API EXAM PREPRATORY COURSE

ON
API 570

Inspection, Repair, Alteration, and

Rerating
of In-service Piping Systems

API STD 570 PRESENTATION

Venue: SGS Head Office,

Karachi
Date: May 25, 2010
1
 Scope of API 570
Coverage:
API 570 covers inspection, repair, alteration and re-
rating procedures for metallic piping systems that
have been in-service.
Intent:
API 570 was developed for the petroleum refining
and chemical process industries but may be used for
any piping system where practical.
Any organization that uses API 570 should maintain
or have access to an authorized inspection agency, a
repair organization, qualified engineers, inspectors
and examiners.
Limitations:
Limited to piping that has been placed in-service.
This standard is not intended to replace any local
statutory requirement.
2
 Scope
Specific Applications: of API 570
Piping systems for process fluids, hydrocarbons and similar
flammable or toxic fluid services.
Included Fluid Services:
1. Raw, intermediate and finished petroleum products.
2. Raw, Intermediate and finished chemical products.
3. Catalyst lines.
4. Hydrogen, natural gas, fuel gas and flare systems.
5. Sour water and hazardous waste streams above threshold
limits.
6. Hazardous chemicals above threshold limits.
Excluded and 0ptional 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. (See API 570 for the lists)
Fitness-for-service:
The "API RP, 579 Fitness-for-Service" concepts may be used
for
evaluating in-service degradation of pressure piping and
components. 3
 Definitions

authorized piping inspector:

An employee of an authorized inspection agency who is
qualified and certified to perform the functions specified in
API 570. 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.

CUI:
Corrosion under insulation, including stress corrosion
cracking under insulation.

4
 Definitions
dead legs:
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.

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 shall be trained and qualified in the applicable
procedures in which the examiner is involved.

5
 Definitions

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.

6
 Definitions

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.

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.

7
 Definitions

thickness measurement locations (TMLs):

Designated areas on piping systems where periodic
inspections and thickness measurements are conducted.

Material verification program:

A documented QA procedure to verify metal alloy for
conformance with the specified requirements.

Positive material identification (PMI)

A physical evaluation or test of a material to confirm that
material in service or will be in service complies with the
specified requirements. The test result may provide
qualitative or quantitative information.

8
 Owner/user inspection organization

General:
This section establishes an inspection organization to
control Inspection programs of piping.

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.

Responsibilities:
The owner-user shall have overall responsibility for
compliance with API 570. The piping engineer is
responsible to the owner / user. The repair organization
shall be responsible to the owner / user.
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 Inspection and testing practices
Risk-Based Inspection:
Risk-base inspection (RBI) combines the analysis of
both consequence of failure and probability of failure to
arrive at an optimum inspection interval. For piping
inspection, the consequence of piping failure involves
safety of peoples, environmental pollution and
economic consequence. The probability of piping failure
entails the study of the materials of construction, their
degradation mechanism, and measured or predicted
corrosion rate.
When the owner/user chooses to conduct a RBI
assessment it must include a systematic evaluation of
both the likelihood of failure and the associated
consequence of failure, in accordance with API RP 580.

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 Inspection and testing practices

Preparation:
Due to the nature of the products that carried in the
pipe and their operating conditions, some safety
precautions shall be taken before and during piping
inspection. Preparation such as isolation a portion of
piping circuits, purging to remove toxic or flammable
gas, permits to enter the area and reviewing history of
the system, etc.

API RP 574 presents an overview of the types of

deterioration and failure modes experienced by
pressure containing equipment.

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Inspection for Specific Types of Corrosion and Cracking
Inspection for Specific Types of Corrosion and Cracking:
The piping systems that are susceptible to specific
degradation mechanism as follows should be inspected.

a. Injection points
b. Deadlegs
c. Corrosion under insulation (CUI)
d. Soil-to-air (S/A) interfaces
e. Service specific and localized corrosion
f. Erosion and corrosion/erosion
g. Environmental cracking
h. Corrosion beneath linings and deposits
i. Fatigue cracking
j. Creep cracking
k. Brittle fracture
l. Freeze damage

12
Inspection for Specific Types of Corrosion and Cracking

Injection Points:
Injection points are sometimes subject to accelerated or localized
corrosion from normal or abnormal operating conditions. Those that
are may be treated as separate inspection circuits, and these areas
need to be inspected thoroughly on a regular schedule.:

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:
12 inches upstream of the nozzle and continuing for at least ten
pipe diameters downstream of the injection point.

