Refinery Turnaround and Inspection Planning Checklist
Refinery turnarounds are the primary opportunity for mandatory mechanical integrity inspections. This planning checklist ensures all API 510, 570, and 653 required inspections are scoped, scheduled, and completed during the turnaround window.
- Industry: Oil & Gas / Energy
- Frequency: Per Turnaround (Typically Every 4-6 Years)
- Estimated Time: 90-120 minutes
- Role: Inspection Manager / Reliability Engineer
- Total Items: 31
- Compliance: API 510 - Pressure Vessel Inspection Code: In-Service Inspection, API 570 - Piping Inspection Code, API 653 - Tank Inspection, Repair, Alteration, and Reconstruction, API 580/581 - Risk-Based Inspection Methodology, OSHA 29 CFR 1910.119 PSM Mechanical Integrity
Risk-Based Inspection Scope Development
Review RBI-driven inspection scope.
- RBI assessment current for all equipment in unit?
- Equipment risk ranking matrix updated with most recent inspection data?
- Inspection intervals justified by RBI or code-maximum intervals met?
- All deferred inspection items from last turnaround included in current scope?
- Any new equipment since last T/A included in inspection scope?
Pressure Vessel Inspection (API 510)',
Plan pressure vessel inspection scope.
- All pressure vessels due for API 510 internal inspection listed in scope?
- Individual inspection plans developed for high-risk vessels?
- Corrosion monitoring location (CML) thickness measurements planned?
- NDE methods (UT, RT, PT, MT, AUT) selected for each vessel per damage mechanism?
- API 510 certified inspectors assigned to all vessels?
Piping Inspection (API 570)
Plan piping circuit inspection.
- All piping circuits identified and categorized by service class?
- Thickness measurement locations (TML) documented and accessible?
- Injection point inspection per API 570 Section 6.5.4 included?
- Dead legs and elbows inspection included?
- Soil-to-air interface inspection for buried piping?
Heat Exchanger Inspection
Plan heat exchanger inspection scope.
- Heat exchanger bundle inspection (tubes, tubesheets, baffles) in scope?
- Eddy current or ultrasonic tube inspection for critical exchangers planned?
- Chemical cleaning or hydro-blasting planned per fouling severity?
- Fitness-for-service evaluation planned for any degraded components?
- Spare bundles or replacement tubes staged for potential repairs?
Storage Tank Inspection (API 653)
Plan aboveground storage tank inspection.
- All ASTs due for API 653 internal inspection in scope?
- Tank bottom MFL or UT scan planned for internal inspection?
- Shell weld examination and thickness measurement planned?
- Tank bottom CP system inspection included?
- API 653 certified inspector assigned?
Documentation and Close-Out
Plan inspection documentation and records.
- Inspection records database current and accessible to inspection team?
- Inspection report templates prepared for all equipment types?
- Process for fitness-for-service evaluations during T/A documented?
- Repair procedures and contractor QC plan approved?
- Return-to-service requirements and final pressure test requirements documented?
- PSM mechanical integrity records update plan for T/A findings?
Related Oil Gas Energy Checklists
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- Oil and Gas Environmental Compliance Inspection Checklist
- Offshore Platform Safety and Operations Inspection Checklist
- Natural Gas Compressor Station Safety Inspection Checklist
Related Refinery Operations Checklists
Why Use This Refinery Turnaround and Inspection Planning Checklist?
This refinery turnaround and inspection planning checklist helps oil & gas / energy teams maintain compliance and operational excellence. Designed for inspection manager / reliability engineer professionals, this checklist covers 31 critical inspection points across 6 sections. Recommended frequency: per turnaround (typically every 4-6 years).
Ensures compliance with API 510 - Pressure Vessel Inspection Code: In-Service Inspection, API 570 - Piping Inspection Code, API 653 - Tank Inspection, Repair, Alteration, and Reconstruction, API 580/581 - Risk-Based Inspection Methodology, OSHA 29 CFR 1910.119 PSM Mechanical Integrity. Regulatory-aligned for audit readiness and inspection documentation.
Frequently Asked Questions
What does the Refinery Turnaround and Inspection Planning Checklist cover?
This checklist covers 31 inspection items across 6 sections: Risk-Based Inspection Scope Development, Pressure Vessel Inspection (API 510)',, Piping Inspection (API 570), Heat Exchanger Inspection, Storage Tank Inspection (API 653), Documentation and Close-Out. It is designed for oil & gas / energy operations and compliance.
How often should this checklist be completed?
This checklist should be completed per turnaround (typically every 4-6 years). Each completion takes approximately 90-120 minutes.
Who should use this Refinery Turnaround and Inspection Planning Checklist?
This checklist is designed for Inspection Manager / Reliability Engineer professionals in the oil & gas / energy industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.
Can I download this checklist as a PDF?
Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.