Chevron Thailand Exploration and Production Co.

, Ltd

Asset Integrity Team / Reliability Group

Facilities Engineering Department

AIT-P-I-001: Inspection of Process Piping

Prepared by:
Opass Vanitchagornsawat
(Asset Integrity Engineer)

Reviewed by:
Anuchai Sompakdee
(Asset Integrity Engineer)

Approved by:
Songpan Svasdikara
(Asset Integrity Team Lead)

Revision No.: 0 Copy No.00 Date: 2-May-12

 Chevron Thailand Exploration &
Production, Ltd.
AIT-P-I-001: Inspection of Process Piping

Amendment List

Revision Date Page/ Reason By

Section
0 2 May 12 All Initial release for comment OPNV
1 3 July 12 All Revised per Anuchai’s comments ATOH
2 5 July 12 All Revised per Abie’s comments APZH
 TABLE OF CONTENTS

1. PURPOSE 1

2. SCOPE 2

3. REFERENCE 3

4. DEFINITIONS 4

5. RESPONSIBILITIES 6

6. INSPECTION PERSONNEL 8

7. PROCEDURES 9
7.1 Safety 9
7.2 Piping identification 9
7.3 Piping inspection 10
7.4 Repair criteria and rejection limit 13
7.5 Inspection interval 14
7.6 Hydrostatic Testing 15

8. RECORDS AND DOCUMENTATION 16

APPENDIX A CORROSION RATE AND REMAINING LIFE CALCULATION 18

APPENDIX B MINIMUM RETIRED THICKNESS 20
APPENDIX C PROCESS PIPING CLASSIFICATION 23
APPENDIX D CORROSION CIRCUITS 25
APPENDIX E EROSION AND CORROSION/EROSION 26
APPENDIX F DETERMINATION OF THE NUMBER OF CMLs 28
APPENDIX G CHECKLIST FOR EXTERNAL INSPECTION OF PIPING 29
APPENDIX H THE PRACTICE OF CMLs 30
 Chevron Thailand Exploration &
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AIT-P-I-001: Inspection of Process Piping

1. PURPOSE
This Work Instruction shall be used by Inspectors as a guide for inspecting the existing process
piping based on recommendations found in the relevant Corrosion Control Manuals or derived
from corrosion/criticality reviews. The objective of such inspection is to confirm the mechanical
integrity of the piping. Scheduled inspection of piping is required to ensure safe and reliable
operation. It also assists in forecasting maintenance and replacement based on the measured or
estimated rate of deterioration of piping’s components.

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2. SCOPE
This document defines inspection requirements and specific responsibilities for both out-of-
service and in-service inspection of piping systems. It applies to all piping subjected to pressure or
vacuum conditions at Chevron Thailand Exploration and Production Co., Ltd (CTEP) area of
operations, including valves, fittings, supports, etc.

It does not apply to submarine piping, non-metallic piping and pipe line under seawater or to
instrumentation piping beyond the first isolation valve and shall not be used for the new
construction (Green Field). The document is not a detailed inspection manual, specific location
selective may change on case-by-case basis.

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AIT-P-I-001: Inspection of Process Piping

3. REFERENCES
1) API STD 570 Piping Inspection Code

2) API RP 574 Inspection of Piping, Tubing, Valve, and Fitting

3) API Public. 2201 Procedures for welding or Hot Tapping on Equipment Containing
Flammables

4) ASME B31.3 Chemical Plant and Petroleum Refinery Piping

5) ASME B31G Manual for Determining the Remaining Strength of Corroded Pipeline

6) ASME BPV Section V Nondestructive Testing

7) ASME Section IX Welding and Brazing Qualifications

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4. DEFINITIONS
A piping system includes all pipes and piping components e.g. flanges, elbows, reducers,
nozzles, supports, instrument connections up to first block valve, bellows, threaded nipples
if any, instrument thermowell nozzles, vents, drains etc.

CMMS: Computerized Maintenance Management System.

Process Piping: A metallic piping system which contains process fluids under pressure.
Fluids may include but are not limited to gas, condensate, produced water, hazardous fluids
used in the processing of products and hazardous waste streams.
Hydrocarbon or chemical piping located at, or associated with, a company production
facility.

External Thickness Monitoring: External thickness measurements normally performed

with, but not limited to, the NDE ultrasonic gauging instrument which may be performed
while the piping either is in-service or out-of-service. This definition coincides with the term
"On-Stream Inspection".

External Inspection: An assessment of the conditions of the piping external surfaces, such
as: insulation, coating & painting, and structures associated with the pipe such as supports and
pipe-rack.

Internal Inspection: This normally refers to, but is not limited to, an assessment of the
condition of the piping internal surfaces.

CMLs: Designated areas on piping systems where periodic examinations are conducted.
Previously, they were normally referred to as “thickness monitoring locations (TMLs).”

Corrosion Circuit: A term used to describe a section of piping of the same design and with
approximately similar corrosive conditions, taking into account the corrosive environment
(internally and externally), temperature, pressure, and the shell material.

Risk: A combination of the probability of occurrence of process piping system failure and
magnitude of the consequence of the failure.