13
Injection Point Piping Circuit

14
Inspection for Specific Types of Corrosion and Cracking
TMLs (thickness measurement locations):

The selection of thickness measurement locations (TMLs) within

injection point circuits subject to localized corrosion should be in
accordance with the following:

a. Establish TMLs on appropriate fittings within the injection point

circuit.
b. Establish TMLs on the pipe wall at the location of expected pipe wall
impingement of injected fluid.
c. TMLs at intermediate locations along the longer straight piping
within the injection point circuit may be required.
d. Establish TMLs at both the upstream and downstream limits of the
injection point circuit.

The preferred methods of inspecting injection points are

radiography and/or ultrasonic, as appropriate, to establish the
minimum thickness at each TML. Close grid ultrasonic
measurements or scanning may be used, as long as temperatures
are appropriate.

15
Inspection for Specific Types of Corrosion and Cracking
Deadlegs:
The corrosion rate in deadlegs can vary significantly from
adjacent active piping. The inspector should monitor wall
thickness on selected deadlegs, including both the stagnant
end and at the connection to an active line. In hot piping
systems, the high-point area may corrode due to convective
currents set up in the deadleg. Consideration should be given
to removing deadlegs that serve no further process purpose.

Corrosion Under Insulation (CUI):

External inspection of insulated piping systems should
include a review of the integrity of the insulation system for
conditions that could lead to corrosion under insulation (CUI)
and for signs of ongoing CUI. Sources of moisture may
include rain, water leaks, condensation, and deluge systems.
The most common forms of CUI are localized corrosion of
carbon steel and chloride stress corrosion cracking of
austenitic stainless steels.
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Inspection for Specific Types of Corrosion and Cracking
Insulated Piping Systems Susceptible to CUI:
a. Areas exposed to overspray from cooling water towers.
b. Areas exposed to steam vents.
c. Areas exposed to deluge systems.
d. Areas subject to process spills, moisture, or acid vapors .
e. Carbon steel piping systems operating between 25°F and
250°F .
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. Austenitic stainless steel piping systems
operating between 150°F and 400°F . (These systems are
susceptible to chloride stress corrosion cracking.)
h. Vibrating piping systems.
i. Steam traced piping systems.
j. Piping systems with deteriorated coatings and/or wrappings.

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Inspection for Specific Types of Corrosion and Cracking
Common Locations on Piping Systems Susceptible
to CUI:

a. All damaged insulation

b. Termination of insulation.
c. Missing insulation.
d. Poorly installed insulation.
e. Termination of insulation on vertical piping.
f. Caulking problems.
g. Bulges in insulation, could be an indication of CUI.
h. Low points.
i. 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.

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Inspection for Specific Types of Corrosion and Cracking
Soil-to-Air Interface:
Soil-to-air (S/A) interfaces without cathodic protection shall be
included in scheduled external piping inspections. Inspection at
grade should check for coating damage, bare pipe and pit depth
measurements.
If the buried pipe is not coated, excavation 6" to 12" deep to assess
any hidden damage. At concrete-to-air and asphalt-to-air interfaces
of buried piping without cathodic protection, the inspector should
look for evidence that the caulking or seal at the interface has
deteriorated and allowed moisture ingress.

Service-specific and localized Corrosion:

The three elements of an inspection program:

1. An inspector with knowledge of the service and where corrosion is

likely to occur .
2. Extensive use of NDE
3. Communication from operations when process upsets occur that
may affect corrosion rates.

Examples of service-specific corrosion are described in the next slides.

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Inspection for Specific Types of Corrosion and Cracking

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:

a. Downstream of control valves.

b. Downstream of orifices.
c. Downstream of pump discharges.
d. Flow direction change.
e. Downstream of piping configurations that produce
turbulence.

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Inspection for Specific Types of Corrosion and Cracking
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.

Examples of environmental cracking include:

a. Chloride SCC of austenitic stainless steels due to moisture and

chlorides under insulation, under deposits, under gaskets, or in
crevices.
b. Polythionic acid SCC of sensitized austenitic alloy steels due to
exposure to sulfide, moisture condensation, or oxygen.
c. Caustic SCC (sometimes known as caustic embrittlement).
d. Amine SCC in piping systems that are not stress relieved.
e. Carbonate SCC.
f. SCC in environments where wet hydrogen sulfide exists, such as
systems containing sour water.
g. Hydrogen blistering and hydrogen induced cracking (HIC) damage.
21
Inspection for Specific Types of Corrosion and 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

