Pressure Equipment - In Service Inspection

Front 1

Q. You have inspected a vessel and found erosion 600 mm long, 50 mm wide and 13 mm deep One erosion is axial while the other is circumferential which one would you accept if one is acceptable AS/NZS 3788 Appendix “N3.3

Back 1

A. The circumferential erosion (Longitudinal stress) will have half the axial erosion stress (Hoop stress) thus implying that the circumferential erosion is less dangerous and may be acceptable?

Front 2

Q1b. You have inspected a class 2a vessel. The actual thickness found is 10% less the MAT. The vessel still gets accepted.How and Why? AS1210

Back 2

By re rating the vessel in accordance to 3788 section 6.3

Alter the original design parameters. Change in process , temperature, pressure, safety factors, location, corrosion allowance. The conditions set out in section 6.3 must be met.

Front 3

Q List 4 essential boiler safety devices (not safety valves)Explainwhy these are used and how would you inspect them. (Marks may not be awardedfor devices that are same in function)

Back 3

Front 4

You have an agreed contract with a new client to establish a documented Inspection management system which he will use as a basis for managing the inspection of 20 items of pressure equipment in his plant.List the 5 mainsubjects, matters or sections that this documented inspectionmanagementsystem should cover, and briefly outline the type of contents of eachsection

Back 4

Hazard Levels, Vessel Identification, Service Records, Vessel Location, Vessels and associated components accountable, Drawings

Front 5

A 10,000 litre horizontal Class 1 LP Gas carbon steel vessel has been purchased from a second hand equipment supplier. The owner requires you to inspect it for use in the next week. It Is reported to be 12 years old and in fair condition.

Back 5

· Ownership Receipt,- This is the owners vessel as per AS 3873- App “C”· MDR, - Check for compliance of Manufacture as per AS 3873- App “C”· Plant Registration Receipt with date (States and Territories have different expiry dates?) as per NOSHC 1010 schedule 1 or WHS Legislation· All past service records- To check the Scope of work with the Inspection Test Plan.c>

Front 6

Give four examples of failure modes in PEwith a related cause

Back 6

Fatigue fracture. Lack of weld penetration in the root

Pitting corrosion. Accumulation of debris or deposits excessive oxygen in boiler feed water

Creep Elevated. temperatures prolonged time causing excessive plastic deformation

Corrosion fatigue. Thermal & pressure cycling, combined with untreated water causing corrosion

Erosion High velocity and turbulent flow

Mechanical damage Accidental impact

SCC Chloride ions in feed water above 50⁰C

Front 7

Give an example of a mixed-mode failure(where the failure Involves two or more failure modes acting together) and briefly explain why the mixed mode is significant.

Back 7

As per AS/NZS 3788 Appendix “M”

Stress Corrosion Cracking (SCC) is thecracking induced from the combined influence of tensile stress and a corrosive environment. • SCC failures are seen in pressure vessels, pipework, highly stressed components and in systems when an excursion from normal operating conditions or the environment occurs.• The stresses that cause SCC are either produced as a result of the use of the component In-service or residual stresses introduced during Manufacturing-

Front 8

A skirt mounted pressure vessel with a design pressure of 1.8 MPa and design temperature of 125. It is 2.5 m in diameter and 40 m tall, and situated in a major petrol chemical plant near the sea.

Back 8

Corrosion/wastage Exposure to the environment/wind/rain/ salt air (near the sea) ultraviolet rays etc protective coating applied, VT, UTT,

(2) CUI Damaged cladding, ingress of moisture VT, Profile RT

(3) Fatigue cracking Temperature change, wind loadings, HAZ of the welds, higher stresses on bottom of tower, eg skirt VT, MPT, UT angle probe

(4) Corroded Anchor bolts Corroded beneath the concrete- Grouting broken causing insufficient drainage creating moisture to seep to the anchor bolts. VT, UT

Front 9

Discuss four important checks that should be made before the vessel is hydro tested after repairs are complete to ensure the INTEGRITY OF THE VESSEL is not compromised.(Note that this question is NOT targeting QA or QC for the repairs.)

