PRESSURE
VESSEL
INSPECTION
PROCEDURE
1. SCOPE
To describe the extent and method for external visual examination of
Vessels to identify concerns and deficiencies.
2. PURPOSE
This work procedure provides the guideline for evaluating the condition of
vessels to identify record and address deficiencies.
3.0 RESPONSIBILITIES
The Inspection Engineer or Plant Inspector (GR) is responsible for the
sustained implementation and development of this work procedure.
It shall be the responsibility of the Inspection Engineer or Plant Inspector
to perform the prescribed examination and issue inspection report. The
plant inspector shall be qualified in accordance with API 510 requirements
or Experienced and conversant with API Codes.
4.0 FORM TO FILL-UP
VESSEL CHECKLIST
5.0 RELATED DOCUMENTS
API 510 Pressure Vessel Inspection Code: Maintenance Inspection,
Rating, Repair, and Alteration
API 572 - Inspection of Pressure Vessels (Towers, Drums, Reactors, Heat
Exchangers, and Condensers)
ANSI/NB-23 National Board Inspection Code
PRESSURE
VESSEL
INSPECTION
PROCEDURE
ASME Code Section VIII Division 1 and 2
6.0 REQUIRED EXAMINATIONS
6.1 Facility Documentation Review
The Inspection Engineer or Plant Inspector shall review the Process
Flow Diagram and Piping and Instrumentation Diagram for the
Facility including any available vendor drawings/data and ensure
that all major process vessels are covered by vessel
Sketches/Drawings.
The Inspection Engineer or Plant Inspector shall, identify missing or
Sketches/Drawings that require Sketching or Revision. And shall
perform the required inspections and report deficiencies in
accordance with this Work Procedure.
The Inspection Engineer or Plant Inspector shall coordinate Vessels
identification with a dedicated Facility Operations Person(s).
Based on the input from the Facility Operation the Inspection
Engineer or Plant Inspector shall determine the priority for
inspection after analysing with the client.
The Inspection Engineer or Plant Inspector shall review available
maintenance / Inspection history to identify repaired areas and areas
of previous concern. Note presence of Temporary Repairs and
Frequent Repairs, shall review available operations records to
identify any pressure/temperature excursions and abnormal
operating conditions i. e. Product contamination, upsets and changes
in service parameters.
PRESSURE
VESSEL
INSPECTION
PROCEDURE
6.2 General Inspection
Vessels shall be visually examined for evidence external mechanical
gouging, external corrosion, buckling and sagging.
Vessels shall be examined for vibration. Paying particular attention
to small bore connections if vibration is present.
Vessels shall be examined for dead legs. All dead legs shall be
recorded for future detailed NDE inspection.
Vessels shall be examined Chemical Injection Locations. Injection
points shall be noted on the inspection sketch.
6.3 Vessels Setting and Supports:
Vessel settings and supports shall be examined to detect signs of
cracking, spalling, shifting or reinforcing bar corrosion.
Structural Steel Supports and Attachments: Vessel supports
members, ladders, platforms, stairs, etc., shall be examined for
cracked welds, missing / loose or broken bolts, damaged paint and
corrosion.
Pipe and Instrument supports attached to the vessel proper or
adjacent to the vessel to be examined for structural stability, cracked
welds, missing / loose or broken bolts or transference of extra loads
to the vessel proper.
Anchor Bolts: Anchor bolts shall be examined for structural
integrity (tap with hammer). Nuts are to be examined for corrosion.
PRESSURE
VESSEL
INSPECTION
PROCEDURE
Grounding System: Ground wire shall be checked for corrosion &
other forms of deterioration. If missing, it shall be properly installed
and coated to prevent corrosion.
Horizontal vessel sliding shoe shall be examined for freedom of
movement. One end of the shoe plate is normally slotted. Cold and
hot settings should be marked for reference.
Stationary saddle caulking to be examined for integrity
6.4 Cladding and Insulation:
Cladding shall be examined for evidence of structural damage, loose
or missing sections, missing fasteners and missing of deteriorated
caulking. In areas of deficient cladding, insulation to be examined
for integrity and weather damage.
Areas of product soaked or sagging / bulged cladding insulation
shall be marked for removal to allow visual inspection of vessel
proper.
Insulation seal ring missing or defective causing water seepage
through cladding. Ensure UT examination points are properly
restored.
6.5 Painting and Coating
Painted areas of heads, shell, boots, man-ways and nozzles to be
examined for signs of paint discoloration due to localized heating
and / or product leakage.
PRESSURE
VESSEL
INSPECTION
PROCEDURE
Blistered, cracked, peeling or spalled paint / coating to be marked
for repair and areas examined for corrosion.
6.6 Physical Appearance
Physical examination shall include examination of all flange
connections for proper stud length, thread engagement and gasket
installation.
Dents, bulges, blisters, etc., on vessel proper shall be marked for
further detailed inspection.
