Inspection Practices for Pressure Vessels API RECOMMENDED PRACTICE 572 FOURTH EDITION, DECEMBER 2016 Special Notes API publications necessarily address problems of a general nature With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed Neither API nor any of API's employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication Neither API nor any of API's employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights API publications may be used by anyone desiring to so Every effort has been made by the Institute to assure the accuracy and 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publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005 Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standards@api.org iii Contents Page Scope Normative References 3.1 3.2 Terms and Definitions Definitions Acronyms and Abbreviations 4.1 4.2 4.3 4.4 4.5 4.6 Introduction to Pressure Vessels General Methods of Construction Materials of Construction Internal Components and Equipment Uses of Pressure Vessels 11 Design and Construction Standards 12 5.1 5.2 5.3 5.4 Reasons for Inspection General Safety Reliability and Efficient Operation Regulatory Requirements 15 15 15 16 16 6.1 6.2 6.3 6.4 6.5 Inspection Plans General Inspection for Specific Types of Damage Developing Inspection Plans Reviewing and Updating Inspection Plans RBI 17 17 17 18 18 19 7.1 7.2 Frequency and Extent of Inspection 19 General 19 Opportunities for Inspection 20 8.1 8.2 Safety Precautions and Preparatory Work 21 Safety Precautions 21 Preparatory Work 21 9.1 9.2 9.3 9.4 9.5 9.6 9.7 Inspection Methods and Limitations General Thickness Measurements External Inspection Internal Inspection Special Methods of Detecting Mechanical Damage Metallurgical Changes and In-situ Analysis of Metals Testing 24 24 24 27 36 48 49 49 10 10.1 10.2 10.3 10.4 10.5 10.6 Condition Assessment and Repair General Visual Inspection Thickness Measurements Remaining Life Methods of Repair Repair of Supporting Vessel Equipment 53 53 53 54 54 54 55 v Contents Page 11 Records and Reports 56 11.1 Records 56 11.2 Reports 56 Annex A (informative) Exchangers 57 Annex B (informative) Towers 74 Annex C (informative) Sample Record Forms 131 Bibliography 144 Figures Type 3016 Stainless-clad Vessel Weld Metal Surfacing Strip-lined Vessel Principal Strip-lining Methods 10 Hex Mesh Installation for Refractory Lining 10 Reinforced Refractory 11 Vertical Heat Exchanger 12 Horizontal Vessel 13 Spheres 14 10 Horton Spheroid (Noded) 14 11 Process Tower 15 12 Exchangers 16 13 Exchanger Installation and Foundation 28 14 Severe Deterioration of Anchor Bolts 29 15 Method of Obtaining Vessel Profile Measurements 35 16 Corrosion in Channel 38 17 Crack in Weld Seen by PT 39 18 Hydrogen Blistering 41 19 Self-vented Hydrogen Blisters 41 20 Radiograph of Self-vented Hydrogen Blisters in Carbon Steel 42 21 Catalytic Reactor Internals—Cyclones 43 22 Corrosion Tab Method of Determining Metal Loss on Vessel Linings 45 23 Strip-liner Damage 46 24 Deteriorated Refractory-tile Lining 48 25 Steps in Using Special Equipment to Test Individual Tubes 52 A.1 Properly Rolled Tube 58 A.2 