API 570 Certification

API 570 Certification

B31.3 - Pipe Fabrication

"And I'm
supposed to
inspect this?"

"The wise man will hear and increase in knowledge"

API 570 Certification - Copyright MSTS - December 2015 1

 B31.3 - Pipe Fabrication

Module Objectives
✓ Determine the Minimum Design Metal Temp
✓ Familiar with welding restrictions
✓ Familiar with basic fabrication requirements
✓ Determine Preheat & PWHT temperatures
✓ Know the NDE requirements for new pipe
✓ Evaluate weld discontinuities
✓ Calculate hydro and pneumatic test pressures
•

This module will cover Chapter III, V & VI in B31.3

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 B31.3 - l'ipe Fabrication

Materials
✓ Listed Materials: Material "listed" in B31.3 in
either; Table A-1 or Table 326.1.
✓ Unlisted Materials: Mat'ls not "listed" in B31.3
■Use only if they meet the material property
requirements of the Code
✓ Unknown Materials
• Can not be used for pressure containing
components
1 Selection of material to resist corrosion is not
within the Scope of the Code. (323.5)

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 B31.3 - Pipe Fabrication

Low Temperature Limits

✓ Brittleness of a material is a major design
issue for all types of pressure equipment. A
brittle material can fail catastrophically !!!
1 Some of the factors that affect brittleness of
a material include:
■Material
■Temperature
• Stress Level
•
■Thickness
The opposite of brittleness is "Toughness". Brittle materials have lox• toughness.

..• A trt fi
Ashland Oil's Brittle
Failure - 120' Tank
Points 4 & 5 used to be
connected!

Classic Brittle Failures:

I. The Titanic
2. World War II - Convoy Ships in North Atlantic
3. Kuwait Refinery - Leveled a 400,000 barrel refinery

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 B31.3 - Pipe Fabrication

Low Temperature Limits

"Minimum Temp per Code Carbon Steel Low Temp Process
• Most Marls - Listed Table A-1 1. Find Curve Letter- Table A-1
• Most CS - Lists Curve Letter 2. Find Initial Min. Temp
• Use Table 323.2.2A (t....4
✓ Below this temperature
• Check Notes - Fig.323.2.2A
• Material can not be used, or
3. If Stress Ratio
• The material must be impact acclucit'oes fern/;
tested at desired temperature • Fig.323.2.2B Reduction Temp
• Enter at Left (Stress Ratio) 1 CX)D F (-1 htio Its° )
Tested
• At Curve go vertical to Red. Temp
Subtract Reduction from Step 2
Impact Test .4cceptance Criteria
Needle Records 1. Each set has 3 bars
String 2. Average > Table 323.3.5
3. Minimum > Table 323.3.5
4. Only 1 specimen < Table Ave
.Specimen

Exercise 3-1 Minimum Design Temperatures!!

I) What is the minimum design temperature for A-335-P5? (5% Cr) — ao `F
%4‘0 2) What is the minimum design temperature for A-358 Type 304L? - (lt

3) What is the minimum design temperature for a 0.750" pipe that

is made from A-106-B?
4) What is the minimum design temperature for a 0.500" pipe that
- 55° F
is made from A-516-60 plate, and is normalized?
5) What is the minimum design temperature for a 0.625" pipe that
is made from A-106-C and has a Stress Ratio of 0.90? - PF
6) If the designer wants to use a pipe material below the minimum temperature allowed by
the B31.3, then the material must be: Aaeci •

7) Impacting testing is performed on an pipe made from A-106-C. (a fully deoxidized

steel). Determine the following:
a. The impact procedure must follow what specs? v9-5 77” 43ft + A 333

b. The set consists of how many bars? 3 bars •

c. The minimum average for the set is: Sr - a 0 .7odd•ei.r

/4 V'en.../o.s. •
d. The minimum value for a single bar is:
e. How many bar(s) can be below the required average? 1Lar .

