Thickness Monitoring Location Guide PDF

ConocoPhillips Indonesia
Maintenance Engineering & Asset

Integrity
Manual
TITLE
Thickness Monitoring Location Guide
DOCUMENT NUMBER
COPI-OPR-OM-MA-00086
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DATE
27 May04
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Integrity
TITLE
THICKNESS MONITORING
LOCATION GUIDE
Manual
DOCUMENT NUMBER
REV
DATE
PAGE
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.
PREPARATIONS PIPING ................................................................................... 0
7.
PREPARATIONS VESSELS............................................................................... 0
8.
PREPARATIONS STORAGE TANKS ................................................................ 0
APPENDIX A: DEFINITIONS AND ABBREVIATIONS .................................................. 0

Integrity
TITLE
LOCATION GUIDE
1.
Manual
DOCUMENT NUMBER
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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
Verify personnel performing Ultrasonic Thickness Measurements are qualified.
6.2
Ensure all instruments to be used have been properly calibrated.

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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
SPECIAL TOOLS AND EQUIPMENT

None
6.5
REFERENCES
API 570: Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems
6.6
PROCEDURE
NOTE
Thickness measurement locations should be identified on the applicable

inspection drawing. New locations not previously inspected should be added
to the drawing when required.
6.7
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.

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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
Injection Point Inspection

Injection points are generally areas of increased risk of corrosion, either from condensation or
incomplete mixing of chemicals. For injection points that use a quill, the TMLs should be
located at 2 and 4 pipe diameters away from the pipe in the downstream direction and
distributed at 90 degree intervals around the pipe

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LOCATION GUIDE
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PREPARATIONS Vessels
7.1
7.2
7.3
7.4

None
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
Thickness measurement locations should be identified on the applicable

7.7
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.

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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.
PREPARATIONS Storage Tanks

8.1
8.2
8.3
8.4

None
8.5
REFERENCES
API-653 Tank Inspection Code
8.6
PROCEDURE
NOTE
Thickness measurement location should be identified on the applicable

8.7
Shell -Course "A" of non-Insulated Tanks Using A Grid System

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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
2 left of vertical seam, 2 above chime weld. A1
BTM RT
8.7.3
2" above chime, midpoint left around shell plate. A2
BTM CN
8.7.4
2 above chime, 2 right of next vertical weld seam. A3
BTM LF
8.7.5
2 right of vertical weld, 2 down from top plate

horizontal weld. A4
TP
LF
2 below horizontal weld seam, directly below each

vertical weld seam from course B. **a.m.a.n.
TP
JCT
2 below horizontal weld seam, 2 left of vertical

weld seam, above 9.1.2.
TP
RT
8.7.6
8.7.8
8.7.9
Pick up nozzles in this plate, right to left; top to bottom if

TP
MW
vertically aligned. Include nominal size in location description;
MTB MW 4NOZ
top, bottom, and both sides on thickness on nozzles and on man-ways.
8.7.10 Continue on the next shell plate to the left in successive

numbering, as in 9.1.2 through 9.1.7 above.
8.8
Shell -Course "B" of non-Insulated Tanks Using A Grid System

NOTE
Course B starting point is left of first vertical weld seam
to left of course A starting seam.
Pipe+ Data Point
8.8.1
2 left of seam, 2 above course A horizontal weld. B1
BTM RT
8.8.2
2 above course A horizontal weld, directly above course

A vertical junctions. **a.m.a.n.
BTM JCT

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8.8.3
2 above course A, 2 right of next vertical weld seam.
BTM LF
8.8.4
Pick up all nozzles in this plate, right to left, and top to

bottom if vertically aligned. Include nominal size in location
description; top, bottom, and both sides on thicknesses on
man-ways and nozzles..
TP
BTM
BTM MW 4NOZ
8.8.5
Continue on shell plate to left in successive numbering, as in

Position Description 9.2.1 through 9.2.3 above.
8.8.6
More data points may be accessible on B course as steps

are ascended. Effort should be given to obtaining thickness
readings at junction welds, when possible.
Additional Shell Courses

Course C and each succeeding course should have starting points at bottom of respective
courses where accessible from steps. Effort should be given to obtaining thickness readings
at junction welds, when possible.
The top 2 of top course is an area of critical importance on tanks with cone roofs. This area
should have data points every two feet (2), starting nearest steps and continuing around tank,
where accessible from, and in direction of, steps.
**a.m.a.n. - as many as necessary. Some plates may not have any intersecting welds. Others may have several.
Include all horizontal-vertical junctions.
8.9
Cone Roof of Insulated and non-Insulated Tanks Using A Grid System

8.9.1
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
Remaining portions of roof shall be shot in an X and 0 pattern. This X will be in

an alignment such that one leg is straight from platform/step attachment over center of
roof. The other leg of the X shall lay perpendicular to the first. One data point
should be defined at each joint junction, i.e., roof course changes, plate changes, or
combination of the two (case #1 in Roof Example drawing). If the first X lies such
that a leg parallels the roof courses, an additional measurement should be taken at
center of each plate (case #2 in Attachment B). The 0 pattern should be made at the
outer most diameter of the tank roof. This area should incorporate at least two roof
patterns wide the full circumference of the roof at the T seams of the roof.
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.
Pipe+ Data Point


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(for each data point in grid row titled STEP)

1)
2)
2 off platform. Facing gauge hatch, the left-most point of grid.

R1, R2, R3
STEP 1
2 step toward gauge hatch, the left-most point of grid.

