API 570 Study Version

Piping Inspection Code
Inspection, Repair, Alteration, and

Rerating
of In-service Piping Systems
API 570
SECOND EDITION, OCTOBER 1998
ADDENDUM 1, FEBRUARY 2000
ADDENDUM 2, DECEMBER 2001
ADDENDUM 3, AUGUST 2003
ADDENDUM 4, JUNE 2006
Copyright American Petroleum Institute
Provided by IHS under license with API Licensee=Chevron Corp/5!"#$$!%%
&ot 'or (esale) %$/%#/"%%* %+5,+5" -./ &o reproduction or networ0ing permitted without license 'rom IHS
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Piping Inspection Code
Inspection, Repair, Alteration, and Rerating
of In-service Piping Systems
Downstream Segment
API 570
SECOND EDITION, OCTOBER 1998
ADDENDUM 1, FEBRUARY 2000
ADDENDUM 2, DECEMBER 2001
ADDENDUM 3, AUGUST 2003
ADDENDUM 4, JUNE 2006
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SPECIAL N!ES
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p%+&#$"%+
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)pp"#*+ '/ &3%& .%&*+#%", '+ &3* .%&*+#%" )%/*&, -%&% )3**&1
N'&3#(0 $'(&%#(*- #( %(, API p!"#$%&#'( #) &' !* $'()&+*- %) 0+%(&#(0 %(, +#03&, !,
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$'5*+*- !, "*&&*+) p%&*(&1 N*#&3*+ )3'"- %(,&3#(0 $'(&%#(*- #( &3* p!"#$%&#'( !*
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)$3 p+'-$&)
-' #( /%$& $'(/'+. &' &3* %pp"#$%!"* API )&%(-%+-1
""
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C'p,+#03& F 1998, 2000, 2001, 2003, 2006 A.*+#$%( P*&+'"*. I()&#&&*
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#RE$RD
I& #) &3* #(&*(& '/ API &' 6**p &3#) p!"#$%&#'( p &' -%&*1 A"" p#p#(0 ),)&*. '4(*+) %(-
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T3#) *-#&#'( '/ API 570 )p*+)*-*) %"" p+*5#') *-#&#'() '/ API 570, Piping Inspection
Code' Inspection, (epair, Alteration, and (erating of In)service Piping Systems. E%$3
*-#&#'(,
+*5#)#'(, '+ %--*(-% &' &3#) API )&%(-%+- .%, !* )*- !*0#((#(0 4#&3 &3* -%&* '/
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+*p%#+*-, .'-#:*-
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.%-* !,
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20005,
)&%(-%+-B%p#1'+01
###
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CN!EN!S
P%0*
1 SCOPE 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
1 1;1
1.1 General Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Specific Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
113
"%
F#&(*));/'+;)*+5#$* 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1;1
2 REFERENCES 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
2;1
3 DEFINITIONS1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
3;1 "&
4 O2NERIUSER INSPECTION ORGANIJATION 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4;1
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-
1
4.2 API Authorized Piping Inspector Qualification and Certification . . . . . . . . . . . 4-1
4.3 esponsi!ilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
"&
5 INSPECTION AND TESTING PRACTICES1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5;1
5.1 Risk-Based Inspection . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 5-1
".2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . "-1
5.3 "% Inspection for Specific Types of Corrosion and
Cracking . . . . . . . . . . . . . . . . . 5-1
".4 #$pes of Inspection and Sur%eillance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . "-&"."
#hic'ness (easure)ent *ocations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . "-
+ "%".& #hic'ness (easure)ent
(ethods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . "-,".+ "% Pressure #esting of
Piping S$ste)s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . "-,
5.8 "" Material Verification and
Traceaility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-!
5.! Inspection of
Val"es. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 5-!
5.1# "& Inspection of $elds In-ser"ice . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . 5-1#
5.11 Inspection of %langed &oints . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 5-1# ' %R()*(+C, -+.
(/T(+T 0%
I+S1(CTI0+ . . . . . . . . . . . . . . . . . . . . . . . . . . . '-1
&.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &-1 "'
&.2 Piping Ser%ice Classes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &-1
&.3 Inspection Inter%als . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &-2
&.4 -.tent of /isual -.ternal and C0I Inspections . . . . . . . . . . . . . . . . . . . . . . . . . &-2 "'
&." -.tent of #hic'ness (easure)ent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . &-2
&.& -.tent of S)all-1ore Au.iliar$ Piping2 and
#hreaded-Connections Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . &-3
7 INSPECTION DATA EKAAUATION, ANAAYSIS, AND RECORDING 1 1 1 1 1 1 1 7;1
+.1 "% Corrosion ate 3eter)ination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +-1
2.3 Ma4i565 -llo7ale $orking 1ress6re
.eter5ination . . . . . . . . . . . . . . . . . . 2-1
+.3 etire)ent #hic'ness 3eter)ination
"%
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7;2 "&
2.8 -ssess5ent of Inspection %indings . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 2-3
+." Piping Stress Anal$sis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +-2
2.' "% Reporting and Records for 1iping Syste5
Inspection . . . . . . . . . . . . . . . . . . . . 2-8
8 REPAIRS, AATERATIONS, AND RERATING OF PIPING SYSTEMS 1 1 1 1 1 1 1 1 8;1
,.1 epairs and Alterations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,-1 "&
,.2 "& 4elding and 5ot #apping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,-2
,.3 erating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ,-
3
5
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P%0*
9 INSPECTION OF BURIED PIPING 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 9;1
9.1 Types and Methods of Inspection . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 9-1
6.2 7re8uenc$ and -.tent of Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
9.3 Repairs to Buried Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 9-3
914 R*$'+-)1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 9;
3
APPENDIL A "& INSPECTOR CERTIFICATION1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 A;1
APPENDIL B "& TECMNICAA INDUIRIES 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 B;1
APPENDIL C ELAMPAES OF REPAIRS 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 C;1
APPENDIL D ELTERNAA INSPECTION
CMECNAIST FOR PROCESS PIPING1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 D;1
F#0+*)
5;1 T,p#$%" I(E*$&#'( P'#(& P#p#(0 C#+$#& 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5;2
C;1 E($#+$"*.*(& R*p%#+ S"**5* 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 C;
1
C;2 S.%"" R*p%#+ P%&$3*)1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
C;2
T%!"*)
6;1 R*$'..*(-*- M%8#.. I()p*$&#'( I(&*+5%") 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
6;3 "'
6;2 R*$'..*(-*- E8&*(& '/ CUI I()p*$&#'( F'""'4#(0 K#)%" I()p*$&#'( 1 1 1 1 1 1 1 1 6;3
7;1 T4' E8%.p"*) '/ &3* C%"$"%&#'( '/ M%8#.. A""'4%!"*
2'+6#(0 P+*))+* >MA2P? I"")&+%&#(0 &3* U)* '/ &3* C'++')#'(
"% M%"/;A#/* C'($*p& 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7;
3
9;1 F+*7*($, '/ I()p*$&#'( /'+ B+#*- P#p#(0 2#&3'& E<*$&#5*
C%&3'-#$ P+'&*$&#'(1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 9;2
1iping Inspection Code9Inspection: Repair: -lteration: and Rerating
of In-ser%ice Piping S$ste)s
1 Scope
1.1 GENERAL APPLICATION
1.1.1 Coverage
API "+9 co%ers inspection2 repair2 alteration2 and rerating
procedures for )etallic piping s$ste)s that ha%e !een
in-ser%ice.
1.1.2 Intent
API "+9 :as de%eloped for the petroleu) refining and
che)ical process industries !ut )a$ !e used2 :here practical2
for an$ piping s$ste). It is intended for use !$ organizations
that )aintain or ha%e access to an authorized
inspection agenc$2 a repair organization2 and technicall$
8ualified piping engineers2 inspectors2 and e.a)iners2 all
as defined in Section 3.
1.1.3 Limitations
API "+9 shall not !e used as a su!stitute for the original
construction re8uire)ents go%erning a piping s$ste) !efore
it is placed in-ser%ice; nor shall it !e used in conflict :ith an$ pre%ailing regulator$
re8uire)ents.
1.2 SPECIFIC APPLICATIONS
1.2.1 Included Fluid Services
-.cept as pro%ided in 1.2.22 API "+9 applies to piping s$ste)s for process fluids2
h$drocar!ons2 and si)ilar fla))a!le or to.ic fluid ser%ices2 such as the follo:ing<
a. a:2 inter)ediate2 and finished petroleu) products.
!. a:2 inter)ediate2 and finished che)ical products.
c. Catal$st lines.
d. 5$drogen2 natural gas2 fuel gas2 and flare s$ste)s.
e. Sour :ater and hazardous :aste strea)s a!o%e threshold
li)its2 as defined !$ =urisdictional regulations.
f. 5azardous che)icals a!o%e threshold li)its2 as defined !$
=urisdictional regulations.
1.2.2 Excluded and Optional Piping Systems
#he fluid ser%ices and classes of piping s$ste)s listed !elo: are e.cluded fro) the
specific re8uire)ents of API "+9 !ut )a$ !e included at the o:ner>s or user>s
?o:ner@user>sA option.
a. 7luid ser%ices that are e.cluded or optional include the
follo:ing<
1. 5azardous fluid ser%ices !elo: threshold li)its2 as
defined !$ =urisdictional regulations.
2. 4ater ?including fire protection s$ste)sA2 stea)2 stea)-condensate2 !oiler feed
:ater2 and Categor$ 3 fluid ser%ices2 as defined in AS(- 131.3.
!. Classes of piping s$ste)s that are e.cluded or optional are
as follo:s<
1. Piping s$ste)s on )o%a!le structures co%ered !$ =urisdictional regulations2 including
piping s$ste)s on truc's2 ships2 !arges2 and other )o!ile e8uip)ent.
2. Piping s$ste)s that are an integral part or co)ponent
of rotating or reciprocating )echanical de%ices2 such as
pu)ps2 co)pressors2 tur!ines2 generators2 engines2 and
h$draulic or pneu)atic c$linders :here the pri)ar$
design considerations and@or stresses are deri%ed fro) the
functional re8uire)ents of the de%ice.
3. Internal piping or tu!ing of fired heaters and !oilers2 including tu!es2 tu!e headers2
return !ends2 e.ternal crosso%ers2 and )anifolds.
4. Pressure %essels2 heaters2 furnaces2 heat e.changers2 and other fluid handling or
processing e8uip)ent2 including internal piping and connections for e.ternal piping.
". Plu)!ing2 sanitar$ se:ers2 process :aste se:ers2 and
stor) se:ers.
&. Piping or tu!ing :ith an outside dia)eter not e.ceeding
that of BPS C.
+. Bon)etallic piping and pol$)eric or glass-lined piping.
1.3 FITNESS-FOR-SERVICE
91
#his inspection code recognizes fitness-for-ser%ice concepts
for e%aluating in-ser%ice degradation of pressure containing
co)ponents. API P "+6 pro%ides general
re8uire)ents and detailed assess)ent procedures for specific
t$pes of degradation that are referenced in this code.
Cop$right A)erican Petroleu) Institute
Pro%ided !$ I5S under license :ith API *icenseeDChe%ron Corp@"6123,,199
Bot for esale2 9,@93@299& 96<"+<"2 (3# Bo reproduction or net:or'ing per)itted
:ithout license fro) I5S
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2-1
SECIO! 2"#EFE#E!CES
#he )ost recent editions of the follo:ing standards2 codes2
and specifications are cited in this code.
API
"19 Pressure /essel Inspection Code
Pu!l 2291 Procedures for 4elding or 5ot #apping on
-8uip)ent Containing 7la))a!les
P "+4 Inspection of Piping S$ste) Co)ponents
P "+, (aterial /erification Progra) for Be:
and -.isting Piping S$ste)s
P "+6 7itness-for-ser%ice
P &"1 Cathodic Protection of A!o%eground
Petroleu) Storage #an's
P +"9 (anage)ent of Process 5azards
Std "6, /al%e Inspection and #esting
Guide for Inspection of efiner$ -8uip)ent2
Chapter II ?#his docu)ent :ill !e
replaced !$ API P "+12 Conditions Cuasing
3eterioration or 7ailures2 currentl$
under de%elop)ent.A
API "+9 Inspector Certification -.a) 1od$ of
Eno:ledge
AS(- 1
11&.34 /al%esF7langed2 #hreaded2 and 4elding
-nd
131.3 Process Piping
131G (anual for 3eter)ining the e)aining
Strength of Corroded Pipelines
1oiler and Pressure /essel Code2 Section /III2 3i%isions 1
and 2; Section IG,
ASB#2
SB#-#C-1A Personnel Qualification and Certification
in Bondestructi%e #esting
CP-1,6 Standard for Qualification and Certification
of Bondestructi%e #esting Personnel
AS#(3
G"+ (ethod for 7ield (easure)ent of Soil
esisti%it$ 0sing the 4enner 7ourelectrode
(ethod
BAC-4
P91&6 Control of -.ternal Corrosion on 0nderground
or Su!)erged (etallic Piping
S$ste)s
P91+9 Protection of Austenitic Stainless Steels
fro) Pol$thionic Acid Stress Corrosion
Crac'ing 3uring Shutdo:n of efiner$
-8uip)ent
P92+4 5igh-%oltage -lectrical Inspection of Pipeline
Coatings Prior to Installation
P92+" Application of Hrganic Coatings to the
-.ternal Surface of Steel Pipe for 0nderground
Ser%ice
B7PA"
+94 Identification of the 7ire 5azards of
(aterials
1AS(- International2 #hree Par' A%enue2 Be: Ior'2 Be: Ior'
1991&-"6692 :::.as)e.org.
91
99
91
2#he A)erican Societ$ for Bondestructi%e #esting2 1+11 Arlingate
*ane2 P.H. 1o. 2,"1,2 Colu)!us2 Hhio 4322,-9"1,2 :::.asnt.org.
3A)erican Societ$ for #esting and (aterials2 199 1arr 5ar!or
3ri%e2 4est Conshohoc'en2 Penns$l%ania 1642,-26"62
:::.ast).org.
4BAC- International2 449 South Cree' 3ri%e2 5ouston2 #e.as
++9,42 :::.nace.org.
"Bational 7ire Protection Association2 1 1atter$)arch Par'2 P.H.
1o. 61912 Quinc$2 (assachusetts 922&6-61912 :::.nfpa.org.
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3-1
SECIO! 3"$EFI!IIO!S
7or the purposes of this standard2 the follo:ing definitions
appl$.
3.1alteration; A ph$sical change in an$ co)ponent that has design i)plications
affecting the pressure containing capa!ilit$ or fle.i!ilit$ of a piping s$ste)
!e$ond the scope
of its original design. #he follo:ing are not considered alterations<
co)para!le or duplicate replace)ents and the addition
of s)all-!ore attach)ents that do not re8uire
reinforce)ent or additional support.
3.3applicale code; #he code2 code section2 or other recognized and generall$
accepted engineering standard or practice to :hich the piping s$ste) :as !uilt or
:hich is dee)ed
!$ the o:ner or user or the piping engineer to !e )ost appropriate for the
situation2 including !ut not li)ited to the latest edition of AS(- 131.3.
3.3-SM( B31.3; A shortened for) of AS(- 131.32 Process Piping2 pu!lished !$
the A)erican Societ$ of (echanical -ngineers. AS(- 131.3 is :ritten for
design and
construction of piping s$ste)s. 5o:e%er2 )ost of the technical
re8uire)ents on design2 :elding2 e.a)ination2 and )aterials
also can !e applied in the inspection2 rerating2 repair2 and
alteration of operating piping s$ste)s. 4hen AS(- 131.3
cannot !e follo:ed !ecause of its ne: construction co%erage
?such as re%ised or ne: )aterial specifications2 inspection
re8uire)ents2 certain heat treat)ents2 and pressure testsA2 the
piping engineer or inspector shall !e guided !$ API "+9 in
lieu of strict confor)it$ to AS(- 131.3. As an e.a)ple of
intent2 the phrase Jprinciples of AS(- 131.3K has !een
e)plo$ed in API "+92 rather than Jin accordance :ith AS(- 131.3.K
3.4 authorized inspection agenc$< 3efined as an$ of
the follo:ing<
a. #he inspection organization of the =urisdiction in :hich
the piping s$ste) is used.
!. #he inspection organization of an insurance co)pan$ that
is licensed or registered to :rite insurance for piping s$ste)s.
c. An o:ner or user of piping s$ste)s :ho )aintains an
inspection organization for acti%ities relating onl$ to his
e8uip)ent and not for piping s$ste)s intended for sale or
resale.
d. An independent inspection organization e)plo$ed !$ or
under contract to the o:ner or user of piping s$ste)s that are used onl$ !$ the
o:ner or user and not for sale or resale.
e. An independent inspection organization licensed or recognized !$ the =urisdiction
in :hich the piping s$ste) is used and e)plo$ed !$ or under contract to the
o:ner or user.
3." authorized piping inspector< An e)plo$ee of an
authorized inspection agenc$ :ho is 8ualified and certified to
perfor) the functions specified in API "+9. A nondestructi%e
?B3-A e.a)iner is not re8uired to !e an authorized piping
inspector. 4hene%er the ter) inspector is used in API "+92 it
refers to an authorized piping inspector.
3.'a64iliary piping; Instru)ent and )achiner$ piping2
t$picall$ s)all-!ore secondar$ process piping that can !e isolated
fro) pri)ar$ piping s$ste)s. -.a)ples include flush
lines2 seal oil lines2 anal$zer lines2 !alance lines2 !uffer gas
lines2 drains2 and %ents.
3.2critical c<eck "al"es; /al%es that ha%e !een identified as %ital to process safet$
and )ust operate relia!l$ in order to a%oid the potential for hazardous e%ents or
su!stantial conse8uences should a lea' occur.
3.8C*I; Corrosion under insulation2 including stress corrosion crac'ing under insulation.
3.!deadlegs; Co)ponents of a piping s$ste) that nor)all$ ha%e no significant flo:.
-.a)ples include the follo:ing< !lan'ed !ranches2 lines :ith nor)all$ closed !loc'
%al%es2 lines :ith one end !lan'ed2 pressurized du))$ support legs2 stagnant control
%al%e !$pass piping2 spare pu)p piping2 le%el !ridles2 relief %al%e inlet and outlet
header piping2 pu)p tri) !$pass lines2 high-point %ents2 sa)ple points2 drains2
!leeders2 and instru)ent connections.
3.1# defect; An i)perfection of a t$pe or )agnitude
e.ceeding the accepta!le criteria.
3.11 design te)perature of a piping s$ste) co)ponent<
#he te)perature at :hich2 under the coincident
pressure2 the greatest thic'ness or highest co)ponent rating is
re8uired. It is the sa)e as the design te)perature defined in
AS(- 131.3 and other code sections and is su!=ect to the
sa)e rules relating to allo:ances for %ariations of pressure or
te)perature or !oth. 3ifferent co)ponents in the sa)e piping
s$ste) or circuit )a$ ha%e different design te)peratures. In
esta!lishing the design te)perature2 consideration shall !e
gi%en to process fluid te)peratures2 a)!ient te)peratures2
heating and cooling )edia te)peratures2 and insulation.
3.13 e4a5iner; A person :ho assists the inspector !$ perfor)ing specific
nondestructi%e e.a)ination ?B3-A on piping s$ste) co)ponents !ut does not
e%aluate the results of
those e.a)inations in accordance :ith API "+92 unless specificall$ trained and
authorized to do so !$ the o:ner or user.
#he e.a)iner need not !e 8ualified in accordance :ith API
"+9 or !e an e)plo$ee of the o:ner or user !ut shall !e
trained and 8ualified in the applica!le procedures in :hich
the e.a)iner is in%ol%ed. In so)e cases2 the e.a)iner )a$ !e
re8uired to hold other certifications as necessar$ to satisf$
o:ner or user re8uire)ents. -.a)ples of other certification
that )a$ !e re8uired are SB#-#C-1A or CP-1,6; or A4S1
4elding Inspector certification. #he e.a)iner>s e)plo$er
9&
Bot for esale2 9,@93@299& 96<"+<"2 (3# Bo reproduction or net:or'ing
per)itted :ithout license fro) I5S
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3-2 API "+9
shall )aintain certification records of the e.a)iners e)plo$ed2 including dates and
results of personnel 8ualifications2 and shall )a'e the) a%aila!le to the inspector.
3.13 <old point; A point in the repair or alteration process !e$ond :hich :or' )a$
not proceed until the re8uired inspection has !een perfor)ed and docu)ented.
3.18 i5perfections; 7la:s or other discontinuities noted during inspection that )a$
!e su!=ect to acceptance criteria during an engineering and inspection anal$sis.
3.15 indication; A response or e%idence resulting fro) the
application of a nondestructi%e e%aluation techni8ue.
