PIPING

SL Contents

1.0 Purpose

2.0 Scope

3.0 Abbreviations /Definitions

4.0 References

5.0 Type of piping

6.0 Need for inspection

7.0 Frequency of inspection

8.0 Protection of austenitic SS piping

9.0 Inspection procedures

10.0 Inspection of new piping

11.0 Hydro testing

12.0 Pneumatic testing

13.0 Corrosion control

14.0 Inspection report

15.0 Documentation

6-1
 PIPING

1.0 PURPOSE

The purpose of this manual is;

1.1 To evaluate the present condition of piping for its soundness.

1.2 To determine the pattern of deterioration and suggesting remedial measures.
1.3 To establish corrosion rate and forecasting future procurement actions.
1.4 To ensure that all the pipelines are inspected as per planned schedule.

2.0 SCOPE

This shall cover the minimum requirement of inspection of unit and offsite
piping. It shall be applicable to inspection.

3.0 ABBREVIATIONS / DEFINITIONS

3.1 PIPE

A pressure tight cylinder used to convey a fluid or to transmit a fluid pressure

ordinarily designed pipe in applicable material specifications.

3.2 TUBE

Tubing is similar to pipe but it is manufactured in many sizes of out side

diameter and wall thickness. Tubes are generally seamless cold drawn/hot
drawn, and the stated size is actual outside diameter.

6-2
4.0 REFERENCE

4.1 API Guide Chapter –XI, Pipe valves and fittings.

4.2 API- 1104, Welding pipelines.
4.3 API-1107, Recommended pipe line maintenance welding practices
4.4 API-5L, Line pipe
4.5 ANSI –31.3, Chemical plant and Petroleum Refinery piping.
4.6 ANSI-B-31.4, Liquid Petroleum Transportation Piping System
4.7 ANSI-B-36.10, Welded seamless wrought steel pipe.
4.8 ANSI-B-16.5, Pipe Flanges and Flanged Fittings, steel metal alloy and other
special alloys.
4.9 ANSI-B-16.9, Factory made wrought steel butt welded fittings
4.10 ANSI-B- 16.11, Forged steel fitting socket welding & threaded.
4.11 NACE -RP-01-69, Recommended practices control of external corrosion on
under ground piping system.
4.12 NACE-RP- 01-70, Protection of Austenitic stainless steel from polytheonic acid
S.C. C during shutdown of Refinery equipment.
4.13 B.S C.P 1021, Cathodic protection.

5.0 TYPE OF PIPING

Various types of pipes are used in Refinery according to the method of

manufacture.
5.1 Electric Resistance welded pipe
5.2 Furnace Butt-welded pipe.
5.3 Electric Fusion welded pipe
5.4 Double submerged Arc-welded –pipe.
5.5 Spiral welded pipe
5.6 Seamless Pipes
5.7 Centrifugal Cast pipes.

6-3
6.0 NEED FOR INSPEECTION

In a Petroleum Refinery or any Chemical Industry, the performance and

reliability of piping net work system play a vital role towards the overall safety
and productivity of the plant. Hydrocarbon is generally non-corrosive but small
amount of impurity e.g. H2S, HCl, Phenol, Cyanide, Naphthenic acid, and
ammonia present in the stream can cause highly corrosive situation. Periodic
inspection, reliability study and testing of the pipelines will help in for smooth
and trouble free operation of the plant. Inspection of the piping should be
carried out as per the following;

6.1 To evaluate the present condition of the pipelines and their soundness to
continue in service.
6.2 To keep the concerned operating & maintenance personnel fully informed
regarding the condition of the piping network.
6.3 To determine the cause of deterioration and advise economical
recommendation to the problem.
6.4 To recommend long term and short term repairs & replacement to ensure
further on-stream of the Plant and its safety.
6.5 To initiate procurement action of material to meet repair/replacement.
6.6 To ensure that all the piping are inspected as per statutory requirement.
6.7 To avoid catrastropic failure of piping network.

