Inspection Planning for New Ammonia - Urea Plant

[qaisarabbas]

We are about to takeover a newly constructed ammonia-urea plant at our site. Belonging from inspection group of stationary equipments, we are looking forward to develop inspection strategy, which includes:
- developing specific inspection plans for each piece of equipment
- defining different inspection surveys
- deciding inspection intervals
For this, we would have different options like:
- replicating inspection plans, surveys & intervals of existing plant
- requesting & asking from licensor / OEM for their recommendations
- working out RBI after the first annual / bi-annual compulsory inspection

Request collective wisdom of the forum members in suggesting the way-forward & guidelines in this matter.

Regards - QAS

[mechcolor]

Inspection plans for new equipment are normally provided by the manufacturers / licencors. First thing to do is to seek their advise. Next what you must do is to study the operational / functional part of each equipment along with process guys. They would be able to tell you about the following:
1. Equipment can be taken out of service while plant is in operation
2. Equipment critical to plant operation
3. Equipment in highly corrosive service
4. Equipment in lethal / hazardous service

After getting this information, do the following:
a. During the initial stages of developing inspection plans, forget those equipment which can be taken out of service
b. Make combinations like:
i) equipment = lethal + corrosive service,
ii) equipment = lethal service,
iii) equipment = corrosive only,
iv) equipment = non-corrosive + normal service
c. Set the frequency in the order mentioned above. Most stringent (every turnaround) for case i) and then others.
d. Now coming to those which can be taken out of service. Set them in order same as mentioned in (b) but the inspection frequency may be set less stringent as the equipment can be taken out of service and not critical to plant operation. But reliability of the equipment must not be compromised.

This is the simplest way to go...

[mechcolor]

In my above post, you can further add many likely failures which can happen to your equipment while assessing the process data. Those failures include susceptibility of brittle fracture, hydrogen attack, metal dusting, temper embrittlement, creep or fatigue failure etc.
Add all these probable failures while making combinations as shown in (b) point.

[qaisarabbas]

Mechcolor, Your detailed answer gave us a good food for thought. Thank you