Api574 my self study notes

1. Fion Zhang/ Charlie Chong API RP 574 In-house training Inspection Practices for Piping System Components My Self Study Notes

2. Fion Zhang/ Charlie Chong -

3. Fion Zhang/ Charlie Chong

4. Fion Zhang/ Charlie Chong Foreword API RP 574 (RP) API 570 API, ; , 5 API , , 2 . 6. -RP, .

5. Fion Zhang/ Charlie Chong Contents 1 Scope 2 Normative References 3 Terms, Definitions, Acronyms, and Abbreviations 4 Piping Components 5 Pipe-joining Methods 6 Reasons for Inspection 7 Inspection Plans 8 Frequency and Extent of Inspection 9 Safety Precautions and Preparatory Work 10 Inspection Procedures and Practices 11 Determination of Minimum Required Thickness 12 Records Annex A (informative) External Inspection Checklist for Process Piping

6. Fion Zhang/ Charlie Chong 1 Scope RP API 570 . RP, . 574-1

7. Fion Zhang/ Charlie Chong 2.Normative References 574-2

8. Fion Zhang/ Charlie Chong 3. Terms, Definitions, Acronyms, and Abbreviations ,, 574-3 Please refer to text

9. Fion Zhang/ Charlie Chong 4 Piping Components 574-4 4 Piping Components 4.1 Piping 4.2 Tubing 4.3 Valves 4.4 Fittings 4.5 Flanges 4.6 Expansion Joints

10. Fion Zhang/ Charlie Chong 574-4 4.1 Piping

11. Fion Zhang/ Charlie Chong 4.1 Piping ASTM A53 , ASTM A106 ( ERW) : NPS16 NPS48 574-4

12. Fion Zhang/ Charlie Chong 4.1 Piping NPS48 574-4

13. Fion Zhang/ Charlie Chong 574-4 Pipe wall thicknesses are designated as: (1) pipe schedules in NPS up to 36 in. (2) The traditional thickness designations: Standard weight, (ST) Extra strong, and (XS) Double extra strong (XXS) differ from schedules and are used for NPS up to 48 in.

14. Fion Zhang/ Charlie Chong 574-4

17. Fion Zhang/ Charlie Chong 4.1.1.2 Pipe wall thicknesses are designated as pipe schedules in NPSs up to 36 in. (914 mm). The traditional thickness designations- standard weight, extra strong, and double extra strongdiffer from schedules and are used for NPSs up to 48 in. (1219 mm). NPS1/8 ~ NPS36 pipe schedules . NPS1/8 ~ NPS48 / / 574-4

18. Fion Zhang/ Charlie Chong 574-4 NPS14 OD=NPS NPS12 ODNPS

19. Fion Zhang/ Charlie Chong 574-4 Joint Efficiency ASME B31.3 Table 302.3.4

20. Fion Zhang/ Charlie Chong NPS16 574-4 Ej?

21. Fion Zhang/ Charlie Chong NPS16 574-4 Ej ?

22. Fion Zhang/ Charlie Chong Ej ? 574-4

29. Fion Zhang/ Charlie Chong 574-4 ERW / Ej = 0.85

30. Fion Zhang/ Charlie Chong 574-4 Ej = 1

32. Fion Zhang/ Charlie Chong SSAW Welded Pipe 574-4 Ej = 0.80~1.0 () Ej = 0.85~1.0 ()

34. Fion Zhang/ Charlie Chong SAW Welded Pipe () 574-4 Ej = 0.8 ~ 1.0 () / 0.85 ~1.0 ()

35. Fion Zhang/ Charlie Chong // 574-4

36. Fion Zhang/ Charlie Chong NPS 13 574-4

37. Fion Zhang/ Charlie Chong 4.1.1.3 Allowable tolerances in pipe diameter differ from one piping material to another. Table 3 lists the acceptable tolerances for diameter and thickness of most ASTM ferritic pipe standards 574-4

38. Fion Zhang/ Charlie Chong 574-4 4.1.1.3 Allowable tolerances in pipe diameter differ from one piping material to another. Table 3 lists the acceptable tolerances for diameter and thickness of most ASTM ferritic pipe standards. The actual thickness of seamless piping can vary from its nominal thickness by a manufacturing tolerance of as much as 12.5 %. The under tolerance for welded piping is 0.01 in. (0.25 mm). Cast piping has a thickness tolerance of +1/16 in. (1.6 mm) and 0 in. (0 mm), as specified in ASTM A530 12.5 % 0.01 (0.25mm) ASTM A530: 1 /16(1.6) -0(0)

39. Fion Zhang/ Charlie Chong 4.1.1.4 Cast iron piping is generally used for nonhazardous service, such as water; it is generally not recommended for pressurized hydrocarbon service. The standards and sizes for cast iron piping differ from those for welded and seamless piping. , . 574-4

40. Fion Zhang/ Charlie Chong : , 574-4

41. Fion Zhang/ Charlie Chong 574-4 : , !

42. Fion Zhang/ Charlie Chong 574-4 4.1.2 Fiber Reinforced Plastic (FRP) Pipe (FRP) 4.1.2.3 FRP ,,,,/ ,, ,,, ,.

43. 4.1.2.4 ~ 4.1.2.9 ASME B31.3 Chapter VII AWWA FRP ,,,,. ,,,. FRB , ,,. . . . . . ,. , , . Fion Zhang/ Charlie Chong

44. 4.1.2.8 Standardized FRP piping systems commonly called commodity piping are manufactured for a variety of services and are sold as products with a predetermined design, resin, corrosion barrier and structure FRP . Fion Zhang/ Charlie Chong

45. 4.1.3 Small-bore Piping (SBP) NPS 2 4.1.4 Linings Fion Zhang/ Charlie Chong

46. Clad pipe has a metallic liner that is an integral part of the plate material (1) rolled or explosion bonded before fabrication of the pipe Fion Zhang/ Charlie Chong

47. They may instead be separate strips of metal fastened to the pipe by welding referred to (2) strip lining Fion Zhang/ Charlie Chong

