report - eagleitechnologies.com - siteeagleitechnologies.com/attachments/report reactor pv.pdf ·...

54
Report No.: 10003 Inspector: Jeff Walling Employer: Eagle Inspection Inspection Date: 5/10/2010 ACME Chemicals Beaumont, TX R-3503 API Certification No. 2782 Solutions Bldg Reactor Inspector Signature An API Standard 510 Inspection based on client criterion for nondestructive examinations was conducted on Reactor Vessel R-3503 in the ACME Chemicals facility located at Beaumont, TX on 5/10/2010. This vessel was originally built to ASME Section VIII, Divison 1. This inspection was conducted in accordance with requirements of the API-510 standard for inspections of Pressure Vessels. The following is a detailed report of the inspection including findings and recommendations. OUT-OF-SERVICE Inspection Report For Report No.: 10003 Page 1

Upload: lynga

Post on 30-Jan-2018

216 views

Category:

Documents


2 download

TRANSCRIPT

Report No.: 10003Inspector: Jeff WallingEmployer: Eagle Inspection Inspection Date: 5/10/2010

ACME ChemicalsBeaumont, TX

R-3503

API Certification No. 2782

Solutions Bldg

Reactor

Inspector Signature

An API Standard 510 Inspection based on client criterion for nondestructive examinations was conducted on Reactor Vessel R-3503 in the ACME Chemicals facility located at Beaumont, TX on 5/10/2010. This vessel was originally built to ASME Section VIII, Divison 1. This inspection was conducted in accordance with requirements of the API-510 standard for inspections of Pressure Vessels. The following is a detailed report of the inspection including findings and recommendations.

OUT-OF-SERVICE

Inspection Report For

Report No.: 10003

Page 1

3.1 Foundation3.2 Vessel Shell 3.3 Vessel Heads3.4 Appurtenances

4.0 RECOMMENDATIONS4.1 Foundation4.2 Vessel Shell 4.3 Vessel Heads4.4 Appurtenances4.5 Next Inspection

5.0 ULTRASONIC THICKNESS MEASUREMENTS5.1 Results 5.2 Recommendations

OUT-OF-SERVICE

1.0 EXECUTIVE SUMMARY

2.0 VESSEL DATA

INSPECTION RESULTS,

TABLE OF CONTENTS

3.0

APPENDIX A

APPENDIX B

APPENDIX C

APPENDIX D

APPENDIX E

APPENDICIES Mechancial Integrity Calculations

Thickness Measurement Records

Inspection Drawings

Inspection Checklist

Manufacturers Data Sheets

APPENDIX F Inspection Photographs

APPENDIX G NDE Records

APPENDIX H References

Report No.: 10003

Page 2

1.0 EXECUTIVE SUMMARY

An API Standard 510 inspection of pressure vessel R-3503 located at Beaumont, TX was conducted on 05/10/2010. This inspection was made to collect data in order to evaluate the mechanical integrity and fitness for service of the vessel. This inspection consisted of Internal and External VT and UT (A scans) exams.

The shell has experienced significant deterioration in the form of concentrated pitting in the mid girth weld and lower shell course longitudinal welds and cracks in the baffle attachment welds that require weld repairs before placing back inservice. Nozzle N16 needs to be replaced due to deep pitting and crack in the internal surface of the nozzle.

There are some deformations of the shell congruent with the half pipe jacket layout. It appears that the shell has undergone plastic deformation due to the effects of thermal shocking (hammering) within the heating/cooling system.

This vessel has been in-service for over 28 years with 1/2 pipe jacket weld leaks possibly related to this issue (see Appendix A for Thermal Shock Stress Evaluation for a detailed discussion and evaluation). The bottom head 1/2 pipe jacket coils have several leaks throughout that need weld repair.

Recommendations in regards to thermal shock include the following:1) Review the standard operating procedures to ensure that it includes a sequencing system that maintains a slow transition between initial heating and cooling the vessel to ensure even temperature gradients in the vessel and jacketwalls.2) Strip the lower 24" to 36" of shell insulation and do a VT exam to identify leaking coil welds.3) Perform a Dye Penetrant examination of the exposed external coil attachment welds and HAZ of the shell and bottom head to identify any incipient cracking.4) Perform Brinell Hardness examination of the exposed external coil attachment welds and shell HAZ of the shell and bottom head to identify any possible hardening of the metal due to the cycle effect of the thermal shocking (hammering). BHN should be between 149 - 217 5) Schedule the next internal inspection in three years to perform follow-up NDE on shell deformations.6) Perform Dye Penetrant & Brinell Hardness examinations on the bulged areas on the internal surfaces of the vessel lower shell and bottom head at the next scheduled internal inspection.

Report No.: 10003

Page 3

Nozzles N8 & N9 were installed with 1" sch 10 pipe which is below the requirement of ASME design code. Recommendations include Installing supports on Nozzle N8 & N9 within 24" of top head penetrations to alleviate possible vibration action of the nozzle necks and replacing nozzle N8 & N9 with 1" sch. 40 to meet design code requirements of ASME Sec VIII, Div 1, UG 45 at the next out of service maintenance/inspection interval.

The isolation valve for the 8" vent has severe degradation to the carbon steel components. The nuts have severe exfoliation type corrosion. The source of the corrosion is a leak in a 1" plug directly over head that drips condensed gases fromthe venting system. These items need to be replaced or repaired.

Other minor discrepancies are listed in Section 3.0 Inspection Results and 4.0 Recommendations.

0.626 0.643 0.596 150Vessel Shell0.626 0.587 0.488 150Top Head0.626 0.620 0.506 150Bttm Head

Component

NominalDesign

Thickness (in.)

Actual MeasuredThickness

(in.)

Minimum RequiredThickness

(in.)

Design MAWP (psi)

Internal

Calculated MAWP

(psi)Internal

RemainingLife

(years)

TABLE A

0.109 0.104 0.063 200Jacket Shell

14.7

14.7

14.7

Design MAWP (psi)

External

>20

71.3

531.8

229.6

162.2

177.9

184.6

587.2

5/10/2013Next external inspection is due by: 5/10/2013Next internal inspection is due by:

5/10/2013Next UT inspection is due by:

Report No.: 10003

Page 4

Product: Unknown

Build Date: 1982

NB No.: 1405

Inside Dia (in.): 102

Length (in.): 165

MAWP (psi): 150

Design Temp.°F: 375

MDMT °F: -20

Oper. Press.(psi): Unknown Const Code: ASME S8 D1

Head Type: 2:1 Ellipsoidal

2.0 VESSEL DATA

Oper. Temp.°F: Unknown

Material Type: Stainless Steel

Vessel Config.: Vertical

Insul. Type: Fiberglass

Insul. Thk (in.): 2

MAWP (psi): 200

Design. Temp.°F: 375

Medium: Stm/Wtr

Oper. Press.(psi): Unknown

Oper. Temp.°F: Unknown

Material: Stainless Steel

General Data:Main Vessel Data

1/2 Pipe Jacket Data_________________________________________________________________________

Report No.: 10003

Page 5

3.1 Foundation:

3.1.1 3.1.1 The vessel has 4 carbon steel supports attached to the lower section and set on concrete footers.

