a a N Contents . Examination Scheme Distribution of Marks Salient Features of the Examination How to Prepare for the Examination . API 570 — Chapter wise Tips for Maximizing the Score . Time Management During the Examination . Test Taking Tips 46Cintegratediii 1, EXAMINATION SCHEME As per the present scheme, API 570 examination is one- day, 8-hour, 2 session examination, comprising of pre- lunch session (4 hours) for “open-book” examination and postlunch session (4 hours) for “closed-book" examination. There are a total of 150 questions carrying 1 mark each (tofal of 150 marks}, split into open-book (approximately 50 questions) and closed-book (approximately 100 questions). The distribution of 50 and 100 questions respectively for open-book and _closed-book examinations is approximate; however the total is always 150 questions. Each question is multiple-choice question with given 4 possible choices. Only one is the comect choice. The candidate has to pick-up the correct choice, and indicate the same on separate answer sheet. The answer sheet along with the question paper should be returned back to the Supervisor. The correct answer is to be indicated by blackening (filing) the relevant circle by a pencil. There is no set passing percentage. However a score of about 95 to 105 out of 150 is a good estimate of passing score. Please note the following: Fill only one circle out of four given Fill the circle fully and completely. Half or less than half blackened circle area is not reckoned for answer. Never indicate the answers by ticking (¥) the circles. There is no negative marking. 47“Clategrated renin During the “open-book" session, you are permitted to refer to the codes and other documents as per “Effectivity Sheets". Code pages may be tabbed, highlightened, underlined or notes in margin of the pages are accepted. Additional new pages to codes are not accepted. Always carry the following to the exam hall. * 2Nos. B or 2B pencils and eraser * Non-programmable calculator * Photo identity (passport, driving license, etc.) * Exam confirmation letter Be present in the exam hall at least 15 minutes prior to scheduled start of exam. The supervisor announces important instructions during this period. Do not miss them. Now relax and attempt the exam calmly. Time is always more than enough. Good luck, friends! 48Cintegratectirainins 2. DISTRIBUTION OF MARKS As per the Effectivity Sheet for December 3, 2003 exam, there are total 7 codes prescribed for examination. However, all of them are not equally important and do not therefore require equal emphasis. About 45 percent questions are asked from one code API 570 which is hardly 20 pages, while all other 6 codes contribute 55% marks which are more than 1,500 pages. Following distribution scheme will help the participant to decide how much time he should spend for each document during preparation. 1 | ‘Approx. ] | Approx. | S.N. Code Questions Out of | | | Weightage (in %) | Total 150 | T | API570 40-42 00-63 } | — 2 | ASMEB313 20-22 30-33 i . 3 | ASME Sec. ik 1213 1819 4 | ASME Sec. V 12-13 ie19 ] 5 | APIRP 574 45 58 | EE EE ee 6 | APIRP 578 3 45 | 7 | ASMEBI6.5 2 “3s 8 General Knowledge 2 49Cintegrated liainin: 3. SALIENT FEATURES OF THE EXAMINATION As stated earlier, the examination comprises of open book and closed book parts. The closed-book examination includes such questions which the inspector is normally expected to know without referring the Codes, i.e., the questions are “awareness level” questions. Whenever you find a very definitive or quantitative statement in body of the Code, a closed book question may be expected on it. Thus, the basic requirements of a code, specific "DO" and “DON'T” statements, important quantified — statements, important definitions and well-known inspection principles wil constitute such questions. Where the student is required to refer to the diagrams or formulas or tables or graphs and curves from the Codes, it will always be an “open-book" question. All calculation oriented questions will normally be “open-book" type. The Code information which is not short and crisp, (i.e.. large paragraphs, several descriptive statements clubbed together) will normally be asked in “open-book” part. Here the participant is expected t to remember the information but should know where to find in the body of the Code. The questions asked in closed book part are straight forward statements directly taken form Code without much of the modifications and therefore are easy to answer. To answer open-book questions, one only needs to know where to find the answer in the code and therefore tabbing of Code pages, highlighting the paragraphs or additional explanatory notes in page margins is useful for saving time. Closed-book part of the exam (100 marks) can be finished in hardly 2 to 2 % hour though 4 hours are allotted. While “open-book" part (50 marks) takes a little longer and may require all the 4 hours that are allotted. 50Kintegratedivai 4. HOWTO PREPARE FOR EXAM: A) If your aim is only to get “certified” only, i.e., to obtain just around 110-115 marks, then, 1) Detailed study of documents nos. 1 to 4 above (Ref. The weightage list given above.) may be adequate. 2) Additionally, one should try to remember all the “Points to Recall" and review the mock examinations attempted during the Preparatory Course. If Wo or more participants from same 6rganization are appearing for exam, then joint discussions and ‘éne putting question to another and vice versa has been found very effective during preparation. 3} Other 3 codes (ie., Sefial No. 5 to 7) may be studied in detail if there is additional preparation time available. An overall “awareness” level knowledge of these 3 Codes may be okay. These contribute only 10% weightage. Still, the Open book Questions from these can always be found out and answered plus the points to recall can help to answer other questions. 8) If your objective is to get certified and also to obtain a good score, (say 135+) then, In addition to preparation as per 1&2 above, It is worthwhile to. study the 3 Codes also. (Serial No. 5 to 7). However, please remember that study of API 570 has to be "thorough" and total, while study of ASME Sec. V, ASME Sec. IX and ASME B31.1 and 16.5 should be such that it can cover the topics mentioned in the "Body of Knowledge”. The last 3 Codes should be read at least once and note the important points. A very “thorough” study of these documents 51Clotegratedirsinin: however will not result in “gains” commensurate with the efforts put in. If you are about a month away from examination, read all the Codes at least once and concentrate on highlighted text in the Codes and also try to solve the question bank. If you are about two weeks away from the exam, concentrate on highlighted text as well as the mock examinations conducted during the course. In the last week of preparation, focus on Points to Recall and highlighted text. 52Cntegrated trainin: 5. API 570 CHAPTERWISE TIPS FOR MAXIMIZING THE SCORE From Chapter 1, just note the scope, application and exclusions. Chap. 2 lists only the reference documents. There are only 8 or 10 important definitions out of total 55 from Chapter 3 of API 570. Normally 3 to 4 definitions are asked in closed-book exam. From Chapter 4, usually 2 or 3 questions are asked. Concentrate on responsibilities clause. Also see App. B for Certification requirements. From Chapter 5, about 15-18 questions are asked. About 10-12 in closed book and 4-6 in open book. Para 5.2 to 5.6, average of 1 or 2 questions are asked while on para 5.7, about 6 to 8 questions ( both open & close book) are asked. From Chapter 6, about 15-18 questions are asked. Particularly pay attention to Inspection intervals, which attracts at least 5 to 6 questions and they could be either open book or closed book. From Chapter 7 also 15-18 questions are asked. This is only four page chapter and almost all paras should be studied thoroughly. 53Cintegmtedivainin: There may be 2 or 3 questions on overall API- 570 code for the purpose of assessing the overall under standing of code. Chapter 8 as well as App. E are excluded from examination, As regards ASME Sec. V and IX, the course content is categorised in 10 categories. 8 of them are listed under calculations while 9 and 10 are listed under welding and NDT . You may expect at least one open book and one closed book question on each of these. Additionally, under the category intemal pressure, you may expect 4 open book questions one each for thickness calculation for the 4 types of end closures. 54Cintegratediivinins 6. TIME MANAGEMENT DURING EXAM: Both “open” and “closed” book sessions are 4 hours each This means about 25 to 28 questions per hour for closed book and 12 to 15 questions per hour for open book. For proper time management following are useful suggestions. ) You may start from Question No. 1 and proceed. If after 1 hour you feel that you are maintaining the required progress as mentioned above proceed serially. b) If, however, you are behind the required rate, start jumping the questions, i.e., start attempting those questions you can answer, deleting whose answer you do not know. Proceed like this till the end. Do not leave any question unanswered whose answer you know. cc) Then come back to “deleted” questions and attempt them using your “feel” factor. Go on like this till say last 10-15 minutes are remaining. d) If there are still some questions where you have no clue at alll just mark the answer at random in last 10-15 minutes. This may give you few chance marks. Do not leave any question unattempted. e) After completion of writing exam, if you have still time (which you normally have) you may go through your answers just to check quickly if you have filled a wrong circle. 