IT AC Inspection Training And Consulting Chapter One API 570 Piping Inspection Code; Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems Summary and Notes Inspection Training And Consulting, 20031 AG Inspection Training And Consulting Wirour 7 www.ltac.net Piping Inspection Code API 570 Second Edition - October, 1998 Addendum 1 - February, 2000 Addendum 2 - December, 2001 Inspection, Repair, Alteration, and Rerating Of In-Service Piping Systems Summary and Notes The notes and summary information supplied is the thoughts and opinions of ITAC and does not represent API Committee interpretations. The use of “Key Phrases” is intended as a study guide only. Prepared by; Ron VanArsdale Owner TTAC API 670 Summary, Copyright Spring 2003 Page 1-1API 570 Second Edition - October, 1998 Addendum 1 - February, 2000 Addendum 2 - December 2001 Inspection, Repair, Alteration, and Rerating Of In-Service Piping Systems Foreword This edition of API 570 supersedes all previous editions of API 570. Key phrase “supersedes previous editions...”. 1.0 SCOPE 1.1.1 General API 570 covers inspection, repair, alteration, and rerating procedures for metallic piping systems that have been in-service. 1.1.2 Intent Any organization that uses AP1570 should maintain or have access to an authorized inspection agency, a repair organization, qualified engineers, inspectors and examiners. Key phrase "maintain ...agencies and qualified technical personnel”. 1.13 Limitations Limited to piping that has been placed in-service. Key phrase "placed in service”. 1.2 Specific Applications Piping systems for process fluids, hydrocarbons, and similar flammable or toxic fluid services. (Specific services listed in the paragraph.) TTAC API 570 Summary, Copytight Spring 2008 Page 1-21.2.1 Included Fluid Services Raw, intermediate, and finished petroleum products. Raw, intermediate, and finished chemical products. Catalyst lines. Hydrogen, natural gas, fuel gas, and flare systems. Sour water and hazardous waste streams above threshold limits. Hazardous chemicals above threshold limits. Key phrase “Services”. SR eRe 1.22 Excluded and Optional Piping Systems Piping systems listed here may be excluded from the specific requirements of API 570, but may be included at the owner's option. Key phrase "owner's option”. 1.3. This edition of API 570 (Second Edition, Addenda 1 and Addenda 2) recognizes API RP 570 “Fitness For Service.” This Recommended Practice is not required by API 570, itis simply allowed if the Owner wants to use it. Key phrase “Fitness For Service”. 2. REFERENCES 3 DEFINITIONS (For the purposes of this standard, the following definitions apply.) 3.1 alteration: A physical change in any component that has design implications affecting the pressure containing capability or flexibility of a piping system beyond the scope of its design. The following are not considered alterations: comparable or duplicate replacement, the addition of any reinforced branch connection equal to or less than the size of existing reinforced branch connections, and the addition of branch connections not requiring reinforcement. 3.2 applicable code: The code, code section, or other recognized and generally accepted engineering standard or practice to which the piping system was built or which is deemed by the owner or user or the piping engineer to be most appropriate for the situation, including but not limited to the latest edition of ASME B31.3. 3.3 ASME B31.3: A shortened form of ‘ASME B31.3, Chemical Plant and Petroleum Refinery Piping, published by the American Society of Mechanical Engineers. ASME B31. is written for design and construction of piping systems. However, most of the technical requirements on design, welding, examination, and materials also can be applied in the inspection, erating, repair, and alteration of operating piping systems. When ‘ASME B31.3 cannot be followed because of its new construction TTAC API 570 Summary, Copyright Spring 2003 Page 1-3coverage (such as revised or new material specifications, inspection requirements, certain heat treatments, and pressure tests), the piping engineer or inspector shall be guided by API570 in lieu of strict conformity to ASME B31.3. As an example of intent, the phrase “principles of ASME B31.3” has been employed in API 570, rather than “in accordance with ASME B313”. 3.4 authorized inspection agency: Defined as any of the following: a. The inspection organization of the _ jurisdiction in which the piping system is used, b. The inspection organization of an insurance company that is licensed or registered to write insurance for piping systems. c. An owner or user of piping systems who maintains an inspection organization for activities relating only to his equipment and not for piping systems intended for sale or resale. d. An independent inspection organization employed by or under contract to the owner or user of piping systems that are used only by the owner or user and not for sale or resale, e. An independent inspection \ organization licensed or recognized by the jurisdiction in which the piping system is used and employed by or under contract to the owner or user. 3.5 authorized piping inspector: An employee of an authorized inspection agency who is qualified and certified to perform the functions specified in API570. A nondestructive examination (NDE) examiner is not required to be an authorized piping inspector. Whenever the term inspector is used in API 570, it refers to an authorized piping inspector. 