AIE-PR-PRJ-005 - in Service Pipework Inspection Procedure Rev 01

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In-Service Pipe Work Inspection Procedure Page 2/20

Table of Contents

1. Objective ...................................................................................................................................... 3
2. Scope ............................................................................................................................................ 3
3. Definitions ................................................................................................................................... 3
3.1 References .......................................................................................................................... 5
4. Responsibilities ......................................................................................................................... 5
5. Safety Requirements ................................................................................................................ 6
5.1 Task Risk Assessment ............................................................................................................. 6
5.2 Pressure Testing ..................................................................................................................... 6

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5.3 General Requirements ........................................................................................................... 6
6. Work Scope ................................................................................................................................. 6

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6.1 Strategy for Pipe Work Inspection ............................................................................................... 6
6.2 Strategy Chart for Pipe work inspection ................................................................................ 7
7. General Preparation .................................................................................................................. 8
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8. Inspection Execution ................................................................................................................ 8
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8.1 General ................................................................................................................................... 8


8.2 External Inspection ................................................................................................................. 8
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8.3 Internal Inspection ................................................................................................................. 9


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8.4 Corrosion Monitoring Locations (CML) .................................................................................. 9


8.5 CML Monitoring...................................................................................................................... 9
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8.6 CML Selection ....................................................................................................................... 10


8.7 Condition Monitoring Methods............................................................................................ 11
8.8 Surface Preparation .............................................................................................................. 11
8.9 UT Shear Wave Examiners.................................................................................................... 12
9.1 Typical Threats...................................................................................................................... 12
10. Reporting ............................................................................................................................... 13
10.1 General ................................................................................................................................. 13
10.2 Review and approval of inspection reports.......................................................................... 14
Appendix I ........................................................................................................................................... 15
Appendix II .......................................................................................................................................... 19

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1. Objective

The objective of this procedure is to describe the minimum requirements to perform in service
inspection of piping systems. This will ensure the conformance to required applicable standards
and practices in order to ensure the integrity of in-service piping systems.

2. Scope

This inspection procedure covers in service inspection of piping system only and does not cover
associated pressure vessels, Tanks, Heat Exchangers, rotating machinery, pumps, casings etc.
This procedure will also addresses pre inspection requirements, including on stream and off stream
inspection.

Additional requirements concerning items to be inspected and nature of such examinations shall
be contained in the inspection work pack.

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This procedure shall be strictly adhered by inspection personnel along with the relevant piping
system work pack and written scheme of examination.

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This procedure is derived from relevant API codes, standards and recommended practices.

3. Definitions
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Inspection Engineer (IE) – Inspection Engineer who is capable of performing in-service inspection
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according to the relevant codes and standards.

Senior Inspection Engineer (SE) – Senior Inspection Engineer who is capable to undertake
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inspection, managing inspection and reviewing inspection results according to the relevant codes
and standards.
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Senior Integrity Engineer (SIE) – Senior Integrity Engineer who is capable to undertake technical
assessment and issuing the inspection work scope and reviewing the inspection results.
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Integrity Team Leader (ITL) – Integrity Team Leader who is deemed to be competent by technical
management to undertake technical tasks to an agreed level with in the integrity management
discipline.

Technical Assistant – Technical Assistant, who is capable of maintaining and updating the
technical reports, registers etc.

Damage Mechanism-Any type of deterioration encountered in the refining and chemical process
industry that can result in flaws/defects that can affect the integrity of piping (e.g. corrosion,
cracking, erosion, dents, and other mechanical, physical or chemical impacts). See API 571 for a
comprehensive list and description of damage mechanisms.

Dead Legs-Components of a piping system that normally have no significant flow. Some
examples include blanked branches, lines with normally closed block valves, lines with one end
blanked, pressurized dummy support legs, stagnant control valve bypass piping, spare pump

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piping, level bridles, relief valve inlet and outlet header piping, pump trim bypass lines, high-point
vents, sample points, drains, bleeders, and instrument connections.

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).

Internal Inspection - An inspection performed on the inside of a piping system using visual
and/or NDE techniques to find conditions that could impact the piping systems’ ability to maintain
pressure integrity.