Tube-bundle Type of Tank Heater 60 A.3 Air-cooled Exchangers 61 A.4 Clean-service Double-pipe Coils 62 A.5 Tank Suction Heater with Everything but Forward End Enclosed; Shell Suction Nozzle Enclosed in Far End 63 A.6 Fin-type Tubes in Double-pipe Coil 64 A.7 Plate-type Exchanger 64 A.8 Tubes Thinned at Baffles 66 A.9 Tubes Fretting at Baffles 67 A.10 Erosion–Corrosion Attack at Tube Ends 67 A.11 Heat Exchanger Parts 70 A.12 Heat Exchanger Types 73 B.1 Typical Trays in a Tower 74 B.2 Random Packing in a Tower 74 Contents Page B.3 B.4 B.5 B.6 B.7 B.8 B.9 B.10 B.11 B.12 B.13 B.14 B.15 B.16 B.17 B.18 B.19 B.20 B.21 B.22 B.23 B.24 B.25 B.26 B.27 B.28 B.29 B.30 B.31 B.32 B.33 B.34 B.35 B.36 B.37 B.38 B.39 B.40 B.41 B.42 B.43 B.44 B.45 B.46 B.47 B.48 B.49 B.50 B.51 Trays with Downcomers 75 Bubble Cap Flow Path 75 Tower Stripping and Rectification Section 76 Disk/Donut Tray 77 Baffle Tray Arrangement 78 Figure Tray 79 Sieve Tray Distortion 79 Typical Trayed Tower 82 Float Valves with Two Weights 83 Fixed Valves 83 Bubble Cap Valves 84 Extruded Valves 84 New Floating Valve Tray 85 Caged Valves 85 Typical Packed Tower Drawing 86 Random Packing, Pall Rings 87 Structured Packing 87 Grid-style Packing 88 Diagram of Required Scaffolding 90 Hexagonal Manways 91 Standing Oil and Water 91 Trays Collapsed 92 Corroded Anchor Bolting 92 Corroded Anchor Bolting 93 Cracked and Bulged Fireproofing 93 Debris in Skirt 94 Preliminary Inspection 94 Bed Damage at Preliminary Inspection 95 Manway Corrosion 95 Manway Liner Damage 96 Corrosion on Gasket Seating Surface 96 Corrosion on Gasket Seating Surface 97 Surface Corrosion of Shell 97 Inspection from the Bottom Head 98 Inspection of Packing via Riser 98 Demister Bypass Deposits 99 Fouled Demister Pads 99 Faulty Demister Installation 100 Preferential Corrosion of the Head-to-Shell Weld 100 Head Seam Preferential Corrosion 101 Preferential Corrosion of the Shell 101 Perforation Degradation 102 Chimney Tray Deformation at Draw Sump 102 Fouled Troughs on Box and Trough Distributor 103 Obstructed Pipe Distributor Perforations 103 Box and Troughs 104 Hit the Washers, Not the Bolts 104 Random Packing on Valve Tray 105 Bed Limiter Above Random Packing 105 Contents Page B.52 B.53 B.54 B.55 B.56 B.57 B.58 B.59 B.60 B.61 B.62 B.63 B.64 B.65 B.66 B.67 B.68 B.69 B.70 B.71 B.72 B.73 B.74 B.75 B.76 B.77 B.78 B.79 B.80 B.81 B.82 B.83 B.84 B.85 B.86 B.87 B.88 B.89 B.90 B.91 B.92 B.93 B.94 B.95 B.96 B.97 Dislodged Packing Damaged Packing Support Grid Support Grid from Below Corrosion Inside Sightglass Nozzle Bottom Head, Vortex Breaker, and Debris Fouled Grid-type Packing Cracked Plug Weld Stainless Steel Donut Cladding Breech Cladding Breech at Gouges in Bottom Head 410 Stainless Steel Clad to Carbon Steel Interface Weld Supplemental UT Markings Cracking at Tray Support Ring Weld WFMPT Discovered Cracking Supplemental NDE May Be Needed Areas of Chemical Activity Areas of Activity Hardware Corrosion Stuck Valves Always Open Clean Square-edged Perforation Valve Fretting Slotting from Below Valve Leg and Perforation Inspection Indentation of Valves New Caged Valves with Dimples New Caged Valve Cage