Fatigue Cracking:
Fatigue cracking usually results from excessive cyclic
stresses that are well below the static yield strength of
the materials. A piping system may subject to a number
of cyclic stresses; frequent heat- up and cool-down
cycles of piping may induce thermal fatigue cracking in
the material. Excessive machinery or flow-induced
vibration may cause fatigue cracking in the piping. This
problem may be detected by PT, MT or (AE) acoustic
emission.
22
 Creep Cracking:
Creep is defined as time dependent plastic deformation under an
Inspection
applied for
loadSpecific
at Types of Corrosion and Cracking
varying temperatures. One of the most common examples of creep
cracking has
been experienced in the industry is in 1¼ Cr steels above 900°F. Creep
cracking
NDE include PT, MT, UT, RT, and in-situ metallography. Under special
conditions
AE may be employed.

Brittle Fracture:
Failure of piping at lower temperatures, usually below 60 of. Most
incidences have occurred during a hydro test or other over load
condition, and usually is not a concern for thin wall piping. Special
attention should be used when re- hydro testing low-alloy steels
(especially 2 ¼ Cr-1 Mo material), because of temper
embrittlement, also to ferritic stainless steels. (API 579 provides
procedure for assessment of equipment for resistance to brittle
fracture).

Freeze Damage:
Inspections should be performed after subfreezing temperatures.
Water and aqueous solutions in piping systems may freeze and
23
cause failure because of expansion of material. Leaks may not be
 Types of Inspection and Surveillance

The basic types of inspection include:

a. Internal visual inspection.
b. Thickness measurement inspection.
c. External visual inspection.
d. Vibrating piping inspection.
e. Supplemental inspection.

24
 Types of Inspection and Surveillance
Internal Visual Inspection:
This type of inspection is not normally performed on
piping systems, unless there is large diameter piping
involved. An additional opportunity for internal
inspection is provided when piping flanges are
disconnected, allowing visual inspection of internal
surfaces with or without the use of NDE. Removing a
section of piping and splitting it along its centerline also
permits access to internal surfaces where there is need
for such inspection.

Thickness Measurement Inspection:

Thickness measurements are used for internal
condition and remaining thickness of piping systems.
Inspectors or examiners may take measurements.

25
 Types of Inspection and Surveillance
External Visual Inspection:
External visual inspection to check the outside condition of
piping such as insulation, coating, and sign of misalignment,
vibration or leakage.

Bellow expansion joints should be inspected for unusual

deformation, misalignment or displacements.

External piping inspection shall include pipe hangers, vertical

and horizontal support dummy legs.

Qualified operating or maintenance personnel also may

conduct external inspections, when acceptable to the
inspector.

The operating or maintenance personnel shall be qualified

through an appropriate amount of training. (See 6.4 for
external inspection)

26
 Types of Inspection and Surveillance
Vibrating Piping and Line Movement Surveillance:
This inspection should be performed at junctions where
vibrating piping systems are restrained. Line movement due
to liquid hammering may occur in non-metallic piping and
abnormal thermal expansion or contraction in metallic
piping.

Supplemental Inspection:
Other inspections may be scheduled as appropriate or
necessary. Examples of such inspections include periodic use
of radiography and/or thermography to check for fouling or
internal plugging, thermography to check for hot spots in
refractory lined systems, or inspection for environmental
cracking. Acoustic emission, acoustic leak detection, and
thermography can be used for remote leak detection and
surveillance. Ultrasonic and/or radiography can be used for
detecting localized corrosion.

27
 Thickness Measurement Locations
General:
CMLs thickness measurement locations are specific areas along the
piping circuit where inspections are to be made. The selection of
CML shall consider the potential corrosion areas and degradation
mechanism.

CML Monitoring:
CMLs 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.

CML Selection:
CML may be selected on locations or areas with high probability of
failure due to corrosion such as the followings:

1. Location where it creates a safety and environmental hazard in the event of

a leak.
2. Areas with higher corrosion rates.
3. Areas with potentially localized corrosion attack.
4. More complexity in terms of fittings, branches, deadlegs, injection points,
and other similar items. 28
 Thickness Measurement Methods
Thickness Measurement Methods:
Piping larger than 1" NPS (Nominal Pipe Size) ultrasonic thickness
measuring instruments are most accurate. The radiographic profile
techniques are preferred for pipe 1" NPS and smaller. When piping
temperatures are above 150°F, a special ultrasonic equipment and
procedures must be used. Factors affect the accuracy of ultrasonic
measurements are:

a. Improper instrument calibration.

b. External coatings or scale.
c. Excessive surface roughness.
d. Excessive "rocking" of the probe (on the curved surface).
e. Subsurface material flaws, such as laminations.
f. Temperature effects (temperatures above 150°F)
g. Small flaw detector screens.
h. Thickness of less than 1/8 inch (3.2 mm).

