Professional Documents
Culture Documents
Visual Inspection
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Inspection
File Reference: COE10303
Engineering Encyclopedia
Inspection
Visual Inspection
CONTENTS
PAGES
Engineering Encyclopedia
Inspection
Visual Inspection
Engineering Encyclopedia
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Visual Inspection
Cleaning tools
When needed, use simple cleaning tools such as a scraper or steel brush to clean a
surface before making a preliminary visual inspection.
Chalk or similar marking device
Use marking materials such as chalk to identify potential or suspected problem areas.
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Visual inspections can include both external and internal surfaces of equipment. Internal
surfaces, especially, are often inaccessible and require the use of special inspection tools. In
addition to the auxiliary items listed earlier, the following tools can be used to gather and
record data during visual inspections.
Fiber Optics
Pit Gauges
Cameras
Mirrors
Magnets
The uses, advantages, and limitations of each of these instruments will be discussed in depth
later in this module.
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Visual Inspection
This method of inspection can be used on the internal and/or external surfaces of equipment
such as:
Pipelines
Chokes
Lines
Fittings
Valves
Tanks
Welds
Tubing
Engineering Encyclopedia
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FIGURE 2. Cracking
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Insulated pipes or vessels often have rust stains; bulged, cracked or distorted insulation; and
hot spots, which are indicative of corrosion damage. These features can be noted during a
visual inspection. Figure 3 illustrates this problem.
As a general rule, the initial check of an area should occur before the area is cleaned. Crack
formations and leaks are often easier to discover when an area has not been cleaned. The
Saudi Aramco DeskTop Standards
Engineering Encyclopedia
Inspection
Visual Inspection
location and amount, or significant changes in surface deposits such as rust or scale, also need
to be noted.
After the initial check, a more thorough inspection should be made. Saudi Aramco
documents entitled AIP (Aramco Inspection Procedure) detail step-by-step procedures for
conducting inspections in specific areas. Figure 4 illustrates the type of data that is included
on a typical visual inspection checklist.
Visual Inspection Form
Owner or User No. __________
Jurisdiction or
National Board No. __________
Date of
Inspection
Thickness at
Critical Points
A
Owner _______
Owner _______
Maximum Metal
Temperature at
Critical Points
Date _____
Manufacturer
____________
Manufacturers
Date _____ Serial No.
_______________
Design Pressure
_________
Temperature
_____________
Original Hydrostatic
Test Pressure
____________
Original Thickness:
A
B
C
D
Corrosion Allowance: A
B
C
D
Minimum
Allowable Metal
Thickness at
Critical Points
A B C D
Date of
Next
Inspection
Signature of
Inspector
}
1
}
2
}
3
Date
Date
Date
Date
Date
______________________
______________________
______________________
______________________
______________________
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The final section, section 3, should be used to document the location and time of each
observation. Location description can include potential problem areas as well as location
identifiers from the manufacturers design specifications.
Following a simple inspection checklist such as this one will not only ensure an organized,
time-efficient visual examination, but it will also ensure that all pertinent observations are
documented for future use.
Visual Inspection in Case of Failure
Up to this point, the discussion of visual inspection has focused on using this method to locate
and evaluate potential problem areas. This section focuses on using this method in case of
equipment or system failure.
Direct visual examination and a few simple tests can often reveal why the failure occurred.
Table 1, originally printed in Corrosion and Water Technology for Petroleum Producers,
contains a suggested list of procedures for this type of visual inspection. These steps can be
used as a guide for preparation of a data acquisition form. Preprinted forms, with blank
spaces for observations and comments, are helpful for use by field crews.
1.
2.
4.
5.
6.
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Table 2 from the same source contains a list of observations that may help to identify the
cause of the failure.
TABLE 2. Characteristics of Some Corrosion-Related Failures
Appearance
Probable Contributing Factors
Hydrogen sulfide attack (H2S may be natural
Small conical pits with steep sides and
or generated by bacteria)
smooth edges. Pits filled with black
deposit.
As above plus transverse cracks.
Hydrogen sulfide attack with tensile stress
(stress corrosion fatigue)
Transverse fracture with little or no pitting
Sulfide stress cracking
but with black deposit.
Excessive metal hardness
Round bottom connecting pits with sharp
Carbon dioxide attack
sides. Grey deposit but pit bottoms are
bright.
