INTRODUCTORY COURSE ON

API 570

Inspection, Repair, Alteration, and

Rerating
of In-service Piping Systems

API STD 570 PRESENTATION

1
 Scope of API 570
Coverage:
API 570 covers inspection, repair, alteration and re-rating
procedures for metallic piping systems that have been in-
service.
Intent:
API 570 was developed for the petroleum refining and
chemical process industries but may be used for any piping
system where practical.
Any organization that uses API 570 should maintain or have
access to an authorized inspection agency, a repair
organization, qualified engineers, inspectors and examiners.
Limitations:
Limited to piping that has been placed in-service. This
standard is not intended to replace any local statutory
requirement.

2
 Scope of API 570
Specific Applications:
Piping systems for process fluids, hydrocarbons and similar
flammable or toxic fluid services.
Included Fluid Services:
1. Raw, intermediate and finished petroleum products.
2. Raw, Intermediate and finished chemical products.
3. Catalyst lines.
4. Hydrogen, natural gas, fuel gas and flare systems.
5. Sour water and hazardous waste streams above threshold limits.
6. Hazardous chemicals above threshold limits.
Excluded and 0ptional Piping systems:
Piping systems listed here may be excluded from the specific
requirements of API 570, but may be included at the owner's
option. (See API 570 for the lists)
Fitness-for-service:
The "API RP, 579 Fitness-for-Service" concepts may be used for
evaluating in-service degradation of pressure piping and components.

3
 Owner/user inspection organization

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

Authorized Piping Inspector Qualification:

Requirements for becoming an "Authorized piping inspector."
The term inspector as used by API 570 refers to an authorized
piping inspector. See Appendix B for certification requirements.

Responsibilities:
The owner-user shall have overall responsibility for compliance
with API 570. The piping engineer is responsible to the owner /
user. The repair organization shall be responsible to the owner
/ user.

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

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

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Inspection for Specific Types of Corrosion and Cracking

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

Upstream:
12 inches or three pipe diameters upstream whichever is greater

Downstream:
The second change in flow direction or 25 feet downstream, beyond the first
flow change whichever is less.

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

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Injection Point Piping Circuit

7
Inspection for Specific Types of Corrosion and Cracking
TMLs (thickness measurement locations):

The selection of thickness measurement locations (TMLs) within injection

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

a. Establish TMLs on appropriate fittings within the injection point circuit.

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

The preferred methods of inspecting injection points are radiography and/or

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

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

Corrosion Under Insulation (CUI):

External inspection of insulated piping systems should include a
review of the integrity of the insulation system for conditions that
could lead to corrosion under insulation (CUI) and for signs of
ongoing CUI. Sources of moisture may include rain, water leaks,
condensation, and deluge systems. The most common forms of CUI
are localized corrosion of carbon steel and chloride stress corrosion
cracking of austenitic stainless steels.

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Inspection for Specific Types of Corrosion and Cracking

Insulated Piping Systems Susceptible to CUI:

a. Areas exposed to overspray from cooling water towers.
b. Areas exposed to steam vents.
c. Areas exposed to deluge systems.
d. Areas subject to process spills, moisture, or acid vapors .
e. Carbon steel piping systems operating between 25°F and 250°F .
f. Carbon steel piping systems above 250°F in intermittent service.
g. Deadlegs and attachments protruding from insulated systems that
may operate at a different temperature than the active line. Austenitic
stainless steel piping systems operating between 150°F and 400°F .
(These systems are susceptible to chloride stress corrosion cracking.)
h. Vibrating piping systems.
i. Steam traced piping systems.
j. Piping systems with deteriorated coatings and/or wrappings.

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

a. All damaged insulation

b. Termination of insulation.
c. Missing insulation.
d. Poorly installed insulation.
e. Termination of insulation on vertical piping.
f. Caulking problems.
g. Bulges in insulation, could be an indication of CUI.
h. Low points.
i. Carbon or low-alloy steel flanges, bolting etc., especially if in a
high-alloy system.
j. Areas where insulation plugs have been removed and not
properly sealed.

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

Service-specific and localized Corrosion:

The three elements of an inspection program:

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

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

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

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Inspection for Specific Types of Corrosion and Cracking

Erosion and Corrosion/Erosion:

Erosion can be defined as the removal of surface material by the

action of numerous individual impacts of solid or liquid particles.
Erosion usually occurs in areas of turbulent flow. Inspect the
following for erosion/corrosion:

a. Downstream of control valves.