55Cintegratediisinins 7. TEST TAKING TIPS * Don't read too much into a question. Do not get too elaborate and ruin your answer. * If two choices are very similar, the answer is probably not either of them. * If two choices are opposite, one of them is probably correct. * Don't go against your first impulse unless you are very sure you were wrong. * Check for negatives and other words that can throw you off. « The answer is usually wrong if it contains “all,” “always,” “never,” or “none.” « The answer has a great chance of being right if it has “sometimes,” probably" or “some.” * When you don't know the answer, look for the wrong ones. * If you are supposed to read a long passage and then answer questions about it, read the question first. That will tell you what you are looking for and affect the way you read the passage. * Be suspicious of choices that seem obvious. * Don't give up on a question that, after one reading, seems complicated. Looking at it from a different angle. restating it in your own words, drawing a picture, or breaking it down, etc., may help you realize that it's not as hard as you thought.PIPING MATERIALS ‘SPEC NOM. COMP. ROPERTIES | REMARKS | —_ SS soars | |-Maybede- | A53GrA | 0.25% C (max) 48,000 | 30,000 | oxidised -Seamless or GrB | 0.3%C (max) 60,000 | 35,000 | ERW Temp up to (Plain c) 300°C A106 Gr.A | 0.25%C(max),0.1%Si(min) | 48,000 } 30,000 | Seamless conly(No ERW) Gr.B | 0.3%C(max),0.1%Si(min) | 60,000 | 38,000 | Killed. Gr.C | 0.35%C(max)0.1%Si(min) | 70,000 | 40,000 (C-Si Steel) \ -Temp. up to a APIBL GrA | 0.25% 48,000 | 30,000 | -Line pipes Gr.B | 0.3% 60,000 | 35,000 (Plain C) i A335 | P11 | 4.25 Cr-0.5 Mo 60000 | 30000 | High Temp. Up to 650°C P22 | 2.25 Cr-1 Mo 60000 | 30000 (Cr-Mo St. | A333 Grit [0.3C-1 Mn 55000 | 30000 | Up to -88 deg c | Gr3 |3.5%Ni | 60000 | 36000 | Up to -100 degc Gr8 | 9%Ni 100000 |s000 | Up to -195 degcTENSILE STRENGTH (N/mm) «HARDNESS, io DEPENDANCE GF EGNIBERIN G PROPERTIES ON SACARDON, 58)) Hitachi Zosen Printed [Avra 1979 As ppearent from thie figure, in order to increase toughness of carbon steel, thé inclease of tin/C 300 (kgf-m) Absorbed Energy , 2vEo ig 30 7 IZ |By Fukuhoro et. 0 | T.S, : 50~58kgf/rrr2(490-568 oe | | |_MPo) A: ASTM AS5I5 Gr.70 B! ASTM ASI6 Gr.60 C: ASTM AS5I6Gr.70 20 : | + 15 -——_ t | 10-——— { t 7 [ k } | 5,-———-« 7 a hg | t | | | ° . . tJ ° 5. !0 Mn/c tio is effectiv — | Effect of Mn/C on absorbed energy of Carbon steels 2) . _ HITACHI SHIPBUILDING & ENGHIEERING CO, (70 59FHKE ce FECT OF ALLOYING ELEMENTS ON THE PROPERTIES OF STEEL — Wechanical propert~r T Ty tt Tel ¢ 2 2 2 g toying A iz] ¢ t 3 z 3| = 3 fs A ‘eleraent g Es) 2 i 23 a ! e 3 a Hg g Suen tptinpiy- tpofupi fe adalat Manganese mperit steele Ty -1=f- tt d- ~{uyt fit ]= Manganese inavsien steels mls}? huf-|-[-[-[e]-[- palma = oi magnetic Chromiam We pape pet ep papa ee ar it TH 3 | Nicketin pein stecis trl feel ee ee Wat Wicket in austeni steels wha [a farfar fry = pan fa [= [= ffi] = [at | rotmaonese ‘Rison =e eT THe ee a inf - uli Tungsten Ta T= {afin ra = init : i Uy afer (=f a ft cs tip ya a= = in = = T fifi | cisodenum Taye = fe ra a a 1 Seppe tital-{-{-{- ={= [T= = Sulohwe -|-J- ia -f- =[-fiatin[=Tr Phosphorous Tre fin = f= |e r= -]- Te increase Te Reduction __~= constara ~ not characievatic orwitnown Several arrows = marelntensve effect Bo 0919 THE EFFECT. OF ALLO.WNG ELEMENTS IN STEEL (CONTO.) SOLID SOLUBILITY INFLUENCE INFLUENCE EXERTED THROUGH ELEMENT mruuence Spon Etnawe in in UPON AUSTENITE PRINCIPAL FUNCTION OF SYMBOL Geuma Fe Alpha Fe FERRITE {HAROEN- Carbide forming Action during ELEMENT ABT) Tendency Tempering actions 3% in a75% Pee Strong. Grester Opposes 1, Ralees coarsening Mo 0.05% C (less with ing effect in herdenability than Cr. softening by temperature of austenite, steels 8%) lowered mgnMore wont Seltpinna paleo temp hardening avdening 3, Raises hot and creep strength, rad hardness, 4. Enhances corrosion resis- tance in stainless steels. 5. Forms abrasion resistant partes, Suhel Unlimited = 10%indepen- Strengthens Increases Grephiices —_Verylitlein 1. Strengthens unquenched NE dentofC & toughens hardenability less than Fe. ‘small per- or annealed steels. content bysola Signy austenite Ecntages, 2 Toughens pearlitic ferttc Seition retention wth Hecke leapectlly st low Foher carbon temperatures) 3. Renders high Cr/Fe alloys tustenite, Tungsten, 6% (in 33% (less Age-harden. Increases Strong Opposes soften. 1%. Forms hard, abrasion w Ae lowered ‘ing system in hardenability ing by secondary resistant particles in tool steels 11%) temperetures) high Wife Stonglyin sna hardening Steels, high speed steels, Aoys. queries " 2. Promotes redhardness Snanot strength Vanadium 1.0% + Unlimited Hardens Increases Very strong Maximum 1. Promotes fine grain, ‘ v (in 0.2% ¢ moderately hardenability ry eree foreecondary - elevatescosrsening steels 2%) inset very strongly hardening. temperature of austenite solution ss olssolved 2. Increases hardenabiity when dissolved, 3. Resists tempering and causes marked secondary hardening79 MOLYBDENUM Molybdenum, when added to chromium-nicke! austenitic’ steels, improves resistance to pitting corrosion especially by chlorides and sulphur chemicals. When added to low alloy stwels, molybdenum improves high temperature strength and hot hardness. When added to chromium steels it greatly diminishes the tendency of steels to embrittle in service or in heat treatment. Also see Pitting Resistance Equivalent PITTING RESISTANCE EQUIVALENT The specific benefits of Chromium, Molybdenum and, more recently, Nitrogen in conferring resistance to pitting in corrosive environments has been recognised its various formulae. The most common of these is the PRE(N) which includes Nitrogen and is PREIN) = %Cr + (3.3 x 9Mo) + (16 x %6N) 13.62. Like nickel, Vanadium is a very important grain refiner in steels and as little as 0.1", is effective in restricting grain growth during normal hardening, processes. Vanadium is present in the microstructure as finely dispersed carbides and nitrides and since these do not dissolve at normal heat-treatment (emperatures, their presence acts as a burrier to grain growth. [f the steel is over -heated so that the particles of carbide and nitride go into solution, then grain growth immediately takes place rapidly.€9 MATERIAL SELECTION CHART - ( CS, AS, SS ) (BASE ) ON SERVICE TEMPERATURE) TEMPERATURE TEMPERATURE SUITASLE MATERIAL TYF{CAL ASTM SPEC. RANGE SCALE 250°C (-428-F) ~~ : CRYOGENIC SS 300 SERIES A 240 TYPE 304, 3041, 347 HIGH Ni STEEL (Ni A353 — + 100% (-150.F) Low- Temp A203 GrATOD A (Ni UP TO 3 1/2%) A350 LF1, LF3 t- 45°C (50 -F) -- ee PLAIN “G” STEEL (FG) A516 Gr 60/70 0". (32 F) = - MODERATE | AIN“C” A285 GrATOC INTERMEDIATE (CUP TO 0.28%) A515 Gr 60/70 A . A516 Gr 60/70 40d c(778F) ~~ ELEVATED Cr-Mo STL (Cr UP TO 8%, MoUP — A387Gr 1 TO 22 ° . TO 1%) A182 F1 TO F22 —-600".C (1100 F) HIGH TEMP SS 300 SERIES, A240 TYPE 304, 316, 347 e ° PLAIN/ H GRADES A182 Gr 304H, 316H, 347H +800" 0 (1500. FF) ~~--~-~-= == -+-- 22-2 -- === 2 VERY HIGH F162 Ge 3044, 31041, Sau ABOVE 808 C == (1690" F) TYPE 310 , INCOLOY HASTELOY NB : MATERIAL SELECTION FOR NON CORROSIVE SERVICEOBJECTIVES OF API - 570 CERTIFICATION To provide accreditation to inspectors who: Possess adequate level of specialised knowledge and skill to draw up and execute quality systems and inspection programs, e Soas to provide high level of integrity, and « Improve management control for safe operation of the Piping Systems. ¢ The rules given in this standard are minimum requirements. . Each edition, revision, or addenda to this API standard may be used beginning with the date of issuance 2. Each edition, revision, or addendum to this API standard becomes effective six months after the date of issuance 3. If any federal, state, or municipal regulation which may conflict with API standard then the regulations shall prevail over API standard. 64API570 EXAMINATION DETAILS The examination is in an all multiple choice format and currently consists of two parts — Open Book & Closed Book: 1. EXAM FORMAT — The format for the API 570 exam is 150 multiple choice questions. Each question has four possible answers with only one correct answer. 2. OPEN BOOK - 40 TO 50 QUESTIONS: ASME/API pipe evaluation calculations, ASME Section IX WPS & PQR review and general questions covering any other areas listed in the API 570 "Body of Knowledge". You will be allowed to use all the codes and standards referenced during the open book portion of the exam. 3. CLOSED BOOK — 100 TO 110 QUESTIONS: This part will consist of general questions covering all the codes and standards required. Memory will be very important on this portion of the exam.wo API Examination Information Questions for the examination will be multiple choice with an open and closed book sections. Total approx. 150 Questions. Total length of examination is 8 hours. Four hours open book (approx. 40-50 questions) and 4 hours closed book (approx. 100-110 questions). The multiple choice questions will be having 4 choices, and only one correct option. lf you pass the examination, and all sections of your application are complete, you will be certified and receive a wallet card and certificate approximately 3 months after the examination date. Test results will be mailed to you approximately 8 weeks after you have taken the exam. 66What to Bring to the Exam No. 2 pencils; A non-programmable calculator (a calculator with only simple functions); The applicable API and ASME _ reference publications. Highlighting, underlining, page tabs, and notes written in margins of the code books are acceptable. Loose pages inserted in the code books are not acceptable. Your test site confirmation letter A picture ID (i.e. driver's license). 