Inspection Division

Technical Service Department

Visakh Refinery

Outlook Report

MEROX-1: HC Loops

[Link] Equipment No Major Observations Major Inspections Repairs Carried Out Future Confirmed
Recommendation
(IWL)

1 017HL-001 Visual inspection of piping loop 1. Visual examination 1. Replacement of 3inch NB line Nil
CDU-I/II LPG from was carried out and following 2. Ultrasonic thickness ~42 m was carried out at 17-PM-
B/L to 16-C- are the observation. examination 01E OVHD.
01 inlet 1. UTG of pipe and piping 3. Witnessed DPT of 3/4” NPS 2. Welding of corrosion pad was
components was carried out, welds, no relevant indications carried out at 16-JBA-313
minimum measured thickness of observed. overhead.
all components are as 4. Hydro test of entire loop 3. Welding of corrosion pad was
follows: was witnessed at 31.0 kg/cm2 carried out at 16-JBA-313 north
Minimum measured thickness- on 01/12/2023. No pressure overhead.
4.0 mm against original 5.49 drop and no leakage 4. Welding of corrosion pad was
mm. (3-inch size)-B1Aspec, observed. Hydro test found carried out at 16-JBA-145 north
CA- 1.5 mm, satisfactory. overhead.
Minimum measured thickness- 5. Replacement of 3inch NB elbow
4.2 mm against original 5.49 – 1 No. was carried out near 16-C-
mm. (3-inch size)-A1Aspec, 01 1st platform.
CA- 1.5 mm, 6. Replacement of 3inch NB elbow
Minimum measured thickness- – 1 No. was carried out east of 16-
5.8 mm against original 6.02 FCV-103.
mm. (4-inch size)-A1Aspec,
CA- 1.5 mm,
2. 17-PM-01E OVHD: Low
thickness 4.1 mm was observed
on 3 inch dia line against
original thickness of 5.49
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

mm over a length of approx. 42

meters.
3. 16-JBA-313 overhead: 16-C-
01 connected 3’’ line was
observed corrosion pad missing
at sleeper support
location.
4. 16-JBA-313 north overhead:
16-C-01 connected 3’’ line was
observed corrosion pad weld
missing at sleeper
support location.
5. 16-JBA-145 north overhead:
16-C-01 connected 3’’ line was
observed corrosion pad weld
missing at sleeper
support location.
6. Near 16-C-01 1st platform: .
Low thickness 4 mm was
observed on 3” dia 90-degree
elbow against original
thickness of 5.49 mm.
7. East of 16-FCV-103: Low
thickness 4 mm was observed on
3 inch dia 90-degree elbow
against original thickness of
5.49 mm
.
2 017HL-002 Visual inspection of piping loop 1. Visual examination 1. Replacement of 3inch NB Nil
CR LPG from Extended was carried out and following 2. Ultrasonic thickness WNRF ~1 No. was carried out at
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

B/L to are the observation. examination 16-C-02 North side.

16-C-02 inlet 1. UTG of pipe and piping 3. Witnessed DPT of 3/4” NPS 2. Replace 3⁄4 X 1⁄2 inch dia line
components was carried out, welds, no relevant indications approx. 4m length was carried out
minimum measured thickness of observed. at 16-C-02 1st platform.
all components are as 4. Hydro test of entire loop 3. Welding of corrosion pad was
follows: was witnessed at 33.3 kg/cm2 carried out at 16-JBA-313 east
Minimum measured thickness- on 29/11/2023. No pressure overhead.
4.7 mm against original 5.49 drop and no leakage 4. Welding of corrosion pad was
mm (3 inch size) - B1Aspec, observed. Hydro test found carried out at 16-JBS-145 north
CA- 1.5 mm, satisfactory. overhead.
2. 16-C-02 North side: The 3”
flange is observed to be severely
corroded.
3. 16-C-02 1st platform: 3⁄4 X
1⁄2 inch dia line was observed
severe bent.
4. 16-JBA-313 east overhead:
16-C-02 connected 3 inch dia
line corrosion pad weld missing.
5. 16-JBS-145 north overhead:
16-C-01 connected 3’’ line was
observed corrosion pad weld
missing.
3 017HL-004 Visual inspection of piping loop 1. Visual examination 1. Replacement of 3 inch dia pipe Nil
16-C-01 O/L to 17-V-01 was carried out and following 2. Ultrasonic thickness line approx. 1m length was carried
& 16- are the observation. examination out at North of 16-C-01 near 16-
C-01 by pass line 1. UTG of pipe and piping 3. Witnessed DPT of 3/4” NPS FCV-103.
components was carried out, welds, no relevant indications 2. Replacement of 3 inch dia pipe
minimum measured thickness of observed. line approx. 1m length was carried
all components are as 4. Hydro test of entire loop out at North of 16-C-01 near 16-
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

follows: was witnessed at 27.5 kg/cm2 FCV-103.

Minimum measured thickness- on 04/12/2023. No pressure
4.3 mm against original 5.49 drop and no leakage 3. Sectional replacement of 3-inch
mm. (3-inch size)-A1Aspec, observed. Hydro test found dia pipe approx. 6m length was
C.A.-1.5mm satisfactory. carried out at North of 16-C-01
Minimum measured thickness- near 16-FCV-
5.5 mm against original 6.02 103.
mm. (4-inch size)-A1Aspec,
C.A.-1.5mm 4 Replacement of 3 inch dia pipe
Minimum measured thickness- line approx. 0.2m length along with
6.2 mm against original 7.11 3⁄4 inch drain was carried out at
mm. (6-inch size)-A1Aspec, North of 16-
C.A.-1.5mm C-01 near 16-FCV-103.
2. North of 16-C-01 near 16-
FCV-103: Low thickness 4.3
mm was observed on 3 inch dia
pipe against original
thickness of 5.49 mm (location
27a on Loop isometric drawing).
3. North of 16-C-01 near 16-
FCV-103: Low thickness 4.3
mm was observed on 3 inch dia
pipe against original
thickness of 5.49 mm (location
56a on Loop isometric drawing).
4 North of 16-C-01 near 16-
FCV-103: Minor oozing traces
were observed on 3- inch dia
pipe near weld joint cleat
locations..
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

5. North of 16-C-01 near 16-

FCV-103: ) 6x3 reducer location
corrosion pad missing at u-
clamp support location.
4 017HL-005 Visual inspection of piping loop 1. Visual examination 1. 0.75 inch dia vent on 3 inch dia Nil
:16-C-02 O/L to 17-V- was carried out and following 2. Ultrasonic thickness pipe for the purpose of Hydro test
02 I/L and are the observation. examination was provided at North of 16-C-01
17-V-02 bypass line; 1. UTG of pipe and piping 3. Witnessed DPT of 3/4” NPS on top of
components was carried out, welds, no relevant indications 16-C-02
minimum measured thickness of observed. 2. Replacement of 3 inch dia line
all components are as 4. Hydro test of entire loop approx. 0.5m along with 90-degree
follows: was witnessed at 34.0 kg/cm2 elbow and provide corrosion pad
Minimum measured thickness- on 28/11/2023. No pressure with pipe
4.2 mm against original 5.49 drop and no leakage support was carried out at North of
mm (3-inch size), C.A.-1.5mm observed. Hydro test found 16-C-02 pipe track location.
Minimum measured thickness- satisfactory. 3. Replacement of 0.75 inch dia
5.3 mm against original 6.02 vent along with 0.5 inch dia sample
mm (4-inch size), C.A.-1.5mm point approx. 1.5m length each was
Minimum measured thickness- 6 carried
mm against original 7.11 mm (6 out and gussets (3mm thick) plates
inch size), C.A.-1.5mm were provided at North of 16-C-02
2. Top of 16-C-02: 0.75 inch dia pipe track location.
vent missing on 3 inch dia
header line for Hydro test
purpose.
3. North of 16-C-02 pipe track
location: Low thickness 4.2mm
was observed on 3 inch dia 90-
degree elbow
against original thickness of
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

5.49mm near isolation valve.

4. North of 16-C-02 pipe track
location: External corrosion and
pitting was observed on 0.75
inch vent along with
0.5 inch dia sample point
approx. 1.5m length on 4 inchx3
inch dia header-02nos
5 017HL-008 Visual inspection of piping loop 1. Visual examination 1. Replacement of 0.75 inch dia Nil
17-V-01 O/L to 17-V-03 was carried out and following 2. Ultrasonic thickness vent line along with 0.5 inch dia
are the observation. examination connected sample point on 3 inch
1. UTG of pipe and piping 3. Witnessed DPT of 3/4” NPS dia header
components was carried out, welds, no relevant indications approx. 10m length was carried out
minimum measured thickness of observed. above 17-V-01.
all components are as 4. Hydro test of entire loop 2. Replacement of 3 inch dia pipe
follows: was witnessed at 33.3 kg/cm2 approx. 3m length along with 1no
Minimum measured thickness- on 25/11/2023. No pressure ‘T’, 02nos 90-degree elbows and
4.1 mm against original 5.49 drop and no leakage 01no flange
mm (3 inch size), C.A.-1.5mm observed. Hydro test found was carried out at North of 17-C-01
2. Above 17-V-01: External satisfactory. above the 2nd platform.
corrosion and pitting was 3. Replacement 3 inch dia line
observed on 0.75 inch dia vent approx. 1m including 1no 90-
and 0.5 inch dia connected degree elbow was carried out at 17-
sample point approx. 10m length PM-01E/F above
on 3 inch dia header. pipe track location.
3. North of 17-C-01 above the
2nd platform: Low thickness
4.1mm was observed on 3 inch
dia pipe against
original thickness of 5.49mm.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

4. 17-PM-01E/F above pipe

track: Low thickness 4.3mm was
observed on 3 inch dia pipe and
1no 90-degree
elbow against original thickness
of 5.49mm.
6 017HL-009 Visual inspection of piping loop 1. Visual examination 1. Providing 1 Nos. of corrosion Nil
17-C-01 O/L to 17-C-01 was carried out and following 2. Ultrasonic thickness pad on 3 dia line with proper U-
bypass are the observation. examination Clamping at pipe support locations
manifold 1. UTG of pipe and piping 3. Witnessed DPT of 3/4” NPS was carried out
components was carried out, welds, no relevant indications West of 17-C-01.
minimum measured thickness of observed. 2. Replacement of Replace 0.75
all components are as 4. Hydro test of entire loop inch dia sample point line approx.
follows: was witnessed at 32.4 kg/cm2 1.5 m length along with necessary
Minimum measured thickness- on 25/11/2023. No pressure fittings was
4.4 mm against original 5.49 drop and no leakage carried out at West of 17-C-01.
mm (3 inch size), C.A.-1.5mm observed. Hydro test found 3. Replacement of 3 inch dia line
2. West of 17-C-01: Corrosion satisfactory. for approx. 1m length was carried
pads were observed missing on out and corrosion pads wit U-
3 dia line at 2nos and loose clamps at 2
bolting and dissimilar locations were provided Near 17-
U-clamping was observed at FT-106.
support locations. 4. Replacement of 2 nos. of 3 inch
3. 17-C-01 OVHD: External dia spools approx. 1m length each
pitting was observed on spacer at upstream and downstream of
connected 0.75 inch dia sample control
point line. valve along with 0.75 inch dia
4. Near 17-FT-106: External drains and vents were carried out
corrosion and deep pitting was and provide corrosion pads and
observed on 3 inch dia line for pipe supports on
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

approx. 1m length at 3 inch dia line elbows at pipe

FT cable connected clamps support locations were provided
location. Near 17-FV-106. Gusset plates
5. Near 17-FV-106: Trunnion (3mm thick) for 0.75
support: 2nos were observed inch dia drain and vent lines were
directly welded 3 inch dia line also provided.
support moment 5. Replacement of 0.75x0.5 inch
restricted at 90-degree elbow dia sample point connected to 17-
locations & 0.75 inch dia drains- FT-106 approx. 1.5m length was
02nos nonstandard half carried out
couplings were observed Near 17-FV-106.
upstream and downstream of
control valve.
6. Near 17-FV-106: External
corrosion and pitting was
observed on 0.75x0.5 inch dia
line connected to 17- FT-106
approx. 1.5m length
7 017HL-010 Visual inspection of piping loop 1. Visual examination 1. Replacement of 3 inch dia Nil
17-V-02 O/L to 17-V-03 was carried out and following 2. Ultrasonic thickness pipeline approx. 3m length flange
are the observation. examination to flange along with 5no’s 90
1. UTG of pipe and piping 3. Witnessed DPT of 3/4” NPS degree elbows and
components was carried out, welds, no relevant indications 1no equal Tee was carried out and
minimum measured thickness of observed. corrosion pad with proper trunnion
all components are as 4. Hydro test of entire loop support was provided at West of
follows: was witnessed at 33.3 kg/cm2 17-FV-106
Minimum measured thickness- 4 on 25/11/2023. No pressure from double block valve.
mm against original 5.49 mm (3 drop and no leakage 2. Replacement of 3" 90° elbow – 1
inch size), C.A.-1.5mm observed. Hydro test found No. was carried out at North of 17-
2. West of 17-FV-106 from satisfactory. C-02.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

double block valve: a) Trunnion

support was observed directly
welded to 3 inch dia 90-
degree elbow. b) Low thickness
4.0mm was observed on 3 inch
dia 90-degree elbow against
original thickness of
5.49mm-02nos
3. North of 17-C-02: 3" 90°
elbow was recorded with low
thickness of 4.0mm against
5.49mm.
8 017HL-011 Visual inspection of piping loop 1. Visual examination Nil
17-C-02 outlet to 17-C- was carried out and following 2. Ultrasonic thickness 1. Corrosion pad on 3 inch dia line -
02 outlet are the observation. examination 2no’s with U_clamp at pipe support
manifold; 1. UTG of pipe and piping 3. Witnessed DPT of 3/4” NPS location in kind was provided at
components was carried out, welds, no relevant indications North of
minimum measured thickness of observed. 17-C-02 OVHD.
all components are as 4. Hydro test of entire loop 2. Replacement of 0.75 inch dia PG
follows: was witnessed at 32.4 kg/cm2 take off line approx. 1m length
Minimum measured thickness- on 15/11/2023. No pressure along with necessary fittings was
4.6 mm against original 5.49 drop and no leakage carried out at
mm (3 inch size), C.A.-1.5mm observed. Hydro test found West of 17-FV-106.
2. North of 17-C-02 OVHD: satisfactory. 3. Replacement of 0.75 inch dia
Corrosion pad missing were vent line approx. 2.5m length along
observed on 3 inch dia pipe at with necessary fittings was carried
U-clamp support locations out at Top
- 2no’s. of 17-C-02.
3. West of 17-FV-106: 3 inch
dia header line connected 0.75
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

