Standard Proc for Insp of Columns

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RELIABILITY DEPARTMENT STANDARD PROCEDURES MANUAL STANDARD PROCEDURE FOR INSPECTION OF COLUMNS

TITLE:

DOCUMENT REFERENCE: SP-425

1.0

Issue:

02

Date:

24-05-2011

Page:

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12

Purpose

The purpose of this Standard Procedure provides guidelines for periodical in-service (On-stream) and/or out-of-service ( off-stream ) inspections of column as per frequency stated in SP-400 or on need basis in order to: o assess its pondition and likelihood of failure. . ensure its integrity and reliability for continued operation. o determine repair and/or replacement requirements.

.

recofirmend maintenance actions. The purpose of this document is to define the minimum requirements for test and inspection of columns.

2.0

Scope

The procedure covors in-service and out of service inspections of columns built in accordance with ASME Section VIII or other specified codes. This document applies to the Ibn Zafu's columns. rl1

3.0

Responsibilities

3.1

ReliabilityDepartment 3.1.1 Reliability Department is responsible for implementing this procedure.

3.1.? 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7

3.2

Inspection & Corrosion Engineer or his designate Inspector is responsible to follow this procedure in inspections. He is called as Authorized Inspector. The Authorized Inspector is responsible for documenting and maintaining inspection records and schedules. Refer Attachment # 1 for inspection personnel qualifi cation. Monitor test frequencies and ensure that the tests are carried out as per this procedure. Develop schedule and maintain test records. Document records of deferments for the test & inspection (as received from Production Department). Ensure appropriate coordination for conducting test and inspection activities both inside and outside lbnZahr.

MaintenanceDepaftment 3.2.1 Provide tlecessary an'allgelnent fbr testing and inspectior-r of coluntns and their components in sat-e and order'ly manner. 3.2.2 Ensure applopriate coordination fbr conducting test and inspection activities both inside and outside lbnZabr.

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RELIABILITY DEPARTMENT STANDARD PROCEDURES MANUAL

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STANDARD PROCEDURE FOR INSPECTION OF COLUMNS

TITLE:

DOCUMENT REFERENCE: SP-425

5.2 5.3 6.0

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Date:

24-05-201r

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TML : Thickness Measurement Location, designated area of the column where periodic inspections and thickness measurements are conducted. CUI : Corosion under insulation which includes stress corrosion cracking under insulation. ( Refer API RP 572 CL.8.2.1)

Classification & Inspection Frequencv

6.1

SHE Critical Column Identification

6.1.1 Al1 New / Existing / Modified facility columns

6.2

shall be reviewed to

identify SHE Critical Columns. 6.1.2 SHE Critical Columns List shall be generated. Process Hazard, Analysis studies of the facility should be used to identify the list. 6.1.3 The SHE Critical Columns List shall be reviewed and approved by MOC Committee and the SHE Critical Columns List shall be maintained in accordance with SHEM-O1: SHE Documentation & Control of Records. 6.1.4 Any change, modification, addition or deletion to the SHE Critical Columns list shall be approved in accordance with SHEM-09: Management of Change. Inspectionfrequency

6.2.1

7.0

Issue:

The tests / inspection program shall comply with the applicable local standards / regulatory requirements. In the absence of any local standards / regulations, fixed inspection frequencies as given in SP-400 or frequency based on RBI program shall be followed. SP-400 provides details on recommended external and intemal inspection intervals.

PROCEDURE

7.1

General 7

.1.1

Periodic Test / Inspection 7

.1.1.1

7

.1.1

.2

7

.1.1

.3

7 .1

.1.4

Instruments on column shall be tested in accordance with SHEM-07.03 : Instrument, Devices & Systems Plogram.

Relief Valves & Devices on column shall be tested in accordance with SHEM -07 .02: Pressure Relief Devices Plogram. Periodic test / inspection program shall include, as appropriate, external inspection, ultrasonic thickness inspection. on-strearn inspection and internal inspection. The scope of inspection shall include condition

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TITLE:

RELIABILITY DEPARTMENT STANDARD PROCEDURES MANUAL STANDARD PROCEDURE FOR INSPECTION OF COLUMNS

DOCUMENT REFERENCE: SP-425

7.2

Issue:

02

Date:

24-05-2011

Page:

6

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12

3.2

The tools required for inspection shall be checked and tested for proper operation.