3.1.2 The supports have coating failure and surface oxidation scatteredthroughout.

3.1.3 The concrete foundations have a few hairline cracks but are in overallsatisfactory condition.

3.2 Shell:

3.2.1 The shell is stainless steel with an external 1/2 pipe heating coil and isinsulated with approximately 2" of fiberglass insulation.

3.2.2 The external surface profiles of the shell appear to be smooth andclean and in satisfactory mechanical condition as viewed through the access windows cut into the insulation.

3.2.3 The majority of the internal surface has relatively smooth profiles withnumerous shallow (0.010" dp) pits scattered throughout the lower half of thevessel. There were isolated areas with grouped pitting to a max depth of0.063" in the mid girth weld, lower course longitudinal weld and baffleattachment welds. (see drawing for specific locations and details).

3.2.4 There are some deformations of the shell congruent with the half pipe jacket attachment welds (most pronounced at the first ring). It appears that the shell has undergone plastic deformation due to the effects of thermal shocking (hammering) within the heating/cooling system.

3.2.5 The shell nozzle penetration welds appeared to be in satisfactory condition except for nozzle N16 which has a crack and pitting internally through out.

3.2.6 Some of the baffle attachment welds have cracks at the shell to weldjunction.

3.2.7 The majority of the insulation on the shell below the second levelappears to be in satisfactory condition with a few isolated areas with minordamage; however, the insulation at the bottom of the shell was wet which is suspect as being from leaking jacket welds behind the insulation.

3.3 Head(s):

3.3.1 The top and bottom heads are stainless steel with an external 1/2 pipeheating coil on the bottom head and are insulated with approximately 2" offiberglass insulation. The heads have a 2:1 elliptical design.

3.0 INSPECTION RESULTS,

The following results are the summarization of a field checklist

that was utilized during the inspection of vessel R-3503

OUT-OF-SERVICE

Report No.: 10003

Page 6

3.3.2 The insulation is 100% covering the top head therefore no visualinspection can made of the surface condition. The external surface profilesof bottom head appear to be smooth and clean and in satisfactorymechanical condition as viewed through the breaches in the insulation.

3.3.3 The majority of the internal surface of the top and bottom head hasrelatively smooth profiles. The bottom head however, has experience minor pitting scattered throughout.

3.3.4 The bottom head 1/2 pipe jacket coils had several weld leaksthroughout. The exposed heater coils on the bottom head show evident of past weld repairs.

3.4 Appurtenances:

3.4.1 The vessel nozzle necks appear to be in satisfactory mechanicalcondition except for the following issues:A. Nozzle N16 which has cracks and pitting internally.B. 1" Nozzles N8 & N9 were found to be sch. 10 pipe which has a nominalthickness of 0.109". This appears to be a fabrication error as the nozzlesshould be sch. 40 in accordance with ASME Sec VIII, Div 1, UG 45 and asstated on the design drawings. The current thickness (0.106") is greaterthan that required for pressure containment. The nozzles are on the top head where they could possibly experience vibration from the agitator motor. Another consideration is the weight of the attached piping that could allow excessive motion due to the vibration which could cause work hardening at the base of the nozzle (the weakest point).

3.4.2 The vessel has no Pressure Safety Relief Valve. There is an 8" vent to the scrubber that has a 6" branch with a rupture disc installed that has an ID Tag showing a set pressure at 152psi @ 366degF.

3.4.3 The isolation valve for the 8" vent has severe degradation to the carbon steel components. The nuts have severe exfoliation type corrosion. The source of the corrosion is a leak in a 1" plug directly over head that drips condensed gases from the venting system.

3.4.4 The ASME Nameplate was located and readable.

3.4.5 A single ground strap was found and appears to be in satisfactory condition.

3.4.6 The agitator motor has oily residue all about.

3.4.7 All fasteners (nuts and bolts) for the agitator blades and baffles weretight and secure.

3.4.8 The baffle plates have some loose bolts but they are tack welded to the nut alleviating any possibility of coming out.

Report No.: 10003

Page 7

4.1 Foundation:

4.1.1 Clean and coat areas of coating failure on the carbon steel foundations.

4.2 Shell:

4.2.1 Shell weld repairs: grind out all areas of degradation as referred to onthe shell drawing. Inspect with PT exam to confirm all indication wereremoved. Weld repair with weld overlay build up to original thickness (0.625" min). Grind the finished weld even with the contour of the vessel shell walls.

4.2.2 Repair cracks in welds of the baffle attachment braces.

4.2.3 Consideration should be given to modifying the operating procedures to provide for some time between heating and cooling evolutions to avoidhammering (thermal shocking) due to sudden extreme differences intemperature of the metal and possible fatigue effects of the shell, coils andweld material.

4.2.4 Strip the lower 24" to 36" of shell insulation and perform a VT exam toidentify suspected leaking coil welds and make weld repairs as needed.

4.2.5 Perform a Dye Penetrant examination of the exposed external coilattachment welds and HAZ of the shell and bottom head to identify anyincipient cracking.

4.2.6 Perform Brinell Hardness examination of the exposed external coilattachment welds and shell HAZ of the shell and bottom head to identify any possible hardening of the metal due to the cycle effect of the thermalshocking (hammering). BHN should be between 149 - 217.

4.2.7 Perform Dye Penetrant & Brinell Hardness examinations on the bulged areas on the internal surfaces of the vessel lower shell and bottom head at the next scheduled internal inspection.

4.2.8 Make repairs to insulation as directed by operations to obtain neededheat retention quality.

4.3 Heads:

4.3.1 Make repairs to insulation as directed by operations to obtain neededheat retention quality.

4.0 RECOMMENDATIONS

4.4 Appurtenances:

4.4.1 Replace nozzle N16.

4.4.2 Install supports on Nozzle N8 & N9 within 24" of top head penetrations

Report No.: 10003

Page 8

to alleviate possible vibration action of the nozzle necks. Consider replacing nozzle N8 & N9 with 1" sch. 40 to meet design code requirements of ASME Sec VIII, Div 1, UG 45 at the next out of service maintenance/inspection interval.

4.4.3 Normally the safety relief systems should not be installed with pressure rating greater than the MAWP of the vessel (in this case 150psi at 375degF). The rupture disc install is set higher to burst by 2 psi but has a lower temperature rating (366degF) than the vessel is rated for. The rupture disc should be verified as being in code for this use. Otherwise replace it with a disc rated for 150@375degF.

4.4.3 Replace the isolation valve for the 8" vent and seal the leak in the 1"plug in the 8" vent line over the isolation valve.