Uniform corrosion in the piping was never truly uniform, thus

thickness measurement should be taken based on the average of
several readings cover few areas rather than rely on a point
measurement.
29
 Pressure Testing of Piping System
Pressure Testing of Piping System:
1. Pressure testing is not normally conducted as part of a
routine inspection. When this test is used, it should be
performed in accordance with ASME B31.3.
2. Piping of 300 series stainless steels should be hydro-
tested with potable water or steam condensate. If the
potable water is not available, water with low chloride
and pH > 10 should be considered.
3. A pneumatic pressure test may be used when it is
impracticable to hydrotest the system. Such tests must
be in compliance with ASME B31.3.
4. Precautions should be used when safety relief valves
are installed in the system. Isolation or removal of the
safety relief valves may be necessary during the test.
5. When a pressure test is required, it shall be conducted
after any heat treatment.
30
 Material Verification and Traceability

Material verification is required during repair or

alteration of pressure containing equipment. PMI may
be used to verify a sample or 100% for critical parts.
Components that do not meet the requirements should
be replaced. API 578 may be used for material
verifications.

31
 Inspection of Valves

Refer to API Standard 598 for closure pressure tests.

Normally wall thickness measurements are not taken
on valve body in a piping circuit, normally valve body is
thicker than the piping. Other inspections include
external visual examinations, as well as internal
inspections if metal loss is suspected.

32
 Inspection of Welds In-Service

The use of profile radiography is recommended when

searching for corrosion or other imperfections in welds
that are in-service.

Weld imperfections may be the result of original weld

fabrication or service. A determination should be made
as to what caused the problem.

This may be evaluated by:

1. Inspector judgment.
2. Certified welding inspector judgment.
3. Piping engineer judgment.
4. Engineering fitness-for-service analysis.

33
 Inspection of Welds In-Service
The following should be considered when assessing the
quality of existing welds:

1. Original fabrication inspection acceptance criteria.

2. Extent, magnitude and orientation of imperfections.
3. Length of time in service.
4. Operating versus design conditions.
5. Presence of secondary piping stresses.
6. Potential for fatigue loads.
7. Potential for environmental cracking.
8. Weld hardness.

Note: Some welds may meet original construction criteria but will
not perform satisfactorily in-service.
A qualified UT shear wave examiner is required for the followings:
1. Detecting internal surface breaking flaws.
2. Detection and assessment of through-wall planar defects.
The requirement becomes effective 2 years after publication of this
code or addendum.
34
 Inspection of Flanged Joints
1. Fasteners should extend completely through their nuts. Any
fastener failing to do so is considered acceptably engaged if the
lack of complete engagement is not more than one thread.

2. If installed flanges are excessively bent, their markings and

thicknesses should be checked against engineering requirements
before taking corrective action.

3. Flange and valve bonnet fasteners should be examined visually for

corrosion.
4. Flanged and valve bonnet joints should be examined for evidence of
leakage, such as stains, deposits, or drips. Process leaks onto flange
and bonnet fasteners may result in corrosion or environmental
cracking.

5. Flanged joints that have been clamped and pumped with sealant
should be checked for leakage at the bolts.

6. Fasteners on instrumentation that are subject to process pressure

and/or temperature should be included in the scope of these
examinations.
35
 Frequency and extent of inspection
General:
Risk-based inspection (RBI) concept may be used to
plan 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.

Piping Service Classes:

Piping shall be categorized into different classes or
hazard levels. Higher class piping requires more
extensive inspection and at shorter interval.
Classification shall be based on potential safety and
environmental hazards should a leak occur. API RP 750
and NFPA 704 (National Fire Prevention Association)
may be used as guidelines.

36
Class 1: Piping Service Classes
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 includes, 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 C2 (ethylenes), C3 (propylenes),
C4 (butanes) streams.
3. Hydrogen sulfide (greater than 3% weight) in a gaseous
Stream.
4. Anhydrous hydrogen chloride.
5. Hydrofluoric acid.
6. Piping over or adjacent to water and piping over public
throughways.

37
 Piping Service Classes

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:

1. On-site hydrocarbons that will slowly vaporize during

release
2. Hydrogen, fuel gas, and natural gas.
3. On-site strong acids and caustics.