Back 9

Check weld repairs have been tested and approved by qualified personnel

2 Hydrostatic procedure/checklist from medium chemistry/mediumtemperature/fill rate/holding pressure/ medium empting procedure.

3 Check foundations and structural supports to support the weight ofthe test medium.

4 Calculations- minimum wall thickness (Hoop Stress Calculations) towithstand hydro pressure.

5 Check Pressure gauges are calibrated and hydro pressure pointer willbe centre of gauge while at holding pressure.

6 Vessel connecting components is not to be compromised PSV’s tobe gaged, remove bellows, ectm

Front 10

A 50m3 carbon steel underground LPG storage vessel. a. Briefly discuss the most likely failure mode and cause(s) expected with such vessels that have been buried for 20 years.

Back 10

External corrosion and break down of protectivecoating due to cathodic protection failuretext

Front 11

50m3 underground LPG

Describe two locations or areas that need to be closely inspected for degradation, and state what examination method is best used for each.

Back 11

Inspection at Bottomof tank using pit gauge or UTT/VTHAZ on Tee weldjoints which has high residual stress VT and wet MP examinationVapour zone wherecondensation may have occurred - examining using UTT

Front 12

50m3 underground LPG

Discuss briefly the main inspection methods and tests that you might use for a 20 year inspection.

Back 12

Routine testing ofthe cathodic impress current system, and checking testing Log results by acompetent person

Front 13

A 30,000 litre quenched and tempered steel anhydrous ammonia road tanker designed for 1.8 MPa.

. Describe one main source of hazard and associated potential failure mode and causes specifically relating to this equipment.

Back 13

Due to dynamic andcyclic stresses in transit filling and discharging LPG may propagate to Fatigue cracks test

Front 14

List four critical areas for required internal and external inspection; indicate when this is required and why each area is of concern, what inspection methods and tests may be used and the extent of inspection.

Back 14

HAZ on all Tee weld joints of the tanker Due to high residual stress that may propagate cracking UT using angle probe 100% every year

2 Side of tank Possible dent caused by driver error Use profile gauge Area of concern

3 King pin Essential safety component MPT 100%

4 All welded auxiliary attachments Probable leaks from cracks in the HAZ MPT/VT 30mm each side of the weld Areas of possible high stress loadings every year

Front 15

You have just inspected a 2m diameter process vessel for the first time and found the following:There is a corroded area at the bottom with a general thickness of 16 mm.Thickness in the remainder of the vessel shell is 20 mm. The date of manufacture was 1972, and the minimum allowable thickness (MAT) is 15 mm.a. Determine the year you expect the vessel to reach MAT. State any assumptions you have made, and show your working. AS/NZS 3788 U5.5 & 4.4.4.2

Back 15

Vessel in service: 2014 – 1972 = 42 yrsActual remaining thickness = 20mm - Bottom of vesselcorroded = 16mm = 4mm over 42 years of service.

4 mm ÷ 42yrs of service = .0952 mm per year

Tm-Tm’= Remaining Life yearsWR 20mm + 16mm ÷ 2 = 18mm actualmean thickness

MATMinimum Allowable Thickness =15 mm

18mm-15mm

.0952 = 31.51 Years

Front 16

a. Determine the year you expect the vessel to reach MAT. State any assumptions you have made, and show your working. AS/NZS 3788 U5.5 & 4.4.4.2

Back 16

AS/NZS 3788 App N· Assume area of corrosion in even. Grind smooth and re check using UTT·

Correct wastage rate for future operation·

Calculate compliance of thinned area in accordance with AS3788 ‘N’

Front 17

How should you check your assumptions?

Back 17

Re-examine by UTT, calipers/ pit gauge the wastageareaRe-evaluate calculations using the comprehensive AppN

Front 18

When should you require the next inspection? Give reasons.