General thinning with sharp feathery or
Mineral acid corrosion
weblike residual metal. Little or no
deposits.
Rust deposits. Shallow, widespread pitting
Oxygen corrosion
or deep pits under rust nodules.
Single, isolated pits in a row on one side.
Electrolytic corrosion due to current
discharge
Worn or abraded areas with numerous small Erosion by solids or metal rubbing presence
pits.
of H2S, CO2, or O2
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The first two items of visible evidence can be indications of stress corrosion fatigue.
The final evidence, the tensile break, is nonbrittle in nature and probably happened rapidly, as
indicated by the rough texture of the area surrounding it. This break more than likely
occurred after the diameter of the rod had been reduced to the point at which it could no
longer sustain the tensile load.
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Fiber Optics
Pit Gauges
Cameras
Mirrors
Magnets
These simple inspection tools can enhance the effectiveness of visual inspections by helping
an inspector locate, inspect, and accurately record observations. Their uses, limitations, and
advantages will be addressed in this segment.
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Fiber Optics
Description/Operation. Fiber optics in a broad sense refers to endoscopes such as
borescopes and fiberscopes. Endoscopes are optical instruments used for visual inspection of
internal surfaces in tubes, holes, or other hard-to-reach places (Figure 6). Rigid endoscopes
are called borescopes. Flexible endoscopes are called fiberscopes.
FIGURE 6. An endoscope can be used for the visual inspection of hard-to-reach locations
Borescope
A borescope is similar to a telescope, a long tubular instrument with optical lenses. While a
telescope narrows the field of view for observation at a distance, a borescope spreads the field
of view for close-up work. A borescope also has relay lenses along its length to preserve
precise resolution. Magnification is usually 3 to 4.
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Borescopes are available as one-piece units or as modular units for easier storage and
handling. Self-illumination is provided either by lamps integral to the viewhead or fiber
optics (Figure 7). Using mirrors and prisms, the viewhead can provide right angle, bottom,
circumference, forward oblique, or retrospective views.
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Fiberscope
Unlike a borescope, a fiberscope can be inserted into curved pipes and cavities. Fiber optics
transmit light inside the fiberscope.
A fiberscope holds two optical bundles with as many as 120,000 individual strands of glass
fiber. The optical bundles carry light down to the inspection area and carry the image back to
the eyepiece (Figure 8). These bundles, protected by a housing of sealed stainless-steel
flexible conduit, allow the fiberscope to bend for passage around corners or sharp elbows
while sending back a clear image.
The tip of a fiberscope is easily steerable to give up to 240 scanning range and sensitive
movement control.
Internal visual inspection of pipes, boilers, cylinders, motors, reactors, heat exchangers,
turbines, compressors, and other equipment with narrow, inaccessible cavities or
channels
Checking process piping internals for blockage prior to start-up. For instance, early
detection of blockages is extremely critical for piping going to release stacks that vent in
emergencies.
Inspection of pressure relief and other valves for damage or blockage that can cause
valve failures
Examination of internal parts of gear boxes to spot bent shafts, floating gears, broken
keys, and teeth
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Advantages and Limitations. Many jobs place special demands upon the endoscopic
equipment. Selecting the proper equipment to meet the inspection requirements is very
important. The following lists some of the endoscopic equipment and their capabilities.
Explosion-proof and watertight. Some equipment can handle up to 3 bars. They can be
used directly in liquid-filled containers and piping systems without the risk of causing an
explosion, short-circuit, or excessive handling.
Ultraviolet illumination. For surfaces treated with fluorescent material, equipment with
ultraviolet (UV) illumination sources and quartz glass conductors provides greater
sensitivity for inspection of cracks and porosity than with white light.
Optical measuring. For accurate length measurements through the viewhead, equipment
with optical measuring gratings are available.
Adjustable viewing angle. Some models have a movable prism located at the tip of the
optical path so that the viewing angle can be varied during inspection.
Locking position. Fiberscopes can normally be maneuvered into any position by means
of a handle and then locked in place.
Camera/video. For permanent recordings, models are available with cameras or video
recorders. The video recordings reduce eye fatigue and permit group viewing during
and after inspection.
A borescope offers the best choice for high resolution and rapid examination. However, it is
limited to straight-line viewing. Because it is a rigid instrument, the borescope cannot be used
in curved sections of piping and complex-shaped equipment.