Piping connections, vessel flanges, structural attachment and repad
weep holes shall be examined for any signs of product leakage. If
leakage is evident, preliminary inspection to determine cause of
leakage shall be performed. Leak locations shall be marked for
detailed Inspection and Operations should be notified immediately
for required actions / repairs.
The Plant Inspector shall examine all connections to ensure
supported loads have not been transferred to the vessel proper.
Skirts should be examined for structural integrity and ensure internal
area is clear of debris.
6.7 Fireproofing
Fireproofing, if installed, shall be examined for structural integrity,
cracks, spalling, voids, corroding & exposed wire mesh and voids
caused by sealant deterioration or mechanical damage.
PRESSURE
VESSEL
INSPECTION
PROCEDURE
6.8 Safety Relief Devices
Installed Safety Relief Devices Tag number and set pressure shall be
recorded to verify correct installation. Last overhaul / pop test date
should also be verified to determine if relief valve is due / overdue
for testing.
Safety relief valves shall be checked for any signs of passing,
chattering, physical condition, etc.
6.9 Instrumentation
Installed Instrumentation Tag number shall be recorded to verify
correct installation
Gauge glasses, level controllers, pressure & temperature gauges,
thermowells shall be examined for leaking joints/ connections,
defects, corrosion & etc.
PRESSURE
VESSEL
INSPECTION
PROCEDURE
Vessel Checklist
Vessel No
Vessel Description Height/Length
Design Pressure or MAWP Diameter
Section Inspection Description Comments & Observation
Review the Process Flow
Diagram and Piping and
Instrumentation Diagram for
the Facility and ensure that all
Sketches/
Facility Review major process
Drawings
vessels are covered by Facility
Vessel and vessel identification
with facility identification
personnel
Review previous repairs,
Visual Records/
Pressure Vessel Review past abnormal
Operational
Records operating
Records
conditions
Concrete Inspect concrete foundation for
support cracking, spalling, shifting, and
Foundation signs of
structure
reinforcing bar corrosion
Inspect support members,
Supports,
ladders, platforms, stairs, etc.
Ladders,
for cracked welds
Platform Stairs
missing / loose, or broken bolts,
Structural Steel damaged paint and corrosion
Support & Inspect for structural stability,
Attachments cracked
Instrument welds, missing / loose or
supports broken bolts
and transference of loads to the
vessel Proper
Inspect anchor bolts for
structural
Anchor Bolt
Anchor Bolts integrity (tap with hammer).
condition
Examine
nuts for corrosion
Inspect ground wire cable for
corrosion,
Grounding disjointed strands /
Grounding
System disconnected /
missing / not coated for
corrosion Protection
PRESSURE
VESSEL
INSPECTION
PROCEDURE
Inspect sliding shoe plate is free
to move and is slotted. Cold and
Hot
Horizontal
Vessel Setting settings should be marked.
Vessel
Inspect stationary saddle
caulking for integrity
Inspect cladding for structural
damage, loose or missing
panels, missing fasteners and
missing or deteriorated caulking
Inspect insulation in areas of
deficient
cladding for integrity and
weather damage.
Cladding and Inspect areas suspected to be
Insulated Vessel
Insulation product soaked, sagging or
bulging. Mark for removal to
allow detailed
inspection.Insulation seal ring
missing/ defective or other
causing water seepage for
cladding
Inspect UT location points for
proper restoration.
Inspect UT location points for
proper
restoration.
Examine painted areas for signs
ofpaint discoloration due to
Un Insulated Painting and
localized
Vessel Coating
heating or product leakage
Mark blistered, cracked, peeling
or spalled coating for repair and
examine for corrosion.
Inspect flange connections for
proper stud length and gasket
Flange
installation.
Connections
Inspect Head, Shell, Manways
and Nozzles for dents, bulges,
Physical Nozzles blisters,gouges etc. (Mark for
Apperance detailed inspection).
Inspect Piping connections,
vesselflanges, repad weepholes
Pipe for signs of product leakage
Connections (Mark for detailed inspection &
notify Operations).
Inspect Skirt for structural
Fire Proofing Skirt integrity and ensure internal is
free of debris.
PRESSURE
VESSEL
INSPECTION
PROCEDURE
Inspect Fireproofing for
structural integrity, cracks,
spalling, voids, corroding &
Fire Proofing exposed wire mesh and
Damage voids caused by sealant
deterioration or mechanical
damage.
Pressure Safety Verify tag number and set
Tag Number
Valve pressure
Verify if PSV is due / overdue
Over Due/ Car for overhaul/ pop testing. Check
Seal whether Car Seal is broken or
missing.
Inspect PSV for physical
Passing/
evidence of passing or
Chattering
chattering.
Inspect Gage Glass, Level
INSTRUMENT
Controllers, Pressure &
INSTRUMENT S DEFECTIVE
Temperature Gages, Thermo
S DEFECTIVE /
wells for leaking connections,
defects, corrosion etc
COMMENTS AND OBSERVATIONS