4.5 Next Inspection:

5/10/2013

4.5.1 Next external inspection is due by 5/10/2013

4.5.2 Next internal inspection is due by

5/10/20134.5.3 Next UT inspection is due by

Vessel Shell4.5.4 Governing component limiting life

Report No.: 10003

Page 9

5.1 Results Summary:

5.1.1 UT measurement of accessible vessel components (shell, heads and nozzles) found no significant material loss due to internal corrosion of the components. Except for two 1" Nozzles (N8 & N9), all of the vessel component thicknesses were above that required by ASME calculations for minimum required thicknesses for internal pressure. Nozzles N8 & N9 were installed with 1" sch 10 pipe which is below the requirement of ASME Sec VIII, Div 1, UG 45.

5.1.2 Calculations of all evaluated components resulted in greater than 20 years remaining life except Nozzles N8 & N9.

5.2 Recommendations:

5.5.1 Consider replacing nozzle N8 & N9 with 1" sch. 40 to meet design code requirements of ASME Sec VIII, Div 1, UG 45.

5.2.2 Next UT inspection of the vessel after repairs may be scheduled in 10 years in accordance with maximum allowable intervals recommended by API-510.

5.0 ULTRASONIC THICKNESS (UT) MEASUREMENTS

Report No.: 10003

Page 10

APPENDIX A

1) Cylindrical Shell Calculations

2) Formed Head Calculations

3) PV Nozzle RL Calculations

4) PV Nozzle Pressure Calculation

5) Half Pipe Jacket Calculations

6) Thermal Shock Stress Analysis

Mechancial Integrity Calculations

Report No.: 10003

Page 11

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-510 PRESSURE VESSEL SHELL EVALUATION

Report No

10003

Inspector

Jeff Walling

Client

ACME Chemicals

Vessel

R-3503

Date

5/10/2010

102.000

MAWP150

Temp.375

SH11.0

E0.85

t act0.643

t prev0.626

t nom0.626

L216

Do103.252 2500

MaterialSS A - 316L

A0.0002

y28.0

MaterialSS A - 304L

R1.500

P200.0

Temp.375

E0.60

t act0.104

t prev0.109

t min0.596

y28.0

t min0.063

t0.506

Vessel Shell(s)

Minimum Thickness Calculations

Internal

External

P154.8

R51.000

t 0.596

PR/(SE-0.6P) = t

Pa (>=)14.7

Internal PR/(SE-0.6P) = t

t 0.063

(in)

(in/year)

(years)

(years)

Ca = t act - t min = 0.047

Cr = t prev - t act / Y = 0

RL= Ca / Cr = >20

Remaining Life Calculations

(in)

(in/year)

(years)

Ca = t act - t min = 0.041

Cr = t prev - t act / Y = 0.00018

RL= Ca / Cr = 229.6

Vac14.7

Vessel Shell Jacket Shell

Vessel Shell

Vessel Shell Jacket Shell

Vessel Shell

D

Jacket Shell

SH0.0

t nom0.109

MAWP200

3.000

D

4B/3(Do/t) = Pa

B

15700

3.0Next Inspection (Yn)

14850

SG1.00

SG1.00

SS

Page 12

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-510 PRESSURE VESSEL SHELL EVALUATION

Report No

10003

Inspector

Jeff Walling

Client

ACME Chemicals

Vessel

R-3503

Date

5/10/2010

MAWP Calculations

MAP - Next Inspection

(in)Where t = t act - 2YnCr = 0.643

(psi)SEt/(R+0.6t) = P = 167.0

MAP - Next Inspection

(in)Where t = t act - 2YnCr = 0.103

(psi)SEt/(R+0.6t) = P = 587.2

Vessel Shell Jacket Shell

162.2P-(SH*.433*SG) = MAWP = (psi) 587.2P-(SH*.433*SG) = MAWP = (psi)

Page 13

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-510 PRESSURE VESSEL SHELL EVALUATION

Report No

10003

Inspector

Jeff Walling

Client

ACME Chemicals

Vessel

R-3503

Date

5/10/2010

Variable Definitions for Shell Calculations:

A = factor determined from Fig. G in Subpart 3 of Section II, Part D and used to enter the applicable material chart in Subpart 3 of Section II, Part D. For the case of cylinders having Do /t values less than 10, see UG-28(c)(2).

B = factor determined from the applicable material chart in Subpart 3 of Section II, Part D for maximum design metal temperature, psi [see UG-20(c)]

Ca = remaining corrosion allowance of the vessel part under consideration, in inches.

Cr = corrosion rate of the vessel part under consideration, in inches per year.

D = inside diameter of the shell course under consideration, in inches.

E = (Internal Calculations) lowest efficiency of any joint in the shell course under consideration. For welded vessels, use the efficiency specified in UW-12.

E = (External Calculations) - Modulus of Elasticity (MOE) at operating temperature for specified material,

P = the design maximum allowable internal working pressure, including static head pressure, in psi.

Pa = maximum allowable external working pressure (includes jacket pressure and vessel internal negative pressure) in psi.

R = inside radius of the shell under consideration, in inches.

Ro = outside radius of the shell under consideration, in inches.

RL = estimated remaining life of the vessel part under consideration, in years.

S = maximum allowable stress value, in psi.

SH = static head, in feet

SG = specific gravity of vessel product.

t = thickness of the vessel part under consideration, variable related to applicable calculation used therein, in inches.

t act = actual thickness measurement of the vessel part under consideration, as recorded at the time of inspection, in inches.

t min = minimum required thickness of vessel part under consideration, as the nominal thickness minus the design corrosion allowance or the calculated minimum required thickness at the design MAWP at the coinciding working temperature, in inches.

t nom = design nominal thickness of head, in inches.

Page 14

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-510 PRESSURE VESSEL SHELL EVALUATION

Report No

10003

Inspector

Jeff Walling

Client

ACME Chemicals

Vessel

R-3503

Date

5/10/2010

t prev = previous thickness measurement of the vessel part under consideration, as recorded at last inspection or nominal thickness if no previous thickness measurements, in inches.

Y = time span between thickness readings or age of the vessel if t nom is used for t prev, in years.

Yn = estimated time span to next inspection of the vessel part under consideration, in years.

Page 15

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-510 PRESSURE VESSEL HEAD EVALUATION

Report No

10003

Inspector

Jeff Walling

Client

ACME Chemicals

Vessel

R-3503

Date

5/10/2010

D102.000

MAWP150

T375

L =

Vessel Head(s)

Minimum Thickness Calculations

Hemispherical Head

t min = 0.488

PL/(2SE-0.2P) = t min

E1.00

DMAWP T E

Head IDTop Head

Head TypeEllipsoidal

t nom0.626

Material SS A - 316L

SH0.0

P150.0

Head IDBttm Head

Head TypeEllipsoidal

t nom0.626

MaterialSS A - 316L

SH13.0

P155.6

Head ID Head Type t nom

Material P

2:1 Ellipsodial Head

PD/(2SE-0.2P) = t min (knl)

Torispherical Head

PLM/(2SE-0.2P) = t min (knl

R =

Top Head Ellipsoidal

M =

For Torispherical Heads

L =

t min = 0.506

R =

Bttm Head Ellipsoidal

M = L =

t min =

R = M =

Internal:

B/(Ro/t) = PaExternal:Note: Minimum thickness calculations for heads under external pressures are determined by an iteration of the "t" variable until Pa = maximum allowable external working pressure = Design Int. Vac (ext. psi) + Jacket PSI