R4, R5, R6
STEP 2
3)
Continue on the roof using X pattern in successive numbering.
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
Shell -Course "A" of Insulated Tanks Using A Grid System

NOTE
Each course is designated by a letter; A for bottom course, B for second course, etc.
All points on shell to be 2 from bottom (chime) weld. A course starting point is left of bottom
step of ladder when facing tank from outside. For intersecting ladders, start with shell data
point to left of ladder attachment point. Continue in clockwise (left) direction.
With insulated tanks, shell course sizes might take some guesswork for size, or some
preliminary work may need to be done. Since vertical welds are generally not accessible,
each course should be graded individually. That is, additional data points may be needed to
confirm any variances in measurements. This will be a judgment call of the inspector at time
of inspection. The approximate distance between data points will be determined by the
inspector, generally not to exceed a maximum of 20 to 30. The number of measurements on
each course should be enough to give representative coverage.
Pipe+ Data Point
8.10.1 2 above chime weld.
A1
8.10.2 Pick up nozzles in this plate, right to left; top to bottom if

vertically aligned. Include nominal size in location description;
with top and bottom thicknesses on man-ways.
TP
MW
BTM MW
TP
4NOZ
8.10.3 Continue on the next data point to the left in successive

numbering.
8.11
Shell -Course "B" of Insulated Tanks Using A Grid System

NOTE
Course B starting point is above or left of the first data point of course A.
Pipe+ Data Point

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8.11.1 2 above course A horizontal weld. B1

8.11.2 Include all nozzles in this plate, right to left, and top to bottom
if vertically aligned. Include nominal size in location
description; - top and bottom thicknesses on man-ways. TP
TP
MW
BTM MW
4NOZ
8.11.3 Continue on shell plate to left in successive numbering.

8.11.4 Additional data points may be accessible on B course as steps
are ascended.
Additional Shell Courses
Course C and each succeeding course should have a starting point at bottom of respective
courses where accessible from steps.
Where accessible, top 2 of top course is an area of critical importance on tanks with cone
roofs. This area should have data points every two feet (2), starting nearest steps and
continuing around tank, where accessible from, and in direction of, the steps.
9.0
ATTACHMENTS
Attachment A Attachment B Attachment C Attachment D -
Examples Of Shell Location Descriptions Non-Insulated Tanks

Examples Of Roof Location Descriptions Insulated And Non-Insulated Tanks
Examples of Shell Location Descriptions Insulated Tanks
Revision History

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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
.
.
.

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ATTACHMENT B
EXAMPLES OF ROOF LOCATION DESCRIPTIONS - INSULATED AND NON-INSULTED TANKS

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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
....

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APPENDIX A: Definitions and Abbreviations

TP
MW
BTM
NOZ
TML
Top
Manway
Bottom
Nozzle
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ConocoPhillips Indonesia

Maintenance Engineering & Asset

REVISION CONTROL SHEET

Maintenance Engineering & Asset

PREPARATIONS PIPING ................................................................................... 0

PREPARATIONS STORAGE TANKS ................................................................ 0

APPENDIX A: DEFINITIONS AND ABBREVIATIONS .................................................. 0

Maintenance Engineering & Asset

Verify personnel performing Ultrasonic Thickness Measurements are qualified.

Ensure all instruments to be used have been properly calibrated.

Maintenance Engineering & Asset

SPECIAL TOOLS AND EQUIPMENT

Thickness measurement locations should be identified on the applicable

Maintenance Engineering & Asset

Injection Point Inspection

Maintenance Engineering & Asset

Verify personnel performing Ultrasonic Thickness Measurements are qualified.

Ensure all instruments to be used have been properly calibrated.

SPECIAL TOOLS AND EQUIPMENT

Thickness measurement locations should be identified on the applicable

Maintenance Engineering & Asset

PREPARATIONS Storage Tanks

Verify personnel performing Ultrasonic Thickness Measurements are qualified.

Ensure all instruments to be used have been properly calibrated.

SPECIAL TOOLS AND EQUIPMENT

Thickness measurement location should be identified on the applicable

Shell -Course "A" of non-Insulated Tanks Using A Grid System

Maintenance Engineering & Asset

2 left of vertical seam, 2 above chime weld. A1

2" above chime, midpoint left around shell plate. A2

2 above chime, 2 right of next vertical weld seam. A3

2 right of vertical weld, 2 down from top plate

2 below horizontal weld seam, directly below each

2 below horizontal weld seam, 2 left of vertical

Pick up nozzles in this plate, right to left; top to bottom if

8.7.10 Continue on the next shell plate to the left in successive

Shell -Course "B" of non-Insulated Tanks Using A Grid System

2 left of seam, 2 above course A horizontal weld. B1

2 above course A horizontal weld, directly above course

Maintenance Engineering & Asset

2 above course A, 2 right of next vertical weld seam.

Pick up all nozzles in this plate, right to left, and top to

Continue on shell plate to left in successive numbering, as in

More data points may be accessible on B course as steps

Additional Shell Courses

Cone Roof of Insulated and non-Insulated Tanks Using A Grid System

Remaining portions of roof shall be shot in an X and 0 pattern. This X will be in

Pipe+ Data Point

Maintenance Engineering & Asset

(for each data point in grid row titled STEP)

2 off platform. Facing gauge hatch, the left-most point of grid.

2 step toward gauge hatch, the left-most point of grid.

Continue on the roof using X pattern in successive numbering.

Shell -Course "A" of Insulated Tanks Using A Grid System

8.10.2 Pick up nozzles in this plate, right to left; top to bottom if

8.10.3 Continue on the next data point to the left in successive

Shell -Course "B" of Insulated Tanks Using A Grid System

Maintenance Engineering & Asset

8.11.1 2 above course A horizontal weld. B1

8.11.3 Continue on shell plate to left in successive numbering.

Examples Of Shell Location Descriptions Non-Insulated Tanks

Maintenance Engineering & Asset