Flammable Materials: As used in this document, includes liquids, vapors and gases,
which will support combustion. All fluids with a flammability hazard rating of four in
NFPA 704 "Identification of the Fire Hazards of Materials" should be considered either
Class 1 or 2, as defined in this document. Fluids with NFPA flammability ratings of two
or three should be considered either Class 2 or 3. Only process fluids with a NFPA
flammability rating of zero or selected fluids rated one should be considered Class 4.

Inspector: Piping inspectors shall be API 570 certified or authorized by company.

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NDT Technician: NDE Technicians who are performing and interpreting non-destructive
examinations must be certified in the method(s) used by one of the following:
- ANST Level I, II or III
- ISO 9712 level I, II or III
- NDT techs pass a CVX test from Practice of NDT Personnel Qualification

Scanning: Inspection technique used to find the thinnest thickness measurement at a

CMLs. Scanning is normally accomplished with ultrasonic measurements, but may also
be accomplished with radiography and eddy current. When accomplished with ultrasonic
measurements, scanning consists of taking several thickness measurements in the vicinity
of the CMLs, searching for localized thinning.

Suggested Corrosion Rate: The minimum corrosion rate that should be used for a circuit
when projecting minimum retired dates. Risk Based Inspection (RBI) program will use
company computerized inspection records system to select the greater of the calculated
corrosion rate or the suggested corrosion rate. This is mainly useful when corrosion rates
increase as a result of changed operation, upsets, or new service when little or no thickness
data is available. If no value is entered, a default corrosion rate is used with a value of 10
mpy (0.25 mm/y) for significant corrosion and 5 mpy (0.13 mm/y) for non-significant
corrosion.

Restricted interval (RI): A factor in company computerized inspection records system

used to shorten the length of the thickness measurement inspection interval when there is a
potential for uneven corrosion rates in the circuit/loops.

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5. RESPONSIBILITIES

5.1 Asset integrity program owner shall be responsible for:

5.1.1 Responsible to implement of the Owner User Program and ensure that resources are
adequate.

5.1.2 Provide necessary qualified people and tools to execute inspection work to follow the
RBI programs.

5.1.3 Responsible for assuring the Authorized Inspector maintains the required
qualifications/certifications. Inspection and nondestructive examination personnel
who perform inspection tasks do not have to be company personnel.

5.2 Asset integrity SME team shall be responsible for:

5.2.1 Providing technical support and fit for purpose solutions to the corrosion, inspection,
repair method and integrity challenges.

5.2.2 Evaluating inspection findings, and providing evaluation of potential repairs and
replacement.

5.2.3 Preparing required inspection, replacement, and repair scopes.

5.3 Asset integrity offshore execution team shall be responsible for:

5.3.1 Performing external and internal inspection of the piping and components in
accordance with this procedure.

5.3.2 Determining if cleaning is needed to achieve a satisfactory thorough inspection.

5.3.3 Establishing circuits and CMLs on-site.

5.3.4 Obtaining ultrasonic thickness readings of piping, valves, and fittings.

5.3.5 Physically identifying CMLs and providing a sketch of the piping marked to indicate
inspection findings and the location of findings.

5.3.6 Identifying the locations of repairs and replacements.

5.3.7 Providing an inspection report and anomaly report to meeting all requirements in this
procedure.

5.4 Asset integrity program shall be responsible for:

5.4.1 Maintain static data, historical data and repair records in Visions4.

5.4.2 Run Visions4 for planning and scheduling of piping system. This will include
generate work order of both inspection and repair scope in CMMS.
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5.4.3 Focal point to conduct Risk Assessment with the RBI group and ETC.

5.5 The FE Construction Team shall be responsible for:

5.5.1. Replacing or repairing the deteriorated piping or components.

5.5.2 Radiographic Examination.

5.6 The field operation and maintenance (O&M), and Asset team shall be responsible for:

5.6.1. Permit to work and isolate for any repairs.

5.6.2. Removal of insulation for inspection and repairs. Re-installation of insulation after
inspection and repairs are completed.

5.6.3. Facilitate and Coordinate with all related parties to achieve repair work efficiently.

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6. INSPECTION PERSONNEL
Personnel performing inspection of piping system and piping components shall be certified in
accordance with Chevron’s written Practice of NDT Personnel Qualification in the SERIP Document.
They should also have at least 3 years of experience in design, construction, repair, operation or
inspection of piping systems and qualified at least level I or higher for UT and level II or higher for
other NDT techniques. API 570 Certified inspectors shall hold valid certificates and recognized by
the Company.

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7. PROCEDURES
7.1 Safety

7.1.1 All necessary permits/clearances in accordance with CTEP Safety Regulations

shall be obtained before commencement of inspection activities.

7.1.2 Appropriate Personal Protection Equipment shall be worn in accordance with

guidelines in the CTEP Safety Regulations or according to Permit to work
requirements.

7.1.3 Proper safe access should be provided for inspection to be conducted.

7.1.4 Hammer testing shall not be carried out on live piping and tight adherent scales
shall not be removed from the pipe surface because of potential leaks.

7.2 Piping identification

7.2.1 All process piping requiring inspection shall be included in Visions4.

Inspector shall provide adequate information to precisely locate and identify the
piping.

1) To assist inspection personnel in locating and identifying piping, process piping

can be shown on isometric sketches or drawings.

2) The piping shall be identified as to process unit, service, design temperature,

design pressure, and piping design classification.
a. Where the design pressure or design temperature is unknown, the design
pressure and temperature of upstream equipment shall be used.
b. Where the piping classification for existing piping is unavailable, the
Engineering Team shall be notified so one may be developed.

