dow visual inspection of miscellaneous equipment

Dow Visual Inspection of Miscellaneous Equipment

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INSPECTION

Dow Owner Visual Training Program consists of 3 modules:– Miscellaneous Equipment (Flex Hoses, Expansion Joints, Sight

Glasses)– PCE (Process Containment Equipment)– Piping, including all mechanical devices in the loop, e.g., pumps,

compressors, valves, and associated instruments

Training Module is designed to:– Provide information necessary to evaluate and document the

condition of particular types of process equipment

After completing the Miscellaneous Equipment training module, you should be able to:

– recognize deficiencies associated with flex hoses, expansion joints and sight glasses

– complete the required documentation form for Miscellaneous equipment and submit it for processing

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PURPOSE OF THIS MODULE

Objective: To provide you with the necessary information to document the conditions of Miscellaneous Equipment within the plant. After completion of the module, you should be able to:

Recognize any unwanted condition associated with flex hoses, expansion joints and sight glasses;

Complete a form which documents the conditions; and

Contact the correct resources when outside help becomes necessary to further evaluate an unwanted condition found during an inspection.

Justification: To deliver the skills and knowledge needed to perform visual inspections of Miscellaneous Equipment and to correctly document the inspection as prescribed in the Global Mechanical Integrity Safety Standard (GMISS).

Module Description: This module provides the participant with the information necessary to correctly document conditions associated with flex hoses, expansion joints and sight glasses. The module describes the conditions which should be documented, the parts of the equipment which should be closely checked and an example of a documentation form.

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INTRODUCTION

• The recently adopted Global Mechanical Integrity Safety Standard addresses the mechanical integrity of process containment equipment, piping, relief systems, and other miscellaneous equipment.

• An installation inspection shall be conducted and documented by either a Qualified Person for Owner Visual Inspection of Flex Hoses and Expansion Joints or Qualified Inspector for Metallic or Non-Metallic PCE and Piping. This requirement is mandatory for Expansion Joints installed after 12/31/04.

• Flex hoses shall have a visual inspection conducted and documented at least every 12 months. A pressure test shall be conducted and documented at least every 60 months at the design pressure rating of the hose assembly or at its registered MAWP in order for a Flex Hose to remain in service.

• Expansion joints shall have a visual inspection conducted and documented at least every 12 months.

• Sight glasses shall have a visual inspection conducted and documented at least every 12 months.

• Corrosion problems may not be critical when first found, but left unattended could lead to LOPC’s, unplanned events, environmental insults, costly repairs and a loss of mechanical integrity of the equipment.

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INTRODUCTION

• A good working knowledge of visual inspection techniques, and administration of an effective program will help prevent unnecessary damage to equipment. A visual inspection is an examination of all external parts of registered equipment. A successful program should include objectives such as:

– Developing and maintaining an effective inspection schedule

– Developing and maintaining an effective documentation system

– Performing self audits

– Documenting requirements for compliance

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INTRODUCTION

• The program should mesh well with production and maintenance schedules and provide management a detailed picture of plant health & reliability. A proper inspection involves a complete documented visual inspection of all equipment components.

• One of the requirements of Owner Visual inspections is documentation. The Flex Hose Inspection Report, Expansion Joint Inspection Report, Glass Device Inspection Report (fused) and the Glass Device Inspection Report (non-fused) are all located in GMIM Appendix B. These inspection reports are the recommended report to use when documenting the owner visual inspections performed by the qualified person.

• One of the most important objectives of the Owner Visual Inspection Program is documenting and following up on the inspection results and proactively addressing failure mechanisms before they develop into a Loss of Primary Containment Incident or deteriorate equipment to the point they have to be taken out of service for unscheduled repairs.

• Sometimes when an inspection is due, immediate access to all components of a vessel is not possible without incurring considerable costs. Carefully document the condition of the equipment components inspected by following your area procedures. The visual inspection should be completed by the equipment owner or other qualified person.

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INTRODUCTION

• The inspection should (at the very least):

– ensure the equipment is properly identified

– determine the condition of :

• the exterior coating, cover and / or insulation (if applicable)

• the supports (the allowance for expansion and the general alignment and support of the equipment)

• the fasteners / bolts

• the end connections, flanges and associated gaskets

• the glass surfaces (should be checked for cracks, scratches etc.)

• Any signs of leakage should be investigated so that the sources can be established and addressed.

Note: If this is not the first visual inspection of the equipment, the initial step in preparation for the inspection is to review the history of the equipment to understand if previous conditions existed that need further attention.