Although a fiberscope can access hard-to-reach locations, it has less resolution than a
borescope.
Before a borescope or fiberscope can be used, the equipment or piping to be inspected must
be out of service.
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Both borescopes and fiberscopes are sensitive to external factors. The following precautions
should be taken to prevent tool damage:
Protect the tool from shocks by storing it in a safe place and handling it with care when
in use.
Pit Gauges
Description/Operation. Pit gauges are instruments used to measure the depth of pitting by
placing a calibrated rod in the pit.
Application. Pit gauges are used to access the severity of localized corrosion pitting. They
can be used to measure the depth and width of a depression or cavity in a pitted metal surface.
The distribution of the attack and an indication of the rate of corrosion can be determined by
using these tools.
Advantages and Limitations. Pit gauges are relatively simple to use and the data gathered by
using them is easily interpreted.
These tools can be used to measure the depth of pitting on any accessible surface.
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Cameras
Description/Operation. In general, downhole cameras and video logging devices can
provide high resolution photographic or video images of the wellbore. Some camera systems
have a joystick that the operator can use to scan an area and focus directly on a particular
section inside a well.
The Visual Inspection System, produced by H. Rosen Engineering GmbH, is an example of a
video logging device. It provides high resolution color video records from empty or waterfilled pipelines. The following description/operation information applies to this device.
Closed circuit television can also be used to monitor well activity. This type of visual
equipment is capable of surveying to a depth of one thousand feet or more in areas as small as
eight inches in diameter.
Application. Cameras can supply observations when ordinary close-up inspections and
measurements are not possible. Through the eye of the camera, the distant and inaccessible
internal surfaces of well casings and production tubing can be observed and evaluated closeup. Damage can be observed and the condition of the wellbore can be checked in this
manner.
Cameras and video systems can also be used to provide pictorial evidence of documented
problems. Along with an inspections observation notes, photographs or video images can be
used to evaluate internal corrosion, check internal coating, check valves and welds, and more.
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Magnets
Application. Magnets can assist in identifying the individual material composition of a piece
of equipment by checking the magnetic properties. Since only a few metals are easily
identified by visual observation alone, a magnet can be used to distinguish, for example,
between magnetic types of steel and nonmagnetic stainless steel and other alloys.
Advantages and Limitations. Magnets provide a simple, easy, and inexpensive means of
identifying certain types of metal. This simplicity is also a limitation since the use of magnets
as an inspection tool is limited to this single application.
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Time for
Individual
Measurements
Type of
Information
Speed of
Relation-ship
Possible
Response to
to
Environment
Change
Plant
Type of
Corrosion
Ease of
Interpretation
Visual,
Slow,
with aid of requires
gauges
entry on
shutdown
Distribution Poor
of attack
Accessible Any
surfaces
General or Easy
localized
Optical
aids
(closed
circuit TV,
light bulbs,
etc.)
Distribution Poor
of attack
Localized
Localized Easy
Fast when
access
available,
otherwise
slow
Any
Technological
Culture
Needed
Relatively
simple, but
experience
needed
Relatively
simple
Advantages
As Table 3 indicates, visual inspections provide a simple and easy method of determining the
location and severity of corrosion-related damage. Often the only tools needed to perform
this inspection technique are the trained eyes of the inspector.
The relative simplicity of auxiliary items and tools contribute to a second advantage of visual
inspections economics. Minimal training and low costs for most equipment make visual
inspections an inexpensive and cost-effective method of monitoring corrosion.
Another advantage of visual inspection is its flexibility. It can be performed on external
surfaces while the equipment or system is on-stream, as well as during planned downtimes or
work stoppages. In addition to scheduled intervals, visual inspections can take place any time
a line is open, a pump is down, or a tank is cleaned.
Limitations
Distance is a limitation for visual inspections. The human eye can only distinguish finer
details when the distance to the object is less than one meter, so visual inspection is usually
confined to objects that can be observed at close range.
Furthermore, a visual examination is often neither accurate nor sensitive enough to analyze
many corrosion-related problems. For example, the presence or severity of stress cracking
cannot always be seen during a visual inspection of damaged equipment.
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GLOSSARY
borescope
closed circuit TV
downhole camera
endoscopes
fiber optics
fiberscope
fluorescent
joystick
localized corrosion
micrometer
pit gauges
prism
telescope
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tensile break
vernier
22