67Fluid Service Categories Category D Service | Category M Service High Pressure (K) | Service by the Code and includes piping not classified within the other fluid services listed below Service in which the fluid is nonflammable, nontoxic, and not damaging to human tissue; the design pressure does not exceed 150 psig (1030 kPag); and the design temperature is from -20°F (-29°C) TO 366°F (186°C) Service in which a_ single exposure to a very small quantity of toxic fluid can produce serious irreversible harm on breathing or body contact, even when prompt restorative measures are taken \Service which applies when designated by the owner, typically for pressures in excess of that allowed by ASME B16.5 Class 2500 rating, for the specified design temperature and material group 68Levels of Generic Classification of Materials Simple Intermediate Complex Carbon Low Carbon Steel | Fully Killed, © Low Steel | Carbon Steel Low Alloy |Cr-Mo Steel 2% Cr-1Mo Steel \ Steel j Stainless | Austenitic |300 Series Austenitic } Steel Stainless Steel Stainless Steel Nickel High Nickel Alloy | NiCrMo Alloy Alloy Common ASTM Carbon Steel Piping Material Specifications and Grades ASTM Materials without Impact Tests ASTM Materials with Impact Tests A53Gr.B A106 Gr.B A 333 Gr. 1 A333 Gr. 6 &} A105 A 350 Gr. |LF2 A 234 Gr. WPB A 420 WPL6 69WELD JOINT QUALITY FACTOR, E, BASIC QUALITY FACTORS. The weld joint quality factors E; tabulated in Table A- 1B are basic factors for straight or spiral longitudinal welded joints for pressure-containing components as shown in Table 302.3.4 INCREASED QUALITY FACTORS. Table 302.3.4 also indicates higher joint quality factors which may be substituted for those in Table A-1B for certain kinds of welds if additional examination is performed beyond that required by the product specification. 70PRESSURE DESIGN OF COMPONENTS : Straight Pipe (330.1.1) The required thickness of pipe shall be : tm=tte The minimum thickness T for the pipe considering manufacturer's minus tolerance, shall be tn... The following nomenciature is used in the equations for pressure design of straight pipe. tm = minimum required thickness, including, corrosion, erosion & mech allowances. t = pressure design thickness. c = the sum of the thickness allowances. T = __ pipe wall thickness as ordered. d = __ inside diameter of pipe. = __ internal design gage pressure. D = __ outside diameter of pipe 71E = quality factor from Table A-1A or A-1B S = __ stress value of materials. Y = coefficient from Table 304.1.1, valid for t < D/6 and for materials shown. For t> D/6, d+2c You — D+d+2c Straight Pipe Under internal Pressure : For t < D/6, the internal pressure design thickness for straight pipe shall be not less than : PD t Se 2(SE + PY) Following Equation may be used instead of above equation 72For t> D/6, or for P/SE > 0.385, calculation of pressure design thickness for straight pipe requires special consideration.. Blanks (304.5.3) The minimum required thickness of a permanent blank (representative configurations shown in Fig. 304.5.3) shall be calculated in accordance with Eq. (15) tm = where- dg = _ inside diameter of gasket for raised or flat face flanges, E = same as defined earlier. P = design gage pressure S = same as defined earlier c = sum of allowances defined earlier. 73BUTT-WELDED FITTINGS Welded fittings are used primarily in systems meant to be permanent. Advantages of butt welded systems are the following : 1. Smooth inner surface,.offer gradual direction change with minimum turbulence. 2. They require much less space for constructing and hanging the pipe system. They form leak-proof constructions. They are almost maintenance free. They have a higher temperature and pressure limit. They form a self-contained system. They are easy to insulate They offer a uniform wall thickness through- out the system. One of the major disadvantages of butt-welded systems is that are not easy to dismantle. 74SOCKET WELDED FITTINGS Socket welded fittings have certain advantages over butt-welded fittings. They are easier to use on small-size pipelines and the ends of the pipes need not be beveled.The advantages of the socket-welded system are : 1. The pipe does not need to be beveled. 2. No tack welding is necessary for alignment since joint and the pipe are self -aligning. 3. Weld material can not extend into the pipeline. 4. It can be used in place of threaded fittings, therefore, reducing the likelihood of leaks, which usually accompany the use of threaded fittings. One of the major disadvantages of this type of fitting is the possibility of a mismatch inside the fitting where improperly aligned or mated parts may create a recess where corrosion could start. 75FLANGED FITTINGS Flanged connections are most common on piping that are a minimum of 2 in.(5.08 cm ) in diameter. e . An assortment of facings, raised, flat, ring joint grooves, etc.are available in flange variations. * One advantage of flanged systems is that they are easily dismantled and assembled. « One of the disadvantages is that they are considerably expensive than an equally rated butt-welded system, « Flanged fittings occupy far more space than the butt-welded or screwed equivalents. e Because of this higher weight load, a flanged system becomes far more expensive to support or hang from the existing structure. 76Wall thk.of flanged fittings(B 16.5 Par- 6.1) For inspection purposes the minimum wall thickness tn of flanged fittings at the time of manufacture shall be as shown in Tables 10, 13, 16, 19, 22, 25 and 28, except as provided in para 6.1.1. See Annex D for the basis used to establish values of tn. .Par-6.1.1Local areas having less than minimum wall thickness will be acceptable provided that : a. the area of subminimum thickness can be enclosed by a circle whose diameter is no greater than 0.35v dtm where d is the inside diameterof fitting and tm is the minimum wall thickness as shown in the tables listed in para 6.1; and b. measured thickness is not less than 0.75 tm; and c. enclosure circles are separated each other by an edge-to-edge distance of more than 1.75v dtm, 77System Hydrostatic Test for flanges. Flanged joints and flanged fittings may be subjected to system hydrostatic tests at a pressure not to exceed 1.5 times the 100°F rating rounded off to the next higher 25 psi. 80MINIMUM THICKNESS OF FLANGE FACE e . Classes 150 and 300 fittings and companion flanges are furnished with a 0.06 in. raised face which is included in the minimum flange thickness C. * Classes 400, 600, 900, 1500 and 2500 fittings and flanges are furnished with 0.25 in. raised face which is additional to the minimum flange thickness C. e Any other facing than the above, when required for any class, shall be furnished as follows.: 1. No metal shall be cut from the minimum flange thickness specified herein. 2. In the case of the 0.25 in. raised face, tongue or male face (other than 0.06 in. raised face for Classes 150 and 300), the minimum flange thickness C shall be first provided and then the raised face, tongue or male face shall be added thereto by providing additional material. 78FLANGE FACINGS Either a serrated concentric or spiral finish having a surface finish from 125 u in. To 250 u in. average roughness shall be furnished. The cutting tool employed should have an approx. 0.06 in. radius, and there should be 45 grooves/in. through 55 grooves/in. Flange Facing Finish Imperfections « Imperfections in the flange facing finish shall not exceed the dimensions shown in Table 3. « Adjacent imperfections shall be separated by at least four times the maximum radial projection. A radial projection shall be measured by the difference between an outer radius and an inner radius encompassing the imperfection where the radii are struck from the centerline of the bore. « Imperfections less than half the depth of the serrations shall not be considered cause for rejection. Protrusions above the serrations are not permitted. 79SPECIFIC APPLICATIONS Included Fluid Services: API 570 applies to piping systems for process fluids, hydrocarbons, and similar flammable or toxic fluid services, such as the following. a. Raw, intermediate, and finished petroleum products. b. Raw _ intermediate, and finished chemical products. Catalyst lines. Hydrogen, natural gas, fuel gas, and flare systems. e. Sour water and hazardous waste streams above threshold limits, as defined by jurisdictional regulations. f. Hazardous chemicals above threshold limits, as defined by jurisdictional regulations. 81AUTHORIZED INSPECTION AGENCY: Defined as any of the following. : a. The inspection organization of the jurisdiction in which the. piping system is used. b. The inspection organization of insurance company licensed to write insurance for piping systems. c. An owner or user of piping systems who maintains an inspection organization for activities relating only to his installation and not intended for sale or resale. d. An independent inspection organization employed / contracted by owner or user for activities relating only to his installation and not intended for sale or resale. e. An independent inspection organization licensed or recognized by the jurisdiction in which the piping system is used. 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 (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.PIPING ENGINEER The piping engineer is responsible to the owner/user for activities involving design, engineering review, analysis, or evaluation of piping systems covered by API 570. REPAIR ORGANIZATION The repair organization shall be responsible to the owner/user and shall provide the materials, equipment, quality control, and workmanship necessary to maintain and repair the piping systems in accordance with the requirements of API 570. AUTHORIZED PIPING INSPECTOR: When inspections, repairs, or alterations are being conducted on piping systems, an API authorized piping inspector shall be responsible to the owner/user for determining that the requirements of API 570 on inspection, examination, and testing are met, and shall be directly involved in the inspection activities. 83RISK BASED INSPECTION (RBI) RBI is identifying and evaluating potential degradation consequence of which may be a risk of creation of unsafe conditions (for plant, process, people ) and / or likely failure of component. RBI involves following essential elements : . Expected type of degradation ie. type of degradation process as well as environmental factors may cause. Likely areas affected i.e. identifying the most prone areas and possible locations to look for the type of degradation. Measurement of degradation i.e. quantifying the amount of degradation. Assessment and evaluation i.e. analysis of degradation and likely consequences. Above all effectiveness of inspection practices, tools techniques employed have a great bearing of success of RBI program. 