Tabs Small Fixed Valves Fixed Valved Lateral Vapor Directional Flow Removable Fixed Valves Reduce Fouling Removable Fixed Valves Tray Damage Bubble Caps on Stepped Trays Fibrous Deposits and Fouling Under Bubble Caps Tray Deck Should Be Scraped Clean Tray Fatigue Cracking Light-to-moderate Weir Corrosion Loose and Missing Hardware Failure Downcomer and Seal Pan Clamps Loose Downcomer Clamp Loose Tray Support Ring Corroded to Failure Shell Corroded to Half Wall Adjacent Top Three Rings Support Ring Grooving Deposits Adjacent to Shell Are on Ring Cracking of Ring Attachment Weld Tray Support Ring Butt Weld Cracking Breeching of the Seal Weld Shadowing Inside the Downcomer Shadow the Downcomer Shell Every Tray 106 106 107 107 108 109 109 110 110 111 111 112 113 113 114 114 115 115 116 116 117 117 118 118 119 120 120 121 121 122 122 123 124 124 125 125 126 126 127 127 128 128 129 129 130 130 Inspection Practices for Pressure Vessels Scope This recommended practice (RP) supplements API 510 by providing pressure vessel inspectors with information that can improve skills and increase basic knowledge of inspection practices This RP describes inspection practices for the various types of pressure vessels (e.g drums, heat exchangers, columns, reactors, air coolers, spheres) used in petroleum refineries and chemical plants This RP addresses vessel components, inspection planning processes, inspection intervals, methods of inspection and assessment, methods of repair, records and reports API 510 has requirements and expectations for inspection of pressure vessels Normative References The following referenced documents are indispensable for the application of this document For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies API 510, Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair, and Alteration API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry API Recommended Practice 574, Inspection Practices for Piping System Components API 579-1/ASME FFS 1, Fitness-For-Service API Recommended Practice 580, Risk-Based Inspection API Publication 2217A, Guidelines for Safe Work in Inert Confined Spaces in the Petroleum and Petrochemical Industries ASME Boiler and Pressure Vessel Code (BPVC), Section VIII: Pressure Vessels Terms and Definitions 3.1 Definitions For the purposes of this document, the following definitions apply 3.1.1 alteration A physical change in any component that has design implications that affect the pressure-containing capability of a pressure vessel beyond the scope described in existing data reports The following should not be considered alterations: any comparable or duplicate replacement, the addition of any reinforced nozzle less than or equal to the size of existing reinforced nozzles, and the addition of nozzles not requiring reinforcement 3.1.2 cladding A metal integrally bonded onto another metal under high pressure and temperature whose properties are better suited to resist damage from the process than the substrate material ASME International, Park Avenue, New York, New York 10016, www.asme.org API PUBLICATION 572 3.1.3 condition monitoring locations CMLs Designated