API 570 Pressure Piping Inspector Certification Preparation Course Shah Alam, Malaysia, October 2010 iTCSkills CASTI Coase ana Stanaarce Trang inatete www.intestmal.com www.casti.ca 12, Jalan Utama 1/14, Taman Perindustrian Pachong Utama, Tel: +603-8060 7V. PRACTICAL KNOWLEDGE - SPECIFIC API-S70, Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems ~ the entire document is subject to testing API RP S71, Damage mechanisms Affecting Fixed equipment in the Refi i Industry ATTN: Examination questions will be based on the following sections only: Par. 3 — Definitions ( included as a frame of reference only) ‘a7 bate Pracie 425— thermal atic 1214 brodon “2.6 Meshania 42.17 Vibrondisd Fatigue 4131 -aaanie Coven e 43.2 aimee Coon 4.3.3 — Corrosion Under Insulation (CUI) 4515 oiler Water Cndeate Comin 415.7 Fuca Dew fin Coosion 4.3.8 — Microbiological Induced Corrosion (MIC) 4139 Soi eareion 442 —suinatn £51 — Cherie Sess Caron Crain (CFSCC) 45.3 Causes coeson aking (case Emtrteen) ‘5.1.3.1 ~ High Temperature Hydrogen Attack (HTTA) API RP-574, Inspection of Piping, Tubing, Valves, and ings - the entire document is subject to testing API RP 577, Welding Inspection and Metallurgy ~ the entire document is subject to testing API Recommended Practice $78 - Material Verification program for New and Existing Alloy piping Systems — the entire document is subject to testing ASME BI65, Pipe Flanges and Flanged Fittings 8) Scope )_ Pressure Temperature Ratings ©) Markings ) Materials ©) Dimensions A) Test 8) Limiting Dimensions of Gaskets fh) Methods for Establishing Pressure-Temperature Ratings 08/2010 9 "Notebook Page 27CASTI API 570 Exam Preparation Formulas Sut Document Formul [On halflife basis, based on short-term or long-term| Inext inspection interval |API670,46.3 _| corrosion: inspection interval = ¥4 x remaining life all corroded metal loss _ tiniiet ~ actual lor jion re se CR = es ee bctwecn long term corrosion rate |API670, 47.1.1 as Sa recent corroded metal loss _ tprovious ~¢ short term corrosion rate |API570,97.1.1 [LDCR = “CCPL COTOCRE eth Ds _ “previous see ‘years between remaining life JAPI 570, 97.1.1 | remaining life = minimum distance between |API570, {8.13.1 |d=4VRe /maximum allowable JASMEB313, | »_ 29Bt lworking pressure 1304.1.1 D fminimum required JASMEBS13, | ,_ PD thickness 1304.1.1 2SE CASTI API 570 Exam Preparation Nomenclature ws wa ee eee ee rT id |API 570, $8.1.3.1 attachments E |ASME B31.3, $304.1.1 | quality factor of weld joints iP |ASME B31.3, {304.1.1 |pressure IR |API 570, 98.1.3. inside radius of on-stream pipes under repair it |ASME B31.3, $304.1.1 | pipe wall thicknes it |API 570, 98.1.3. minimum required thickness of the fillet-welded patch [thickness at the same location as tyczyqi measured at the time of am bine ras a fe fe eae nea |thickness at the same location as tactua) measured during one or more escent |previous inspections see Htrequired JAP 570, 17.1.1 lformulas before corrosion allowance and manufacturer's tolerance are ladded © Codes and Standards Training Intitute (CASTI) Notebook Page 29Body of Knowledge — API 570 ICP Exam ‘The API 670 Body of Knowledge provides a list of topies covered by the ICP examination. Exam caindidates are expected to be familiar with the following subjects from the API 570 document. Practical Knowledge - General ‘The following topics may be covered: 1. Organization and Certification Requirements ‘Types and Definitions of Maintenance Inspections Welding on Piping Corrosion and Minimum Thickness Evaluation Estimated Remaining Life Inspection Interval Determination and Issues Affecting Intervals ‘Maintenance Inspection Safety Practices Inspection Records and Reports Ropairs/Alterations/Reratings to Piping 10, Rerating Piping Pressure Testing After Repairs, Alterations, or Rerating Pressure Temperature Ratings ‘Markings 14, Materials 15. Dimensions 16. Test 17, Limiting Dimensions of Gaskets 18. Methods for Establishing Pressure-Temperature Ratings 19. Methods of Performing Positive Material Identification and Related Record Keeping BoP rare eD BEE ‘© Codes and Standards Tralning institute (CAST) "Notebook Page 31oe Scope - Section 1 APPL $78 ~ MS Coverage 111-1 ony wekont . ee 41.1.1 defines coverage of the API 570 document to include inspection, repair, alteration, rerating procedures for in-service metallic piping systems. Intent 11.1.2 ‘The purpose of API 570 is to determine the integrity of piping systems by specifying the in-service inspection and condition-monitoring program. ‘The in-service inspection and condition-monitoring program should provide reasonably accurate and timely assessments to determine if any changes in the condition of piping could possibly compromise continued safe operation. API 570 is also intended to ensure owner-users act in response to inspection related corrective actions to ensure safe operation. It was developed for the petroleum refining and chemical proce industries but may be used, where practical, for any piping system. API 570 requires organizations to maintain or have access to: 1. an authorized inspection agency, 2. a repair organization, and 3. technically qualified piping engineers, inspectors, and examiners. Limitations 11.1.3 API 570 is not a substitute for original construction requirements and not to be used in conflict with regulatory requirements. ({1.1.3) Specific Application 1.2.1 ‘The services listing is similar to ASME B313 but it is not identical (91.2.1). A long list of fuid services and classes of piping that are excluded from API 570, but may be included at owner's or user's option. (See {11.2.2 Optional Piping Systems and Fluid Services.) Fitness-for-Service (FFS) 11.3 ‘The API 570 document ({1.3) recognizes API RP 579, Fitness-for-Service (which is now designated API RP 579-VASME FFS-1, June 5, 2007) and API 580 Risk-Based Inspection (RBD). oa wae os rire ey (© Codes and Standards Training institute (CAST) Notebook Page 32Practice Problem Q001: Intent [Although API 570 was developed for the petroleum refining and chemical process industries, when Jpractical, where else may it be used? ) for piping systems over 15 psi b) for piping systems over 15 psig ©) for any piping system 4) where identified by the piping engineer \See the answer key at the end of this CASTI Notebook section. femiacak ee |What shall be done when API 570 is in conflict with any prevailing regulatory requirements? a) API570 may not be used at the piping engineer's discretion b) API570 may not be used at the piping engineer's and inspector's discretion ©) API570 shall not be used 4) ASME BS1.9 shall be used [See the answer key at the end of this CASTI Notebook section. ence eee ees |Which document provides general requirements and detailed assessment procedures for specific ltypes of degradation that are referenced in API 570? a) APIRP 580 b) APIRP 579 ©) ASME BS1.3 @) ASME FFS-1 |Sce the answer key at the end of this CASTI Notebook section. ‘© Codes and Standerds Training institute (CAST) Notebook Page 33References - Section 2 API 570 references a long list of API, ASME, ASNT, ASTM, NACE, and NFPA codes and standards. ‘These documents are to be used in concert with API 570 when referenced. Sometimes these documents are referenced within the API 570 text body, sometimes within footnotes, or in the Appendices, consequently API 570 should not be used as a standalone document. make [Which document does API 570 reference for valve inspection and testing? a) API Standard 598 b) API Publ 2201 ©) APIRP 750 @) ASME B313 [Se the answer key at the end of this CASTI Notebook section. |Which document does API 570 reference for protection of austenitic stainless steels from polythionic lacid stress corrosion cracking during shutdown of refinery equipment? a) NACE RPO170 b) NFPA 704 ©) ASME B31G 4) ASME B16.34 [See the answer key at the end of this CASTI Notebook section. (© Codes and Standards Training Inaitute (CAST) Notebook Page 24Definitions - Section 3 Section 8 contains a list of 91 definitions applicable to API 570. Some notable API 570 definitions include: ‘© 13.12 alteration: A physical change in any component that has design implications affecting the pressure containing capability or flexibility of a piping system beyond the scope of its original design. The following are not considered alterations: comparable or duplicate replacements and the addition of small-bore attachments that do not require reinforcement or additional support. © 18.1.6 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 an insurance company that is licensed or registered to ‘write insurance for piping systems. ©. An owner or user of piping systems who maintains an inspection organization for activities relating only to his equipment and not for piping systems intended for sale or resale. d. An independent inspection organization employed by or under contract to the owner or user of piping systems that are used only by the owner or user and not for sale or resale. fe. An independent inspection organization licensed or recognized by the jurisdiction in which the piping system is used and employed by or under contract to the owner or user. © 9.1.7 authorized piping inspector: an employee of an authorized inspection agency who is qualified and certified to perform the functions specified in API 570. An NDE examiner is not required to be an authorized piping inspector. Whenever the term inspector is used in API 870, it refers to an authorized piping inspector. © 13.1.77 repair: The work necessary to restore a piping system to a condition suitable for safe operation at the design conditions. If any of the restorative changes result in a change of design temperature or pressure, the requirements for rerating also shall be satisfied. Any welding, cutting, or grinding operation on a pressure-containing piping component not specifically considered an alteration is considered a repair. ‘© 8.1.79 repair organization: Any of the following: ‘a, An owner or user of piping systems who repairs or alters his or her own equipment in accordance with API 570. b, A contractor whose qualifications are acceptable to the owner or user of piping systems and who makes repairs or alterations in accordance with API 570. ‘One who is authorized by, acceptable to, or otherwise not prohibited by the jurisdiction and who makes repairs in accordance with API 570. © 3.1.81 rerating: A change in either or both the design temperature or the maximum allowable working pressure of a piping system. A rerating may consist of an increase, a decrease, or a combination of both. Derating below original design conditions is a means to provide increased corrosion allowance. Note: the definitions listed in API 570, Section 8 are not in strict alphabetical order, such that newer definitions have been added to the end of this list. (© Codes and Standards Training institute (CAST) "Notebook Page 35Smee [Which one of the following is considered an alteration? a) comparable replacements b) duplicate replacements ©) reduction in wall thickness from grinding repair 4) addition of small-bore attachments that do not require reinforcement or additional support [See the answer key at the end of this CASTI Notebook section. See |What is a point in the repair or alteration process beyond which work may not proceed until the lrequired inspection has been performed and documented? a) critical point b) hold point ©) inspection point @) QA point [See the answer key at the end of this CAST Notebook section. fee ne |What is an inspection organization of a linsurance for piping systems? a) authorized inspection organization b) authorized inspection agency ©) authorized piping inspector @) authorized jurisdiction \Sce the answer key at the end of this CASTI Notebook section. eee |What are designated areas on piping systems where periodic inspections and thickness lmeasurements are conducted? ) technical measurement locations (TMLs) ) condition monitoring locations (CMLs) ©) inspection measurement locations (IMLs) 4) periodic inspection locations (PILs) [See the answer key at the end of this CASTI Notebook section. (© Codes and Standerds Training nsttute (CAST) Notebook Page 36Owner/User Inspection Organization - Section 4 14.1 specifies that an owner/user of piping systems is responsible for: ‘exercising control of the piping system inspection program, ‘* inspection frequencies, © maintenance, + control of activities relating to the rating, repair, and alteration, and + the function of an authorized inspection agency for API 570. {4.1 also introduces the concept of an integrity operating envelope, sometimes called an integrity operating window, as defined below. ‘+ 19.140 integrity operating envelope (integrity operating window): established limits for process variables that can affect the integrity of the piping system if the process operation deviates from the established limits for a predetermined amount of time. Integrity operating envelopes (windows) should be established for process parameters (both physical and chemical) that could impact equipment integrity if not properly controlled. Examples of the process parameters include: a) temperatures, b) pressures, ¢) fluid velocities, @ pH, ©) flow rates, 9) chemical or water injection rates, g) levels of corrosive constituents, 1) chemical composition, et. Persea a eee |Which of the following variables is not typically a part of an integrity operating envelope? a) piping material specification b) pH ©) flow rates 4) chemical composition |See the answer key at the end of this CAST! Notebook section. ‘© Codes and Standards Tralning inaitute (CAST) Notebook Page 37Authorized Piping Inspector Qualification and Certification 14.2 [API RP 570 - Piping Inspection Code Exam Preparation Guidance, ) \This section of API 570 is listed in the API Body of Knowledge: + Authorized Piping Inspector Qualification and Certification (API 570, 14.2) API 570, 4.2 has requirements, including specifics mentioned in Annex A, for the qualification and certification of authorized piping inspectors. These details will be covered at the end of this notebook under Annex A. ‘Responsibilities 14.3 [API RP 570 - Piping Inspection Code Exam rat (Guidance Wf [This section of API 570 is listed in the API Body of Knowledge: + _ Responsibilities (API 670, 14.3) {4.3 makes owner/user responsible for the documentation, execution, and assessment of piping inspection procedures. 