inch dia PG take off was

observed leak marks and
minor pitting.
4. Top of 17-C-02: External
pitting and gusset plates missing
was observed on 0.75 inch dia
vent takeoff line
approx. 2.5 m length connected
to 3 inch dia header.
9 017HL-10 Visual Inspection and UTG of 1. Visual examination 1. i) Replacement of 2nos 3” dia Nil
17-V-03 outlet to 17- Piping loop was carried out. 2. Ultrasonic thickness 90-degree elbows and corrosion
PM-02A/B both General condition of pipeline examination pad with trunnion supports was
suctions; was found satisfactory. 3. 10% DPT of 1⁄2” & 3⁄4” provided at
-Minimum measured thickness- NPS fillet welds, no relevant South of 17-PM-02A/B suction
4.1 mm against original 5.49 indications observed. line.
mm. (3” size)-A1Aspec 4. Hydro test of entire loop 2. Replacement of 0.75x0.5” dia
-Minimum measured thickness- was witnessed at 34 kg/cm2 on PG & TG take off lines for approx.
4.8 mm against original 5.54 30/11/2023. No pressure drop 4m length along with necessary
mm. (2” size)-A1Aspec. C.A.- and no leakage fittings and
1.5mm observed. Hydro test found valves was carried out at South of
1. South of 17-PM-02A/B satisfactory. 17-PM-02A/B suction line.
suction line: 2. Replacement of 3” dia spool for
i) Trunnion supports were approx. 2m length along with 3
observed directly welded to 3” No’s 90-degree elbows including 1
dia 90-degree elbow at 2 T-joint was
locations. carried out at east of 17-PM-02A/B.
ii) Severe scaling and moderate 3. Replacement of 3” dia line for
pitting was observed on approx. 1m length was carried out
0.75x0.5” dia PG&TG take off at west of 17-PM-02A/B OVHD.
lines on 3” dia header 4. Provided 1No. Corrosion pad on
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

line 3” dia line at west of 17-V-04

2. East of 17-PM-02A/B: platform crossing area.
i) Trunnion supports were 5. 1) Replacement of 0.75x0.5” dia
observed directly welded to 3” line for approx. 2m length along
dia 90-degree elbow at 2Nos. of necessary fitting and valves was
locations. Flange carried out at
gasket location fouling with west of 17-V-04 2nd platform
concrete beam. 2) Replacement of 1no 3 inch dia
3. West of 17-PM-02A/B 90-degree elbow was carried out at
OVHD: 3” dia spill back line west of 17-V-04 2nd platform.
was observed fouling with
concrete pillar.
4. West of 17-V-04 platform
crossing area: Corrosion pad
missing was observed on 3 inch
dia pipe at U-clamp
support location.
5. West of 17-V-04 2nd
platform:
i) Gusset plate missing was
observed on 3x0.75” dia line
and 0.75x0.5” dia line was
observed severely
corroded.
ii) Low thickness 4.3 mm was
observed on 3” dia 90-degree
elbow against original thickness
of 5.49mm.
6. Top of 17-V-04: End cap
missing and nipple threading
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

corroded was observed on 0.5”

dia line.
10 017HL-011 Visual Inspection and UTG of 1. Visual examination 1. 2) 1No. Corrosion pad on 3” dia Nil
17/PM-02A/B Piping loop was carried out. 2. Ultrasonic thickness line along with packing was
Discharge to B/L; General condition of pipeline examination provided at South of 17-PM-02A/B
was found satisfactory. 3. 10% DPT of 1⁄2” & 3⁄4” Discharge line.
-Minimum measured thickness- NPS fillet welds, no relevant
4.6 mm against original 5.49 indications observed. 3) End cap was provided for 0.5”
mm. (3” size)-A1Aspec 4. Hydro test of entire loop dia small bore line connected to 3
-Minimum measured thickness- was witnessed at 34 kg/cm2 on inch dia orifice flange at South of
4.3 mm against original 3.91 30/11/2023. No pressure drop 17-PM-
mm. (2” size)-A1Aspec. and no leakage 02A/B Discharge line.
1. South of 17-PM-02A/B observed. Hydro test found
Discharge line: satisfactory. 2. 1) Replacement of 2no’s 3” x 2”
2) Corrosion pad missing and dia spools for approx. 1m length
line not resting at support each along with 2no’s 3” dia 90-
location was observed on 3 inch degree elbows
dia pipe D/S of 1st and 0.75 inch dia drains lines was
isolation valve. provided was carried out at west of
3) End cap missing was 17-PM-02A/B (17-PCV-01).
observed on 0.5 inch dia small
bore line connected to 3 inch dia 3) Replacement of 2” dia 90 degree
orifice flange. elbow and corrosion pad with pipe
2. West of 17-PM-02A/B (17- support was provided at west of 17-
PCV-01): PM-
1) U/S and D/S of 17-PCV-01 02A/B (17-PCV-01).
control valve 2no's 3-inch x 2
inch dia spools were observed 3. 1) Replacement of 2no’s 2” dia
trunnion supports 90-degree elbow and corrosion pad
directly welded to 3 inch dia 90- with trunnion support was
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

degree elbow. provided.

3) Pipe support was observed 2) Replacement of 2” dia pipeline
directly welded to 2 inch dia 90- for approx.0.5 m length along with
degree elbow. corrosion pad was provided at west
3. West of 17-V-03 (15-FV- of 17-
2302): V-03 (15-FV-2302)
1) Trunnion supports were 4. Pipe support along with
observed directly welded to 2 corrosion pad was provided on 3”
inch dia 90-degree elbow at 2 dia line at West of 17-PM-02A/B
locations. OVHD.
2) 2 inch dia pipeline support
corrosion pad was observed Prepared By Reviewed By
external corrosion and cold Approved By
compound.
4. West of 17-PM-02A/B Sunit Ranjan Xalxo B M Jeelani M
OVHD: Temporary u-clamp V N S S Sastry
support was observed on 3 inch Manager - Inspection Sr. Manager
dia pipeline. (i/c) – Inspection General Manager
5. South of 17-PM-02B – Inspection
Discharge line: Low thickness 5. Replacement of 3 inch dia 90-
4.6 mm was observed on 3 inch degree elbow was carried out at
dia 90-degree elbow south of 17-PM-02B Discharge
against original thickness of line.
5.49mm. 6. Replacement of 3 inch dia pipe
6. East battery limit: External line for aprrox.1m length along
corrosion and pitting was with corrosion pad was provided at
observed on 3 inch dia pipeline east battery
at sleeper support location. limit.
11 17HL-12 Visual Inspection and UTG of 1. Visual examination 1. Provided 1No. Corrosion pad on Nil
17-V-01 PSV take off Piping loop was carried out. 2. Ultrasonic thickness 3” dia line at17-PSV-01B.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

General condition of pipeline examination 2. 1) Replacement of 3x2.5” dia

was found satisfactory. 3. 20% DPT of 1 1⁄2” NPS spool for approx. 400mm length
-Minimum measured thickness- fillet welds, no relevant along with fittings was carried out
4.2 mm against original 5.49 indications observed. 2) Provided 1No. Corrosion pad on
mm. (3” size)-B1Aspec 4. Hydro test of entire loop 3” dia line.
-Minimum measured thickness- was witnessed at 33.3 kg/cm2 3) Replacement of 3” dia line for
4.8 mm against original 5.08 on 25/11/2023. No pressure approx. 0.5m length along with
mm. (1.5” size)-B1Aspec. drop and no leakage 1No. 90degree elbow.
1. 17-PSV-01B: Corrosion pad observed. Hydro test found 3. Provided 1No. Pipe support 3”
was not provided for 3” dia line satisfactory. dia along with corrosion pad at
at support location. north of 17-V-01 OVHD.
2. 17-PSV-01A:
1) External corrosion and deep
pitting was observed on 3x2.5”
dia pipe spool for approx.
400mm length
between PSV and isolation
valve.
2) Pipe support was observed
directly welded to 3” dia
pipeline (17-PSV-01A u/s of
isolation valve).
3) Low thickness 4.2mm was
observed on 3” dia line against
original thickness of 5.49mm.
3. North of 17-V-01 OVHD: 3”
dia line was observed hanging
without pipe support.
12 17HL-013 Visual Inspection and UTG of 1. Visual examination 1. Provided 1No. Corrosion pad on Nil
17-V-02 PSV take off Piping loop was carried out. 2. Ultrasonic thickness 3” dia line at 17-PSV-03A.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

General condition of pipeline examination 2. 1) Replacement of 3x2.5” dia

was found satisfactory. 3. 20% DPT of 1 1⁄2” NPS spool for approx. 400mm length
-Minimum measured thickness- fillet welds, no relevant along with fittings was carried out
4.9 mm against original 5.49 indications observed. at 17-PSV-03A.
mm. (3” size)-B1Aspec 4. Hydro test of entire loop 2) Provided 1No. Corrosion pad on
-Minimum measured thickness- was witnessed at 33.3 kg/cm2 3” dia line.
5.9 mm against original 5.08 on 26/11/2023. No pressure 3. Provided 1No. Pipe support 3”
mm. (1.5” size)-B1Aspec. drop and no leakage dia along with corrosion pad at
1. 17-PSV-03A: Pipe support observed. Hydro test found north of 17-V-01 OVHD.
was observed directly welded to satisfactory.
3” dia pipeline (17-PSV-03A u/s
of isolation valve).
2. 17-PSV-03A:
1) External corrosion and deep
pitting was observed on 3x2.5”
dia pipe spool for approx.
400mm length
between PSV and isolation
valve.
2) Corrosion pad was not
provided for 3” dia line at
support location (17-PSV-01A
u/s of isolation valve).
3. North of 17-V-01 OVHD: 3”
dia line was observed hanging
without pipe support.
13 17HL-14 Visual Inspection and UTG of 1. Visual examination 1. Replacement of entire line Nil
17-C-01 PSV take off Piping loop was carried out. 2. Ultrasonic thickness 2x1.5” dia line for approx. 5m
General condition of pipeline examination length along with necessary fittings
was found satisfactory. 3. 20% DPT of 1 1⁄2” NPS and provided pipe
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

-Minimum measured thickness- fillet welds, no relevant support along with corrosion pad
4.0 mm against original 5.54 indications observed. was carried out at 17-C-02 OVHD.
mm. (2” size)-B1Aspec 4. Hydro test of entire loop
-Minimum measured thickness- was witnessed at 32.4 kg/cm2
4.2 mm against original 5.08 on 15/11/2023. No pressure
mm. (1.5” size)-B1Aspec. C.A.- drop and no leakage
1.5mm observed. Hydro test found
1. 17-C-02 OVHD: satisfactory.
1. a. Low thickness 4mm was
observed on 2” dia pipe against
original 5.54 mm.
b. 17-C-01 connected 2x1.5” dia
PSV take-off line was observed
deep pitting at random location
on entire
line.
c. Platform crossing area 2” dia
line observed vibration and pipe
supports missing.
14 17HL-15 Visual Inspection and UTG of 1. Visual examination 1. Replacement of entire line Nil
17-C-02 PSV take off Piping loop was carried out. 2. Ultrasonic thickness 2x1.5” dia line for approx. 4m
General condition of pipeline examination length along with necessary fittings
was found satisfactory. 3. 20% DPT of 1 1⁄2” NPS and provided pipe
-Minimum measured thickness- fillet welds, no relevant support along with corrosion pad
4.0 mm against original 5.54 indications observed. was carried out at 17-C-02 OVHD.
mm. (2” size)-B1Aspec 4. Hydro test of entire loop
-Minimum measured thickness- was witnessed at 32.4 kg/cm2
4.6 mm against original 5.08 on 15/11/2023. No pressure
mm. (1.5” size)-B1Aspec. C.A.- drop and no leakage
1.5mm observed. Hydro test found
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

1. 17-C-02 OVHD: satisfactory.