3.6 auxiliary piping: Instrument and machinery piping, typically small-bore secondary process piping that can be isolated from primary piping systems Examples include flush lines, seal oil lines, analyzer lines, balance lines, buffer gas lines, drains, and vents. 3.7 Critical check valves: Valves that have been identified as vital to process safety and must operate reliably in order to avoid the potential for hazardous events or substantial consequences should a leak occur. 3.8 CUI: Corrosion under insulation, including stress corrosion cracking under insulation. 3.9 deadlegs: Components of a piping system that normally have no significant flow. Examples include the following: blanked branches, lines with normally closed block valves, lines with one end blanked, pressurized dummy support legs, stagnant control valve bypass piping, spare pump piping, level bridles, relief valve inlet and outlet header piping, pump trim bypass lines, high-point vents, sample points, drains, bleeders, and instrument connections. 3.10 defect: An imperfection of a type or magnitude exceeding the acceptable criteria. 3.11 design temperature of a piping system component: The temperature at which, under the coincident pressure, the greatest thickness or highest component rating is required. Itis the same as the design temperature defined in ASME B31.3 and other code sections and is subject to the same rules relating to allowances for variations of pressure or temperature or both. Different components in the same piping system or circuit may have different design temperatures. In establishing the design temperature, consideration shall be given to process fluid temperatures, ambient temperatures, ITACAPI570 Summary, Copyright Fall 2001 Page 1-4heating and cooling media temperatures, and insulation. 3.12 examiner: A person who assists the inspector by performing specific nondestructive examination (NDE) on piping system components but does not evaluate the results of those examinations in accordance with API 570, unless specifically trained and authorized to do so by the owner or user. The examiner need not be qualified in accordance with API 570 or be an employee of the owner or user but shal be fained and qualified in the applicable procedures in which the examiner is involved. In some cases, the examiner may be required to hold other certifications as necessary to satisfy owner or user requirements. Examples of other certification that may be required are American Society for Non-Destructive Testing SNT-TC- 1A or CP 189 or American Welding Society Welding Inspector certification. The examiner's employer shall maintain certification records of the examiners employed, including dates and results of personnel qualifications, and shall make them available to the inspector. 3.13 hold point: A point in the repair or alteration process beyond which work may not proceed until the required inspection has been performed and documented. 3.14 imperfections: Flaws or other discontinuities noted during inspection that may be subject to acceptance criteria during an engineering and inspection analysis. 3.15 indication: A response or evidence resulting from the application of a nondestructive evaluation technique. 3.16 injection point: Locations where relatively small quantities of materials are injected into process streams to control chemistry or other process variables. Injection points control chemistry or other process variables. Injection points do not include locations where two process streams join (mixing tees). Examples of injection points include chlorine in reformers, water injection in overhead systems, polysulfide injection in catalytic cracking wet gas, antifoam injections, inhibitors, and neutralizers. 3.17 in-service: Refers to piping systems that have been placed in operation, as opposed to new construction prior to being placed in service. 3.18 inspector: An authorized piping inspector. 3.19 jurisdiction: A legally constituted government administration that may adopt rules relating to piping systems. 3.20 level bridle: A level gauge glass. piping assembly attached to a vessel. 3.21 maximum allowable working pressure: (MAWP): The maximum internal pressure permitted in the piping system for continued operation at the most severe condition of coincident internal or external pressure and temperature (minimum or maximum) expected during service. Itis the same as the design pressure, as defined in ASME B31.3 and other code sections, and is subject to the same rules relating to allowances for variations of pressure or temperature or both. 3.22 mixing tee: A piping component that combines two process streams of differing composition and/or temperature. 3.23 MT: Magnetic-particle testing. TTAC API570 Summary, Copyright Fall 2001 Page 1-3.24 NDE: Nondestructive examination. 3.25 NPS: Nominal pipe size (followed, when appropriate, by the specific size designation number without an inch symbol). 3.26 on-stream: Piping containing any amount of process fluid. 3.27 owner/user: An owner or user of piping systems who exercises control over the operation, engineering, inspection, repair, alteration, testing, and rerating of those piping systems. 3.28 owner/user inspector: An ‘Authorized Inspector employed by an Owner-User who has qualified either by written examination under the provisions of Section 4 and Appendix ‘Aof API 570 or has qualified under the provisions of A.2, and who meets the requirements of the jurisdiction. 3.29 PT: A liquid-penetrant testing. 3.30 pipe: A pressure-tight cylinder used to convey a fluid or to transmit a fui pressure and is ordinarily designated “pipe” in applicable material specifications. (Materials designated “tube” or “tubing” in the specifications are treated as pipe when intended for pressure service.) 