4.3 also contains a detailed list of 18 items for inclusion in the owner/user’s quality assurance inspection/repair management system. Read this list and become familiar with it. Section {43 also contains considerable wording on personnel, organizations, and their responsibilities, including management of change (MOC). The various parties are categorized in the following manner: © Owner/User ‘+ Authorized Piping Inspector © Piping Engineer © Repair Organization © Examiner © Operating, Maintenance, and Other Personnel. Examiners 14.3.5 © 9.1.22 examiner: A person who assists the inspector by performing specific NDE on piping system components but does not evaluate the results of those examinations in accordance with API 570, unless specifically trained and authorized to do so by the owner or user. ‘© Codes and Standorde Training nettute (CAST) Notebook Page 38It is the examiner's responsibility to perform the NDE work in accordance with job requirements (14.3.5.1), However, {4.3.5.2 stipulates that the examiner: is not required to be certified as an API ICP 570 inspector, does not need to be an employee of the owner/user; ‘must be trained and competent in the NDE procedures being used; and may be required by the owner/user to prove competency by holding certifications in those procedures, such as: + ASNT SNT-TC-1A + ASNT CP-189 + aws Qc. In accordance with {4.9.5.8, the examiner's employer is required to maintain: ‘certification records of the examiners employed, ‘+ dates of personnel qualifications, and ‘results of personnel qualifications, ‘The above records must be available to the inspector. ) no, they need not be authorized piping inspectors ») no, provided they are certified to SNT-TC-1A ©) yes, since an examiner must evaluate the results of nondestructive examinations 4) no, provided they are certified to AWS QC1 [See the answer key at the end of this CASTI Notebook section. Table of API 570 Responsibilities and Responsible Parties ‘The following table summarizes various responsibilities and the responsible parties as described in API570. This summary organizes the information scattered throughout API 570 into a single table, making the information easier to find and easier to understand. Specific API 570 paragraph numbers have been listed in the table to make the references easier to find. This summary table is not available in the API 570 document. [API 570 - Piping Inspection Code lExam [Preparation |aithough this summary table is not available in the API 570 document, the API 570] |Guidance #' /icp exam candidate will be challenged on the responsibilities listed in API 570 during| the open and closed book portions of the exam. (© Codes and Standarde Training intitute (CAST) "Notebook Page 39” oe ‘Table of API 570 Responsibilities and Responsible Parties AP ve gt [Responsible Party “API 570 Paragraph - Responsibilities authorized piping inspector {2.36 shall review and approve the results of NDE| conducted by examiners {{4.3.4: be directly involved in the inspection activities which jin most cases will require field activities to ensure that| [procedures are followed. 75.3.5: shall familiarize themselves with prior history of the [piping system for which they are responsible 1954.12: be familiar with the material of construction, design, construction, operating conditions, and causes and| characteristics of potential defects and damage mechanisms| associated with the equipment being inspected [{5.5.2: authorizing and approving all on-stream inspection| |work performed by an examiner e 175.54: external visual inspection, includin |- field modifications or temporary repairs not. previously| recorded on the piping drawings and/or records |+ presence of any components in the service that may be| ‘unsuitable for long-term operation | threaded components that may be easily removed and| installed |_ record keeping and repair inspection 75.5.6; inspect other susceptible areas on the equipment if] [CUI damage is found during spot checks 75.6.3: evaluating, selecting, adjusting, and optimizing the| number of condition monitoring locations (CML) 75.7.1: be aware of possible sources of measurement| inaccuracies in UT and RT and make every effort to| eliminate their occurrence '{5.9: material verification and traceability, including: |- if piping fails because of incorrect material substitution, |consideration of the need for further verification of existing| e piping materials |- extent of further verification | periodic NDE, as necessary, on the identified components| luntil the replacement (5.11: assess preferential weld corrosion and determine Iwhether crack-like imperfections detected in welds that have| Ibeen in-service are from original weld fabrication or from an| lenvironmental cracking mechanism /i7.10: inspection deferral or interval revisions, including: |- review of the piping history and condition |- documentation, including the technical basis supporting] the interval revision |— approval of an interval revision or deferral {17.10: allowing for a deferral by accepting an extension of the inspection date based on a documented risk analysis process ‘© Codes and Standards Training Institute (CAST) Notebook Page 40[Responsible Party ‘API 670 Paragraph - Responsibilities Jauthorized piping inspector |(continued) rad VV 8.8 Par Sy mae ESA | ity 13g ~ | {{8.1.2: authorization of repairs and alterations, including: |- authorization of all repair and alteration work prior to its commencement | designate any inspection hold points |- general authorization for limited routine repairs and procedures, provided the inspector is satisfied with the lcompetency of the repair organization {{8.1.3: approve all repair and alteration work at designated Ihold points and after the repairs and alterations have been| lcompleted in accordance with API 570 [¥8.1.4.1: for minor leaks, properly designed enclosures may| Ibe welded over the leak while the piping system is in-service, provided it is confirmed that adequate thickness remains in| the vicinity of a weld and that the piping component can| withstand welding without the likelihood of further material damage /¥8.1.4.2; approve NDE procedures for Class 1 and Clase 2| piping system welds using 100% radiography or ultrasonic| testing '¥8.2.3.2: determine that the minimum preheat temperature| is measured and maintained during all welding {18.2.7: determine whether a pressure test in accordance with| 145.8 shall be performed after welding is completed. (8.2.7: when it is not practical to perform a pressure test of a| final closure weld, determine if welds examined with| lappropriate NDE would be a suitable substitution '19.3.6: for piping contained inside a casing pipe, verify the| condition of the casing, including: |- both ends of the casing extend beyond the ground line |- the ends of the casing are sealed if the casing is not self draining |- the pressure-carrying pipe is properly coated and wrapped authorized piping inspector in |consultation with engineers/specialists| '¥4.3.4: extending the scope of the inspection where justified| Jdepending upon the findings of the inspection 95.7.2: define the type of damage, the NDE technique, and| lextent of examination needed during piping inspection '{7.10: approval of interval changes if there are potentially] lany unusual types of degradation involved in the inspection| piping engineer lof the piping systems, fauthorized piping inspector and/or __|95.1.1.1: inspection plan development [¥6.1.3: for repairs and alterations, all proposed methods o ldesign, execution, materials, welding procedures, lexamination, and testing {18.1.5: determine and review repair methods and procedures {for on-stream nonwelding repairs {18.(@): perform rerating calculations when changing the temperature rating or the MAWP_ (© Codes and Standards Training inetitute (CAST) Notebook Page 41[Responsible Party API 570 Paragraph - Responsibilities jauthorized piping inspector or (5.2.2: conducting all on-stream inspections jexaminer 15.5.3: obtaining thickness measurements fauthorized piping inspector in consultation with the piping engineer (7.5: when unexpected piping movement is observed, levaluate the need for a piping stress analysis, {18.1.2: authorization of alteration work, including rior consultation and approval by the eer 18.1.3: identify and correct the cause of the in-service lcracking in piping prior to welding repairs of cracks {{8.2.3.2: evaluate the use of the preheat alternatives fauthorized piping inspector in 118.2.7: permit substituting appropriate NDE procedures for consultation with the piping engineer _|a pressure test after an alteration, rerating, or repair authorized piping inspector, in {{7.1.1: selection of corrosion rate consultation with corrosion specialist lauthorized piping inspector in I¥7.10: approval of interval changes if there are polentially| consultation with the piping engineer |any unusual types of degradation involved in the inspection| lor corrosion specialist lof the piping systems [authorized piping inspector, engineer, lor other qualified individual per the Jowner/user’s quality assurance {program '$6.7.3.1: determining the inspection interval for all pressure-| relieving devices [{4.3.4: determining that the requirements of API 570 on| authorized piping inspector is N4.34: determining ¢ i 7 570 oa lresponsible to the owner/user inspect 7 ation, quality assurance and testing fowner/aser (1.12: respond to any inspection results that require corrective actions to assure the continued safe operation o i [14.1 exercise control of the piping system inspoction| program, inspection frequencies, and maintenance and responsible for the function of an authorized inspection| agency in accordance with the previous provisions of API 570. I{4.3.1: developing, documenting, implementing, executing, Jand assessing piping inspection systems and inspection| [procedures of API570 (4.3.1.2: implement an effective MOC process that will review and control changes to the process and to the hardware (© Codes and Standards Training institute (CAST) Notebook Page 42[Responsible Party ‘API 570 Paragraph - Responsibilities lowner/user (continued) 15.4.2: provide specific attention to the need for inspection piping systems that are susceptible to the following specific types and area of deterioration: jection points and mix points |- deadlegs |-cur |- soil air interfaces | service specific and localized corrosion |- erosion and corrosion/erosion |- environmental cracking |- corrosion beneath linings and deposits |- fatigue cracking |- creep cracking — brittle fracture |- freeze damage | contact point corrosion /75.5.3: ensure that all individuals conducting thickness measurements are trained and qualified in accordance with] the applicable procedure used during the examination 15.8: avoid exceeding 90% of the SMYS during pressure testing for the material at test temperature and especially for equipment used in elevated temperature service '15.9: material verification and traceability, including: |- risk assessment procedures — assess the need and extent of the practices consistent with| APL RP 578 76.11: specify industry-qualified UT shear wave examiners for inspection of welds in-service when required by this| {paragraph (6.3.4.1: maintain a record of process piping fluids handled, including their classifications {7.6.1: maintain permanent and progressive records for| {piping system inspections {{8.1.3: approval of on-stream welding is required 18.2.7: specify industry-qualified UT shear wave examiners for closure welds that have not been pressure tested and for| lweld repairs identified by the piping engineer or authorized| [piping inspector {]9.3.1: survey the surface conditions on and adjacent to each| lpipeline