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 B31.3 - Pipe Fabrication

Fabrication - Welding
V Qualified Weld Procedure V Welder Identification
• ASME B&PV Section IX • UniquelD or Symbol
• Can accept some Procedures • Stamp each weld, or;
qualified by Others
• Use weld maps
V Welder Qualification
V Tacks weld
• ASME B&PV Section LV
• Can accept Qualifications by
others
✓ Welding Records
• Employer maintain
procedures and performance
records
• Fused with the root pass
• Made by a qualified welder
V Bad weather - don't weld
V Fillet weld sizing
• Figure 328.5.2
•
• Min. weld size 1/8"
-/05 49

Other Miscellaneous Requirements

I. If excessive misalignment, taper with a maximum angle of 30 degrees.
2. Peening is prohibited on the root & final pass.
3. Seal welds allowed, but must cover all exposed threads.
4. Flange Alignment o•oos")
a. Parallel within 1/16" per foot (diameter)
b. Bolt holes aligned within 1/8" ( 0- 051
5. Bolt Length: Bolts should extend completely through the nut. If not, has to be
within one thread of complete engagement
6. Gaskets: Only 1 per flange assembly

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 B31.3 - Pipe Fabrication

Welding & Distortion

✓ The Principles
■ Ther►nal Growth - As metals heat up they• -111111r—
expand. When cooled, they shrink
■ A metal 's strength decreases with
increasing temperatures
tit
✓ How Distortion Occurs

•
2—‘111111111111"
I. The arc is initiated.
2. Hot surface expands & distorts the plate
■ Not much since the hot side is much
weaker than the cool side
3. Completed weld, as heat moves away from
weld Weld contracts
4. Completed weld is distorted & has 4
residual stresses

Notes! Stresses from Welding

1) When we apply heat in a non-uniform method (welding) the result is a
dimensional change causing the part to be distorted or warped

2) The Principle - As the metals cool they shrink A CS weld that is 3/4 " wide
will shrink about 10 mils.
• The base metal is "anchored". As the weld shrinks, the base pulls the
cooling weld. (Tensile Stress)
• At higher temperatures, the weld metal is weak and ductile. It can be
pulled and reshaped to account for shrinkage.
• At low temperature, the weld metal is stronger and less ductile. It is
not easily "reshaped".
• Remaining pull on the weld once cool - "Residual Stresses"
• If Residual Stresses exceed, strength of weld — Crack

3) Residual stresses can be reduced or eliminated by:

• Preheat
• Thermal heat treatment
• Peening — pneumatic hammer used to pound on welds, e.g. jitterbug
type of equipment

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 B31.3 - Pipe Fabrication

Preheat & PWHT

17 Preheating (330)
• Used to minimize detrimental effects caused from welding
• Preheat temps: Use Table 330.1.1 (if not listed, preheat 50'1)
• Preheat zone: Greater of 3"or 1.5T from point of welding
1/ Post Weld Heat Treating (331)

•
• Used to relieve detrimental effects caused from welding
• PWHT temps: Use Tables 331.1.1 & 331.1.3 (Exceptions)
• Heating & Cooling Rates: 331.1.4 (600 • F/hr)
• PWI-H- zone: Width is at least 3 times wall thickness
• Partial HT: Minimum overlap of 1'

Exercise 3-2 Pre-Heat and PWHT!!

1) Determine the minimum Preheat Temperatures for the following:
a. 0.500" thick, P-1 material, 0.35% Carbon /0 °c st° F
b. 1.250" thick, P-1 material, 0.08% Carbon 10° c is-0° F
c. 0.625" thick, P-5B material, SMTS = 70 ksi ,dco*c voo.k-
d. 0.325" thick, P-5B material, SMTS = 60 ksi, 9.0% Chrome .100° c /Am' F
e. 0.325" thick, P-5B material, SMTS = 60 ksi, 5.0% Chrome 15ec / -fic° °P

f 0.250" thick, P-8 material fec /5-7)°F

g. 0.750" thick, P-1 material, 0.1% Carbon dvo need -11) Pftheet 111110

2) Determine the PWHT Temperatures for the following:

a. 0.750" thick, P-1 Group 1 material, Multi-layers used NWT not requew%1
b. 0.250" thick, P-8 Group 1 material paws 40t- redi;Nrc:t
c. 1.250" thick, P-1 Group 2 material, Preheat 50°F Oeiaire 41 P who) selre° —6r0°
d. 1.250" thick, P-1 Group lmaterial, Preheat 300°F A/0,1 mewl:ea
e. 0.325" thick, P-5B Group 1 material 615- c — uocc,
f 0.750" thick, P-1 Group 4 material, Multi-layers used oVolL ref GI/it'd

3) Determine the minimum PWHT Holding Time for the following:

a. Carbon Steel (P-1 Group 1 material) pipe, 1.500" thick /hr go mins •
b. Carbon Steel (P-I Group 2 material) pipe, 0.188" thick minor) urn

c. P-SB Group I material, 3.0" thick .,hr /5" sm:Is •

d. Carbon Steel (P-1 Group 4 material) pipe, 0.322" thick Rusegripn c

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 B31.3 - Pipe Fabrication

Examination
1,4 Category D RT Criteria; Table 341.3.2
• Some visual • Dr = wall thickness
• "and" means "lesser of values"
I( Normal Service
✓ Progressive Sampling
• Some visual: materials,
fabrication & assembly • Random Exam Reject
• Take 2 more
• Visual: 5% of all welds
• If these are OK, repair & stop
• RT: 5% of circ weld • If any defects, then
1 Severe Cyclic • Take 2 more for each reject
• If these are OK, repair & stop
• Visual: 100% of
• if any defects, then
Fabrication & assembly
• Exam all or Repair all
• RT: 100% of circ welds • Only those represented by
• MT/PT: All socket-welds this Random Exam

Exercise 3-3 NDE!! le 30), • 3 . .2 •

1) A new Normal Service seamless pipe is fabricated. The wall thickness is 0.500" For the
circ welds, determine the maximum allowed dimension for the following discontinuities.

a. Crack Alo crokot allowe.ol •

b. Lack offusion Zero

c. Length of a slag inclusion

d. Width of a slag inclusion /
e. Cumulative Length of slag inclusions
I/3a
f Depth of Undercut
g. Length of Undercut lensiA •

h. Maximum Cap Height Onim / re "

2) All NDE methods shall be performed in accordance with Acmc

3) All NDE personnel should be qualified in accordance with As-me

NDE Definitions - Texas Style

100% Examination: "All ofAll"
Random Examination: "All of Some"
Spot Examination: "Some of All"
Random Spot Examination: "Some of Some "

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 1331.3 - Pipe Fabrication

Pressure Testing
17 Purpose of testing Hydrotest
• Find leaks in joints
• Create higher stress than 1.5Px Sr
the operation stress Pr —
• Minimize the risk of brittle
fracture while in-service Pneumatic test
1( All new pipe is tested
Pr =1.I 11
• Cat D - Service Test
NAHA = 0.5 PT OT 25 psig (lesser)
✓ Minimum Hold Time
• 10minutes PRA" = 1.1PT OT PT + 50 psig (lesser)
Plospect = P
"Joints - Uninsulated

ST: Allowable Stress at Test Temperature (Usually @ 100 °F. )

Why ST/ S?
Note that ST / S will always be > 1.0. If greater than 1.0, then the pipe will be tested at a
pressure higher than 1.5 x Pr . A pipe will always be tested at or near ambient
temperatures. But at ambient temperature, a material is stronger than at some elevated
temperature. So, for pipe that is designed for elevated temperatures, ST / S adjusts the
test pressure upward, recognizing that the material is stronger at test temperature.
(Actually (P x ST /S) is basically the pressure this pipe is "good for" if it was rerated to
a design temperature of 100 °F.)

Exercise 3-4 Pressure Test!!

•
1) Determine the required hydrotest pressure for a 8 NPS pipe. The design pressure is
500 psig at 600°F. The pipe is made of A-106 Gr A material.

