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Interval/Frequency and Extent of Inspection: Piping Installation

This document discusses inspection intervals and extent for piping systems. It outlines that piping should be inspected at installation to verify cleanliness and proper installation. Inspection intervals are established based on piping service changes and classifications. Piping is classified into four categories based on consequences of failure, with Class 1 having the highest potential consequences. The document provides recommended thickness measurement and visual inspection intervals for each class. It also describes the extent that visual inspections and thickness measurements should cover, including external inspections to check insulation and corrosion. Statistical sampling methods and point-to-point analysis approaches are discussed. Inspection and testing intervals of 5-10 years are recommended for pressure relief devices depending on service conditions.

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Muhammad Bilal
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233 views

Interval/Frequency and Extent of Inspection: Piping Installation

This document discusses inspection intervals and extent for piping systems. It outlines that piping should be inspected at installation to verify cleanliness and proper installation. Inspection intervals are established based on piping service changes and classifications. Piping is classified into four categories based on consequences of failure, with Class 1 having the highest potential consequences. The document provides recommended thickness measurement and visual inspection intervals for each class. It also describes the extent that visual inspections and thickness measurements should cover, including external inspections to check insulation and corrosion. Statistical sampling methods and point-to-point analysis approaches are discussed. Inspection and testing intervals of 5-10 years are recommended for pressure relief devices depending on service conditions.

Uploaded by

Muhammad Bilal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Interval/Frequency and Extent of Inspection

 due date may exceed the typical half-life interval used in a more conventional analysis
Piping Installation
 The purpose of installation inspection is to verify that the piping is clean and safe for operation, and
to initiate plant inspection records for the piping systems
 piping is installed correctly
 correct metallurgy
 supports are adequate
 exterior attachments
 flanged and other mechanical connections are properly assembled
 pressure-relieving devices satisfy design requirements
 This installation inspection should document base-line thickness measurements to be used as initial
thickness
Piping Service Change
 Inspection intervals shall be established for the new service condition
 review of applicable pressure relieving device settings
 If both the ownership and the location of the piping are changed, the piping shall be inspected
before it is reused
Piping Inspection Planning
 piping classification scheme in 6.3.4 is based on the consequence of a failure
Setting Inspection Intervals without the Use of RBI
 the corrosion rate and remaining life calculations
 the piping service classification
 the applicable jurisdictional requirements
 judgment of the inspector, the piping engineer, the piping engineer supervisor, or a materials
specialist(based on operating conditions, previous inspection history, current inspection results, and
conditions)
 owner/user or the inspector shall establish inspection intervals for thickness measurements and
external visual inspections
 For Class 1, 2, and 3 piping, the period between thickness measurements for CMLs or circuits should
not exceed one-half the remaining life or the maximum intervals recommended in Table 1,
whichever is less
Type of Circuit Thickness Measurements Visual External
Class 1 5 years 5 years
Class 2 10 years 5 years
Class 3 10 years 10 years
Class 4 Optional Optional
Injection points a 3 years By class
Soil to Air Interfaces b — By class

 Class 4 piping are left to the determination of the owner/user


 For piping that is in non-continuous service, the interval between thickness measurements may be
based on the number of years of actual service
 inspection interval shall be reviewed and adjusted as necessary after each inspection or significant
change in operating conditions and/or inspection results
Interval/Frequency and Extent of Inspection