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INTRODUCTION

• The Flex Hose Inspection Report, Expansion Joint Inspection Report, Glass Device Inspection Report (fused) and Glass Device Inspection Report (non-fused) are all visual inspection reports found in GMIM Appendix B “Forms”. They are the recommended inspection reports to be used by the Qualified Person / Inspector for the purpose of documenting the inspection results for Flex Hoses, Expansion Joints, Glass Devices (fused) and Glass Devices (non-fused).

• A detailed explanation of what sections are included in the forms, guidance on how to fill out the forms and an explanation of what each of the sections are referring to will be discussed later in this module.

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DEFINITIONS• GMISS: Global Mechanical Integrity Safety Standard

• GMIM: Global Mechanical Integrity Manual

• GEMTS: Global Equipment & Maintenance Tracking System orEquivalent Computer Maintenance Management System (e.g. SAP, MMS, etc.)

• Hazardous Service is defined as the following:

• Corrosive to Human Tissue

• Temperature Limits

– Liquids hotter than 60° C (140° F)

– Gases and vapors hotter than 93.3° C (200° F)

– Liquids, gases and vapors colder than -23.2° C (-10° F)

• Corrosion (to wetted materials of construction)

• Regulatory

– Materials that are considered by regulatory agencies to be a hazardous substance or hazardous waste, a reportable material, and to be environmentally harmful if not adequately contained.

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DEFINITIONS• Hazardous Chemical is defined as the following:

– Explosive– Oxidizing– Extremely Flammable– Highly Flammable– Flammable– Very Toxic– Toxic– Dangerous to the Environment– Water Reactive

• Flex Hose (Flexible Connector): Flexible metal or non-metal corrugated connector used in Hazardous Service or containing Hazardous Chemicals used to minimize the effects of vibration, differential settlement, misalignment or other unusual conditions. Normally Flex Hoses have braided stainless steel or elastomeric covers.

• Expansion Joint: Any corrugated metal or non-metal flexible transition device designed to minimize the effects of thermal expansion and contraction.

• Sight Glass: Any equipment, instrument, or piping component in which glass, plastic or other brittle transparent material is used as an observation barrier between a fluid and the atmosphere. Typical examples are gauge glasses, rotameters and manometers, vessel sight glasses, and bubblers.

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EQUIPMENT COMPONENT VISUAL INSPECTION

• Flexible Hoses– Common Types of Flex Hoses– Tagging and Marking– Installation Guides– Properly Attached, Tagged & Installed– Types of Damage to Flex Hoses– Proper & Improper Storage Practices– Inspection Challenges– Hose Restraints

• Expansion Joints– Common Types of Expansion Joints– Types of Expansion Joints not Designed to be Externally Inspected– Movement– Pressure Thrust– Proper Anchoring– Types of Squirm– Common Causes of Failure– Common Installation Errors

Items to be reviewed when visually inspecting the following equipment components:

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EQUIPMENT COMPONENT VISUAL INSPECTION

• Sight Glasses

– Tempered Glass Sight Glasses

– Shielded Sight Glasses

– Fused Glass Sight Glasses

– Refrigeration Service Sight Glasses Fused - Glass

• Documentation

– GEMTS

– Forms

Items to be reviewed when visually inspecting the following equipment components:

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FLEX HOSES

• Consider hard piping or tubing alternatives

• Register if in “Hazardous Service or Contains Hazardous Chemicals”

• Individual and Group registration options

• Initial pressure test (1.5 x rating)

• Visual inspection (1 year max. interval)

• Replace or pressure test (5 yr max. interval)

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FLEXIBLE HOSE TYPES Bellows or Corrugated Construction

Smooth-Bore Construction

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TAGGING AND MARKING

NOTE: It is the Visual Inspector’s responsibility to verify that the Flex Hose is properly tagged and that it matches the specification on the registration documentation.

~2” (or 5.08 cm)

Leader for Insulation

~2” (or 5.08 cm)

Leader for Insulation

LooseLoose

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INSTALLATION GUIDES

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PROPERLY TAGGED AND INSTALLED

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PROPERLY ATTACHED AND TAGGED PUSH-ON HOSE

Unnecessary Stress

Unnecessary Stress

TagsTags

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BEND RADIUS EXCEEDED: Dispose

Kinked or flattened cross-section from too small of a bend radius or crushing is the most common failure mechanism for smooth-bore flex hoses.