Back 18

half the remaining life 31.51 years RL÷ 2 = 15.755 years

next external inspection or AS/NZS 3788 Table

4.1 Assume the process vessels has a HL:

B Which is lesser?Table 4.1 row 9.2 Process vessel

Next External Inspection: 2yrs = 2016 Next Internal Inspection: 4yrs = 2018

Front 19

Under what circumstances might you allow the corrosion to thin the vessel shell below minimum allowable thickness (MAT) without detailed calculations?

Back 19

De-rate the pressure and Temperature Change to less hazard substance Vessel in a remote area thus modification factor removed Risk Base Analyse performed to complement the risk assessment.

Front 20

List four essential safety devices fitted to a fully attended 10MW firetube boiler.Do NOT include Safety Valves which are the subject of a specificquestion in part b below.For each device, describe why it is fitted and what are the essentialinspection checks neededfor it at shut down for periodic inspection.

Back 20

Flame Failure Device Monitors the flame and provides complete starting and flame failure protection of both pilot and main burner. Remove the flame failure device while boiler is in operation causing the boiler to trip. Test the flame failure Device and safety management system

Water Level Controller. Controlling the water level in the boiler. Regulating the amount of feed water being admitted. Low and high water level trips operate correctly General condition; corrosion, blockages If float type; No holes in float, no build-up of scale Boiler survey and boiler abnormalities.

Water Gauge Show the correct level of water in the boiler. Two of them are used, they provide additional safety and reliability and one can be checked against the other Bounce test-to test the correct boiler water reading Replace gauge glass after each inspection

Pressure Gauge Indicate the pressure levels above atmosphere pressure. Indicate check correct working pressure. Used by the operator as a balance with relieving valve settings. Shows pressure inside the boiler. Visual gauge pressure Compared with the Management computer system Calibrated annually as per ASME VI requirement. Good Practice

Front 21

What is the purpose of the "easing gear" provided on boiler safety valves?

Back 21

Easing gearshall be fitted to pressure-relief valves for use with steam, air and thosefluids which promote sticking of the valve disc to the seat but do not create ahazard when released, (e.g. leakage of the fluid is prevented at all placesother than through the discharge piping to a safe location).Easing gearis fitted so that in a event of an emergency the safety valve can be opened byhand to a full lift, releasing pressure

Front 22

FAILURE INVESTIGATIONA large stainless steel pressure vessel at a process plant, which you inspected a year before,ruptured recently. The owner has asked you to investigate the failure and prepare a report for submission to the regulators and the insurance company.Out line how you should conduct this investigation, and indicate your preliminary considerations. What data you should seek, and their likely sources.

Back 22

(a) Visually and non-destructively examine the pressure equipment forpertinent evidence.

(b) Identify the location of the failure, using sketches, marked up drawings, or photographs to show the relationship to the remainder of pressure equipment.

(c) Remove a sample of the failed component if possible, directed by a competent person.

(d) Collect any corrosion product or deposit that is not adherent to the sample, and preserve it in a sealed container.

(e) Review the design and operating conditions, discuss the failure with the operators and note any significant differences or abnormalities.

(f) Interview witnesses of failure and obtain information relating to the incident such as the time, temperature, and pressure conditions prior to and at time of failure.

(g) Prepare a failure analysis report form.

Front 23

Discuss when you would, or would not, include an opinion on the cause(s) of the failure

Back 23

The In service inspector is limited to include an opinion that is out of his/herapproved qualification of competency.Professional experts (Engineers/Metallurgist ect) submit reports thatare compiled by the In-service Inspectors final report.

Front 24

A DN 100 insulated carbon steelprocess gas piping system, with a design pressure of 1 MPa andtemperature of 135⁰C has not been inspected for 12 years and CUI is suspected.a .How should you examine a 2 metre length ofpiping which includes a Tee, a gate valve and a20mm drain? Mark 3 areas on the sketch where you would focus inspection. Givereasons and state any assumptions you have madee

Back 24

UTT- check for possible erosion adjacent to the inlet pipe.

