Overview of Process Plant

Piping System Maintenance

and Repair

Participants Workbook

CONTACT INFORMATION
ASME Headquarters
1-800-THE-ASME

ASME Professional Development

1-800-THE-ASME
Eastern Regional Office
8996 Burke Lake Road - Suite L102
Burke, VA 22015-1607
703-978-5000
800-221-5536
703-978-1157 (FAX)
Midwest Regional Office
1117 S. Milwaukee Ave.
Building B - Suite 13
Libertyville, IL 60048-5258
847-680-5493
800-628-6437
847-680-6012 (FAX)
Northeast Regional Office
326 Clock Tower Commons
Route 22
Brewster, NY 10509-9241
914-279-6200
800-628-5981
914-279-7765 (FAX)
International Regional Office
1-800-THE-ASME

Southern Regional Office

1950 Stemmons Freeway - Suite
5037C
Dallas, TX 75207-3109
214-746-4900
800-445-2388
214-746-4902 (FAX)
Western Regional Office
119-C Paul Drive
San Rafael, CA 94903-2022
415-499-1148
800-624-9002
415-499-1338 (FAX)

You can also find information on

these courses and all of ASME,
including ASME Professional
Development, the Vice President
of Professional Development,
and other contacts at the ASME
Web site...
http://www.asme.org

Overview of Process Plant Piping System

Maintenance and Repair
Edited by:
Vincent A. Carucci
Carmagen Engineering, Inc.

Copyright 1999 by

All Rights Reserved

TABLE OF CONTENTS

Part 1: PARTICIPANT NOTES.3

Part 2: BACKGROUND MATERIAL36
I. Introduction .... 37
II. Inspection and Testing Practices ....40
III. Inspection Frequency and Extent .45
IV. Evaluation and Analysis of Inspection Data ....49
V. Repairs, Alterations, and Rerating ....55
VI. Inspection of Buried Piping .....65
VII. Summary ..68
VIII. Suggested Reading ......69

Part 1:
Participant Notes

Overview of Process Plant

Piping System
Maintenance and Repair

Notes:

Course Outline
Introduction
General
Inspection and Testing Practices
Inspection Frequency and Extent
Evaluation and Analysis of Inspection Data
Repairs, Alterations, and Rerating
Inspection of Buried Piping
Closure
2

Notes:

Scope of API 570

Inspection, repair, alteration, rerating of inservice metallic piping systems
To be used by qualified organizations and
individuals
Included fluid services: process fluids,
hydrocarbons, similar flammable or toxic
services
3

Notes:

Scope of API 570 (Cont.)

Excluded and optional piping systems
Hazardous services below threshold limits
Water, steam, steam-condensate, BFW, Category
D services
Systems on movable structures governed by
jurisdictions
Systems integral with mechanical devices
Internal piping
Plumbing and sewers
Size NPS 1/2
Non-metallic or lined piping
4

Notes:

Definitions
Alteration

- Physical change affecting

pressure containing capability
or flexibility

Repair

- Work to restore piping system

to be suitable for design
conditions

MAWP

- Maximum permitted internal

pressure for continuous
operation at design temperature

Notes:

Definitions (Cont.)
Rerate

- Change in design pressure,

design temperature, or both

Piping Circuit - Pipe section exposed to

similar corrosivity, with
similar design conditions
and material

Notes:

Types of Pipe Deterioration

Injection points

Deadlegs

CUI

Soil-to-air interfaces

Service-specific and
localized corrosion

Erosion and
corrosion/erosion

Environmental
cracking

Corrosion under
linings and deposits

Fatigue cracking

Creep cracking

Brittle fracture

Freeze damage

Notes:

Typical Injection
Point Circuit
O ve rh ead L in e

G re ate r of
3D or 1 2"

*
*

In jectio n
p oin t
*

*
O ve r hea d
Co nde ns e rs

*
D istilla tion
T o we r

In jectio n p oint
pipin g cir cuit

* = Typical T M L

Figure 1

Notes:

Systems Susceptible to CUI

Areas exposed to:

Mist overspray from cooling water towers

Deluge systems
Steam vents
Process spills, moisture ingress, acid vapors

CS systems operating in range 25-250F

CS systems in intermittent service over 250F
Deadlegs and attachments protruding from
insulation
9

Notes:

Systems Susceptible to CUI

(Cont.)
Austenitic stainless steels operating in range
150-400F
Vibrating systems with damaged insulation
jacketing
Steam-traced systems with tracing leaks
Systems with deteriorated coatings and/or
wrappings
10

Notes:

Locations Susceptible to CUI

Penetrations/breaches in
jacket
Damaged/missing
jacketing
Hardened, separated, or
missing caulking
Piping low points in
systems that have
insulation breach
Insulation plug locations

Insulation termination points

Jacket seams on top of
horizontal piping or
improperly lapped/sealed
jacket
Bulges or staining of
insulation or jacketing, or
missing bands
Carbon or low-alloy steel
components in high-alloy
systems

11

Notes:

Inspection Types
Internal visual
Thickness measurement
External visual
Vibrating piping
Supplemental inspection
Radiography
AET

Thermography
UT

12

Notes:

External Visual Inspection

Observations by non-inspectors
Scheduled inspections by qualified inspector
and documented
Check for:

Leaks
Vibration
Corrosion
Paint condition
Incorrect components

Misalignment
Support condition
Insulation condition
Unrecorded field
modifications or
temporary repairs

13

Notes:

Thickness Measurement
Locations (TMLs)
Specific inspection areas along piping circuit
Nature of TML varies by location
Selection considers potential for local corrosion
and service-specific corrosion

Thickness monitoring at TMLs

TMLs distributed in circuit
More TMLs and more frequent monitoring based
on situation
14

Notes:

10

Thickness Measurement
Locations (TMLs) (Cont.)
Test points - circles
Within TMLs
Pipe Size

Circle Diameter

NPS 10

> NPS 10

Thickness averaging

Mark TMLs for follow-up measurements

15

Notes:

TML Selection
More TMLs:
Leak has high risk potential
High potential for localized
corrosion
High CUI potential

Higher corrosion rates

Complex system

Fewer TMLs:
Low risk if leak
Long, straight piping

Relatively non-corrosive
service

No TMLs:
Extremely low risk if leak
Non-corrosive service
16

Notes:

11

Thickness Measurement
Methods
UT for pipe over NPS 1
RT for pipe NPS 1
Use appropriate UT procedures
Pit depth measurements
17

Notes:

Pressure Testing
Normally not part of routine inspections
Some jurisdictional exceptions

Done per ASME B31.3

Normally a hydrotest
Special considerations for stainless steel
piping
18

Notes:

12

Other Inspections
Material verification and traceability
Valve inspection
Weld inspection
Flanged joint inspection

19

Notes:

Piping Service Classes

Class
1

Description
Highest potential of immediate emergency if leak
Examples:
Flammable service that may auto-refrigerate
Pressurized services that may rapidly vaporize and form explosive
mixture
H2S in gas stream (> 3 wt. %)
Anhydrous hydrogen chloride; HF
Pipe over or adjacent to water; over public throughways

2
3

Services not in other classes

Includes most process unit piping and selected off-site piping

Flammable services that do not significantly vaporize when leak

Services harmful to human tissue but located in remote areas

20

Notes:

13

Inspection Intervals
By Owner-user or inspector based on:

Corrosion rate and remaining life calculations

Piping service classification
Applicable jurisdictional requirements
Judgment based on operating conditions,
inspection history, current inspection results,
conditions warranting supplemental inspections

21

Notes:

Inspection Intervals (Cont.)

