Integrity Management of Static Equipments and Piping

1 Introduction

Safety and integrity of plant equipments comes through continuous efforts at all stages. The Technical integrity of a system exists when , under specified operating conditions , there is no foreseeable risk of it s failure endangering personnel , environment or asset value. The objectives of Integrity management are : y y y To maximize asset availability To minimize health , safety and environment risk To safeguard and be able to demonstrate technical integrity throughout the asset life

To achieve these objectives the following approach shall be implemented : y Ensuring that assets are designed , constructed and tested as per design requirements and subsequently maintained as per established engineering standards consistent with safety and economical life cycle. Identification of critical factors and technical requirements Structured planning over the life cycle of the asset Single point responsibility and accountability Feed back loop and control mechanism for performance monitoring

y y y y

2 Scope

This covers minimum inspection requirements to enable inspectors to achieve efficient inspection of static equipments / piping and for management to be assured of the system integrity. This covers types of inspection , inspection frequencies , inspection procedures for unfired pressure vessels and process piping. This excludes all mobile and portable pressure vessels and gas cylinders , civil and steel structures , Lifting equipment and devices .

3 Inspection Philosophy
Inspection is intended to verify the integrity of facilities and to provide information for corrective maintenance. The objective is to apply the optimum level of inspection consistent with safe and economic operation of plant. Safety considerations are paramount and are achieved mainly by ensuring that new equipments confirms to standards and specifications. Thereafter regular condition monitoring determines the rate and cause of deterioration in order to predict the extent and type of repair. Inevitably maintenance work following an inspection will be a balance between the lowest life cycle cost and equipment availability. The interval between off stream inspections shall be condition and risk based rather time based , however in certain circumstances for certain equipments & services ; depending on the judgement of inspection engineer it can be time based. Off stream inspections should be scheduled to coincide with planned plant shutdowns. Advantage should also be taken of unplanned shutdown to inspect problem areas of equipment. In certain specific circumstances viz operational constraints or inspection requirements a Non intrusive inspection can replace an Off stream inspection involving visual inspection.

3.1 Role of Inspection and Inspection Activities : The authorized personnel performing the inspection shall be suitably qualified and experienced. Typically personnel performing NDT and inspection activities shall be ASNT Level II ; AWS/CSWIP authorized welding inspectors . For pressure vessel & piping inspection API 510/ 570 / ASME BPV authorized inspectors shall be directly involved in the inspection activities. The key aspects of inspection activities can be divided into following and their interrelation with other sections is depicted in the chart : 1. 2. 3. 4. Planning Scheduling Execution Analysis

INSPECTION MANAGEMENT
PLANNING
y y y Provide due date of inspection Raise work request for inspection Authorize work request Provide budget cover

y
SOFTWARE
Due date of inspection Work request Technical description/specification Inspection data Historical records

SCHEDULING
y y y Determine manpower / material availability Issue work orders for inspection Provide safe access Monitor progress

y
Specialist Advice
API 510 /ASME BPV Inspector

EXECUTION
y y y y y y y Familiarize with equipment details & review equipment history Carry out inspection Prepare inspection records Raise work request for maintenance / repair work Authorize maintenance / repair work Update inspection data Input inspection history

Contractor Activity

Operation

Maintenance ANALYSIS
y y Evaluation of inspection data and findings Make recommendation for j Next inspection date j Change in service condition j Modification to restore to code j Operation outside code j Change in inspection interval

4 TYPES OF INSPECTION
4.1 Pre commissioning Inspection :

Each new equipment shall receive where possible a pre commissioning inspection the results of which shall be documented. The purpose of the pre commissioning inspection shall be to :

y y y y

Confirm that materials of construction and workmanship are in accordance with relevant drawings , specifications , including any special surface treatment and coating. To ensure that all examinations and tests during fabrication , erection and hydrotesting have been carried out in line with the design standard/ approved procedure. Establish a record of the new condition of the equipment. Form a sound basis for judgement of deterioration when compared with the results of subsequent examinations , with particular reference to any original imperfections of the equipment may contain.

