FrequencyFactors affecting Inspection Frequency

The frequency of inspection depends broadly on the following factors.

1. Operating conditions2. Physiochemical characteristics of process streams and operating

environment3. Process licensor’s recommendation4. Manufacturer’s recommendation5. Statutory requirements6. Recommendations of various codes and standards like API, OISD

etc which are applicable to our types of refinery.7. Past practices in similar types of operation in other refineries /

plants for e.g. Shell DEP’s8. History of operation of the equipment.9. Risk based Inspection criteria

The above factors shall be analyzed for each and every equipment and thefrequency of inspection shall be fixed.

DESIGN/INSPECTION – CODES & STANDARDS

Few important codes and standards used in Refinery:

• ASME Sec VIII Div 1 & 2 - for pressure vessels

• ASME Sec IX- Welding & Brazing Qualifications.

• IBR - for boilers

• TEMA - for shell & tube heat exchangers

• API 661 - for air fin coolers

• API 650 - for storage tanks

• API 572 - inspection of Pressure Vessels

• API 560 - for fired heaters

• API 520 I/ II - for Relief valves

• API 598 - for Valve inspection and testing

• ANSI B 31.3 - for process piping

• ANSI B 16.5 - for Pipe flanges and flanged fittings

Thank You