Piping Service Classes


 All process piping systems shall be categorized into different piping classes except for piping that has
been planned based on RBI.
 focused on piping systems that
 may have the highest potential consequences if failure or loss of containment should occur
 Classifications should be based on potential safety and environmental effects should a leak occur
Class 1
 Flammable services that can auto-refrigerate and lead to brittle fracture
 Pressurized services that can rapidly vaporize during release
 Hydrogen sulfide (greater than 3 % weight)
 Anhydrous hydrogen chloride
 Hydrofluoric acid
 Flammable services operating above their auto-ignition temperature
Class 2
 includes the majority of unit process piping and selected off-site piping
 on-site hydrocarbons that will slowly vaporize
 below the boiling point but above the flash point
 on-site hydrogen, fuel gas, and natural gas
 on-site strong acids and caustics
Class 3
 either flammable but do not significantly vaporize i.e. below the flash point,
 Services that are potentially harmful to human tissue but are located in remote areas may be
included in this class
 on-site hydrocarbons that will not significantly vaporize during release such as those operating
below the flash point
 off-site distillate and product lines to and from storage and loading
 tank farm piping
 off-site acids and caustics
 off-site hydrogen, fuel gas and natural gas
 Other lower risk hydrocarbon piping
Class 4
 nonflammable and nontoxic
 steam and steam condensate;
 air;
 nitrogen;
 water, including boiler feed water or stripped sour water;
 lube oil, seal oil;
 ASME B31.3, Category D services;
 plumbing and sewers
Interval/Frequency and Extent of Inspection

Extent of Visual External and CUI Inspections


 external visual inspection for potential CUI is also to assess insulation condition and shall be
conducted on all piping systems susceptible to CUI
 Damaged insulation at higher elevations may result in CUI in lower areas remote from the damage.
 RT or insulation removal and visual inspection is normally required for this inspection at damaged or
suspect locations
 Other NDE assessment methods may be used where applicable
 If the inspection of the damaged or suspect areas has located significant CUI, additional areas should
be inspected and, where warranted, up to 100 % of the circuit should be inspected.
 several factors may affect the likelihood of CUI to
 include:
 a) local climatic conditions,
 b) insulation design and maintenance,
 c) coating quality,
 d) service conditions
 An exact accounting of the CUI inspection targets is not required
 the owner/user may confirm inspection targets with operational history or other documentation
 remaining life of over 10 years or that are adequately protected against external corrosion need not
be included for the NDE inspection
 condition of the insulating system or the outer jacketing, such as a cold-box shell, should be
observed periodically by operating or other personnel
Extent of Thickness Measurement Inspection and Data Analysis
 It is not the intent of this Code that every established CML needs to be measured each time.
 A statistical sampling of active CMLs may be monitored
 Some CMLs may be documented as inactive and therefore do not need to be measured and would
not be considered overdue.
 should include data for all the various types of components and orientations (horizontal and
vertical) found in each circuit
 CMLs to be monitored at each inspection shall be determined by the inspector in consultation with a
piping engineer and/or corrosion specialist
Point-to-Point Method
 An analysis method, whereby the corrosion rate, remaining life and re-inspection interval is
determined for each individual CML
 During a re-inspection of a piping system, all of the CMLs may be re-inspected or only those that are
coming due
 is generally not possible to apply a statistical analysis with the point-to-point method since
 it difficult to compare corrosion rates in the circuit or between CMLs
 Individual CML rates may be generated over significantly different times, when operating conditions
may have changed.
Circuit Analysis Method
 properly circuitized into common corrosion mechanisms and expected rates
Interval/Frequency and Extent of Inspection

 Approach is generally applicable to damage mechanisms that produce uniform and some mildly
localized corrosion environments.
Inspection and Maintenance of Pressure-relieving Devices (PRDs)
 PRDs shall be tested and repaired by a repair organization experienced in pressure relieving device
maintenance
 Pressure-relieving devices shall be tested and inspected at intervals that are frequent enough to
verify that the valves perform reliably in the particular service conditions
 Other pressure-relieving devices (e.g. rupture disks and vacuum breaker valves) shall be inspected at
intervals based on service conditions.
 determined by the inspector, engineer, or other qualified individual per the owner/user's quality
assurance system
 5 years for typical process services, and
 10 years for clean (non-fouling) and noncorrosive services
 use a max 150 % of set pressure beyond which the valve is classified as stuck shut if it does not pop,
and the test is discontinued

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