BASE LINE SURVEY OF PIPING,

PRESSURE VESSELS & TANKS

PROCEDURE

DOCUMENT NO : ESP/ESA/II/01-14

TITLE: BASE LINE SURVEY OF PIPING, PRESSURE VESSELS ANDTANKS

PROCEDURE

ISSUE AND REVISION STATUS:

Ref. Date of Revision

Prepared by Signature Approved by Signature
Revision Revision Details
00 07/06/11 Full document S.JALLALI
01 12/04/14 7.0 S.JALLALI

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BASE LINE SURVEY OF PIPING,
PRESSURE VESSELS & TANKS
PROCEDURE

DOCUMENT INDEX PAGE NO

1.0 PROCEDURE .................................................................................. 3

2.0 REFERENCE CODES ..................................................................... 3

3.0 EQUIPMENTS:................................................................................. 3

4.0 PERSONNEL QUALIFICATION: ..................................................... 3

5.0 REVIEW OF DOCUMENTATION: ................................................... 3

6.0 VISUAL INSPECTION...................................................................... 4

7.0 UT SCAN OF PIPING ...................................................................... 4

7.1 STRAIGHT PIPES:................................................................... 5
7.2 ELBOWS: (10% of elbows) ...................................................... 5
7.3 TEES: ....................................................................................... 6
7.4 REDUCERS: ............................................................................ 7

8.0 UT SCAN OF PRESSURE VESSELS ............................................. 7

9.0 UT SCAN OF TANKS....................................................................... 7

10.0 ASSESSMENT THE INSPECTION RESULTS................................ 8

11.0 REPORTING: ................................................................................... 9

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BASE LINE SURVEY OF PIPING,
PRESSURE VESSELS & TANKS
PROCEDURE

1.0 PROCEDURE

The present procedure details the requirements and extent of the Base line survey of piping, pressure vessels
and Tanks.

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

1. Review of all relevant documentation.

2. Visual inspection.

3. A-Scan Ultrasonic inspection.

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

2.0 REFERENCE CODES

API 510: Pressure Vessel Inspection Code In-Service Inspection, Rating, Repair, and Alteration.
API 570: Piping Inspection Code Inspection, Repair, Alteration, and Rerating of In-service Piping
Systems.
API 653: Tank Inspection, Repair, Alteration, and Reconstruction.
API 650: Welded Steel Tanks for Oil Storage.
API 579: Fitness for Service.
ASME VIII: Rules for Construction of Pressure Vessels.
ASME B-31.3: Process Piping.
ASME V: Non Destructive Examination.

3.0 EQUIPMENTS:

UT Equipments Crautekramer DMS II,

Camera,
Meter, Depth gauge

4.0 PERSONNEL QUALIFICATION:

Project Engineer certified API 510/API 570/API 653

UT Inspectors level II.
Coordinator.

5.0 REVIEW OF DOCUMENTATION:

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

P&IDs.

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BASE LINE SURVEY OF PIPING,
PRESSURE VESSELS & TANKS
PROCEDURE

Isometric & drawings.

Datasheets details (Material Grade, Diameter, Nominal Thickness and Corrosion Allowance) for
each component.

Previous inspection reports.

Details of Modifications and repairs.

Details of any process excursions.

6.0 VISUAL INSPECTION.

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

Shell & Heads,

Manways and nozzles,

Coatings, insulation and painting,

Welded and bolted Attachments,

Mechanical damage,

Supports, Skirts and Mounts,

Leakage,

Earthing and Cathodic protection

The results of the inspection should be reported using report, containing sections relating to the items
identified above. A classification of findings with comments should be made as described in table below.

Definition of Vessel, Piping & Tanks Condition

A1 Imminent
C Nothing to Report B Less Significant Fault A2 Significant Fault
Danger
Vessel in excellent condition; Surface rust, light scale or Corrosion greater than Heavy corrosion and /
no signs of damage or corrosion not exceeding 0.5mm 0.5mm, possible or deep pitting or
corrosion nothing to report and within the corrosion cracking adjacent to cracking of any
allowance damage judged not welds more description; vessel
to be dangerous significant damage operating above SOL
than B but no significant damage
immediate risk of with risk of imminent
failure danger

