VISUAL INSPECTION PROCEDURE

FOR RBI TYPE INSPECTION OF FCDS

PNOC EDC Procedure Issue No:

Prepared by:
Date:
Checked by:
Approved by:
1.0

SCOPE
1.1
This procedure provides guidelines for visual inspection of FCDS as an
aid to personnel required to conduct Risk Based Inspections.
1.2
PNOC EDC Inspection Procedure for Visual Inspection (of new and
repaired plant) should be referenced when the aim of the inspection is
related to Quality Assurance and Quality Control of construction or
repair activities.

2.0

PERSONNEL QUALIFICATIONS
2.1
Personnel performing visual inspections to this procedure shall have an
understanding of corrosion and erosion damage mechanisms and in
identifying locations where cracks may be initiated, and be trained by
experienced staff in the ability to recognise tell-tale signs of localised
and general corrosion.
2.2
Individuals or a team of skilled persons may be involved in visual
inspections. The experienced individuals and team members may
include staff from:
QA/QC Section from Design
Maintenance and Operations
Geochemistry
Environment Management Division
Corrosion and Metallurgy Specialist.
2.3
The qualifications requirements for Visual Assessment as described in
AS/NZS 3788: 1996 focus on inspector competency. This procedure is
intended to allow PNOC EDC staff and contractors without formal
inspection training to contribute to the visual inspection programme at
a level commensurate with their experience and competency.

3.0

PROCEDURE
3.1
External Visual Inspection

Observe and record (refer report form outline in Section 8) the local
environmental conditions and the condition of external surfaces and
mechanical supports of static and moving parts of the FCDS.
3.1.1 External Environmental and Plant Conditions
Drainage / Standing Water: Evidence of well cellars having water
standing for extended periods of time, ie blocked drains, steaming
or bubbling ground, water standing around other plant items.
Concrete Condition: Evidence of concrete corrosion or mechanical
damage to concrete support structures and well cellars
Insulation / Cladding: Evidence of wear and damage to insulation
and insulation coatings.
Corrosion Under Insulation: Corrosion under damaged or wet
insulation.
Infrastructure / Coatings: Condition of coatings, evidence of coating
breakdown and corrosion scale formation on bolting and supports,
particularly on edges and in crevices, surface deterioration or
damage to coatings on flat surfaces.
Manways / Cover Plates: Condition of bolting, coatings, gaskets,
nuts and bolts.
Soil Contact: Evidence of plant touching or being covered with soil
and evidence of soil contact corrosion.
Leakage (flanges, valve seals, valve drains): Evidence of leakage at
flanges or valve seals or relief valve seats and condition of
surrounding equipment.
Discharge Points: External scaling and corrosion around intentional
fluid discharge points.
Plastic Deformation / Line Sagging: Dinted or deflected plant
walls, distance between fixed supports and allowable vs observed
sagging.
Excessive Thermal Stresses / Previous Cracking Areas: Provisions
for thermal expansion, deflection or other damage of load carrying
structural steel members, condition of anchor points, evidence of
anchor deflection or soil movement, extension over intermediate
support guides. Appearance of stressed surfaces where tensile
stress is expected to be high at times of operation or which cycle
through tension at start-up and shut-down.
Vibration: Evidence of vibration and a qualitative measure of the
extent of movement particularly at points of fatigue such as
expansion compensators.
Compensators: Condition of compensators, evidence of correct
operation, evidence of corrosion on external surfaces, support rings
and moving parts.

Exposed Welds (Profile / Corrosion): Indications of potential defects

or stress raisers in the vicinity of components experiencing high
thermal stress or vibration
Manifolds and Nozzles: Damage around potential sites for cracking
including manifolds with short pipe lengths entering at closely
spaced nozzles.
Safety Valves: Condition and last period of testing if known.
3.1.2 Electrical and Instrumentation Systems:
Switch Boxes / Connectors: Evidence of rust or corrosion staining
(tarnishing) around wires, switch boxes and connections.
Lines / Insulation: Swelling of multi-strand conductors, evidence of
arcing or melting, broken strands or mechanical damage on
conductors. Damage to insulation on cables ie rodent attack,
chalking, crazing or cracking.
Cable Trays: Mechanical integrity, access for rodents, free draining.
Power Poles: Soundness of wood at ground level.
3.1.3 Population and Eco-System
Habitation: Evidence of authorised and non-authorised persons
living in the vicinity of the wells, lines, manifolds and separator
stations
Local Livelihood Activity: Evidence of activity such as using the
lines for crop drying, fruit and vegetable harvesting or animal
grazing of grasses in the vicinity of the lines and equipment
Other Activity: Evidence of damage to plant either intentional or
unintentional by unauthorised persons
Eco-System Description: Type of eco-system in the vicinity of the
plant and equipment
Eco-System damage: Evidence of any fluid spills and the apparent
impact
3.1.4 Inspection Test Plan Supporting Observations for Internal
Condition Assessment
Dead Legs: Indications of dead-legs that can experience low process
side temperatures and condensate formation and collection or scale
formation
Unlagged Pipe: Evidence of unlagged pipe sections that can have
condensate formation internally or excess scale formation
Erosion Risk: Plant layout details that indicate locations where
erosion might be most severe, at pipe bends, Tees, manifolds
opposite nozzles, tangential vessel entry points
High Velocity (Noise / Vibration): Evidence of excessive noise of
fluid passing through the pipes and restrictions such as valves and
Tees indicating high flow rates or geometric constraints.
High Stress Areas: Summary of those noted above to suggest
locations for risk of cracking.

