api-570_20150909133250 Flashcards
Code to follow when performing an internal inspection on pipe
API 510 570: 5.5.1
Positive Material Identification (PMI)
API 578 570: 5.9
Fitness for Service (FFS)
API 579 570: 7.4
Risked Based Inspection (RBI)
API 580 570: 5.2
Valve Inspection and Testing
API 598 570: 5.10
Cathodic Protection
API 651 570: 9.3.5
Welding on In-Service Equipment containing Flammables
API 2205 570: 8.2.1
NDE Procedure Guidelines
ASME Sect V B31.3: 343
Design code for fabrication of piping relief devices
ASME Sect 8 B31.3: 322.6.3
Welder & Weld Procedure Qualification
ASME Sect 9 B31.3: 328.2.1.a
NDE Personnel Qualification
ASNT SNT-TC-1A B31.3: 342.1 Note
When fitting up a socket weld joint the male end is welded in the female socket with
An approx 1/16” gap at the base of the joint
The zone for preheat shall extend
At least 1 inch beyond each edge of the weld
Where a hardness limit is specified in table 33 1.1.1 at least ________% of welds, hot bends, and hot formed components in each furnace heat treated batch and 100% of those locally heat-treated shall be tested
10
What is acceptable as an alternate heat treatment
Normalizing, normalizing and tempering, or annealing
When an entire piping assemble is to be heat treated cannot fit into the furnace, it is permissible to heat treat in more than one heat treat, provided there is at least _______ overlap between successive heats, and that the parts of the assembly outside the furnace are protected from harmful temp gradients
1 foot
Flattening of a bend, the difference between maximum and minimum diameter’s at any cross-section, shall not exceed _______% on nominal outside diameter for internal pressure
8
Flattening of a Bend, the difference between maximum and minimum diameter’s at any cross-section, shall not exceed ________% on nominal outside diameter for external pressure
3
Flanged joints: Before bolting, mating gaskets contact surfaces should be within ________ in/ft, measured across any Dia.
16-Jan
Flange Bolt holes should be aligned within ______ max offset
1/8 in.
Bolts should extend completely through their nuts. Any which failed to do so or considered acceptably engaged if the lack of complete engagement is not more then
One thread
How many gaskets shall be used between Contacts faces in the Assembling a flanged joint
No more than one gasket
What is the minimum time that a leak tests must be maintained
10 minutes
ASME code is not intended to apply to piping:
That has been placed in service
Compatibility of materials with the service and hazards from instability of contained fluids:
Are not within the scope of ASME B31.3
A fluid service that is nonflammable non-toxic and not damaging to human tissue and it’s gage pressure does not exceed 150 psi in the design temperature from -20° through 366°F is known as category
D
A fluid service in which the potential personal exposure is judged to be significant any which a single exposure to a very small quantity of toxic fluid caused by leakage can produce serious in reversible harm persons on breathing or bodily contact even when prompt restorative measures are taken is known as category
M
The heating of metal to and holding at a suitable temperature and then cooling at a suitable rate for such purposes as reducing hardness improving machinability facilitating cold working producing a Desired microstructure or obtaining desired mechanical physical or other properties is known as
Annealing
What might happen to a piping system that has a gas or vapor in it “ like steam” and it is allowed to cool significantly
The pressure in the piping system may reduce sufficiently to create an internal vacuum
What happens to a piping system that has fluids in it and the fluids are heated with the system blocked
The internal pressure will increase
Loads on a piping system that include the weight of the medium transported or the medium used for test and snow loads or ice loads or examples of -______ loads
Live
When the service is erosive if there is crevice corrosion present or if cyclic loadings occur slip on flanges shall
Be double welded
The use of slip on flanges should be ________ where many large temperature cycles or expected particularly if the flanges or not insulated
Avoided
Unless save guarded, flanges is severe cyclic service conditions or limited to
Welding neck flanges
Bolting having not more than __________ ksi specified minimum yield Strength shall not be used for flange joints rated ASME B16.5 class 400 and higher
30
Tapped holes for pressure retaining bolting in metallic piping components shall be of sufficient depth that the thread engagement will be at least __________ Times the nominal thread diameter
8-Jul
What type of backing rings shall not be used under severe cyclic conditions
Split backing rings
Socket weld joints should be avoided in any service where ________ or _________ occur
Crevice corrosion , severe erosion
Socket weld’s larger than NPS _______ shall not be used under severe cyclic conditions
2
Where flanges of different ratings are bolted together
The rating of the joint shall not exceed that of the lower rated flange
Where a metallic flange is bolted to a nonmetallic flange