1. a. Low thickness 4mm was
observed on 2” dia pipe against
original 5.54 mm.
b. 17-C-02 connected 2x1.5” dia
PSV take-off line was observed
deep pitting at random location
on entire
line.
c. Platform crossing area 2” dia
line observed vibration and pipe
supports missing.
15 17HL-16 Visual Inspection and UTG of 1. Visual examination 1. Provided 1No. Corrosion pad on Nil
17-V-03 PSV take off Piping loop was carried out. 2. Ultrasonic thickness 3” dia line at 17-V-03 OVHD.
General condition of pipeline examination 2. Replacement of 1No. 3” dia
was found satisfactory. 3. Hydro test of entire loop 90degree elbow and pipe support
-Minimum measured thickness- was witnessed at 34 kg/cm2 on along with corrosion pad was
4.7 mm against original 5.49 15/11/2023. No pressure drop carried out at North
mm. (3” size)-B1Aspec and no leakage of 17-V-03 OVHD.
-Minimum measured thickness- observed. Hydro test found 3. Provided 1No. Corrosion pad on
5.0 mm against original 5.08 satisfactory. 3” dia line at 17-PSV-05A.
mm. (1.5” size)-B1Aspec. C.A.- 4. Replacement of 3x2.5” dia spool
1.5mm for approx. 1.5m length along with
1. 17-V-03 OVHD: Corrosion necessary fittings was carried out at
pad was not provided for 3” dia 17-
line at support location. PSV-05B.
2. North of 17-V-03 OVHD:
Pipe support was observed
directly welded to 3” dia
90degree elbow location.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

3. 17-PSV-05A: Pipe support

was observed directly welded to
3” dia pipeline (17-PSV-05S u/s
of isolation valve).
4. 17-PSV-05B: External
corrosion and deep pitting was
observed on 3x2.5” dia spool for
approx. 0.5m length
between PSV and isolation
valve.
16 17HL-17 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 1No. 3” dia Nil
17-V-04 PSV take off Piping loop was carried out. 2. Ultrasonic thickness 90degree elbow and pipe support
General condition of pipeline examination along with corrosion pad was
was found satisfactory. 3. 20% DPT of 1.5” NPS fillet carried out at North
-Minimum measured thickness- welds, no relevant indications of 17-V-04 OVHD.
4.8 mm against original 5.49 observed. 2. 1. Replacement of 3x2.5” dia
mm. (3” size)-B1Aspec, C.A.- 4. Hydro test of entire loop spool for approx. 0.3m length along
1.5mm was witnessed at 34 kg/cm2 on with necessary fittings was carried
1. North of 17-V-04 OVHD: 1. 20/11/2023. No pressure drop out.
Pipe support was observed and no leakage 2. Replacement of 1No. 3” dia
directly welded to 3” dia observed. Hydro test found 90degree elbow and pipe support
90degree elbow location. satisfactory. along with corrosion pad was
2. 17-PSV-06A: carried out.
1. External corrosion and deep 3. Replacement of 1.5” dia take-off
pitting was observed on 3x2.5” line for approx. 0.3m length along
dia spool for approx. 0.3m with gate valve and necessary
length between PSV fittings was
and isolation valve. carried out.
2. Pipe support was observed 4. Replacement of 3x2.5” dia spool
directly welded at 3” dia 90- for approx. 0.3m length along with
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

degree elbow at u/s of isolation necessary fittings was carried out at

valve. 17-
3. External corrosion and deep PSV-06A.
pitting was observed on 1.5” dia
take-off line on 3” dia header for
approx. 0.3m
length.
4. External corrosion and deep
pitting was observed on 1.5” dia
spool for approx. 0.3m length
connected to
flare header.
17 17HL-18 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 2” dia 2Nos. of Nil
16-C-01 PSV take off Piping loop was carried out. 2. Ultrasonic thickness spools flange to flange for approx.
General condition of pipeline examination 2m length along with necessary
was found satisfactory. 3. Hydro test of entire loop fittings was
-Minimum measured thickness- was witnessed at 34 kg/cm2 on carried out at North of 16-C-01
4.4 mm against original 5.54 11/11/2023. No pressure drop OVHD.
mm. (3” size)-B1Aspec. and no leakage
1. 16-C-01 OVHD: 1. Moderate observed. Hydro test found
pitting and moderated scaling satisfactory.
was observed on 2” dia, 2Nos.
of spools.
18 17HL-19 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 2” dia 2Nos. of Nil
16-C-02 PSV take off Piping loop was carried out. 2. Ultrasonic thickness spools flange to flange for approx.
General condition of pipeline examination 2m length along with necessary
was found satisfactory. 3. Hydro test of entire loop fittings was
-Minimum measured thickness- was witnessed at 34 kg/cm2 on carried out at North of 16-C-02
4.4 mm against original 5.54 11/11/2023. No pressure drop OVHD.
mm. (2” size)-B1Aspec. and no leakage
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

1. 16-C-02 OVHD: 1. Moderate observed. Hydro test found

pitting and moderated scaling satisfactory.
was observed on 2” dia, 2Nos.
of spools.
19 17HL-20 Visual Inspection and UTG of 1. Visual examination 1. Provided 1No. Corrosion pad on Nil
PRU Feed FCV 106 Piping loop was carried out. 2. Ultrasonic thickness 6” dia line at North of 17-C-02.
General condition of pipeline examination. 2. Replacement of 3” dia pipe line
was found satisfactory. 3. 10% DPT of 1” & 0.75” for approx. 1m length along 1No.
-Minimum measured thickness- NPS fillet welds, no relevant 90-degree elbow and 0.75” dia
5.8 mm against original 7.11 indications observed. drain line on 3”
mm. (6” size)-A1Aspec 4. Hydro test of entire loop dia pipe was carried out at North of
-Minimum measured thickness- was witnessed at 32.4 kg/cm2 17-C-02, Near 17-FV-106.
4.6 mm against original 5.49 on 21/11/2023. No pressure 3. Replacement of 6” dia pipe for
mm. (3” size)-A1Aspec. drop and no leakage approx. 2m length along with 2Nos.
1. North of 17-C-02 (17-FV-106 observed. Hydro test found 90-degree elbows and necessary
OVHD PRU Feed line): satisfactory. fittings
Corrosion pad was not provided was carried out at west battery
for 6” dia line at support limit.
location.
2. North of 17-C-02, Near 17-
FV-106: Low thickness 4.6mm
was observed on 3” dia pipe
against original
thickness of 5.49mm and 0.75”
dia drain line directly welded on
3” dia 90-degree elbow.
3. West battery limit: Low
thickness 5.8 mm was observed
on 6” dia pipe against original
thickness 7.11 mm.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

20 017HL-21 -Minimum measured thickness- 1. Visual examination 1. Provided 2No. Of corrosion pads Nil
Lean amine from new 4.3 mm against original 5.54 2. Ultrasonic thickness at North of 16-C-01 OVHD.
Merox to 16-C-01/C-02 mm. (2” size)-B7Aspec examination 2. Provided 3No. Of corrosion pads
-Minimum measured thickness- 3. 100% DPT of 3⁄4” NPS at North of 16-C-01 OVHD.
4.7 mm against original 5.54 welds, no relevant indications 3. Replacement of 0.5” dia lead line
mm. (2” size)-B7Aspec observed. for approx. 7m length each along
-Minimum measured thickness- 4. Hydro test of entire loop with necessary fittings and valves
6 mm against original 7.14 mm. was witnessed at 31.1 kg/cm2 was
(1.5” size)-B7Aspec on 09/12/2023. No pressure carried out at West of 16-PM-
-Minimum measured thickness- drop and no leakage 01C/D.
7 mm against original 5.08 mm. observed. Hydro test found 4. 2) Replacement of 5” dia lead
(1.5” size)-A9Aspec satisfactory. line for approx. 2m length each
-Minimum measured thickness- along with necessary fittings and
3.8 mm against original 5.54 valves was
mm. (2” size)-A9Aspec carried out at East of 16-G-01.
-Minimum measured thickness- 5. Replacement of 0.5” dia lead
4.1 mm against original 5.49 line, approx. 2.5 m length each
mm. (3” size)-A9Aspec along with necessary fittings and
-Minimum measured thickness- valves was
4.9 mm against original 5.08 carried out at North of 16-G-01.
mm. (1.5” size)-A9Aspec 6. 0.75” dia line structural supports
-Minimum measured thickness- was provided at west of 16-G-
4.8 mm against original 5.54 01/02.
mm. (2” size)-B19Aspec 7. 2) Replacement of ISA 50
-Minimum measured thickness- structural support angles approx.
4.9 mm against original 5.54 0.5 m length was carried out at
mm. (2” size)-B19Aspec north of 16-T-01.
1. North of 16-C-01 OVHD: 2) 8. 2) Replacement of 3x2” dia
Corrosion pad missing was Spool flange to flange approx. 1.5
observed on 2 “dia line at 2 m length. Provide 3” dia corrosion
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

support locations. pad along with

2. North of 16-C-01 OVHD: 2) proper trunnion support was carried
Corrosion pad missing was out at north of 16-E-02.
observed on 2 “dia line at 3 9. 2) Replacement of 0.75 “dia
support locations. drain line-2nos along with
3. West of 16-PM-01C/D: 16- necessary fittings and valves was
FI-204 orifice flange connected carried out.
0.5 “dia lead lines were 4) Replacement of 0.5 “ dia lead
observed severely corroded. line for approx. 6 m length along
4. East of 16-G-01: 2) Orifice with necessary fittings and valves
flange connected 0.5 “dia lead was carried
lines were observed non- out at South of 16-PM-01C/D
standard fitting and severely Suction & Discharge lines.
corroded. 10. Replacement of 2 “ dia line
5. North of 16-G-01: Orifice approx. 1 m length and provide
flange connected 0.5 “dia lead corrosion pad at support location
lines were observed severely was carried out
corroded. at west of 47-PM-02A OVHD
6. West of 16-G-01/02: 0.75 beam.
“dia line was observed support 11. 3) Replacement of 2nos 2” dia
missing and hanging. spools for approx. 200 mm length
7. North of 16-T-01: 2) ISA50 along with 0.75” dia drain lines and
structural support angles on 1.5 corrosion
“dia line were observed severely pad along with pipe supports was
corroded and carried out at south of 16-PM-
perforated. 01C/D Suction & Discharge lines.
8. North of 16-E-02: 2) low
thinness and trunnion support
was observed directly welded to
3” dia 90-degree elbow.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

9. south of 16-PM-01C/D
Suction & Discharge lines:
2) Pump suction line connected
3x0.75 “dia drain lines-2nos
were observed severely corroded
and perforated.
4)16-PM-01D discharge line
connected 0.75x0.5 “dia lead
line was observed moderate
pitting and severely
corroded.
10. West of 47-PM-02A OVHD
beam: 2” dia line was observed
severely corroded at sleeper
beam support
location.
11. south of 16-PM-01C/D
Suction & Discharge lines:
3) D/S of NRV Pipe support:
2nos were observed directly
welded to 2” dia 90-degree
elbows.
21 17HL-22 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 2” dia 1No. 90- Nil
16-C-01/C-02 outlet to Piping loop was carried out. 2. Ultrasonic thickness degree elbow was carried out at
16-E-01A/B,47-C-03 General condition of pipeline examination North of 16-C-02.
inlet was found satisfactory. 3. 100% DPT of 3⁄4” NPS 2. 1) Replacement of 2” dia 90-
-Minimum measured thickness- fillet welds, no relevant degree elbow and provided
3.4 mm against original 5.54 indications observed. corrosion pad along with pipe
mm. (2” size)-A9Aspec 4. Hydro test of entire loop support was carried out.
-Minimum measured thickness- was witnessed at 30 kg/cm2 on 2) Replacement of 2” dia T and
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

4.7 mm against original 5.54 12/12/2023. No pressure drop provided corrosion pad along with
mm. (2” size)-A9Aspec and no leakage pipe support was carried out at
-Minimum measured thickness- observed. Hydro test found North of 16-
4.3 mm against original 5.49 satisfactory. C-02 near 16-LCV-102.
mm. (3” size)-A9Aspec
-Minimum measured thickness-
4.8 mm against original 5.54
mm. (2” size)-A19Aspec
-Minimum measured thickness-
3.8 mm against original 5.54
mm. (2” size)-A19Aspec
1. North of 16-C-02: 3) Low
thickness 3.4 mm was observed
on 2” dia 90-degree elbows
against original thickness
of 5.54 mm.
2. North of 16-C-02 near 16-
LCV-102:
1) 1no pipe support was
observed directly welded to 2
“dia 90-degree elbow.
2) 1no pipe support was
observed directly welded to 2
“dia T-joint.
3. North of 16-C-01: 2) 2 “dia
OWS line was observed
perforated.
4. North of 16-C-01 near 16-
LCV-102:
1) 1no pipe support was
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

observed directly welded to 2

“dia 90-degree elbow and 0.75
“dia drain severely
corroded.
2) Pipe support was observed
directly welded to 2 “dia T.
5. 16-FCV-103 OVHD: Severe
corrosion was observed on 2
“dia line at sleeper beam support
location.
6. 16-G-01/02 OVHD:
1) Low thickness 3.4 mm was
observed on 2 “dia 90-degree
elbows against original
thickness of 5.54 mm.
2) Corrosion pad missing and
line not resting at ISA 75 angle
support location.
7. 47-PM-02A/B OVHD Beam:
Severe corrosion was observed
on 2 “dia line at sleeper beam
support location.
8. East of 47-C-01/02: 2” dia
line was observed severe
corrosion at 2nos sleeper beam
support locations. External
corrosion and continuous water
spillage from top platform was
observed.
22 017HL-35 Visual Inspection and UTG of 1. Visual examination 1. 3) Replacement of 0.75x0.5” dia Nil
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

17-V01/02 make up Piping loop was carried out. 2. Ultrasonic thickness PG take off line for approx. 300
manifold General condition of pipeline examination mm length along with valve was
was found satisfactory. 3. 20% DPT of 3⁄4” NPS carried out.
-Minimum measured thickness - welds, no relevant indications 4) Replacement of 0.75” dia drain
4.6 mm against original 5.54 observed. for line Approx. 100 mm along
mm. (2” size)-B1A spec 4. Hydro test of entire loop with gate valve was carried out.
-Minimum measured thickness - was witnessed at 42.75 kg/cm2 5) Replacement of 4nos 0.5” dia
2.5 mm against original 5.08 on 10/12/2023. No pressure lead lines for approx. 300 mm
mm. (1.5” size)-B1A spec. drop and no leakage length along with gate valves was
1. East of 17-V-02 1st platform: observed. Hydro test found carried out.
3) Nonstandard fitting was satisfactory. 2. 1) a) Replacement of 1” dia line
observed on 0.75x0.5” dia PG for approx. 14 m length along with
take off line and nipple necessary fittings and valves.
corroded. b) Replacement of 1.5” dia spool
4) 1.5x0.75” dia drain line gate for approx. 1 m length along with
valve leak marks observed and valves.
nipple perforated. c) Provided structural support for
5) 1.5” dia (charging line) 1” dia line along with u-clamp and
orifice flange connected 4nos provided Tie rod at support location
0.5” dia lead lines severely at
corroded. north of 17-C-02 (17-LCV-702).
2. North of 17-C-02 (17-LCV- 3. 1) a) Replacement of 1.5 dia line
702): flange to flange approx. 3 m length
1. (a) 1” dia line was observed along with necessary fittings and
with temporary clamp and leak. valves.
(b) 1” dia line observed b) Replacement of 1” dia line
moderate pitting and Support approx. 11 m length along with
missing. necessary fittings and valves.
(c) 1” dia line observed severely c) Replacement of 1” dia line
corroded and misalignment at approx. 8 m length along with
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