48. Corrosion-resistant metal can also be applied to the pipe surfaces by various (3) weld overlay processes. Fion Zhang/ Charlie Chong

49. Some common nonmetallic lining materials for piping are concrete, castable refractory, plastic, and thin-film coatings , , Fion Zhang/ Charlie Chong

51. Fion Zhang/ Charlie Chong 574-4 4.2 Tubing

52. . ODNPS Fion Zhang/ Charlie Chong

53. 4.3 Valves Fion Zhang/ Charlie Chong

55. 4.3 Valves 4.3.1 General The basic types of valves are gate, globe, plug, ball, diaphragm, butterfly, check, and slide valves. : , , ,., , , . ,: ASME B16.34 or API 599, API 600, API 602, API 603, API 608, or API 609, as applicable. Fion Zhang/ Charlie Chong

56. 4.3.2 Gate Valves (), . 2 full-ported valve. reducing port valve , Fion Zhang/ Charlie Chong

57. Gate Valves ,. Full-ported valve. Reducing port valve , Fion Zhang/ Charlie Chong

58. Fion Zhang/ Charlie Chong Reducing Port Valve 574-4 Reducing port valve ,

61. Fion Zhang/ Charlie Chong 4.3.3 Globe Valves -(?) , . , () ,, , 574-4

63. Fion Zhang/ Charlie Chong ,, , 574-4

66. Fion Zhang/ Charlie Chong 4.3.4 Plug Valves . . 574-4

69. Fion Zhang/ Charlie Chong 4.3.5 Ball Valves ,. . 574-4

72. Fion Zhang/ Charlie Chong 4.3.6 Diaphragm Valves , /, , 250o F/121o C . 574-4

75. Fion Zhang/ Charlie Chong 4.3.7 Butterfly Valves . . . . . : 574-4

77. Fion Zhang/ Charlie Chong 4.3.8 Check Valves .: / 574-4 /

81. Fion Zhang/ Charlie Chong 574-4 / /

82. Fion Zhang/ Charlie Chong 4.3.9 Slide Valves : . . . . 574-4

85. Fion Zhang/ Charlie Chong 4.4 Fittings 574-4

86. Fion Zhang/ Charlie Chong 4.4 Fittings 4.4.1 Metallic Fittings . 574-4

90. Fion Zhang/ Charlie Chong 4.5 Flanges 574-4

91. Fion Zhang/ Charlie Chong 4.5 Flanges 4.5.1 Metallic Flanges ASME B16.5 NPS 24 ASME B16.47 NPS 26 ~ NPS 60. 574-4

94. Fion Zhang/ Charlie Chong 574-4 Welding Neck Flange

95. Fion Zhang/ Charlie Chong Lap-Joint Flange 574-4

96. Fion Zhang/ Charlie Chong Socket Welded Flange 574-4

97. Fion Zhang/ Charlie Chong Slip-on Flange 574-4

98. Fion Zhang/ Charlie Chong Blind Flange 574-4

99. Fion Zhang/ Charlie Chong Thread Flange 574-4

100. Fion Zhang/ Charlie Chong 4.6 Expansion Joints 574-4

101. Fion Zhang/ Charlie Chong 574-4 Expansion joints are devices used to absorb dimensional changes in piping systems, such as those caused by thermal expansion, to prevent excessive stresses/strains being transmitted to other piping components, and connections to pressure vessels and rotating equipment. While there are several designs, those commonly found in a plant are metallic bellows and fabric joint designs. Metallic bellows can be single wall or multilayered, containing convolutions to provide flexibility. Often, these joints will have other design features, such as guides, to limit the motion of the joint or type of loading applied to the joint. Metallic bellows are often found in high-temperature services and are designed for the pressure and temperature of the piping system. Fabric joints are often used in flue gas services at low pressure and where temperatures do not exceed the rating of the fabric material. (1) (2) . . .

109. Fion Zhang/ Charlie Chong 5 Pipe-joining Methods 574-4 5 Pipe-joining Methods 5.1 General 5.2 Threaded Joints 5.3 Welded Joints 5.4 Flanged Joints 5.5 Cast Iron Pipe Joints 5.6 Tubing Joints 5.7 Special Joints 5.8 Nonmetallic Piping Joints.

110. Fion Zhang/ Charlie Chong 5.1 General 574-4

111. Fion Zhang/ Charlie Chong 5.1 General 5.2 Threaded Joints NPS2 24(610)(ASME B1.20.1) 574-4

112. Fion Zhang/ Charlie Chong Threaded Joint Fittings 574-4

113. Fion Zhang/ Charlie Chong 574-4 5.3 Welded Joints

114. Fion Zhang/ Charlie Chong 574-4 5.3 Welded Joints 5.3.1 General NPS2 ,. 5.3.2 Butt-welded Joints . 5.3.3 Socket welded Joints .

115. Fion Zhang/ Charlie Chong 5.3.4 Welded Branch Connections , , , . 574-4

117. Fion Zhang/ Charlie Chong 5.4 Flanged Joints 574-4

118. Fion Zhang/ Charlie Chong 5.4 Flanged Joints : ,; , , . 574-4

119. Fion Zhang/ Charlie Chong 5.5 Cast Iron Pipe Joints 574-4

120. Fion Zhang/ Charlie Chong 5.5 Cast Iron Pipe Joints : flanged, packed, sleeve, hub-and-spigot-end or hub-and-plain-end, or bell-and spigot-end or bell-and-plain-end type. Push-on joints with rubber or synthetic ring gaskets are available. Clamped joints are also used. Threaded joints are seldom used for cast iron. 574-4