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

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Inspection for Specific Types of Corrosion and Cracking
Environmental Cracking:
The topics mentioned here are SCC (Stress Corrosion Cracking) and HIC
(Hydrogen Induced Cracking) these types of cracking are results of specific
services reacting with the basic metallurgy of the piping. If this type of
cracking is found in pressure vessels, then the related piping may have the
same problem.

Examples of environmental cracking include:

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

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

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Inspection for Specific Types of Corrosion and Cracking
Corrosion beneath Linings and Deposits:
Usually it is not necessary to remove the linings, internal or
external, if there is no evidence of damage. However, if
deposits, such as coke, are present, it is important to
determine if any active corrosion is beneath the deposits

Fatigue Cracking:
Fatigue cracking usually results from excessive cyclic stresses
that are well below the static yield strength of the materials. A
piping system may subject to a number of cyclic stresses;
frequent heat- up and cool-down cycles of piping may induce
thermal fatigue cracking in the material. Excessive machinery
or flow-induced vibration may cause fatigue cracking in the
piping. This problem may be detected by PT, MT or (AE)
acoustic emission.

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Inspection for Specific Types of Corrosion and Cracking
Creep Cracking:
Creep is defined as time dependent plastic deformation under an applied load at
varying temperatures. One of the most common examples of creep cracking has
been experienced in the industry is in 1¼ Cr steels above 900°F. Creep cracking
NDE include PT, MT, UT, RT, and in-situ metallography. Under special conditions
AE may be employed.

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

Freeze Damage:
Inspections should be performed after subfreezing temperatures. Water and
aqueous solutions in piping systems may freeze and cause failure because of
expansion of material. Leaks may not be evident until the system thaws.

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 Types of Inspection and Surveillance

The basic types of inspection include:

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

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

Thickness Measurement Inspection:

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

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

Bellow expansion joints should be inspected for unusual deformation,

misalignment or displacements.

External piping inspection shall include pipe hangers, vertical and

horizontal support dummy legs.

Qualified operating or maintenance personnel also may conduct

external inspections, when acceptable to the inspector.

The operating or maintenance personnel shall be qualified through an

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

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 Types of Inspection and Surveillance

Vibrating Piping and Line Movement Surveillance:

This inspection should be performed at junctions where vibrating
piping systems are restrained. Line movement due to liquid
hammering may occur in non-metallic piping and abnormal thermal
expansion or contraction in metallic piping.

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

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

TML Monitoring:
TMLs should be monitored based on the corrosiveness of the system.
Thickness measurements should include measurements at each of the four
quadrants on pipe and fittings, with special attention to the inside and
outside radius of elbows and tees.

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

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

a. Improper instrument calibration.

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

Uniform corrosion in the piping was never truly uniform, thus thickness
measurement should be taken based on the average of several readings
cover few areas rather than rely on a point measurement.

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

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 Inspection of Welds In-Service

The use of profile radiography is recommended when searching

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

Weld imperfections may be the result of original weld

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

This may be evaluated by:

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

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 Inspection of Welds In-Service

The following should be considered when assessing the quality of

existing welds:

1. Original fabrication inspection acceptance criteria.

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

A qualified UT shear wave examiner is required for the followings:

1. Detecting internal surface breaking flaws.
2. Detection and assessment of through-wall planar defects.

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 Inspection of Flanged Joints

1. Fasteners should extend completely through their nuts. Any fastener failing to
do so is considered acceptably engaged if the lack of complete engagement
is not more than one thread.

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

should be checked against engineering requirements before taking corrective
action.

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

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

6. Fasteners on instrumentation that are subject to process pressure and/or

temperature should be included in the scope of these examinations.

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 Frequency and extent of inspection
General:
Risk-based inspection (RBI) concept may be used to plan a
piping circuit inspection strategy. Inspection may be based on
the expected forms of degradation, the optimal inspection
frequency, extent of inspection and the prevention and
mitigation steps to reduce the likelihood and consequence.