path at approximately six month intervals '19.3.7: if a tracer fluid is added to the service fluid for leal| testing, the owner/user shall confirm suitability for process land product {{4.3.1.1: developing, documenting, implementing, executing, land assessing piping inspection systems and inspection procedures that will meet the requirements of this inspection code lowner/aser option [¥.1.2.2; excluded or optional piping systems [95.2: conduct a RBI assessment Jowner/user organization (© Codes and Standards Training institute (CAST) ‘Notebook Page 43[Responsible Party ‘API 570 Paragraph - Responsibilities 76.3.3: inspection interval establishment for thickness ee lmeasurements (UT) and external inspections and, where ieee lapplicable, for internal and supplemental inspections lowner/user authorized inspection 95.13: take the necessary corrective actions when| lagency Inonconformances are found by the audit team lowner/user, authorized piping 95.9: material verification and traceability, including inspector, corrosion specialist | establishing schedule for replacement of incorrect material piping engineer 175.8: review supporting structures and foundation design before applying a hydrostatic test '¥6.8.3; evaluate the potential for a brittle failure prior to Ihydrostatic testing 5.11: environmental cracking assessment [78.1.2: approval for alteration work to a piping ystom [18.1.4.1: design of full encirclement welded split sleeve or box-type enclosure for temporary repairs, including on- stream repairs @ 178.1.4.1: approve the design of temporary enclosures and| airs 118.1.4.1; if a temporary repair is made by fillet welding a| properly designed split coupling or plate patch over the [pitted or locally thinned area, approval the material for the repair if it does not match the base metal {78.1.4.1: approve and document all temporary repairs that| may remain in place after the next available maintenance| 118.15: approval and documentation of temporary leak sealing and leak dissipating devices which are to remain in| [place for a longer period of time 118.2.8.2: for temporary repairs, approval ofall exceptions to the prior qualified welding preheat requirements {8.2.5.5 for temporary repairs, approval of all exceptions to the prior qualified postweld heat treatment requirements {18.2.3.3: review, develop, and approve all welding procedures where local PWHT is substituted for 360° banding.on local] @ repairs on all materials [[8.2.4: approval of temporary enclosures and repairs 18.2.4: design ofall fillet weld patches piping engineer and authorized piping |¥5.8.5: approve the substitution of NDE procedures for al inspector pressure test after an alteration {16.5.2: review and approve RBI assessments at intervals not to exceed the respective limits in Table 2, or more often i warranted by process, equipment, or consequence changes __| 14.3.2: activities involving design, engineering review. rating, analysis, or evaluation of piping systems covered by| [API 570 piping engineer is responsible to the lowner/user (© Codes and Standards Training Instituto (CAST) [Notebook Page 44[Responsible Party ‘API 570 Paragraph - Responsibilities piping engineer, in consultation with a| fracture analyst in some cases '¥8.1.4.1: if longitudinal cracks are present under a full lencirclement welded split sleeve or box-type enclosure, determine if the cracks would be expected to propagate or| not repair organization {16.7.2: have a fully documented quality assurance system land training program {$8.1.2: performance of all repair and alteration work {18.2.2 welding procedures, qualifications, and records, including: - welders and welding procedures qualifications to ASME B31.3 or the original construction code | maintain records of welding procedures and welder| performance qualifications |- make records available to the authorized piping inspector prior to the start of welding repair organization is responsible to the owner/user (4.3.3: provide the materials, equipment, quality control, land workmanship necessary to maintain and repair the piping systems in accordance with the requirements of API| 570 [when acceptable to the inspector, {qualified operating or maintenance ersonnel 1{6.5.4: external visual inspection operating, maintenance, or other |personnel who have special knowledge lor expertise related to particular [piping systems [43.6 alerting the inspector or piping engincer of any| [unusual conditions that may develop and for providing other| assistance, where appropriate organizations that maintain or have Jaccess to an authorized inspection agency, a repair organization, and technically qualified piping engineers, {inspectors examiners {1.1.2: use of API 570 |The owner/user-inspection organization lof the following activities? a) ») ° a requirements of an API 570 designated piping system shall control which erating, repair, and alteration of its piping systems repair and alteration of its piping systems ‘workmanship necessary for repairs temporary repair approval of all exceptions to the prior qualified welding preheat [See the answer key at the end of this CASTI Notebook section. (© Codes and Standards Training institute (CAST) Notebook Page «5|What shall operators and maintenance staff do when they notice an unusual condition in a piping lsystem? ) timely notification to the inspector or engineer of the unusual condition ») report the unusual condition at the next staff meeting ©) report the unusual condition to the operating manager identified in the QA manual 4) contact the local jurisdiction inspector [See the answer key at the end of this CASTI Notebook section. 14: Responsibilities What shall API 570 piping inspection systems and procedures include? a) controls necessary s0 that only qualified NDE personnel and procedures are utilized b) controls necessary so that only materials conforming to the applicable section of the NBIC NB-23 Code are utilized for repairs and alterations ©) controls necessary s0 that NDE inspections are carried out only by authorized inspectors, 4) external auditing requirements for the quality control system for pressure-relieving devices [See the answer key at the end of this CASTI Notebook section. |When inspections, repairs, or alterations are being conducted on piping systems, is an authorized |piping inspector required to be directly involved in the inspection activities? a) No, provided a full report is signed by the authorized piping inspector. b) No, provided all of the inspection, examination, and testing are met. ©) Yes, an authorized piping inspector is required to be directly involved in the inspection activities. 4) Yes, only if the inspector is declared to be qualified for the work by the owner/user. |See the anewer key at the end of this CASTI Notebook section. (© Codes and Standar Trlning Instute (CAST) Notobook Page 46Inspection, Examination, and Pressure Testing Practices - Section 5 [API RP 670 - Piping Inspection Code Per raparation (Guidance uP |This section of API 570 is listed in the API Body of Knowledge: ‘+ _Inspection Plans (API 570, $5.1) Inspection Plans 5.1 Development of an Inspection Plan 15.1.1 5.1.1.1 requires that a formal inspection plan for all piping systems within the API 570 scope must be developed by the inspector and/or engineer, where a corrosion specialist should be consulted to: ‘+ identify potential damage mechanisms; ‘* develop inspection plan for elevated temperatures above 750 °F (400 °C), and * develop inspection plan for piping that operates below the ductile-to-brttle transition temperature, NDE methods and coverage must be evaluated to ensure they are adequate for the potential damage mechanism identified ({5.1.1.2). Examinations must be scheduled at intervals that consider the: a) type of damage, b) rate of damage progression, ©) tolerance of the equipment to the type of damage, 4) capability of the NDE method to identify the damage, e) maximum intervals as defined in codes and standards, and 1) extent of examination. Minimum Contents of an Inspection Plan 96.1.2 ‘The inspection plan must contain: the inspection tasks and schedule required to monitor identified damage mechanisms, and ‘assure the pressure integrity of the piping systems. ‘The inspection plan should: 1) define the type(s) of inspection needed, e.g. internal, external, on-stream (nonintrusive); b) identify the next inspection date for each inspection type; ©) describe the inspection methods and NDE techniques; 4) describe the extent and locations of inspection and NDE at CMLs; ) describe the surface cleaning requirements needed for inspection and examinations for each type of inspection; 1) deseribe the requirements of any needed pressure test (e.g. type of test, test pressure, test temperature, and duration); and 18) describe any required repairs if known or previously planned before the upeoming inspection. (© Codes and Standards Training inethute (CAST) "Notebook Page 475.1.8 Additional Contents of an Inspection Plan Inspection plans may also contain other details, including: 1a) describing the types of damage anticipated or experienced in the piping systems; b) defining the location of the expected damage; ©) defining any special access, and preparation needed. loping an inspection plan for operating piping systems? ) inspector and/or engineer ) lead inspector ©) inspection group of personnel under the guidance of the lead inspector 4) piping engineer in consultation with the corrosion specialist e \See-the anewer key at the end of this CASTI Notebook section. |API RP 570 - Piping Inspection Code —_ [Guidance Wf |This section of API 570 i listed in the API Body of Knowledge: + Risk-Based Inspection - RBI (API 570, $5.2) Risk-Based Inspection (RBD) 15.2 Inspection locations have always been based on a perception or experience of the areas most susceptible to material degradation in service. However, before RBI ({6.2), the frequency of inspection was based on a simple fixed interval. For example, every “K” number of years, an inspector looked at the same things in the same places. Inspectors were not ignorant of RBI concepts in the “early” days, but there was no formalized way of dealing with it in a consistent manner. The introduction of formal RBI (API RP 580) RBI has allowed us to: ‘* determine inspection intervals e ‘+ determine the type of future inspection/examinations ‘+ determine the extent of future inspection/examinations Important steps in assessing the probability of piping failure include identifying and evaluating: ‘+ potential damage mechanisms, ‘+ current equipment condition, and ‘+ the effectiveness of past inspections ‘© Codoe and Standarde Training institute (CAST) Notebook Page 48pyre - by pn Use Leg Soy te Important stepe in assessing the consequence of piping failure include identifying and evaluating: process fluids), potential injuries, environmental damage, ‘equipment damage, and ‘+ equipment downtime. Note: identifying integrity operating envelopes for key process variables is important to support RBI. Probability and consequence assessments covered in 5.2.1 and $522 must be made and documented (95.2.3) in accordance with API 580. e Frequency of RBI Assessments 15.2.4 ‘When RBI assessments are used to determine inspection intervals, they must be u * after each equipment inspection + each time process or hardware changes are made, oF @ ‘Mer any event occurs that could significantly affect damage rates or damage mechanisms. 