Maximum thickness measurement intervals
shorter of:
Half remaining life (considers corrosion rate)
Maximum specified in API 570

Review/adjust intervals as needed

22

Notes:

14

Maximum Inspection
Intervals
Circuit
Type

Thickness
Measurements, years

Visual
External, years

Class 1

Class 2

10

Class 3

10

10

Injection points

By Class

Soil-to-air interfaces

By Class

23

Notes:

Extent of Visual
External Inspection
Bare piping
Assess condition of paint and coating systems
Check for external corrosion, other deterioration

Insulated piping
Assess insulation condition
Additional inspection if susceptible to CUI
24

Notes:

15

CUI Inspection
Considerations
Insulation damage at higher elevations may cause
CUI at lower areas remote from damage
RT or insulation removal and VT normally required
Expand inspection as necessary
CUI inspection targets specified in API 570
Systems that may be excluded
Remaining life over 10 years
Adequately protected against external corrosion
25

Notes:

CUI Inspection Targets

Pipe
Class

Amount of Follow-up
NDE or Insulation
Removal Where
Insulation Damaged

Amount of NDE at
Suspect Areas on Piping
Within Susceptible
Temperature Ranges

75%

50%

50%

33%

25%

10%

26

Notes:

16

Extent of Thickness
Measurements
Obtain thickness readings on representative
sampling of TMLs on each circuit
Include sampling data for various
components and orientations in each circuit
Include TMLs with earliest renewal date
based on prior inspection
More TMLs more accurate prediction of
next inspection date
27

Notes:

Extent of Other Inspections

Small-bore piping (SBP), NPS 2
Primary process lines and Class 1 secondary lines:
+ Per all API 570 requirements

Classes 2 and 3 SBP

+ Inspection optional
+ Inspect deadlegs where corrosion expected

Secondary, auxiliary SBP

Inspection optional if associated with instruments
or machinery
Consider classification and potential for cracking,
corrosion, CUI
28

Notes:

17

Extent of Other Inspections

(Cont.)
Threaded connections
Inspection based on SBP and auxiliary piping
requirements
Select TMLs that can be radiographed
Additional considerations if potentially subject to
fatigue damage

29

Notes:

Remaining Life Calculations

RL

tact tmin
CR

Where: RL = Remaining life, years

tact = Minimum measured thickness,
in. (May average at test point)
tmin = Minimum required thickness
for location, in. Per B31.3 or
detailed calculations.
30

Notes:

18

Remaining Life Calculations

(Cont.)
RL for circuit based on shortest calculated RL
Determines
Inspection interval
Repair/replacement needs

31

Notes:

Corrosion Rate Calculations

Long term and short term
Compare to determine which governs
Rationalize if significantly different
t initial t last

CR (LT) = ( years between last and initial inspection s)

t previous t last

CR (ST) = ( years between last and previous inspection s)

32

Notes:

19

Corrosion Rate Estimation

New Systems or Changed
Service Conditions
Determine using one of the following:
Data from other systems of similar material in
comparable service
Estimated from Owner-users experience or from
published data on systems in comparable service
Thickness measurements
After maximum 3 months service
Consider using corrosion coupons or probes to help
establish measurement timing
Repeat until establish CR
33

Notes:

Example 1
Pipe

= NPS 16, tinitial = 0.375

Service = Gas with 3.5% H2S

treq

= 0.28

tmeas

= 0.36, 0.32, 0.33, 0.34, 0.32

In operation 10 years

34

Notes:

20

Example 1 (Cont.)
Service Class 1 5-year interval
CR/Maximum =

0.375 0.32
= 5.5 x 10-3 in./yr.
10

= (0.32 - 0.28) = 0.04 in.

0.04
Maximum Interval =
= 3.6 years
2 x 5.5 x 10 3
< 5 years

CA/Available

Maximum thickness measurement interval =

3.6 years
35

Notes:

MAWP Determination
Based on applicable code (ASME B31.3)
MAWP of system based on weakest component
(e.g., pipe, flanges, valves, fittings, etc.)
Unknown material - Calculate based on lowest
grade material and joint efficiency of code
MAWP calculation based on:
Actual measured thickness
Double estimated corrosion until next inspection
Allowances needed for other loadings
36

Notes:

21

Example 2
DP

= 500 psig,

DT = 400F

Pipe = NPS 16, STD weight, A-106 Gr. B,

OD = 16 in.
S

= 20,000 psi,

E = 1.0

tmeas = 0.32 in.

CR

= 0.01 in./yr.

Next planned inspection - 5 years

37

Notes:

Example 2 (Cont.)
Estimated thinning until next inspection 5 x 0.01 = 0.05 in.
MAWP = 2 S Et/D
= 2 x 20,000 x 1 x [0.32 - 2 x 0.05]/16
= 550 psig > 500 psig
OK
38

Notes:

22

Example 3
Same system as Example 2
Change next planned inspection to 7 years
Estimated thinning until next inspection 7 x 0.01 = 0.07 in.
MAWP = 2 S Et/D
= 2 x 20,000 x 1.0 [0.32 - 2 x 0.07]/16
= 450 psig
39

Notes:

Example 3 (Cont.)
Not acceptable. Must either:
Reduce inspection interval
Confirm maximum operating pressure will not
exceed 450 psig before 7th year
Renew pipe before 7th year

40

Notes:

23

Minimum Required
Thickness Determination
Based on:
Pressure, mechanical, structural considerations
Appropriate design formulae and code allowable stress

Consider general and localized corrosion

Consider increasing calculated value if high
potential failure consequences
Unanticipated/unknown loads
Undiscovered metal loss
Resistance to normal abuse
41

Notes:

Local Thin Area

Evaluation Alternatives
ASME B31.G criteria
Numerical stress analysis and ASME Section VIII,
Division 2, Appendix 4 criteria
Code allowable stress but < 2/3 SMYS at temperature
Additional considerations if temperature in creep range

Additional considerations if corroded longitudinal weld

and E < 1.0
Weld includes base metal each side of weld within greater
of 1 in. or twice measured thickness

Additional considerations for corroded pipe caps

42

Notes:

24

Piping Stress Analysis

Piping to be supported and restrained to:
Safely carry weight
Have sufficient flexibility for thermal movement
Not vibrate excessively

Not normally part of inspection, but:

Prior analyses identify high stress locations
Compare predicted thermal movements with actual
Analysis often needed to solve vibration problems

New analyses may be needed if conditions

change or system modified
43

Notes:

Recordkeeping Requirements
Owner-user responsibility
Permanent/progressive records required
To include:
Service
Identification
Inspection and test details
and responsible individual
Repairs (temporary and
permanent), alterations,
reratings done

Classification
Inspection interval
Results of thickness measurements
and other inspections and tests done
Pertinent design information and
piping drawings

Maintenance and other

events affecting system
integrity

Date and results of external

inspections

44

Notes:

25

Authorization and Approval of

Repairs, Alterations, and Rerating
Authorization

Work by appropriate repair organization

Authorized by inspector before starting
Piping engineer must approve alterations first
Inspector may designate hold points

Approval
Design, execution, materials, welding procedures, examination,
testing to be approved by inspector or piping engineer
Owner-user to approve on-stream welding
Consult piping engineer before repairing service-induced cracks
Inspector to approve all repairs/alterations at hold points and
after completion
45

Notes:

Welded Repairs
Follow principles of ASME B31.3 or original
construction code
Temporary repairs
Full encirclement split sleeve or box-type
enclosure (generally not for cracks)
Fillet welded split coupling or lap patch if:
Localized deterioration
SMYS < 40,000 psi
Material matches base metal unless otherwise approved
46

Notes:

26

Welded Repairs (Cont.)

May be welded onstream with proper design,
inspection, procedures
Replace with permanent repair next opportunity
+ May extend if approved/documented by piping engineer
+ Owner-user establishes appropriate procedures

Defect repair
Remove defect to sound metal
Deposit weld metal

47

Notes:

Welded Repairs (Cont.)

Locally corroded areas
Remove surface irregularities and contamination
Deposit weld metal

Remove/replace cylindrical section

Insert patch
Full-penetration weld
100% RT or UT for Class 1 or 2 systems
Rounded corners, 1 in. minimum radius

NDE after welding (e.g., PT, MT, etc.)

48

Notes:

27

Typical Welded Repairs

ts

MT or PT
See Detail 1

C
L

See Detail 2
LEGEND:

1/8"
Maximum Gap

ts = Sleeve Thickness
t = Pipe Thickness

Field Weld
CL

F ield Weld

ts
ts
Backing Strip
t
Detail 2
Butt Weld for Seam

Detail " 1 "

Fillet Girth Weld

Figure 2
Split Sleeve
49

Notes:

Typical Welded Repairs

(Cont.)
Lifting Lugs
CL
Typ.

Split Box and

End Plates on CL

Typ.

CL

Typ.

CL (2) 3/4" - 3000# Couplings

New
Containment
Box

End Plate,
(2) Required

Typ.

Figure 3
Complete-Encirclement Box
50

Notes:

28

Typical Welded Repairs

(Cont.)

Figure 4
Partial Box
51

Notes:

Typical Welded Repairs

(Cont.)

1/8"
Maximum Gap

See Detail 1

LEGEND:
t p = Sleeve Thickness
t = Pipe Thickness

tp

t
Detail " 1 "

Figure 5
Lap Patch
52

Notes:

29

Non-Welded Repairs
Temporary onstream repairs of locally
thinned sections, circumferential linear
defects, flange leaks, etc.
Bolted leak clamp or box
Design must consider:
Control of axial thrust load if piping may separate
Effect of clamping forces on pipe component
Need for and properties of leak sealing fluids
53

Notes:

Typical Non-Welded Repairs

Figure 6
Flange Clamp
54

Notes:

30

Typical Non-Welded Repairs

(Cont.)

Figure 7
Bolted Box
55

Notes:

Welding and Hot

Tapping Requirements
Per principles of ASME B31.3 or original
construction code
Procedures, qualifications, recordkeeping
Hot tapping (or other onstream welding)
Per API Publication 2201
Detailed inspection, design, installation, safety
procedures required

56

Notes:

31

Welding and Hot Tapping

Requirements (Cont.)
Preheat
Per applicable code and welding procedure
May be alternative to PWHT

PWHT
Per applicable code and welding procedure
May be needed due to service
Local PWHT may be possible

57

Notes:

Welding and Hot Tapping

Requirements (Cont.)
Design
Full-penetration groove welds for butt joints
New and replacement components per applicable code
Special design considerations for fillet-welded patches

Materials
NDE

58

Notes:

32

Pressure Testing
Done if practical and deemed necessary by
inspector
Normally required after alterations and major
repairs
May use NDE instead after consultation with
inspector and piping engineer

59

Notes:

Pressure Testing (Cont.)

If not practical to pressure test final closure
weld:
Pressure test new or replacement piping
Closure weld is full-penetration butt weld between
WN flange and standard pipe component, or
straight pipe sections of equal diameter and
thickness, axially aligned, equivalent materials.
SO and SW flange alternatives identified
100% RT or UT
MT or PT root pass and completed weld for buttwelds, and on completed weld for fillet welds
60

Notes:

33

Rerating
Requirements to be met:
Design calculations
Inspection verifies
condition and CA provided
Safety valves reset
All system components
acceptable
Records updated
Meet original or latest
code

Must be pressure tested

unless already done at
sufficient pressure
Acceptable to inspector or
piping engineer
Piping flexibility adequate
for design temperature
changes
Temperature decrease
justified by impact test
results

61

Notes:

Inspection of Buried Piping

Significant external corrosion possible
Inspection hindered by inaccessibility
Above-grade visual surveillance for leak indications
Close-interval potential survey
Pipe coating holiday survey
Soil resistivity
Cathodic protection monitoring
62

Notes:

34

Other Requirements for

Buried Pipe
Inspection Methods
Intervals
Extent
Repair Methods

63

Notes:

Summary
Inspection, repair, alteration, rerating of inservice piping systems are normal activities
Requirements and procedures are necessary
to maintain piping system integrity
API 570 is industry standard to be used

64

Notes:

35

Part 2:
Background Material

36

I. Introduction
The structural integrity of piping systems must be maintained after they have
been placed into service so that they will provide safe, reliable, long-term
operation. Therefore, existing piping systems require periodic inspection to
determine their current condition and permit evaluation of their structural integrity
to permit future operation. Should unacceptable deterioration or flaws be
identified, pipe repairs may be required. Existing piping systems might also
require alterations or rerating to accommodate new operational needs (or to
accommodate deterioration that cannot or will not be repaired).
Process plants must adopt and follow established procedures for the inspection,
repair, alteration, and rerating of piping systems after they have been placed into
service. API 570, Piping Inspection Code Inspection, Repair, Alteration, and
Rerating of In-Service Piping Systems, provides the basic procedures to be
followed by process plants. This course is based on API 570.
Scope of API 570
API 570 was developed for the petroleum refining and chemical process
industries. But since most of its requirements have broad applicability, it may be
used for any piping system. It must be used by organizations that maintain or
have access to an authorized inspection agency, a repair organization, and
technically qualified piping engineers, inspectors, and examiners (as defined in
API 570).
While API 570 applies to all petroleum refineries and chemical plants, its scope
defines both specific included fluid services, and excluded and optional piping
systems. Thus, API 570 requirements do not necessarily have to be applied to
every piping system in a refinery or chemical plant.
Included Fluid Service
Unless identified by API 570 as being an excluded or optional system, API 570
applies to piping systems for process fluids, hydrocarbons, and similar flammable
or toxic fluid services. Examples of these are the following:

Raw, intermediate, and finished petroleum or chemical products.