38
 Piping Service Classes
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.

39
 Inspection Intervals
The criteria for inspection intervals are as follows:

1. Corrosion rate and remaining life calculations.

2. Piping services classification.
3. Applicable jurisdictional requirements.
4. Judgment of the inspector, piping engineer, engineer
supervisor, or a corrosion specialist, based on operating
conditions, history, current results and special conditions.

The owner/user shall establish inspection intervals for

thickness measurements and external visual inspections.
Table 6-1 shows maximum inspection intervals. Inspections
should be based on Table 6-1 or half the remaining life
determined from the corrosion rates which ever is shorter.

The inspection interval must be reviewed and adjusted as

necessary after each inspection or significant change in
operating conditions.
40
Inspection Intervals

41
 Extent of Inspection
Extent of Visual External and CUI Inspections:
External inspections should be scheduled in accordance with Table
6-2 using the checklist in Appendix D, external inspection checklist
for process piping.

Alternatively, external visual inspection intervals can be established

by using a valid RBI assessment conducted in accordance with API
RP 580.

It is recognized that several factors may affect the likelihood of CUI

to include:

a. Local climatic conditions (see 5.3.3).

b. Insulation design.
c. Coating quality.
d. Service conditions.

Piping systems that are known to have a remaining life of over 10

years or that are adequately protected against external corrosion
need not be included for the NDE inspection recommended in Table
6-2.
42
Extent of Inspection

43
Inspection Checklist

44
 Extent of Inspection

Extent of Thickness Measurement Inspection:

As a minimum, a representative sampling of TMLS shall be

measured, including various types of components and
orientations (horizontal and vertical) found in each circuit.
The more TMLs measured for each circuit, the more
accurately the next inspection date will be projected.
Therefore, scheduled inspection of circuits should obtain as
many measurements as necessary.

45
 Extent of Inspection
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. SBP that is secondary process piping has different
minimum requirements depending upon service
classification.

Auxiliary Piping Inspection:

Inspection of secondary, auxiliary SBP associated with

instruments and machinery is optional. Criteria to consider in
determining whether auxiliary SBP will need some form of
inspection include the following:

a. Classification.
b. Potential for environmental or fatigue cracking.
c. Potential for corrosion based on experience with adjacent
primary systems.
d. Potential for CUI.
46
Inspection Data Evaluation, Analysis, And Recording
Remaining Life Calculations:
The remaining life of the piping system shall be calculated from
the
following formula:

47
Inspection Data Evaluation, Analysis, And Recording
The long-term (LT) corrosion rate of piping circuits
shall
be calculated from the following formula:

48
Inspection Data Evaluation, Analysis, And Recording
The short term (ST) corrosion rate of piping circuits
shall
be calculated from the following formula:

49
Inspection data evaluation, analysis, and recording

Corrosion Rate Determination:

Statistical analysis employing point measurements is

not applicable to piping systems with significant
localized unpredictable corrosion mechanisms.

Long-term and short-term corrosion rates should be

compared to see which results in the shortest
remaining life as part of the data assessment.

The authorized inspector, in consultation with a

corrosion specialist, shall select the corrosion rate that
best reflects the current process.

50
CORROSION RATE
Inspection data DETERMINATION:
evaluation, analysis, and recording
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.

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, use the
higher 51
Inspection Data Evaluation,
Maximum Allowable Working Analysis,
Pressure And Recording
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:

1. Upper and/or lower temperature limits for specific

materials.
2. Quality of materials and workmanship.
3. Inspection requirements.
4. Reinforcement of openings.
5. Any cyclical service requirements.
52
API 570 uses the "Half-Life" concept (See Table 7-1)
Table 7-1: Examples of the Calculation of (MAWP)

53
Table 7-1: Examples of the Calculation of (MAWP)

54
 Retirement Thickness Determination
The retirement thickness shall be equal or greater than
the minimum required thickness, and shall be based on
pressure, mechanical, and structural considerations
using the appropriate design formulae and code
allowable stress.

Consideration of both general and localized corrosion

shall be included.

For services with high potential consequences if failure

were to occur, the piping engineer should consider
increasing the required minimum thickness above the
calculated minimum thickness to provide for
unanticipated or unknown loadings, undiscovered metal
loss, or resistance to normal abuse.

