API 570

1 SCOPE
Q – What activities are covered by API 570?
A – I.R.R.A

Q – What piping system can be applied to API 570?

A – Any piping system

Q – Who can use API 570?

A – Organizations having access to authorized inspection agency, repair organization, qualified engineers,
examiners, etc.

1.2 SPECIFIC APPLICATIONS

1.2.1 Included fluid services

• API 570 applies to piping systems for process fluids, hydrocarbons, flammable or toxic fluid
services

Raw, intermediate, and finished petroleum or chemical products

Catalyst lines

Hydrogen, natural gas, fuel gas, flare systems

Sour water and hazardous waste streams above threshold limits

Hazardous chemical above threshold limits, as defined by jurisdiction

1.2.2 Excluded and optional piping systems

• Excluded fluid services

Hazardous fluid below threshold limits

Water (including fire protection systems), steam, steam-condensate, BFW, and Category D
fluid as per B31.3

• Excluded/optional piping systems

On movable structures

Integral part of components

Internal piping or tubing of boilers

Inside pressure vessels

OD not exceeding NPS ½”

Non-metallic or polymeric or glass-lined piping

1.3 FITNESS FOR SERVICE

• Can use API 579 to assess damage

2. REFERENCES

3. DEFINITIONS
Alteration Mixing tee Rerating
Authorized inspection agency On-stream Secondary process piping
Authorized piping inspector Owner/user Small bore piping ≤ 2 NPS
Auxiliary piping Piping circuit Soil-to-air interface
Critical check valves Piping engineer Temper embrittlement
Deadlegs Piping system Temporary repairs
Design temperature Primary process piping Test point – 2” vs. 3”
Injection points Renewal Material verification program
Level bridle Repair Off-site piping
MAWP Repair organization On-site piping

4. OWNER/USER INSPECTION ORGANIZATION

4.1 GENERAL
Q – Who shall exercise control of piping system inspection program?
A – Owner/user

Q – Who shall exercise control of inspection frequencies?

A – Owner/user
 API 570
Q – Who shall exercise control of piping maintenance?
A – Owner/user

Q – Who shall control activities relating to piping I.R.R.A?

A – Owner/user

4.2 INSPECTOR EDUCATION

4.3 RESPONSIBILITIES

4.3.1 Owner/user
Q – Who is responsible for developing, documenting, implementing, executing, and assessing piping
inspection systems and procedures?
A – Owner/user

Q – What should be included in the inspection manual or procedures?

A – Reporting structure, training requirements, etc.

4.3.2 Piping engineer (D.E.R.A)

Q – Who is responsible for activities involving Design, engineering Review, Analysis, or Evaluation of
piping system?
A – Engineer

4.3.3 Repair organization

Q – Who is responsible to provide materials, equipment, quality control, and workmanship necessary to
maintain and repair piping systems?
A – Repair organization

4.3.4 Authorized piping inspector (T.I.E)

Q – Who is responsible to ensure API 570 requirements on Inspection, Examination, and Testing, are met
during inspections, repairs, or alterations on piping?
A – Authorized inspector

Q – Who may assist authorized inspector to perform visual inspection?

A – Properly trained and qualified individuals

• All examination results must be evaluated and accepted by authorized inspector

4.3.5 Other personnel

5. INSPECTION & TESTING PRACTICES

5.1 RBI

Q – What are important steps in assessing likelihood of piping failure?

A – Identifying & evaluating potential degradation mechanisms

Q – What are essential elements of RBI?

A – Likelihood of failure & consequence of failure

Q – What is the basis for likelihood assessment?

A – Based on all forms of degradation that could be expected on a piping circuit

Q – What else should be evaluated in likelihood assessment?

A – Effectiveness of inspection practices and techniques used to detect the expected degradation
mechanisms

Q – When should likelihood assessment be made?

A – Every time when making equipment or process change
 API 570
Q – What are other factors considered by RBI assessment?
A – Construction materials, piping circuit design conditions relative to operating conditions, effectiveness
of corrosion monitoring programs, etc.

Q – What are usually considered by consequence assessment?

A – Potential incidents due to fluid release, including explosion, fire, toxic exposure, health &
environmental impacts

• All RBI assessments shall be thoroughly documented & clearly define factors contributing to both
likelihood and consequence of piping failure

5.2 Preparation

Q – What is extremely important when opening pipe for examining internal surfaces?
A – Safety precaution

Q – What should be taken before opening any pipe system?

A – Safety precautions

Q – What are the integral parts of safety practices?

A – Procedures for segregating piping systems, installing blinds, and testing tightness

Q – What should be done when opening pipe?

A–  Isolate pipe from all sources of harmful liquids, gases, or vapors
 Purge pipe to remove all oil and toxic or flammable gases and vapors

Q – What should inspection personnel do before starting work?

A – Get permission to work from operating personnel responsible for piping system

• NDT equipment used is subject to operating facility’s requirements for electrical equipment

Q – What should inspection personnel know before doing inspection?

A – Be familiar with prior inspection results and repairs, by briefly reviewing the piping history

5.3 Inspection for specific corrosion & cracking

Q – Who should provide specific attention to the need for inspection of piping for various types of failure
mechanisms?
A – Owner/user

5.3.1 Injection points

Q – What normally goes wrong with injection point?
A – Accelerated or localized corrosion from normal or abnormal operating conditions

Q – What to do when found accelerated or localized corrosion at injection points?

A–  Treat them as separate inspection circuits
 Thoroughly inspect on regular schedule

Q – What is the recommended upstream minimum limit for injection point circuit?
A – The greater of 12” or 3D

Q – What is the recommended downstream minimum limit for injection point circuit?
A – The lesser of 2nd change in flow direction or 25 feet after 1st change in flow direction. Or until next
vessel

Q – Where are the typical locations for measuring thickness within an injection point circuit, subject to
localized corrosion?
A – See Figure 5-1 – F.I.S.U.D. → Fittings, Impingement, Straight, Upstream, & Downstream

Q – What are the preferred methods to inspect injection points?

A – RT, UT → to establish minimum thickness at each TML. Can also use UT scanning if temperatures
allowed
 API 570

Q – Where should extensive inspection be performed during periodic scheduled inspections?

A – From 12” upstream of injection nozzle → 10D downstream of injection point. Additionally, measure all
TML within injection point circuit

5.3.2 Deadlegs
Q – What should inspector monitor on deadlegs?
A – Wall thickness at stagnant section & connection to the active line

Q – What is the common failure mode at deadlegs in hot piping system?

A – Corrosion at high-point due to convective currents set up in the deadlegs

5.3.3 CUI
Q – What should be included in external inspection of insulated piping?
A – Inspect insulation for conditions that could lead to CUI

Q – What are the most common forms of CUI?