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POORLY INSTALLED (Horizontal): Dispose and Re-design

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OVERPRESSURE AND COVER DAMAGE: Dispose

Outer protective shield is cut away to show internal damage

due to overpressure.

Outer protective shield is cut away to show internal damage

due to overpressure.

NOTE: Take notice of how the internal hose has deep impressions made from contact with the outer shield.

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REINFORCEMENT AND MOTION DAMAGE: Dispose

When severe vibration of a flex hose is detected during the visual inspection, a deficiency should be noted on the Inspection Form and reported to the Equipment Owner or the PCE Focal Point.

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COVER DAMAGE: Dispose

CauseCause

EffectsEffects

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END FITTING DISENGAGEMENT: Dispose

Unsafe Disengagement

Unsafe Disengagement

Pipe nipples are not safe or acceptable

Pipe nipples are not safe or acceptable

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PROPER END FITTING ENGAGEMENT

Preferred Crimping Style

Preferred Crimping Style

Unsafe EngagementUnsafe Engagement

Proper EngagementProper Engagement

Push-on HoseAssembly Progression

Push-on HoseAssembly Progression

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MISCELLANEOUS DAMAGE: Dispose

Indications of Corrosion Under Cover

Indications of Corrosion Under Cover

Corrosion of Reinforcement Wires

Corrosion of Reinforcement Wires

Fitting CorrosionFitting Corrosion

Swelling of Elastomer

Swelling of Elastomer

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STORAGE

Improper Connection to Reel

Improper Connection to Reel

Proper StorageProper Storage

Improper StorageImproper Storage

Storage Reel or Rack Guide

Storage Reel or Rack Guide

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INSPECTION CHALLENGES: Auxiliary

Silicone Insulation Sleeve:

Must slit sleeve in two spots (min) to inspect.

Silicone Insulation Sleeve:

Must slit sleeve in two spots (min) to inspect.

Opaque Shrink Fit Covers:

May be inspected without removing the cover.

Opaque Shrink Fit Covers:

May be inspected without removing the cover.

Anti-Kink Armor:

Can only be inspected out-of-service.

Anti-Kink Armor:

Can only be inspected out-of-service.

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HOSE RESTRAINT

Quick ConnectQuick Connect

Hose RestraintHose Restraint

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EXPANSION JOINTS

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ELASTOMERIC EXPANSION JOINTS

Teflon®Liner

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TEFLON® EXPANSION JOINTS

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BELLOWS NOT INSPECTED EXTERNALLY

Non-Bellows Style: Yarway Gun-PAKT®

These type of expansion joints should always be inspected internally to determine their condition.

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EXPANSION JOINTS: MOVEMENT

Axial: • Extension• Compression• Movement parallel to flow

Angular: • Flanges not parallel• Convolution spacing

consistent across length

Lateral: • Flanges remain parallel and

perpendicular to flow• Inconsistent convolution

spacing• Most stressful movement!

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PRESSURE THRUST

An expansion joint installed in a piping system acts as if it’s ends were capped.

When pressurized, it extends uncontrollably until something external to the expansion joint stops it.

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PROPER ANCHORING

MAIN ANCHORS

• Must be designed to withstand forces (spring rate, pressure thrust, pipe guide friction) and moments lever arm imposed upon it by each pipe section to which it is attached.

• Main anchors are installed at any of the shown locations (close to expansion joint).

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COLUMN SQUIRM

Excessive internal pressure may cause a bellows to become unstable and squirm.

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IN-PLANE SQUIRM

A shift or rotation in the plane of one or more convolutions such that the plane of these convolutions is no longer perpendicular to the axis of the bellows.

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VIBRATION CAUSED FATIGUE

Symptoms are Z-shaped cracks, usually starts in the second convolution

from the end.

Symptoms are Z-shaped cracks, usually starts in the second convolution

from the end.

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CORROSION FAILURES

Expansion joints are fabricated out of various types of thin materials designed to expand and contract to eliminate the possibility of associated equipment failure due to excessive movement / stress. In most cases, expansion joints are not designed to withstand failures due to corrosion.

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A COVER CAN HIDE SURPRISES

An expansion joint cover can protect the expansion joint from external damage and serve as personnel protection from heat, but can also hide conditions that can cause a failure over time if not detected.

The expansion joint cover was removed and external stress corrosion cracking was revealed.

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COMMON INSTALLATION ERRORS

This is an example of why flow direction is important when a flow liner is used!

Remove the shipping supports before operation!

Remove the shipping supports before operation!