3.31 piping circuit: A section of piping that has all points exposed to an environment of similar corrosivity and that is of similar design conditions and construction material. Complex process units or piping systems are divided into piping circuits to manage the necessary inspections, calculations, and record keeping. When establishing the boundary of a particular piping circuit, the inspector may also size it to provide a practical package for record keeping and performing field inspection. 3.32 piping engineer: One or more persons or organizations acceptable to the owner or user who are knowledgeable and experienced in the engineering disciplines associated with evaluating mechanical and material characteristics affecting the integrity and reliability of piping components and systems. The piping engineer, by consulting with appropriate specialists, should be regarded as a composite of all entities necessary to properly address a technical requirement. 3.33 piping system: An assembly of interconnected piping that is subject to. the same set or sets of design conditions and is used to convey, distribute, mix, separate, discharge, meter, control, or snub fluid flows. Piping system also includes pipe- supporting elements but does not include support structures, such as structural frames and foundations. 3.34 primary process piping: Process piping in normal, active service that cannot be valved off or, if it were valved off, would significantly affect unit operability. Primary process piping normally includes all process piping greater than NPS 2. 3.35 PWHT: Postweld heat treatment. 3.36 renewal: Activity that discards an existing component and replaces it with new or existing spare materials of the same or better qualities as the original component. 3.37 repair: The work necessary to restore a piping system to a condition suitable for safe operation at the design conditions. If any of the restorative changes result in a change of design temperature or pressure, the requirements for rerating also shall be satisfied. Any welding, cutting, or ITAC API 570 Summary, Copytight Fall 2001 Page 1-6grinding operation on a pressure containing piping component not specifically considered an alteration is considered a repair. 3.38 repair organization: Any of the following: a. An owner or user of piping systems who repairs or alters his or her own equipment in accordance with API 570. b. A contractor whose qualifications are acceptable to the owner or user of piping systems and who makes Tepairs or alterations in accordance with API570. c. One who is authorized by, acceptable to, or otherwise not prohibited by the jurisdiction and who makes repairs in accordance with API 570. 3.39 rerating: A change in either or both the design temperature or the maximum allowable working pressure of a piping system. A rerating may consist of an increase, a decrease, ora combination of both. Derating below original design conditions is a means to provide increased corrosion allowance. 3.40 secondary process piping: Small- ore (less than or equal to NPS 2) process piping downstream of normally closed block valves. 3.41 small-bore piping (SBP): Piping that is less than or equal to NPS 2. 3.42 soil-to-air (S/A) interface: An area in which external corrosion will vary depending on factors such as moisture, oxygen content of the soil, and operating temperature. The zone generally is considered to be from 12 inches (305 millimeters) below to 6 inches (150 millimeters) above the soil surface. Pipe running parallel with the soil surface that contacts the soil is included. 3.43 spool: A section of piping encompassed by flanges or other connecting fittings such as unions. 3.44 temper embrittlement: A loss of ductility and notch toughness in susceptible low-alloy steels, such as 1 1/4 Cr and 2 1/4 Cr, due to prolonged exposure to high-temperature service [700°F to 1070°F (370°C to 575°C). 3.45 temporary repairs: Repairs made to piping systems in order to restore sufficient integrity to continue safe operation until permanent repairs can be scheduled and accomplished within a time period acceptable to the inspector or piping engineer. 3.46 test point: An area defined by a circle having a diameter not greater than 2 inches (50 millimeters), or a line diameter not exceeding 10 inches (254 millimeters), or not greater than 3 inches (76 millimeters) for larger lines. Thickness readings may be averaged within this area. A test point shall be within a thickness measurement location. 3.47 thickness measurement locations (TMLs): Designated areas on piping systems where periodic inspections and thickness measurements are conducted. 3.48 WEMT: Wet fluorescent magnetic-particle testing. 3.49 alloy material: Any metallic material (including welding filler materials) that contains alloying elements, such as chromium, nickel or molybdenum, which are intentionally added to enhance mechanical or physical properties and/or corrosion resistance. 3.50 material verification program: A documented quality assurance procedure used to assess metallic alloy materials (including weldments and TTAC API570 Summary, Copyright Fall 2001 Page 1-7attachments where specified) to verify conformance with the selected or specified alloy material designated by the owner/user. This program may include a description of methods for alloy material testing, physical component marking and program record-keeping, 3.51 positive material identification (PMD testing: Any physical evaluation oF test of a material to conform that the material which has been or will be placed into service is consistent with the selected or specified alloy material designated by the owner/user. These evaluations or ~ tests may provide qualitative or quantitative information that is sufficient to verify the nominal alloy composition. 