16.3.2, Table 2 lists the maximum intervals between RBI assessments. Practice Problem Q017: RBI [How can risk-based inspection be used? a) determine inspection intervals b) determine the type of future inspection/examinations ©) determine the extent of future inspection/examination 4) all ofthe above @ [score answer ey atthe end ofthis CASTI Notebook section, Greene) |Which of the following documents covers probability assessments? a) APIRP571 >) APIRP 580 ©) APIRP 579 @) ASME FFS-1 [See the answer key at the end of this CASTI Notebook section. (© Codes and Standards Training institute (CAST!) Notebook Page 49Sees eea [What does an RBI assessment involve? a) probability assessment 1) consequence assessment ©) NDE assessment 4) aandb [See the answer key at the end of this CASTI Notebook section. Preparation for Inspection 5.3 [API RP 670 - Piping Inspection Code lExam [Preparation i lGuidance # |This section of API 570 is listed in the API Body of Knowledge: e@ ‘+ _ Preparation for Inspection (API 570, 5.3) In a general manner, {5.3 discusses things to consider when getting ready to do an inspection. API 570 proposes that inspectors familiarize themselves with: Safety Precautions 15.3.1 Inspection Equipment Preparation 15.3.2 Communication 16.3.3, Piping Entry 15.3.4 Records Review 15.3.5 Peace eee |What should an inspector do before starting any piping system inspection and maintenance lactivities? a) obtain the qualified welding procedure b) review the RT procedure with the examiner e ©) have a fully documented repair program 4d) obtain permission from operating personnel responsible for the piping to work in the vicinity. |See the answer key at the end of this CASTI Notebook section. (© Codes and Standarde Training inetuto (CAST) Notebook Page 0Inspection for Types and Locations of Damage Modes of Deterioration and Failure 95.4 lExam [Guidance [API RP 670 - Piping Inspection Code [Proparation) he following sections of API 570 are listed in the API Body of Knowledge: ‘© Inspection for Types and Locations of Damage Modes of Deterioration and| Failure (API 570, 16.4) ‘Typical damage types and mechanisms of piping systems are listed in Table 1 (see below), although this table is not complete. Refer to API 571 for more details involving damage mechanisms and additional recommended inspection practices for specific types of damage mechanisms are referenced in API 574. ‘Table 1 - Some Typical Piping Damage Types and Mechanisms Damaj [General and local metal loss, Damage Mechanism [Sulfidation [Oxidation [Microbiologically influenced corrosion [Organie acid corrosion [Brosion/erosion-corrosion [Galvanic corrosion [cur [Surface connected cracking [Fatigue [Caustic stress corrosion cracking Sulfide stress cracking [Other forms of environmental cracking [Subsurface cracking Hydrogen induced erack [Microfissuring/microvoid formation lHigh temperature hydrogen attack [Creep [Metallurgical changes (Graphitization [Temper embrittlement, [Blistering [Hydrogen blistering [Dimensional changes [Creep and stress rupture [Material INOTE: API 571 has lexperienced in the refining and petrochemical industry. of damage mechanisms| ‘© Codes and Standards Training inetitute (CAST) Notebook Page 51eee |Which of the following is a surface connected cracking mode? a) erosion b) hydrogen induced cracking ©) chloride stress corrosion cracking ) creep |Sce the answer key at the end of this CASTI Notebook section. General Types of Inspection and Surveillance 15.5 [API RP 570 - Piping Inspection Code Exam Preparation)| [Guidance # |The following sections of API 570 are listed in the API Body of Knowledge: + Types of Inspection and Surveillance (API-570, 15.5) 5.5.1 to 15.5.9 covers the different types of inspection and surveillance that are appropriate for Piping systems, as follows: ) internal visual inspection, b) on-stream inspection, ©) thickness measurement inspection, 4) external visual inspection, including buried equipment, ©) corrosion under insulation (CUD inspection, ) vibrating piping and line movement surveillance g) supplemental inspection, h) injection point inspection. Review 95.5.1 to 5.5.9 and the following definitions, {3.141 internal inspection: an inspection performed of the inside of a piping system using visual and/or NDE techniques. {13.1.57 on-stream: a condition where in-service piping systems have not been prepared for an internal inspection. NOTE Piping systems that are on-stream can also be empty or may still have residual process fluids in them and not be currently part of the process system, 3.1.58 on-stream inspection: an inspection performed from the outside of piping systems while they are on-stream using NDE procedures to establish the suitability of the pressure boundary for continued operation. 8.1.23 external inspection: a visual inspection performed from the outside of a piping system to find conditions that could impact the piping systems’ ability to maintain pressure integrity or conditions that compromise the integrity of the coating and insulation covering, the supporting structures and attachments (e.g. stanchions, pipe supports, ladders, platforms, shoes, hangers, instrument, and small branch connections). (© Codes and Standards Training Inettute (CAST) "Notebook Page 52a ee |Who is responsible for authorizing all on-stream inspection work performed by an examiner? a) the piping engineer b) the inspector ©) the inspector in consultation with the piping engineer @) the NDE organization supervisor lsee the answer key at the end of this CASTI Notebook section. Sea ene ae nes During an external visual inspection ofa horizontal support dummy leg, an inspector notices slight [displacements from the horizontal. What should the inspector be aware of, that may happen in this situation? 1) slight horizontal displacement is not an inspector's concern b) moisture traps against the external surface of active piping components could occur ©) count the number of pipe hangers and report the situation to the piping engineer @) aande lSee the answer key at the end of this CASTI Notebook section. Seen eee [During spot checks, an inspector notices evidence of piping areas with wet insulation. What should |they do? a) inspect other susceptible areas on the equipment b) notify the piping engineer ©) require further NDE 4) request profile UT to evaluate potential CUI lSee the answer key at the end of this CASTI Notebook section. Penson [During spot checks, an inspector notices evidence of piping areas with wet insulation. What should |they do? nee a) It should be reported to engineering personnel for assessment. b) It should be reported to the maintenance supervisor for immediate repair at the next shutdown. ©) It should be reported to inspection personnel for assessment. @) Either a ore, lsee the answer key at the end of this CASTI Notebook section. (© Codes and Standards Training intitute (CAST) Notebook Page 83Injection Points 15.5.9 Injection points are sometimes inherently subject to accelerated or localized corrosion from normal or abnormal operating conditions. As such, injection points may be treated as separate inspection circuits and these areas need to be inspected thoroughly on a regular schedule. The recommended upstream and downstream limits for designating an injection point circuit for inspection are listed in 5.5.9 and shown in Figure 1 (see table and figure below). ‘Recommended Upstream and Downstream Limits for Injection Point Circuits U Limits, min. Downstream Limits, min. 12 inches (800 mm) or 3 pipe diameters ‘the second change in flow direction past the upstream of the injection point, whichever is | injection point, or 25 feet (7.6 m) beyond the ter first change in flow direction, whichever is less In some cases, it may be more appropriate to extend this circuit to the next piece of pressure equipment, as shown below, from API 570 Figure 1. Overhead vapor line oF 12° minimum, Whichever is greater Injection poini{ Overhead piping circuit} condensers Distillation column “Typical condition monitoring locations (CMLs) within injection point circuits API 570 Figure 1—Typical Injection Point Piping Cireuit ‘© Codes and Standards Training Institute (CASTI) Notebook Page S¢When condition monitoring locations (CMLs) within injection point circuits subject to localized corrosion are selected, they should be in accordance with the following guidelines: a, Establish CMLs on appropriate fittings within the injection point cireuit. >, Establish CMLs on the pipe wall at the location of expected pipe wall impingement of injected fluid. c. CMLs at intermediate locations along the longer straight piping within the injection point circuit may be required. d. Establish CMLs at both the upstream and downstream limits of the injection point circuit. Note: During periodic scheduled inspections, more extensive inspection should be applied to an area beginning 12 inches (300 mm) upstream of the injection nozzle and continuing for at least ten pipe diameters downstream of the injection point. Additionally, measure and record the thickness at all CMLs within the injection point circuit. Pees IHow should injection points be treated that are subject to accelerated corrosion from normal} loperating conditions? a) may be treated as separate inspection circuits b) these areas may need to be inspected from time-to-time ©) no additional requirements are necessary provided normal operating conditions are maintained 4) both a and b [See the answer key at the end of this CASTI Notebook section. Senne eee |When using UT to establish the minimum thickness at each CML, close grid ultrasonic| |measurements or scanning may be used, under which of the following provisions? e a) as long as temperatures are-appropriate b) provided the UT skip lengths are appropriate for the close grid amplitude ©) provided the UT angle beam and skip lengths are appropriate for close grid amplitude @) aande . |See the answer key at the end of this CASTI Notebook section. (© Codes and Standords Training Institute (CAST) Notebook Page 55eee |What guidelines should be followed for the selection of condition monitoring locations (CMLs) within| linjection point circuits subject to localized corrosion? a) establish CMLs only at upstream limits of the injection point circuit, b) establish CMLs on all fittings within the injection point circuit ©) establish CMLs at both the upstream and downstream limits of the injection point circuit, 4) establish CMLs on 180° of the pipe wall [See the answer key at the end of this CASTI Notebook section. (© Codes and Standar Tralning Inctitute (CAST) Notebook Page 56Condition Monitoring Locations (CML) 115.6 " [API RP 670 - Piping Inspection Code am Proparat Gra0raton P Ire following sections of API 570 are listed in the API Body of Knowledge: ‘+ Condition Monitoring Locations (API-570, $5.6) + 3.1.9 condition monitoring locations, CMLs: Designated areas on piping systems where periodic examinations are conducted. ‘Note: Previously, CMLs were referred to as “thickness monitoring locations” (TMLs). CMLs may contain one or more examination points. CMLs can be a plane through a section of piping or a nozzle or an area where CMLs are located on a piping circuit. General 15.6.1 ‘The selection of CMLs shall consider the potential for localized corrosion and service-specific corrosion as described in API 574 and API 571. CML Monitoring 95.6.2 API 570 95.6.2 makes it mandatory that each piping system shall be monitored by taking thickness ‘measurements at CMLs. However, it does not specifically address a minimum number of required CMLs or their specific locations, only to mention that: CMLs should be distributed appropriately throughout each piping. API 570 45.6.2 does suggest that more CMLs and more frequent monitoring should be done when: + the potential for high failure consequences exists, and + higher corrosion rates or localized corrosion are expected, API 570 5.6.2 does permit CMLs to be elimifated or the number reduced under certain circumstances, such as: ‘© olefin plant cold side piping © anhydrous ammonia piping ‘+ clean noncorrosive hydrocarbon product, or ‘© high alloy piping for product purity. However, persons knowledgeable in corrosion should be consulted when CMLs are substantially reduced or eliminated. ‘API 570 §5.6.2 makes it mandatory that the thinnest reading or an average of several measurement readings taken within the area of a test point shall be recorded and used to calculate corrosion rates, remaining life, and the next inspection date in accordance with API 570 Section 7. UT or RT can be ‘used to measure the minimum thickness at each CML. API 570 95.6.2 suggests that 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 (© Codes and Standards Training Institute (CAST) "Notebook Page 87and tees where corrosion/erosion could increase corrosion rates. However it is important to note that, as a minimum, the thinnest reading and its location shall be recorded. ‘As a recommendation, API 570 5.6.2 states that CMLs should be marked on inspection drawings and on the piping system to allow repetitive measurements at the same CMLs. eee eee |When will more CMLs normally be placed and monitored more frequently? 