Both should be flat-faced
Where a metallic flange is bolted to a nonmetallic flange
A fullface gasket is preferred
What type of joint should not be used under severe cyclic conditions
Expanded joints
Threaded joints should be avoided in any service where
Crevice corrosion, severe erosion, or cyclic loadings may occur
What is an example of a straight threaded joint
An union comprising male and female ends joined with a threaded union nut
Poisons ratio may be taken as _______ at all temperatures for all metals
0.3
For a liquid thermal expansion relief device which protects only a blocked in portion of piping system the set pressure shall not exceed the lesser of the system test pressure or ______% of design
120
Physical change of the piping component that has design applications affecting the pressure containing capabilities of flexibility of the piping system is an
Alteration
And imperfection of a type of magnitude exceeding the acceptable criteria
Defect
An __________ could be flaws or other types of discontinuities that were discovered during inspection that might be subject to some code acceptance criteria during further analysis
Imperfections
MDMT is the __________. __________ at which a significant pressure load can be applied to piping system as defined in applicable construction code
Lowest temperature
Injection points subject to accelerated or localized corrosion may be treated as
Separate inspection circuits
Pressure relieving devices should be tested and inspected at
Frequent enough intervals to make sure the PRDs perform reliably in service
Barlow formula for t
t= PD/2SE
Remaining life formula
t actual - t required / corrosion rate
Long term corrosion rate formula
t initial - t actual / years between
Short term corrosion rate
t previous - t actual / years in between
Any welding conducted on piping components in operation must be done in accordance with
API publication 2201
All repair and alteration welding to piping systems shall be done in accordance with the
Principles of ASME B31.3 or the code to which it was built
How often should cathodically protective buried piping be monitored to assure adequate levels of protection
Regularly
How often should above grade visual surveillance of a buried pipeline right-of-way be made
Approximately six month intervals
How often should poorly coated pipes with inconsistent cathodic protection potentials have a pipe to soil potential survey made
Every five years
The leak test for buried piping should be for a period of
Eight hours
Barlow formula for MAWP
MAWP= 2SET / D. T is projected thickness
Services with the highest potential of resulting in an immediate emergency if it leak were to occur are in class
1
Services not included in other classes or in class? This classification includes the majority of unit process piping and selected offsite piping
2
Services that are flammable but do not significantly vaporize when they leak and are not located in high activity areas or in class? Services that are potentially harmful to human tissue but are located in remote areas may be included in this class
3
Services that are essentially nonflammable and non-toxic or in class? As are most utility services. Inspections of this class of piping is optional and usually based on reliability needs and business impacts as opposed to safety or environmental impact
4
API 574 is
Inspection practices for piping systems components
Piping normally made by rolling plates to size and welding the seams is a larger then
16 NPS
Steel and alloy piping or manufactured to standard dimensions and normal pipe sizes up to
48 inches
Steel and alloy piping or also manufactured to standard thickness is designated as schedules in normal pipe sizes up to
36 inches
Gas piping has thickness tolerance of +_______ inch and - ________ inch
1/16, 0
For all nominal pipe sizes of _________ inches and smaller, the size refers to the nominal inside diameter
12
Under tolerance of welded pipe often used in refinery service is
0.010 inch
Tubing is generally seamlessly drawn, but it may be welded. It’s stated size is it’s actual
Outside diameter
The basic types of valves
Gate, globe, plug, ball, diaphragm, butterfly, check, and slide valves
Minimum thickness without corrosion allowance, based on structural and other loadings. The thickness is either determined from the standard chart or engineering calculations. It does not include thickness for corrosion allowance or mill tolerance
Structural minimum thickness
API RP 571 is
Damage mechanisms affecting fixed equipment in the refining industry
Article 2
Radiographic examination
Article 4
Ultrasonic examination
Article 6
Liquid penetrant
Article 7
Magnetic particle
Article 9
Visual examination
Article 10
Leak testing
Are class 200 flanges included in the standard
No
Are temperature markings required on all flanges
No
Bolting material having no more than 30 KS I specified Minimum yield strength or considered
Low strength
Class 400, 600, 900, 1500 and 2500 pipe flanges and companion flanges of fittings are regularly finished with _________ raised face
0.25
Class 150 and 300 pipe flanges and companion flanges of fittings or regularly finished with ______ raised face
0.06 in.