3.1' in=ection point; *ocations :here relati%el$ s)all
8uantities of )aterials are in=ected into process strea)s to
control che)istr$ or other process %aria!les. In=ection points
do not include locations :here t:o process strea)s =oin
?)i.ing teesA. -.a)ples of in=ection points include chlorine
in refor)ers2 :ater in=ection in o%erhead s$ste)s2 pol$sulfide in=ection in catal$tic
crac'ing :et gas2 antifoa) in=ections2 inhi!itors2 and neutralizers.
3.12 in-ser"ice; efers to piping s$ste)s that ha%e !een placed in operation2 as
opposed to ne: construction prior to !eing placed in ser%ice.
3.18 inspector; An authorized piping inspector.
3.1! =6risdiction; A legall$ constituted go%ern)ent
ad)inistration that )a$ adopt rules relating to piping s$ste)s.
3.3# le"el ridle; A le%el gauge glass piping asse)!l$
attached to a %essel.
3.21 )a.i)u) allo:a!le :or'ing pressure<
>M-$1?; #he )a.i)u) internal pressure per)itted in the
piping s$ste) for continued operation at the )ost se%ere condition
of coincident internal or e.ternal pressure and te)perature
?)ini)u) or )a.i)u)A e.pected during ser%ice. It is the
sa)e as the design pressure2 as defined in AS(- 131.3 and
other code sections2 and is su!=ect to the sa)e rules relating to allo:ances for %ariations
of pressure or te)perature or !oth.
3.33 5i4ing tee; A piping co)ponent that co)!ines t:o
process strea)s of differing co)position and@or te)perature.
3.33 MT; (agnetic-particle testing.
3.38 +.(; Bondestructi%e e.a)ination.
3.35 +1S; Bo)inal pipe size ?follo:ed2 :hen appropriate2 !$ the specific size
designation nu)!er :ithout an inch s$)!olA.
3.3' on-strea5; Piping containing an$ a)ount of process
fluid.
3.32 o7ner@6ser; An o:ner or user of piping s$ste)s :ho
e.ercises control o%er the operation2 engineering2 inspection2 repair2 alteration2
testing2 and rerating of those piping s$ste)s.
3.2, o:ner@user inspector< An authorized inspector
e)plo$ed !$ an o:ner@user :ho has 8ualified either !$ :ritten e.a)ination under the
pro%isions of Section 4 and Appendi. A of API "+9 or has 8ualified under the
pro%isions of A.22 and :ho )eets the re8uire)ents of the =urisdiction.
3.3! 1T; A li8uid-penetrant testing.
3.3# pipe; A pressure-tight c$linder used to con%e$ a fluid
or to trans)it a fluid pressure and is ordinaril$ designated JpipeK in applica!le
)aterial specifications. ?(aterials designated Jtu!eK or Jtu!ingK in the specifications
are treated as pipe :hen intended for pressure ser%ice.A
3.31 piping circ6it; A section of piping that has all points
e.posed to an en%iron)ent of si)ilar corrosi%it$ and that is
of si)ilar design conditions and construction )aterial. Co)ple.
process units or piping s$ste)s are di%ided into piping
circuits to )anage the necessar$ inspections2 calculations2
and record 'eeping. 4hen esta!lishing the !oundar$ of a particular
piping circuit2 the inspector )a$ also size it to pro%ide
a practical pac'age for record 'eeping and perfor)ing field
inspection.
3.33 piping engineer; Hne or )ore persons or organizations accepta!le to the o:ner
or user :ho are 'no:ledgea!le and e.perienced in the engineering disciplines
associated :ith e%aluating )echanical and )aterial characteristics affecting the
integrit$ and relia!ilit$ of piping co)ponents and s$ste)s.
#he piping engineer2 !$ consulting :ith appropriate
specialists2 should !e regarded as a co)posite of all entities
necessar$ to properl$ address a technical re8uire)ent.
3.33 piping syste5; An asse)!l$ of interconnected piping
that is su!=ect to the sa)e set or sets of design conditions
and is used to con%e$2 distri!ute2 )i.2 separate2 discharge2
)eter2 control2 or snu! fluid flo:s. Piping s$ste) also
includes pipe-supporting ele)ents !ut does not include support structures2 such as
structural fra)es and foundations.
3.34 pri)ar$ process piping< Process piping in nor)al2
acti%e ser%ice that cannot !e %al%ed off or2 if it :ere %al%ed off2 :ould significantl$
affect unit opera!ilit$. Pri)ar$ process piping nor)all$ includes all process piping
greater than BPS 2.
3.35 1$AT; post:eld heat treat)ent.
3.3' rene7al; Acti%it$ that discards an e.isting co)ponent and replaces it :ith ne:
or e.isting spare )aterials of the sa)e or !etter 8ualities as the original co)ponent.
3.32 repair; #he :or' necessar$ to restore a piping s$ste)
to a condition suita!le for safe operation at the design conditions.
If an$ of the restorati%e changes result in a change of
design te)perature or pressure2 the re8uire)ents for rerating
1A)erican 4elding Societ$2 ""9 B.4. *eLeune oad2 (ia)i2 7lorida
3313".
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PIPIBG IBSP-C#IHB CH3-FIBSP-C#IHB2 -PAI2 A*#-A#IHB2 AB3 -A#IBG
H7 IB-S-/IC- PIPIBG SIS#-(S 3-3
also shall !e satisfied. An$ :elding2 cutting2 or grinding operation on a pressure-
containing piping co)ponent not specificall$ considered an alteration is considered a
repair.
3.3, repair organization< An$ of the follo:ing<
a. An o:ner or user of piping s$ste)s :ho repairs or alters
his or her o:n e8uip)ent in accordance :ith API "+9.
!. A contractor :hose 8ualifications are accepta!le to the o:ner or user of piping
s$ste)s and :ho )a'es repairs or alterations in accordance :ith API "+9.
c. Hne :ho is authorized !$2 accepta!le to2 or other:ise not prohi!ited !$ the
=urisdiction and :ho )a'es repairs in accordance :ith API "+9.
3.3! rerating; A change in either or !oth the design te)perature
or the )a.i)u) allo:a!le :or'ing pressure of a
piping s$ste). A rerating )a$ consist of an increase2 a
decrease2 or a co)!ination of !oth. 3erating !elo: original
design conditions is a )eans to pro%ide increased corrosion
allo:ance.
3.8# secondary process piping; S)all-!ore ?less than or e8ual to BPS 2A process
piping do:nstrea) of nor)all$ closed !loc' %al%es.
3.41 s)all-!ore piping ?S1PA< Piping that is less than or
e8ual to BPS 2.
3.83 soil-to-air >S@-? interface; An area in :hich e.ternal corrosion )a$ occur on
partiall$ !uried pipe. #he zone of the corrosion :ill %ar$ depending on factors such as
)oisture2 o.$gen content of the soil2 and operating te)perature.
#he zone generall$ is considered to !e fro) 12 inches ?39" ))A !elo: to & inches
?1"9 ))A a!o%e the soil surface. Pipe running parallel :ith the soil surface that
contacts the soil is included.
3.83 spool; A section of piping enco)passed !$ flanges or
other connecting fittings such as unions.
3.88 te5per e5rittle5ent; A loss of ductilit$ and notch
toughness in suscepti!le lo:-allo$ steels2 such as 11@4 Cr and
21@4 Cr2 due to prolonged e.posure to high-te)perature ser%ice
M+99N7 O 19+9N7 ?3+9NC O "+"NCAP.
3.85 te5porary repairs; epairs )ade to piping s$ste)s
in order to restore sufficient integrit$ to continue safe operation
until per)anent repairs can !e scheduled and acco)plished
:ithin a ti)e period accepta!le to the inspector or
piping engineer.
3.8' test point; An area defined !$ a circle ha%ing a dia)eter not greater than 2
inches ?"9 ))A for a line dia)eter not e.ceeding 19 inches ?2"9 ))A2 or not greater
than 3 inches
?+" ))A for larger lines. #hic'ness readings )a$ !e a%eraged :ithin this area. A
test point shall !e :ithin a thic'ness )easure)ent location.
3.82 t<ickness 5eas6re5ent locations >TMBs?; 3esignated areas on piping
s$ste)s :here periodic inspections and thic'ness )easure)ents are conducted.
3.88 $%MT; 4et fluorescent )agnetic-particle testing.
3.8! alloy 5aterial; An$ )etallic )aterial ?including
:elding filler )aterialsA that contains allo$ing ele)ents2 such as chro)iu)2 nic'el2 or
)ol$!denu)2 :hich are intentionall$ added to enhance )echanical or ph$sical
properties and@or corrosion resistance.
3."9 )aterial %erification progra)< A docu)ented
8ualit$ assurance procedure used to assess )etallic allo$ )aterials ?including
:eld)ents and attach)ents :here specifiedA
to %erif$ confor)ance :ith the selected or specified
allo$ )aterial designated !$ the o:ner@user. #his progra)
)a$ include a description of )ethods for allo$ )aterial testing2 ph$sical co)ponent
)ar'ing2 and progra) record-'eeping.
3."1 positi%e )aterial identification ?P(IA testing<
An$ ph$sical e%aluation or test of a )aterial to confir) that
the )aterial :hich has !een or :ill !e placed into ser%ice is
consistent :ith the selected or specified allo$ )aterial designated
!$ the o:ner@user. #hese e%aluations or tests )a$ pro%ide
8ualitati%e or 8uantitati%e infor)ation that is sufficient
to %erif$ the no)inal allo$ co)position.
3."2 fitness-for-ser%ice assess)ent< A )ethodolog$
:here!$ fla:s and conditions contained :ithin a structure are assessed in order to
deter)ine the integrit$ of the structure for continued ser%ice.
3."3 industr$-8ualified 0# shear :a%e e.a)iner< A
person :ho possesses an ultrasonic shear :a%e 8ualification
fro) API or an e8ui%alent 8ualification appro%ed !$ the
o:ner@user.
3.58 off-site piping; Piping s$ste)s not included :ithin
the plot ?!atter$A li)its of a process unit2 such as2 a h$drocrac'er2
an eth$lene crac'er or a crude unit. -.a)ples of offsite
piping include tan' far) paiping and other lo:er
conse8uence piping outside the li)its of the process unit.
3.55 on-site piping; Piping s$ste)s included :ithin the
plot li)its of process units2 such as a h$drocrac'er2 an eth$lene crac'er2 or a crude
unit.
3."& corrosion specialist< A person accepta!le to the
o:ner@user :ho is 'no:lega!le and e.perienced in the specific
process che)istries2 corrosion degradation )echanis)s2
)aterial selection2 and other corrosion )itigation )ethods2
corrosion )onitoring techni8ues2 and their i)pact on process e8uip)ent.
3."+ pressure design thic'ness< (ini)u) thic'ness
:ithout corrosion allo:ance !ased on design code calculations for pressure.
99
91
93
9&
9&
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3-4 API "+9
3.58 reC6ired t<ickness; #he greater of the pressure
design thic'ness ?see 3."+A or the structural )ini)u) thic'ness ?see 3."6A.
3."6 structural )ini)u) thic'ness< (ini)u) thic'ness
:ithout corrosion allo:ance2 !ased on structural and
other loadings.
9&
9&
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4-1
SECIO! %"O&!E#'(SE# I!SPECIO! O#)*!I+*IO!
4.1 G-B-A*
An o:ner@user of piping s$ste)s shall e.ercise control of the piping s$ste) inspection
progra)2 inspection fre8uencies2 and )aintenance and is responsi!le for the function of
an authorized inspection agenc$ in accordance :ith the pro%isions of API "+9. #he
o:ner@user inspection organization also shall control acti%ities relating to the rerating2
repair2 and alteration of its piping s$ste)s.
4.2 A0#5HIQ-3 PIPIBG IBSP-C#H
QUALIFICATION AND CERTIFICATION
Authorized piping inspectors shall ha%e education and
e.perience in accordance :ith Appendi. A of this inspection
code. Authorized piping inspectors shall !e certified in accordance :ith the pro%isions of
Appendi. A. 4hene%er the ter) inspector is used in this code2 it refers to an authorized
piping inspector.
4.3 -SPHBSI1I*I#I-S
4!" O#ner$User
An o:ner@user organization is responsi!le for de%eloping2
docu)enting2 i)ple)enting2 e.ecuting2 and assessing piping
inspection s$ste)s and inspection procedures that :ill )eet
the re8uire)ents of this inspection code. #hese s$ste)s and
procedures :ill !e contained in a 8ualit$ assurance inspection )anual or :ritten
procedures and shall include<
a. Hrganization and reporting structure for inspection
personnel.
!. 3ocu)enting and )aintaining inspection and 8ualit$
assurance procedures.
c. 3ocu)enting and reporting inspection and test results.
d. Correcti%e action for inspection and test results.
e. Internal auditing for co)pliance :ith the 8ualit$ assurance inspection )anual.
f. e%ie: and appro%al of dra:ings2 design calculations2
and specifications for repairs2 alterations2 and reratings.
g. -nsuring that all =urisdictional re8uire)ents for piping inspection2 repairs2 alterations2
and rerating are continuousl$ )et.
h. eporting to the authorized piping inspector an$ process
changes that could affect piping integrit$.
i. #raining re8uire)ents for inspection personnel regarding
inspection tools2 techni8ues2 and technical 'no:ledge !ase.
=. Controls necessar$ so that onl$ 8ualified :elders and procedures are used for all
repairs and alterations.
'. Controls necessar$ so that onl$ 8ualified nondestructi%e
e.a)ination ?B3-A personnel and procedures are utilized.
l. Controls necessar$ so that onl$ )aterials confor)ing to the applica!le section of the
AS(- Code are utilized for repairs and alterations.
). Controls necessar$ so that all inspection )easure)ent and test e8uip)ent are
properl$ )aintained and cali!rated.
n. Controls necessar$ so that the :or' of contract inspection
or repair organizations )eet the sa)e inspection re8uire)ents as the o:ner@user
organization.
o. Internal auditing re8uire)ents for the 8ualit$ control s$ste) for pressure-relie%ing
de%ices.
4!% Piping Engineer
#he piping engineer is responsi!le to the o:ner@user for
acti%ities in%ol%ing design2 engineering re%ie:2 anal$sis2 or
e%aluation of piping s$ste)s co%ered !$ API "+9.
4!! Repair Organi&ation
#he repair organization shall !e responsi!le to the
o:ner@user and shall pro%ide the )aterials2 e8uip)ent2
8ualit$ control2 and :or')anship necessar$ to )aintain
and repair the piping s$ste)s in accordance :ith the
re8uire)ents of API "+9.
4!4 Authori&ed Piping Inspector
4hen inspections2 repairs2 or alterations are !eing conducted
on piping s$ste)s2 an authorized piping inspector
shall !e responsi!le to the o:ner@user for deter)ining that the
re8uire)ents of API "+9 on inspection2 e.a)ination2 and
testing are )et2 and shall !e directl$ in%ol%ed in the inspection
acti%ities. #he authorized piping inspector )a$ !e
assisted in perfor)ing %isual inspections !$ other properl$
trained and 8ualified indi%iduals2 :ho )a$ or )a$ not !e certified
piping inspectors. Personnel perfor)ing nondestructi%e
e.a)inations shall )eet the 8ualifications identified in 3.122
!ut need not !e authorized piping inspectors. 5o:e%er2 all
e.a)ination results )ust !e e%aluated and accepted !$ the
authorized piping inspector.
4!' Other Personne(
Hperating2 )aintenance2 or other personnel :ho ha%e special
'no:ledge or e.pertise related to particular piping s$ste)s
shall !e responsi!le for pro)ptl$ )a'ing the inspector or
piping engineer a:are of an$ unusual conditions that )a$
de%elop and for pro%iding other assistance2 :here appropriate.
9&
9&
9&
9&
9&
9&
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"-1
SECIO! ,"I!SPECIO! *!$ ESI!) P#*CICES
".1 ISE-1AS-3 IBSP-C#IHB
Identif$ing and e%aluating potential degradation )echanis)s
are i)portant steps in an assess)ent of the li'elihood
of a piping failure. 5o:e%er2 ad=ust)ents to inspection strateg$
and tactics to account for conse8uences of a failure
should also !e considered. Co)!ining the assess)ent of li'elihood
of failure and the conse8uence of failure are essential
ele)ents of ris'-!ased inspection ?1IA.
4hen the o:ner@user chooses to conduct a 1I assess)ent
it )ust include a s$ste)atic e%aluation of !oth the li'elihood
of failure and the associated conse8uence of failure2 in accordance
:ith API P ",9. #he li'elihood assess)ent )ust !e
!ased on all for)s of degradation that could reasona!l$ !e
e.pected to affect piping circuits in an$ particular ser%ice.
-.a)ples of those degradation )echanis)s include< internal
or e.ternal )etal loss fro) an identified for) of corrosion
?localized or generalA2 all for)s of crac'ing including h$drogen
assisted and stress corrosion crac'ing ?fro) the inside or
outside surfaces of pipingA2 and an$ other for)s of )etallurgical2
corrosion2 or )echanical degradation2 such as fatigue2
e)!rittle)ent2 creep2 etc. Additionall$2 the effecti%eness of
the inspection practices2 tools2 and techni8ues utilized for
finding the e.pected and potential degradation )echanis)s
)ust !e e%aluated. #his li'elihood of failure assess)ent
should !e repeated each ti)e e8uip)ent or process changes
are )ade that could significantl$ affect degradation rates or
cause pre)ature failure of the piping.
Hther factors that should !e considered in a 1I assess)ent
conducted in accordance :ith API P ",9 include<
appropriateness of the )aterials of construction; piping circuit
design conditions2 relati%e to operating conditions;
appropriateness of the design codes and standards utilized;
effecti%eness of corrosion )onitoring progra)s; and the 8ualit$
of )aintenance and inspection Qualit$ Assurance@Qualit$
Control progra)s. -8uip)ent failure data and infor)ation
:ill also !e i)portant infor)ation for this assess)ent. #he
conse8uence assess)ent )ust consider the potential incidents that )a$ occur as a result
of fluid release2 including e.plosion2 fire2 to.ic e.posure2 en%iron)ental i)pact2 and
other health effects associated :ith a failure of piping.
It is essential that all 1I assess)ents !e thoroughl$ docu)ented in accordance :ith API
P ",92 clearl$ defining all the factors contri!uting to !oth the li'elihood and
conse8uence of a piping failure.
".2 P-PAA#IHB
1ecause of the products carried in piping s$ste)s2 safet$ precautions are i)portant :hen
the s$ste) is inspected2 particularl$ if it is opened for e.a)ining internal surfaces.
Procedures for segregating piping s$ste)s2 installing
!lan's ?!lindsA2 and testing tightness should !e an integral
part of safet$ practices. Appropriate safet$ precautions shall
!e ta'en !efore an$ piping s$ste) is opened and !efore so)e
t$pes of e.ternal inspection are perfor)ed. In general2 the
section of piping to !e opened should !e isolated fro) all
sources of har)ful li8uids2 gases2 or %apors and purged to
re)o%e all oil and to.ic or fla))a!le gases and %apors.
1efore starting inspection2 inspection personnel should
o!tain per)ission to :or' in the %icinit$ fro) operating personnel responsi!le for the
piping s$ste).
Protecti%e e8uip)ent shall !e :orn :hen re8uired !$ regulations or !$ the o:ner@user.
Bondestructi%e testing e8uip)ent used for inspection is su!=ect to the operating facilit$>s
safet$ re8uire)ents for electrical e8uip)ent.
In general2 inspectors should fa)iliarize the)sel%es :ith
prior inspection results and repairs in the piping s$ste)s for
:hich the$ are responsi!le. In particular2 the$ should !riefl$
re%ie: the histor$ of indi%idual piping s$ste)s !efore )a'ing an$ of the inspections
re8uired !$ API "+9. ?See Section , of API P "+4 for supple)entar$ reco))ended
practices.A A general o%er%ie: of the t$pes of deterioration and failure )odes
e.perienced !$ pressure containing e8uip)ent is pro%ided in API P "+62 Appendi. G.
".3 IBSP-C#IHB 7H SP-CI7IC #IP-S H7
CORRO)ION AND CRAC*IN+
Bote< 7or )ore thorough and co)plete infor)ation2 see API I-
Chapter II.
-ach o:ner@user should pro%ide specific attention to the
need for inspection of piping s$ste)s that are suscepti!le to
the follo:ing specific t$pes and areas of deterioration<
a. In=ection points.
!. 3eadlegs.
c. Corrosion under insulation ?C0IA.
d. Soil-to-air ?S@AA interfaces.
e. Ser%ice specific and localized corrosion.
f. -rosion and corrosion@erosion.
g. -n%iron)ental crac'ing.
h. Corrosion !eneath linings and deposits.
i. 7atigue crac'ing.
=. Creep crac'ing.