84INSPECTION FOR SPECIFIC TYPES OF CORROSION AND CRACKING Each owner/ user should provide specific attention to the need for inspection of piping system that are susceptible to the following specific types & areas of deterioration: Injection points. Deadlegs. Corrosion under insulation ( CUI ). Soil-to-air (S/A ) interfaces. Services specific & localized corrosion. Erosion &c orrosion/erosion. Environmental cracking. Fenmoaoso Corrosion beneath linings & deposits. Fatigue cracking . Creep cracking. k. — Brittle fracture. I Freeze damage. 852 API570 (Qvernead vapor tna 12" medmum, whichever is ‘*Typicat neinees measurement ‘ccatons (TMs) witanifecton pant crete Figure 5-1—Typicalnjacion Point Piping Circuit ‘pore appropriate to extend this circuit to the next piece of pressure equipment, as shown in Figure 51. ‘The selection of thickness measurement locations (TMLs) ‘within injection point circuits subject to localized currorion should be in accordance withthe folowing guidelines: 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 fd. ‘¢. TMLs at intermediate locations along the longer straight Piping within te injection point circuit may be required. dd. Establish TMLs at both tbe upstream and downstream lim its of the injection point cenit. “The prefered methods of inepecting injection paints ae radiography and/or ultnsonics, as eppropite, to establish the minimum thickness at each TML, Close grid ultrasonic measurements or scanning may be wed, as long as tempert- tures are appropriate. ‘For some spplicadoas, itis beneficial to remove piping spools to faclitwe a visual ingpecton of the inside surface. However, thickness measuremeats will sil be required to determine the remaining thickness, During periodic scheduled inspections, more extensive {inspection should be applied to an area beginning 12 inches (200 mm) upstream of the injection nozze and continuing for atleast ten pipe diameter downstream of the injection point Additionally, measure wod record tbe thickness at all TMLs Within tbe injection point circuit. 53.2 Deadiegs ‘The corrosion re in deadlegs can vary significantly from Adjacent active piping. The inspector should monitor wall thickness on selected deadlegs, incinding both the smgnant 86SPECIFIC INSPECTIONS..... CONTD Injection Points: Injection points are sometimes subject to accelerated or localized corrosion. Guide Lines For Selecting TMLS : « Establish TMLs on appropriate fittings within the injection point circuit. Establish TMLs on the pipe wall at the location of expected pipe wall impingement of injected fiuid. « TMLs at intermediate locations along the longer straight piping within the injection point circuit may be required. Establish TMLs at both the upstream & downstream limit of the injection point circuit. Deadlegs: The corrosion rate in deadlegs can vary significantly from the adjacent active piping. The inspector should monitor wall thickness on selected deadlegs Remove deadilegs that serve no further process purpose Corrosion Under Insulation: External inspection of insulated piping systems should include conditions that could lead to corrosion under insulation (CUI) and for signs of ongoing CUI The most common forms of CUI are localized corrosion of carbon steel and chloride stress corrosion cracking of austenitic stainless steels. 87SPECIFIC INSPECTIONS..... CONTD Insulated Piping Systems Susceptible to CUI: Certain areas and types of piping systems are potentially more susceptible to CUI, including the following: Areas exposed to mist over spray from cooling water towers. Areas exposed to steam vents. * Carbon steel piping systems, including those insulated for Personnel protection, operation between 25° F- 250° F (-4 C-120 C). Austenitic stainless steel piping systems operating 150° F- 400 F (65° C-204 C). (These systems are susceptible to chloride cracking.) Vibrating piping systems that have a tendency to inflict damage to insulation jacketing providing a path for water ingress. « Steam traced piping systems that may experience tracing leaks, especially at tubing fitting beneath the insulation. « Piping systems with deteriorated coatings and/or wrappings. 88Soil-to-Air Interface: Soil-to-air (S/A) interfaces for buried piping without adequate cathodic protection shall be included in scheduled external piping inspections. Service Specific & Localized Corrosion: An inspection program should include consideration for service related corrosion like, « Dew point corrosion in condensing streams. * Carbon steel piping in hot corrosive oil service & sulfur content in the oil greater than 0.5 percent by weight. Corrosion due to sour services ¢ Hot-spot corrosion on piping with external heat tracing (in partial / two phase flow piping) Erosion & 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, such as at change of direction in a piping system or downstream of control valves where vaporization may take place. Erosion damage is usually increased in streams with large quantities of solid or liquid particles flowing at high velocities. A combination of corrosion & erosion results in significantly greater metal loss than can be expected from corrosion occurs at high velocity & high turbulence areas + Downstream of control valves, especially when flashing is occurring, Downstream of orifices are areas for potential erosion 89Environmental Cracking: Piping system may be susceptible to environmental cracking like, « Chloride SCC of austenitic stainless steels due to moisture & chlorides under insulation, »* Caustic SCC (sometimes known . as_ caustic embrittlement). ¢ Scc in environments where wet hydrogen sulfide exists, such as systems containing sour water. « Hydrogen blistering & hydrogen induced cracking (HIC) damage. CORROSION BENEATH LININGS AND DEPOSITS If external or internal coatings, refractory linings, and corrosion-resistant linings are in good condition it is usually not necessary to remove them for inspection of the piping system. The linings should be inspected for separation, breaks, holes, and blisters If any of these conditions are noted, it may be necessary to remove portions of the internal lining to investigate the condition of the metal piping beneath the lining. Corrosion beneath refractory linings can result in separation and bulging of the refractory. If bulging or separation of the refractory lining is detected, portions of the refractory may be removed to permit inspection of the piping.beneath.the refractory. 90FATIGUE CRACKING « Fatigue cracking of piping systems may result from excessive cyclic stresses of the material, like the number of heat-up and cool-down cycles. + Excessive vibration (such as machine or flow-induced vibrations) also can cause high-cycle fatigue damage. + The vast majority of cycles are requiréd to initiate a crack and relatively fewer cycles are required to propagate the crack to failure. CREEP CRACKING: Creep is dependent on time, temperature, and stress Cracking is accelerated by creep and fatigue interaction when operating conditions in the creep range are cyclic BRITTLE FRACTURE Carbon and low-alloy may be susceptible to brittle failure at or below ambient temperatures. Brittle fracture usually is not a concern with relatively thin wall piping FREEZE DAMAGE: At subfreezing temperatures, water and aqueous solutions in piping systems may freeze and cause failure because of the expansion of these materials 91THICKNESS MEASUREMENT INSPECTION: A thickness measurement inspection is performed to determine the remaining thickness of the piping components. Thickness measurements may be obtained when the piping system is in or out of operation and shall be performed by the inspector or examiner. Thickness measurement locations (TML’s) are specific areas along the piping circuit where inspections are to be made. The nature of the TML varies according to its location in the piping system. TML MONITORING: The minimum thickness at each TML can be located by ultrasonic scanning or radiography. 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 where corrosion/erosion could increase corrosion rates. As a minimum, the thinnest reading and its location shall be recorded. 92TMLs should be marked on inspection drawings and on the piping system to allow repetitive measurements at the same TMLs. This recording procedure provides data for more accurate corrosion rate determination. TML SELECTION: More TMLs should be selected for piping systems with any of the following characteristics: « Higher potential for creating a safety or environmental emergency in the event of a leak. « Higher expected or experienced corrosion rates. ¢ Higher potential for localized corrosion. « More complexity in terms of fittings, branches, deadlegs injection points, and other similar items. « Higher potential for CUI Fewer TMLs can be selected for piping systems with any of the following three characteristics « Low potential for creating a safety or environmental emergency in the event of a leak. e Relatively non-cordsive piping systems. * Long, straight-run piping systems. 