Visual Inspection - Sample Report For Spherical Vessel

Report :
NDT Inspection and Integrity Date: XYX

Assessment of Ammonia Rev:00
Spherical Vessel
INSPECTEST SUBJECT GROUP DATE

REPORT NO. II DIVISION XYZ
TITLE OF REPORT DEPARTMENT PROJECT NO.

NDT Inspection and Integrity Assessment of Ammonia INDUSTRIAL
Spherical Vessel at XYZ INSPECTION
APPROVED BY INSPECTEST
CLIENT / SPONSOR OF PROJECT / ADDRESS CHECKED BY

XYZ PAKISTAN
ATTN: MR. ABC
MAINTENANCE MANAGER
WORK CARRIED OUT BY

REPORTED BY
DISTRIBUTION STATEMENT:
NO DISTRIBUTION WITHOUT
X PERMISSION FROM THE
LOCATION RESPONSIBLE DEPARTMENT
XYZ
LIMITED DISTRIBUTION WITHIN
INSPECTEST
FREE DISTRIBUTION
NUMBER OF
SUBMISSION DATE OF REV. NO. 0 PAGES
8
The item/s described above was/were examined in prescribed manner. The information contains hereon reflects the companys finding at time of inspection only and
within clients instructions & premises. Inspection and certification becomes null and void if any changes made in equipment that alters safety features of above
described equipment. This inspection report does not relieve the contractor/user from his obligations to keep the equipment maintained and used safely.
Any unsanctioned alteration, forgery or falsification of the content or appearance of document is unlawful and delinquents may be prosecuted to the completest extent
of law.
Inspectest(Pvt.)Limited18km,FerozepurRoad,Lahore,Pakistan
T:+92423540205358UAN:IIIINSPECIF:+924235402050E:inspectest@inspectest.com.pk1|P a g e
Report :
NDT Inspection and Integrity Date: XYZ
Spherical Vessel
TABLE OF CONTENTS
1 Executive Summary................................................................................................3
2 Abbreviations............................................................................................................3
3 Objective......................................................................................................................3
4 Scope of Work...........................................................................................................4
5 Reference documents.............................................................................................4
6 Deliverables...............................................................................................................4
7 Equipment Details...................................................................................................4
7.1 Design Detail.................................................................................................................4
7.2 Previous Inspection Detail........................................................................................5
8 Inspection Equipment/Tools................................................................................5
9 Visual Inspection.....................................................................................................5
9.1 External Visual Inspection........................................................................................5
9.2 Internal Visual Inspection........................................................................................6
10 Non-Destructive Testing........................................................................................6
10.1 Ultrasonic thickness gauging...............................................................................6
10.2 Magnetic Particle Inspection...............................................................................6
11 Integrity Calculations............................................................................................6
11.1 Calculation of Minimum Required Thickness................................................6
11.2 Calculation of Corrosion Rate.............................................................................7
11.3 Calculation of Remaining Life.............................................................................7
11.4 Calculation of Next Inspection Interval...........................................................8
12 Conclusion..................................................................................................................8
13 Attachments..............................................................................................................8

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Report :
Spherical Vessel
1 Executive Summary
In compliance with the instruction from M/s XYZ Company Limited, we attended
their Plant at above mentioned date and place.Our purpose of visit was to assess
the mechanical integrity of ammonia spherical vessel to establish the suitability of
the pressure boundary for continued operation. We have conducted visual
external and internal Inspection, Flouroscent Magnetic Particle Testing, Ultrasonic
Thickness gauging of differnet components of Sphere. Our findings are as under
which were also communicated with client representative via preliminary
inspection reports.
Inspection team comprised of the following personnel:

01 API 510 Authorized Vessel Inspector
01 Inspection Engineer
05 ASNT Level 2 Examiner
2 Abbreviations
API : American Petroleum Institute
ASNT : American Society for Non-Destructive Testing
ASME : American Society for Mechanical Engineer
ASNI : American Standards National Institute
AC : Alternating Current
DPT : Dye Penetrant Testing
FFS : Fitness for Service Analysis
IPL : Inspectest Private Limited
ID : Internal Diameter
MPI : Magnetic Particle Inspection
MFL : Magnetic Flux Leakage
NDT : Non-Destructive Testing
NBIC : National Boiler Inspection Code
NPS : Nominal Pipe Size
SCC : Stress Corrosion Cracking
RP : Recommended Practice
RT : Radiography Testing
UT : Ultrasonic Testing
UTG : Ultrasonic Thickness Gauging
VT : Visual Testing
3 Objective
For integrity assessment of vessel, external and internal visual inspection was
perfomed as per API-510 (In Service Pressure Vessel Inspection Code) to to find
conditions that could impact the vessels ability to maintain pressure integrity or

