Fixed Structures Inspection

IPL
Zeeshan Ibad
 Inspection Program
Following approach is taken to develop this program.

• Categorization of Fixed structures

• Structure-type-wise Threats identification
• Defining inspection program scope (and eliminations)
• Inspections methods aligned with threats
• Defining data-heads, to be gathered of all structures for future
reference.
• Standardized checklists, for Quality execution
 Types of Structures covered
1. Floodlight Poles
2. Cross Overs
3. Portable Platforms
4. Fixed Platforms
5. Piping Structural supports
6. Pipe racks
7. Equipment support structures
8. Sheds
9. Loading docks
10. Manifold Skids
11. Chemical injection skids
12. Cellar Grating
13. Windsock pole
 Not Covered
• Fence
• Sign Boards
• Communication towers and Antinas
• Lifting equipment and associated structures
• Gentry Cranes and their rails, as above
• Portacabins
• Concrete buildings and sheds
• I&E Systems support structure
Threats  Affected Types/segments 
Excessive Wind Loading • Floodlight Poles
• Piping Structural Support
• Sheds
• Loading Docks
Atmospheric Corrosion/Soil • All
Corrosion • Corrugated sheets
• Flooring (Checkered plates
• Gratings)
Vibration induced fatigue • Piping Structural Support
• Piping Racks
• Equipment Support Structure
• Manifold
Foundation Settlement • Piping Support Structure
• Pipe racks
• Equipment support structure
• Loading docks
• Manifold Skids
• Floodlight poles
Mechanical Damage • All
(including damages due to • Pad Eyes
relocation/transportation) • Lifting Lugs
Corrosion Under • Fireproofed structure
Fireproofing (CUF)
Appearance/ Morphology  Recommended Inspection Method & CMLs
• Deformation (bending, buckling • VT
etc) • DPT of baseplate joints
• Tearing • Hammer Testing of Bolts
• Anchor Bolts/Baseplate Fatigue • UTG/Caliper (spot readings) on the
cracking member around baseplate for thickness
• Joints Fatigue cracking
• Cracks btw bolt holes
• Corrosion and pitting VT and pit gauging.
• Weld Joints corrosion
Cracking • VT
• DPT of potentially affected joints
• Deformation • VT
• Vibration • DPT of potentially affected joints
• Cracking
• (stressed joints/components)
• Missing Bolts • VT (including missing bolts/anchors etc)
• Deformations • DPT of potentially affected joints
• Gouges
• General to localized metal loss To be addressed separately later.
• VT
• PET/DR
 Listing of structure
• Tag
• Location
• Duty
• Material of construction
• Year Built
• Type
• Load bearing structure Joint Type (Bolted/Welded/Both)
• Dimensions
– TOS (Top Of Steel, for working platform/X-overs) / Shed height
– Area Dimension (length X Span)
• Fireproofing
 Inspection Plan
• Area wise distribution of work, single w/o for each area.
• No PM in Maximo, just CM w/os.
• Approved checklists for equipment categories
• Additional inspector for execution
• Additional technician.
• Marking on Equipment Layout plan (red-lining) (or on Google Earth Map incase equipment plot plan is not
available).
• Reporting on filled checklists along with photographs
• Data Shall be complied in a Data base (format attached).
• Recording in documentum

Summary of inspection Methods

• VT
• UT/Caliper/Pit Gauge
• Hammer Testing
• PT
• PET/RT (in CUF inspections only, program to be developed later)
 Checklists.
Database format

Floodlight poles

Portable Equipment support Chemical injection

Fixed Platforms Manifold Skids Cellar Grating
Platforms structures skid

Piping Structural
Pipe racks Sheds Loading docks
supports
 CUF inspection
• To be developed later.