3) All pertinent piping inspection information shall be indicated in inspection

documentation, such information shall include:
a. Component type (pipe, elbow, tee, valve, etc.)
b. Piping connection type (flanged, welded, screwed, etc.)
c. Piping component sizes, etc.

7.2.2 Each service shall be further subdivided into corrosion a circuit which identifies a
common corrosive environment. Each circuit shall be uniquely identified for record
keeping purposes. Factors to consider in defining a corrosion circuit are:

1) Main fluid flow from one piece of process equipment to another piece of process
equipment.

2) For mixed phase flow and certain corrosive services, where velocity effects can
cause erosion/corrosion, each different piping size can be considered as a separate
circuit.

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3) Each circuit shall contain the same piping materials except for valve internals,
orifices, etc.

7.2.3 Within each corrosion circuit CMLs shall be identified. The number and strategic
placement of these locations depends on a number of factors:

1) The higher the potential for corrosion, hazard, or risk, the more CMLs may be
selected.

2) Less complex circuits normally require fewer locations than more complex
circuits in similar service.

3) CMLs should be selected where they are easily accessible to the inspector. Care
should be taken to minimize locations where scaffolding is required, except where
it is necessary to meet other inspection location requirements.

4) Where possible CMLs shall be selected at the following locations:

a. Dead legs (a location that water is trapped or no flow) shall contain at least
one CMLs.
b. Any location where a change in fluid temperature could causes water
condensation.
- Where turbulence, changes in flow direction, or changes in velocity may
occur.
- Where two streams join within a piping circuit.
- Dissimilar material joints subject to having high galvanic corrosion.

5) As piping corrodes in a corrosion circuit and nears the retirement thickness,

additional CMLs may be added to increase the accuracy of the corrosion size and
depth measurement for maximum allowable operating pressure calculation and
corrosion rate estimation.

7.3 Piping inspection

The following provides general guidelines for the inspection of piping systems that are an
integral part of a plant or facility and are subject to internal and external pressures. Asset
Integrity Program should generate work order for PPI in CMMS approximately 3 months
in advance. The Inspector shall determine the suitable NDT technique to be applied. When
NDT personnel are employed to conduct the work, Asset integrity Supervisor should assist
the NDT personnel to co-ordinate with the maintenance planning where scaffolds,
insulation removal, power supply, etc. are required. The inspector shall specify the
specific number of thickness monitoring locations CMLs that require measurement in each
circuit before start inspection in advance and identify those CMLs that must be measured,
e.g., the CMLs associated with injection points or the CMLs that resulted in setting the
required inspection interval as a result of the previous inspection.

7.3.1 External inspection

External inspection of piping systems for either in-service or out-of-service conditions should
include visual checks on the condition of the lines and its components. A checklist is given in
Appendix F. Note: this checklist is intended as a guide for external inspection, covering
items that should be considered during inspection of piping. Inspector shall apply knowledge
and experience in the interpretation and application of the inspection findings.
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7.3.2 External corrosion

External corrosion can be a significant problem particularly in industrial and coastal areas
where sulphur oxides and chlorides are substantial. Corrosion can be serious where moisture
can gather and any protective coating or painting has broken down. Coating/painting
breakdown on paintwork, bitumen wrapping, fiberglass wrapping, etc. can be localized and is
often difficult to detect.
External corrosion on insulated piping can give rise to unexpected failures. Hence piping
surveys should be over full length. Likely places to corrode include pipe clamps, dummy
supports, pipe rest locations, near seawater front, pipes beneath leaking seawater and
industrial water piping/equipment, uninsulated low temperature pipes (sweating pipes),
broken insulation locations and etc.

7.3.3 Corrosion under insulation (CUI)

Certain areas and types of piping systems are potentially more susceptible to CUI, including
the following:
1) Areas exposed to process spills, ingress of moisture, or acid vapors.
2) Carbon steel piping systems, including those insulated for personnel protection,
operating between 10o F and 350o F. CUI is particularly aggressive where
operating temperatures cause frequent or continuous condensation and re-
evaporation of atmospheric moisture.
3) Carbon steel piping systems that normally operate in-service above 350o F but are
in intermittent service.
4) Austenitic stainless steel piping systems operating between 120oF and 400oF.
(These systems are susceptible to chloride stress corrosion cracking.)

7.3.4 Carbon Steel Piping

Premature failures have been experienced due to corrosion, erosion or a combination of both.
Corrosion frequently occurs at stagnant or low flow locations where deposits have settled e.g.
dead ends and bends. Locations where a change of direction occurs, e.g. bends, tees, reducers
can suffer local erosion by impurities or abrasives carried in the process stream. Pipe
thickness and internal condition can be determined by commonly used NDT techniques such
as ultrasonic thickness gauging and radiography.

7.3.5 Stainless Steel Piping

Corrosion rates of these pipes are generally very low. However failures can occur due to
thermal fatigue, where significant temperature differences exist, or due to aqueous chloride
or polythionic acid stress corrosion cracking. The problem areas are mostly at highly
stressed locations e.g. welds, bends, nozzles etc. Additionally Amine and Cl- stress
corrosion cracking generally threaten to this piping as well especially in stagnant locations
(e.g. drains, vents); locations where insulation is poor or broken and internal parts exposed
to atmosphere without an alkaline wash are particularly conducive to pitting corrosion.