122. Fion Zhang/ Charlie Chong bell-and spigot-end 574-4

123. Fion Zhang/ Charlie Chong Sleeve Joint / Clamped joints 574-4

124. Fion Zhang/ Charlie Chong Packed Joint 574-4

125. Fion Zhang/ Charlie Chong 574-4 5.6 Tubing Joints

126. Fion Zhang/ Charlie Chong 574-4 5.6 Tubing Joints , ,

127. Fion Zhang/ Charlie Chong 5.7 Special Joints : : , 574-4

128. Fion Zhang/ Charlie Chong 5.8 Nonmetallic Piping Joints 574-5

129. Fion Zhang/ Charlie Chong 5.8 Nonmetallic Piping Joints 5.8.1 General API570 / 574 : FRB/GRP Some common joint designs in FRP pipe systems include a bell-and-spigot, butt-and-wrap, taper-taper and flange-flange. : , bell-and-spigot , butt-and-wrap , taper-taper . flange-flange 574-5

131. Fion Zhang/ Charlie Chong 5.8.2 Bell and Spigot/Taper-taper 574-5

132. Fion Zhang/ Charlie Chong 574-5 5.8.2 Bell and Spigot /Taper-taper

133. Fion Zhang/ Charlie Chong 574-5 Bell and Spigot

134. Fion Zhang/ Charlie Chong 5.8.3 Butt and Wrap 574-5

135. Fion Zhang/ Charlie Chong Butt and Wrap 574-5

136. Fion Zhang/ Charlie Chong 5.8.4 Flange-flange 574-5

137. Fion Zhang/ Charlie Chong 6 Reasons for Inspection 574-6 6 Reasons for Inspection 6.1 General 6.2 Safety 6.3 Reliability and Efficient Operation 6.4 Regulatory Requirements

139. Fion Zhang/ Charlie Chong 6.1 General The primary purposes of inspection are to identify active deterioration mechanisms and to specify repair, replacement, or future inspections for affected piping. These actions should result in increased operating safety, reduced maintenance costs, and more reliable and efficient operations. API 570 provides the basic requirements for such an inspection program. () : (1), (2) (3) 574-6

140. Fion Zhang/ Charlie Chong 6.2 Safety 574-6

141. Fion Zhang/ Charlie Chong 6.2 Safety Adequate inspection is a prerequisite for maintaining this type of piping in a safe, operable condition. In addition, federal regulations such as OSHA 29 CFR 1910.119 has mandated that equipment, including piping, which carries significant quantities of hazardous chemicals be inspected according to accepted codes and standards which includes API 570. OSHA 29 CFR 1910.119 , (API 570). 574-6

143. Fion Zhang/ Charlie Chong 6.3 Reliability and Efficient Operation 574-6

144. Fion Zhang/ Charlie Chong 6.3 Reliability and Efficient Operation Thorough inspection and analysis and the use of detailed historical records of piping systems are essential to the attainment of acceptable reliability, efficient operation, and optimum on-stream service. Piping replacement schedules can be developed to coincide with planned maintenance turnaround schedules through methodical forecasting of piping service life. (1) , (2) 574-6 , , ,.

145. Fion Zhang/ Charlie Chong 6.4 Regulatory Requirements 574-6

146. Fion Zhang/ Charlie Chong 6.4 Regulatory Requirements API 570 was developed to provide an industry standard for the inspection of in-service process piping. It has been adopted by a number of regulatory and jurisdictional authorities. In addition, in some areas other requirements have been specified for the inspection of piping. Each plant should be familiar with the local requirements for process piping inspection. API570. 574-6

147. Fion Zhang/ Charlie Chong : Reasons for Inspection (//) + 574-6

148. Fion Zhang/ Charlie Chong 7 Inspection Plans 574-7 7 Inspection Plans 7.1 General 7.2 Developing an Inspection Plan 7.3 Monitoring Process Piping 7.4 Inspection for Specific Damage Mechanisms 7.5 Integrity Operating Envelopes

150. Fion Zhang/ Charlie Chong 7.1 General API570 574-7 An inspection plan should contain the inspection tasks, scope of inspection, and schedule required to monitor damage mechanisms and assure the mechanical integrity of the piping components in the system. (1) (2) (3) -

151. Fion Zhang/ Charlie Chong : a) (,, CUI) b) c) ; d) ; e) f) . 574-7

152. Fion Zhang/ Charlie Chong 574-7 : 1., 2., 3.. :

153. Fion Zhang/ Charlie Chong 7.2 Developing an Inspection Plan 574-7

154. Fion Zhang/ Charlie Chong 7.2 Developing an Inspection Plan (1) , (2) (3) (4) : Operating temperature ranges, operating pressure ranges, process fluid corrosive contaminant levels, piping material of construction, piping system configuration, process stream mixing and inspection/maintenance history./ 574-7 .

155. Fion Zhang/ Charlie Chong . , API NACE . , 574-7

156. Fion Zhang/ Charlie Chong (1): ;CML (CUI); 574-7

157. Fion Zhang/ Charlie Chong (2): (Dead Legs) (PMI); 574-7

158. Fion Zhang/ Charlie Chong , 1. RBI580 2. API570 574-7

159. Fion Zhang/ Charlie Chong 7.2.1 Risk-Based Inspection (RBI) Plans 574-7

160. Fion Zhang/ Charlie Chong Inspection plans based upon an assessment of the likelihood of failure and the consequence of failure of a piping system or circuit is RBI. RBI may be used to determine inspection intervals and the type and extent of future inspection/examinations. API 580 details the systematic evaluation of both the likelihood of failure and consequence of failure for establishing RBI plans. API 581 details an RBI methodology that has all of the key elements defined in API 580. API 580/581 RBI - (1)(2) RBI (1) (2) (3) 574-7

161. Fion Zhang/ Charlie Chong 7.2.1.2 . API571 . 574-7

162. Fion Zhang/ Charlie Chong 7.2.1.3 (1) (), (2) , (3) , (4) (5) 7.2.1.4 API 580. 574-7

163. Fion Zhang/ Charlie Chong 7.2.1.5 RBI : ,; , , 574-7

164. Fion Zhang/ Charlie Chong 7.2.2 Interval-based Inspection Plans 574-7

165. Fion Zhang/ Charlie Chong 574-7 Inspection plans which are based upon the specific inspection intervals for the various types of piping inspection and of specific types of damage are considered interval based. The types of inspection where maximum intervals are defined in API 570 include: external visual, CUI, thickness measurement, injection point, S/A interface, SBP, auxiliary piping and threaded connections. The interval for inspections is based upon a number of factors, including the corrosion rate and remaining life calculations, piping service classification, applicable jurisdictional requirements and the judgment of the inspector, the piping engineer, or a corrosion specialist. The governing factor in the inspection plan for many piping circuits is the piping service classification. (API570 )