6000 6100Ro 91.813 Ro 91.813Pa > 14.7 Pa > 14.7

0.0625E/(Ro/t)^2 = Pa (for all three head types)or

(in)

(in)

(in)

SH

P0.9D/(2S-0.2P) = t min (crwn) PL/(2S-0.2P) = t min (crwn)

B B

15700 15700

1/2 Pipe JacketMain Vessel Data

SG11.00

SG21.00

SG3

S S S

(reference supplemental calcs for other head type formulas)

Page 16

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-510 PRESSURE VESSEL HEAD EVALUATION

Report No

10003

Inspector

Jeff Walling

Client

ACME Chemicals

Vessel

R-3503

Date

5/10/2010

t act0.587

t prev0.626

y28.0

t min0.488

(in)

(in/year)

(years)

(years)

Ca = t act - t min = 0.099

Cr = t prev - t act / Y = 0.00139

RL= Ca / Cr = 71.3

Next Inspection (Yn) 3.0

Remainng Life Calculations

MAWP Calculations

(in) t = 0.579

Top Head

Top Head

t act0.620

t prev0.626

y28.0

t min0.506

(in)

(in/year)

(years)

Ca = t act - t min = 0.114

Cr = t prev - t act / Y = 0.00021

RL= Ca / Cr = 531.8

t = 0.619

Bttm Head

Bttm Head (in)

t actt prev yt min

(in)

(in/year)

(years)

Ca = t act - t min =

Cr = t prev - t act / Y =

RL= Ca / Cr =

t = (in)

Hemispherical Head

2SEt/(R+0.2t) = P

2:1 Ellipsodial Head

2SEt/(D+0.2t) = P (knl)

Torispherical Head

2SEt/(LM+0.2t) = P (knl)Internal

MAP

Ellipsoidal

Ellipsoidal

Where t = t act - 2YnCr Where P = MAP at the Next Inspection

2St/(0.9D+0.2t) = P (crwn) 2St/(L+0.2t) = P (crwn)

(reference supplemental calcs for other head type formulas)

Where MAWP = P-(SH*.433*SG)

(psi)P = 177.9

P = 190.2 (psi)

P = (psi)

MAWP = (psi)

(psi)

(psi)

MAWP =

MAWP =

177.9

184.6

Page 17

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-510 PRESSURE VESSEL HEAD EVALUATION

Report No

10003

Inspector

Jeff Walling

Client

ACME Chemicals

Vessel

R-3503

Date

5/10/2010

A = factor determined from Fig. G in Subpart 3 of Section II, Part D and used to enter the applicablematerial chart in Subpart 3 of Section II, Part D. For the case of cylinders having Do /t values less than 10, see UG-28(c)(2).

B = factor determined from the applicable material chart in Subpart 3 of Section II, Part D for maximum design metal temperature, psi [see UG-20(c)]

Ca = remaining corrosion allowance of the vessel part under consideration, in inches.

Cr = corrosion rate of the vessel part under consideration, in inches per year.

D = inside diameter for the head skirt, in inches.

Do = outside diameter for the head skirt, in inches.

E = (Internal Calculations) lowest efficiency of any joint in the vessel part under consideration. For welded vessels, use the efficiency specified in UW-12.

E = (External Calculations) - Modulus of Elasticity (MOE) at operating temperature for specified material.

h = inside height for the head, in inches.

ho = outside height for the head, in inches.

H = inside head height from tangent, in inches.

K = factor depending on head proportions D/2h and determined as 1/6[2+(D/2h)^2]

Ko = factor depending on head proportions Do/2ho (see table UG 33.1)

L = Hemi. Hds - inside spherical or crown radius of the head under consideration, in inches,. Ellip. and Tor. Hds - inside spherical or crown radius, in inches,

M = a factor used in the formulas for torispherical heads where M= 0.25(3+(L/r)^.5)

P = the design maximum allowable internal working pressure, including static head pressure, in psi.

Pa = maximum allowable external working pressure, including static head pressure, in psi.

r = inside knuckle radius, in inches.

R = inside radius of the shell under consideration, in inches.

Ro = Hemi - outside radius in inches. Ellip. - the equivalent outside spherical radius taken as KoDo. Tor. - outside radius of the crown portion of the head, in inches.

Varible Definitions for Head Calculations:

Page 18

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-510 PRESSURE VESSEL HEAD EVALUATION

Report No

10003

Inspector

Jeff Walling

Client

ACME Chemicals

Vessel

R-3503

Date

5/10/2010

RL = estimated remaining life of the vessel part under consideration, in years.

S = maximum allowable stress value, in psi.

SH = static head, in feet

SG = specific gravity of vessel product.

t = thickness of the vessel part under consideration, variable related to applicable calculation used therein, in inches.

t act = actual thickness measurement of the vessel part under consideration, as recorded at the time of inspection, in inches.

t min = minimum required thickness of vessel part under consideration, as the nominal thickness minus the design corrosion allowance or the calculated minimum required thickness at the design MAWP at the coinciding working temperature, in inches.

t nom = design nominal thickness of head, in inches.

t prev = previous thickness measurement of the vessel part under consideration, as recorded at last inspection or nominal thickness if no previous thickness measurements, in inches.

Y = time span between thickness readings or age of the vessel if t nom is used for t prev, in years.

Yn = estimated time span to next inspection of the vessel part under consideration, in years.

Page 19

Minimum Thickness Determinations:

a) The following nozzle minimum thicknesses are based on current ASME Standards. Minimum thickness allowed for nozzles walls are based on standard pipe thicknesses minus 12.5% or connecting shell/head required thickness whichever is smaller. (ASME Sect VIII, UG-45)

b) Large size nozzles or nozzles subject to high pressures are calulated per ASME Sect VIII, DIV 1, UG-27 as follows: PR/SE-0.6P = t.

Size 2" 3" 4" 6" 8" 10" 12"t min 0.135" 0.189" 0.207" 0.245" 0.282" 0.319" 0.328"

>12"0.328"

1"0.116"

3/4"0.100"

1.5"0.127"

MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS

API-510 PRESSURE VESSEL NOZZLE EVALUATION

Report No

10003

Inspector

Jeff Walling

Client

ACME Chemical

Vessel

R-3503

Date

5/10/2010

Size t prev t act t min Ca Cr RL

Nozzle Remaining Life Calculations:

Noz ID MaterialTML AgeMW1 0.513 0.185 0 >2028.0 0.50024008 SS A - 316L 0.328N1 0.529 0.201 0 >2028.0 0.50020009 SS A - 316L 0.328N2 0.210 0.021 0.00021 98.028.0 0.2163010 SS A - 316L 0.189N3 0.153 0.018 0.00004 >2028.0 0.1542011 SS A - 316L 0.135N4 0.153 0.018 0.00004 >2028.0 0.1542012 SS A - 316L 0.135N5 0.213 0.024 0.00011 224.028.0 0.2163013 SS A - 316L 0.189N6 0.395 0.076 0 >2028.0 0.36510014 SS A - 316L 0.319N7 0.388 0.106 0.00064 164.928.0 0.4068015 SS A - 316L 0.282N8 0.106 -0.010 0.00011 028.0 0.1091016 SS A - 316L 0.116N9 0.107 -0.009 0.00007 028.0 0.1091017 SS A - 316L 0.116N10 28.06018 SS A - 316LN11 28.06019 SS A - 316LN12 0.209 0.020 0.00025 80.028.0 0.2163020 SS A - 316L 0.189N13 0.154 0.019 0.00000 >2028.0 0.1542021 SS A - 316L 0.135N14 28.0 0.1542022 SS A - 316L 0.135N15 28.0 0.1542023 SS A - 316L 0.135N16 28.0 0.1451.5024 SS A - 316L 0.127N17 28.06025 SS A - 316LN18 28.0 0.1542026 SS A - 316L 0.135N19 28.06027 SS A - 316LN20 28.0 0.1791028 SS A - 316L 0.116

10003Report No.:

Page 20

Client: ACME Chem

Date 5/11/2010PRESSURE VESSEL NOZZLE CALCULATIONS

Project No.: 10003-001 Vessel R-3503Year Built

1982ASME S8 D1, UG-27_45

Inside Radius, in. 0.560

Design Pressure, psi150.0

Joint Efficeincy0.60

Stress, psi15700

Int. Pressure Min. Thickness Calc

Calculated t, in. 0.063

Outside Diameter, in.1.32

Minimum Thickness, in.0.100

External Pressure Minimum Thickness CalculationEffective Length, in. 9 A 0.007

L/Do 6.8182

Do/t 13.2

Thickness, in.0.100 Internal Pressure, psi1519.4

Cu Ft0

Cylinder Capacities

Plate DataSq In

32

Gals0

lb's ofWater

0

ProdS.G.1.00

Sq Ft

0

lb's of Prod.

0

lb's of Steel

1

MetalCu in

3

Prod + Steel

1

Shell Length, in. 9.000

Shell Thickness, in0.109

Variables for Capacities

Total lb's

Shell Radius, in.0.560

Comp. N8 & N9

r

P

E

S

t

L

t

Do

External Pressure, psi

Internal Pressure Calculation SEt/R+0.6t = P

Pt = tnom - Ca =

Material SS A - 316L

Factor from Figure G

Thickness, in.0.100

External Pressure CalculationA 0.007

L/Do 6.8182

Do/t 13.2

4B/3(Do/t) = Pa

t

External Pressure

Factor from Figure G

X-Chart HA-4

X-Chart HA-4

MAWP150

Temp.375

tnom0.109

Ca0.009

S.H.0.0

Do1.32

Prod. SG1

t for Reinf. Calc0.005

PR/SE-0.6P = t and PR/S-0.6P = t

t

Noz. Type Sch 10 Pipe / WN

04

Size1

0.116Minimum Required Thickness =0.488Attaching Component tmin =

Standard Pipe - 12.5% = 0.116Minimum Design t = 0.125

9400

Pa 949.5

B

4B/3(Do/t) = Pa

Stress Value

9400

Pa 949.5

B Stress Value

NOTE:Flange Weight Not Considered

Page 1 of 1Project No.: 10003-001 Author: JLW

Page 21

Client: ACME Chem

Date 05/11/10PRESSURE VESSEL HALF PIPE JACKET CALCULATIONS

Project No.: 10003-001 Vessel R-3503

Year Built1982

ASME SECTION VIII, D1 NON-MANDATORY APP. EE

Cu Ft23.53

Cylinder Capacities

Plate DataSq In

52850.23

Gals176.02

lb's ofWater 1467.5

ProdS.G.

1

Sq Ft

367.3

lb's of Prod.1467.5

lb's of Steel

1632.2

MetalCu in

5760.7

Prod + Steel

3099.6

Shell Length, in. 9613

Shell Thickness, in0.109

Variables for Capacities

Total lb's

Shell Radius, in.1.750

Component: VesseJacket Material SS A - 304L

MAWP200

Temp.375

tnom0.109

Ca0.000

Sch1010 3.5

Size3.5

F17430

K11

Sc6120

Max Permisible Jckt Int. Pressure

Pjm1585

F/K = Pjm

Sv15700

Dv102

tv0.625

Pv150

Tv375

Condition Acceptable, Pjm >Jacket Design MAWP

Attaching Component Variables

R1.641

P200

S14850

Half Pipe Jacket Internal Pressure Minimum Thickness Calcs

t0.063 PR/.85S-0.6P = t (but not < 0.063")

R1.641

t0.109

S14850

Half Pipe Jacket Internal Pressure Calculations

P806.3 .85St/R+0.6t = P

Page 1 of 1Project No.: 10003-001 Author: JLW

Page 22

THERMAL SHOCK EVALUATION FOR ACME CHEMICALS REACTOR R-3503 IN BEAUMONT, TX

Page: 1 of 4

References:

ASME B&PV Code, Section VIII, Division 1, 2010 Edition, July 1st

ASME B&PV Code, Section II Part D, 1995 Stress Tables, Addenda 1997

API-510 Pressure Vessel Inspection Code Ninth Edition, June 2006

API-572 Inspection Practices for Pressure Vessels, Third Edition, Nov. 2009

DOE Fundamentals Handbook, Material Science Module 3 Thermal Shock, DOE-HDBK-1017/2-93Rev-0

Pressure Vessel Handbook, Eighth Edition, by Eugene F. Megyesy

Thermal Shock Stresses:

Thermal shock (stress) in the vessel wall is the result of sudden exposure of the shell wall material, that is constrained in some manner so it cannot expand/contract, to a heating or cooling medium with an extreme temperature difference from the existing metal temperature thereby causing momentary non-uniform temperature zones in the metal. These forces (tensile stress created as it cools or compressive stress as it expands against the constraints) can be instantly jacked up to well over the yield stress of the material. Thin walled vessels can yield to the point of plastic deformation in some cases. These stresses, cyclic in nature, can also lead to brittle fracture and fatigue failure of the materials (often manifested as cracks in the heat affected zone (HAZ) or toe of the weld of jacketed vessels). Standard operating procedures should include a sequencing system that ensures a slow transition between heating and cooling of the vessel to maintain even temperature gradients in the vessel and jacket walls thereby avoiding the extreme stresses that can be induced into the jacket and shell material by sudden and extreme temperature changes. A stress analyses of the prevailing conditions show that the thermal shock experienced by Reactor Vessel R-3503 can reach up to greater than yield stress of the material thereby being a possible cause of the internal bulges apparent on the inside of the vessel congruent with the half pipe jacket attachment welds (most prominent at the first ring). Additionally, the vessel has a history of leaking coil welds and is presently leaking in the bottom head coils and has wet insulation in the shell that is suspect to the source possibly being leaking shell coils as well. Recommendations:

1) Review the standard operating procedures to ensure that it includes a sequencing system that maintains a slow transition between initial heating and cooling the vessel to ensure even temperature gradients in the vessel and jacket walls.