If internally accessible, these locations should be visually inspected and or dye-penetrant

tested. If internally inaccessible, radiographic or ultrasonic inspection should be
conducted at selected locations.

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Locations under clamp-supports should be checked for crevice corrosion. If the clamped
section had not been previously painted or coating is damaged, it should be exposed
visually inspected. While dye penetrant testing shall be performed on where area is
susceptible to Chloride stress corrosion cracking.

7.3.6 Inspection at Injection Points

Potentially corrosive injection points are those that could experience highly localized
deterioration (corrosion/erosion) and led to piping failure during operation especially the
injection system fails to perform as designed. It is recommended to carry out focused
inspection on areas most susceptibility to failure. The following is guideline to monitor
thickness using UT and RT at selected locations in the potential corrosion zone.

- Defined inspection scopes for pipe & inline mixer are the same scope.
- From upstream 3D or12” whichever is greater /Downstream to10D or 25ft is
the inspection area.
- Carry out UTM WI every D
- RT one shot for checking quill.
- Inspection interval could coincide with PPI based on actual CR via RBI
process.
- 360 deg around the injection point.
- Impingement point opposite the nozzle shall be inspected.

Sketch for inspection monitoring

Injectant
stream

D
Main process stream

3D 10D

Inspection area

Note:
D = Outside diameter of main process stream.

Inspection should include examination of the injection quill or spray nozzle when possible
and confirmation that removed injection quills are reinstalled in the correct orientation. A
process to confirm and record this is done should be in place.

When the NDT technician and inspector confirms that corrosion rates have changed
significantly in injection point circuits, that fact shall be immediately reported to asset
integrity team, assets engineer and operations for appropriate corrective action.

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7.3.8 Inspection of Dead-legs

Inspections should include profile radiography on small diameter dead-legs, such as vents
and drains, and ultrasonic or radiography on larger diameter dead-legs.

7.3.9 Localized Erosion-Corrosion

Areas of localized erosion-corrosion should be inspected using visual inspection internally

if possible or by using profile radiography. Scanning of the areas with ultrasonic is also a
good technique and should be used if the line is larger than 8" NPS.

7.3.10 Small bore piping

Small bore piping should be inspected down to the block valve that is normally used in
operations. Inspections should include profile radiography on small diameter where UT is
not practical. While either ultrasonic or radiography should be applied on larger diameter.
When vibration is observed, MT and PT should be applied on the suspected weld joint.

7.4 Repair criteria and rejection limit

Generally, the acceptable condition of an existing piping system should be such that the
remaining corrosion allowance can last till the next planned shutdown based on the
calculated rate of corrosion.

If the wall of piping has thinned below the minimum required thickness (The minimum
required thickness is the greater value of the pressure design thickness or the structural
minimum thickness, See Appendix B), the affected area may be reviewed for fitness-for-
purpose for the maximum allowable operating pressure using applicable codes or
standards. In such cases, AI engineer shall approve recommendations for continued
operation.

A list of repair or replacement recommendations which impact pressure equipment

integrity is required and shall be kept current. The recommendation tracking system shall
include:
- Recommended corrective action, repaired location and repair date shall be
specified in Visons4 and CMMS.
- Actual work done and completed date shall updated in Visons4 and CMMS
immediately after repair work is completed.

7.4.1 When in the judgment of the Inspection Authority, conditions in the piping exist
which would render it unfit or unsafe for continued service, the identified piping shall
be either repaired or replaced. Such conditions include, but are not limited to, the
following:

1) Consumption of the corrosion allowance as determined by engineering

calculations or applicable code requirements and identified by the thickness
monitoring program.

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2) Excessive pitting which may lead to penetration of the piping wall and result in
leakage of its contents.
3) Sufficient deterioration of the piping material properties as to render it unfit which
may be caused by one or more of the following: graphitization, embitterment,
creep, hydrogen attack, etc.
4) Mechanical factors in the piping system which may result in excessive cyclic or
steady state stresses beyond code allowances in piping components. Such
conditions may arise from excessive piping movement, insufficient pipe support,
improper design, etc.
5) Environmental cracking caused by such substances as caustics, hydrogen sulfide,
amines, chlorides, etc.

7.4.2 The piping service life may be extended beyond its allowable limit only if an
engineering analysis of the piping verifies that its life can safely be extended. The
extension shall be acceptable to and approved by the authorized inspector and AI
Engineer. The analysis shall recommend a maximum life extension interval or new
minimum wall thickness limit. This analysis shall be documented and included in
Visons4 and CMMS.

7.4.3 Whenever possible, piping repair or replacement should be identified with sufficient
lead time to allow for a scheduled maintenance outage to perform the work.

7.4.4 Temporary and permanent repairs shall be performed and inspected in accordance
with the requirements of API 570 and the approved welding procedure specifications.
No welding should be carried out on any piping unless approval of CTEP QA/QC
team and AI Engineer. MOC is always required for temporary repair and permanent
repair may be required as per MOC procedure.