areas on pressure vessels where periodic examinations are conducted in order to directly assess the condition of the vessel CMLs may contain one or more examination points and utilize multiple inspection techniques that are based on the predicted damage mechanism to give the highest probability of detection CMLs can be a single small area on a pressure vessel (e.g a in diameter spot or plane through a section of a nozzle where recording points exist in all four quadrants of the plane) NOTE CMLs now include but are not limited to what were previously called TMLs 3.1.4 corrosion specialist A person, acceptable to the owner/user, who has knowledge and experience in corrosion damage mechanisms, metallurgy, materials selection, and corrosion monitoring techniques 3.1.5 corrosion under fireproofing CUF Corrosion of piping, pressure vessels, and structural components resulting from water trapped under fireproofing 3.1.6 corrosion under insulation CUI External corrosion of carbon steel piping, pressure vessels, and structural components resulting from water trapped under insulation External chloride stress corrosion cracking of austenitic and duplex stainless steel under insulation is also classified as CUI damage 3.1.7 damage mechanism Any type of damage encountered in the refining and chemical process industry that can result in flaws/defects that can affect the integrity of vessels (e.g corrosion, cracking, erosion, dents, and other mechanical, physical, or chemical impacts) See API RP 571 for a comprehensive list and description of damage mechanisms 3.1.8 damage mode The physical manifestation of damage (e.g wall thinning, pitting, cracking, rupture) 3.1.9 defect One or more flaws whose aggregate size, shape, orientation, location, or properties not meet specified acceptance criteria and are rejectable 3.1.10 design temperature The temperature used in the design of the pressure vessel per the applicable construction code DATE NOTE: MANUFACTURER’S DRAWING CAN BE USED TO SHOW THE LOCATION OF A, B, C, AND D DATE D DESCRIPTION OF LOCATION C DATE B DESCRIPTION OF LOCATION A DATE D DESCRIPTION OF LOCATION C DATE B A B C MINIMUM ALLOWABLE METAL THICKNESS AT CRITICAL POINTS A CORROSION ALLOWANCE DESCRIPTION OF LOCATION A MAXIMUM METAL TEMPERATURE AT CRITICAL POINTS A ORIGINAL THICKNESS WORKING PRESSURE B B D OWNER OWNER MAXIMUM ALLOWABLE ORIGINAL HYDROSTATIC DESIGN PRESSURE MANUFACTURER’S SERIAL NO DESCRIPTION OF LOCATION DATE OF INSPECTION THICKNESS AT CRITICAL POINTS INSPECTION RECORD FOR PRESSURE VESSEL IN SERVICE MANUFACTURER NATIONAL BOARD NO JURISDICTION OR OWNER OR USER NO DATE OF NEXT INSPECTION C C TEST PRESSURE TEMPERATURE DATE DATE D SIGNATURE OF INSPECTOR D 132 API PUBLICATION 572 INSPECTION PRACTICES FOR PRESSURE VESSELS 133 NAME OF UNIT VESSEL NAME PERMANENT PRESSURE VESSEL RECORD LOCATION ORIGINAL ITEM NO DATE HISTORY ESTIMATE NO MANUFACTURER’S TEST PRESSURE ORDER NO DATE RECEIVED MANUFACTURED BY DATE INSTALLED MANUFACTURER’S SERIAL NO COMPANY NO MANUFACTURER’S INSPECTOR COMPANY INSPECTOR DESCRIPTION REINFORCEMENT GENERAL FACTORY OR FIELD DRAWING NO TOP HEAD TYPE FABRICATOR’S CONTRACTOR’S