OISD - 128

Amended edition

FOR RESTRICTED
CIRULATION

No.

INSPECTION
OF
UNFIRED PRESSURE VESSELS

OISD - STANDARD-128
First Edition, November 1988
Amended edition, August, 1999

OIL INDUSTRY SAFETY DIRECTORATE

Government of India
(Department of Petroleum & Natural Gas)

I
 OISD – STD- 128
First Edition, November, 1988
Amended edition, August, 1999

FOR RESTRICTED
CIRCULATION

INSPECTION
OF
UNFIRED PRESSURE VESSELS

Prepared by

COMMITTEE ON INSPECTION
OF STATIC EQUIPMENT

OIL INDUSTRY SAFETY DIRECTORATE

2nd Floor, KAILASH BUILDING,
26, KASTURBA GANDHI MARG,
NEW DELHI - 110 001.

II
 NOTE

OISD publications are prepared for use in the Oil and gas
industry under Ministry of Petroleum and Natural Gas. These are the
property of Ministry of Petroleum and Natural Gas and shall not be
reproduced or copied and loaned or exhibited to others without written
consent from OISD.

Though every effort has been made to assure the accuracy

and reliability of the data contained in these documents, OISD hereby
expressly disclaims any liability or responsibility for loss or damage
resulting from their use.

These documents are intended only to supplement and not to

replace the prevailing statutory requirements.

Note 1 in superscript indicates the

modification/changes/addition based on the
amendments approved in the 17 th Safety Council
meeting held in July, 1999.

III
 FOREWORD

The Oil Industry in India is nearly 100 years old. Due to

various collaboration agreements, a variety of international codes,
standards and practices have been in vogue. Standardisation in
design philosophies and operating and maintenance practices at a
national level was hardly in existence. This, coupled with feed back
from some serious accidents that occurred in the recent past in India
and abroad, emphasized the need for the industry to review the
existing state of art in designing, operating and maintaining oil and
gas installations.

With this in view, the Ministry of Petroleum & Natural Gas, in

1986, constituted a Safety Council assisted by Oil Industry Safety
Directorate (OISD), staffed from within the industry, in formulating and
implementing a series of self regulatory measures aimed at removing
obsolescence, standardising and upgrading the existing standards to
ensure safer operations. Accordingly, OISD constituted a number of
Functional Committees comprising of experts nominated from the
industry to draw up standards and guidelines on various subjects.

The present document on “Inspection of Unfired Pressure

Vessels” has been prepared by the Functional Committee on
“Inspection of Static Equipment”. This document is based on the
accumulated knowledge and experience of industry members and the
various national and international codes and practices. It is
recognised that failure of internals of a pressure vessel may only
affect its performance and at most times may not materially affect the
safety of the vessel. However, it is also recognised that failure of an
internal component may load to unit upsets which in turn could lead to
a leak of hydrocarbons. Keeping this in view the Committee decided
to include inspection of internals also as a part of this standard. This
document is meant to be used as a supplement and not as a
replacement for existing codes and practices. It is hoped that the
provisions of this document, when adopted may go a long way to
improve the safety and reduce accidents in the Oil and Gas Industry.
Users are cautioned that no standard can be a substitute for the
judgment of a responsible qualified inspection Engineer. Suggestions
are invited from the users, after it is put into practice, to improve the
document further.

This standard in no way supercedes the statutory regulations

of CCE, Factory Inspectorate or any other Govt. body which must be
followed as applicable.

Suggestions for amendments to this document should be

addressed to

The Co-ordinator,
Committee on
“Inspection of Static Equipment,
Oil Industry Safety Directorate,
2ND Floor, “Kailash”
26, KasturbaGandhi Road,
New Delhi – 110 001
COMMITTEE

IV
 ON
INSPECTION OF STATIC EQUIPMENT
List of Members
---------------------------------------------------------------------------------------------------------------------------------------
Name Designation & Position in
Organisation Committee
---------------------------------------------------------------------------------------------------------------------------------------
1. Sh. R.K. Sabharwal CMNM-IOC (R & P) Leader
2. Sh.A.S. Soni DGM (P)-ONGC Member
3. Sh.R.H. Vohra DGM-IOC (Mkt.) Member
4. Sh.D.P. Dhall CH INSP & AE MGR-BPC (REF) Member
5. Sh.P. Dasgupta SIPM-IOC ( R & P) Member
6. Sh.I.M. Advani MGR INSP-(PROJ) HPC (REF) Member
7. Sh.R.M.N. Marar Jt.Director OISD Member Co-ordinator.
---------------------------------------------------------------------------------------------------------------------------------------
In addition to the above, several other experts from industry contributed in the preparation, review and
finalisation of this document.

V
 INSPECTION OF UNFIRED PRESSURE VESSELS

CONTENTS

SECTION PAGE NO.

1.0 Introduction

2.0 Scope

3.0 Definition and Types of Pressure Vessels

3.1 Pressure Vessel
3.2 Types of Pressure Vessels

4.0 Role of Inspection

5.0 Inspection Tools

6.0 Inspection of New Pressure Vessels During Fabrication

7.0 Check List for Inspection of Pressure Vessels Prior to Erection and
Commissioning.

8.0 Likely Locations of Metal Wastage

8.1 Main Fractionating Towers of Crude Distillation Unit
8.2 Crude Distillation Unit-Overhead Accumulators
8.3 Dehydration, LP./HP. Separators
8.4 Vacuum Distillation Columns
8.5 Reactors in Reformers
8.6 Reactors in FCCU
8.7 Regenerator in FCCU
8.8 Orifice Chamber in FCCU
8.9 Coke Chambers
8.10 Bullets and Spheres
8.11 Vessels in Low Temperature Service
8.12 Ammonia Storage Vessels
8.13 Columns & Vessels in Diethyl Amine & Monoethyl Amine Service

9.0 Frequency of Inspection

10.0 Inspection Procedures

10.1 Inspection of Columns
10.1.1 External Inspection
10.1.2 Internal Inspection
10.1.3 Inspection of Lined Columns
10.1.4 Inspection of Pressure Vessels in FCCU
10.2 Inspection of Vessels
10.2.1 External Inspection
10.2.2 Internal Inspection
10.2.3 Riveted Vessels
10.3 Corrosion Coupons/Probes
10.4 Safety Relief Devices

11.0 Retiring Thickness

VI
12.0 Inspection During Maintenance
12.1 Weld Build Up
12.2 Nozzles Replacement
12.3 Partial Replacement of Shell Plates and Domes
12.3.1 Hydrostatic Test
12.3.2 Pneumatic Testing
12.4 Repair of Cladding and Striplining
12.5 Repair of Painted and Rubberlined Areas
13.0 Documentation

14.0 References

ANNEXURES

I Inspection Check List for Column in Service

II Inspection of Welding
III Hydrogen Blisters-Inspection, Evaluation and
Repair of Pressure Vessels

VII
 INSPECTION OF UNFIRED PRESSURE VESSELS

1.O INTRODUCTION

The contents of a pressure vessel are 4.0 ROLE OF INSPECTION

always under pressure. Any deterioration of the
vessel could lead to a large release of The following are the activities of the
hydrocarbon vapour and consequent creation inspection division:
of a flammable atmosphere. Timely inspection
and Preventive Maintenance will go a long way i) To inspect, measure and record the
in ensuring safe operation of pressure vessels. deterioration of materials and to evaluate
present physical condition of the pressure
2.0 SCOPE vessel for its soundness to continue in
service.
This standard covers the minimum ii) To corelate the deterioration rate with
inspection to be carried out during operation design life for further run.
and maintenance of pressure vessels. The iii) To determine causes of deterioration and to
standard specifies frequency of inspection, advise remedial measures.
inspection procedures, areas to be inspected in iv) To recommend/forecast short-term and
the pressure vessels and inspection during and long-term repairs and replacements to
after repairs. This standard also covers in brief, ensure further run length on the basis of
fabrication and pre-commissioning inspection economics and safety.
checks. v) To advise regarding equipment/component
replacement so that procurement action
could be initiated.
3.0 DEFINITION AND TYPES OF vi) To inspect while doing the repairs and to
PRESSURE VESSELS accept after completion of repairs.
vii) To maintain uptodate maintenance &
3.1 PRESSURE VESSEL inspection records and history of pressure
vessels.
A pressure vessel is defined as a viii) To keep the concerned operating and
vessel designed to safely withstand an internal maintenance personnel fully informed as to
pressure in excess of 1.05 Kg/Sq.cm. Some the condition of the various pressure
vessels in a refinery may be subjected to vessels.
external pressure caused by an internal ix) To advise regarding schedules of pressure
vacuum or by a fluid pressure between an vessels inspection and also statutory
outer jacket and the vessel wall. Such vessels requirement schedules.
are usually inspected in the same manner as
vessels with internal pressure.
5.0 INSPECTION TOOLS
3.2 TYPES OF PRESSURE VESSELS
Tools required for Pressure Vessels Inspection
The following four types of pressure are as follows:
vessels are normally used in hydrocarbon
service: i) Ultrasonic Thickness Gauge.
ii)Ultrasonic Flaw Detector.
i) Cylindrical vessels with flat, conical, iii)
Radiography Equipment.
toriconical, torispherical, semiellipsodial or iv)Magnetic Particle Testing Kit. (Wet
hemispherical heads. Fluorescent Type)
ii) Spheroids. v) Metallographic Equipment.
iii) Spherical.
iv) Jacketted Vessels
vi) Infra-red Scanner for Thermography.
Cyllindrical vessels can be vertical or vii) Dye Penetrant Kit.
horizontal and may be supported in different viii) Paint Thickness Gauge.
ways. ix) Shore Hardness Meter.