3.2
Internal Visual Inspection Procedure
The visual inspection of internal surfaces must comply with company safety
requirements (refer PNOC EDC Maintenance Manual) including:
entry permission / co-ordination
gas detection
suitable clothing
adequate lighting.
3.2.1 Surface Preparation
Surface preparation such as cleaning, grinding or other methods may
be necessary where surface irregularities could mask observation.
3.2.2 Direct Observation
Direct visual examination may usually be made when access is
sufficient to place the eye within 24 inches of the surface to be examined
and at an angle not less than 30 to the surface to be examined. Mirrors
may be used to improve the angle of vision, and aids such as
magnifying lens may be used to assist examination.
3.2.3 Indirect Observation
Where necessary, remote visual examination may be substituted for
direct visual examination.
Visual aids such mirrors, telescope,
borascope, fibre optics, cameras or other suitable instruments shall be
permitted. Such systems shall have a resolution capacity at least
equivalent to that obtained by direct visual examination.
3.2.4 Supplement Illumination
Where required, supplementary illumination can be supplied by a drop
light or a flashlight in good working condition.
3.2.5 Surface Corrosion and Scaling Observations
Special attention shall be given to areas where surface corrosion and
localised pitting or erosion occurs. Some of these areas will have been
identified by the external inspection while others will only become
obvious from internal inspection. The measurement of macroscopic
depth of corrosion attack or scale deposition may be completed at the
time of the visual inspection provided that a suitable tool such as depth
gauge be used to aid the inspector on measuring the extent of damage
in the affected area. The inspection will focus on:
Wetness on Shutdown: Evidence of wetness and standing water on
shutdown, ie rusty red corrosion products, water stain marks from
behind compensator sleeves.
Contaminants: Evidence of concentrated corrodents such as
chloride salts and sulphur formed on-line or at shutdown.
Corrosion Products: Presence of absence, appearance of surface
corrosion products, coverage and colour as well as relative
thickness.
Adhesion of Corrosion Products: Adherence and relative hardness
of corrosion products.

Scales: Presence or absence and indication of thickness on pipe and

vessel walls and in turbulent areas in drains, elbows, Tees and
valves.
Adhesion of Scales: Adherence and relative hardness of scales.
Areas of Erosion: Erosion in tangential entry points, bends, Tees,
valves, elbows and other in-line obstructions. Erosion in condensate
and water collection points such as vessel drains and pipeline
catchpots.
Welds and Nozzles: Appearance of weld beads and geometry with
emphasis on erosion and pitting.
3.2.6 Mechanical Effects and Cracking
Onset of cracking will be difficult to detect by simple optical
observation. Tell-tale signs may however indicate a risk of cracking that
needs to be confirmed or denied by other inspection techniques such as
Magnetic Particle Inspection or Dye Penetrant Testing. Potential sites
for internal cracking are:
Surface Cracking: Cracks in corrosion products may indicate areas
of metal cracking some surface preparation may be required to
inspect the metal surface optically.
Welds: beads having unsuitable geometry and which act as local
stress raisers.
Arc Strikes: Arc strikes or other mechanical defects on the internal
surfaces as a result of construction activities or solids being
transported in the plant.
Plastic Deformation: Points of plastic deformation from for example
from pipe thermal expansion and contraction, landslide or
earthquake activity.
Rubbing / Fretting: Evidence of inter-surface moving contact.
Nozzles / High Stress: Regions identified from the external
examination as being potential sites for internal cracking, vessel and
pipe nozzles, especially where pipework is heavily constrained.
Compensators: Pitting on surfaces subject to cyclic stress as
precursors to cracking.

4.0

DOCUMENTATION
4.1
Visual Inspection Report Sheet
Separate Inspection Report Sheets are available for tabulating the results of
condition inspections for various Vessels and Pipelines.
Visual Inspection Report Sheet is illustrated in Section 8.
4.2
Report Notes and Photographs
Written notes may be collected in a record book with supporting
photographic records or video recording.