2) A pneumatic pressure test is going to be performed on a 16 NPS piping system. The

design pressure is 100 psig at 300°F. The pipe is made of A-106 Gr C material.
Determine the following pressures..
a. Test Pressure
b. Initial System Pressure
c. Maximum Relief Valve Pressure
d. Inspection Pressure

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 API 570 Certification
Module #3 Homework
Name:

() )en Book

1. What is the test pressure for a piping system that will be tested with air? The system is designed
for 400 psig at 600 °F, pipe material is A 106 gr. B.

a) 440 psig
b) 476 psig
c) 509 psig
d) 518 psig
e) 600 psig
f) 694 psig

2. What is the minimum allowed temperature for the described pipe?

Pipe Material: A515 Gr 60 (A672 Gr B60) Nominal Wall thickness: 1.000"

Impact tests were not performed. Minimum Wall thickness: 0.875"

a) 68 °F
b) 25 °F
c) 33 °F
d) 0 °F
e) -3 °F
f) -10 °F
g) -30 °F

3. Determine the required preheat temperature for the following pipe.

Material: Carbon Steel - A-I06 Gr. B with maximum Carbon content of 0.12%
PP
Wall Thickness: 1.25

a) 10 °F
b) 50 °F
c) 95 °F
d) 200 °F
e) Preheat is not required

4. A pipe is made from A106 Gr B material. A preheat of 50 °F is performed. The weld is made
with multi-layers. Which of the following is correct pertaining to postweld heat treatment?

a) PWHT is required if thickness is less than 1"

b) PWHT is required if thickness is greater than 1"
c) PWHT is never required for this material
d) PWHT is always required for this material

5. What is the quality factor "E" for a pipe with an electric fusion long weld that is single welded and
has been spot radiographed?

a) 0.60
b) 0.80
c) 0.85
d) 0.90
e) 1.00
f) designer's judgment

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 API 570 Certification
Module #3 Homework
6. Determine the minimum hydrotest pressure for a new piping system. The system is designed for
225 psi at 750 °F, and the pipe material is A 106 gr. C

7. A new pipe circ weld is made with 8 NPS Schedule 40 pipe. Determine the maximum allowed
limits for the following weld discontinuities. Pipe is considered Normal Service.
a) length of crack
b) length of lack of fusion
c) dopth of inoomploto panotrution

d) length of incomplete penetration

e) length of individual slag inclusion

0 width of slag inclusion

g) cumulative length of slag inclusion

h) cap height (weld reinforcement)

8. A pneumatic test is conducted on a new pipe system. The design pressure for this pipe system is
80 psig. Determine the following pressures.

a) pneumatic test pressure psig

b) pressure for the preliminary check psig
c) maximum pressure for relief device used during test psig
d) pressure for performance of inspection psig

9. Calculate the minimum temperature for the following pipe systems:

a) Plate wall 0.500" thick, Material A-387 Gr. 9 Cl 1 (9Cr-1 Mo)
b) Pipe wall 1.000" thick, Material A-672 Gr. C55 (CS)
c) Pipe wall 1.250" thick, Material A-106 Gr. A, Stress Ratio 0.80

10. Calculate the minimum hydrotest pressure for the following pipe systems:
a) Design Pressure 100 psig @ 500 °F, Material A-106 Gr. B

b) Design Pressure 400 psig @ 800 °F, Material A A-672 Gr. C70

11. Calculate the pneumatic test pressure for the following pipe systems:
a) Design Pressure 200 psig @ 600 °F, Material A-106 Gr. C

b) Design Pressure 400 psig @ 800 °F, Material A A-672 Gr. C70

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 API 570 Certification
Module #3 Homework

12. A pipe is being replaced. Calculate the most cost effective pipe schedule for this system. Material
is A-106 Gr. B. Line size is 6 NPS. Design Pressure is 500 psig @ 700 °F. The corrosion
allowance is 0.125".