sleeper support location. necessary fittings and valves and

3. North of 17-C-01 (17-LCV- provided pipe
01): support for 1” dia line along with u-
1. (a) 1.5 x 1” dia line was clamps at North of 17-C-01 (17-
observed with temporary clamp LCV-01).
and leak. 4. 1) Replacement of 0.5” dia lead
(b) 1.5 x 0.75” dia line observed lines for approx.10 m length along
external corrosion and moderate with gate valve was carried out at
pitting. west of
(c) 1” dia line observed 17-C-02.
moderate pitting and Support 2) Provided 4nos. of u-clamp on
missing. support location at West of 17-C-
4. West of 17-C-02: 02.
1) Orifice flange connected 0.5” 3) Provided structural support for
dia lead lines were observed 2” dia line and provided corrosion
severely corroded. pad at support location at west of
2) 0.75” dia drain line was 17-C-02.
observed U-clamp support 5. Replacement of 0.5” dia lead
missing and tied with rope. lines for approx. 10 m length along
3) 2” dia line was observed pipe with gate valve was carried out at
support freely hanging. east of 17-
5. East of 17-C-01: Orifice C-01.
flange connected 0.5” dia lead 6. 1) Replacement of 1.5” dia line
lines were observed severely for approx. 2.5 m length along with
corroded. necessary fittings and valves and
6. East of 17-V-01: provided
1) Low thickness 2.5 mm was corrosion pad at support location.
observed on 1.5” dia (dumping 2) Replacement of 1.5” dia line for
line) pipeline against original approx. 14 m length along with
thickness of 5.08 necessary fittings and valves was
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

mm. carried out

2) Low thickness 3.4 mm was at east of 17-V-01.
observed on 1.5” dia (charging 7. Replacement of 1.5” dia line for
line) pipeline against original approx.16 m length along with
thickness of 5.08 necessary fitting, take off lines and
mm. valves was
7. 17-PM-01F OVHD: carried out at 17-PM-01F OVHD.
1) (a) Low thickness 3.5 mm 8. Replacement of 1.5” dia line for
was observed on 1.5” dia approx. 1 m length and provided
pipeline against original corrosion pad at support location
thickness of 5.08 mm. was carried
(b) 2nos 1.5” gate valves out at west of 17-PM-01C OVHD.
(welded type) were observed 9. Replacement of 1.5” dia line for
leak marks at gland packing approx. 1 m length and provided
location. corrosion pad at support location
(c) 1.5” dia line observed was carried
severely corroded at sleeper out at south of 17-PM-01D OVHD.
support location.
8. West of 17-PM-01C OVHD: 10. 2) Replacement of 1.5” gate
1.5” dia line observed severely valve was carried out.
corroded and embedded in 4) Replacement of 1” dia line for
concrete at sleeper approx. 4 m length was carried out.
support location. 5) Replacement of 1” dia line for
9. South of 17-PM-01D OVHD: approx. 1 m length along with
1.5” dia line observed severely necessary fittings and valves and
corroded and embedded in including
concrete at sleeper 0.75” dia line approx. 1 m length
support location. along with fittings and valves was
carried out at South of 17-PM-01D.
10. South of 17-PM-01D: 6) Provided 2nos 3” x 2” dia OWS
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

2) 1.5” gate valve (welded type) funnel along with mesh was carried
was observed leak marks at out at South of 17-PM-01D.
gland packing location. 11. 1&2) Replacement of 1.5” dia
4) 1” dia line was external line for approx. 0.5 m length and 1”
corrosion and moderate pitting. dia line for approx. 10 m length
5) Nonstandard fittings were along with
observed on 1” dia line. necessary fittings and valves and
6) OWS funnel was observed provide Tie rod at support location
missing. for 1” dia line at East of 17-V-03.
11. East of 17-V-03: 12. 1) 3nos. of corrosion pads
1) (a) Gland leak marks were provided on 1.5” dia line at 17-PM-
observed on 2nos 1.5” gate 01E OVHD.
valves and 1no 1” gate valve
(welded type). 2) Replacement of 0.5” dia lead
(b) 1.5”X1” dia line was lines for approx. 10m length along
observed external scaling and with gate valve was carried out at
moderate pitting. 17-PM-
12. 17-PM-01E OVHD: 01E OVHD.
1) Corrosion pad missing was
observed on 1.5” dia lines and 13. 1) Replacement of 0.75” dia PG
1no temporary corrosion pad take off line for approx. 400 mm
observed. length along with fittings and valve
2) Orifice flange connected 0.5” and 0.5”
dia lead lines were observed dia drain line approx. 2.5 m length
leak marks and severely along with necessary fittings and
corroded. valves was carried out at 17-PM-
13. 17-PM-01F Discharge line: 01F
1) 0.75” dia PG take off Discharge line.
connected 0.5” dia drain line 2) Carry out replacement of 1.5”
was observed moderate pitting gate valve was carried out at 17-
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

and severely corroded. PM-01F Discharge line.

2) 1.5” dia gate valve (welded 14. Replacement of 0.75” dia PG
type) was observed gland leak take off line for approx. 400 mm
marks at gland and bonnet length along with fittings and valve
location. and 0.5” dia
14. 17-PM-01E Discharge line: drain line approx. 2.5 m length
0.75” dia PG take off connected along with necessary fittings and
0.5” dia drain line was observed valves was carried out at 17-PM-
moderate pitting 01E Discharge
and severely corroded. line.
15. 17-V-07 Outlet line: 1) 1” 15. 1) Replacement of 1” dia spool
dia spool was observed flange to flange for approx. 1.5 m
moderate pitting and severely length along with necessary fittings
corroded. and
16. North of 17-E-01: valve was carried out at 17-V-07
1) 17-E-01 Inlet connected 1” Outlet line.
dia was observed moderate 16. 1&2)Replacement of 1” dia line
pitting and external corrosion. for approx. 12 m length along with
2) 1” and 0.75” gate valves were necessary fittings and valves was
observed leak marks at gland carried
packing location. out at north of 17-E-01.
17. North of 17-V-04: 2”x1” dia
line was observed external 17. Replacement of 2”x1” dia line
corrosion and moderate pitting. for approx. 9 m length along
necessary fittings was carried out at
north of 17-V-
04.
23 17HL-36 Visual Inspection and UTG of 1. Visual examination 1. 1) Replacement of 1” dia drain Nil
17-E-01 outlet to 17-V- Piping loop was carried out. 2. 20% DPT for 1” & 3⁄4” line including valve was carried out
05 inlet General condition of pipeline NPS fillet welds, no relevant at east of 17-E-01A/B.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

was found satisfactory. indications observed. 2) Replacement of 0.75x0.5 inch

-Minimum measured thickness- 2. Hydro test of entire loop dia line for approx. 1 m length
6.4 mm against original 7.11 was witnessed at 13.5 kg/cm2 along with necessary fittings and
mm. (6” size)-B1A spec on 21/11/2023. No pressure 0.5” dia
-Minimum measured thickness- drop and no leakage flange was carried out at east of 17-
7.1 mm against original 5.08 observed. Hydro test found E-01A/B.
mm. (1.5” size)-B1A spec. satisfactory. 3) Replacement of 0.75x0.5 inch
1. East of 17-E-01A/B: dia PG take off line for approx. 0.5
1) Oozing was observed on 6x1 m length along with necessary
inch dia drain line. fittings and
2) 0.75x0.5 inch dia line was valves was carried out at east of 17-
observed moderate pitting and E-01A/B.
0.5 inch dia flange was observed
severely corroded.
3) 0.75x0.5 PG take off was
observed nonstandard fittings
and externally corroded.
24 017HL-37 Visual Inspection and UTG of 1. Visual examination 1. Carried out welding at S/W of Nil
17-V-06 Shell flange to Piping loop was carried out. 2. Ultrasonic thickness 17-V-06.
17-PM-01C/D/E/F General condition of pipeline examination 2. 1) Replacement of 0.5 “dia gate
Suction; was found satisfactory. 3. 20% DPT of 1.5”, 1” & 3⁄4” valve was carried out at west of 17-
-Minimum measured thickness- NPS welds, no relevant V-06.
4.0 mm against original 5.54 indications observed. 2) Replacement of 1” dia flange
mm. (2” size)-B1Aspec 4. Hydro test of entire loop was carried out at west of 17-V-06.
-Minimum measured thickness- was witnessed at 13.5 kg/cm2 3. 1) Replacement of 2” dia spool
4.4 mm against original 5.08 on 10/12/2023. No pressure flange to flange for approx. 4 m
mm. (1.5” size)-B1Aspec drop and no leakage length along with 2no’s 90-degree
1. S/W of 17-V-06: Leak marks observed. Hydro test found elbows and
and welding not carried out on satisfactory. 1no T-joint was carried out at North
1.5 “dia line at socket joint of 17-V-05.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

location. 2) Replacement of 1.5” dia spool

2. West of 17-V-06: flange to flange for approx. 1.5 m
1) 0.5 “dia sample point gate length along with necessary fittings
valve handle wheel was and
observed damaged. valves was carried out at North of
2) 1 “dia flange was observed 17-V-05.
deep pitting and severely 3) Replacement of 2” dia gate valve
corroded. was carried out at North of 17-V-
3. North of 17-V-05: 05.
1) Low thickness and moderate
pitting was observed on 2 “dia 4) Replacement of 2” dia spool
line. flange to flange for approx. 12 m
2) Gland Leak marks were length along with 4 no’s 90-degree
observed on 1.5-” gate valve. elbows and
Externally corrosion was necessary fittings was carried out at
observed on 1.5 “dia line. North of 17-V-05.
3) 2 “dia isolation valve was 4. 1) Replacement of 2x1.5” dia
observed severely corroded at spools for approx. 3.5m length
flange gasket location. along with 2no’s strainers and
4) Oozing and moderate pitting necessary fittings &
was observed on entire 2 “dia valves was carried out at South of
spool. 17-PM-01D Suction line.
4. South of 17-PM-01D Suction 5. Replacement of 2x1” dia spool
line: 1) (a) Moderate pitting, flange to flange approx. 2 m length
Nonstandard fittings and leak along with strainer and necessary
marks were observed fittings
2no’s spools. was carried out at South of 17-PM-
5. South of 17-PM-01C Suction 01C Suction line.
line: Moderate pitting and 6. 1) Replacement of 2” dia line for
severe corrosion was observed approx. 10 m length was carried out
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

on 2x1 “dia spool. at west of 17-V-06.

6. West of 17-V-06: 2) Replacement of 2’’-300# gate
1) Line was directly rested on valves was carried out at west of
the ground and P2 wrapping 17-V-06.
moderate damages were 7. 1) Replacement of 2” dia line for
observed. approx. 12 m length was carried out
2) 2 “dia isolation valve at south of 17-PM-01E/F to 17-PM-
observed embedded in the soil. 01C/D.
7. South of 17-PM-01E/F to 17- 2) Replacement of 0.75 “dia drain
PM-01C/D: line for approx. 1.5 m length along
1) 2 “dia suction line P2 with necessary fittings and valves
wrapping was damaged at soil – was
air interface areas. carried out at south of 17-PM-
2) 17-PM-01E: 2 “dia Suction 01E/F to 17-PM-01C/D
line connected 0.75 “dia drain
line badly corroded.
25 017HL-38 Visual Inspection and UTG of 1. Visual Examination Carry out Replacement of Entire Nil
17-V-06 top flange to piping loop was carried out. 2. Ultrasonic Thickness loop
Disulphide off gas line General Condition of Pipeline Examination Flange to Flange :
was found satisfactory. [Link] -1” Dia Meter line approx.. 20m
17-V-06 top Flange connected 4. Hydro Test Length
DSO small bore Lines(1”,0.75” -0.75 Dia line approx.. 25m
& 0.5”) were observed scattered -0.5” Dia line approx. 7m length
Pitting and External Corrosion along with necessary fittings and
valves.
Provide proper supports and U-
clamps on 1” and 0.75 “ Dia new
lines.
Carry out surface preparation and
Apply painting as per painting
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

Advisory.

[Link] API 5L GR, B/ASTM

A106GR.
B material for 0.5” to 1” sch 80 as
per B1A Specification.
2. Carry out welding with ER70S2
3. Offer 100% DPT ASR & BSR
Followed by PWHT For fillet weld
joints .
4. Use full TIG welding uprto 2”
dia line
[Link] 100% weld for inspection
6. Carry out Hydrotest at 13.5kg/cm
-
26 017HL-39 Visual Inspection and UTG of [Link] Examination Carry out Replacement of Entire of Nil
17-V-06 PSV take off piping loop was carried out. [Link] Thickness Entire 3” dia line flange to flange
flange to Off gas General Condition of Pipeline Examination approx. 27m length along with
/DSO/flare was found satisfactory. [Link] necessary fittings and flanges
-Minimum Measured Thickness- [Link] Test -Including 1.5 inch dia take off line
3.2mm against original approx. 2.5m length.
5.49mm(3” INCH Size) B1A -Provide corrosion pad along with
Spec proper pipe supports
Low Thickness 3.2mm was -Carry out sectional replacement of
observed on 3” dia line against 1inch dia line approx. 6m length
original thickness of 5.49 due to along with necessary fittings.
internal corrosion. Provide 3 no’s U-Clamp supports
Random locations of thickness along with packing at support
gauging was carried out location.
suspecting internal corrosion on
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

entire line
3x1 inch dia line was observed 1) Carry out sectional replacement
External Corrosion and of 1x0.5 inch dia line approx. 2.5m
moderate pitting. length along with strainer and 2no’s
3no’s U-CLAMP Supports gate valves.
severely corroded.
1x0.5 inch dia suction line was 2) Provide 4 No’s U-Clamp
observed severely corroded and supports along with packing
Leak marks at Stainer Flange support location
Gasket Location
1 inch dia line was observed Carry out sectional replacement of
leak marks at Gland Packing 1inch dia line approx. 0.5m length
Location. along with 2no’s flanges and 1 no
2. U-CLAMPS Supports gate valve.
missing and Perforated on 1” dia
line at 4 locations.