3.52 fitness-for-service assessment: A methodology whereby flaws and conditions contained within a structure are assessed in order to determine the integrity of the structure for continued service. 3.53 industry-qualified UT shear wave examiner: A person who possesses an ultrasonic shear wave qualification from APT or an equivalent qualification approved by the owner /user. TTACAPI570 Summary, Copyright Fall 2001 Page 1-841 42 43 51 52 OWNER/USER INSPECTION ORGANIZATION General This section establishes an inspection organization to control inspection programs of piping. Key phrase “inspection”. Authorized Piping Inspector Qualification Requirements for becoming an "Authorized piping inspector.” The term inspector as used by API 570 refers to an authorized piping inspector. See Appendix B for certification requirements. Key phrase “Authorized Piping Inspector”. Responsibilities The owner-user shall have overall responsibility for compliance with API570. The piping engineer is responsible to the owner-user. The repair organization shall be responsible to the owner-user. Key phrase “ownerluser”. INSPECTION AND TESTING PRACTICES, Risk-Based Inspection The paragraph contains a few general statements about an RBI program. This paragraph neither requires or prevents inspection based on RBI. Key phrase "Risk-Based Inspection”. Preparation This section covers the preparation usually done before the piping inspection begins, such as, permits to enter the area, reviewing history of the system, etc. Key phrase "preparation". TAC API570 Summary, Copyright Fall 2001 Page 1-953 Inspection for Specific Types of Corrosion and Cracking ‘Areas that should be inspected for possible problems are listed, see API Recommended Practice 571 for additional information. The areas of deterioration are: Injection points Deadlegs Corrosion under insulation (CUI) Soil-to-air (S/A) interfaces Service specific and localized corrosion Erosion and corrosion /erosion Environmental cracking Corrosion beneath linings and deposits Fatigue cracking Creep cracking Brittle fracture Freeze damage Key phrase “deterioration”. 5.3.1 Injection Points Often subject to accelerated or localized corrosion, more than under normal conditions. Suggestions for establishing injections point circuit, for inspection circuits: * Upstream 12 inches or three pipe diameters upstream whichever is greater. + Downstream The second change in flow direction or 25 feet downstream, beyond the first flow change whichever is less. * Injection nozzles 12inches upstream of the nozzle and continuing for at least ten pipe diameters downstream of the injection point. TMLs (thickness measurement locations) a. Establish TMLs on fittings b. Establish TMLs on the pipe wall c. Establish TMLs on longer straight piping d. Establish TMLs on both upstream and downstream limits of injection points circuit. The preferred methods of inspection of injection points are radiography and/or ultrasonics. These methods are used to established thickness, not weld quality. Key phrase “injection points”. TTAC API570 Summary, Copyright Fall2001 Page 1- 105.3.2 5.3.3 Deadlegs Due to the corrosion rate variation both the active and stagnant end of a deadleg should be inspected. Consideration should be given to removing the deadlegs that serve no useful purpose. Key phrase “deadlegs”. Corrosion Under Insulation (CUD External corrosion of an insulated piping system. The corrosion is usually from trapped moisture that may include rain, water leaks, condensation, and deluge systems. The most common form of CIU is localized corrosion of carbon steel and chloride stress corrosion cracking of austenitic stainless steels. Key phrase “CUI”. 5.3.3.1 Insulated Piping Systems Susceptible to CUI Areas exposed to overspray from cooling water towers Areas exposed to steam vents Areas exposed to deluge systems ‘Areas subject to process spills, moisture, or acid vapors Carbon steel piping systems operating between 25°F and 250°F Carbon steel piping systems above 250°F in intermittent service g. Deadlegs and attachments protruding from insulated systems that may operate at a different temperature than the active line h. Austenitic stainless steel piping systems operating between 150°F and 400°F i. Vibrating piping systems j. Steam traced piping systems k. Piping systems with deteriorated coatings and/or ‘wrappings Key phrase “CUI” eaege 5.3.3.2 Common Locations on Piping Systems Susceptible to CUI All damaged insulation. Termination of insulation. Missing insulation. Poorly installed insulation. ‘Termination of insulation on vertical piping. Caulking problems. Bulges in insulation, could be an indication of CUL Low points. Carbon or low-alloy steel flanges, bolting etc,, especially if in a high-alloy system. j. Areas where insulation plugs have been removed and not properly sealed. Key phrase “CUI”. rem me ao oe ITAC API 570 Summary, Copyright Fall 2001 Page 1- 1153.4 5.3.6 5.3.7 5.3.8 Soil-to-Air Interface Soil-to-air (S/A) interfaces without cathodic protection shall be included in scheduled external piping inspections. Special interest in this area, note also concrete-to-air and asphalt-to-air have special requirements. Caulking in these areas are often a main concern. Key phrase “SIA”. Service-specific and Localized Corrosion The three elements of an