Flange Bolt holes are in multiples of
4
A flanged joint is composed of three interrelated components
The flanges, gasket, and bolting
At temperatures above 400° for class 150 and above 750° for other class designations flanged joints may
Develop leakage problems
When class 300 steel flanges are bolted to class 250 cast iron flanges what gasket should be used
Group No. Ia
ASME B16.5 covers flanges through NPS
24
ASME B16.47 covers the total range of larger flanges in size range NPS
26 through 60
API 570 Scope (Alteration, Inspection, Repair, Rerate)
AIRR 570: 1.1.1
API 570 Repair Organization (authorized by Jurisdiction, Owner, Contractor)
JOC 570: 3.1.79
API 570 AI’s Employer (Jurisdiction, User, Insurance company, Contractor)
JUIC 570: 3.1.6
Determine Corrosion Rate for New Service or Change in Service (Same or Similar Service, Owner’s Experience, Published Data, or Inspect in 3 months)
SOPI 570: 7.1.2
Primary responsibilities of API 570 AI (Testing, Inspection, Examination)
TIE 570: 4.3.4
Define Alteration
Physical Change 570: 3.1.2
Define Repair
Restore - Suitable 570: 3.1.78
Define Imperfection that exceeds the acceptance criteria
Defect 570: 3.1.17
Define Discontinuity that may or may not exceed the acceptance criteria
Imperfection 570: 3.1.30
Define RBI’s two Primary Factors
Probability-Consequence 570: 5.2
NDE - Number of CMLs to obtain thickness readings during inspection
Represent- active 570: 6.5
NDE - CML that must be measured during a Thickness Inspection
CML w/ earliest renewal date 570: 6.5
How relief device intervals are determined
Performance 570: 6.7.3.1
Insp - Basis of API 570’s Piping Classification
Consequence of failure 570: 6.3.1
Corrosion - Method by which process leaks can lead to brittle failure
Auto-refigeration 570: 6.3.4.2.a
Corrosion - Cause for fatigue crack
Cyclic Stress 574: 7.4.10.1
Corrosion - Factors that affect the creep rate
Time, Temp, & Stress 574: 7.4.11.1
Corrosion - Type of soil that is most corrosive
Low Resistivity 570: 9.2.4
Repairs - # of new flange assemblies to be inspected during repairs and alteration
Represent- active 570: 5.12
SCC can develop at hot spots, including where the heat tracing attaches to pipe
Caustic 574: 7.4.6.2.n
Where dew point corrosion often occurs
Overhead fractionation 574: 7.4.6.2.b
Potential for none or very few CMLs on circuit
Olefin cold side, Anhydrous ammonia 570: 5.6.2
Relatively uniform corrosion
Sulfidation, Sour water 570: 5.6.3
Valves that should be inspected for thermal fatigue
Cat Reformer 570: 5.10
Design - Mill tolerance for rolled and welded pipe
-0.010” 574: 4.1.1.3
NDE - Maximum length of Crack, or Incomplete Fusion allowed on a new weld
0” B31.3: Tbl 341.3.2
Flanges - Typical flange face finish
125-250 micro-inch B16.5: 6.4.5.3
Flanges - When mating flanges, the maximum amount of unparallel allowed (per diameter of flange in feet)
1/16” per foot B31.3: 335.1.c.1
Flanges - Max offset for bolt-holes for mating flanges
1/8” B31.3: 335.1.c.3
Welding - Maximum allowed size of open discontinuity in a Bend Test
1/8” ASME IX: QW-163
Preheat Zone - Distance from toe of weld
1” B31.3: 330.1.4
PWHT Zone - Distance from toe of weld
1” B31.3: 331.2.6
NDE - Minimum distance beyond the area to be examined to clean a part when performing a MT examination
1” ASME V: T-741.1.b
NDE - Minimum distance beyond the area to be examined to clean a part when performing a PT examination
1” ASME V: T-642.b
Repairs - Minimum radius of insert patch
1” 570: 8.1.4.2.c
Repairs - Minimum radius of insert patch
1” 570: Fig C.2
NDE - Max diameter of CML exam point for lines
2” 570: 3.1.20
NDE - Max diameter of CML exam point for lines > 10 NPS