Fitting - Piping component usually associated with a change in direction or diameter. Flanges are
not considered fittings.

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Corrosion Monitoring Location (CML) - Designated areas on the piping system where periodic
examinations are conducted.

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General Corrosion -Corrosion that is distributed more or less uniformly over the surface of the
piping, as opposed to being localized in nature.

Localized Corrosion - Deterioration, e.g. corrosion that is confined to a limited area of the metal
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surface.
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Corrosion Under Insulation - Corrosion of piping system normally found underneath insulation
which results from water trapped under the insulation.
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Pipe - A pressure-tight cylinder used to convey a fluid or to transmit a fluid pressure and that is
ordinarily designated “pipe” in applicable material specifications.
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Piping Circuit (corrosion circuit) - A section of piping that is exposed to a process environment
of similar corrosivity or expected damage mechanisms and is of similar design conditions and
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construction material.

Piping System - An assembly of interconnected piping circuits that are subject to the same set or
sets of design conditions and is used to convey, distribute, mix, separate, discharge, meter,
control, or snub fluid flows.

Indication - A response or evidence resulting from the application of a non-destructive evaluation


technique.

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3.1 References

API 570 Piping Inspection Code: Inspection, Repair, Alteration, and


Rerating of In- Service Piping Systems, 3rd Edition, November
2009
API 571 Damage Mechanisms Affecting Fixed Equipment in the Refining
Industry, SECOND EDITION, April 2011
API 574 Inspection Practices for Piping System Components, 3rd Edition,
November 2009.
API 577 Welding Inspection and Metallurgy,1st edition, October 2004.
API 578 Material Verification Program for New and Existing Alloy Piping
Systems, 2nd Edition, March 2010
API 581 Risk Based Inspection (May 2000 Edition)

ASME Boiler and Pressure Vessel Code, 2010 Edition, w/2011


Addendum, July 2011
Section V,Non-destructive Examination
Section IX,Welding and Brazing Qualifications

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ASME B16.5,Pipe Flanges and Flanged Fittings, 2009 Edition
B31.3,Process Piping, 2012 Edition
NACE RP 01-70-97 Protection of Austenitic Stainless Steels and other Austenitic

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Alloys from Polythionic Acid Stress Corrosion Cracking
NACE MR 01-75 Sulphide Stress Cracking Resistant Metallic Materials for Oilfield
Equipment
The Control of Corrosion Under Thermal Insulation and
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NACE RP 01-98-98 Fireproofing Materials – A Systems Approach
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4. Responsibilities

The guardian of this procedure is the sole responsible for its update and ensuring, developing,
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scheduling, executing, project comply with its content.

This procedure shall be reviewed annually or more frequently based on the specific site
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requirements or changes in legislation to ensure the compliance of the latest revision of the
applicable codes and standards.
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The Integrity Team Leader (ITL) is to manage and deliver integrity management system program
to ensure all strategies, methods and practices adopted and also solely responsible for endorsing
technical reports and assessments.

Senior Integrity Engineer (SIE) is responsible to clearly define the scope of work, including the
required format and content of reports will be completed in one work pack and also responsible for
review of inspection reports and technical assessment.

Senior Inspection Engineer (SE) is responsible for completing the inspection and the supervision
of Inspection Engineer / technicians (e.g. NDT technicians) including where this work is conducted
by an AIE sub-contractor (or contractor to the Client). He is also responsible for monitoring the
progress of the work under the defined work scope in the work packs and written scheme of
examination in order to ensure compliance with the scope.

Inspection Engineer (IE) is responsible for executing the inspection in accordance to this
procedure along with the work pack and written scheme of examination, and also responsible to

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produce the inspection reports along with associated reports prior to final submission.

Technical Assistant (Tech A) is responsible for maintaining & updating the technical reports and
associated documents and also responsible for generating work packs (if required). The TA also
maintains the inspection plan.

Non Destructive Technician (NDT Tech) is responsible to perform Non Destructive Examination
in accordance with approved NDE procedures and subsequent reporting.

5. Safety Requirements

5.1 Task Risk Assessment

Prior to the commencement of any activity, appropriate permit to work task risk assessment of
relevant risks and measures employed to reduce them shall be undertaken.

