Plant Inspection Manual (PIM)

Piping
General Piping Inspection Procedure

Revision Authorization
Rev. Changed Changed
Date Endorsed Endorsed Approved
No. Section By
1.0 12 Mar14 All SS PVR RJR

Summary of Revision (of attached document)

Rev.
Date By Description of Key Changes
No.
1.0 12 Mar 2014 PVR Initial Version

Document No: T13-X01-009 Revision No: 1.0 Cover Sheet: 1 of 13

Document Part: 361 Unclassified Issue Date: 12-Mar-14
 Plant Inspection Manual (PIM)
Piping
General Piping Inspection Procedure

Distribution List
Introduction

The Distribution List shows current users of this practice. Users will be provided with the data
link for this document. To receive an electronic copy, contact the Head of Documents /
Standards.

Manual Distribution
Original Signed Copy with
Documents and Standards
Controlled Electronic Copy Posted in
RGDMS

Document No: T13-X01-009 Revision No: 1.0 Cover Sheet: 2 of 13

Document Part: 361 Unclassified Issue Date: 12-Mar-14
 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

File name:

1.0 SCOPE
2.0 INTRODUCTION
2.1 Purpose
2.2 Objectives
3.0 REFERENCES
4.0 INSPECTION PROGRAM.
4.1 Purpose of Inspection
4.2 Inspection Frequency
4.3 Data Compilation
4.4 Inspection Plan
4.5 Inspection scheduling
4.6 External Visual Inspection (GVI)
4.6.1 Inspection for CUI
4.7 Inspection for Internal Corrosion
4.8 Inspection of Non-metallic Piping
4.8.1 Glass reinforced plastic (GRP) piping
5.0 REPAIRS AND QA/QC
6.0 COMPETENCY ASSURANCE
7.0 DOCUMENTATION AND REVIEW
7.1 Activity Results Analysis
7.2 Corrosion rate calculations
7.3 Remaining Life Assessment
7.4 Fitness for service evaluation (FFS)
7.5 Assessing the probability of failure due to corrosion
8.0 VERIFICATION AND MEASUREMENT
9.0 EXCEPTION REPORTING
10.0 APPENDICES
10.1 Appendix A- Piping retirement thickness

12 Mar 14, Rev 1.0 Page 3 of 13

 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

1.0 SCOPE
The requirements of this General Piping Inspection Procedure apply mainly to all criticality
“A” and “B” piping, as defined in Equipment Criticality Assessment. Requirements will also
be applied to selected criticality “C” and “D” piping at RasGas’s option (refer Table 1-1).

For the purpose of this document, any piping located between the nozzle of a pressure
vessel, tank, or heat exchanger and the first isolation valve upstream or downstream of that
equipment, is considered to be part of the equipment. This procedure includes the
equipment degradation monitoring, inspection, and welding activities required to assure
the integrity of piping designed to ASME B-31.3 (or similar piping code) for the following
facilities:

 All RasGas existing onshore and offshore facilities.

 Any facility modifications projects for the above facilities after being commissioned.
This procedure address the general inspection requirements of piping circuits (corrosion
loops) like planning and scheduling of inspections, inspection WP, method of inspections,
etc., but specific inspection requirements like injection points, mix points, dead legs, etc.
are captured under Sec 3.6.2 through 3.6.4 of PIM (T13-X01-009).

2.0 INTRODUCTION

This General Piping Inspection Procedure is designed to meet the implementation

requirements of Facility Integrity Management System (FIMS) under RGEE 6-6. This
Procedure provides the guidelines to be followed and the techniques to be made available
while physically inspecting the piping facilities of RasGas.

2.1 Purpose
The purpose of this procedure is to provide a framework document that identifies:

 Various techniques available to inspect/monitor various degradation mechanisms in

piping.
 The methods to be adopted while engaging in inspection activities of piping facilities.
 Guide lines in identifying various degradation mechanisms in piping.
 The qualification requirements of piping inspection personnel.
 To establish the piping components retirement criteria, remaining life assessment and
fitness-for-service assessment methodology to be followed.
 Documentation of inspection activities/ recommendations in a structured manner.
 Selection of repair procedure, welding procedure, QA/QC and MOC requirements.
 Feedback and continuous improvement opportunities.

12 Mar 14, Rev 1.0 Page 4 of 13

 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

2.2 Objectives
This procedure seeks to conduct and manage Piping Inspections, to achieve the following
objectives:
 Comply with applicable regulatory requirements.
 Comply with RasGas piping ES requirements and thereby meeting FIMS (RGEE6-6)
requirements.
 Maintain standards of mechanical integrity and reliability required to meet business
objectives established by the OLT, TLT and Asset team.
 Minimize significant failures over the design life of piping and facilities.
 Help to achieve optimum life-cycle maintenance costs.

