Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
TITLE
Thickness Monitoring Location Guide
DOCUMENT NUMBER
COPI-OPR-OM-MA-00086
REV
0
DATE
27 May04
PAGE
2 of 16
DATE ISSUED
PREPARED
REVIEWED
APPROVED
COMMENTS
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-00086
27 May 04
3 of 16
TABLE OF CONTENTS
1.
INTRODUCTION .................................................................................................... 0
2.
PURPOSE .............................................................................................................. 0
3.
SCOPE ................................................................................................................... 0
4.
RESPONSIBILITIES .............................................................................................. 0
5.
PREPARATIONS GENERAL.............................................................................. 0
6.
7.
PREPARATIONS VESSELS............................................................................... 0
8.
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
1.
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-00086
27 May 04
4 of 16
INTRODUCTION
This document is to provide guidance to the Asset Integrity Engineer or the Inspection Engineer
when establishing or reviewing locations of thickness monitoring locations (TMLs). It is applied to
any process equipment that is subject to thinning either from corrosion or erosion. It is not
applicable to finding damage from other mechanisms such as Stress Corrosion Cracking which
requires a substantially different inspection program. Corrosion resistant piping and vessels are
generally exempt from thickness monitoring except where erosion is identified as a potential
damage mechanism.
2.
PURPOSE
This Thickness Monitoring Location Guide provides instructions for locating sites for performing
ultrasonic thickness measurements on piping, pressure vessels and tanks systems when conducting
an on-stream thickness survey. The TML locations should be designed to pick up the areas of
highest predicted or expected corrosion rates. The intention is to do more thickness monitoring in
areas where corrosion is likely and a lesser extent when corrosion is unlikely. To achieve this the
Asset Engineer must understand the applicable corrosion mechanisms and the physical features,
such as injection points, that might cause localized corrosion. The inspector must also understand
that the TML location is only a starting point, if thinning is found then the inspector shall continue
scanning outside the TML to characterize the entire extent of thinning.
3.
SCOPE
This procedure applies to ultrasonic thickness measurements taken on piping systems, vessels and
tanks at ConocoPhillips Indonesia (COPI).
4.
RESPONSIBILITIES
The Asset Integrity Engineer in cooperation with the Inspection Engineer is responsible for ensuring
proper location for ultrasonic measurements in accordance with this procedure and other applicable
codes and specifications.
5.
PREPARATIONS General
5.1
6.
Obtain Process Flow Diagrams, Process and Instrumentation Diagrams and, if possible,
System Isometric drawings for piping. Obtain vessel or tank general arrangement drawings
as applicable. Identify materials of construction, pipe classes and insulations specifications.
Identify sand production that may lead to erosion. Determine predicted corrosion rates for
the process fluid.
PREPARATIONS Piping
6.1
6.2
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-00086
27 May 04
5 of 16
6.3
Before starting the inspection, the Inspector Engineer should review the results of the
previous inspections and check with the operators in order to determine if the equipment has
operated under any unusual conditions, such as high/low temperature excursions,
overpressure, or any leakage.
6.4
6.5
REFERENCES
API 570: Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems
6.6
PROCEDURE
NOTE
Insulated Piping
Insulated piping is only separated out from Non-insulated piping because of the need for
special inspection windows and the need to look for Corrosion Under Insulation (CUI). For
each TML a window will have to be cut into the insulation. Ideally, a replaceable plug will be
inserted into this window to simplify future inspections. If this is not possible the insulation must
be restored after inspection.
Once the lines have been established to be subject to thinning corrosion, either by the
Corrosion Engineer or from a RBI study, TMLs should be established at the following
locations:
On the center line of outer radius of elbows. The inspection point should be in line with the
fluid flow and will cover the target zone where entrained particles would be expected to
strike the inside of the elbow. This is generally the most severely attacked area from both
erosion and corrosion. An additional TML shall be located one pipe diameter
downstream from the elbow and on the same side of the pipe as the TML on the elbow.
In cases where severe erosion is likely, an additional TML on the opposite side of the
pipe at the same distance from the elbow should be established.
A pipe run in a known corrosive service should have TMLs at least every 5 meters. If the
corrosion is known to be due to condensations then it is logical to have TMLs only along
the bottom of the pipe but where corrosion is more generalized it is good practice to
have TMLs located at 90-degree intervals around the pipe. In cases where severe
erosion is likely an additional TML on the opposite side of the pipe at the same distance
from the elbow should be established.