ELLIPTICAL COMPANY DISHED CROWN REGION POSITION (VERTICAL OR HORIZONTAL) YEAR CODE STAMP MATERIAL SPECIFIED AND GRADE OR TYPE FLAT JOINT EFFICIENCY ORIGINAL THICKNESS BASE CORROSION ALLOWANCE LINING MANWAYS THICKNESS NO STRESS RELIEVED (ORIGINAL) SIZE RADIOGRAPHED (ORIGINAL) FLANGE RATING COMPLETE WELD INTERSECTION SIZE REINFORCEMENT FACTORY OR FIELD BOTTOM HEAD TYPE NOMINAL INSIDE DIAMETER ELLIPTICAL LENGTH BASE LINE TO BASE LINE DISHED DESIGN PRESSURE, PSI TEMPERATURE, °F STRESS, PSI CROWN REGION FLAT ORIGINAL THICKNESS CORROSION ALLOWANCE TYPE OF CONSTRUCTION MANWAYS NO SIZE JOINT EFFICIENCY FLANGE RATING TYPE OF SUPPORT REINFORCEMENT INTERIOR OR EXTERIOR STIFFENERS ORIGINAL THICKNESS CORROSION ALLOWANCE MANWAYS NO SIZE KNUCKLE REGION JOINT EFFICIENCY MAXIMUM ALLOWABLE TEMPERATURE, °F SHELL HEMISPHERICAL CONICAL (ANGLE) MAXIMUM ALLOWABLE OPERATING PRESSURE, PSI LIMITED BY KNUCKLE REGION CONICAL (ANGLE) CODE CONSTRUCTED CODE HEMISPHERICAL FACTORY OR FIELD NOZZLES MINIMUM FLANGE RATING TYPE FACING OPENINGS REINFORCED REMARKS FLANGE RATING NOTE: A COPY OF THIS SHEET SHALL BE PREPARED FOR EACH INDIVIDUAL VESSEL IN A UNIT IF NEW VESSELS ARE INSTALLED OR ANY CHANGES ARE MADE TO PRESENT VESSELS AFFECTING THE DESCRIPTION ITEMS, A NEW OR REVISED COPY OF THIS SHEET SHALL BE SUBMITTED WITH THE CURRENT INSPECTION REPORT 134 API PUBLICATION 572 UNIT NAME OF VESSEL VESSEL INSPECTION SHEET DIAMETER LENGTH VESSEL NO DRAWINGS SHELL LINING INTERNAL FABRICATOR CONTRACTOR COMPANY SKETCH WALL THICKNESS MEASUREMENTS POINT NO MINIMUM INSPECTION INTERVALS NO ORIGINAL ALLOWABLE THICKNESS THICKNESS DATE INSPECTION PRACTICES FOR PRESSURE VESSELS 135 UNIT NAME OF VESSEL VESSEL INSPECTION SHEET DIAMETER LENGTH VESSEL NO DRAWINGS SHELL LINING INTERNAL FABRICATOR CONTRACTOR COMPANY 2’-0” 2’-6” 4’-0” 000 cone 15 Spaces at 2’-6” = 37’-6” all trays 4-6% Cr 0.05% Mo 11 Stiffeners at 2’-6” centers (4” x 4” x 3/4” s-Cs) 2’-6” 97’-6” B.L to B.L 59’-0” MINIMUM NO ALLOWABLE THICKNESS THICKNESS 11/2 in 02063A in 12 in 02059A in in Base line 1’-6” 19’-0” POINT NO ORIGINAL 3’-0” 2’-0” 12 Stiffeners at 2’-6” centers (5/8” x 3” bars-S.S.) 2’-6” WALL THICKNESS MEASUREMENTS INTERVALS 18 in Manway x T-3 T-2 T-1 24 in 1 /2 in 14 in 02042C 14 in 02040C 10 in 02012C 5’-0” 34’-6” INSPECTION 10 in Steam inlet Spiral horn 5% CrMo T-4 02110A x 24 in Manway Spaces at 2’-0” 12 in T-6 T-5 T-7 T-8 T-9 T-11 T-10 T-12 T-13 T-14 T-16 T-15 T-17 T-18 T-19 T-20 T-21 T-23 T-25 T-26 3’-0” clad 15% ASTM A 240, Type 410 6’-6” 12 in 02053E 12 in.4 02054E 11/2 in 10 in 02049C 24 in Manways 14 in 02057E 10’-0” clad 15% cladding ASTM A 240, Type 410 X 10 in 02112C 10 in 02034C T-22 X 10 in 24 in Manways T-24 X T-27 T-28 T-29 T-30 12 in HH 10 in 02032B 02015B 0000 4’-6” 24 in 24 in 02111B Tray spaces at 2’-6” = 22’-6” 13 Stiffeners at 2’-6” centers (3” x 3” x 1/4” s-Monel) 11’-6” Base line 24 in Manway 6’-0” 24 in Manways 3’-0” Raschig rings 14 in 02043C 10 in 02048C 13’-10” clad R 15% Monel cladding (S8-160) 10 in 02013C 24 in Manways 14 in 02041C SKETCH DATE 136 API PUBLICATION 572 UNIT NAME OF VESSEL VESSEL INSPECTION SHEET DIAMETER LENGTH VESSEL NO DRAWINGS SHELL