1
x) Adhesion Testing Kit. tori cones etc.) as per relevant codes /
xi) Holiday Detector. drawings. NOTE 1
xii) Spark Tester. xii) Ensure all internal attachments are welded
xiii) Pit Depth Gauge. as per drawing. NOTE 1
xiv) ID & OD Gauges. xiii) Witness pneumatic tests of the liner
xv) Plumb & Bob. welds (lined nozzles) and reinforcement
xvi) Magnet.
pads. NOTE 1
xvii) Measuring Tape.
xviii) Magnifying Glass. xiv) Inspect for ferrous contamination of
xix) Temp. Indicating Crayons. corrosion overlay welding/flange facings
xx) Inspector’s Hammer. etc., as per code. NOTE 1
xxi) Straight Edge. xv) Ensure proper welding of insulation bearing
xxii) Safety Torch. nuts wherever applicable. NOTE 1
xvi) Ensure proper welding of refractory
6.0 INSPECTION OF NEW bearing lugs/hexes etc. wherever
PRESSURE VESSELS DURING applicable.”NOTE 1
FABRICATION xvii) Ensure repairs and reinspection of
damaged parts, if any, are carried out
before giving clearance for hydrostatic
Pressure vessels are designed as per testing.
various codes available like IS, BS, ASME etc. xviii) Check the procedure for various types
The design and consequently, inspection of of testing.
pressure vessels shall be as per any one code
xix) Ensure all the tests are carried out
only and not by a combination of different
strictly as per the approved procedures.
codes since factor of safety used while arriving
at design stresses for different materials vary xx) Inspect quality of painting as specified in
with codes. Inspection of the new pressure the tender document.
vessel at the time of fabrication is done as per xxi) Check that vessel has been stamped
the inspection requirements of relevant code. as per code.
xxii) Prepare and certify the relevant
Inspection shall be carried out in the following documents.
stages:
7.0 CHECK LIST FOR
i) Study of the tender document and all the INSPECTION OF PRESSURE
technical specifications.
VESSELS PRIOR TO
ii) Identification and inspection of the
materials.
ERECTION AND
iii) Check bonding of cladded plates, wherever COMMISSIONING.
applicable before and after forming.
iv) Approve the welding procedures in The check list format shall contain the following
accordance with tender specifications/ information.
code requirements.
v) Carry out welders performance Equipment No.
qualification test as per the code. Plant
vi) Check nozzle orientation, joints fitup and Duty
Purchase Order No. & Date
overall dimensions as per the approved
Serial No. & Type
drawings.
Manufacturer
vii) Ensure that welding is carried out as per Main Dimensions
agreed welding sequence and welding Material of Construction
procedure with approved electrodes and Max. Allow. working pressure/Vacuum
tested welders. Max. Allow. Working Temperature
viii) Inspect the weld joints for proper Stress-relieved
quality during welding. Radiography
ix) Ensure proper post weld heat treatment Hydrostatic Test Pressure
whenever required. Erection Contractor
x) Inspect weld joints by radiography as per Contractor’s Inspector
the code. Company’s Inspector
xi) “Ensure proper heat treatment is carried Date of Inspection
out for cold formed parts (like dishends,
CHECKLIST