55
 Assessment Of Inspection Findings
Fitness-for-service techniques, such as those documented in API RP
579, may be used for this evaluation. The fitness-for-service
techniques used must be applicable to the specific degradation
observed. The following techniques may be used as applicable:

56
 Assessment
PIPING STRESS Of Inspection Findings
ANALYSIS:
Piping must be supported and guided so that:

a. its weight is carried safely;

b. it has sufficient flexibility for thermal expansion or
contraction;
c. it does not vibrate excessively.

When unexpected movement of a piping system is

observed, such as during an external visual inspection,
the inspector should discuss these observations with
the piping engineer and evaluate the need for
conducting a piping stress analysis.

Piping stress analysis also can be employed to help

solve observed piping vibration problems. The natural
frequencies in which a piping system will vibrate can be
predicted by analysis.
57
Reporting and Records for Piping System Inspection
The owner/user shall maintain appropriate permanent and
progressive records of each piping system covered by API
570. These records shall contain pertinent data such as the
following:

a. Piping system service & classification.

b. Identification numbers.
c. Inspection intervals.
d. Documents necessary to record the name of the individual
performing the testing.
e. The date of Inspection.
f. The types of testing.
g. The results of thickness measurements and other tests.
h. Design information and piping drawings may be included.

API 574 offers guidance for piping inspection records.

58
Repairs, Alterations, And Re-rating 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.

Authorization:
All repair and alteration work must be done by a repair organization
as defined in Section 3 of API 570 and must be authorized by the
inspector prior to its commencement. Authorization for alteration
work to a piping system may not be given without prior consultation
with, and approval by, the piping engineer.

Approval:
All proposed methods of design, execution, materials, welding
procedures, examination, and testing must be approved by the
inspector or by the piping engineer. Welding repairs of cracks that
occurred in-service should not be attempted without prior
consultation with the piping engineer in order to identify and correct
the cause of the cracking.

59
 Welding Repairs (Including On-Stream)

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.

Longitudinal cracks shall not be repaired in this manner

unless the piping engineer has determined that cracks would
not be expected to propagate from under the sleeve.

The material for the repair shall match the base metal unless
approved by the piping engineer.

60
 Welding Repairs (Including On-Stream)
Permanent Repairs:
Repairs to defects found in piping components may be made by
preparing a welding groove that completely removes the defect and
then filling the groove with weld metal deposition.
Corroded areas may be restored with weld metal deposited in
accordance with 8.2. of API 570.
Surface irregularities and contamination shall be removed before
welding.
If it is feasible to take the piping system out of service, the
defective area may be removed by cutting out a cylindrical section
and replacing it with a piping component that meets the applicable
code.
Insert patches (flush patches) may be used to repair damaged or
corroded areas if the following requirements are met:
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.
61
 Non-welding Repair (on-stream)
 Temporary repairs of locally thinned sections or
circumferential linear defects may be made on-stream
by installing a properly designed and fabricated bolted
leak clamp. The design shall include control of axial
thrust loads if the piping component being clamped is
(or may become) insufficient to control pressure thrust.

 The effect of clamping (crushing) forces on the

component also shall be considered.

 During turnarounds or other appropriate opportunities,

temporary leak sealing and leak dissipating devices,
including valves, shall be removed and appropriate
actions taken to restore the original integrity of the
piping system.
62
All repair and alteration welding shall be done in accordance
with the
Welding And Hot Tapping
principles of ASME B31.3 or the code to which the piping
system was
built.

Hot Tapping:
Any welding conducted on piping components in operation
must be done
in accordance with API Publ 2201. The inspector shall use as a
minimum
the “Suggested Hot Tap Checklist” contained in API Publication
2201 for
hot tapping performed on piping components.

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.

The repair organization shall maintain records of welding

procedures and 63
 Preheating and Postweld Heat Treatment
Preheating:
Preheat temperature used in making welding repairs
shall be in accordance with the applicable code and
qualified welding procedure.

Preheating to not less than 300°F (150°C) may be

considered as an alternative to postweld heat
treatment (PWHT) for alterations or repairs of piping
systems initially postweld heat treated as a code
requirement.

The inspector should determine that the minimum

preheat temperature is measured and maintained. After
welding, the joint should immediately be covered with
insulation to slow the cooling rate.

64
Postweld Heat Treatment:
PWHTPreheating and
of piping system Postweld
repairs Heatshould
or alterations Treatment
be made using
the applicable requirements of ASME B31.3 or the code to which the
piping was built.

Exceptions for temporary repairs must be approved by the piping

engineer.

