PROCEDURE FOR INSPECTION OF PIPING

VISUAL INSPECTION
External visual inspections are performed to determine the external
condition of piping, insulation system, painting/coating systems and
associated hardware to check for signs of misalignment, vibration, and
leakage.

1. LEAKS
Leaks can be safety or fire hazards, they can cause the premature
shutdowns of equipment, and they often result in economic loss. Frequent
visual surveillance are carried out for leaks. Particular attention is given to
flanged joints, packing glands, bonnet of valves and expansion joints.

2. MISALINGNMENT
Piping network is inspected for misalignment, which may be indicated by
the following conditions:
 Piping dislodged from one or more supports so that its weight is not
being properly distributed on the remaining hangers or saddles.
 The deformation of a vessel in the vicinity of a piping attachment.
 Piping supports forced out of plumb by expansion or contraction of
piping.
If significant piping misalignment is discovered, workscope and
maintenance notes are prepared for prompt correction.

3. SUPPORTS
Pipe supports consists of shoes, hangers (chains, rods or support springs)
and braces. Supports are visually inspected for
 Deterioration of protective coatings or fire proofing.
 Evidence of corrosion, especially at or near the foundation
attachments.
 Distortion
 General physical damage
 Movement or deterioration of concrete footings
 Failure or loosening of foundation bolts
 Insecure attachments of brackets and beams to the supports
 Insecure attachment or improper adjustment of pipe hangers

4. VIBRATION
If vibration or swaying is observed, welds are inspected for cracks,
particularly at points of restraint, such as areas where piping is attached
to equipment and near anchors.

5. EXTERNAL CORROSION & CUI

External inspection of insulated piping systems includes a review of the
integrity of the insulation system for conditions that could lead to
corrosion under insulation (CUI) and for signs of ongoing CUI. Sources of
moisture may include rain, water leaks, condensation, and deluge
systems.
For painted pipelines, condition of the paint is monitored for deterioration.
The complete pipe length is visually inspected for presence of all kinds of
external corrosion mechanisms especially in the areas where the pipe
comes into contact with the supports and near welds for deterioration in
the HAZ area.

THICKNESS MEASUREMENTS
Thickness monitoring with the aid of ultrasonic thickness meter is carried
out at numerous locations on the entire length of the pipe under
inspection. Readings of thickness in HAZ area, offshoot sections, stub-
ends, injection points and deadlegs are especially taken.
The inspection engineer is responsible for the taking the thickness
measurements

THICKNESS MEASUREMENT LOCATIONS (TMLs/CMLs)

Each piping system shall be monitored by taking thickness measurements
at TMLs. TMLs should be distributed appropriately throughout each piping
circuit. TMLs may be eliminated or the number reduced under certain
circumstances, such as clean non-corrosive hydrocarbon product, or high
alloy piping for product purity.

Usually 04 Nos. locations all around the pipe distributed circumferentially

(900 from each other) are monitored in one TML. The intermittent distance
between subsequent TMLs varies between 2 – 5 feet depending upon the
size and length of the pipe.

OTHER NDE METHODS

These include; radiography and liquid penetrant methods of welded joints
and offshoots. These are usually employed in shutdown/refinery
turnaround.

INSPECTION FREQUENCY/INTERVALS
An inspection plan is available to schedule the next inspection of a
particular piping system which is set to be five years from a particular
inspection date. The execution of the plan might be disturbed depending
upon various factors, which include; availability of scaffolding, removal of
insulation and the occurrence of any non-planned work/ project.

INSPECTION REPORT
Inspection findings are documented in the form of isometric sketches and
approved performas.

WORKSCOPES
Workscope, after detailed inspection, is prepared in the form of isometric
layouts and issued to the maintenance section for execution of repairs.