2

The following checks shall be made
prior to commissioning of new pressure
vessels.
CHECKS
1. Check for proper
alignment of supports.
2. Check nameplate
attachment.
3. Check nameplate rating.
4. Check foundation bolts
and shims.
CHECKS
5. Inspect shell wall for out
of roundness, bulges and
dents.
6. Inspect visually, weld
joints.
7. Check alterations made
during plant construction.
8. Check wall thickness of
shell and nozzles.
9. Check and test
reinforcement plates and
test holes.
10. Check and test nozzles,
facings, gaskets and
bolts.
11. Check outside bolting and
stiffening rings.
12. Check insulation and fire
proofing.
13. Check insulation
protection.
14. Check painting quality.
15. Check internals.
16. Check and test internal
lining of shell nozzles.
17. Check for internal
cleanliness before final
boxing up.
18. Check whether design of
vessel and foundation
allows vessel to be
hydrotested in situ.
19. Test shell hydrostatically,
if any alteration has been
made in the shell.
20. Check whether proper
relief valve is installed.
21. Check that connected
pipings do not strain the
vessel nozzles.
22. Check for verticality of
columns and tall vessels.
Note 1
REMARKS 8.0 LIKELY LOCATIONS OF
METAL WASTAGE
8.1 MAIN FRACTIONATING TOWERS OF
CRUDE DISTILLATION UNIT
The fractionating column bottom and
internals are subjected to high temperature
corrosion due to presence of sulphur whereas
column top is prone to low temperature acidic
REMARKS
corrosion because of salts and H2S present in
the crude. The crude containing naphthenic
acid also causes the corrosion of the column
shell, and the same is pronounced in the
sections where temperature ranges from 200oC
to 400oC. Severity of naphthenic acid attack is
higher where the turbulent conditions exist.
The impingement plate particularly in the
columns where the feed nozzle is radial is
subjected to severe erosion. Noticeable
corrosion or erosion is also generally observed
where the steam impinges the shell. The
dislodging of the trays (particularly valve trays)
is common due to steam surge.
Galvanic corrosion is also observed at
the location where cladded shells and
uncladded shells join together. Where the
lining is bulged, the parent metal is subjected
to corrosion. Liquid level corrosion is
noticeable in the top tray downcomer collectors
particularly at the reflux collector trays.
8.2 CRUDE DISTILLATION UNIT-
OVERHEAD ACCUMULATORS
Pronounced corrosion is generally
noticed at the interface level of water and
hydrocarbons. Mostly the corrosion is noticed
in the bottom portion of the accumulators,
which are not internally protected.
8.3 DEHYDRATOR, LP/HP SEPARATORS
Dehydrators & LP/HP separators of
crude stabilising units are likely to get corroded
in the bottom portion from 5 to 7 O’ clock
position due to presence of salt & water.
8.4 VACUUM DISTILLATION COLUMNS
The sections where the turbulent
conditions exist like impingement plate/flash
zone are subjected to corrosion erosion due to
naphthenic acid and sulphur in the crude.
Columns, shells are also liable to corrode
3
opposite to impingement plate due to rebound
of fluid. Weldments and Heat Affected Zone
are also susceptible to corrosion.
8.5 REACTORS IN REFORMERS
Generally the reactors are of low alloy
steels like 2-1/4Cr-1 Mo or cladded with
stainless steel. Due to this superior metallurgy
metal wastage is generally not observed.
However, the following locations give indication
of deterioration/cracking.
i) Cracking of weldment of grid with shell at
the bottom..
ii) Baskets for collecting the catalyst dust are
also prone to corrosion.
iii) Liners installed in the big diameter nozzles
are susceptible to bulging due to failure of
weld joints at the end.
iv) Reactors made of low allow steel specially
2-1/4Cr-1 Mo are prone to temper
embrittlement. (Temper embrittlement is
defined as a loss of ductility and notch
toughness due to post weld heat treatment
or high temperature service above 3700 C.)
8.6 REACTORS IN FCCU
The shell, riser O.D. and portion of the
cyclone dipleg O.D. are severely attacked in
the riser extension type of installation. Where
the grids are still used, erosion is found fairly
uniform over most of the grid when high
velocities are employed through cyclones.
Some erosion occurs to the wall of the plenum
chambers and to the top head where small
plenums are in use. For those reactors with
only two cyclones, high swirl of catalyst through
the nozzles cause severe erosion.
The refractory lining generally stands
up quite well in reactor cyclones. Normal
repairs require some resurfacing of small areas
or replacement of small localised sections.
There are two kinds of valves at the bottom of
dipleg. The one mostly in use is the flapper
type with counter weight. The other is the
trickle valve type, with the flapper plate
hanging over the opening suspended by rings.
The flapper type of valves are subjected to
erosion.
8.7 REGENERATOR IN FCCU
In the plate type of distribution grid,
erosion to the grid plates is a common
phenomenon. Due to considerable vibration
and heat differentials cracking of the grid plate
can also take place.
4
In pipe type of grid design where seals
are still in use, these seals may leak. Migration
of catalyst past the seal could destroy a pipe
grid in a very short time.
The branches (pipe coming off each
lateral) experience metal loss, mainly to the top
circumference. Occasionally the steam
coming out of jet blowing directly into another
branch, lateral or end plate creates erosion.
Warpage of pipe grids can take place due to
overheating during startup and during
operation. Many 5% Cr. grids experience weld
cracking.
The failure of refractory lining on the
shell is another common problem. During
operation, it may cause hot spots on the shell.
Erosion of cyclone dip legs, failure of cyclone
welds alongwith weld of cyclone supports may
also take place.
8.8 ORIFICE CHAMBER IN FCCU
Erosion of the double disc sliding valve
gates, erosion at the core near the inlet and at
holes/sleeves in the grid plate are common
problems. Bulging or cracking on the shell
adjacent to the gridplate also may take place.
The erosion problems in orifice chamber are
caused by the catalyst carryover from the
Regenerator.
8.9 CHOKE CHAMBERS
Cracking of skirt and shell weld joints is
quite common particularly in the coke
chambers where the skirt is not of slotted type.
In the coke chambers generally feed, stripping
steam and water quench nozzles are installed
at the bottom. Due to thermal cyclic shocks
lower portion of the coke chamber gets bulged.
At the advanced stages of bulging,
circumferential welds which act as stiffeners
get cracked in the axial direction. However,
the effect is pronounced just opposite the feed
entry nozzle at an elevation of about 1 meter.
The chambers where the feed enters from the
top, bulging is confined in the top portion. The
conical portion of the coke chamber where the
feed enters is also prone to cracking at the
knuckle portion. Bottom flange to shell weld
joint, weld joints of feed, water quench and
steam nozzles are also likely to crack under
thermal cyclic conditions.
8.10 BULLETS AND SPHERE
The corrosion and scaling is generally
confined to the bottom between 5 to 7 O’ clock
positions probably due to the presence of
corrodents like H2S and water. LPG storage
vessels are also prone to stress corrosion
cracking. The circumferential weld joints below
the equitorial plates in the LPG Horton
spheres are more prone on such cracking.
8.11 VESSELS IN LOW TEMPERATURE
SERVICE
Vessels in low temperature service e.g.
in KTU of refineries and propane circuit of LPG
recovery units of Gas Processing Plants are
prone to external corrosion due to faulty
insulation, which causes condensation of the
vessels. The severity of corrosion increases in
case of corrosive atmosphere as in KTU.
In these vessels internal corrosion due
to moist So2 where condensation can take
place, also occurs. Internals and shell are
affected due to this.
8.12 AMMONIA STORAGE VESSELS
Generally the storage vessels are
fabricated from Carbon steel and Nickel steels.
For the operating conditions prevailing at
refineries, material of construction used for
Ammonia storage vessels in the refineries are
carbon steels. The weld joints of C.S. vessels
are prone to stress corrosion cracking
particularly in the vessels, which have not been
stress relieved initially or after fabrication
repairs.
8.13 COLUMNS & VESSELS IN DIETHYL
AMINE OR MONOETHYL AMINE
SERVICE
The weld joints and heat affected zone
of the columns and vessels in DEA and MEA
service which have not been stress relieved
are also prone to cracking due to presence of
H2S or H2S and H2.
Further details about corrosion in
pressure vessels are available in corrosion
Manual-OISD Publication No. 136.
9.0 FREQUENCY OF INSPECTION
i) All new vessels, regardless of service shall
be inspected within first 2 years of
operation. Thereafter, the periods of future
inspection shall be scheduled on the basis
of established corrosion rates, the type of
service, remaining corrosion allowance and
the life expectancy.
ii) The frequency of inspection shall be
determined based on history, corrosiveness
5
of the fluid handled and operating
conditions. The periods between
inspection shall be planned so that
minimum corrosion allowance remains for
the next run. In any case inspection
frequencies as per statutory requirements
shall be strictly adhered to.
Internal inspection of all the columns,
and vessels installed in battery area should
be done during scheduled turnarounds,
unless inspection observations and
corrosion rates dictate otherwise. Other
pressure vessels installed in offsite shall be
internally inspected at the time when these
are due for hydrostatic test as per statutory
requirements.
iii) The internal inspection of reactors is
generally programmed when the catalyst is
dumped or topped up. However, it is
recommended that in-situ metallography
be carried out once in 5 years or at the
time of replacement of catalyst. The
reactors shall be inspected externally in
every turnaround and the internal,
inspection shall be carried out within 10
years.
10.0 INSPECTION PROCEDURES
Prior to initiating the inspection of
pressure vessels, the inspector should
familiarise himself with the complete previous
history of the vessel, design parameters,
service, original thickness, corrosion
allowance, corrosion rate and vulnerable
locations of corrosion.
10.1 INSPECTION OF COLUMNS
10.1.1 External Inspection
Most of the external inspection can be
done while the column is in operation. The
following shall be checked during the external
inspection.
I) FOUNDATION AND SUPPORTS
a) Foundations
Foundations for pressure vessels are
mostly constructed of steel reinforced concrete
or of fireproofed structural steel. These shall
be checked for spalling cracking and
settlement. Settlement shall be checked till it
gets stabilised Note 1. If due to cracks, big gaps
have been formed, steel should be checked for
external corrosion by removing the concrete at
cracked locations.
b) Skirts
Skirts shall be inspected for corrosion,
distortion and cracking from outside as well as
from inside. The weather proofing on the
extremities and fire proofing of structural
supports shall be checked for water tightness.
The inside of the skirt is often
subjected to corrosion. This is particularly true
for vessels operating under cryogenic
conditions. Thickness measurements shall
also be done to assess the extent of
deterioration. The condition of fire proofing on
support beams and skirts shall be inspected for
bulging and cracks. Very light taps with a
hammer will indicate lack of bond between fire
proofing and steel. Appearance of rust stains
on the surface of fire proofing is an indication
of moisture ingress and presence of corrosion
on the metal underneath. If there is reason to
suspect that water or moisture has seeped
through to the steel, pockets of insulation
should be removed to determine the extent of
corrosion. however, inspection of the skirt after
removal of fireproofing insulation shall be done
at an interval not greater than 5 years. Skirt to
shell weld joint shall be checked for cracking.
c) Support of Horizontal Vessels
Horizontal vessels resting on concrete
saddle supports where water can accumulate
and cause external corrosion shall also be
inspected. Horizontal vessels operating at high
temperatures shall be checked to ensure free
thermal expansion.
ii) FOUNDATION/ANCHOR BOLTS
Foundation bolts shall be inspected for
corrosion and damage. The nuts on anchor
bolts may be inspected to see that these are
properly tightened.
iii) LADDERS, STAIRWAYS,
PLATFORMS AND STRUCTURALS
These shall be inspected visually for
corrosion, cracks, paint failure etc. Visual
inspection shall be supplemented by hammer
testing. Corrosion is most likely to occur at
points where moisture can accumulate.
Crevice corrosion may exist around the heads
and nuts of bolts. Ladders shall be examined
for free movement to take up expansion of the
vessels.
iv) INSULATION AND PROTECTIVE
COATINGS
6
Visual examination of insulation will
reveal its condition. Insulation shielding shall
also be checked for quality and thickness. At
few locations samples may be removed to
determine condition of the insulation and of the
metal underneath. Paint or protective coating
shall be examined for peeling or rusting .
Insulation shielding should be intact. If at any
time insulation shielding/cladding is blown off
or damaged the same shall be put back
immediately after repairs to avoid corrosion.
The insulation retaining rings shall be checked
to see that moisture is not trapped between the