Severe corrosion was observed

at flange to flange gasket
location on 1” dia line
27 017HL-39A Visual Inspection and UTG of 1. Visual examination C. Repairs Carried Out: Nil
17-C-01/02 to 17-V-08 Piping loop was carried out. 2. Ultrasonic thickness 1. Replacement of entire 1.5” dia
inlet General condition of pipeline examination spools flange to flange approx. 20
was found satisfactory. 3. 20% DPT of 1.5” NPS fillet m length along with 0.5 “ & 1 “
-Minimum measured thickness- welds, no relevant indications take off lines
2.9 mm against original 5.08 observed. and necessary fittings & valves was
mm. (1.5” size)-B1A spec 4. Hydro test of entire loop carried out at North of 17-C-01/02.
1. North of 17-C-01/02: was witnessed at 42.75 kg/cm2 2. Replacement of entire 1.5” dia
1) Leak marks and temporary on 08/12/2023. No pressure spool for approx. 7 m length along
clamp was observed on 17-C- drop and no leakage with necessary fittings and valves
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

01/02 connected 1.5 “dia spools. observed. Hydro test found was carried
2) 1.5” dia OWS line was low satisfactory. out at North of 17-V08.
BOP, embedded with and
severely corroded.
2. North of 17-V08: Severe
corrosion, low BOP and Low
thickness 2.9 mm was observed
on 1.5 “ dia OWS line
against original thickness of
5.08 mm due to internal
corrosion.
28 017HL-39B Visual Inspection and UTG of 1. Visual examination 1. 1) provided corrosion pad on Nil
17-V-08 O/L to 17-PM- Piping loop was carried out. 2. Ultrasonic thickness 1.5” dia line and also provided
03 General condition of pipeline examination permanent support at north of 17-
was found satisfactory. 3. 20% DPT of 1.5” NPS fillet V-08.
-Minimum measured thickness- welds, no relevant indications 2) Replacement of 1.5” dia line for
4.6 mm against original 5.49 observed. approx. 8m length and provided
mm (3” size)-B1A spec. 4. Hydro test of entire loop corrosion pads along with pipe
-Minimum measured thickness- was witnessed at 42.75 kg/cm2 support and
4.3 mm against original 5.08 on 08/12/2023. No pressure maintain BOP was carried out at
mm (1.5” size)-B1A spec. drop and no leakage north of 17-V-08.
1. North of 17-V-08: observed. Hydro test found
1) 1.5” take off line on 3” dia satisfactory.
line was observed directly
resting on temporary support.
2) 1.5” dia OWS line was
observed external corrosion and
line was directly resting on the
ground.
29 017-HL-39D Visual Inspection and UTG of [Link] Examination -Carry out Sectional replacement of Nil
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

CDU-ll,/CDU-l 17-PM- Piping loop was carried out. 2. Ultrasonic thickness 2” dia approx. 1m length.
03 dis spent caustic to General condition of pipeline examination -Provide corrosion pad at support
19-TK-03I/L Drain was found satisfactory. [Link] location.
--Minimum measured thickness- [Link] Test
4mm against original 5.49mm. -Carry out Sectional replacement of
(3-inch size)-A19A Spec 2” dia line approx. 1m length.
-Minimum measured thickness- -provide corrosion pad at support
3.3mm against original 5.54 location.
mm.(2-inch size )-A19 spec
!)carry out sectional replacement of
3”150# gate valve was observed 2” dia line approx. 14m length.
severely corroded at flange -provide corrosion pad at support
gasket location and leak marks location.
at gland packing location Carry out surface preparation and
apply paint as per painting
3” dia line was observed fouling advisory.
with adjacent 3” dia line. [Link] API 5L GR. B/ASTM A 106
GR. B Material for 0.5-ich to 1-
1)(a) Clamp was observed on 2” inch dia sch 80, for 2-inch dia
dia line. sch.80, as per A19A Specification.
(b) Low thickness 3.8mm was 2. Carry out welding with
observed on 2 inch dia pipeline ER70S2/E7018.
against original thickness of [Link] radiography 100% BSR
5.54mm & ASR followed by PWHT.
2) 1 no 3” gate valve and 1 no 4)Offer 100% DPT BSR & ASR
3” globe valve was observed followed by PWHT For socket
severely corroded at flange weld joints.
gasket location 5)offer hardness test for inspection
1)(a) Low thickness 3.5mm was 6)Use full TIG Welding up to 2
observed on 2” dia pipeline inch dia size.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

against original thickness of 7) Offer 100% weld visual for

5.54mm inspection.
(b) 0.75 dia drain line was 8) Carry out Hydro test at
observed severely corroded. 9Kg/Cm2 and offer for inspection

1)Pipe support was observed

directly welded to 2”dia 90-
degree elbow.
2)2” dia line was observed
severely corroded support
location
3)2” gate valve was observed
severely corroded at flange
gasket location.

1)(a) NRV U/S 2” dia spool

flanges were observed severely
corroded and moderate pitting
was observed.
(b) 2x0.75” dia PG take off was
observed leak marks and
moderate pitting

30 19HL-40 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 3⁄4” x 1⁄2” inch Nil
From B/L to 19-PM- Piping loop was carried out. 2. Ultrasonic thickness line for approx. 1.5m length along
07A/B suction General condition of pipeline examination with support was carried out at 19-
was found satisfactory. 3. 10% DPT of 1⁄2” & 3⁄4” PM-07B
-Minimum measured thickness- NPS fillet welds, no relevant North side.
5.4 mm against original 6.02 indications observed. 2. Provided 1No. Of support at 19-
mm (4” size)-A1A spec. 4. Hydro test of entire loop PM-07B.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

1. 19-PM-07B North side: PG was witnessed at 3.1 kg/cm2 3. Replacement of 4” dia line for
connected 3⁄4” x 1⁄2” dia line on 27/11/2023. No pressure approx. 1m length was carried out
was observed paint blisters and drop and no leakage at near battery limit.
temporary rope support. observed. Hydro test found
2. 19-PM-07B: Suction satisfactory.
connected 4 inch dia line was
observed with temporary
wooden support.
3. Near battery limit: 16-FT-
2104 overhead sleeper beam
area 4’ line was observed
corrosion due to severe paint
failure at bottom location.
31 19HL-41 Visual Inspection and UTG of 1. Visual examination 1. Provided [Link] U-clamps on Nil
19-PM-07A/B discharge Piping loop was carried out. 2. Ultrasonic thickness 3⁄4” dia instrumentation line at west
to 19-W-01 General condition of pipeline examination of 19-W-01.
was found satisfactory. 3. 10% DPT of 1⁄2” & 3⁄4” 2. Replacement of 3⁄4” dia 2no’s
-Minimum measured thickness- NPS welds, no relevant flanges was carried out at west of
5.1 mm against original 6.02 indications observed. 19-W-01.
mm (4” size)-A1A spec. 4. Hydro test of entire loop 3. Replacement of 1⁄2” dia 2no’s
1. 19-W-01 west side: 2) 3⁄4” was witnessed at 26.1 kg/cm2 valves was carried out at near
vent connected instrument lines on 26/11/2023. No pressure battery limit.
were observed U clamps drop and no leakage
missing. observed. Hydro test found
2. 19-W-01 West side: satisfactory.
1) 3⁄4” x 1⁄2” dia take-off line
flanges were observed thinning.
2) 3⁄4” x 1⁄2” dia sample
collecting line was observed not
resting properly on the support
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

and U clamp missing.

3. 19-PM-07/B: Pump discharge
to PG connected 4” x 3⁄4” dia
take-off line 2no’s valves was
observed handle
wheel missing.
32 19HL-42 Visual Inspection and UTG of 1. Visual examination 1. 1) Replacement of 1no 4” dia 90- Nil
19-W-01 outlet to Piping loop was carried out. 2. Ultrasonic thickness degree elbow and provided
Vertex inlet General condition of pipeline examination corrosion pad along with trunnion
was found satisfactory. 3. 10% DPT of 1” & 3⁄4” NPS support South of
-Minimum measured thickness- fillet welds, no relevant 19-W-01.
5.5 mm against original 6.02 indications observed. 2) Provided gusset plate (3mm
mm (4” size)-A1A spec. 4. Hydro test of entire loop thick) for 0.75 inch dia sample
1. South of 19-W-01: was witnessed at 26.1 kg/cm2 point line at south of 19-W-01.
1) Trunnion support was on 25/11/2023. No pressure 2. Provided 1no corrosion pad on
observed directly welded to 4” drop and no leakage 4” dia line at OVHD of 19-W-01.
dia 90-degree elbow location. observed. Hydro test found 3. Replacement of 1” dia pipe line
2) Gusset plates was observed satisfactory. flange to flange for approx.5m
missing on 0.75” dia sample length with necessary fittings and
point line on 4 inch dia header also provided
line u-clamps with standard supports
2. OVHD of 19-W-01: was carried out at Vertex OVHD
Corrosion pad was observed near 19-FIC-01 & 01A.
missing on 4” dia pipe at U-
clamp support location.
3. Vertex OVHD near 19-FIC-
01 & 01A: Vertex connected 1”
dia pipe line was observed
external pitting and
nonstandard supports.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

33 19HL-43 Visual Inspection and UTG of 1. Visual examination 1. 1) Replacement of 4” dia pipe for Nil
Vertex outlet to 19-R-01 Piping loop was carried out. 2. Ultrasonic thickness approx. 1m length and provided
inlet General condition of pipeline examination corrosion pad was provided at
was found satisfactory. 3. 10% DPT of 3⁄4” NPS fillet Sample Point
-Minimum measured thickness- welds, no relevant indications (ATF after 19-W-01 OVHD).
6.8 mm against original 7.11 observed. 2. Replacement of 2no’s 4” dia 90-
mm. (6-” size)-A1Aspec 4. Hydro test of entire loop degree elbow and provided
-Minimum measured thickness- was witnessed at 26.1 kg/cm2 corrosion pad along with trunnion
4.2 mm against original 6.02 on 27/11/2023. No pressure support was
mm. (4-” size)- A1Aspec drop and no leakage carried out at South of 19-R-01.
-Minimum measured thickness- observed. Hydro test found 3. 1No. Corrosion pad was
5.1 mm against original 5.49 satisfactory. provided at missing location.
mm. (3-” size)- A1Aspec. 4. Replacement of 4“ dia spool,
1. Sample Point (ATF after 19- flange to flange with 1no 90 degree
W-01 OVHD): elbow and provided 0.75” dia drain
1) Low thickness 4.2 mm on 4“ dia
against original thickness- 6.02 pipeline as per operation
mm on 4” dia pipe and corrosion requirement was carried out at
pad missing at North of 19-PM-05 Discharge line.
sleeper support location. 5. 1) Replacement of 4“ dia spool,
2. South of 19-R-01: Trunnion flange to flange with 1no 90 degree
supports were observed directly elbow and provided 0.75” dia drain
welded to 4” dia 90-degree on 4“
elbow at 2 locations. dia pipeline as per operation
3. East of 19-R-01 OVHD: requirement was carried out at
Corrosion pad missing at U- North of 19-PM-05 Discharge line.
clamp support location on 4” dia 2) Replacement of 0.5x0.75” dia
line. PG take off for approx.0.5m length
4. North of 19-PM-05 Discharge and provided gusset plates (3mm
line: 0.75” drain line was thick) for
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

observed directly welded to 4” 0.75” dia drain line was carried out
dia 90° elbow location. at North of 19-PM-04 Discharge
5. North of 19-PM-04 Discharge line.
line:
1) Trunnion support and 0.75 Prepared By Reviewed By
“dia drain line were observed Approved By
directly welded to 4 “dia 90-
degree elbow. Sunit Ranjan Xalxo B M Jeelani M
2) Oozing and drain end cap V N S S Sastry
missing was observed on Manager - Inspection Sr. Manager
0.5x0.75 “dia PG take off on 4 (i/c) – Inspection General Manager
“dia header line. – Inspection
6. West of 19-PM-04: 6. 1) Replacement of 1.5x0.75” dia
1) Severe corrosion and scaling spool for approx. 200mm length
was observed on 1.5x0.75 “dia was carried out at west of 19-PM-
spool approx. 200mm length. 04
2) Non-standard flange (6mm 2) Replacement of 0.5” dia spool
thick plate) used instead of 0.5 for approx.300mm length along
“dia flange. with necessary fittings was carried
7. North of 19-PM-04: out at west
1) Orifice flange connected 0.5 of 19-PM-04.
“dia lead lines were observed 7. Replacement of 0.5” dia lead
external corrosion and paint lines for approx. 3 m length along
failure. with necessary fittings was carried
out at north
of 19-PM-04.
34 19HL-44 Visual Inspection and UTG of 1. Visual examination 1. a &b. Replacement of entire Nil
19-R-01 PSV take off to Piping loop was carried out. 2. Ultrasonic thickness spool, 3” dia line for approx. 2m
PSV inlet General condition of pipeline examination length and provided corrosion pad
was found satisfactory. 3. 10% DPT of 0.75” NPS with PSV
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

-Minimum measured thickness- fillet welds, no relevant support angles on 3” dia pipe was
4.5 mm against original 5.49 indications observed. carried out at 19-R-01 OVHD.
mm. (3” size)-A1A spec. 4. Hydro test of entire loop 2. Provided 0.75” dia vent on 3” dia
1. 19-R-01 OVHD: was witnessed at 23.85 kg/cm2 header line.
1) (a) Low thickness 4.5 mm on 22/11/2023. No pressure
was observed on 3” dia pipe drop and no leakage
against original thickness of observed. Hydro test found
5.49 mm. satisfactory.
(b) 19-PSV-01 support angles
were observed directly welded
to 3-inch pipe line.
2. 1) 0.75” dia vent not available
on 3” dia header line for Hydro
test purpose.
35 19HL-45 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 4” dia 1no. 90- Nil
19-R-01 outlet to 19-V - Piping loop was carried out. 2. Ultrasonic thickness degree elbow and provided
01 inlet General condition of pipeline examination corrosion pad along with trunnion
was found satisfactory. 3. 10% DPT of 0.75” NPS support was
-Minimum measured thickness- fillet welds, no relevant carried out at west of 19-R-01 1st
5.3 mm against original 6.02 indications observed. platform.
mm. (4” size)-A1A spec. 4. Hydro test of entire loop 2. Replacement of 0.75” dia vent
1. West of 19-R-01 1st platform: was witnessed at 23.85 kg/cm2 was carried out at south of 19-W-01
Trunnion support was observed on 23/11/2023. No pressure pipe track.
directly welded to 4” dia 90 drop and no leakage
degree elbow observed. Hydro test found
location. satisfactory.
2. South of 19-W-01 pipe track:
1) Oozing was observed on
0.75” dia vent line connected to
4” dia header line.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