Catalyst lines.

Hydrogen, natural gas, fuel gas, and flare systems.

Sour water and hazardous waste streams or chemicals above threshold

limits, as defined by jurisdictional regulations.

37

Excluded and Optional Piping Systems

API 570 permits the following fluid services and classes to be excluded from its
specific requirements. This is done to focus attention (with associated manpower
and budget expenditures) on applications that would have the most significant
consequences should a pipe failure occur. However, any of these excluded
systems may be included in a plants API 570 program at the option of the owner.

Fluid services that are excluded or optional include the following:

-

Hazardous fluid services below threshold limits, as defined by

jurisdictional regulatories.

Water (including fire protection systems), steam, steam condensate, boiler

feedwater, and Category D fluid services (as defined by ASME B31.3).

Classes of piping systems that are excluded or optional are as follows:

-

Piping systems on movable structures covered by jurisdictional regulation

(e.g., piping systems on trucks, ships, barges, etc.).

Piping systems that are an integral part or component of rotating or

reciprocating mechanical devices (e.g., pumps, compressors, etc.) where
the primary design considerations and/or stresses are derived from the
functional requirements of the device.

Internal piping or tubing of fired heaters or boilers.

Pressure vessels, heaters, furnaces, heat exchangers, and the fluid

handling or processing equipment (including internal piping and
connections for external piping).

Plumbing, sanitary sewers, process waste sewers, and storm sewers.

Piping or tubing with an outside diameter not exceeding that of NPS

Nonmetallic piping and polymeric or glass-lined piping.

API 570 permits these services and systems to be excluded from its specific
requirements to focus inspection, engineering, and maintenance resources on
areas that would have the largest potential effect should leakage or failure occur.
However, this should not be interpreted that these excludable or optional
systems should be completely ignored. Furthermore, the consequences of a
failure in some of these systems could be dangerous or unacceptable in
particular circumstances. Therefore, owners may wish to include some of these
services or systems in their API 570 program in all respects, and different
requirements and procedures may be used for other services or systems. For
example:

38

The failure of a high pressure steam or boiler feedwater system could have
significant personnel safety consequences. An owner might include such
services in his API 570 program.

The failure of an NPS vent connection in an included fluid service could

have significant personnel safety and economic consequences. An owner
might wish to include such systems in his API 570 program.

Definitions
API 570 contains definitions of technical terms that are used in the standard.
The following are several of these terms used in this course:

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.

Repair

The work necessary to restore a piping system to a condition

suitable for safe operation at the design conditions.

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.

Rerate

A change in either or both the design temperature or the

maximum allowable working pressure.

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.

39

II. Inspection and Testing Practices

Types of Pipe Deterioration
The piping inspection techniques that are used must consider the type(s) of
deterioration that might be found in particular services or locations. The following
types and areas of deterioration might occur:

Injection point corrosion

Deadleg corrosion

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 fractures

Freeze damage

Several of these items are briefly discussed below.

Injection Points
Portions of a piping system that are in the vicinity of injection points may be
subject to accelerated or localized corrosion. Such regions should be treated as
separate inspection circuits and be thoroughly inspected periodically. API 570
provides suggested lengths of pipe upstream and downstream of the injection
point that should be included in the injection point circuit. Figure 1 illustrates a
typical injection point circuit.

40

Greater of
3D or 12"

Overhead Line

*
*

Injection
point
*
*

*
Distillation
Tower

Overhead
Condensers

Injection point
piping circuit

* = Typical TML

Typical Injection Point Circuit

Figure 1
Systems Susceptible to CUI
Piping systems may be subject to external corrosion under insulation (CUI) in
situations where the integrity of the insulation system has been compromised.
Therefore, special inspection attention should be paid to situations where CUI
might be a concern. The following highlights areas and types of piping systems
that might be more prone to CUI:

Areas exposed to :
-

Mist overspray from cooling towers

Steam vents

Deluge systems

Process spills, moisture ingress,

acid vapors

Carbon steel piping operating in the range 25F to 250F.

Carbon steel piping operating intermittently above 250F.

Deadlegs or other attachments protruding from insulation and at a different

temperature than the active line.

Austenitic stainless steel piping operating between 150F and 400F.

Vibrating piping that may damage insulation jacketing.

41

Steam traced piping that may have leaking tracers.

Piping with deteriorated coating or wrapping.

Locations Susceptible to CUI

For systems that are susceptible to CUI, inspection efforts should be focused first
on the most likely locations where corrosion might be found. The following
summarizes such locations:

Penetrations through or breaches in the insulation jacketing.

Insulation terminations at flanges and other piping components.

Damaged or missing insulation jacketing.

Insulation jacket seams located on the top of horizontal piping.

Improperly lapped or sealed insulation jacketing.

Insulation termination points in vertical pipe.

Caulking that has hardened, separated, or is missing.

Bulged or stained insulation or jacketing, or missing bands.

Piping low points in systems that have a breach in the insulation system.

Carbon or low-alloy steel flanges, bolting, or other components under

insulation.

Types of Inspection
The particular type of inspection that is used depends on the details of the piping
system, the service, and the type(s) of deterioration expected.

Internal Visual. Only applicable for large diameter piping, by using remote
inspection techniques, or at local areas that are accessible at openings.

Thickness Measurement. Used to determine the extent of pipe thinning and

may be done with the system either in or out of service.

External Visual. Done to determine the condition of the pipe exterior,

insulation, paint and coating systems. Also used to check for misalignment,
leakage, or vibration.

42

Vibrating Piping. Excessive piping vibration should be reported to

engineering for evaluation. Excessive pipe vibration or other line movement
could result in leakage at flanged joints or threaded connections, or a fatigue
failure. It should be remembered, however, that some amount of pipe
vibration is normal.

Supplemental Inspection. Other inspection methods may also be used based

on the specific situation. These include radiography, thermography, acoustic
emission testing (AET), or ultrasonic thickness surveys.

Thickness Measurement Locations (TMLs)

TMLs are the specific areas in a piping circuit where inspections are made. TML
locations and their number are selected based on the potential for localized or
service-specific corrosion and the consequences should a failure occur.
Pipe wall thicknesses are measured at test points within the TMLs, and the
thickness readings may be averaged to arrive at a composite thickness reading
at the TML. A test point is a circle having the following maximum diameters.
Pipe Size

Circle Diameter

NPS 10

> NPS 10

TML Selection
The number and location of the TMLs must be based on the expected types and
patterns of corrosion expected in the particular service.
More TMLs

Leak has high potential to cause damage

High potential for localized corrosion

High CUI potential

Higher corrosion rates

Complex system

Relatively non-corrosive
service

Fewer TMLs

Low risk if leak

Large, straight piping

No TMLs

Extremely low risk if leak

Non-corrosive service

43

Thickness Measurement Methods

The following thickness measurement methods are normally used.