Measurement points should also be assigned to areas with unusually high historical or
predicted corrosion rates.
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-00086
27 May 04
6 of 16
If further inspection is required due to corrosion rates or if the piping is approaching the
retirement thickness, additional inspection holes will need to be provided.
Additional inspection windows should be established at low points to look for corrosion
from water condensation or drop out and to look at the external condition of the pipe for
CUI.
Obtain thickness measurements in accordance with the approved Inspection Procedure for
Ultrasonic Thickness Measurement.
6.8
Non-Insulated Piping
Once the lines have been established to be subject to thinning corrosion, either by the
Corrosion Engineer or from a RBI study, TMLs should be established at the following
locations:
On the center line of outer radius of elbows. The inspection point should be in line with the
fluid flow and will cover the target zone where entrained particles would be expected to
strike the inside of the elbow. This is generally the most severely attacked area from both
erosion and corrosion. An additional TML shall be located one pipe diameter
downstream from the elbow and on the same side of the pipe as the TML on the elbow.
In cases where severe erosion is likely, an additional TML on the opposite side of the
pipe at the same distance from the elbow should be established.
A pipe run in a known corrosive service should have TMLs at least every 5 meters. If the
corrosion is known to be due to condensations then it is logical to have TMLs only along
the bottom of the pipe but where corrosion is more generalized it is good practice to
have TMLs located at 90-degree intervals around the pipe. In cases where severe
erosion is likely an additional TML on the opposite side of the pipe at the same distance
from the elbow should be established.
Measurement points should also be assigned to areas with unusually high historical or
predicted corrosion rates.
If further inspection is required due to corrosion rates or if the piping is approaching the
retirement thickness, additional inspection holes will need to be provided.
Additional inspection windows should be established at low points to look for corrosion
from water condensation or drop out and to look at the external condition of the pipe for
CUI.
Obtain thickness measurements in accordance with the approved Inspection Procedure for
Ultrasonic Thickness Measurement.
6.9
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
7.
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-00086
27 May 04
7 of 16
PREPARATIONS Vessels
7.1
7.2
7.3
Before starting the inspection, the Inspector Engineer should review the results of the
previous inspections and check with the operators in order to determine if the equipment has
operated under any unusual conditions, such as high/low temperature excursions,
overpressure, or any leakage.
7.4
7.5
REFERENCES
7.6
API 510: Pressure Vessel Inspection Code, Maintenance Inspection, Rating, Repair
and Alteration of Pressure Vessels
ASME Boiler and Pressure Vessel Code, Section VIII, Div. 1.
PROCEDURE
NOTE
Insulated Vessels
Where specified in an equipment specific analysis such as a RBI study, the TML locations
shall be located per the study. Where no specific studies have been made, one TML
minimum should be assigned to each pressure-containing component. For example, each
head, each shell diameter transition and all accessible nozzles shall be checked.
It is preferred to have a TML in each shell section if accessible.
TMLs should also be assigned to areas of known or predicted high corrosion rates.
TMLs shall be located on drain nozzles.
TMLs shall be located on any water boots on the bottom and at the normal water line.
If further inspection is required due to abnormal corrosion rates, or if the vessel is
approaching the retirement thickness, additional inspection insulation holes will need to be
provided.
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-00086
27 May 04
8 of 16
For each TML a window will have to be cut into the insulation. Ideally, a replaceable plug will
be inserted into this window to simplify future inspections. If this is not possible the insulation
must be restored after inspection.
7.8
Non-Insulated Vessels
As above, where a specific study provides locations for TMLs then that study shall be
followed. Otherwise, one TML minimum should be assigned to each pressure-containing
component. For example, each head, each shell diameter transition and all accessible
nozzles shall be checked.
It is preferred to have a TML in each shell section if accessible.
TMLs should also be assigned to areas of known or predicted high corrosion rates.
TMLs shall be located on drain nozzles.
TMLS shall be located on any water boots on the bottom and at the normal water line.
8.
8.2
8.3
Before starting the inspection, the Inspector Engineer should review the results of the
previous inspections and check with the operators in order to determine if the equipment has
operated under any unusual conditions, such as high/low temperature excursions,
overpressure, or any leakage.
8.4
8.5
REFERENCES
API-653 Tank Inspection Code
8.6
PROCEDURE
NOTE
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-00086
27 May 04
9 of 16
NOTE
A letter shall designate each course: A for the bottom course, B for the second course and
so on.