A–  Localized corrosion of CS
 Chloride SCC of ASS

5.3.3.1 Insulated piping systems susceptible to CUI

• Areas susceptible to CUI are those exposed to:
→ Overspray from cooling water towers
→ Steam vents
→ Deluge systems
→ Process spills, ingress of moisture, or acid vapors
→ Insulated CS piping operating between 25oF → 250oF, especially where there is continuous
condensation & re-evaporation
→ Insulated ASS piping operating between 150oF → 400oF
→ Insulated CS piping operating above 250oF but in intermittent service
→ Deadlegs and attachments protruding from insulated piping and operating at different
temperature than the active line

5.3.3.2 Common locations on piping systems susceptible to CUI

• The typical specific locations are:
→ All penetrations / breaches in insulation jacketing system

Deadlegs – vents, drains

Pipe hangers and supports

Valves and fittings

Bolted pipe shoes

Steam tracer tubing penetrations
→ Point of insulation termination at flanges
→ Damaged insulation sections
→ Bulged insulation areas – usually due to corrosion product build up
→ Insulated CS pipe fittings attached to high-alloy piping systems
• Pay attention to insulation plug locations where pipe thickness measurements are usually made.
They should be promptly put back and sealed.

5.3.4 Soil-to-air interface

• The soil-to-air interfaces for buried piping without CP should be part of external piping inspections
• Inspection at grade should check coating damage, bare pipe, and pit depth measurements

Q – Significant corrosion was found when inspecting soil-to-air interface. What next?
A – Perform UT measurement & excavate pipe to determine if corrosion is localized to S/A interface, or
more pervasive

Q – What is the extent of inspection if CP is adequate?

A – Excavate only if there is evidence of coating or wrapping damage

Q – How to inspect if pipe is not coated at grade?

A – Excavate 6” to 12” deep to assess the potential for hidden damage
 API 570

Q – What to look for in concrete-to-air and asphalt-to-air interfaces, of buried piping without CP?
A – Evidence of caulking or seal deterioration, which will allow moisture ingress.

Q – What to do if found evidence of caulking or seal deterioration while inspecting concrete-to-air and
asphalt-to-air interfaces, of buried piping without CP, where piping system is older than 10 years?
A – Inspect corrosion beneath surface before resealing the joint

5.3.5 Service-specific and localized corrosion

Q – What are the objectives of a piping inspection program?

A–  To identify potential for service-specific and localized corrosion
 To identify TML points

Q – What are the 3 elements of an effective piping inspection program?

A–  Inspector knowledgeable of service and potential location of corrosion
 Extensive use of NDT
 Communication from operation personnel when process upsets may affect corrosion rates

• The common locations for service-specific and localized corrosions are:

→ Downstream of injection points
→ Upstream of product separators – hydroprocess reactor effluent lines
→ Dew-point corrosion in condensing streams – overhead fractionation
→ Unexpected acid or caustic carryover from processes into nonalloyed piping systems
→ Caustic carryover into piping system not PWHT
→ Ammonium salt condensation locations in hydroprocess streams
→ Mixed-phase flow and turbulent areas in acidic systems
→ Hot spot corrosion on piping with external steam tracing. SCC can occur at hot spots with low-
flow conditions

5.3.6 Erosion and corrosion/erosion

• Defined as removal of surface material by the action of numerous individual impacts of solid or
liquid particles
• Characterized by grooves, rounded holes, waves, valleys in directional pattern

Q – Where are the common locations of erosion?

A – Areas with turbulent flow → change of direction, downstream control valve where vaporization may
take place

• Erosion damage can be increased by streams with large quantities of solid or liquid particles
flowing at high velocities

Q – Where are the common locations of erosion/corrosion?

A – Areas with turbulent flow + high-velocity

• Common areas susceptible to erosion/corrosion

→ Downstream of control valve, especially when there is flashing
→ Downstream of orifices
→ Downstream of pump discharges
→ Point of flow direction change e.g. inside & outside radii of elbow
→ Downstream of piping configurations, such as welds, thermowelds, and flanges

Q – What are typical velocity-sensitive systems?

A – Ammonium hydrosulfide and sulfuric acid systems

Q – How to inspect areas with erosion/corrosion?

A – Use NDE methods that will give thickness data over a wide range → UT scanning, RT, ECT
 API 570
5.3.7 Environmental cracking

Q – What are the typical causes of SCC?

A – Upset process conditions, CUI, unexpected condensation, exposure to wet hydrogen sulfide or
carbonates

• Examples of environmental cracking / SCC

Chloride SCC of ASS, due to moisture and chlorides under insulation, under deposits, under
gaskets, in crevices

Polythionic acid SCC of sensitized ASS, due to exposure to sulfide, moisture condensation,
or oxygen

Caustic SCC, sometimes called caustic embrittlement

Amine SCC in piping systems not stress relieved

Carbonate SCC

SCC where wet hydrogen sulfide exists e.g. sour water

Hydrogen blistering & HIC

Q – What should the inspector do if he suspects presence of environmental cracking?

A–  Schedule supplemental inspections, such as:
 NDE → DPT, WFMT, UT
 Removal of suspected pipe spool to be split open for internal surface examination
 Perform inspection before TA to forecast maintenance requirements before TA

Q – What to do if environmental cracking is detected during internal inspection of pressure vessel?

A – Inspect associated piping
 Inspector to designate piping spools upstream and downstream of pressure vessel for
environmental cracking inspection

5.3.8 Corrosion beneath linings and deposits

Q – If external or internal coatings, refractory linings, and corrosion-resistant linings are in good condition,
then what?
A – Corrosion is unlikely and no need to remove them to inspect piping

Q – What can reduce effectiveness of corrosion-resistant linings?

A – Breaks, holes in the lining

Q – What to inspect lining for?

A – Separation, breaks, holes, blisters

Q – What are the inspection options if these defects are found?

A–  Remove portions of internal lining to investigate effectiveness of lining and condition of metal
piping beneath lining
 Perform UT to measure wall thickness and detect separation, holes, and blisters

Q – What to do if found bulging or separation of refractory lining?

A–  Remove portion of refractory to inspect piping beneath refractory
 Alternatively, perform UT from external surface

Q – What to consider if operating deposits such as coke, are present on piping surface?
A – Determine if such deposits have active corrosion beneath them. Larger areas may need to be
inspected.
 Large lines – Remove deposits at selected critical areas for spot examination
 Small lines – Remove selected spools or perform NDE e.g. RT in selected areas

5.3.9 Fatigue cracking

• Due to excessive cyclic stresses well below static yield strength → high-cycle fatigue or low-cycle
fatigue

Q – What is the main cause of low-cycle fatigue?