3.0 REFERENCES

3.1 EIG References

All Piping Inspection tasks and their intervals are strictly guided by the following EIGs:
 EIG 01-670 (Corrosion Control & Chemical Injection)
 EIG 02-400 ~ 02-680 (Pressure Equipment)

3.2 Guidelines on Use of References

Requirements regarding integrity program activities are defined only by regulations,
applicable EIGs, and approved equipment strategies.

The industrial and international standards and references contained in this section are
provided strictly for reference and are not represented as requirements except if specified
within this document and design basis for the facilities. References are as follows:

 Design references:
 ASME B31.1 Power Piping
 ASME B31.3 Process Piping
 ASME B31.8 Gas Transmission and Distribution Piping

 Welding references:

 ASME Section IX, Welding Procedure Specifications (pressure vessels)

 ASME B31 Welding Procedure Specifications (pressure piping)
 AWS D1.1, Welding Procedure Specifications (structural)

12 Mar 14, Rev 1.0 Page 5 of 13

 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

 Inspection references:

 API 570, “Piping Inspection Code”, American Petroleum Institute.

 API 574, “Inspection Practices Piping System Components”, American Petroleum
Institute.
 API RP 580, “Risk-Based Inspection”, American Petroleum Institute.
 ISO 14692-4, “Petroleum and Natural Gas Industries - Glass-reinforced plastics (GRP)
piping”

 Fitness for service references:

 API 579 / ASME PCC-1 “Fitness for Service"

 ASME B31G Manual
 ASME B31.1 Power Piping
 ASME B31.3 Process Piping

Other references:

 NACE MR 0175-ISO 15156-2001, “Materials for use in H2S containing environments

in oil and gas production”.

12 Mar 14, Rev 1.0 Page 6 of 13

 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

Table 1-1 Equipment Criticality Levels

Criticality Level Description Criteria Guidelines

A SHES Equipment failures that  Failure results in consequence defined
Critical result in a serious in Safety, Health, Environment, and
threat to people, Security (SHES) categories I or II of the
property, or the POBP maintenance and reliability
environment system (M&RS) work selection risk
matrix, or
 Regulatory requirements apply to the
equipment
B Business Equipment failures that Failure results in consequences defined in
Critical result in significant business categories I or II of the POBP M&RS
business impact work selection risk matrix
C Essential Equipment failures that  Equipment that typically requires
(SHES or result in unacceptable (SAP/CMMS) scheduled maintenance,
business SHES or business or
) consequences that are  Equipment where failure results in the
not included in consequence defined in either the SHES
categories A or B or business category III of the
Production operations Best Practices
(POBP) M&RS work selection risk matrix
D Non- Equipment not Low cost equipment that typically does not
critical included in criticality require SAP/CMMS scheduled maintenance
categories A, B, or C and where:
 Failure has little impact on unit
performance objectives, or
 Maintenance costs offer no significant
opportunity for savings, or
 Equipment is typically run to
malfunction

12 Mar 14, Rev 1.0 Page 7 of 13

 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

4.0 INSPECTION PROCEDURE.

4.1 Purpose of Inspection

Piping inspections, i.e. both on stream and off stream inspections, are carried out to
detect, measure and monitor various deterioration mechanisms that may be active
depending on its internal / external environment. The purposes of these inspections are
to ensure that deterioration in piping condition is detected before its integrity is at risk.

4.2 Inspection Frequency

Inspection activities and frequencies are defined in equipment specific Equipment

Strategies (ES) and all inspections are scheduled in SAP. All inspection tasks are
scheduled based on (a) approved ES frequency, (b) 5 year plan (RBI) and (c) on-
stream/off-stream status.

4.3 Data Compilation

Accurate compilation of data on piping segments at the facility is the first step. If a
piping line list does not exist, one is created from the piping and instrumentation
diagrams (P&IDs) and piping isometric. The line list contains all the line segments for the
facility with information regarding service, size, temperature and pressure rating,
material, pipe class or specification, description of origin and exit, and whether it is
insulated.

4.4 Inspection Plan

Piping inspection program consists of planned piping circuit (Corrosion loop, CL) to be
inspected, inspection locations (CMLs or TMLs) on a given CL, and the type and method
of inspection at the identified location. Given the large number of piping segments in an
operating facility, the setting up and maintenance of the piping program can be time
consuming and requires adequate planning, preparation, resource allocation, and
budgeting. For effective and manageable inspection program, piping circuits (corrosion
loops, CL) are used, that group pipe segments exposed to similar modes of internal and
external degradation (considered as a best practice).