rings and weldment. The pressure vessels
operating at high temperature are insulated
from outside and the skirt is insulated from
outside as well as inside to reduce the thermal
gradient between skirt and shell weld joint. Any
damage to this insulation is likely to cause the
cracking of this joint. Hence the insulation
shall be inspected to ensure that the same is
intact.
v) GROUND CONNECTIONS
Grounding connections shall be
visually examined to see that good electrical
contact is maintained. The cable shall be
examined for broken strands. Its resistance
shall be checked at intervals as outlined in
OISD standard-137 (Inspection of Electrical
Equipment).
vi) NOZZLES AND SMALL
CONNECTIONS
The nozzles on a pressure vessel shall
be visually inspected and thickness surveyed.
When vessel is out of service, carbon steel
nozzles may be hammer tested. Small
diameter nozzles (less than 50mm) are difficult
to be thickness surveyed ultrasonically. The
thickness may be determined by taking
radiographs wherever possible. The tell-tale
hole in the reinforcement pad shall be checked
for possible leaks.
Special attention should be given to
nipples used for pressure and temperature
gauges etc. These nipples shall be checked
thoroughly in every shutdown. Test nipples of
the lined nozzles shall be checked for any
leakage. Any leakage will indicate damage of
the lining. If leakage is observed, pressure
testing through tell-tale hole and test-nipples
shall be done during internal inspection to
locate the leaks. Care shall be taken to keep
the plugs on the tell-tale holes loose.
vii) EXTERNAL INSPECTION OF METAL
SURFACE
a) Visual Inspection
The external surface of the pressure
vessel shall be inspected visually. The external
surface may show signs of deterioration due to
atmospheric corrosion, caustic embrittlement,
hydrogen blistering, thermal fatigue and
mechanical damage. If caustic is stored or
used in a vessel it shall be checked for caustic
embrittlement. The areas around the nozzles
and in or adjacent to weld seams are
susceptible to this type of corrosion.
External corrosion takes place in
humid areas and in areas where corrosive
chemical vapours are present. External
corrosion can be determined by visual
inspection. Hydrogen blistering is more often
found on the inside rather than outside but may
be found at either place depending upon the
location of the void which causes the condition.
Blisters are found most easily by visual
examination. The shell should be checked for
buckles and bulges. These can be found and
measured by placing a straight edge against
the shell.
b) Weld Joints
The weld joints and heat affected
zones (HAZ) shall be checked visually for
cracks. In case of doubt it should be checked
by dye penetrant test.
c) Hot Spots on Lined Vessels
Hot spots, which might have developed
on the outer surface due to the failure of
internal linings of lined vessels, shall be
checked during operation. The areas, which
have developed hot spots during service, shall
also be checked for mechanical damage such
as gouges and dents, leaks, cracks and
oxidation of any external stiffeners.
d) Ultrasonic Inspection
Thickness measurement of the shell
and domes may be taken from outside. Exact
location of thickness measurement may be
decided after internal inspection only.
e) Vessels in High Temperature Service
Pressure vessel which operates on
thermal cycle like coke chamber and at high
temperature like orifice chamber in FCCU shall
be thoroughly inspected from outside. In case
7
of coke chamber if the entry of feed is at the
bottom, insulation of at least 2 to 3 courses all
around shall be removed. The skirt to shell
weld joints shall be thoroughly checked for
cracks. The bottom flange welding with the
shell shall also be inspected. The weld joints,
HAZ and shell of 2 to 3 courses shall be
checked for cracks and apparent bulging etc.
Presence of suspected cracks should be
confirmed by using Dye Penetrant Kit. Welding
of the nozzles shall also be checked for
cracking.
f) LPG vessels
LPG Bullets and spheres having fire
proofing on the outside surface shall be
examined for cracks, spalling, bulging and
deterioration of fire proofing. Appearance of
rust stains on the surface of fire proofing is an
indication of presence of corrosion of metal
underneath. If above indications are apparent
the fire proofing in suspected areas shall be
removed and the external surface shall be
inspected for any corrosion.
10.1.2 Internal Inspection
Pressure vessels entry shall be made
only with an applicable work permit as detailed
in OISD-STD-105 on work permit systems.
The area of the column to be inspected
internally shall be decided based on the past
history of the equipment. Available past history
shall supplement the standard inspection
procedure of the equipment. The inspection of
a column is divided into the top, feed and
bottom zones. If installed equipment is being
inspected for the first time, then all tray
manways shall be opened and the complete
inspection shall be carried out. Internal
inspection can be divided into two parts.
i) PRELIMINARY INSPECTION
Prior to scheduled shutdown of the unit
the pressure vessel shall be examined from the
outside to detect any unusual condition during
operation, such as leaks in nozzle welds
through tell-tale holes or gaskets, the condition
of the bolts and flanges, the apparent condition
of insulation and any other visible defects.
During shutdown, before cleaning the column
from inside, preliminary internal inspection
shall be done. Observations regarding internal
dislodging etc. shall be noted. Samples of
deposits shall be collected for analysis.
Preliminary inspection will also reveal the
areas having deposits, scales etc. requiring
thorough cleaning to detect metal wastage
underneath the deposits during detailed
inspection. After the preliminary inspection,
clearance for internal cleaning may be given.
ii) DETAILED INSPECTION
a) Top Zone
Top dome, shell and internals in the top
zone shall be visually inspected. Inspection
shall be done to locate corrosion, erosion,
hydrogen, blistering, cracking, laminations or
mechanical damage. Special attention shall be
given to weld joints and surface conditions. If
pits are noticed, depth of pits should be
measured with depth gauge or pit gauge. Shell
plates below the refux nozzle shall be
inspected for any possible grooving. Reflux
collector shall be checked for thinning. Spouts
and counter spouts shall be checked by
hammer testing for finding any possible
deterioration. The trays and valves shall be
checked for pitting and cracking. Thickness of
dome and shell near the shell and dome
welding shall be taken in all four directions
(E,W,N and S). Thickness of the dome around
the nozzles shall be taken. Sample thickness
of column internals like downcomer,
downcomer collectors and support plates
should be taken. Besides this, if at certain
locations of shell or dome, corrosion is
observed thickness shall be measured at these
locations to know the exact loss. Shell at the
downcomer collector level shall be checked for
any possible liquid level corrosion in the form
of grooving. Reference points should be
marked on shell, dome and nozzles and same
should be monitored for thickness during every
inspection to determine rate of metal wastage.
b) Feed Zone
While inspecting the feed zone (flash
zone), the impingement plate shall be checked
for any corrosion, erosion and proper
attachment with shell. Shell plates shall be
inspected near the impingement plate where
there is a possibility of fluid impingement. The
internals shall also be inspected. Thickness of
the shell plates in four direction and the
impingement plate shall be taken. Sample
thickness should also be taken on internals.
c) Bottom Zone
In the bottom zone, bottom dome and
shell shall be inspected. Special care is to be
taken at the area near the bottom drawoff. If
pittings are observed, pit depth should be
8
measured. At steam injection points, the shell
plate opposite to steam nozzles shall be
thoroughly inspected for possible impingement.
All the internal pipings etc. shall be inspected.
Thickness and hammer testing wherever
possible should be carried out. All the nozzles
including the manhole nozzles and retractable
spool piece shall be thickness surveyed. In
case of insulated column, insulation around
nozzles should be broken to facilitate thickness
survey. Wherever, it is not possible to
approach the nozzle, ID measurements from
inside shall be taken to determine thickness.
d) Columns in Hydrogen Service
Column in hydrogen service shall be
thoroughly inspected for possible hydrogen
blistering. Hydrogen blisters shall be inspected
and evaluated as outlined in Annexure III.
In catalytic Reactors and
Regenerators, the supporting bars for internal
equipment such as cyclones shall be closely
examined for this type of attack. In these, the
catalyst and air distribution facilities are
particularly susceptible to erosion and shall be
closely examined for this type of attack.
Welding of the grid supporting rings shall also
be checked for cracking and damage. Out of
roundness or bulging may be evaluated by
measuring the inside diameter of the vessel at
the cross section of maximum deformation and
comparing it with the original inside diameter.
If the bulging is at intervals, the measurement
can be done by dropping a plumb line and
taking the measurements at selected intervals.
This will also reveal the contour of the shell.
10.1.3 Inspection of Lined Columns
Austenitic stainless steel columns and
columns lined with austentic SS plates shall be
passivated as per the procedure given NACE
RP-01-70 before opening them in order to
protect them against stress corrosion cracking.
i) STRIPLINED COLUMN
Procedure for inspection of striplined
column is similar to the unlined column as
explained above with certain critical locations
as outlined below needing special attention.
Strips shall be visually inspected. Special
attentions shall be given to the weld joints and
HAZ of welds, where cracking can take place.
If cracks are suspected, dye penetrant test
should be carried out. The strips shall also be
inspected for bulging. The striplining should be
checked by air and soap solution. The
pneumatic pressure should be around 0.2
kg/sq. cm. but in no case should it exceed 0.2
kg/sq. cm. The area where the striplining ends
shall be checked carefully as corrosion may
take place due to galvanic action of striplining
and Carbon steel shell. Thickness on the CS
portion shall be measured. Nozzle liner should
be tested by pressurising the area between the
liner and nozzle by air through test nipple. The
pressure shall not exceed 0.5 kg/sq. cm. After
testing, the test nipple shall be kept open and
capped only when the plant/equipment is
commissioned. Otherwise bulging of the liner
may take place. Thickness of the strips shall
be measured at places to ascertain whether
strips have been subjected to any corrosion.
Thickness survey of the column shall be done
from outside to check the parent material
thickness.
ii) CLADDED COLUMNS
Cladding shall be visually checked for
any deterioration like corrosion/erosion, pitting,
bulging etc. Thickness at designated locations
shall be measured to check the bonding of the
cladding metal with parent metal. The portion
where the cladding ends, shall be checked for
corrosion which may take place due to galvanic
action. The weld joints and HAZ shall be
checked for cracks. Nozzle liners should be
checked in a similar way as explained in para
(i) above.
iii) INSPECTION OF INTERNALLY
PAINTED AREA
The temperature limitations of the
painting systems used inside the vessel should
be known. While shutting down a unit, water
flushing shall be resorted to instead of steam
flushing. If steam flushing is necessary, care
should be taken that flushing steam
temperature should not go beyond 100oC or as
recommended by the paint manufacturer. The
painted surface shall be cleaned by water
washing and then mopping with cotton or jute.
Cleaning with wire brush shall not be resorted
to. Man entry shall be by wearing soft-shoes or
bare foot. Painting shall be visually inspected
and thickness should be measured with paint
thickness gauge and the same shall be
compared with original DFT of painting system.
The paint should be checked for holidays
FRE/FRP linings shall be visually checked for
mechanical damage and cracks. Thickness of
the pressure vessel shall be measured from
outside (Inspection checklist for column is
given in Annexure-I)
9
10.1.4 INSPECTION OF PRESSURE
VESSELS IN FCCU
i) REACTORS
Shell of the Reactor shall be visually
inspected and thickness surveyed.
Thermowells shall be inspected for oxidation,
cracking or distortion. Linings for the primary
cyclone shall be visually inspected at locations
like inlet horns, barrel and helix cones etc.
Dipleg shall be inspected for perforations by
lowering a light through the cyclones. Lining of
the secondary cyclones shall be visually
inspected at the locations like barrel, cone etc.
Dipleg should be inspected for
perforation/plugging by lowering a light through
the cyclones after cutting a window in seal port.
Aeration points in the secondary dipleg shall be
hammer tested. Grid holes shall be inspected
for erosion and plugging. Condition of
deflector plate lining, grid cone lining and riser
pipe shall be checked.
In the stripping section, stripper shell
and steam nozzle shall be inspected for
erosion. Thickness measurements of stripper
shell shall be done. Condition of the lining in
the fixed and removable sections in feed riser
pipe shall be checked. Inverted V-type bellows