LINING INTERNAL FABRICATOR CONTRACTOR COMPANY SKETCH in Base line 3’-0” 18-8 S.S A 167 Gr Installed 12/47 3’-10” C.I trays 39’-01/2” 1/ X 4’-6” 4’-0” Lug level 3 in 23’-65/8” in Relief valve in Vapor 24 in Manway in X X 1’-91/2” 4’-10” 11/2 in Makeup Spaces at 1’-6” = 10’-6” 4-6% Cr 1/ in thick 440 sq coil 11’-0” 5’-0” Installed 4/53 Hexteel gunite Dwg 3-440 in Thick in 12’-0” Installed 10/50 11/2 in Base line in Cleanout suct X X 4-6% Cr 1/ in thick 1’-0” 16 in 6’-5” 20 in Manway 6’-0” I.D WALL THICKNESS MEASUREMENTS POINT NO MINIMUM INSPECTION INTERVALS NO ORIGINAL ALLOWABLE THICKNESS THICKNESS DATE EXTENT INSPECTION UNDER INSULATION OUTSIDE WELDS INSIDE WELDS LAST INSPECTION BOTTOM TOP HEAD FACTOR HEADS SHELL JOINT EFFICIENCY BOTTOM HEAD TOP HEAD LOCATION SHELL MINIMUM THICKNESS NOMINAL INSIDE DIAMETER INSPECTOR INSPECTION AND TEST DATA NO COILS NO BAFFLES NO TRAYS BOTTOM TOP AVERAGE MAXIMUM OPERATING TEMPERATURE, °F AVERAGE MAXIMUM OPERATING PRESSURE, PSI SERVICE DATA HOURS UNDER PRESSURE TO DATE OPERATING DATA COMPANY VESSEL AND SKETCH NO NAME OF VESSEL RECORD OF ALL PRESSURE VESSELS ON AN OPERATING UNIT (SHEET 1) DATE INSPECTION AND TEST NO LOCATION NAME OF UNIT INSPECTION PRACTICES FOR PRESSURE VESSELS 137 REMARKS CAUSE OF REMOVAL DATE PREVIOUS LINING REMOVED EXTENT OF REPAIRS DATE REPAIRED SECTION LINED MATERIAL AND TYPE DATE INSTALLED DRAWING NO PROTECTIVE LINING DATA SAFETY VALVE SETTING, PSI APPROVED OPERATING TEMPERATURE, °F APPROVED OPERATING PRESSURE, PSI TEMPERATURE, PSI WORKING STRESS AT OPERATING LIMITED BY TEMPERATURE, °F MAXIMUM ALLOWABLE OPERATING MAXIMUM ALLOWABLE OPERATING PRESSURE, PSI TIME PRESSURE HELD -(1) + (2) TEST MEDIUM COILS, PSI VESSEL, PSI TEST PRESSURE COMPANY VESSEL AND SKETCH NO NAME OF VESSEL RECORD OF ALL PRESSURE VESSELS ON AN OPERATING UNIT (SHEET 2) DATE INSPECTION AND TEST NO LOCATION NAME OF UNIT 138 API PUBLICATION 572 E 10 B E Floating head W T B Tubes Type Shell cover T Fluid thru Temperature Pressure Size Material Mfr Design Data: W Shell E 11 B T Channel cover 12 13 14 W DATE 1 10 11 12 13 14 15 16 17 18 19 20 10 11 12 13 14 15 16 17 18 19 20 TELL TALE HOLD CALIPERED WELDED TEST PLUG REMOVABLE TEST PLUG NOZZLE LOCATIONS WITH THICKNESS MEASURED IN 0.01 INCHES DRILL POINT LOCATIONS WITH THICKNESS MEASURED IN 0.01 INCHES REVISIONS LEGEND ORIGINAL THICKNESS DATE ORIGINAL THICKNESS INSPECTION PRACTICES FOR PRESSURE VESSELS 139 EXCHANGER INSPECTION FIELD DATASHEET 19 18 20 17 X 16 15 X 14 11 13 12 10 X X Shell Temp X Bundle Tubes: Size Mat Design: Press Temp Tube Sheet Mat Baffle Mat Balance Mat Type: Design: Pressure Corrosion Allow.: Material 3 1 10 11 12 13 14 15 16 17 18 19 20 DATE SCALE SHOWN DRAWN BY CHECKED BY APPROVED BY X DRAWING NO REVERSE SIDE SIDE SHOWN 10 11 12 13 14 15 16 17 18 19 20 TELL TALE HOLD a WELDED TEST PLUG NOZZLE LOCATIONS WITH THICKNESS MEASURED IN 0.01 INCHES REMOVABLE TEST PLUG 2 DRILL POINT LOCATIONS WITH THICKNESS MEASURED IN 0.01 INCHES REVISIONS LEGEND DATE ORIGINAL THICKNESS DATE ORIGINAL THICKNESS 140 API PUBLICATION 572 EXCHANGER DATA RECORD INSPECTION PRACTICES FOR PRESSURE VESSELS 141 EXCHANGER INSPECTION REPORT FORM TO: DATE UNIT EQUIPMENT SERVICE DOWN TIME RETURNED TO SERVICE DATE OF LAST INSPECTION REASON INSPECTION COMMENTS MINIMUM THICKNESS ORIGINAL LAST INSPECTION PRESENT SHELL SHELL COVER CHANNEL CHANNEL COVER TOP NOZZLE (SHELL) BOTTOM NOZZLE (SHELL) TOP NOZZLE (CHANNEL) BOTTOM NOZZLE (CHANNEL) TUBES RECOMMENDATIONS WORK REQUESTED BY INSPECTED BY CC: SIGNED CHIEF INSPECTOR RETIRING THICKNESS 142 API PUBLICATION 572 AIR COOLER EXCHANGER INSPECTION REPORT FORM NAME OF UNIT PLANT A B C D E F G H I EXCHANGER NAME ORIG ITEM NO PLANT NO PLUG TYPE – REMOVABLE HEADER 10 15 20 25 30 35 40 45 50 10 15 20 25 30 35 40 45 50 DATE ORIG EXCH INST DATE PREV BDLE INST A B C D E F G H I CAUSE REMOVAL DATE PRES BDLE INST MAT’L HANDLED DESIGN – PRESS PSI TEMP °F OPER – PRESS PSI 10 15 20 25 30 35 40 45 50 TEMP °F TUBE – MATERIAL North-South East-West – DIAMETER – THICK – LENGTH East-West North-South FIN – MATERIAL THICKNESS DATA DATE POINT NO INSP INT NO INSP & TEST DATA DATE GENERAL CONDITION CHANNEL SECTION TUBE SECTION FINS FAN FAN HOUSING NO TUBES PLUGGED CHEMICALLY CLEANED MAX ALLOW PRESS PSI TEMP °F TEST PRESS PSI APPROVED – PRESS PSI TEMP °F ORIG THK PREV MIN INSPECTION PRACTICES FOR PRESSURE VESSELS 143 DOUBLE-PIPE EXCHANGER INSPECTION REPORT FORM NAME OF UNIT PLANT EXCHANGER NAME ORIG ITEM NO 12 PLANT NO SERVICE DATA DATE INT TUBE INST 10 DATE PREV INT TUBE INSTALLED REMOVED 11 CAUSE REMOVAL DATE EXTER TUBE INSTALLED REMOVED THICKNESS DATA CAUSE REMOVAL DATE POINT NO OPERATING DATA INSP INT TYPE OF SERVICE INT PIPE NO ORIG THK PREV MIN EXT PIPE STATE OF MEDIUM MED OR MAT’L HAND DESIGN – PRESS PSI TEMP °F OPER - PRESS PSI TEMP °F 10 11 12 13 INSP & TEST DATA DATE INSPECTION INTERVAL LIMITING - INT TUBE THK LIMITING - A TUBE THK GENERAL CONDITION INT TUBE SECTION EXT TUBE SECTION INT TUBE MATERIAL EXT TUBE MATERIAL DATE LAST INSPECTED CHEMICALLY CLEANED INT MAX ALL - PRESS PSI TEMP °F EXT MAX ALL - PRESS PSI TEMP °F INT TEST PRESS PSI EXT TEST PRESS PSI INT TUBE EXT TUBE INT TUBE EXT TUBE INT TUBE EXT TUBE INT TUBE EXT TUBE INT TUBE EXT TUBE INT TUBE EXT TUBE Bibliography [1] API Recommended Practice 577, Welding Inspection and Metallurgy [2] API Recommended Practice 581, Risk-Based Inspection Methodology [3] API Recommended Practice 583, Corrosion Under Insulation [4] API Recommended Practice 584, Integrity Operating Windows [5] API Recommended Practice 585, Pressure Equipment Integrity Incident Investigations [6] API Standard 660, Shell-and-Tube Heat Exchangers [7] API Standard 661, Air-Cooled Heat Exchangers for General Refinery Service [8] API Recommended Practice 751, Safe Operation of Hydrofluoric Acid Alkylation Units [9] API Recommended Practice 932-B, Design, Materials, Fabrication, Operation, and Inspection Guidelines for Corrosion Control in Hydroprocessing Reactor Effluent Air Cooler (REAC) Systems [10] API Recommended Practice 936, Refractory Installation Quality Control Guidelines—Inspection and Testing Monolithic Refractory Linings and Materials [11] API Recommended Practice 945, Avoiding Environmental Cracking in Amine Units [12] ASME PCC-2, Repair of Pressure Equipment and Piping 144 Product No C57204