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BOLTS INSERTED FROM WRONG SIDE

Impinging and damaging first convolution

Impinging and damaging first convolution

close-up view

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TEMPERED-GLASS SIGHT GLASSES

NOTE: Damage to any surface and/or edge requires replacement.

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• When a tempered-glass device is found during the visual inspection to be scratched, chipped or etched it should be IMMEDIATELY replaced or seek IMMEDIATE approval to continue operating via a deficiency form.

• The pressure side gasket thickness of a sight glass must be between 1/8” (3 mm) and 1/4” (6 mm).

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• A TEMPERED sight glass must always be replaced if the assembly is loosened such that the element and/or gaskets move freely or if the element is removed from the sight glass assembly.

• Spiral wound, metal gasket components, or other metal-containing gaskets cannot contact any glass face of a NON-FUSED glass device.

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http://www.ljstar.com/products/viewProduct.asp?ProductID=40&pl=7

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SHIELDED SIGHT GLASSON HOT WATER SYSTEM EXPANSION TANK

Most tubular sight glasses are protected from external damage by two bars located along each side of the glass tube allowing accessibility to view the level of the tank.

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FUSED-GLASS SIGHT GLASSES: Always Circular

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REFRIGERATION SERVICE SIGHT GLASSES FUSED-GLASS: Insult Test

Twelve hits with hammer at 500 psig / (34 bar) -

No leak

Twelve hits with hammer at 500 psig / (34 bar) -

No leak

Two hits with hammer at 500 psig / (34 bar) -

Before leak

Two hits with hammer at 500 psig / (34 bar) -

Before leak

Both subject to 2500 psig / (172 bar) with no effect before insult test.Conclusion: Impact shielding is best defense.

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NOT ALL FUSED-GLASS IS THE SAME

Fuseview®:

Metal-Glass Fusion

Fuseview®:

Metal-Glass Fusion

Metaglas®:

No Fusion, Compression Only

Metaglas®:

No Fusion, Compression Only

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FUSEVIEW®: METAL-GLASS FUSION

GlassGlass

Glass Fused to Metal

Glass Fused to Metal

Bubbles at Metal-Glass Interface - Fusing Temperature

was Reached

Bubbles at Metal-Glass Interface - Fusing Temperature

was Reached

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DOCUMENTATION & GEMTS

• Send original documentation to Maintenance Representative.

• Review any damage or deficiencies with the Owner.• Maintain a Site Record Center where the “Official File”

can be located.

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DOCUMENTATION AND FOLLOW-UP

One of THE MOST IMPORTANT OBJECTIVES of the Owner Visual Inspection Program is the documentation and subsequent follow-up of the inspection results PLUS proactively addressing failure mechanisms before they develop into a loss of primary containment (LOPC) incident or deteriorate equipment to the point they have to be taken out of service for unscheduled repairs.

Note:

If a deficiency is found, initiate work request to evaluate or resolve the condition.

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DOCUMENTING THE INSPECTION

• The Flex Hose Inspection Report, Expansion Joint Inspection Report, Glass Device Inspection Report (Fused) and Glass Device Inspection Report (non-Fused) all include the following sections with a equipment specific checklist:

– Section 1 – Identification– Section 2 – Purpose of Report– Section 3 – Inspection Results– Section 4 – Inspection Information– Section 5 - Inspector

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• GEMTS ID#/Registration#: Unique Identification Number issued by a Computer Maintenance Management System (e.g. GEMTS, SAP, MMS, etc.)

• Item/ Tag/Registration Number: Number or item name associated with the equipment.• Cost Center: Cost center or account that is tied to the equipment and plant code,

identifying where the equipment is located.• Submission Date: When the documentation was submitted to the Maintenance

Representative.• Date of Inspection: Date the inspection was performed.• Work Order: Work Order Number issued by a Computer Maintenance Management

System (e.g., GEMTS, SAP, MMS, etc.) to perform the inspection.• Building: Building Number location of the Qualified Person performing the inspection.• Plant or Location Description: Where in the plant facility the equipment is physically

located. • Plant Code: Plant Code chosen or issued by a Computer Maintenance Management

System (e.g., GEMTS, SAP, MMS, etc.) usually tied to an account or production and process unit.

Section 1 - Identification

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• Production Unit: What part of the production unit that the equipment is associated with, usually is tied to the location of the equipment.

• Process Unit: What part of the process unit that the equipment is associated with, usually is tied to the location of the equipment.

• Block: Plant Facility• Owner: Equipment Owner or designee, (usually the Production Process Leader),

his or her employee number ( Dow assigned unique identification number), and his or her phone number.