'. 1rittle fracture.
l. 7reeze da)age.
Hther areas of concern are noted in I- Chapter II2 and
Section & of API P "+4.
51#1! In2ection Points
In=ection points are so)eti)es su!=ect to accelerated or localized corrosion fro) nor)al
or a!nor)al operating conditions.
#hose that are )a$ !e treated as separate inspection
circuits2 and these areas need to !e inspected thoroughl$ on a
regular schedule.
93
93
93
91
99
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"-2 API "+9
4hen designating an in=ection point circuit for the purposes
of inspection2 the reco))ended upstrea) li)it of the
in=ection point circuit is a )ini)u) of 12 inches ?399 ))A or
three pipe dia)eters upstrea) of the in=ection point2 :hiche%er
is greater. #he reco))ended do:nstrea) li)it of the
in=ection point circuit is the second change in flo: direction
past the in=ection point2 or 2" feet ?+.& )A !e$ond the first
change in flo: direction2 :hiche%er is less. In so)e cases2 it
)a$ !e )ore appropriate to e.tend this circuit to the ne.t
piece of pressure e8uip)ent2 as sho:n in 7igure "-1.
#he selection of thic'ness )easure)ent locations ?#(*sA
:ithin in=ection point circuits su!=ect to localized corrosion
should !e in accordance :ith the follo:ing guidelines<
a. -sta!lish #(*s on appropriate fittings :ithin the in=ection point circuit.
!. -sta!lish #(*s on the pipe :all at the location of
e.pected pipe :all i)pinge)ent of in=ected fluid.
c. #(*s at inter)ediate locations along the longer straight
piping :ithin the in=ection point circuit )a$ !e re8uired.
d. -sta!lish #(*s at !oth the upstrea) and do:nstrea) li)its
of the in=ection point circuit.
#he preferred )ethods of inspecting in=ection points are
radiograph$ and@or ultrasonics2 as appropriate2 to esta!lish
the )ini)u) thic'ness at each #(*. Close grid ultrasonic
)easure)ents or scanning )a$ !e used2 as long as te)peratures are appropriate.
7or so)e applications2 it is !eneficial to re)o%e piping
spools to facilitate a %isual inspection of the inside surface.
5o:e%er2 thic'ness )easure)ents :ill still !e re8uired to
deter)ine the re)aining thic'ness.
3uring periodic scheduled inspections2 )ore e.tensi%e
inspection should !e applied to an area !eginning 12 inches
?399 ))A upstrea) of the in=ection nozzle and continuing for at least ten pipe dia)eters
do:nstrea) of the in=ection point.
Additionall$2 )easure and record the thic'ness at all #(*s
:ithin the in=ection point circuit.
51#1" .eadlegs
#he corrosion rate in deadlegs can %ar$ significantl$ fro)
ad=acent acti%e piping. #he inspector should )onitor :all
thic'ness on selected deadlegs2 including !oth the stagnant
7igure 1F#$pical In=ection Point Piping Circuit
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H7 IB-S-/IC- PIPIBG SIS#-(S "-3
end and at the connection to an acti%e line. In hot piping s$ste)s2
the high-point area )a$ corrode due to con%ecti%e currents
set up in the deadleg. Consideration should !e gi%en to
re)o%ing deadlegs that ser%e no further process purpose.
51#1# Corrosion 3nder Insulation
-.ternal inspection of insulated piping s$ste)s should
include a re%ie: of the integrit$ of the insulation s$ste) for
conditions that could lead to corrosion under insulation ?C0IA
and for signs of ongoing C0I. Sources of )oisture )a$
include rain2 :ater lea's2 condensation2 and deluge s$ste)s.
#he )ost co))on for)s of C0I are localized corrosion of
car!on steel and chloride stress corrosion crac'ing of austenitic stainless steels.
#his section pro%ides guidelines for identif$ing potential C0I areas for inspection. #he
e.tent of a C0I inspection progra) )a$ %ar$ depending on the local cli)ateF:ar)er
)arine locations )a$ re8uire a %er$ acti%e progra); :hereas cooler2 drier2 )id-continent
locations )a$ not need as e.tensi%e a progra).
51#1#1! Insulated Piping Systems Susceptible to
CUI
Certain areas and t$pes of piping s$ste)s are potentiall$
)ore suscepti!le to C0I2 including the follo:ing<
a. Areas e.posed to )ist o%erspra$ fro) cooling :ater
to:ers.
!. Areas e.posed to stea) %ents.
c. Areas e.posed to deluge s$ste)s.
d. Areas su!=ect to process spills2 ingress of )oisture2 or acid
%apors.
e. Car!on steel piping s$ste)s2 including those insulated for
personnel protection2 operating !et:een 2"N7 O 2"9N7 ?O4NC
129NCA. C0I is particularl$ aggressi%e :here operating
te)peratures cause fre8uent or continuous condensation and
re-e%aporation of at)ospheric )oisture.
f. Car!on steel piping s$ste)s that nor)all$ operate in-ser%ice a!o%e 2"9N7
?129NCA !ut are in inter)ittent ser%ice.
g. 3eadlegs and attach)ents that protrude fro) insulated
piping and operate at a different te)perature than the operating te)perature of the
acti%e line.
h. Austenitic stainless steel piping s$ste)s operating !et:een 1"9N7 O 499N7 ?&"NC
O 294NCA. ?#hese s$ste)s are suscepti!le to chloride stress corrosion crac'ing.A
i. /i!rating piping s$ste)s that ha%e a tendenc$ to inflict da)age to insulation
=ac'eting pro%iding a path for :ater ingress.
=. Stea) traced piping s$ste)s that )a$ e.perience tracing
lea's2 especiall$ at tu!ing fittings !eneath the insulation.
'. Piping s$ste)s :ith deteriorated coatings and@or
:rappings.
51#1#1" Common Locations on Piping Systems
Susceptible to C3I
#he areas of piping s$ste)s listed in ".3.3.1 )a$ ha%e specific locations :ithin the) that
are )ore suscepti!le to C0I2 including the follo:ing<
a. All penetrations or !reaches in the insulation =ac'eting
s$ste)s2 such as<
1. 3eadlegs ?%ents2 drains2 and other si)ilar ite)sA.
2. Pipe hangers and other supports.
3. /al%es and fittings ?irregular insulation surfacesA.
4. 1olted-on pipe shoes.
". Stea) tracer tu!ing penetrations.
!. #er)ination of insulation at flanges and other piping
co)ponents.
c. 3a)aged or )issing insulation =ac'eting.
d. Insulation =ac'eting sea)s located on the top of horizontal
piping or i)properl$ lapped or sealed insulation =ac'eting.
e. #er)ination of insulation in a %ertical pipe.
f. Caul'ing that has hardened2 has separated2 or is )issing.
g. 1ulges or staining of the insulation or =ac'eting s$ste) or )issing !ands. ?1ulges
)a$ indicate corrosion product !uildup.A
h. *o: points in piping s$ste)s that ha%e a 'no:n !reach in
the insulation s$ste)2 including lo: points in long unsupported piping runs.
i. Car!on or lo:-allo$ steel flanges2 !olting2 and other co)ponents
under insulation in high-allo$ piping s$ste)s.
*ocations :here insulation plugs ha%e !een re)o%ed to
per)it piping thic'ness )easure)ents on insulated piping
should recei%e particular attention. #hese plugs should !e
pro)ptl$ replaced and sealed. Se%eral t$pes of re)o%a!le
plugs are co))erciall$ a%aila!le that per)it inspection and
identification of inspection points for future reference.
51#14 Soil5to5Air Inter'ace
Soil-to-air ?S@AA interfaces for !uried piping :ithout ade8uate
cathodic protection shall !e included in scheduled
e.ternal piping inspections. Inspection at grade should chec'
for coating da)age2 !are pipe2 and pit depth )easure)ents. If
significant corrosion is noted2 thic'ness )easure)ents and
e.ca%ation )a$ !e re8uired to assess :hether the corrosion is
localized to the S@A interface or )a$ !e )ore per%asi%e to the
!uried s$ste). #hic'ness readings at S@A interfaces )a$
e.pose the )etal and accelerate corrosion if coatings and
:rappings are not properl$ restored. If the !uried piping has
satisfactor$ cathodic protection as deter)ined !$ )onitoring
in accordance :ith Section 62 e.ca%ation is re8uired onl$ if
there is e%idence of coating or :rapping da)age. If the !uried
piping is uncoated at grade2 consideration should !e gi%en
to e.ca%ating & inches to 12 inches ?1"9 )) to 399 ))A
deep to assess the potential for hidden da)age.
At concrete-to-air and asphalt-to-air interfaces of !uried
piping :ithout cathodic protection2 the inspector should loo'
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"-4 API "+9
for e%idence that the caul'ing or seal at the interface has deteriorated and allo:ed
)oisture ingress. If such a condition e.ists on piping s$ste)s o%er 19 $ears old2 it )a$ !e
necessar$ to inspect for corrosion !eneath the surface !efore resealing the =oint.
51#15 Service5Speci'ic and Locali6ed Corrosion
An effecti%e inspection progra) includes the follo:ing
three ele)ents2 :hich help identif$ the potential for ser%ice
specific and localized corrosion and select appropriate #(*s<
a. An inspector :ith 'no:ledge of the ser%ice and :here
corrosion is li'el$ to occur.
!. -.tensi%e use of nondestructi%e e.a)ination ?B3-A.
c. Co))unication fro) operating personnel :hen process
upsets occur that )a$ affect corrosion rates.
A fe: e.a)ples of :here this t$pe of corrosion )ight !e
e.pected to occur include the follo:ing<
a. 3o:nstrea) of in=ection points and upstrea) of product
separators2 such as in h$droprocess reactor effluent lines.
!. 3e:-point corrosion in condensing strea)s2 such as o%erhead fractionation.
c. 0nanticipated acid or caustic carr$o%er fro) processes
into nonallo$ed piping s$ste)s or caustic carr$o%er into steel piping s$ste)s that
are not post:eld heat treated.
d. A))oniu) salt condensation locations in h$droprocess
strea)s.
e. (i.ed-phase flo: and tur!ulent areas in acidic s$ste)s.
f. (i.ed grades of car!on steel piping in hot corrosi%e oil
ser%ice M4"9N7 ?239NCA or higher te)perature and sulfur content
in the oil greater than 9." percent !$ :eightP. Bote that
nonsilicon 'illed steel pipe2 such as A-"3 and API "*2 )a$
corrode at higher rates than does silicon 'illed steel pipe2 such as A-19&2 especiall$ in
high-te)perature sulfidic en%iron)ents.
g. 0nderdeposit corrosion in slurries2 cr$stallizing solutions2
or co'e producing fluids.
h. Chloride carr$o%er in catal$tic refor)er regeneration
s$ste)s.
i. 5ot-spot corrosion on piping :ith e.ternal heat tracing. In
ser%ices that !eco)e )uch )ore corrosi%e to the piping :ith increased te)perature2
such as caustic in car!on steel2 corrosion or stress corrosion crac'ing ?SCCA can occur
at hot spots that de%elop under lo:-flo: conditions.
51#1* 7rosion and Corrosion/7rosion
-rosion can !e defined as the re)o%al of surface )aterial
!$ the action of nu)erous indi%idual i)pacts of solid or li8uid
particles. It can !e characterized !$ groo%es2 rounded holes2
:a%es2 and %alle$s in a directional pattern. -rosion usuall$
occurs in areas of tur!ulent flo:2 such as at changes of
direction in a piping s$ste) or do:nstrea) of control %al%es
:here %aporization )a$ ta'e place. -rosion da)age is usuall$
increased in strea)s :ith large 8uantities of solid or li8uid
particles flo:ing at high %elocities. A co)!ination of
corrosion and erosion ?corrosion@erosionA results in
significantl$ greater )etal loss than can !e e.pected fro)
corrosion or erosion alone. #his t$pe of corrosion occurs at
high-%elocit$ and high-tur!ulence areas.
-.a)ples of places to inspect include the follo:ing<
a. 3o:nstrea) of control %al%es2 especiall$ :hen flashing is
occurring.
!. 3o:nstrea) of orifices.
c. 3o:nstrea) of pu)p discharges.
d. At an$ point of flo: direction change2 such as the inside
and outside radii of el!o:s.
e. 3o:nstrea) of piping configurations ?such as :elds2 ther)o:ells2
and flangesA that produce tur!ulence2 particularl$ in
%elocit$ sensiti%e s$ste)s such as a))oniu) h$drosulfide
and sulfuric acid s$ste)s.
Areas suspected of ha%ing localized corrosion@erosion
should !e inspected using appropriate B3- )ethods that :ill $ield thic'ness data o%er a
:ide area2 such as ultrasonic scanning2 radiographic profile2 or edd$ current.
51#1, 7nvironmental Crac0ing
Piping s$ste) construction )aterials are nor)all$ selected to resist the %arious for)s of
stress corrosion crac'ing ?SCCA. 5o:e%er2 so)e piping s$ste)s )a$ !e suscepti!le to
en%iron)ental crac'ing due to upset process conditions2 C0I2 unanticipated
condensation2 or e.posure to :et h$drogen sulfide or car!onates.
-.a)ples of en%iron)ental crac'ing include<
a. Chloride SCC of austenitic stainless steels due to )oisture
and chlorides under insulation2 under deposits2 under gas'ets2 or in cre%ices.
!. Pol$thionic acid SCC of sensitized austenitic allo$ steels
due to e.posure to sulfide2 )oisture condensation2 or o.$gen.
c. Caustic SCC ?so)eti)es 'no:n as caustic
e)!rittle)entA.
d. A)ine SCC in piping s$ste)s that are not stress relie%ed.
e. Car!onate SCC.
f. SCC in en%iron)ents :here :et h$drogen sulfide e.ists2
such as s$ste)s containing sour :ater.
g. 5$drogen !listering and h$drogen induced crac'ing ?5ICA da)age.
4hen the inspector suspects or is ad%ised that specific circuits
)a$ !e suscepti!le to en%iron)ental crac'ing2 the
inspector should schedule supple)ental inspections. Such
inspections can ta'e the for) of surface B3- Mli8uid-penetrant
testing ?P#A2 or :et fluorescent )agnetic-particle testing
?47(#AP2 or ultrasonics ?0#A. 4here a%aila!le2 suspect
spools )a$ !e re)o%ed fro) the piping s$ste) and split open for internal surface
e.a)ination.
If en%iron)ental crac'ing is detected during internal
inspection of pressure %essels and the piping is considered
e8uall$ suscepti!le2 the inspector should designate appropriate
--,,,,,,,,,,,,,,,,,--,,,,,,,---
H7 IB-S-/IC- PIPIBG SIS#-(S "-"
piping spools upstrea) and do:nstrea) of the pressure %essel
for en%iron)ental crac'ing inspection. 4hen the potential for
en%iron)ental crac'ing is suspected in piping circuits2 inspection
of selected spools should !e scheduled prior to an upco)ing
turnaround. Such inspection should pro%ide infor)ation
useful in forecasting turnaround )aintenance.
51#1$ Corrosion 8eneath Linings and .eposits
If e.ternal or internal coatings2 refractor$ linings2 and corrosion-
resistant linings are in good condition and there is no
reason to suspect a deteriorated condition !ehind the)2 it is
usuall$ not necessar$ to re)o%e the) for inspection of the
piping s$ste).
#he effecti%eness of corrosion-resistant linings is greatl$
reduced due to !rea's or holes in the lining. #he linings
should !e inspected for separation2 !rea's2 holes2 and !listers.
If an$ of these conditions are noted2 it )a$ !e necessar$ to
re)o%e portions of the internal lining to in%estigate the effecti%eness
of the lining and the condition of the )etal piping
!eneath the lining. Alternati%el$2 ultrasonic inspection fro)
the e.ternal surface can !e used to )easure :all thic'ness
and detect separation2 holes2 and !listers.
efractor$ linings )a$ spill or crac' in-ser%ice :ith or
:ithout causing an$ significant pro!le)s. Corrosion !eneath
refractor$ linings can result in separation and !ulging of the
refractor$. If !ulging or separation of the refractor$ lining is
detected2 portions of the refractor$ )a$ !e re)o%ed to per)it
inspection of the piping !eneath the refractor$. Hther:ise2
ultrasonic thic'ness )easure)ents )a$ !e )ade fro) the
e.ternal )etal surface.
4here operating deposits2 such as co'e2 are present on a
pipe surface2 it is particularl$ i)portant to deter)ine :hether
such deposits ha%e acti%e corrosion !eneath the). #his )a$
re8uire a thorough inspection in selected areas. *arger lines
should ha%e the deposits re)o%ed in selected critical areas for spot e.a)ination. S)aller
lines )a$ re8uire that selected spools !e re)o%ed or that B3- )ethods2 such as
radiograph$2 !e perfor)ed in selected areas.
51#1 9atigue Crac0ing
7atigue crac'ing of piping s$ste)s )a$ result fro) e.cessi%e
c$clic stresses that are often :ell !elo: the static $ield
strength of the )aterial. #he c$clic stresses )a$ !e i)posed
!$ pressure2 )echanical2 or ther)al )eans and )a$ result in
lo:-c$cle or high-c$cle fatigue. #he onset of lo:-c$cle
fatigue crac'ing is often directl$ related to the nu)!er of
heat-up and cool-do:n c$cles e.perienced. -.cessi%e piping
s$ste) %i!ration ?such as )achine or flo:-induced %i!rationsA
also can cause high-c$cle fatigue da)age. ?See ".4.4
for %i!rating piping sur%eillance re8uire)ents and +." for
design re8uire)ents associated :ith %i!rating piping.A
7atigue crac'ing can t$picall$ !e first detected at points of
high-stress intensification such as !ranch connections. *ocations
:here )etals ha%ing different coefficients of ther)al
e.pansion are =oined !$ :elding )a$ !e suscepti!le to ther)al
fatigue. ?See &.&.3 for fatigue considerations relati%e to
threaded connections.A Preferred B3- )ethods of detecting
fatigue crac'ing include li8uid-penetrant testing ?P#A or )agnetic-particle testing ?(#A.
Acoustic e)ission also )a$ !e used to detect the presence of crac's that are acti%ated !$
test pressures or stresses generated during the test.
It is i)portant that the o:ner@user and the inspector understand
that fatigue crac'ing is li'el$ to cause piping failure
!efore it is detected :ith an$ B3- )ethods. Hf the total
nu)!er of fatigue c$cles re8uired to produce a failure2 the
%ast )a=orit$ are re8uired to initiate a crac' and relati%el$
fe:er c$cles are re8uired to propagate the crac' to failure.
#herefore2 proper design and installation in order to pre%ent
the initiation of fatigue crac'ing are i)portant.
51#1!% Creep Crac0ing
Creep is dependent on ti)e2 te)perature2 and stress. Creep
crac'ing )a$ e%entuall$ occur at design conditions2 since
so)e piping code allo:a!le stresses are in the creep range.
Crac'ing is accelerated !$ creep and fatigue interaction :hen
operating conditions in the creep range are c$clic. #he
inspector should pa$ particular attention to areas of high
stress concentration. If e.cessi%e te)peratures are encountered2
)echanical propert$ and )icrostructural changes in
)etals also )a$ ta'e place2 :hich )a$ per)anentl$ :ea'en
e8uip)ent. Since creep is dependent on ti)e2 te)perature2
and stress2 the actual or esti)ated le%els of these para)eters
shall !e used in an$ e%aluations. An e.a)ple of :here creep
crac'ing has !een e.perienced in the industr$ is in 11@4 Cr
steels a!o%e 699N7 ?4,9NCA.
B3- )ethods of detecting creep crac'ing include li8uid
penetrant testing2 )agnetic-particle testing2 ultrasonic testing2
radiographic testing2 and in-situ )etallograph$. Acoustic
e)ission testing also )a$ !e used to detect the presence of
crac's that are acti%ated !$ test pressures or stresses generated during the test.
51#1!! 8rittle 9racture
Car!on2 lo:-allo$2 and other ferritic steels )a$ !e suscepti!le
to !rittle failure at or !elo: a)!ient te)peratures. 1rittle
fracture usuall$ is not a concern :ith relati%el$ thin-:all
piping. (ost !rittle fractures ha%e occurred on the first application of a particular stress
le%el ?that is2 the first h$drotest or o%erloadA unless critical defects are introduced during
ser%ice.
#he potential for a !rittle failure shall !e considered
:hen reh$drotesting or )ore carefull$ e%aluated :hen testing
e8uip)ent pneu)aticall$ or :hen adding an$ other additional
loads. Special attention should !e gi%en to lo:-allo$
steels ?especiall$ 2 R Cr-1 (o )aterialA2 !ecause the$ )a$
!e prone to te)per e)!rittle)ent2 and to ferritic stainless
steels.