Potential breaks incladding leaks from flanges

Lowpoint and may be open to atmosphere

Potential breaks incladding leaks from flanges and valve

Front 25

CORROSIONUNDER INSULATION (CUI) IN PIPING

Back 25

Request cladding tobe removed from the 2m length to be examined using pit gauge or externalcalipersAssume intermittentoperations over time may result in temperature between -10⁰C to 120⁰C causingCUI

Front 26

Describe and explain how you would inspect a further 100 metres of this piping vessels located at different heights through the plant.

Back 26

For large areas,identify, point where water is most likely to ingress such as breaks ininsulation and where fitting or supports etc protrude from insulation. Thereareas should then be stripped of insulation and corrosion be checked by visualinspection. Alternatively the suspected area can be radiographed.

Front 27

What general recommendations should you make to the owner concerning management of CUI in piping, including advice on prevention?

Back 27

I would recommend checking the operational procedures and material dataand corrosion allowances, check the inspection reports for excursions and checksimilar systems under the same condition and carry out a visual inspectionbefore recommending comprehensive NDTOwner must beinformed that if CUI is found and it is detrimental to the integrity of thepipe, the effected pipe must be repaired or replaced and properly sealedinsulation must be reinstated.Check temperaturerange is not between -10ºC to 120°C and if a variation in temperaturee

Front 28

List four significant surface signs you shouldlook for during visual inspection of a naturalgas filter at a natural gas high pressure reciprocating compressor station, andexplain whyeach is important.

Back 28

Discolouration blistering andbreak down of protective coating caused by weathering exposureCorrosion to follow aftercoating break downFatigue cracks caused by excessivevibration Staining of surfaceindicates possible gas leakage

Front 29

Pressure vessels are sometimes inspected using UT externally instead of by visual examination through inspection openings. Discuss the acceptability of this approach.

Back 29

Lack of visual accessibility for internal inspection may call for an alternative methodof NDE this being UT to examine the integrity of the vessel observing wall thinning, cracking, pitting and the like. Where practical internalinspection may be carried out whilst the equipment is operating using UT

Front 30

Describe four methods that can be used to assess the integrity of protective non-metallic internal linings installed in carbon steel pressure vessels.

Back 30

Visual examination (check for surface bubbling, cracking and the like)Holiday high voltage spark testing (refer AS 3894.1 and BS 6374-1)Wet sponge (conductivity) testing (refer AS 3894.2 and BS 6374-1) Leak testing (see Paragraph D18) (check via telltale holes)Thickness checks using magnetic dry-film thickness gauge BQѵ

Front 31

Outline he major considerations for external inspection of a 15000L liquid nitrogen vessel at a food packaging plant.

Back 31

Leaking nitrogen may displace the oxygen causing asphyxiation sicknessor death.Breathing apparatus may be required.Observe signs of possible leaking from fittings/flanges fatigue crackscaused by vibration.Emergency evacuation is required.

Front 32

explain what is meantby the terms ‘mode of failure and cause of failure

Back 32

Mode of failure – The process by which the failure occurse.g. Fatigue.

Cause of failure – That which can be changed to preventfuture failures e.g. Lack of weld

Front 33

Give four examples offailure modes with cause of Failure

Back 33

Mode of Failure Cause of Failure.

Pitting corrosion Accumulation of debris or deposits.

Creep Operating at elevated temperatures, or incorrectmaterial for application.

Corrosion fatigue. Thermal & pressure cycling, combinedwith untreated water causing corrosion.

Erosion High velocity and turbulent flow

Front 34

4a). what is the primary (basic or intrinsic) source of thehazard which is common to all pressure vessels and addressed by vesselconstruction (i.e. design and manufacture) and operations?

4b). Name three factors that contribute to the aboveprimary source of hazard.

Back 34

> Energy .

1. Pressure

2. Temperature

3. Volume

Front 35

Confined space entry. Check list

Back 35

Potentially explosive atmosphere only antistaticintrinsically safe equipment to be used.

Safe entry and exit.

Select appropriate personnel protective equipment for taskand environment. Confirm isolation and tagging in accordance with AS2865.

Ensure rescue plan in place.