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5.2 Pressure Testing

If pressure testing is conducted at site, adequate safety precautions must be in place prior to

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pressurizing the equipment. Task risk assessment shall be reviewed and approved by appropriate
plant Team leader/HSE Team.

5.3 General Requirements


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Tool box talk shall be discussed and agreed prior to commencement of any inspection activity.
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During the tool box talk hazards and control measures shall be clearly defined and understood by
all personnel involved in the activity.
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6. Work Scope
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6.1 Strategy for Pipe Work Inspection


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A inspection workpack will be compiled to manage the exaction of each piping system
inspection.

The work pack shall consist of the following but not limited to:

 Integrity Assessments report with clear scope of work.


 Asset Piping Register (RBI)
 P & ID’s.
 Inspection isometric drawings.
 Written scheme of examination
 NDT calibration report
 Limitations report
 Preparation certificate (if required)
 Safety risk Assessment prior to inspection commencements.

Once the piping system inspection is completed all the appropriate reports shall be compiled
in to the relevant work pack and signed off by the inspection engineer and NDT technicians. A

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final assessment and sign off of the result will then be completed by the senior Integrity
engineer and / or Integrity team leader.

6.2 Strategy Chart for Pipe work inspection


The execution of the piping system inspection shall be performed in accordance with the below
strategy.
WORK BOOK

P & ID REFERENCE SELECT PIPE WORK

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LINE ID
ACCESS REQUIREMENTS
RISK CODE (RBI)
(SCAFFOLDINGS), INSULATION
INSULATION STATUS
REMOVAL, LIGHTING

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INTEGRITY REVIEW VISUAL SURVEY REQUIREMENTS (NIGHT TIME
ISOMETRICS
RADIOGRAPGHY), CSE
HISTORY
CLIENT REQUIREMENTS
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SELECT NDT UT, RADIOGRAPGHY, ADVANCED
METHODS NDT, SELECT
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FEATURES:STRAIGHTS,ELBOWS,
TEES, REDUCERS.
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DETERMINE EXTENT
OF INSPECTION
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DETERMINE TRESHOLD FOR


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ADIVISING SUPERVISOR OF
ANOMALIES
(E.G CONC)

PERFORM
INSPECTION
UPDATE/CREATE
ISOMETRICS,
UPDATE ASSET
INSPECTION REPORT REGISTER, UPDATE
ANOMALY
REGISTER, RAISE
RO’S, RAISE FM’S,
UPDATE S/D EQUIPMENT
INTEGRITY REVIEW
PLAN/CMMS, AND WORKPACK
UPDATE RBI CLOSE OUT

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7. General Preparation

This may entail a pre-inspection site visit to finalize any inspection assistance (i.e. Scaffoldings,
Insulation removal, etc.) required to execute the inspection.

Prior to commencing the work, the person undertaking the inspection shall:

 Review the work pack with the work scope addressing the scope of examination, design
data, previous inspection report reference, limitations to the inspection, access points, etc.
 Review the history of the piping system to be inspected, noting any previous
anomalies/repairs/uninspected areas.
 Note design and operating pressures and temperatures.
 Review of construction drawings, P & ID’s and Inspection isometric drawings for details and
process familiarization.
 Make an initial site visit in order to arrange any preparation assistance for the inspection
from the client. If required a preparation certificate will be raised and issued to the client with

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documents support requirements.

8. Inspection Execution

8.1 General

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Pipework to be inspected includes parent metal, welds, fittings, flanges, valves, screwed
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connections, thermowells, instrumentation penetrations, plugs, injection points, drip rings and
small bore pipework take-off fittings.
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Dependent upon the established written schemes of examination and inspection workbook, the
scope may include general or close visual examination and a range of NDE techniques
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Where NDE is used, the specification of equipment used and its calibration shall be in
accordance with specified sub-contractor procedures which must be present onsite and signed
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off by a level 3 NDT specialist.

The client is responsible to deliver the inspection list to AIE for execution or if a Integrity service
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is being provided by AIE then the inspection list will be derived from the RBI and CMMS.