A typical pre commissioning check list is as per Annexure-1

4.2 INSERVICE INSPECTION : All inspection activities associated with a pressure vessel once it has been placed in service.

INSERVICE INSPECTION

OFF STREAM INSPECTION

ON STREAM INSPECTION

INTERNAL

EXTERNAL

NON INTRUSIVE

EXTERNAL NON INTRUSIVE

4.2.1 Off Stream Inspection : Detailed examination of the equipment which is isolated from the system . It usually involves internal visual examination.

All new pressure vessels within a two year service period shall be subjected to a thorough internal examination to ensure the following: y y y y y Overall design , fabrication and materials used in construction of the equipments are sound for its service Any deficiencies are investigated and corrected All essential components are examined and checked/measured. Measurements / inspection results are recorded to form the basis for calculations for assessment of corrosion and remaining life prediction Any modifications , renewals or repairs required by the equipment are executed in accordance with design code or engineering specifications / requirements.

Certain type of static equipments ( i.e. filters /suction bottles ) may not be subject to specific inspection schedule but can be inspected as part of normal maintenance or be subject to onstream inspection as piping components.

Subsequent off stream inspections are essentially follow-up examinations, and ensure that : y y y y Equipment and all essential components and fittings are examined and measured / tested. Inspection results are compared with previous results Corrosion patterns or other possible defects are assessed and remaining safe life is reliably predicted. Modification , renewal or repair of the equipment is in accordance with the requirements.

4.2.2 On Stream Inspection : An inspection performed from the outside of a pressure vessel while it is in operation using NDE procedures to establish the suitability of an equipment for continued operation.

4.2.3 External inspection A visual inspection performed from the outside of a pressure vessel to find conditions that could impact the vessels ability to maintain pressure integrity or conditions that compromise the integrity of the supporting structures e.g. ladders , platforms etc. This inspection may be done while the vessel is in operation or while the vessel is out of service. 4.2.4 Internal Inspection An inspection performed from the inside of a pressure vessel using visual and or NDE techniques. 4.2.5 Non Intrusive inspection

5 Frequency and Time of Inspection

5.1 Factors Governing Frequency of Inspection Factors governing the frequency of inspection of pressure vessel are as follows: y y y Type of damage , rate of damage progression / deterioration and the remaining corrosion allowance of the equipment Tolerance of the equipment to the type of damage , Quality of internal linings and their resistance to process conditions Service history record of that equipment A service history record should be established after the first inspection by on-stream methods or internal examination. On the basis of this history ; an inspection interval based on time , condition , or risk based factors can be set in accordance with API 510 or jurisdictional requirements. Service history record of similar equipment under similar operating condition Insurance and legal requirements Changes in process conditions- changes in process operations should be reviewed to determine whether they might affect the deterioration rate . When a change in the deterioration rate occurs or is anticipated , the recommended inspection interval should be changed accordingly. Risk , probability and consequences of failure of the equipment Maximum intervals as defined in codes and standards

y y y

y y

5.2 Opportunities for Inspection The actual time for inspection will usually be determined through the collaboration of process , mechanical , and inspection groups or by the mandate of a jurisdiction. Unscheduled shutdowns due to mechanical or process problems often present opportunities for checks of vessel areas where rapid corrosion , erosion , or other deterioration is known or suspected to occur. Partial shutdowns of units for process reasons also provide opportunities for making some internal inspections to determine conditions and verify on-stream findings and for making needed repairs. However , internal inspections during unscheduled shutdowns should be motivated by specific process or inspection observations. 5.3 Inspection Schedule External Inspection : Each aboveground vessel shall be given a visual external inspection at an interval that does not exceed the lesser of five years or the required internal/on-stream inspection.

Internal and On-stream Inspection : The period between internal or on-stream inspections shall not exceed one half the remaining life of the vessel or 10 years , whichever is less. Pressure relieving Devices Pressure relieving devices should be inspected , tested and maintained in accordance with API 576. Test and inspection intervals for Pressure relieving devices should not exceed: y y Five years for typical process services Ten years for clean and noncorrosive services