Inspection Summary - V-1000C

Non Intrusive Inspection of TUCO C
Train Scrubbers (V-1000 C)

Inspection Summary
JKHI No: JKHI-150230

Rev: 00
Page: 1 of 6
Date: 25-05-2015
NON INTRUSIVE INSPECTION OF PHASE-1 HP 1ST STAGE SUCTION

SCRUBBER (V-1000C)
Project Title:
Non Intrusive Inspection of TUCO C Train Scrubbers
Client:
Pakistan Petroleum Limited
Contract Ref No:
Call Out Agreement (COA) No. 4600000468
Location:
Kandhkot Field Gas Compression Site, Kandhkot (KFGCS)
Inspection Date:
14th May to 17th May, 2015
1.0
Introduction:
As per instructions of M/s Pakistan Petroleum Limited, SGS Pakistan team visited Kandhkot Field Gas
Compression Site, Kandhkot in order to carry out Non Intrusive Inspection of Suction Scrubber V-1000C;
Subject vessel was manufactured in 2008 (reference to Name Plate / data sheets available with the client).
Details of vessel collected from Name plate / client data sheet at the time of inspection is,
Vessel Tag:
Manufacturer:
Service:
Material:
Design Pressure:
Design Temperature:
Date Manufactured:
Design Thickness S/H:
Corrosion Allowance S/H/N:
Years in Service:
V-1000C (Suction Scrubber)

DESCON ENGINEERING LIMITED
Natural Gas
SA-516 Gr 70
6895 kPa (G)
-29 to 160 C
2008
70/70
6 mm
7 Years
Subject vessel V-1000C is required to undergo periodic inspection as per API-510 to ensure continued safe
and reliable operation. Traditionally this has been achieved by means of an internal visual inspection (IVI),
however very high costs are associated with shutting down a vessel (loss of production), isolating it and
preparing it for entry. Indeed, these costs can be much higher than the cost of the inspection itself.
Furthermore, the mechanical disturbances involved in preparing the vessel for internal inspection and
reinstating it may adversely affect its future performance. It would be of significant advantages if
inspections are performed from the outside of the vessel without breaking containment i.e. non-invasively.
2.0
Scope of Work:
Scope of work for the subject vessel included the following techniques to cover 100% of vessel;
Visual Inspection.
Ultrasonic A Scanning.
Ultrasonic Thickness Gauging.
This document is issued by the Company under its General Conditions of Service accessible at http://www.sgs.com/terms_and_conditions.htm. Attention is drawn to the limitation of liability, indemnification and
jurisdiction issues defined therein. Any other holder of this document is advised that information contained hereon reflects the Companys findings at the time of its intervention only and within the limits of Clients
instructions, if any.
The Companys sole responsibility is to its Client and this document does not exonerate parties to a transaction from exercising all their rights and obligations under the transaction documents.
Any unauthorized alteration, forgery or falsification of the content or appearance of this document is unlawful and offenders may be prosecuted to the fullest extent of the law.
Title: Inspection Summary Report, Ref: IND-QMS-FOR- 121, Revision: 00, Page: 1 of 1, Dated: 01-10-2014

Inspection Summary
3.0

Rev: 00
Page: 2 of 6
Date: 25-05-2015
Time of Flight Diffraction (complemented with Ultrasonic Flaw detection).

Phased Array.
Flange Face Scanning.
Surface Eddy Current Testing.
Inspection Findings:
Inspection has been carried out at KFGCS, Kandhkot, in order to ascertain the health of Suction Scrubber
V-1000C while in service, below are the inspection findings,
3.1
External Visual Inspection:
External visual inspection was carried out by API-510 Inspector; the detail of findings is given below;
Over all external surface condition found satisfactory with minor paint deterioration.
Nuts and bolts of attached nozzle flanges of almost all nozzles and other bolted attachments found
minor corroded.
Minor corrosion found on flanges of almost all nozzles.
Crevice corrosion found along the weld of the Lifting Lug1 and Lifting Lug2 with the Shell due to
entrapment of moisture.
Minor mechanical gouges found on the surface of the vessel between 90 and 135 and near LS-1 in
Shell-1.
Some bolts at the top nozzle N-2 found short length.
Paint deterioration found at some locations on the vessel shell and platforms.
Attachment welded with shell, below Man Way platform, found bent.
Cracks found in the concrete skirt all along the circumference.
Cracks found in the foundation and floor which might cause entrapment of water and further
deterioration of foundation and floor.

