I N S P E C T I O N R E L I A B I LI T Y

Reliability- An Inspection Approach

Introduction
Of late, Reliability of plant operation has been an area of deep concern due to
the fragileness and frequent break down of equipments/ machineries, all over
IOCL Refineries. A need was felt for soul searching and technically analyse
the root causes of failure, to prevent recurrence of incidence.
On deliberating the issue, it was felt necessary to review in house inspection
system and procedures, and find out the likely areas where further attention is
required to be focused for improvement and making the system fool proof by
all means.
In order to find out GAP, comprehensive study and in-depth analysis was
carried out. The outcome of the analysis indicates, quite a large number of
failures are attributable to static equipments / piping malfunctioning. This
obviously raised a deep concern towards adequacy of present Inspection
monitoring frequency/ procedures/ Practices etc.
In the process of the study, visit was made to all the Refineries wherein the
total system and procedures was reviewed and discussed with Inspection
HODs of all the Refineries. This was precisely done with a view to locate the
weak areas and identify the task needing development. All the established
inspection procedures, during the survey have been examined. Finally, a
fresh and renewed look has been given into the total systems and procedures
and areas of attention / improvement identified. The action plan for
implementation has also been finalized and sent to Refineries or appropriate
action within the time frame mentioned in plan.
In subsequent chapters, the details have been documented.
To begin with, the following key issues were shortlisted to dwell upon:

The road map to ensure and improve upon the reliability.

Check for Loopholes, if any.
Organisational goal and role of Inspection in meeting the objective of Zero
Interruption.

Reliability approach:
Reliability of equipment and piping can be enhanced by stepping up the
monitoring through a structured inspection plan and procedure. The health
condition of equipment etc. if tracked down properly and trending is set
appropriately, the forecasting for any repair/ replacement becomes more
authentic. The data based inspection observation can be thus further fine
tuned to asses the remnant service life of the component. Thus, with the stepby-step approach, covering all the areas of likely weaknesses, a scientific and

Page 1 of 119

definite inference is possible to be drawn to finally certify the workability of the

component. This needs to be enforced, in a dedicated manner.
The Shortcoming
While, most of all the areas of inspection are well defined and to the large
extent practiced as well, there appears to be some laxity in the process with
the passage of time. The causes of some of the failures that have taken
place, if analyzed properly, shall confirm the apprehensions. The main aim, of
the present study is to remove these variables, bring about uniformity in the
attitude and approach for handling any task and look into all possible avenues
to correctly identify & diagnose the problem and forecast the actions to be
taken, well ahead of time and without jeopardizing the continuity of operation.
Role & Function of Inspection:
The equipment availability for operation on sustained basis emerges as an
extremely important key function that has to be upheld by inspection, by all
means. The vital and crucial role of inspection, therefore, is in balancing the
act of monitoring the equipment health in a rigorous way on continuous basis
and certification for equipment integrity for operational safety, on the basis of
analytical and systematic approach with a clear understanding of material
behaviour and true assessment of performance. The incident of unscheduled
interruption due to malfunctioning of static equipments shall be brought down
to nil.
The Study and Focus:
With the above spirit in mind, this study was under taken to find out the areas
of attention, ways and means to further consolidate inspection effectiveness,
sharpen the analytical skill, understanding the material behaviour to squeeze
out maximum value of the asset for a most reliable, uninterrupted operation.
On the basis on the study that has been made, Road maps have been
prepared to achieve goal by strengthening of core areas of inspection
function.
The informations have been compiled with inputs from all refinery locations.
The present report is an effort to address the issues of Reliability with an aim
to enhance the plant availability factor to its best so as to be at per with world
bench marking. Few case studies are also included to have better in sights on
the issues.
The path forward:
The Reliability study from Inspection viewpoint has been grouped in various
key task. The total task further has been divided into sixteen broad action
areas, which are the given in the index for reference. Detailing of each action
area with time frame have been made to a great extent so as to have a better
understanding of the subject and total clarify in order to execute the
actionable items with ease and confidence.

Page 2 of 119

The Inspection schedules are pretty tight and may consume little time to take
off. Considering the above, the time frames have been divided into 3
categories i.e. immediate, short term and long term. Once stream lined the
task will yield the desired effect that is overall improvement in equipment
and plant safety.

Page 3 of 119

5.0

Inspection Effectiveness and Static Equipment Reliability:

Inspection of static equipments, such as vessels and piping is basically
performed to maintain the containment function that is to avoid failure.
In order to establish an inspection programme for static equipments, it
is not only necessary to know when and where to inspect but also by
which inspection technique and what is the probability of detection
(POD)?
It may be absolutely essential by an inspection engineer to perform a
detailed evaluation than usually done, go for selection and utilization of
newer and advanced techniques, take full care for enhancement of
extent of inspection in order to formulate the data base before
declaring the equipment fit for use even for a stretched period of run,
with full reliability. To establish optimal inspection intervals require
knowledge of damage mechanism behaviour, which depends on
properties of material, internal fluid characteristics and aggressiveness,
and also external operational environment. The inspection programme,
therefore, should be based on total understanding of the system, the
type of metallurgical degradation that may occur and deterioration
mechanism.
The possibility and probability factors of failure shall be understood,
analysed and inspection plan to be devised in accordance.
The following chapters describe the path forward by either extending
the present inspection practices, or by re introducing some proven
practices with greater emphasis on frequency so as to achieve total
reliability with zero interruption target. The strengthening of present
inspection practices shall yield maximum result. The balance can be
achieved by introducing advanced NDT methods etc., which have also
been dealt in greater details.

5.1.0 Monitoring of Equipment and Piping Health Condition: Online and

Offline
For the convenience, the implementation procedure has been sub
divided into various key functions with further breaking down into the
tasks.
To begin with, it was Monitoring task, which was selected for detailing.
It was further divided to On Line Monitoring and Inspection Procedures
and Offline Monitoring and Inspection Procedure. The following are the
break ups and brief details of the areas of importance, which need
continuous attention on sustained basis. The surveillance shall lead to
total control on the proceedings, evaluation for corrective measures,
and action for implementation within time frame.
5.1.1 Strengthening of Online Monitoring and Inspection procedure:
(Equipment and Piping)

Page 4 of 119

Online monitoring relates to the job of health monitoring during the run
of unit and without disrupting the process. Various methods are
deployed to carry out this job. The most significant procedure are
highlighted here with frequency, methodology etc. for overall
guidelines. To enforce the effectiveness, the frequencies are to be
adhered to along with the extent of checking. There is no substitute of
assimilation of online data for effective monitoring and control. The
reliability of equipment is largely dependent on the thoroughness of the
task, which need maximum attention in the present day scenario.
5.1.2 Daily Routine Inspection
Daily Routine Inspection job is a significant task to be performed by
unit inspection engineer daily. The integrity of unit operational condition
can substantially be judged by analyzing the data collected. Therefore,
this aspect of online monitoring has a vital role which is to be viewed in
a right perspective.
The online date must be obtained by physically inspecting the items, by
the inspector. This activity is followed by evaluation of the data, which
shall project the actual operating condition of plant. Thus the
monitoring activity shall not only get confined to daily physical check
but also followed by evaluation and recommendation for corrective
action. The activity and actions by an inspection engineer on daily
basis shall automatically bring about the effective and desirable
reliability and assured quality.
Addendum-1
The online observation must be obtained by physically inspecting the
items, by the inspector. This activity is followed by evaluation of the
critical operating parameters, which are directly related to equipment
reliability.
The steps to be followed:

Frequency of Inspection- daily

Routine Inspection of units by physically checking and recording the
parameters, measuring the values at field etc.
Evaluation of the parameters / values and generating report.
Discussing the problem areas with unit operation Manager.
Information to management with highlighting the problem area on
daily basis.
Recommendation to operations and Maint. group.
Follow up.
Documentation.

Addendum-2
Routine Inspection of units by physically checking and recording
the critical operating parameters, measuring the values at field etc.

Page 5 of 119

Evaluation of the parameters / values and generating report on

format AIP-1.
Daily inspection report shall also be reviewed by concerned SIPM/
CIPM.
Weekly inspection highlights shall be published for information to
Management and all concerned HODs.
RTDBMS facility shall be made available to Inspection for
continuous monitoring of critical parameters.
It is also imperative to follow uniformity in logging the data by all the
Refineries. The format, produced by M&I, HO shall be followed by all
the Refineries for the same. The copy of formats to be followed by all
the units are enclosed as Annexure-AIP1.
5.1.3 Walk Through Inspection
Walk through inspection is to be undertaken by inspection engineer at
unit / offsite area of all refineries.
Addendum-3
Walk through inspection of all units & offsite areas are to be
undertaken by inspection engineers and observation to be recorded in
the checklist approved by Inspection Head. Offsite area may be divided
into several blocks. A yearly schedule of walk through inspection shall
be prepared and approved by HOD.
This inspection methodology has been proven to be very effective by
physically checking the plant. A close look to individual items can bring
out several non-conformities, which can be documented and submitted
as checklist, for corrective action by concerned department.
The Methodology is by visual check with a frequency of once in three
months.
Steps to be followed:

Frequency- every 3 months.

Visual inspection of items.
Recording the non-conformities
Recommendation to concerned depts. Like PN, MN etc.
Follow up of job and reminder in every 2 months, as per the MIS
format.
Major jobs to include in shutdown job list.
Documentation of the total activity (observation, recommendation,
implementation)

The procedure for walk through inspection is given below which can be
followed as a guideline.

Page 6 of 119

Objective: To asses the physical health condition of a running plant/

offsite areas (piping / equipment etc.) by visual inspection from
operational safety/ reliability/ cleanliness point of view (walk through
inspection).
Inspection Gadgets: Photographic Camera, Safety Torch Etc.
Jobs Procedure:

Understand the overall layout of the plant with Equipment No / Type

/ Service and major piping circuits etc.
Check the operational details of the plant from production. Collect
information for critical equipments and piping circuits and note.
Visually check all the Equipment (Heat, Excel Column, Vessel,
Heater etc. so on and so forth) and look for the following:
Insulation damages and exposure of bare metal areas.
Oil soaked insulation column, vessel, Heat Exch., Piping etc.
All flanges like Equipment M/Hole flange, Product Inlet / Outlet
flanges and tightness condition, Heat exchangers flange for
leakages, if any, critical circuit piping flange in particular and
other flanges etc.
Sizes of Bolts provided (short / Long Bolting Lesser dia etc.)
If possible, look for gasket through flanges.
Safety valve (if any) isolation in lock open condition.
Painting condition of equipment + piping.
Stairs / Hand rails, Ladder, Landing Platform physical condition
(corrosion / damage / in adequate support etc) To ensure safe
and unrestricted movement.
Debris loose items at platforms
Davit on column / vessel especially at bottom sleeved portion
for corrosion / water accumulation
Piping supports
Equipment foundation condition / fire proofing condition /
cleanliness inside the column / vessel skirts.

Heater overall condition

Vibration of lines, Flat arch condition, Casing plate condition, Burner

floor condition, Platform Ladder condition, Soot blower / Burner
frame condition, oil leakages from Burners etc.
Inlet / outlet lines, flange connection condition, supports condition
etc.
Insulation of lines, PG/TG/ other instrument lapping condition.
Man way, Access door, Peep holes, Explosion door at Radiation
zone, and convection zone.
General condition of stack:
Condition of bolts, flanges etc. and foundation (if mounted on
foundation)
Ladder / Platform Condition.
Page 7 of 119

Hot spot, if any on stack shell.

Painting condition and visual abnormality, if any.
Any other physical observation of the Heater condition.
Oil accumulation in trench / bottom of equipment.
Any other general observation of plant needing attention /
correction.
Photograph of critical observations to be taken and attached to the
report
Oil leaks from pump / compressor, abnormality in operating
condition if any to be checked.
Physical look at earthing strip for checking its condition (static &
rotary equipments).
Report to be published within 24 Hrs of observation and sent to
MN/ PN / P&U / Civil HODs and concerned DGMs, with
classification of action time like immediate / short-term / shutdown
etc.
The pending recommendation, if any with actions marked as
immediate and short-term etc. shall be reminded to MN (PLG),
through the MIS at every 3 months. The jobs earmarked for
shutdown shall be included in the shutdown job list.
Inspection Frequency: Once in 3 months.

Addendum-4
Insulation of lines, PG/TG/ other instrument tapping points.
Pending inspection recommendation of walk through inspection
report shall be included in the quarterly pending inspection
recommendations which are being circulated to all concerned
HODs.
Note: It is preferable to take MN and PN persons along with while
carrying out survey so that there is job clarity & repetition of explaining
the job once again is avoided.
5.1.4 Temperature Survey
Temperature Survey of Boiler / Stack / Hot Line In Critical Services/
Insulated Equipment / Casing Plates of Heaters / Boilers etc.
Temperature survey (external surface) of the above areas are required
to be done to monitor the temperature profile of the component and to
find out the integrity of internal lining that is provided normally at Stack /
Heaters / etc. The survey of insulated objects shall directly reflect the
effectiveness of insulation. Higher temp. profile may be caused due to:
Addendum-5
5.1.4 Temperature Survey through Infrared Thermometer (Cyclops)
Temperature survey of reformer tubes, critical internally refractory lined
and insulated equipment such as Reactors / Regenerators / Orifice

Page 8 of 119

Chambers / Risers / Incinerators / MCCs / Cold Collectors / PG Cooler

etc.
Temperature survey (external surface) of the above areas is required
to be done to monitor the temperature profile of the component and to
find out the integrity of internal lining. Higher temp. profile may be
caused due to

Deterioration of insulating material it self (i.e. deterioration of

property)
Lack of proper shielding, disintegration of lining, creation of cracks /
voids etc.
The component itself is HOT beyond limit (due to upset in process /
any other contributory factor etc.)

The temperature survey result can give a directional approach in

understanding the condition of the equipment and propose corrective
action accordingly. This job is to be performed by process engineer
(ENCON) in general and equipment specific by inspection engineer.
Steps to be followed:
Frequency of Monitoring Once in three months.
Areas of applications: Hot piping circuits in critical services (like
Transfer line, Bottom draw off circuit of column, Heater Inlet Circuit,
Pre-Heat Exchanger, Column Side draw off etc., vessel / exchanger
with lining / external lagging etc., Stack, Heater / Boiler Casing
Plates etc.
Record all abnormalities
Observations and Recommendation to be sent to Production
Maintenance (Civil / Mechanical) and Process dept.
Follow up for corrective action to be done once in two months
through MIS.
Observations leading to major job shall be put into shut down job
list.
Documentation of the total process i.e. Observation,
Recommendation, Implementation.
Addendum-6
Frequency of Monitoring Weekly.
Observations and Recommendation to be sent to concerned dept.
5.1.5 Cathodic Protection Survey
The Cathodic Protection Survey shall be performed once in a month
and recorded. Evaluation of results to be made subsequently to judge
the effectiveness of protection provided. This job is to be performed by
Electrical Maintenance Department.
Addendum-7

Page 9 of 119

The Cathodic Protection Survey PSP survey shall be performed once

in a month by Electrical Maintenance Dept. and the result shall be
forwarded to Inspection for review & evaluation.
Operation & Maintenance of Cathodic Protection System:
Most of the Refineries have installed the Permanent impressed current
Cathodic Protection System to control the external surface corrosion of
the buried pipelines, LPG Mounded Bullets etc using Transformer
Rectifier units and anode ground beds. Test stations have been
installed at an interval of around 1 km in order to monitor the health of
the pipelines and performance of the CP system.
The CP system is to be maintained so as to achieve the following
protection criteria:

The Structure to electrolyte potential measurements for steel

structures in soil will be between 0.85 and 1.25 volts with respect to
a Copper/ Copper Sulphate reference electrode.
The Structure will be considered protected when a minimum 300
millivolts potential shift has been achieved from the OFF potentials
to the ON potentials.
A minimum polarization shift of -100 millivolts will indicate adequate
levels of cathodic protection on the pipeline.
With the relative cathodic protection system cycled ON and OFF
any positive potential shift (with the system ON) in excess of 20
millivolts will be investigated for interference.

The Major Components of the CP system are as follows:

Auto/ Manual Transformer / Rectifier units, Ground bed, Anode
Junction Box, Cathodic Junction Box, Reference Electrodes, Test
Stations, Power Distribution Boxes, Earthing system, Insulating joints,
Foreign line crossing, Associated cablings
Purpose:
To ensure correct performance
maintenance of the CP System.

and

proper

Monitoring Steps to be followed:

Monitoring of CP system shall include the following:
1.
2.
3.
4.

Operating parameters of CP stations (TR units)

Anode Ground bed circuit resistance.
Feeding & Drainage potential.
Test stations Monitoring:

Page 10 of 119

monitoring

and

5.
6.
7.
8.

Pipe to soil potential (PSP) w.r.t. Cu-CuSO4 half cell for (i) Carrier
& casing pipes; (ii) Protected and unprotected sides of IJs (iii)
Foreign pipeline crossings.
Condition monitoring of all installations including chain link
fencing, A.C. power supply system, permanent reference
Electrodes, supporting structures,
Cathodic Junction Boxes, Cabling works etc.
Any other parameters/data as may be required form time to time.

Monitoring of the CP system as mentioned above is to be carried out

once in a month (min) in order to study the health/operating status of
each and every installation and the protection level of the structure.
Preventive Maintenance
Scope of Preventive Maintenance Activities
Addendum-8
Scope of Preventive Maintenance Activities to be carried out by
Electrical Maintenance Dept. on monthly basis.
T/R Units Checks:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Monitoring/Reading of T/R units (Weekly)

Cleaning & tightening of all bolted current carrying connections
(M).
A light film of petroleum should be applied on contacting surfaces
(M)
Check indicating meters for accuracy (FN).
Replace insulated wires on which insulation has cracked or
damaged (FN).
Check transformer proper oil level (M).
Die-electric strength to be tested as per ISI specification (Y).
Check all protective devises (fuses, circuit breakers and lighting
arrestors), to be sure that they are undamaged and in satisfactory
operating condition, (FN).
Visual check of T/R unit fencing, earthing cables, nut bolts etc
(FN).
Over-hauling or T/R unit, control panels etc. (Y)
Pesticides to be spread surrounding T/R unit & control panel to
keep it free from insects (M).
Topping of oil & also replacement of total oil on payment basis at
TR if needed. (as per rule).
Carbonised parts of the TR unit and fuse carrier & fuse base
should be cleaned with carbon tetrachloride (FN).
Clean complete TR unit with hot air blower (M).

Page 11 of 119

Ground Bed Checks

1.

2.

3.

Make sure that there has been no disturbances of the earth above
the header cable and line of anodes in a conventional type bed. If
any part of the ground bed is subject to washout with exposure of
cable, the cable should be covered again for protection. This
should be done after making sure that there has been no
insulation damage, washes to be diverted to prevent re-exposure
of the cable (M).
If construction activity is noted in the ground bed vicinity which
may involve its disturbance, the location of ground-bed should be
safe guarded so that inadvertent damaged may be avoided. If new
construction involves installation of under ground structure, test
whether or not they will be within the potential gradient field
surrounding the ground bed and possible stray-current as & when
required.
If routine tests show a marked increase in ground bed resistance
or an open circuit, locate the cable breaks or anodes that have
failed and repair the necessary cables watering of ground bed to
bring down the circuit resistance.

Test Station / Junction Box Checks

1.
2.
3.
4.

Cleaning of the test-station Wires, Allen bolt, top cover to be

checked & tightened properly to protect from vandalism (M).
Screws/Ellen bolt to be greased for ease of operation (M).
Check the pipe to cable connection and its insulation for open-ckt
or loose ckt (M).
Check bonding connection if any (M).

Earthing Junction Box Checks

1.
2.
3.
4.

Cleaning of the Junction Box, Allen bolt, top cover to be checked

& tightened properly to protect from vandalism (M).
Screws/Ellen bolt to be greased for ease of operation (M).
Check Oil Level in the Polarization Cell (M)
Replacement of Oil / KOH Solution (Y)

General Checks
1.
2.
3.
4.

Cleaning the total fence area of TR units and removal of grass,

crippers, thorns, debris etc (M).
Check the doors of TR unit fencing for tightness, bolts, hook etc
(M).
Clean TR unit outer body and ensure that it is free form dust,
grease, oil etc (FN).
Over-hauling of breakers and switches for their smooth operation
(Y).

Page 12 of 119

5.
6.

Any other job which is necessary to maintain the system in

operative condition.
In case of failure of power supply of any of the CP station from
Electricity Board, the immediate action to restore the power
supply.
(FN)
(M)
(Qtr)
(Y)

=
=
=
=

Fortnightly
Monthly
Quarterly
Yearly

It is desirable that the monitoring and maintaining of CP System is

mainly out sourced to professional agencies, through ARC, as it is
being followed by some of our Refineries. This is a better option, as the
task will be performed with professional acumen.
The Checklist is given in Annexure-AIP2
5.1.6 Corrosion Inhibitor Dosing to Equipment:
To mitigate the corrosion problem of piping and equipment, Corrosion
Inhibitor Dosing system is introduced at the vulnerable areas of piping /
equipment in the Refinery. The dosing is done on line, on continuous
basis. The end result is evaluated by obtaining sample liquid / product
from the down stream of the injection point and evaluated at chem.
Lab. Day to day field check is also performed by process and
inspection to have control on quality.
Generally pH, Cl is checked regularly. Special tests like Fe are done at
lower frequency at units, sometimes done once / month. This aspect is
to be looked into. Outsourcing the complete activity, as done in PR,
may be a better option as in all the Refineries. The C.I. Dosing has still
remained as a weak area. The leakages at overhead circuits etc. are
the manifestation of weaknesses and indications for a better
management of the system.
The existing system is found deficient in establishing:

Quantity of C.I dosing.

Quality of C.I dosing, i.e. the correctness of strength of mix.
Duration of dosing.
Monitoring of dosing.
Maint. Promptness in repairing the pump as it is very small.
Rotameter in the line mostly missing.
The field check is not consistent.

Further detailing on the topic has been made in operation write-up,

which may please be referred.
In Panipat Refinery, the complete job has been entrusted to out side
agency, on LSTK basis. The performance of the dosing has to be
Page 13 of 119

monitored by the vendor including that of the end result. It has been
reported that the system is under better control in PR and the end
results are also consistent.
In view of the same, Refineries may consider to adopt the system of
out sourcing depending upon the suitability. A procedure for out
sourcing has been given in Annexure-AIP3.
Addendum-9
The corrosion monitoring system particularly for CDU / VDU overhead
circuit may be implemented on comprehensive basis i.e. supplying of
inhibitors / de-emulsifier, testing & monitoring of all corrosion controlling
parameters like salt level, pH, chlorides, Fe, corrosion rates on
coupons, online corrosion readings. Performance shall be evaluated
based on the controlling parameters and penalties for any deviation
shall be imposed.
5.1.7 Pre-Monsoon Inspection
Procedure for Storage Tank Inspection (Pre Monsoon Check):
Before the on set of Monsoon, it is mandatory to check the physical
condition of both cone roof type and floating roof type storage tanks
from safety and operational reliability point of view.
The following steps may be followed:
Dismantling of appurtenances (like flame Arrestors, Goose Neck,
Breathes v/v etc.

Cleaning, calibration and repair the components

Mark the dates of calibration in the appurtenances
Dechoking of roof drain valve, drain pipe, emergency drain etc.
Checking of earthing connection / electrical continuity etc. of TK and
ladder etc.
Checking of paint condition and paint at depressed areas.
Checking of external insulation condition and carry out repair / part
replacement etc.
Checking of seal condition
Checking of all PONTOONS
Checking of annular plate condition / gap etc.
Checking of pad condition, drainage etc.
Checking for wild grass growth upon pad etc.

The inspection of the tank and recommendation shall be completed by

the month of February. The execution job shall be done between
March to May, as normally the monsoon arrives in June only.

Page 14 of 119

The recommendation and implementation shall be documented

properly by inspection. MIS to be generated (as per proforma attached)
in case of non-compliance of any job, by the month of May.
Final Report shall be issued giving all details by June every year.
5.1.8 Thermography Survey
Thermography of Heater Reformer Tubes, Reactor / Regenerators /
FCCU Riser etc.
Addendum-10
5.1.8 Thermography Survey by thermal imaging camera (Petro Scanner)
Thermography of Heater tubes for accurate skin temperature trending
using suitable camera of appropriate frequency / heater casing / stack /
Reformer Tubes, Reactor / Regenerators / FCCU Riser and all critical
internally lined equipment shall be carried out once in a three months.
Infrared Thermography is a technology which provides opportunity to
improve plant operating safety, Reliability and cost of operations. This
technology is used to monitor skin temperature on fired process
heaters and temperature mapping of internally lined vessels / reactors /
lines etc. extensively.
In course of time, it has proven to be an invaluable online monitoring
tool.
It is used to determine hot spots on flow restricted tubes, deter flame
impingement due to burner firing / alignment problem and verify
temperatures when the thermocouple malfunctions. The usage is
extensive for internally lined vessels / pipes etc.
In modern Refineries, world wide, Thermographic Inspection of Heaters
/ Reformers are done every month. Short wave / Mid wave infrared
thermographic imagers with optional flame filters are the best for such
application. The frequency of inspection of critical refractory lined
Reactors, Regenerators, Riser Pipes, Flare Tip etc. are done fort
nightly i.e. twice a month, world over.
In IOCL Refineries, this online monitoring tool can be proactively used
whenever needed or once in three months, at least. There are several
other applications, which have been detailed below. The areas of
applications are significant and some covers new field altogether,
which can be experimented at all units, for enhancement of reliability. .
Brief Description On Thermography Survey
The heart of any refinery is their fired process heater. There are a
number of opportunities when dealing with fired heaters to optimize

Page 15 of 119

refinery performance, reliability and economics. Fired process heaters

are substantial consumers of fuel. It is very important to use only the
amount of fuel required to properly fire the heater. Over firing and
under firing can occur, which has high negative impacts on operating
costs and tube service life.
Flame impingement can also results from the fuel setting changes.
Flame impingement can reduce the long-term life of the heater tubes.
The fired heater burners will get fouled with time and their efficiency will
be reduced. This results in higher emissions/ inefficient fuel utilization/
higher operating costs. The process tubes can get fouled both
internally and externally. Tube fouling results in reduced heat transfer
through the tubes. External fouling can also occur around the
thermocouples resulting in erroneous temperature indications.
The operating person cant simultaneously check firing/ flame pattern
when they make fuel setting changes. It is difficult to determine when
the normally occurring tube internal and external build-up exceeds
economical energy usage. Using Infrared to monitor and survey fired
heater assist the operators in visualizing how efficient the heater is
operating and what are the effects of the changes they have made.
In brief, the uses of Thermography technique verifies/ covers the
following vital aspects:

Verification of flame impingement when maximizing firing rates

efficiencies
Verification of heat transfer reliability.
Detect / predict tube fouling problems, both internal and external.
Detect / predict in burner fouling.
Monitor decoking to determine economical cleaning frequency.
Verify the reliability of permanently mounted tube thermocouples
Determine firing / mixing problems.
Ensure safe operating temperatures are maintained if a
thermocouples accuracy becomes questionable.
Heater insulation and refractory integrity
Heater tube hanger and support integrity.