166. Fion Zhang/ Charlie Chong 574-7 API570

167. Fion Zhang/ Charlie Chong API570- CUI Inspection -API570 574-7

168. Fion Zhang/ Charlie Chong 7.2.3 Classifying Piping Service API 570, . 1 ~ 3 Factors to consider when classifying piping are: Toxicity, Volatility Combustibility location of the piping w.r.t to personnel / equipment experience and history 574-7

170. Fion Zhang/ Charlie Chong 574-7 Class?

173. Fion Zhang/ Charlie Chong 574-7 API 570- Classification of piping for inspection

174. Fion Zhang/ Charlie Chong 574-7 API 570- 6.3.4.2 Class 1 Services with the highest potential of resulting in an immediate emergency if a leak were to occur are in Class 1. Such an emergency may be safety or environmental in nature. Examples of Class 1 piping include, but are not necessarily limited to those containing the following. Flammable services that can auto-refrigerate and lead to brittle fracture. Pressurized services that can rapidly vaporize during release, creating vapors that can collect and form an explosive mixture, such as C2, C3, and C4 streams. Fluids that can rapidly vaporize are those with atmospheric boiling temperatures below 50 F (10 C) or where the atmospheric boiling point is below the operating temperature (typically a concern with high-temperature services). Hydrogen sulfide (greater than 3 % weight) in a gaseous stream. Anhydrous hydrogen chloride. Hydrofluoric acid. Piping over or adjacent to water and piping over public throughways (refer to Department of Transportation and U.S. Coast Guard regulations for inspection of over water piping). Flammable services operating above their auto-ignition temperature.

175. Fion Zhang/ Charlie Chong 574-7 API 570- 6.3.4.3 Class 2 Services not included in other classes are in Class 2. This classification includes the majority of unit process piping and selected off-site piping. Typical examples of these services include but are not necessarily limited to those containing the following: on-site hydrocarbons that will slowly vaporize during release such as those operating below the flash point, hydrogen, fuel gas, and natural gas, on-site strong acids and caustics.

176. Fion Zhang/ Charlie Chong 574-7 API 570- 6.3.4.4 Class 3 Services that are flammable but do not significantly vaporize when they leak and are not located in high-activity areas are in Class 3. Services that are potentially harmful to human tissue but are located in remote areas may be included in this class. Examples of Class 3 service include but are not necessarily limited to those containing the following: on-site hydrocarbons that will not significantly vaporize during release such as those operating below the flash point; distillate and product lines to and from storage and loading; tank farm piping; off-site acids and caustics.

177. Fion Zhang/ Charlie Chong 574-7 API 570- 6.3.4.5 Class 4 Services that are essentially nonflammable and nontoxic are in Class 4, as are most utility services. Inspection of Class 4 piping is optional and usually based on reliability needs and business impacts as opposed to safety or environmental impact. Examples of Class 4 service include, but are not necessarily limited to those containing the following: steam and steam condensate; air; nitrogen; water, including boiler feed water, stripped sour water; lube oil, seal oil; ASME B31.3, Category D services; plumbing and sewers.

178. Fion Zhang/ Charlie Chong Some NDT methods used (information) 574-7

179. Fion Zhang/ Charlie Chong Profile Radiography 574-7

180. Fion Zhang/ Charlie Chong 574-7 Profile Radiography

181. Fion Zhang/ Charlie Chong 574-7 , LT

182. Fion Zhang/ Charlie Chong 574-7 UT

183. Fion Zhang/ Charlie Chong 574-7 UT

184. Fion Zhang/ Charlie Chong 574-7 UT A-Scan

185. Fion Zhang/ Charlie Chong 574-7 UT B-Scan

186. Fion Zhang/ Charlie Chong 574-7 UT B-Scan B-Scan of Notched Steel Sheet

187. Fion Zhang/ Charlie Chong 574-7 UT C-Scan

188. Fion Zhang/ Charlie Chong 574-7 TOFD

189. Fion Zhang/ Charlie Chong 574-7 VI

190. Fion Zhang/ Charlie Chong 574-7 http://www.sonotronndt.com/vidGallery.htm TOFD

191. Fion Zhang/ Charlie Chong ACFM 574-7

192. Fion Zhang/ Charlie Chong ACFM 574-7

193. Fion Zhang/ Charlie Chong 574-7 Thermography

194. Fion Zhang/ Charlie Chong Thermography 574-7

195. Fion Zhang/ Charlie Chong Thickness Gauging 574-7

196. Fion Zhang/ Charlie Chong Smart Pigging 574-7

197. Fion Zhang/ Charlie Chong 574-7 Smart Pigging

198. Fion Zhang/ Charlie Chong Thickness Gauging 574-7

199. Fion Zhang/ Charlie Chong 574-7 Thickness Gauging

200. Fion Zhang/ Charlie Chong 7.3 Monitoring Process Piping 574-7

201. Fion Zhang/ Charlie Chong 7.3 Monitoring Process Piping 7.3.1 General , ; (1) (2) (3) (4) A key to the effective monitoring of piping corrosion is identifying and establishing CMLs. CMLs are designated areas in the piping system where measurements are periodically taken. Ultrasonic (UT) thickness measurements are obtained within examination points on the pipe. Thickness measurements may be averaged within the examination point. By taking repeated measurements and recording data from the same points over extended periods, damage rates can more accurately be calculated or assessed. 574-7

202. Fion Zhang/ Charlie Chong 574-7 7.3.2 Piping Circuits 7.3.2.1 1. piping metallurgy; 2. process fluid and its phase (e.g. gas, liquid, two phase, solid); . 3. flow velocity; 4. temperature; 5. pressure; 6. changes in temperature, velocity, pressure, direction, phase, metallurgy, or pipe cross section; ,,,,,, 7. injection of water or chemicals; 8. process fluid contaminants; 9. mixing of two or more streams; 10. piping external conditions, including coating/painting, insulation, and soil conditions, as applicable; 11.stagnant flow areas (e.g. dead-legs).