7.4.5 Each CMLs in Visions4 shall have a minimum required thickness.

7.5 Inspection interval

For inspection of piping, the thickness data obtained shall be entered into RBI system.
Comparison should be made against those obtained at previous two consecutive
shutdowns/OSI where available. Where thicknesses are found to be reduced, more
measurements should be taken both up and downstream of the monitored points. From a
review of these inspection results, the Inspector should then add new or delete inspection
points/sketches, as appropriate.

API 570 sets the recommended maximum inspection intervals for thickness measurements
and visual external inspections for piping systems. Shorter or longer intervals may be
dictated by corrosion rates, jurisdictional requirements, and risk based inspection (RBI).

The inspection interval shall be established using the lesser value of the following criteria:

1. Corrosion rate and remaining life calculation (See Appendix A)

2. Risk Based Inspection assessment (See Vision 4)
3. Piping service classification as in API_570 (See Appendix A)

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Thickness measurements should be scheduled based on the calculation of not more than half
the remaining life determined from corrosion rates and the maximum interval suggested in
Appendix A.

7.6 Hydrostatic Testing

Replacement and repaired piping should normally be tested at 1.5 times the design pressure
based on corrosion condition. Where the design pressure is not known, the piping class
design limit at ambient temperature should be used (e.g. class 150#, 300#, 600# etc.).
When testing a piping system or when testing with other equipment as a system, the test
pressure shall be not greater than 1.5 times the design pressure of the weakest component
in the system.

In circumstances when a hydrostatic test is not practical, an alternative test is permitted

such as Pneumatic test (see PIM-PU-5284), subject to the approval of the Authorized
Inspector and AI Engineer. Golden weld procedure shall be applied.

Test medium shall be water for general carbon steel pipe. While piping fabricated of or
having components of 300 series stainless steel should be hydrotested with a solution made
up of potable water, de-ionized/de-mineralized water or steam condensate having a total
chloride concentration of less than 50 ppm. Holding time shall not less than 30 minutes or
per codes.

Prior to final acceptance of the piping, inspection and test results shall be reviewed and
approved by the inspector to assure appropriate quality has been maintained and all the
inspection requirements of the applicable codes and standards have been met.

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8. RECORDS AND DOCUMENTATION

Piping inspection findings (all sketches, photographs, results and reports of NDT),
recommendations and actions taken shall be recorded in Visions4. While any recommendation for
repair or replace shall be recorded into CMMS.

For piping, which is replaced, a set of thickness data should be obtained on the new piping as base
measurements for future calculation of corrosion rates.

All records on the piping systems shall be kept until the piping is permanently removed from
service.

8.1 Piping Circuit Information

The following information should be recorded for each piping circuit on which CMLs are
located:
a) Pipe material or piping class
b) operating and design pressures and temperatures
c) ANSI flange rating
d) process fluids
e) whether the circuit is a dead-leg, injection point, intermittent service, or other
special circuit
f) the corrosion rate and remaining service life
g) maximum interval for external inspection
h) maximum interval for thickness measurement inspection
i) any unusual or localized corrosion mode that would require specialized
inspection techniques
j) Particular circuit features that might subject it to rapid corrosion increases in
the event of a process upset or loss of injection fluid flow.

In most cases, much of the above information will be the same for all circuits in a system
and may be recorded at the system level rather than requiring duplication for each circuit.

To prevent discrepancies, CMLs information shall be recorded in RBI Visions4 Program.

8.2 Inspection Isometric Drawings (ISOs)

The primary purpose of inspection ISOs is to identify the location of CMLs and to identify
the location of any recommended maintenance.

Inspection ISOs should contain the following:

a) all significant components of the piping system (e.g., all valves, elbows, tees,
branches, etc.)
b) all CMLs
c) adequate orientation information
d) piping system and circuit numbers and changes
e) Continuation drawing numbers.

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Inspection ISOs do not need to be drawn to scale or show dimensions unless necessary to
locate CMLs.

8.3 Piping Failure and Leak Reports

Leaks and failures (including recommendations and action taken if any) in piping that
occur as a result of corrosion, cracking and etc. must be reported and recorded as part of
the leak recording requirement in Visions4. As with other pressure equipment failures,
leaks and failures in piping systems must be investigated to identify and correct the cause
of failure. Temporary repairs to piping systems shall also follow the requirement of CTEP
MOC process.

All thickness data should be entered into the records, analyzed for corrosion rates and
inspection interval adjustments, and validated, as necessary, within 30 working days of
being measured by the data taker unless high priority issues.

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APPENDIX A

CORROSION RATE AND REMAINING LIFE CALCULATION

1. The long-term (LT) corrosion rate shall be calculated from

tinitial −tlast
LT corrosion rate =
time (year)between tlast and tinitial

2. The short-term (ST) corrosion rate shall be calculated from:

tprevious −tlast
ST Corrosion rate =
time (year)between tlast and tprevious

3. The remaining life of piping shall be calculated from:

tlast −trequire
Remaining life =
Selected corrosion rate

The selected corrosion rate shall be determined from the maximum value whether LT or ST, that best
reflects the current process.

Where:
t initial = The piping original wall thickness before service.

t last = The piping wall thickness at time of last inspection.

t previous = The piping wall thickness at time of previous inspection.

t required = the greater value of the pressure design thickness (MAWP) or the structural
minimum thickness.