Periodic Infrared surveys of the fired heaters internal assists in making

process operation decision to maintain good economics, good
mechanical integrity and to plan for needed heater outage for repairs
and tube decoking. It also assists in determining the optimum duration
for decoking fired heater tubes.
Furnace reliability assessment:
To scan fireboxes for furnace tube hot spots, excessive scale, coking,
flame impingement, and burner performance. Infrared Thermography
methodology is used Thermal images provides a documented visual

Page 16 of 119

representation of where energy losses from poor heat transfer or

burner performance are occurring. The estimated tube temperature
measurements are used toward estimated remaining life calculations
as well as to identify hot spots that could lead to an unexpected tube
failure. Infrared is also used to validate burner optimization
adjustments and furnace tube cleaning such as decoking and shell
blasting of external deposits. When tube thermocouple readings are in
question, Infrared is also used to approximate the actual tube skin
temperature.
Equipment Reliability Assessment:
Refineries use refractory lined vessels and piping systems in
processes that involve temperatures that exceed the design metal
temperature of most carbon steel materials. Two design metal
temperature limitations occur for each type of carbon steel; one for
stress rupture failure, and one for high temperature hydrogen attack.
Since Infrared thermal imagers indicate actual temperature on the
surface, they are crucial to the safe operation of these systems. Where
fast detection of refractory loss is desired, equipment may be painted
with a temperature-indicating paint that changes color when a
maximum temperature is reached. Follow-up thermal imaging is then
performed to confirm the hot spot condition.
The various significant online applications of the Thermography
tool that can be opted by Refineries are as below:

Thermography at Electrical Field: used for fault detection,

condition monitoring are wide spread. This can be utilized in
Refineries effectively. Some of the Refineries have started this.
Thermography for Rotating Equipment: Detects faulty shaft
coupling alignment, motor / pump bearing, seal performance etc. It
is used to trend the estimated remaining life of rotary equipment.
Thermography to check loses: It can detect heat loss from steam
traps, leaking steam tracing under insulation, etc. which, provides
substantial data for improvement.
Thermography to examine tank data and sludge details: The
measurement of product level and level of sludge in a storage tank
can be measured by using Thermography. M/s NIL, Kankinada is
utilizing this method successfully.
Thermography to detect corrosion under wet insulation
(CWUI): This is a new way of carrying out Inspection. The case
study is enclosed in Annexure-AIP4.
Thermography for detection of health condition of critical
overhead line: The thermography technique can detect the holdup
of condensate at overhead line. A case study is enclosed which will
give an insight for utilization of technology in an innovative way
(Refer Annexure-AIP4).

Page 17 of 119

Limitations
There are some limitations to using infrared cameras on fired heaters.
These limitations need to be recognized by the thermographer when
performing the survey and predicting internal operating conditions and
integrity. The most significant factor is the inability to determine the true
emissivity of the targeted surface. The type of fouling that can occur on
the exterior of the tubes can change depending on the type of fuel and
the cause of the fouling.
The emmissivity of the wall surface can be approximated enough to
determine relative accuracy of the highest temperature indications.
Values of 0.85 0.97 have found to give the most creditable readings.
Conclusions:
Temperature is often an indicator of material, process and mechanical
condition. When used in conjunction with the infrared programme,
Thermography plays a vital role of plants maintenance and inspection
strategy without re-inventing the wheel.
Thermography has become an excellent tool to optimize the operation
with the passage of time. It improves reliability, increases availability,
and decreases fuel consumption. Variety of application makes it more
versatile and effective. Engineers worldwide are making best use of the
Technique to ascertain the health of equipments, thereby improving the
operational reliability.
Leading Infrared- Imager manufacturers in the world:
M/s FLIR, USA; M/s Land infrared UK, M/s CediP Infrared, France, M/s
NEC Japan, M/s Guide, China, M/s SAT China etc.
5.1.9 Videography Survey
Videography technique can be utilized to check and record the
condition of items placed at a height like the flare tip, top portion of
stack etc. which is otherwise in accessible during the run of the plant.
Addendum-11
5.1.9 Videography Survey / through Binocular or Zoom Camera
Videography technique / binocular or zoom camera can be utilized to
check and record the condition of items placed at a height like the flare
tip, top portion of stack etc. which is otherwise in accessible during the
run of the plant.
Presently both video camera and digital camera are available as one
unit. Therefore, the video part can be utilized for monitoring of the
above areas effectively. Alternatively, Commercial videographer is

Page 18 of 119

required to be hired for the task. Refineries to think over and decide on
the best option acceptable to them.
The videograph record can be edited suitably and produced in CD for
general viewing and achieving.
A brief procedure is given below:
Procedure Of Videography In Flare Tip/ Stack Top Zone

The job can be performed through outside agency or in-house using

video camera. In house job is preferred, as videography by outside
agency inside Refinery area is normally not encouraged.
Inspection Engineer is to be associated with the videographer
during recording.
Videography with camcorder movie camera with close zoom facility
from grade level is to be carried out.
Recording is to be done from all four direction i.e. N/S/E/W covering
the entire circumference of flare tip / stack top.
Damage location, if any, is to be focused / zoomed and recorded.
Generally cloudy day is preferred for videography, due to availability
of contrasting background.
After making movie in camcorder, the same need to be captured,
edited & write in CD format.
The directions are specified in the CD by Editing.
The CD should be compatible for viewing in multi media
The CD Duration is normally 10-12 minutes.
The frequency of inspection may be fixed once in six months.
Documentation and preservation of CD to be made properly with
Equipment No. and date of Videography written on the CD, for easy
reference.
Recommendation if any, shall be sent to concerned dept. In case of
long term the point to be included in s/down job list.

5.1.10 External Health Monitoring- Cold Services

External Health Checking (On Line) Of Cold Lines / Equipments, In
Critical Services
Although cold lines / equipments are available for external visual
inspection and monitoring online, there is a need to fix the frequency of
such check for critical services to avoid any abrupt failure.
The inspection is both by visual and ultrasonic thickness checking, in
general. However, for Air Vessels (under Factory, Inspectorate) the
online external Inspection is to be done utilizing other NDT methods, as
well. This is mainly because the Air Storage Vessels cannot be spared
for Internal Inspection and hydrotest etc. In many of the Refineries,
outage of the same shall call for shut down of couple of units at a time,
or even the whole of refinery at some unit locations.

Page 19 of 119

The steps for inspection are given below:

Frequency of visual and Ultrasonic Thickness Survey Checking
Once a year
Provision of scaffolding / scizzors lift, to be planned in advance.
Inspection / Thickness Survey at each bend and at every 5 mtr. Of
pipe length.
Ensuring availability of as built isometric drgs.
Documentation and analyzing the data for thickness trending to
establish rate of deterioration.
For Air vessels etc. under factory inspectorate. (This is optional, as
this may not be applicable to all the Refineries).
The following inspection steps are to be followed:
Common for all vessels:

Visual inspection of equipments.

Thickness survey of all nozzle,
Four places (E/W/N/S) of both top and bottom dome,
Four places (E/W/N/S) of each shell segments
Analysis of result
Documentation

For Air Vessels only:

Dye Penetrant check of 10% length of Butt weld, and all fillet welds.
UT Check of 10% length of Butt weld.
in case of UT check is not possible, (for low thickness equipments).
MPI to be done at the same area.
Documentation
Submission to statutory Authority.

Addendum-12
The following salient inspection points shall be followed and
implemented for improvement of pressure vessel and piping reliability.
The inspectors carrying out inspection of pressure vessel & piping must
be familiar with API 510 & API 570 codes. Thickness and observations
should be recorded in drawing & checklist.
Pressure Vessel

Any pressure vessel if idle for more than six month shall be
internally inspected or hydrotested before taking into service.

Page 20 of 119

The existing strip lined segments of columns should be replaced

with cladded segments, if the strip lining is worn out, repetitively
repaired and shell leak has occurred in strip lined section. Moreover
metal spray coating should be preferred over strip lining for
corrosion protection.
All nozzles in the strip-lined/ metal coated segment of column
should be provided liner from inside.
Column / Over head injection dosing lines should be modified to
protruded injection design and properly supported with addition
stiffener.
The design of protruded inlet nozzle should avoid direct
impingement on the shell.
Threaded connection shall be seal welded.
Hydrotest is mandatory if hot job done on pressure boundary or
nozzle replacement. Part hydotest can be done by welding box
around repair locations / replaced nozzles in case of column and
reactor to avoid total hydrotest.
Inspection frequency for comprehensive Inspection (Offline or M&I)
shall be as per Annexure- AIP-A.

Heat Exchanger

Gasket faces of shell, channel box, tube sheet and other

components should be visually inspected.
Gasket conformity as per OEM recommendation.
No short bolting and substandard fastener are to be accepted.
Bull plugs threaded joint should to be modified to flange joint with
isolation valves.
Replacement / re-tubing Identification of carbon steel tube bundle
for metallurgy upgradation in cooling water service.
Deviation to be acceptable after endorsement through Management
of Change (MOC).
Inspection of fixed tube sheet type bundles in critical service shall
be carried out through eddy current testing in each M&I.
Inspection of tubes internal condition by pulling out sample tubes
from the bundle and splitting it into two halves.
The metallurgy of taper plug should be as per tube and taper plugs
should have an included angle of 5-1/2 degree or less. As a
guideline a typical plug dimension and fitment arrangement is
enclosed in Annexure-AIP-C.

Piping

Any piping circuit if idle for more than six month shall be inspected
or hydrotested before taking into service. Inspection shall be
informed of such idle lines before taking into service.
Piping under culverts / trench / chambers shall be made
approachable to facilitate inspection every year. If required culvert
height may be increased and all the lines may be re-routed through

Page 21 of 119

a new culvert with increased height or alternatively, all lines may

be routed through sleeves.
Stagnant and accumulated water in culverts, trench and isolation
valves chambers of circulating water lines shall be siphoned off &
kept dry.
Ensure adequate wrapping & coating and at least 0.5mtr wrapping
& coating shall be visible externally at both ends on above ground
portion of pipe. The sleeve if provided shall also be wrapped &
coated. The procedure & QAP of wrapping and coating shall be
approved by head of Inspection and Maintenance.
All piping route in off-site area shall be made grass & debris
free.100% hard surfacing under piping route shall be done and a
ground clearance of min. 6" shall be maintained.
Meticulous Inspection of main pipe at injection points & mixing tee
junctions. The preferred NDT is radiography and phase array for
assessing heath condition.
Mixing tee junction should be modified to quill design (Fig-1) on
existing stainless steel piping circuits (one time exercise) if
temperature difference exist between two streams. In case if is not
possible to incorporate quill design, the integrity of piping shall be
ensured with phase array NDT or the segment is to be replaced
within 8 years.

Fig -1

Quill design to be incorporated in P&ID at mixing tee junctions in

Stainless steel piping circuits for all forthcoming modification and
projects.
All tap-off points i.e. high point vent (HPV), tee connections; LPD
shall be inspected and documented with observation during
inspection of piping circuit
DP test of small bore piping up to main isolation valve including
LPD and HPV should be done.
Low point drain (LDP) shall be offset by 1 meter from the supports
and shall not be embedded into soil.

Page 22 of 119

Modification in wash water injection point from common header to

individual headers in Reactor Effluent Air Cooler (REAC), if
corrosion found localized to some circuits.
Improvement in rigidity of small bore connection in critical service in
existing line by providing clamps on the main pipe and small bore
pipe by bolting arrangement as shown in fig. 2 below.

Fig.-2 Clamping arrangement for small bore piping

Stabilization heat treatment of weld joint between pipe and pipe

supports shall be carried out for stabilized grade of SS type 347 /
321 material.
Instrument lines in high temperature & critical piping circuits should
be designed in accordance with piping standard upto pressure &
temperature transmission junctions and same to be executed
through piping agency.
In Hydrocarbon service dia. 2 pipe shall be of minimum Schedule
80.
Use of threaded & seal welded galvanized piping for fire water
sprinkler & foam pourer lines to avoid corrosion due to stagnant
water/ foam in project and replacement jobs.
All welding of small bore piping including tracer lines shall be
carried out by TIG welding with minimum 2 runs of welding.
The pipe specifications for Cooling Water and Fire Water services
of different diameters should be as follows:
Diameter
Upto 6
8 to 14
16 and above

Recommended Pipe Specification

Seamless Pipes Of A 106 Gr.B Or API 5L Gr.B
Standards
ERW/ EFSW pipes of API 5L Gr. B Standard
EFSW pipes as per API 5L Gr. B Standard

Caulking or sealing of soil to air interfaces for buried piping / Circulating

Cooling Water lines shall be checked for damage / deterioration at
interface and if sign of moisture ingress is noticed, 0.5 meter buried
portion of pipe to be exposed for inspection. The damaged caulking /
sealing of interfaces shall be properly sealed.

Page 23 of 119

The piping system shall be classified based on the consequence of

failures. The frequency and extent of inspection of piping system shall
depend upon the form of degradation that can affect the piping
performance and consequence of piping failures. This shall allow more
focused inspection regime for piping systems that have the highest
potential consequences if failure or loss of containment occur.
Maintain list of piping circuits (considering corrosion potential) in each
unit and off-site area with frequency of inspection as per reliability
document 2005 or as approved by head of Inspection. It shall be
broadly divided into three categories i) cold critical lines upto 50 deg C
ii) intermediate hot critical lines more than 50 deg C upto 200 deg C iii)
critical hot lines beyond 200 deg C. Establish the corrosion rate in each
piping circuit as per API 570.
Review of critical lines & inspection frequency by CIPM in a structured
departmental meeting once a year and finally to match the
classification of line and inspection frequency in-line with OISD 130 /
API 570 as placed at Annexure-AIP-B.

5.1.11 External Health Monitoring Hot Services

External Health Checking Of Piping/ Equipment in Hot Service (Once in
a Year)
The online inspection methodology of equipment / piping in Hot
services are discussed here along with the sequences of operation.
The piping / equipment in hot services are necessarily insulated
externally except some cold wall design equipments / piping which are
lined for inside.
For insulated line visual inspection of bare surface cannot be carried
out. Since majority of hot services contain hydrocarbons, it is
imperative to chalk out a plan for inspection covering critical services at
a frequency of once in a year.
The following considerations have been made in order to make the
survey effective and purpose for:

Equipment / piping to check Only in critical services

Ensurance of As Built drgs piping ISOs of units to be updated.
Temperature range to cover upto and including temp. of 2000C
Frequency of Inspection Once in a year.

Note:
The new and updated ultrasonic thickness survey machine with
compatible probe / couplant can measure up to 350 Deg C with
consistency, full repeatability and accuracy. Most of the refineries
are having this type of machines and probe. However, the limit of
200 Deg C has been mentioned considering the human safety only,

Page 24 of 119

as the probe has to be held in hand while contacting the hot bare
metal.
However, if adequate precautious can be taken by the operator, the
upper limit can be extended. This can be decided by unit inspection
heads. The details of machine and probe which has reading
repeatability and consistency at 350 Deg C is given below as a
reference. The machines manufactured by M/s Kraut Krammer are
also equally applicable.
Machine Model :
Probe
:
Frequency

37DL Plus, Panametrics, USA make

D790 (Air Cooled Type)
:
5 MHZ

Alternatively, one advanced NDT technique is available in the

market called PEC (Pulsed Eddy Current Technique), for online
monitoring of thickness through insulation, upto 500 Deg C. In this
method, the insulation cover need not to be removed and the probe
can pick up thickness through insulation upto 200 mm thick. It can
also measure temp through concrete, coatings etc. and the lower
range of temp. range is () 100 Deg C. The accuracy of reading is
within +0.05 mm. However this methodology can be applied only on
Alloy Steel and Carbon Steel Metallurgy. The wall thickness range
is 3-35 mm. A detailed write-up on this is given in chapter 5.1.13 of
the report.
Since this methodology has not been tried in any of our refineries, a
demo by the supplier to be arranged in near future, by any of the
Refineries.

Steps to be followed for Hot Line Survey:

To carry out on line monitoring of Hot lines / equipments upto 2000C,
the following steps are to be followed:

Preparation of scaffolding or making provision of Scizzors Lift

wherever needed.
Provision of Inspection Pockets with removable covers:
For pipes at 6Oclock position at each 5 mtr. Distance of
straight line.
For elbow Pockets are to be made at stretched portion of
elbow.
For equipments Pockets are to be made at all the nozzles,
Top / Bottom dished ends, shell from all the four direction (East/
West / North / South).
All such opening shall be with suitable cover and handles, for
ease of handling.
Carry out ultrasonic thickness survey with Hot Probe and
compatible thickness m/c. The temperature range may be upto and
including 2000C. The above consideration is made only on human

Page 25 of 119

safety ground. The data collected shall be analysed to establish

thickness trending and determination of corrosion rate.
Monitoring of health of components beyond 200 Deg C shall be
decided by Inspection heads of individual units considering
personnel safety.
Other points
The thickness shall be repeated at the same pocket location,
each year.
Special attention to be paid towards human safety, the operator
who performs the probing. Heat resistance hand gloves to be
worn.
The opening shall be suitably made with enough space so that
probe can be inserted held in hand.

The pockets with removable covers shall be made impermeable to

ingress of rainwater. The 6Oclock position of pockets are preferred, to
avoid water entry by gravity.
5.1.12 Health Monitoring of Lines Passing through Dykes, Culverts and
Roads
Health monitoring of lines passing through Dykes, culverts and roads
and also running underground.
In all over the Refineries a considerable quantity of pipes of both critical
and non-critical services are either passing through various road
crossings / dykes / culverts or traveling underground. Some of these
lines are insulated as well.
The problem being faced by inspection is the inaccessibility/ lack of
space for checking. No physical look is possible to be given at these
areas, neither any other methodology could be applied so far to
mitigate corrosion online. Therefore, these remain as an area of
concern. The culverts being at low level, water logging during rainy
season also cause deterioration of health. Wild vegetation also adds to
the misery. There are sporadic leaks / failures of the lines because of
corrosion taking place externally. While some of the refineries have
taken up actions on piece meal basis, the majority of portions are left
unattended.
Since the problem is being faced by all the Refineries. In this write-up,
an effort has been made to analyse the issue and find out some way
out to remove / minimize the grey area of inspection.
Physical Inspection of Lines:
The lines cannot be physically checked, as most of the road crossings
are low and no headroom is available for entering inside.
However, in one of the Refineries it was found that the culverts slabs
are of removable type. The slabs are removed for creating passage for
Page 26 of 119

inspection. Physical check is carried out on removal of insulation at

places and recommendation given.
However, this process is slow and necessarily operational hazard for
stoppage of fire vehicle movement, as the road remains blocked for the
whole day or even more in case of pipe replacement.
The lines passing through dykes / roads remain unattended, forever as
the same cannot be exposed.
There are some alternative Suggestions for Betterment of Condition:

The lines under the culverts can be laid at upper elevation so that
the problem of water ingress, vegetation growth etc. does not affect
externally. However, this involves considerable amount of hot job.
The lines may be provided with sacrificial anodes on both the ends
of culvert and the culvert is filled up with sand and blocked from
both sides, so that no water can accumulate inside.

However, both the above methods are time consuming, and may not
be practicable.

The third approach is to adopt online Advanced NDT Technique to

monitor the health condition once in a year and plan for phase wise
replacement as and when needed, as per the physical condition.
The Advanced NDT Technique is called Guided Wave Inspection
Technique or Long Range Ultrasonic Technique (LRUT), which can
be used, online, even on the insulated lines by opening small bands
at both side of the culvert.
This technique shall produce online data on the health condition of
pipe irrespective of the location i.e. underground, under the culver,
under the dykes or through road crossings.

In this procedure, both internal and external corrosion mapping is

possible.
The range of diameter that can be inspected is from a dia of 2
inch to dia of 48.
0

Pipes upto 125 C temperature can be checked.

Around km of pipelines can be covered in 8 hours.
Limitations: Only straight line can be monitored, without interruption of
flanges etc. A brief procedure on LRUT is given at 5.1.13 for clarity.
Addendum-13
5.1.13 Thickness measurement, NDE and Hydro Test

Thickness measurements to be done at designated thickness

monitoring locations (TMLs) marked on equipment & piping for

Page 27 of 119

corrosion rate calculation. TML should cover corrosion sensitive

locations, both side of weld joint, fittings and deadlegs.
All NDEs shall be done by qualified and skilled NDT Examiner with
minimum level-II certification. NDT instrument must be calibrated
and skill of examiner must be demonstrated before start of the work
at site. The accuracy of the instrument shall be checked on
reference blocks and templates. The reference & calibration blocks
and templates should be preserved for future applications.
The hydrotest is required for the strength and integrity confirmation.
Test pressure shall be as per design code or inscribe on name plate
and test temperature above minimum design metal temperature
(MDMT). Two nos of calibrated pressure gauges having range 3
times the test pressure to be used. The minimum holding time at
test pressure should not be less than hrs. No seepage &
sweating are acceptable.

5.1.14 Advanced NDT Techniques - Online

Addendum-14
Advanced NDT techniques as discussed below can be carried out on
need basis. The NDT observations are compared with previous data or
base data for corrosion rate calculation and evaluation of equipment
health assessment
There is always a demand on plants to improve their on stream days
with complete safety and Reliability for maximizing profit. In todays
competitive market, there is no other option than to run the plant to full
efficiency and capacity and even beyond the rated capacity, to survive
and sustain growth. To run the plant with utmost safety, it is necessary
to monitor and check the health condition of the equipment during
operation. Periodical checking gives at idea about the soundness of
system to decide on the continuance in operation with full efficiency,
reliability and safety.
To lift the equipments operation to the desired efficiency level, the
equipments need to be in fit for use condition. Normally, the
equipments are checked thoroughly during the shut down only, as it is
a time-based maintenance. To certify the functioning of the equipments
on run needs something more than normal activities.
This was not feasible until some years back. But with the advent of
various state of art technology, checking of equipment integrity during
the run of unit has become possible, and the effectiveness of such
investigation is quite high.
In the developed world, there are various new experimentations and
applications, on the job which we are yet to examine. Whatever proven
methodologies are in vogue have been collected and put here for
benefit of all users. In IOCL, we are always a step ahead. Many of the
online proven inspection methodologies, available in the market, have

Page 28 of 119

been given a trial in one or other Refineries. Therefore, already some

pool of experience is available which can be further developed so that
all Refineries are benefited equally.
Some of the online advanced Inspection methodologies are listed
below with description which can be utilized at unit locations, whenever
needed. These methodologies, beyond doubt, are helpful to inspection
engineers to strengthen their decision making. Therefore it is expected
that wide utilization of the same shall be beneficial for all of us in the
long run.
The following advanced online NDT techniques are discussed below:
Acoustic Emission Test (AET)
This NDT methodology is widely used in Refineries / Petrochemical
sector, to detect deterioration of Tank floor plates due to corrosion,
without opening the tank with product inside.
Few of our Refineries have already adopted this technique and the
results are positive. On the basis of the feedback, further tests are
being planned in most of our Refineries.
Acoustic Emission Testing (AET) utilizes highly sensitive acoustic
sensors, which are attached to the tank wall for online assessment of
storage tank floor. The fracture of corrosion products is detected
together with leaks which are active during the actual monitoring.
Based on findings, the values are assigned a grading on an A to E
scale. During monitoring the valves are closed, the tank is kept in still
condition with steam coils and agitators turned off.
Details of AET
Acoustic Emission Testing (AET) is a non-intrusive condition
monitoring technique and now a days widely used for on-line
evaluating the integrity of storage tank floor and maintenance planning
strategy. AET identifies areas where active / growing defects are
present and ignores non-active (fabrication) defects, which are unlikely
to result in equipment failure.
The sound emissions of fibre breaking can be felt while tearing a piece
of paper. These emissions are a mixture of waves having wide range of
frequencies. Much of this is in the ultrasonic region, detectable only
with specialized AE sensors. Such AE sensors can detect emissions
emerging out of dynamic defects in a pressure vessel or storage tank
under pressure.
Chemical processes such as corrosion, metal fatigue fracture and
disbanding, also release acoustic emissions. However, the above are
very slow process and emissions are almost fully in ultrasonic region.