203. Fion Zhang/ Charlie Chong 574-7 7.3.2.2 . , , , . , , CML, .

204. Fion Zhang/ Charlie Chong 7.3.3 Identifying Locations Susceptible to Accelerated Corrosion : / (,,,) CML. CML 574-7

205. Fion Zhang/ Charlie Chong 7.3.4 Accessibility of CMLs . ; , , , . 574-7

206. Fion Zhang/ Charlie Chong 574-7 Confined space entry - . ()

207. Fion Zhang/ Charlie Chong 7.4 Inspection for Specific Damage Mechanisms 574-7

208. Fion Zhang/ Charlie Chong 7.4 Inspection for Specific Damage Mechanisms : injection points, process mix points, dead-legs, CUI, S/A interfaces, service specific and localized corrosion, erosion and erosion-corrosion, environmental cracking, corrosion beneath linings and deposits, fatigue cracking, creep cracking, brittle fracture, freeze damage, contact point corrosion, dew-point corrosion. 574-7

209. Fion Zhang/ Charlie Chong 7.4.1 Injection Points ,. . 574-7 : 123D 25

210. Fion Zhang/ Charlie Chong 574-7 : More extensive inspection should be applied to the injection point circuit in an area beginning 12 in. (300 mm) upstream of the injection nozzle and continuing for at least 10 pipe diameters downstream of the injection point

211. Fion Zhang/ Charlie Chong 7.4.2 Process Mix Points ; , , NACE Publication 34101 . , , 574-7

212. Fion Zhang/ Charlie Chong 7.4.3 Dead-legs . , In hot piping systems, the high point area can corrode due to convective currents set up in the dead-leg. Additionally, water can collect in dead-legs that can freeze in colder environments resulting in pipe rupture. , , . ,,. 574-7

213. Fion Zhang/ Charlie Chong 7.4.4 CUI / 574-7

214. Fion Zhang/ Charlie Chong 7.4.4.1 Insulated Piping Systems Susceptible to CUI : 1. those exposed to mist over-spray from cooling water towers; 2. those exposed to steam vents; 3. those exposed to deluge systems; 4. those subject to process spills or ingress of moisture or acid vapors; 5. carbon steel piping systems, including ones insulated for personnel protection, operating between 10o F (12o C) and 350o F (175o C); CUI is particularly aggressive where operating temperatures cause frequent or continuous condensation and re-evaporation of atmospheric moisture; 574-7

215. Fion Zhang/ Charlie Chong 6. carbon steel piping systems which normally operate in service above 350o F (175o C), but are in intermittent service; (- ) 7. dead-legs and attachments that protrude from insulated piping and operate at a different temperature than the operating temperature of the active line; 8. austenitic stainless steel piping systems operating between 120o F (60o C) and 400o F (205o C) (susceptible to chloride SCC); ,- 574-7

216. Fion Zhang/ Charlie Chong 9. vibrating piping systems that have a tendency to inflict damage to insulation jacketing providing a path for water ingress; ( ) 10. steam traced piping systems that can experience tracing leaks, especially at tubing fittings beneath the insulation; - 11.piping systems with deteriorated insulation, coatings, and/or wrappings; bulges or staining of the insulation or jacketing system or missing bands (bulges can indicate corrosion product buildup); ,, 574-7

217. Fion Zhang/ Charlie Chong 574-7 7.4.4.2 Typical Locations on Piping Circuits Susceptible to CUI CUI 1. , ,,, 2. (/). 3. . 4. . 5. , , . 6. CML/TML .

218. Fion Zhang/ Charlie Chong 7.4.5 Soil-to-air (S/A) Interface / If the buried piping has satisfactory cathodic protection as determined by monitoring in accordance with API 570, excavation is required only if there is evidence of coating or wrapping damage. If the buried piping is uncoated at grade, consideration should be given to excavating 6 in. (150 mm) to 12 in. (300 mm) deep to assess the potential for hidden damage. Alternately, specialized UT techniques such as guided wave can be used to screen areas for more detailed evaluation. API 570, . , 612 , API570 9.3.1 , 574-7

219. Fion Zhang/ Charlie Chong , API570 API570, 9.3.6 External and Internal Inspection Intervals 574-7

220. Fion Zhang/ Charlie Chong 25) Soil-to-air (S/A) interfaces for buried piping are a location where localised corrosion may take place. If the buried part is excavated for inspection, how deep should the excavation be to determine if there is hidden damage? (API574-7.4.5) a) 12 to 18 inches b) 6 to 12 inches c) 12 to 24 inches d) 6 to 18 inches 574-7 26) At concrete-to-air and asphalt-to-air interfaces of buried piping without cathodic protection, the inspector look for evidence that the caulking or seal at the interface has deteriorated and allowed moisture ingress. If such a condition exists on piping systems over ______ years old, it may be necessary to inspect for corrosion beneath the surface before resealing the joint. (API574-7.4.5) a) 8 b) 5 c) 15 d) 10

221. Fion Zhang/ Charlie Chong 7.4.6 Service-specific and Localized Corrosion 7.4.6.1 CML 574-7

222. Fion Zhang/ Charlie Chong 7.4.6.2 , a. downstream of injection points and upstream of product separators (e.g. hydroprocessor reactor effluent lines); b. dew-point corrosion in condensing streams, (e.g. overhead fractionation); - c. unanticipated acid or caustic carryover from processes into non-alloyed piping systems or in the case of caustic, into non-post-weld heat treated (PWHTed) steel piping systems; 574-7

223. Fion Zhang/ Charlie Chong d. where condensation or boiling of acids (organic and inorganic) or water is likely to occur; e. where naphthenic or other organic acids can be present in the process stream. f. where high-temperature hydrogen attack can occur (see API 941); 574-7