API P "+62 Section 3 pro%ides procedures for the assess)ent
of e8uip)ent for resistance to !rittle fracture. #3
--,,,,,,,,,,,,,,,,,--,,,,,,,---
"-& API "+9
51#1!" 9ree6e .amage
At su!freezing te)peratures2 :ater and a8ueous solutions in piping s$ste)s )a$ freeze
and cause failure !ecause of the e.pansion of these )aterials. After une.pectedl$ se%ere
freezing :eather2 it is i)portant to chec' for freeze da)age to e.posed piping
co)ponents !efore the s$ste) tha:s. If rupture has occurred2 lea'age )a$ !e te)poraril$
pre%ented !$ the frozen fluid. *o: points2 driplegs2 and deadlegs of piping s$ste)s
containing :ater should !e carefull$ e.a)ined for da)age.
".4 #IP-S H7 IBSP-C#IHB AB3 S0/-I**ABC-
3ifferent t$pes of inspection and sur%eillance are appropriate depending on the
circu)stances and the piping s$ste) ?see noteA. #hese include the follo:ing<
a. Internal %isual inspection.
!. #hic'ness )easure)ent inspection.
c. -.ternal %isual inspection.
d. /i!rating piping inspection.
e. Supple)ental inspection.
Bote< See Section & for fre8uenc$ and e.tent of inspection.
'4" Interna( ,isua( Inspection
Internal %isual inspections are not nor)all$ perfor)ed on
piping. 4hen possi!le and practical2 internal %isual inspections
)a$ !e scheduled for s$ste)s such as large-dia)eter
transfer lines2 ducts2 catal$st lines2 or other large-dia)eter
piping s$ste)s. Such inspections are si)ilar in nature to pressure
%essel inspections and should !e conducted :ith )ethods
and procedures si)ilar to those outlined in API "19.
e)ote %isual inspection techni8ues can !e helpful :hen
inspecting piping too s)all to enter.
An additional opportunit$ for internal inspection is pro%ided
:hen piping flanges are disconnected2 allo:ing %isual
inspection of internal surfaces :ith or :ithout the use of
B3-. e)o%ing a section of piping and splitting it along its
centerline also per)its access to internal surfaces :here there is need for such inspection.
'4% Thic-ness .easure/ent Inspection
A thic'ness )easure)ent inspection is perfor)ed to deter)ine
the internal condition and re)aining thic'ness of the
piping co)ponents. #hic'ness )easure)ents )a$ !e
o!tained :hen the piping s$ste) is in or out of operation and shall !e perfor)ed !$ the
inspector or e.a)iner.
'4! E0terna( ,isua( Inspection
An e.ternal %isual inspection is perfor)ed to deter)ine the
condition of the outside of the piping2 insulation s$ste)2
painting and coating s$ste)s2 and associated hard:are; and
to chec' for signs of )isalign)ent2 %i!ration2 and lea'age.
4hen corrosion product !uildup is noted at pipe support contact
areas2 lifting off such supports )a$ !e re8uired for
inspection. 4hen doing this2 care should !e e.ercised if the
piping is in-ser%ice.
-.ternal piping inspections )a$ !e )ade :hen the piping
s$ste) is in-ser%ice. efer to API P "+4 for infor)ation
helpful in conducting e.ternal inspections. A chec'list to
assist in conducting e.ternal piping inspections is pro%ided in Appendi. 3.
-.ternal inspections shall include sur%e$s for the condition
of piping hangers and supports. Instances of crac'ed or !ro'en
hangers2 J!otto)ing outK of spring supports2 support
shoes displaced fro) support )e)!ers2 or other i)proper
restraint conditions shall !e reported and corrected. /ertical
support du))$ legs also shall !e chec'ed to confir) that
the$ ha%e not filled :ith :ater that is causing e.ternal corrosion
of the pressure piping or internal corrosion of the support
leg. 5orizontal support du))$ legs also shall !e chec'ed to
deter)ine that slight displace)ents fro) horizontal are not
causing )oisture traps against the e.ternal surface of acti%e
piping co)ponents.
1ello:s e.pansion =oints should !e inspected %isuall$ for
unusual defor)ations2 )isalign)ent2 or displace)ents that
)a$ e.ceed design. #he inspector should e.a)ine the piping
s$ste) for the presence of an$ field )odifications or te)porar$
repairs not pre%iousl$ recorded on the piping dra:ings
and@or records.
#he inspector also should !e alert to the presence of an$
co)ponents in the ser%ice that )a$ !e unsuita!le for longter)
operation2 such as i)proper flanges2 te)porar$ repairs
?cla)psA2 )odifications ?fle.i!le hosesA2 or %al%es of
i)proper specification. #hreaded co)ponents that )a$ !e
)ore easil$ re)o%ed and installed deser%e particular attention
!ecause of their higher potential for installation of
i)proper co)ponents.
#he periodic e.ternal inspection called for in &.4 should
nor)all$ !e conducted !$ the inspector2 :ho also shall !e
responsi!le for record 'eeping and repair inspection. Qualified
operating or )aintenance personnel also )a$ conduct
e.ternal inspections2 :hen accepta!le to the inspector. In
such cases2 the persons conducting e.ternal piping inspections
in accordance :ith API "+9 shall !e 8ualified through
an appropriate a)ount of training.
In addition to these scheduled e.ternal inspections that are
docu)ented in inspection records2 it is !eneficial for personnel
:ho fre8uent the area to report deterioration or changes to
the inspector. ?See Appendi. 3 and Section &.3 of API P
"+4 for e.a)ples of such deterioration.A
'44 ,i1rating Piping and Line .o2e/ent
Surveillance
Hperating personnel should report %i!rating or s:a$ing piping to engineering or
inspection personnel for assess)ent.
Hther significant line )o%e)ents should !e reported that )a$
ha%e resulted fro) li8uid ha))er2 li8uid slugging in %apor
--,,,,,,,,,,,,,,,,,--,,,,,,,---
H7 IB-S-/IC- PIPIBG SIS#-(S "-+
lines2 or a!nor)al ther)al e.pansion. At =unctions :here
%i!rating piping s$ste)s are restrained2 periodic )agneticparticle
testing or li8uid-penetrant testing should !e considered
to chec' for the onset of fatigue crac'ing. 1ranch
connections should recei%e special attention.
'4' )upp(e/enta( Inspection
Hther inspections )a$ !e scheduled as appropriate or necessar$.
-.a)ples of such inspections include periodic use of
radiograph$ and@or ther)ograph$ to chec' for fouling or
internal plugging2 ther)ograph$ to chec' for hot spots in
refractor$ lined s$ste)s2 or inspection for en%iron)ental
crac'ing. Acoustic e)ission2 acoustic lea' detection2 and
ther)ograph$ can !e used for re)ote lea' detection and sur%eillance.
0ltrasonics and@or radiograph$ can !e used for
detecting localized corrosion.
"." #5ICEB-SS (-AS0-(-B# *HCA#IHBS
''" +enera(
#hic'ness )easure)ent locations ?#(*sA are specific
areas along the piping circuit :here inspections are to !e
)ade. #he nature of the #(* %aries according to its location
in the piping s$ste). #he selection of #(*s shall consider
the potential for localized corrosion and ser%ice-specific corrosion as descri!ed in ".3.
''% T.L .onitoring
-ach piping s$ste) shall !e )onitored !$ ta'ing thic'ness
)easure)ents at #(*s. Piping circuits :ith high potential
conse8uences if failure should occur and those su!=ect to
higher corrosion rates or localized corrosion :ill nor)all$
ha%e )ore #(*s and !e )onitored )ore fre8uentl$ ?see &.3A.
#(*s should !e distri!uted appropriatel$ throughout each
piping circuit. #(*s )a$ !e eli)inated or the nu)!er
reduced under certain circu)stances2 such as olefin plant cold
side piping2 anh$drous a))onia piping2 clean noncorrosi%e
h$drocar!on product2 or highallo$ piping for product purit$.
In circu)stances :here #(*s :ill !e su!stantiall$ reduced
or eli)inated2 persons 'no:ledgea!le in corrosion should !e
consulted.
#he )ini)u) thic'ness at each #(* can !e located !$
ultrasonic scanning or radiograph$. -lectro)agnetic techni8ues
also can !e used to identif$ thin areas that )a$ then !e
)easured !$ ultrasonics or radiograph$. 4hen acco)plished
:ith ultrasonics2 scanning consists of ta'ing se%eral thic'ness )easure)ents at the #(*
searching for localized thinning.
#he thinnest reading or an a%erage of se%eral )easure)ent
readings ta'en :ithin the area of a test point shall !e recorded
and used to calculate corrosion rates2 re)aining life2 and the
ne.t inspection date in accordance :ith Section +.
4here appropriate2 thic'ness )easure)ents should
include )easure)ents at each of the four 8uadrants on pipe
and fittings2 :ith special attention to the inside and outside
radius of el!o:s and tees :here corrosion@erosion could
increase corrosion rates. As a )ini)u)2 the thinnest reading
and its location shall !e recorded.
#(*s should !e esta!lished for areas :ith continuing
C0I2 corrosion at S@A interfaces2 or other locations of potential localized corrosion as
:ell as for general2 unifor) corrosion.
#(*s should !e )ar'ed on inspection dra:ings and on
the piping s$ste) to allo: repetiti%e )easure)ents at the
sa)e #(*s. #his recording procedure pro%ides data for )ore accurate corrosion rate
deter)ination.
''! T.L )e(ection
In selecting or ad=usting the nu)!er and locations of
#(*s2 the inspector should ta'e into account the patterns of
corrosion that :ould !e e.pected and ha%e !een e.perienced
in the process unit. A nu)!er of corrosion processes co))on
to refining and petroche)ical units are relati%el$ unifor) in
nature2 resulting in a fairl$ constant rate of pipe :all reduction
independent of location :ithin the piping circuit2 either
a.iall$ or circu)ferentiall$. -.a)ples of such corrosion pheno)ena
include high-te)perature sulfur corrosion and sour
:ater corrosion ?pro%ided %elocities are not so e.cessi%e as to
cause local corrosion@erosion of el!o:s2 tees2 and other si)ilar
ite)sA. In these situations2 the nu)!er of #(*s re8uired
to )onitor a circuit :ill !e fe:er than those re8uired to )onitor
circuits su!=ect to )ore localized )etal loss. In theor$2 a
circuit su!=ect to perfectl$ unifor) corrosion could !e ade8uatel$
)onitored :ith a single #(*. In realit$2 corrosion is
ne%er trul$ unifor)2 so additional #(*s )a$ !e re8uired.
Inspectors )ust use their 'no:ledge ?and that of othersA of
the process unit to opti)ize the #(* selection for each circuit2
!alancing the effort of collecting the data :ith the !enefits
pro%ided !$ the data.
(ore #(*s should !e selected for piping s$ste)s :ith
an$ of the follo:ing characteristics<
a. 5igher potential for creating a safet$ or en%iron)ental
e)ergenc$ in the e%ent of a lea'.
!. 5igher e.pected or e.perienced corrosion rates.
c. 5igher potential for localized corrosion.
d. (ore co)ple.it$ in ter)s of fittings2 !ranches2 deadlegs2
in=ection points2 and other si)ilar ite)s.
e. 5igher potential for C0I.
7e:er #(*s can !e selected for piping s$ste)s :ith an$
of the follo:ing three characteristics<
a. *o: potential for creating a safet$ or en%iron)ental e)ergenc$ in the e%ent of a
lea'.
!. elati%el$ noncorrosi%e piping s$ste)s.
c. *ong2 straight-run piping s$ste)s.
--,,,,,,,,,,,,,,,,,--,,,,,,,---
"-, API "+9
#(*s can !e eli)inated for piping s$ste)s :ith either of
the follo:ing t:o characteristics<
a. -.tre)el$ lo: potential for creating a safet$ or en%iron)ental e)ergenc$ in the
e%ent of a lea'.
!. Boncorrosi%e s$ste)s2 as de)onstrated !$ histor$ or si)ilar ser%ice2 and s$ste)s
not su!=ect to changes that could cause corrosion.
".& #5ICEB-SS (-AS0-(-B# (-#5H3S
0ltrasonic thic'ness )easuring instru)ents usuall$ are the
)ost accurate )eans for o!taining thic'ness )easure)ents
on installed pipe larger than BPS 1. adiographic profile
techni8ues are preferred for pipe dia)eters of BPS 1 and
s)aller. adiographic profile techni8ues )a$ !e used for
locating areas to !e )easured2 particularl$ in insulated s$ste)s or :here nonunifor) or
localized corrosion is suspected.
4here practical2 ultrasonics can then !e used to
o!tain the actual thic'ness of the areas to !e recorded. 7ollo:ing
ultrasonic readings at #(*s2 proper repair of insulation
and insulation :eather coating is reco))ended to
reduce the potential for C0I. adiographic profile techni8ues2
:hich do not re8uire re)o%ing insulation2 )a$ !e
considered as an alternati%e.
4hen corrosion in a piping s$ste) is nonunifor) or the
re)aining thic'ness is approaching the )ini)u) re8uired
thic'ness2 additional thic'ness )easuring )a$ !e re8uired.
adiograph$ or ultrasonic scanning are the preferred )ethods in such cases. -dd$ current
de%ices also )a$ !e used.
4hen ultrasonic )easure)ents are ta'en a!o%e 1"9N7
?&"NCA2 instru)ents2 couplants2 and procedures should !e
used that :ill result in accurate )easure)ents at the higher
te)peratures. (easure)ents should !e ad=usted !$ the
appropriate te)perature correction factor.
Inspectors should !e a:are of possi!le sources of )easure)ent
inaccuracies and )a'e e%er$ effort to eli)inate their
occurrence. As a general rule2 each of the B3- techni8ues
:ill ha%e practical li)its :ith respect to accurac$. 7actors
that can contri!ute to reduced accurac$ of ultrasonic )easure)ents include the
follo:ing<
a. I)proper instru)ent cali!ration.
!. -.ternal coatings or scale.
c. -.cessi%e surface roughness.
d. -.cessi%e Jroc'ingK of the pro!e ?on the cur%ed surfaceA.
e. Su!surface )aterial fla:s2 such as la)inations.
f. #e)perature effects Mat te)peratures a!o%e 1"9N7
?&"NCAP.
g. S)all fla: detector screens.
h. #hic'nesses of less than 1@, inch ?3.2 ))A for t$pical digital thic'ness gauges.
In addition2 it )ust !e 'ept in )ind that the pattern of corrosion
can !e nonunifor). 7or corrosion rate deter)inations
to !e %alid2 it is i)portant that )easure)ents on the thinnest
point !e repeated as closel$ as possi!le to the sa)e location.
Alternati%el$2 the )ini)u) reading or an a%erage of se%eral
readings at a test point )a$ !e considered.
4hen piping s$ste)s are out of ser%ice2 thic'ness )easure)ents )a$ !e ta'en through
openings using calipers.
Calipers are useful in deter)ining appro.i)ate thic'nesses of
castings2 forgings2 and %al%e !odies2 as :ell as pit depth
appro.i)ations fro) C0I on pipe.
Pit depth )easuring de%ices also )a$ !e used to deter)ine
the depth of localized )etal loss.
".+ P-SS0- #-S#IBG H7 PIPIBG SIS#-(S
Pressure tests are not nor)all$ conducted as part of a routine
inspection. ?See ,.2.& for pressure testing re8uire)ents
for repairs2 alterations2 and rerating.A -.ceptions to this
include re8uire)ents of the 0nited States Coast Guard for
o%er:ater piping and re8uire)ents of local =urisdictions2 after
:elded alterations or :hen specified !$ the inspector or piping
engineer. 4hen the$ are conducted2 pressure tests shall !e
perfor)ed in accordance :ith the re8uire)ents of AS(-
131.3. Additional considerations are pro%ided in API P "+4 and API P "+6. *o:er
pressure tests2 :hich are used onl$ for tightness of piping s$ste)s2 )a$ !e conducted at
pressures designated !$ the o:ner@user.
#he test fluid should !e :ater unless there is the possi!ilit$
of da)age due to freezing or other ad%erse effects of :ater on
the piping s$ste) or the process or unless the test :ater :ill
!eco)e conta)inated and its disposal :ill present en%iron)ental
pro!le)s. In either case2 another suita!le nonto.ic li8uid
)a$ !e used. If the li8uid is fla))a!le2 its flash point
shall !e at least 129N7 ?46NCA or greater2 and consideration
shall !e gi%en to the effect of the test en%iron)ent on the test
fluid.
Piping fa!ricated of or ha%ing co)ponents of 399 series
stainless steel should !e h$drotested :ith a solution )ade up
of pota!le :ater ?see noteA or stea) condensate. After testing
is co)pleted2 the piping should !e thoroughl$ drained ?all
high-point %ents should !e open during drainingA2 air !lo:n2
or other:ise dried. If pota!le :ater is not a%aila!le or if
i))ediate draining and dr$ing is not possi!le2 :ater ha%ing a
%er$ lo: chloride le%el2 higher p5 ?S19A2 and inhi!itor addition
)a$ !e considered to reduce the ris' of pitting and
)icro!iologicall$ induced corrosion.
Bote< Pota!le :ater in this conte.t follo:s 0.S. practice2
:ith 2"9 parts per )illion )a.i)u) chloride2 sanitized :ith
chlorine or ozone.
7or sensitized austenitic stainless steel piping su!=ect to
pol$thionic stress corrosion crac'ing2 consideration should !e
gi%en to using an al'aline-:ater solution for pressure testing
?see BAC- P91+9A.
If a pressure test is to !e )aintained for a period of ti)e
and the test fluid in the s$ste) is su!=ect to ther)al e.pansion2 precautions shall !e ta'en
to a%oid e.cessi%e pressure.
4hen a pressure test is re8uired2 it shall !e conducted after
an$ heat treat)ent.
91
--,,,,,,,,,,,,,,,,,--,,,,,,,---
H7 IB-S-/IC- PIPIBG SIS#-(S "-6
1efore appl$ing a h$drostatic test to piping s$ste)s2 consideration should !e gi%en to the
supporting structure design.
A pneu)atic pressure test )a$ !e used :hen it is i)practica!le
to h$drostaticall$ test due to te)perature2 structural2 or
process li)itations. 5o:e%er2 the potential ris's to personnel
and propert$ of pneu)atic testing shall !e considered :hen
carr$ing out such a test. As a )ini)u)2 the inspection precautions
contained in AS(- 131.3 shall !e applied in an$
pneu)atic testing.
3uring a pressure test2 :here the test pressure :ill e.ceed
the set pressure of the safet$ %al%e on a piping s$ste)2 the
safet$ relief %al%e or %al%es should !e re)o%ed or !lan'ed for
the duration of the test. As an alternati%e2 each %al%e dis'
)ust !e held do:n !$ a suita!l$ designed test cla)p. #he
application of an additional load to the %al%e spring !$ turning
the ad=usting scre: is not reco))ended. Hther appurtenances
that are incapa!le of :ithstanding the test pressure2
such as gage glasses2 pressure gages2 e.pansion =oints2 and
rupture dis's2 should !e re)o%ed or !lan'ed. *ines containing
e.pansion =oints that cannot !e re)o%ed or isolated )a$
!e tested at a reduced pressure in accordance :ith the principles
of AS(- 131.3. If !loc' %al%es are used to isolate a piping
s$ste) for a pressure test2 caution should !e used to not
e.ceed the per)issi!le seat pressure as descri!ed in AS(-
11&.34 or applica!le %al%e )anufacturer data.
0pon co)pletion of the pressure test2 pressure relief
de%ices of the proper settings and other appurtenances
re)o%ed or )ade inopera!le during the pressure test shall !e
reinstalled or reacti%ated.
"., (A#-IA* /-I7ICA#IHB AB3
TRACEA3ILIT4
3uring repairs or alterations allo$ )aterial piping s$ste)s2
45-- #5- A**HI (A#-IA* IS -Q0I-3 #H
(AIB#AIB P-SS0- CHB#AIB(-B#2 the inspector
shall %erif$ that the installation of ne: )aterials is consistent
:ith the selected or specified construction )aterials. #his
)aterial %erification progra) should !e consistent :ith API
P "+,. 0sing ris' assess)ent procedures2 the o:ner@user
can )a'e this assess)ent !$ 199-percent %erification2 P(I
testing in certain critical situations2 or !$ sa)pling a percentage
of the )aterials. P(I testing can !e acco)plished !$ the
inspector or the e.a)iner :ith the use of suita!le )ethods as
descri!ed in API P "+,.
If a piping s$ste) co)ponent should fail !ecause an incorrect
)aterial :as inad%ertentl$ su!stituted for the proper piping
)aterial2 the inspector shall consider the need for further
%erification of e.isting piping )aterials. #he e.tent of further
%erification :ill depend upon circu)stances such as the conse8uences
of failure and the li'elihood of further )aterial
errors.