Page 29 of 119

To detect such emissions, sufficient time and special sensors are

required.
The AE arising from the corrosion process on the floor of a storage
tank will travel through the product contained in the tank, through the
tank wall and into the sensors attached to external surface of the shell.
AE signals from a ring of sensors can be used to pinpoint the location
and extent of corroding surface. Based on AE observations tanks are
rated on an alphabetical scale from A to E (very minor to highly active
damage).
Hence AET is a sorting system which can separate good tanks from
bad tanks so that tank M&I activities can be scheduled accordingly.
Advance information on the tank condition helps in scheduling the
timing of M&I.
Advantages Of AET

Tank bottom plates together with the steam coils can be inspected
without emptying out and while the tank is in service. However, the
tank needs to be in non turbulent condition without any product
movement / circulation including isolation of steam coils for about 8
12 hrs, prior to test and also during the test.
Quick inspection method as internal cleaning of tanks and tank
outage avoided. It can scan a tank floor of 50 M dia in one day.
Effective re-scheduling of M&I activities.
Internally painted tanks, insulated tanks can also be inspected.
However, pockets need to be provided in insulation for installation
of sensors.
Generates database for future reference.
Increased Safety and reduced Environmental releases.

Gamma Ray Scanning

This advanced online NDT Technology is utilized basically to locate
online the tray position in a column by utilizing Gamma Ray Scanning
method. Other than the tray dislocation, the following also can be
detected.
Flooding of Column
Blockage
Packed
bed
verification/
Other bid condition
Packing Material
Column Internal

Location and extent

Location
Position of Top and Bottom Portion
Collapsing beds
Mal distribution of packing material in packed
beds
Liquid distribution status.

This methodology can also be used in distillation columns for recording

of signature scan prior to commissioning so that at later date

Page 30 of 119

troubleshooting shall be easy. It also helps in optimization of process

parameters.
In Mathura Refinery this Technique has been successfully utilized in
the recent past.
A detailed write-up with scanning procedure is given below. Our R&D
Centre (Faridabad) can undertake this job along with BARC.
Gamma Ray Scanning Methodology:
The technique is based upon the principal of differential absorption of
the gamma rays being emitted by a radioactive source. The extent of
absorption of gamma rays from a radioactive source is directly related
to the density of the intervening medium. The comparison of the
absorption profiles within the column with that of the base profiles
recorded earlier can provide vital information on the upset conditions in
the process as well any other mechanical damages in the column
internals.
The transmission of gamma rays through any material is governed by
the equation I = Io exp (-x)
Wherein I = intensity of radiation transmitted through a material of
thickness x (cm) and is the density in (g/sq. cm), Io = Intensity of
radiation from the gamma-ray radioactive source reaching the detector
in the absence of the material, = absorption coefficient of the material
in sq. cm/g. The technique depends on the proper source selection,
collimation of the radiation, radiation detector and its accuracy and also
proper synchronization & alignment of the source with respect to the
detector.
Gamma ray Scanning of Distillation columns:
As gamma ray scanning is an online NDT technique it helps to pinpoint
the cause of malfunctioning within the column to arrive at a solution.
The technique is widely applied for:

Verification of the Presence or absence of trays and other internals

inside a column
Location and extent of flooding
Identification and location of blockage caused by Downcomer
obstruction, Tray fouling, High liquid loading on trays etc.
Presence of liquid weeping
Verification of the Top and bottom positions of packed beds
Maldistribution of packing material in packed beds
Crushed or collapsed bed
Uneven liquid distribution in the column

Page 31 of 119

Gamma ray scanning in addition provides information on the

performance of a distillation process within the column beyond the
gross fault diagnosis. Scanning of grids on packed bed distillation
column provides information on the possible non-uniformity of packing
material or flow mal-distribution of liquid through the beds. Repeated
scans under different operating conditions such as temperature,
pressure, feed flow rate and reflux ratios can give additional
information on the extent of entrainments, tray flooding and foaming
characteristics. In the recent times recording of the signature scan of
the distillation column prior to commissioning of the newer unit is
practiced almost invariably for trouble shooting at a later date. In
addition, the results of a process simulation can be verified and
quantified through column scans and the process parameters can be
optimized.
Planning for Gamma Ray Scanning:
Before conducting a gamma ray scanning on a distillation column, the
following information are in general required to be studied in detail for
the proper selection of radioactive source, type of detector, etc.
Process Description
The mechanical drawing indicating the details of internals
Inside diameter and thickness of the column
Bulk density and type of packing material for packed bed
Operating problem experienced
Signature scans if available
Accessibility and any other major obstruction in the way of
source/detector.
In general columns of diameter upto 18 meter can be easily scanned
by the use of gamma ray scanning technique. The radioactive sources
192

60

such as Am241, Ir and Co are chosen depending upon the column

diameter. For smaller columns of less than 30cm dia., Am241 source is
preferred. On the contrary, column size of diameter 30cm to 3.0 meter
60

dia. and more than 3.0 metre, Ir192 source and Co are generally used
respectively. Solid-state scintillation detector of NaI (Tl) is generally
used for detecting the transmitted radiation across the chord of the
column. During the test adequate precautions are followed for the
proper collimation of the radioactive source for the sensitivity of the
detection especially with respect to the minimum thickness of the
column internal to be detected. Appropriate selection of the source
strength is made using the following equation:
2

w/hvt

Activity = (D.d .2

)/T

D = Dose rate, d = Diameter of column, W = Total wall thickness and

hvt = Half value thickness of material, T = Gamma ray constant for a
specific source.

Page 32 of 119

Effective diameter considered for the source strength calculation

requires consideration of clearances of around 200mm required for the
vertical movement of the source and the detector assemblies. A
sensitivity of 5000 to 7000 counts per second (cps) at the detector
through the vapor zone of the column is normally considered. The
count rate will reduce to approximately 1000 to 2000 cps at the position
of the trays/ solid internal.
Scanning Procedure:
During Gamma ray scanning of columns, the source and detector are
lowered concurrently in small increments on opposite sides across a
suitable chord at the column cross section. Motorised arrangements
are made which synchronously lower the detector and source
assemblies along with data logging systems. A relative density profile
of the contents of the column is thus obtained in the form of transmitted
intensity of radiation with distance. Areas containing relatively highdensity material such as liquid/metal would result in relatively low
intensity of transmitted radiation. While areas of relatively low density
(vapor phase between trays) would result in a higher intensity level. By
comparing the density profile obtained with respect to the mechanical
assembly drawing of the unit as well as process anomalies such as
flooding, blockages, weeping etc. a first hand information is obtained
on the problem areas in the column.
In scanning of a tray column, a line scan is made either along a chord
or multiple chords depending on the number of passes. Scanning
through the down comers of the trays is often avoided. For packed bed
columns, grid scanning is adopted wherein at least four or more
intersecting chords are chosen for scanning. During the grid scan
operating parameters such as feed rate, temperature etc. are generally
kept constant.
Interpretation of signals/density profile- an illustration:
The Gamma ray scan profile is obtained in terms of height of the
column verses the response of the detectors in count per second.
The interpretation of the signals obtained is carried out keeping in view
the mechanical details of the internals and externals of the column.
Signature scan of the column from previous studies if available, makes
the interpretation for problem solving easier and quicker.
Conclusion:
Gamma ray scanning technique is a quick and effective on-line, noninvasive technique to diagnose problems in process columns. Adoption
of this technique can reduce the down time during trouble shooting of
column. It has been established world wide that the technique is very

Page 33 of 119

cost effective, improves efficiency, and makes plant operators task

easier.
Pulsed Eddy Current Testing (PEC)
This is a new Advanced NDT Technique that has come to the market.
It has so far not been used by any of our Refineries. In this process,
the wall thickness measurement of carbon steel and Alloy steel pipes /
vessels can be taken without removing Hot/ Cold Insulation Coverage.
Moreover, this technique can be used for high temperature application
0

(upto 500 C) making it very useful for monitoring of high temperature

circuits like transfer line, column bottom lines, reactor outlets etc.
The technology is based on Pulsed Eddy Current, and can be utilized
for insulation upto 200 mtr thick. However, this technique cannot be
utilized when the line is under steam tracing, near support locations
and at sharp bend area.
The wall thickness can be measured by the technique is from 3mm
35mm with +0.5 mm accuracy.
A detailed write-up is given below for ready reference and further
information.
Inspection through insulation by PEC System
A new inspection instrument has been developed by shell global, called
Pulsed Eddy Current (PEC) which can measure wall thickness of steel
objects like pipes and vessels without making contact with the steel
surface. The instrument can measure through coatings, insulation
materials, weather sheeting and even corrosion products.
The main benefits include:

No production loss: the instrument can inspect while the equipment

is in service;
Ability to monitor the integrity of the plant while in service helps to
prevent unplanned shutdowns;
Reduction of inspection costs: no need to remove insulation
materials;

The technology is based on pulsed eddy current, or simply PEC.

The PEC instrument has been applied extensively at Shell refineries,
chemical plants and offshore installations.
Working Principle

Page 34 of 119

Pulsed Eddy Current is an electromagnetic method to determine wall

thickness of electrical conductors. The PEC instrument probe is placed
against the metal weather sheeting of an insulation pipe or vessel. A
magnetic field is created by an electrical current in the transmitting coil
of the probe. This field penetrates through the weather sheeting and
magnetises the pipe wall. Next, the electrical current in the
transmission coil is switched off, causing a sudden drop in the
magnetic field. As a result of electromagnetic induction, eddy currents
will be generated in the pipe wall. The eddy currents diffuse inwards
and decrease in strength. The decrease of eddy currents is monitored
by the PEC probe and is used to determine the wall thickness. The
thicker the wall the longer it takes for the eddy currents to decay to
zero.
Strengths and Limitations
As any NDT technique, pulsed eddy current has its strong and weak
points.
Strength
The main strengths of the pulsed eddy current technique are:

No need for direct contact.

Wall thickness can be measured through any material that does not
conduct electricity: Insulation material, coatings, paint, concrete,
bitumen, dirt, sludge and so forth. The layers can be as thick as 200
mm.
PEC can measure through aluminum and stainless weather
sheeting. It is in principle also possible to measure through
galvanized weather sheeting, but the performance is less.
There is no need for surface preparation. In particular, surface
roughness does not affect the PEC readings. Moreover it is not
required to remove corrosion products, even up to 20 mm thick.
o

Limitation
The main limitations of pulsed eddy current are:

Wide temperature range: 100 C to 550 C (-150 F to 1000 F).

The above qualities ensure that the instrument can be applied in
service.
Very good reproducibility of PEC readings at the same locations,
typically + 0.05 mm. This makes PEC very suitable as corrosion
monitoring device.
The PEC instrument can be operated by remote control,
e.g. for use in Remotely Operated Vehicles (ROVs).

Only applicable to carbon steel and low-alloy steel:

Page 35 of 119

PEC is suitable for general wall loss, but isolated pitting defects
cannot be detected.
The PEC wall thickness readings are relative values, showing
variations in wall thickness on the object being inspected. Whilst
this is sufficient in many applications, absolute readings can be
obtained by a wall thickness calibration at one point of the object.
The PEC readings depend on the electromagnetic properties of the
material. Variations in these will influence the PEC wall thickness
readings. Variations in material properties within one object will
result in spurious variations in PEC wall thickness readings of
typically 10%.
The geometry of the test object should be simple; e.g. straight
sections of pipe work. Wall thickness readings are affected by
nearby nozzles, welds, internals, and support structures. A
clearance of typically 2 is needed. It is not possible to inspect
under steam tracing, near supports and in sharp bends. The
limitation in geometry is relevant when inspecting for corrosion
under insulation.
Typical Performance Parameters
Wall thickness range
Typical accuracy
Same spot
reproducibility
Lift-off range
Pipe diameter
Material temperature
Defect sensitivity
Remaining wall
thickness of defect

3 35 mm
+ 0.5 mm
+ 0.05 mm
0 - 200 mm
75 mm flat plate
o

-100 C to +550 C
Diameter larger than 50% of insulation
thickness (at 30 120 mm lift-off)
+ 1mm

The Pulsed Eddy Current Instrument

The main characteristics of the pulsed Eddy Current Instrument are:
Single operator-tool, portable instrument, and handheld probe

Instrument weight is 6 kg (12 pounds); size is 350 x 200 x 130 mm

(13.5 x 8 x 5).

Battery operated

Suitable for use outdoors: robust design and splash-water tight.

No computer required during data taking.
Suitable for use in safety zone 2 (i.e. no sparks are generated
under normal (conditions).
Up to 1000 points can be stored in the data logger.

Page 36 of 119

Downloading of stored data to personal computer is done using an

EXCEL spreadsheet.

Data Collection
Is simple and fast (about 5 seconds per reading; still being improved)
and can be done by a single Level operator. The PEC instrument
takes point measurements. During the 5 seconds it takes for a PEC
reading, the probe has to be held stationary; it is not possible to move
the probe while collecting data.
Data Analysis
The instrument gives an instantaneous estimate of the wall thickness.
For some applications this is sufficiently accurate and no further
analysis is required. More demanding applications require more
detailed analysis. This is done after the inspection by connecting the
instrument to a PC and downloading the stored data. The data can be
processed using dedicated software by a level II or III inspector. This
off-line processing can be done remotely, e.g. by sending the data by
electronic mail. This implies that the level II inspector does not need to
be on site nor present during data collection. This split in data
collection and analysis proves to be cost-effective.
Corrosion Under Insulation
A large range of insulated and coated equipment has been inspected
for corrosion under insulation (CUI): pipes, vessels, columns, heat
exchanger shells and storage tanks. Inspections have been carried out
on equipment both with and without metal weather sheeting around the
insulation. The inspection involves taking several readings on the
equipment and searching for variations in wall thickness.
High temperature applications
PEC offers an alternative for these applications. By placing a ceramic
block in between probe and hot wall, the probe can be shielded from
the heat and readings can be taken as normal. In this way, PEC is able
o

to measure up to about 550 C.

In-service corrosion monitoring
Pulsed eddy current measurements are generally highly repeatable.
This makes it well suited for corrosion monitoring purposes. Corrosion
rates can be deduced from wall thickness measurements over a time
interval at fixed locations.
Inspection of heavily corroded equipment

Page 37 of 119

Another application of PEC is in-service assessment of heavily

corroded pipes and vessels. Often safety considerations do not allow
the corrosion products to be removed on stream. In this case PEC has
the crucial advantage that it can be applied without disturbing or even
touching the corrosion products. The inspection procedure involves
taking reading on the defect and comparing these with readings next to
it. To this end, a slider was developed to move the probe over the
defect area without having to touch the surface of the pipe.
Long Range Ultrasonic Test (LRUT)
This advanced NDT Technique shall be useful to detect corrosion of
pipes crossing the roads, crossing the dykes, passing through culverts
and also on underground lines. This is an on line method to detect
corrosion even under insulation. However, this has not been utilized in
any of our Refineries.
This technique can detect corrosion both inside and outside of pipe and
can cover diameter from 2 48 .Per day coverage is upto 500 Mtrs.
Limitations:

Can measure upto 1250C only

Can examine straight length (with elbows, supports etc.) but not
through break up flanges
Useful for offsite lines.

A brief write-up is given below for ready reference:

Guided waves are Long-range ultrasonic waves guided by the
geometry of the object in which they are propagating. In case of a pipe,
the waves are transmitted along the whole circumference of the pipe.
Therefore no geometric spreading arises and attenuation is low. The
system uses Flexural, Torsional and Longitudinal modes. These waves
can travel across straight stretches of pipes, bends, supports, and
welds.
Application:
Guided waves inspection is primarily used for monitoring of corrosion in
piping. It is being widely accepted as a technique for assessing the
condition of pipes and pipelines, particularly difficult or expensive for
access for inspection. The system has the ability to detect defects in a
part of a pipe that is buried or inaccessible. A probe ring is placed
around the pipe and transmits guided waves (Surface/ Lamb waves)
through the pipe in either direction of the probe ring. The pulse echo
type operation provides information on feature position and
approximates size. The interpretation of results is done with
sophisticated analysis tools.

Page 38 of 119

Only a limited amount of coating or insulation has to be removed to

place the probe ring on the pipe. Because of the outside application of
the probe ring the inspection can be carried out while the pipe is in
service. The system is most applicable to buried pipes, sleeved
crossings, coated pipes etc. Because the probe ring is applied at large
intervals of the pipe and the measurement itself is a matter of minutes.
The total inspection time is short compared to other NDT techniques.
Features:
1.
2.
3.
4.
5.
6.
7.

Detection of internal as well as external metal loss.

Dia range 2 inch to 48 inch.
Test Range upto 30 mts. from the single test point.
Sensitive to metal loss down to 10% of metal loss.
Discrimination between metal loss and pipe features weld,
bends and supports.
Temp: -40 C to 125 C
Testing rates of around 500 mt per day.

Limitations:
1.
2.
3.

Doesnt differentiate between internal and external loss although it

detects both.
Water line testing is not possible as the hard scales of calcium
compounds results in high attenuation of sound waves.
Sound wave emitted will not propagate through the Flange.

Addendum-15
Remote Visual Inspection (RVI)
It is a technique used for internal inspection of inaccessible locations
such as cyclones, riser, stand pipes, cyclone dip legs, in FCCU,
overhead lines of column & reactors, transfer lines, Reactor Effluent Air
fin Cooler (REAC) with connecting piping in hydro-processor. It can
also be used for internal inspection of small vessel, coke drums, soaker
drums intermediate tube sheet & refractory condition in convection
zone of heater.

Page 39 of 119

The video photographs obtained through RVI are capable of identifying

and documenting a wide variety of visual features. The capability of the
camera systems allowed the operator to zoom in on irregularities in
the surface of the vessel wall. Dents on cladding scratches, and nozzle
weld detail could be well identified with the camera system. Previously
repaired areas, thermo wells, vapor lines, PSV inlet nozzle and utilities
injection nozzle could be easily inspected with this system.
Requirement of man entry & scaffolding can be avoided with
application of remote visual inspection in coke drums.
5.2.0 Strengthening of Offline Monitoring and Inspection Procedure:
Offline monitoring of plant and equipments are normally taken up
during down time of unit. This methodology can be best applied when
the equipments etc. are out of service.
Various methods are available for offline inspection other than a close
visual look. However, the methodologies which are more significant
and contribute to enhanced reliability are discussed here. Although
common NDT methods (like ultrasonic thickness survey, MPT, DPT,
RT, UT etc.) are equally important and play a crucial role, the same
have not been included for detailing, as it is practiced regularly by all
Refineries.
Total individual attention to each equipment by inspection engineer is a
prime requirement to judge the health status, and to run the plant
safely. Never the less the equipment reliability is also dependent on
understanding the process it undergoes, the effect of the same on the
material of construction, behaviour of material under such exposure
and degree of deterioration it undergoes with the time. The inspection
cycle therefore comprises of physical check, understanding operation
and process, clarity on material behaviour and finally thorough analysis
of the data for a comprehensive understanding.
The monitoring procedure of equipment shall address and take into
consideration of all possible factors that contribute to health of
equipment. Various methodologies including Advanced NDT
Technique have been explained in this chapter, which ultimately
supplements to the inspection decision-making.
Addendum-16
Use of advanced NDT for assessing equipment integrity should be
decided by Inspection Head in consultation with Inspection group;
however, the maximum periodicity should be as follows.
Equipment

Type of NDT

Reformer tube
Reformer tube

H-Scan
AUS

High pressure reactors

TOFD

Page 40 of 119

Maximum
Periodicity
in yrs.
10
Alternate
M&I
10

High pressure air fin coolers (tube ends

IRIS
inaccessible)
In accessible location (cyclone, cyclone Remote Visual
dip-leg, riser, RCSP, SCSP etc.
Inspection
(RVI)
Underground piping at culvert, road
LRUT or
crossing & dyke
Inspection by
exposing
Mixing Tee Junction of two streams at Phase Array
different Temp. in Stainless Steel
Metallurgy
Tank Bottom
LFET
Temperature scanning of Reformer
Pyro meter
tubes, refractory lined equipment &
(Cyclops )
Heater casing plate,
Thermal image scanning of heater
Infra red
tubes , refractory lined equipment & Camera (Petro
Heater casing plate,
Scanner)
Over due Tank inspection
AET
Boiler tubes & H/E Tubes
RFET
Column internal condition
Y-Ray
Scanning
Equipment & piping operating in
In situ
environment
promoting
material Metallography
degradation
(
Carburization
,
graphitization, sensitization, Sigmma
phase formation, Hydrogen attack and
Embrittlement)
or
leading
to
environment cracking
Fixed tube bundles of PG coolers and Eddy current
other critical bundle
testing

Alternate
M&I
Alternative
M&I
5
Alternative
M&I
Need based
Fortnightly
Quarterly
Need based
Need based
Need based
Alternate
M&I

Need based

5.2.1 Positive Material Identification (PMI)

Positive Material Identification (PMI) is a very powerful methodology for
assuring reliability and safety of item and therefore is very important
task to be performed by inspection engineer. In many of our Refineries,
interruptions have taken place due to failure of components which were
of spurious nature / substandard with lower grade of composition etc.
and could not be detected at the time of fitment / use.
Of late, the urgency and importance of PMI has been felt by all
concerned and in many of the Refineries this task is performed
regularly and with due diligence. However still some of our Refineries
do not have this Alloy Analyser m/c and they are dependent on outside
parties. At those locations, this activity was found irregular, which is an
area of concern.
During our study, some anomalies were noticed in the process of doing
the job. Therefore it was felt necessary to bring uniformity in inspection
Page 41 of 119

procedure, so as to have a very stringent guideline all over the

Refineries. Moreover, there is a need for availing latest technology
development that has been put into devising the latest Alloy Analyser
M/cs. Given the cost saving by avoidance of failures that these
machines can provide, there is no reason why every Refinery should
not have their own instrument, when it is of day to day use for vital
cause. Present day M/cs are not radioisotope based but are of X-ray
tube based. Therefore there is no need for the replacement of the
source, which is otherwise a cumber some and time consuming
process.

A brief procedure/guideline is given below for reference and follow

up:
Objective of Positive Material Identification (PMI):
Positive Material Identification or PMI, is an integral part of
process safety management in the petroleum refining industries.
In response to a series of accidents resulting from material mixups, Refiners worldwide have framed stringent PMI programmes
to assure that the materials utilized in a process system are
consistent with design specifications. 100% PMI is must in
critical / high-risk components.

Purpose of PMI:

Verification of fresh incoming items at warehouse prior to

acceptance.
Verification of already received material and kept in inventory which
have not undergone PMI.
Verification of materials prior to issuance for use (irrespective of
checks performed at entry level).
RPMI Retrospective Positive Material Identification i.e. in service
PMI applications in order to detect spurious items at running plant
and arrange for replacement after fresh procurement.

As per the present day practice world wide, the PMI procedure has to
be mandatorily followed in three stages, by all IOCL Refineries, as well.
The following are the stages:
a) All incoming materials (either procured by IOCL directly, or by LSTK
contractor or by any other source) has to undergo PMI.
Addendum-17
All incoming alloy steel, stainless steel & non-ferrous materials (either
procured by IOCL directly, or by LSTK contractor or by any other
source) has to undergo PMI at fabricators / suppliers shop.
The results are to be documented and protocol prepared and
signed by inspection / project / maint./ store persons.

Page 42 of 119

 Colour coding as per standard to be provided on each item by

stores and record maintained.
In case of any rejection, the same shall be taken away from the
storage place of the particular items. The rejected items are
either to be returned to the supplier or to be put into scrap yard.
The inventory stocks at warehouse, which have not undergone
PMI, at any stage, shall be subjected to identification followed by
painting as per established colour code.
Prior to release of materials from Stores to site, each item has to
undergo PMI irrespective of checks carried out earlier at entry
level. This is true for both departmental and contractor issues.
b) All materials brought to fabrication yard need to undergo PMI for
individual items. The results are to be documented and a joint
protocol to be signed by inspection and execution dept. (PJ/Maint.
Etc.) The rejected items, if any shall immediately be shifted from
site to avoid any mix up.
Addendum-18
All materials brought to fabrication yard need to undergo PMI for
individual items prior to start of fabrication job. The results are to be
documented. The rejected items, if any shall immediately be shifted
from site to avoid any mix up.
c) The final stage of PMI needs to be carried out after mechanical
completion of any job and prior to hydrotest. In fact the clearance
for hydrotest shall only be given by the PMI group, on completion of
Inspection, to avoid any job been performed subsequently.
This step also to be documented and protocol signed by Insp./ Maint./
Project Engineers.
Addendum-19
d) Confirmation of metallurgy through Positive Material Identification
(PMI) to be done during the construction of new piping system,
retroactively on existing piping system (one time exercise for
existing units if not done & established) and
during the
maintenance, repair or modification of existing piping system and
project execution.
e) In addition to PMI, confirm carbon content in cast material for high
temperature application.
f) When welding is conducted, one electrode or wire sample from
each lot or package of alloy weld rod should be positively identified.
g) Material verification program for new and existing alloy piping
systems shall be followed as per API recommended practice 578.
The Machine:
PMI machines are either isotope based or X-ray tube based. As has
been discussed earlier, the isotope-based machines are having

Page 43 of 119

problem of periodical replacement of radioactive sources which has its

own procedural problem. The job is cumber some and time taking
because various agencies like BARC, Airport Authority of India, DGCA
etc. are involved as the source is of radioactive type, and needs
clearances from all Govt. bodies.
The X-ray tube based machines do not have this problem and quite
handy as well. However, the cost of the machine is more than the
isotope based one.
The world leaders in Alloy Analyser machine manufacturing are:

Thermo Electron Corporation - USA

Metorex - Finland
Niton - USA etc.-

Note:
i) The Alloy Analyser machine does emit small amount of radiation
because of the basic mechanism of m/c. The user, therefore,
should strictly follow the manufacturers guideline.
ii) There are various models available in PMI. Individual Refinery to
select out the best suitable for them.
iii) The Alloy Analyser machine can be utilized for identification from
0

ambient temperature level and upto 500 C, online. For the inservice test at high temperature there are suitable accessories
available.
iv) The Alloy Analyser machine can provide both qualitative (name of
elements present) and quantitative (% composition of the elements
present) analysis making it very simple for on the spot identification.
Limitations of Portable Alloy Analyser Machine:
i) The probe fixing is difficult for small bore pipes / tubes (upto ).
Therefore this remains as a grey area.
ii) The online use at high temperature is difficult due to longer
response time (in some cases upto 20 seconds for one reading.
iii) Since the general portable Alloy Analyser machine detects upto 20
alloys and do not detect carbon content, therefore, detection of 304
vs 304L and 316 vs 316L are not possible by this methodology.