All points on shell to be 2 from full seams (partial door sheet and patch plate seams
not inclusive, unless through adjoining weld seam). If thickness readings vary more
than .01", the area will be scanned and the average thickness will be recorded.
8.7.1
A course starting point is, facing tank from outside, left of first vertical weld seam left
of the north most plate. (This area is normally identified by a man-way or tank piping.)
Pipe+ Data Point
Position Description
Location Description
8.7.2
BTM RT
8.7.3
BTM CN
8.7.4
BTM LF
8.7.5
TP
LF
TP
JCT
TP
RT
8.7.6
8.7.8
8.7.9
Location Description
8.8.1
BTM RT
8.8.2
BTM JCT
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-00086
27 May 04
10 of 16
8.8.3
BTM LF
8.8.4
TP
BTM
BTM MW 4NOZ
8.8.5
8.8.6
8.9
The roof data points will be designated by a letter; R. Critical portions of roof are
from platform to gauging hatch where Operations and gauging personnel walk. This
area will be inspected on a 2 grid, or Walkway, a minimum of 3 points (4) wide.
Grid starting point is determined by best fit of the Walkway from platform to gauge
hatch. Each 2 row of grid will be designated by successive Steps (see Attachment
B).
8.9.2
8.9.3
The extent of the X pattern will therefore be determined by the diameter and
alignment of roof to steps and platform. Thickness measurements should be taken on
each end of plate as the line passes the course, and each junction near the line.
Location Description
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-00086
27 May 04
11 of 16
2)
STEP 1
STEP 2
3)
4)
Continue using the 0 pattern starting at the left side of the stairway platform continuing
clockwise around the tank. The numbering system should alternate from the outer course T
seam location to the inner until the complete circumference of the tank has been completed.
8.10
Location Description
A1
TP
MW
BTM MW
TP
4NOZ
Location Description
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-00086
27 May 04
12 of 16
TP
MW
BTM MW
4NOZ
ATTACHMENTS
Attachment A Attachment B Attachment C Attachment D -
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
ConocoPhillips Indonesia
TITLE
Thickness Monitoring Location Guide
DOCUMENT NUMBER
COPI-OPR-OM-MA-00086
REV
0
DATE
27 May04
PAGE
13 of 16
ATTACHMENT A
EXAMPLES OF SHELL LOCATION DESCRIPTIONS NON- INSULATED TANKS
A1/BTM RT
A2/BTM CN
A3/BTM LF
A4/TP LF
A5/TP JCT
A6/TP JCT
A7/TP JCT
A8/TP RT
A9/TP MW
A10/BTM MW
A11/6NOZ
A12/BTM RT
.
.
.
B1/BTM RT
B2/BTM LF
B3/BTM RT
.
.
.
B85/BTM RT
B86/BTM JCT
B87/BTM JCT
B88/BTM LF
B89/TP JCT
.
.
.
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
ConocoPhillips Indonesia
TITLE
Thickness Monitoring Location Guide
DOCUMENT NUMBER
COPI-OPR-OM-MA-00086
REV
0
DATE
27 May04
PAGE
14 of 16
ATTACHMENT B
EXAMPLES OF ROOF LOCATION DESCRIPTIONS - INSULATED AND NON-INSULTED TANKS
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
ConocoPhillips Indonesia
TITLE
Thickness Monitoring Location Guide
DOCUMENT NUMBER
COPI-OPR-OM-MA-00086
REV
0
DATE
27 May04
PAGE
15 of 16
ATTACHMENT C
EXAMPLES OF SHELL LOCATION DESCRIPTION - INSULATED TANKS
A1 / BTM RT
A2 / BTM CN
A3 / BTM LF
A4 / BTM
A5 / 4NOZ
A6 / BTM
.
.
.
A44 / BTM
.
.
.
B1 / BTM
B2 / BTM
B3 / BTM
.
.
.
B27 / BTM
B28 / MID
.
.
.
C1 / BTM
C2 / MID
....
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped
TITLE
THICKNESS MONITORING
LOCATION GUIDE
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
COPI-OPR-OM-MA-000ZZ
03 May 04
16 of 16
Top
Manway
Bottom
Nozzle
Thickness monitoring location
Paper Copies are UNCONTROLLED Check with Document Control for latest available Revision COPI
CONTROLLED copies should be RED stamped