Piping Service Classes:

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

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 Piping Service Classes

Class 1:
Class 1 piping is piping whose services have the highest potential of
resulting in an immediate emergency if a leak were to occur. Class 1
piping includes, but not limited to, the following:

1. Flammable services that may auto-refrigerate and lead to brittle

fracture.
2. Pressurized services that may rapidly vaporize during release,
creating vapors that may collect and form an explosive mixture, such
as C2 (ethylenes), C3 (propylenes), C4 (butanes) streams.
3. Hydrogen sulfide (greater than 3% weight) in a gaseous Stream.
4. Anhydrous hydrogen chloride.
5. Hydrofluoric acid.
6. Piping over or adjacent to water and piping over public throughways.

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 Piping Service Classes

Class 2:
Class 2 piping is usually unit process piping and selected off-
site piping that is not included in Class 1 piping. Examples are
as follows:

1. On-site hydrocarbons that will slowly vaporize during release

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

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 Piping Service Classes

Class 3:

Class 3 piping contains services that are flammable but do not

significantly vaporize and are not located in high-activity areas.
Examples are:

1. On-site hydrocarbons that will not significantly vaporize during

release.
2. Distillate and product lines to and from storage and loading.
3. Off-site acids and caustics.

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Inspection Intervals

31
 Inspection Intervals
Extent of Visual External and CUI Inspections:
External inspections should be scheduled in accordance with Table 6-2 using
the checklist in Appendix D, external inspection checklist for process piping.

Alternatively, external visual inspection intervals can be established by using

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

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

include:

a. Local climatic conditions (see 5.3.3).

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

Piping systems that are known to have a remaining life of over 10 years or
that are adequately protected against external corrosion need not be included
for the NDE inspection recommended in Table 6-2.

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Inspection Intervals

33
Inspection Intervals

34
 Inspection Intervals

Extent of Thickness Measurement Inspection:

As a minimum, a representative sampling of TMLS shall be measured,

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

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Inspection Data Evaluation, Analysis, And Recording
Remaining Life Calculations:
The remaining life of the piping system shall be calculated from the
following formula:

36
Inspection Data Evaluation, Analysis, And Recording
The long-term (LT) corrosion rate of piping circuits shall
be calculated from the following formula:

37
Inspection Data Evaluation, Analysis, And Recording
The short term (ST) corrosion rate of piping circuits shall
be calculated from the following formula:

38
Inspection data evaluation, analysis, and recording

Corrosion Rate Determination:

Statistical analysis employing point measurements is not

applicable to piping systems with significant localized
unpredictable corrosion mechanisms.

Long-term and short-term corrosion rates should be compared

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

The authorized inspector, in consultation with a corrosion

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

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

Newly Installed Piping Systems or Changes in Service:

Probable corrosion rates may be determined by use of the
following:
1. Corrosion rate of similar service.
2. Owner user's experience or published data on comparable
service.
3. Initial thickness shall be made after 3 months of service by
using NDT.

Existing Piping Systems:

Corrosion rates shall be calculated on either a short-term basis,
using the two most recent inspections or long-term basis, using
original wall thickness and most recent inspection, use the higher
result in most cases.
40
 Retirement Thickness Determination

The retirement thickness shall be equal or greater than the

minimum required thickness, and shall be based on pressure,
mechanical, and structural considerations using the appropriate
design formulae and code allowable stress.

Consideration of both general and localized corrosion shall be

included.

For services with high potential consequences if failure were to

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

41
Reporting and Records for Piping System Inspection

The owner/user shall maintain appropriate permanent and

progressive records of each piping system covered by API 570. These
records shall contain pertinent data such as the following:

a. Piping system service & classification.

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

API 574 offers guidance for piping inspection records.

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Repairs, Alterations, And Re-rating Of Piping Systems

Repairs and Alterations:

The principles of ASME B31.3 or the code to which the piping system was
built shall be followed for repairs and alterations.

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

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

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 Welding Repairs (Including On-Stream)

Temporary Repairs:

Temporary repairs may be used, full encirclement welded split sleeve

or box type enclosure. Split coupling or plate patch may also be used.
Temporary repairs should be removed and replaced at the next
available maintenance opportunity.

Longitudinal cracks shall not be repaired in this manner unless the

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

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

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 Welding Repairs (Including On-Stream)
Permanent Repairs:
Repairs to defects found in piping components may be made by preparing a
welding groove that completely removes the defect and then filling the
groove with weld metal deposition.

Corroded areas may be restored with weld metal deposited in accordance

with 8.2. of API 570.
Surface irregularities and contamination shall be removed before welding.