at the expansion joint shall be inspected for
perforation. Inspection of steam and catalyst
feed injections piping and nozzles shall be
carried out.
In the plenum chamber, shell shall be
inspected for erosion and thickness
measurements shall be taken. Safety valve
inlet nozzles and vapour outlet line shall be
inspected for thinning and plugging.
In the anticoking chamber, peripheral
holes shall be checked for plugging. Cyclone
supports should be hammer tested. Shell and
weld joints between shell and bottom plate
shall be inspected. Thickness measurements
of the shell should be made.
The internal lining of riser pipe shall be
inspected with the help of a cage lowered from
the reactor. The bud bayonet shall be removed
and the condition of Y section shall be critically
examined for erosion and cracking.
Whenever, dissimilar weld joints exist in the
riser pipe, these should be checked for cracks.
The Reaction and Regeneration stand pipes
shall be examined for failure of internal lining
and metal deterioration. The convolutions of
expansion bellows shall be checked for
deposits. The slide valves shall be examined
for erosion and proper operation.
ii) REGENERATOR
The shell lining shall be checked for
deterioration. Particular attention should be
given just near manway and in areas behind
the grid seal. Aeration connections,
thermowells and trickle valves shall be
inspected.
Lining for primary cyclones shall be
checked. Special care should be taken in the
areas at inlet horn, barrel, helix and cones.
Diplegs shall be inspected for perforations.
Hangers and supports, spray shields and
support lugs for cyclones shall be inspected. In
the secondary cyclones, barrel, cones and
dipleg shall be inspected. Lining of the plenum
chamber and stack above the plenum chamber
shall be inspected. Emergency steam sprays
shall be inspected for oxidation. If the plenum
chamber is of SS material, the bimetal weld
joint between chamber and shell shall be
examined from inside.
Grid plates shall be checked for bulges
and thickness. Grid seal shall be inspected for
cracks or perforations. Overflow well and seal
boxes shall be checked for erosion and
perforations. Lining of the cone below grid
shall be inspected. Auxiliary burner tips, air
door and the pilot shall be inspected visually.
Inspection of aux-burner dome and the lining of
the dome on the inside shall be carried out.
Lugs and supports for the auxiliary burner
dome shall also be inspected.
iii) ORIFICE CHAMBER
The orifice chamber shell shall be
inspected for erosion. The areas just after the
Double Disc Slide Valve (DDSV) shall be
inspected critically. The holes/sleeves on the
grid plate shall also be examined for increased
diameter due to erosion. The shell adjacent to
grid plate should be examined for any
deformation, cracks or deterioration after
removing the insulation at random from
outside. The discs of DDSV shall be examined
for erosion and proper operation.
10.2 INSPECTION OF VESSELS
10.2.1 External Inspection
External inspection of the vessel is
carried out in a manner similar to the external
inspection of column. Various steps detailed in
the previous chapters shall be followed. In
10
addition to above, attention should be given to
metal surface in contact with concrete saddles.
Vessels which are partially or completely
underground are subject to soil corrosion
where they are in contact with ground.
Therefore, inspection of the external surface
should be done, after cleaning of the surface.
10.2.2 Internal Inspection
Normally there are no trays inside the
vessels. Inspection of the vessel is done
similar to internal inspection of the column.
Care should be taken to inspect the liquid level
corrosion. Nozzle weldings, internal stiffners
and area around them shall be checked
thoroughly from inside.
Pressure vessels which can not be
internally inspected due to mechanical
restrictions shall be inspected using ultrasonic
equipments. In addition they shall be pressure
tested as per statutory requirements.
All weld joints in Ammonia and LPG
storage vessels shall be checked internally by
wet fluorescent magnetic particle examination
to detect cracks due to stress corrosion
cracking, once in ten years, besides the normal
inspection.
Similarly, for vessels in DEA/MEA
service spot checking of T-weld joints shall be
carried out by radiography/ultrasonic testing. If
defects or cracks are detected 100% weld
joints shall be checked by
Radiography/Ultrasonic Testing.
i) CONCRETE, GUNITE AND
REFRACTORY LININGS
Concrete, Gunite and Refractory
Linings inside a pressure vessel shall be
visually checked for mechanical damage such
as spalling and cracks.
Particular attention should be given at
locations where hot spots have been noticed
during operation. Minor cracks and areas of
porosity are more difficult to find. Light
scrapping will sometimes reveal such
conditions. Bulging which can be located
visually is usually accompanied by cracking in
most cases. If corrosion occurs behind a
concrete lining, the lining will lose its bond with
steel. The sound and feel of light hammer
tapping will usually make such looseness
evident. If corrosion behind a lining is
suspected, small sections of the linings shall be
removed for shell inspection. This will also
permit a cross sectional examination of the
lining. In cases where bare metal has been
exposed because of lining failure, visual
inspection shall be made of the exposed metal.
Thickness of the shell shall be measured from
outside.
Concrets, Gunite and Refractory
Linings inside a pressure vessel shall
be visually checked for mechanical
damage such as spalling and cracks.
Particular attention should be given at
locations where hot spots have been
noticed during operation. Minor cracks
and areas of porosity are more difficult
to find. Light scrapping will sometimes
reveal such conditions. Bulging which
can be located visually is usually
accompanied by cracking in most
cases. If corrosion occurs behind a
concrete lining, the lining will lose its
bond with steel. The sound and feel of
light hammer tapping will usually make
such looseness evident. If corrosion
behind a lining is suspected small
section of the linings shall be removed
for shell inspection. This will also
permit a cross sectional examination of
the lining. In cases where bare metal
has been exposed because of lining
failure, visual inspection shall be made
of the exposed metal. Thickness of the
sell shall be measured from outside.
ii) RUBBER LINED PRESSURE
VESSEL
Some pressure vessels are rubber
lined from inside for protection against
corrosion. The rubber lining shall be
inspected for mechanical damage,
holes, cracking, blistering, bonding etc.
Holes in the lining is evidenced by
building. A holiday detector should be
used to thoroughly check the lining for
leaks and holidays. Care must be
taken so that the test voltage does not
approach a value that might puncture
the lining. Standards are available for
values of test voltages as per thickness
of rubber lining. For inspecting rubber
11
lined vessels, IS-4682-Part-I shall be
referred. Bonding of the rubber lining
should be checked ultrasonically from
the outside.
ii) RUBBER LINED PRESSURE VESSEL
Some pressure vessels are rubber lined
form inside for protection against corrosion.
The rubber lining shall be inspected for
mechanical damage, holes, cracking,
blistering, bonding etc. Holes in the lining is
evidenced by bulging. A holiday detector
should be used to thoroughly check the lining
for leaks and holiday. Care must be taken so
that the test voltage does not approach a value
that might puncture the lining. Standards are
available for values of test voltages as per
thickeness of rubber lining. For inspecting
rubber lined vessels, IS-4682-Part-I shall be
referred. Bonding of the rubber lining should
be checked ultrasonically from the outside.
10.2.3 Riveted Vessels
Besides the internal and external
inspection as given earlier, Riveted vessels
shall be examined for tightness of rivets,
soundness of caulking and seal welds and
other conditions. For the insulated riveted
vessel, insulation should be removed from all
joints for checking at 18 months’ intervals.
10.3 CORROSION COUPONS/PROBES
Corrosion coupons are installed in the
pressure vessels to evaluate accurately the
corrosion rate or to evaluate a new material in
the existing environment. While doing the
internal inspection the corrosion coupons if
installed should be taken out. Nature of
corrosion attack on the corrosion coupons shall
be studied. The coupons are then thoroughly
cleaned and weight loss in a specified length of
time shall be calculated. This gives the
corrosion rate and cleaned coupons are again
installed for future evaluation. Corrosion
probes may be installed at vulnerable locations
on the pressure vessels for onstream
monitoring of corrosion rates. Coupons and
probes can be either fixed or retractable type.
10.4 SAFETY RELIEF DEVICES
The safety valves and safety relief
valves on the pressure vessels should be
revisioned and tested. For details on
inspection of pressure relieving devices OISD-
Std-132 shall be referred.
11.0 RETIRING THICKNESS
Before determining the limiting or retiring
thickness of any pressure vessel, it should be
determined under which code it has been
manufactured. Retiring thickness shall be
calculated as per applicable code as most
vessels are built with some excess thickness in
vessel walls and heads, over that required to
withstand the internal operating pressure. The
excess thickness may result from any one or
more of the following factors:
i) Excess thickness as a result of using a
nominal thickness of plate rather than the
exact (smaller) value calculated.
ii) Excess thickness available as a result of
setting minimum thickness of the plates for
construction purposes.
iii) Excess thickness available as a result of
change in vessel service, by reducing
safety valve setting or maximum metal
temperature or both.
Retiring thickness for many accessories of
pressure vessels are not covered in the ASME
code; neither are the methods of calculating
such thickness. Some of these parts are trays,
internal tray supports, valves, grid, baffles,
ladders and platforms. For some of the
equipment, there are generally accepted
methods of setting retiring thickness. Minimum
thickness should be developed for all such
equipment. The results of possible failure of
such equipment. The results of possible failure
of such equipment should be considered for
setting these limits. Safety and continuous
efficient operation are the prime factors
affecting retiring thickness for these
components. Repair or replacement should be
carried out when they have lost one half their
original thickness. The retiring thickness for
nozzles and internal pipings shall be calculated
by applicable codes or ANSI standards.
Widely scattered pits may be ignored provided:
a) no pit depth is more than one half the
vessel wall thickness exclusive of the
corrosion allowance.
b) the total area of the pits does not exceed
45 square centimeters within any 20
centimeter diameter circle, and
c) the sum of their dimensions along any
straight line within the circle does not
exceed 5 centimeters.
As an alternative to the procedures
described above, any thinning of components
below minimum required wall thickness due to
corrosion or other wastage may be evaluated
to determine the adequacy for continued
12
service by employing the design by analysis
methods of the ASME code. Section VIII Divn.
2 Appendix- 4.
12. INSPECTION DURING
MAINTENANCE
12.1 WELD BUILD UP
In pressure vessels where some of the
small areas within rejection limit as specified in
11.0 sub clause b, have thinned down and
entire corrosion allowance has been eaten
away, repair by local weld filling may be
required to build up the thickness . The area to
be repaired should be marked at site and
should be cleaned thoroughly. The area is
filled with weld deposits, in a staggared manner
to avoid warping, with suitable electrodes
matching with the base part. After weld build
up, the area should be visually/dye penetrant
inspected for cracks and defects. Thickness
spots are made at a few locations at the built
up area by grinding. Thickness shall then be
measured ultrasonically to check whether
requisite thickness has been obtained.
Preheating and post weld heat treatment
whenever required should be carried out as per
the code.
12.2 NOZZLE REPLACEMENT
Thinned and deteriorated nozzles shall
be replaced. Rejected nozzle shall be
removed by gouging the welding. New nozzles
fabricated out of piping having thickness
equivalent to original nozzles are installed.
Welding shall be carried out from inside as well
as outside with suitable electrodes matching
with base metal and nozzle material.
Preheating and post weld heat treatment of the
welding shall be carried out as per the
requirement of relevant code. The weld joints
shall be checked visually and also by dye
penetrant test. Defects, if found are repaired.
The weld joints shall be checked for leaks by
pressurising with air at a pressure 1.03 kg/cm2
through the tell-tale hole provided in the
reinforcing pad. Pressurising the entire column
to check the nozzle weld joints should be
avoided. In some cases where the area is
accessible from inside, a box may be provided
around the nozzle. The box is pressurised with
water to the test pressure of the column/vessel
calculated by applicable code. The weld joints
and HAZ are checked for possible leaks. If any
defect is found in the weld joints, these are
gouged, rewelded and retested.
12.3 PARTIAL REPLACEMENT OF SHELL
PLATES AND DOMES