224. Fion Zhang/ Charlie Chong g. ammonium salt condensation locations in hydro-processing streams (see API 932-B); h. mixed-phase flow and turbulent areas in acidic systems, also hydrogen grooving areas; i. where high-sulfur streams at moderate-to-high temperatures exist; j. mixed grades of carbon steel piping in hot corrosive oil service [450 F (232 C)] or higher temperature and sulfur content in the oil greater than 0.5 % by weight); / 0.5% wt 574-7 NOTE Non-silicon-killed steel pipe (e.g. ASTM A53 and API 5L) can corrode at higher rates than silicon-killed steel pipe (e.g. ASTM A106) in high-temperature sulfidation environments. (e.g. ASTM A53 and API 5L) (e.g. ASTM A106) http://richmond.chevron.com/Files/richmond/pdf/IndustryAlertvFinal2.pdf

225. Fion Zhang/ Charlie Chong k. under deposit corrosion in slurries, crystallizing solutions, or coke- producing fluids;/ l. chloride carryover in catalytic reformer units, particularly where it mixes with other wet streams; m. welded areas subject to preferential attack; n. hot spot corrosion on piping with external heat tracing; note 1 o. steam systems subject to wire cutting, graphitization, or where condensation occurs. -/ 574-7 NOTE 1: In services which become much more corrosive to the piping with increased temperature (e.g. sour water, caustic in carbon steel), corrosion or SCC can develop at hot spots that develop under low flow conditions. , , .

226. Fion Zhang/ Charlie Chong 27) An example of service-specific and localised corrosion is- API574, 7.4.6) a) Corrosion under insulation in areas exposed to steam vents b) Unanticipated acid or caustic carryover from processes into non-alloyed piping c) Corrosion in deadlegs d) Corrosion of underground piping at soil-to-air interface where it ingresses or egresses. 574-7

227. Fion Zhang/ Charlie Chong 7.4.6.3 , , (,). , lock- out/tag-out 574-7

228. Fion Zhang/ Charlie Chong 7.4.7 Erosion and Erosion-corrosion Erosion can be defined as the removal of surface material by the action of numerous individual impacts of solid or liquid particles, or cavitation. It can be characterized by grooves, rounded holes, waves, and valleys in a directional pattern. Erosion is usually in areas of turbulent flow such as at changes of direction in a piping system or down stream of control valves where vaporization can take place. . : (1) / (2) . , . 574-7

229. Fion Zhang/ Charlie Chong This type of corrosion occurs at high-velocity and high-turbulence areas. Examples of places to inspect include: 1. downstream of control valves, especially where flashing or cavitation is occurring; 2. downstream of orifices; 3. downstream of pump discharges; 4. at any point of flow direction change, such as the outside radii of elbows; 5. downstream of piping configurations (welds, thermowells, flanges, etc.) that produce turbulence particularly in velocity sensitive systems, such as ammonium hydrosulfide and sulfuric acid systems. (, ,) , . 574-7 , , UT ()RT

231. Fion Zhang/ Charlie Chong574-7 28) Erosion can be defined as:(API574, 7.4.8) a) Galvanic corrosion of a material where uniform losses occur b) Removal of surface material by action of numerous impacts of solid or liquid particles c) Gradual loss of material by a corrosive medium acting uniformly on the material surface d) Pitting on the surface of a material to the extent that a rough uniform loss occurs 29) A combination of corrosion and erosion results in significantly greater metal loss that can be expected from corrosion or erosion alone. This type of loss occurs at: a) High-velocity and high-turbulence areas b) Areas where condensation or exposure to wet hydrogen sulphide or carbonates occur c) Surface-to-air interfaces f buried piping d) Areas where gradual loss of material occurs because of a corrosive medium

232. Fion Zhang/ Charlie Chong 7.4.8 Environmental Cracking 7.4.8.1 SCC . Some piping systems can be susceptible to environmental cracking due to: : upset process conditions CUI, unanticipated condensation exposure to wet hydrogen sulfide or carbonates. 574-7

233. Fion Zhang/ Charlie Chong Examples of this include the following. 574-7 1. Chloride SCC of austenitic stainless steels resulting from moisture and chlorides under insulation, under deposits, under gaskets, or in crevices. 2. Polythionic acid SCC of sensitized austenitic alloy steels resulting from exposure to sulfide/moisture condensation/oxygen. 3. Caustic SCC (sometimes known as caustic embrittlement). 4. Amine SCC in nonstress-relieved piping systems. 5. Carbonate SCC in alkaline systems. 6. Wet hydrogen sulfide stress cracking and hydrogen blistering in systems containing sour water. 7. Hydrogen blistering and hydrogen induced cracking (HIC) damage. This has not been as serious of a problem for piping as it has been for pressure vessels. It is listed here because it is considered to be environmental cracking and can occur in piping although it has not been extensive. One exception where this type of damage has been a problem is longitudinally-welded pipe fabricated from plate materials.

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235. Fion Zhang/ Charlie Chong 7.4.8.2 , When the inspector suspects or is advised that specific circuits may be susceptible to environmental cracking, he/she should schedule supplemental inspections. : (PT, MT, WFMT), LRUT, UT, RT) . Such inspections can take the form of surface NDE [liquid penetrant examination technique (PT) or wet fluorescent magnetic particle examination technique (WFMT)], UT, or eddy current examination technique (ET). Where available, suspect spools may be removed from the piping system and split open for internal surface examination. 574-7

236. Fion Zhang/ Charlie Chong 7.4.8.3 ,. If environmental cracking is detected during internal inspection of pressure vessels, and the piping is considered equally susceptible, the inspector should designate appropriate piping spools, upstream and downstream of the pressure vessel, for environmental cracking inspection. When the potential for environmental cracking is suspected in piping circuits, inspection of selected spools should be scheduled before an upcoming turnaround. Such inspection should provide information useful in forecasting turnaround maintenance. , , ,(). , , . 574-7

237. Fion Zhang/ Charlie Chong574-7 30) Environmental cracking of austenite stainless steels is caused many times by:- (API574-7.4.8) a) Exposing areas to high-velocity and high-turbulence streams b) Excessive cyclic stresses that are often very low c) Exposure to chlorides from salt water, wash-up water, etc. d) Creep of the material by long time exposure to high temperature and stress Q- When the potential for environmental cracking is suspected in piping circuits, inspection of selected spools should be scheduled; (2013/June) a) Within 6 months. b) 5 years c) 10 years d) Before an upcoming turnaround.