5.2.2 Strengthening the Shutdown Inspection

In many of the Refineries, the shut down of late are not taken up as per
schedule, for various compelling reason of product demand,
emergency at other units etc. This led to stretching the run length
considerably. This phenomenon is happening very often and all the
Refineries, and there is every possibility that the same situation shall

Page 44 of 119

continue in future as well. To continue with the situation, the reliability

of the equipments / piping are to be ensured thoroughly. Therefore, in
each M&I shutdown, the inspection activity shall be planned
considering the above.
In order to supplement & strengthen the departmental job, outside
agencies can be lined up for thorough inspection by advanced NDT
methods. For other NDT jobs, good agencies can be lined up as per
the guidelines given. Hiring of inspection engineers, if needed also can
be planned to augment the inspection activity. All the above action
finally should contribute to enhanced equipment reliability even if the
operation is stretched beyond scheduled shut down plan.
5.2.3 Advanced NDT Techniques Offline
In the field of NDT, there are lot of advancement has been made. The
technology has progressed very fast. There are various techniques
available in market, and they claim to be of excellent use. However, on
examining various techniques the following could be found to be of our
utility. Infact, some of the technologies have already been adopted by
us and the feedback from Refineries is encouraging.
In this chapter, some of the advanced NDT techniques have been
described and the work procedures are also given so that it becomes
easy for individual unit to select and opt for any methodology.
The offline advanced NDT techniques have come to stay and with
ageing of our plant, these techniques are to be applied in greater
frequency. For the new plants, some of the techniques are applicable
which need to be put into use right from beginning to have base line
date recorded for future reference, so as to exercise total control on the
proceedings.
The cost of such application may appear to be higher. However, if
compared with the advantages the technique is giving on return, the
investment can be justified. Especially for the ageing plants and
considering the operational severity, the availability, reliability and
safety of equipment are of paramount importance. The advanced NDT
techniques if applied properly and effectively, the desired result shall
definitely show up. However, a detailed Inspection plan is needed to be
drawn to cover all critical equipments, phase wise. This may take little
longer time to cover all, but the beginning has to be made now, before
it is too late.
Once the latest technologies are available at our disposal, it is prudent
to make use of the same to ensure a safe, reliable operation of plant on
sustained basis.
The following Advanced NDT Techniques which are applicable offline
are detailed below one by one.

Page 45 of 119

High Temperature Hydrogen Attack (HTHA)

High temperature hydrogen attack (HTHA) is one form of degradation
of material: which can cause serious effect on equipment reliability and
overall plant safety. HTHA can occur (either at parent material or weld
metal due to formation of methane by reaction with carbide in steel,
where the equipment is operating at high temperature and pressure in
presence of hydrogen.
Detection of HTHA in parent material can be done in a combination of
two ultrasonic methods.
i) Pulse Echo Back Scatter Technique (Microplus Sce Scan)
ii) Velocity Ratio Measurement (Microplus)
Detection of HTHA in weld material can be done in a combination of
two ultrasonic methods
i) TOFD Technique
ii) Manual Pulse Echo
With the advancement of NDT techniques High Temperature Hydrogen
Attack can be monitored by recording the bare data and comparing the
baseline data at a later date by carrying out scanning once more.
The accuracy level can be at the tune of 1 mm or better. For special
circumstances, this activity can be performed on line at about 4000C so
that the defect growth rate is instantaneously measured.
A brief write-up is given below for further clarity and understanding.
At High Temperature and High Partial Pressure
(HTHA) Can occur in several types of alloys
T> 315o C and H partial pressure > 1.3 Mpa absolute
Or
T> 250o C and H partial pressure > 7.0 Mpa absolute
The following phenomena can occur:

Decarburisation
Micro/Macro Cracks
Blisters

Stages of Hydrogen Attack

Nucleation or incubation, the primary states of hydrogen attack

which take part in de whole period of equipments lifetime. No
changes in mechanical properties. (Not detectable with NDT)

Page 46 of 119

Incipient Attack microscopic indication form on grain boundaries. No

significant changes in mechanical properties. (Not detectable with
NDT, only with an electron microscope.)
Formation of decarburisation at grain boundaries, it is desirable to
detect Hydrogen Attack at this stage. (Detectable with techniques
described further down the approach)
Formation of microcracking. Mechanical properties are severely
degraded. (Detectable with techniques described further down the
approach)
Crack growth to failure. The time for microcracks to grow into
macrocracks is usually short and leads to failure.
Final failure can result from two origins. The first is the linking from
the micro/macro cracks. The second is by reduction of toughness
and leads to a rapid failure because of hydrogen attack.

Inspection setups
To be able to perform a full inspection of parent-, and weld material the
Microplus, TOFD, Velocity Ratio and Sees can inspection setups as
described in the following are used.
Microplus
The Microplus instrument is a very versatile digital ultrasonic flaw
detector based on state of the art technology, that can use Pulse Echo
techniques as well as the Time Of Flight Diffraction (TOFD) technique.
Using the resident data manipulation techniques a through sectional
view in longitudinal (D-scan) or transverse direction (B-scan) of a weld
or material section can be produced. By using the colourgraphic pulseecho routines it is also possible to produce a depth- or amplitude
related topographical map (C-scan) of an inspected area.
Time Of Flight Diffraction Mode (TOFD)
On both sides of the weld an ultrasonic probe is positioned. One acts
as an emitter of ultrasound, the other as a receiver. The longitudinal
sound beam can encounter obstacles on its path, which cause reflected
and diffracted signals. When the probes are moved parallel along the
weld, the resultant waveforms are digitised, stored on hard disk and
displayed on the video-screen as a grey scale image. The image build
up is in effect a through sectional view of the weld examined and can
be used for accurate sizing and monitoring of indications.
Seescan
Seescan combines conventional ultrasonic practice with the technology
of miniature CCD (Charged Coupled Device) video cameras to provide
a simple yet highly effective method of recording and presenting
ultrasonic data during corrosion and erosion inspection applications.

Page 47 of 119

Techniques used
High Temperature Hydrogen Attack can be present in welds or parent
material. Different techniques are used for both.
High Temperature Hydrogen Attack detection in parent material
A combination of two ultrasonic methods is used for High Temperature
Hydrogen Attack detection.
1)

Pulse Echo Backscatter Technique. (Manual or Microplus

Seescan)
2) Velocity Ratio Measurement. (Microplus)
The pulse-echo backscatter technique is based on detection of the
backscatter received from the microcracks. With this technique a 100%
scan for detection of possible attack is possible.
The Velocity Ratio measurements are based on the velocity ratio
changes between the longitudinal and transverse sound waves as a
result of propagating HTHA damage. These measurements are done at
several locations. With an advanced calculation algorithm it is possible
to determine which percentage of the wall thickness is attacked, with a
detection limit of 10% of the wall thickness.
Backscatter technique
To inspect a plant for the possible presence of HTHA an inventarisation
is made with the PE backscatter technique on the most critical places
(highest temperature and/or highest partial H2 pressure). For pipes and
vessels areas of approximately 100 to 250 mm are scanned utilising
the backscatter technique at several locations.
The front of attack in the material can be measured and imaged. The
remaining sound wall thickness (unattacked) is assigned a colour.
When indications of HTHA are found with the above technique,
greyscale imaging can be used to verify and display the through wall
extent of the HTHA in parent material.
Velocity Ratio verification Of Backscatter Technique
To discriminate between HTHA and small inclusions and to verify the
attack, additional measurements are taken with the Velocity Ratio
Technique.
The longitudinal and transverse sound velocities are affected by High
Temperature Hydrogen Attack.

Page 48 of 119

By measuring with both sound propagation modes and use of an

advanced calculation algorithm the percentage of attack can be
measured.
A differentiation between small inclusions and High Temperature
Hydrogen Attack can be made.
High Temperature Hydrogen Attack detection in weld material
To detect micro and/or macro cracks induced by High Temperature
Hydrogen Attack the Time of Flight Diffraction Technique with
Microplus is used. With this technique it is possible to detect macro
cracks directly. Micro cracks can be detected, but it is not possible to
discriminate them from other weld defects. However when a baseline is
established, differences between subsequent inspections reveal the
growth of micro cracks. A Pulse Echo technique is used for
confirmation of TOFD indications.
Welds that are inaccessible for TOFD measurements can be inspected
by using the PE backscatter technique. For this the weld cap needs to
be removed, and a baseline survey (finger print) is necessary. In this
examination the Velocity Ratio can not be applied, because there is no
parallel ground inner side.
Approach in the field
To inspect a plant for the presence of HTHA in the weld material, the
most critical places (highest temperature and/or highest partial H2
pressure) are inspected with:
1)
2)

TOFD technique
Manual Pulse Echo

For pipes and vessels selected welds or parts thereof are scanned with
Microplus at several locations.
High Temperature Hydrogen Attack Monitoring
Once a detection survey has been carried out, the results of this survey
are stored on digital media (floppy/laserdisc/cd).
The data collected serves as a baseline measurement. Measurements
taken at a later date are compared against the baseline measurement
such that possible growth of the High Temperature Hydrogen Attack
can be accurately established.
Under site conditions an accuracy of 1 mm or better can be achieved.
In certain conditions it is even possible to monitor indications detected
during operation of the plant. Successful applications under extreme

Page 49 of 119

conditions exist, for example a series of repeat inspections was carried

out at over 400 C.
Indications found during an outage were monitored successfully,
proving that the growth rate was low enough allowing the client to have
a replacement reactor build without having to shut down the existing
reactor.
Time of Flight Diffraction (TOFD)
Time of flight defraction (TOFD) is an advanced NDT technique used
for thick wall pressure vessels / piping. This technique is utilized to
locate flows and monitor the growth of the same, in cause of time.
TOFD technique is at present widely used world wide for pressure
vessel inspection. It is particularly useful for high integrity application.
As TOFD can measure the through thickness height of flaws
accurately, it is ideal for ECA (Engineering Critical Assessment).
TOFD replaces conventional Ultrasonic Inspection or Radiography
Technique. JR has utilized this technique successfully.
A brief write-up is given below:
Objective: Locating and sizing of the flaws (Pre-service or in-service)
in materials
Method:
TOFD is a pitch & catch probe method, with one probe placed on either
side of the weld to be inspected, and the probes are moved as a pair
along the length of the weld. Unlike conventional Pulse Echo method,
in TOFD Longitudinal waves are used in place of Shear waves.
In TOFD, there is no need to raster along the weld, and most weld
configurations can be covered entirely in a single scan. The accuracy of
the technique is so high because the flaw is directly measured from the
exact positions of the amplitude of the echo of the flaws. This provides
exactly the information needed for fracture mechanics and Engineering
Critical Assessment (ECA).
Application:
TOFD can be used to inspect either newly constructed items for
acceptance or as a pre-service fingerprint or in service to detect and
size service-induced flaws such as corrosion or cracking. The method
is flexible and versatile enough to be applied in almost any situation: in
some cases it is more capable than pulse echo inspection because
there is no need to have a full skip distance clear of obstructions.
Although it is very good for general inspection tasks. TOFD is
particularly valuable for high integrity applications. It has a number of

Page 50 of 119

technical advantages over alternative methods, but like all methods, it

must be used correctly and within its limits.
Features

Simple and very fast to apply. Flaw detection and sizing can be
performed immediately.
Largely independent of flaws orientation for detection.
Measures the through-thickness height of flaws accurately, and is
therefore ideal for ECA (Engineering Critical Assessment).
Most sensitive to planar flaws, but can detect all types of flaws.
Better probability of detection than conventional ultrasonic
inspection or radiography.
Probability of detection is high and defined as the ratio of flaws
detected to the total number of flaws.
Excellent repeatability and therefore can be utilized for future
inspection.
Evaluates signals fast.
Can be utilized upto a temperature of 2000C.
Base data can be obtained during fabrication to distinguish in
service defects.
TOFD can substitute Radiography for thick walled equipment.
Limitations

Difficult to apply to thin materials (<6 mm)

Cannot characterize flaws in terms of planar / voluminous.

Internal Rotary Inspection System (IRIS)

This technique is utilized to assess wall thickness loss in smaller
diameter tubes especially of Air Fin Coolers, Heat exchangers or
Boilers. Basically the scanning is done from ID side throughout the
length of tube.
This method needs high degree cleaning of tube internal so as to
reflect the existing condition.
The range of ID that can be inspected is from 9 mm 50 mm ID of
tubes of any metallurgy.
If the tube internal cleaning is satisfactory, about 100 tubes can be
inspected per 12 hr. shift. The accuracy of this technique is very high.
This methodology has been adopted by JR and PR with encouraging
feedback.

The internal Rotary Inspection System (IRIS) is an ultrasonic

inspection system used for assessment of wall loss in smaller
diameter tubes of Air fin coolers, exchangers or boilers. A 360 deg
scan of the entire tube length is performed from ID side due to
inaccessibility from OD side.

Page 51 of 119

The Internal Rotary Inspection System (IRIS) is a computerized

ultrasonic inspection system used for evaluation of wall loss in heat
exchanger or boiler tubing.
The IRIS test head consists of a high frequency, high-resolution
transducer and a 45 deg mirror mounted on water driven turbine. The
test head fits centrally into the water-flooded tube to be inspected and
ultrasonic pulses are transmitted along a path parallel to the tube axis.
These pulses are then redirected radially to the tube wall by the 45
mirror. The mirror rotates at high speed and reflects the ultrasonic
beam around the tube circumference to perform a 360 deg scan of the
wall thickness. Thus, entire tube length can be scanned from one end
to the other by slowly withdrawing the test head.
The unique feature of the IRIS is the method of display. The vertical
axis of the image represents 0 360 degrees around the tube
circumference and the horizontal axis represents the tube wall
thickness. Thus, the resulting display includes a cross section of the
tube (B-scan) and thickness map (C-scan). Real-time C-scan
eliminates missed defects due to operator fatigue and real-time B-scan
is used for flaw sizing.
Fresh water supply at 40 psi or greater is required to ensure rotation of
the head of the probe and also for better transmission of the ultrasonic
signal. As with all ultrasonic techniques, the effectiveness of inspection
relies on a high level of surface cleanliness, it is essential that all
deposits / scales are removed from the bore of the tube prior to
inspection. In ideal conditions, defects as small as 1.5 mm diameter
and 0.1 mm in depth can be detected. Tubes made of virtually any
material and in the range of 9mm to 50mm ID can be inspected.
Production rates depend on factors such as tube cleanliness, tube
length and the number of defects encountered but are typically in the
region of 100 tubes per 12-hour shift.
Typical applications for the IRIS include; boiler tubes, heat exchangers,
air coolers, feed water heaters and condensers.
Advantage of IRIS

A variety of defects including remaining wall thickness and the

extent of local or general corrosion can be detected with high level
of accuracy.
A high examination speed reduces the shutdown time.
The examination data are documented and can be compared with
the subsequent examinations to determine the development of
detected defects.
The results can be presented visually in the form of an explicit tube
sheet map, which gives a quick survey of the condition of the heat
exchanger.

Page 52 of 119

Accurate measurement even at support / baffle plates.

IRIS is transportable and lightweight.
The technique is best suited for accurately scanning air fin cooler
tubes, which are inaccessible from external sides because of fins
and thus, commonly used world wide for inspection.

IRIS (Internal Rotary Inspection System)

Name of the Agencies:

M/s Sigma Specialized Inspection Services, Abu Dhabi

M/s ESCON Technologies (M) Sdn Bhd, Malaysia
M/s Blue Star, Mumbai

Remote Field Electromagnetic Testing (RFET)

REET is another Advanced NDT Technique which is widely used for
ferrous is ferromagnetic tubes of Heat Exchanger, Boilers, Reactions,
Air Fin Coolers etc.
REET, does not require a very clear surface to inspect: It detects wall
thickness loss and defects line pitting etc. it cannot however identify the
location (inside / outside) of defect.
A brief write-up is given below.
REET is one of the most effective and rapid methods for determining
the condition of ferrous and particularly ferromagnetic tube of heat
exchangers, boilers, reactors, air fin coolers, and similar equipment.
The principle is based on remote field eddy current testing where an
exciter coil generates eddy current at low frequency in the
circumferential direction and direction and electromagnetic field
transmit through the thickness and travels on the outer diameter. A
receiver coil is placed at remote field zone of exciter and picks up this
field. In this zone wall current source dominates the primary field
directly from exciter. The separation between the two coils is between
2 to 5 times of tube ID. As the magnetic field penetrates the tube wall
twice, it will undergo a delay (Phase lag) and attenuates (amplitude
attenuation). The phase lag and attenuation incurred will depend on the
local wall thickness and it is measured.
REET has many advantages over other NDT techniques as it does not
require any couplant, does not require a very cleaned surface (normal

Page 53 of 119

water jetting to remove blockage in tube is enough), is largely forgiving

to fill factor 50% to 70%) gives excellent result.
The technique is volumetric inspection technique which detects such
as general wall losses, pitting, erosion, and fettling near support
locations. Though both internal and external defects can be detected
and quantified it is however not possible to determine whether the
defect is located on the interior or exterior surface of the tubes.

Name of the Agencies:

i)
ii)
iii)
iv)
v)

M/s Tes Tex NDT India Pvt. Ltd., Mumbai

M/s Plextech Technologies (I) Pvt. Ltd., Mumbai
M/s Engineering Inspection Services, Mumbai
M/s Eddysonic NDT Engineering and consultants, Pune
M/s Kalva Engineers Pvt. Ltd., Hyderabad

PR is planning to adopt this technique.

Automatic Ultrasonic Scanning (AUS)
This technique is utilised for condition monitoring of Reformer catalyst
tubes.
This methodology has been adopted by all the Refineries. A brief writeup is given for reference.
Objective of AUS
Condition monitoring of Reformer Catalyst tubes by automatic
ultrasonic scanning technique.
Pre-requisite for AUS

External surface of Catalyst tubes shall be thoroughly cleaned with

DM water soaked cloth.
Supply of compressed air at 7 8 kg/cm2 pressure with discharge
rate 2.5 M3 per minute required for up and down movement of AUS
probe crawler system over catalyst tubes.
Continuous supply of DM water at the top of furnace, which will be
used as couplant.

Page 54 of 119

220 V, AC power supply with 3 pin, 5 amps plug sockets with

switches and voltage stabilizer.
Water collectors to be provide at the tube bottom to avoid water
soaking of floor refractory bricks.

Methodology of AUS Procedure

The automatic ultrasonic scanning technique is based on Snells Law
of wave transmission through various mediums and well known
principle increased ultrasonic attenuation by in-homogeneities within
the medium of travel. Since the most probable site for creep voids /
fissures in reformer tube is mid wall region, the ultrasonic beam in this
technique is so oriented that it passes through the mid wall region and
the degree of attenuation / amplitude of receiving signal is record. The
AUS consists of an air power crawler assembly actuated by pneumatic
motor capable of moving freely up and down on the outer surface of
the tubes without rotation. From the crawler, are attached two fixtures
on the two hot sides of the tube. Two ultrasonic probes sensitive for
cast stainless steel tubes are fitted in each fixture in such a manner
that the ultrasonic signal passes through the mid wall of the tubes.
Each fixture assembly serves as one channel. The entire four probes in
two fixtures are water coupled during the entire scan height.
Compressed air is required for crawler movement. At the site station
located outside the furnace, two ultrasonic equipments monitor the
signal on continuous basis and two channel strip chart recorder record
the output signals.
Reporting of AUS result
After AUS, present condition of each tube will be assessed in terms of
degree of deterioration and degree of deterioration is estimated by
percentage of retention of transmitted ultrasonic energy and is reported
in terms of A, B, C and D grades, D being the worst.
A - 70 100%
B - 30 70%
C - 10 30%
D - 0 10%
Limitation of AUS
Inspection of weld joints is not possible. About 1.0 meter length from
top and 0.2 meter from bottom floor of each tube cannot be scanned.
However, on many occasions, sound tubes may be identified as
defective tube and the technique should not be used in isolation.
Perhaps a better approach is to record the results a function of time
and monitor for deterioration rather than for absolute sizing of defects.
The best approach is to use several techniques and interpret the
results with help of expert.

Page 55 of 119

H-Scan Technology:
This is an advanced scanning technology for reformer tubes which is
much superior to normal AUS technology being deployed now by all
Refineries.
This technique (H-Scan) is adopted by combining four different
techniques to make it into a comprehensive examination system.
The four proprietary H-Scan procedures are:

Ultrasonic Examination
Eddy Current Testing
Ultrasonic Wall Thickness
Profilometry (Creep Strain Measurement)

A brief write-up is given below. This is methodology is yet to be applied

in any of the IOCL Refineries.
Introduction
Alloys used in fired heaters in the hydrogen, ammonia and methanol
industries are subject to evolving damage due to temperature and
stresses.
Changes in material characteristics, the formation of damage, and
delectability of defects, are all considerations for engineers conducting
life assessment studies. Since all NDE techniques have strengths and
limitations, not all techniques respond favorably to the different stages
of damage within the various alloys.
IESCO has eliminated the drawbacks of a single technique approach
by combining four different techniques into a comprehensive
examination system. This allows for a proper evaluation of tube
condition. IESCOs combined experience includes the inspection of
1MM reformer tubes over a twenty year period.
Comprehensive Remaining Life Assessment of Reformer Radiant
Tubes
The approach for the assessment will be carried out by combining an
H scan inspection survey and utilization of Win Tube Software for the
remaining life calculation of each individual tube, and the overall
furnace. Highlights of the combined approach are as follows:

H Scan Inspection includes all optimum techniques which will

identify the true extent of damage, Ultrasonic, Eddy Current, Wall
Thickness and Creep strain (O.D. measurement).
IESCO employs multiple techniques to overcome the limitation of
relying on a single inspection method, which may have limitations

Page 56 of 119

as a stand-alone assessment tool. These limitations have been

demonstrated and quantified by IESCO in program research.
Detailed explanation of the techniques, is given below.
Life prediction methodology includes calculations for stresses
caused by pressure, thermal and axial loading using the elastic
creep finite element analysis, which determines the accumulation of
creep damage throughout the tube wall thickness.
This technique is considered much superior to the AUS techniques,
which has so for been deployed by all IOCL refineries or reformer
tube inspection.

Techniques Descriptions
IESCO will be using our proprietary H Scan procedures, consisting of
two (2) Ultrasonic techniques, two (2) Eddy current probes, and
diameter measurement (profilometry) of the full tube length.

Ultrasonic examination: This technique measures the amount of

energy absorption within the material wall, which may be caused by
creep voids, micro-fissures or cracking. Each facet of the ultrasonic
signal is represented by a color from the imaging palet, and is
averaged for overall values.
Eddy Current: IESCO employs proprietary eddy current probes, on
the fire side and reverse side of the tube. Each probe is sequenced
to alternately focus at different depths of the tube wall. By
employing this sequencing, eliminate the lack of penetration
normally associated with eddy current examination. The resulting
scans are then compared to the calibration scans for changes in
energy patterns.
Ultrasonic Wall Thickness: This is accomplished by employing a
proprietary ultrasonic technique.
Profilometry (Creep Strain Measurement) This is achieved by
displacement sensors linked to a custom software program that
calculates deviation from a given dimension. The program allows
the information to be displayed in chart of graph format. Combined
with the wall thickness, and the outside profile information, an
accurate internal diameter measurement can be achieved. Physical
deformation of the tube may represent creep damage.

Client-Supplied Items & Services H Scan

Client to provide drawings of units to be inspected.

Water supply for scanning couplant (demineralized water or water
with less than 3ppm chlorides for HP/ HK materials. A drainage
hose will also be required.
Compressor to supply compressed air at 130PSI, 300 CFM
minimum.
Two-inch (2) or fifty-millimeter (50mm) clearance between tubes to
allow scanner access.

Page 57 of 119

Ten-inch (10) clearance between tunnel wall and scanner face to

permit 100% tube length coverage (for furnaces with tunnel design
only).
Artificial lighting inside the furnace.
Equipment surfaces prepared/ cleaned in order to perform the
inspection (normally the tubes do not require preparation unless
there is severe scaling of the material).
Uninterruptible 11V6Hz power supply.

Low Frequency Electromagnetic Testing (LFET)

This advanced NDT technique is utilized to scan the tank floor plate to
detect corrosion. This technique can detect corrosion both at product
side and soil side of tank floor plate.
In this method, the inspection job becomes very fast and thus the down
time can be reduced.
JR has utilized this method. Other Refineries may ask for a demo at
one of their tanks before directly adopting the process.
A brief write-up, as published by JR earlier, is given below:
Low Frequency Electromagnetic Technique (LFET) uses Low
Frequency Electromagnetic Field to map corrosion of tank bottom plate
both on product as well as soil sides.
Advantages of LFET

Inspection can be done directly over coated / painted bottom plate

without removing the lining. Blast cleaning may not be required.
Rapid inspection of bottom plate at the rate of 6M2 / min. results in
reduced tank outage (4 to 5 days for tank with Dia. 40 M) with
enhanced reliability and more justified decision.
No couplant or magnets are required.
Lighter and faster in comparison to the conventional Magnetic Flaw
leakage (MFL) technique.
Penetrates metals up to 1.25 (32 mm).
Real Time Data Display and storage in CD.
Topside and Bottom side defects evaluated in a single scan using
new dual frequency electronics option.