inspection program: * An inspector with knowledge of the service and where corrosion is likely to occur. Extensive use of NDE. ‘Communication from operations when process upsets occur that may affect corrosion rates. Examples of service-specific corrosion are listed in the rest of the paragraph. Key phrase “Inspection Program”. Erosion and Corrosion/Erosion Erosion can be defined as the removal of surface material by the action of numerous individual impacts of solid or liquid particles. Erosion usually occurs in areas of turbulent flow. Inspect the following for erosion/corrosion: Downstream of control valves. Downstream of orifices. Downstream of pump discharges. Flow direction change. e. Downstream of piping configurations that produce turbulence Key phrase “erosion and corrosion”. Bose Environmental Cracking The topics mentioned here are SCC (Stress Corrosion Cracking) and HIC (Hydrogen Induced Cracking) these types of cracking are results of specific services reacting with the basic metallurgy of the piping. If this type of cracking is found in pressure vessels, then the related piping may have the same problem. Key phrase “cracking”. Corrosion Beneath Linings and Deposits Usually it is not necessary to remove the linings, internal or external, if there is no evidence of damage. However, if deposits, such as coke, are present, it is important to determine if any active corrosion is, beneath the deposits. Key phrase “corrosion”. ITAC API570 Summary, Copyright Fall 2001 Page 1- 1254 5.3.9 Fatigue Cracking Fatigue cracking is cracking that usually results from cyclic stresses. A piping system may be designed below the static yield strength of the material, but due fo the number of heat-up high cycles changing to cool-down low cycles the material may fail. This problem may be detected by PT, MT or (AE) acoustic emission. Key phrase “fatigue cracking”. 5.3.10 Creep Cracking Creep is dependent on time, temperature, and stress. One of the most common examples of creep cracking has been experienced in the industry is in 11/4 Cr steels above 900°F. Creep cracking NDE include PT, MT, UT, RT, and in-situ metallography. Under special conditions ‘AE may be employed. Key phrase “creep cracking”. 5.3.11 Brittle Fracture Failure of piping at lower temperatures, usually below 60°F. Most incidences have occurred during a hydrotest or other over load condition. Special attention should be used when rehydrotesting low- alloy steels (especially 2 1/4 Cr-1 Mo material), because of temper embrittlement, also to ferritic stainless steels. (See API RP 579, Sec. 3). Key phrase “brittle fracture”. 5.3.12 Freeze Damage Inspections should be performed after subfreezing temperatures. Water and aqueous solutions in piping systems may freeze and cause failure because of expansion. Leaks may not be evident until the system thaws. Key phrase “freeze damage”. Types of Inspection and Surveillance The basic types of inspection include: Internal visual inspection. Thickness measurement inspection. External visual inspection. Vibrating piping inspection. Supplemental inspection. Key phrase “inspection”. 5.4.1 Internal Visual Inspection This type of inspection is not normally performed on piping systems, unless there is large diameter piping involved. Key phrase “internal inspection”. TAC AP!570 Summary, Copyright Fall 2001 Page 1-1355 5.6 54.2 Thickness Measurement Inspection Thickness measurements are used for intemal condition and remaining thickness of piping systems. Measurements may be taken by inspectors or examiners. Key phrase “thickness measurements”. 5.4.3 External Visual Inspection Items to inspect are listed in this section. Inspections may be performed by inspectors, qualified operating or maintenance personnel. The operating or maintenance personnel shall be qualified through an appropriate amount of training. Key phrase “external visual inspection”. 54.4 Vibrating Piping and Line Movement Surveillance This inspection should be performed at junctions where vibrating piping systems are restrained. Key phrase “vibrating”. 5.4.5 Supplemental Inspection Profile radiography, thermography, acoustic emission, acoustic leak detection and ultrasonics can be used where appropriate. Thickness Measurement Locations 5.5.1 General ‘TMLs thickness measurement locations are specific areas along the piping circuit where inspections are to be made. This section outlines general TML monitoring and selection. Extremely basic. Key phrase “TML”. 5.5.2 TML Monitoring TMLs should be monitored based on the corrosiveness of the system. Thickness measurements should include measurements at each of the four quadrants on pipe and fittings, with special attention to the inside and outside radius of elbows and tees. Key phrase “TML”. 5.5.3 TML Selection Basic broad rules for TML selection are found in this section, the information found here is extremely basic. Key phrase “TML”. Thickness Measurement Methods Piping larger than 1” NPS (Nominal Pipe Size) ultrasonic thickness measuring instruments are accurate. The radiographic profile techniques are preferred for pipe 1” NPS and smaller. When piping temperatures are above 150°F, a special procedure and equipment must be used. Typical problems when using UT digital instruments are discussed. Key phrase “UT Thickness”. ITAC API 570 Summary, Copyright Fall 2001 Page 1-145.11 61 6.2 Note: Some welds may meet original construction criteria but will not perform satisfactorily in-service. In addition to radiography, UT shear wave examination is now allowed. Fitness-for-service monitoring is one application. Key phrase “welds