13. A blind is to be installed into a piping system. Calculate the plate thickness to order for this blind.
Material is A-516-60. Gasket ID is 12.5". Design Pressure is 300 psig @ 400 °F. The corrosion
allowance is 0.125".

14. Determine the thermal growth of a carbon steel pipe that is 600' long pipe and operates at 400 °F.

15. A piping system is fabricated from a P# 5B Group I material, that has a Tensile Strength of 70 ksi.
The wall thickness is 1.5" thick. Determine the following:

a. Minimum Preheat Temperature

b. PWHT Temperature

c. PWHT minimum Holding Time

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 API 570 Certification
module #3 Homework
Closed Book

1. During fabrication, how many welds should be radiographed for a pipe in a Normal Service?
a) 5%
b) 10%
c) 100%
d) Depends of flange class rating

2. If a defect is found when radiographing a pipe weld, how many follow-up radiographs should be
taken?
a) One
b) Two
c) Four
d) Number based on Inspector's judgment

3. Which of the following discontinuities are never acceptable when fabricating a normal service
piping system?
a) Lack of fusion
b) Incomplete penetration
c) Undercutting
d) Slag inclusion

4. Flange bolts are unacceptable if:

a) they are not the same metallurgy as the flange.
b) the threads do not extend beyond the nut.
c) the threads do not extend within the last thread on the nut.
d) the threads extend 1" beyond the nut.

5. The maximum inspection interval for a relief device in normal services is:
a) 3 years.
b) 5 years.
c) 10 years.
d) lesser of 1/2 life or 10 years.

6. According to API 570, an on-site gasoline piping system would be classified as a:

a) Class 1 system.
b) Class 2 system.
c) Class 3 system.
d) Normal Service system.

7. UT readings are generally accurate on pipe diameters greater than:

a) 1 NPS.
b) 2 NPS.
c) 3 NPS.
d) 4 NPS.

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 API 570 Certification
Module #3 Homework

8. A leak test on a new pipe system must be held at least:

a) 5 minutes.
b) 10 minutes.
c) 1 hour.
d) 8 hours.

9. Which material is most susceptible to polythionic cracking?

a) carbon steel
b) low chromes
c) stainless steel
d) aluminum

10. The code covering inspection and testing of valves is:

• 'v a) API 578.
b) API 598.
c) API 2201.
d) ASME 16.34.

11. Which material is most susceptible to temper-embrittlement?

a) carbon steel
b) low chromes
c) stainless steel
d) aluminum

12. The remaining life on a Class 2 pipe is 16 years. Determine the maximum inspection intervals?
a) 5 years for both the thickness measurements and external inspections
b) 8 years for both the thickness measurements and external inspections
c) 10 years for both the thickness measurements and external inspections
d) 5 years external, 8 years thickness measurements
e) 5 years external, 10 years thickness measurements

• 13.
0
g)
8 years external, 5 years thickness measurements
8 years external, 10 years thickness measurements

The maximum diameter of an examination point for an 8 NPS pipe is:

a)
b)
1".
2".
c) 3".
d) 8".

14. During a repair, preheat in lieu of a full PWHT may be considered only:
a) for P1 & P3 materials.
b) if pipe is classified as Category D.
c) if pipe is not classified as Class I piping.
d) Piping operates above 700 °F.

15. When impact testing is required, how many bars are needed for a "set"?

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 API 570 Certification
Module #3 Homework

16. When performing a PWHT, the width of the heat affected zone is a minimum of:
a. 1.0" from either side of the weld.
b. 2 times the width of the weld.
c. 3 times the thickness of the pipe wall.
d. 4 times the width of the weld.
e. 6".

17. Determine the following limits for an injection point. The line size is 14 NPS.
a. Upstream circuit limit:
b. Downstream circuit limit:
c. Upstream limit for extensive inspection:
d. Downstream limit for extensive inspection:

18. Which of the following codes can be used to evaluate an in-service crack?
a. ASME B31.3
b. ASME B&PV Section VIII, Div. 1
c. ASME B&PV Section VIII, Div. 2
d. API 579
e. API 651
f. API 2201

19. During welding if there is excessive misalignment between 2 components, then the thicker
component should be taper at an angle not exceeding:
a. 22.5 degrees.
b. 30 degrees.
c. 37.5 degrees.
d. 45 degrees.