7.0 FREQUENCY OF INSPECTION

7.1 ONSITE PIPING (PLANT AREA)

Inspection of process piping in units should be done on-stream as far as

possible once between two scheduled turnarounds. Inspection, which cannot
be made during operation, shall be done during the major M&I plant shutdown.

6-4
 However, depending on the corrosion rate and type of deterioration, the
frequency of inspection of process piping can be varied suitably.

On-line thickness gauging using hot probes is done based on-stream

inspection and when O/H pH is not maintained continuously as specified.

7.2 OFFSITE PIPING

The frequency of inspection for offsite pipe shall be as below;

7.2.1 Hydrocarbon Services

SL Service Frequency of inspection years
External Comprehensive
1 CRUDE

Sweet 5 10
Sour 3 6
2 LP/Natural Gas

Sweet 3 6
Sour 2 4
3 Natural gas
Condensate 2 4
4 Gasolene / Naphtha 2 4
5 ATF/HSD/LDO/SKO/
Gas oil 3 5
6 FO/RCO/VBO/Bitumen 3 5
7 Flare fuel gas 3 5 or during the s/d of the line
8 Lube oil 5 10

7.2.1.1 Where crude source cannot be established the frequency specified for sour
crude shall apply

6-5
7.2.2 Utilities

SL Service Frequency of inspection

years
External Comprehensive
1 Sweet Water

Lined pipe 3 6
Unlined pipe 2 4
2 Salt water

Cement lined pipe 3 6

Unlined pipe 1 2
3 Fire water

Above ground unlined pipe 3 5

Unlined pipe 1 2
Underground lined pipe 3 5
Unlined pipe 2 4
4 Air / Steam 3 6
5 Steam condensate 2 4
6 Ammonia 2 4
7 Caustic 2 4
8 DEA/MEA 3 5
9 Sulphur Dioxide 2 4
10 Sulphuric acid (conc.98%)
2 4
11 Furfural Phenol 2 3
12 Lined pipes (excluding water 3 6
lines)
13 Benzene 2 4

6-6
7.2.2.1 External inspection includes both visual inspection and ultrasonic thickness
readings taken externally.

7.2.2.2 Comprehensive inspection covers some or all of the following tests;

7.2.2.2.1 Visual inspection

7.2.2.2.2 Hammer test
7.2.2.2.3 Ultrasonic Thickness Measurement
7.2.2.2.4 Dye Penetrant Test
7.2.2.2.5 Magnetic Particle Test
7.2.2.2.6 Radiographic test
7.2.2.2.7 Hydrotest

7.2.2.3 Piping in corrosive environment shall be visually inspected once a year. Years
of inspection experience have revealed that failures of most of the offsite
pipelines are due to external corrosion and that internal corrosion failures are
minimum.

7.2.2.4 Inspection as well as thickness data of newly constructed pipelines shall be

collected as base data within two years of commissioning for establishment of
corrosion rates.

8.0 PROTECTION OF AUSTENITIC PIPING

All the Austenitic SS piping where there is chance of Stress corrosion

Cracking due to formation of polytheonic acid should be kept under inert
atmosphere. If at all they are to used/opened to atmosphere, passivation of
should be done as per the NACE; RP 01-70.

6-7
9.0 INSPECTION PROCEDURE

9.1 TOOLS REQUIRED / PREPARATORY JOB

The most practical tools generally used for pipeline inspection are as under.

9.1.1 Inspector Hammer

9.1.2 Ultrasonic Thickness gauge
9.1.3 Pit depth gauge
9.1.4 Measuring tap
9.1.5 Radiography equipment
9.1.6 Bore scope/ Fiber scope
9.1.7 Small mirror
9.1.8 Magnifying Glass
9.1.9 Magnet
9.1.10 Safety Torch.
9.1.11 Paint thickness gauge
9.1.12 Thermal cryons
9.1.13 D.P KIT
9.1.14 Holiday detector
9.1.15 Inside /outside Calipers
9.1.16 Hardness testing machine.
9.1.17 Thermography equipment

9.2 PREPARTORY JOBS

9.2.1 Before start of inspection, necessary information like isometric drawings,

design data and last inspection observation shall be examined by the
Inspector and explained to the Technicians who have been allotted the
inspection job of any piping.