8.2 External Inspection

The following should be checked in the appropriate piping system to perform external
inspection, but not limited to:

 Any signs of Leaks or seepage (salt build up or straining).


 Any impact, mechanical damage, abrasion, deformation, bulging
 Flange and associated bolting deformation
 Condition of seals, glands,
 Visual condition of the Weldments.
 Misalignment if any.
 Condition of the pipe supports (i.e. civil foundations, Pipe shoe, Guide supports,
spring hangers, etc)
 Any signs of vibration movements especially small bore piping’s.

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 Any evidence of the external corrosion (type and extent).


 Any accumulation of corrosive fluids on the pipe surface.
 Any signs of Hot spots on the piping.
 Any evidence of ice formation
 Condition of the Fasteners.
 Condition of hangers and spring supports
 Condition of the Coating.
 Condition of the Insulation (wet insulation, water ingress, breaks in barrier, signs of
corrosion product).
 Any evidence of dissimilar metals
 Any abnormality on the Expansion loops.
 Pressure relieving devices (I.e. PSV’s, Rupture disk etc)
 Associated instruments
 Condition of the Valves.
 Corrosion coupons.

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 Threaded/Screwed connections.

8.3 Internal Inspection

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The following should be checked in the appropriate piping to perform internal inspection, but
not limited to:
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 Any evidence of internal corrosion or pitting on the pipe surface.
 Condition of the Flange faces (i.e. Mechanical damage, Service Cracks, Corrosion
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etc).
 Condition of the Gaskets.
 Condition of the Refractory.
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 Condition of the Linings.


 Condition of the Weldments.
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8.4 Corrosion Monitoring Locations (CML)


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The condition monitoring locations shall be clearly defined in the work scope for the designated
areas of the piping system where periodic measurements are conducted.

The nature of the CML varies according to its location in the piping system. The selection of
the CMLS shall consider the potential for localized corrosion and service specific corrosion
based on the RBI (failure risk assessment) and integrity assessment report in the work pack.

8.5 CML Monitoring

Each piping system shall be monitored at designated CMLs according to the integrity
assessment which shall be clearly highlighted in the appropriate inspection isometric drawings.
Piping circuits with high potential consequences of failure and those subject to higher corrosion
rates or localized corrosion will normally have more CMLs and be monitored more frequently.
CMLs should be distributed appropriately throughout each piping circuit.

The minimum and average thickness at each CML shall be defined and documented by the
use of NDE techniques such as ultrasonic scanning or radiography.

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Electromagnetic techniques also can be used to identify thin areas that may then be measured
by UT or radiography. When accomplished with UT, scanning consists of taking several
thickness measurements at the CML searching for localized thinning. The minimum and
average measurement readings taken within the area of an examination point shall be recorded
and used to calculate corrosion rates, remaining life, and the next inspection date.

CMLs should be established for areas with continuing CUI, corrosion at S/A interfaces, or other
locations of potential localized corrosion as well as for general, uniform corrosion.

CMLs should be marked on inspection isometric drawings and on the piping system to allow
repetitive measurements at the same CMLs. The rate of corrosion/damage shall be determined
from successive measurements and the next inspection interval appropriately established
based on the remaining life or Risk Based Inspection analysis.

8.6 CML Selection

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A decision on the number and the location of the CMLs shall consider the results from previous
inspection, the patterns of corrosion that would be expected and have been experienced in the

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process unit. CMLs should be distributed appropriately over the piping system to provide
adequate monitoring coverage according to the scope defined in the work pack with locations
highlighted in the inspection Isometric drawings. Thickness measurement sat CMLs are
intended to establish general and localized corrosion rates in different sections of the piping
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circuits.
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In some cases, the number of CMLs required to monitor a circuit will be fewer than those
required to monitor circuits subject to more localized metal loss. A circuit subject to perfectly
uniform corrosion could be adequately monitored with a single CML. Corrosion is never truly
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uniform and in fact may be quite localized, so additional CMLs may be required based on the
initial inspection findings.
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More CMLs should be selected for piping systems with any of the following characteristics:
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a) Higher potential for creating a safety or environmental emergency in the event of a


leak;
b) Higher expected or experienced corrosion rates;
c) Higher potential for localized corrosion;
d) More complexity in terms of fittings, branches, deadlegs, injection points, and other
similar items;
e) Higher potential for CUI.