Ensure written authority is issued to enter confined space.

Ensure vessel is: * Empty * Cooled * Cleaned * Dried * Vented * Tested by competent person to ensure safe atmosphere

Front 36

some inspections of vessels are conducted with UTthickness meters externally instead of visual examination through inspectionopenings. i) Discuss the acceptability of this approach >

Back 36

This approach to inspection may be acceptable whenimplemented using risk analysis and management techniques (AS3788 App B). Theextent, methods and frequency of PE inspections greatly affects the level ofrisk. A high risk pressure vessel (e.g. due to lethal contents, high pressure, location etc) will requirefrequent and rigorous inspections while a low risk pressure vessel (e.g. withnon harmful contents, clean service, location etc) will require a more relaxedinspection regime. For the purpose of risk assessment each item of pressureequipment is assessed on its own situation. The probability of failure shouldinclude consideration of potential failure modes, quality of design andconstruction, current plant conditions and integrity, previous inspections,severity of operation, future operating strategy, previous failures, andexperience of inspection personnel

Front 37

Must the inspection report statethe NDT method is used? Explain

Back 37

The inspection report should state that this method ofinspection has been adopted so future inspection personnel can take this intoconsideration when performing future risk analysis to determine the extent ofinspection required. AS3788 Section 8.4)

Front 38

List four surfacesigns you should look for during external inspection of pressure pipingconnected to high pressure gas compressor and briefly describe the significanceof each.

Back 38

Corrosion, thinning

Frequent cause of deterioration e.g. general corrosion,CUI, Chemical attack,

Defects, crack, creep, distortion

Vibration fatigue, high temp creep,

Coatings, protective and thermal insulationLeads to

corrosion Condition of supports and hangers d

Front 39

If a drain nozzle is foundto be corroded what criteria should be used to determine if it should berepaired or replaced?

Back 39

The criteria for rejection or acceptance for CUI wastageis:-

* AS/NZS 3788 App “N”

* AS 4041 pipe only- Hoop stress analysis

* With reference to the MDR normally the MAT allowance iscalculated.

Front 40

OWNER INSPECTION SYSTEM

Back 40

Organisation

> Structure

> Roles / responsibilities of personnel interacting withPE

*Identification and competency of personnel responsiblefor inspections of PE

> Training requirements / assessments and records ofpersonnel interacting with PE Risk Management

> Safety /

risk management policy

> Safety Instructions

> Procedures for reporting and investigating dangerousoccurrences

> Preparation and Safety during inspection Register of PE

> All items of PE listed in register

> Next required inspection date for PE ¬ification of overdue inspections

> PE Identification number

> Design registration or notification number

> Location of markings PE Data

> Equipment registration number

> As built & design verified drawings, calculations,and critical operating parameters > Manufacturer’s documentation & certification forsafety

/ pressure relief valves

> Design verification certificate

> Repairs, alterations, re-rating to original design andrelated records

> Service condition, hazard classification to AS4343

> Design life if applicable PE History

Records of activities

> Overall Inspection test plan

> External inspections

> Internal inspections

> Safety / PRV and other safety device tests

> Significant repairs, alterations, and correctiveactions carried out

> Deviation from normal operating or design conditionsand duration

> Periodic reporting and certificates of inspection

Front 41

Hazard LEVEL,INSPECTION and REGISTRATION

Back 41

A pressure vessel 150 mm internal diameter by 1.0 meterslong with a design pressure of 2.5 MPa is used for sampling toxic process gasin a large chemical works.

1a) Determine the hazard level of this vessel. Showcalculations and state major assumptions. For calculation purposes candidatesmay assume the heads are flat.