2) in piping circuits with more than 100 joints of pipe >) in piping circuits with larger diameter piping, normally 24 inches or over ©) in piping cireuits with high potential consequences of failure should occur and those subject to higher corrosion rates or localized corrosion 4) in piping circuits with normal potential consequences if failure should oceur and those subject to normal corrosion rates or localized corrosion [See the answer key at the end of this CASTI Notebook section. ia eee [When should more CMLs be selected for piping systems? ) with higher potential for creating a safety or environmental emergency in the event of a leak ) with higher expected or experienced corrosion rates ©) with higher potential for localized corrosion d) allofthe above [See the answer key at the end of this CAST! Notebook section. CML Selection 15.6.3 When selecting or changing the number and locations of CMLs, the inspector should consider the type of corrosion expected in the process unit. However, in actual practice, corrosion is not always uniform, so additional CMLs may be required, e@ More CMLs should be selected with any of the following: a) Higher potential for creating a safety or environmental emergency in the event of a leak. b) 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, e) Higher potential for CUI. ‘© Codes and Standards Training Institute (CASTH) "Notebook Page seFewer CMLs can be selected with any of the following: 12) Low potential for creating a safety or environmental emergency in the event of a leak. ). Relatively noneorrosive piping systems ) Long, straight-run piping systems. CMLs can be eliminated with any of the following: a) Extremely low potential for creating a safety or environmental emergency in the event of a Teak. b)_ Noncorrosive systems, as demonstrated by history or similar service, and systems not subject to changes that could cause corrosion. ©) Systems not subject to changes that could cause corrosion as demonstrated by history and/or periodic reviews. Practice Problem [How many CMLs are required when higher corrosion rates are expected? a) 10% more than the standard number b) 20% more than the standard number ©) more than the standard number 4) fewer than the standard number |See the anwer key at the end of this CASTI Notebook section. Condition Monitoring Methods 95.7 [API RP 570 - Piping Inspection Code lExam [Preparation . . IGuidance uf |The following sections of API 570 are listed in the API Body of Knowledge: + Condition Monitoring Methods (API-570, $5.7) UT wall thickness measurement equipment usually is the most accurate means for measuring the thickness on installed pipe larger than NPS 1. However, for pipe diameters of NPS 1 and smaller, radiographie profile techniques are preferred. When ultrasonic measurements are taken above 160°F (85°C), UT probes, couplants, and procedures should be adjusted to ensure that accurate measurements at the higher temperatures will be obtained with the appropriate temperature correction factor. © Codes and Standards Tralning Institute (CAST) Notebook Page 59Factors that can contribute to reduced accuracy of ultrasonic measurements include the following: improper instrument calibration external coatings or scale excessive surface roughness |. excessive “rocking” of the probe (on the curved surface) subsurface material flaws, such as laminations temperature effects [at temperatures above 150°F (65°O)] small flaw detector screens thicknesses of less than 1/8 inch (3.2 mm) for typical digital thickness gauges improper coupling of probe to the surface (too much or too little couplant). ‘When piping systems are out of service, thickness measurements may be taken through equipment ‘openings using calipers, such as castings, forgings, and valve bodies, as well as pit depth approximations from CUI on pipe. Pit depth measuring devices also may be used to determine the depth of localized metal loss. e Pee eee |What is the preferred technique for obtaining thickness measurements on installed pipe diameters of INPS 1 and smaller? 4) ultrasonic thickness measuring ) radiographic profile techniques ©) UTorRT @) EC [See the answer key at the end of this CASTI Notebook section. eee eee eee |How should thickness measurements be taken when piping systems are out of service? a) may be taken through openings using a straight edge ruler e b)_ may be taken through openings using calipers ©) may be taken through openings using "eye ball" method @) all of the above [See the answer key at the end of this CASTI Notebook section. ‘© Code and Standards Training Institute (CASTH) "Notebook Page 60Other NDE Techniques for Piping Systems 18.7.2 In addition to CMLs, other NDE techniques may be more suitable to identify and monitor other specific types of damage mechanisms. The inspector should consult with a corrosion specialist or an engineer to help define: + the type of damage, + the appropriate NDE technique for the situation, + and the extent of examination. Examples of NDE techniques that may be used are listed in 5.7.2(a) to (k). Surface Preparation for NDE 15.7.8 ‘Surface preparation is important for visual examination and can be done by wire brushing, blasting, chipping, grinding, or a combination of these preparations may be required. NDE specialists may be consulted to assist with selecting and applying the proper surface reparation for each individual NDE technique. UT Shear Wave Examiners 15.7.4 5.74 makes it mandatory that the owner/user requires industry-qualified UT shear wave examiners for the following situations: a) detection of interior surface (ID) breaking flaws when inspecting from the external surface (OD); or b) detection, characterization, and/or through-wall sizing of defects. Examples for the use of industry-qualified UT shear wave examiners include: + detecting and sizing planer flaws from the external surface, and * collecting data for Fitness-For-Service evaluations. Smee eee eee eed lWhen would it be required to use an industry-qualified UT shear wave examiner to perform flaw ldetection? a) CML measurements b) thickness measurement of original piping ©) through-wall sizing of defects 4) allofthe above |See the answer key at the end of this CASTI Notebook section. (© Codes and Standards Training Institute (CAST) Notebook Page 61ASHE prer - Pressure Testing of Piping Systems 5.8 ea yap newt |API RP 570 - Piping Inspection Code lExam |Preparation . 7 lGuidance # [The following sections of API 570 are listed in the API Body of Knowledge: + Pressure Testing of Piping Systems (API-570, 15.8) Pressure tests are not normally conducted as part of a routine inspection. When pressure testing is performed, the requirements of ASME B31.3 must be followed (see B31.3 1345.4.2). Although pressure tests would commonly cover a complete piping circuit, where practical, pressure tests of individual components or piping spools can be performed in lieu of entire circuit. However, ‘an engineer should be consulted in this situation to ensure it is suitable for the intended application. Before pressure testing, the supporting structures should be reviewed by an engineer to be sure they are suitable for the additional loading of the test fluid. Pressure testing must always be performed after any heat treatment. See |When shall a pressure test be conducted? a) prior to any heat treatment b) after any heat treatment ©) prior to and after any heat treatment 4) in the afternoon when the warmest temperatures are available |See the answer key at the end of this CASTI Notebook section. Test Fluid 16.8.1 The test uid should be water unle: adverse effects of water. there is the possibility of damage due to freezing or other If water cannot be used, then another suitable nontoxic liquid may be substituted provided its flash point is at least 120°F (49°C) or greater and consideration shall be given to the effect of the test environment on the test fluid. Although 5.8 includes a "Nate" that the ownerfuser should avoid exceeding 90 % of the SMYS for the material at test temperature, ASME B31.3 4345.4.2(c) has different requirements. new We Piping systems made with the 300 series of austenitic stainless steels should be hydrotested with a solution made up of potable water or steam condensate. Note: Potable water in this context follows U.S. practice, with 250 parts per million maximum chloride, sanitized with chlorine or ozone. Notebook Page 62For sensitized austenitic stainless steel piping subject to polythionic stress corrosion cracking, consideration should be given to using an alkaline-water solution for pressure testing (see NACE RPO170 Protection of Austenitic Stainless Steels from Polythionic Acid Stress Corrosion Cracking During Shutdown of Refinery Equipment. PRs lif water cannot be used for a pressure test due to possible freezing damage and another suitable lnontoxic liquid is used, what is the liquid’s required minimum flash point? 1a) shall be at least 120°F (49°C) or greater ) shall be at least 240°F (116°C) or greater ©) flammable liquids are not suitable as a pressure test liquid 4) all flammable liquids are suitable at any flash point [See the answer key at the end of this CASTI Notebook section. Pneumatic Pressure Tests 15.8.2 ‘The safety risks to personne] and property during pneumatic testing must be considered prior to Pneumatic test. At a minimum, the ASME B31.3 requirements in 345.5 Pneumatic Leak Test and {1845.6 Hydrostatic-Pneumatic Leak Test must be applied. ‘Test Temperature and Brittle Fracture Considerations 15.8.3 ‘The potential for a brittle failure must be evaluated prior to hydrostatic and especially prior to pneumatic testing because of the high potential energy in the vessel during the test. ‘To minimize the risk of brittle fracture during a pressure test the metal temperature should be maintained at least: * 30°F (17°C) above the MDMT for piping that is more than 2 in. (5 em) thick, or ‘+ 10°F (6°C) above the MDMT for piping that have a thickness of 2 in. (5 cm) or less; and ‘+ not exceed 120°F (50°C) unless there is information on the brittle characteristic piping construction material indicating a higher test temperature is needed. of the (© Codes and Standarde Training inetitute (CAST) Notebook Page 63Semen int |To minimize the risk of brittle fracture in an in-service vessel during a pressure test after a repair lwhat is the minimum metal temperature that should be maintained during the pressure test for al |vessel thickness of 4 inches with a MDMT of 40°F? |Task: Determine the minimum Drawing: metal temperature. Formula: [From API 510 $5.8.6.2: er lfor vessels that are more than 2 in, thick: Min. Metal Temperature = MDMT + 30°F MOMT = -40°F [Required Variables: MDMT =-40°F Min. Metal Temperature = MDMT + 30°F |thickness of 2.5 inches with a MDMT of 0°F? a) 50°F b) 30°F ©) OF @) -10F [Solve this example problem and then check the solution at the end of this CAST Notebook section. Precautions and Procedures 15.8.4 1. Before applying a pressure test, assure safety of personnel. 2, Ifthe test pressure will exceed the relief valve's set pressure, the valve should be removed or blanked for the duration of the test. 3, Alternatively, each valve disk can be held down by a suitably designed test clamp (see 15.8.4 for more details). 4. Piping with expansion joints that cannot be removed or isolated, may be tested at a reduced pressure as specified in ASME B313. 5. If block valves are used to isolate a piping system for a pressure test, do not exceed the app (O34 permissible seat pressure in ASME B16.34 or the manufacturer's data. wo 6. After testing, if pressure relief devices are removed or were made inoperable during the test, they must be reinstalled or reactivated. 7. Visual inspection should not be performed until the equipment pressure is at or below the MAWP. (© Codes and Standards Training nethute (CAST) Notebook Page 64Seka ce ne ies [What should be done when an inspector notices that the hydrostatic test pressure will exceed the| |relief valve's set pressure during testing? 12) the valve should be removed for the duration of the test b) remove all valve disks ©) the valve should be blanked for the duration of the test @) aande |Solve this example problem and then check the solution at the end of this CASTI Notebook section. Pressure Testing Alternatives 15.8.5 Although substituting NDE (usually RT or UT) for a pressure test after an alteration or major repair is permitted by API 570, 95.8.5, it must be approved by the engineer and inspector after an alteration. Material Verification and Traceability 15.9 |API RP 670 - Piping Inspection Code lexam Preparation [Guidance Wf |The following sections of API 570 are listed in the API Body of Knowledge: ‘+ _ Material Verification and Traceability (API-570, 95.9) API 570 $5.9 makes it mandatory that during repairs or alterations of pressure containing equipment with alloy material piping systems, the inspector shall verify that the installation of new materials is consistent with the selected or specified construction materials. ‘A materiel verification program should be consistent with API RP 578 Material Verification Program for New and Existing Piping Systems. If a piping system component should fail because an incorrect material was inadvertently substituted for the proper piping material, API 570 95.9 makes it mandatory that the inspector shall: ‘consider the need for further verification of existing piping materials, and b. the extent of further verification will depend upon circumstances, such as the consequences of failure and the likelihood of further material errors. (© Codes and Standards Training institute (CASTI) Notebook Page 65kee [During repairs or alterations to alloy material piping systems, when shall the inspector verify that] |the installation of new materials is consistent with the selected or specified construction materials? 