7

J.J

7

3.4

NDE instruments shall be calibrated and tested. Blank inspection formats shall be kept at hand to record inspection obsenrations and data.

Initial Test / Inspection & Installation 7.2.1 Initial tests shall be performed on all new columns for new projects, modifications or replacements of existing columns to ensure they are satisfactory for the intended service and are installed consistently with design specifications and manufacturer's instructions prior to taking them in service. For new projects, the thickness measurement locations (TMLs) shall be identified for all columns and thickness data shall be included in mechanical completion.

7.2.2

Test / inspection shall also comply with applicable local standards / regulatory requirement.

7.2.3

For new columns internal inspection is not required if the manufacturer's inspection I data report is available that states that the column is satisfactory for the intended service.

7.2.4 If the test is carried out by contractors then the tests shall be witnessed by qualified personnel from Ibn Zahr or by a representative designated by the IbnZahrlSABIC. Test results shall be documented and signed offby the aathoized representative.

" /.7

External (In- service or On-stream ) Inspection 7.3.1 Column shall be extemally inspected when it is in operation (visual and with Ultrasonic thickness measurement), as per frequency recommended in sP-400.

7.3.2

Visual inspection of ladders, stairways, platforms & walkways shall be done for corroded or broken parts, weld cracks, bolt tightness, paint/galvanizing failure and the condition of treads, handrails and flooring

7.3.3

Foundation shall be checked for deterioration such as settling, spalling cracking and corrosion ofre-bars.

7.3.4 7.3.5

Anchor bolts shall be checked for corrosion, distortion, nut tightness. Skirt support shall be checked for corrosion, scale / rust build up on inside surface, damaged insulation or fire proofing concrete. Visual inspection of its weld seam with bottom dished end shall be done to ensure its integrity.

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RELIABILITY DEPARTMENT STANDARD PROCEDURES MANUAL STANDARD PROCEDURE FOR INSPECTION OF COLUMNS

TITLE:

DOCUMENT REFERENCE: SP-425

7.3.6 7

.3.7

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Date:

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Grounding connections shall be visually examined to verify that good electrical contact is maintained. Gauge connections, float wells, sight glasses, thermowells and safety valves shall be inspected for vibrations, leakage, loosened bolts, breakage etc.

L3.8

Nozzles shall be visually checked for signs of corrosion, distortion due to settling or piping stresses, corrosion ofexposed gasket surface, leakage though weep holes on reinforcement pads and leaking flange joints if any.

7.3.9

Condition of protective coating or insulation shall be checked. Rust spots, blisters and film lifting are signs of paint failure. Sample of insulation shall be removed from suspected area to detect CUI 7 .3.10 Thickness survey shall be carried out (Insulated or non-insulated) at accessible locations. At least one point (depending upon size of platform) shall be taken on shell at each level. 7

.3.I1 Inspection for leakage , if any, shall be done and its source shall be identified. Ultrasonic Noise Detecting Instruments can be used for detection ofpressure or vacuum leaks.

7.3.12 Thickness measurement for column operating above 300"C & below 0'C ' shall be taken at the time of shutdown when the metal temperature comes to ambient. 7.3.13 Record the observation in "External Inspection Form", P.DIF14211001 & thickness readings in Thickness Survey Inspection Reporl Form F.D1Ft421t003. 7.4

Internal (. out of seruice or off-stream ) Inspection 7.4.1 Intemal inspection shall be performed usually during shutdown or Tum around when Column is accessible for entry. Intemal inspection shall pref'erably start from bottom entry point / manhole.

7.4.2

Pre-cleaning internal inspection of column shall be performed and observations of locations of deposit /foreign matter , dislocation of intemals, mechanical breakages, corosion / erosion damage shall be recorded . Sufficient photographic record shall be made for reference. Samples shall be collected for analysis purpose.

1.4.3 Visually inspect deposit / corosiorr

product accumulation in manholes, manhoie gasket surface for damage and manhole weld sealrrs for corosion / erosion, oracks etc. Check integrity of intemal ladder mngs and their attachrnerrt welds with shell.

7.4.4 Visually inspect vofiex

breaker fbr erosion, lveld cracks. breakage of its vanes. Check lor accurlulation of dislodged fasteners, broken rnctallic pieces fiom column internals.