5.3.0 Run Length Improvement Plan And Monitoring:

5.3.1 Extension of Inspection Frequency- Possibilities and Approach
There had been a constant demand for improvement of Run Length of
process units all over IOCL Refineries. While many contributory factors
are there to consider before taking such a decision, the basic

Page 58 of 119

consideration shall be on the healthiness of the equipments for the

extended period of time.
Before planning / executing of such a proposal a detailed in depth study
to be carried out on each equipment on the following aspects;

Observation on health condition made in last s/down

The deterioration trend of equipment / component
The trend of thickness loss / year
Causes of deterioration
History of damage/ Repair (internal/ external)
Compilation of observation / records since commissioning.
Present health condition based on external on line health survey, if
any
Any other observation / recommendation

The purpose of assimilating the above data is two fold:

1) The whole plant operation is stretched beyond the stipulated period
i.e. the scheduled shutdown gap is extended.
2) The shut down is taken as per schedule, but equipments are taken
up for maint. selectively to reduce the shut down job/ period which
means the Inspection frequency of individual equipments are
required to be extended.
While point no 1, a holistic approach is required to be taken by all the
departments together considering their individual problems / weak areas
etc. and a study is also to be made in totality.
The above exercise therefore should not be attempted in isolation.
The focus of Present Study is therefore has been made on point no (2)
which deals with extension of Inspection Frequency Possibilities and
approach.
Under the above circumstances also, all the above observations are to
be noted and analysed. Depending upon the outcome, a decision can
be arrived at pertaining the operability for further stretched period. The
approach for the same are two fold as detailed below.
a. During shut down, the selected equipments are to be subjected to
thorough inspection including application of advanced NDT
Technique if any so as to make sure the checks have been
conducted from all possible angles.
The results of the examination are to be analysed and compared
with the Historical data that is available in the dept. In case of
finding normal trend of thickness loss and without significant
observations, a projection can be made in the shut down report
indicating its stretched inspection schedule.
Page 59 of 119

b. While the equipments are under operation, a regular check (online)

needs to be performed to keep a vigil on the health condition. The
data / observations need to be recorded and analysed at regular
intervals. This is a must-do task for Inspection.
In case the analysis is satisfactory, and there is no drastic operational
changes have taken place and the equipment is running within design
parameters, a final view can be taken before next shut down for
inclusion / exclusion of the particular equipment(s) from shut down.
It is desirable that CIPM/ CTSM/ CPNM should discuss jointly prior to
arriving at any decision.
The following need to be adhered to strictly:

Thorough check of equipment(s) during s/down using advanced

NDT etc. as applicable, collect data, and compare the acquired data
with history and establish deterioration trend. Analyse the complete
system and come to a conclusion.
During Post shutdown period, keep constant vigil with online
monitoring techniques on the earmarked equipments, collect data
and analyse.
Take a final view jointly by CIPM/ CTSM/ CPNM at end of the run of
the unit. However, projection can be made in advance to the shut
down team tentatively, for working out details by them.

The safety is reliability of equipment and plant can be ensured if the

above steps are followed properly.
5.3.2 Upgradation of Existing Heater Thermocouples to Xtracto Pad
Type
Addendum-20
5.3.2 Upgradation of Existing Heater Thermocouples to Xtracto Pad Type
can be done on need basis after examining track record performance
The existing Thermocouples need welding with heater coil directly in
case of replacement. This call for hydrotest of Heater which is both
time consuming and does cost money. Xtracto pad type
Thermocouples replacement does not require welding as it is fitted
inside the housing provided on coil.
A brief write-up is given below:
Accurate reliable temperature measurement for process furnaces is a
priority throughout the refining and petrochemical industry. Traditionally
tube skin temperature measurement systems have required the
welding of the thermocouples on the tube. This activity had to be
repeated if the thermocouple failed. Each such hot job necessarily calls
for hydrotesting of heater which is not only time consuming but also

Page 60 of 119

involves considerable cost. To overcome the same, the replaceable

type, XTRACTO-PAD thermocouple system can be considered which
allows for replacement of the thermocouple without rewelding.
The basic configuration for the XTRACTO-PAD design has proven to
be a popular means of furnace tube skin temperature measurement
throughout industry. The novelty of the XTRACTO-PAD involves
improvement in the area of replace ability, while maintaining the
accuracy and dependability of the device.
The salient feature of the thermocouple:

The weld pad is fabricated as part of the guide assembly.

The heat shield is modified to keep the weld pad / guide assembly
in position.
The tube clips that hold the thermocouple in place are reusable.

Advantages of Thermocouple:

Accurate Based on industry proven design

Replaceable Following initial application, thermocouple element
can be replaced by a single craft without welding.
Cost Effective Considerable savings in installation time,
manpower and replacement thermocouple cost.
Ease of Installation Only single pass welds required for initial
installation.
Reliable When properly installed the Xtracto-Pad provides
dependable temperature measurement in a variety of process
furnace and boiler application.

5.3.3 Upgradation of Heater Hanger / Tube Sheet Metallurgy

Addendum-21
It is to be reviewed in the light of fuel quality, fire box design
temperature and other conditions. Suitable decision can be taken by
concerned Inspection Head.
With the ageing of plant, the old tube support / hangers are also give
way. While, the items which are already in use need not be disturbed,
but for any new project job or on further maint. replacement work the
modified metallurgy of 50 Cr, 48.5 Ni and 1.5 Nb shall be utilized. This
has got very long life and is highly dependable too. So far, no failure of
this metallurgy has been reported. In refineries abroad, this metallurgy
is widely used.
The insurance spares, if being procured as new, to be of the revised
metallurgy.
5.3.4 Upgradation of Refractory Lining

Page 61 of 119

The old process Heaters were internally lined with castable refractories
which caused lot of problems in form of cracking, spalling etc. in
subsequent period of run. The thermal efficiency also came down and
the casing plates were getting oxidized due to cracks in castables.
To resolve the problem, the castables need to be replaced with ceramic
fibre lining. The following points to be noted while carrying out ceramic
fibre lining:
1) The heater casing plates to be cleaned and painted internally with
anti corrosive, Heat resisting Paint.
2) There should be a vapour barrier (made of SS foil) put between two
layers of ceramic fibre lining modules to arrest vapours to travel to
casing plate.
3) In the final module, the anchors shall be provided with SS stopper
and the same should be covered with ceramic putty to avoid
oxidation.
5.3.5 Additional Thermo Couple on Tube Surface
In order to meet the stretched targets, the furnaces are always under
higher heat load. The burners are also fired hard to maintain COT. In
this process, the skin temp. of tubes tends to shoot up. With only few
thermo couples provided now a days in any Heater, the availability of
on line data on skin paint temp. is grossly inadequate, and not truly
representative of the actual temperature condition due to either
malfunctioning of the Thermocouples or uneven burner firing.
It has therefore been proposed to fix additional thermocouples at
middle level and top level of Heater tubes so that representative
temperature is drawn and actual figure is obtained. This will give
Operation department much flexibility & more confidence in running the
heater within design limit.
The location for fixing new Thermocouple in each Heater shall be
decided by unit CITM/ CIPM/ CTSM/ CPNM. Drawings / Documents
shall be made as built. A short write up an X-Tracto pad type

Page 62 of 119

Thermocouple has already been given above. The new thermocouples

shall be of X-Tracto pad type only.
Addendum-22
Safety Valve, Gate Valves/ Ball Valves and NRVs

Inspection and test of safety valves in as brought condition before

dismantling. The record of the same shall be maintained.
Bellows are to be inspected for damage & tested for leak.
Bellow type safety valves are to be tested for backpressure.
Safety Vales are to be sealed after testing.
Safety valve on the Steam service shall be floated and adjusted for
blow down online if possible or gagging arrangement shall be
available for S/V.
Revisioning & testing of above Gate Valves/ Ball Valves and NRVs
valves in critical service is to be carried out on need basis during
shutdown.

5.4.0 First Inspection of Plant after Commissioning

As per existing guideline the first inspection of plant shall be carried out
after 2 years of commissioning. This basically is done to establish the
condition of equipments / piping, finding out corrosion / erosion effect
or any other degradation so that the corrective action can be initiated,
at the initial stage before major damage is inflicted.
In many of the Refineries, new plants have been commissioned and
running excellently since last 2 years without any interruption. There
are no major observations on equipments, neither any failure has
occurred. With this in backdrop, a discussion was held to find out the
possibility to extend the run length further without jeopardizing the
safety and equipment reliability of the plant.
This was debated and discussed further. The following action plan
finally was drawn which are to be considered by Refineries before
arriving at any conclusion of running the unit beyond two years with
safety:

Shutdown experience of typical plant of any other organization,

pertaining to the corrosion / other deterioration of equipment / area
of concern etc. to be obtained and analysed.
Licensors view to be taken for continuance of operation beyond two
years.
On line plant monitoring data analysis to be done from the date of
commissioning to ascertain plant operational stability.
Collection of online data of critical / super critical items to be done
both for Rotary / Static equipments obtained by various methods
including NDT methods and to be analysed to assess the present
health condition.

Page 63 of 119

5.5.0 Improving Equipment Reliability

Identification of critical circuits / equipment and strengthening of
monitoring and control procedure.
Classification and Identification of Critical Piping / Equipment
Classification and identification of Critical piping / equipment are to be
done on the basis of product corrosivity / erosion potential / in service
damage capability/ environmental damage potential, and vulnerability
to unit operation etc. Procedure for monitoring and control of such
items at unit and offsite areas, in order to improve service reliability, is
detailed below.
The piping and equipments can be categorized on the identification of
critical services of unit and offsite area. Therefore the services are to
be identified first followed by piping circuits and connected equipment.
Once the same is established, there could be a detailed inspection to
monitoring plan, with frequency and procedure.
Some of the major critical lines and equipments are highlighted below.
The details, however are given in the Annexure-AIP5. It is imperative
for each Refinery to carry out the exercise of identification of such
service, equipment and piping and frame up details of inspection
activity, unit-wise and execute the job to ensure fitness for operation.

The inspection guideline/ procedure for equipments and pipelines

of critical services shall be as under:

For Cold Critical Services: The guideline is discussed in Chapter

5.1.10

Page 64 of 119

For Insulated and Hot Critical Services: The guideline is discussed

in Chapter 5.1.11.
For Shut Down Inspection- Refer Chapter 5.2.0.

Alternatively, utilize the latest advanced NDT technique for online

thickness monitoring through insulation by PEC method, which have
been, described under advanced online NDT Technique. In this
method, the insulation is not required to remove for probing and the
probe can be utilized upto 5000C.

For equipments (like Reactors) and high wall thickness piping, the
detection of High Temp. Hydrogen Attack to be undertaken.
Advance NDT Technique like TOFD (Time of flight diffraction) can
be deployed in finding and sizing in service flaws in materials.
However, this method is better-suited offline.
TOFD technique is particularly useful for high integrity applications.
Since TOFD can measure the through thickness height of flaws
accurately, and therefore it is ideal for ECA (Engineering Critical
Assessment). TOFD has edge over conventional ultrasonic
inspection or radiography.

The frequency for inspection such identified circuit shall normally be

once in a year. However, each Refinery can reduce the frequency
depending upon their critical observations made on the
serviceability of the circuit, past history, rate of deteriorations,
frequency of failure etc.

Identification of Critical Tap Off Points in Critical Equipments/ Circuits

and Strengthening of Monitoring and Control Procedure.
Objective: To improve the reliability of Small Bore Tap Off Points of
Critical Circuits / Equipments.
Procedure:
For Cold Uninsulated Lines/ Equipments:

Each tap off weld joints shall be cleaned and visually inspected
along with nipple / flange / valve / Cap as the case may be.
The weld joints shall be DP tested 100%
In case of alloy steel (if any in cold services) the joint to undergo
MPI test also.
For critical service, it is preferred to have nipple fitted with double
valves and pair of flange / blind flange. The existing nipple and cap
assembly is to be replaced with as mentioned above. Till
replacement the threaded cap is to be seal welded with nipple.
All tap off points shall be provided with double block valves. In case
of extreme difficulty (like that in pressure vessels due to lack of
space if any). Single valve with pair of flange and blind flange is
mandatory.
Page 65 of 119

For Hydrogen, Ammonia, LPG Service, all the Tap Off Points shall
be with double block valves and pair of flanges, mandatorily.
The schedule of nipple shall be xtra strong (XS) to bear the load of
fitments provided with it. In case of need, supports can be provided
(especially the horizontal tappings need this extra thickness).
In case of Alloy Steel / Stainless Steel PMI to be done and record
maintained.
All such tap off points are to be marked in drawings / isometrics,
documented and inspection record to maintained. Individual
equipment / piping folder to contain details of such examination.
Painting, of all tap off points along with piping / equipments to be
done every year.
The frequency of inspection is once in a year.

For Hot and Insulated Lines:

The tap off points shall be mandatorily checked at each shut down,
after removal of insulation. Balance inspection procedure is same
as that of cold lines.
Since the tap off points' inspection frequency in hot service are less
than cold line, extra care to be taken during such inspection.
For initial record, all tap off weld joints of Hot Services are to be
hardness tested (AS, SS, CS, NACE) and record maintained.
All Alloy Steel / S.S. Tap Off Points to under go PMI mandatorily.
Documentation for each tap off points, shall be kept along with the
folders of piping / equipment for easy reference.
Painting of tap off points along with pipe / equipments to be done in
each shutdown.
The frequency of Inspection shall be in each shutdown.
5.5.1 Corrosion Under Insulation Causes, Concern and Control
Feasibility.
Approach and procedure for Quality Assurance of Insulation
Corrosion under insulation or CUI is a common phenomenon for piping
and equipments happening throughout the industry, and world over.
Various attempts have been made for mitigation of the same, with
varying results. All inspection engineers are fully aware of this issue
and each refinery has considered this as a major area of concern.
The committee appointed by HO on reliability study has also taken
cognizance of the views expressed by all the Refinery units and tried to
find a way out to control the menace. It is not an easy task especially
for the coastal refinery like Haldia and high rainfall area like Guwahati,
Digboi and Barauni Refineries to control the corrosion attack. However
after giving a relook into the system and reviewing the current
procedure being followed, a need was felt to address the issue once
again and share the fresh approach with all, so that renewed attention

Page 66 of 119

is paid to this area for more reliable operability and trouble free life of
component.
Inspection of insulation, and monitoring of component health under
insulation therefore, is a prime task and the role of inspection is critical
considering the responsibility in certifying the component as fit for use.
For better clarification and understanding, the study and inspection
procedures have been divided into three parts, as below:
a)
b)
c)

The first part is for new lines / equipments as executed in project

and maintenance jobs i.e. procedure for inspection and quality
assurance during installation to be strengthened.
The second part is for old lines / equipments which are in
operation i.e. periodic inspection and quality assurance procedure
after installation / prolonged service, shall be strengthened.
The final part discusses causes of Corrosion Under Insulation
(CUI), and concern for CUI towards reliability of equipment and
piping various NDT methods to detect / monitor and control of CUI
are to be elaborated.

The point a and b on quality aspect of insulation application has been

detailed in 5.5.2.
CUI - Causes and Concern:
As has been indicated that corrosion under insulation is activated under
the following condition:

High Humid Area

High Saline Atmosphere
High Rainfall Area / Prolonged Rainy Season
Coastal Location
Wind Directed from Sea / River Side to Refinery Side.
Lines passing besides cooling tower and subjected to moist
atmosphere.

The impact of such corrosion, as it is known, may lead to various

consequences like

Unscheduled shutdown of plant and machines

Environmental damages
Fire Hazard / Safety Hazard.
Loss of Production.
Extra Maintenance Cost
Loss of Confidence

The CUI activates maximum when:

Page 67 of 119

The equipment operating temperature ranges between 4 C to

0

+120 C.
The equipment remains idle or not subjected to continuous
operation.
Water finds passage through the cover weather shield i.e. through
the damaged locations, and through the support location of pipe.
The external anti corrosive paint on pipes are damaged or not
provided at all.
The moisture barrier is damaged or not provided at all.

API 570 summarizes the areas which are susceptible to CUI:

Areas exposed to mist overspray from cooling water towers.

Areas exposed to steam vents.
Areas exposed to deluge systems.
Areas subject to process spills, ingress of moisture, or acid vapors.
Carbon steel piping systems, including those insulated for
0

personnel protection, operating between 25 F and 250 F (-4 C and

0

120 C). CUI is particularly aggressive where operating

temperatures cause frequent condensation and re-evaporation of
atmospheric moisture.
Carbon steel piping systems that normally operate in-service above
0

250 F (120 C) but are intermittent service.

Deadlegs and attachments that protrude from insulated piping and
operate at a temperature different than the active line.
Austenitic stainless steel piping systems that operate between
9

150 F and 400 F (60 C and 204 C). These systems are susceptible
to chloride stress corrosion cracking.
Vibrating piping systems that have a tendency to inflict damage to
insulation jacketing providing a path for water ingress.
Steam traced piping systems that may experience tracing leaks,
especially tubing fittings beneath the insulation.
Piping systems with deteriorated coatings and / or wrappings.
Locations where insulation plugs have been removed to permit
thickness measurements on insulated piping should receive
particular attentions.

Other than the above the CUI takes place if the quality of project and
maintenance job is poor and also the steps as mentioned in the
Procedure for Insulation is not adhered to. (Refer details in 5.5.2). The
quality of insulation material, of course plays a significant role which
need to be procured as per established QAP. Material quality to be
rechecked prior to field application through an independent testing
laboratory, for specification compliance. Thereafter, focusing on quality
of execution to be intensified.
Mechanism of Corrosion
Page 68 of 119

The mechanism of corrosion, its basic reason and manifestation of the

same on the object can be summarized as below:

Galvanic Corrosion
Acid / Alkali Corrosion
Chloride Stress corrosion cracking (SCC) on austenitic SS Pipe /
Equipment.
The Galvanic Corrosion results from insulation acting as electrolyte
or salt present which allows flow of current between dissimilar
metals. The less noble metal is affected due to potential difference.
Deep grooves on pipe / equipment may occur due to galvanic
corrosion.
The corrosion due to acid / alkali attack happens when moisture are
present in insulation. It may cause localized corrosion, in the form of
deep pits, surface roughening etc.
The SCC is resulted due to presence of leachable chloride in
insulation material and activates in presence of water which can
ingress through damaged cover and when the component temp. is
0

> 70 C. This corrosion is specific to austenitic stainless steel. In this

type of corrosion, the components crack, especially at heat-affected
zone of weld.
Methodology of protection of components:
The basic painting on pipeline / equipment shall be done properly at
the initial (project / Maint period) stage and moisture barrier to be
provided.
Whenever part replacement is done subsequently, the pipe is to be
painted properly. The moisture barrier is to be replaced with new one.

The weather shield on the insulated lines is found mostly damaged

giving way to water ingress. These shields are not attended/
replaced. Action plan to be drawn for periodical renewal of all such
damaged weather shield in Refineries. It shall be done before on
set of monsoon.
The basic insulation, with the passage of time gets disintegrated.
The looseness in the insulation also loosens the shield grip and
water ingress takes place. The insulation shall be renewed every 57 years of operation, at least on critical circuits and equipments.
This is also recommended by API-570.

Control of Corrosion under Insulation (CUI):

The major challenges the inspection group encounters in this field are:

Detection of CUI
Control of CUI

This is true for every refinery in varying intensity. Refineries away from
coastal areas are less prone to this attack. However, the corrosion

Page 69 of 119

process only delays, it does not stop. The concern lies there and hence
this discussion.
Detection of CUI:
There are several methods of detection of CUI. Some of the methods
are age old and practiced but some of the techniques are relatively
new which have not been tried in IOCL refineries. Both the areas are
briefly touched upon and divided to conventional and non-conventional
methods.
Detection of CUI conventional method

All critical piping and equipments shall be provided with inspection

windows with suitable removable covers fitted with handle.
Detection of corrosion to be made through such opening. These are
to be checked mandatorily once in a year. Documentation to be
prepared and action plan drawn accordingly for either replacement
of pipe, or for cleaning / repairing / repainting etc.
Alternatively, small area of insulation from critical/ corrosion prone
zones can be removed for checking the surface. This can be done
0

upto a temperature of 150 200 C, which should be suffice in

locating the damages.
Identify idle lines / equipments and remove insulation, for complete
inspection. Corrosion is predominant on such areas, as per the past
experience.
Thorough visual inspection shall be made for corrosion prone
circuits, in order to locate damaged areas of insulation for
anticipation of corrosion on base material. Such areas can be
crosschecked by opening spot insulation.
As a practice, make an action plan to remove insulation from critical
piping and equipments after 5-7 years of service partially and
inspect. In case of corrosion, replace complete insulation. In most of
the cases, this may call for repair, repaint and reinsulation,
especially at coastal refineries or high rainfall areas.
The insulation barrier, provided mostly on pipes at ground level or
on equipments some times for personnel protection are the
corrosion prone areas. Remove such insulation and check for
corrosion.
The steam-traced lines may develop leaks inside insulation
triggering localized corrosion. While carrying out visual inspection,
look for steams / condensate drips coming out of insulation.

Detection of CUI Non conventional Method

The techniques described below are of NDT based. Some are of
advanced technique. However all can be performed online.
Infrared Technique:

Page 70 of 119

In refineries abroad, infrared inspection has been done on lines

having wet insulation. The CUWI (Corrosion Under Wet Insulation)
could be detected successfully and corrective measures taken. This
is done anticipating distinct possibility of corrosion at wet condition.
A case study on this has been enclosed as Annexure-AIP6. This is
an online method

PEC Method:

A new advanced NDT technique of pulsed eddy current testing

method (PEC) has been introduced. This can measure on line and
0

upto a temperature of 500 C through insulation, i.e. the insulation

0

need not be removed at all. Since CUI occurs around 120 C, the
0

scanning of pipes upto 200 C shall be sufficient. However, by this

technique inspection at spots only can be checked which could be a
limitation.
LRUT Method:

Another advanced online NDT method is long-range ultrasonic test

(LRUT), which can find corrosion under insulation. However, the
0

limitation is that it can only measure upto 120 C. Offsite lines can
be examined through this technique.
Profile Radiography:

The alternative inspection method is Profile Radiography with either

iridium 192 or cobalt 60 source.
It can be done upto a diameter of 10 of pipe and exposure to
smaller area. Since radioactive sources are used, radiation hazards
in a limited way shall be there. It also does not detect chloride SCC
in SS material. This is better utilized at offsite areas.

Neutron Back Scatter Method:

This system is designed to detect wet insulation on pipes/

equipments. This is again radioisotope based which emits high
energy neutrons into the insulation. The moisture in insulation
attenuates the energy of neutrons. The low energy is detected by
the gauge. Since the source strength is low, it does not pose usual
radiation hazard. This is used online.

Real Time Radiography:

Real time radiography (RTR) or fluoroscopy provides a clear view of

the pipes under insulation and can be connected to a video monitor

Page 71 of 119

to view during inspection and come to a definite conclusion. Printout

can be taken of the image for record. This methodology is widely
practiced in Refineries abroad. There are two types of machines one is x-ray based and the other one is isotope based. Limitation in
this radiography is that it can scan only upto 24 dia of pipe. There
are radiation hazards as well. It also cannot be used inside the unit
due to very close piping network, which prohibits clear image. The
set up is also difficult. It can be used at Office area or inside units
where density of lines is less.
LIXI Gadscope Technique:

This is again an advanced NDT method which can be used on line.

It is portable, simple to operate. This also has a wide applicability
due to its portability and area of coverage.
It can also detect:

Corrosion under insulation

Weld location in pipes.
Insulation integrity etc.

The Lixi Gadscope is used over the insulation. The results from
Gadscope are instantaneous. It utilizes a low energy source
(Gadolinium 153 isotope), therefore, not a considerable radiation
hazard. The job can be accomplished at much faster rate.
Control of CUI:
Control of corrosion under insulation adoption of conventional
method:
The following actions are suggested:

For all critical circuits/ equipments, arrange for provision of

inspection windows with covers. The windows shall preferably be at
6O clock position, on pipes. Equipments to have windows on both
the domes and on shell, at all four directions (N/S/E/W).
The frequency of inspection, for all critical circuits/ equipments
(through the windows) shall be once in a year minimum. The
physical condition on inspection can be judged and
recommendation given.
The damaged weather shield of the insulation shall be replaced
every year prior to monsoon mandatorily.
The insulated pipes, especially near tank farms at offsite areas are
used as walk ways damaging the weather shield and making wide
gaps for water ingress. A steel walkway can be made cover the
pipelines, where man movements are maximum.
The very old insulation (10 years and above) provided at pipes and
equipments and found in badly damaged condition, shall be
Page 72 of 119

replaced completely. The pipe / equipment to be painted and barrier

shield provided mandatorily, prior to fixing of insulation. This job is
to be taken up in M&I shutdown. QAP to be followed as per 5.5.2
for fresh application of insulation.
For new projects, and maintenance replacement jobs, the quality
procedure to be followed as given in chapter 5.5.2. Civil department
to ensure quality compliance. CMNM to review the quality of
material and execution every fortnightly.
The joints in the weather shielding should be properly sealed with
sealant to arrest water entry. For all critical circuits and equipments
this shall be renewed by civil department at each M&I. However, it
should be surveyed by civil department prior to monsoon every year
and sealant to be provided wherever needed.
In case of idling of any pipe/ equipment for longer time, complete
removal of insulation to be made. A period of 4 6 months shall be
considered as benchmark. However, this period may vary
depending on location specific weather condition. Units to take final
decision on this issue. The surface to be cleaned properly, applied
with corrosion resistant paint and left without providing insulation.
Insulation provided exclusively for personnel safety, shall be totally
removed, surface cleaned and painted with heat resistant paint. For
human safety, caging around the area with GI wire mesh can be
taken up. This should be made compulsory all over IOCL
Refineries.
After 5-7 years of service, each insulated equipments/ pipelines in
critical service shall be checked by opening substantial area of
insulation (like top / bottom dome, shell nozzles areas etc of
vessels). In case of deterioration, the complete removal of
insulation is recommended, followed by cleaning, painting and fresh
insulation. This job to be planned in M&I shutdown, as a preventive
inspection action. This is also suggested in API 570.
The tank curb angle insulation can be extended little beyond tank
shell so that no water can seep through the shell top to curb angle
insulation joint.
Tank insulation and weather shielding along with insulation shall be
completely renewed at every M&I shutdown, which should be
normally between 8 10 years of service.
The leaky steam tracer line to be identified and replaced
immediately after isolation. The mother pipe shall be painted with
heat resistant paint. Fresh insulation material to be provided around
the affected zone, on complete removal of wet insulation.
All maintenance replacement jobs (part replacements mainly) shall
be executed as per the procedure given in 5.2.2 i.e. as new
execution. The painting, fixing of moisture barrier etc. shall be
judiciously followed, under inspection by civil engineer.