Local PWHT may be substituted on local repairs, provided the

following:
a. The application is reviewed, and a procedure is developed by the piping
engineer.
b. Consideration shall be given to applicable factors, such as base metal
thickness, thermal gradients, material properties, changes resulting
from PWHT, the need for full-penetration welds, and surface and
volumetric examinations after PWHT.
c. A preheat of 300°F (150°C), or higher as specified by specific welding
procedures, is maintained while welding.
d. The required PWHT temperature shall be maintained for a distance of
not less than two times the base metal thickness measured from the
weld. The PWHT temperature shall be monitored by a suitable number
of thermocouples (a minimum of two).
e. Controlled heat also shall be applied to any branch connection or other
attachment within the PWHT area.
f. The PWHT is performed for code 65 compliance and not for environmental
cracking resistance.
Repairs, Alterations, And Re-rating Of Piping Systems
Designs:
Butt joints shall be full-penetration groove welds.

New connections and replacements shall be designed and

fabricated according to the principles of the applicable code.

Fillet-welded patches require special design considerations,

especially relating to weld-joint efficiency and crevice
corrosion.

Fillet-welded patches shall be designed by the piping

engineer. A patch may be applied to the external surfaces of
piping.

Material:
The materials used in making repairs or alterations shall be
of known weldable quality, shall conform to the applicable
code, and shall be compatible with the original material.
66
Repairs, Alterations, And Re-rating Of Piping Systems

Pressure Testing:
Pressure tests are normally required after alterations
and major repairs.

When a pressure test is not necessary or practical, NDE

shall be utilized in lieu of a pressure test.

The owner/user shall specify industry-qualified UT shear

wave examiners for closure welds that have not been
pressure tested and for weld repairs identified by the
piping engineer or authorized inspector.

67
Repairs, Alterations, And Re-rating Of Piping Systems
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.
4. Rerated piping systems shall be leak tested.
5. All pressure relieving devices are checked and appropriately set
6. The piping system rerating is acceptable to the inspector or piping
engineer.
7. All piping components are adequate for the new pressure and
temperature.
8. Piping flexibility is adequate for design temperature changes.
9. Engineering records are updated.
10.A decrease in minimum operation temperature is justified by Impact
test results.
68
 Inspection Of Buried Piping

Types and Methods of

Inspection:

1. Above-Grade Visual
Surveillance
2. Close-Interval Potential
Survey
3. Pipe Coating Holiday
Survey
4. Soil Resistivity
5. Cathodic Protection
Monitoring
6. Inspection Methods

69
 Types and Methods of Inspection
Above-Grade Visual Surveillance:
Indications of leaks in buried piping may include a change in
the surface contour of the ground, discoloration of the soil,
softening of paving asphalt, pool formation, bubbling water,
or noticeable odor.

Surveying the route of buried piping is one method of

identifying problem areas.

Close-Interval Potential Survey:

The close-interval potential survey performed at ground level
over the buried pipe can be used to locate active corrosion
points on the pipe’s surface.

Corrosion cells can form on both bare and coated pipe where
the bare steel contacts the soil. Since the potential at the
area of corrosion will be measurably different from an
adjacent area on the pipe, the location of the corrosion
activity can be determined by70this survey technique.
 Types and Methods of Inspection
Pipe Coating Holiday Survey:
The pipe coating holiday survey can be used to locate
coating defects on buried coated pipes, and it can be
used on newly constructed pipe systems to ensure that
the coating is intact and holiday-free.
More often it is used to evaluate coating serviceability
for buried piping that has been in-service for an
extended period of time.

Soil Resistivity:
Corrosion of bare or poorly coated piping is often
caused by a mixture of different soils in contact with
the pipe surface. The corrosiveness of the soils can be
determined by a measurement of the soil resistivity.
Lower levels of resistivity are relatively more corrosive
than higher levels.
71
Types and Methods of Inspection

72
 Types and Methods of Inspection

Cathodic Protection Monitoring:

Cathodically protected buried piping should be
monitored regularly to assure adequate levels of
protection. Monitoring should include periodic
measurement and analysis of pipe-to soil potentials by
personnel trained and experienced in cathodic
protection system operation.

Refer to NACE RP0169 and Section 11 of API RP 651 for

guidance applicable to inspecting and maintaining
cathodic protection systems for buried piping.

73
 Types and Methods of Inspection
Inspection Methods:
Several inspection methods are available. Examples are as
follows:

Intelligent pigging: This method involves the movement of a

device (pig) through the piping either while it is in-service or
after it has been removed from service. The line must also
have facilities for launching and recovering the pigs.