2) Strip the lower 24” to 36” of shell insulation and do a VT exam to identify leaking coil welds. 3) Perform a Dye Penetrant examination of the exposed external coil attachment welds and HAZ of

the shell and bottom head to identify any incipient cracking. 4) Perform Brinell Hardness examination of the exposed external coil attachment welds and shell

HAZ of the shell and bottom head to identify any possible hardening of the metal due to the cycle effect of the thermal shocking (hammering). BHN should be between 149 - 217

5) Perform Dye Penetrant & Brinell Hardness examinations on the bulged areas on the internal surfaces of the vessel lower shell and bottom head at the next scheduled internal inspection.

Page 23

THERMAL SHOCK EVALUATION FOR ACME CHEMICALS REACTOR R-3503 IN BEAUMONT, TX

Page: 2 of 4

Thermal Shock Stress Analysis: R-3503 Material: 300 Series Stainless Steel, SA 240 316L Yield Stress: 25,000 psi Tensile Stress: 70,000 psi

Thermal Shock Stress Evaluation

E = MOE, psiα = COE, °F-1

Tmin = Operating temperature of cooling mediumTmax = Operating temperature of heating medium∆T = Temperature Diff., ºF (=Tmax-Tmin)S1 =Stress in compression of vessel wall, psi (= Eα∆T)

E α Tmin Tmax ∆T S1

26750000 0.0000091 50 350 300 73028PSI °F-1 ºF ºF ºF PSI

Hoop Stress (Operating Pressure) Evaluation

p = maximum pitch, in. (dist between stiffeners)P = max operating pressure on vessel wall, psiC = 2.1, Coeff. for welded stays for plates < 7/16 in. in thicknesst = thickness of the vessel part under consideration, inS2 = hoop stress in vessel wall, psi (= P/((t/p)^2C))

p P C t S2

3.5 140 2.1 0.25 13067in psi in ºF

Final Stress Analysis

S = total stress on vessel wall, psi (S1 + S2)Y = yield stress of material, psiRatio = S/Y Ratio's > 0.6 may experience chronic damage in the form of brittle fracture (cyclic effect).

Ratio's > 1.0 may experience acute damage in the form of brittle fracture, weld cracks, and deformation.

S Y Ratio

86094 25000 3.44

psi psi Overstress condition

(when area of interest is not slowly and evenly heated over sufficient period of time)

Page 24

THERMAL SHOCK EVALUATION FOR ACME CHEMICALS REACTOR R-3503 IN BEAUMONT, TX

Page: 3 of 4

Page 25

APPENDIX B

1) Component Thickness Measurements

2) Nozzle Thickness Measurements

Thickness Measurement Records

Report No.: 10003

Page 26

Inspection Data

Components with Vert. Axis: tml-1 N., tml-2 E., tml-3 S., tml-4 W. (Drawing N.)

Components with Horz. Axis: tml-1 Top, tml-2 Side, tml-3 Bttm., tml-4 Side (Clock Wise)

API-510 PRESSURE VESSEL COMPONENT THICKNESS RECORD

Report No

10003

Inspector

Jeff Walling

Client

ACME Chemical

Vessel

R-3503

Date

5/10/2010

Comp ID Location Service tml-1 tml-2 tml-3 tml-4 MinimumCML #

Top Head Crown Radius Product 0.616 0.603 0.603 0.587 0.587001

Vessel Shell Upper Shell Product 0.655 0.655 0.650 0.652 0.650002

Vessel Shell Mid Shell Product 0.654 0.656 0.663 0.643 0.643003

Vessel Shell Lower Shell Product 0.659 0.665 0.664 0.660 0.659004

Bttm Head Crown Radius Product 0.646 0.620 0.640 0.637 0.620005

Jacket Coil Shell Steam 0.107 0.106 0.106 0.108 0.106006

Jacket Coil Bttm Head Steam 0.106 0.105 0.107 0.104 0.104007

24" MW MW1 Manway 0.531 0.521 0.513 0.528 0.513008

20" MW N1 Agitator 0.542 0.538 0.539 0.529 0.529009

3" Nozzle N2 Blank 0.213 0.212 0.212 0.210 0.210010

2" Nozzle N3 GOAG 0.154 0.154 0.154 0.153 0.153011

2" Nozzle N4 Injection 0.153 0.155 0.153 0.155 0.153012

3" Nozzle N5 Reflux 0.213 0.213 0.214 0.213 0.213013

10" Nozzle N6 Reflux 0.395 0.396 0.396 0.399 0.395014

8" Nozzle N7 Vent 0.400 0.401 0.388 0.392 0.388015

1" Nozzle N8 Nitogen 0.110 0.106 0.106016

1" Nozzle N9 PSI Gage 0.110 0.107 0.107017

6" Boss N10 Site Glass018

6" Boss N11 Site Glass019

3" Nozzle N12 MEA 0.214 0.215 0.212 0.209 0.209020

2" Nozzle N13 NOAH 0.154 0.155 0.154 0.155 0.154021

2" Nozzle N14 T.I.022

Report No.: 10003

Page 27

Comp ID Location Service tml-1 tml-2 tml-3 tml-4 MinimumCML #

2" Nozzle N15 T.I.023

1.5" Nozzle N16 T.I.024

6" Boss N17 Cooling025

2" Nozzle N18 Recirc026

6" Boss N19 Cooling027

1" Nozzle N20 Injection028

Report No.: 10003

Page 28

APPENDIX C

1) Vessel Drawing

2) Shell Layout Drawing

Inspection Drawings

Report No.: 10003

Page 29

Page 30

Page 31

APPENDIX D

1) Pressure Vessel Inspection Checklist

Inspection Checklist

Report No.: 10003

Page 32

Company: ACME Chemical Vessel: R-3503 Report No.: 10003 Date: 5/10/2010

Inspector: Jeff WallingCert No.: 2782

API-510 PRESSURE VESSEL INSPECTION CHECKLIST

a. Xb. Xc. Xd. X

a. Xb. Xc. X

b.

c.

a.b.c.d.e.

a. Xb.c.d.e. Xf.g. X

a. Xb. Xc. Xd. Xe. Xf.g. Xh.

a. Xb. Xc. Xd. Xe. Xf. Xg. X

a. Xb. X

X Inlet: 6" Outlet: 6"d. Xe. X None Foundf. X 152psi@366degFg. X Ruprtur Disc - FIKE

a.b.

c.

1.1 Steel Members

Visually inspect for pitting, and corrosion.

Check fnd bolts secure with minimum thrd engagement.

Check for coating failures

Check attachment welds for cracking and corrosion.

1.3 Concrete Foundation Supports

Inspect for broken concrete, spalling and cracks.

Inspect for erosion under foundation.

Check for settlement around perimeter of tank.

1 FOUNDATION

1.4 Wooden Saddle Support

Check for degradaded members (split, broken, dry rotted et.).

Inspect for errosion and vegetation tank fnd.

Check for settlement around perimeter of tank.

1.2 Containment

Inspect the area for buildup of trash, vegetation and obstructions.