All the above requirements are captured in a work pack (IE WP) which describes the
lines included in a CL, damage mechanisms expected (driver for inspection), type of
inspections, time required for each inspection, logistics required to complete each
inspection, inspection locations, marked up P&IDs & ISOs and some relevant tables

12 Mar 14, Rev 1.0 Page 8 of 13

 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

which summarizes inspection activities; and is developed for each CL. Documentation of
the inspection findings in Meridium, review the inspection findings and approving
recommendation are part of this program. This is required to determine fitness for
service of the piping segment, with a clear and timely set of recommendations to ensure
safe and reliable operations.

4.5 Inspection scheduling

Once circuits are defined, inspection intervals are defined, CMLs & TML’s are identified,
and entered into the inspection database; the final step is to schedule the inspection.
The dates for the inspection should be scheduled by CMMS team (computerized
maintenance management system) in SAP as per frequency set by RBI program and
inspection reports will entered in Meridium.

4.6 External Visual Inspection (GVI)

Corrosion loops (CL) are inspected externally to determine the condition of the outside
of piping, insulation, painting and coating systems, associated supports and hardware. It
also helps to check for leaks, misalignments, vibration, corrosion at supports, etc. Where
possible, inspections take place while the line is in-service to enhance the detectability
of the above items. External visual inspection also serves to uncover any field
modifications or temporary repairs not previously recorded on the piping drawings or
records (or both).

Detail visual inspection of corroded surfaces is facilitated (after initial observation) by

cleaning (eg: wire brushing) to remove loose paint and scale prior to examination.
Magnifying glasses, pit depth gauges, surface profilers, and digital cameras are used to
characterize and document visual inspection findings.
The list of piping components that are visually inspected by the inspector during a piping
external visual inspection are described in Appendix-B (Piping inspection check list).

4.6.1 Inspection for CUI

Insulated piping which operates in –4°C to 150°C GIP4.2.1 temperature range is susceptible
to external corrosion if water is able to penetrate the insulation weather jacketing.
Sources of water include rain, deluge, and condensation (particularly on cold lines).
Corrosion under insulation (CUI) can occur anywhere the jacket is breached, including
improperly caulked jacket seams, cutouts for pipe supports and connections, damaged
jackets, and termination points (especially for vertical lines).

12 Mar 14, Rev 1.0 Page 9 of 13

 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

For complete guidance on the details required for a CUI inspection program, refer to CUI
Manual and XOM MPM TMEE-062, GIP 4.2.1.

4.7 Inspection for Internal Corrosion

Internal visual inspections are not normally performed on piping, except in some
refractory lined piping of SRU. When possible and practical (for large diameter pipe or
when flanges are disconnected), the same can be undertaken and is similar to vessel
internal inspection and should be conducted with the same methods and procedures
used of vessel internal inspection. Remote visual inspection techniques (Boroscope,
Rover camera, etc.) can be helpful for both small and large diameter pipes.

4.8 Inspection of Non-metallic Piping

This section of the procedure outlines the inspection practices adopted by RasGas to
verify and maintain mechanical integrity of its nonmetallic piping systems during
operation.

4.8.1 Glass reinforced plastic (GRP) piping

The scope of this section is limited to in-service inspection of GRP systems to assure
adequate levels of safety during operation. During visual inspections GRP piping systems
are checked for evidence of impact damage and breakdown of the outer surface due to
weld splatter, abrasion, chalking (ultraviolet [UV] degradation) or aging. An illumination
source is used to maximize the extent and accuracy of the visual inspection. Flanges are
examined closely for evidence of cracking and leaks, and earthing cables are checked for
signs of corrosion. Checks are made to verify that the GRP piping is adequately
supported, especially near valves and heavy equipment items installed on the system.
Design or fabrication concerns identified during external visual inspections are noted for
follow-up action.

5.0 REPAIRS AND QA/QC

See PIM section No: T13-X01-009_0061 for detailed procedure for repairs and modifications.

6.0 COMPETENCY ASSURANCE

See PEPM section No: T13-X01-003_0040 QMS for details of competency assurance.

12 Mar 14, Rev 1.0 Page 10 of 13

 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

7.0 DOCUMENTATION AND REVIEW

See PIM section No: T13-X01-009_0061 for detailed procedure for documentation.

7.1 Activity Results Analysis

This part describes how Piping Inspection results are analyzed for the evaluation of
individual piping/components fitness-for-service determinations.