in-service”. Inspection of Flanged Joints Check the gaskets and bolting. If the flanges have been clamped and pumped with sealant, check for additional leakage. See API Recommended Practice 574 for procedures when flanges are opened. Key phrase “flanges”. FREQUENCY AND EXTENT OF INSPECTION General This extremely general section discusses the RBI concept used to establish a piping circuit inspection strategy. Inspection may be based on the expected forms of degradation, the optimal inspection frequency, extent of inspection and the prevention and mitigation steps to reduce the likelihood and consequence. Key phrase “RBI”. Piping Service Classes This section suggests piping be categorized into different classes, or hazard levels, using API Recommended Practice 750 and NFPA (National Fire Prevention Association) 704 as guidelines. Key phrase “service classes”. 6.2.1 Class 1 Class 1 piping is piping whose services have the highest potential of resulting in an immediate emergency if a leak were to occur. Class 1 piping include, but not limited to, the following: 1, Flammable services that may auto-refrigerate and lead to brittle fracture. 2. Pressurized services that may rapidly vaporize during release, creating vapors that may collect and form an explosive mixture, such as C, (ethylenes), C, (propylenes), C, (butanes) streams. Hydrogen sulfide (greater than’3 percent weight) in a gaseous stream. Anhydrous hydrogen chloride. Hydrofluoric acid. Piping over or adjacent to water and piping over public throughways. Key phrase “emergency”. ae & 6.2.2 Class 2 Class 2 piping is usually unit process piping and selected off-site piping that is not included in Class 1 piping. Examples are as follows: ITAC API 570 Summary, Copyright Fall 2001 Page 1- 1663 64 65 6.6 1. Oncsite hydrocarbons that will slowly vaporize during release. 2. Hydrogen, fuel gas, and natural gas. 3, On-site strong acids and caustics. Key phrase “process piping”. 6.2.3 Class 3 Class 3 piping contains services that are flammable but do not significantly vaporize and are not located in high-activity areas. Examples are: 1. On-site hydrocarbons that will not significantly vaporize during release. 2. Distillate and product lines to and from storage and loading. 3. Off-site acids and caustics. Key phrase “Class 3”. Inspection Intervals The criteria for inspection intervals are as follows: Corrosion rate and remaining life calculations. Piping services classification. Applicable jurisdictional requirements. Judgment of the inspector, piping engineer, engineer supervisor, or a corrosion specialist, based on operating conditions, history, current results and special conditions. Bepe The owner-user shall establish inspection intervals for thickness, measurements and external visual inspections. Refer to Table 6-1 (page 6-3) fot recommended inspection intervals. Inspections should be based on Table 6-1 or half the remaining life determined from the corrosion rates which ever is shorter. Key phrase “inspection interval”. Extent of Visual External and CUI Inspections External inspections should be scheduled in accordance with Table 6-1 (page 6-3) using the checklist in Appendix D, EXTERNAL INSPECTION CHECKLIST FOR PROC] PIPING. See Table 6-2 - Recommended Extent of CUI Inspection Following Visual Inspection. Key phrase “visual external inspections”. Extent of Thickness Measurement Inspection Asa minimum, a representative sampling of TMLs shall be measured, including various types of components and orientations in each circuit. See 3.2.1 for inspection of injection points. Key phrase “TML”. Extent of Small-Bore, Auxiliary Piping, and Threaded- Connections Inspections TTAC API 570 Summary, Copyright Fall 2001 Page 1-176.6.1 Small-Bore Piping Inspection Small-bore piping (SBP) that is primary process piping should be inspected in accordance with all the requirements of API 570. Key phrase “SBP”. 6.6.2 Auxiliary Piping Inspection Inspection of auxiliary SBP is optional, dependent on classification, cracking potential, corrosion, and potential for CUI. INSPECTION DATA EVALUATION, ANALYSIS AND RECORDING 7.1.1 Remaining Life Calculations Remaining life (years)= corrosion rate [inches (millimeters) per year] Where: t saan = the actual minimum thickness, in inches (millimeters), determined at the time of inspection. t jeqiea = the required thickness, in inches (millimeters), for the limiting section or zone. The long term (L. T.) corrosion rate: Corrosion rate (L. T.) = ¢ spits ~ # actuat time (years) between initial and actual inspections The short term (S. T.) corrosion rate: Corrosion rate (S. T.) = f previous ~ seu time (years) between previous and actual inspections Long Term and Short Term rates should be compared to see which results in the shortest remaining life as part of the data assessment. Key phrase “corrosion rate”. TTAC API 570 Summary, Copyright Fall2001 Page 1- 1872 73 74 7.1.2 Newly Installed Piping Systems or Changes in Service Probable corrosion rates may be determined by use of the following: 1. Corrosion rate of similar service. 2. Owner user’s experience or published data on comparable service. 3. Initial thickness shall be made after 3 months of service by using NDT. Key phrase “corrosion rate”. 