Cracks found in the foundation of ladder which might cause entrapment of water.
Pressure gauge found faulty, observed pressure value to be 0 while vessel is in pressurized
condition, pressure gauge (PG-1011B) found without calibration tag at nozzle N-8.
Grounding connection found in satisfactory condition.
Pressure safety of the vessel was ensured through nozzle N-3 leading to the flare header.
Report of Visual inspection is attached as Annexure-A.
3.2
Time of Flight Diffraction (ToFD) / Ultrasonic Flaw Detection (UFD):
Time of Flight Diffraction (ToFD) in complement with Ultrasonic Flaw Detection (UFD) was used for the
scanning of circumferential and longitudinal welds of vessel in order to identify cracking or any other
defects in or near weld joints.
No major anomalies were found during the ToFD / UFD of circumferential and longitudinal butt welds.
Report of Time of Flight Diffraction is attached as Annexure-D.

Inspection Summary
3.3

Rev: 00
Page: 3 of 6
Date: 25-05-2015
Phased Array:
Phased Array (PA) examination technique was used for the scanning of nozzle welds of vessel in order to
identify cracking or any other defects in or near weld joints.
No major anomalies were found during the Phased Array of nozzle welds.
Report of Phased Array is attached as Annexure-E.
Inaccessible area in CW1:
Lifting lug 1 start from (1000mm to 1450mm) long seam start from( 2750 to 2815) Lifting lug 2 start from
(5050mm to 5500mm)
Inaccessible area in CW4:
Platform support start from (5350mm to 6950mm)
All accessible Circular Seam, Nozzles, Flanges could be scanned. Data disturbance observed due to pass
scanner over the inaccessible areas i.e. Attachments, long seams & Nozzles obstruction.)
3.4
Shell, End Plates and Nozzles A scanning and UT Gauging:
Ultrasonic A-scanning carried out on shell external surface, dish ends, Nozzles, man ways in order to
identify uniform or localized wall loss due to corrosion, erosion or pitting (The only excepted area is the
base metal area inaccessible due to Lifting Lugs 1 & 2, area of the vessel adjacent to permanent platform
and small area of the bottom dish end just under the shell to dish end joint due to geometry of skirt).
Ultrasonic thickness gauging was performed on the 100% of the vessel to obtain representative readings
from all parts.
No metal loss was observed during the A scanning of shell external surface, both dish ends, nozzles necks,
Nozzles Reinforcement plates, Man way neck, Man way cover plate and Man way Reinforcement plate.
Minimum thickness measured by UTG was found to be 68.80 mm on shell, 69.19 mm on Top Dish end and
69.76 mm on Bottom Dish end.
Ultrasonic A Scanning report is attached as Annexure B Ultrasonic Thickness Gauging report is attached as
Annexure C. TML ID Sketch is attached as Annexure H.
3.5
Minimum thickness observed on Shell is

Minimum thickness observed on Top Dish end is
Minimum thickness observed on Bottom Dish end is
68.80 mm.
69.19 mm.
69.76 mm.
Flange Face Scanning:
Flange Face Scanning technique was carried out to identify any metal loss on flanges due to corrosion,
erosion, pitting etc.
No major anomalies were found during the flange face scanning of flanges scanned.
Report of flange face scanning is attached as Annexure-F.
All accessible, Flanges could be scanned. Data disturbance observed due to pass scanner over the
inaccessible areas i.e. Attachments & Valves obstruction.

Inspection Summary
3.6

Rev: 00
Page: 4 of 6
Date: 25-05-2015
Surface Eddy Current Testing:
Eddy current testing, based on electromagnetic induction principle, was used to find surface or sub surface
defects in nozzle welds and attachment welds.
No major anomalies were found during the surface eddy current testing of nozzles and attachment welds
scanned.
Report of surface eddy current testing is attached as Annexure-G.
4.0
Calculation of Shell thickness According to Code Applicable Formula:
The design parameters available at the time of inspection are as follows;
Design Pressure:
Inner Radius
Material Stress
Joint efficiency
Minimum Required Thickness
P
R
S
E
t
=
=
=
=
=
1000 psi (G)

[6895 kPa (G)]
48 inch
20,000 psi (G) (SA-516 Gr. 70)
1.0
?
As per above values and design parameters the minimum required thickness of vessel is calculated as
62.84 mm for shell and 61.27 mm for dish ends through the applicable formula as per ASME Sec VIII Div
I for shell and dish ends.
5.0
Determination of Corrosion Rate:
As the original thickness of the vessel is obtained from the provided design data, Long term Corrosion rate
of the tank is determined with following formula from API-510;
For Shell:
Long Term Corrosion rate
t original t actual
Time b/w t original t actual (years)
70.0 68.80
7
0.17 mm / year
For Dish End:

6.0
t original t actual
Time b/w t original t actual (years)
70.0 69.19
7
0.118 mm / year
Remaining Life:

Inspection Summary

Rev: 00
Page: 5 of 6
Date: 25-05-2015
The remaining life of the subject suction scrubber V-1000C is calculated on the basis of inspection data as
35 years for shell and 67 years for dish ends.
7.0
Next Inspection Interval:
As per API 510 recommended next inspection interval are as follows.