#he o:ner@user shall assess the need and e.tent regarding
application of the practices consistent :ith API P "+,
addressing inad%ertent )aterial su!stitution in e.isting allo$
piping s$ste)s. A )aterial %erification progra) consistent
:ith API P "+, )a$ include procedures for prioritization
and ris' ran'ing piping circuits. #hat assess)ent )a$ lead to
retroacti%e P(I testing2 as descri!ed in API P "+,2 to confir)
that the installed )aterials are consistent :ith the
intended ser%ice. Co)ponents identified during this %erification
that do not )eet acceptance criteria of the P(I testing
progra) ?such as in API P "+,2 Section &A :ould !e targeted
for replace)ent. #he o:ner@user and authorized piping
inspector2 in consultation :ith a corrosion specialist2 shall
esta!lish a schedule for replace)ent of those co)ponents.
#he authorized inspector shall use periodic B3-2 as necessar$2 on the identified
co)ponents until the replace)ent.
".6 IBSP-C#IHB H7 /A*/-S
Bor)all$2 thic'ness )easure)ents are not routinel$ ta'en
on %al%es in piping circuits. #he !od$ of a %al%e is nor)all$
thic'er than other piping co)ponents for design reasons.
5o:e%er2 :hen %al%es are dis)antled for ser%icing and
repair2 the shop should !e attenti%e to an$ unusual corrosion
patterns or thinning and2 :hen noted2 report that infor)ation
to the inspector. 1odies of %al%es that are e.posed to steep
te)perature c$cling ?for e.a)ple2 catal$tic refor)ing unit
regeneration and stea) cleaningA should !e e.a)ined periodicall$ for ther)al fatigue
crac'ing.
If gate %al%es are 'no:n to !e or are suspected of !eing
e.posed to corrosion@erosion2 thic'ness readings should !e
ta'en !et:een the seats2 since this is an area of high tur!ulence and high stress.
Control %al%es or other throttling %al%es2 particularl$ in
high-pressure drop-and-slurr$ ser%ices2 can !e suscepti!le to
localized corrosion@erosion of the !od$ do:nstrea) of the
orifice. If such )etal loss is suspected2 the %al%e should !e
re)o%ed fro) the line for internal inspection. #he inside of
the do:nstrea) )ating flange and piping also should !e
inspected for local )etal loss.
4hen %al%e !od$ and@or closure pressure tests are perfor)ed
after ser%icing2 the$ should !e conducted in accordance
:ith API Std "6,.
Critical chec' %al%es should !e %isuall$ and internall$
inspected to ensure that the$ :ill stop flo: re%ersals. An
e.a)ple of a critical chec' %al%e )a$ !e the chec' %al%e
located on the outlet of a )ultistage2 high head h$droprocessing
charge pu)p. 7ailure of such a chec' %al%e to operate
correctl$ could result in o%erpressuring the piping during a
flo: re%ersal. #he nor)al %isual inspection )ethod should
include<
a. Chec'ing to insure that the flapper is free to )o%e2 as
re8uired2 :ithout e.cessi%e looseness fro) :ear.
!. #he flapper stop should not ha%e e.cessi%e :ear. #his :ill
)ini)ize the li'elihood that the flapper :ill )o%e past the
top dead central position and re)ain in an open position
:hen the chec' %al%e is )ounted in a %ertical position.
99
99
99
--,,,,,,,,,,,,,,,,,--,,,,,,,---
"-19 API "+9
c. #he flapper nut should !e secured to the flapper !olt to
a%oid !ac'ing off in ser%ice.
*ea' chec's of critical chec' %al%es are nor)all$ not
re8uired.
".19 IBSP-C#IHB H7 4-*3S IB-S-/IC-
Inspection for piping :eld 8ualit$ is nor)all$ acco)plished
as a part of the re8uire)ents for ne: construction2
repairs2 or alterations. 5o:e%er2 :elds are often inspected for
corrosion as part of a radiographic profile inspection or as
part of internal inspection. 4hen preferential :eld corrosion
is noted2 additional :elds in the sa)e circuit or s$ste) should !e e.a)ined for corrosion.
Hn occasion2 radiographic profile e.a)inations )a$ re%eal
:hat appears to !e i)perfections in the :eld. If crac' li'e
i)perfections are detected :hile the piping s$ste) is in operation2 further inspection :ith
:eld 8ualit$ radiograph$ and@or ultrasonics )a$ !e used to assess the )agnitude of the
i)perfection.
Additionall$2 an effort should !e )ade to deter)ine
:hether the crac'-li'e i)perfections are fro) original :eld
fa!rication or )a$ !e fro) an en%iron)ental crac'ing )echanis).
-n%iron)ental crac'ing shall !e assessed !$ the piping
engineer.
If the noted i)perfections are a result of original :eld fa!rication2 inspection and@or
engineering anal$sis is re8uired to assess the i)pact of the :eld 8ualit$ on piping
integrit$. #his anal$sis )a$ !e one or )ore of the follo:ing<
a. Inspector =udg)ent.
!. Certified :elding inspector =udg)ent.
c. Piping engineer =udg)ent.
d. -ngineering fitness-for-ser%ice anal$sis.
Issues to consider :hen assessing the 8ualit$ of e.isting
:elds include the follo:ing<
a. Hriginal fa!rication inspection acceptance criteria.
!. -.tent2 )agnitude2 and orientation of i)perfections.
c. *ength of ti)e in-ser%ice.
d. Hperating %ersus design conditions.
e. Presence of secondar$ piping stresses ?residual and
ther)alA.
f. Potential for fatigue loads ?)echanical and ther)alA.
g. Pri)ar$ or secondar$ piping s$ste).
h. Potential for i)pact or transient loads.
i. Potential for en%iron)ental crac'ing.
=. 4eld hardness.
In )an$ cases for in-ser%ice :eld)ents2 it )a$ not !e
appropriate to use the original construction code radiograph$
acceptance criteria for :eld 8ualit$ in AS(- 131.3. #hese
acceptance criteria are intended to appl$ to ne: construction
on a sa)pling of :elds2 not =ust the :elds e.a)ined2 in order to assess the pro!a!le
8ualit$ of all :elds ?or :eldersA in the s$ste). So)e :elds )a$ e.ist that :ill not )eet
these criteria !ut :ill still perfor) satisfactoril$ in-ser%ice after !eing h$drotested. #his is
especiall$ true on s)all !ranch connections that are nor)all$ not e.a)ined during ne:
construction.
#he o:ner@user shall specif$ industr$-8ualified 0# shear
:a%e e.a)iners :hen the o:ner@user re8uires the follo:ing<
aA detection of interior surface ?I3A !rea'ing planar fla:s
:hen inspecting fro) the e.ternal surface ?H3A; or !A :here
detection2 characterization2 and@or through-:all sizing is
re8uired of planar defects. Application e.a)ples for the use
of such industr$-8ualified 0# shear :a%e e.a)iners include
fitness-for-ser%ice and )onitoring of 'no:n fla:s. #he
re8uire)ent for use of industr$-8ualified 0# shear :a%e
e.a)iners !eco)es effecti%e t:o $ears after pu!lication in
this code or addendu).
".11 IBSP-C#IHB H7 7*ABG-3 LHIB#S
#he )ar'ings on a representati%e sa)ple of ne:l$ installed fasteners and gas'ets should
!e e.a)ined to deter)ine :hether the$ )eet the )aterial specification.
#he )ar'ings are identified in the applica!le AS(- and
AS#( standards. Questiona!le fasteners should !e %erified
or rene:ed.
7asteners should e.tend co)pletel$ through their nuts.
An$ fastener failing to do so is considered accepta!l$
engaged if the lac' of co)plete engage)ent is not )ore than
one thread.
If installed flanges are e.cessi%el$ !ent2 their )ar'ings and
thic'nesses should !e chec'ed against engineering re8uire)ents !efore ta'ing correcti%e
action.
7lange and %al%e !onnet fasteners should !e e.a)ined
%isuall$ for corrosion.
7langed and %al%e !onnet =oints should !e e.a)ined for
e%idence of lea'age2 such as stains2 deposits2 or drips. Process
lea's onto flange and !onnet fasteners )a$ result in corrosion
or en%iron)ental crac'ing. #his e.a)ination should include
those flanges enclosed :ith flange or splash-and-spra$
guards.
7langed =oints that ha%e !een cla)ped and pu)ped :ith
sealant should !e chec'ed for lea'age at the !olts. 7asteners
su!=ected to such lea'age )a$ corrode or crac' ?caustic
crac'ing2 for e.a)pleA. If repu)ping is conte)plated2
affected fasteners should !e rene:ed first.
7asteners on instru)entation that are su!=ect to process
pressure and@or te)perature should !e included in the scope
of these e.a)inations.
See API P "+4 for reco))ended practices :hen flanged
=oints are opened.
91
9&
--,,,,,,,,,,,,,,,,,--,,,,,,,---
&-1
SECIO! -"F#E.(E!C/ *!$ E0E! OF I!SPECIO!
&.1 G-B-A*
#he fre8uenc$ and e.tent of inspection on piping circuits
depend on the for)s of degradation that can affect the piping
and conse8uence of a piping failure. #he %arious for)s of
degradation that can affect refiner$ piping circuits are
descri!ed in ".32 :hile a si)plified classification of piping
!ased on the conse8uence of failure is defined in &.2. As
descri!ed in ".12 inspection strateg$ !ased on li'elihood and
conse8uence of failure2 is referred to as ris'-!ased inspection.
#he si)plified piping classification sche)e in Section &.2
is !ased on the conse8uence of a failure. #he classification is
used to esta!lish fre8uenc$ and e.tent of inspection. #he
o:ner@user )a$ de%ise a )ore e.tensi%e classification
sche)e that )ore accuratel$ assesses conse8uence for certain
piping circuits. #he conse8uence assess)ent :ould consider
the potential for e.plosion2 fire2 to.icit$2 en%iron)ental
i)pact2 and other potential effects associated :ith a failure.
After an effecti%e assess)ent is conducted2 the results can
!e used to esta!lish a piping circuit inspection strateg$ and
)ore specificall$ !etter define the follo:ing<
a. #he )ost appropriate inspection )ethods2 scope2 tools and techni8ues to !e
utilized !ased on the e.pected for)s of degradation;
!. #he appropriate inspection fre8uenc$;
c. #he need for pressure testing after da)age has !een
incurred or after repairs or )odifications ha%e !een co)pleted;
and
d. #he pre%ention and )itigation steps to reduce the li'elihood and conse8uence of a
piping failure. A 1I assess)ent )a$ !e used to increase or decrease the
inspection li)its descri!ed in #a!le &-1. Si)ilarl$2 the e.tent
of inspection )a$ !e increased or decreased !e$ond the targets
in #a!le &-22 !$ a 1I assess)ent. 4hen used to
increase inspection inter%al li)its or the e.tent of inspection2
1I assess)ents shall !e conducted at inter%als not to e.ceed
the respecti%e li)its in #a!le &-12 or )ore often if :arranted
!$ process2 e8uip)ent2 or conse8uence changes. #hese 1I
assess)ents shall !e re%ie:ed and appro%ed !$ a piping engineer
and authorized piping inspector at inter%als not to e.ceed
the respecti%e li)its in #a!le &-12 or )ore often if :arranted
!$ process2 e8uip)ent2 or conse8uence changes.
&.2 PIPIBG S-/IC- C*ASS-S
All process piping s$ste)s shall !e categorized into different
classes. Such a classification s$ste) allo:s e.tra
inspection efforts to !e focused on piping s$ste)s that )a$
ha%e the highest potential conse8uences if failure or loss of
contain)ent should occur. In general2 the higher classified
s$ste)s re8uire )ore e.tensi%e inspection at shorter inter%als in order to affir) their
integrit$ for continued safe operation.
Classifications should !e !ased on potential safet$ and en%iron)ental effects should a
lea' occur.
H:ner@users shall )aintain a record of process piping fluids
handled2 including their classifications. API P +"9 and
B7PA +94 pro%ide infor)ation that )a$ !e helpful in classif$ing
piping s$ste)s according to the potential hazards of the
process fluids the$ contain.
#he three classes listed !elo: in &.2.1 through &.2.3 are
reco))ended.
5%" C(ass "
Ser%ices :ith the highest potential of resulting in an
i))ediate e)ergenc$ if a lea' :ere to occur are in Class 1.
Such an e)ergenc$ )a$ !e safet$ or en%iron)ental in nature.
-.a)ples of Class 1 piping include2 !ut are not necessaril$
li)ited to2 those containing the follo:ing<
a. 7la))a!le ser%ices that )a$ auto-refrigerate and lead to
!rittle fracture.
!. Pressurized ser%ices that )a$ rapidl$ %aporize during
release2 creating %apors that )a$ collect and for) an e.plosi%e )i.ture2 such as
C22 C32 and C4 strea)s. 7luids that :ill rapidl$ %aporize are those :ith
at)ospheric !oiling te)perature !elo: "9N7 ?19NCA.
c. 5$drogen sulfide ?greater than 3 percent :eightA in a gaseous strea).
d. Anh$drous h$drogen chloride.
e. 5$drofluoric acid.
f. Piping o%er or ad=acent to :ater and piping o%er pu!lic
through:a$s. ?efer to 3epart)ent of #ransportation and
0.S. Coast Guard regulations for inspection of o%er:ater
piping.A
5%% C(ass %
Ser%ices not included in other classes are in Class 2. #his classification includes the
)a=orit$ of unit process piping and selected off-site piping. #$pical e.a)ples of these
ser%ices include those containing the follo:ing<
a. Hn-site h$drocar!ons that :ill slo:l$ %aporize during
release such as those operating !elo: the fash point.
!. 5$drogen2 fuel gas2 and natural gas.
c. Hn-site strong acids and caustics.
5%! C(ass !
Ser%ices that are fla))a!le !ut do not significantl$
%aporize :hen the$ lea' and are not located in high-acti%it$
areas are in Class 3. Ser%ices that are potentiall$ har)ful to
93
93
--,,,,,,,,,,,,,,,,,--,,,,,,,---
&-2 API "+9
hu)an tissue !ut are located in re)ote areas )a$ !e included in this class. -.a)ples of
Class 3 ser%ice are as follo:s<
a. Hn-site h$drocar!ons that :ill not significantl$ %aporize
during release such as those operating !elo: the flash point.
!. 3istillate and product lines to and fro) storage and
loading.
c. Hff-site acids and caustics.
&.3 IBSP-C#IHB IB#-/A*S
#he inter%al !et:een piping inspections shall !e esta!lished
and )aintained using the follo:ing criteria<
a. Corrosion rate and re)aining life calculations.
!. Piping ser%ice classification.
c. Applica!le =urisdictional re8uire)ents.
d. Ludg)ent of the inspector2 the piping engineer2 the piping
engineer super%isor2 or a corrosion specialist2 !ased on operating conditions2 pre%ious
inspection histor$2 current inspection results2 and conditions that )a$ :arrant
supple)ental inspections co%ered in ".4.".
#he o:ner@user or the inspector shall esta!lish inspection
inter%als for thic'ness )easure)ents and e.ternal %isual
inspections and2 :here applica!le2 for internal and supple)ental inspections.
#hic'ness )easure)ents should !e scheduled !ased on the calculation of not )ore than
half the re)aining life deter)ined fro) corrosion rates indicated in +.1.1 or at the
)a.i)u) inter%als suggested in #a!le &-12 :hiche%er is shorter.
Shorter inter%als )a$ !e appropriate under certain circu)stances.
Prior to using #a!le &-12 corrosion rates should !e
calculated in accordance :ith +.1.3.
#a!le &-1 contains reco))ended )a.i)u) inspection
inter%als for the three categories of piping ser%ices descri!ed
in &.22 as :ell as reco))ended inter%als for in=ection points
and S@A interfaces.
#he inspection inter%al )ust !e re%ie:ed and ad=usted
as necessar$ after each inspection or significant change in
operating conditions. General corrosion2 localized corrosion2
pitting2 en%iron)ental crac'ing2 and other for)s of
deterioration )ust !e considered :hen esta!lishing the
%arious inspection inter%als.
&.4 -G#-B# H7 /IS0A* -G#-BA* AB3 C0I
IN)PECTION)
-.ternal %isual inspections2 including inspections for corrosion
under insulation ?C0IA2 should !e conducted at )a.i)u)
inter%als listed in #a!le &-1 to e%aluate ite)s such as
those in Appendi. 3. Alternati%el$2 e.ternal %isual inspection
inter%als can !e esta!lished !$ using a %alid 1I assess)ent
conducted in accordance :ith API P ",9. #he e.ternal %isual
inspection on a !are pipe is to assess the condition of paint and
coating s$ste)s2 to chec' for e.ternal corrosions2 and to chec'
for other for)s of deterioration. #his e.ternal %isual inspection
for potential C0I is also to assess insulation condition and
shall !e conducted on all piping s$ste)s suscepti!le to C0I
listed in ".3.3.1. #he results of the %isual inspection should !e docu)ented to facilitate
follo:-up inspections.
7ollo:ing the e.ternal %isual inspection of suscepti!le s$ste)s2 additional e.a)ination is
re8uired for the inspection of C0I. #he e.tent and t$pe of the additional C0I inspection
are listed in #a!le &-2. 3a)aged insulation at higher ele%ations )a$ result in C0I in
lo:er areas re)ote fro) the da)age.
B3- inspection for C0I should also !e conducted as listed in
#a!le &-2 at suspect locations of ".3.3.2 ?e.cluding cA )eeting
the te)perature criteria for ".3.3.1 ?e2 f2 hA. adiographic
e.a)ination or insulation re)o%al and %isual inspection is
nor)all$ re8uired for this inspection at da)aged or suspect
locations. Hther B3- assess)ent )ethods )a$ !e used :here
applica!le. If the inspection of the da)aged or suspect areas
has located significant C0I2 additional areas should !e
inspected and2 :here :arranted2 up to 199 percent of the circuit should !e inspected.
#he e.tent of the C0I progra) descri!ed in #a!le &-2
should !e considered as target le%els for piping s$ste)s and
locations :ith no C0I inspection e.perience. It is recognized
that se%eral factors )a$ affect the li'elihood of C0I to include<
a. *ocal cli)atic conditions ?see ".3.3A.
!. Insulation design.
c. Coating 8ualit$.
d. Ser%ice conditions.
7acilities :ith C0I inspection e.perience )a$ increase or
reduce the C0I inspection targets of #a!le &-2. An e.act
accounting of the C0I inspection targets is not re8uired. #he
o:ner@user )a$ confir) inspection targets :ith operational
histor$ or other docu)entation.
Piping s$ste)s that are 'no:n to ha%e a re)aining life
of o%er 19 $ears or that are ade8uatel$ protected against
e.ternal corrosion need not !e included for the B3-
inspection reco))ended in #a!le &-2. 5o:e%er2 the condition
of the insulating s$ste) or the outer =ac'eting2 such
as a cold-!o. shell2 should !e o!ser%ed periodicall$ !$
operating or other personnel. If deterioration is noted2 it
should !e reported to the inspector. #he follo:ing are
e.a)ples of these s$ste)s<
a. Piping s$ste)s insulated effecti%el$ to preclude the
entrance of )oisture.
!. Lac'eted cr$ogenic piping s$ste)s.
c. Piping s$ste)s installed in a cold !o. in :hich the at)osphere is purged :ith an
inert gas.
d. Piping s$ste)s in :hich the te)perature !eing )aintained
is sufficientl$ lo: or sufficientl$ high to preclude the presence of :ater.
93 93
93
--,,,,,,,,,,,,,,,,,--,,,,,,,---
P
IPIBG
I
BSP-C#IHB
C
H3-
I
BSP-C#IHB
2
-PAI
2 A
*#-A#IHB
,
AB3
R
-A#IBG
H7
I
B
S
-/IC-
P
IPIBG
S
IS#-(S
&-3
&." -G#-B# H7 #5ICEB-SS (-AS0-(-B#
IN)PECTION
#o satisf$ inspection inter%al re8uire)ents2 each thic'ness
)easure)ent inspection should o!tain thic'ness readings on
a representati%e sa)pling of #(*s on each circuit ?see "."A.
#his representati%e sa)pling should include data for all the
%arious t$pes of co)ponents and orientations ?horizontal and
%erticalA found in each circuit. #his sa)pling also )ust
include #(*s :ith the earliest rene:al date as of the pre%ious inspection. #he )ore
#(*s )easured for each circuit2 the )ore accuratel$ the ne.t inspection date :ill !e
pro=ected.
#herefore2 scheduled inspection of circuits should o!tain as
)an$ )easure)ents as necessar$.
#he e.tent of inspection for in=ection points is co%ered
in ".3.1.