Fewer CMLs can be selected for piping systems with any of the following two characteristics:

a) Low potential for creating a safety or environmental emergency in the event of a leak;
b) Relatively noncorrosive piping systems;

CMLs can be eliminated for piping systems with any of the following characteristics:

a) Extremely low potential for creating a safety or environmental emergency in the event
of a leak;

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b) Noncorrosive systems, as demonstrated by history or similar service; and


c) Systems not subject to changes that could cause corrosion as demonstrated by history
and/or periodic reviews.

Every CML should have at least one or more examination points identified. Examples include:

a) Locations marked on the pipe using paint stencils, metal stencils, or stickers;
b) Isometrics or documents showing CMLs;

Careful identification of CMLs and examination points are necessary to enhance the accuracy
and repeatability of the data gathering exercise.

The inspection sketches in Annex A confirm the scanning requirements for typical CML’s.

8.7 Condition Monitoring Methods

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The examination technique shall be clearly defined in the works pack and written scheme of
examination based on the possible types of damage mechanisms for the equipment.

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Examples of such techniques include:

a. Magnetic particle examination for cracks, surface and sub-surface defects of the
ferromagnetic materials.
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b. Fluorescent or dye-penetrant examination for surface defects in nonmagnetic
materials.
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c. Radiographic examination for detecting internal imperfections such as porosity, weld


slag inclusions, cracks, and thickness of components.
d. Ultrasonic thickness measurement and flaw detection for detecting the thickness of
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components and for detecting internal and surface breaking cracks and other
elongated discontinuities.
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e. Alternating current flux leakage examination technique for detecting surface-breaking


cracks and elongated discontinuities.
f. Eddy current examination for detecting localized metal loss, cracks, and elongated
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discontinuities.
g. Field metallographic replication for identifying metallurgical changes.
h. Acoustic emission examination for detecting structurally significant defects.
i. Thermography for determining cold spots or hot spots of components.

In addition to thickness monitoring, other examination techniques may be appropriate to identify


or monitor for other specific types of damage mechanisms which shall be addressed in the
work pack.

8.8 Surface Preparation

Adequate surface preparation is important for proper visual examination and for the satisfactory
application of any examination procedures, such as those mentioned above. The type of
surface preparation required depends on the individual circumstances and NDE technique, but
surface preparations such as wire brushing, blasting, chipping, grinding, or a combination of
these preparations may be required.

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8.9 UT Shear Wave Examiners

The integrity engineer shall specify industry-qualified UT shear wave examiners when requires
the following:

a. Detection of interior surface (ID) breaking flaws when inspecting from the external surface
(OD);
b. Where detection, characterization, and/or through-wall sizing is required of defects.

9. Additional Scope

Wall thickness measurement of piping shall be performed on specific CML locations as per the work
pack. Any additional non-destructive examination shall be performed as per the internal condition of
the piping, based on the expected damage mechanism and internal inspection.

Hydrostatic testing might be required for the piping system which is not fully examined with the

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appropriate non-destructive examination or visual inspection.

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9.1 Typical Threats

Piping systems are susceptible to various types of damage by several mechanisms. Typical
damage types and mechanisms are as follows;
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i. General and local metal loss:
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 Sulfidation
 Oxidation
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 Microbiologically influenced corrosion


 Organic acid corrosion
 Erosion/erosion-corrosion
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 Galvanic corrosion
 CUI
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ii. Surface connected cracking:

 Fatigue
 Caustic stress corrosion cracking
 Sulfide stress cracking
 Chloride stress corrosion cracking
 Polythionic acid stress corrosion cracking
 Other forms of environmental cracking

iii. Subsurface cracking:

 Hydrogen induced cracking.

iv. Microfissuring/microvoid formation:

 High temperature hydrogen attack


 Creep

v. Metallurgical changes:

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 Graphitization;
 Temper Embrittlement

vi. Blistering:

 Hydrogen blistering

vii. Dimensional changes:


 Creep and stress rupture
 Thermal.

viii. Material Properties Changes:

 Brittle fracture

The susceptible threats for relevant piping system will be assessed and specific CML locations
for examination shall be clearly marked in the work pack for inspection. In addition, detailed

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information concerning common damage mechanisms (critical factors, appearance, and typical
inspection and monitoring techniques) is found in API 571.