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Recommended Maximum Inspection Intervals (API570)

Pipe Class Thickness Measurement External Visual Inspection

Class 1 5 Years 5 Years
Class 2 10 Years 5 Years
Class 3 10 Years 10 Years
Class 4 > 10 Years (Arbitrary) > 10 Years (Arbitrary)

Class 1: Services with highest potential of resulting in an immediate emergency if a leak were
to occur.
1. Flammable services that may rapidly auto-refrigerate and lead to brittle fracture.
2. Pressure services that may rapidly vaporize during release, creating vapors that
may collect and form an explosive mixture, such as C 2 , C 3, and C 4 streams.

Class 2: Services include the majority of unit process piping and selected offsite piping.
1. On-site hydrocarbon that will slowly vaporize during release.
2. Hydrogen, fuel gas, and natural gas.

Class 3: Services that are flammable but do not significantly vaporize when they leak and are
not located in high-activity areas, such as on-site hydrocarbons that will not
significantly vaporize during release.

Class 4: Process and utility services which are essentially non-flammable or non-toxic e.g.
air, nitrogen, steam, lube oil.

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APPENDIX B

MINIMUM RETIRED THICKNESS

Pressure design thickness for piping

The pressure design thickness shall be calculated using Barlow formula:

PD
t =
2(SE+PY)

Where:

t = the pressure design thickness for internal pressure, in inches

P = the internal design gauge pressure of the pipe, in pounds per square inch
D = the OD of the pipe, in inches
S = the allowable unit stress at the design temperature, in pounds per square inch
E = Quality Factors for Longitudinal Weld Joints in Pipes from table A-1B of
B31.3
Y = coefficient from Table 304.1.1 of B31.3, valid for t < D/6 and for materials
shown. The value of Y may be interpolated for intermediate temperatures.

Structural minimum thickness for piping

Practical Wall Limits for Carbon and Low Alloy Steel Piping

Nominal Pipe Size Alert Thickness Required

(NPS) T-min Thickness

Inches (mm) Inches (mm)

0.5 0.08 (2.0) 0.07 (1.8)
0.75 0.08 (2.0) 0.07 (1.8)
1 0.08 (2.0) 0.07 (1.8)
1.5 0.09 (2.3) 0.08 (2.0)
2 0.10 (2.5) 0.08 (2.0)
3 0.11 (2.8) 0.08 (2.0)
4 0.12 (3.1) 0.09 (2.3)
6 0.13 (3.3) 0.11 (2.8)
8 0.13 (3.3) 0.11 (2.8)
10-18 0.13 (3.3) 0.11 (2.8)
20-24 0.14 (3.6) 0.12 (3.1)

Table 1 Retired Thickness of piping from Structure Force

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Table 1 generally applies to piping systems fabricated from carbon steel, low alloy steels, and
chromium molybdenum alloy steels. Any piping systems which operate beyond the
pressure/temperature ratings for these flange classes or above 650°F require that the retired
thickness be calculated in accordance with the applicable code. This table does not typically apply
to valves, cast pipe, cast fittings, austenitic stainless steel, high alloy components, or non-standard
fittings.

Minimum retired thickness requirements for threaded connections under 1" NPS should be
evaluated by engineering if significant corrosion is detected. Circumstances may be such that
these components will need to be upgraded to schedule 160 or to welded components. As a
general rule, the minimum retired thicknesses in Table 1 also apply to the unthreaded portion of
threaded pipe.

For areas of external corrosion of considerable size, in which the circumferential stresses govern,
or for widely scattered external pits, the principles of API-570, API579 or ASME B31G regarding
area averaging, may be applied.

Pressure design thickness for valve

The formula to be used for calculation of the minimum allowable thickness of carbon steel and
alloy steel valves and fitting shall be a modification of Barlow’s formula (API570)

PDx1.5
t =
2S
Where:
t = Minimum Allowable Thickness (MAT)
P = Design Pressure or Maximum Allowable Working Pressure
S = Allowable Stress based on temperature as show in ASME Code

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Structural minimum thickness for Valves

Minimum Wall Thickness of Valves and Fittings to be used where

calculation results in a smaller values of Carbon and Low Alloy
Steel materials
Outside Minimum Allowable Minimum Allowable
Diameter Thickness Thickness
(Inches) t-min t-min

Operating Temperature Operating Temperature

Below 450F Above 450F
2.99” and below 0.10” (2.54 mm) 0.13” (3.30mm)
3.00” to 3.99” 0.11”(2.79 mm) 0.14” (3.56mm)
4.00” to 4.99” 0.12”(3.05mm) 0.15” (3.81mm)
5.00” to 5.99” 0.13” (3.30mm) 0.16” (4.06mm)
6.00” to 7.99” 0.15” (3.81mm) 0.18” (4.57mm)
8.00” to 9.99” 0.17” (4.32mm) 0.20” (5.08mm)
10.00” to 11.99” 0.19” (4.83mm) 0.22” (5.59mm)
12.00” and over 0.21” (5.34mm) 0.24” (6.10mm)

Table 2 Retired Thickness of Valves and Fittings from Structure Force

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APPENDIX C

PROCESS PIPING CLASSIFICATION

Process piping systems are classified into four classes for the purposes of establishing maximum
visual external inspection and thickness monitoring frequencies.

This classification system shall take into account the hazards associated with the fluid contained in
the Piping system, and any other factors that Asset Integrity Team may deem relevant.