36 19HL-46 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 4” dia 1no flange Nil
19-V-01 outlet to 19-E- Piping loop was carried out. 2. Ultrasonic thickness was carried out at 19-E-01
01 inlet General condition of pipeline examination connected nozzle flange.
was found satisfactory. 3. 10% DPT of 0.75” & 0.5” 2. Replacement of 0.75” dia line for
-Minimum measured thickness- NPS fillet welds, no relevant approx. 6m length along with
5.4 mm against original 6.02 indications observed. fitting and also provide U-clamps at
mm. (4” size)-A1A spec. 4. Hydro test of entire loop support
1. 19-E-01 connected nozzle was witnessed at 25.65 kg/cm2 locations, was carried out at 19-V-
flange: External corrosion was on 23/11/2023. No pressure 01 Top.
observed on 4” dia flange gasket drop and no leakage
location. observed. Hydro test found
2. 19-V-01 Top: Gusset plates satisfactory.
missing, pitting and line resting
on grating was observed on 0.75
inch dia line
connected to 4” dia header line.
37 19HL-47 Visual Inspection and UTG of 1. Visual examination 1. Provided 3Nos. Of corrosion Nil
19-V-01 PSV take off to Piping loop was carried out. 2. Ultrasonic thickness pads on 4” dia line at West of 19-R-
PSV inlet General condition of pipeline examination 01.
was found satisfactory. 3. Hydro test of entire loop
-Minimum measured thickness- was witnessed at 25.65 kg/cm2
5.1 mm against original 6.02 on 23/11/2023. No pressure
mm. (4” size)-A1A spec drop and no leakage
1. West of 19-R-01: corrosion observed. Hydro test found
pads missing were observed on satisfactory.
4” dia line at 3nos. of pipe
support locations.
38 19HL-48 Visual Inspection and UTG of 1. Visual examination 1. Provided 3nos. of corrosion pad Nil
19-E-01 O/L to 19-V-02 Piping loop was carried out. 2. Ultrasonic thickness on 4” dia line at east of 19-V-02 1st
inlet General condition of pipeline examination platform.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

was found satisfactory. 3. 10% DPT of 1.5” NPS fillet 2. Replacement of 1.5” dia OWS
-Minimum measured thickness- welds, no relevant indications pipe line for approx. 3m length
6.8 mm against original 7.11 observed. along with fittings was carried out
mm. (6” size)-A1Aspec 4. Hydro test of entire loop at west of 19-
-Minimum measured thickness- was witnessed at 26.1 kg/cm2 E-01.
5.5 mm against original 6.02 on 23/11/2023. No pressure
mm. (4” size)- A1Aspec drop and no leakage
-Minimum measured thickness- observed. Hydro test found
4.5 mm against original 5.08 satisfactory.
mm. (1.5” size)- A1Aspec
1. East of 19-V-02 1st platform:
1) Corrosion pads and U-clamps
were observed missing on 4” dia
pipe 3no’s at pipe support
locations.
2. West of 19-E-01: Low
thickness 4.5 mm against
original thickness- 5.08 mm for
1.5” dia pipe line due to
internal corrosion.
39 19HL-49 Visual Inspection and UTG of 1. Visual examination 1. Replacement 0.75x0.5” dia drain Nil
19-V-02 outlet to B/L Piping loop was carried out. 2. Ultrasonic thickness line for approx.3 m length along
General condition of pipeline examination with necessary fittings provided
was found satisfactory. 3. 10% DPT of 1⁄2” & 3⁄4” gusset plates
-Minimum measured thickness- NPS fillet welds, no relevant (3mm thick) for 0.75 “ dia drain
5.3 mm against original 6.02 indications observed. line was carried out at East of 19-
mm. (4” size)-A1Aspec 4. Hydro test of entire loop V-04 1st platform.
-Minimum measured thickness- was witnessed at 27 kg/cm2 on 2. 1) b. Replacement of 0.5“dia line
4.9 mm against original 5.49 04/12/2023. No pressure drop approx. 1 m length was carried out
mm. (3” size)-A1Aspec. and no leakage at east of 19-V-05 2nd platform.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

1. East of 19-V-04 1st platform: observed. Hydro test found 3. 1) Replacement of 2no’s 4” dia
Gusset plates missing, satisfactory. 90-degree elbow and provided
nonstandard fittings and minor corrosion pad with trunnion support
pitting was observed on was carried
0.75x0.5” dia drain line on 4” out at south of 19-V-05 near 19-
dia header line. PCV-01 control valve.
2. East of 19-V-05 2nd platform: 2) Replacement of 0.75” dia PG &
1) b. 0.75“dia header line FT lead line for approx. 3m length
connected 0.5“dia line was and provided gusset plates (3mm
observed bend and oil marks. thick) for
3. South of 19-V-05 near 19- 0.75” dia line along with u-clamp
PCV-01 control valve: supports was carried out at south of
1) 2no’s Trunnion support was 19-V-05 near 19-PCV-01 control
observed directly welded to 4 valve.
“dia 90-degree elbow location. 3) Replacement of 0.75” dia drain
2) 4 “ dia header line connected nipple connected to 4” dia header
0.75 “ dia PG & FT lead lines line was carried out at south of 19-
were observed with oil marks, V-05
gusset plates near 19-PCV-01 control valve.
missing and hanging.
3) D/S 19-PCV-01 control valve
0.75 “ dia drain line connected
to 4“ dia header line was
observed end cap
missing and nipple threading
corroded.
4. East Battery limit: External
corrosion and pitting was
observed on 4“dia line at sleeper
beam support location.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

40 19HL-50 Visual inspection and U’rO“ of [Link] Examination [Link] 3 inch dia pipeline
19-V-01 Caustic shell to Piping loop was carried out. [Link] Thickness approx.2m length flange to flange
East B/L General condition of pipeline Examination along with 2no’s 90 degree elbows
was found satisfactory. [Link] and 1 equal T and replace 1.5-inch
-Minimum measured thickness- [Link] dia pipe on 3 inch dia header
4.3 mm against original 5.49 approx. Sin length along with
mm. (3-inch size)-AlAspec necessary fittings as marked in field
-Minimum measured thickness- and provide corrosion pad with
4.5 mm against original 5.08 proper lnsulation support in kind
mm. (4-inch size)- AlAspec
- 1) a) Trunnion support was Replace 1.5-inch dia pipe approx.
observed directly Welded to 3 lm length as marked in field and
inch dia 90° elbow location. provide proper parking to maintain
b) Low diickness 4.3 mm was BOP.
observed on 3 Provide proper space in order to
inch dia 90-degree elbow avoid mechanical damage.
against original thickness of5.49 Provide corrosion pad with proper
mm. u-clamp support on 3 inch dia pipe.
c) 1.5 incb dia OWS and CBD Replace 3 inch dia line approx. 1.5
take offline on 3 inch dia header m length with standard tapping and
line was observed pitting and provide corrosion pad a sleeper
exteinal corrosion beam support location.
1.5 inch dia OWS take off line
on 3inch dia header line was Replaoe 3 inch dia pipe approx. l m
observed pitting, external length and provide corrosion pad at
corrosion and support missing sleeper beam support location.
3inch dia pipeline was observed Replace 3 inch dia pipe approx. 1 m
fouling with adjacent.3 inch dia length and provide corrosion pad at
pipeline. sleeper beam support
Corrosion pad missing at U-
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

clamp support location on 3inch Replace 3 inch dia pipe approx. 1 m

dia line. length and provide corrosion pad at
1)(a) 3 x 3inch dia line observed sleeper beam support
Nonstandard Replace 3 inch dia pipe approx. 1
tapping with RF pad and dead m length and provide corrosion pad
end flange. at sleeper beam support location.
(b) External corrosion and Replace 3 inch dia pipe approx. m
pitting was observed on 3inch length and provide corrosion pad at
dia line at sleeper beam support sleeper beam support location.
location. Replace 3 inch dia pipe approx 1 m
length and provide corrosion pad at
External corrosion and pitting sleeper beam support location.
was observed on 3 inch dia line Replace 3 inch dia pipe approx. 6 m
at sleeper beam support location length and provide corrosion pad at
External corrosion and pitting sleeper beam support location along
was observed on 3 inch dia line with permanent
at sleeper beam support location SUj§OR.

External corrosion and pitting Carry out paint as per perming

was observed on 3 inch dia line advisory.
at sleeper beam support location.
[Link] API 3L Gr. B material for
0.5-inch to 1.5-inch Sch. 80, for 3-
External corrosion and pitting inchsch. 40 as per AIA
was observed on 3 inch dia line specification.
at sleeper beam support location [Link] welding with
External corrosion and pitting ER70S2/E70I8.
was observed on 3 inch dia line [Link] radiography 100% BSR
at sleeper beam support location & ASR followed by PWHT.
External corrosion, pitting and [Link] hardness test for inspection.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

temporary support was observed [Link] Full TIG welding up to 2

on 3 inch dia line at sleeper inch size.
beam support location. [Link] 100% DPT for socket weld
Minor paint failure was joints.
observed at isolaled locations [Link] 100% weld visusl for
throughout the loop inspection.
8. Offer hydro test at 27.9 kg/cm2
& offer for inspection.

41 19HL-51 Visual Inspection and UTG of 1. Visual examination 1. a & b. Replacement of 4” dia line Nil
19-V-02 PSV take off Piping loop was carried out. 2. Ultrasonic thickness for approx. 3m length and provide
General condition of pipeline examination corrosion pad with PSV support
was found satisfactory. 3. 10% DPT of 3/4” NPS fillet angles
- Minimum measured thickness- welds, no relevant indications was carried out at 19-V-02 OVHD.
4.5 mm against original 6.02 observed. c. 0.75” dia vent was provided at
mm. (4” size)-A1A spec. 4. Hydro test of entire loop 19-V-02 OVHD.
1. 19-V-02 OVHD: was witnessed at 27 kg/cm2 on
a) Low thickness 4.5 mm was 08/12/2023. No pressure drop
observed on 4” dia pipe against and no leakage
original thickness of 6.02 mm. observed. Hydro test found
b) 19-PSV-04 support angles satisfactory.
were observed directly welded
to 4” pipe line.
c) 0.75 inch dia vent not
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

available on 4” dia header line

for Hydro test purpose.
42 19HL-52 Visual Inspection and UTG of 1. Visual examination 1. Corrosion pad and u-clamp was Nil
19-V-02 PSV take off to Piping loop was carried out. 2. Hydro test of entire loop provided at East of 19-V-05.
PSV inlet General condition of pipeline was witnessed at 25.2 kg/cm2 2. Corrosion pad with PSV support
was found satisfactory. on 25/11/2023. No pressure angles was carried out at 19-PSV-
-Minimum measured thickness- drop and no leakage 04 OVHD.
5.4 mm against original 6.02 observed. Hydro test found
mm. (4” size)-A1A spec. satisfactory.
1. East of 19-V-05: Corrosion
pad missing was observed on 4”
dia line at u-clamp support
location.
2. 19-PSV-04 OVHD: Support
angles were observed directly
welded to 4” pipe line.
43 19HL-53 -Visual Inspection and UTG of 1. Visual examination 1. Corrosion pad with PSV support Nil
19-V-05 PSV take off; Piping loop was carried out. 2. Hydro test of entire loop angles was carried out at 19-PSV-
Piping General condition of pipeline was witnessed at 26.55 kg/cm2 04 OVHD.
was found satisfactory. on 24/11/2023. No pressure
Minimum measured thickness- drop and no leakage
5.8 mm against original 6.02 observed. Hydro test found
mm. (4” size)-A1A spec. satisfactory.
1. 19-PSV-05 OVHD: Support
angles were observed directly
welded to 4” pipe line.
44 16HL-54 Visual Inspection and UTG of 1. Visual examination 1. Line was in service (Live line) IWL No: 19-15999
19-V-05 PSV take off Piping loop was carried out. 2. Hydro test of entire loop ([Link]: 20 to 230 to
General condition of pipeline was witnessed at 8 kg/cm2 on be done).
was found satisfactory. 03/12/2023. No pressure drop
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

Due to access constraint at pump and no leakage

bay location scaffolding was not observed. Hydro test found
provided approx. 24 m length satisfactory.
and other
location thickness was found
satisfactory.
- Minimum measured thickness-
4.8 mm against original 6.02
mm. (4” dia)-A9Aspec
- Minimum measured thickness-
4.5 mm against original 5.54
mm. (2” dia)-A9Aspec
- Minimum measured thickness-
4.0 mm against original 5.54
mm. (2” dia)-A9Aspec
- Minimum measured thickness-
5.2 mm against original 5.49
mm. (3” dia)-A9Aspec
- Minimum measured thickness-
4.1 mm against original 5.54
mm. (2” dia)-A19Aspec
45 16HL-55 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 3” dia line 2Nos. Nil
16-V-05 PSV take-off Piping loop was carried out. 2. Hydro test of entire loop of spools for approx. 3m length
flanges to PSV inlet General condition of pipeline was witnessed at 8 kg/cm2 on along with necessary fittings was
flange; was found satisfactory. 02/12/2023. No pressure drop carried out
-Minimum measured thickness- and no leakage at 16-V-05 OVHD.
4.5 mm against original 5.49 observed. Hydro test found
mm. (3” size)-A19Aspec. satisfactory.
1. 16-V-05 OVHD: 16-PSV-
1106/1107 U/S spools observed
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

external pitting, non-standard

flange bolting and PSV
support angles directly welded
to 3” dia pipeline.
46 19HL-56 -Visual Inspection and UTG of 1. Visual examination 1. Replacement of 4” dia spool for Nil
PSV outlet to flare Piping loop was carried out. 2. Hydro test of entire loop approx. 1m length along with
header inlet General condition of pipeline was witnessed at 8 kg/cm2 on necessary fittings and provide
valve U/S; was found satisfactory. 02/12/2023. No pressure drop corrosion pads with
Minimum measured thickness- and no leakage PSV support angles was carried out
4.4 mm against original 6.02 observed. Hydro test found at 16-V-05 OVHD.
mm. (4” size)-A19A spec. satisfactory. 2. Replacement of 4” dia spool for
1. 16-V-05 OVHD: 16-PSV- approx. 9 m length along with
1106/1107 D/S Spool moderate 2No’s 90deg elbows and provide
pitting, PSV support angles corrosion pads
directly welded to 4” dia was carried out at north of 16-V-05
pipeline and flange gasket platform crossing location.
location was observed severely
corroded.
2. North of 16-V-05 platform
crossing:
a). Low thickness 4.4 mm was
observed on 4” dia 90-degree
elbow and pipe line against
original thickness of
6.02 mm
b). Platform crossing area pipe
supports were observed directly
welded to 4” dia pipe line.
c). External corrosion, moderate
pitting and shoe support was
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