93TMLs can be eliminated for piping systems with either of the following two characteristics: Extremely low potential for creating a safety or environmental emergency in the event of a leak. + Non-corrosive systems, as demonstrated by history or similar service, and systems not subject to changes that could cause corrosion. THICKNESS MEASUREMENT METHODS: Ultrasonic thickness measuring instruments usually are the most accurate mean for obtaining thickness measurements on installed pipe larger than NPS 1. Radiographic profile techniques are preferred for pipe diameters of NPS 1 and smaller. Radiographic profile techniques may be used for particularly in insulted systems « When piping systems are out of service, thickness measurements may be taken through openings using calipers. « Pit depth measuring devices also may be used to determine the depth of localized metal loss. 94INSPECTION OF VALVES: Normally, thickness measurements are not routinely taken on valves in piping circuits. The body of a valve is normally thicker than other piping components for design reasons. Control valves or other throttling valves, particularly in high pressure drop-and-slurry services, can be susceptible to localized corrosion/erosion of the body downstream of the orifice. Critical check valves should be visually and internally inspected to ensure that they will stop flow reversals. + Checking to insure that the flapper is free to move, as required, without excessive looseness from wear. ¢ The flapper stop should not have excessive wear. Or else valve will remain in an open position. EE)INSPECTION OF WELDS IN- SERVICE : Issues to consider when assessing the quality of existing welds include the following a. Original fabrication inspection acceptance criteria. b. Extent, magnitude, and orientation of imperfections. Length of time in-service. Operating versus design conditions. e. Presence of secondary piping stresses (residual and thermal) f. Potential for fatigue loads (mechanical and thermal). g. Primary or secondary piping system. h. Potential for impact or transient loads. i. Potential for environmental cracking. j. Weld hardness. It is not appropriate to use the random or spot radiography acceptance criteria for weld quality in ASME B 31.3 Some welds may exist that Will not meet these criteria but will still perform satisfactorily in service. 96INSPECTION OF FLANGED JOINTS: The markings on a representative sample of newly installed fasteners and gaskets should be examined to determine whether they meet the material specification. The markings are identified in the applicable ASME and ASTM standards. Questionable fasteners should be verified or renewed. 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 m €. than one thread. Flanged and valve bonnet joints should be examined for evidence of leakage, such as stains, deposits, or drips. Procéss leaks onto flange and bonnet fasteners may result in corrosion or environmental cracking. This examination should include those flanges enclosed with flange or splash-and-spray guards. 97FREQUENCY AND EXTENT OF INSPECTION The frequency and extent of inspection piping circuits depend on the forms of degradation that can affect the piping and consequence of a piping failure. Inspection strategy based on likelihood and consequence of failure, is referred to as risk-based inspection. Piping classification scheme in Section given below is based on the consequence of a failure. The classification is used to establish frequency and extent of inspection. The owner/user may devise a more extensive classification scheme that more accurately assesses consequence for certain piping circuits. 98PIPING SERVICE CLASSES All process piping systems shall be categorized into different classes bsed on potential consequences. This allows extra inspection efforts to be focused on piping systems that may have the highest potential consequences if failure or loss of containment should occur. In general, the higher classified systems require more extensive inspection at shorter intervals in order to affirm their integrity for continued safe operation. Classifications should be based on potential safety and environmental effects should a leak occur. 996.2.1CLASS 1 : Services with the highest potential of an immediate emergency if a leak were to occur are in Class 1 for example, 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, C3 and C4 streams. 3. Hydrogen sulfide (greater than 3 percent weight ) in a gaseous stream. +, Anhydrous hydrogen chloride. 5. Hydrofluoric acid. 6. Piping over or adjacent to water and piping over public through ways. 1006.2.2 CLASS2: Services not included in other classes are in Class 2. This classification includes the majority of unit process piping and selected off-site piping . Typical examples of these services include those containing the following : . On-site hydrocarbons that will slowly vaporize during release. 2. Hydrogen, fuel gas and natural gas 3. On-site strong acids and caustics 5.2.3 CLASS3: Services that are flammable but do not significantly vaporize when they leak and are not located in high activity areas are in Class 3. Services that are potentially harmful to human tissue but are located in remote areas may be included in this class. Examples of Class 3 service are as follows : 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. 1016.3 INSPECTION INTERVALS : The interval between piping inspections shall be established and maintained using the following criteria Corrosion rate and remaining life calculations. Piping service classification. Applicable jurisdictional requirements aogp Judgment of the inspector, the piping engineer,or a corrosion specialist, based on operating conditions, previous inspection history and current inspection results, ¢ Thickness measurements should be scheduled based on the calculation of not more than half the remaining life determined ffom corrosion rates indicated or at the maximum intervals suggested in Table 6-1, whichever is shorter. « Shorter intervals may be appropriate under certain circumstances. Prior to using Table 6-1, corrosion rates should be calculated in accordance with 7.1 of code. > 102INSPECTION INTERVALS ...contd * The inspection interval must be reviewed and adjusted as necessary after each inspection or significant change.in operating conditions. e General corrosion, localized corrosion, _ pitting, environmental cracking, and other forms of deterioration must be considered when establishing the various inspection intervals. 103VISUAL EXTERNAL AND CUI INSPECTIONS « External visual inspections, including inspections for corrosion under insulation (CUI), should be conducted at maximum intervals listed in Table 6-1 « This external visual inspection for potential CUI is also to assess insulation condition and shall be conducted on all piping systems susceptible to CUI listed in 5.3.3.1 of code Following the external visual inspection of susceptible systems, additional examination is required for the inspection of CUI. The extent and type of the additional CUI inspection are listed in Table 6-2 . « NDE inspection for CUI should also be conducted as listed in Table 6-2 at suspect locations of 5.3.3.1 (excluding c ) meeting the temperature criteria for 5.3.3.1 (e,f,h). « If the inspection of the damaged or suspect areas has located significant CUI, additional area should be inspected and, where warranted, up to 100 percent of the circuit. + CUI inspection experience may increase or reduce the CUI inspection targets of Table 6-2 Piping that have a remaining life of over 10 years or that are adequately protected against external corrosion need not be included for the NDE inspection in Table 6-2. However, the condition of the insulating or the outer jacketing, should be observed periodically by operating other personnel. 104EXTENT OF THICKNESS MEASUREMENT To satisfy inspection interval requirements, each thickness measurement inspection should obtain thickness readings on a representative sampling of TMLs on each circuit . This representative sampling should include data for all the types of components and orientations (horizontal and vertical) found in each circuit. This sampling also must include TMLs with the earliest renewal date as of the previous inspection The extent of inspection for injection points is covered in 5.3.1 of code. SMALL BORE PIPING INSPECTION : Small bore piping (SBP) that is primary process piping should be inspected as process piping. SBP that is secondary process piping : Class1 secondary SBP shall be inspected to the same requirements as primary process piping. Inspection of Class2 and Class 3 secondary SBP is optional. SBP deadlegs (such das level bridles) in Class 2 and Class 3 systems Should be inspected where corrosion has been experienced or is anticipated. 105TABLE 6-1---RECOMMENDED MAXIMUM INSPECTION INTERVALS Types of Circuit ~~ ‘Thickness: | Visual External Measurements _ Class 7 5 years 3 years Class 2 10 years ~~" BS years Class 3 YOyears Injection pe - By Class Soil-to-air interfaces ~ By Class Note : Thickness measurements apply to systems for which TMLs have been established in accordance with 5.5 TABLE D6-2 —- RECOMMENDED EXTENT OF CUI INSPECTION FOLLOWING VISUAL INSPECTION ‘Approximate Amount of CUI Approximate Amount of Followup Inspection by NDE at Suspect Examination with NDE or Insulation Areas ( 5.3.3.2) on Piping Systems. Removal at Areas with within Susceptible Temperature Damaged Insulation Ranges (5.3.3.2 e.f.h) Pipe Class = 1 75% [ 50% 2 50% 33% 3 25% 10% 1061 AUXILIARY PIPING INSPECTION Inspection of secondary, auxiliary SBP associated withinstruments and machinery is optional Inspection of threaded connections will be according to the requirements listed above for small-bore and auxiliary piping. When selecting TMLs on threaded connection, include only those that can be radio-graphed during scheduled inspection. Threaded connections associated with machinery and subject to fatigue damage should be periodically assessed and considered for possible renewal with a thicker wall or upgrading to welded components. The schedule for such renewal will depend on several issues, including the following Classification piping a. b. c. d. e Magnitude and frequency of vibration. Amount of unsupported weight. Current piping wall thickness. Corrosion raté. Intermittent service. 