The results of these observations should be summarised on the Inspection

Report Sheets, referenced and filed or otherwise archived for future
retrieval.
4.3
Drawings
Copies of drawings of the plant or sketch illustrations should be carried
and notes made on the drawings as appropriate throughout the inspection.
The results of these observations should be summarised on the Inspection
Report Sheets, referenced and filed or otherwise archived for future
retrieval.
Marked copies of drawings and sketch drawings with reference points for
observations may be added to the Inspection report Sheets.

5.0

RBI ASSESSMENT
5.1
Phase 1 RBI Plant Risk Assessment
The first and subsequent visual inspections will provide:
Input data for the spreadsheet (developing database) for conducting Phase
1 RBI Plant Risk Assessments
Input data for initial confirmation of the spreadsheet (developing database)
prediction of remaining life
5.2
Implications from the Visual Inspection Results
The first formal external visual inspection reports will provide:
Indication of the general condition of the plant:
external surfaces
essential infrastructure
surrounding environment
Input data for preparation of Internal Inspection Test Plans.
Suitable timescales for repeat External Visual Inspection.
Guidance for the application of other NDT techniques for
measurement of wall thickness and detection of cracks and materials
defects either internal or external.

6.0

REPORTS AND REPEAT ASSESSMENT PERIOD

6.1
Visual Inspection Reports
These shall be prepared to a specific schedule as set out by AS/NZS 3788
and agreed by the RBI Task Force.
6.1.1 External Inspections
These should be scheduled on an annual or bi-annual basis as required or
allowed by AS/NZS 3788:1996
6.1.2 Internal Inspections
These should be scheduled on an annual, bi-annual, 4 year, 8 year or a 12
year basis as allowed by AS/NZS 3788:1996 and as indicated by the level of

damage, apparent damage accumulation rate and remaining life

prediction.
7.0

REFERENCE DOCUMENT
AS/NZS 3788:1996 Australian Standard / New Zealand Standard Pressure
equipment In-service inspection.

8.0

FORM FOR EXTERNAL AND INTERNAL INSPECTIONS FOR RBI

TYPE INSPECTION
See Attached.

VESSEL INSPECTION REPORT SHEET (see also reverse side)

Official No

Identification

Component
Notes

Maker

Max ASWP

Location

Serial No
Max/Min
Temp
Purpose

DWG No
:
Sketch
See attached sheets for additional detail

No. of cycles since last inspection

:
:
:
:

External Environmental and Plant Conditions

Drainage / Standing Water:
Concrete Condition:
Insulation / Cladding:
Corrosion Under Insulation
Infrastructure / Coatings:
Manways / Cover Plates:
Soil Contact:
Leakage (flanges, valve seals, valve
drains):
Discharge Points:
Plastic Deformation / Line Sagging:
Excessive
Thermal
Stresses
/
Previous Cracking Areas:
Vibration:
Compensators:
Exposed Welds (Profile / Corrosion):
Manifolds and Nozzles:
Safety Valve
In order/Not tested Last Tested

Inspector :

On ass. PV/PP

Date of last inspection

Signed :

Date :

Electrical and Instrumentation Systems

Switch Boxes / Connectors:
Lines / Insulation (Conductors):
Cable Trays:
Power Poles:
Population and Eco-Systems
Habitation:
Local Livelihood Activity:
Other Activity:
Eco-System Description:
Eco-System damage:
Inspection Test Plan Supporting Observations for Internal Condition
Assessment
Dead Legs:
Unlagged Pipe:
Erosion Risk:
High Velocity (Noise / Vibration):
High Stress Areas:

Comments / Sketch Illustrations:

Inspector :

Signed :

Date :

INTERNAL INSPECTION COMMENTS / RESULTS

SURFACE CORROSION
Wetness on Shutdown:
Contaminants:
Corrosion Products:
Adhesion
of
Corrosion
Products:
Scales:
Adhesion of Scales:
Areas of Erosion:
Welds and Nozzles:
MECHANICAL EFFECTS AND CRACKING
Surface Cracking:
Welds:
Arc Strikes:
Plastic Deformation:
Rubbing / Fretting:
Nozzles / High Stress:
Compensators:
Previous Inspection Reports:
File Reference
Location

Scope

Date

RBI ANALYSIS:
Criteria for External and Internal On-Line Monitoring:
Identified Locations for External NDT Monitoring
Location
Reason
Frequency

Identified Locations for Targeted Internal NDT Monitoring:

Location
Reason
Frequency

Inspector :

Signed :

Date :