The steps as mentioned above need to be practiced on a continuous

basis. It could happen that, some of our Refineries have some other
methods / better methods than this to control the corrosion. Those can
be shared with all other Refineries so that overall reliability of
Page 73 of 119

components are improved and we need not have to face unscheduled

interruption/ loss of products due to CUI.

Addendum-23
Insulation work shall be carried out through skilled manpower &
professional agency.
Insulation Material should be of low wetting characteristic. Formed
insulation shall be preferred over blankets.
Low chloride containing Inhibited type insulation shall be used on
austenitic stainless steel material.
Aluminum foil for moisture / vapor barrier to be wrapped on the bare
painted piping prior to putting insulation for piping upto 1700C.
Irrespective of temperature, all insulated austenitic stainless steel
(ASS) piping shall be wrapped with only stainless steel (SS) foil
prior to putting insulation.
All insulated lines shall be wrapped with bituminous coated cloth
prior to fixing aluminum cladding.
All vent points to be capped/ plugged & covered by a suitable
canopy to avoid water ingress.
All joints shall be sealed.
Proper sealing of the insulation shall be carried out at the supports,
projections, attachments, nozzles, valves etc. Proper support
design should be followed to avoid any loading on the insulation
jacket.
Wherever it is not possible to provide proper sealing like skirt
bottom, tank bottom such locations canopy shall be provided to
prevent water ingress inside the insulation.
Inspection guidelines and procedures for mitigation of corrosion
under insulation as placed at Annexure-AIP-D shall be followed in
totality.
5.5.2 Quality Assurance/ Control Procedure of Insulation Job
Quality control in insulation job at the inception is of prime importance.
The first application stars with providing paint in piping after through
cleaning. The fineness in application can retard corrosion to a great
extent. Secondly, there is a provision of moisture barrier which is also
of equal importance to arrest water ingress. Therefore the barrier also
acts as a shield against corrosion.
In maintenance replacement job, all these precautions are grossly
missing especially during shut down job. This is because, the insulation
job comes as a last activity and no time could be devoted for quality
work. Due to urgency for unit hand over, the quality gets a beating and
ultimately it reflects on the service life of the component.
The insulation provided at Refineries is also age old. There is no
concerted effort given so far for periodical replacement. There is also

Page 74 of 119

no record available regarding last replacement made. In the process,

the old insulation continues to remain years together although the
insulating property for retaining the heat might have lost. Moreover, in
most of the lines, the weather shield is damaged / twisted. There are
passages available for water to ingress and wet the insulation leading
to a long-term damage through corrosion under insulation.
In this chapter, therefore attempt has been made to formulate a QAP
both for new job and also for the items continuing in service for quite a
long period.
The procedures are both for Hot and Cold types of insulation, which
also deals with Inspection frequencies. The same are enclosed as
Annexure-AIP8.
5.5.3 Online Corrosion Meter for control of corrosion
Online corrosometers are provided to measure the corrosivity of the
hydrocarbon product and to obtain real time information on corrosion
rate of equipment and piping, where the profiles are installed. This
helps to anticipate advance corrective action by adjusting the corrosion
inhibitor dosing. Thereby the component health can be protected.
This method is also advantageous from the viewpoint of cross
checking in directly the corrosion inhibitor quality, its consistency, and
ascertaining right quantity dosing. Right now, there is no online
corrosion monitoring system (LPRM type i.e. Liner Polarisation
Resistance Measuring) in IOCL Refineries that are provided to
Hydrocarbon lines. However, the procedure / working principles are
same with that of C.W. line corrosometer.
Units to consider for installation of this item at critical monitoring point.
The criticality / location etc. is to be decided by CIPM / CTSM jointly.
5.5.4 Thickness Trending for assessment of component health.
This is applicable primarily for critical piping circuits. However, critical
equipments also to be included. The following actions are required to
be initiated:
Identification of Critical Piping / equipment
Compilation of as built drawings, circuit wise / equipment wise.
Calculation of retiring thickness of each item.
Posting the record in each history card (History card of each
piping circuit to be made, if not already available)
v) Posting thickness data as recorded for last 10 years or more in
History card, or from commissioning period.
vi) Loss of thickness to be checked and calculated on per year basis.
vii) Cross checking of present condition w.r.t. retiring thickness and
latest data obtained.
i)
ii)
iii)
iv)

Page 75 of 119

viii) Recommendation to forward if any

ix) Firming up inspection schedule as per guideline.
x) Comprehensive Health Assessment Study may be planned (if felt
necessary) for further clarify.
xi) Review by CIPM once in six months.
5.6.0 Comprehensive Health Assessment Study (CHAS):
With the ageing of equipments, there is a need to carry out
comprehensive health assessment study in order to ensure safety and
reliability of the equipment so as to decide upon their safe continuation
in service, for further period.
The comprehensive health assessment study is required to be made
considering the following:

Criticality of the equipment from plant operation point of view.

Criticality of the equipment from corrosion / erosion / metallurgical
degradation / in service damage point of view.
Criticality of the equipment from the service life point of view
(ageing factor)
Criticality of the equipment from service severity point of view
(pressure / temp. / aggressiveness of processing medium etc.
Criticality of the equipment from statutory rules view point (like
Boiler etc.)
Criticality of the equipment due to external factors (like fire /
external damage caused by falling object etc.)
Criticality of the equipment for any other reason, than the above.

The equipments are to be categorized accordingly and identified. An

action plan to be drawn to carry out health assessment with fixed time
frame.
Agency, if any to be lined up and provided with proper guideline for
executing the task in structured manner.
The comprehensive health assessment study report with analysis shall
be sent to all concerned with a copy to DGM / GM (T) and ED by CIPM.
A sample copy of CHAS of Boiler carried out at Haldia Refinery and
coker drum at Barauni Refinery is enclosed as Annexure AIP7.
Addendum-24
Comprehensive health assessment of equipment shall be carried out
on completion of its design life. However, if any abnormality /
metallurgical degradation observed in any of the equipment, the RLA
can be carried out before design life.
5.7.0 Failure Analysis of Component Approach and Action

Page 76 of 119

In Refineries there are various mode of failures of components. Some

are usual and of common nature but many of them are complex as
there are contributing factors from surroundings environment like
metallurgical, in service degradation, process changes, corrosive
elements, Temp./ pressure factors etc.
Given below are the failure modes due to various corrosion effects that
are encountered in Refineries. The clarity on mechanism or mode of
failure shall also give an insight to the practicing engineers to find out
weak areas proactively and take preventing action.
In any investigation of failure, the mode of failure and its reasons are to
be analysed. The failures therefore need to be categorized. The
present list may be handy in categorizing. On doing so, the various
steps are to be checked and elaborated. The stages have been
clarified so as to have a clear path forward in finalizing the issue. There
obviously some additions and deletions in case-to-case basis which
have to be taken into account by the failure analysis group finalizing
the report.
A.

Modes of failure in refining industry:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.

General corrosion
Localised corrosion
Aqueous corrosion
Galvanic corrosion
Hydrogen induced cracking (hic)
Stress oriented hydrogen induced cracking (sohic)
Temper embrittlement
Sigma phase embrittlement
Dezincification
Crevice corrosion
Liquid metal embrittlement
Microbiological induced corrosion
Flow assisted corrosion
Creep damages
High temperature oxidation
Erosion corrosion
High temperature hydrogen attack
Sensitization damages
Carburization
High temperature sulfidation
Decarburization
Polythionic acid corrosion
Wet h2s cracking
Brittle failure at low temp
Hydrogen blistering
High fluid velocity and cavitation damages
Sulfide stress corrosion cracking (sscc)
Fuel ash corrosion/molten metal damage

Page 77 of 119

29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
B.

Ammonium chloride/ ammonium bi-sulfide corrosion

Naphthanic acid corrosion
Intergranular corrosion
Corrosion fatigue
Atmospheric corrosion damages
Corrosion under insulation damages
Stress corrosion cracking
Hydrogen embrittlement
Mechanical Failures (Vibration, Misalignment, Mismatching
etc.)
Impact Failure
Failure due to Fire / other damage etc.
Wear & Tear Failure
Failure due to wrong selection of metallurgy
Failure due to ageing
Failure at dead end due to stagnation

Stages in failure analysis:

1.
2.
3.
4.
5.

6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

Study of the background of the failure- history of the

equipment
Operating condition study
Visual examination and general physical condition
assessment
NDT studies with LPT, RT, UT etc.
Other studies as follows:
a. Metallography
b. Scanning Electron Microscopy (SEM)/EDS (energy
dispersive x-ray spectroscopy) study
c. If
necessary,
TEM
(Transmission
Electron
Microscope) study
d. Chemical analysis and identification
e. Macro and micro hardness measurement
f.
Physical Tests (Tensile, Bend, Impact, Elongation
etc.)
Study on performance of other equipment in similar service
Experiences of other refineries worldwide
Final conclusion on the failure
Suggested remedial actions
Recommendation
Documentation
Sharing with inspection colleagues in detail by CIPM.
Report circulation to all concerned with copies to DGMS /
GM(T) / ED.
Sharing with other refineries / M&I through DGM (TS)/GM
(T)
Follow up of recommendation after every two months as
per the standard proforma

5.8.0 Operational Variables: Effect, Activated Deterioration and Control

Page 78 of 119

Due to changing demand of product, processing of different types of

crudes with varying acid nos. etc. there are variations in process
conditions. This variations have definite effect on the materials of
components. Failures have been recorded at some units within a short
Span because of activated corrosion / erosion due to operational
changes variation. To sort out this issue, it has been decided that
whenever such process changes are inevitable, a thorough study of the
system and likely consequential effect shall be jointly undertaken by
CTSM/ CPNM/ CIPM.
Online monitoring also shall be reinforced by CIPM/ CTSM according
to the need. Change / upgradatin of metallurgy shall also be
considered if needed, through MOC. The main aim is to make
equipment fully reliable irrespective of feed changes, which shall be
henceforth taken care by the multidisciplinary group, well in advance.
Addendum-25
Metallurgy of hardware shall be critically reviewed for processing of
opportunity crudes, high TAN crudes and high sulphur crudes.
5.9.0 Quality Assurance Procedure Sample QAP And Path Forward
st

Quality Assurance Plan is the 1 Step towards total quality approach.

Whether the job is of maintenance or of project, quality assurance plan
is needed everywhere to maintain uniformity in quality deliverance.
The QAP is needed by the manufacturer, the trader, the executor, the
vendor, the TPI Agency, the PMC, the Inspection / Maint. / Project /
Matl dept. Therefore, the requirement of the items to be carefully
judged, before arriving at execution stage, and procedure formulated in
advance.
Excess demand on quality shoots up the price, where in relaxing on the
same shall make avenue for sub standard material. QAP therefore has
a very crucial role to play both for procurement and execution, and this
need to be formulated by a multidisciplinary team so that the document
becomes fool proof.
To initiate the issue, few sample QAPs have been prepared for
manufacturing/ procurement of pipes / fittings etc. and given in
Annexure AIP-9 for ready reference.
Path forward: To upheld the quality at the top, all units are to form a
multidisciplinary committee comprising of HODs of respective
disciplines including that of materials to take care of procurement
quality at individuals area of requirement.
For project execution, the PMC has to formulate QAP which shall be
routed through inspection for their comments and finally shall be
Page 79 of 119

approved by IOCL Project department. In some of the ongoing

projects, as could be seen during the teams visit, there is no provision
kept by PMC for clients approval neither there is any scope of IOCL
inspection for intermediate/ stage inspection either for procurement /
manufacturing or execution work.
This trend needs to be revised. Involvement of IOCL engineers with
responsibility sharing shall be intensified for project work irrespective of
whether the job is undertaken on LSTK or conventional basis. The
greater awareness to quality can only improve upon reliability and
safety of the plant. The quality of work at inception has to be excellent,
for a trouble free run later. This is mostly applicable for project work
and replacement jobs by maintenance.
Addendum-26
Review of process packages w.r.t. metallurgy and corrosion
Feedback on material of construction should be obtained from
inspection for all new projects & modifications.
Quality Assurance Plan (QAP) is to be approved by Inspection dept.
Only IOCL approved brand of consumables (electrodes) are to be
used. Adherence to approved quality assurance plan (QAP) and use of
certified consumables & tested welders. WPS & PQR shall be available
at site.
One electrode or wire sample from each lot or package of alloy weld
rod should be positively identified for correctness of material. In
addition to this, PMI of undiluted deposited weld metal button shall be
carried out for conformity of welding consumable (electrode / rode) to
requirement of specification before acceptance of consumable for use.
Stage wise inspection of mechanical fabrication including small bore
tapping points & piping, instrument piping and steam tracing lines.
Ensure quality of small bore piping using certified welders, TIG process
with minimum of two runs of welding, stage wise inspection and
approved QAP.
Improvement in rigidity of small bore connection by welding the
stiffeners.
All permanent threaded joints should be seal welded
Compliance with licensors recommendations.
Involvement of owner in pre dispatch inspection and material
identification at vendor shop for critical items.
Adherence to codes & recommended practices.
Quality assurance audit during project execution & before
commissioning.
Surveillance of mechanical executive work under PMC through owner
Inspection personnel reporting to Inspection Department.
Base data generation and thickness recording for critical equipment
and piping at thickness measurement locations (TMLs).
Guideline for quality assurance of any new project / major modification
job placed at Annexure-AIP-E for implementation.
5.9.1 TPI- Role, Function and Responsibility.

Page 80 of 119

Role of Third Party Inspection Agency:

1.

The TPIA forms a voluntary contractual relationship between the

Company (IOCL) and the party auditing the facility and will have to
work as a Company (IOCL) representative. TPIA is to carry out
the surveillance/inspection on behalf of the company at vendors,
contractors and Company premises. The inspection shall be
based on the Quality Assurance Plan (QAP) furnished by the
vendor and approved by the company, general inspection
requirement as specified by the company from time to time or
approved drawings issued by the company. The work will include,
without limitation, inspections at various locations on behalf of the
company for various materials, work, processes etc.

2.

Third party (TPIA) can simply play the role of informing the firm
that it is in violation of a regulation or going one step further, it can
assist the firm in developing a program for reducing its risks to
comply with a particular standard and regulation.

3.

The OBJECTIVE of TPI is to have a proper quality check and

control by an independent organization compliance w.r.t.
requirements of appropriate national / International Standards and
companys specifications.

4.

TPIA Shall provides personnel with appropriate qualification and

experience to carry out the inspection and issue report. TPIA shall
provide the resumes of the personnel that would be assigned for
the work for approval by the company. Assigned personnel should
have inspected and certified similar job facilities.

Personnel Competency Matrix:

1.
2.

3.

4.
5.
6.

Inspector should be a regular employee of TPIA and should have

full time Degree in respective discipline.
The effectiveness of inspections will depend upon the capabilities
of the personnel who are responsible to perform. The agency shall
have certified inspectors for all activities like NDT, Welding, and
NACE etc where applicable.
The predefined / documented responsibility of each level of
certified inspectors for determining the acceptability of materials or
components in accordance with the applicable codes, standards,
specification and procedures.
The predefined / documented performance monitoring system of
personnel.
The TPIA inspectors shall be mobilized / demobilised with a
formal request from client.
All the inspectors shall be deployed as per their expertise and as
approved by the IOCL for the specific activity.

Page 81 of 119

7.

TPIA shall designate a dedicated coordinator to coordinate

between site and IOCL in respect information services,
deployment etc.

Responsibility:
1.

2.

Review the various deliverables prepared by the Vendor/

Contractor and/or his sub-Vendors to ensure the content and
standard of the work meet certifiable requirements, satisfy the
Company (IOCL) general and technical requirements and that the
work will be fit for purpose.
Verify the standard of workmanship and completion and to ensure
that all work performed by Vendors/Contractor satisfy the
requirements specified in the appropriate international standards,
Company's project specifications and appropriate statutory
requirements. International standards applicable in Oil and Gas
industry and statutory requirements like DGMS, OISD, and CCOE
etc. shall be applied.

3.

Inspection essentially consists of 'design document review (and

approval if required under the QAP), inspection at Vendor's\
works, and inspection at the Vendor's yard site during
construction/fabrication, and final post installation survey. In case
of ambiguity in scope, the TPIA shall seek clarifications from the
Company. Such situations shall not be a reason for delay in
carrying out inspection. Inspection shall be conducted in a manner
so that no unreasonable extra cost is incurred on the Company
and the vendor.

4.

For bought-out items, inspection shall be carried out by the TPIA

at the Vendor's works or will be required to review the test
certificates, etc, as per the Inspection and Test plan approved by
the Company. On carrying out each inspection, the TPIA shall
issue an Inspection Release Report for all the material/activity that
fulfills the requirements of the project specifications.

5.

After completion of each inspection as per the quality plan, the

TPIA shall furnish a detailed report to the Company. The report
shall include Certificates of Conformance, indicating compliance
to all project specifications and statutory requirements.

6.

Communication regarding Acceptance / Rejection of the material

shall reach the Company within 48 hours of carrying out
inspection. In case of rejections/ nonconformity, the report shall be
faxed to the Company on the same day, to enable timely disposal.
Acceptance/Rejection of an activity/material at site shall be
reported immediately to the Company.

7.

Inspection and testing requirement to achieve the best

engineering results are to be identified and performed as per

Page 82 of 119

discussion and approval of Company. During the course of

inspection, the TPIA is to ensure that the vendor abides by the
latest issue of the standards indicated in the purchase order and
the related Company specifications, and also the statutory
requirements associated with the material and the industry. Since
the result of inspection has a bearing on future orders on the
vendor, the TPIA shall report any observations that may have
negative impact on the interests of the Company.
8.

The TPIA shall pay particular attention to the Vendor's

consciousness towards safety and environmental aspects of the
material being offered for inspection as well as at their works. The
TPIA shall bring to the notice of the Company in case of any
incident noticed by the TPIA during the course of inspection.

9.

An indicative detailing and staging of the Scope of Work for the

TPIA at Vendor's work and at Company's Site both through QAP
and detailed technical specification shall be available prior to start
of the job.

Functions:
1.

To ensure communication between the manufacturer and buyer

regarding any changes to the control plan or manufacturing
process plan.

2.

Apart from these, TPIA can extend services for vendor evaluation
/ Approval, Assessment for self-certification, Field Inspection
services, Training on quality systems / inspection methods and
consultancy services for various management system like ISO
9001 and others. Through these services end user shall be able to
judge the capabilities and maturity levels of manufacturer.

3.

TPIA shall be responsible for effective flow of information that is

reporting timely. The information should reach the proper place in
proper time before it is too late to take any corrective or preventive
action thereof. Therefore all reports shall be transmitted through e
mail followed by a hard copy, as follows:

Daily Report within 24 hrs (As applicable)

NCR report within 24 hrs (As applicable)
Inspection report Within 24 hrs
Activity completion report As per requirement.
The distribution list of each of the reports shall be defined by
IOCL and shall be updated from time to time as per
requirement.
All the reports shall carry a unique identification followed by
last four digits of PO no issued to vendor, first four digits of
client and vendor respectively.

Page 83 of 119

To enhance authenticity, all the hard copies shall be signed

and stamped by the originator.

Addendum-27
For all critical equipment and high value critical spares, pre-dispatch
inspection shall be carried out by owner.
The effectiveness of TPIA shall be evaluated periodically at RHQ level
after getting feedback from the units.
5.9.2 Quality Assurance Approach Small Bore Piping
Inspection and Quality Control of the Small-Bore Piping (SBP) In
Refining/ Petrochemical Industry:
Introduction:
SBP (NPS less than equal to 2 inch) are most critical in any process
units as they are more prone to failures than high dia piping, and even
cause unit catastrophic failures causing shutdown and safety hazards.
Proper inspection of SBP during Maintenance S/d and stringent quality
control during Project stage shall be exercised to avoid unwarranted
failures of SBP.
Inspection/Quality Assurance Procedure:
Inspection in process Units:

SBP in primary process piping shall be inspected as per the

Scope of API-570/510.
Following factors to be taken into consideration before finalizing
inspection programme:
Classification of Piping:
Primary process piping (piping upstream of main block
valve); which can cause unit upsets.
Secondary process piping (downstream of main block
valve); which can be isolated.
Safety and environmental emergency in the event of
leak
Leaks cause Unit shut-down
Magnitude and frequency of Vibration in the line; any
history.
Amount of unsupported weight
Present Piping wall thickness (use of Miniature tip
probes for thickness measurements) Vs. Original
Corrosion rate: History
Potential for CUI (Corrosion Under insulation)
Intermittent Service line or not.

Page 84 of 119

Priority to given for Inspection of Dead legs, Injection

Points, CUI, Soil to air interface.
Inspection by: External visual inspection, hammer
testing and Thickness measurement mainly.
Phase wise replacement plan may be framed.

Alteration/ Repair Maintenance And Project Stage Quality Control:

Besides stringent quality control and Third Party inspection at Vendors
Shop, Stage wise Quality Plan as given below to be strictly adhered to:
a. Thickness/Schedule cross-checking of the pipe and fittings.
Rejection of low schedule ones.
b. Material Verification Programme by PMI of Pipes with Alloy
Analyser equipped with special gadgets (refer API 578); If not
possible due to low dia and unavailability of gadgets, use of Spot
check. Colour coding at Store to be followed.
c. Special care to be taken for the lines as given below:

Warm-up and bypass lines on pumps or check valves.

Thermowells.
SBP a part of a packaged system.
100 % fit-up check as per Design code/Approved Drawing.
Min. gap of 1.6 mm to be maintained between the mating
surfaces of socket weld: to be crosschecked by joint cutting
(random) or by radiography.
Branch fit-up as per (ANSI B-31.3 for piping) and (ASME SEC
VIII Div 1 for pressure vessel)
Welding by GTAW only. Qualified piping welder to be employed
only. CS-ER70S2/P11-ER80SB2/P5-ER-80SB6/P22-ER90SB3
etc.
Proper quality i.e. Purity of Argon to be ensured.
Weld reinforcement/Fillet Leg/throat as per Code. Seal welding
of
threaded
connections
in
consultation
with
Instrumentation/Project
100% LPT in critical circuits; 25% in others. Common defects:
Pinholes/Porosities and Cracks.
Pre-heating & PWHT requirement as per (ANSI B-31.3 for
piping) and (ASME SEC VIII Div 1 for pressure vessel).
PWHT to be done in P5/P9 and in P22 material. For P11, as per
code. Preheating in all Alloy steels. Stabilization heat treatment
of SS piping may be required; Refer approved design drawing. A
detailed procedure on Post Weld Heat Treatment has been
enclosed as Annexure-AIP13.
In CS also PWHT may be required depending on service like
Amine/NACE etc.
Hardness checking after PWHT; P11- Max-225 BHN,
P22/P5/P9-Max-241 BHN. CS (Amine/NACE: 200 BHN Max)

Page 85 of 119

100% hydrotesting of SBP after fabrication / Repair-Alteration,

including Instrument Impulse lines.
RPMI (Retrospective PMI) at critical locations during
maintenance.

Reference:
1)
2)
3)
4)
5)
6)

ANSI B31.3
ASME SECVIII DIV-1/II
API 570
API 510
API 578
API580

5.10.0 Knowledge Management Approach For Bridging Gap

The inspection engineers deployed on job need to update their
knowledge and skill to keep pace with world standards. While basic
NDT training is given to all, there are specific need based trainings
which are also to be considered.
The committee could identify the following training needs for the
personnel, which are to be imparted selectively as the course fees are
very high. These trainings are followed by examination which is
undertaken by API, USA. The certification is by API is valid all over the
world and recognized by all the oil sector companies. To begin with,
one engineer from each unit to be exposed to these courses and this
can be further reviewed at unit level for extending this to others.
The engineer upon acquiring the qualification shall train other
engineers so as to minimize the knowledge and skill Gap. The
certification course fees is around Rs. 80,000/- presently (all inclusive
i.e. the preparatory course followed by examination fees).
Total duration of the course is for around two weeks with 2 days for
examination. The following courses are considered.
API 510 = Certification course for pressure vessels
API 570 = Certification course for pressure piping
API 579 = Certification course for Fitness for Service
The other certification courses like NACE, corrosion control, welding
course by IIW, Eddy Current Test Training etc. are conducted in India
by Indian faculties with nominal course fees. More engineers on such
courses can be nominated. The whole exercise is to bridge the
knowledge Gap, which is occurring more predominantly due to
advancement of world technology in a faster pace. To cope up with the
technique, knowledge advancement and to have wider vision, such
exposures are essential.