8) where the alloy material is required to maintain pressure containment b) where the alloy material is required to be welded ©) where the alloy material is required to be welded and PWHT 4) PMI should be performed on 100% during repairs or alterations of alloy materials [See the answer key at the end of this CASTI Notebook section. Inspection of Valves 95.10 [API RP 670 - Piping Inspection Code lExam tion enero line following sections of API 570 are listed in the API Body of Knowledge: + Inspection of Valves (API-570, $5.10) Thickness measurements are not routinely taken on valves in piping circuits since the body of a valve is usually thicker than most piping components for design reasons. However, valves that are exposed to steep temperature cycling (for example, catalytic reforming unit regeneration and steam cleaning) should be examined periodically for thermal fatigue eracking. In severe or unusual corrosivelerosive service, if gate valves are used, thickness readings should be taken on the body between the seats, since this is an area of high turbulence and high stress. Similarly, control valves or other throttling valves can be susceptible to localized corrosion/erosion of the body downstream of the orifice, particularly in high-pressure drop-and-slurry services. If such ‘metal loss is suspected, the valve should be removed from the line for internal inspection, including the inside of the downstream mating flange and piping should be inspected for local metal loss. When valve body and/or closure pressure tests are performed after servicing, they should be conducted in accordance with API 598 Valve Inspection and Testing. See iar |An inspector notices that a gate valve is experiencing severe corrosion-erosion in a piping system, |What should be done? a) thickness readings should be conducted on the body between the seats ) thickness readings should be conducted on the inlet flange ©) thickness readings should be conducted on the outlet flange 4) thickness readings should be conducted on the inlet and outlet flanges [See the answer key at the end of this CAST Notebook section. (© Codes and Standards Training Institute (CAST) Notebook Page 66Inspection of Welds In-Service 95.11 |API RP 570 - Piping Inspection Code Exam Proparat (Guidance Wf |The following sections of API 570 are listed in the API Body of Knowledge: + In-Service Inspection of Welds (API-570, 15.11) During repairs, alterations, or shutdown inspections, radiographic profile examinations may reveal weld imperfections that were not expected. If crack-like indications are detected while the piping system is in operation, further inspection with RT and/or UT may be used to assess the magnitude of the indication. ‘The engineer is responsible for assessing crack-like flaws and environmental cracking using API 579-VASME FFS-1 and/or the assistance of a corrosion specialist. ‘The inspector is responsible for assessing preferential weld corrosion. {16.11 lists the following issues to consider when assessing the quality of existing welds in-service: original fabrication inspection acceptance criteria, extent, magnitude, and orientation of imperfections length of time in-service operating versus design conditions presence of secondary piping stresses (residual and thermal) potential for fatigue loads (mechanical and thermal) primary or secondary piping system potential for impact or transient loads potential for environmental cracking repair and heat treatment history weld hardness, Frere meee ge Pee ee |What should the inspector do when preferential weld corrosion is noted? a) additional welds in the same circuit or system should be examined for corrosion b) after the corroded weld is repair, 5% of the welds in the same circuit or system should be examined ©) after the corroded weld is repair, 10% of the welds in the same cireuit or system should be examined 4) no further inspection is provided the corroded weld is repair [See the answer key at the end of this CASTI Notebook section. (© Codes end Standards Training Institute (CAST) Notebook Page 67femeaeeree |What are some of the issues to consider when assessing the quality of existing welds? a) presence of secondary piping stresses (residual and thermal) b) potential for environmental cracking ©) weld hardness 4) all of the above [See the answer key at the end of this CAST! Notebook section. Inspection of Flanged Joints 95.12 [API RP 570 - Piping Inspection Code lExam Preparati IGutance & |The following sections of API 570 are listed in the API Body of Knowledge: e@ ‘+ Inspection of Flanged Joints (API-570, 115.12) Flanged joints should be visually inspected for leaks (ie., stains, deposits, or drips), keeping in mind that process leaks onto flange fasteners may result in corrosion or environmental cracking. Flanged joints that have been clamped and pumped with sealant should be checked for leakage at the bolts since they may corrode or crack. If re-pumping is considered, then the affected fasteners should be renewed first. If flanges are excessively bent or distorted, check their markings and thicknesses against the engineering requirements before taking corrective action. Fasteners should be fully engaged. However, if a fastener is not fully engaged, it is acceptable if the Jack of engagement is not more than one thread. The markings on a representative sample of newly installed fasteners and gaskets should be examined to check the appropriate material specification. @ Guidance on the inspection of flanged joints can be found in ASME PCC-1. See eee eae ns |When are flange fasteners considered acceptably engaged if a lack of complete engagement is noticed| lby an inspector? a) if'a lack of complete engagement is not more than 1/2 thread b)_if'a lack of complete engagement is not more than 1 thread ©) if'a lack of complete engagement is not more than 3 threads 4) if lack of complete engagement is acceptable to the inspector [See the answer key at the end of this CASTI Notebook section. (© Codes and Standards Trlning Institute (CAST), Notebook Page 68Inspection Organization Audits 1.13 Although API 570 does not make it mandatory, it is recommended that each owner/user organization should be audited periodically to determine if the authorized inspection agency is meeting the requirements of this inspection code. The audit team should consist of: + people experienced and competent in the application of this code + people typically from another owner/user plant site, or + people typically from a third party organization experienced and competent in refining and/or petrochemical process plant inspection programs, or * a combination of people from third party organizations and other owner/user sites. ‘The audit team must at least determine that: ) the requirements and principles of this inspection code are being met; b) all owner-user responsibilities are being properly discharged; ©) documented inspection plans are in place for covered piping systems; 4) intervals and extent of inspections are adequate for covered piping systems; ©) all general types of inspections and surveillance are being adequately applied; 1) inspection data analysis, evaluation, and recording are adequate; g) all repairs, reratings and alterations comply with this code. Audit findings must be reported to the owner/user, with the following actions: 1. Establish a system for tracking and completion of audit findings. 2, Nonconformances are corrected by owner/user authorized inspection agency. 8, The audit findings should be reviewed by the audit team and during subsequent audits. (© Codos and Standards Training institute (CAST) Notebook Page 69Inspection Data Evaluation, Analysis and Recording - Section 7 API 570, Section 7 provides a numerical basis for data evaluation, analysis, and recording. Of all the items in API 570, this is potentially most useful. Before publication of API 570, industry lacked ‘uniformity in the methods used for data evaluation and analysis. In Section 7, data from corrosion inspection is used to calculate corrosion rates, the remaining life of a piping system, and the next inspection date for each condition monitoring location (CML), either by the corrosion half-life concept described in $6.3 or by a fixed time in accordance with Table 6-1. Corrosion Inspection Corrosion of metals is a natural process. For the most part, corrosion is quiet, gradual, and unspectacular, unlike other forces of nature such as earthquakes and tornadoes. These natural, dramatic processes we can do very little about except to watch for them, but corrosion can be e inspected and monitored so that the metals can perform their required tasks. Since corrosion is inevitable, the question to be answered by inspection is "When?" When must equipment be repaired or replaced, or how must conditions be altered to safeguard the metal’s life? ‘Visual examination will spot more problems and potential problems than any other NDE method. During operation and shutdowns, inspection of all metal gives a good idea of remaining life of the equipment as well as revealing locations needing immediate repair. One method of monitoring corrosion is to measure its rate of progress. API 570 has specific rules for calculating corrosion rate ({7.1.1), calculating remaining life using the corrosion rate (47.1.1), and establishing the next inspection interval based on remaining life (96.3.3). ‘© Codes and Standards Training Institute (CAST) Notebook Page 70Corrosion Rates, Remaining Life, Inspection Intervals |API 570 - Piping Inspection Code rates. exam Preparai (Guidance Wf |Candidates must be able to calculate: the exam. ‘© Corrosion Rates (API-570, 17.1) |Candidates will need to correctly interpret inspection data and determine corrosion| INote: the formulas required to calculate corrosion rates may not be provided during} ‘The progressive steps of evaluating the data required to calculate and analyze corrosion rates, remaining life, and inspection intervals are as follows: Step 1 document the time of operation since the last inspection Step 2 measure piping wall thickness at selected CMLs Step 3 calculate both long term and short term corrosion rates Step 4 calculate remaining life Step 5 establish the next inspection date Note: Some of the information presented this CASTI notebook deviates from the order shown in API570 in order to produce a more logical work-flow. ‘The following table summarizes the different order of presentation. CASTI Notebook. API 570 ‘Step 1 Document the time of operation since the | Step 2 Measure piping wall thickness at last inspection. selected CMLs. (45.6.2) ‘Step2 Measure piping wall thickness at|Step 1 Document the time of operation since the selected CMLs. ($5.6.2) Jast inspection. ‘Step 3 Calculate both long term and short term|Step 5 Establish the next inspection date. (96.3) corrosion rates. (97.1.1) ‘Step 4 Calculate remaining life, (7.1.1) Step 4 Calculate remaining life. (97.1.1) ‘Step 5 Establish the next inspection date. ({6.3) |Step 3 Calculate both long term and short term corrosion rates. (97.1.1) ‘After doing the above calculations, a difficult decision must be made if the measured wall thickn is below the current minimum value for safe maximum allowable working pressure (MAWP) or some future point (e.g., should the equipment be derated by lowering the pressure to make it safe until the next shut down which may also lower production rates)? (© Codes and Standards Training inetitute (CAST) Notebook Page 71Corrosion Rates 7.1 The corrosion rate measures amount of metal loss during the time it occurred. The units used in API 570 to measure corrosion rate are inches per year, which are sometimes referred to mils per year (thousands of an inch per year). The metric measurements used in API 570 for corrosion rate is mm per year. Corrosion rate can be calculated as an average value over the current life of the equipment, called long term corrosion rate (LTCR), or it can be calculated over its last two measurements, called short term corrosion rate (STCR). ‘The equipment thickness measurements used to determine both LTCR and STCR are shown in ‘Figure 1 and defined as follows. time ‘Figure 1 Showing the equipment thickness measurements for calculating corrosion rates. initial the thickness, in inches (millimeters), at the same location as tyctual measured at initial installation or at the commencement of a new corrosion rate environment previous = the thickness, in inches (millimeters), at the same location as tyciua] measured during one or more previous inspections tactual = the actual thickness, in inches (millimeters), measured at the time of inspection for 1 given location or component as specified in API 570, 5.7. Calculating the Long-Term Corrosion Rate (LTCR) 97.1.1 e ‘The long term corrosion rate can be calculated by the following steps. all corroded metal loss LICR = ‘time years between Step 1: by subtracting the current or actual thickness (tycjua!) from the original initial thickness (tii), the loss in thickness since installation can be determined. lividing the corrosion allowance by the equipment operating time from the initial installation to actual measurement, the average or long term corrosion rate can be calculated. (© Codes and Standards Training Institute (CASTI) Notebook Page 72Sane [Calculate the long-term corrosion rate from the following wall thickness data: original thickness was| [0.500 in., year 2: 0.480 in.; year 4: 0.465 in., year 6: 0.447 in., year 8: 0.409 in., year 10; 0.401 in, \(round-off to nearest 0.001 i |Task: Calculate the LTCR. Drawing: ay ‘ya 0-500 in [From API 570, 47.1.1: ror = finial taint | ‘years between tine tactual = 0.401 in. (in year 10) years between = 10 years = initial —tactual, LICR = years between 0.500in.— O401%0. 