UT for pipe over NPS 1

RT for pipe NPS 1

Pit depth measurements for pitted areas using pit depth gauges

In all areas, appropriate inspection procedures must be used to obtain reliable

results.
Pressure Testing
Except where local jurisdictions require it, pressure tests are not normally done
as part of a routine inspection. When pressure tests are done (e.g., after
alterations) they should be based on the following:

Must meet ASME B31.3 requirements.

Test fluid must be water unless this would have adverse consequences (e.g.,
freezing, process contamination, water disposal problem).

Stainless steel piping requires special attention (e.g., potable water and blown
dry).

Other Inspections
Other inspections may also be required.

Material verification and traceability. When alterations or repairs are made on

low or high-alloy piping systems, the inspector must ensure that the correct
materials are used.

Valve inspection. Inspect valves for any unusual corrosion patterns or

thinning. Valves in high temperature cyclic service might be subject to fatigue
cracking. All subsequent pressure tests should be per API 598.

Weld inspection. Welds are always inspected as part of new construction,

repairs, and alterations. They are also sometimes inspected for deterioration
as part of the normal inspection activity if problems are suspected.

Flanged joint inspection. Flanged joints should be examined for signs of

leakage. The cause of any leakage found should be determined. Special
attention should be paid to flanges that have been clamped and pumped with
sealant to stop leaks since the bolting might corrode and/or crack with time.

44

III. Inspection Frequency and Extent

Piping Service Classes
Process piping systems are categorized into different classes to help identify
systems where greater inspection efforts should be made. Greater effort should
be devoted to systems where there would be more significant safety or
environmental impact should a leak occur.
Class
1

Description

Highest potential of immediate emergency if leak.

Examples:
- Flammable service that may auto-refrigerate
- Pressurized services that may rapidly vaporize and form
explosive mixture
- H2S in gas stream (> 3 wt. %)
- Anhydrous hydrogen chloride; HF
- Pipe over or adjacent to water; over public throughways

Services not in other classes

Includes most process unit piping and selected off-site piping

Flammable services that do not significantly vaporize when leak

Services harmful to human tissue but located in remote areas

Inspection Intervals
Inspection intervals are determined based on the following:

Corrosion rate and remaining life calculations

Piping service classification

Jurisdictional requirements

Judgment of inspector and piping engineer based on experience

The maximum interval between thickness measurements should be the lower of

half the remaining life or what is specified in the following table:

45

Thickness
Measurements, Years

Visual External, Years

Class 1

Class 2

10

Class 3

10

10

Injection Points

By Class

Soil-to-Air Interfaces

By Class

Circuit Type

The inspection intervals must be reviewed and adjusted as necessary based on

the results of the thickness measurements that are made.
Extent of Visual External Inspection
External visual inspection should also be conducted at the same maximum
intervals as are used for thickness measurements.
Bare piping should be checked for:

The condition of paint and coating systems

External corrosion

Other deterioration (e.g., leakage, damaged supports, etc.)

Insulated piping should be checked for:

Damaged insulation or jacketing

Signs of CUI for systems that might be subject to this

CUI Inspection Considerations

After external visual inspection, additional inspection must be done for systems
potentially subject to CUI. The additional inspection required depends on the
pipe class and whether the insulation is damaged, as specified in the following
table:

46

Pipe
Class

Amount of follow-up NDE or

insulation removal where
insulation is damaged

Amount of NDE at suspect areas

on piping within susceptible
temperature ranges

75%

50%

50%

33%

25%

10%

The inspection may be expanded as necessary based on the initial results.

Systems with a remaining life of over 10 years, or that are adequately protected
against external corrosion, need not be included in the CUI inspection program.
However, the condition of the insulation system should be periodically checked
by operating personnel to identify signs of deterioration.
Extent of Thickness Measurements
Each thickness measurement inspection must obtain thickness readings from a
representative sampling of TMLs in each circuit. The sampling should include
data from the various components in the circuit and in different orientations (i.e.,
horizontal and vertical). TMLs with the shortest remaining life must be included.
The inspection should obtain as many measurements as necessary to accurately
assess the condition of the piping system.
Extent of Other Inspections
Other inspections are also required to adequately assess the condition of a
piping system.
Small-Bore Piping (SBP) [ NPS 2]
Inspect SBP per the following:
Service

Class

Primary Process Piping

All

Inspect per all requirements of API 570

Secondary Process Piping

Inspect per all requirements of API 570

Deadlegs

Inspection Requirement

2&3

Inspection is optional

2&3

Inspect where corrosion was experienced

or is anticipated

Note that while inspection is optional for Class 2 or 3 SBP, the owner must
always consider the potential consequence should a leak develop in SBP that
has not been inspected.

47

Secondary, Auxiliary SBP

Inspection is optional for SBP associated with instruments and machinery.
Consider the following in determining whether inspection will be done:

Piping system classification

Potential for environmental or fatigue cracking

Potential for corrosion based on experience with adjacent primary systems

Potential for CUI

Threaded Connections
Threaded connections are inspected based on the same criteria as other SBP.
TMLs for threaded connections should only include those that can be
radiographed during scheduled inspections.
Threaded connections that might be subject to fatigue damage (e.g., those
associated with machinery systems) should be periodically assessed.
Consideration may be given to using a thicker wall, adding bracing, and/or using
a welded connection in situations where the potential fatigue damage is a
concern.

48

IV. Evaluation and Analysis of Inspection Data

Remaining Life Calculations
The remaining life of piping systems must be calculated based on the corrosion
rate using the following:
Calculation
Remaining Life, RL

Equation
t act t min
corrosion rate

tact = Actual minimum thickness, in

inches, determined at inspection
tmin = Minimum required thickness, in
inches, for the limiting section or
zone

Corrosion Rate, CR (LT)

t initial t last
D1

D1 = Time (years) between last and

initial (nominal) inspections

Corrosion Rate, CR (ST)

t previousl t last

D2 = Time (years) between last and

previous inspections

D2

The long term and short term corrosion rates should be compared and the higher
value used in the remaining life calculations. If there is a significant difference
between the two corrosion rates, further evaluations should be made in an
attempt to determine the cause. The remaining life of the circuit should be based
on the shortest calculated remaining life.
Corrosion Rate Estimation

The expected corrosion rate must be estimated for new piping systems or for
systems whose service has been changed. One of the following methods must
be used to determine the probable corrosion rate.

Data collected from other piping systems fabricated of similar material and in
comparable service.

Estimate based on the owner-users experience or from published data for

similar material in comparable service.

Make initial thickness measurements after no more than three months of

service. Corrosion coupons or probes may be useful to help determine when
thickness measurements should be made. Make additional thickness
measurements as necessary until the corrosion rate is determined.

