Plant Inspection

The Industrial Plant Inspection provides you with information about in-service inspection of fix equipment in the industrial plants.

The inspections are done according to the following timelines:

  • Periodic external inspections.
  • Overhaul or shutdown internal inspections .
  • Emergency shutdown inspections.

The phrases "Industrial plant inspection activities" refers to the inspection or integrity department in oil, gas, chemical or other industrial plants, which is responsible for carrying out the inspection in an operating unit.

The inspection department in the industrial plants generally takes care of the static equipment; rotating, electrical and instrumental equipment are not in the scope of the inspection department, and normally, maintenance department takes care of those.

Some local authorities mandate that pressurized equipment be inspected in specific intervals by third party inspection agencies. This is normally called third party inspection of a plant.

The static equipment can be categorized as follows when referring to industrial plant inspections:

  • Pressure vessels
  • Piping Systems
  • Storage Tank
  • Steam Boiler
  • Process Heater
  • Industrial Valves
  • Coating Inspection

The in-service inspection code for your pressure vessel inspection is API Standard 510. The other API and ASME Codes can be used as supplementary information.

The following standards, codes and recommended practices are used for pressure vessel inspection:

  • API Standard 510; Pressure Vessel Inspection Code: In-Service Inspection, Rating, Repair, and Alteration.
  • API Recommended Practice 572; Inspection Practices for Pressure Vessels.
  • API Recommended Practice 576; Inspection of Pressure-relieving Devices.
  • API Recommended Practice 577; Welding Inspection and Metallurgy.
  • API Recommended Practice 571; Damage Mechanism Affecting Fixed Equipment in the Refining Industry.
  • ASME PCC-2; Repair of Pressure Equipment and Piping.
  • National Board Inspection Code NB-23.
  • ASME Section VIII; Rules for Constructing Pressure Vessels.
  • Section IX, Welding and Brazing Qualifications.

The last two items are specific codes for new construction; however, most of the technical requirements for design, welding, NDE, and materials can be applied to the inspection, rerating, repair, and alteration of in-service pressure vessels.

ASME PCC-2, NB-23 and API 510 can be used for pressure vessel repair. The NB-23 code covers the rules and guidelines for in-service inspection, repair, and alteration of pressure- retaining items.

The in-service inspection code for your piping system inspection is API Standard 570. The other API and ASME Code can be used as supplementary information.

The following standards, codes and recommended practices are used for pressure vessel inspection:

  • API Standard 570; Piping Inspection Code: In-service Inspection, Rating, Repair, and Alteration of Piping Systems.
  • API Recommended Practice 574; Inspection Practices for Piping System Components .
  • API Recommended Practice 577; Welding Inspection and Metallurgy .
  • API Recommended Practice 571; Damage Mechanism Affecting Fixed Equipment in the Refining Industry.
  • API Recommended Practice 578; Material Verification Program for New and Existing Alloy Piping Systems .
  • ASME PCC-2; Repair of Pressure Equipment and Piping.
  • ASME B16.5, Pipe Flanges and Flanged Fittings .
  • ASME Section B31.3; Rules for Constructing Process Piping.
  • Section IX, Welding and Brazing Qualifications .

The last three items are specific codes for new construction; however, most of the technical requirements for design, welding, NDE, and materials can be applied to the inspection, rerating, repair, and alteration of in-service piping systems.

ASME PCC-2, NB-23 and API 570 can be used for Piping repair.

The in-service inspection code for storage tank inspection is API Standard 653. The other API and ASME Codes can be used as supplementary information.

Following standards, codes and recommended practices are used for storage tank inspection:

  • API Standard 653; Tank Inspection, Repair, Alteration, and Reconstruction.
  • API Recommended Practice 575; Inspection of Atmospheric and Low-Pressure Storage Tanks.
  • API Recommended Practice 651; Cathodic Protection of Aboveground Petroleum Storage Tanks.
  • API Recommended Practice 652; Lining of Aboveground Petroleum Storage Tank Bottoms.
  • API Recommended Practice 577; Welding Inspection and Metallurgy.
  • API Recommended Practice 571; Damage Mechanism Affecting Fixed Equipment in the Refining Industry.
  • API Standard 650, Welded Steel Tanks for Oil Storage.
  • Section IX, Welding and Brazing Qualifications.

The last two items are specific codes for new construction; however, most of the technical requirements for design, welding, NDE, and materials can be applied to the inspection, rerating, repair, and alteration of in-service storage tanks.

The In-Service Inspection code for your steam boiler is ASME Section VII. The API also has recommended practice for boiler inspection.

The following standards, codes and recommended practices are used for steam boiler inspection:

  • ASME Section VII Recommended Guideline for the Care of Power Boilers.
  • API Recommended Practice 573; Inspection of Fired Boilers and Heaters.
  • API Recommended Practice 577; Welding Inspection and Metallurgy.
  • API Recommended Practice 571; Damage Mechanism Affecting Fixed Equipment in the Refining Industry.
  • ASME Section I; Rules for Constructing of Power Boiler.
  • Section IX, Welding and Brazing Qualifications.

The last two items are specific codes for new construction; however, most of the technical requirements for design, welding, NDE, and materials can be applied to the inspection, rerating, repair, and alteration of boilers.

The In-Service Inspection code for your process heater is API Recommended Practice 573.

The following standards, codes and recommended practices are used for process heater inspection:

  • API Recommended Practice 573; Inspection of Fired Boilers and Heaters .
  • API Recommended Practice 577; Welding Inspection and Metallurgy .
  • API Recommended Practice 571; Damage Mechanism Affecting Fixed Equipment in the Refining Industry.
  • API Standard 560; Fired Heaters for General Refinery Services .
  • API Recommended Practice 556; Fired Heaters and Steam Generators.
  • API Recommended Practice 535; Burners for Fired Heaters in General Refinery Services.
  • API Recommended Practice 534; Heat Recovery Steam Generators.
  • ASME Section IX, Welding and Brazing Qualifications.

The last five items are specific codes for new construction; however, most of the technical requirements for design, welding, NDE, and materials can be applied to the inspection, rerating, repair, and alteration of in-service process heaters.

The in-service inspection code for your Pressure-relieving Devices is API Recommended Practice 576. This code needs to be used in conjunction with API STD 510.

The API 510 determines the requirement for inspection interval and API RP 576 specifies the inspection practice.

The in-service code for other industrial valves such as Globe Valve, Gate Vale, Check Valve and Plug Valve is addressed in the piping in-service inspection code as stated in above. In other words, in API STD 570 and API RP 574.

If a major repair is carried out, then valve testing might be needed, which can be done based on API Standard 598.

The coating inspection article explains the chloride test, surface profile measurements, wet and dry film thickness measurement, etc.

SSPC-SP1 Solvent Cleaning.

Chloride Testing / Bresle Bresle Patch Method .

Air Compressor Blotter Test .

SSPC-SP 10 Near-White Metal Blast Cleaning (NACE No. 2) .

SSPC-SP 6 Commercial Blast Cleaning .

SSPC-SP 7 Brush off Blast Cleaning allows for a great amount of the original coating to remain on the surface and to roughen the surface prior to applying the new coating system. SSPC-SP 7/NACE No. 4 removes all visible oil, grease, dust, dirt, as well as loose mill scale but tightly adherent mill scale, rust, and the coating may remain.

Paint Dry Film Thickness Measurement is addressed on SSPC-PA 2 and provides information to how to average the readings and determine DFT acceptability.

Painting Inspection and test plan