If it is feasible to take the piping system out of service, the defective area
may be removed by cutting out a cylindrical section and replacing it with a
piping component that meets the applicable code.

Insert patches (flush patches) may be used to repair damaged or corroded

areas if the following requirements are met:
1. Full-penetration groove welds are provided.
2. For Class 1 and Class 2 piping systems, the welds shall be 100%
radiographed or ultrasonically tested.
3. Patches may be any shape but shall have rounded corners.

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 Non-welding Repair (on-stream)

Temporary repairs of locally thinned sections or circumferential

linear defects may be made on-stream by installing a properly
designed and fabricated bolted leak clamp. The design shall
include control of axial thrust loads if the piping component
being clamped is (or may become) insufficient to control
pressure thrust.

The effect of clamping (crushing) forces on the component also

shall be considered.

During turnarounds or other appropriate opportunities,

temporary leak sealing and leak dissipating devices, including
valves, shall be removed and appropriate actions taken to
restore the original integrity of the piping system.

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Repairs, Alterations, And Re-rating Of Piping Systems

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

When a pressure test is not necessary or practical, NDE shall

be utilized in lieu of a pressure test.

The owner/user shall specify industry-qualified UT shear wave

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

47
 Inspection Of Buried Piping

Types and Methods of

Inspection:

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

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

Surveying the route of buried piping is one method of identifying

problem areas.

Close-Interval Potential Survey:

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

Corrosion cells can form on both bare and coated pipe where the bare
steel contacts the soil. Since the potential at the area of corrosion
will be measurably different from an adjacent area on the pipe, the
location of the corrosion activity can be determined by this survey
technique.
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 Types and Methods of Inspection

Pipe Coating Holiday Survey:

The pipe coating holiday survey can be used to locate coating
defects on buried coated pipes, and it can be used on newly
constructed pipe systems to ensure that the coating is intact
and holiday-free.
More often it is used to evaluate coating serviceability for
buried piping that has been in-service for an extended period
of time.

Soil Resistivity:
Corrosion of bare or poorly coated piping is often caused by a
mixture of different soils in contact with the pipe surface. The
corrosiveness of the soils can be determined by a measurement
of the soil resistivity. Lower levels of resistivity are relatively
more corrosive than higher levels.
50
Types and Methods of Inspection

51
 Types and Methods of Inspection

Cathodic Protection Monitoring:

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

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

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

52
 Types and Methods of Inspection
Inspection Methods:
Several inspection methods are available. Examples are as follows:

Intelligent pigging: This method involves the movement of a device

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

Video cameras: Television cameras are available that can be inserted

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

Excavation: In many cases, the only available inspection method that

can be performed is unearthing the piping in order to visually inspect
the external condition of the piping and to evaluate its thickness. Care
should be exercised in removing soil from above and around the
piping to prevent damaging the line or line coating.

53
 Frequency and Extent of Inspection
Above-Grade Visual Surveillance:
The owner/user should, at approximately 6-month intervals survey
the surface conditions on and adjacent to each pipeline path.

Pipe-to-Soil Potential Survey:

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

Pipe Coating Holiday Survey:

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

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 Frequency and Extent of Inspection

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

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

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 Frequency and Extent of Inspection

External and Internal Inspection Intervals:

The external condition of buried piping that is not cathodically protected
should be determined by either pigging, which can measure wall thickness, or
by excavating according to the frequency given in Table 9-1.

Significant external corrosion detected by pigging or by other means may

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

Piping inspected periodically by excavation shall be inspected in lengths of 6

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

If inspection reveals damaged coating or corroded piping, additional piping

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

If the piping is contained inside a casing pipe, the condition of the casing
should be inspected to determine if water and/or soil has entered the casing.

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 Frequency and Extent of Inspection

External and Internal Inspection Intervals (Table 9-1):

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 Frequency and Extent of Inspection
Leak Testing Intervals:

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

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

piping.

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

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

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

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

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

Coating repairs may be tested using a high voltage holiday detector.

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

Clamp Repairs:

If piping leaks are clamped and reburied, the location of the

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

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

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

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Examples of Repairs

Small Repair Patches:

Examples of small
repair patches are
shown in figure C-2.

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 End
Course Facilitator:

ASHOK KUMAR
API 570 (APPEARED)

mailto : [email protected]

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