Process piping systems shall be classified in accordance with the piping service classes described
in API 570 Para 6.2. There are three classes: Class 1, Class 2, and Class 3.

Proper classification of piping systems may require input from specialists, AI Engineer in the
fields of Safety, Environmental Conservation, Process and/or Engineering Materials.

If increased inspection of a particular piping system is desired for operating or reliability reasons,
the extent of inspection and inspection interval may be altered, but the classification shall not be
changed.

A fourth piping service class designated Class 4 is added to the three classes described in API 570
Para 6.2. Class 4 is intended to provide a means to classify utility services piping. Class 4 piping
shall be designated as follows:

Class 4 - Process and utility services which are essentially non-flammable or non-toxic.
Typical examples of Class 4 services include:
1) steam and steam condensate
2) air
3) nitrogen
4) water, including boiler feed water, stripped sour water
5) lube oil, seal oil, heat transfer oil
6) ANSI B 31.3 category D services
7) plumbing and sewers

Certain process piping systems may be exempted from the thickness monitoring requirements of this
Practice, at the discretion of the Asset Integrity Team, Operations and Process Engineer provided that
the piping system is not considered critical and has the following characteristics:

1) Extremely low potential for creating a safety or environmental emergency in the event of a
leak.
2) Non corrosive system, as demonstrated by history or similar service, and the system is not
subject to changes that could cause future corrosion.

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PIPING CLASSIFICATION LOGIC DIAGRAM

Utility Service Yes Class 4

No

Process leaks normally considered Yes Class 4

Non-hazardous (Process fluid 150 F and flash
Point 400 F)

No

Service has a high likelihood Yes Class 1

Of causing an environmental or health
Related emergency if a small leak occurs

No

Vapors from a leak may collect Yes Class 1

And result in an explosive mixture

No

Small leak may auto-refrigerate Yes Class 1

And leave piping system vulnerable
To a brittle fracture

No

Off-site line which operates Yes Class 3

Below the boiling point, but May
Still be flammable

No

Process unit line which will Yes Class 2

Significantly vaporize after leakage

No

Class 3

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APPENDIX D

CORROSION CIRCUITS

1 The prime objective of the Corrosion Circuits is to provide information on the

deterioration rate, corrosion mechanism of the selected locations and also to reduce
shutdown inspection activities wherever feasible. The Corrosion Engineer in consultation
with the Inspector determines selection of piping registration and monitoring points. In the
selection process, the following factors should be considered:

a) Process Stream
This should include Pressure, Temperature, Flow Velocity, Corrosivity, Erosivity,
Phase separation, Phase change, Toxicity and any other factor deemed relevant.

b) Piping System
Material of construction and its reaction with the process medium/media.

c) Consequence
Consequence of failure.

d) Service Life
Minimum service life available.

2 A process pipe run may be of significant length and involve several changes of direction,
branch connections, fittings, etc. The following forms of degradation should be considered
to select monitoring points.

a) Straight horizontal pipe:

i) general corrosion
ii) groove corrosion due to stratified flow, phase separation or stagnant
conditions

b) Vertical pipe:
i) general corrosion
ii) stagnant conditions leading to local attack at liquid/vapour or liquid/liquid
interface

c) Bends, Tees, Reducers - points of change of direction can suffer local erosion or
corrosion. These are normally the first components of a piping system to fail.

d) Thermowell Nozzles - points of local turbulence.

Operating conditions e.g. stratified flow, phase separation turbulence or stagnation at

different locations of each piping system may differ significantly, as does the rate of
corrosion. The selection of the locations where wall thickness measurements are to be
conducted, should take account of which of the circumferential portions of the pipe, elbow
or fittings would be most sensitive to internal corrosion or erosion e.g. bottom, side or top,
inner or outer radius of an elbow and vent/drain etc.

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3 Where possible, during construction stage, the provision of inspection windows or

insulation covers should be arranged to facilitate future inspection. This should be
indicated on marked up isometric sketches.

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APPENDIX E

EROSION AND CORROSION/EROSION

Erosion can be defined as the removal of surface material by action of numerous individual impacts
of solid or liquid particles. It can be characterized by grooves, rounded holes, waves, and valleys in
a directional pattern. Erosion usually occurs in areas of turbulent flow, such as changes of direction
in piping system or downstream of control valves where vaporization may take place. Erosion
damage is usually increased in streams with large quantities of solid or liquid particles flowing at
high velocities. A combination of corrosion and erosion results in significantly greater metal loss
than can be expected from corrosion or erosion alone. This type of corrosion occurs at high-velocity
and high-turbulence areas.

Examples of places to inspect include the following:

1) Downstream of control valves, especially when flashing is occurring.

2) Downstream of orifices.
3) Downstream of pump discharges.
4) At any point of flow direction change, such as the inside and out side radius of elbows and
tees.
5) Downstream of piping configurations (such as welds, thermo-wells, flanges, and couplings)
that produce turbulence, particularly in velocity sensitive systems such as low pH (acid) fluid
system.

Areas suspected of having localized corrosion/erosion should be inspected using appropriate NDE
methods that will yield thickness data over a wide area, such as ultrasonic scanning, or radiographic
profile.

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APPENDIX F

DETERMINATION OF THE NUMBER OF CMLs

This appendix is a guide for establishing the minimum number of CMLs for each circuit in a
Class 1, 2 or 3 process unit piping system. The method takes into account the classification of the
piping system as well as the length of the line, number of fittings, and circuit average corrosion
rate.