In accordance with AS4343 the pressure vessel is HazardLevel B Assumptions are: Л x r² x L x MPa x 1000 x 3 = MPaLtrs Л x .075² x 2.5Mpa x 1000 x 3 = 132.535MPaLtrs

pV modified by a factor of 3 in accordance with AS4343table 1 note 4 (iii) assuming site is a major hazard facility

pV = 132.525 MPa L

Fluid type of contents is toxic gas and is classified asVery Harmful Contents in accordance with AS4343 Table 1 note 1

Front 42

Determine the Inspection frequency

In accordance with AS4343 the pressure vessel is Hazard Level B

Assumptions are: Л x r² x L x MPa x 1000 x 3 = MPaLtrs Л x .075² x 2.5Mpa x 1000 x 3 = 132.535MPaLtrs

pV modified by a factor of 3 in accordance with AS4343 table 1 note 4 (iii) assuming site is a major hazard facility pV = 132.525 MPa L Fluid type of contents is toxic gas and is classified as Very Harmful Contents in accordance with AS4343 Table 1 note 1

Back 42

In accordance with AS3788 Table 4.1 section 9.2 Processvessel Hazard level B, this pressure vessel requires a commissioning inspection, a first yearlyinspection, an external inspection every 2 years, and an internal inspection every 4 years.

Front 43

The criteria which determines the design and plantregistration is set by NOSCH 1010 Schedule 1

Back 43

Design Registration Hazard Level A, B, C &D Plant Registration Hazard Level A, B & C

Front 44

A 7,000 litre vertical Class 2A carbon steel process drumin LPG service has been out of service for 3 years and the owner wishes you toinspect it for use in the next week. It is reported to be 5 years old and ingood condition. It has an inspection man way and full reports of previousinspections are available.

i) Describe the location and extent of areas to beexamined.

Back 44

Visual inspection of vessel externals for condition ofprotective coatings,

corrosion at vessel areas around insulation penetrations,CUI, and corrosion caused by leaking fixed fire systems.

Inspection for correctly fitted earth straps Protective devices, PRV’s, bollards & barriers, correctoperation of fixed fire systems Inspection for bulging, burns, fire damage, dents, cuts andgouges

Check foundations for security, concrete surface,subsidence, bolting, cracking, ladders, handrails, flooring and walkways

Internal inspection of the vessel, particular attention tothe bottom of the vessel (Vapour zone) AS3788 G4 for corrosion. Circumferentialand longitudinal welds for cracking.

Determine effectiveness of preservation procedure Determine from previous inspection reports any areas withidentified problems, repairs, corrective action needing further attention

Front 45

INSPECTION PLANNINGand PREPARATION

What type of NDTwould you use to supplement your visual inspection which showed pittingcorrosion estimated to be up to 2 mm deep on the inside of the bottom end?

Back 45

Areas identified with pitting corrosion, to be furtherassessed using Ultrasonic thickness measurements. Calculate compliance ofthinned area using AS3788 App N. Determine year of installation and calculaterate of wastage and remaining safe life U5.5. Half remaining life 4.4.4.2 andrefer Table 4.1 whichever is the lesser for next inspection. Follow up bydesign engineer or SISI to confirm findings and calculations

Front 46

A) Briefly discuss thecircumstances under which may require further NDT

b) Estimate the probableadded % increase in time and cost of the NDT you recommend

c) Increase in inspection time for MPI is estimated at 50%,additional cost estimate is labour 50% plus consumables (Cleaners, lacquers, fluxindicators)

Back 46

A general problem of cracking in field erected LPG storagevessels. Cracking is associated with fabrication defects and in some casesinitiation and propagation during service. Under these circumstances furtherNDT may be required. Magnetic particle ion

Increase in inspection time for MPI is estimated at 50%,additional cost estimate is labour 50% plus consumables (Cleaners, lacquers, fluxindicators)

Front 47

You are informedthat the above vessel is open and ready for you to inspect so you drive to thefacility to perform the inspection. Briefly describe the main tasks you need toperform after arriving on site and before you enter the vessel to ensure theinspection is conducted safely.

