TUV INDIA – EXPERTISE FOR YOUR SUCCESS

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 PIPING INSPECTION
To ensure safe and reliable operation

 To evaluate the present condition of piping for

its soundness.

 To determine the pattern of deterioration and

suggesting remedial measures.

 To establish corrosion rate and forecasting

future procurement actions.

 To ensure that all the pipelines are inspected

as per planned schedule.

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 Inspection tools required
The most practical tools generally used for pipeline inspection are as under.
 Inspector Hammer.
 Ultrasonic Thickness gauge.
 Pit depth gauge .
 Measuring tap
 Radiography equipment
 Bore scope/ Fibre scope
 Small mirror
 Magnifying Glass
 Safety Torch.
 Paint thickness gauge
 D.P KIT
 Holiday detector
 Inside /outside Callipers
 Hardness testing machine.
6  Thermography equipment
 PREPARTORY JOBS

Following shall be examined by the Inspector and explained to the Technicians :

 Isometric drawings,
 design data
 last inspection observation
 Arrangements for scaffolding and ladder
 Insulation removal
 Valid work permit

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 Area of deterioration:
 Injection points
 mixing points
 Dead ends,
 CUI
 Soil air interfaces
 Specific service

Forms of deterioration:
 Localized corrosion
 Erosion
 Environmental cracking
 Corrosion beneath lining and deposits
 Fatigue cracking
 Creep
 Brittle fracture
 Freeze damage
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 Contact point corrosion
 Method of inspection
 In case of carbon steel and alloy steel piping where lines mostly deteriorate due to corrosion / erosion :
ultrasonic thickness survey shall be carried out In bends
-3 readings on outer periphery and
-3 readings on bottom side
On straight piping
-minimum 4 readings
at locations of direction change like
- bends
- tee
- valves
- expansion loops
 The thickness measurement of the present shutdown of the line shall be compared with the original
thickness and the rate of corrosion shall be calculated.
 If the thickness is found less than retiring thickness the piping loop shall be recommended for
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replacement.
 Method of inspection
 Visual inspection shall be carried out for signs of leaks and cracks, painting / coating condition, insulation
condition and external corrosion.
 In the piping where internal corrosion is suspected, certain spool pieces shall be dropped and internal visual
inspection should be carried out. If this is not possible, radiography shall be done.
 The repair / replacement jobs shall be inspected as per furnished recommendation.
 The pipe supports shall be visually inspected for-
condition of protective coating like fire proofing,
evidence of corrosion,
distortion,
condition of foundation bolts,
attachment of beams,
bracings,
pipe hangers in cold and hot condition,

 During replacement, stage-wise inspection like DP & Radiography shall be carried out. Finally, the complete
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line shall pressure tested 1.5 times of its working pressure.
 Corrosion rate and remaining life calculation

LT – long term
ST- short term
CR- corrosion rate

Remaining life

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 CUI Examination

CUI Examination required in case :

 History of CUI for the specific piping system
 Visual condition of external covering and insulation
 Evidence of fluid leakage
 Condition and age of external coating if known
 Evidence of areas of wet insulation

If the external covering are in good condition and there is no reason of suspect corrosion full insulation
removal not required.

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 Dead leg
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CUI in piping
15 Thickness measurement
 Piping modification/replacement

Material inspection
 Detail inspection of material, with third party inspection reports along with various tests carried out from
the approved Laboratory.
 Requirement of IBR if any should have proper approval and stamp of CIB.
 Physical condition to be checked for
 Pipe and fittings supplied by required specifications
 Pipe and fittings Dia & schedule of pipe.
 No ovality at the pipe edges
 No Dent mark should be present
 External corrosion/pitting marks
 Test certificates

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 Stage wise inspection

 All inspection shall be performed as per approved Drawing/Procedure/QAP/ITP/WPS/PQR

 Witnessing all stage wise inspection such as
 fit-up
 Before welding
 During welding
 After welding
 Stage wise NDT
 Pre heat/ post heat
 PWHT
 Supervision and interpretation of NDT data and results.
 Hydro test
 Painting
 Wrapping/coating

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 insulation
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 PWHT Process

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 DPT at branch RT setup

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 Fit up inspection

 Check material as per drawing

 Check root gap
 Check ID matching
 Check Bevel angle

Welding inspection
 Check parameters required before welding as per WPS
 Check interpass temperature during welding.
 Root weld inspection
 Final weld visual inspection. Weld visual acceptance criteria as per ASME B31.3.
 Use Torch, Magnifying glass, bridge cam gauge.

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 Hydro test of piping :

 For carbon steel/alloy steel piping use test medium as water ( chloride content 10-250 ppm)

 For stainless steel use DM water (chloride content 10-50 ppm)

 Hydro test to be done with only approved procedure

 Only calibrated pressure gauge should be used for test purpose

 PG range 1.5 to 4 times of test pressure

 Minimum two pressure gauges should be used during the test. One pressure gauge should be at the highest place of

the system and one at lowest position.

 Equipment not included in the test, shall be isolated by providing blinds.

 During testing air shall be vented through top vent only.

 The increase in pressure should be gradual.

 Hold time - 30 min.

 API RP-1110 may be referred for guidance for hydro testing.

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 INSPECTION REPORT
 Reason of inspection
 Last inspection done
 Size of the line
 Service of the line
 Present condition of the line
 Future course of action/recommendations
 Thickness survey reports
 Dead end RT record.
 An isometric sketch in case any repair/replacement
 welding electrodes detail
 preheating post weld heat treatment report
 NDT reports with results
 Hydro test/pneumatic testing report of the piping
 Supports condition report
 External insulation report
 Painting/coating report.
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 Referencing code and standards

 API- 1104, Welding pipelines

 ASME B31.3 process piping

 API 570

 ASME SEC IX for welding

 DPT as per ASME SEC V article 6, ASME sec VIII div-1, App-8

 Wet fluorescent magnetic particle inspection (WFMPI)/MPI as per ASME SEC V article 7, ASME sec

VIII div-1, App-6

 Radiography as per ASME SEC V, article 2. ASME SEC VIII DIV-1 app-4

 UT as per ASME SEC V article 6, ASME sec VIII div-1, App-12

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