7.1.3. Existing Piping Systems Corrosion rates shall be calculated on either a short-term basis, using the two most recent inspections or long-term basis, using original wall thickness and most recent inspection, tse the higher result in most cases. Key phrase “corrosion rate”. Maximum Allowable Working Pressure Determination The maximum allowable working pressure (MAWP) for the continued use of piping systems shall be established using the applicable code. Computations may be made if all the following comply with the applicable code: Upper and /or lower temperature limits for specific materials. Quality of materials and workmanship. Inspection requirements. Reinforcement of openings. ‘Any cyclical service requirements. veep See Table 7-1 API 570 uses the “Half-Life” concept Key phrase “MPWA”. ‘Minimum Required Thickness Determination The minimum required pipe wall thickness shall be based on pressure, mechanical, and structural considerations using the appropriate design formulae and code allowable stress. Key phrase “minimum thickness”. ‘Assessment of Inspection Findings Fitness-for-service techniques may be evaluated by API579. Key phrase “fitness-for-service assessment”. ITAC API 570 Summary, Copyright Fall 2001 Page 1- 1975 7.6 8.1 Piping Stress Analysis Piping must be supported and guided so that: 1. its weight is carried safely; 2. ithas sufficient flexibility for thermal expansion or contraction; 3. it does not vibrate excessively. Key phrase “stress analysis”. Reporting and Records for Piping System Inspection API574 offers guidance for piping inspection records. Key phrase “records”. REPAIRS, ALTERATIONS, AND RERATING OF PIPING SYSTEMS Repairs and Alterations The principles of ASME B31.3 or the code to which the piping system was built shall be followed for repairs and alterations. Key phrase “ASME B 31.3”. 8.1.3 Welding Repairs (Including on-stream) 8.1.3.1 Temporary Repairs ‘Temporary repairs may be used, full encirclement welded split sleeve or box-type enclosure. Split coupling or plate patch may also be used. Temporary repairs should be removed and replaced at the next available maintenance opportunity. Key phrase “temporary repairs”. 8.1.3.2 Permanent Repairs Replacement pipe may be installed or insert patches (flush patches) may be used if: 1. Full-penetration groove welds are provided. 2. For Class 1 and Class 2 piping systems, the welds shall be 100% radiographed or ultrasonically tested. 3. Patches may be any shape but shall have rounded corners. Key phrase “permanent repairs”. 8.14 Nonwelding Repairs (on-stream) Temporary repairs may be made by installing a bolted leak clamp. Pumping of such clamps is allowed. All temporary repairs shall be removed and appropriate actions taken to restore the original integrity of the system. Key phrase “nonweld repairs”. ITAC API 570 Summary, Copyright Fall 2001 Page 1-208.3 8.2.1 Procedures, Qualifications, and Records Procedures and welders shall be qualified in accordance with ASME B31.3 or the code to which the piping was built. Key phrase “ASME B31.3 8.2.2 Preheating and Postweld Heat Treatment * Preheating shall be in accordance with the applicable code and qualified welding procedure, exceptions must be approved by the piping engineer. Preheating may not be considered as an alternative to environmental cracking prevention. ‘* Postweld Heat Treatment (PWHT) should be in compliance with ‘ASME B313 or the code to which the piping was built. Local PWHT may be substituted for 360-degree banding on local repairs. Key phrase “preheating and PWHT”. 8.2.3 Designs Butt joints shall be full-penetration groove welds. Fillet welded patches are allowed if approved by the piping engineer. Key phrase “patches”. 8.2.6 Pressure Testing Pressure testing after repairs or alterations may be employed. Nondestructive examination (NDE) shall be utilized in lieu of a pressure test. Key phrase “pressure test”. Rerating Rerating piping systems by changing the temperature rating or MAWP may be done only if: 1. Calculations are performed by the piping engineer or the inspector. 2. All reratings shall be in accordance with the requirements of code to which the system was built, newest edition. 3. Current records verify the system is satisfactory and corrosion allowance is provided. Rerated piping systems shall be leak tested. All pressure relieving devices are checked and appropriately set. The piping system rerating is acceptable to the inspector or piping engineer. All piping components are adequate for the new pressure and temperature. Piping flexibility is adequate for design temperature changes. Engineering records are updated. 0. A decrease in minimum operation temperature is justified by impact test results, Key phrase “rerating”. N aye Bee ITAC API 570 Summary, Copyright Fall 2001 Page 1-21O41 9.2 93 INSPECTION OF BURIED PIPING ‘Types and Methods of Inspection Above-grade visual surveillance Close-interval potential survey Pipe coating holiday survey Soil resistivity Cathodic protection monitoring Inspection Methods 1. Intelligent pigging 2. Video cameras 3. Excavation Key phrase “buried piping”. Frequency and Extent of Inspection 1. The owner-user should, at approximately month intervals, survey the surface conditions on and adjacent to each pipeline path. 2. 5-year intervals for poorly coated pipes with little or no cathodic protection. 3. 5-year intervals for piping not cathodically protected. 4, Piping systems cathodically protected see Section 10 of NACE RPO169 or Section 9 of API RP 651. 5. External and internal inspection intervals see Table 3 - Frequency of Inspection for Buried Piping Without Effective Cathodic Protection. Key phrase “buried piping”. 