3” 570: 3.1.20
NDE - Minimum length of Spot RT
6” B31.3: 344.5.2.c
Welding - Min length to RT/UT when qualifying a welder with test coupon or 1st production weld
6” ASME IX: QW-302.2/ 304.1
Welding - Minimum length of RT when qualifying a welding operator with a test coupon
6” ASME IX: QW-302.2
Corrosion - Soil-to-Air area – distance in air from interface
6” 570: 3.1.87
Corrosion - Distance to dig when inspecting for Soil-to-Air corrosion
6-12” 574: 7.4.5
NDE - Distance of eye-to-part to count as a Visual Exam
6-24” 577: 9.3.1.e
Corrosion - Soil-to-Air area – distance in soil from interface
12” 570: 3.1.87
NDE - Minimum upstream limit of intensive examination of injection point circuit
12” 570: 5.5.9
PWHT - Min overlap for PWHT when using multiple heats
12” B31.3: 331.2.5
Welding - Minimum length of RT/UT when qualifying a welding operator on first production weld
3’ ASME IX: QW-305.1
Underground - Minimum length of buried pipe to expose when excavating for inspection
6-8’ 570: 9.3.6
Repairs - Maximum size of fillet weld patch on pipe
½ Diameter 570: Fig C.2
Circuits - Minimum upstream limit of injection point circuit
Greater of: 12” or 3 Dia. 570: 5.5.9
NDE - Minimum downstream limit of intensive examination of injection point circuit
10 Diameters 570: 5.5.9
Circuits - Min downstream limit of injection point circuit
Lesser of:1st direction change + 25’or2nd direction change 570: 5.5.9
Corrosion - CUI affects Carbon Steel & low alloy (temperature range)
10 - 350 F 574: 7.4.4.1.e
UT Calibration - Calibration Block must be within what temperature of the part to be examined
25 F 577: 9.9.1
NDE - Standard temperature range for a PT exam
40 - 125 F V: T-652/653
Testing - Min flash point of hydrocarbons used for leak testing
120 F 570: 5.8.1
Corrosion - CUI affects Austenitic Stainless Steel (temperature range)
120 - 400 F 574: 7.4.4.1.h
Corrosion - Typical dew point of hydrochloric acid
130 F 571: 4.3.7.3.d
Corrosion - Temperature where chloride stress corrosion cracking becomes a concern
> 140 F 571: 4.5.1.3.g
NDE - Special procedures needed for UT thickness readings
> 150 F 570: 5.7.1
Corrosion - Temperature swings that can cause thermal fatigue
+/- 200 F 571: 4.2.9.3.c
Corrosion - Most aggressive CUI temperature range
212–350 F 571: 4.3.3.3.b
Corrosion - Typical dew point of sulfuric acid
280 F 571: 4.3.7.3.c
Welding - Minimum pre-heat temperature, when pre-heat is substituted for PWHT
300 F 570: 8.2.3.2
Welding - Minimum pre-heat temperature, when a local PWHT is substituted for a full encirclement PWHT
300 F 570: 8.2.3.3.c
Corrosion - Starting temp for Sulfidation on Carbon Steel per API 574
450 F 574: 7.4.6.2.j
Corrosion - Starting temp for Sulfidation on Iron-based Alloys per API 571
500 F 571: 4.4.2.3.c
Corrosion - Temperature range causing temper embrittlement in low chromes
650–1100 F 574: 3.1.39
Inspection - Operating Temp when a Corrosion Specialist must input on an Inspection Plan
> 750 F 570: 5.1.1.1
Corrosion - Graphitization occurs in Carbon Steel materials
> 800 F 574: 10.3.5.2.4
Corrosion - Creep occurs in 1-1/4% Chrome materials
> 900 F 574: 7.4.11.1
NDE - Maximum temperature for UT readings per ASME Sect V
1000 F ASME V: SE-797 8.5
NDE - Maximum temperature for UT readings per API 574
1100 F 574: 10.2.1.5.1
Materials - Carbon Steel PWHT temperature
1100-1200 F B31.3: Tbl 331.1.1
Testing - Minimum base metal temp during pressure testing when wall thickness is
MDMT + 10 F 570: 5.8.3
Testing - Minimum base metal temp during pressure testing when wall thickness is > 2” thick
MDMT + 30 F 570: 5.8.3
NDE - Maximum temperature for magnetic particles
Manufacturer Recommendation ASME V: 731.c