A – Number of heat-up and cool-down cycles
 API 570
Q – What is the main cause of high-cycle fatigue?
A – Excessive piping system vibration

Q – Where are typical locations of fatigue cracking?

A – Points of high-stress intensification → branch connections

Q – Where are typical locations of thermal fatigue?

A – Locations where metals having different coefficients of thermal expansion are joined by welding
(dissimilar weld metal joints)

Q – What are the preferred NDE for fatigue?

A – DPT, MPT, AE for cracks activated by test pressures or stresses generated during test

Q – Why is fatigue failure difficult to detect by NDE?

A – Because it usually happens before application of NDE. Of the total number of fatigue cycles required
to produce failure, the vast majority of cycles are required to initiate crack, and relatively fewer cycles
are required to propagate crack to failure

Q – What is the best defense against fatigue cracking?

A – Proper design and installation to prevent INITIATION

5.3.10 Creep cracking

• Creep depends on time, temperature, & stress
• If operating range is cyclic, cracking is accelerated by interaction between creep & fatigue
• Excessive temperatures may weaken equipment by affecting mechanical properties &
microstructural changes

Q – Which areas should be given attention?

A – Areas of high stress concentration

Q – What is the creep range for 1¼Cr steels?

A – Above 900oF

Q – What are NDE methods for detecting creep?

A – DPT, MPT, UT, RT, AE, replica

5.3.11 Brittle fracture

• Affecting CS & ferritic steels at or below ambient temperatures
• Usually not a concern in thin wall structure
• Usually encountered during first application of a particular stress (e.g. hydrotest) unless critical
defects are introduced during service

Q – When to re-evaluate possibility of brittle fracture?

A–  During another re-hydrotesting
 Pneumatic testing
 Adding additional loads

• 2¼Cr-1Mo steels most prone to temper embrittlement

Q – Which group of SS is prone to brittle fracture?

A – Ferritic SS

5.3.12 Freeze damage

• Expansion of water inside piping at subfreezing temperatures
• After severe freezing weather, check piping for freeze damage before it thaws. Leakage from
existing rupture may have been temporarily prevented by frozen liquid
• Potential areas – low points, driplegs, and deadlegs containing water
 API 570

5.4 Types of inspection & surveillance

5.4.1 Internal visual inspection

• When possible & practical, only for large diameter
• Performed as per API 510 since nature is similar to pressure vessel
• Can also use remote visual inspection techniques
• Remove selected section of pipe spool and then split it open, when necessary

5.4.2 Thickness measurement

• To determine:
→ Internal condition
→ Remaining thickness of piping components
• Done on-stream or off-stream, by inspector or examiner

5.4.3 External visual inspection

• To determine:
→ Condition of outside of piping
→ Insulation system
→ Painting and coating systems
→ Associated hardware
→ Signs of misalignment, vibration, and leakage
• May be done when pipe is in service

Q – What to do if there’s corrosion product buildup at pipe support contact areas?

A – Lift pipe support. Be careful if pipe is in service

Q – What other things should be checked by external inspection?

A – Condition of pipe hangers and supports – cracked or broken hangers, bottoming out of spring
supports, displaced shoes, improper restraint conditions.

Q – How do you check vertical support dummy legs?

A - Ensure vertical support dummy legs not filled with water which will cause external corrosion of the
pressure piping or internal corrosion of support leg

Q – How do you check horizontal support dummy legs?

A – Ensure no moisture is trapped against pressure piping, due to slight displacements from horizontal

Q – How to inspect bellows expansion joints?

A – Visually inspect for unusual deformations, misalignment, displacements that may exceed design

• Inspector should examine piping for presence of any field modifications or temporary repairs not
recorded on piping drawings or records
• Inspector should be alert for presence of any components that may not be suitable for long term
operations e.g. improper flanges, temporary repairs (clamp), modifications (flexible hoses), valves
with improper specifications.
• Pay special attention to threaded components that are easily removed because they are easily
installed with improper components

Q – Who normally conducts periodic inspection?

A – Inspector

Q – Who else may conduct external inspections?

A – Qualified operating or maintenance personnel – who are qualified through an appropriate amount of
training

Q – Who is responsible for record keeping & repair inspection?

A – Inspector

Q – Who else may highlight conditions of piping?

A – People who frequent the area – and report findings to Inspector
 API 570

5.4.4 Vibrating piping and line movement

Q – Who shall report vibrating or swaying piping?

A – Operating personnel

Q – Who shall receive and assess the report of vibrating or swaying piping?
A – Engineering or inspection personnel

Q – What other findings should be reported?

A – Movements due to liquid hammer, liquid slugging in vapor lines, or abnormal thermal expansion

Q – How to inspect these lines?

A – Perform periodic MPT or DPT at restrained junctions, to check for fatigue cracks. Pay special attention
to branch connections

5.4.5 Supplemental inspection

Q – What are examples of supplemental inspection?

A–  RT or thermography to check for fouling or internal plugging
 Thermography to check for hot spots in internally lined refractory lines
 Inspection for environmental cracking
 AE, acoustic leak detection, thermography for remote leak detection and surveillance
 UT or RT for localized corrosion

5.5 Thickness measurement locations

5.5.1 General

Q – What shall influence selection of TML?

A – Potential for localized corrosion and service specific corrosion

5.5.2 TML monitoring

• Each piping system shall be monitored by taking thickness measurements at TML
• Piping with higher potential of failure consequences and those with high corrosion rates, should
have more TML and be inspected more often

Q – What are typical circumstances where number of TML may be reduced?

A–  Olefin plant cold side piping
 Anhydrous ammonia piping
 Clean noncorrosive hydrocarbon product
 High alloy piping for product purity

Q – Who shall be consulted before reducing TML?

A – Person knowledgeable in corrosion

Q – What can locate minimum thickness at TML?

A – UT or RT. Can also scan by using electromagnetic, and then follow up by UT or RT

Q – How to perform UT on TML?

A – Scan i.e. take several measurements on TML to look for localized thinning

Q – What thickness shall be recorded and used to calculate corrosion rates, remaining life, and next
inspection date?
A – The thinnest reading or an average of several measurement readings taken within the area of that
test point

Q – How to perform thickness measurement?

A – Include measurements at each of the 4 quadrants on pipe and fittings, especially the inside and
outside radius of elbow and tee, where corrosion/erosion could increase corrosion rates

Q – What else should be recorded?

 API 570
A – Location and value of thinnest reading

Q – Where should TML be established?