49

Example 1 - Inspection Interval Determination

An NPS 16 piping system has been in operation for 10 years and has been taken
out of service for its first thorough inspection. The following information is given:

Pipe service - Gas with 3.5% H2S

Minimum required thickness - 0.28 in.
Originally installed thickness - 0.375 in.
Thicknesses measured at five locations: 0.36, 0.32, 0.33, 0.34, 0.32

Based on the information provided, what maximum thickness measurement

interval should be used for this system?
Solution:

The pipe service places this system into Class I. Therefore, the maximum
interval cannot be more than 5 years based only on the service. Now check the
remaining life criterion.
CR/Maximum =

0.375 0.32
= 5.5 x 10-3 in./yr.
10

Available corrosion allowance = (0.32 - 0.28) = 0.04 in.

Maximum Interval =

0.04
= 3.6 years < 5 years
2 x 5.5 x 10 3

Maximum thickness measurement interval is 3.6 years.

MAWP Determination

The MAWP of a piping system must be determined based on the requirements of

the applicable piping code (i.e., ASME B31.3 in the case of process plant piping
systems). The MAWP of the system is that of the weakest component within the
system. Thus, in addition to the pipe itself, all other system components must be
considered (e.g., flanges, valves, etc.). If the pipe material is unknown, the
MAWP calculations must be based on the lowest grade (i.e., weakest) material
and lowest weld joint efficiency that would be permitted by the code.
The MAWP calculation is based on:

The actual thicknesses determined by inspection.

Double the estimated corrosion loss until the next inspection is done.
Additional allowances that might be necessary in specific cases to account for
applied loadings other than pressure.

The following examples illustrate calculation of the MAWP. Note that in both
cases, only the pipe thickness is considered.
50

Example 2 MAWP Determination

Design Pressure

500 psig

Design Temperature

400F

Pipe Material

A 106 Gr. B

Pipe Size

NPS 16

Allowable Stress

20,000 psi (from B31.3)

Longitudinal Weld Efficiency

1.0 (A 106 Gr. B is seamless pipe)

Thickness Measured During Inspection

0.32 in.

Observed Corrosion Rate

0.01 in./year

Next Planned Inspection

5 years

Estimated Thinning Until Next Inspection

5 x 0.01 = 0.05 in.

MAWP =

2 S Et
D

MAWP =

2 x 20,000 x 1 x (0.32 2 x 0.05 )

16

(from B31.3)

MAWP = 550 psig > 500 psig

Since the MAWP exceeds the system design pressure, the system may remain
in service at the design pressure without repairs, replacements, or rerating.

51

Example 3 Check Increased Inspection Interval

For the same system as in Example 1, determine if the inspection interval can be
increased to seven years.
Estimated thinning until next inspection = 7 x 0.01 = 0.07 in.
MAWP =

2 S Et
D

MAWP =

2 x 20,000 x 1 x (0.32 2 x 0.07 )

16

(from B31.3)

MAWP = 450 psig

The MAWP is less than the design pressure. Therefore, either the inspection
interval must be reduced, the operating pressure must not exceed 450 psig, or
the pipe must be repaired or replaced.

52

Minimum Required Thickness Determination

The minimum required thickness of a piping system (i.e., the retirement

thickness) must be determined considering all applicable design loads. The
design pressure of the system will normally govern the minimum required
thickness. However, local loading conditions (e.g., wind or earthquake, valve
weights, local thermal displacement stresses, etc.) might govern the minimum
required thickness in particular situations. Both general and localized corrosion
must be considered.
In cases where there are significant safety or economic loss consequences
should a failure occur, it is prudent to increase the minimum required thickness
above the calculated value. This additional allowance is meant to account for
unanticipated or unknown loads, undiscovered metal loss, tolerance in the
thickness measurements, and resistance to normal abuse.
In all cases, the normal code design formulas and allowable stresses must be
used.
Local Thin Area Evaluation

Local areas of a pipe may have thinned much more than the surrounding region.
A conservative evaluation approach for such regions is to consider the locally
corroded region in isolation and determine the minimum thickness there. If this
approach produces an acceptable MAWP, then there is no need to go further.
However, if the resulting MAWP is not acceptable, then a more detailed
evaluation approach using one of the following methods may be used.

ASME B31.G criteria. This simplified approach considers the maximum depth
and length of the locally thin area, the pipe diameter, and nominal thickness
to determine whether the thin area is acceptable. It intrinsically accounts for
the additional strength that the surrounding uncorroded pipe provides to the
thin area.

ASME Section VIII, Division 2, Appendix 4 criteria. This is a detailed

numerical stress analysis approach that permits a more exact calculation and
evaluation of the local stresses. The basic code allowable stress (rather than
the Division 2 allowable stress) is used in this analysis, but not less than 2/3
of the specified minimum yield stress (SMYS). Additional considerations are
required if the design temperature is in the creep range of the material.

Weld joint efficiency considerations. If the pipe has a longitudinal weld seam
and its joint efficiency is less than one, the proximity of a thinned area to the
weld is relevant.

53

If the thinned area is more than the larger of 1 inch or twice the measured
thickness away from the weld, then weld joint efficiency does not need to
be considered.

If the thinned area is closer to the weld, then weld joint efficiency must be
considered.

If a pipe cap is corroded, the location of the corrosion is relevant (i.e., in the
knuckle region or central portion). The knuckle region of a cap requires a
larger minimum thickness than the central portion.

Piping Stress Analysis

Performing a piping stress analysis is not normally a part of inspection and

maintenance. However, stress analysis considerations must still be kept in mind.

The pipe must be adequately supported to carry its weight. Locations where
supports have become damaged or are otherwise ineffective should be
identified for further evaluation or repair.

Adequate flexibility to accommodate thermal displacements must be

provided. Identify situations where thermal expansion might be restricted
(e.g., due to interference by adjacent items).

The pipe must not vibrate excessively, since this could cause leakage at
flanged joints and threaded connections, or cause a fatigue failure.

A new stress analysis may be required if the design conditions are changed
(e.g., due to equipment rerate) or if the system is modified (e.g., adding a new
equipment item with associated piping to the system).

Recordkeeping Requirements

The owner-user is responsible for maintaining permanent and progressive

records for all piping systems covered by API 570. These records form the basis
for developing a cost-effective inspection and maintenance program. The
records must include the following information:

Service

Classification

Identification

Inspection interval

Inspection and test details and

responsible individual

Results of thickness measurements

and other inspections and tests done

Repairs (temporary and permanent),

alterations, reratings done

Pertinent design information and

piping drawings

Maintenance activities and other

events affecting system integrity

Date and results of external

inspection

54

V. Repairs, Alterations, and Rerating

In all cases, repairs and alterations must meet ASME B31.3 requirements.
Authorization and Approval

All repairs and alternations must be done by a qualified repair organization

(defined in API 570) and must be authorized by the inspector before beginning.
Alterations must also be approved by a qualified piping engineer. The inspector
may designate hold points during repairs and alterations to permit sufficient time
for inspection.
Additional approvals are required as follows:

The inspector or piping engineer must approve the design, execution,

materials, welding procedures, examination, and testing.

The owner-user must approve all on-stream welding.

The piping engineer should be consulted prior to weld repair of any cracks
that occurred in-service. The purpose of this is to attempt to identify the
cause of the crack and correct it.