Page 86 of 119

Knowledge gives confidence and also opens up avenues for various

alternatives which makes decision making not only fast but effective as
well.
Reliability of plants and equipments shall be dealt not only be mere
acquiring data but also by analyzing it with wisdom for eventual benefit
to the company. Therefore the unlearn and relearn process shall have
to continue.
Other than the above areas, the Inspection Engineers shall have
technical inputs on ceramic engineering for effective quality control on
Refractory, Insulation, and Ceramic fibre application job.
5.11.0 Documentation
Documentation, data preservation and drawing upkeepment are the
three important areas for any organization especially like process units
of ours.
Most of our Refineries are quite old and the equipments are on run
between 20 40 years at many places. The reliability goes down with
ageing due to various metallurgical and mechanical factors. Proper
health tracking needs perfect past documentation and this is also valid
for future references. Therefore, documentation is a key area where
attention needs to be focused fully in order to maintain a knowledge
data bank of each equipment in minute details. Reliability and
operability of any equipment and piping circuits are to be decided on
the basis of the data that is generated and documented and preserved
properly.
The advantage we have now is to prepare and preserve a soft copy as
well for future reference / record. Therefore action plan to be drawn by
all Refineries to make documentation an area of strength and arrange
to maintain both hard and soft copies of each equipment and critical
piping circuits in detail. Most of the Refineries are on the process of
carrying out the task. All Refineries therefore are to review once more
and complete the activity within the time frame.
It has also been found that the handing over process of document from
project department to user department is not fool proof. There is a
need for streamlining the process. Therefore a checklist has been
prepared and enclosed as Annexure-AIP12 as a guideline for smooth
transaction of documents.
Unit History Record /Diary of Events
Unit history cards are to be opened for each operating unit which shall
reflect the following information, by and large.

Record of Failures and isolation of static equipment TAG

No./Date / and Type.

Page 87 of 119

Type of outage

Brief of Inspection Activity

Type of Inspection
Repairment recommended
Hydrotest/ other test
Back to operation

Routine Maintenance
Emergency

Internal / External
---------------------date
date

Any other relevant Data / Information pertaining to the equipment:

Introduction of Diary of Events

Diary of Events is to be maintained for the following events.

Unit interruption Details due to problems Like: Emergency / Feed /

Ullage / Idling
Type of Emergency:
Down time Duration: - Date and Time
Planned shutdown detail:
Feed cut off date:
Feed cut in date:
Time over run, if any:
Any other relevant observations

The data to be reviewed by CIPM every month, on the first working

day.
Inspection Manual Updation

In view of addition of many new units in all the Refineries, unit

specific inspection manuals are to be prepared and hard copies
shall be available with all Inspection Engineers soft copies can be
put in intranet.
The old Inspection manuals, need to be updated as per the
present unit condition (post revamp, if any)
Both the documents are to be made available in hard and soft
copies.
The manual to be put to local intranet for easy access to all. This
is done in some of the Refineries already, others to follow.
Equipment specific inspection checklist to be added in the
manual, if not already there. This is true for new and typical
equipments, not existing before.
Any specific / special procedure for inspection of equipment shall
be recorded in the manual.

Software Package for Inspection Department

Page 88 of 119

There is a dire need for a common package for all the Refineries. At
present, there is no commonality between even two refineries. This
needs to be standardized.
COIS has been informed on this issue and they are on the job, to make
a common package through SAP. M&I shall co-ordinate this with COIS
and finalise within six months period.
Addendum-28
Common inspection package
implemented in all the refineries.

compatible

with

SAP

may

be

Digitization of Document
The document/ drgs. of inspection department need to be digitised.
This is being done in many refineries. All others to follow, within the
time frame.
5.12.0 Inspection Gadgets
List of Standard Gadgets:
Inspection Gadgets (Major items) to be ideally available at units:

Alloy analyzer M/C (imported, X-Ray based)

Thermography M/C (imported)
Infrared thermometer / pyrometer (imported) for reformer tubes etc.
Ultrasonic thickness gauge M/C (B-scan facility) imported.
Ultrasonic thickness gauge (normal probe, pencil probe, curvature
probe, high temperature probe etc (imported stuff)
Ultrasonic flaw detector.
Corrosion monitoring system (on line) corrosiometer
DFT gauge (Paints).
Shore hardness tester (rubber).
Spark tester.
Hardness tester (microprocessor based) (imported)
Film viewer
Ferrite meter.
Tank floor scanner.
Boro scope with video attachment.
Digital Camera
PH Mtr.
Radiation survey meter.
Pit depth gauge
OD gauge / Tape
PH meter (Pocket type-Digital)
Ultrasonic Leak detector
Humidity meter
Surface profile gauge (Digital)
Page 89 of 119

Contact type thermometer

Holiday testing M/C.
Binoculars
MPI M/C
DP Kit
Digital vernier
Weld thickness gauge
Digital ID calipers
Film viewer
Digital TDS measurement M/C
Digital conductivity measurement M/C

Units to go through the list and decide about further individual need.
Any other new items required to reinforce effective inspection shall be
procured by units, so as to ensure reliability of equipment in totality.
CIPM to review the status once in six months.
5.13.0 Inspection Library

Standards / Codes

Codes / Standard For Inspection Library

S. No
1.

5.
6
7

Code / Standard
ASME SEC II PART
A
ASME SEC II PART
B
ASME SEC II PART
C
ASME SEC VIII DIV
1
ASME SEC V
ASME SEC IX
ANSI B 31.3

8.
9.

API 510
API 520

10.

API RP 530

11.

API 560

12.
13
14

API 570
API 650
API 653

2.
3.
4

Description
Ferrous material specification
Non ferrous material specification
Specification for welding electrodes
Rules for construction of pressure
vessels
Non Destructive Testing
Welding and brazing qualifications
Chemical plant and petroleum refinery
piping
Pressure Vessel Inspection Code
Sizing, Selection, and Installation of
Pressure-Relieving
Devices
in
Refineries
Calculation of Heater Tube Thickness
in Petroleum Refineries
Fired Heaters for General Refinery
Services
Piping Inspection Code
Welded Steel Tanks for Oil Storage
Maintenance of welded steel tanks for

Page 90 of 119

S. No

Code / Standard

15

API RP 941

16

TEMA standard-8
edition

17
18

EJMA standard-8
edition
NACE MR 0175

19

NACE TM 0177

20

NACE TM0284

21

NACE RP0170

22

NACE RP0296

23

NACE RP0472

th

th

Description
storage
Steels for Hydrogen Services at
Elevated
Temperatures
and
Pressures in Petroleum Refineries
and Petrochemical Plants
Heat exchanger design
Selection and application of metallic
bellows type expansion joints
Petroleum and Natural Gas Industries
Materials for Use in H2S-containing
Environments in Oil and Gas
Production.
Laboratory Tessting of Metals for
Resistance to Sulfide Stress Cracking
in Hydrogen Sulfide (H2S)
Standard Test Method-Evaluation of
Pipeline and Pressure Vessel Steels
for Resistance to Hydrogen induced
Cracking
Protection of Austenitic Stainless
Steels and Other Austenitic Alloys
from
Polythionic
Acid
Stress
Corrosion Cracking During Shutdown
of Refinery.
Guidelines for detection, Repair, and
Mitigation of Cracking of Existing
Petroleum Refinery Pressure Vessels
in
Wet
Hydrogen
Sulfide
Environments
Standard Recommended Practice
Methods and Controls to Prevent in
Service Environmental Cracking of
Carbon Steel Weldments in Corrosive
Petroleum Refining Environments

In addition journals like material performance, NDT Journals, NACE,

Welding Journals, Inspectioneering Journal (Houston, USA) etc. are to
be kept on regular basis.
5.14.0 Spares Management Insurance Spares For Static Equipment
As decided by M&I, the revised guideline for Insurance spares for static
equipment shall be issued within a short period. CIPM / CMNM at each
unit to take a stock of items those are available at unit level and
compare with the desired inventory level.

Page 91 of 119

The short fall, if any, to be initiated for procurement. Like wise, the
excess, if any shall be transferred to maint. Spares. The procurement
actions shall be taken considering both insurance spare and maint.
Spare requirement. In case of commonality in items, between units, the
quantity can be clubbed together to get a better offer with possible
lesser price.
For the upcoming projects, current ongoing projects and recently
commissioned ones, an action plan to be drawn to procure Insurance
spares, as per the latest guideline.
In case of upcoming projects, the LSTK contractor can be advised in
advance for the requirements. For ongoing projects, the spares can be
diverted first as insurance spares. Balance, if any can be kept as maint.
Spares. The same logic shall apply for recently commissioned projects.
5.15.0 Passivation Of Equipment - Need and Procedure
The stainless Steel Pipes, Heaters Tubes, Exchangers and other SS
Equipments are necessarily to be protected by neutralization (with
soda Ash solution) to prevent stress corrosion cracking especially
during shutdown time.
The general procedure is given below and to be followed as guideline.
A sample procedure from Mathura Refinery is given in Annexure-AIP10
and an elaborate procedure is placed at Annexure-AIP-F
.
NACE RP-0170 On Protection Of Austenitic Stainless Steel Equipment
Protection of Austenitic Stainless Steel and Other Austenitic Alloys
from Polythionic Acid Stress Corrosion Cracking during Shutdown of
Refinery Equipment.
General
If sulfide corrosion products are present on the surfaces of austenitic
stainless steel and other austenitic alloy process equipment, there is a
definite risk of polythionic acid stress corrosion cracking (SCC) when
oxygen (air) and water are admitted during an outage. Tensile
stresses, both residual and applied, are usually present in cold
equipment. In the presence of polythionic acids, SCC may occur in
stressed austenitic stainless steels and other austenitic alloys that are
in a sensitized condition.
Polythionic acid SCC normally occurs with the standard (0.08% carbon
max.) and high carbon (0.10% max.) grades that have become
sensitized either by weld fabrication or by operation in the sensitizing
0

range of 370 to 815 C (700 to 1500 F).

Page 92 of 119

Low-carbon (0.03% max) and chemically stabilized grades (e.g., alloys

with titanium or columbium alloying additions) may also become
sensitized by prolonged exposure in the sensitizing temperature range.
Sensitization will be more rapid in the presence of carbon (coke).
The resistance of chemically stabilized stainless steels and other
austenitic alloys to polythionic acid SCC may be significantly improved
by thermal stabilization treatment.
The degree of sensitization and stress levels are generally not known.
Therefore, austenitic stainless steel and other austenitic alloy process
equipment on which sulfide corrosion products may be present should
be protected using one or more of the following methods.
Exclusion of oxygen (air) and water by using a dry nitrogen purge.
Alkaline washing of all surfaces to neutralize any polythionic acids that
may form. (Field experience has demonstrated that austenitic stainless
steels and other austenitic alloys are effectively protected with properly
applied alkaline solutions.)
Exclusion of water by using a dry air purge with a dew point lower
0

than15 C (5 F).
If process equipment remains unopened and hot (above the water
dew point of the gas in the equipment), additional protection is
unnecessary.
The internal surface of austenitic stainless steel and other austenitic
alloy furnace tubes maybe susceptible to polythionic acid SCC whether
or not they have been thermally decoked and should be protected. If
thermally decoked, protection should be performed after decoking.
Protection of the external surfaces of austenitic stainless steel and
other austenitic alloy furnace tubes should be considered when sulfur
containing fuels have been used for furnace firing.
5.16.0 Material/ Equipment Preservation Need and Procedure
Idle time preservation of equipments (like Heat Exch, Vessels, Heaters,
Columns, Boilers and Sulphur Recovery and Amine Regeneration
units).
To prevent corrosion / deterioration of internal surface of the
equipments (mentioned above), and also of Boilers, unit piping /
equipments during the idling time, Idle time preservation procedure
shall be undertaken for all such individual equipments and piping as a
whole. A guideline in this regard has been enclosed as Annexure
AIP11.

Page 93 of 119

For material preservation at store, the following steps are to be

followed:

All smaller materials (like elbow, reducer, flanges etc shall be kept
under shade and stacked neatly in steel racks, with proper
identification marks.
All the items are to be sprayed fully with linseed oil twice a year,
for preservation. One such frequency shall be before monsoon i.e.
in the month of March / April. The next one shall be during
September.
For bigger size materials (like Pipes etc.) the same should be
stacked upon elevated steel rack with sleeper below each layer.

The pipes can be spread side by side with wooden sleeper at bottom
and top. The spraying frequency of linseed oil shall be twice in a year.
The pipes are preferably to be kept under shed to avoid atmospheric
corrosion.
For the plates, since it occupies more space, these are generally
stored in open. To avoid corrosion, the plates are to be stacked one
after other separated by wooden sleeper only. The oil spray again to be
done twice a year.
The physical inspection shall be done thrice a year. One such
inspection shall be before monsoon and the other one at post monsoon
period.
The storage area shall be free of:

Water logging
Growth of vegetation
Falling / Spraying of water (as happens near cooling tower)

Periodic inspection by stores person shall be made to ascertain the

preservation status.
The pipes/ plates lying now without preservation shall also be brought
under the scheme forthwith. Inspection engineer to check sample
preservation by oil at the beginning to clear the procedure. In between
checks need to be performed, once in a week (during oil spraying
exercise only) jointly by inspection and store person and prepare a
signed Protocol for proper documentation. CIPM/ CMTM to review the
situation, once in a year before monsoon.
5.17.0 Inspection Recommendation- Follow up Format and Procedure.
While carrying out survey in all the refineries it was found that there is
no structured follow up system for the recommendations given by
inspection to maintenance etc. This has at some places resulted in
non-availability of the recommended item at the time of need. The

Page 94 of 119

procurement status was also found not available fully with the
recommending department and there was gap between the
recommending and indenting department.
To streamline the process it has been decided to introduce one MIS for
inspection department which will content the list of all
recommendations pending for execution.
The frequency for issuance of this MIS is every two months. The status
of items recommended vis--vis a procurement status shall be
reviewed by CIPM/ CMNM/ CMTM & CESM every quarterly and
corrective action taken. The proforma is enclosed as Annexure-AIP14.

Page 95 of 119

Annexure-AIP-A
Comprehensive Inspection frequency of Pressure Vessel

Half of remaining life or 10 years whichever is less.

Remaining life is to be calculated as per the following procedure
Remaining life (Years)

T (actual)
T (minimum)

=
T (actual) T (minimum)
---------------------------------Corrosion Rate
=
Actual minimum thickness recorded
Min. required thickness as per design code

Operational requirement / Licensor recommendation.

Statutory requirement of factory act / SMPV rule.

Page 96 of 119

ANNEXURE-AIP-B

UNIT AREA

Carry out inspection of hot (above 2000C) lines with M&I shutdown of
units.

Carry out on-stream inspection of cold & intermediate hot (2000C &
below) piping as per approved frequency as stipulated in reliability
document 2005 or decided by inspection head or as per OISD 130
whichever is earlier.

The piping system and inspection frequency shall be reviewed by

inspection head to categorize them in line with OISD 130 / API 570
based on corrosion rate and consequences of failure.

OFFSITE AREA

Visual surveying the route of buried piping is to be done once in six month.

Carry out inspection of under ground piping in offsite area at culvert, road
crossing & tank dykes (at expose ends), into trench ( lifting selected
covers) and circulating cooling water isolation chamber & tap off locations
once in year.

Soil to air interfaces of buried pipe / circulating water line should be

checked by exposing 0.5 meter portion of buried length of pipe once in 5
years.

The underground buried & unexposed pipe condition should be checked

by LRUT or exposing full circumference of pipe of at least 2.0 -2.5 meter
length at one and more locations judged to be more susceptible to
corrosion once in five years.

Underground Pipelines with CP should be inspected pipe to soil potential

(PSP) once in a month and close interval potential survey (CIPS)/ Direct
Current Voltage Gradient (DCVG) survey /Current Attenuation Technique
(CAT) for condition monitoring of wrapping & coating once in five years.

Alternatively, leak testing of buried piping at pump shut off pressure can be
done once in 5 years in line with API 570.

Carry out inspection of offsite lines at a frequency stipulated in reliability

document 2005 or decided by inspection head or as per OISD whichever
is earlier.

Page 97 of 119

Annexure-AIP-C
DETAILS OF HEAT EXCHANGER TUBE PLUGS
Heat exchanger tube plugs seal the ends of leaking tubes, providing longer
use of the heat exchanger. The uniform taper and the smooth surface finish
assures positive sealing with a minimum installation force.
Sizes
Tube plugs are sized to fit tube diameters from through 1 with standard
wall thicknesses of:

11 through 14 gauge
12 through 17 gauge
15 through 20 gauge

Based on Birmingham or Stubs gauge system.

Materials
Tube plugs are to be fabricated from materials as per system compatibility.
The common ASTM specifications are as follows:

Brass ASTM B16

Stainless steel ASTM A479
Carbon Steel ASTM A108
Alloy 600 ASTM B166
Alloy R-405 ASTM B164

Common Plug Dimensions

Page 98 of 119

Annexure-AIP-D
INSPECTION GUIDELINES AND PROCEDURES FOR MITIGATION OF
CORROSION UNDER INSULATION (CUI)
1.0 Introduction:
The equipments in a process units and utilities service in a complex refinery
operate under various process conditions. This includes fluctuating
temperatures, pressure, external environmental conditions, dew points etc.
This leads to deterioration of the equipment health leading to decrease in its
remnant life. The problem becomes all the more alarming in an insulated
system where it acts as a silent killer. Corrosion under insulation is caused
by the ingress of water and moister into the insulation that remained trapped
like a sponge in contact with the metal surface.
Insulation of equipment and piping operating above 60C is done for human
protection in accessible area. However at higher operating temperatures it
often becomes necessary to insulate in order to prevent heat losses and to
improve the efficiency of the process. Moisture ingress into conventional
insulation materials usually results in accelerated corrosion of the underlying
steel surface which, if left unchecked, can result in catastrophic failure of the
pipe, vessel or other insulated item. Typically, insulation used has been based
on Rockwool, rigid polyurethane foam, Foam Glass or Calcium Silicate. These
materials have different degrees of water uptake, but all require cladding
material in order to keep in place and to seal from the weather and prevent
water ingress.
2.0 Scope
This specification covers corrosion mechanism, area prone to CUI, minimum
inspection requirements of insulated lines, frequency of inspection, and
insulation material and insulation procedures to protect the line from corrosion
under insulation.
3.0 Purpose of Insulation:
Insulation is provided primarily for the following reasons:
a)
b)
c)
d)

Heat preservation and freeze protection

Process control
Protection from heat
Fire protection etc.

4.0 Corrosion Mechanism:

Corrosion of piping, equipment and structural components resulting from
water trapped under Insulation or fireproofing comes under CUI. Sources of
moisture may include: rain, water leaks, condensation, deluge systems, and
cooling towers. The rate of CUI depends upon design of insulation system,

Page 99 of 119

insulation type, temperature, environment (humidity, rainfall and chlorides

from marine environment, industrial environments containing high SO2). The
marine locations in warmer areas may result in severe corrosion whereas
cooler, drier, mid-continent locations may not face any significant corrosion.
Corrosion rates increase with increasing metal temperature up to the point
where the water evaporates quickly. It becomes more severe at metal
temperatures between the boiling point 1000C to1210C, where water is less
likely to vaporize and insulation stays wet longer. In marine environments or
areas where significant amounts of moisture may be present, the upper
temperature range where CUI may occur can be extended significantly above
1210C. Uses of insulating materials that hold moisture (wick) are more
detrimental. Equipment under Cyclic thermal operation or intermittent service
is more affected due to CUI. Equipment that operates below the water dew
point tends to condense water on the metal surface thus providing a wet
environment and increasing the risk of corrosion. Damage is aggravated by
contaminants that may be leached out of the insulation, such as chlorides.
Plants located in areas with high annual rainfall or warmer, marine locations
are more prone to CUI than plants located in cooler, drier, mid-continent
locations. Environments that provide airborne contaminants such as chlorides
(marine environments, cooling tower drift) or SO2 (stack emissions) can
accelerate corrosion. The most common forms of CUI are localized corrosion
of carbon steel and chloride stress corrosion cracking of austenitic stainless
steels and the mechanism is outlined below
Carbon Steel: When CS metal surface comes in contact with aerated water
corrosion takes place. The corrosion rate depends on the metal temperature.
The water infiltrates the damaged insulation and condenses on the surface.
During this process the leach able chloride, halides or sulfates present in the
insulation material, binder, etc makes the environment conductive and
conducive for corrosion. In open system corrosion rate drops below 80 deg C
whereas in closed system it increases. CUI in CS is more prevalent in the
temperature range (120C) to 1750C. Insulation that holds least amount of
water and dries most quickly should result in least corrosion. CUI damage
often appears as loose, flaky scale covering the corroded component in
carbon and low alloy steels, Damage may be highly localized. In some
localized cases, the corrosion can appear to be carbuncle type pitting.
Austenitic Stainless Steel (ASS):
The 18/8 series are more susceptible to CUI. The critical temperature ranges
also called hot water range are 600C to 2050C. The major corrosion
mechanism is the External stress corrosion cracking (E.S.C.C) and Liquid
metal embitterment LME. The super austenitic grades, duplex grades give
better resistance to ESCC. The mechanism of ESCC is due to the presence
of leach able chloride, halides from the insulation material or environment
coming in contact with the stressed ASS component leading to such failures.
Application of silicate inhibitor in insulation or metal surface has been tried to
reduce the effect of chloride to a reasonable success. For 300 Series SS,
specifically in older calcium silicate insulation localized pitting and chloride

Page 100 of 119

stress corrosion cracking can occur. ASTM C692, C795, C871, C929 deals
with selection, testing of insulation for .ASS material for prevention of ESCC.
5.0 Area Prone to CUI
CUI is likely to be found on equipment with damaged insulation, vapor
barriers, weatherproofing or mastic, or protrusions through the insulation or at
insulation termination points such as flanges. Equipment designed with
insulation support rings welded directly to the vessel wall (no standoff);
particularly around ladder and platform clips, and lifting lugs, nozzles and
stiffener rings. Piping or equipment having leaking steam tracing and
damaged paint / coating systems are affected due to CUI. Locations where
moisture/water will naturally collect (gravity drainage) before evaporating
(insulation support rings on vertical equipment) and improperly terminated
fireproofing are prone to CUI. The first few feet of a horizontal pipe run
adjacent to the bottom of a vertical run is a typical a CUI location. Common
areas of concern in process units are higher moisture areas such as those
areas down-wind from cooling towers, near steam vents, deluge systems,
acid vapors, or near supplemental cooling with water spray. Common
Locations on Piping Systems Susceptible to CUI includes all penetrations or
breaches in the insulation jacketing systems, such as dead legs (vents,
drains, and other similar items), pipe hangers and other supports. valves and
fittings (irregular insulation surfaces), bolted-on pipe shoes, steam tracer
tubing penetrations, termination of insulation at flanges and other piping
components, damaged or missing insulation jacketing, insulation jacketing
seams located on the top of horizontal piping or improperly lapped or sealed
insulation jacketing, termination of insulation in a vertical pipe, caulking that
has hardened, has separated, or is missing, bulges or staining of the
insulation or jacketing system or missing bands. (Bulges may indicate
corrosion product buildup.), low points in piping systems that have a known
breach in the insulation system, including low points in long unsupported
piping runs, carbon or low-alloy steel flanges, bolting, and other components
under insulation in high-alloy piping systems, locations where insulation plugs
have been removed to permit piping thickness measurements on insulated
piping should receive particular attention. These plugs should be promptly
replaced and sealed. As per API 581 typical rate of CUI is listed below:
Operating Temperature Marine/CT Drift
in F
area
CUI in mpy
10 or less
0
11-60
5
61-120 (15-50 C)
2
121-200 (50-100 C)
10
201-250 (100- 120 C)
2
>250 (> 120 C)
0

Page 101 of 119

Temp
Arid/Dry
CUI
in CUI in mpy
mpy
0
0
3
1
1
0
5
2
1
0
0
0

6.0 Inspection methods and Extent of Inspection:

External Visual Inspection after insulation removal at select areas
Ultrasonic thickness survey at TML(thickness measurement locations)
Radiography methods
Pulsed Eddy Current method
Long range ultrasonic testing method
Infrared methods etc.
In spite of lot many advanced NDT systems in vogue, external inspection after
insulation removal followed by Ultrasonic thickness survey is still the most
reliable and effective one in assessing CUI. Most of the refiners worldwide,
particularly in high humid, high temp coastal/marine locations, frame stringent
CUI detection programmed in line with API-570 and go for Visual/Ultrasonic
thickness gauge (UTG) combination. Advanced NDEs are useful in specific
applications. However, all these methods have their limitations.
Radiographic examination or insulation removal and visual inspection is
normally required for this inspection at damaged or suspect locations. Other
NDE assessment methods may be used where applicable. If the inspection of
the damaged or suspect areas has located significant CUI, additional areas
should be inspected and, where warranted, up to 100 percent of the circuit
should be inspected. It is recognized that several factors may affect the
likelihood of CUI to include local climatic conditions, insulation design,
painting/coating quality and service conditions. Piping systems that are known
to have a remaining life of over 10 years or that are adequately protected
against external corrosion need not be included for the NDE inspection
recommended in Table below. However, the condition of the insulating system
or the outer jacketing, such as a cold-box shell, should be observed
periodically by operating or other personnel. The inspection priority can be
decided based on the operating temperature conditions. Equipment and
piping operating 800C to 1200C should be considered priority I, (- 40C) to 800C
priority II and above 150 0C priority III.
7.0 Inspection interval:
Inspection interval and extent of inspection should be established based on
following criteria:
Corrosion rate and remaining life calculation
Piping service classifications
On operating condition, previous inspection history, current inspection results
etc.
Judgment of the Inspector/ Piping Engineer based on the past failure history
of the plant
The following general inspection frequency should be followed as per
criticality of content.
Type of Circuit

Thickness
measurement

Page 102 of 119

Visual External

Thickness
measurement
Class 1 (highest risk potential and 5 Years
consequences).
Class 2 (unit process piping &selected 10 years
off-site piping)
Class
3
(Low
risk
&
low 10 years
consequences)
Type of Circuit

Visual External
5 Years
5 Years
10 years

8.0 Procedures for CUI Mitigation:

Corrosion under insulation can be prevented by a combined approach of
using a coating system which will prevent corrosion in the potentially hot, wet
conditions existing under the insulation and insulation design which will not be
easily damaged and will prevent water/ moisture ingress.
Selection & Application of Coating system
Protective coatings / Paintings are to be applied on the bare metal surface of
carbon steel prior to application of insulation as stated below
a)
b)
c)

For temperature range (0 to 600C ): Sand blasting to Sa2.5 std. Primer

and finish coats both high-built epoxy (DFT 130 Microns each).
For temperature range (-45 to 1500C ) : Sand blasting to Sa2.5 std.
Primer and finish paint shall be phenolic or high temperature rated
amine cured coal tar epoxy paint (DFT 150 Microns each ).
For high temperature range piping above 1500C: Sand blasting to Sa2.5
std. followed by HR-47 paint (DFT 15 microns).