20. During a repair a naphtha line at a crude unit about 1000' of piping will be replaced. How many of
the new welds should be visually inspected?
a. 5%
b. 10%
c. 100%
d. None is required if RT is performed

21. Who must approve all repair work at any designated hold points?
a. any inspector
b. authorized inspector
c. piping engineer
d. authorized inspector and the piping engineer
e. authorized inspector or the piping engineer

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 API 570 Certification
Module #3 Homework - Answers
Open Book
I. a) 440 psig PT = 1.1 X 400 = 440 psig
2. c) 33 °F Curve B @ 1.000" is 33 °F
3. b) 50 °F
4. b) PWHT is required if thickness is greater than 1"
5. d) 0.90
6. 531.3 psig PT = (1 .5 x 225 x 23,300)/14,800 = 531.3 psig
7. Tw = 0.322" (8 NPS, Sch. 40)
a) 0"
b) 0"
c) 1/32" LeF,ser of 1/32" or 0.064" (0.2 x 0.322)
d) 1.5" in 6" of weld
e) 0.644" 2 x 0.322
f) 1/8" Lesser of 1/8" or 0.161" (0.322 / 2)
g) 1.288" in 6" of weld (4 x 0.322)
h) 1/8"
8. a) 88 psig PT = 1.1 X 80 = 88 psig
b) 25 psig Lesser of 25 psig or 44 psig (0.5 x 88)
c) 96.8 psig Lesser of 96.8 psig (1.1 x 88) or 138 psig (88 + 50 )
d) 80 psig Same as Design Pressure
9. a) - 20 °F From "S" Table
b) -3 °F Curve C Material
c) 26 °F Curve B, Initial MDMT 44 °F, Stress Ratio Reduces it by about
18 °F
10. a) 157.8 psig PT = (1.5 x 100 x 20,000)/19,000 = 157.8 psig
b) 1165 psig PT = ( 1 .5 x 400 x 23,300)/12,000 = 1165 psig
11. a) 220 psig PT = 1.1 X 200 = 220 psig
b) 440 psig PT = 1 . 1 X 400 = 440 psig

12. Order Schedule 40 Cale t„„„: = (500 x 6.625) / 2[(16,700 x 1.0) + (500 x 0.4)] = .098"
Add CA: t wk. = 0.098 + 0.125 = 0.223"
Adjust for mill tolerance: t adj = 0.223 / 0.875" = 0.255"
Pick pipe schedule: Schedule 40 (0.280" nominal thickness)
13. Order 7/8" plate t„,u, = 12.5 x sq root of: (0.1875 x 300) /18,200) = 0.695"
Add CA: t = 0.695 + 0.125 = 0.820"
Pick plate thickness: 7/8" (0.875" nominal thickness)
14. 16.8" G = (2.80 x 600) / 100 = 16.8"
15. a) 400 °F
b) 1250 - 1400 °F
c) 1.5 hrs

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 API 570 Certification
Module #3 Homework - Answers
Closed Book

I. a) 5%

2. b) two

3. a) Lack of fusion

4. c) the threads do not extend within the last thread on the nut

5. b) 5 years

6. b) Class 2 system

7. a) 1 NPS

8. b) 10 minutes

9. c) stainless steel

10. b) API 598

11. b) low chromes

12. d) 5 years external, 8 years thickness measurements

13. b) 2"

14. a) for PI & P3 materials

15. 3 bars

16. c) 3 times the thickness of the pipe wall.

17. a) 42" Greater of: 12" or 42" (3 x 14)
b) Is' ElI + 25' or second change of direction
c) 12"
d) 140" (10 x 14)
18. d) API 579

19. b) 30 degrees

20. a) 5%

21. b) authorized inspector

MSTS 8 February 20/6