The inspector must approve all repairs and alterations at the designated hold
points and at completion of the work.

Welded Repairs

Welded repairs are preferably done while the piping system is out of service.
However, it may be possible to make weld repairs while the piping system is in
operation in particular situations provided appropriate inspections, precautions,
and hot work permit procedures are used. API 570 does not distinguish between
shut down and on-stream repairs with respect to the specified requirements, and
the owner must develop appropriate on-stream repair procedures.
API 570 recognizes that it may be necessary to temporarily repair a piping
system to permit its continued operation as fast as possible. Thus, a distinction
is made between temporary and permanent repairs.

55

Temporary Repairs

A full encirclement welded split sleeve or a box-type enclosure may be

installed over the damaged or corroded area (See Figures 2 through 4). The
sleeve or box must be welded to the pipe at locations that are thick enough to
remain intact during welding. A piping engineer must design these repairs.
This method will typically not be used to repair longitudinal cracks in the pipe
wall unless the piping engineer is convinced that the crack will not propagate
from under the repair.

A fillet-welded split coupling or a lap patch may be used to repair localized

deterioration (e.g., pitting or pinholes) if the SMYS 40,000 psi (See Figure
5).

Temporary repairs should be removed and replaced with permanent repairs at

the next available maintenance opportunity. However, temporary repairs may
remain longer if the piping engineer approves this and documents it. In most
situations, temporary repairs should generally be designed as if they will remain
installed for a long time.

56

ts

MT or PT
See Detail 1

CL

See Detail 2
LEGEND:

1/8"
Maximum Gap

ts = Sleeve Thickness
t = Pipe Thickness

Field Weld
CL

Field Weld

ts
ts
Backing Strip
t
Detail " 1 "
Fillet Girth Weld

Detail 2
Butt Weld for Seam

Welded Split Sleeve

Figure 2

57

Lifting Lugs
CL

Split Box and

End Plates on CL

Typ.

Typ.

CL

Typ.

CL (2) 3/4" - 3000# Couplings

New
Containment
Box

End Plate,
(2) Required

Typ.

Complete-Encirclement Box
Figure 3

Partial Box
Figure 4

58

1/8"
Maximum Gap

See Detail 1

LEGEND:
tp = Sleeve Thickness
t = Pipe Thickness

tp

t
Detail " 1 "

Lap Patch
Figure 5
Permanent Repairs

A relatively small defect may be repaired by completely removing it and then

filling the resulting groove with weld metal.

Locally corroded areas may be repaired by first removing any surface

irregularities and contamination, and then restoring the thickness with weld
metal. This approach is only practical for relatively small areas.

If the system can be taken out of service, a cylindrical section of pipe that
contains the defective area can be removed and replaced.

59

An insert patch (i.e., flush patch) may be used as a repair if:

-

Full penetration groove welds are used.

The welds are 100% radiographed or ultrasonically examined for Class 1

or 2 piping systems.

The patches have rounded corners with a 1 inch minimum radius.

Care must be taken to ensure that insert patches conform to the pipe
curvature to avoid local geometric discontinuities that could act as stress
concentration points.

In all cases, appropriate NDE should be done of the final welds to ensure that
they are high quality. Butt welds will typically be 100% radiographically (RT)
or ultrasonically (UT) examined, along with either liquid penetrant (PT) or
magnetic particle (MT) examination. Other welds will typically be PT or MT
examined.

Non-Welded Repairs

Non-welded repairs may be used to temporarily repair a locally damaged portion

of a pipe or piping component while the system remains on-stream (or possibly
depressured but not gas-freed and cleaned). This approach may be used for
locally thinned sections or linear defects (either partially or completely through
the pipe thickness), or leaking flanges.
Non-welded repairs typically employ a bolted clamp or box which encompasses
the damaged component (See Figures 6 and 7). The design of the clamp or box
must be adequate for the pressure thrust force from the damaged pipe if there is
concern that the pipe will completely separate at the area of deterioration. The
pipe must also have adequate thickness at the clamp or box attachment points to
withstand the applied bolting force needed to hold the clamp in place.
Bolted clamps or boxes will often require injection of a leak sealing fluid to
provide a tight seal at the pipe or component interface. The sealant must be
compatible with the service fluid and design conditions.

60

Bolted Flange Clamp

Figure 6
Courtesy of Plidco International, Inc.

Bolted Pipe Box

Figure 7
Courtesy of Plidco International, Inc.

61

Welding and Hot Tapping Requirements

All welding must be done in accordance with ASME B31.3 or the original piping
construction code using qualified procedures and welders. Any welding that is
done while the system is in operation (e.g., hot tapping) must meet the
requirements of API Publication 2201. All local design, inspection, testing, and
hot work permit procedures developed by the owner must also be followed.
Preheat and Postweld Heat Treatment (PWHT)

Preheat and PWHT requirements must be per the applicable code (i.e., ASME
B31.3). Preheating to at least 300F may be used as an alternative to PWHT if
the system was originally given PWHT as a code requirement (i.e., based only on
material type and thickness), provided:

The pipe is P-1 steel.

Mn-Mo steels are operated at a high enough temperature to provide adequate

fracture toughness and there is no hazard associated with pressure testing,
startup, and shutdown.

The minimum preheat temperature is measured and maintained, and the joint
is covered with insulation immediately after welding to slow the cooling rate.

In situations where PWHT is required due to service considerations (e.g.,

caustic), then the 300F preheat alternative may not be used.
PWHT is preferably done in a 360 band around the pipe that encompasses the
weld area. Local PWHT may be substituted on local repairs for all materials
provided:

An appropriate procedure is developed by a piping engineer.

The procedure considers thickness, thermal gradients, material properties,

charges resulting from PWHT, the need for full penetration welds, local
strains and distortions caused by local heating, and surface and volumetric
NDE done after PWHT.

A minimum 300F preheat is maintained while welding.

The PWHT temperature is maintained for a distance of at least twice the pipe
thickness from the weld.

The PWHT temperature is monitored by two or more thermocouples.

Controlled heat is also applied to any branch connection or other attachment

located within the PWHT area.

62

The PWHT is required for code compliance and not for service considerations
(e.g., caustic).

Design, Materials, and NDE

All butt joints must be full-penetration groove welds.

Piping components must be replaced if a repair is not likely to be adequate.

Fillet welded patches must be designed by the piping engineer considering

the following requirements:
-

Appropriate weld joint efficiency

The possibility of crevice corrosion

- Adequate strength per criteria specified in API 570

New and replacement component materials must be per the applicable code.

NDE must be per the applicable code, owner-user specifications, and API
570.

Pressure Testing

Pressure testing is normally required after alterations and major repairs, or if

otherwise practical and deemed necessary by the inspector. NDE may be
considered as an alternative to pressure testing only after consultation with the
inspector and the piping engineer.
There may be situations where it is not practical to pressure test a final closure
weld in a replacement section of pipe. The following requirements must be met
in these cases:

The new or replacement pipe section must be pressure tested. Thus, only
the final closure weld is not pressure tested.