Video cameras: Television cameras are available that can be

inserted into the piping. These cameras may provide visual
inspection information on the internal condition of the line.

Excavation: In many cases, the only available inspection

method that can be performed is unearthing the piping in
order to visually inspect the external condition of the piping
and to evaluate its thickness. Care should be exercised in
removing soil from above and around the piping to prevent
damaging the line or line coating.
74
 Frequency and Extent of Inspection
Above-Grade Visual Surveillance:
The owner/user should, at approximately 6-month intervals
survey the surface conditions on and adjacent to each
pipeline path.

Pipe-to-Soil Potential Survey:

For poorly coated pipes where cathodic protection potentials
are inconsistent, the survey may be conducted at 5-year
intervals for verification of continuous corrosion control.
For piping with no cathodic protection or in areas where
leaks have occurred due to external corrosion, a pipe-to-soil
potential survey may be conducted along the pipe route.

Pipe Coating Holiday Survey:

The frequency of pipe coating holiday surveys is usually
based on indications that other forms of corrosion control are
ineffective.

75
 Frequency and Extent of Inspection

Soil Corrosivity:
For piping buried in lengths greater than 100 feet (30
m) and not cathodically protected, evaluations of soil
corrosivity should be performed at 5-year intervals.

Cathodic Protection:
The system should be monitored at intervals in
accordance with Section 10 of NACE RP0169 or Section
11 of API RP 651.

76
 Frequency and Extent of Inspection
External and Internal Inspection Intervals:
 The external condition of buried piping that is not cathodically
protected should be determined by either pigging, which can
measure wall thickness, or by excavating according to the
frequency given in Table 9-1.

 Significant external corrosion detected by pigging or by other

means may require excavation and evaluation even if the piping is
cathodically protected.

 Piping inspected periodically by excavation shall be inspected in

lengths of 6 feet–8 feet (2.0 m–2.5 m) at one or more locations
judged to be most susceptible to corrosion.

 If inspection reveals damaged coating or corroded piping, additional

piping shall be excavated until the extent of the condition is
identified.

 If the piping is contained inside a casing pipe, the condition of the

casing should be inspected to determine if water and/or soil has
entered the casing.
77
 Frequency and Extent of Inspection

External and Internal Inspection Intervals (Table 9-

1):

78
 Frequency and Extent of Inspection
Leak Testing Intervals:
 An alternative or supplement to inspection is leak testing
with liquid at a pressure at least 10 percent greater than
maximum operating pressure at intervals one-half the length
of those shown in Table 9-1 for piping not cathodically
protected.

 Same intervals as shown in Table 9-1 for cathodically

protected piping.

 The leak test should be maintained for a period of 8 hours.

Four hours after the initial pressurization of the piping
system, the pressure should be noted and, if necessary, the
line repressurized to original test pressure and isolated from
the pressure source.

 If, during the remainder of the test period, the pressure

decreases more than 5 percent, the piping should be visually
inspected externally and/or inspected internally to find the
leak and assess the extent of79corrosion.
 Repairs to Buried Piping Systems
Repairs to Coatings:
Any coating removed for inspection shall be renewed and
inspected appropriately.
For coating repairs, the inspector should be assured that the
coating meets the following criteria:

1. It has sufficient adhesion to the pipe to prevent under film

migration of moisture.
2. It is sufficiently ductile to resist cracking.
3. It is free of voids and gaps in the coating (holidays).
4. It has sufficient strength to resist damage due to handling
and soil stress.
5. It can support any supplemental cathodic protection.

Coating repairs may be tested using a high voltage holiday

detector. The detector voltage shall be adjusted to the
appropriate value for the coating material and thickness.
80
 Repairs to Buried Piping Systems
Clamp Repairs:

If piping leaks are clamped and reburied, the location of

the clamp shall be logged in the inspection record and
may be surface marked. Both the marker and the
record shall note the date of installation and the
location of the clamp. All clamps shall be considered
temporary. The piping should be permanently repaired
at the first opportunity.

Welded Repairs:
Welded repairs shall be made in accordance in 8.2.

81
 Examples of Repairs
The longitudinal welds (number 1, Figure C-1) on the
reinforcing sleeve shall be fitted with a suitable tape or mild
steel backing strip (see note) to avoid fusing the weld to the
side wall of the pipe.

82
Examples of Repairs

Small Repair
Patches:
Examples of small
repair patches are
shown in figure C-
2.

83
 End
Course Facilitator:

Muhammad Aqeel
API 653, 510, 570, 571, 577 & 580 Certified

mailto : [email protected]

84