9 949 n year TO years Seeeseeen: |An inspector is asked to review the following data and calculate the long-term corrosion rates for| lpiping in circuit 231XZ that is constructed with ASTM A 933 Grade A, NPS 12, schedule 40; required [thickness 0.285 in. original thickness in 1990 was 0.406 in; 1995 thickness: 0.400 in; 2000] thickness: 0.391 in.; 2005 thickness: 0.385 in.; 2008 thickness: 0.75 in.; 2009 thickness: 0.300 in, |(round-off to nearest 0.001 in.) a) 0.060 inJyr. b) 0.006 inJyr. ©) 0.053 inJyr. 4) 0.530 inJyr. \Solve this example problem and then check the solution at the end of this CAST! Notebook section. (© Codes and Standards Training nettute (CAST) Notebook Page 73Calculating the Short-Term Corrosion Rate (STOR) 97.1.1 ‘The short term corrosion rate can be calculated by the following steps. recent corroded metal lose ‘time STCR Step 1: by subtracting the current or actual thickness (tactual) from the previous thickness (previous), the loss in thickness since the last inspection can be determined, Step 2: dividing the corrosion allowance by the equipment operating time between the previous and the actual thickness measurements, the short term corrosion rate can be calculated. Caution: 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. Note: the authorized inspector, in consultation with a corrosion specialist, shall select the corrosion rate that best reflects the current process. Sane ae een [Calculate the short-term corrosion rate from the following wall thickness data: minimum required| thickness 0.150 in; original thickness: 0.250 in.; year 2: 0.240 in.; year 4: 0.238 in.; year 6: 0.230 in. |year 8: 0.210 in.; year 12: 0.156 in. (round-off to nearest 0.001 in.) |Task: Calculate the STOR. Drawing: fot =0:250 0. ye =0210 9. tyes = 0.155 in, |Formula: 7 [From API 570, 7.1.1: . I Fann = 0.50%, ston atmeie—taten | ean bee |Required Variables: previous = 0.210 in. (in year 8) tactual = 0.155 in. (in year 12) years between = 12-8 = 4 years t, xt STCR = previous ~tectual years between _0.210%n, -0.155in, years 0.014 in/year (© Codes and Standards Training Institute (CAST) "Notebook Page 74ese [Calculate the short-term corrosion rate from the following wall thickness (WT) data: required WT 0.150 in, original WT 0.250 in.; year 2 WT 0.240 in; year 4 WT 0.240 in; year 6 WT 0.220 in.| lyear 8 WT 0.210 in,; year 12 WT 0.150 in. (round-off to nearest 0.001 in.) a) 0.053 inJyr. b) 0.002 inJyr. ©) 0.015 inJyr. 4) 0.150 inJyr, |Solve this example problem and then check the solution at the end of this CASTI Notebook section. Corrosion Rates Changes 17.1.1 ‘The corrosion rate may change during the life of the equipment due to many factors, such as process condition changes (e.g, increasing temperature, flow rates, pH, etc.). Consequently, the corrosion rate must be continually calculated to ensure there is sufficient corrosion allowance for diminishing thickness due to changing corrosion conditions. ‘There are occasions when the long term corrosion rate may differ from the short term corrosion rate, or the most recent corrosion rate, and the higher of these two corrosion rates may control the remaining life. To determine which corrosion rate to use, both the LTCR and STCR should be compared to see which results in the shortest remaining life as part of the inspector's data assessment. © Codes and Standards Training Inettute (CAST) Notebook Page 75,Remaining Life of Equipment 47.1 [API 570 - Piping Inspection Code |Candidates will need to correctly interpret inspection data and determine remaining| hife. Exam Preparation Guanes MP |Candidates must be abe to calculate: © Remaining Service Life (API-570, 17.1) INote: the formula required to calculate remaining life may not be provided during the| lexam. Pressure equipment in general must never be used below the minimum design thickness (trequred) for its operating conditions. For example, if pressure equipment were to be used in dry air service at room temperature, the amount of corrosion over the life of this equipment would be negligible and e near zero corrosion allowance would be required. But most API 570 piping systems operate in some type of corrosive environment, where corrosion allowance is required for safe operation during the shown in Figure 2. life of the equipment, t, heaured ‘ia corrosion allowance time Figure 2 Showing the diminishing corrosion allowance and minimum required thickness for safe operation. 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. Subsequently, the authorized inspector in consultation e with a corrosion specialist is required to select the controlling corrosion rate that best reflects the current process. ‘To calculate the remaining life of equipment in accordance with API 570, the remaining corrosion allowance thickness may be divided by the controlling corrosion rate, either LTCR or STCR, as follows. remaining corrosion allowance _ tacwual ~ trequired corrosion rate corrosion rate Remaining Life trequirea = the required thickness, in inches (millimeters), at the same location or component: as the tactual measurement computed by the design formulas (e.g., pressure and structural) before corrosion allowance and manufacturer's tolerance are added. Caution: the governing remaining life is based on its thinnest measured component. (© Codes and Standerde Training Inatitute (CAST) Notebook Page 76Serra g life for the worst lcondition for a recycle effluent piping circuit #232D that is constructed with ASTM A 53 seamless} lpipe, Grade B, NPS 8; the minimum required thickness is 0.205 in. and the initial thickness was} j0.840 in. The following thickness measurements were taken over the 15 years of operating service} lvear 2: 0.836 in.; year 4: 0.329 in.; year 6: 0.820 in.; year 10: 0.312 in.; year 15: 0.230 in. (round-down| |to nearest year). lrask: Calculate the remaining life of the pipe before it is not fit for service. Drawing: [From API 570, 47.1.1: factunt ~ trou Remaining Life = “sstual —“reauired corrosion rete Required Variables: tactual = 0.230 in, (in year 15) troquired = 0.205 in, corrosion rate = unknown lhe corrosion rate is not known, but can be calculated by taking the higher of the long term| corrosion rate and short term corrosion rate to obtain the worst condition. [From API 670, 47.1.1: ‘inital ~t ‘ror = initial ~ factual ‘years between initia = 0.940 in. years between = 15 years [From API 570, 47.1.1: t = tactuat STCR = {previous —tactual, ‘years between 312 in, (in year 10) 15 ~ 10 = 5 years = 0.016 indyr. ‘© Codes and Standarde Training Ineitute (CAST) Notebook Page 77,jd vi vey wv. ee got See eee ee |The higher of short term and long term corrosion rate is used to calculate the remaining life. In this |case, the short term corrosion rate (0.016 in /yr.) is used. tactual ~ trequired Remaining Life Sree |An inspector is asked to review the following data and calculate the remaining life for the worst lcondition of piping circuit #123A that is constructed with ASTM A 53 seamless pipe, Grade B| INPS 8; required thickness 0.205 in. original thickness 0.340 in.; year 2 thickness: 0.300 in,| lyear 4 thickness: 0.280 in; year 6 thickness: 0.260 in; year 10 thickness: 0.255 in, |year 15 thickness: 0.280 in. (cound-down to nearest year) e a) 2years b) 8 years ©) 4 years d) 5 years [Solve this example problem and then check the solution at the end of this CAST Notebook section. Newly Installed Piping Systems or Changes in Service 17.1.2 For a newly installed piping system or change in service where you have no service history, remaining life shall be estimated using one of the following in 17.1.2: ‘+ data collected by Owner/User for similar material in comparable service ‘+ from Owner/User’s other experience or published data on similar piping in comparable ‘+ ifyou can’t obtain any data, you must do your initial thickness survey within 3 months of e service, with subsequent measurements at appropriate intervals until the corrosion rate is established. oe Gee Ley (© Codes and Standards Tralning Institute (CAST), —== Notebook Page 78Sass For new piping eystems and piping systems for which service conditions are being changed, what Imethods shall be employed to determine the probable rate of corrosion from which the remaining |wall thickness at the time of the next inspection can be estimated? a) if data for the same or similar service are not available, a corrosion rate for a piping circuit may be from published data on piping systems in comparable service b) if'data for the same or similar service are not available, a corrosion rate for a piping cireuit may be estimated by a corrosion specialist ©) a corrosion rate for a piping circuit may be calculated from data collected by a corrosion survey specialist 4) alllof the above |See the answer key at the end of this CAST! Notebook section. Existing Piping Systems {17.1.3 API 570 requires that corrosion rates must be calculated on either a short-term or a long-term basis. ‘The corrosion rate must be continually monitored so that if it is found to be inaccurate, the corrosion rate for the next inspection period must be adjusted to agree with the actual rate. [For existing piping systems, how shall corrosion rates be calculated? a) on either a short-term or a long-term basis b) oneither a short-term or a long-term basis as selected by the authorized inspector ©) oneither a short-term or a long-term basis as selected by the piping engineer 4) oneither a short-term or a long-term basis, whichever is the longest \Sce the answer key at the end of this CASTI Notebook section.Frequency and Extent of Inspection - Section 6 [API 570 - Piping Inspection Code |Candidates will need to correctly interpret inspection data and determine inspection| \exam intervals, frequency, and extent of inspection. |Preparation [Guidance ‘+ Inspection Intervals/Frequency - General (API-570, 16.1) ‘+ Inspeetion During Installation (API-570, 16.2) + Piping Inspection Planning (API-570, 16.3) Purpose of Inspection Intervals 6.1 Section 6 of API 570 provides rules and guidance in determining the inspection frequency for all piping systema and presoure-relieving devices in-service. The purpose of establishing mar inspection e interval is to ensure the integrity of the equipment to operate safely until the next scheduled inspection. Planned inspections are mandated to be done on or before their due date, and if not done in time, are then be considered overdue for inspection. RBI planning may be used to extend the due date and thus are not considered overdue until the extended period date. Inspection During Installation 96.2 Piping should be inspected at the time of any installation to verify the equipment is safe for operation. At this time plant inspection records for the equipment can be started and should include base-line information such as the initial thickness readings at designated CMLs. Other items to be considered during installation inspection should include: a) verifying that piping, supports, attachments, insulation, flanges, and other mechanical connections are installed correctly and the piping is clean and dry; ) verifying the correct pressure-relieving devices are installed, including the correct set pressure. ‘The base-line thickness measurements are better euited as initial thickness readings for corrosion rate calculations in lieu of nominal and minimum thickness data in specifications since they will provide more accurately calculated data, such as corrosion rates after the first in-service thickness measurements. (© Codes and Standards Training nettute (CASTI) Notebook Page 80eee en ene lWhat is the purpose of inspecting a piping system at the time of installation if't has already passed |Snal fabricating inspections? ‘a) to verify the proper number of piping hangers and supports were installed b) to verify the welding procedures used for fabrication ©) to verify the correct nominal piping thicknesses were used a) to verify the equipment is safe for operation and to initiate plant inspection records for the equipment [See the answer key at the end of this CASTI Notebook section. Piping Service Changes 16.2.2 If the service conditions are changed, such as process contents, maximum operating pressure, and the maximum and minimum operating temperatures, the inspection intervals need to reflect the new service conditions. If both the ownership and the location of the piping are changed, the piping must be inspected before it can be placed into service. In this situation, once the piping has been relocated, the allowable service conditions and the inspection interval need to be established for the new service. Sa lif both the ownership and the location of a piping spool are changed, what needs to be done? 1a) the piping shall be internally and externally inspected before it is reused b) an internal inspection is required prior to releasing the piping spool for transportation to the new owner ©) anexternal inspection is required prior to releasing the piping spool for transportation to the new owner 4) nothing new has to be done provided the inspectors at both locations approves its use