Some portion of shell plates and
domes of pressure vessels may get thinned
due to corrosion or erosion. The thickness of
the affected area may reach the retiring
thickness. In such cases, partial replacement
of shell plate or dome is carried out as weld
repair of the big area is not practically possible.
The affected portion is cut and removed. The
new plates matching with the metallurgy and
thickness of the original plate is made
available.
The edge preparation shall be done as
per the code requirement by grinding. The
prepared edges shall be checked for cracks,
flaws and defects by magnifying glass and by
using dye penetrant kit. The welding procedure
is developed for welding the old and new piece
as per the relevant code. The welding may be
performed either from inside or outside. The
root run shall be thoroughly inspected for
cracks and flaws. After completing the welding
from one side, the other side is chipped and
grounded. Before welding again, the groove is
checked for cracks and defects. Welding is
then completed from the other side. Complete
welding shall be visually checked and
radiographed as per the applicable code.
Detailed inspection of welding shall be done as
outlined in Annexure II.
Preheat and post weld heat treatment
shall be carried out as per the requirement of
relevant code. In order to check whether post
weld treatment has been carried out properly,
hardness readings on the weldment and HAZ
shall be taken after PWHT. The hardness
readings should be minimum as indentation
marks required during hardness measurement
act as stress riser and this leads to stress
concentration. If post weld heat treatment is
required it is recommended to carry out
radiography before post weld heat treatment
also. The defects in the welding are repaired
by gouging and rewelding. In lieu of
radiography, ultrasonic inspection of weld joints
may be carried out.
12.3.1 Hydrostatic Test
After satisfactory inspection and
radiography, the column/vessel is
hydrostatically tested at a pressure calculated
by applicable code. The pressure should be
held for a minimum of 30 minutes. During
hydraulic testing the pressure gauge should be
installed at the highest point. It is
13
recommended that two pressure gauges be
used. The range of the pressure gauge should
be 30% more than test pressure and calibrated
pressure gauges shall be used. The area
which has been repaired should be thoroughly
checked for leaks and signs of deformation.
The pressure drop shall also be noted. Before
subjecting the column/ vessels to hydrostatic
test, the foundation/supporting structures of the
pressure vessels should be checked for water
load. Austenitic SS pressure vessels shall be
pressure tested using DM water or passivating
solution. Hydrostatic testing of vessel operated
under vacuum conditions shall be done as per
the relevant code.
12.3.2 Pneumatic Testing
When testing pneumatically, a soap
solution should be used as an aid to visual
inspection. This soap solution is brushed over
the seams and joints on the vessel. The vessel
is then examined for evidence of bubbles as an
indication of leaks. Often a vessel which
operates at a vaccum may be pressure tested.
This is the preferable testing method when
feasible, because it permits the location of any
leaks. When pressure testing is not feasible, a
vacuum vessel can be tested for leaks by
creating a vacuum by means of evacuators or
vacuum pumps installed in the units. If the
vacuum can be held for a specified time after
closing of the evacuators or vacuum pumps, it
is an indication that the vessel is free of leaks.
If the vacuum cannot be held, leaks
are present but this method gives no indication
of their location. A search, which may be
difficult, must then be made to trace the leaks.
It is suggested that pneumatic testing should
be avoided as far possible and if at all is to be
carried out it should be done in accordance
with relevant code.
12.4 REPAIR OF CLADDING AND
STRIPLINING
The bulged, cracked or heavily pitted
cladding inside the pressure vessels shall be
repaired. The deteriorated cladding is removed
by cutting. The edges of the remaining
cladding is sealed by welding, using proper
electrodes as per cladding and shell metallurgy.
If the area of the damaged cladding is small,
the area is weld overlaved using suitable
electrodes. The area is then ground smooth.
The repaired portion shall be checked visually
and by using D.P. for defects and cracks etc.
The welding should be done in a staggerd
manner to avoid distrotion of the shell. When
the damaged area is big, after sealing the
remaining cladding, striplining of the area can
be done. (Details of striplining and welding
procedure is given in Annexure - II). Bulged
striplining is replaced by puncturing the lining
to remove entrapped air. The bulged portion of
the lining is flattened by light hammering and
then welded. If the striplining has cracked or
heavily pitted the damaged lining should be
removed and fresh lining put. The weld joints
are checked for flaws and cracks by DP and
visual examination. While removing or
puncturing the cladding/striplining, necessary
precautions should be taken as hydrocarbon
may be entrapped in between the lining and
shell.
iii) History card (Ref. Form No.3)
iv) Data record card (Ref. Form No. 4)
v) Development sketch (Ref. Figure 5 & 6)
14.0 REFERENCES
The following codes standards and
publication have either been referred or used in
the preparation of this standard, and the same
shall be read in conjunction with this standard.
i) API Guide for Inspection of Refinery
Equipment - Chapter VI - Unfired Pressure
Vessels.