107CORROSION RATE DETERMINATION REMAINING LIFE CALCULATIONS : The remaining life of the piping system shall be calculated from the following formula ‘actual —' minimum Remaining life (years) = = ——------------------- Corrosion rate [inches (mm) per year] where : ‘actual = the actual minimum thickness, in inches (mm),determined at the time of inspection. ‘minimum = the minimum required thickness, in inches (mm) for the limiting section or zone.CORROSION RATE DETERMINATION..contd The long term (L.T.) corrosion rate of piping circuits shall be calculated from the following formula : ‘initial - ‘last Corr, rate (L.T.) = — time (years) between last and initial inspections The short term (S.T.) corrosion rate of piping circuits shall be calculated from the following formula : Corrosion rate (S.T.) = ' previous —'last time (years) between last and previous inspections Long term and short term corrosion rates should be compared to see which results in the shortest remaining life. 109EXISTING PIPING SYSTEMS Corrosion rates shall be calculated on either a short term or a long term basis. For the short term calculation, readings from the two most recent inspections shall be used. For the long term calculation, wall thicknesses from the most recent and initial (or nominal) inspections shall be used. In most cases, the higher of these two rates should be used to estimate remaining life and so set the next inspection interval. If calculations indicate that an inaccurate rate of corrosion has been assumed, the rate to be used for the next period shall be adjusted to agree with the actual rate found. 110MAXIMUM ALLOWABLE WORKING PRESSURE The maximum allowable working pressure (MAWP) for the continued use of piping systems shall be established using the applicable code thickness formula and using the stress values from code tables. For unknown materials, computations may be made assuming the lowest grade material and joint efficiency in the applicable code. When the MAWP is recalculated, the wall thickness used in these computations shall be the actual thickness as determined by inspection minus twice the estimated corrosion loss before the date of the next inspection. MINIMUM REQUIRED THICKNESS (Retirement thk) The minimum required pipe wall thickness, or retirement thickness, shall be based on pressure, mechanical, and structural considerations using the appropriate design formulas and code allowable stress. Consideration of both general and lo€alized corrosion shall be included. aiiREPORTING AND RECORDS FOR PIPING SYSTEM INSPECTION Any significant increase in corrosion rates shall be reported to the owner/user for appropriate action. The owner/user shall maintain appropriate permanent and progressive records of piping system covered by API 570. These records shall contain pertinent data such as piping system service; classification; identification numbers; inspection intervals; The record should contain date, the types of testing, the results of thickness measurements and other tests, inspections, repairs (temporary and permanent), alterations, or rerating. Design information and piping drawings may be included. Information on maintenance activities and events affecting piping system integrity also should be included. The date and results of required external inspections shall be recorded. 112REPAIRS, ALTERATIONS, RERATING AUTHORIZATION AND APPROVAL: All repair and alteration work must be done by a repair organization as defined in Section 3 of API 570 code The repair/alternation work must be authorized by the inspector prior to its commencement. The inspector will designate any inspection hold points required during the repair or alteration sequence. All proposed methods of design, execution, materials, welding procedures, examination, and testing must be approved by the inspector or by the piping engineer. Owner/user approval of on-stream welding is required. The inspector shall approve all repair and alteration work at designated hold points and after the repairs and alterations have been satisfactorily completed in accordance with the requirements of API 570 113TEMPORARY WELDING REPAIRS For temporary repairs, including on steam, a full encirclement welded split sleeve may be applied over the damaged or corroded area. 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. If the repair area is localized (for example, pitting or pinholes) and the specified minimum yield strength (SMYS) of the pipe is not more than 40,000 psig (275,800 kPa), a temporary repair may be made by fillet welding a properly designed split coupling or plate patch over the pitted area The material for the repair shall match the base metal unless approved by the piping engineer. For minor leaks, properly designed enclosures may be welded over the leak while the piping system is in service. Temporary repairs should be removed. and replaced with a suitable permanent repair at the next available maintenance opportunity. Temporary repairs may remain in place for a longer period of time only if approved and documented by the piping engineer. 114. PERMANENT WELDING 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. Corroded areas may be restored with weld metal deposit. Appropriate NDE methods shall be applied on completion of weld. 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 new 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 : > Full penetration groove welds are provided. > For Class 1 and Class 2 piping systems, the welds shall be100 percent radio-graphed or ultrasonically tested > Patches may be any shape but shall have rounded comers (1 inch (25mm) minimum radius) 115NON-WELDING REPAIRS (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. During turnarounds appropriate actions shall be taken to restore the original integrity of the piping system. Procedures that include leak sealing fluids for process piping should be reviewed for acceptance by the inspector or piping engineer. WELDING AND HOT TAPPING All repair and alteration welding shall be done in accordance with the principles of ASME B 31.3 or the code to which the piping system was built. 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 22017 for hot tapping performed on piping components. 116PREHEATING AND POSTWELD HEAT TREATMENT Preheat temperature used in making welding repairs shall be in accordance with the applicable code. Preheating to not less that 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. This applies to piping constructed of the P-1 steels listed in ASME B31.3. P-3 steels , with the exception of Mn-Mo steels, also may receive the 300°F(150°C) minimum preheat alternative. After welding, the joint should, immediately be covered with insulation to slow the cooling rate. Piping systems constructed of other steel initially requiring PWHT normally are postweld heat treated if alterations or repairs involving pressure retaining welding are performed. 117Preheating & Postweld Heat Treatment (Contd.....) PWHT of piping system repairs or alterations should be made using.the applicable requirements of ASME 31.3 Local PWHT can be carried out provided the require PWHT temperature is maintain for a distance for at least two times wall thickness from edge of the weld on either side. DESIGN Butt joints shall be full penetration groove welds. Piping components shall be replaced when repair is likely to be inadequate. New connections and replacements shall be designed and fabricated according to the principles of the applicable code. New connections may be installed on piping systems provided the design, location, and ‘method of attachment conform to the principles of the applicable code. 118MATERIALS 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 materials. The carbon equivalent shall not exceed .3%. PRESSURE TESTING Pressure tests are normally required after alternations and major repairs. : When a pressure test is not necessary or practical, NDE shall be utilized in lieu of a pressure test. The extend of NDE. shall be decided in consultation with piping engineer and NDE expert. 119cm RERATING Rerating piping systems by changing the temperature rating or the MAWP may be done only after all of the following % requirements have been met: > Calculations are performed by the piping engineer or the inspector. > All ratings shall be established in accordance with .the requirements of the code. > Current inspection records verify that the piping system is satisfactory for the proposed service conditions and that the appropriate corrosion allowance is provided. > An increase in the rating temperature that does not affect allowable tensile stress, does not require a leak test. > All piping components in the system (such as valves, flanges, bolts, gaskets, packing, and expansion joints) are adequate for the new combination of pressure and temperature. _ > Piping flexibility is adequate for design temperature changes. > A decrease in minimum operating temperature is justified d by impact test results, if required by the applicable code. 120PIPING & TUBES Pipes and Tubes are hollow, pressure -tight longitudinal products. However, Pipes Tubes |1. | Pipes always have circular cross- | May have non-circular cross- section only section through circular are common. 2. Normally used for conveying Normally used within battery process fluid between two limits of an equipments equipments | 3. | Usually designated by nominal _| Usually designated by actual dimension dimension. Whatis - Nominal Pipe Size (NPS) - Nominal diameter (ND) - Nominal Bore (NB) What is a pipe schedule? Sch No. = 1000 XP S = Safe design stress (psig) —— P = Safe internal pressure (psig) s Sch No. : Dimension less 121STRAIGHT PIPES CLASSIFICATION A. MANUF. METHOD: - SEAMLESS - ERW - EFW - SPIRAL -SEAM WELDED - CENTRIFUGALLY CAST B. END USE : a PRESSURE PIPES (PROC. PIPES) - LINE PIPES - PLUMBING / STRUCTURAL. C. MOST COMMON SPECS : ASTM A 53, A 106 D. AVAILABILITY ; (OFF THE SHELF) - Manufactured to standard dimensions up to 48 NPS are readily available - Pipe schedule designation : upto 36 NPS - Weight designations : upto 48 NPS a Above 48 NPS : Against special order In house fabrication Table 3 (API 570) Gives tolerances 122FITTINGS Fittings are used to connect pipe sections, change the direction of flow or allow the flow to be diverted or added to: Fittings may be + Flanged or + Beveled for butt welding or + Recessed for socket welding or + Threaded for thread connection 123BUTT-WELDED FITTINGS Welded fittings are used primarily in systems meant to be permanent. Advantages of butt welded systems are the following : 1. Smooth inner surface,.offer gradual direction change with minimum turbulence. 2. They require much less space for constructing and hanging the pipe system. 3. They form leak-proof constructions. They are almost maintenance free. They have a higher temperature and pressure limit. 