Common material with an endurance limit (fatigue cracking cannot occur below this stress level)
CS 571: 4.2.16.3.b.i
Subject to temper-embrittlement
Low Chromes 574: 7.4.12.1
Common material without an endurance limit
SS 571: 4.2.16.3.b.ii
Subject to chloride stress-corrosion cracking
300 SS 574: 7.4.8.1.a
Subject to polytheonic acid stress-corrosion cracking
Sensitized 300 SS 574: 7.4.8.1.b
P-numbers allowed to use pre-heat in lieu of PWHT
P1 & P3 570: 8.2.3.2
Flanges - Thread engagementellaneous acceptance criteria
-1 570: 5.12 / B31.3: 335.2.3
Ratio of Endurance Limit Stress to Ultimate Tensile Stress for Carbon Steel
0.4 – 0.5 571: 4.2.16.3.b.ii
Testing - Minimum range of pressure gauge used during a pressure test (multiplied by test pressure)
1.5 ASME V: T-1031.a
Testing - Preferred range of pressure gauge used during a pressure test (multiplied by test pressure)
2 ASME V: T-1031.a
NDE - # of additional welds or joints to examine when a weld defect is found during a Random examination
2 B31.3: 341.3.4.a
PWHT - Minimum # of thermocouples required when performing a local PWHT instead of a 360 degree band
2 570: 8.2.3.3.d
Weld Qualification - Number of tension tests to qualify a WPS
2 ASME IX: QW451.1
Weld Qualification - Number of bend tests to qualify a welder or welding operator in welding positions 1G-4G
2 ASME IX: QW452.1.a
NDE - Minimum # of exposures to RT 360o of a weld using a double-wall technique, double-wall view (elliptical shot)
2 ASME V: T-271.2.b.1
NDE - RT film Density Range - allowed for the weld & IQI when using a gamma ray source
2.0 – 4.0 ASME V: T-282.1
NDE - Minimum # of exposures to RT 360o of a weld using a double-wall technique, single-wall view
3 ASME V: T-271.2.a
Impact Test - Number of test bars required in each set
3 B31.3: 323.3.3
NDE - When using a shim under a hole-type IQI, the number of sides of the IQI that must be seen in the RT image
3 ASME V: T-277.3
Testing - Maximum range of pressure gauge used during a pressure test (multiplied by test pressure)
4 ASME V: T-1031.a
Weld Qualification - Number of bend tests to qualify a WPS
4 ASME IX: QW451.1
Weld Qualification - Number of bend tests to qualify a welder or welding operator in welding positions 5G & 6G
4 ASME IX: QW452.1.a Note 1
Design - # of Stress Cycles needed to become rated as Severe Cyclic Service
7000 B31.3: 300.2
NDE - Minimum time an examiner should be in a darkened area prior to using a black light for MT & PT exams
5 minutes ASME V: T-676.4.b & T-777.2.b
Testing - Minimum duration for a pressure test
10 minutes B31.3: 345.2.2.a
NDE - Final interpretation of a PT exam after application of developer (time range)
10-60 minutes ASME V: T-676.1
Testing - Minimum duration of hydro to evaluate integrity of buried pipe
8 hours 570: 9.3.7
NDE - Max Calibrating Interval – MT Permanent Magnet Yoke
Daily ASME V: T-762.a
NDE - Max Calibrating Interval - RT densitometer
90 days ASME V: T-262.1
Maximum time for obtaining thickness readings when corrosion rate on new pipe is not known (no other data available)
3 months 570: 7.1.2.c
Welding - Max Time a Welder or Welding Operator maintains qualifications for a process without using that process
6 months ASME IX: QW-322.1.a
Interval - Suggested interval for Above-grade Visual Surveillance of buried pipe
6 months 570: 9.3.1
NDE - Max Calibrating Interval - Electromagnetic MT Yoke
1 year ASME V: T-762.a
NDE - Maximum Interval for a visual examiner’s eye exam
1 year ASME V: T-923
NDE - Max interval to calibrate pressure gauge used in testing
1 year ASME V: T-1061.a
AI - Length of time before an API 570 AI must recertify
3 years 570: A.3.1