12.5 REPAIR OF PAINTED AND

RUBBERLINED AREAS

If the painting in a small area of a

vessel has peeled off or has been damaged
patch painting repair can be done. The
damaged areas shall be painted with original
painting system with proper curing time etc. If
the area of damage is large, the area is shot
blasted to Swedish, standard Sa 2-1-/2 to clean
the surface and original painting system is
applied with proper curing time. DFT is
measured with paint thickness gauge. If
internal rubber lining of vessels has bulged or
cracked in a small area, the deteriorated lining
shall be removed and fresh rubber lining is put
in that small area. New lining shall be checked
for holes and flaws. Local curing should be
done to achieve hardness of 65+50A (shore
hardness-A). When a large area of the rubber
lining has cracked and bulged, the damaged
lining is taken out. Bare metal is cleaned by
shot blasting. New rubber lining is provided.
Curing shall be done to achieve 65 + 50A
(shore hardness A). The lining shall be visually
checked for cracks, holiday and bulging. The
holidays shall be checked by using holiday
detector. For inspecting the rubber lining IS-
4682-Part I shall be referred.
ii) API Guide for Inspection of Refinery
Equipment - Chapter V - Preparation of
Equipment for Safe Entry and Work.
13.0 DOCUMENTATION
iii) ASME - Pressure Vessel Code. Section
Observations of each inspection shall VIII Divn. I & II.
be properly recorded. After determining the
corrosion rate and remaining corrosion iv) Indian Standard for Unfired Pressure
allowance, repair and replacement of a Vessels - IS-2825.
pressure vessel can be planned. The following
cards shall be used for proper documentation v) BS-5500-Specification for Unfired Fusion
of the Inspection findings: Welded Pressure Vessels.

i) Data card (Ref. Form No. 1) vi) API-510-Pressure Vessels, Inspection

ii) Index card (Ref. Form No. 2) Code-Maintenance, Inspection, Rating,
Repair & Alteration.

14
vii) IS-9964 Part-I, Preparation of Tank for
Safe Entry and Work.

viii) IS-4682 part I, Code of practices for lining

of vessels and equipment for chemical
processes-Rubber Lining.

ix) Pressure Vessel Inspection Safety Code-

Part 12 Institute of Petroleum.

15
 FORM 1

VESSEL DATA CARD

INFORMATION WEIGHTS
DESIGN CODE_________________________ SHELL______________________________

MANUFACTURER_______________________ INTERNALS_________________________

MANUFACTURER’S INSULATION_________________________
ORDER NO.____________________________

DRG.NO.______________________________ EMPTY VESSEL______________________

JOB NO._______________________________ FULL OF WATER

DIMENSIONS OPERATING CAPACITY________________

TOTAL HEIGHT________________________ MATERIALS

HEIGHT BETWEEN TANGENTS__________
SHELL_________________________________

DIAMETER___________________________ HEADS_____________________________

WALL THICKNESS____________________ SKIRT_______________________________

TYPE OF HEADS______________________ BASE PLATE_________________________

CORR. BENCH MARKS_________________ MANWAY NOZZLE______________________

CONDITIONS
DESIGN TEMP OC_____________________ OPERATION TEMPO C_______________________

DESIGN PRESSURE KG/SQ.CM__________ OPERATING PRESSURE KG/SQ.CM____________

HYDROTEST PRESSURE KG/SQ.CM_____ CORROSION ALLOWANCE mm________________

STRESS RELIEVED____________________ RADIOGRAPHED____________________________

JOINT EFFICIENCY LONG SEAM________ HEAD_____________________________________

16
17
18
 FORM 4

DATA RECORD CARD

UNIT_________
INSP. DESCRIPTION SIZE SCHDL ORG. RET THICKNESS
POINT THICKN THICKN
1986 1987 1988 1989 1990 1991

19
20
UJ+

21
 ANNEXURE – I
INSPECTION CHECK LIST FOR COLUMNS IN SERVICE

UNIT_______________ EQUIPMENT No_____________ DATE_______________

1. SERVICE

2. REASON FOR INSPECTION

I) Shutdown
ii) On-Stream
II) Breakdown

3. INTERNAL INSPECTION

A. TOP ZONE

a) Scaling Nature
b) Dome
c) Shell
d) Welding
e) Nozzle Welding
f) Internals
g) Spouts and Counter Spouts

B. MIDDLE ZONE

a) Scaling Nature
b) Shell
c) Welding
d) Nozzle Welding
e) Internal
f) Spouts and Counter Spouts

C. BOTTOM ZONE

a) Scaling Nature
b) Shell
c) Dome
d) Welding
e) Nozzle Welding
f) Steam Coils

4. EXTERNAL INSPECTION

22
 a) Foundation & Foundation Bolts
b) Insulation
c) External Corrosion
d) Ladder and Stair Case
e) Nozzle Flanges
f) Bosses and Nipples
g) Grounding Connections
h) Testing Nipple of Liners on Nozzle