6. They forma self-contained system. They are easy to insulate They offer a uniform wall thickness through- out the system. One of the major disadvantages of butt-welded systems is that are not easy to dismantle. 124SOCKET WELDED FITTINGS Socket welded fittings have certain advantages over butt-welded fittings. They are easier to use on small-size pipelines and the ends of the pipes need not be beveled.The advantages of the socket-welded system are : The pipe does not need to be beveled. 2. No tack welding is necessary for alignment since joint and the pipe are self -aligning. 3. Weld material can not extend into the pipeline. 4, It can be used in place of threaded fittings, therefore, reducing the likelihood of leaks, which usually accompany the use of threaded fittings. One of the major disadvantages of this type of fitting is the possibility of a mismatch inside the fitting where improperly aligned or mated parts may create a recess where corrosion could start. 125FLANGED FITTINGS Flanged connections are most common on piping that are a minimum of 2 in.(5.08 cm ) in diameter. e . An assortment of facings, raised, flat, ring joint grooves, etc.are available in flange variations. © One advantage of flanged systems is that they are easily dismantled and assembled. ¢ One of the disadvantages is that they are considerably expensive than an equally rated butt-welded system, ° Fla ings occupy far more space than the butt-welded or screwed equivalents. ¢ Because of this higher weight load, a flanged system becomes far more expensive to support or hang from the existing structure. 126ASME B 16.11 FORGED FITTINGS, SOCKET WELDING AND THREADED This code Covers ratings, dimensions, tolerances, marking and material requirements. __Class Type. Pipe used for rating basis Sch no. Wail des _ 2000 Threaded 80 [xs 3000, 160 _— 6000 _ XXS 3000 Socket welded 80 Xs 6000 160 — ‘9000 — __XXS The thinner or thicker pipe can be used but lower rating of the two is the rating of joint. - Socket welded fittings are not recommended above 50 NB and for high pressures / temps. - Pipe / fittings threads ASME B1 20.1TYPES VALVES Gate Globe Plug Ball Diaphragm Butterfly Check Slide valvesValves (Cont'd... +» Valves available in Standard Pipe Sizes and Standard Pressure rating. « ASME B 16.34 : Specification for valves — flanged, threaded and welding type + Construction : Valve Body - cast, forged, fabricated by welding or machined from bar stock Trim - Valve disc, seat and steam Valve truin - cast formed, forged or machined from bar stock - Valve ends — flanged, threaded, recessed for s/w beveled for butt welding - Valve operation — gear operation, motor operated, larger sizes, Manual operation for small and medium + Body thickness & other design data—- ASME B 16, 34, API 594, 599, 600, 602, 603, 604, 609Gate Valve : Gate valve — Body with a gate . Used for isolation purposed ite. Fully open or fully closed Size > 2”- port opening = valve end openings. Full ported valves Reduced port GV + Port openings < end openings + Not to be used as block valves associated with pressure relief devilesor Erosive services (je) slurries on lines are to be pigged. + Not to be used for piggin operation. Globe valves + To regulate fluid flow. Body with a circular disc that moves parallel to disc axis and contracts with seat. + Stream flow — Upwards and changes direction to flow through the body to the outlet disc. + Seating surface / flat or tapered + Very steep tapered — fix through lining service — Needle valve, suitable for fine throttling service. 130PLUG VALVES : + Tapered or cylindrical plug fitted snugly into a correspondingly shaped seat in the valve body. + Block valves to close off flow - When open — plug opening in line with flow + Closing — by turning plug to one quarter turn + Operation — gear operated or wheel operated. + Types — lubricated uses grease — like lubricant pumped into the valve through grooves. 131BALL VALVES Similar to plug valve (except plug) instead a drilled sphere is used. Used as Block valves to close off flow Elastomeric seating material Good shut off characteristics, one quarter turn operation. DIAPHRAMGM VALVES : Low pressure corrosive service as shut off valves Diaphragm - flexible material like PTEF or rubber Secured between bonnet and body — presses against the body to give positive shut off. Body — lined or unlined « Application - Corrosive services below, - 7 to 10 Kg /em? pressure and - 121°C temperature 132BUTTERFLY VALVES : Disc mounted on a stem in the flow path within the body. Can open or close with one quarter turn Body — flanged (usually) Application — low pressure service and coarse flow control Variety of seating materials Nitrile rubber seal fitted to the disc for better closing Mechanical operation (lever with locking mechanism) ensures - Slamming shut is prevented during service. 133CHECK VALVES + To automatically prevent block flow + Types — swing, lift — piston — spring load used for type « Small bores (upto 1.5”) — lift lift check valves WATER CHECK VALVE + Two spring loaded semi circular plates + Sizes 2” NB to 48” (API 594) 134SLIDE VALVES « Specialized gate valve + Erosive + High temperature service, lined with refractory - Flat plate slides against a seat + Do not make a gas tight shut off APPLICATION + Controlling fluidized flow, + Internal surface — lined with erosion resistant refractory 135Art1 - General Requirements ...contd 3. T-130/140 Responsibilities - Ensure that NDE equipments confirm to ASME Sec V requirements - Personnel are qualified in accordance with one of the following: 1) SNT-TC-1A (1996 Ed.) Society for NDT ~ Technical Committee — 14 2) ANSI/ASNT ~ CP (1995 Ed): ASNT Standard for qualification and certification of personnel. - Ensure records/documentation are generated and maintained as required by code. 4. 1-150 Procedures: - Written procedures for NDT shall be in place in - Procedures in Sec V can be directly adopted where applicable - Manufacturer shall develop special procedures which are equivalent / superior to Sec V, incase of special configurations 136Art 1 - General Requirements ...contd 5. T-160 Calibration - Ensure that relevant equipment calibration required by Sec V for the specific NDE are performed. - When special procedures are developed specify what calibration is necessary and when. 6. T-170 (a)Inspector means Authorized inspector who possess required qualification (i.e. third party, or API 510, or NBBR) (b) Examination — Internal QC functions performed by personnel employed by the company (owner user of manufactures) (c) Subsection B documents (ASTM documents) may however refer examination inspection (since there is no authorized inspector concept in ASTM) 7. T-180 Evaluation: - Shall be as stated in construction code 8. -T-190 Records - Records / Documentation shall be in accordance with construction code and as applicable in subsection A and B. 137Art 2 — Radiographic Examination Scope: Specifies methods for radiographic examination and shall be used together with article 1, whenever it is referenced in construction code. Marking & Traceability : - There shall be permanent identification on tadiograph, traceable to contract, equipment, component , weld or weld part. - Manufacture’s symbol (or name) and date shall appear on radiograph T-221 Procedure Requirements T 221.1 Compliance without a written Radiographic procedure T 221.2 Compliance to a written Radiographic procedure, when required by referencing code or to cover non-standard configurations T-223 Backscatter Radiation Lead symbol, B, min dimension of % in x 1/16 int Light image of B on dark background-- Unacceptable A dark” B” on lighter background —may be acceptable 138ee = = THE WELDING | Sect 2 ( SWS! middle = doubie wall single image ( DVIS! } bene » daubia wall double image For fat plates single wall single Image techniques sinilar to thasa lor pipes aya used, Fig.5.4 Radiographic Techniques SCHOOL OF APPLIED NON-DESTRUCTIVE TES? Wis11-1193 139T-225 Monitoring Density Limitations of Radiographs Either Densitometer or step wedge comparison film shall be used, Density Limitations Single film viewing - Min 1.8 for X Ray / 2.0 for G-Ray - Max 4.0 forX/G Ray Composite viewing - Min 1.3 forX /G Ray - Max 4.0 forX/G Ray A tolerance of 0.05 is allowed. Density Variation -15 % to + 30% Where shims used, +30 % may be exceeded T-272 Radiographic Technique T-271.1 Single wall Technique T-271.2 Double wall Technique Single wall viewing (DWSI) Double wall viewing (DWDI)-upto 3.5" dia. 140T-276 IQI Selection Hole Type: No 5 to NO. 200, Hole size --1T, 2T, 4T Wire Type: SetAtoD , set of 6 wires Selection: Table T-276 Thickness includes weld reinf. But not backing. Number of Penetrameters. At least one Penetrameter to appear on.each radiograph Special cases: 1. For Cyl. Components where source is at axis, 3 Penn. at 120 degrees, under following conditions: a. complete circumference is radiographed using one or more film holders b. when section or sections, 240 degrees or more c. 3 Penne with one at ends and one at centre for 120 degrees to 240 degrees 141T-276 !QI Selection....contd 3.Where sections of longi. Welds adjoining the circ. Weld are radiographed simultaneously; One more penetrameter shall be placed on longi. Weld at the end of the section most remote from junction 4. For Spherical components, 3 penne: 120 deg. Apart. 