A– → Areas with continuing CUI
→ S/A interface
→ Areas with potential for localized corrosions
→ Areas with general corrosion

Q – How should TML be identified, to ensure repetitive measurements and accurate corrosion rate
determination?
A – Marked on drawings and on piping system

5.5.3 TML selection

Q – What should be considered when selecting locations of TML?

A – Patterns of corrosion to be expected & have been experienced

Q – What are examples of sources of relatively uniform corrosion?

A – High temperature sulfur corrosion and sour water corrosion (if velocities are not excessive)

Q – Why is additional TML required for a piping circuit?

A – Because corrosion is rarely uniform and usually localized

Q – When should more TML be selected?

A–  High safety or environmental risk when leaking
 High expected or experienced corrosion rates
 High potential for localized corrosion
 Complex piping configuration
 High potential for CUI

Q – When should less TML be selected?

A–  Low safety or environmental risk when leaking
 Relatively noncorrosive service
 Long, straight-run piping systems

Q – When can TML be eliminated altogether?

A–  Extremely low safety or environmental risk
 Noncorrosive, as demonstrated by history or similar service and operating under stable
operation parameters

5.6 Thickness measurement methods

• UT – most accurate for above NPS 1
• RT profile – preferred for NPS 1 and below
• RT profile – for locating areas to be measured, especially in insulated pipe or where localized
corrosion is suspected, then follow up with UT for actual thickness values, if practical. After this,
properly repair insulation.
• If insulation is not to be removed, use RT profile as alternative

Q – What to do if corrosion is nonuniform or remaining thickness approaching minimum required

thickness?
A – Take more readings, preferably using RT or UT

Q – When using UT at temperature above 150oF, what are the precautions?

A–  Use couplants or instruments that would give accurate readings at higher temperature.
 Adjust readings using appropriate temperature correction factor

Q – What factors can contribute to reduced accuracy of UT instruments?

A–  Improper calibration
 External coatings or scale
 Excessive surface roughness
 Curved surface
 Subsurface material flaws e.g. laminations
 API 570
 Thickness less than 1/8” for typical digital thickness gauges

• For corrosion rate to be valid, measurement on thinnest point must be repeated as closely as
possible to the same location
• Alternatively, use the minimum reading or an average of several test point readings

Q – What is another way to measure thickness of pipe when it is out service?

A – Use calipers through openings

Q – What are useful applications of calipers?

A – Determining approximate thickness of castings, forgings, valve bodies, as well as pit depth
approximations from CUI

Q – How to determine depth of local metal loss?

A – Use pit gauge

5.7 Pressure testing of piping systems

• Not normally conducted as part of routine inspection except:
→ Required by US Coast Guard for overwater piping
→ Required by local jurisdictions
→ After welded alterations
→ Specified by inspector or engineer
• Conducted as per ASME B31.3
• Conducted after any heat treatment (as opposed to B31.3 → before heat treatment)
• Before performing HT, take into account supporting structure design

Q – When are lower pressure tests conducted?

A – When testing tightness of piping systems

Q – Who shall designate pressure of lower pressure tests?

A – Owner/user

Q – When is it OK not to use water for testing?

A–  Possibility of damage due to freezing
 Water has other damaging effect to the piping system or process
 Water will be contaminated and its disposal present environmental problem

Q – What are the requirements if fluid other than water is used for pressure testing?
A–  Nontoxic
 If flammable, flash point at least 120oF
 No effect to the environment

Q – How to test piping made of 300 series SS?

A – Use potable water or steam condensate – to avoid chloride SCC. When done, completely drain pipe
and air blow pipe to ensure it is dry.

Q – What if potable water is not available or pipe cannot be immediately drained?

A – Use water with low chloride level, pH > 10, with addition of inhibitor to reduce risk of pitting and MIC

Q – What is potable water?

A – Maximum 250 ppm chloride, sanitized with chlorine or ozone

Q – How to test sensitized ASS subject to polythionic acid SCC?

A – Use alkaline- water solution

Q – What precaution should be taken if pressure test takes a long time and subject to thermal expansion?
A – Avoid excessive pressure

Q – When to use pneumatic test?

A – When HT is impractical due to temperature, structural, or process limitations

Q – What should be considered when doing pneumatic test?

 API 570
A – Risks to personnel and property. Use precautions outlined in B31.3

Q – What to do if pressure test exceeds safety valve set pressure?

A – Remove or blank the valve. Alternatively, use suitably designed clamp to hold down valve disk. Never
apply additional load to the spring by turning adjusting screw.

• Remove all other attachments which are not capable of taking the pressure test e.g. gauge glasses,
pressure gauges, expansion joints.
• Rupture disks should be blanked or removed
• When HT is completed, re-install all of the above

Q – What if the expansion joint cannot be removed?

A – Test at lower pressure

• When block valves are used to isolate piping, do not exceed the permissible seat pressure as
described in ASME B16.34 or applicable manufacturer data

5.8 Material verification and traceability

New work
• During repair or alteration of alloy material pressure retaining component, inspector shall ensure
the installation of new materials is consistent with selected material specification
• Material verification program as per API 578

Q – How to make the risk assessment above?

A-  100% verification
 Sampling percentage
 PMI for critical situations

Q – Who will do PMI?

A – Inspector or examiner

Existing material
• When pipe failure occurs due to incorrect material use, inspector shall consider further verification
of existing piping materials
• Extent of further verification depends on consequence of failure & likelihood of further material
errors

Q – What is a key component of a material verification program, consistent with API 578?
A – Procedures for prioritization and risk ranking of piping circuits, which may lead to retroactive PMI
testing

Q – If a material verification program finds an operating pipe component with the wrong spec, what next?
A–  Establish schedule for replacement – by owner/user & inspector, consulted by engineer
 Periodically inspect using appropriate NDE – by authorized inspector

5.9 Inspection of valves

• When servicing valves in the workshop, shop personnel must pay attention to any unusual
corrosion patterns or thinning on valve. If found, report to inspector.

• Valve bodies exposed to thermal cycling → inspect for thermal fatigue cracks
• Gate valves operating in erosive/corrosive service → perform thickness gauging between the seats
• Control or throttling valves in high-pressure drop or slurry service are susceptible to localized
corrosion/erosion in the body downstream of the orifice → remove valve from line for internal
inspection. Inspect downstream mating flange and piping for local metal loss
• Critical check valves → inspect visually and internally to ensure they will stop flow reversal, which
may lead to over pressurizing of upstream piping

How?
→ Ensure flapper is free to move, without excessive looseness from wear
→ No excessive wear on flapper stop → or else flapper will move past top dead central
position and remain in open position if check valve is mounted in vertical position
→ Flapper nut is secured to flapper bolt to avoid backing off in service
 API 570

• Leak checks on critical check valves are normally not required

• Use API 598 for valve body and/or pressure tests after servicing

5.10 Inspection of welds in-service

• For in-service piping, weld inspection is normally part of RT profile or internal inspection, for
detection of corrosion, especially preferential weld corrosion

Q – What to do if found preferential weld corrosion?