The closure weld is a full-penetration weld between a weld neck flange and a
standard pipe component; or between straight pipe sections, axially aligned
(not miter cut) of equal diameter, thickness, and material. Alternatives that
involve slip-on and socket welded flanges are also identified in API 570.

The final closure weld must be 100% RT or UT examined.

MT or PT must be done on the root pass and final weld for butt welds, and on
completed fillet welds.

63

Rerating

The following requirements must be met to permit rerating a piping system to a

new design temperature or MAWP:

Design evaluations must be done by the piping engineer or inspector to verify

the system for the new conditions.

The rerating must meet the requirements of either the original construction
code or the latest edition of that code.

Current inspection data must verify that the system is adequate for the
proposed conditions and has sufficient remaining corrosion allowance.

The system must be pressure tested for the new conditions, unless records
indicate that a previous test was done at a pressure that was greater than or
equal to that required for the new conditions.

The safety valves must be reset for the new design pressure and confirmed to
have adequate relieving capacity.

The rerating must be acceptable to the inspector or piping engineer.

All components in the system (e.g., valves, flanges, bolts, gaskets, etc.) must
be checked and found to be acceptable for the new design conditions.

Piping flexibility is adequate for the new design temperature. New

calculations may be required to confirm this.

The engineering records for the system must be updated.

A decrease in the minimum operating temperature is justified by impact test

results (or exemptions) if required by the code.

64

VI. Inspection of Buried Piping

Corrosive soil conditions may cause significant external deterioration of buried
piping. Buried piping is typically protected from these soil conditions by using an
external coating or wrap, or by using a cathodic protection system. Periodic
inspection of a buried piping system is still required to ensure that the external
protection system is effective; however, this inspection is hindered by
inaccessibility.
Inspection Methods

Several methods may be used to inspect a buried piping system.

A visual surveillance may be made above the area of the pipe for visible
indications of leaks. These indications could include:
- Surface contour change

Soil discoloration

- Softening of paving asphalt

Formation of liquid pools

- Bubbling crater puddles

Odor

A close-interval electric potential survey can be conducted over the buried

pipe. This survey may locate active corrosion points on the pipe surface.
Corrosion cells can be located in this way since the electric potential at a
corrosion area will be measurably different from that of an adjacent area.

A holiday survey may be done on coated pipe to ensure that the coating is
intact and free of holidays. The survey data can be used to determine the
effectiveness of the coating and the rate of coating deterioration.

Soil resistivity measurements may be used to determine the corrosiveness of

the soils in contact with the pipe. A mixture of different soils in contact with
the pipe can cause corrosion.

If a cathodic protection (CP) system is used for corrosion protection, it should

be periodically monitored to ensure that it is providing adequate protection.
NACE RP0169 and API RP 651 provide guidance for this monitoring.

Direct inspection of buried piping may be done using intelligent pigging, video
cameras, or excavation.

65

Inspection Frequency and Extent

Method

Frequency/Comment

Above-grade visual

6 Months

Pipe-to-soil potential survey

- 5 year interval for poorly coated pipe

where CP potentials are inconsistent
- Conduct survey along pipe route if
no CP or where leaks have occurred
due to external corrosion

Coating holiday survey

Frequency based on indications that

other corrosion control methods are
ineffective

Soil corrosivity

5 year interval if no CP system and

over 100 ft. is buried

CP system monitoring

Per NACE 0169 and API RP 651

Internal

Base on results of above-ground

inspections

External (if no CP)

Pigging or excavation intervals based

on measured soil resistivity per Table 1

Leak testing (i.e., pressure testing)

Alternative or supplement to inspection.

Hydrotest at 1.1 x MAOP

Interval of Table 1 if no CP

Interval per Table 1 if CP

Soil Resistivity, ohm-cm

Inspection Interval, years

< 2000

2000 10,000

10

> 10,000

15
Table 1

66

Repair of Buried Piping

Repairs to buried piping may involve coatings, clamps, or welding.

Coating repairs must be inspected to ensure that they meet the following
criteria:
-

Sufficient adhesion to prevent underfilm migration of moisture

Sufficient ductibility to resist cracking

Free of voids and gaps

Adequate strength to resist damage due to handling and soil stress

Can support supplemental CP

Tested with a high-voltage holiday detector

The location of clamp repairs must be logged in the inspection records. They
are considered temporary repaired and are to be replaced with a permanent
repair at the first opportunity.

Welded repairs of buried piping must meet the same requirements as those
for above-ground piping.

67

VII. Summary
Inspection, repair, alteration, and rerating of in-service piping systems are normal
activities that must be dealt with in process plants. Requirements and
procedures are necessary in carrying out these activities to ensure that piping
system integrity is maintained. API 570 is the industry standard that is used to
form the basis for more detailed procedures that must be developed by process
plant owners.

68

VIII. Suggested Reading

1. API 570

Piping Inspection Code

2. ASME B31.3

Process Piping

3. ASME B31G

Manual for Determining the Remaining Strength of

Corroded Pipelines

4. API Publication 2201

Procedure for Welding or Hot Tapping on Equipment

Containing Flammables

5. NACE RP0169

Control of External Corrosion on Underground or

Submerged Metallic Piping Systems

6. API RP651

Cathodic Protection of Aboveground Petroleum

Storage Tanks

69

YOUR PATH TO LIFELONG LEARNING

ASME offers you exciting, rewarding ways to sharpen your technical
skills, enhance personal development and prepare for advancement.
*Short Courses - More than 200 short courses offered each year keep
you up to speed in the technology fast lane--or, help you fill in any gaps
in your technical background.
*Customized Training at your organizations site - Do you have ten or
more people at your site who could benefit from an ASME course?
Most of our courses can be offered in-house and tailored to your latest
engineering project. Bring a course to your company too.
*Self-study materials meet the needs of individuals who demand
substantive, practical information, yet require flexibility, quality and
convenience. Return to each program again and again, as a
refresher or as an invaluable addition to your reference library.
*F.E. Exam Review - A panel of seasoned educators outline a wide
range of required topics to provide a thorough review to help
practicing engineers as well as engineering students prepare for
this challenging examination. 24 hours of videotape and notes.
*P.E. Exam Review - A comprehensive review of all the major exam topics
that demonstrates the necessary math, logic and theory...and provides
shortcuts that reduce the time and effort required to prepare yourself
for this challenging exam. 15 hours of videotape and notes.
FOR INFORMATION CALL 1-800-THE-ASME AND MENTION CODE CD.
INFORMATION REQUEST FORM
Please mail to ASME at 22 Law Drive, P.O. Box 2900, Fairfield, New Jersey, 07007-2900
or fax to 201-882-1717, call 1-800-THE-ASME, or email [email protected]
Send me information on the following:
_____Short Courses
_____ In-House Training _____ Self-Study Programs
_____F.E. Exam Review _____ P.E. Exam Review
Name___________________________________________________________
Title____________________________________________________________
Organization_____________________________________________________
Business Address_________________________________________________
City____________________________State_______________Zip___________
Business Phone ( )____________________Fax ( )______________________
E-mail Address____________________________________________________