Back 47

Identify & familiarize with owner’s safety and workpermit requirements

Perform risk assessment and hazard identification Implement control measures for identified hazards(Hierarchy of control) Inspect equipment, portable electrical equipment, lightingAS2865 Potentially explosive atmosphere only antistaticintrinsically safe equipment to be used

Safe entry and exit (Confined space entry procedure)

Front 48

300,000 litre quench and tempered steel B-double LPG tanker

a) List two specific sources of hazard and associatedpotential failure modes and causes relating to this equipment :

Back 48

Fatigue cracks –Dynamic and cyclic stresses, transit, fillingand discharging of LPG 2. Damaged vessel – Accident in transit or stationary

Front 49

300,000 litre quenchand tempered steel B-double LPG tanker

Why might you inspectthe rear bumper bar? What findings may concern you?

Back 49

* Inspect bumper for signs of dents, deformation and cracksthat might indicate a previous accident.

* If found may be concerns that repairs have not beenperformed correctly, verified by a competent person, welder quals, weldprocedures, non destructive exam, heat treatment,

Front 50

300,000 litre quench and tempered steel B-double LPG tanker

c) List three (other) critical areas for annual inspection.Indicate why each area is of concern, what inspection methods and test may beused and the extent of inspection.

Back 50

Area Why? Methods Extent

Shell & Heads Corrosion, abrasion, dents, distortion and weld defects VT,MT, UTT 100% Internal & External Welds

Bottom of Vessel Corrosion form accumulated condensation VT UTT 100% Asidentified by VT Emergency Devices Check for correct operation and no leaks Visual Hydro TestAll items

Front 51

OWNER INSPECTIONSYSTEM

Organisation

Back 51

> Structure

> Roles / responsibilities of personnel interacting withPE

> Identification and competency of personnel responsiblefor inspections of PE

> Training requirements / assessments and records ofpersonnel interacting with PE

Front 52

OWNER INSPECTION SYSTEM Risk Management

Back 52

> Safety / risk management policy

> Safety Instructions

> Procedures for reporting and investigating dangerousoccurrences

> Preparation and Safety during inspection PE

Front 53

OWNER INSPECTION SYSTEM Register of PE

Back 53

All items of PE listed in register > Next required inspection date for PE ¬ification of overdue inspections

> PE Identification number

> Design registration or notification number

> Location of markings

Front 54

OWNER INSPECTION SYSTEM

PE Data

Back 54

> Equipment registration number

> As built & design verified drawings, calculations,and critical operating parameters > Manufacturer’s documentation & certification forsafety / pressure relief valves

> Design verification certificate

> Repairs, alterations, re-rating to original design andrelated records

> Service condition, hazard classification to AS4343

> Design life if applicable lags

Front 55

OWNER INSPECTION SYSTEM

PE History

Back 55

> Records of activities

> Overall Inspection test plan

> External inspections

> Internal inspections

> Safety / PRV and other safety device tests

> Significant repairs, alterations, and correctiveactions carried out

> Deviation from normal operating or design conditionsand duration

> Periodic reporting and certificates of inspection

Front 56

Pressure Relief Devices P.R.D.s

Suchdevices are primary safety mechanisms for safe guarding a system from overpressure and are fitted to Pressureequipment and auxiliary equipmentPipingsystems.

Adocumented system for each safety valve shall be in place and include: Manufacturersdate (serial no, size, set point)Identificationof value, plant No, LocationInspectionrecords, Maintenanceintervals Recordof adjustment and authorizer. Wherea device is outside manufacturers specs or set parameters the cause shall beinvestigated and one or more of the following actions taken:- Eliminateroot causeDecreaseinspection test intervalsInstalldevice of more appropriate spec.

Back 56

A CLEAN SERVICE (fluids - nitrogen, methane, hydraulic or lubricant oils).Clean fluids and characterized by condition of device or removal only needing awipe over with no particles of matter attached to valve. There still may besigns of wear or damage.

DIRTY OR CORROSIVE SERVICE operating fluids and particles adhered to device components resulting inits performance being impaired. Capability of fluids to corrode parts ofassociated system should be specified and key component made corrosiveresistant. Wherea fluid is prevented from contact with pressure relief device component i.e. bybursting disc or bellows then the application may be considered a clean duty.However confidence in method must be proven before Clean Duty categorized.