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Report :
Spherical Vessel
`
conditions. Ultrasonic thickness gauging was conducted in accordance with SE-
797 of ASME Section V and as per approved procedure. Magnetic Particle testing
was carried out as per ASME Section V article 7.
4 Scope of Work
Following Inspection and NDT techniques were used for assessment and
evaluation of different parts of pressure vessel.
To perform external and internal visual inspection by API 510 certified

inspector to locate any visible imperfection / discontinuity.
To perform flouroscent MPI on longitudinal and circumferential welds to locate
any surface opening discontinuities.
To perform UTG on shell plates, nozzles and man hole to locate any thinning
due to corrosion/erosion.
To furnish detailed inspection report along with repair recommendation (if any)
in case of unacceptable condition such as low thickness, deep and isolated
pitting or cracks etc.
5 Reference documents
Following international codes and standards were followed during inspection.
API 510 Pressure Vessel Inspection Code

API RP 572 Inspection Practices for Pressure Vessels
ASME Section VII,Div 2 Rules for construction of pressure vessel
API RP 571 ` Damage Mechanisms
API RP 577 Welding Inspection & Metallurgy
ASME Section V Nondestructive Examination
NBIC 23 Part 2 National Boiler Inspection Code
6 Deliverables
The deliverables of the work assigned as per contract were follows:

1. A comprehensive report from API authorized inspector in hard form.
2. Soft copy of report in pdf format.
7 Equipment Details
7.1 Design Detail

Following detail of Sphere was taken from available Inspection dossier and
Client;
Equipment Name : Ammonia Spherical Vessel

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Report :
Spherical Vessel
`
Manufacturer : Mitsubishi Corporation
ID : 19500 mm
Material of construction : A-537 CL2
Corrosion Allowance : 2 mm
Manufacturer Code : ASME Section VIII,Div 2
Design Pressure : 9 Bar
Operating Pressure : 5.5 Bar
Hydrotest Pressure : 11.3 Bar
Design Temperature : 60 0C
Operating Temperature : 0-40 0C
Extent of Radiography : Full
Joint Efficiency : 1
Manufacture Year : 1999
7.2 Previous Inspection Detail

Previous inspection of vessel was carried out in January, 2011. Measured
thickness of shell in 2011 was 12.10 mm. MPI was also performed, no significant
crack like flaws was observed in this inspection tenure.
8 Inspection Equipment/Tools
Following equipments were used for inspection;
Complete visual inspection kit

DMS-Go (Ultrasonic Thickness Meter)
MPI consumables
AC hand yoke
Cam gauge
Pit depth gauge
Meter Tape
Vernier Calliper
9 Visual Inspection
Vessel was properly purged and vented for entry and all the pre-requisites of
internal and external inspection were fulfilled. Platform was provide outside the
vessel for external visual inspection and lighting and scafolding was provided
inside the vessel for internal visual inspection.
9.1 External Visual Inspection
Vessel was insulated externally at the time of inspection. External visual

inspection of isulation was carried out for assessment of insulation mechanical
and operational integrity specially attention was meted out to the areas where