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10. Reporting

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10.1 General
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The following are the minimum requirements to be addressed while reporting on the results of
inspection findings. An example sample report is included in the Appendix 1.
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Each inspection report shall contain but not limited to the following:

 Client information and location details.


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 Date of inspection, Date of issue and unique report number.


 Relevant Inspection procedure reference numbers.

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Work pack reference number.


 Piping system identification.
 Piping system service.
 Inspection Limitations.
 Inspection findings category (Severity description with codes/grades).
 Additional comments.
 Pictures of the inspection if applicable.
 Supporting documents (i.e NDE reports, etc).
 Repair recommendations.
 The inspection personal stamp or seal with signatures.
 The inspection report shall not be reproduced without the approval of inspection party
which shall be stated in the inspection report.

All the inspection reports are to be submitted within 10 days on completion of full scope of the
work. If any anomaly noted during inspection must be reported within 24 hours of anomaly
identification.

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10.2 Review and approval of inspection reports

Upon completion of inspections all the inspection reports shall be reviewed and signed off by
the senior integrity engineer / Integrity Team leader subject to final submission to the client
based.
All approved inspection reports hard copies shall be maintained in the appropriate work pack
and the electronic copies shall be updated in the client database.

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Appendix I
CMLs for Spot Reading and Local Scans

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 The above diagram is a general view of test point numbering and coverage. Specific
component coverage requirements are referenced in the following diagrams.
 The min and average thickness of each test point should be documented

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STRAIGHT PIPE

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 All size pipes are to be scanned to 100mm bands at each CMLs.
 If the spool length is 12m then 2 additional mid sample locations should be performed (i.e
after every 3m)
 The minimum reading shall be permanently marked on the pipe next to the CMLS for future
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identification.
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BENDS
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 Bends less than 10” Diameter shall be scanned 100 % on CMLs. The min and average
thickness over the entire scanned area to be recorded.
 Bends more than 10” Diameter shall be scanned inner radius (TP 2-1) and outer radius (TP 2-
2) to 100 MMband or 100 % where ever required. The min and average thickness over the
scanned areas of the inner and outer radius to be recorded.
 The minimum reading shall be permanently marked on the pipe next to the CMLS for future
identification.

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REDUCERS

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 Reducers less than 10” Diameter shall be scanned 100 % on CMLs.
 Reducers more than 10” Diameter shall be scanned 100 MM band at high diameter (TP 2-1),
lower diameter (TP 2-3) and 6’O clock position(TP 2-2) or 100 % where required.

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 The min and average thickness of each test point should be reported
 The minimum reading shall be permanently marked on the pipe next to the CMLS for future
identification.
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TEES
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 Tees less than 10” diameter shall be scanned 100 % on CMLs.


 Tees more than 10” diameter shall be scanned at points TP 3-1/ TP 3-2/ TP 3-3&TP 3-4to
100mmstrip or 100 % where required.
 The min and average thickness of each test point should be reported
 The minimum reading shall be permanently marked on the pipe next to the CMLS for future
identification.

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END CLOSURES

 End Closures less than 10” diameter shall be scanned 100 % on CMLs.
 End Closures more than 10” diameter shall be scanned to half of the diameter or 100 % where
required.

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 The min and average thickness of each test point should be reported
 The minimum reading shall be permanently marked on the pipe next to the CMLS for future
identification.

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Appendix II

All the inspection findings shall be report in the below attached report format.

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PROCEDURE NO. AIE-PR-PRJ-005 In-service Pipework Inspection Procedure REV/ISSUE 01 May 2016
In-Service Pipe Work Inspection Procedure Page 20/20

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PROCEDURE NO. AIE-PR-PRJ-005 In-service Pipework Inspection Procedure REV/ISSUE 01 May 2016

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