Inspect sump drain operation.

Check that runoff rainwater drains away from the tank.

Describe type of construction - Earthen, Concrete, Asphalt, Grav

Inspect condition of containment.

2.1 External Visual Inspection

2 SHELLS

Visually inspect shell surface for paint failures, pitting, corrosion, denting, out-of-round and part deformation.

Check for broken, unused insulation rod supports causing corrosion nodes.

Visually inspect weld joints for cracking, pitting, corrosion and signs of leaking (product residue).

Perform dye penetrant or magnetic particle tests if leaks or cracks are suspected.

Check for proper grounding

2.2 Internal Visual Inspection

Check atmospheric conditions, fill out and post safe entry permit form.

Appropriate and wear required PPE for safe entry.

Inspect shell surfaces for coating failures, pitting and corrosion.

Inspect baffle plate surfaces weld attachments for cracking, pitting, or corrosion. Check bolts are secure with minimum thread engagement.

Inspect agitator shaft and blade surfaces for cracking, pitting, corrosion. Check bolts are secure and have minimum thread engagement.

Inspect heating coils surfaces and weld attachments, for cracking, pitting, corrosion. Check bolts are secure with minimum thread engagemen

Inspect pressure containing weld joints for cracking, pitting, and corrosion.

Perform dye penetrant or magnetic particle tests if cracks are suspected.

3.1 Manways and Nozzles

3 SHELL APPURTENANCES

Inspect for cracks or signs of leakage on weld joints at nozzles, manways, and reinforcing plates.

Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection.

Inspect for flange leaks and leaks around bolting.

Check flange bolts are secure and have minimum thread engagement.

Inspect sealing of insulation around manways and nozzles.

Check for inadequate manway flange and cover thickness on mixer manways.

Check exposed flange and cover faces.

3.2 Relief Devices

Inspect for flange leaks and leaks around bolting.

Check flange bolts are secure and have minimum thread engagement.

Record inlet and outlet sizes sizes.

Check that relief system outlet discharges to safe location (outside of building).

Record certification date

Record pressure setting

Record type and ID

Inspect sample lines for function of valves and plugging of lines, including drain or return-to-tank line.

Check circulation pump for leaks and operating problems.

Test bracing and supports of sample system and equipment.

3.3 Shell-Mounted Sample Station

a.

c.

Clean angles and other components that form catch basins and check for degradation and corrosion..

Inspect nozzle penetration surfaces and welds for corrosion, cracking and deformation.

Page 1 of 3

Page 33

Company: ACME Chemical Vessel: R-3503 Report No.: 10003 Date: 5/10/2010

Inspector: Jeff WallingCert No.: 2782

API-510 PRESSURE VESSEL INSPECTION CHECKLIST

a. X

a. Xb. Xc. X

a.b.

c.d.

a.b.c.

a. Xb. Xc. Xd.e.f.g. Xh.

a. Xb. Xc. X

a.b.c.d.

a. Xb. X

Inspect condensate drain for presence of oil, indicating leakage.

3.4 Heater (Steam Coils)

Inspect for proper mounting flange and support.

3.5 Mixer/Agitator

Inspect for leakage.

Inspect condition of power lines and connections to mixer.

Inspect deck plate for corrosion-caused thinning or holes (not drain holes) and paint failure.

Inspect plate-to-frame weld for rust scale buildup.

Inspect grating for corrosion-caused thinning of bars and failure of welds.

Check grating tie down clips. Where grating has been retrofitted to replace plate, measure the rise of the step below and above the grating surface and with other risers on the stairway.

3.6 Deck Plate and Grating

Inspect stairway stringers, rungs and treads for corrosion, paint failure and weld failure.

Inspect stairway supports to shell welds and reinforcing pads.

Inspect steel support attachment to concrete base for corrosion.

3.7 Stairway Stringers/Rungs/Treads

Identify type of jacket (half pipe, cylindrical, dimpled and spot welded, etc.)

Measure and record pitch distances.

Visually inspect shell surface for paint failures, pitting, corrosion, denting, out-of-round and part deformation.

4 VESSEL JACKET

Clean angle support rings and inspect for corrosion and thinning on plate, annular space and welds.

Inspect the shell-to-foundation seal or barrier.

Check for broken, unused insulation rod supports causing corrosion nodes.

Visually inspect for weld joints for cracking, pitting, corrosion and signs of leaking (product residue).

Perform dye penetrant or magnetic particle test if leaks or cracks are suspected.

Check for holes, missing portions, deterioration due to corrosion or abuse.

Check for sufficient sealing, especially around vessel appurtenances.

Check for wetness

5 INSULATION

4.1 Jacket Shell

5.1 Visual Inspection

Check that indicators are securely attached and operating properly.

Check that indicators are in accessible locations and readable.

Check that indicators have current calibration date.

6 PRESSURE /TEMPERATURE INDICATORS

6.1 Physical and Operating Conditions

Check for any damage, and corrosion build up.

Check that ASME plate is securely attached

Check that ASME plate is in accessible location and readable.

7 ASME/NAME PLATE DATA

7.1 Physical Condition

Page 2 of 3

Page 34

Company: ACME Chemical Vessel: R-3503 Report No.: 10003 Date: 5/10/2010

Inspector: Jeff WallingCert No.: 2782

API-510 PRESSURE VESSEL INSPECTION CHECKLIST

a. X 1405b. X 2444-1c. X RT3d. X FV/[email protected]. X 0.625"g. X 0.625"h.i.j.

k.l. X Alloy Fab

m. X 1982

Board Number

Serial Number

7.2 Record Following ASME Data

Radiography Examination

MAWP

MDMT

Nominal Shell Thickness

Nominal Head Thickness

Nominal Hieght

Head Material

Shell Material

Jacket Material

Manufacturer

Year Built

a.b.c.d. Xe. Xf. X

Head and skirt lengths and type.

8 VESSEL LAYOUT DRAWINGS

8.1 Record Following Data

Shell lines of support (Head Tang, Braces, Jckt Closures)

Foundation support member dimensions and orientation.

Inside/Outside diameter.

Vessel part nominal thicknesses.

Nozzle layouts, sizes and uses.

a. Xb. Xc. Xd. X

9 UT THICKNESS READINGS

9.1 Measure and Record Vessel Part Thicknesses

Shell - (4) locations, (1) in each quadrant for each course.

Jacket - As required (at least (4) locations).

Nozzles - (4) locations, (1) in each quadrant for 2 inches and greater, (1) for < 2"

Heads - (4) locations, (1) in each quadrant.

Notes:

1) Vessel has issues with pitting and cracking in the lower half of shell internally 2) The 8" vent to scrubber Isolation valve has significant deterioration and exfoliation of the carbon steel components. 3) There are issues with Insulation degradation.

Page 3 of 3

Page 35

APPENDIX E

1) U1 Mfg Data Sheet

Manufacturers Data Sheets

Report No.: 10003

Page 36

Page 37

Page 38

Page 39

APPENDIX F

Inspection Photographs

Report No.: 10003

Page 40

ACME CHEMICALS. - R-3503 REPORT – 10003-001 INSPECTION PHOTOGRAPHS

Reactor vessel R-3503 top head

ASME Nameplate.