7.0 UT SCAN OF PIPING

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

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BASE LINE SURVEY OF PIPING,
PRESSURE VESSELS & TANKS
PROCEDURE

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

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

7.1 STRAIGHT PIPES:

For all diameters with length L 3 m

Band 1 Band 2
100 mm 100 mm
12 O'clock

Flow
3 or 9 direction
O'clock

6 O'clock
W1 L W2

For all diameters with length 3 < L 9 m

Band 1 Band 2 Band 3
100 mm 100 mm 100 mm
12 O'clock

Flow
3 or 9 direction
O'clock

6 O'clock
W1 (L-300)/2 (L-300)/2 W2

For all diameters with length L > 9 m

Band 1 Band 2 Band 3 Band 4

100 mm 100 mm 100 mm 100 mm
12 O'clock

Flow
3 or 9 direction
O'clock

6 O'clock
W1 (L-400)/3 (L-400)/3 (L-400)/3 W2

7.2 ELBOWS: (10% of elbows)

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BASE LINE SURVEY OF PIPING,
PRESSURE VESSELS & TANKS
PROCEDURE

For diameter 4 (100% Scan) For diameter > 4

Band 4
Band 1
50 mm

11 O'clock

W2 5 O'clock

W2

Band 3

50 mm
W1
W1
Band 2

7 O'clock

1 O'clock
12 O'clock
6 O'clock

O'clock
3 or 9

12 O'clock
6 O'clock

O'clock
3 or 9
7.3 TEES:

For diameter 4 (100% Scan) For diameter > 4

12 O'clock

6 O'clock
12 O'clock

6 O'clock

9 O'clock
9 O'clock

Band 1
W3 W3

Band 4 Band 2

Band 3

5 To 7
O'clock

W1 W2
W1 W2

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BASE LINE SURVEY OF PIPING,
PRESSURE VESSELS & TANKS
PROCEDURE

7.4 REDUCERS:

For all diameters (100% Scan) W2

12 O'clock
W1

3 O'clock

6 O'clock

8.0 UT SCAN OF PRESSURE VESSELS

The UT inspection for pressure vessels (Separator, Scrubber, Skimmer, heat exchanger and Pig Launcher &
Receiver) will be:
Scan of all nozzles pipes greater than or equal to 2;
For Nozzle with diameter 4: Scan of 5 cm area of shell around the nozzle.
For Nozzle with diameter > 4: Scan of 10 cm area of shell around the nozzle.
For Nozzle with reinforcement plate: Scan of 5 cm area of shell around the reinforcement.
For shell area: Scan of windows 20x20 cm or more in critical zones defined by the Engineer
according to the process.
For heads area: Scan of windows 20x20 cm or more in the crown surface.

Area around nozzle

Area in crown surface Area in Top shell diam: 10 cm

Area around nozzle

diam: 5 cm

9.0 UT SCAN OF TANKS

The UT inspection for Tanks (Oil & Water) will be:

Scan of all nozzles pipes in the first course and roof;
For Nozzle with diameter 4: Scan of 5 cm area of shell around the nozzle.
For Nozzle with diameter > 4: Scan of 10 cm area of shell around the nozzle.
For Nozzle with reinforcement plate: Scan of 10 cm area of shell around the reinforcement.
For shell area:

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BASE LINE SURVEY OF PIPING,
PRESSURE VESSELS & TANKS
PROCEDURE

Inspection zone

Course N4
Interface
oil/gas

Course N3

Course N2

Plate N5 Plate N6 Plate N1 Plate N2 Plate N3 Plate N4

Course N1

Water Level

For roof area: Measure thickness in critical zones defined by the Engineer according to the visual
inspection.

10.0 ASSESSMENT THE INSPECTION RESULTS

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

The assessment is based on:

All thickness measurements should be compared to the required thickness calculated according
to the construction code.
Calculation of the short and long-term corrosion rate.
Calculation of the remaining life (RL).
Evaluation of the next planned inspection.

The acceptance criteria for piping are described below:

RL 5 years: Device Should be replaced.

5 < RL 10: Device Should be periodically monitored.
RL > 10 years Device is Safe and can operate at their appropriate MAWP.

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BASE LINE SURVEY OF PIPING,
PRESSURE VESSELS & TANKS
PROCEDURE

11.0 REPORTING:

The project engineer should delivery:

Weekly reports describe the progress for Visual and UT inspection of pressure vessels, piping
components and tanks;
Visual Inspection reports;
UT inspection reports;
Assessment reports;
Summary of defects detected.

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