&.& -G#-B# H7 S(A**-1H-2 A0GI*IAI
PIPIN+, AND T6READED7CONNECTION)
IN)PECTION)
*1*1! Small58ore Piping Inspection
S)all-!ore piping ?S1PA that is pri)ar$ process piping
should !e inspected in accordance :ith all the re8uire)ents
of this docu)ent.
S1P that is secondar$ process piping has different )ini)u)
re8uire)ents depending upon ser%ice classification.
Class 1 secondar$ S1P shall !e inspected to the sa)e re8uire)ents as pri)ar$ process
piping. Inspection of Class 2 and Class 3 secondar$ S1P is optional. S1P deadlegs ?such
as le%el !ridlesA in Class 2 and Class 3 s$ste)s should !e inspected :here corrosion has
!een e.perienced or is anticipated.
*1*1" Au:iliary Piping Inspection
Inspection of secondar$2 au.iliar$ S1P associated :ith instru)ents and )achiner$ is
optional. Criteria to consider in deter)ining :hether au.iliar$ S1P :ill need so)e for)
of inspection include the follo:ing<
a. Classification.
!. Potential for en%iron)ental or fatigue crac'ing.
c. Potential for corrosion !ased on e.perience :ith ad=acent
pri)ar$ s$ste)s.
d. Potential for C0I.
*1*1# /hreaded5Connections Inspection
Inspection of threaded connections :ill !e according to the re8uire)ents listed a!o%e for
s)all-!ore and au.iliar$ piping.
4hen selecting #(*s on threaded connections2 include onl$
those that can !e radiographed during scheduled inspections.
#hreaded connections associated :ith )achiner$ and su!=ect
to fatigue da)age should !e periodicall$ assessed and considered
for possi!le rene:al :ith a thic'er :all or upgrading to
:elded co)ponents. #he schedule for such rene:al :ill
depend on se%eral issues2 including the follo:ing<
a. Classification of piping.
!. (agnitude and fre8uenc$ of %i!ration.
c. A)ount of unsupported :eight.
d. Current piping :all thic'ness.
e. 4hether or not the s$ste) can !e )aintained on-strea).
f. Corrosion rate.
g. Inter)ittent ser%ice.
Bote< #hic'ness )easure)ents appl$ to s$ste)s for :hich #(*s
ha%e !een esta!lished in accordance :ith ".".
a
See ".3.1. Inspection inter%als for potentiall$ corrosi%e in=ection@
)i. points can also !e esta!lished !$ a %alid ris'-!ased inspection
anal$sis in accordance :ith API P ",9.
!
See ".3.4.
#a!le &-1Feco))ended (a.i)u)
Inspection Inter%als
#$pe of Circuit
#hic'ness
(easure)ents
/isual
-.ternal
Class 1 " $ears " $ears
Class 2 19 $ears " $ears
Class 3 19 $ears 19 $ears
In=ection points
a
3 $ears 1$ Class
Soil-to-air interfaces
!
1$ Class
#a!le &-2Feco))ended -.tent of C0I Inspection
7ollo:ing /isual Inspection
Appro.i)ate A)ount of 7ollo:up
-.a)ination :ith B3- or
Insulation e)o%al at Areas :ith
3a)aged Insulation
Appro.i)ate A)ount of C0I
Inspection !$ B3- at Suspect
Areas ?".3.3.2A on Piping S$ste)s
:ithin Suscepti!le #e)perature
anges ?".3.3.22e2f2hA
Pipe Class
1 +"T "9T
2 "9T 33T
3 2"T 19T
93
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--,,,,,,,,,,,,,,,,,--,,,,,,,---
+-1
SECIO! 1"I!SPECIO! $** E2*L(*IO!3 *!*L/SIS3 *!$
#ECO#$I!)
,1! C;((;SI;& (A/7 .7/7(-I&A/I;&
,1!1! (emaining Li'e Calculations
#he re)aining life of the piping s$ste) shall !e calculated
fro) the follo:ing for)ula<
:here
tactua( D the actual thic'ness2 in inches ?)illi)etersA2
)easured at the ti)e of inspection for a gi%en
location or co)ponent as specified in ".&.2
tre8uired D the re8uired thic'ness2 in inches ?)illi)etersA2
at the sa)e location or co)ponent as the tactua(
)easure)ent co)puted !$ the design for)ulas
?e.g.2 pressure and structuralA !efore corrosion
allo:ance and )anufacturer>s tolerance are
added.
#he long-ter) ?*#A corrosion rate of piping circuits shall
!e calculated fro) the follo:ing for)ula<
tinitia( and tactua(
#he short ter) ?S#A corrosion rate of piping circuits shall
!e calculated fro) the follo:ing for)ula<
tpre2ious and tactua(
:here
tinitia( D the thic'ness2 in inches ?)illi)etersA2 at the
sa)e location as tactua( )easured at initial
installation or at the co))ence)ent of a ne:
corrosion rate en%iron)ent2
tpre2ious D the thic'ness2 in inches ?)illi)etersA2 at the sa)e
location as tactua( )easured during one or )ore pre%ious
inspections.
#he preceding for)ulas )a$ !e applied in a statistical
approach to assess corrosion rates and re)aining life calculations
for the piping s$ste). Care )ust !e ta'en to ensure that
the statistical treat)ent of data results reflects the actual condition
of the %arious pipe co)ponents. Statistical anal$sis
e)plo$ing point )easure)ents is not applica!le to piping
s$ste)s :ith significant localized unpredicta!le corrosion
)echanis)s.
*ong-ter) and short-ter) corrosion rates should !e co)pared to see :hich results in the
shortest re)aining life as part of the data assess)ent. #he authorized inspector2 in
consultation :ith a corrosion specialist2 shall select the corrosion rate that !est reflects
the current process. ?See &.3 for inspection inter%al deter)ination.A
,1!1" &ewly Installed Piping Systems or Changes
in Ser%ice
7or ne: piping s$ste)s and piping s$ste)s for :hich ser%ice
conditions are !eing changed2 one of the follo:ing )ethods
shall !e e)plo$ed to deter)ine the pro!a!le rate of
corrosion fro) :hich the re)aining :all thic'ness at the
ti)e of the ne.t inspection can !e esti)ated<
a. A corrosion rate for a piping circuit )a$ !e calculated fro) data collected !$ the
o:ner@user on piping s$ste)s of si)ilar )aterial in co)para!le ser%ice.
!. If data for the sa)e or si)ilar ser%ice are not a%aila!le2 a
corrosion rate for a piping circuit )a$ !e esti)ated fro) the
o:ner@user>s e.perience or fro) pu!lished data on piping
s$ste)s in co)para!le ser%ice.
c. If the pro!a!le corrosion rate cannot !e deter)ined !$
either )ethod listed in ite) a or ite) !2 the initial thic'ness
)easure)ent deter)inations shall !e )ade after no )ore
than 3 )onths of ser%ice !$ using nondestructi%e thic'ness
)easure)ents of the piping s$ste). Corrosion )onitoring
de%ices2 such as corrosion coupons or corrosion pro!es2 )a$
!e useful in esta!lishing the ti)ing of these thic'ness )easure)ents.
Su!se8uent )easure)ents shall !e )ade after
appropriate inter%als until the corrosion rate is esta!lished.
,1!1# 7:isting Piping Systems
Corrosion rates shall !e calculated on either a short-ter) or
a long-ter) !asis.
If calculations indicate that an inaccurate rate of corrosion
has !een assu)ed2 the rate to !e used for the ne.t period shall !e ad=usted to agree :ith
the actual rate found.
,1" -A<I-3- ALL;=A8L7 =;(>I&?
PRE))URE DETER.INATION
#he )a.i)u) allo:a!le :or'ing pressure ?(A4PA for
the continued use of piping s$ste)s shall !e esta!lished using
the applica!le code. Co)putations )a$ !e )ade for 'no:n
e)aining *ife ?$earsA tactua( tre8uired O
corrosion rate
Minches ?))A per $earP
------------------------------------------------------------------------------- D
Corrosion rate ?*#A tinitia( tactua( O
ti)e ?$earsA !et:een
-------------------------------------------------- D
Corrosion rate ?S#A tpre2ious tactua( O
ti)e ?$earsA !et:een
-------------------------------------------------- D
91
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+-2 API "+9
)aterials if all the follo:ing essential details are 'no:n to
co)pl$ :ith the principles of the applica!le code<
a. 0pper and@or lo:er te)perature li)its for specific
)aterials.
!. Qualit$ of )aterials and :or')anship.
c. Inspection re8uire)ents.
d. einforce)ent of openings.
e. An$ c$clical ser%ice re8uire)ents.
7or un'no:n )aterials2 co)putations )a$ !e )ade
assu)ing the lo:est grade )aterial and =oint efficienc$ in the
applica!le code. 4hen the (A4P is recalculated2 the :all
thic'ness used in these co)putations shall !e the actual thic'ness
as deter)ined !$ inspection ?see ".& for definitionA
)inus t:ice the esti)ated corrosion loss !efore the date of
the ne.t inspection ?see &.3A. Allo:ance shall !e )ade for the
other loadings in accordance :ith the applica!le code. #he
applica!le code allo:ances for pressure and te)perature
%ariations fro) the (A4P are per)itted pro%ided all of the
associated code criteria are satisfied.
#a!le +-1 contains t:o e.a)ples of calculations of (A4P
illustrating the use of the corrosion half-life concept.
,1# (7@3I(7. /HIC>&7SS .7/7(-I&A/I;&
#he re8uired thic'ness of a pipe shall !e the greater of the pressure design thic'ness or
the structural )ini)u) thic'ness.
7or ser%ices :ith high ris'2 the piping engineer should
consider increasing the re8uired thic'ness to pro%ide for
unanticipated or un'no:n loadings2 or undisco%erd )etal
loss.
,14 ASS7SS-7&/ ;9 I&SP7C/I;& 9I&.I&?S
Pressure containing co)ponents found to ha%e degradation that could affect their load
carr$ing capa!ilit$ ?pressure loads and other applica!le loads2 e.g.2 :eight2 :ind2 etc.2 per
API P "+6A shall !e e%aluated for continued ser%ice. 7itness-forser%ice techni8ues2 such
as those docu)ented in API P "+62 )a$ !e used for this e%aluation. #he fitness-for-
ser%ice techni8ues used )ust !e applica!le to the specific degradation o!ser%ed. #he
follo:ing techni8ues )a$ !e used as applica!le<
a. #o e%aluate )etal loss in e.cess of the corrosion allo:ance2 a fitness-for-ser%ice
assess)ent )a$ !e perfor)ed in accordance :ith one of the follo:ing sections of
API P "+6. #his assess)ent re8uires the use of a future corrosion allo:ance2 :hich
shall !e esta!lished2 !ased on Section +.1 of this inspection code.
1. Assess)ent of General (etal *ossFAPI P "+62
Section 4.
2. Assess)ent of *ocal (etal *ossFAPI P "+62 Section
".
3. Assess)ent of Pitting CorrosionFAPI P "+62 Section
&.
!. #o e%aluate !listers and la)inations2 a fitness-for-ser%ice
assess)ent should !e perfor)ed in accordance :ith API P "+62 Section +. In so)e
cases2 this e%aluation :ill re8uire the use of a future corrosion allo:ance2 :hich shall
!e esta!lished2 !ased on Section +.1 of this inspection code.
c. #o e%aluate :eld )isalign)ent and shell distortions2 a fitness for ser%ice assess)ent
should !e perfor)ed in accordance :ith API P "+62 Section ,.
d. #o e%aluate crac'-li'e fla:s2 a fitness for ser%ice assess)ent should !e perfor)ed in
accordance :ith API P "+62 Section 6.
e. #o e%aluate the effects of fire da)age2 a fitness for ser%ice assess)ent should !e
perfor)ed in accordance :ith API P "+62 Section 11.
+." PIPIBG S#-SS ABA*ISIS
Piping )ust !e supported and guided so that ?aA its :eight
is carried safel$2 ?!A it has sufficient fle.i!ilit$ for ther)al
e.pansion or contraction2 and U it does not %i!rate e.cessi%el$.
Piping fle.i!ilit$ is of increasing concern the larger
the dia)eter of the piping and the greater the difference
!et:een a)!ient and operating te)perature conditions.
Piping stress anal$sis to assess s$ste) fle.i!ilit$ and support
ade8uac$ is not nor)all$ perfor)ed as part of a piping
inspection. 5o:e%er2 )an$ e.isting piping s$ste)s :ere anal$zed
as part of their original design or as part of a rerating or
)odification2 and the results of these anal$ses can !e useful
in de%eloping inspection plans. 4hen une.pected )o%e)ent
of a piping s$ste) is o!ser%ed2 such as during an e.ternal
%isual inspection ?see ".4.3A2 the inspector should discuss
these o!ser%ations :ith the piping engineer and e%aluate the
need for conducting a piping stress anal$sis.
Piping stress anal$sis can identif$ the )ost highl$ stressed
co)ponents in a piping s$ste) and predict the ther)al )o%e)ent
of the s$ste) :hen it is placed in operation. #his infor)ation
can !e used to concentrate inspection efforts at the
locations )ost prone to fatigue da)age fro) ther)al e.pansion
?heat-up and cool-do:nA c$cles and@or creep da)age in
high-te)perature piping. Co)paring predicted ther)al
)o%e)ents :ith o!ser%ed )o%e)ents can help identif$ the
occurrence of une.pected operating conditions and deterioration
of guides and supports. Consultation :ith the piping
engineer )a$ !e necessar$ to e.plain o!ser%ed de%iations
fro) the anal$sis predictions2 particularl$ for co)plicated
s$ste)s in%ol%ing )ultiple supports and guides !et:een end
points.
Piping stress anal$sis also can !e e)plo$ed to help sol%e
o!ser%ed piping %i!ration pro!le)s. #he natural fre8uencies
in :hich a piping s$ste) :ill %i!rate can !e predicted !$
anal$sis. #he effects of additional guiding can !e e%aluated to
assess its a!ilit$ to control %i!ration !$ increasing the s$s-
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H7 IB-S-/IC- PIPIBG SIS#-(S +-3
#a!le +-1F#:o -.a)ples of the Calculation of (a.i)u) Allo:a!le 4or'ing Pressure
?(A4PA Illustrating the 0se
of the Corrosion 5alf-*ife Concept
-.a)ple 1<
3esign pressure@te)perature "99 psig@ 499N7 ?344+ 'Pa@294NCA
Pipe description BPS 1&2 standard :eight2 A 19&-1
Hutside dia)eter of pipe2 3 1& in. ?49& ))A
Allo:a!le stress 292999 psi ?13+2699 'PaA
*ongitudinal :eld
efficienc$2 -
1.9
#hic'ness deter)ined fro) inspection 9.32 in. ?,.13 ))A
H!ser%ed corrosion rate
?see +.1.1A
9.91 in.@$r. ?9.2"4 ))@$r.A
Be.t planned inspection " $rs.
-sti)ated corrosion loss !$ date of inspection D " : 9.91 D 9.9" in. ?" : 9.2"4 D
1.2+ ))A
(A4P D 2S-t@3
In 0.S. units
In S.I. units
Conclustion< HE
-.a)ple 2<
Be.t planned inspection + $rs.
-sti)ated corrosion loss !$ date of ne.t inspection D + : 9.91 D 9.9+ in. ?+ :
9.2"4 D 1.+, ))A
(A4P D 2S-t@3
In 0.S. units
In S.I units
Conclusion< (ust reduce inspection inter%al or deter)ine that nor)al operating pressure
:ill not e.ceed this ne: (A4P during
the se%eth $ear2 or rene: the piping !efore the se%enth $ear.
Bote<
1. psig D pounds per s8uare inch gauge; psi D pounds per s8uare inch
2. #he for)ula for (A4P is fro) AS(- 131.32 -8uation 3!2 :here t D corroded
thic'ness
2 29999 2 ? A 1.9 ? A V V 9.32 2 9.9" A A V ? O ? V
1&
---------------------------------------------------------------------------------------------------
--- ""9psig D
2 13+ 699 2 ? A V 1.9 ? A V ,.13 ? V 2 1.2+A A V ? O M
49&
---------------------------------------------------------------------------------------------------
--------- 3+4+'Pa D
2 29999 2 ? A 1.9 ? A V V 9.32 2 9.9+ A A V ? O ? V
1&
---------------------------------------------------------------------------------------------------
--- 4"9psig D
2 13+ 699 2 ? A V 1.9 ? A V ,.13 ? V 2 1.+,A A V ? O M
49&
---------------------------------------------------------------------------------------------------
--------- 3194'Pa D #1
--,,,,,,,,,,,,,,,,,--,,,,,,,---
+-4 API "+9
te)>s natural fre8uencies !e$ond the fre8uenc$ of e.citing
forces2 such as )achine rotational speed. It is i)portant to
deter)ine that guides added to control %i!ration do not
ad%ersel$ restrict ther)al e.pansion.
+.& -PH#IBG AB3 -CH3S 7H PIPIBG
)4)TE. IN)PECTION
An$ significant increase in corrosion rates shall !e
reported to the o:ner@user for appropriate action.
#he o:ner@user shall )aintain appropriate per)anent and
progressi%e records of each piping s$ste) co%ered !$ API
"+9. #hese records shall contain pertinent data such as piping
s$ste) ser%ice; classification; identification nu)!ers; inspection
inter%als; and docu)ents necessar$ to record the na)e of
the indi%idual perfor)ing the testing2 the date2 the t$pes of
testing2 the results of thic'ness )easure)ents and other tests2
inspections2 repairs ?te)porar$ and per)anentA2 alterations2
or rerating. 3esign infor)ation and piping dra:ings )a$ !e
included. Infor)ation on )aintenance acti%ities and e%ents
affecting piping s$ste) integrit$ also should !e included. #he date and results of re8uired
e.ternal inspections shall !e recorded. ?See API P "+4 for guidance on piping
inspection records.A
#he use of a co)puter-!ased s$ste) for storing2 calculating2
and anal$zing data should !e considered in %ie: of the
%olu)e of data that :ill !e generated as part of a piping
testpoint progra). Co)puter progra)s are particularl$ useful for the follo:ing< a.
Storing the actual thic'ness readings. !. Calculating short- and long-ter) corrosion rates2
retire)ent dates2 (A4P2 and reinspection inter%als on a test-point !$ test-point !asis.
c. 5ighlighting areas of high corrosion rates2 circuits o%erdue for inspection2 circuits
close to retire)ent thic'ness2 and other infor)ation.
d. 7itness-for-ser%ice assess)ent docu)entation re8uire)ents
are descri!ed in API P "+62 Section 2.,. Specific
docu)entation re8uire)ents for the t$pe of fla: !eing
assessed are pro%ided in the appropriate section of API P
"+6.
Algorith)s for the anal$sis of data fro) entire circuits also
)a$ !e included in the progra). Care should !e ta'en to
ensure that the statistical treat)ent of circuit data results in
predictions that accuratel$ reflect the actual condition of the
piping circuit.
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,-1
SECIO! 4"#EP*I#S3 *LE#*IO!S3 *!$ #E#*I!) OF PIPI!)
S/SE5S
,.1 -PAIS AB3 A*#-A#IHBS
#he principles of AS(- 131.3 or the code to :hich the
piping s$ste) :as !uilt shall !e follo:ed.
,.1.1 Authorization
All repair and alteration :or' )ust !e done !$ a repair
organization as defined in Section 3 and )ust !e authorized
!$ the inspector prior to its co))ence)ent. Authorization
for alteration :or' to a piping s$ste) )a$ not !e gi%en :ithout prior consultation :ith2
and appro%al !$2 the piping engineer.
#he inspector :ill designate an$ inspection hold points
re8uired during the repair or alteration se8uence. #he inspector
)a$ gi%e prior general authorization for li)ited or routine
repairs and procedures2 pro%ided the inspector is satisfied
:ith the co)petenc$ of the repair organization.
,.1.2 Appro%al
All proposed )ethods of design2 e.ecution2 )aterials2
:elding procedures2 e.a)ination2 and testing )ust !e
appro%ed !$ the inspector or !$ the piping engineer2 as appropriate.
H:ner@user appro%al of on-strea) :elding is re8uired.
4elding repairs of crac's that occurred in-ser%ice should
not !e atte)pted :ithout prior consultation :ith the piping
engineer in order to identif$ and correct the cause of the
crac'ing. -.a)ples are crac's suspected of !eing caused !$
%i!ration2 ther)al c$cling2 ther)al e.pansion pro!le)s2 and
en%iron)ental crac'ing.
#he inspector shall appro%e all repair and alteration :or'
at designated hold points and after the repairs and alterations
ha%e !een satisfactoril$ co)pleted in accordance :ith the
re8uire)ents of API "+9.