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Report :
Spherical Vessel
`
isulation joint ends meet and any susceptibility of protusion of water or other
external environmental fluid or debri etc was analysised visually and by
available drawings. No major discrepancy was observed during inspection and
overall condition of insulation was decalred to be satisfactory.
9.2 Internal Visual Inspection
Internal visual inspection of vessel was performed to locate any visible

imperfection / discontinuity. No signs of corrosion, pitting and buging was
observed at the time of inspection. Longitudinal and circumferential welds were
visually inspected, No signs of visible deterioration was observed.Vessel
opportenances were also inspected, found satisfactory. Special attention was
given to the areas inside vessel where localized stresses were supposed to be act
on further where internal support or other structure which can act as stress
raisers for susceptibility of Ammonia Stress Corrosion Cracking (SCC), no such
anomaly was observed visually.
10 Non-Destructive Testing
NDT inspection of Vessel was done as deemed appropriate for suitability for
service analysis. Following is the details of NDT inspection.
10.1 Ultrasonic thickness gauging
Ultrasonic thickness gauging of Tank Shell plates, openings and other

appurtenances was done. Calibrated thickness meter was used for UTG. UTG
was perfomed by taking five point on each plate. No major variation was
observed in the thickness readings. Minimum observed thickness reading was
11.81 mm. See attached report for reference.
10.2 Magnetic Particle Inspection
Flourscent MPI of longitudinal and circumferential welds from internal side for
assessments of any cracks surface or subsurface in weld joints was done.
Calibrated AC hand yoke was used for magnetization of welds. No crack like flaw
was observed at the time of inspection. Details are to be found in Appendix-D.
11 Integrity Calculations
11.1 Calculation of Minimum Required Thickness
Minimum required thickness can be calculated by using the following formula:

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Report :
Spherical Vessel
Where
t = Minimum required thickness
P = Internal Design Pressure
D = Internal Diameter
S = Maximum Allowable Stress
E = Joint Efficiency
P = 130.54 Psi, D= 19500 mm, S= 70000 Psig (From ASME Section II Part D),
E= 1 (As mentioned on drawing and on the basis of full RT)
t = 9.09 mm
11.2 Calculation of Corrosion Rate
Corrosion rate can be calculated by using the following formulae as per API 510
clause 7.1.1.1:
Where
tprevious = Measured thickness in 2011 = 12.10 mm

tactual = Measured thickness in 2016 = 11.81 mm
The corrosion rate as per above given formula was calculated as 0.058
mm/year.
11.3 Calculation of Remaining Life
Remaining life of vessel can be calculated by using the following formulkae as

per API 510 clause 7.2.1.
Where
tactual = Measured thickness in 2016 = 11.81 mm
trequired = Minimum required thickness = 9.09 mm
Corrosion Rate = 0.058 mm/year

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Report :
Spherical Vessel
The remaining life as per above given formula was calculated as 47 year.
11.4 Calculation of Next Inspection Interval
Next inspection interval as per above calculation and on the basis of API 510 is
05 year for external Visual and ultrasonic inspection and 10 years for internal
thourough inspection.
12 Conclusion
In light of our inspection and NDT techniques applied, vessel is fit for service.
Vessel shell thickness as measured during inspection satisfies the requirement of
ASME Section VIII, Div 2 determined in section 11.1 of this report. Measured
minimum value of shell is greater than minimum required thickness.
13 Attachments
Appendix-A Ultrasonic Thickness Measurement Reports
Appendix-B Photographic Presentation
Appendix-C Conceptual Sketches
Appendix-D Magnetic Particle Inspection Reports

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Visual Inspection - Sample Report For Spherical Vessel

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Report :

NDT Inspection and Integrity Date: XYX

INSPECTEST SUBJECT GROUP DATE

TITLE OF REPORT DEPARTMENT PROJECT NO.

CLIENT / SPONSOR OF PROJECT / ADDRESS CHECKED BY

WORK CARRIED OUT BY

Inspection team comprised of the following personnel:

To perform external and internal visual inspection by API 510 certified

API 510 Pressure Vessel Inspection Code

7.1 Design Detail

7.2 Previous Inspection Detail

Complete visual inspection kit

9.1 External Visual Inspection

Vessel was insulated externally at the time of inspection. External visual

9.2 Internal Visual Inspection

Internal visual inspection of vessel was performed to locate any visible

10.1 Ultrasonic thickness gauging

Ultrasonic thickness gauging of Tank Shell plates, openings and other

10.2 Magnetic Particle Inspection

Minimum required thickness can be calculated by using the following formula:

11.2 Calculation of Corrosion Rate

tprevious = Measured thickness in 2011 = 12.10 mm

11.3 Calculation of Remaining Life

Remaining life of vessel can be calculated by using the following formulkae as

11.4 Calculation of Next Inspection Interval

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