6-8
9.2.2 Arrangements for scaffolding, insulation removal, ladder shall be planned and
the concerned departments shall be requested to provide these facilities.
9.2.3 Ultrasonic thickness instruments shall be used for thickness measurements.
9.2.4 Mirror, magnifying glass and torch shall be arranged to aid visual inspection.

9.3 LIKELY AREAS OF CORROSION

Areas most prone to corrosion, erosion and other forms of deterioration are;

9.3.1 Points where condensation of acid gases and or water vapour is likely to
occur.
9.3.2 Points at which acid carryover from process operations are likely to occur.
9.3.3 Points at which Naphthenic or other organic acids may be present in the
process stream.
9.3.4 Points at which high sulphur streams of moderate to high temperature exists.
9.3.5 Points at which high temperature and low temperature hydrogen attack may
occur.
9.3.6 Dead ends and locations where liquid vapour inter phasing or condensation
occur.
9.3.7 Valve bodies and rims, fittings, ring grooves and rings, flange faces and
unexposed threads.
9.3.8 Welded areas (subject to preferential attack)
9.3.9 Catalyst, flue gas and slurry piping.
9.3.10 Steam systems subject to channeling or where condensation occurs.
9.3.11 Ferrous and non-ferrous piping subject to stress corrosion cracking.
9.3.12 Alkali lines subject to caustic embrittlement with resultant cracking at stressed
areas such as weld joints, bends etc.
9.3.13 Areas near flanges or welded attachments, which act as cooling fins, thereby
causing localised corrosion because of condensation.
9.3.14 Locations where fluid impinges or fluid velocity changes.

6-9
9.3.15 Chrome-Nickel and chrome-molybdenum lines in high temperature service at
stressed point such as bends and anchor points.
9.3.16 Areas where steam or electric tracing come in contact with pipes handling
materials such as caustic soda.
9.3.17 Austenitic stainless steel lines where polytheonic acid formation takes place
with resultant cracking.
9.3.18 Areas immediately down stream of chemical injection points where localised
corrosion might occur in the reaction zone.
9.3.19 Dissimilar metals in contact, which may lead to galvanic corrosion.
9.3.20 Rubber-lined and glass-lined pipes which may get damaged near the flanges
or due to cracks in the lining.
9.3.21 Conditions in areas of pipelines carrying crude oils with high sulphur / chloride
content.
9.3.22 Terminal pipelines carrying sea ballast water
9.3.23 Locations having low pH and high chloride ions.

9.4 METHODS & PROCEDURES

The following inspection procedures shall be adopted while inspecting piping

net work in offsite as well as in units;

9.4.1 In case of carbon steel and alloy steel piping where lines mostly deteriorate
due to corrosion / erosion, ultrasonic thickness survey shall be carried out In
bends 3 readings on outer periphery and 3 readings on bottom side of the
bends shall be taken and minimum shall be recorded. On straight piping,
minimum 4 readings at a interval of 30 M shall be measured for line size NB 3”
or more. In lower dia lines, 2 readings in top and bottom shall be taken.
Additional thickness measurement in straight pipes shall be done at locations
of direction change like bends, valves, TEE connections, expansion loops etc.