for service ISce the answer key at the end of this CAST! Notebook section. (© Codes and Standard Training incthute (CAST) "Notebook Page 81Piping inspection Planning 96.3 General 16.3.1 The suggested piping service classes in 96.34 is a simplified approach to establish frequency and extent of inspection, although the owner/user may choose a classification system that more accurately assesses consequence for their piping systems. This consequence assessment would consider the potential for: * explosion, * fire, toxicity, ‘+ environmental impact, and ‘© other potential effects associated with a failure. With a consequence assessment, 6.3.4 suggests that the piping circuit inspection strategy can e determine: ) the appropriate inspection methods, scope, tools and techniques to be utilized based on the expected forms of degradation; b) the appropriate inspection frequency; ©) the need for pressure testing after damage has been incurred or after repairs or ‘modifications have been completed; and 4) the prevention and mitigation actions that could reduce the probability and consequence of a piping failure. ema nee ee e |What is the purpose of defining a piping service classification system? ) toestablish a consequence assessment, ) todetermine the consequence of failure ©) toestablish an RBI plan 4) toestablish frequency and extent of inspection e [See the answer key at the end of this CASTI Notebook section. RBI for Inspection Planning 16.3.2 An RBI assessment may be used to change the recommended inspection intervals listed in Tables 2 and 3. In doing so, the RBI assessment must be conducted at intervals not exceeding the values in ‘Table 2. When warranted, RBI assessments can be done more often if the process, equipment, or consequence changes. It is the piping engineer's and authorized piping inspector's responsibility to review and approve these RBI assessments, (© Codos and Standards Training institute (CAST), Notebook Page 82Inspection Intervals 16.3.3 When RBI is not used, the piping inspection interval is established and maintained with: ) corrosion rate and remaining life calculations; b) piping service classification (see 6.3.4); ©) applicable jurisdictional requirements; 4) judgment of the inspector, the piping engineer, the piping engineer supervisor, or a materials specialist, based on operating conditions, previous inspection history, current inspection results, and conditions that may warrant supplemental inspections covered in 6.5.6. It is the owner/user's or inspector's responsibility to establish inspection intervals for: © thickness measurements, ‘+ external visual inspections, and + where applicable, for internal and supplemental inspections. ‘The focus of API 570, 16.3.3 is on thickness measurement and introduces the process of recommended interval scheduling at: ‘Thickness Measurement Inspection Intervals < 1/2 Remaining Life or Limits in Table 2 ‘The fixed maximum inspection intervals in Table 2 are not related to the 4 remaining life concept, as are inspection internals based on thickness measurements, but rather, on recommended values. Note: setting inspection intervals is a dynamic process and must always be reviewed after each inspection or significant change in operating conditions and updated when warranted. 4) shall not exceed one half the remaining life b) Syears ©) shall not excoed one half the remaining life or the limits in Table 2, whichever is less 4) 10 years [See the answer key at the end of this CASTI Notebook section. ‘© Codes and Standarde Training Inaituto (CAST) Notebook Page 83Piping Service Classes 16.3.4 ‘The piping classifications proposed in 6.3.4 is a simplified approach based on the consequence of failure. API 570, 16.3.4 addresses the consequence of piping failure by recommending four different piping service classes. Intuitively, these are: Class 1 - high consequences Class 2.~ moderate consequences Class 3 - low consequences Class 4 - minimal consequences |What is the basis for API 570 Class 1 piping? 1) services with normal potential of resulting in an immediate emergency if @ leak were to occur b) services with a rare potential of resulting in an immediate emergency if a leak were to occur e ©) services with the highest potential of resulting in an immediate emergency if a leak were to occur 4) class 1 piping is defined by the piping engineer to meet their specific plant size |See the answer key at the end of this CAST! Notebook section. ek et |What kind of services are included in Class 2 piping? ) on-site hydrocarbons that will slowly vaporize during release such as those operating below the flash point b) hydrogen, fuel gas, and natural gas ©) onsite strong acids and caustics 4) all ofthe above [See the answer key at the end of this CASTI Notebook section. Peete! |What kind of piping services are a) services that are potentially harmful to human tissue but are located in remote areas b) services that are flammable but do not significantly vaporize when they leak ©) services that are not located in high-activity areas @) all of the above [See the answer key at the end of this CASTI Notebook section. (© Codes and Standards Training Institute (CAST), Notobook Page 84|An inspector is asked to classify a new lube oil piping system. What class should it be? a) Class 1 d) Class 2 ©) Class 3 d) Class 4 [See the answer key at the end of this CASTI Notebook section. [API RP 570 - Piping Inspection Code Exam Preparation) A [Guidance d# |Note: since past closed-book exam questions have involved using Table 2, it is| lrecommended that you memorize this table. APL 570 Table 2 Recommended Maximum Inspection Intervals ‘Type of Circuit Visual External, Class 1 ‘Syears: Class 2 ~Byears, Class 3 10 years, Class 4 ‘Optional Injection points by class Soil-to-air interfaces? = by class, ‘Note: Thickness measurement apply to systems for which CMLs have been established in accordance with 15.6. 4 Inspection intervals for potentially corrosive injection/mix points can also be established by a valid risk- based inspection analysis in accordance with API RP 580. Soo API RP 674. |What is the recommended inspe jon interval maximum for Class 2 piping thickness measurements? a) 3 years b) 5 years ©) 8 years d) 10 years |See the answer key at the end of this CASTI Notebook section. (© Codes and Standards Training Institute (CAST!) Notebook Page 85fee or = IIf the remaining life of a Class 2 piping system is determined to be 16 years and the last inspection [date was May 31, 2008, when is the next recommended thickness measurement inspection date? a) May 31, 2013, b) May 31,2016 ©) May 31, 2018 d) May 31, 2024 [See the answer key at the end of this CASTI Notebook section. Visual External Inspection Intervals and CUI Inspections 916.4 [API RP 570 Piping Inspection Code lExam (This section of API 570 is listed in the API Body of Knowledge: [Preparation ‘+ Extent of Visual External and CUI Inspections (API 570, 6.4) IGuidance Note: since past closed-book exam questions have involved using Table 3, it is| recommended that you memorize this table. Following external visual inspection of susceptible piping, additional examination is required for the inspection of CUI in accordance with 16.4 the recommendations in Table 3, as follows. API 570 Table 3 Recommended Extent of CUI Inspection Following Visual Inspection ‘Approximate Amount of CUI : Inspection by NDE at Suspect Areas Approximate Amount of Fipe | (6.3.32) on Piping Systems within | “ollow-up Examination with NDE or Class - Insulation Removal at Areas with Susceptible Temperature Ranges. Damaged Insulation in APIRP 574 Class 1 50% 75% Class 2 33% 50% Class 3 10% 25% Class 4 Optional Optional Damaged insulation on higher elevated piping may result in CUI in lower piping areas remote from the original damage. Radiographic examination or insulation removal and visual inspection is generally required for damaged or suspect locations of this type. ‘When significant CUI is identified, additional areas should be inspected, up to 100 percent when warranted. (© Codes and Standards Training Institute (CAST) Notebook Page 86Piping with a remaining life over 10 years or protected against external corrosion need nat be included for the NDE inspection recommended in Table 3, although the condition of the insulating system should be observed periodically. Semen If the inspection of the damaged or suspect areas has located significant CUI, where warranted, how lmuch additional areas should be inspected? or a) up to 1/8 of the circuit should be inspected b)_up to 50 percent of the circuit should be inspected ©) up to 100 percent of the circuit should be inspected 4) none, unless warranted by the piping inspeetor's judgment [See the answer key at the end of this CASTI Notebook section. lWhat is the approximate amount of follow up examination with NDE or insulation removal at areas |with damaged insulation to evaluate the extent of CUI of class 1 piping? a) 25% b) 50% ©) 75% 4) 100% \See the answer key at the end of this CASTI Notebook section, Next inspection Date ‘The next inspection date for piping systems is simply the last inspection date plus the newly calculated inspection interval, as follows. ‘Next Inspection Date = Last Inspection Date + New Inspection Interval eee ee [A class 1 piping system is determined to have a remaining life of 12 years. When is the next] |recommended inspection interval? HTask: Determine the next inspection interval Formula: lOn a half-life basis: Ye x 12 years = 6 years |API 570 Table 2 recommends a maximum of 5 years. [The next inspection interval is 5 years (the lesser of the two options). (© Codes and Standards Training institute (CAST) Notebook Page 87[For a class 3 piping system, if the remaining life is determined to be 18 years and the last inspection| |date was July 1, 2009, when is the next inspection date? a) July 1, 2019 b) duly 1, 2018 ©) duly 1, 2027 a) July 1, 2014 \Solve this example problem and then check the solution at the end of this CASTI Notebook section. Extent of Thickness Measurement Inspection 16.5 JAPI RP 670 - Piping Inspection Code Exam Preparation Icuidance M |This section of API 570 is listed in the API Body of Knowledge: + Extent of Thickness Measurement Inspection (API 570, 16.5) To satisfy inspection interval requirements, each thickness measurement inspection should obtain thickness readings on a representative sampling of CMLs on each circuit (see 45.6). This representative sampling: * should include data for all the various types of components and orientations (horizontal and vertical) found in each cireuit, and © must include CMLs with the earliest renewal date as of the previous inspection. Deadlegs with CMLs should be classified as a separate piping circuit from the main piping. Note: the more CMLs measured for each circuit, the more accurately the next inspection date will be projected. (© Codes and Standards Training Institute (CAST) Notebook Page BeExtent of Small Bore, Auxiliary Piping, and Threaded-Connections Inspections 16.6 [API RP 570 - Piping Inspection Code Exam [Preparation)}|This section of API 570 is listed in the API Body of Knowledge: [Guidance * Extent of Small Bore, Auxiliary Piping, and Threaded-Connections| Inspections (API 570, 16.6) Definitions of small-bore piping (SBP), auxiliary piping, primary and secondary process piping are as follows: + small-bore piping (SBP): Piping that is < to NPS 2 (3.1.86) + auxiliary piping: Instrument and machinery piping, typically small-bore secondary process piping that can be isolated from primary piping systems. Examples include flush lines, seal oil lines, analyzer lines, balance lines, buffer gas lines, drains, and vents (93.1.8) ‘© primary process piping: Process piping in normal, active service that eannot be valved off or, if it were valved off, would significantly affect unit operability. Primary process piping normally includes all process piping greater than NPS 2 and typically does not include small bore or auxiliary process piping ($3.1.72) + secondary process piping: Process piping, often SBP downstream of block valves that can be closed without significantly affecting the process unit operability (93.1.85). ‘Small bore primary process piping is inspected according to all requirements of API 570, whereas small bore secondary process piping is inspected on the basis of service classification: ‘+ Class 1 - per same requirements as primary process piping ‘+ Class 2 and 8 - inspection is optional, except for deadlegs (bridles) should be inspected where corrosion has been experienced or anticipated. For secondary auxiliary small bore piping, inspection is optional, but could be performed depending upon: Classification Potential for environmental or fatigue cracking Potential for corrosion based on experience with adjacent primary piping systems Potential for CUL pees For threaded connections, treat it as small-bore and auxiliary piping, except where threat of fatigue failure exists with machinery, periodic assessment is recommended. (© Codes and Standerds Training institute (CASTI) Novebock Page 89