A – Inspect additional welds in same circuit

Q – If RT profile found crack-like defect in operating pipe, what next?

A–  Perform further inspection using RT or UT to assess magnitude of imperfection
 Determine if origin of defect is from service (i.e. environmental cracking) or from fabrication

Q – If crack is due to environmental cracking, then what?

A – Engineer will assess

Q – If crack is from fabrication, then what?

A – Perform inspection and/or engineering analysis to assess impact of weld quality on piping integrity

Q – How to perform above analysis?

A–  Inspector judgment
 Welding inspector judgment
 Engineer judgment
 FFS analysis

Q – What are issues to consider when assessing quality of existing welds?

A–  Original fabrication acceptance criteria
 Extent, magnitude, orientation of defect
 Length of time in service
 Operating versus design conditions
 Presence of secondary stresses
 Potential for fatigue loads
 Potential for environmental cracking
 Weld hardness

Note: Acceptance criteria for random/spot RT in B31.3 apply to new construction, to assess the probable
quality of all welds/welders in the system. Do not use these criteria when assessing in-service welds.

• Owner/user should engage industry-qualified UT shear wave examiner to do the following:

Detect interior surface (ID) breaking planar flaw when inspecting from outside (OD)

Detect, characterize, and size planar defect
• The purpose is to perform FFS & monitoring of flaw

5.11 Inspection of flanged joints

Q – How to ensure newly installed fasteners and gaskets meet spec?

A – Inspect markings on a representative sample

• Fasteners should extend completely through their nuts → can still be accepted if lack of complete
engagement is not more than 1 thread
• Excessively bent flanges → check their markings and thicknesses against engineering requirements
before taking corrective actions
• Flange and valve bonnet, and fasteners → inspect visually for corrosion, evidence of leak such as
stains, deposits, drips. Leaks can cause environmental cracking
• Clamped flange & pumped with sealant → check for leak at bolts, which can cause corrosion or
cracking (caustic). Affected fasteners should be renewed before any further repumping
 API 570

6. FREQUENCY & EXTENT OF INSPECTION

Q – What 2 factors determine frequency & extent of inspection?

A–  Forms of degradations affecting pipe
 Consequence of failure

Q – What is the basis of the simplified piping classification scheme, as per Section 6.2?
A – Consequence of failure

Q – What is the purpose of the simplified piping classification scheme, as per Section 6.2?
A – Establish frequency & extent of inspection

Q – What aspects are considered by a consequence assessment?

A – Potential for explosion, fire, toxicity, environmental impact, etc.

Q – What is the purpose of consequence assessment?

A – To establish piping circuit inspection strategy and define the following:
1. Inspection methods, scope, tools
2. Inspection frequency
3. Need for pressure testing after damage has been incurred, or after completion of repair or
modifications
4. Prevention & mitigation steps to reduce likelihood and consequence of piping failure

• RBI assessment may be used to increase or decrease:

1. Inspection limits as per Table 6-1
2. Extent of inspection as per Table 6-2

• If RBI is used to increase inspection interval limits or extent of inspection → conduct RBI
assessment at intervals not to exceed limits as per Table 6-1

Q – Who shall review and approve RBI assessments?

A – Engineer and inspector

6.2 Piping service classes

• All process piping shall be categorized into different classes → allows extra inspection efforts to be
focused on piping systems that have highest potential consequences in the event of failure or loss
of containment
• Higher classified systems → more extensive inspection at shorter intervals
• Classification → based on potential safety & environmental effects if leak (Not economic reason!)

Q – Who shall maintain record of process piping fluids handled, including their classification?
A – Owner/user

6.2.1 Class 1
• Highest potential of emergency (safety or environmental) if leak
1. Flammable services that may auto-refrigerate and lead to brittle fracture
2. Pressurized services that may rapidly vaporize during release, creating vapors that may collect
and form explosive mixture e.g. C2, C3, C4 streams. These fluids have atmospheric boiling
temperature below 50oF
3. Hydrogen sulfide (> 3% weight) in gaseous stream
4. Anhydrous hydrogen chloride
5. Hydrofluoric acid
6. Piping affecting public – located in high-activity area

6.2.2 Class 2
• Those not in Class1 or Class 3
1. On-site hydrocarbons that will slowly vaporize during release such as those operating below the
flash point
2. Hydrogen, fuel gas, natural gas
3. On-site strong acids and caustics
 API 570

6.2.3 Class 3
• Flammable services but do not significantly vaporize when leak & not located in high-activity area
• Services harmful to human tissue but located in remote areas
1. On-site hydrocarbons that do not significantly vaporize when leak such as those operating
below the flash point
2. Distillate and product lines connecting storage & loading
3. Off-site acids and caustics

6.3 Inspection intervals

Q – What are the criteria for establishing piping inspection intervals?
A– 1. Corrosion rate and remaining life calculations
2. Piping service classification
3. Applicable jurisdictional requirements
4. Judgment of inspector, engineer, engineer’s boss, corrosion specialist, → based on operating
conditions, inspection history, and current inspection results

Q – Who shall establish interval for thickness measurement, external visual inspection, internal &
supplemental inspections?
A – Owner/user

• Thickness measurement interval → the smaller of Table 6-1 or ½ pipe life, or even shorter when
appropriate

Table 6-1: Recommended maximum inspection intervals

Type of circuit Thickness measurements Visual external e.g. CUI
Class 1 5 years 5 years
Class 2 10 years 5 years
Class 3 10 years 10 years
Injection points 3 years By class
S/A interface - By class

Q – When are inspection intervals reviewed and adjusted?

A – After each inspection or significant change in operating conditions

Q – What must be considered when establishing inspection intervals?

A – General corrosion, localized corrosion, pitting, environmental cracking, other forms of deterioration

6.4 Extent of visual external and CUI inspections

• Use Table 6-1, or alternatively RBI, to determine interval of external visual inspection
• Bare piping – check conditions of:
→ Paint & coating systems
→ External corrosion
→ Others
• Insulated piping – check for:
→ Potential for CUI
→ Condition of insulation

• Results of visual inspection should be documented to facilitate follow up

• Type & extent of additional inspection for CUI (with no CUI experience) → refer to Table 6-2:
Recommended extent of CUI inspection following visual inspection

Q – What could be the consequence of a damaged insulation located at high elevation?

A – CUI at location well below and remote from the damage

Q – What is normally required to check for CUI?