The general formula is:

Number of CMLs = (L+F) x (C)

The factors for this equation are defined in the following table.

FACTOR CLASSIFICATION

L = LENGTH FACTOR CLASS I CLASS II CLASS III

0-30 ft 0.5 0.5 0.25
31-100 ft 1.0 1.0 0.50
101-200 ft 1.5 1.5 0.75
201-500 ft 2.0 2.0 1.00
501-1000 ft 2.5 2.5 1.25
>1000 ft 3.0 3.0 1.50

F = FITTING FACTOR 0.75(X) 0.35(X) 0.25(X)

C = CORROSION RATE FACTOR

(CR < 2 MPY) 0.5 0.25 0.10
(CR = 2-10 MPY) 1.0 1.0 0.25
(CR > 10 MPY) 2.0 2.0 0.50

X = Number of fittings
CR = Circuit Average Corrosion Rate

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APPENDIX G

CHECKLIST FOR EXTERNAL INSPECTION OF PIPING

1. External corrosion
2. Paint/coating condition/breakdown
3. Insulation condition
4. Damaged insulation/cladding
5. Potential for under-lagging corrosion
6. Cladding applied for personnel protection
7. Corrosion at penetrations
8. Small bore fittings – fatigue, cracking especially for any socket weld, corrosion
9. Screwed fittings
10. Pipe supports/sleepers - condition
11. Freedom for expansion
12. Fretting/local damage to pipe under supports
13. Pipe hanger function (Hot/Cold set –check)
14. Vibrations
15. Leaks at flanges
16. Clamps – registered?
17. Buried sections/soil build-up
18. Steam tracing leaks and functioning properly
19. Steam traps functioning
20. House-keeping/weeds/etc
21. Dead-legs/seldom used lines/low points
22. Sleeves/wrapping intact/damaged

Note: this checklist is intended as a guide for external inspection, covering items that should be
considered during inspection of piping. The list is not exhaustive, and the inspector should apply
knowledge and experience in the interpretation and application of the inspection findings.

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APPENDIX H

THE PRACTICE OF CMLs

Thickness measurements shall be taken at designated CMLs to monitor the rate of corrosion using
inspection methods as practical.

1. An inspection plan must be developed to define the best method of obtaining

thickness data for each inspection location to be monitored.

2. When possible, initial readings shall be taken when the piping is new to establish the
un-corroded thickness of the piping. It is recommended to do UTM in 1,000 hrs after
service to establish a base line if that system is excluded in Visions4. When initial
readings are taken, the area of the CMLs shall be scanned to determine a typical
thickness. When it is not possible to take initial readings, the value of the nominal
thickness of new, un-corroded piping shall be used.

3. Subsequent thickness readings should include scanning the entire CMLs where
possible to identify a minimum reading (if profile radiography is used, two films
taken at 90 degrees to each other should be taken)

4. The minimum thickness reading, CMLs ID number, inspector’s name, measurement

method, and date shall be recorded. Any unusual visual observations shall also be
noted and recorded.

5. Where practical, profile radiography may be used to assess the general internal and
external condition of insulated piping at the CMLs without insulation removal.

a. The film shall be of adequate size to provide as much information on the

CMLs as practical.
b. Thickness measurements may be taken directly from the radiograph utilizing
appropriate sizing factors if there is sufficient confident I the accurate of the
reading.
c. If the information from the radiograph indicates unusual conditions, further
inspection adjacent to or nearby the CMLs may be warranted.
d. Radiography shall be the preferred thickness measurement method for small
diameter piping (1 NPS and less).
e. Radiography should not be done on a pipe filled with liquid.

6. The minimum required pipe wall thickness or retirement thickness shall be based
on piping class flange rating and structure force considerations using the design
formula in AMSE Code, API570 and table 1. Locally thinned areas shall be evaluated
using guideline in API579 and ASME B31G.

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When utilizing ultrasonic testing to measure thickness:

1. Where experience/service indicates a greater erosion/corrosion concern, accessible

pipe elbows shall have ultrasonic thickness scanning performed at the outside bend
radius at several CMLs.

2. Accessible tees and branch connections shall have ultrasonic thickness scanning
performed along the backside of the connections (directly opposite the neck of the
branch inlet and at adjacent locations) when fluid flow is from the branch into the
main piping.

3. Accessible reducers shall have ultrasonic thickness scanning taken at the transition.

4. Where appropriate, thickness measurements should include measurements at each of

the four quadrants on a pipe and fitting.

5. When Ultrasonic testing is used to monitor thickness of insulated piping, inspection

hole (insulation plug) designed to prevent the ingress of moisture under the insulation
shall be installed. They shall be placed at the CMLs point where the highest rate of
corrosion is anticipated. Profile radiography may be utilized where possible to assist
to initially locate this point.

6. When scanning a CMLs with ultrasonic testing, the minimum reading shall be
recorded for thickness monitoring purposes.

7. When subsequent readings at a CMLs indicate a thickness, outside the precision error
of the inspection method, additional readings shall be taken to verify the reading
value.
8. The number of gauging point shall be followed Piping Component Sketch for UT
Measurement.

Piping_Component_Sketch_for_UT_Measurement.pdf

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