7.2 Corrosion rate calculations

Long term corrosion rates (CRLT) and short term corrosion rates (CRST) are calculated
using the equations indicated below (per API 570). Confidence levels in calculated
corrosion rates are a function of the accuracy of the wall thickness measuring technique
and the number of thickness readings taken.

Where:
tI = thickness of wall recorded in baseline survey (mm or inches)
tL = last recorded thickness of wall (mm or inches)
tP = thickness of wall recorded in previous survey (mm or inches)

7.3 Remaining Life Assessment

Remaining life of the corrosion allowance (in years) is calculated for the worst case
corrosion rate (CRWC), using the equation:
t  MAWT
REMAINING LIFE (Years )  L
CRW C
where MAWT = minimum acceptable wall thickness, as defined by the relevant piping
design code.
Unless a common activity is more cost efficient, follow the below process:
If remaining life of the corrosion allowance is less than double the time to next
inspection, one of the following actions is taken:
1) Verify readings and data
2) Check t-min
3) Check CR.
4) Assess POF per 7.5
5) Consider FFS for period to next inspection.

12 Mar 14, Rev 1.0 Page 11 of 13

 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

6) Consider a one time reinspection recommendation before next due inspection per
the current Equipment Strategy.
7) Inspection frequency is increased (that is, inspection interval is reduced) to closely
monitor deterioration prior to failure. Re-inspection frequency is estimated by
using one-half of the calculated remaining life. Conduct RBI analysis and adjust the
inspection frequency.
 Plan repair / replacement as required.
 The affected pipework is re-rated to a lower pressure.
Note: Inspection does not mitigate risk; it better defines the probability of failure.

7.4 Fitness for service evaluation (FFS)

If the last recorded wall thickness measurement (tL) is very near or below the minimum
acceptable wall thickness (MAWT), a Fitness for Service (FFS) evaluation is to be initiated
on the degraded component to determine whether the piping:
 Can remain in service.
 Requires repair.
 Requires replacement.
7.5 Assessing the probability of failure due to corrosion
Using the approach as outlined in ExxonMobil TMEE 062 Appendix B, and the
consequence of failure stated in the equipment strategy, the date at which a corroded
component will reach an unacceptable risk can be calculated. Any equipment which will
not be inspected or repaired prior to reaching a risk category 2 should have a fitness for
service evaluation initiated.
8.0 VERIFICATION AND MEASUREMENT
See PIM section No: T13-X01-009_0061 for detailed procedure for verification and
measurement.
EXCEPTION REPORTING
See PIM section No: T13-X01-009_0061 for detailed procedure for exception and reporting.

9.0 APPENDICES
10.1 Appendix A- Piping retirement thickness

Piping requires sufficient thickness for pressure containment and for structural
requirements/mechanical integrity. Piping thickness data for FFS determination is to be
collected as per Piping Thickness Monitoring Procedure (T13-X01-0043). The retirement
thickness is taken to be the greater of the value shown below (to assure that sufficient

12 Mar 14, Rev 1.0 Page 12 of 13

 Piping Plant Inspection Manual(PIM)
General Piping Inspection Procedure T13-X01-009_0361

mechanical strength remains in the pipe after the specified corrosion allowance has
been expended)API-574.

Minimum Thickness for Pipe Retirement

For piping >24” and/or calculated wall thickness piping (versus nominal schedule piping): (A)
calculate the minimum require thickness for pressure per the calculation below; (B) calculate
the required thickness per vacuum design requirements and (C) calculate t = D*0.169 where D
is the Nominal Pipe Size in inches and the resulting t is in mm (for NPS>24). Take the higher of
the three as the “minimum thickness” required before retirement.

For all other piping, unless subject to unusually large loads (many valves, etc), use the following:
Nominal Pipe Size (NPS) Retirement Thickness (mm)

3/4 through 2 2.1

3 through 18 3.4

20 through 22 3.8

24 4.2

The above is to be used as a first pass flag thickness for input to Meridium as the “minimum
thickness” requirement for determining remaining life. If we have readings at or below the
retirement thickness, FFS should be performed.

WARNING: When selecting a t-min (required thickness) or running the t-min calculator in
Meridium for piping >=24” (or for any other piping with calculated wall thickness vs nominal
wall thicknesses), check the calculated required thickness considering vacuum and pressure
thickness requirements as applicable before using the Nominal t-min which is based on
0.169*D.
10.2 Appendix B- Piping Inspection Checklist

Refer to JobAid No: FIMS02-JA-INS-11_General Piping Inspection Checklist.

12 Mar 14, Rev 1.0 Page 13 of 13