Page 41

ACME CHEMICALS. - R-3503 REPORT – 10003-001 INSPECTION PHOTOGRAPHS

Rupture Disc and corroded iso vent valve

Corroded iso vent valve

Page 42

ACME CHEMICALS. - R-3503 REPORT – 10003-001 INSPECTION PHOTOGRAPHS

1” Plug leaking condensed vent gases onto iso vent valve

Page 43

ACME CHEMICALS. - R-3503 REPORT – 10003-001 INSPECTION PHOTOGRAPHS

Agitator (oily residue all about)

Reactor ½ pipe jacket view through insulation cutout

Reactor bottom view with ½ pipe jacket coils

Page 44

ACME CHEMICALS. - R-3503 REPORT – 10003-001 INSPECTION PHOTOGRAPHS

Support leg corroded at foundation and foundation cracking

T.I. nozzle (N16) with internal pitting and crack

Page 45

ACME CHEMICALS. - R-3503 REPORT – 10003-001 INSPECTION PHOTOGRAPHS

Internal view (distinct coloration/pattern where the heater coils affix to the shell)

Area about mid shell girth weld (N Side) with concentrated pitting

Page 46

ACME CHEMICALS. - R-3503 REPORT – 10003-001 INSPECTION PHOTOGRAPHS

Stress cracks at the baffle attachment weld to shell

Cracks in nozzle N16

Page 47

ACME CHEMICALS. - R-3503 REPORT – 10003-001 INSPECTION PHOTOGRAPHS

Bottom head coil with leak (Typical)

Bottom head coil with active and repaired leaks (Typical)

Page 48

ACME CHEMICALS. - R-3503 REPORT – 10003-001 INSPECTION PHOTOGRAPHS

Bottom coils with most pronounced deflections

Bottom head internal surface

Page 49

APPENDIX G

1) UT Exam Record

2) NDE Technician Certification

3) API Inspector Certification

NDE Records

Report No.: 10003

Page 50

ULTRASONIC EXAMINATION REPORT CLIENT: ACME Chemicals CLIENT PO #: 257REPORT NO.: 10003 EIT JOB #: 10003 EQUIP ID: Reactor R-3503 SERVICE: Propane JOB DESCR.: Out-of-Service Inspection EXAM DATE: 5/10/2010 PROCEDURE #: EIT-UTT-01 SPECIFICATION: API-510 MATERIAL: CS

TEST PARAMETERS

UT UNIT Unit: Panameterics DL37+ S/N: 5904 Cal Date: 3/23/2010

PROBE SPECIFICATIONS Long Frq 5 mHZ Size: .375 Type: D790 S/N 905216 SW Frq: mHZ Size: Type: S/N SW Frq: mHZ Size: Type: S/N SW Frq: mHZ Size: Type: S/N

COUPLANT MFG: Ultra Grade Gel-40 Surface Cond: Coated

CALIBRATION STANDARD Type: Raycheck 6 Step Block S/N: 00-7235

Calibration Reference Level (db) 0: 39 45: 60: 70: Other: 0: 45: 60: 70: Start Time: 0800 End Time: 1200 Start Time: End Time:

Results/Comments: All measurement at nominal UT Level II Technician: Jeff Walling

Page 51

NAME:

METHOD LEVEL DATE EXAMINER GENERAL SPECIFIC PRACTICAL COMPOSITEUTT II 4/9/2010 Joe Monroe 86% 100% 95% 94% 4/9/2015PT II 9/3/2010 Wayne Bailey 93% 95% 91% 93% 9/3/2015MT II 9/3/2010 Wayne Bailey 93% 95% 85% 91% 9/3/2015

MFE II 1/21/2011 Brian Rotto 90% 85% 89% 88% 1/21/2016

FROM TO6/2009 9/2013

1/19/2004 11/20/20099/1/1998 4/15/2003

9/16/1995 9/1/1998

EAGLE I. TECHNOLOGIES Jeffrey WallingNDT CERTIFICATION / QUALIFICATION RECORD Employee ID Number: 3965

NDT CERTIFICATIONS EXAM SCORES EXPIRATION DATE RESTRICTIONS

thickness onlyNoneNoneNone

PREVIOUS EMPLOYER NDT CERTIFICATIONSCOMPANY NAME/ADDRESS NDT METHODS & HIGHEST LEVEL ATTAINED

Westech Inspection Level II UT thickness limitedBP/GIANT Level II UTT/MT/PT/LT

MATIS Level II UTT/MT/PT

CAPE Level II UTT/MT/PT/MFE

EYE EXAMINATION EDUCATION AND TRAININGDATE TYPE TESTED BY PASS / FAIL ORG DATE LENGTH

10/22/2012 Far Amer. Best Pass MATIS 12/16/1997 12 hours10/22/2012 Near Amer. Best Pass MATIS 12/16/1997 12 hours10/22/2012 Color Contrast Amer. Best Pass Eastern NDT 4/9/2010 24 hours

WCFS 8/25/2010 20 hoursWCFS 8/27/2010 12 hoursCAPE 1/21/2011 8 hours

CERT EXP DATE CERT EXP DATEAPI 653 4/30/2014 PD DEP 1/10/2016API 510 6/30/2014 NB Comm. 2014API 570 6/30/2014 VA-B&PV Com 2013 HOURS

STI 9/18/2017 MET.AS 2012

-ASNT

CERT No.

10/22/2012DATE

INSTRUCTOR SUBJECTDavid Spooner Level II UTT

Joe Monroe Level II UTTDavid Spooner Level II PT

refer to employee eye exam cert (CAPE-FRM-101) Stan Meyer Level II MT

OTHER NOTABLE CERTIFICATIONS OR QUALIFICATIONS

Stan Meyer Level II PTBrian Rotto Level II MFE

TRAINEE / LEVEL I NDT HOURS (IF APPLICABLE)METHOD EMPLOYER TOTAL DATE

Jeff Walling

This NDT Qualification record is in accordance with EIT-WP-01 and SNT-TC-1A (2006). All historical information supplied for this document is true and accurate to the best of my knowledge.SIGNATURE

EIT Certification Record Form: CAPE-FRM-102

NDE PROGRAM MANAGER

Page 52

Page 53

APPENDIX H

ASME B&PV Code, Section VIII, Division 1, 2010 Edition, July 1st

ASME B&PV Code, Section II Part D, 1995 Stress Tables, Addenda 1997

API-510 Pressure Vessel Inspection Code Ninth Edition, June 2006

API-572 Inspection Practices for Pressure Vessels, Third Edition, Nov. 2009

DOE Fundamentals Handbook, Material Science Module 3 Thermal Shock, DOE-HDBK-1017/2-93Rev-0

Pressure Vessel Handbook, Eighth Edition, by Eugene F. Megyesy

ASNT SNT-TC-1A 2011 Edition

References

Report No.: 10003

Page 54