In-Service Pressure Vessel Inspection

Concerned about the safety and compliance of your pressure vessels while they’re in operation?

In-Service Pressure Vessel Inspection is essential to ensure that your equipment continues to operate safely and efficiently. By regularly inspecting pressure vessels during their service life, you can detect potential issues early, prevent accidents, and comply with regulatory requirements.

What Is In-Service Pressure Vessel Inspection?

In-Service Pressure Vessel Inspection involves the examination of pressure vessels while they are in operation or during planned shutdowns. The goal is to assess the vessel’s integrity, identify any signs of degradation or damage, and ensure compliance with industry standards and regulations, such as AS3788-2024 in Australia.

Pressure vessels operate under high pressure and temperature conditions, making them critical components in many industrial processes. Regular inspections help maintain their safety, reliability, and performance.

Why Is Pressure Vessel Inspection Important?

• Safety Assurance: Prevent catastrophic failures that could lead to injuries or fatalities.
• Regulatory Compliance: Meet legal obligations under standards like AS3788-2024 and avoid penalties.
• Operational Efficiency: Minimise unplanned downtime by detecting issues early.
• Asset Management: Extend the lifespan of your equipment through proper maintenance.
• Environmental Protection: Prevent leaks or emissions that could harm the environment.

Industries That Rely on Pressure Vessel Inspection

Pressure vessels are used across various industries, making regular inspections vital:

Oil & Gas

• Refineries and Processing Plants: Inspect vessels that handle volatile substances to prevent leaks and explosions.
• Offshore Platforms: Ensure the integrity of vessels exposed to harsh marine environments.

Mining

• Processing Facilities: Maintain vessels used in mineral processing and chemical storage.
• Compressed Air Systems: Inspect air receivers and other pressure equipment.

Power Generation

• Boilers and Heat Exchangers: Regular inspections prevent failures in critical power plant components.
• Steam Systems: Ensure safe operation of steam drums and associated vessels.

Chemical and Petrochemical

• Reactors and Storage Tanks: Monitor vessels that handle hazardous chemicals.
• Pressure Reactors: Ensure safe processing conditions.

Food and Beverage

• Sterilisation Equipment: Inspect vessels used in food processing to maintain safety standards.
• Storage Tanks: Ensure the integrity of vessels storing liquids under pressure.

Manufacturing

• Compressed Air Systems: Maintain air receivers and other pressure equipment used in production.
• Hydraulic Systems: Inspect accumulators and other pressure-containing components.

Pharmaceutical

• Processing Equipment: Ensure vessels meet strict cleanliness and safety standards.
• Sterile Environments: Maintain the integrity of pressure vessels in controlled environments.

How Does the In-Service Pressure Vessel Inspection Process Work?

Here’s how we conduct In-Service Pressure Vessel Inspections:

1. Planning and Preparation

• Review Documentation: Gather design records, previous inspection reports, and operating history.
• Risk Assessment: Identify potential hazards and critical areas to focus on.
• Inspection Plan: Develop a tailored plan outlining methods, frequency, and scope based on regulatory requirements and vessel usage.

2. External Inspection

• Visual Examination: Inspect the vessel’s external surfaces for signs of corrosion, leaks, cracks, or deformation.
• Protective Coatings: Assess the condition of coatings or insulation.
• Attachments and Supports: Check the integrity of nozzles, flanges, supports, and connections.

3. Internal Inspection (If Applicable)

• Access Internal Surfaces: During shutdowns, enter the vessel to inspect internal walls and components.
• Corrosion and Erosion Assessment: Look for thinning, pitting, or other forms of degradation.
• Internal Components: Check baffles, trays, and other internal structures.

4. Non-Destructive Testing (NDT)

Apply NDT methods to detect hidden defects without damaging the vessel:

• Ultrasonic Testing (UT): Measure wall thickness and detect internal flaws.
• Magnetic Particle Testing (MPI): Find surface and near-surface cracks in ferrous materials.
• Dye Penetrant Testing (DPI): Reveal surface-breaking defects.
• Radiography (RT): Use X-rays or gamma rays to view internal structures.
• Visual Examination with Remote Tools: Use cameras or borescopes for inaccessible areas.

5. Pressure Relief Devices Inspection

• Safety Valves and Devices: Inspect and test pressure relief valves to ensure proper operation.

6. Documentation and Reporting

• Record Findings: Document all observations, measurements, and test results.
• Assess Compliance: Compare findings against standards like AS3788-2024.
• Recommendations: Provide guidance on repairs, maintenance, or monitoring.

7. Follow-Up Actions

• Repairs and Maintenance: Address any identified issues promptly.
• Re-Inspection: Verify that corrective actions have been effective.
• Update Inspection Schedule: Adjust future inspection intervals based on findings.

Benefits of In-Service Pressure Vessel Inspection

• Enhanced Safety: Protect personnel and property by preventing vessel failures.
• Regulatory Compliance: Meet legal requirements and avoid penalties or shutdowns.
• Cost Savings: Reduce unplanned downtime and extend equipment life.
• Operational Confidence: Ensure that vessels are performing reliably.
• Environmental Responsibility: Prevent incidents that could lead to environmental damage.

FAQs

Q: Why is In-Service Pressure Vessel Inspection required?

A: Regular inspections are mandated by standards like AS3788-2024 to ensure that pressure vessels remain safe to operate throughout their service life. They help detect issues early, preventing accidents and ensuring compliance.

Q: How often should pressure vessels be inspected?

A: Inspection intervals depend on factors like vessel type, operating conditions, and regulatory requirements. Typically, inspections are scheduled every 1 to 5 years. We can help determine the appropriate frequency for your equipment.

Q: What qualifications do your inspectors have?

A: Our inspectors are certified professionals with qualifications such as API 510 Certified Pressure Vessel Inspector and AICIP certification. They have extensive experience in pressure vessel inspection.

Q: Can inspections be performed while the vessel is in operation?

A: Yes, external inspections and certain NDT methods can be performed while the vessel is in service. Internal inspections require the vessel to be taken offline and prepared safely for entry.

Q: What standards govern pressure vessel inspections in Australia?

A: AS3788-2024 is the primary Australian Standard for pressure equipment—In-service inspection. It outlines the requirements and procedures for inspections.

Q: What happens if defects are found during the inspection?

A: We’ll provide a detailed report with findings and recommendations. Depending on the severity, corrective actions may include repairs, monitoring, or taking the vessel out of service.

Q: Do you assist with regulatory compliance and documentation?

A: Yes, we help ensure all inspections are documented properly, meeting regulatory requirements and providing necessary records for audits or inspections by authorities.

Q: Can you develop an inspection plan for my facility?

A: Absolutely. We can create a customised inspection plan tailored to your equipment, operating conditions, and compliance needs.

Ready to Ensure the Safety and Compliance of Your Pressure Vessels?

In-Service Pressure Vessel Inspection is crucial for maintaining safe and efficient operations. Our experienced and certified inspectors are equipped to provide thorough inspections that meet all regulatory standards.