• Initiated by: Person who initiated the inspection to be performed, his or her employee number ( Dow assigned unique identification number), and his or her phone number.

• Comments: Place holder for comments.

Section 1 - Identification

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Check which one applies:

• Visual Inspection Results: visual inspection performed by a Qualified Person.

• Installation Inspection: performed before the equipment is put into service and after installation.

• Pressure Test Results: pressure test performed on a flex hose.

• Enter Information into History: Information that is normally an action or a recommendation that needs to be documented for history.

• Other: Place holder for any other type of Inspection or comment.

• Comments: Place holder for comments.

NOTE: Section 1 “Identification” and Section 2 “ Purpose of Report” need to be filled out before the inspection is performed. This will ensure the correct inspection is being performed and the correct equipment is being inspected.

Section 2 - Purpose of Report

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• Inspection Test Type:– Visual: Visual inspection performed by a Qualified Person– Pressure: Pressure test performed on a Flex Hose.– Other: Other type of inspection such as internal or remote.

• Inspection Results:– Acceptable for Continued Use: Check the box if the equipment is acceptable for

continued use.– Not Acceptable for Continued Use: Check the box if the equipment is not

acceptable for continued use.• Text for Entry into GEMTS History: or a Computer Maintenance Management System

(e.g. GEMTS, SAP, MMS, etc.) – Information that is normally an action or a recommendation that needs to be documented for history.

• Comments: Placeholder for comments.

Section 3 – Inspection Results

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• Checklists Attached:

– None Used (Optional): Check box if the checklist was not used to document inspection information.

– Visual Inspection Checklist: Check box if the checklist was used to document inspection information.

– Installation Inspection Checklist: Check box if the checklist was used as an installation checklist or if this was an inspection performed at installation.

• Notes: These are notes to explain, clarify and inform the Qualified Person and / or Equipment Owner different steps to take if certain conditions exist with the equipment.

Section 4 – Inspection Information

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Deficiencies have been Communicated to: – Equipment Owner: Check the box if the Equipment Owner was communicated to about a deficiency.– Other: Check the box if someone else other than the Equipment Owner was communicated to.– N/A (No Deficiencies): Check the box if no deficiencies were noted.– Yes: Check the box if deficiencies were noted during the inspection.

– No, see Comments: Check the box if no deficiencies were noted and comments are needed to identify follow up actions.

– Is Owner follow-up required to address issues that are concerns, but not deficiencies: • Check box if answer is No• Check box if the is Yes, and add comments to clarify.

– Qualified Person: Qualified Person for Owner Visual Inspections.– Employee Number: Master Number or Dow Identification Number of employee and date of inspection.– Date: Date the inspection was performed.– Comments: Place holder for comments.

Section 5 - Inspector

Note: Anytime a deficiency or unwanted condition is found during an inspection, the Qualified Inspector should document and communicate to the equipment owner the condition immediately so that a more detailed evaluation/inspection can be performed. The more detailed evaluation may include Non-Destructive Testing techniques and an inspection from a more experienced Certified Inspector.

Note: These are issues currently identified during the inspection performed, but if left unattended or unreported could lead to an unwanted condition.

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MISCELLANEOUS EQUIPMENT INSPECTION FORMS

• Glass Device Inspection Report (non-Fused)– Example Glass Device Inspection Report (non-Fused)

• Glass Device Inspection Report (Fused)– Example Glass Device Inspection Report (Fused)

• Expansion Joint Inspection Report– Example Expansion Joint Inspection Report

• Flex Hose Inspection Report– Example Flex Hose Inspection Report

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INSPECTION DOCUMENTATION

After the results of the inspection have been reviewed by the Qualified Person/Inspector and Equipment Owner, the inspection report must be filed in the Official Mechanical Integrity Equipment File.

It is the responsibility of the Qualified Person/Inspector to notify production and/or Inspection Department immediately if at anytime a condition that is observed during the inspection would lead to an unplanned event, LOPC, environmental insult, or a loss of mechanical integrity.

At any time, the Qualified Person/Inspector has questions about determining the degree of severity of corrosion or the extent of damage, contact the Inspection / NDE Department or use the appropriate Technical Resources.

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You’ve now completed “Dow Visual Inspection of Miscellaneous Equipment”.

Return now to Learn@Dow to take the post-test. Successful completion of this test will result in automatic credit for this course.

GREAT JOB!!

dow visual inspection of miscellaneous equipment

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