238. Fion Zhang/ Charlie Chong574-7 31) When the inspector suspects or is advised that specific piping circuits may be susceptible to environmental cracking, the inspector should: (API574- 7.4.8) a) Call in a piping engineer for consultation. b) Investigate the history of the piping circuit. c) Obtain advice from a Metallurgical Engineer. d) Schedule supplemental inspections. 32) If environmental cracking is detected during internal inspection of pressure vessels, what should the inspector do? (API574-7.4.8 / 2013 June) a) The inspector should designate appropriate piping spools upstream and downstream of the vessel to be inspected if piping is susceptible to environmental cracking. b) The inspector should consult with a metallurgical engineer to determine extent of the problems c) The inspector should review history of adjacent piping to determine if it has ever been affected. d) The inspector should consult with a piping engineer to determine the extent of the problems.

239. Fion Zhang/ Charlie Chong 7.4.9 Corrosion Beneath Linings and Deposits ,. 7.4.9.1 If external or internal coatings, refractory linings, and corrosion-resistant linings are in good condition and there is no reason to suspect a deteriorated condition behind them, it is usually not necessary to remove them for inspection of the piping system. , , , /. . 574-7

240. Fion Zhang/ Charlie Chong 7.4.9.2 () , .. , , . The effectiveness of corrosion-resistant linings is greatly reduced due to breaks or holes in the lining. The linings should be visually inspected for separation, breaks, holes, and blisters. If any of these conditions are noted, it may be necessary to remove portions of the internal lining to investigate the effectiveness of the lining and the condition of the metal piping beneath the lining. Alternatively, ultrasonic inspection from the external surface can be used to measure the base metal thickness. When the lining is metallic and is designed to be fully bonded, external ultrasonic examination can also be used to detect separation, holes and blisters. 574-7

241. Fion Zhang/ Charlie Chong 7.4.9.3 Refractory linings used to insulate the pipe wall can spall or crack in service, causing hot spots that expose the metal to oxidation and creep cracking. Periodic temperature monitoring via visual, infrared, temperature indicating paints should be undertaken on these types of lines to confirm the integrity of the lining. Corrosion beneath refractory linings can result in separation and bulging of the refractory. Microwave examination technique (MW) can examine the refractory for volumetric flaws and for separation from the shell surface. If bulging or separation of the refractory lining is detected, portions of the refractory may be removed to permit inspection of the piping beneath the refractory. Otherwise, thickness measurements utilizing UT or profile RT may be obtained from the external metal surface. , // ., , . MW/UT/RT . 574-7

242. Fion Zhang/ Charlie Chong 7.4.9.4 Where operating deposits, such as coke are present on the internal pipe surface, NDE techniques employed from the outside of the pipe such as profile radiography , UT, and/or ET should be used to determine whether such deposits have active corrosion beneath them. , (), UT, ET, . 574-7

243. Fion Zhang/ Charlie Chong 574-7 32) If environmental cracking is detected during internal inspection of pressure vessels, what should the inspector do? (API574-7.4.9/2013 June) a) The inspector should designate appropriate piping spools upstream and downstream of the vessel to be inspected if piping is susceptible to environmental cracking. b) The inspector should consult with a metallurgical engineer to determine extent of the problems c) The inspector should review history of adjacent piping to determine if it has ever been affected. d) The inspector should consult with a piping engineer to determine the extent of the problems.

244. Fion Zhang/ Charlie Chong 574-7 33) If external or internal coatings or refractory liners on a piping circuit are in good condition, what should an inspector do? (API574-7.4.9/2013 June) a) After inspection, select a portion of the liner for removal b) The entire liner should be removed for inspection c) Selected portions of the liner should be removed for inspection d) After inspection, if any separation, breaks, holes or blisters are found, it may be necessary to remove portions of the lining to determine the condition under it. Q- Refractory linings used to insulate the pipe wall can spall or crack in service, causing hot spots that expose the metal to oxidation and creep cracking. NDT method undertaken on these types of lines to confirm the integrity of the lining is; (2013 June) a) Infrared thermography b) High temperature UT c) WFMT d) PT

245. Fion Zhang/ Charlie Chong 574-7 34) What course of action should be followed it a coating of coke is found on the interior of a large pipe of a reactor on a Fluid Catalytic Cracking Unit? (API574-7.4.9/ 2013June) a) Determine whether such deposits have active corrosion beneath them. If corrosion is present, thorough inspection in selected areas may be required. b) The coke deposits should be removed from the area for inspection. c) The coke deposits may be ignored the deposits will probably protect the line from corrosion. d) Consult with a Process Engineer and a Metallurgist on the necessity of removing the coke deposits.

247. Fion Zhang/ Charlie Chong 7.4.10 Fatigue Cracking 7.4.10.1 Fatigue cracking of piping systems can result from excessive cyclic stresses that are often well below the static yield strength of the material. , . (1) (2) () (3) . - 574-7 The onset of low-cycle fatigue cracking is often directly related to the number of heat-up/cool-down cycles experienced. For example, trunnions or other attachments that extend beyond the pipe insulation can act as a cooling fin that sets up a situation favorable to thermal fatigue cracking on the hot pipe. Thermal fatigue can also occur at mix points when process streams at different operating temperatures combine. Excessive piping system vibration (e.g. machine or flow induced) can also cause high-cycle fatigue damage.