External Inspection:
05 years
Internal Inspection:
10 years
8.0
Maximum Allowable Working Pressure (MAWP):
In corrosive service, the wall thickness used in these computations of MAWP shall be the actual thickness
as determined by inspection minus twice the estimated corrosion loss before the date of the next
inspection, as defined by:
t = tactual 2(Crate Iinternal)
The maximum Allowable Working Pressure (MAWP) for next internal inspection is calculated to be 1039
Psi(G) for the shell and 1089 Psi(G) for dish ends.
9.0
Recommendations:
In the light of findings during visual inspection and analysis of the NDT data, following are the
recommendations for the subject suction scrubber V-1000C;
The affected areas, due to paint deterioration and corrosion, of the subject Suction Scrubber V1000C external surface, nuts, bolts, flanges, lifting lugs crevices and platform needs to be cleaned
and painted as per project specifications.

The mechanical gouged areas mentioned above should be monitored regularly for any surface
defects.
The lack of complete engagement of the fasteners must not be more than one thread.
All pressure monitoring devices (pressure gauges, pressure safety valve etc) should be calibrated
annually and their record shall be maintained.

Cracks in the concrete skirt support, ladder foundation and floor need to be rectified as per project
specifications.
10.0
Conclusion:
On the basis of collected Non Intrusive Inspection data and its evaluation it has been concluded that there
is no major wall loss in the pressure boundary and no major / repairable defect in all the welds of the
vessel. Thickness of the base metal is sufficient enough to operate vessel on design pressure, hence the
subject Suction Scrubber V-1000C is SAFE to operate at design temperature and pressure till the next
inspection interval.

Inspection Summary
11.0

Rev: 00
Page: 6 of 6
Date: 25-05-2015
Attachments:
Report of Visual Inspection as
Annexure A
Ultrasonic A-Scanning Reports as

UT Thickness Gauging Reports as
ToFD / UFD Reports as
Phased Array Reports as
Flange Face Scanning as
Surface Eddy Current Testing
TML ID Sketch as
Annexure B
Annexure C
Annexure D
Annexure E
Annexure F
Annexure G
Annexure H
Particulars
Prepared By
Reviewed By
Signature
Name:
Ahmad Hasan
Syed Muhammad Ali
Date:
05/06/2015
05/06/2015

Inspection Summary - V-1000C

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Non Intrusive Inspection of TUCO C

Train Scrubbers (V-1000 C)

JKHI No: JKHI-150230

NON INTRUSIVE INSPECTION OF PHASE-1 HP 1ST STAGE SUCTION

Non Intrusive Inspection of TUCO C Train Scrubbers

Pakistan Petroleum Limited

Contract Ref No:

Call Out Agreement (COA) No. 4600000468

Kandhkot Field Gas Compression Site, Kandhkot (KFGCS)

14th May to 17th May, 2015

V-1000C (Suction Scrubber)

Non Intrusive Inspection of TUCO C

JKHI No: JKHI-150230

Time of Flight Diffraction (complemented with Ultrasonic Flaw detection).

External Visual Inspection:

deterioration of foundation and floor.

Report of Visual inspection is attached as Annexure-A.

Time of Flight Diffraction (ToFD) / Ultrasonic Flaw Detection (UFD):

Non Intrusive Inspection of TUCO C

JKHI No: JKHI-150230

Shell, End Plates and Nozzles A scanning and UT Gauging:

Minimum thickness observed on Shell is

Flange Face Scanning:

Non Intrusive Inspection of TUCO C

JKHI No: JKHI-150230

Surface Eddy Current Testing:

Calculation of Shell thickness According to Code Applicable Formula:

The design parameters available at the time of inspection are as follows;

1000 psi (G)

Determination of Corrosion Rate:

Long Term Corrosion rate

Long Term Corrosion rate

For Dish End:

Long Term Corrosion rate

Long Term Corrosion rate

Non Intrusive Inspection of TUCO C

JKHI No: JKHI-150230

Next Inspection Interval:

As per API 510 recommended next inspection interval are as follows.

Maximum Allowable Working Pressure (MAWP):

and painted as per project specifications.

annually and their record shall be maintained.

Non Intrusive Inspection of TUCO C

JKHI No: JKHI-150230

Report of Visual Inspection as

Ultrasonic A-Scanning Reports as

Syed Muhammad Ali

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