observed directly welded to 4”

dia pipe line at
sleeper beam support location.
47 16HL-57 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 0.75” x 0.5” dia Nil
16-V-05 outlet to 16- Piping loop was carried out. 2. 100% DPT of 0.75” & 0.5” sample line for approx. 1.5 m
PM-06A/B General condition of pipeline NPS fillet welds, no relevant length and gusset plate (3mm Thk)
suction; was found satisfactory. indications observed. was carried
-Minimum measured thickness- 3. Hydro test of entire loop out at 16-PM-06A Suction line.
5.6 mm against original 7.11 was witnessed at 8 kg/cm2 on
mm. (6” size)-A19Aspec. 29/11/2023. No pressure drop
-Minimum measured thickness- and no leakage
5.3 mm against original 6.02 observed. Hydro test found
mm. (4” size)-A19Aspec. satisfactory.
-Minimum measured thickness-
4.6 mm against original 5.54
mm. (2” size)-A19Aspec.
1. 16-PM-06A Suction line: 0.75
x0.5” dia sample line on 6-inch
header line was observed gusset
plate missing
and external pitting.
48 16HL-58 Visual Inspection and UTG of D. Major Inspection/ NDT/ 1. 1) Replacement of 0.75” x 0.5” Nil
16-PM-06A/B Piping loop was carried out. Testing: dia OWS line for approx. 2.5 m
Discharge to 16-C- General condition of pipeline 1. Visual examination length along with necessary fittings
04 Inlet was found satisfactory. 2. 100% DPT of 3⁄4” and 1⁄2” and gusset
-Due to access constraint at welds, no relevant indications plate (3mm Thk) was carried out at
pump bay location scaffolding observed. East of 16-PM-06B.
was not provided approx. 18 m 3. Hydro test of entire loop 2) Replacement of 0.75” x 0.5” dia
length and other was witnessed at 13.5 kg/cm2 PG take-off line for approx. 1.5 m
location thickness was found on 11/12/2023. No pressure length along with necessary fittings
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

satisfactory. drop and no leakage and

-Minimum measured thickness- observed. Hydro test found gusset plate (3mm Thk) was carried
4.6 mm against original 6.02 satisfactory. out at East of 16-PM-06B.
mm. (4” size)-A19Aspec 2. 1) Replacement of 0.75” x 0.5”
-Minimum measured thickness- dia OWS line for approx. 2.5 m
4.5 mm against original 5.49 length along with necessary fittings
mm. (3” size)-A19Aspec and gusset
-Minimum measured thickness- plate (3mm Thk) was carried out at
5.2 mm against original 6.02 East of 16-PM-06A.
mm. (4” size)-A19Aspec 2) Replacement of 0.75” x 0.5” dia
-Minimum measured thickness- PG take-off line for approx. 1.5 m
4.7 mm against original 5.49 length along with necessary fittings
mm. (3” size)-A19Aspec and
-Minimum measured thickness- gusset plate (3mm Thk) was carried
5.1 mm against original 5.49 out at East of 16-PM-06A.
mm. (3” size)-A19Aspec 3. 1) Replacement of 4”dia line
1. East of 16-PM-06B: approx. 0.5 m length along with
1) 0.75x0.5 “dia OWS line necessary fittings was carried out at
flange gasket location corroded 16-PM-07A/B
and moderate pitting was OVHD pipe track.
observed. 2) Replacement of 0.75“dia drain
2) Nonstandard fittings and line was carried out at 16-PM-
gusset plates missing was 07A/B OVHD pipe track.
observed on 0.75x0.5 “dia PG
take line. Prepared By Reviewed By
2. East of 16-PM-06A: Approved By
1). 0.75x0.5 “dia OWS line
flange gasket location corroded Sunit Ranjan Xalxo B M Jeelani M
and moderate pitting was V N S S Sastry
observed. Manager - Inspection Sr. Manager
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

2). Nonstandard fittings and (i/c) – Inspection General Manager

gusset plates missing was – Inspection
observed on 0.75x0.5 “dia PG 3) Provided corrosion pad along
take line. with shoe supports at 3Nos. of
3. 16-PM-07A/B OVHD pipe locations at 16-PM-07A/B OVHD
track location: pipe track.
1) Continuous spillage of water 4. Replacement of 0.75“dia PG take
on 4 “dia line from adjacent line. off line along with necessary
2) 0.75 “dia drain line on fittings was carried out at North of
3”header line was observed 16-E-5A/B/C
severely corroded. Outlet line.
3) Shoe supports missing and 3 5. 2). Replacement of 4”dia line
“dia line was directly resting at approx. 1m length U/S and D/S of
support location. elbow along with 1no. 90-degree
4. North of 16-E-5A/B/C Outlet elbow was
line: 0.75 “dia PG take off line carried out at South of 16-C-04
bosh joint location observed
severely corroded.
5. South of 16-C-04:
2) Severe Corrosion and thick
scales were observed on 4 “dia
pipe line and 90-degree elbow
due to CUI.
Pipe support was observed
directly welded to 90-degree
elbow.
49 16HL-59 -Visual Inspection and UTG of 1. Visual examination 1. Provided 0.75” dia vent at Nil
16-C-04 stripped water Piping loop was carried out. 2. 100% DPT of 3⁄4” dia weld highest point of the line.
outlet to 16-E-09 General condition of pipeline joints, no relevant indications
was found satisfactory. observed.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

-Minimum measured thickness- 3. Hydro test of entire loop

6.2 mm against original 7.11 was witnessed at 8 kg/cm2 on
mm. (6” size)-A19Aspec 20/11/2023. No pressure drop
-Minimum measured thickness- and no leakage
6.1 mm against original 6.02 observed. Hydro test found
mm. (4” size)-A19Aspec. satisfactory.
1. 0.75” dia vent was not
available on 6-inch dia header
line for Hydro test purpose.
50 16HL-60 Visual Inspection and UTG of 1. Visual examination 1. Provided 0.75” dia vent at Nil
16-E-09 outlet vapour Piping loop was carried out. 2. 100% DPT of 3⁄4” dia fillet highest point of the line.
line to 16-C-04 General condition of pipeline weld joints.
was found satisfactory. 3. Hydro test of entire loop
-Minimum measured thickness- was witnessed at 8 kg/cm2 on
6.3 mm against original 6.35 29/11/2023. No pressure drop
mm. (10” size)-A19Aspec. and no leakage
1. 0.75” dia vent not available observed. Hydro test found
on 10” dia header line for Hydro satisfactory.
test purpose.
51 16HL-61 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 6” dia 2No’s Nil
16-PM-06A/B Piping loop was carried out. 2. Ultrasonic thickness 90deg elbows along with corrosion
Discharge to 16-C-04 General condition of pipeline examination pad was carried out at 16-PM-16A
Inlet was found satisfactory. 3. Hydro test of entire loop suction line.
-Minimum measured thickness- was witnessed at 8 kg/cm2 on 2. Replacement of 6” dia 2No’s
6.6 mm against original 7.11 01/12/2023. No pressure drop 90deg elbows along with corrosion
mm. (6” size)-A19Aspec and no leakage pad was carried out at 16-PM-16B
-Minimum measured thickness- observed. Hydro test found suction
6.9 mm against original 7.11 satisfactory. line.
mm. (6” size)-A19Aspec 3. 1) Replacement of 2” dia line
-Minimum measured thickness- approx. 2 m length and 2Nos.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

4.1 mm against original 5.54 90deg elbows along with corrosion

mm. (2” size)-A19Aspec pad was carried
1. 16-PM-16A suction line: D/S out at North of 16-PM-16B.
of 1st isolation valve trunnion 4. Provided shoe support along with
support directly welded to 6“ dia corrosion pad at east of 16-PM-
90-degree elbow 16A/B.
and severely scaling & moderate
pitting was observed due to
CUI.
2. 16-PM-16B suction line: D/S
of 1st isolation valve trunnion
support directly welded to 6“ dia
90-degree elbow
and severely scaling & moderate
pitting was observed due to
CUI.
3. North of 16-PM-16B:
1. a) Low thickness 4.1 mm was
observed on 2“ dia OWS line
and elbow against original
thickness of 5.54 mm.
b) 2“ dia OWS line was
observed directly resting on
concrete pedestal.
4. East of 16-PM-16A/B: shoe
support badly corroded and
directly welded to 6” dia pipe
line.
52 16HL-62 -Visual Inspection and UTG of 1. Visual examination 1. 4” dia 1No. Corrosion pad was Nil
16-PM-16A/B discharge Piping loop was carried out. 2. Hydro test of entire loop provided at north of 16-PM-16A.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

to 16-C-05 inlet; General condition of pipeline was witnessed at 13.5 kg/cm2 2. 4” dia 1No. Corrosion pad was
was found satisfactory. on 07/12/2023. No pressure provided at north of 16-PM-16B.
-Minimum measured thickness- drop and no leakage 3. 4” dia 4No’s corrosion pad was
4.5 mm against original 6.02 observed. Hydro test found provided at south of 16-C-04 pipe
mm. (4” size)-A19Aspec satisfactory. track.
-Minimum measured thickness- 4. 4” dia 6No’s corrosion pad was
4.5 mm against original 6.02 provided at N/E of 16-C-04 pipe
mm. (4” size)-A19Aspec track.
-Minimum measured thickness- .
4.6 mm against original 5.49 5. Replacement of 4” dia 1No.
mm. (3” size)-A19Aspec 90deg elbow was carried out at 16-
1. North of 16-PM-16A: 3) PM-08A/B OVHD.
Trunnion support directly 6. 1) 4” dia 2No’s corrosion pad
welded to 4” dia 90-degree was provided at east of 16-C-05
elbow. near 16-LV-1101.
2. North of 16-PM-16B: 3) 7. 4” dia 1No. Corrosion pad was
Trunnion support directly provided at east of 16-C-05.
welded to 4” dia 90-degree
elbow.
3. South of 16-C-04 pipe track:
1) Shoe support was observed
directly welded to 4” dia line at
4 locations.
4. N/E of 16-C-04 pipe track: 1)
Shoe support was observed
directly welded to 4” dia line at
6 locations.
5. 16-PM-08A/B OVHD: Pipe
support was observed directly
welded to 4” dia 90-degree
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

elbow and external

corrosion observed.
6. East of 16-C-05 near 16-LV-
1101: 1) Trunnion supports were
observed directly welded to 4”
dia 90-degree
elbow-2No’s.
7. East of 16-C-05: 2) Shoe
support was directly welded to
3” dia pipe line.
53 16HL-63 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 1.5” dia for Nil
16-C-04 top shell flange Piping loop was carried out. 2. UTG examination approx. 3m length along with 0.75”
to 16-E-6 General condition of pipeline 2. 100% DPT of 1-1⁄2”, 3⁄4” dia vent and necessary fittings was
inlet was found satisfactory. and 1⁄2” NPS fillet welds, no carried out
Due to access constraint and hot relevant indications observed. at 16-C-04 OVHD.
air radiation at air fin cooler 3. Hydro test of entire loop 2. 1) Replacement of 4” dia for
OVHD location scaffolding was was witnessed at 8 kg/cm2 on approx. 0.5m length was carried out
not provided approx. 03/12/2023. No pressure drop at 16-C-04 OVHD.
6m length and other location and no leakage 3. Replacement of 0.5” dia stream
thickness was found observed. Hydro test found tracing line aprrox.10 m length
satisfactory. satisfactory. each, along with necessary fittings
- Minimum measured thickness- was carried
6.2 mm against original 6.35 out at north of 16-C-03.
mm. (12” size)-A9Aspec
- Minimum measured thickness-
6.7 mm against original 6.02
mm. (4” size)-A19Aspec
- Minimum measured thickness-
6.9 mm against original 6.02
mm. (4” size)-A19Aspec
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

- Minimum measured thickness-

6.9 mm against original 7.11
mm. (6” size)-A9Aspec
1. 16-C-04 OVHD:
A) 1.5 “dia FG line on 12 “dia
header line was observed deep
pitting and severe corrosion.
b) 0.75 “dia line on 1.5 “dia
header line was observed end
cap missing and choked.
2. 16-C-04 OVHD: 1) D/S of
16-PSV-1104 4“dia spool was
observed severe paint failure
and deep pitting.
3. North of 16-C-03: 1) (a)
Steam tracing to manifold
connected 0.5“dia lines-3No are
badly corroded.
54 16HL-64 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 0.5” dia drain for Nil
16-E-06 outlet to 16-V- Piping loop was carried out. 2. 100% DPT of 3⁄4” welds, no approx. 1.5m length was carried out
06 inlet General condition of pipeline relevant indications observed. at 16-PM-08A/B OVHD.
was found satisfactory. 3. Hydro test of entire loop 2. 3Nos .of 4” dia corrosion pads
-Minimum measured thickness- was witnessed at 8 kg/cm2 on was provided.
5.8 mm against original 7.62 04/12/2023. No pressure drop
mm. (3” size)-A13A spec and no leakage
-Minimum measured thickness- observed. Hydro test found
6.2 mm against original 8.56 satisfactory.
mm. (4” size)-A13A spec
1. 16-PM-08A/B OVHD:
4”x0.75” dia bosh joint location
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

severely corroded.
2. Entire Loop: 2) 3No’s shoe
supports were observed severely
corroded.
55 16HL-64A Visual Inspection and UTG of 1. Visual examination 1. Replacement of entire loop, 3x2” Nil
16-V-06 outlet to 16- Piping loop was carried out. 2. 100% DPT of 1.5”, 1” & dia line for approx. 14m length and
PM-08A/B General condition of pipeline 3⁄4” NPS fillet welds, no strainers, including (1.5”, 1”, &
suction was found satisfactory. relevant indications observed. 1.75x0.5”
-Minimum measured thickness- 3. Hydro test of entire loop dia) take-off lines along with along
4.2 mm against original 5.49 was witnessed at 13.5 kg/cm2 with necessary fittings was carried
mm. (3” size)-A19A spec on 03/12/2023. No pressure out at west of 16-PM-08A/B
-Minimum measured thickness- drop and no leakage suction line.
4.1 mm against original 5.49 observed. Hydro test found 2. Structural support was provided
mm. (3” size)-A19A spec satisfactory. at west of 16-PM-08A/B.
-Minimum measured thickness-
3.6 mm against original 5.08
mm. (1.5” size)-A19A spec
1. West of 16-PM-08A/B
suction line: Continuous steam
spillage on 3” dia insulated line
from top and severe
corrosion was observed due to
CUI. Pipe supports were
observed directly welded to 3”
dia 90deg elbows.
Pump suction line connected
spools was observed severely
corroded, nonstandard bolting
and oozing at strainer
flange location.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