A – RT or insulation removal and visual inspection

Q – If inspection has located CUI, what next?

A – Inspect additional areas, and where necessary, 100% of circuit

Q – What factors may affect likelihood of CUI?

 API 570
A – Local climatic conditions, insulation design, coating quality, service conditions

Q – What can be excluded from Table 6-2?

A – If remaining life > 10 years or adequately protected against external corrosion

• Condition of insulating system or outer jacketing e.g. cold box shell, should be periodically
observed by operating personnel, such as;
A. Effectively insulated piping system → no moisture ingression
B. Jacketed cryogenic piping system
C. Piping system in cold box which atmosphere is purged with inert gas
D. Piping system with temperature too low or too high to preclude presence of water

6.5 Extent of thickness measurement

• Representative TML sampling → data for all various types of components and orientations in each
circuit, including TML with the earliest renewal date. Should be as many as necessary.

6.6 Extent of small bore, auxiliary piping, and threaded-connections inspections

6.6.1 Small-bore piping inspection

Class Primary Secondary Auxiliary Threaded
1 By class By class Optional See left
2 By class Optional* Optional See left
3 By class Optional* Optional See left
* Dead legs → may want to check
Threaded → based on primary or secondary requirements

6.6.2 Auxiliary piping inspection

• As per table above
• Criteria to consider if inspection is needed:
A. Classification
B. Potential for environmental or fatigue cracking
C. Potential for corrosion based on experience with adjacent primary systems
D. Potential for CUI

6.6.3 Threaded-connection inspection

• Follow requirements for small-bore and auxiliary piping
• Pick only TML that can be RT
• Threaded-connections associated with machinery and subject to fatigue should be periodically
assessed and considered for possible renewal with thicker wall or upgrading to welded component
• Renewal schedule depends on:
A. Classification
B. Magnitude & frequency of vibration
C. Amount of unsupported weight
D. Current thickness
E. Corrosion rate
F. Etc.

7. INSPECTION DATA EVALUATION, ANALYSIS, AND RECORDING

7.1 Corrosion rate determination

7.1.1 Remaining life calculations

Remaining life = (tactual – trequired)/CR

Long term CR = (tinitial – tactual)/ time between tinitial and tactual

Short term CR = (tprevious – tactual) / time between tprevious and tactual

• Use the lower value of short term CR or long term CR, for data assessment
• Authorized inspector, in consultation with corrosion specialist, will select CR that best reflects
current process
 API 570

• Statistical treatment of data results must reflect actual condition of various pipe components
• Do not use statistical analysis employing point measurements on piping system with significant
localized unpredictable corrosion mechanisms

7.1.2 Newly installed piping systems or changes in service

Q – How to calculate the probable CR for newly installed piping system or where service condition is
changed?
A – SEPI 3
→ S - Similar material
→ E – Experience
→ P – Published data
→ I 3 – Inspection after no more than 3 months. Can use corrosion coupons or probes

7.1.3 Existing piping systems

• CR can be calculated either by short term or long term

7.2 Maximum allowable working pressure determination

Q – How to establish MAWP for piping system?

A – Use applicable code

• For known material – MAWP computations can be made if the following essential details of the
material comply with code spec:
A. Upper and/or lower temperature limits
B. Quality of materials & workmanship
C. Inspection requirements
D. Reinforcements of openings
E. Any cyclical service requirements

• For unknown materials – MAWP computations will use lowest grade material & joint efficiency

Q – When recalculating MAWP, what is the thickness to be used?

A – Actual thickness minus (2 x CR x time until next inspection)

7.3 Retirement thickness determination

• tmin ≥ trequired or tretirement

7.4 Assessment of inspection findings

• May use API 579 if pressure component is found with defect
Section 4 – General metal loss
Section 5 – Local metal loss
Section 6 – Pitting
Section 7 – Blisters & Laminations
Section 8 – Weld misalignment & shell distortions
Section 9 – Cracks
Section 11 – Fire damage

7.5 Piping stress analysis

• Stress analysis on support and adequacy is not normally done as part of piping inspection
• Usually done for rerating or modification
• Piping must be supported and guided so that:
A. Its weight is carried safely
B. Has sufficient flexibility
C. Does not vibrate excessively

• Piping flexibility becomes more important when

A. Large piping diameter
B. Large difference between ambient and operating temperature conditions

Q – What to do if external visual inspection observed unexpected movement of piping system?

 API 570
A – Authorized inspector to discuss with piping engineer and evaluate need for doing stress analysis

Q – How can stress analysis help determining inspection plans?

A – By indicating areas with highest stress, predicting movement when placed in operation, and solving
piping vibration problems. Inspection can then focus on areas prone to fatigue or creep, or identify
deterioration of guides or support, or areas that need additional guides to hold vibration without
restricting thermal expansion.

7.6 Reporting and records for piping system inspection

Q – What to do if observe increased CR?

A – Report to owner/user

Q – Who shall maintain permanent and progressive records?

A – Owner/user

Q – What shall these records contain?

A – Piping system service, classification, identification numbers, inspection intervals, name of individual
performing tests, date & type of testing,

• Computers are useful for:

A. Storing actual thickness readings
B. Calculating short & long term CRs
C. Highlighting areas of high CR, circuits overdue for inspection, close to retirement thickness

8. REPAIRS, ALTERATIONS, AND RERATING OF PIPING SYSTEMS

8.1 Repairs and alterations

8.1.1 Authorization

Q – Who shall carry out repair work?

A – Repair organization

Q – Who shall authorize repair work?

A – Authorized inspector

Q – When can authorization for alteration work be obtained?

A – After consulting the engineer

Q – Who shall approve alteration work?

A – Engineer

Q – Who shall designate hold points during repair or alteration?

A – Authorized inspector

8.1.2 Approval

Q – Who shall approve methods of design, execution, materials, WPS, examination, and testing?
A – Authorized inspector or engineer

Q – Who shall approve on-stream welding?

A – Owner/user

Q – Who shall approve repair of cracks that occurred while in-service e.g. vibration, thermal cycling,
expansion, environmental cracking?
A – Engineer
 API 570

8.1.3 Welding repairs (including on-stream)

8.1.3.1 Temporary repairs

Q – What are possible options while doing on-stream welding repair on corroded or damaged area?
A–  Full encirclement welded split sleeve
 Box-type enclosure

Q – Who shall design options above?

A – Engineer

• Do not use these options for longitudinal crack unless engineer says it will not propagate from
under sleeve

Q – Who shall be consulted when longitudinal crack is found?

A – Fracture analyst

Q – How to repair localized problem e.g. pinholes, pitting, on material with SMYS not more than 40 ksi?
A – Fillet welding of split coupling or patch plate over pitted area. Use same material as base metal,
unless approved by engineer

Q – How to repair minor leaks while pipe is in service?