Commissioning and Re-Commissioning 4.7.2 PRDsnot attached to flare or vent system shall be discharged or piped to safe areaand be arranged to prevent accumulation of water, fouling and blockage byvermin. Each P.R.D. shall have unique I.E. and location recorded. New or servicedPRDs shall be inspected prior to installation or process start up to ensureintegrity has not changed during transport or storage and gags, plugs or othersuch items have been removed. It may be appropriate for device to be re-testedprior to installation to verify settings. New Pop action relief values withsoft weats used for storage or transport of liquefiable gas do not requirepre-installation testing other than manufacturers witness stamp. Where value isnot used for 5 years of test date value may be reconditioned and tested to AppX. Softseated valves suffer from memory affect and sticking is common and may resultin excess over pressure lifts.

Front 57

On-line External Visual Inspection 473

On-lineinspection of PRDs nominal interval of 1 year and regular operatingsurveillance.Inspectionconsiderations consequence of failure,PRDs history, specific local conditions (operating environment, nearbyconstruction or maintenance activities).

Back 57

On-line inspection to ensure:

Correctdevice is installedI.D.

provides means to establish the correct set pressure for equipment protected bydevice. Nogags, blinds or closed values would prevent devise from functioning.

Nounacceptable external mechanical damageBonnetsof non-balanced valves are pluggedBonnetsof balanced valves are vented to safe location and clear and not dischargingprocess fluidVentstacks, discharge piping and receiving vess are properly supportedUpstreamand downstream block valves (where applicable) are secure and interlocks aremanaged appropriately.(Note AS121requried the use of interlocks with PRDs forPVs)Anylife lever is operable and positioned properlyExternalcorrosion not recessiveNoevidence of device tamperingBlockageto discharge piping has not occurred or to any drains fitted or its dischargepipingDeviceis leak tightAdequacyand condition of weather protectionWheredischarge piping terminates outdoors or where ingress of water, dust, vermin,debris is possible, control measures are in place to prevent above Whereweather protection has failed device should be examined externally and assessedfor continuing service. PRDswith easing gear should be manually operated unless sufficient risk thatoperation will:-CompromisePlant integrityDamagedevice or Cratea hazard for personnel in vicinity. WherePRDs are found to not function properly it requires testing in accordance withClause 4.7.4. to 4.7.9.

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TEST INTERVALS 4.7.4.2

Followingcommissioning test intervals of 1 year canbe varied based on type of service (clean, sticking, corrosive) contents ofP.E., experience with similar devices (design, service, manufacture) commonindustry practice, previous testing, and include a full risk assessment ofsafety and environmental consequences of leakage for failure and documented andfiled in P.E. documentation. Testintervals shall not EXCEED INTERNAL INSPECTION intervals for P.E. its designedto protect Tab. 4.1 extended intervals may be applied - Note 1 to TAB 4.1 IfP.R.D. passes first year or subsequent as received tests and in clean service,next test interval may be extended to the lesser of: -a) Requirementsof applicable standard (AS2593)b) Internalinspection of P.E. that it protects or c) 5years. Whereinternal inspection is greater than 5 years and service is clean, non-stickyand non-corrosive, test intervals can be extended to internal inspectionintervals but subject to: - 1. Justifiedby in-service inspector in consultation 2. Agreementbetween all parties concerned3. Riskassessment documentation providing audible test for inspection process. Canuse risk base techniques to optimise test and overall intervals and requires: -1. Detailedknowledge of equipment and plant, consequence of failure and reliablehistorical data.2. Applicationof mandatory reduced test intervals in “fail to danger” situations IfP.R.D. fails under testing or inspection next interval will be set to max. of 1year and require resetting and overhaul of valve. PRDs in dirty service use max test intervalsof 1 year see TAB 4.2 Test intervals for PRDs. .ܷvN

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On-line External Visual Inspection 473 On-line inspection of PRDs nominal interval of 1 year and regular operating surveillance. Inspection considerations consequence of failure, PRDs history, specific local conditions (operating environment, nearby construction or maintenance activities).