248. Fion Zhang/ Charlie Chong 7.4.10.2 Fatigue cracking can typically be first detected at points of high stress intensification such as branch connections. Locations where metals having different coefficients of thermal expansion are joined by welding can be susceptible to thermal fatigue. Preferred NDE methods of detecting fatigue cracking include PT, magnetic particle examination technique (MT), and angle beam UT when inspecting from the OD for ID cracking. Suggested locations for UT on elbows would include the 3 and 9 oclock positions. Acoustic emission examination technique (AE) also may be used to detect the presence of cracks that are activated by test pressures or stresses generated during the test. MT/PT/UT AE AE- : UT39 574-7

249. Fion Zhang/ Charlie Chong 7.4.10.3 It is important for the owner/user and the inspector to understand that fatigue cracking is likely to cause piping failure before detection with any NDE methods. Of the fatigue cycles required to produce failure, the vast majority are required to initiate cracking and relatively few cycles are required to propagate the crack to failure. As such, proper design and installation to prevent fatigue cracking are important. , , , . , . 574-7

250. Fion Zhang/ Charlie Chong () 574-7

251. Fion Zhang/ Charlie Chong () 574-7

253. Fion Zhang/ Charlie Chong 574-7 Beach marks - Macro

254. Fion Zhang/ Charlie Chong 574-7 Striation marks Striation marks

257. Fion Zhang/ Charlie Chong Corrosion Fatigue 574-7

258. Fion Zhang/ Charlie Chong 574-7 http://www.me.metu.edu.tr/courses/me307/useful_info.htm

259. Fion Zhang/ Charlie Chong 574-7 http://www.fgg.uni-lj.si/kmk/esdep/master/wg12/l0200.htm

260. Fion Zhang/ Charlie Chong 574-7 35) Fatigue cracking of piping systems may result from a) Embrittlement of the metal due to it operating below its transition temperature b) Erosion or corrosion / erosion that thin the piping where it cracks c) Excessive cyclic stresses that are often well below the static yield strength of the material d) Environmental cracking caused by stress corrosion due to the presence of caustic, amine, or other substance. 36) Where can fatigue cracking typically be first detected? a) At points of low-stress intensification such as reinforced nozzles b) At points of high-stress intensification such as branch connections c) At points where cyclic stresses are very low d) At points where there are only bending or compressive stresses.

261. Fion Zhang/ Charlie Chong 574-7 37) What are the preferred NDE methods for detecting fatigue cracking? (API574-7.4.10/ 2013 June) a) Eddy current testing ultrasonic A-scan testing, and / or possibly hammer testing b) Liquid penetrant testing, magnetic particle testing and / or possibly acoustic emission testing. c) Visual testing, eddy current testing and / or possibly ultrasonic testing d) Acoustic emission testing, hydro-testing, and / or possibly ultrasonic testing.

262. Fion Zhang/ Charlie Chong 574-7 2013 June Paper Beach Mark -the characteristic fracture surface marks on fatigue fracture.

263. Fion Zhang/ Charlie Chong 7.4.11 Creep Cracking 574-7

264. Fion Zhang/ Charlie Chong 7.4.11 Creep Cracking 7.4.11.1 Creep is dependent on time, temperature, and stress. Creep cracking can eventually occur at design conditions since some piping code allowable stresses are in the creep range. Cracking is accelerated by creep/ fatigue interaction when operating conditions in the creep range are cyclic. Particular attention should be given to areas of high stress concentration. If excessive temperatures are encountered, mechanical property and microstructural changes in metals can also take place, which can permanently weaken equipment. An example of where creep cracking has been experienced in the industry is in 1 1/4 Cr steels above 900o F (482o C). , . . , . 1 1/4 Cr steels >900 Deg F (482 Deg C). 574-7

269. Fion Zhang/ Charlie Chong 574-7 Damage mechanism in weldment of 2.25Cr1Mo steel under creepfatigue loading

271. Fion Zhang/ Charlie Chong 574-7 http://www.nationalboard.org/Index.aspx?pageID=181

272. Fion Zhang/ Charlie Chong 7.4.11.2 NDE methods of detecting creep cracking include PT, MT, UT, RT, ET and alternating current field measurement (ACFM), in-situ metallography and dimensional verification (i.e. strapping pipe diameter) are other common practices for detection. NDE volumetric examination methods, including profile RT and UT, can be used for detection of creep cracking. AE can be utilized to identify active creep cracking. The examination can be conducted whilst piping is in or out of operation. When the examination is conducted, the probability of detecting creep cracks can be a function of crack orientation. Any piping examined out of operation requires a pressure stimulus to activate any damage present. PT,MT, UT, RT, ET( ACFM). () . RTUT . AE. , . AE . 574-7

273. Fion Zhang/ Charlie Chong574-7 38) Creep is dependent on: a) Time, temperature, and stress b) Material, product contained, and stress c) Temperature, corrosive medium, and load d) Time, product contained and load 39) An example of where creep cracking has been experienced in the industry is in the problems experienced with cracking of 1.25 % Chrome steels operating at temperatures above ______F. a) 500 b) 900 c) 1000 d) 1200

274. Fion Zhang/ Charlie Chong 7.4.12 Brittle Fracture 574-7

275. Fion Zhang/ Charlie Chong 7.4.12 Brittle Fracture 7.4.12.1 Carbon, low-alloy, and other ferritic steels can be susceptible to brittle failure at or below ambient temperatures. In some cases, the refrigerating effect of vaporizing liquids such as ammonia or C2 or C3 hydrocarbons can chill the piping and promote brittle fracture in material that may not otherwise fail. Brittle fracture usually is not a concern with relatively thin wall piping. Most brittle fractures have occurred on the first application of a particular stress level (that is, the first hydrotest or overload) unless critical defects are introduced in service. The potential for a brittle failure should be considered when pressure testing or more carefully evaluated when pressure testing equipment pneumatically or when adding any other additional loads. Special attention should be given to low-alloy steels (especially 2 1/4 Cr-1 Mo material), because they can be prone to temper embrittlement, and to ferritic stainless steels. , , . , C2C3 . : 2 1/4 Cr-1 Mo () . 574-7

Api574 my self study notes

Engineering

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