A – Use properly designed enclosures if remaining thickness in areas next to leak is still thick enough to
take welding heat, and welding heat will not cause further damage from corrosive service

• Temporary repair should be removed and replaced with suitable permanent repair at next
opportunity unless approved and documented by piping engineer

8.1.3.2 Permanent repairs

Q – How to do this online?

A – Prepare weld groove which completely removes defect & build up, then do NDE

Q – How to this offline?

A – Cut out a cylindrical section & replace

Q – When can you use insert patch?

A–  Full penetration groove welds
 100% RT or UT for Class 1 & 2 piping
 Minimum 1” radius rounded corner

8.1.4 Nonwelding repairs (on-stream)

Q - How to repair locally thinned section or circumferential linear defects?

A – Bolted leak clamp, which shall include control of axial thrust load. Take into consideration effect of
clamping/crushing forces.

• During TA or other opportunities, remove temporary leak seal and leak dissipating devices,
including valves. After that, restore original integrity of piping system.

Q – Who shall be involved in determining repair methods and procedures?

A – Authorized inspector and/or engineer

Q – Who shall review repair procedure that includes leak sealing fluids?
A – Authorized inspector or engineer

Q – What should be considered when doing repair that includes leak sealing fluids?
A – Compatibility of sealant with leaking material, pumping pressure, risk of sealant affecting downflow
meters, PSV, etc.
 API 570

8.2 Welding & hot tapping

• Must be done as per B31.3 or original construction standard
• When piping is in operation, welding must be as per API Publication 2201 – which contains
Suggested Hot Tapping Checklist

8.2.1 Procedures, qualifications, records

Q – What shall repair organization do?

A–  Use qualified welders & procedures
 Maintain records of welding procedures and welder performance qualifications

8.2.2 Preheating & PWHT

8.2.2.1 Preheating
• As per original code & WPS
• Any exceptions – get engineer’s approval

Q – When should minimum preheat of 300oF be applied (in lieu of PWHT)?

A – When the following are met:
→ P-1 material - if pipe was initially PWHT
→ P-3 materials (except Mn-Mo steels) - Operating at temperature where toughness is reasonable
& No hazard associated with pressure testing, shutdown, and start up
→ Other material – Get engineer’s approval who should consider potential for environmental
cracking and whether the welding procedure will provide adequate toughness e.g. seal welds,
build up of thin areas, welding support clips

• Do not use preheating if intent of PWHT was to prevent environmental cracking

• Inspector should ensure minimum preheat temperature is measured and maintained
• Cover joint with insulation immediately after welding to prevent fast cooling

8.2.2.2 PWHT
• As per original code & B31.3

Q – When can local PWHT be substituted for 360-degree banding on local repairs on all materials?
A – When the following are met:
A. Reviewed and approved by engineer
B. Give consideration to base metal thickness, thermal gradients, material properties, changes
resulting from PWHT, need for full penetration welds, overall and local strains and distortions due
to heating of local restrained area
C. Minimum preheat of 300oF is maintained during welding
D. Maintain PWHT temperature at distance at least 2 times base metal thickness from weld
E. Monitor PWHT temperature using at lest 2 thermocouples
F. Apply controlled heat to any branch connection or attachment within PWHT area
G. PWHT is for code compliance, not for environmental cracking resistance

8.2.3 Design
• Butt joint shall be full penetration

Q – Who shall design temporary enclosures and repair?

A – Engineer

Q – Who shall design fillet-welded patches?

A – Engineer – who shall consider joint efficiency and crevice corrosion potential

Q – When can patch be used?

A – It is as per 8.1.3 and meets one of the following:
1. Provides strength equivalent to reinforced opening, designed as per applicable code
2. Absorbs membrane stress in a manner that;
→ Allowable membrane stress is not exceeded
→ Strain in patch plate does not cause fillet weld stresses exceeding allowable stresses for such
welds
 API 570
→ Have rounded corners

8.2.4 Materials
Q – What are the material requirements?
A-  Have known weldable quality
 Conform to applicable code
 Compatible with original material

8.2.5 NDE
• Acceptance as per applicable code or owner/user spec, unless otherwise specified in API 570

8.2.6 Pressure testing

• Normally required after repair or alteration
• Inspector to decide if practical and necessary
• If not done, use NDE, and after consultation with inspector and engineer
• If not done, must meet all requirements below:
A. New or replacement piping is pressure tested and examined as per design code, or welds
examined using NDE specified by authorized inspector
B. Closure weld is full-penetration butt weld between any pipe of equal diameter and thickness,
axially aligned, not miter cut, and equivalent materials. Acceptable alternatives:
 Slip-on flanges up to Class 150 & 500oF
 Socket welded flanges or socket welded unions for NPS 2 or less, and up to Class 150 &
500oF. Establish minimum 1/16” gap using spacer or suitable means. Socket weld is as
per ASME B31.3, with minimum 2 passes
C. 100% RT on butt welds or UT if acceptance criteria established
D. MT or DPT on root pass and completed welds for butt-welds, and completed welds for fillet-
welds

Q – Who shall perform UT on welds that have not been pressure tested or welds repair?
A – Industry qualified UT shear wave examiner, as specified by owner/user

8.3 Rerating

• Done by changing temperature rating or MAWP

• Must meet all requirements below:
A. Calculations – done by engineer or inspector
B. Code – done as per original design code or latest edition
C. Records – current inspection records show pipe is satisfactory for proposed service
D. Leak tested – as per code. Can be exempted if:

Had been done before at similar or greater pressure for new service condition

Increase of rating temperature does not affect allowable tensile stress
E. Relieving devices – are present, set at appropriate pressure, have appropriate capacity at set
pressure
F. Acceptable – to inspector or engineer
G. Components – valves, flanges, bolts, gaskets, expansion joints, are adequate for new
combination of pressure and temperature
H. Flexibility – adequate for design changes
I. Engineering records – updated

• Impact test – to justify decrease in minimum operating temperature, if required by code

9. INSPECTION OF BURIED PIPING

Q – What buried piping not applicable to API 570?

A – Those regulated by Department of Transportation

Q – What is significantly different about buried piping?

A – May have significant external deterioration due to corrosive soil conditions

• Nonmandatory references for buried piping → NACE documents RP0169, RP0274, RP0275, and API
651
 API 570

9.1 Types & methods of inspection

9.1.1 Above-grade visual surveillance

Q – What are typical indications of leak in buried piping?
A – Change in surface contour, soil discoloration, softening of paving asphalt, pool formation, bubbling
water paddles, noticeable odor

Q – What is one method of identifying problem areas?