,.1.3 4elding epairs ?Including Hn-Strea)A
,.1.3.1 #e)porar$ epairs
7or te)porar$ repairs2 including on-strea)2 a full encircle)ent
:elded split slee%e or !o.-t$pe enclosure designed
!$ the piping engineer )a$ !e applied o%er the da)aged or
corroded area. *ongitudinal crac's shall not !e repaired in
this )anner unless the piping engineer has deter)ined that
crac's :ould not !e e.pected to propagate fro) under the
slee%e. In so)e cases2 the piping engineer :ill need to consult :ith a fracture anal$st.
If the repair area is localized ?for e.a)ple2 pitting or pinholesA
and the specified )ini)u) $ield strength ?S(ISA of
the pipe is not )ore than 492999 psi ?2+"2,99 'PaA2 and a fitness-
for-ser%ice anal$sis sho:s it>s accepta!le2 a te)porar$
repair )a$ !e )ade !$ fillet :elding a properl$ designed
split coupling or plate patch o%er the pitted or locall$ thinned
area. ?See ,.2.3 for deisng consideration and Appendi. C for
an e.a)ple.A #he )aterial for the repair shall )atch the !ase
)etal unless appro%ed !$ the piping engineer. A fillet-:elded
patch shall not !e installed on top of an e.isting fillet-:elded
patch. 4hen installing a fillet-:elded patch ad=acent to an
e.isting fillet-:elded patch2 the )ini)u) distance !et:een
the toe of the fillet-:elded shall not !e less than<
:here
d D the )ini)u) distance !et:een the toes of fillet
:elds of ad=acent fillet :eld attach)ents2 in in.
?))A2
D the inside radius in in. ?))A.
t D the )ini)u) re8uired thic'ness of the fillet:elded
patch in in. ?))A.
7or )inor lea's2 properl$ designed enclosures )a$ !e
:elded o%er the lea' :hile the piping s$ste) is in-ser%ice2
pro%ided the inspector is satisfied that ade8uate thic'ness
re)ains in the %icinit$ of the :eld and the piping co)ponent
can :ithstand :elding :ithout the li'elihood of further )aterial da)age2 such as fro)
caustic ser%ice.
#e)porar$ repairs should !e re)o%ed and replaced :ith a
suita!le per)anent repair at the ne.t a%aila!le )aintenance
opportunit$. #e)porar$ repairs )a$ re)ain in place for a
longer period of ti)e onl$ if appro%ed and docu)ented !$
the piping engineer.
,.1.3.2 Per)anent epairs
epairs to defects found in piping co)ponents )a$ !e )ade !$ preparing a :elding
groo%e that co)pletel$ re)o%es the defect and then filling the groo%e :ith :eld )etal
deposited in accordance :ith ,.2.
Corroded areas )a$ !e restored :ith :eld )etal deposited
in accordance :ith ,.2. Surface irregularities and conta)ination
shall !e re)o%ed !efore :elding. Appropriate B3-
)ethods shall !e applied after co)pletion of the :eld.
If it is feasi!le to ta'e the piping s$ste) out of ser%ice2 the
defecti%e area )a$ !e re)o%ed !$ cutting out a c$lindrical
section and replacing it :ith a piping co)ponent that )eets
the applica!le code.
Insert patches ?flush patchesA )a$ !e used to repair da)aged
or corroded areas if the follo:ing re8uire)ents are )et<
a. 7ull-penetration groo%e :elds are pro%ided.
!. 7or Class 1 and Class 2 piping s$ste)s2 the :elds shall !e 199 percent
radiographed or ultrasonicall$ tested using B3- procedures that are
appro%ed !$ the inspector.
c. Patches )a$ !e an$ shape !ut shall ha%e rounded corners
M1 inch ?2" ))A )ini)u) radiusP.
,.1.4 Bon:elding epairs ?Hn-Strea)A
#e)porar$ repairs of locall$ thinned sections or circu)ferential
linear defects )a$ !e )ade on-strea) !$ installing a
properl$ designed and applied enclosure ?e.g. !olted cla)p2
d 4 t D
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Pro%ided !$ I5S under license :ith API *icenseeDChe%ron
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,-2 API "+9
non)etalic co)posite :rap2 )etallic and epo.$ :raps2 or
other non-:elded applied te)porar$ repairA. #he design shall
include control of a.ial thrust loads if the piping co)ponent
!eing cla)ped is ?or )a$ !eco)eA insufficient to control
pressure thrust. #he effect of cla)ping ?crushingA forces on
the co)ponent also shall !e considered.
3uring turnarounds or other appropriate opportunities2
te)porar$ lea' sealing and lea' dissipating de%ices2 including
%al%es2 shall !e re)o%ed and appropriate actions ta'en to
restore the original integrit$ of the piping s$ste). #he inspector
and@or piping engineer shall !e in%ol%ed in deter)ining
repair )ethods and procedures.
Procedures that include lea' sealing fluids ?Jpu)pingKA for
process piping should !e re%ie:ed for acceptance !$ the
inspector or piping engineer. #he re%ie: should ta'e into consideration the co)pati!ilit$
of the sealant :ith the lea'ing )aterial; the pu)ping pressure on the cla)p ?especiall$
:hen repu)pingA; and an$ resulting crushing forces; and the ris' of sealant affecting
do:nstrea) flo: )eters2 relief %al%es2 or )achiner$; the ris' of su!se8uent lea'age at
!olt threads causing corrosion or stress corrosion crac'ing of !olts; and the nu)!er of
ti)es the seal area is repu)ped.
,.2 4-*3IBG AB3 5H# #APPIBG
All repair and alteration :elding shall !e done in accordance
:ith the principles of AS(- 131.3 or the code to
:hich the piping s$ste) :as !uilt.
An$ :elding conducted on piping co)ponents in operation
)ust !e done in accordance :ith API Pu!l 2291. #he
inspector shall use as a )ini)u) the JSuggested 5ot #ap
Chec'listK contained in API Pu!lication 2291 for hot tapping perfor)ed on piping
co)ponents.
,.2.1 Procedures2 Qualifications2 and ecords
#he repair organization shall use :elders and :elding procedures
8ualified in accordance :ith AS(- 131.3 or the
code to :hich the piping :as !uilt.
#he repair organization shall )aintain records of :elding
procedures and :elder perfor)ance 8ualifications. #hese
records shall !e a%aila!le to the inspector prior to the start of
:elding.
,.2.2 Preheating and Post:eld 5eat #reat)ent
,.2.2.1 Preheating
Preheat te)perature used in )a'ing :elding repairs shall !e in
accordance :ith the applica!le code and 8ualified :elding procedure.
-.ceptions for te)porar$ repairs )ust !e appro%ed !$ the piping
engineer.
Preheating to not less than 399N7 ?1"9NCA )a$ !e considered
as an alternati%e to post:eld heat treat)ent ?P45#A for
alterations or repairs of piping s$ste)s initiall$ post:eld heat
treated as a code re8uire)ent ?see noteA. #his applies to piping
constructed of the P-1 steels listed in AS(- 131.3. P-3
steels2 :ith the e.ception of (n-(o steels2 also )a$ recei%e
the 399N7 ?1"9NCA )ini)u) preheat alternati%e :hen the
piping s$ste) operating te)perature is high enough to pro%ide reasona!le toughness and
:hen there is no identifia!le hazard associated :ith pressure testing2 shutdo:n2 and
startup.
#he inspector should deter)ine that the )ini)u) preheat
te)perature is )easured and )aintained. After :elding2
the =oint should i))ediatel$ !e co%ered :ith insulation to
slo: the cooling rate.
Bote< Preheating )a$ not !e considered as an alternati%e to en%iron)ental crac'ing
pre%ention.
Piping s$ste)s constructed of other steels initiall$ re8uiring
P45# nor)all$ are post:eld heat treated if alterations or
repairs in%ol%ing pressure retaining :elding are perfor)ed.
#he use of the preheat alternati%e re8uires consultation :ith
the piping engineer :ho should consider the potential for
en%iron)ental crac'ing and :hether the :elding procedure
:ill pro%ide ade8uate toughness. -.a)ples of situations
:here this alternati%e could !e considered include seal :elds2 :eld )etal !uildup of thin
areas2 and :elding support clips.
,.2.2.2 Post:eld 5eat #reat)ent
P45# of piping s$ste) repairs or alterations should !e
)ade using the applica!le re8uire)ents of AS(- 131.3 or
the code to :hich the piping :as !uilt. See ,.2.2.1 for an
alternati%e preheat procedure for so)e P45# re8uire)ents.
-.ceptions for te)porar$ repairs )ust !e appro%ed !$ the
piping engineer.
*ocal P45# )a$ !e su!stituted for 3&9-degree !anding
on local repairs on all )aterials2 pro%ided the follo:ing precautions and re8uire)ents are
applied<
a. #he application is re%ie:ed2 and a procedure is de%eloped
!$ the piping engineer.
!. In e%aluating the suita!ilit$ of a procedure2 consideration
shall !e gi%en to applica!le factors2 such as !ase )etal thic'ness2
ther)al gradients2 )aterial properties2 changes resulting
fro) P45#2 the need for full-penetration :elds2 and surface
and %olu)etric e.a)inations after P45#. Additionall$2 the
o%erall and local strains and distortions resulting fro) the
heating of a local restrained area of the piping :all shall !e
considered in de%eloping and e%aluating P45# procedures.
c. A preheat of 399N7 ?1"9NCA2 or higher as specified !$ specific :elding
procedures2 is )aintained :hile :elding.
d. #he re8uired P45# te)perature shall !e )aintained for a distance of
not less than t:o ti)es the !ase )etal thic'ness )easured fro) the
:eld. #he P45# te)perature shall !e
)onitored !$ a suita!le nu)!er of ther)ocouples ?a )ini)u) of t:oA
!ased on the size and shape of the area !eing heat treated.
e. Controlled heat also shall !e applied to an$ !ranch connection or other
attach)ent :ithin the P45# area.
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H7 IB-S-/IC- PIPIBG SIS#-(S ,-3
f. #he P45# is perfor)ed for code co)pliance and not for
en%iron)ental crac'ing resistance.
,.2.3 3esign
1utt =oints shall !e full-penetration groo%e :elds.
Piping co)ponents shall !e replaced :hen repair is li'el$
to !e inade8uate. Be: connections and replace)ents shall !e
designed and fa!ricated according to the principles of the
applica!le code. #he design of te)porar$ enclosures and
repairs shall !e appro%ed !$ the piping engineer.
Be: connections )a$ !e installed on piping s$ste)s pro%ided
the design2 location2 and )ethod of attach)ent confor)
to the principles of the applica!le code.
7illet-:elded patches re8uire special design considerations2
especiall$ relating to :eld-=oint efficienc$ and cre%ice
corrosion. 7illet-:elded patches shall !e designed !$ the piping
engineer. A patch )a$ !e applied to the e.ternal surfaces
of piping2 pro%ided it is in accordance :ith ,.1.3 and )eets
either of the follo:ing re8uire)ents<
a. #he proposed patch pro%ides design strength e8ui%alent to a reinforced
opening designed according to the applica!le code.
!. #he proposed patch is designed to a!sor! the )e)!rane
strain of the part in a )anner that is in accordance :ith the
principles of the applica!le code2 if the follo:ing criteria are
)et<
" The a((o#a1(e /e/1rane stress is not e0ceeded in the
piping part or the patch.
% The strain in the patch does not resu(t in 9i((et #e(d
stresses e.ceeding allo:a!le stresses for such :elds.
! An o2er(a: patch sha(( ha2e rounded corners ;see
Appendi. CA.
,.2.4 (aterials
#he )aterials used in )a'ing repairs or alterations shall !e of 'no:n
:elda!le 8ualit$2 shall confor) to the applica!le code2 and shall !e
co)pati!le :ith the original )aterial. 7or )aterial %erification
re8uire)ents2 see ".,.
,.2." Bondestructi%e -.a)ination
Acceptance of a :elded repair or alteration shall include
B3- in accordance :ith the applica!le code and the o:ner@
user>s specification2 unless other:ise specified in API "+9.
,.2.& Pressure #esting
After :elding is co)pleted2 a pressure test in accordance
:ith ".+ shall !e perfor)ed if practical and dee)ed necessar$
!$ the inspector. Pressure tests are nor)all$ re8uired after
alterations and )a=or repairs. 4hen a pressure test is not necessar$
or practical2 B3- shall !e utilized in lieu of a pressure
test. Su!stituting appropriate B3- procedures for a pressure
test after an alteration2 rerating2 or repair )a$ !e done onl$
after consultation :ith the inspector and the piping engineer.
7or e.isting insultated lines that are !eing pressure tested
after repairs2 rerating2 or alteration2 it is not necessar$ to strip
insulation on all e.isting :elds. Pressure test :ith longer hold
ti)es and o!ers%ations of pressure gauges can !e su!stituted
for insulation stripping :hen the ris's associted :ith lea's
under the insulation are accepta!le.
4hen it is not practical to perfor) a pressure test of a final
closure :eld that =oins a ne: or replace)ent section of piping to an e.isting s$ste)2 all
of the follo:ing re8uire)ents shall !e satisfied<
a. #he ne: or replace)ent piping is pressure tested and e.a)ined in
accordance :ith the applica!le code go%erning the design of the piping
s$ste)2 or if not practical2 :elds are
e.a)ined :ith appropriate B3-2 as specified !$ the authorized piping
inspector.
!. #he closure :eld is a full-penetration !utt-:eld !et:een
an$ pipe or standard piping co)ponent or straight sections of
pipe of e8ual dia)eter and thic'ness2 a.iall$ aligned ?not
)iter cutA2 and of e8ui%alent )aterials. Accepta!le alternati%es
are< ?1A slip-on flanges for design cases up to Class 1"9
and "99N72 ?2&9NCA and ?2A soc'et :elded flanges or soc'et
:elded unions for sizes BPS 2 or less and design cases up to
Class 1"9 and "99N7 ?2&9NCA. A spacer designed for soc'et
:elding or so)e other )eans shall !e used to esta!lish a )ini)u)
1@1& inch ?1.& ))A gap. Soc'et :elds shall !e per
AS(- 131.3 and shall !e a )ini)u) of t:o passes.
c. An$ final closure !utt-:eld shall !e of 199-percent radiographic
8ualit$; or angle-!ea) ultrasonic fla: detection )a$
!e used2 pro%ided the appropriate acceptance criteria ha%e
!een esta!lished.
d. (# or P# shall !e perfor)ed on the root pass and the
co)pleted :eld for !utt-:elds and on the co)pleted :eld for fillet-:elds.
#he o:ner@user shall specif$ industr$-8ualified 0# shear
:a%e e.a)iners for closure :elds that ha%e not !een pressure
tested and for :eld repairs identified !$ the piping engineer
or authorized piping inspector. #he re8uire)ent for use of
industr$-8ualified 0# shear :a%e e.a)iners !eco)es effecti%e t:o $ears after
pu!lication in this code or addendu).
,.3 -A#IBG
erating piping s$ste)s !$ changing the te)perature rating
or the (A4P )a$ !e done onl$ after all of the follo:ing
re8uire)ents ha%e !een )et<
a. Calculations are perfor)ed !$ the piping engineer or the
inspector.
!. All reratings shall !e esta!lished in accordance :ith the
re8uire)ents of the code to :hich the piping s$ste) :as !uilt or !$
co)putation using the appropriate )ethods in the latest edition of the
applica!le code.
c. Current inspection records %erif$ that the piping s$ste) is
satisfactor$ for the proposed ser%ice conditions and that the
appropriate corrosion allo:ance is pro%ided.
91
9&
93
9&
9&
93
93
--,,,,,,,,,,,,,,,,,--,,,,,,,---
,-4 API "+9
d. erated piping s$ste)s shall !e lea' tested in accordance
:ith the code to :hich the piping s$ste) :as !uilt or the latest
edition of the applica!le code for the ne: ser%ice
conditions2 unless docu)ented records indicate a pre%ious
lea' test :as perfor)ed at greater than or e8ual to the test
pressure for the ne: condition. An increase in the rating te)perature that does not affect
allo:a!le tensile stress does not re8uire a lea' test.
e. #he piping s$ste) is chec'ed to affir) that the re8uired
pressure relie%ing de%ices are present2 are set at the appropriate pressure2 and
ha%e the appropriate capacit$ at set pressure.
f. #he piping s$ste) rerating is accepta!le to the inspector
or piping engineer.
g. All piping co)ponents in the s$ste) ?such as %al%es2
flanges2 !olts2 gas'ets2 pac'ing2 and e.pansion =ointsA are
ade8uate for the ne: co)!ination of pressure and
te)perature.
h. Piping fle.i!ilit$ is ade8uate for design te)perature
changes.
i. Appropriate engineering records are updated.
=. A decrease in )ini)u) operating te)perature is =ustified
!$ i)pact test results2 if re8uired !$ the applica!le code.
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6-1
SECIO! 6"I!SPECIO! OF 7(#IE$ PIPI!)
Inspection of !uried process piping ?not regulated !$ the
3epart)ent of #ransportationA is different fro) other process
piping inspection !ecause significant e.ternal deterioration
can !e caused !$ corrosi%e soil conditions. Since the inspection
is hindered !$ the inaccessi!ilit$ of the affected areas of
the piping2 the inspection of !uried piping is treated in a separate
section of API "+9. I)portant2 non)andator$ references
for underground piping inspection are the follo:ing BAC-
docu)ents< P91&62 P92+42 and P92+"; and Section 11 of API P &"1.
6.1 #IP-S AB3 (-#5H3S H7 IBSP-C#IHB
6.1.1 A!o%e-Grade /isual Sur%eillance
Indications of lea's in !uried piping )a$ include a change
in the surface contour of the ground2 discoloration of the soil2
softening of pa%ing asphalt2 pool for)ation2 !u!!ling :ater
puddles2 or noticea!le odor. Sur%e$ing the route of !uried
piping is one )ethod of identif$ing pro!le) areas.
6.1.2 Close-Inter%al Potential Sur%e$
#he close-inter%al potential sur%e$ perfor)ed at ground le%el o%er the !uried pipe can !e
used to locate acti%e corrosion points on the pipe>s surface.
Corrosion cells can for) on !oth !are and coated pipe
:here the !are steel contacts the soil. Since the potential at
the area of corrosion :ill !e )easura!l$ different fro) an
ad=acent area on the pipe2 the location of the corrosion acti%it$ can !e deter)ined !$ this
sur%e$ techni8ue.
6.1.3 Pipe Coating 5olida$ Sur%e$
#he pipe coating holida$ sur%e$ can !e used to locate
coating defects on !uried coated pipes2 and it can !e used on
ne:l$ constructed pipe s$ste)s to ensure that the coating is
intact and holida$-free. (ore often it is used to e%aluate coating
ser%icea!ilit$ for !uried piping that has !een in-ser%ice
for an e.tended period of ti)e.
7ro) sur%e$ data2 the coating effecti%eness and rate of
coating deterioration can !e deter)ined. #his infor)ation
is used !oth for predicting corrosion acti%it$ in a specific
area and for forecasting replace)ent of the coating for corrosion control.
6.1.4 Soil esisti%it$
Corrosion of !are or poorl$ coated piping is often
caused !$ a )i.ture of different soils in contact :ith the
pipe surface. #he corrosi%eness of the soils can !e deter)ined
!$ a )easure)ent of the soil resisti%it$. *o:er le%els
of resisti%it$ are relati%el$ )ore corrosi%e than higher
le%els2 especiall$ in areas :here the pipe is e.posed to significant changes in soil
resisti%it$.
(easure)ents of soil resisti%it$ should !e perfor)ed
using the 4enner 7our-Pin (ethod in accordance :ith
AS#( G"+. In cases of parallel pipes or in areas of intersecting
pipelines2 it )a$ !e necessar$ to use the Single-Pin
(ethod to accuratel$ )easure the soil resisti%it$. 7or )easuring
resisti%it$ of soil sa)ples fro) auger holes or e.ca%ations2
a soil !o. ser%es as a con%enient )eans for o!taining
accurate results.
#he depth of the piping shall !e considered in selecting the
)ethod to !e used and the location of sa)ples. #he testing
and e%aluation of results should !e perfor)ed !$ personnel
trained and e.perienced in soil resisti%it$ testing.
<"' Cathodic Protection .onitoring
Cathodicall$ protected !uried piping should !e )onitored
regularl$ to assure ade8uate le%els of protection. (onitoring
should include periodic )easure)ent and anal$sis of pipe-tosoil
potentials !$ personnel trained and e.perienced in cathodic
protection s$ste) operation. (ore fre8uent )onitoring of critical
cathodic protection co)ponents2 such as i)pressed current
rectifiers2 is re8uired to ensure relia!le s$ste) operation.
efer to BAC- P91&6 and Section 11 of API P &"1 for
guidance applica!le to inspecting and )aintaining cathodic
protection s$ste)s for !uried piping.