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RELIABILITY DEPARTMENT STANDARD PROCEDURES MANUAL

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STANDARD PROCEDURE FOR INSPECTION OF COLUMNS

TITLE:

DOCUMENT REFERENCE: SP-425 7

.4.5

7.4.6

Issue:

02

Date:

24-0s-2011

Page:

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12

Check for erosion corrosion caused by process streams at nozzle openings and in the shell around the impingement plate. Visually inspect column intemals such as impingement plate, distribution piping, baffles, agitator and supports for corrosion, mechanical damage or breakage.

7.4.7 If thick deposit or sludge accumulation

is noticed, check for under deposit

corrosion / pitting.

7.4.8

Inspect distributors for choking, loosed clamps, missing bolts, missing gasket of flange joints. Recommend for cleaning, repair or replacement as the case may be. Inspect steam heating coils, if any. Perform its thickness survey and hydrotest , ifneed be.

7.4.9 Visually inspect demister

for deposit accumulation, damaged mesh, channelling though elements, missing elements etc. Recommend cleaning / repairs according to the condition found.

1.4.10 Check all small bore tapping connections for choking / blockage. 7.4.11 Circumferential and longitudinal weld seams of the columns shal1 be inspected visually and appropriate NDT to ensure their integrity. Metal loss by corrosion I erosion shall be repaired by re-welding. 7.4.12 Thickness sulvey (intemally) shall be carried out as per following guidelines:

a. b. c. d.

At least 2-points on each nozzle pipe equally apart up to 6" &

4

points from 8" & higher size. At least 4 points 90o apad, close to ( about 2" ) weld seams of the dished ends and at the center of the column. At each manhole level for vertical column, as in b above. At visible metal loss area column and its internals.

7.4.13 Visual inspection of shell plate shall be done for metal loss by corosion / erosion, blisters and mechanical darnage by impact of broken metallic objects. Sufficient thickness readings of abnormal conoded area on shell should be taken to evaluate the condition. 7.4.14 Record the observation in format Intemal lnspection Report Form P*DIF14211002 and thickness data in Thickness Survey Report fonn P.DIFl4211003. 7

.5

Pressure Test 1

.5.1

Generally pressure test of colurnn is not perfomed, instead a tl-rorougl-i NDE of the column and its components sl-rould be carried out to ensure its integrity. Reliability Deparlment shall select suitabie NDE and it u,ill be in concurred by TSQA Deparlrnent.

RELIABILITY DEPARTMENT STANDARD PROCEDURES MANUAL TITLE:

STANDARD PROCEDURE FOR INSPECTION OF COLUMNS

DOCUMENT REFERENCE: SP-425

7.5.2

7

.6

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Date:

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Before performing a pressure test, consideration should be given to the design of supporting structure and the foundation. Plant Support Section and TSQA Department advice should be sought.

Review of inspection results & recommendations

7.6.1

Corrosion Rate Determination

Guidelines given in API 510 shall be followed to determine probable corrosion rate.

7.6.2

Corrosion & Minimum Thickness Evaluation Guidelines given in API 510 shall be followed for corrosion and minimum thickness evaluation._For a new sphere or for a sphere for which condition are changed, corrosion rate may be estimated from past experience or from published data on spheres in comparable service. On- stream thickness measurements shal1 be made after approximately 1000 hrs of service. Subsequent determination shall be made after suitable interval until the corosion rate is established.

7.6.3

Corrosion rate / Remaining Life Calculation

The corosion rate

&

remaining

life can be

by following

calculated

formulae:

Long term

:

Corosion Rate : ( t;ni,iur - tactual ) / years between tinitial & Shorl Term

:

Corosion Rate: Remaining Life Remaining life Where,

tactual

-

tactual

) / years between

(tpr.evious

-

( tactual -

tnrinimurn

taot.al

tprevious

&

tactual

:

:

) / Conosion rate (mm/year)

the thickness, in "mm", recorded at the time of inspection for given location or component.

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RELIABILITY DEPARTMENT STANDARD PROCEDURES MANUAL

ir.r"

STANDARD PROCEDURE FOR INSPECTION OF COLUMNS

TITLE:

DOCUMENT REFERENCE: SP-425

Issue:

02

Date:

24-05-2011

Page:

10

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t-ioi-rr-

-

tprevious

- the thickness, in "mm", at the same location as tactual

minimum allowable thickness, in "mm", for a given location or component (normally it will be difference of nominal thickness & corrosion allowance).

measured during a previous inspection.