5. THICKNESS SURVEY OF COLUMN INCLUDING ALL NOZZLES YES/NO

6. CONDITION OF INTERNAL LINING, IF ANY

7. REPAIR, IF ANY

8. CORROSION COUPONS: YES / NO

9. REMARKS

INSPECTION ENGINEER

23
 ANNEXURE-II
INSPECTION OF WELDING
1. DUTIES OF WELDING INSPECTOR
The duties of a welding inspector usually
involve the performance of a number of
operations, including :
i) Interpretation of drawings and
specifications.
ii) Verification of the metal being welded.
iii) Verification of procedure and welder
qualification.
iv) Checking application of approved welding
procedures.
v) Verification of proper heat treatment.
vi) Assuring acceptable quality of welds.
vii) Preparation of records and reports.
2. INSPECTION PRIOR TO WELDING
i) The faces and edges of material should be
examined for laminations, blisters, scabs
and seams.
ii) Heavy scale, oxide films, grease, paint, oil
and moisture should be removed.
iii) The pieces to be welded should be
checked for size and shape. Warped, bent
or otherwise damaged material should be
detected in the early stages of fabrication.
iv) Edge preparations, bevel angle, alignment
of parts and fit up should be checked. The
groove surface should be smooth
(equivalent to machined/filled/ground
surface). The root gap should be uniform.
v) Tacks to hold alignment of joint must be
checked for soundness. Tacks which are to
be included in weld must be done by
qualified welders in accordance with the
welding procedure and must be of the
same quality as root pass.
3. INSPECTION DURING WELDING
Visual inspection is employed to check details
of the work while welding is in progress. The
details to be considered are:
i) Welding process
24
ii) Cleaning.
iii) Preheat and interpass temperatures.
iv) Joint preparation.
v) Distortion control.
vi) Filler Metal.
vii) Interpass chipping, grinding or gouging.
The inspector should be thoroughly familiar
with the items involved in the qualified welding
procedures. Compliance with all details of the
procedure should be verified. The root pass is
most important from the point of view of weld
soundness. The root pass may be checked by
dye-penetrant testing. The inspection of root
pass offers another opportunity to inspect for
plate laminations.
In the case of double-groove welds, slag
form the root pass on the side of the plate may
from slag deposits on the other side. Such
deposits should be chipped, ground or gouged
out prior to welding the opposite side. Where
slag removal is incomplete, it will remain in the
root of the finished welds. Emphasis should be
placed on the adequacy of the tack welds and
clamps or braces used to maintain the root
opening to assure penetration and alignment.
4. INSPECTION AFTER WELDING
Visual examination is the first stage in the
inspection of a finished weld. The following
quality factors should be checked:
i) Dimensional accuracy of the weldment
(including distortion).
ii) Comformity to specification requirements
regarding extent, distribution, size, contour
and continuity of the welds.
iii) Weld appearance, surface roughness, weld
spatter etc.
iv) Surface flaws, such as cracks, porosity,
unfilled craters and crater cracks
particularly at the end of welds,
undercutting, overlap, excessive weld
reinforcement, excessive grinding etc.
v) The areas where fitup lugs were attached
or where handling lugs, machining blocks
or other temporary attachments were
 welded on, must be checked carefully after iv) ULTRASONIC TESTING.
the attachment is removed. The area must v) EDDY CURRENT TESTING.
be ground smooth and any pits or tears vi) FERRITE DETERMINATION.
shall be filled in with weld metal ground vii) ULTRASONIC HARDNESS TESTING
smooth Air hardening materials should be
preheated before any thermal cutting. Hardness testing by portable hardness testers
may be considered as NDT method. Hydraulic
vi) Postweld heat treatment time, temperature testing may be done to check for leaks through
and heating/cooling rates. For groove welds, cracks etc.
welds, the width of finished welds will
fluctuate in accordance with the groove 6. DESTRUCTIVE TESTS
angle, root face, root opening and
permissible tolerances. The height of i) Mechanical tests like tensile, bend, impact,
reinforcement should be consistent with the hardness, drift, flattening tests etc.
specified requirements. Where not
specified the inspector may have to rely on ii) Chemical analysis, microscopic
his judgement, guided by what he examination, grain size determination etc.
considers a good welding practice.
The method and extent of examinations will be
The finished weld, should be thoroughly governed by applicable code requirements.
cleaned of oxides and slag for its final
inspection. 7. REPAIR OF WELDS

After visual inspection the finished weld may
be examined by one or more than one of the
following techniques.
5. NON DESTRUCTIVE TESTS
i) DYE PENETRANT TESTING: Unless
otherwise specified, the extent of this test
will be 100% for all root runs for alloy steel
welds. Adequate precautions as specified
in applicable code should be taken while
interrupting the welding cycle.
ii) MAGNETIC PARTICLE TESTING
iii) RADIOGRAPHY: Unless otherwise
specified the extent of radiographic
examination will be as follows:
i) No repair should be carried out without
prior permission of the inspector.
ii) Weld discontiniuties which are beyond
acceptable limits shall be removed from
the joint completely by the process of
chipping and grinding.
iii) Where random radiography is specified,
the first weld of each welder shall be
completely radiographed. In case of pipe
size 150 mm dia and below, the first two
welds shall be completely radiographed.
iv) For each weld found unacceptable due to a
welders fault two additional checks should
be carried out on welds performed by the
same welder.

a) carbon and carbon molybdenum steels-

10% of the welds.

b) alloy steel - 100% of the welds. The weld

joint for radiography will be marked by the
inspector.

Radiographic examination of weld joints of two

dissimilar materials shall be considered as per
the higher metallurgy stipulations.

25
 ANNEXURE-III
HYDROGEN BLISTERS-INSPECTION, EVALUATION AND
REAPIR OF PRESSURE VESSELS
1. INSPECTION
A. Visually inspect exterior and interior of
vessel to determine location of all
hydrogen blisters.
B. Determine blister thickness by ultrasonic
survey or by drilling.
C. Conduct magnetic particle inspection at the
edge and crown of any blister 2 inches and
greater in diameter to locate cracks which
originate at, or have progressed near to the
surface.
D. In order to detect plate cracks (fissures),
conduct magnetic particle inspection of the
plate for a distance of 6 inches beyond the
limits of blisters 2 inches and greater in
diameter appearing on the inside of the
vessel. See Figure 1.
2. EVALUATION
A. If the blisters are clustered and originate at
varying depths, replace the plate.
B. If plate fissures are detected under
Paragraph II. F, replace the affected plate.
C. Hydrogen blisters vissible in the cylindrical
section of the shell, the crown of flanged
and dished or eliptical heads, or in
hemispherical heads and those that are
away from seams of localised loading such
26
as support pads should be considered
acceptable.
D. Hydrogen blisters visible in and very near
highly stressed areas such as head
knuckles, openings, seam and seam
junctures, and support pads should be
considered unacceptable in pressure
vessels.
1. Affected components should be repaired
or replaced. Repair or replacement
should be approved by an appropriate
inspector aided by material and design
specialists as required.
E. If the diameter of any blisters listed in
paragraph III.C exceeds the thickness of
the plate, and the vessel is operated below
the metal transition temperature, the
material should be replaced.
USE ASME Code, Section VIII Division 2,
impact Test Exemption Curves for Carbon
Steels.' as a measure of transition temperature.
3. REPAIRS
A. Cracked blisters on the outside surface of
vessels in hydrofluoric acid service and
cracked blisters on either inside or outside
surfaces of vessels in other services shall
be repaired as follows:
1. Drill 1/8" diameter holes at ends of each
crown crack or edge crack to a depth
equal to blister depth as determined by
thickness measurement.
B. Relieve hydrogen pressure in uncracked
blisters 2 inches and larger in diameter by
drilling a 1/16 inch diameter hole in the
center of the crown as follows:
1. Blisters showing on outside of vessels.
a. Drill from outside.
2. Blisters showing on inside of vessel.
a. Drill from inside.
 b. For vessels in hydrofluoric acid service,
drill from outside.
3. Blisters showing on both inside and outside
of vessel.
a. Drill from inside.
b.For vessels in hydrofluoric acid service,
drill from outside surface only.
D. Vessels in hydrofluoric acid service.
1. If blisters 2 inches and larger in diameter
on the inside surface have crown or edge
cracks, gouge out complete blister, fill with
weld metal and grind smooth with plate
surface.
2. If blisters on the outside surface are
cracked, treat as in Paragraph III A.
3. Other dead spaces of significant volume
D. Preheat, welding procedures, stress-relief,
etc. should be in accordance with current
acceptable practice for the specific vessel
material.
1. Hydrogen may diffuse through the vessel
wall and become trapped inside tubular
legs that are welded to the vessel. This
can form an explosive mixture with air in
the legs.
2. Prior to any welding or cutting on or near
the legs of a blistered vessel, the legs
should be purged of any explosive gases
as follows:
a) Drill 1/4" diameter holes at top and
bottom of legs, with a non-sparking
drill.
b) Flush with inert gas or with air from the
bottom hole.
should be treated in a similar manner.

E. Spheres and other vessels with tubular legs.

27