5. For Spherical components, 3 penne - 120'to 240 degrees, ends, and centre. T-290 Documentation 142ASME SECV Nondestructive Examination Article 6 Liquid Penetrant Examination T-600: Introduction When referenced, Art 6 shall be used together with Art 1 7 621.1 Initial Procedure Procedure shall consider: * The materials, shape, sizes to be examined * Type of chemicals « Pre cleaning details * Penetrant - dwell time, removal, temperature * Developer, time « Post cleaning Penetrant materials: includes all Solvents, Penetrants, Developers, etc. T-641 Control of Contaminants + Especially for test materials miade of Ni, Ni alloys, Austenitic SS, Titanium ¢ The sulphur, chlorine, or fluorine co exceed 1 % of the residue by weight 1431-642 Surface Preparation e As welded, as rolled, as cast or as forged is satisfactory « Surface preparation by grinding, machining may be required where surface irregularities could mask indications * Cleaning agents shall consists less than 1 % halogens T-643 Drying after preparation e Surface shall be dry before penetrant application T-650 Procedure/Technique T-651 Technique « WW ° PE ° SR T-652 Techniques for Standard Temperatures * Temp shall be between 10°C to 52°C * Local heating or cooling is permitted mnT-670 Examination T-671 Penetrant Application ¢ Dipping, Brushing, Spraying T-672 Penetration Time Material | Form Types of Discontinuity | Dwell Times-_ | Minutes (10 °C to 52 | : Al, Mg,| Castings, [Cold Shut, Porosity, |5 [7 | Fe, Br, | Welds LOF, Cracks |8z, Ti & [Wrought |Laps, Cracks 10 Alloys Carbide | All Forms }LOF, Porosity, cracks |5 [7 | tipped | | | tools | | Plastic All Forms | Cracks [5 [7 | | Glass All Forms | Cracks [5 [7 | | | Cracks, Porosity 5 \7 | | Ceramic | All Forms 145T-673 Excess Penetrant removal « WW © PE © SR T-674 Drying after Excess Penetrant removal * (If required, but not heated above 52 °C e For SR method, dries by itself 1-675 Developing T-675.1 Dry Developer T-675.2 Wet Developer T-675.3 Developing time T-676 Interpretation T-676.1 Final interpretation T-876.2 Characterizing Indication(s) T-676.3 Color Contrast Penetrants - 50 fc (500 lux) 2T-676.4 Fluorescent Penetrants * Darkened area ¢ Examiner in darkened area for atleast 1 min * Black light warm up time min of 5 min Black light intensity minimum of 1000 microwatts/cm? T-680 Evaluation as per referencing code T-690 Documentation / Records 147Article 7 Magnetic Particle Examination T-710: Scope When referenced, Art 7 shall be used together with Art 1 T-731 Examination Medium ° Dry Particles Dry - Not for surface temp above 316 °C ° Wet Particles Wet - Not above 57 °C ¢ Florescent —_ Particles Darkened area Examiner in darkened area for atleast 5 min Black light warm up time min of 5 min Black light intensity min. of 1000 microwatts/cm? oeee T 741.1 Preparation . As welded, cast as rolled, as forged is satisfactory * Prior to exam., dry atleast 1” either side . Cleaning shall be any methods - detergents, solvents, blasting, ect. 1-752 Techniques and Materials . Wet or Dry ¢ Flourescent or Visual . Magnetization ¢ Prod * Yoke 148T-762 Lifting Power of Yokes « Checked atleast once in a year or whenever yoke has been damaged. If more than one year not in use, prior to first use. AC shall have lifting power of at least 4.5 Kg DC shail have lifting power of at least 18.1 Kg Weight too shall be checked prior to first use 1-770 Examination T-771 Direction of Magnetization e Atleast two examinations on each area, the second is perpendicular to first one T-772 Examination Coverage t » Sufficient overlap to assure 100 % coverage 1-773 Prod Technique e Procedure: contact, Switch-on, Two shots @ 90 deg * Current © 100 to 125 Amp/ in. of prod spacing for Thk.,0.75” or more * 90 Amp! in. prod spacing for T less than 0.75" « Prod Spacing - Not exceed 8” and not less than 3" T-776 Yoke Technique To be used for surface discontinuities T-780 Evaluation : As per referencing code. T-790 Records 149Cintegrate Training, 9. VISUAL TESTING A. PROCEDURES 1. VT shall be performed as per written procedure, and as minimum should contain Table T-923 requirements. Procedure needs to be qualified. Detection of a fine defect 1/32” (0.8 mm) or less in width, located on similar surface will qualify the procedure. If E.V.s are changed, re-qualification is required. Personnel shall have annual vision test to read standard Jaeger J-1 letters for near vision. B. TECHNIQUES 1. Direct visual is made if access is sufficient to place eye within 2 feet of surface to be examined at an angle not less than 30° to surface. Magnifying glass may be used 150Cintegratedt Training, Prafessiaa ine net Cas 3. Natural or artificial white light may be used. Intensity shall be min 100 foot candles (1000 lux) 4. Light source and light level verification is required one time. 5. Personnel shall have annual vision check of Jaeger, J-1. 6. Remote visual test may use mirrors, telescope, cameras, etc. Resolution capability shall be the same as direct visual test (0.8 mm) 7. Preparation of checklist of the items to be VT examined is recommended. C. DOCUMENTATION: As per T-991Cintegratediraining 10. LEAK TESTING A. GENERAL 1. Testing shall be as per written procedure. 2. Gauge range = 2x Testpr. — Preferred = (1-1/2 to4)x Testpr. — Acceptable 3. Gauges shall be calibrated prior to use and recalibrated at least once a year. B. BUBBLE TEST 1. Air or inert gases may be used as test medium. 2. Water or other compatible medium may be used for bath. 3. Temperature of surface: 40° F to 125° F (4° C to 52°C) 4. Presence of continuous bubble growth indicates leakage. 5. After repair, repaired area shall be re-tested. 152“integrated raining SE-797 UT THICKNESS MEASUREMENT BY PULSE - ECHO METHOD 1 Scope: 1) Method suitable up to 200°F (93°C) 2) Can be adopted for materials giving back echo (ie., for fine grain materials) 2 Operating principle: The thickness (T) of a material is given by T=w2 v= velocity T = transit time The P-E method measures transit time (T) approximate value of velocity (v) can be obtained for different materials from ASTM document E 494 Fig 1 shows relation between T & t Time t is plotted on X-axis of CRT. Hence, X-axis represents thickness also. 1533) 4) Calibrate the range using reference blocks for maximum and minimum thickness. Apparatus 3 types a) CRT read out b) CRT + direct read out c) Direct thickness read out Search Units 3 types a) Straight beam contact type b) Delay line type c) Dual element type High frequency and low damping is suitable for low thickness (more than 10 MHZ for 0.6 mm) a) straight beam contact type: 1. The beam travels through the thickness and comes back giving initial pulse and echo pulse. 154CintegratedtTraining, 2. Zero correction of initial pulse for wear plate thickness 3. Calibrate range with known thickness block for maximum reading. 4. Lower thickness check and adjustment improves the accuracy. b) Delay line type search units. 1. Use delay block to minimize dead zone. 2. Set front surface echo to zero and back wall echo gives the upper range of thickness. 3. Calibrate using two test blocks — minimum and maximum thickness. c) Dual search unit 1. There are separate transducers (crystal) and receiving the pulse and they are set at a small angle. 2. More suitable for higher thickness. For small thickness the error (due to vee. path variation) Fig 2(a) and (b). 155CintegratedTraining 3. Low roof angle suitable for higher range (2 - 200mm) and higher angle suitable for low tange (0.5 - 5mm). d) High thickness measurement 1. Use of multiple echo is made. 2. For example, if we have to measure thickness between 50 mm and 60 mm accurately — use 10 mm calibration block, then 5" back echo will be 50 mm and 6" will be 60 mm. 3. Set the 5” echo to zero and 6" at the screen range then screen is calibrated to 50 - 60mm. 4. Confirm the read out with known thickness (say 55 mm) before first use. 156Technical precautions: 1. Calibration should be done on material with same velocity and attenuation. Scanning speed should not be excessive. 3. While taking measurement for high temperature condition, a positive error of 1% per 55°C (100°F) results. Hence temperature correction is necessary. 4. The horizontal linearity CRT shall be checked as per E 317. 5. CRT read out is recommended on corroded and rough surface. 6. Awritten procedure is required. 7. Calibration block should confirm to similar curvature as the job. 8. Reporting of test should as per Art. 23 of Sec. V. 157“Cintegratedtiraining API 578 - MATERIAL VERIFICATION Scope — API 578 gives guidelines to verify alloy content for new and existing alloy piping system. — Carbon steel piping is not covered in API 578. — While substituting Alloy steel in place of C-steel, suitability of Alloy steel for the required service should be verified. 158Cintegrated raining API 578... (CONT’D) 1 One inspection lot should be from one heat. 2 “Material verification program” is documented QUALITY ASSURANCE PROCEDURE to assess alloy content. 3 “PMI testing” means test/evaluation of a material to confirm the alloy content. 4 Owner-user shall establish the MATERIAL VERIFICATION PROGRAM indicating type/extent of PMI testing. 5 “Mill-test report” should not be considered as substitute for a PMI test. 159Cintegratediiraining API 578... (CONT’D) 1 For testing welding consumables, one electrod / wire should be PMI tested. 2 For longitudinally welded pipes/fittings random PMI testing shall be done for based metals & weld metals (except autogenous welds). 3 PMI testing for receiving alloy materials may be performed at receiving inspection stage or at supplier's location before shipping release. 4 If PMI testing is specified after fabrication, testing above (ie. PMI at receiving stage) is not alternative to PMI after fabrication. 160—Cintegratedii raining, PMI METHODS 1 Portable X-ray Fluorescence: - Different materials emit characteristic spectrum X-ray’s specific to that material. - Element lighter than sulfur can not be detected. 2 Portable Optical Emission Spectrometer - Different materials emit characteristic spectrum of light if stimulated by electric arc - It may be used to detect carbon content also. 3 Chemical Laboratory Analysis - Adopted when accuracy required is higher 7 than normally required in PMI test, but it s slower. 4 Chemical spot check (color change method) resistivity testing are some other methods used for PMI. 161“Cintegratedtiraining API 578 — PMI METHOD (cont'd) 1) Calibrate equipment as per specifications of equipment manufacturer. 2) Operators shall have qualifications and training suitable for the task. 3) If any one of a representative sample is rejected, the entire lot is considered “suspect”. More extensive analysis shall be considered for remaining lot. 4) PMI tested and accepted materials shall be identified by color coding/stamping/documents. 5) PMI records shall be retained as long as piping system existing in its original location. 162