7.6.4 A comparison 7.6.5

7

.6.6

7.6.7

, 7.7

of current inspection results and previous results shall be carried out to ascertain deterioration and loss ofthickness. Recommendations for corrective actions of SHE Critical Columns inspection shall be addressed and implemented in a timely marurer. Recommendations shall onlybe deleted or changed after approval of the SHE Committee (or equivalent commifiee responsible for the integrity of the facility). In case of deficiencies that cannot be corrected in a timely manner, MOC review shall be conducted to identiff necessary precautions. SHE Committee (or equivalent committee responsible for the integrity of the facility) shall annuallyreview the test and inspection program of SHE Critical Columns to ensure testing schedule is complied with and to determine the need for any changes in frequency of tests, inspections, or preventive maintenance for each SHE Critical Columns If the SHE Critical Columns test/inspection is carried out by contractors then the tests shall be witressed by qualified personnel from Ibn ZaJu orby a representative designated by the Ibn ZaIwISABIC and test results documented *d signed offbythe Ibn ZfuTISABIC representative.

Deferments

7.7.I

The status of SHE Critical Columns testing schedule shall be monitored periodically and documented. SHE Critical Columns delayed/overdue for tests and inspection shall be identified, the causes analyzed, and their deferment reviewed, approved and tracked as follows:

7.7.1.1

Columns that are more than 3 months overdue shall undergo a review and written authorization (for continued operation) from the Production Depaftment Manager.

1 .7

.1.2

Columns that are more than 6 rnonths overdue shall undergo levierv and written authorization (for continued operation) by the SHE Cormnittee. This authorization shall be valid up to the first test/ inspection opporlunity ol to a maxitnum of-the next test/irispection cycie of those columns.

,-ii,+l TITLE:

RELIABILITY DEPARTMENT STANDARD PROCEDURES MANUAL STANDARD PROCEDURE FOR INSPECTION OF COLUMNS

DOCUMENT REFERENCE: SP-425

7.8

Training and Oualification

Issue:

02

Date:

24-05-2011

Page:

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12

:

1.8.1

Employees conducting testing and maintenance of columns shall be trained and qualified to carryout the task.

7.8.2

Specific Requirements for columns training & qualification program: 7

.8.2.1

Training consisting of initial and refresher training shall be provided to all employees who are responsible to maintain the ongoing integrity of columns. Training shall include:

a. An overview of the facility and its hazards. b. An introduction to the SABIC Divisions, Affiliates and Subsidiaries' columns Program.

c. 7

.8.2.2

7

.8.2.3 If a contractor perfonns

.8.2.4 7.8.2.5 7

8.0

Procedures applicable to the employee's task and the use specialized equipment or unique tools.

of

The qualification and certification process shall be established to ensure that the ernployee understands the initial and refresher training and is qualified to perform the assigned tasks. the inspections and tests for columns, , Ibn ZaIv shall develop a management system to ensure the contractor's qualification and certification meet the requirements of this standard. Refresher training shall be carried out within three years.

Documentation of all colurnns initial and refresher training shall be in accordance with SHEM-04: Training & Competence.

References

8.1 8.2 8.3 8.4 8.5 8.6

SHEM-07.04 : Tanks & Pressure Vessels Program

API- 510: Pressure vessel inspection

code.

API -572: Inspection of pressure vessel.

ASME Sec-VIII Div- 1 : Boiler & Pressure Vessel Code. Q01-T01 : SABIC Engineering Standard for Pressure vessel testing &inspection Q01-T02 : SABIC Errgineering Standard fbr Inspection Requirements for Pressure Vessels

8.7

SP-400: Inspection Policy and Freqr-renc1, ol Inten'al fbl plant equiprner.rt & piping.

RELIABILITY DEPARTMENT STANDARD PROCEDURES MANUAL

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STANDARD PROCEDURE FOR INSPECTION OF COLUMNS

TITLE:

DOCUMENT REFERENCE: SP-425

8.8 8.9 8.i0

RD/F/421/001

8.11 8.12

RD/F/403/001 : Pressure Test Report Form

RD/F1421i002

Issue:

02

Date:

24-05-2011

Page:

12

: External Inspection Report Form. : Internal inspection Report Form

RD/Fi421l003 : Thickness Survev Report Form. RD/F/421/4 : Intemal lnspection of Spheres

Prepared by:

Reviewed trv:

Approved by:

K. Jeganathan

Yasser Al-Shaikh

Faisal Al-Bader

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