2. West of 16-PM-08A/B: 3” dia

shoe support was observed
hanging and associated
structural support missing.
56 16HL-64B Visual Inspection and UTG of 1. Visual examination 1. 1 & 2) Replacement of 2” dia Nil
16-PM-08A/B to 16-C- Piping loop was carried out. 2. Hydro test of entire loop Reflux line end to end over an
04 stripper -The line is in service (for was witnessed at 27 kg/cm2 on approx. 30 m length from 16-PM-
column 25yrs) beyond its design life of 13/12/2023. No pressure drop 08A/B pump
15yrs. and no leakage discharge upto NRV flange U/S of
1. 16-PM-08A/B to 16-C-04 observed. Hydro test found 16-C-04.
stripper column: satisfactory.
1) The line developed a leak
from 2” dia elbow to pipe weld
joint at 6’O clock position.
2) The bottom elbow severe CUI
had occurred due to insulation
damaged & insulation missing
matters.
57 16HL-65 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 6” dia line for Nil
16-V-06 outlet to 16-V- Piping loop was carried out. 2. UTG examination approx. 3.5 m length along with
09/flare General condition of pipeline 3. 100% DPT of 1.5”, 1”, 3⁄4” 2Nos 1.5” stub joints and 1No.
was found satisfactory. and 1⁄2” NPS fillet welds, no 90deg elbow and
-Minimum measured thickness- relevant indications observed. 3⁄4” dia drain line was carried out at
4.6 mm against original 7.11 4. Hydro test of entire loop East of 16-V-06.
mm. (6” size)-A19A spec was witnessed at 8 kg/cm2 on 2. Replacement of 4” dia line
-Minimum measured thickness- 11/12/2023. No pressure drop approx. 3 m length was carried out
6.0 mm against original 6.02 and no leakage at 16-PV-1125 manifold.
mm. (4” size)-A19A spec observed. Hydro test found 3. Replacement was carried out for
-Minimum measured thickness- satisfactory. 0.5” dia steam tracing lines for
5.4 mm against original 5.49 aprrox.100 m length along with
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

mm. (3” size)-A19A spec necessary

1. East of 16-V-06: fittings and valves.
1) 6” dia line was observed with
thick scales and severely
corroded due to CUI.
2) Continuous steam condensate
spillage from 0.5” dia steam
tracing line.
3) 0.75” dia drain line on 6” dia
header severely corroded due to
CUI.
2. 16-PV-1125 manifold:
1) LSE Clamp was observed on
4” dia pipeline at D/S of Globe
valve.
3. Steam tracing line:
1) 0.5” dia Steam tracing line on
6” dia header line was observed
severely corroded.
2) LSE clamp and leaks (2
locations) were observed on 0.5”
dia steam tracing line.
58 16HL-66 Visual Inspection and UTG of 1. Visual examination 1. Replacement of 1” dia spool Nil
19-TK-01 take-off 19- Piping loop was carried out. 2. UTG examination flange to flange approx. 1 m length
PM-01A/B, 2A/B General condition of pipeline 2. 100% DPT of 1”, 3⁄4” and along with necessary fittings and
was found satisfactory. 1⁄2” NPS fillet welds, no strainer and
-Minimum measured thickness- relevant indications observed. 0.5- inch take off line approx. 2 m
4.5 mm against original 5.54 3. Hydro test of entire loop length. Was carried out at North of
mm. (2” size)-B1Aspec. was witnessed at 8 kg/cm2 on 19-PM-01B suction line.
1. North of 19-PM-01B suction 01/12/2023. No pressure drop 2. Replacement of 1” dia spool
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

line: Leak marks and oozing was and no leakage flange to flange approx. 1 m length
observed on 1” dia suction line observed. Hydro test found along with necessary fittings and
spool. satisfactory. strainer and
2. North of 19-PM-01A suction 0.5- inch take off line approx. 2 m
line: Leak marks and oozing was length. Was carried out at North of
observed on 1” dia suction line 19-PM-01A suction line
spool. 3. Replacement of 1” dia spools
3. North of 19-PM-02A/B flange to flange approx. 1 m length
suction lines: 1” dia suction line each along with necessary fittings
spools were observed leak and
marks and embedded with strainers was carried out at North of
concrete. 19-PM-02A/B suction lines.
4. South of 19-TK-01: 4. 1) Replacement of 4no’s 0.75”
1) 2 inch dia line (level gauge) dia flanges was carried out.
connected 4no’s 0.75” dia take- 2) Replacement of 2no’s 0.5” dia
off lines were observed severely OWS lines approx. 5 m length
corroded at along with necessary fittings was
flange gasket location. carried out at
2) Level gauge connected South of 19-TK-01.
0.75x0.5” dia OWS lines were
observed misalignment, severely
corroded and
embedded with concrete.
59 16HL-67 Visual Inspection of Piping loop 1. Visual examination 1. Replacement of 1” dia spool Nil
19-PM-01A/B, 2A/2B was carried out. General 2. UTG examination flange to flange approx. 1 m length
discharge to 19-W-01 condition of pipeline was found 3. 100% DPT of 1”, 3⁄4” and along with 0.5 “ take off line
feed/CRN feed line satisfactory. 1⁄2” NPS fillet welds, no approx. 1.5 m
1. 19-PM-01B Discharge line: relevant indications observed. length and necessary fittings at 19-
Leak marks and oozing was 4. Hydro test of entire loop PM-01B Discharge line.
observed on 1“dia spool at was witnessed at 33.75 kg/cm2 2. Replacement of 1 “ spool approx.
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

socket weld joint location. on 02/12/2023. No pressure 2 m length along with 0.5 “ take off
2. 19-PM-01A Discharge line: drop and no leakage line approx. 3 m length and
Leak marks and oozing was observed. Hydro test found necessary
observed on 1” dia spool at satisfactory. fittings at 19-PM-01A Discharge
socket weld joint location line.
and 0.5” dia at union. 3. Replacement of 1” dia spool
3. 19-PM-02A Discharge line: flange to flange approx. 2 m length
Leak marks and oozing was and 0.5” dia OWS line approx.2.5
observed on 1” dia line and m length
0.75” dia OWS take-off was along with necessary fittings was
observed embedded with carried out at 19-PM-02A
concrete. Discharge line
4. 19-PM-02B Discharge line: 4. a. Replacement of 1” spool
1) Leak marks and oozing was flange to flange approx. 1.5 m
observed on 1” dia spool and length along with PSV take off and
0.75” dia OWS line was 0.75 “ take off line
observed embedded with approx. 2 m length and necessary
concrete. fittings
2) Pump discharge line b. Carry out replacement of 0.75”
connected 1x0.75” dia OWS line dia OWS line approx.7m length
was observed embedded with along with necessary fittings was
concrete and low BOP. carried out
5. 19-PM-01 A/B OVHD Beam: at 19-PM-02B Discharge line.
Serve corrosion and pitting was 5. Replacement of 1” dia lines
observed on 1” dia line at approx. 1 m length each and
sleeper beam support provide tie rod at support location
location. was carried out at
6. 19-PM-02A OVHD Beam: 19-PM-01 A/B OVHD Beam
Serve corrosion and pitting was
observed on 1” dia line at 6. Replacement of 1” dia line
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

sleeper beam support approx. 1 m length and provide tie

location. rod at support location was carried
7. 19-PM-02A/B OVHD: Leak out at 19-PM-
marks and gate valve damaged 2A.
was observed on 1” dia line.
8. 19-PM-03B OVHD Beam: 7. Replacement of 1” dia line
Serve corrosion and pitting was approx.1 m length along with
observed on 1” dia line at necessary fittings was carried out at
sleeper beam support 19-PM-02A/B
location. OVHD
9. 19-PM-7A/B OVHD Beam:
Serve corrosion and pitting was 8. Replacement of 1” dia line
observed on 2 no’s 1” dia lines approx. 1 m length and provide tie
at sleeper beam rod at support location was carried
support location. out at 19-PM-
10. 19-FIC-01A OVHD Beam: 03B OVHD Beam
Serve corrosion and pitting was
observed on 2 no’s 1” dia lines 9. Replacement of 1” dia lines
at sleeper beam approx. 1 m length each and
support location. provide tie rod at support location
11. ATF feed Sample point was carried out at
OVHD Beam: Serve corrosion 19-PM-7A/B OVHD Beam.
and pitting was observed on 2 10. Replacement of 1” dia lines
no’s 1” dia lines at approx. 1 m length each and
sleeper beam support location. provide tie rod at support location
12. West of 19-W-01: Leak was carried out at
marks was observed on 1” dia 19-FIC-01A OVHD Beam
lever valve and 0.75” dia drain 11. Replacement of 1” dia lines
line. approx. 1 m length each and
13. East of 18-PM-02A/B: provide tie rod at support location
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

1) Leak marks were observed on was carried out at

1” dia gate valve at gland ATF feed Sample point OVHD
packing location. Beam
2) Leak marks and nipple not 12. Replacement of 1x0.75” dia line
provide for 0.75” dia gate valve. approx. 1 m length along with
necessary fittings and valves was
carried out at
West of 19-W-01
13. Replacement of 1x0.75 Spool
flange to flange approx.0.5 m
length along with necessary fittings
and valves
was carried out at East of 18-PM-
02A/B
60 016HL-68A Visual inspection and UTG of 1. Visual examination 1. Replacement of 1.5” dia line Nil
FG header from EBL to pipe and piping components was 2. Ultrasonic thickness approx. 6 m length along with
WBL carried out, minimum measured examination necessary fittings was carried out at
thickness of all 3. 10% DPT of 1” & 1⁄2” NPS East of 16-C-04
components are as follows: fillet welds, no relevant Top platform.
- Minimum measured thickness- indications observed. 2. Replacement of 7nos. Of shoe
3.5 mm against original 5.44 supports along with corrosion pad
mm (2” size)-A1A spec. Prepared By Reviewed By was carried out at EBL to WBL
1. East of 16-C-04 Top Approved By pipe track.
platform: 1.5” dia line was 3. Replacement of 2” dia line,
observed severe external Sunit Ranjan Xalxo B M approx. 0.5m length was carried out
corrosion and moderate pitting. Jeelani M V N S S Sastry at North of 18-PM-02A/B OVHD
2. From EBL to WBL pipe Manager - Inspection Sr. Pipe track.
track: 7nos. Of shoe supports Manager (i/c) – Inspection 4. Replacement of 2” dia line,
were observed directly welded General Manager – Inspection approx. 20m length was carried out
to 2” dia line and not 4. Hydro test of entire loop at 17-PM-03 to 17-PM-02B OVHD
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

resting at sleeper support and was witnessed at 11.25 kg/cm2 pipe track.
hanging. on 12/12/2023. No pressure 5. Replacement of 0.5” dia lead
3. North of 18-PM-02A/B drop and no leakage line, approx. 8m length along with
OVHD Pipe track: 2” dia line observed. Hydro test found necessary fittings was carried out at
observed externally corroded satisfactory. East of
due to water spillage. 17-PM-01D OVHD.
4. 17-PM-03 to 17-PM-02B 6. Replacement of 1” and 0.5” dia
OVHD pipe track: External steam tracing line approx. 48 m
scaling and low thickness 3.5 length each along with necessary
mm was observed on 2” dia fittings was
pipeline against original carried out at East B/ (120-PM-
thickness of 5.54 mm. 08A/B OVHD to east of 16-V-06
5. East of 17-PM-01D OVHD: PSV platform).
Orifice flange connected 0.5”
dia lead lines were observed
leak marks and severely
corroded.
6. East B/L (120-PM-08A/B
OVHD to east of 16-V-06 PSV
platform):
A. 1” dia FG take off line was
observed severely corroded and
perforated.
B. 0.5” dia steam tracing line on
1” dia header line severely
corroded and perforated.
61 016-HL-69 Visual inspection of piping loop 1. Visual examination 1. Replacement of 3” dia line for Nil
Brain outlet line starting was carried out and following 2. Ultrasonic thickness approx. 36 m length along with
from battery limit; are the observation. examination necessary fittings was carried out at
1. North of 120-PM-08A: 3. 10% DPT of 1.5” & 3⁄4” North of
 Inspection Division
Technical Service Department
Visakh Refinery

Outlook Report

Scaling was observed of 3” Pipe NPS fillet welds, no relevant 120-PM-08A.

from tee joint up to exchanger indications observed.
16-E-05A/B/C. 4. Hydro test of entire loop 2. Replacement of 3” dia line for
2. East of 16-E-05A/B/C: was witnessed at 17.5 kg/cm2 approx. 16 m length along with
A. Scaling and corrosion was on 12/12/2023. No pressure trunnion support was carried out at
observed on pipe and elbow. drop and no leakage East of 16-E-
B. Trunnion support and elbow observed. Hydro test found 05A/B/C.
fully corroded. satisfactory.
3. West of 16-PY-1102: 3” dia 3. Replacement of 3” dia line for
bypass line along with trunnion approx. 2Nos. of 90deg elbow
support observed externally along with 6Nos. of flanges and
corroded. 2Nos .of “T” was
4. West of 16-PM-07B: 4” dia carried out at West of 16-PY-1102.
bypass line along with trunnion 4. Replacement of 4” dia line for
support observed externally approx. 15m length was carried out
corroded. at West of 16-PM-07B.
5. East of 16-PM-07B: 4” dia
line fully corroded which is 5. Replacement of 4” dia line for
connected to pump from check approx. 6m length along with
valve to bypass line. necessary fittings was carried out at
6. South of 16-PM-14A/B: 4” East of 16-PM-
dia line fully corroded which is 07B.
connected to pump from check
valve to bypass line. 6. Replacement of 4” dia line for
approx. 6 m length each along with
necessary fittings was carried out at
South of
16-PM-14A/B.