6-10
9.4.2 In case of SS piping, generally thinning / corrosion shall not be a cause of
concern. Only sample thickness measurement at critical locations shall be
done. Additionally, depending upon service condition, ultrasonic flaw
detection / DP test of weld joints shall be arranged after 5 to 10 years of
service life to know if any deterioration due to stress corrosion cracking has
taken place.
9.4.3 Visual inspection shall be carried out for signs of leaks and cracks; painting /
coating condition, insulation condition and external corrosion.
9.4.4 In the piping where internal corrosion is suspected, certain spool pieces shall
be dropped and internal visual inspection should be carried out. If this is not
possible, radiography shall be done.
9.4.5 On the piping where the material and service conditions can cause cracking,
dye penetrant testing shall be conducted at the locations like weld joints, small
bore tapings.
9.4.6 Piping NB dia 2” and smaller size shall be thoroughly but carefully hammer
tested with the right amount of hammer pressure and after informing
Production deptt., the hammer testing shall be done to supplement thickness
measurement, which becomes difficult and a bit less reliable for line size dia 2”
and below. DP / WFMPI test of small-bore stub joints and pneumatic test of
critical lines in high pressure & temperature service should be done during
plant shutdown to ensure reliability.
9.4.7 Based on the inspection findings, repair / replacement jobs shall be
recommended.
9.4.8 The thickness measurement of the present shutdown of the line shall be
compared with the original thickness and the rate of corrosion shall be roughly
calculated. If the thickness is found adequate from retiring thickness point of
view and taking care of further corrosion up to next shutdown of the line, it
shall not be replaced. However, if it is likely to cross retiring thickness, the
complete line or portion of the line, bend etc. shall be recommended for
replacement.

6-11
9.4.9 During replacement, stage-wise inspection like DP & Radiography shall be
carried out. Finally, the complete line shall pressure tested 1.5 times of its
working pressure.
9.4.10 The repair / replacement jobs shall be inspected as per furnished
recommendation.
9.4.11 All piping in hydrocarbon service, shall be hydrotested as per test pressure
after every hot job. Hydrotest of piping in other services shall be decided on
critically of the service.
9.4.12 The pipe supports shall be visually inspected for condition of protective
coating like fire proofing, evidence of corrosion, distortion, condition of
foundation bolts, free operation of pipe rollers, attachment of beams, bracings,
pipe hangers in cold and hot condition, anchors and free operation of pulleys
and pivot points for counter balance piping system.

9.5 UNDERGROUND PIPING

9.5.1 For ascertaining the condition of external wrapping and coating, lines shall be
visually inspected after excavation at selected location in case of planned
inspection and at the location of leak in case of breakdown inspection.

10.0 INSPECTION OF NEW PIPING

During erection of piping, it is very essential to inspect the condition of the

pipes before use. Detail inspection of material, with third party inspection
reports along with various tests carried out from the approved Laboratory.
Requirement of IBR if any should have proper approval and stamp of CIB.
Following should be inspected after receiving the pipe at site.
10.1.1 Pipe supplied by required specifications
10.1.2 Pipe Dia and schedule of pipe.
10.1.3 No ovality at the pipe edges

6-12
10.1.4 No Dent mark should be present
10.1.5 External corrosion/pitting marks
10.1.6 Test certificates
10.1.7 Stage wise inspection of fabrication during construction / project execution.

11.0 HYDROTESTING

The piping system should be hydro tested after completion of all the welding
jobs or the line have completed. After Hydro test, it is not advisable to do any
hot job on the piping.

11.1 TEST FLUID

The test shall be hydrostatic using water. If possibility of damage due to

freezing or the presence of water in the system may adversely affect the
operation of the units/ contaminate the catalyst, pneumatic test may be carried
out. DM water shall be used if the piping is made of austenitic stainless steel.

11.2 TEST PREPARATIONS

11.2.1 All the weld joints shall be left un-insulated/ un-painted before the test.
11.2.2 Piping designed for vapour and gas shall be provided extra temporary
supports if required to support the weight of test fluid/liquid.
11.2.3 Expansion joint in the piping line system shall be provided temporary restraint
if required.
11.2.4 Relief valves and rupture discs should not be subjected to hydro test.
11.2.5 Equipment not included in the test, shall be isolated by providing blinds.
11.2.6 Minimum two pressure gauges should be used during the test. One pressure
gauge should be at the highest place of the system and on at the pressurising
point.

6-13
11.2.7 Only calibrated pressure gauge should be used for test purpose.
11.2.8 During testing air shall be vented through top vent only.
11.2.9 The increase in pressure should be gradual.
11.2.10 The test pressure shall be 1.5 times of the pump shut off pressure or
maximum operating pressure.
11.2.11 Where the test pressure of piping are attached to the vessel, the test pressure
shall be as per the test pressure of the piping.
11.2.12 API RP-1110 may be referred for guidance for hydro testing.

