Base Line Survey

BASE LINE SURVEY OF PIPING & PRESSURE

VESSELS PROCEDURE

Code : PQ/RSC-BLS/01AGSEREPT

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Uncontrolled Digital Version

Emitter : R.S.C Department

Diffusion: Members of the Technical Direction

I.E N°:

Chapter Description Date

Prepared by

Checked by Approved by

0 all Technique 14/08/2013 Ettoumi Yamen

Hamaidi Mohamed Ali

Karray Walid


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TABLE OF CONTENTS

1. Object ............................................................................................................................................. 3

2. Scope ............................................................................................................................................... 3

3. Definitions and abbreviations ....................................................................................................... 4

4. References Standards .................................................................................................................... 4

5. Applicable documents ................................................................................................................... 4

6. Resources ........................................................................................................................................ 5

6.1 Personnel and Qualification ................................................................................................. 5

6.2 Equipements........................................................................................................................... 5

7. HSE requirements ......................................................................................................................... 5

8. Inspections ...................................................................................................................................... 5

8.1 Review of documentation: .................................................................................................... 5

8.2 Visual inspection .................................................................................................................... 6

8.3 UT Wall thickness measurements ........................................................................................ 6

9. Assessment of the inspection results ............................................................................................ 9

10. Reports ..................................................................................................................................... 10


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1. Object

Serept has assigned TIC to conduct a base line survey of its ASHTART platforms located at Gabes bight near Sfax. The main object of this activity is to asset the inspection results and to provide Serept with inspection and assessment reports of all vessels and pipings within the scope of work.

2. Scope

The present procedure details the requirements and extent of the Base line survey of pressure vessels and Piping in ASHTART Platforms:

• AS PP1.

• AS PF1.

• AS PP2.

• AS PF2.

• AS PF3.

The base line survey is a study of the mechanical integrity of sites by carrying out:

1. Review of all relevant documentation.

2. Visual inspection.

3. A-Scan Ultrasonic inspection.

4. Review and assess the inspection results obtained according to API Standards and

codes.

The survey work will include the following 3 steps:

Step Inspection service Personnel

Duration

(days)

01 Data collection and work preparation - (01) Integrity Engineer certified

API 510

10

02 Wall thickness measurement A-SCAN &

Visual Inspection

- (01) Integrity Engineer certified

API 510

- 02 UT inspectors level II

- 01 assistant

48

03 FFS Assessment

- (01) Integrity Engineer certified

API 510

21

The planning of these three steps is described in Appendix 1.


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3. Definitions and abbreviations

• UT: Ultrasonic Testing.

• P&ID: Piping & Instrumentation Diagram

• Z: Area of A-Scan Inspections

• P: thickness measurement locations

• RL: Remaining life

• PPE: Personal Protective Equipments

4. References Standards

• API 510: Pressure Vessel Inspection Code In-Service Inspection, Rating, Repair, and Alteration.

• API 570: Piping Inspection Code Inspection, Repair, Alteration, and Rerating of In-service Piping Systems.

• API 572: Inspection Practices for Pressure Vessels.

• API 574: Inspection Practices for Piping System components.

• API 579: Fitness For Service.

• ASME VIII: Rules for Construction of Pressure Vessels.

• ASME B-31.3: Process Piping.

• ASME V: Non Destructive Examination.

5. Applicable documents

• Components’ Design Data Sheets;

• Pressure Vessels’ Drawings;

• Previous Maintenance and Inspection Reports;

• Piping’s Isometric;

• P&IDs


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6. Resources 6.1 Personnel and Qualification

• Project Engineer certified API 510.

• Engineer certified API 510.

• 02 UT Inspectors level II.

• Assistant.

6.2 Equipements

• 02 UT Equipments Crautekramer DMS II,

• Camera,

• Meter, Depth gauge…

7. HSE requirements

Before starting the inspection works, these are the minimum requirements that should be followed:

• Preparing permits of work and a Risk assessment reports for each activities and should be signed before starting by each team leader

• All inspectors shall wear their PPE

• Serept procedures shall be respected

8. Inspections 8.1 Review of documentation:

Prior to carrying out the inspection the inspector should ensure that all relevant documentation relating to vessels, piping and Tanks is available. This will include:

• P&IDs.

• Isometric & drawings.

• Datasheets details (Material Grade, Diameter, Nominal Thickness and Corrosion

Allowance) for each component.

• Previous inspection reports.

• Details of Modifications and repairs.

• Details of any process excursions.


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8.2 Visual inspection

The visual inspection is carried out of all accessible external areas of pressure vessels, piping and tanks should be visually inspected to ensure that its condition conforms to acceptable standards. That include:

• Shell & Heads,

• Manways and nozzles,

• Coatings, insulation and painting,

• Welded and bolted Attachments,

• Mechanical damage,

• Supports, Skirts and Mounts,

• Leakage,

• Earthing and Cathodic protection…

The results of the inspection should be reported using report, containing sections relating to the items identified above. A classification of findings with comments should be made for described any damage or anomalies detected (corrosion, cracks, distortion, blisters & dents...).