The common paint system for Carbon steel to prevent CUI is placed at
Annexure-1.Utmost care shall be exercised to prevent failure by Stress
corrosion cracking and Liquid Metal Embitterment (LME) in Austenitic
Stainless Steel (ASS). Coating /Painting of austenitic stainless steel is
generally not required. However, if done under special circumstances the
paint should be free from soluble chlorides, halides, Zn, Pb, Cu or its
components. Annexure-I gives typical paint system for ASS. SS foils barrier
shall be used to avoid direct contact of insulation material on ASS material.
Selection & Application Insulation system

Selection of water repellant grade of insulation material (rock wool, slag

wool or glass wool, cellular glass, organic foam, perlite or calcium silicate
the detail is placed at annexure-II).
Selection of inhibited insulation for Austenitic Stainless steel.
Selection of binding material and sealing component
Selection of vapor barrier e.g of mastic or metallic
Selection of proofing/jacket Eg Al, GI, SS, or FRP.

Page 103 of 119

The criteria for selection of the above different components should be based
on specific end use. However, the following points should be considered in
selection criteria:

Better design of protrusions, attachment and supports of piping/vessel in

the mechanical design as far as possible. At these projected/protruded
locations the insulation design should look into details that water does
ingress inside and wet the insulation.
Complete and proper insulation specification to be provided /used.
At Failed ESCC ASS locations chloride concentrations in the range of 350
to 1000 ppm were noticed. A clue should be taken from these readings so
as to fix /freeze the chloride content in the insulation material.
All kinds of stress generation points in the mechanical system should be
rectified.
PU foam, Polyisocynurate foam and phenolic foam do not prevent against
ESCC due to chloride present in them.
Weather barrier, sealants, mastics contain chloride and doesnt allow
moisture to escape causing the insulation to be moist and concentrated
with Chloride leading to ESCC in ASS.
The complete insulation system design should provide for an expansion
joint e.g. cellular glass insulation coefficient of expansion is similar to CS
whereas cellular foam expands 9 times to CS. During expansion and
contraction the vapor barrier and insulation may get damaged and metal
surface may be exposed to environment.

Insulation Application Procedure

A written quality assurance plan duly approved by inspection and civil

heads for stage wise quality monitoring shall be documented.

The damaged insulation shall be removed and the surface shall be

cleaned by sand blasting confirming to Sa2.5.
If the surface is severely corroded then suitable decision for
repair/replacement shall be carried out. Otherwise it shall be painted with
specified painting system:
Moisture/ vapor barrier of aluminum foil or SS foil shall be provided over
the painted surface.
Formed insulation shall be preferred for use (ASTM C 547). The insulation
shall be fitted in such a manner that the joints fall in 3oclcok and 9 oclock
positions. These joints shall be bonded with adhesives.
Further these joints shall be sealed with proper sealing compound. Sealing
compound shall be taken from reputed parties. Till the time these formed
insulation is procured the conventional insulation system may be used. But
proper QAP shall be followed like sample thickness measurement,
specification, mill certificate, sample wt measurement of 1 meter length to
compare density and adequate thickness of application.
Finally Aluminum jacket shall be provided on the insulation for external
protection. Further these joints shall be sealed with proper sealing
compound.

Page 104 of 119

When cleaning by sand blasting is not possible then the surface may be
cleaned manually and painting need not be carried out.
For Austenitic stainless steel (SS304, SS316, SS321, SS347) equipments
SS foil shall be provided on the surface to act as barrier against the
infiltration of chloride/halides bearing fluid, which may otherwise lead to
ESCC/LME. Inhibited insulation shall be used.
For temperatures up to 540 deg C Aluminum jackets shall be used. Above
540 deg C SS jackets shall be used.
Proper sealing of the insulation shall be carried out at the supports,
projections, attachments, nozzles, valves etc. Proper support design
should be followed to avoid any loading on the insulation jacket.
Wherever it is not possible to provide proper sealing like skirt bottom, tank
bottom such locations canopy shall be provided to prevent water ingress
inside the insulation.

Page 105 of 119

Annexure-I

Page 106 of 119

Annexure -II
TYPES OF INSULATION MATERIALS

Calcium silicate( spec as per ASTM C 533) : This is hygroscopic in

nature. It can hold 400% wt of water if immersed completely in water.
Normally it is used for temperatures >150 deg C.
Expanded Perlite (spec as per ASTM C610): Used for moderate to high
temperatures. At low temperatures the additives provide for water
resistance and protection against corrosion. This is available in block
and pipe cover form.
Man made fiber(Rock wool, slag wool, glass wool) : Used form
moderate to high temperatures. Available in various densities. Water
retention property also varies widely
Cellular Glass (spec ASTM C 552): It is a foamed type closed cell
structure. It is used for temperature range 25 to 200 deg C. These are
water resistant.
Organic foam: These are available in preformed shapes. .These
include PU foam, Polyisocynurate foam and phenolic foam,
elastomers. The specification is as per ASTM C591, 534, 1029, 1126,
578. These materials contain chloride, fluoride, silicate , sodium which
can cause corrosion after coming in contact with the metal surface.
Ceramic fiber: used for high temperature in furnace.
Aluminum Jacket: should not be used above 540 deg C . This will lead
to LME of ASS.
GI Jacket : Should not be used above 370 deg C.
FRP jacket : should not be used on high temp line.

Page 107 of 119

Annexure-AIP-E
QUALITY ASSURANCE
All those planed and systematic actions necessary to provide adequate
confidence that a structure, system or component will perform satisfactorily in
service is Quality Assurance (QA). A QA system identifies responsibilities and
procedures. It is structured to ensure that:

Qualified and certified welders are engaged for welding

Welding procedure Specification (WPS) must be available at the welding
site.
Procedure qualification record (PQR) must be available with the welding
engineer.
The minimum welding quality requirement, the actual welding quality
achieved and quality assessment through NDT shall be clearly mentioned
in the QAP.

Quality Assurance Plan (QAP)

The quality assurance plan shall be approved by inspection and should

include the following:

Material Traceability / Documentation

Material required to be welded is as per specification.

Cross checking with material test certificates and identification marks.
Checking for proper colour coding.
Cross-checking by PMI.
Recording of material traceability data.

Weld Consumable Traceability / Conditioning / Issue Control

Check selection of required electrode as per specification / composition.

Check material manufacturer's test certificates and identification marks.
Check purity level and flow of Argon Gas used for purging / shielding.
Check issue of welding consumables from the right place.
Check transferring consumables from main store to secondary storage
area with proper record.
Check storage areas to be dry & warm.
Ensure disposal of damaged consumables from the storage / usage areas.
Ensure availability of written procedure for the systematic receipt, issue
and control of welding consumables.

Welder Testing

Check for qualification of welders in accordance with ASME sec IX or

other applicable codes.
Check deployment of approved welders at right place of application.
Check welder qualification test reports are submitted in proper formats.

Page 108 of 119

Check welder to have identification card with validity of time. Requalification to be ensured on expiry of validly.
Ensure for welding of steam piping, falling under IBR, only IBR approved
welders are put on job.

Defect Location / Welder Records

Check marking of joint numbers and welder number in each joint in the
drawings and ensure existence of the corresponding numbers in the field.
Identify the weld defect by NDT / DT methods.
Mark defects on the drawing and transfer it to site.
Ensure area of defect is correctly marked on the site joint for repairs and
the same is repaired by preferably the same welder.
Repair the weld as per approved repair procedure.
Ensure removal of defects and record final acceptance.
Keep record of defective welds, welder wise to assess site performance of
a welder.

Preheat / PWHT Contract & Records

Check for selection of correct post / preheat temperature condition to be

as per specification.
Carryout pre-qualification of pre & post heat treatment procedures and
record the results.
Calibrate each temperature recorder and keep record of the same.
Check application of corresponding pre-qualification procedure for site
joint.
Check submission of heat treatment chart and record of the same jointwise.
Check hardness of PWHT joints and record final acceptance of each joint.
Defective joints shall be re-stress relieved and final accepted.
Check with drawing for PWHT of all required weld joints / connections.

NDT Record Control

All NDT records shall be unit wise / line wise / circuit wise for each type of
NDT application.
Check for all weld joints / segments are subjected to required NDT checks
as per specification.
Carryout random NDT checks at site for conformity.

Calibration record for each equipments / instruments

The calibration chart of each equipment & instrument used by the

contractor / inspector shall be kept as a record for each job.
Wherever post weld heat treatment of weld is required to be carried out it
is advisable to carry out radiography examination before and after
completion of heat treatment.

Page 109 of 119

Post weld heat treatment shall be repeated if the hardness after PWHT
exceeds the maximum specified limit. Sometimes commercial heats of 5Cr
1/2Mo to 9Cr 1Mo-alloy steels do not respond to the stress relieving heat
treatment and exhibit high hardness values. In such cases a double heat
treatment involving normalizing and tempering or annealing, must be
employed. This is particularly the case when a high preheat temperature
prevents the austenite-to-martensite transformation during welding.

Inspection of Welding
Responsibilities of Welding Inspector
The responsibilities of a welding inspector usually involve the performance of
a number of operations, including:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.

Interpretation of drawings and specifications.

Material traceability of metals being welded.
Material traceability of welding consumables.
Verification of welding procedure and welder qualification.
Checking application of approved welding procedures and welder.
Verification of proper heat treatment.
Verification of application of required DT / NDT to assure acceptable
quality of welds.
Preparation of records and reports.

Stages of Inspection
Welding inspection is done in following three stages:
1.
2.
3.

Inspection prior to welding.

Inspection during welding.
Inspection after welding.

Inspection Prior to welding

i.
ii.
iii.
iv.
v.
vi.

Material traceability as per drawing/document.

The faces and edges of material should be examined for laminations,
blisters, scabs and seams.
Heavy scales, oxide films, grease, paint, oil and moisture should be
removed.
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.
Edge preparations, bevel angle, alignment of parts and fitups should be
checked. The groove surface should be smooth (equivalent to
machined/filed/ground surface). The root gap should be uniform.
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.

Page 110 of 119

vii.
viii.
ix.

Weld joint is numbered as per drawing.

Deployment of qualified welder for welding.
Availability of required access for welding and protection / quardening
of weld area is made.

Inspection during Welding

Visual inspection is employed to check detail of the work while welding is in
progress. The details to be considered are:
i.
ii.
iii.
iv.
v.
vi.
vii.
viii.

Welding process.
Cleaning.
Preheat and interpass temperatures.
Joint preparation.
Distortion control.
Filler Metal and other welding consumables.
Interpass chipping, grinding or gouging.
Post weld heat treatment.

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 inspections of
root pass offer another opportunity to inspect for plate laminations.
In the case of double-groove welds, slag from the root pass on the side of the
plate may form 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
bracings used to maintain the root opening to assure penetration and
alignment.
Inspection after Welding
Visual examination is the first stage in the inspection of a finished weld. The
following quality factors should be checked:
i.
ii.
iii.
iv.
v.

Dimensional accuracy of the weldment (including distortion).

Conformity to specification requirements regarding extent, distribution,
size, contour and continuity of the welds.
Weld appearance, surface roughness, weld spatter etc.
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.
The areas where fitup lugs were attached or where handling lugs,
machining blocks or other temporary attachments were welded on,

Page 111 of 119

vi.
vii.

viii.

must be checked carefully after the attachments is removed. The area

must be ground smooth and any pits or tears be filled in with weld
metal and ground smooth. Air hardening materials should be preheated
before any thermal cutting or weld repair is done.
Postweld heat treatment time, temperature and heating/cooling rates.
Checking of weld hardness after cleaning.
For groove welds, the width of finished welds will fluctuate in
accordance with the groove angle, root face, root opening and
permissible tolerances. The height of reinforcement should be
consistent with the specified requirements. Where it is not specified the
inspector may have to rely on his judgement, guide by what he
considers a good welding practice.
The finished weld should be thoroughly cleaned of oxides and slag for
its final inspection.

After visual inspection the finished weld may be examined by one or more
than one of the following techniques.
Destructive and Non Destructive Tests
Non Destructive Tests
i.
ii.
iii.
iv.
v.

vi.
vii.
viii.
ix.
x.
xi.

Dye penetrant test of 100% root run weld of branch connections

irrespective of grade of material.
Dye penetrant testing-unless otherwise specified, the extent of this test
will be 100% for all root runs for alloy steel welds.
All fillet/socket weld joints of high-pressure system to be DP Tested.
Magnetic particle testing.
Radiography -unless otherwise specified, the extent of radiographic
examination will be as follows:
a) Carbon and carbon-molybdenum steels-10% of the welds.
b) Alloy steels - 100% of the welds. The inspector will mark the weld
joints for radiography. Radiography examination of weld joints of
two dissimilar materials shall be considered as per the higher
metallurgy stipulations.
Ultrasonic testing.
Eddy current testing.
Ferrite determination.
Ultrasonic hardness testing.
Hardness testing by portable hardness testers may be considered as
NDT method.
Hydraulic testing may be done to check for leaks through welds, cracks
etc.

Page 112 of 119

Annexure-AIP-F
NACE RP-0170 ON PROTECTION OF AUSTENITIC STAINLESS STEEL
EQUIPMENT
Protection of Austenitic Stainless Steel and Other Austenitic Alloys from
Polythionic Acid Stress Corrosion Cracking during Shutdown of
Refinery Equipment
1.0

General

1.1

If sulfide corrosion products are present on the surfaces of austenitic

stainless steel and other austenitic alloy process equipment, there is a
definite risk of polythionic acid stress corrosion cracking (SCC) when
oxygen (air) and water are admitted during an outage. Tensile
stresses, both residual and applied, are usually present in cold
equipment. In the presence of polythionic acids, SCC may occur in
stressed austenitic stainless steels and other austenitic alloys that are
in a sensitized condition.

1.1.1 Polythionic acid SCC normally occurs with the standard (0.08% carbon
max.) and high carbon (0.10% max.) grades that have become
sensitized either by weld fabrication or by operation in the sensitizing
range of 3700 to 8150C (7000 to 15000F).
1.1.2 Low-carbon (0.03% max) and chemically stabilized grades (e.g., alloys
with titanium or columbium alloying additions) may also become
sensitized by prolonged exposure in the sensitizing temperature range.
Sensitization will be more rapid in the presence of carbon (coke).
1.1.3 The resistance of chemically stabilized stainless steels and other
austenitic alloys to polythionic acid SCC may be significantly improved
by thermal stabilization treatment.

1.2

The degree of sensitization and stress levels are generally not known.
Therefore, austenitic stainless steel and other austenitic alloy process
equipment on which sulfide corrosion products may be present should
be protected using one or more of the following methods.

1.2.1 Exclusion of oxygen (air) and water by using a dry nitrogen purge.
1.2.2 Alkaline washing of all surfaces to neutralize any polythionic acids that
may form. (Field experience has demonstrated that austenitic stainless

Page 113 of 119

steels and other austenitic alloys are effectively protected with properly
applied alkaline solutions.)
1.2.3 Exclusion of water by using a dry air purge with a dew point lower than
150C (50F).

1.3

If process equipment remains unopened and hot (above the water

dew point of the gas in the equipment), additional protection is
unnecessary.

1.4

The internal surface of austenitic stainless steel and other austenitic

alloy furnace tubes maybe susceptible to polythionic acid SCC whether
or not they have been thermally decoked and should be protected. If
thermally decoked, protection should be performed after decoking.

1.5

Protection of the external surfaces of austenitic stainless steel and

other austenitic alloy furnace tubes should be considered when sulfur
containing fuels have been used for furnace firing.

2.0

Nitrogen Purging

2.1

Process equipment may be protected by keeping it tightly closed and

purging with dry nitrogen to exclude oxygen (air). Use of dry nitrogen is
an effective means of lowering the water dew point temperature to less
than ambient. Nitrogen purging provides optimum protection for
catalysts.

2.2

If reactors to be opened but furnaces are not, the furnaces may be

purged with nitrogen and blinded off. A small positive nitrogen pressure
should be maintained.

2.2.1 Nitrogen should be dry and free of oxygen. (The user is cautioned that
oxygen levels as high as 1000 ppm have been found in commercial
nitrogen).
2.3

At the users discretion, 5000 ppm ammonia may be added to the

nitrogen.
The addition of ammonia is generally unnecessary when purging with
dry nitrogen, but may be advantageous where water and/ or oxygen
may be present.
Ammonia is toxic, and fresh air breathing equipment must be worn
during installation and removal of blinds.
Copper based alloys must be isolated from ammoniated nitrogen.

Page 114 of 119

It should be determined that ammonia will not have an adverse effect

on catalyst.
2.4

Nitrogen purging is preferable for protection of vertical tube heaters if

alkaline wash solutions cannot be drained fully.

2.5

If steam is being used for purging or steam air decoking, steam

injection should be stopped before the metal temperature cools to 560C
(1000F) above the water dew point. When de-pressured, but before
cooling lower than 560C (1000F) above the water dew point, the system
should be purged with dry nitrogen. Some purge flow should be
maintained until blinds are installed. A positive nitrogen purge pressure
should be maintained on the system after blinding.

2.6

The user is cautioned that wearing fresh-air breathing equipment in

nitrogen-purged equipment requires special precautions, in accordance
with local plant safety procedures.

3.0

Alkaline Wash Solutions

3.1

Sodium carbonate (soda ash) solutions are used to protect austenitic

stainless steels and other austenitic alloys from polythionic acid SCC.
Solution pH should be greater than 9. These solutions may also
contain an alkaline surfactant and corrosion inhibitor.

3.2

The recommended wash solution is 2 wt% soda ash (industry practice

varies from 1 to 5 wt%, with a majority using 2 wt% solutions). A 1.4 to
2 wt% soda ash solution will provide a sufficient level of residual
alkalinity on metal surfaces after the solution drain from the equipment.
Additionally, this low concentration will facilitate solution preparation.

3.2.1 The use of caustic soda is not recommended.

3.2.2 Experience with potassium carbonate is limited. No cracking has been
reported by those who have substituted it for soda ash.
3.3

Because of successful past experience with solutions containing small

amounts of chloride, it is not always necessary to provide chloride-free
solutions.

3.3.1 Chloride concentration in the freshly mixed wash solution should be

limited to 150 ppm. This nominal chloride limit is attainable with
commercially available chemicals.
3.4

In special cases, flushing with ammoniated condensate may be

necessary. The solution should have a pH above 9 and a chloride
content of less than 5 ppm.

3.5

The addition of an alkaline surfactant to the wash solution at 0.2 wt%

concentration is recommended to promote penetration of coke, scale,

Page 115 of 119

or oil films. Heating of the wash solution to 490C (1200F) may

accelerate the penetration of oily films and residues.
3.6

Corrosion inhibitors have been used to decrease the possibility of

chloride SCC by these alkaline solutions.

3.6.1 At the users option, 0.4 wt% sodium nitrate maybe added. (In
laboratory tests, low concentrations of sodium nitrate have been found
to be effective in suppressing SCC of austenitic stainless steel in
boiling magnesium chloride solutions). Caution: Excess NaNO3 can
cause SCC of carbon steel.
4.0

Alkaline Washing

4.1

Austenitic stainless steel and other austenitic alloy equipment to be

opened to the air is best protected with a soda ash solution (defined in
section-3). Soda ash solutions neutralize acids and, after draining,
leave a thin alkaline film on the surface that can neutralize any
additional acid formation. It is vital that this film not be washed off and
that it remains in place as the equipment goes back on-stream.

4.1.1 The equipment must be alkaline washed before any exposure to air. It
is very important to contact 100% of the equipments internal surfaces.
4.1.2 The equipment should be soaked for a minimum of two hours. If
deposits or sludges are present, the solution should be circulated
vigorously (two hours minimum). Longer times are not detrimental in
either case.
4.1.3 The circulating solution should be analyzed at appropriate intervals to
ensure that pH and chloride limits are maintained.
4.1.4 It is essential that the alkaline wash not be followed by a water wash.
4.1.5 Each system must be evaluated individually and precautions taken to
ensure that unvented gas pockets or cascading through down-flow
sections do not prevent complete surface contact.
4.1.6 If washing the outside of furnace tubes is necessary to remove
deposits, a soda ash solution should be used because these surfaces
my be subject to polythionic acid SCC.
4.2

Hydrojetting of equipment should be conducted using a soda ash

solution.

4.2.1 After hydrojetting, equipment should be kept dry and out of the
weather. If this is not possible, the soda ash wash should be repeated
as required to maintain a residual film of soda ash. Equipment shall be
reinstalled with soda ash residual film left on surfaces.

Page 116 of 119

4.3

4.4

Hydrostatic testing of equipment should be conducted using a soda

ash solution. Ammoniated condensate may be used if the equipment is
not reopened or exposed to oxygen (air).
If sodium chloride ions cannot be tolerated in the process system, the
equipment can be washed with ammoniated condensate after being
closed. If the unit is not started up immediately, the solution can be left
in place or displaced with nitrogen or dry hydrocarbon. The unit must
not be exposed to oxygen (air) after this procedure. Ammonia solutions
do not leave a residual alkaline film after being drained.

4.5

On completion of alkaline washing, all remaining alkaline solution must

be drained from all low points in the system prior to returning
equipment to service. Failure to do so can result in concentration of
carbonate and chloride salts by evaporation, which can also lead to
SCC in austenitic stainless steels.

5.0

Protection of Reactors

5.1

Reactors containing catalyst require special consideration. Personnel

safety and protection of the catalyst may dictate the use of procedures
that are less than optimum in terms of protection from polythionic acid
SCC.

5.1.1 Non-regenerated catalysts frequently are pyrophoric. This may require

that such catalysts either be kept wet or out of contact with oxygen (air)
by the use of nitrogen purging.
5.2

Industry experience suggests that austenitic low-carbon and stabilized

grade weld overlays and stabilized grade wrought internals in reactors
are very resistant to polythionic acid SCC for reactor operating
temperatures below 4500C (8500F).

5.3

Recommended procedures for protection of reactors that will be

opened for entry and have a history of successful use in the field are as
follows:

5.3.1. Catalyst unloading and loading can be conducted under nitrogenblanketing conditions by personnel using appropriate fresh-air
breathing equipment. Following unloading, the reactor is purged with
dry air and this purge is maintained while the reactor is open. Purge air
dew point temperatures from 150 to 460C (50 to 500F) have been
used.
5.3.2 If the catalyst is to be discarded, the reactor can be filled with soda ash
solution to wet both catalyst and reactor parts. The solution strength
should be increased to 5 wt% to compensate for the acidity of deposits
held by the catalyst. Unloading can then be conducted in air while
keeping the catalyst wetted with soda ash solution to prevent
pyrophoric ignition. The reactor should then be washed down with soda
ash solution and dried prior to repairs or catalyst loading.

Page 117 of 119

5.3.3 If the user wishes to eliminate the use of soda ash solutions and fresh
air breathing equipment while unloading the catalyst, the catalyst may
be dumped, following wetting with good quality fresh water (less than
50 ppm chloride), without nitrogen purging. This should be preceded by
a careful investigation to determine that:
(1)

Only stabilized grades have been used where austenitic stainless steel
materials have been specified.

(2)

These alloy materials have not become sensitized as a result of either

vessel fabrication procedures or the reactors thermal history during
operation.

This procedure involves some risk of polythionic acid SCC through either
accidental use of unstabilized grades or misinterpretation of the thermal
history of the reactor.

Page 118 of 119

Annexure-AIP-G
Standard Pre-monsoon Job list

CIVIL JOBS
A. TANKS
1. Cleaning of roof drain sumps of FR tanks.
2. Cleaning of roof deck plate of all FR tanks.
3. Gooseneck & its wire mesh cleaning of all fixed roof tanks.
4. Cleaning of all flame arresters (wherever applicable) on tank roofs.
5. Soil removal and grass cutting under the foam lines and inlet/ outlet lines
of all tanks.
6. Tank pad repair and removing wild vegetation, if any on tank pad.
7. Cleaning of tank dyke pits and open channels.
8. Water filling in all emergency drains of FR tanks.
9. Re-visioning and testing of all PVRVs of fixed roof tanks.
10. Cleaning / Re-visioning of breather vents(pipes) of all FR tanks.
B. PIPING
1. Cleaning & painting of pipes under culvert.
2. Insulation repair, tightening of insulation sheet, overlapping of sheets to
prevent water ingress.
3. Freeing of buried LPDs wherever required.
4. Removal of soil under the buried pipe wherever required.
MECHANICAL JOBS
1. Tightening of weather shroud sheets in all FR tanks
2. Freeing / greasing of guide rollers and staircase rollers of all FR tanks.
ELECTRICAL JOBS
1. Checking and rectification of earthing connections of all tanks.

Page 119 of 119