A – Surveying route of buried piping

9.1.2 Close-interval potential survey

• To detect active corrosion points on the pipe’s surface

9.1.3 Pipe coating holiday survey

• To detect coating defects on buried coated pipes
• To evaluate coating serviceability for in-service buried piping
• Survey data will help determine coating effectiveness & rate of coating deterioration

9.1.4 Soil resistivity

Q – How to determine soil corrosiveness?
A – Measure soil resistivity: low resistivity→ more corrosive, especially in areas where pipe is exposed to
significant changes in soil resistivity

• Performed using Wenner Four-Pin Method as per ASTM G57

• Use Single-Pin method for parallel pipes or intersecting pipelines
• Use a soil box to get accurate results for measuring soil resistivity of soil samples from auger holes
or excavations

Q – Who should perform soil resistivity test?

A – Trained & experienced personnel

9.1.5 Cathodic protection monitoring

• Regular monitoring should include periodic measurement and analysis of pipe-to-soil potentials
• Critical CP component should be monitored more frequently e.g. impressed current rectifiers
• Done by trained & experienced personnel
• Reference documents: NACE RP0169 & API 651

9.1.6 Inspection methods

1. Intelligent pigging → Ensure five diameter bends or else pig will get stuck
2. Video cameras
3. Excavation → Last few inches of soil should be manually removed to prevent damaging pipe.
When line is too deep, shore the trench to prevent collapse, as per OSHA requirements. If
coating is damaged, it should be removed in that area to inspect condition of underlying metal.

9.2 Frequency & extent of inspection

9.2.1 Above-grade visual surveillance

• Done every 6 months

9.2.2 Pipe-to soil potential survey

• Done every 5 years
• Can also be done on piping with no CP or in areas where leaks have occurred due to external
corrosion
• Excavate areas if active corrosion cells are detected, to determine extent of corrosion damage

Q – What is required to locate active corrosion cells?

A – Continuous potential profile or close-interval survey

9.2.3 Pipe coating holiday survey

• Frequency of survey based on indications that other forms of corrosion controls are ineffective
 API 570

Q – What to do if you detect gradual loss of CP protection on a coated pipe?

Q – What to do if you detect external corrosion leaks on a coated pipe?
A – Perform pipe coating holiday survey

9.2.4 Soil corrosivity

• Done every 5 years on buried piping not protected by CP & > 100 feet long

Q – What are other considerations when doing soil resistivity?

A – Changes in soil chemistry, polarization resistance of soil and piping interface

9.2.5 Cathodic protection

• Interval as per NACE RP0169 or API 651

9.2.6 External and internal inspection intervals

Q – What to do if you suspect internal corrosion of buried piping?
A – Adjust the inspection methods and interval

• Watch out for accelerated internal corrosion in deadlegs

Q – How to determine external condition of piping without CP?

A– 1 - Pigging which can measure wall thickness or,
2 - Excavating as per frequency in Table 9-1

Table 9-1: Frequency of inspection for buried piping without CP

Soil resistivity (ohm-cm) Inspection interval (years)
<2,000 5
2,000 to 10,000 10
>10,000 15

Q –What to do on piping protected by CP if pigging has detected significant external corrosion?

A – Excavate

Q – What is the length of excavation?

A – 6 to 8 feet per location, exposing full circumference

Q – What to do if excavation found damaged coating?

A – Dig at more locations until extent of problem is identified

Q – What to do if average wall thickness is at or below retirement thickness?

A – Repair or replace

Q – What to do if pipe is contained inside a casing pipe?

A–  Check if water and/soil has entered casing.
 Verify:
 Both ends of casing extend beyond ground line
 Ends of casing are sealed, if casing is not self-draining
 Pressure-carrying pipe is properly coated and wrapped

9.2.7 Leak testing intervals

• An alternative or supplement to inspection
• Test pressure = 1.1 Maximum operating pressure
• Holding time: 8 hours
• Acceptance standard: Pressure cannot drop more than 5% during the last 4 hours of test
• Interval:

Good CP → same as Table 9-1

No CP → ½ of Table 9-1

Q – What may be helpful to locate leaks during leak testing?

A – Sonic measurements
 API 570

• Other options to determine integrity of buried piping:

Temperature-corrected volumetric test

Pressure test

Acoustic emission

Addition of tracer fluid e.g. helium or sulfur hexafluoride

9.3 Repairs to buried piping systems

9.3.1 Repair to coatings

• Criteria for repaired coating

Sufficient adhesion to prevent underfilm migration of moisture

Sufficient ductility to prevent cracking

No voids and gaps

Sufficient strength to resist damage due to soil stress and handling

Can support supplemental CP

• Use high-voltage holiday detector to test repaired coating

9.3.2 Clamp repairs

• If piping leaks are clamped and reburied → log location of clamp in inspection record & surface
mark at site. Indicate dates of installation and location of clamp
• All clamps are temporary
• During next opportunity, carry out permanent repair

9.3.3 Welded repairs

• As per Section 8.2

9.4 Records
• As per Section 7.6 + include date and location of installation of temporary clamps

APPENDIX C – EXAMPLES OF REPAIRS

C.1 Repairs
• May use gas metal-arc or shielded metal-arc processes (GMAW or SMAW)
• If temperature < 50oF, use low-hydrogen electrodes AWS E-XX16 or E-XX18 for materials
conforming to;

A-53 Grades A & B

A-106 Grades A & B

A-333

A-334

API 5L

• If temperature < 32oF, use these electrodes for all lower grade materials
• When different materials are used → consult engineer
• All repair and welding procedures must be as per API Publication 2201
• When welding sleeve-to-pipe fillet weld (as per Figure C-1: Encirclement repair sleeve) using low-
hydrogen electrodes AWS E-XX16 or E-XX18

Weld upward i.e. start from bottom to top

Electrode diameter should not exceed 5/32”
• When welding sleeve-to-sleeve butt joint (as per Figure C-1: Encirclement repair sleeve) using
low-hydrogen electrodes AWS E-XX16 or E-XX18

Electrode diameter should not exceed 3/16”

Fit the sleeve with suitable tape or backing strip to prevent fusing weld to the pipe side wall.
This may be omitted if pipe thickness along this weld has sufficient thickness as determined
by UT

C.2 Small repair patches

• Refer to Figure C-2: Small repair patches
• Patch size should not exceed ½ pipe diameter. If larger, use full encirclement sleeve repair as per
Figure C-1
 API 570
• Patch has rounded corner 1” radius
• Electrode diameter should not exceed 5/32”
• If base metal temperature < 32oF, use low-hydrogen electrodes
• Avoid weaving of weld beads when using low-hydrogen electrodes