6.1.& Inspection (ethods
Se%eral inspection )ethods are a%aila!le. So)e )ethods
can indicate the e.ternal or :all condition of the piping2
:hereas other )ethods indicate onl$ the internal condition.
-.a)ples are as follo:s<
a. Intelligent pigging. #his )ethod in%ol%es the )o%e)ent
of a de%ice ?pigA through the piping either :hile it is in-ser%ice
or after it has !een re)o%ed fro) ser%ice. Se%eral t$pes
of de%ices are a%aila!le e)plo$ing different )ethods of
inspection. #he line to !e e%aluated )ust !e free fro) restrictions
that :ould cause the de%ice to stic' :ithin the line. 7i%e
dia)eter !ends are usuall$ re8uired since standard 69-degree
pipe ells )a$ not pass a pig. #he line )ust also ha%e facilities
for launching and reco%ering the pigs.
!. /ideo ca)eras. #ele%ision ca)eras are a%aila!le that can
!e inserted into the piping. #hese ca)eras )a$ pro%ide %isual
inspection infor)ation on the internal condition of the line.
c. -.ca%ation. In )an$ cases2 the onl$ a%aila!le inspection
)ethod that can !e perfor)ed is unearthing the piping in order
to %isuall$ inspect the e.ternal condition of the piping and to
e%aluate its thic'ness and internal condition using the )ethods
discussed in ".4.2. Care should !e e.ercised in re)o%ing soil
fro) a!o%e and around the piping to pre%ent da)aging the
line or line coating. #he last fe: inches ?))A of soil should !e
re)o%ed )anuall$ to a%oid this possi!ilit$. If the e.ca%ation
is sufficientl$ deep2 the sides of the trench should !e properl$
--,,,,,,,,,,,,,,,,,--,,,,,,,---
6-2 API "+9
shored to pre%ent their collapse2 in accordance :ith HS5A
regulations2 :here applica!le. If the coating or :rapping is
deteriorated or da)aged2 it should !e re)o%ed in that area to
inspect the condition of the underl$ing )etal.
9.2 FRE!E"#$ %"& E'TE"T (F I"S)E#TI("
6.2.1 A!o%e-Grade /isual Sur%eillance
#he o:ner@user should2 at appro.i)atel$ &-)onth inter%als
sur%e$ the surface conditions on and ad=acent to each
pipeline path ?see 6.1.1A.
6.2.2 Pipe-to-Soil Potential Sur%e$
A close-inter%al potential sur%e$ on a cathodicall$ protected
line )a$ !e used to %erif$ that the !uried piping has a
protecti%e potential throughout its length. 7or poorl$ coated
pipes :here cathodic protection potentials are inconsistent2
the sur%e$ )a$ !e conducted at "-$ear inter%als for %erification of continuous corrosion
control.
7or piping :ith no cathodic protection or in areas :here
lea's ha%e occurred due to e.ternal corrosion2 a pipe-to-soil
potential sur%e$ )a$ !e conducted along the pipe route. #he
pipe should !e e.ca%ated at sites :here acti%e corrosion cells ha%e !een located to
deter)ine the e.tent of corrosion da)age.
A continuous potential profile or a close-inter%al sur%e$
)a$ !e re8uired to locate acti%e corrosion cells.
6.2.3 Pipe Coating 5olida$ Sur%e$
#he fre8uenc$ of pipe coating holida$ sur%e$s is usuall$
!ased on indications that other for)s of corrosion control are
ineffecti%e. 7or e.a)ple2 on a coated pipe :here there is
gradual loss of cathodic protection potentials or an e.ternal
corrosion lea' occurs at a coating defect2 a pipe coating holida$ sur%e$ )a$ !e used to
e%aluate the coating.
6.2.4 Soil Corrosi%it$
7or piping !uried in lengths greater than 199 feet ?39 )A
and not cathodicall$ protected2 e%aluations of soil corrosi%it$
should !e perfor)ed at "-$ear inter%als. Soil resisti%it$ )easure)ents
)a$ !e used for relati%e classification of the soil
corrosi%it$ ?see 6.1.4A. Additional factors that )a$ :arrant
consideration are changes in soil che)istr$ and anal$ses of the polarization resistance of
the soil and piping interface.
6.2." Cathodic Protection
If the piping is cathodicall$ protected2 the s$ste)
should !e )onitored at inter%als in accordance :ith Section
19 of BAC- P91&6 or Section 11 of API P &"1.
<%5 E0terna( and Interna( Inspection Inter2a(s
If internal corrosion of !uried piping is e.pected as a
result of inspection on the a!o%e-grade portion of the line2
inspection inter%als and )ethods for the !uried portion
should !e ad=usted accordingl$. #he inspector should !e
a:are of and consider the possi!ilit$ of accelerated internal
corrosion in deadlegs.
#he e.ternal condition of !uried piping that is not cathodicall$ protected should !e
deter)ined !$ either pigging2 :hich can )easure :all thic'ness2 or !$ e.ca%ating
according to the fre8uenc$ gi%en in #a!le 6-1. Significant e.ternal corrosion detected !$
pigging or !$ other )eans )a$ re8uire e.ca%ation and e%aluation e%en if the piping is
cathodicall$ protected.
Piping inspected periodicall$ !$ e.ca%ation shall !e
inspected in lengths of & feetO, feet ?2.9 )O2." )A at one or
)ore locations =udged to !e )ost suscepti!le to corrosion.
-.ca%ated piping should !e inspected full circu)ference for
the t$pe and e.tent of corrosion ?pitting or generalA and the
condition of the coating.
If inspection re%eals da)aged coating or corroded piping2
additional piping shall !e e.ca%ated until the e.tent of the
condition is identified. If the a%erage :all thic'ness is at or
!elo: retire)ent thic'ness2 it shall !e repaired or replaced.
If the piping is contained inside a casing pipe2 the condition
of the casing should !e inspected to deter)ine if :ater
and@or soil has entered the casing. #he inspector should %erif$ the follo:ing< ?aA !oth
ends of the casing e.tend !e$ond the ground line; ?!A the ends of the casing are sealed if
the casing is not self-draining; and2 U the pressure-carr$ing pipe is properl$ coated and
:rapped.
6.2.+ *ea' #esting Inter%als
An alternati%e or supple)ent to inspection is lea' testing
:ith li8uid at a pressure at least 19 percent greater than )a.i)u)
operating pressure at inter%als one-half the length of
those sho:n in #a!le 6-1 for piping not cathodicall$ protected
and at the sa)e inter%als as sho:n in #a!le 6-1 for cathodicall$
protected piping. #he lea' test should !e )aintained for
a period of , hours. 7our hours after the initial pressurization
of the piping s$ste)2 the pressure should !e noted and2 if necessar$2
the line repressurized to original test pressure and isolated
fro) the pressure source. If2 during the re)ainder of the
test period2 the pressure decreases )ore than " percent2 the
piping should !e %isuall$ inspected e.ternall$ and@or
inspected internall$ to find the lea' and assess the e.tent of
corrosion. Sonic )easure)ents )a$ !e helpful in locating
lea's during lea' testing.
1uried piping also )a$ !e sur%e$ed for integrit$ !$ using
te)perature-corrected %olu)etric or pressure test )ethods.
#a!le 6-1F7re8uenc$ of Inspection for 1uried Piping
4ithout -ffecti%e Cathodic Protection
Soil esisti%it$ ?oh)-c)A Inspection Inter%al ?$earsA
W 22999 "
22999 to 192999 19
192999 1"
--,,,,,,,,,,,,,,,,,--,,,,,,,---
H7 IB-S-/IC- PIPIBG SIS#-(S 6-3
Hther alternati%e lea' test )ethods in%ol%e acoustic e)ission e.a)ination and the
addition of a tracer fluid to the pressurized line ?such as heliu) or sulfur he.aflorideA. If
the tracer is added to the ser%ice fluid2 the o:ner@user shall confir) suita!ilit$ for process
and product.
9.3 RE)%IRS T( B!RIE& )I)I"* S$STEMS
!.3.1 Repairs to Coatings
An$ coating re)o%ed for inspection shall !e rene:ed and
inspected appropriatel$.
7or coating repairs2 the inspector should !e assured that
the coating )eets the follo:ing criteria<
a. It has sufficient adhesion to the pipe to pre%ent underfil)
)igration of )oisture.
!. It is sufficientl$ ductile to resist crac'ing.
c. It is free of %oids and gaps in the coating ?holida$sA.
d. It has sufficient strength to resist da)age due to handling
and soil stress.
e. It can support an$ supple)ental cathodic protection.
In addition2 coating repairs )a$ !e tested using a high-
%oltage holida$ detector. #he detector %oltage shall !e
ad=usted to the appropriate %alue for the coating )aterial and
thic'ness. An$ holida$s found shall !e repaired and retested.
!.3.3 Cla5p Repairs
If piping lea's are cla)ped and re!uried2 the location of the cla)p shall !e logged in the
inspection record and )a$ !e surface )ar'ed. 1oth the )ar'er and the record shall note
the date of installation and the location of the cla)p. All cla)ps shall !e considered
te)porar$. #he piping should !e per)anentl$ repaired at the first opportunit$.
6.3.3 4elded epairs
4elded repairs shall !e )ade in accordance in ,.2.
9.+ RE#(R&S
ecord s$ste)s for !uried piping should !e )aintained in
accordance :ith +.&. In addition2 a record of the location and
date of installation of te)porar$ cla)ps shall !e )aintained
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--,,,,,,,,,,,,,,,,,--,,,,,,,---
A5!
*PPE!$I0 *"I!SPECO# CE#IFIC*IO!
A.1 -.a)ination
A :ritten e.a)ination to certif$ inspectors :ithin the
scope of API "+9 shall !e !ased on the current API "+9
Inspector Certification 1od$ of Eno:ledge as pu!lished !$
API.
A.2 Certification
An API "+9 authorized piping inspector certification :ill
!e issued :hen an applicant has successfull$ passed the API
"+9 certification e.a) and satisfies the criteria for e.perience and education. 5is@her
education and e.perience2 :hen co)!ined2 shall !e e8ual to at least one of the follo:ing<
a. A 1achelor of Science degree in engineering or technolog$2
plus one $ear of e.perience in super%ision of inspection
acti%ities or perfor)ance of inspection acti%ities as descri!ed
in API "+9.
!. A t:o $ear degree or certificate in engineering or technolog$2 plus t:o $ears of
e.perience in the design2 construction2 repair2 inspection2 or operation of piping
s$ste)s2 of :hich on $ear )ust !e in super%ision of inspection acti%ities or
perfor)ance of inspection acti%ities as descri!ed in API "+9.
c. A high school diplo)a or e8ui%alent2 plus three $ears of e.perience in the design2
construction2 repair2 inspection2 or operation of piping s$ste)s2 of :hich one $ear
)ust !e in
super%ision of inspection acti%ities or perfor)ance of inspection acti%ities as
descri!ed in API "+9.
d. A )ini)u) of fi%e $ears of e.perience in the design2 construction2 repair2 inspection2
or operation of piping s$ste)s2 of :hich on $ear )ust !e in super%ision of inspection
acti%ities or perfor)ance of inspection acti%ities as descri!ed in API "+9.
A.3ecertification
-.3.1 ecertification is re8uired three $ears fro) the date
of issuance of the API "+9 authorized piping inspector certificate.
ecertification !$ :ritten e.a)ination :ill !e re8uired
for authorized piping inspectors :ho ha%e not !een acti%el$
engaged as authorized piping inspectors :ithin the )ost
recent three-$ear certification period and for authorized piping inspectors :ho ha%e not
pre%iousl$ passed the e.a).
-.a)s :ill !e in accordance :ith all pro%isions contained in
API "+9.
%.3.2 =Acti2e(: engaged as an authori&ed piping inspector>
shall !e defined as a )ini)u) of 29T of ti)e spent perfor)ing
inspection acti%ities or super%ision of inspection
acti%ities2 or engineering support of inspection acti%ities2 as
descri!ed in the API "+9 o%er the )ost recent three $ear certification period.
Bote< Inspection acti%ities co))on to other API inspection docu)ents ?B3-2
record'eeping2 re%ie:2 of :elding docu)ents2 etc.A )a$ !e considered here.
-.3.3 Hnce e%er$ other recertification period2 ?e%er$ si.
$earsA inspectors acti%el$ engaged as an authorized piping
inspector shall de)onstrate 'no:ledge of re%isions to API
"+9 that :ere instituted during the pre%ious si. $ears. #his
re8uire)ent shall !e effecti%e si. $ears fro) the inpector>s
initial certification date. Inspectors :ho ha%e not !een
acti%el$ engaged as an authorized piping inspector :ithin the
)ost recent three-$ear certification period shall recertif$ as
re8uired in A.3.1.
9&
9&
9&
99
9&
Corp@"6123,,199
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85!
*PPE!$I0 7"EC8!IC*L I!.(I#IES
3" Introduction
API :ill consider :ritten re8uests for interpretations of
API "+9. API staff :ill )a'e such interpretations in :riting
after consultation2 if necessar$2 :ith the appropriate co))ittee
officers and the co))ittee )e)!ership. #he API co))ittee
responsi!le for )aintaining API "+9 )eets regularl$ to
consider :ritten re8uests for interpretations and re%isions2
and to de%elop ne: criteria as dictated !$ technological
de%elop)ent. #he co))ittee>s acti%ities in this regard are
li)ited strictl$ to interpretations of the latest edition of API
"+9 or to the consideration of re%isions to API "+9 !ased on
the ne: data or technolog$.
As a )atter of polic$2 API does not appro%e2 certif$2 rate2
or endorse an$ ite)2 construction2 proprietar$ de%ice2 or
acti%it$; and accordingl$2 in8uiries re8uiring such consideration
:ill !e returned. (oreo%er2 API does not act as a consultant
on specific engineering pro!le)s or on the general
understanding or application of the rules. If2 !ased on the
in8uir$ infor)ation su!)itted2 it is the opinion of the co))ittee that the in8uirer should
see' engineering or technical assistance2 the in8uir$ :ill !e returned :ith the
reco))endation that such assistance !e o!tained.
All in8uiries that do not pro%ide the infor)ation needed
for full understanding :ill !e returned.
1.2 In8uir$ 7or)at
In8uiries shall !e li)ited strictl$ to re8uests for interpretation of the latest edition of API
"+9 or to the consideration of re%isions to API "+9 !ased on ne: data or technolog$.
In8uiries shall !e su!)itted in the follo:ing for)at<
a. ScopeF#he in8uir$ shall in%ol%e a single su!=ect or
closel$ related su!=ects. An in8uir$ letter concerning unrelated su!=ects :ill !e
returned.
!. 1ac'groundF#he in8uir$ letter shall state the purpose of
the in8uir$2 :hich shall !e either to o!tain an interpretation of API "+9 or to propose
consideration of a re%ision to API "+9. #he letter shall pro%ide concisel$ the
infor)ation needed for co)plete understanding of the in8uir$ ?:ith s'etches2 as
necessar$A
and include references to the applica!le edition2
re%ision2 paragraphs2 figures2 and ta!les.
c. In8uir$F#he in8uir$ shall !e stated in a condensed and
precise 8uestion for)at2 o)itting superfluous !ac'ground
infor)ation and2 :here appropriate2 co)posed in such a
:a$ that J$esK or JnoK ?perhaps :ith pro%isosA :ould !e a
suita!le repl$. #his in8uir$ state)ent should !e technicall$
and editoriall$ correct. #he in8uirer shall state :hat he or
she !elie%es API "+9 re8uires. If in the opinion of the
in8uirer a re%ision to API "+9 is needed2 the in8uirer shall
pro%ide reco))ended :ording.
Su!)it the in8uir$ in t$pe:ritten for); ho:e%er2 legi!l$
hand:ritten in8uiries :ill !e considered. Include the na)e
and the )ailing address of the in8uirer. Su!)it the proposal
to the follo:ing address< director of the Standards 3epart)ent2 A)erican Petroleu)
Institute2 1229 * Street2 B.4.2 4ashington2 3.C. 2999"2 )&%(-%+-)B%p#1'+0.
7.3 ec9nical In:uiry #esponses
esponses to pre%ious technical in8uires can !e found on
the API :e!site at 3&&pOII$'..#&&**)1%p#1'+0I)&%(-%+-)I&*$3I
inde..ht)l.
91
9&
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C5!
*PPE!$I0 C"E0*5PLES OF #EP*I#S
C.1 epairs
(anual :elding utilizing the gas )etal-arc or shielded
)etal-arc processes )a$ !e used.
4hen the te)perature is !elo: "9N7 ?19NCA2 lo:-h$drogen
electrodes2 A4S --GG1& or --GG1,2 shall !e used
:hen :elding )aterials confor)ing to AS#( A-"32 Grades
A and 1; A-19&2 Grades A and 1; A-333; A-334; API "*;
and other si)ilar )aterial. #hese electrodes should also !e
used on lo:er grades of )aterial :hen the te)perature of the
)aterial is !elo: 32N7 ?9NCA. #he piping engineer should !e
consulted for cases in%ol%ing different )aterials.
4hen A4S --GG1& or --GG1, electrodes are used on
:eld nu)!ers 2 and 3 ?see 7igure C-1 !elo:A2 the !eads shall
!e deposited !$ starting at the !otto) of the asse)!l$ and
:elding up:ard. #he dia)eter of these electrodes should not
e.ceed "@32 inch ?4.9 ))A. -lectrodes larger that "@32 inch
?4.9 ))A )a$ !e used on :eld nu)!er 1 ?see 7igure C-1A2
!ut the dia)eter should not e.ceed 3@1& inch ?4., ))A.
#he longitudinal :elds ?nu)!er 12 7igure C-1A on the
reinforcing slee%e shall !e fitted :ith a suita!le tape or )ild
steel !ac'ing strip ?see noteA to a%oid fusing the :eld to the
side :all of the pipe.
Bote< If the original pipe along :eld nu)!er 1 has !een chec'ed thoroughl$ !$ ultrasonic
)ethods and it is of sufficient thic'ness for :elding2 a !ac'ing strip is not necessar$.
All repair and :elding procedures for on-strea) lines
)ust confor) to API Pu!l 2291.
C.2 S)all epair Patches
#he dia)eter of electrodes should not e.ceed "@32 inch ?4.9 ))A. 4hen the te)perature of
the !ase )aterial is !elo: 32N7 ?9NCA2 lo:-h$drogen electrodes shall !e used. 4ea%ing of
:eld !eads deposited :ith lo:-h$drogen electrodes should !e a%oided.
All repair and :elding procedures for on-strea) lines
)ust confor) to API Pu!lication 2291.
-.a)ples of s)all repair patches are sho:n !elo: in
7igure C-2.
7igure C-1F-ncircle)ent epair Slee%e
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C5" API 5,%
9igure C5"ASmall (epair Patches
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.5!
*PPE!$I0 $"E0E#!*L I!SPECIO! C8EC;LIS FO# P#OCESS
PIPI!)
3.1 -.ternal Inspection Chec'list for
Process Piping
Pu!lication #itle X
3ate Inspected
Ite) Inspected 1$ Status
a. *ea's.
1. Process.
2. Stea) #racing.
3. -.isting Cla)ps.
!. (isalign)ent.
1. Piping )isalign)ent@restricted )o%e)ent.
2. -.pansion =oint )isalign)ent.
c. /i!ration.
1. -.cessi%e o%erhung :eight.
2. Inade8uate support.
3. #hin2 s)all-!ore2 or allo$ piping.
4. #hreaded connections.
". *oose supports causing )etal :ear.
d. Supports.
1. Shoes off support.
2. 5anger distortion or !rea'age.
3. 1otto)ed-out springs.
4. 1race distortion@!rea'age.
". *oose !rac'ets.
&. Slide plates@rollers.
+. Counter !alance condition.
,. Support corrosion.
e. Corrosion.
1. 1olting support points under cla)ps.
2. Coating@Painting deterioration.
3. Soil-to-air interface.
4. Insulation interfaces.
". 1iological gro:th.
f. Insulation.
1. 3a)age@penetrations.
2. (issing =ac'eting@insulation.
3. Sealing deterioration.
4. 1ulging.
". 1anding ?!ro'en@)issingA.
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9&@9&
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Additional copies are available through IHS
Phone Hrders< 1-,99-,"4-+1+6 ?#oll-free in the 0.S. and CanadaA
393-36+-+6"& ?*ocal and InternationalA
7a. Hrders< 393-36+-2+49
Hnline Hrders< glo!al.ihs.co)
Infor)ation a!out API Pu!lications2 Progra)s and Ser%ices
#) %5%#"%!"* '( &3* 4*! %& www(api(org
1229 * Street2 B4
4ashington2 3C 2999"-49+9
0SA
202168218000 Product Bo. C",99"
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Piping Inspection Code

Inspection, Repair, Alteration, and

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