8.3 UT Wall thickness measurements

For Pressure Vessels:

The UT inspection for pressure vessels (Separator, Scrubber ...) will be:

• For shell area: Scan of windows 10x10 cm² or more in critical zones defined by

the API 510 Inspector according to the process parameters (exp: region of:

interface Oil/Gas, water and gas compartments...), stress concentration and historic

results of inspection.

• For heads area: Scan of windows 10x10 cm² or more in the crown surface.

• For Nozzles of outlet water and gas: Scan of 5 cm area of shell around them or

their reinforcement plates if exist.

• For dead legs and appendices,

• Random wall thickness reading by points measurements in the other regions and

nozzles.

BASE LINE SURVEY

VESSELS PROCEDURE


Here is an example of Pressure Vessel Inspec

The UT inspection for heat exchanger will be Scan of critical zones defined by the API 510 Inspector according to their accessibilities.

For Piping:

For each piping line the followingthickness measurement:

• One horizontal stra

• One vertical straight pipe

• One elbow

• One Tee

• One reducer

• Injection Points

• Dead legs

The selection of these components and its localization is which has to take into considerationpiping and the susceptibility of corrosion in some areas.

The location of the UT scan of pipes, Elbows, Tees and Reducer will be scanned as shown below.

All corrosion imperfections (general or local metal loss and pitting corrosion)greater than the corrosion allowance will be reported.

For roughness surface or external corroded surface, the UT inspection will be randomly after brushing the surface.


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mple of Pressure Vessel Inspection Locations:

The UT inspection for heat exchanger will be Scan of windows 10x10 cm² or more in critical zones defined by the API 510 Inspector according to their accessibilities.

For each piping line the following components and areas are selected to conduct

One horizontal straight pipe

One vertical straight pipe

The selection of these components and its localization is the free choice of the which has to take into consideration the inspections’ histories, the external aspect of the piping and the susceptibility of corrosion in some areas.

The location of the UT scan of pipes, Elbows, Tees and Reducer will be scanned as shown

All corrosion imperfections (general or local metal loss and pitting corrosion)greater than the corrosion allowance will be reported.

For roughness surface or external corroded surface, the UT inspection will be randomly

PQ/RSC-BLS/01AGSEREPT

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windows 10x10 cm² or more in critical zones defined by the API 510 Inspector according to their accessibilities.

are selected to conduct UT wall

the free choice of the Engineer external aspect of the

The location of the UT scan of pipes, Elbows, Tees and Reducer will be scanned as shown

All corrosion imperfections (general or local metal loss and pitting corrosion) with depth

For roughness surface or external corroded surface, the UT inspection will be randomly


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STRAIGHT PIPES:

• For all diameters

W1 W2

12 O'clock

3 or 9O'clock

6 O'clock

100 mm 100 mm

Band 1

L

Band 2

Flowdirection

ELBOWS:

For diameter ≤ 4’’ For diameter > 4’’

W1

W2

6 O

'clo

ck

12 O

'clo

ck

3 or

9O

'clo

ck

W1

W2

6 O

'cl o

ck

12 O

'clo

ck

3 or

9O

'clo

ck

11 O'clock

7 O

'clo

ck

1 O

'cl o

ck

Band 4Band 1

Band 3

Band 2

5 O'clock

50 mm

50 m

m


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TEES:

For diameter ≤ 4’’ For diameter > 4’’

W2W1

W3

12 O

'clo

ck

6 O

'clo

ck

9 O

'clo

ck

W2W1

W3

12 O

'clo

ck

6 O

'clo

ck

9 O

'clo

ck

5 To 7O'clock

Band 1

Band 2

Band 3

Band 4

REDUCERS:

For all diameters

6 O'clock

3 O'clock

12 O'clockW1

W2

9. Assessment of the inspection results

The assessment of the inspection results of devices should be performed according to their appropriate code (See Reference Codes).

The assessment is based on:

• All thickness measurements should be compared to the required thickness

calculated according to the construction code.

• Calculation of the short and long term corrosion rate.

• Calculation of the remaining life (RL).

• Evaluation of the next planned inspection.


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The acceptance criteria for piping are described below:

10. Reports

The project engineer should deliver:

• Daily reports describe the progress for Visual and UT inspection of pressure

vessels and piping components;

• Visual Inspection reports;

• UT inspection reports;

• Assessment reports;

• Summary of defects detected.

Appendix 2 provides an example of reporting and Appendix 3 an example of daily report.

RL ≤ 5 years: Device Should be replaced.

5 < RL ≤ 10: Device Should be periodically monitored.

RL > 10 years Device is Safe and can operate at their appropriate MAWP.

Base Line Survey

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