12.0 PNEUMATIC TESTING

Wherever hydrotest is not practicable, pneumatic testing of the piping shall be

carried out using air or inert gas only. It involves hazards due to release of
energy stored in compressed gas. Therefore, proper care shall be taken to
minimise the chance of brittle failure. Any pneumatic test shall include the
preliminary check at not more than 25 psi gage pressure. The pressure shall
be increased gradually in steps.

13.0 CORROSION CONTROL

There are two types of corrosion taking place in piping system;

13.1 EXTERNAL CORROSION

13.1.1 Unlike corrosion, which occurs in an aqueous environment, Oxidation is high

temperature degradation of metal due to reaction of dry gaseous environment
with metal and alloys. Atmospheric corrosion is also contributing factor for
external corrosion. It is severe in low coastal area where humidity & moisture
content is more.

6-14
13.1.2 To over come these problem, the pipe line should be externally painted
properly with suitable painting system .The frequency of painting should be
decided depending upon the severity of the area.
13.1.3 The piping net work near cooling Tower area may require painting once in
year.
13.1.4 Crevice corrosion may take place near the support/clamps etc. The same
should be checked and area should be protected by painting.
13.1.5 Grass and growth of plant and herbs underneath the piping shall be removed
and hard surfacing should be done under the piping net work.
13.1.6 The condition of the piping net work area should be checked every year before
monsoon for proper drainage of rain water

13.2 INTERNAL CORROSION

The selection of material depends upon the type of liquid is handled and the
presence of corrosive constitutes in the product. The rate of corrosion is
decided based on the thickness records between two consecutive inspections.
Depending upon the corrosivity the piping metallurgy may be up graded.

13.2.1 Where austenitic stainless steel grade materials has been used it should be
passivated externally and internally before exposing to atmosphere to avoid
S.C.C.

13.2.2 If SS Pipes need insulation the chloride content in the insulation should not be
more than 15 PPM in the insulating material. For further detail regarding
passivation Refer API-RP-01-70.

13.2.3 CS piping are corroded internally due to low pH in the system. It should be
maintained above 6.5+0.2.

6-15
13.2.4 The bend are more prone to erode due to angular velocity of the fluids, hence
extra care shall be taken in thickness while designing piping net work.
13.2.5 The CS piping used for Caustic and Amine service .the weld joints shall be
stress relieved after welding.
13.2.6 The high temp. piping are prone to brittle failure, cracking graphitisation, voids
formations, creep failure etc. It should be inspected for metallurgical
degradation at a fixed frequency.
13.2.7 Alloying is the most common method for increasing the oxidation resistance by
adding Chromium, Nickel etc.
13.2.8 High temperature hydrogen attack causing blistering, forming fissures and
thus reducing load carrying capacity lead to rupture. Hydrogen damage in the
metal exposed to hydrogen should be tested for hydrogen damaged test. More
over the piping in hydrogen service shall be PWHT at 625 Deg C to 650 Deg
C to increase to resistance to hydrogen attack.

14.0 INSPECTION REPORT

The inspection report shall be prepared after inspection of the pipe line. The
report should be contains the followings;

14.1.1 Reason of inspection

14.1.2 Last inspection done
14.1.3 Size of the line
14.1.4 Service of the line
14.1.5 Present condition of the line and
14.1.6 Future course of action/recommendations etc.

An isometric sketch should be attached in case any repair/replacement has

been recommended with complete detail of welding electrodes, preheating
post weld heat treatment and hydro test/pneumatic testing of the piping net

6-16
 work. The condition of supports, external insulation, painting etc shall be
included in the report. Copy of the report should be distributed to concerned
personnel for timely actions.

15.0 DOCUMENTATION

A separate file shall be maintained for every service of piping both for unit
piping and offsite piping. The file shall contain;

15.1.1 Inspection reports and recommendations

15.1.2 Thickness survey reports
15.1.3 Other NDT reports

A master list of piping shall be maintained for every unit and offsite area along
with frequency and dates of last inspection.

6-17