9.2.7 Leak Testing Intervals The leak testing procedure of buried piping systems has been changed, the new procedure calls for an 8 hour test as opposed to the old requirement for 12 hours, repressurization is now to be done at 4 hours after initial pressurization, the 5 percent drop in pressure is still acceptable. Key phrase “pressure test”. Repairs to Buried Piping Systems Repairs to coatings, any coating removed for inspection shall be renewed and inspected. Key phrase “buried piping”. ITAC API570 Summary, Copyright Fall 2001 Page 1-22APPENDIX A - INSPECTOR CERTIFICATION This Appendix covers the examination, grading, and validation of the API'570 exam. Certification and recertification guidelines are also found in this section. APPENDIX B - TECHNICAL INQUIRIES This is an avenue to allow communications from interested parties and the API 570 Committee. APPENDIX C - EXAMPLES OF REPAIRS D-1 Repairs See figure D-1 Encirclement Repair Sleeve and Figure D-2 Small Repair Patches. APPENDIX D - EXTERNAL INSPECTION CHECKLIST FOR PROCESS PIPING See page D - 1 for the short external inspection checklist for process piping. ITAC API570 Summary, Copyright Fall2001 Page 1- 23; TE A C Inspection Training And Consulting Winn our webster www 7 API 570 fe Quiz 1. APIL570 covers inspection of: A. new construction i B. new tank construction C. in-service piping D. in-service vessels 2. CUI is the acronym for: A. Corrosion Under Insulation B. Cold Under-ground In-service piping C. Corrosion Under Inside flow D. Carpet Under Infra-structure 3. A person who assists the inspector by performing specific NDE on piping systems is termed: A. NDE technician B. Inspector assistant ~ C. Level Il inspector D. Examiner 4, The response or evidence resulting from the application of a nondestructive evaluation technique is termed: A. Acrack B. Porosity C. Aleak D. Anindication 5. The MAWP is: A. The maximum internal pressure permitted in the piping system. B. The minimum internal pressure permitted in the piping system. C. The maximum external pressure permitted in the piping system. D. The maximum external stress permitted in the piping system. ITAC API 870 Summary, Copyright Fall 2001 Page 1-24 =p npot oe6. A section of piping encompassed by flanges or other connecting fittings is called: A. A flanged pipe B. A ready to be installed pipe C. A spooled piece D. A fabricated piping assembly 7. Ifa person has a degree in engineering he is automatically qualified to be: ‘A. An Authorized Piping Inspector B. A piping inspector C. ANDE Level If or Ill in any technique D. None of the above 8. ATMLis: ‘A. Thickness Material Laboratory B. Taiwan Made Label CC. Thickness Measurement Location D. Time Medium Length 9. The result of excessive cyclic stresses that are often well below the static yield strength of the material is titled: A. material failure B. fatigue cracking C. failure cracking D. creep cracking 10. Thickness measurements may be taken by ultrasonic instruments or what other method: A. AET B, ET Cc. MT D. RT 11. Which of the following tests are not normally conducted as part of a routine inspection: A. UT Thickness B. Visual Inspection C. Radiographic profile D, Pressure tests TTAC API570 Summary, Copyright Fall 2001 Page 1- 2512. 13. 14. 15, 16. VW. Thickness measurements are not routinely taken on circuits. in piping A. valves B. straight run pipe C. fittings D. deadlegs During the installation of a flanged connection, the bolts should: A. Extend two threads past their nuts. B. Extend completely through their nuts. C. Extend only half way through their nuts. D. Extend at least .5 inches (1.25 mm) past their nuts. Services with the highest potential of resulting in an immediate emergency if a leak were to occur are A. Class 3 B. Class 2 C. Class 1 D. Owner/user designated system The classification that includes the majority of unit process piping is labeled: A. Class 3 B. Class 2 C. Class 1 D. Owner/user designated system Services that are flammable but do not significantly vaporize when they leak and are not located in high activity areas: A. Class 3 B. Class 2 C. Class 1 D. Owner/user designated system What is the remaining life in years of a piping systems whose corrosion rate is .074 inches per year, the actual wall thickness is 370 inches and the minimum required thickness is .1 inches? A. 36.48 years B. 364.8 years C. 36 years D 3.6 months TTA API570 Summary, Copyright Fall2001 Page 1-2618. What is the long term corrosion rate of a piping circuit that started at 375 inches and is now .1 inch, the measurements were taken over a five year period. ‘A. .055 inches per year B. .005 inches per year C. .550 inches per year D. Not enough information given 19. What is the short term corrosion rate of the above piping circuit. ‘A. .055 inches per year B. .005 inches per year C. ITAC API 570 Summary, Copyright Fall 2001 Page 1-27Inspection Training And Consulting mer API 570 Quiz Answer Key Lc Paragraph 1.1.1 7. C Paragraph 7.1.1 z graph 7.1. 2A Paragraph 3.8 life Seer 3.D Paragraph 3.12 a oe oD Paragraph 3.15 corrosion rate 'aragrap! ches (milli SA Peo eases linches (millimeters) per year] 7.D Paragraph A.2.1 t gat = the actual minimum thickness, in| 8c Paragraph 3.47 inches (millimeters), determined at the 9.8 Paragraph 5.3.9 time of inspection 10. D Paragraph 5.6 u.D Paragraph 5.7 = the required thickness, in 12,4 Paragraph 5.9 sched (millimeters), for the limiting 13. B Paragraph 5.11 section or zone. 4. c Paragraph 6.2.1 15. B Paragraph 6.2.2 16. A Paragraph 6.2.3 18. A Paragraph 7.1.1 The long term (L.. T.) corrosion rate: Corrosion rate (L. T.) = # iu ~ time (years) between initial and actual inspections 19.4 Paragraph 7.1.1 The short term (S. T.) corrosion rate: Corrosion rate (S. T.) = # previous ~# scat time (years) between previous and actual inspections 20.D Paragraph 8.1.3.1 TAC API 570 Summary, Copyright Fall2001 Page 1-28