Insp - Max Thickness Inspection interval for an Injection Point
Lesser 3 yr or ½ Life 570: Table 2
Insp - Max External Inspection interval for Class 1 & 2 Piping
5 year 570: Table 2
Insp - Maximum Interval for Relief devices in fouling or corrosive service
5 year 570: 6.7.3.2
Insp - Suggested interval for Close-interval Potential Survey of buried pipe with poor CP
5 year 570: 9.3.2
Insp - Suggested interval for evaluation of Soil Corrosivity for buried pipe with no CP
5 year 570: 9.3.4
Insp - Max Thickness Inspection interval for Class 1 Piping
Lesser 5 yr or ½ Life 570: Table 2
Insp - Maximum Interval for Relief devices in non-fouling or non-corrosive service
10 years 570: 6.7.3.2
Insp - Minimum years of experience for Owner’s inspector during new fabrication
10 years B31.3: 340.4.b
Insp - Maximum External Inspection interval for Class 3 Piping
10 years 570: Table 2
Insp - Maximum Thickness Inspection interval for Class 2 & 3 Piping
Lesser 10 yr or ½ Life 570: Table 2
RBI - Maximum Interval for the RBI Reassessment
Per Table 2 570: 5.2.4
Repairs - When should temporary welded pipe repairs be replaced
Next opportunity 570: 8.1.4.1
Repairs - When shall non-welded repairs & temporary leak sealing devices and be removed and pipe repaired
Next turnaround 570: 8.1.5
NDE - Max Calibrating Interval - Check the light intensity of a black light used in a MT or PT exam
Before & after use ASME V: T-676.4.e & T-777.2.e
NDE - Pipe size where RT is preferred for thickness readings
Equal or
NDE - Pipe size where UT thickness readings may require specialized UT equipment
Equal or
Terms - Small bore piping
Equal or
Maximum pipe size normally allowed for threaded pipe
Equal or
Maximum pipe size normally allowed for socket-welded pipe
Equal or
NDE - Maximum pipe size for performing an elliptical shot (double-wall technique, double-wall view)
3 NPS ASME V: T-271.2.b
Pipe size where pipe OD is equal to pipe size (NPS)
Equal or > 14 NPS 574: 4.1.1.2
Pipe size where pipe is almost always made using rolled & welded plate
> 16 NPS 574: 4.1.1.1
NDE - Weight used to check magnetic strength of an AC yoke
10 lb. ASME V: T-762.b
NDE - Weight used to check magnetic strength of a DC yoke
40 lb. ASME V: T-762.c
NDE - Weight used to check magnetic strength of a permanent magnet yoke
40 lb. ASME V: T-762.c
NDE – Min angle of eye-to-part to count as a Visual Exam
30 degrees ASME V: T-952
NDE - Two primary gamma-ray RT sources
Ir 192, Co 60 577: 9.8.4
NDE - Lead letter used during RT to check for backscatter radiation
B ASME V: T-223
NDE - Lead letter used during RT to indicate a film-side IQI
F ASME V: T-277.1.b
NDE - Hole size that must be visible in RT when using a hole-type IQI
2T ASME V: Tbl T-276
NDE - Minimum light intensity when performing non-fluorescent MT or PT or VT exams
100 ft-candles ASME V: T-676.3, T-777.1 & T-952
NDE - Minimum black light intensity when performing MT or PT fluorescent exams
1000 mW/cm2 ASME V: T-676.4.c & T-777.2.c
NDE - Maximum UT scanning speed
6”/sec 574: 10.2.1.4.3
Weld Qualification - Maximum allowed thickness on a WPS based on the plate thickness (T) of a PQR test coupon
2T ASME IX: QW451.1
Weld Qualification – The “all-position” test coupon
6G ASME IX: QW461.9
Weld Qualification – Rejectable in RT when qualifying a welder
Crack, LoF, IP ASME IX: QW191.1. 2.2.a.1
Weld Qualification – Which welding process can a welder NOT be qualified by RT/UT
GMAW - SC ASME IX: QW-304
Welding - Variables needed on WPS
Essential & Non-Essent. ASME IX: QW200.1.b
Welding - Variables needed on PQR
Essential ASME IX: QW200.2.a
Welding - Minimum taper required for welds with mismatch
30 degrees B31.3: Fig 328.4.3
Design - Two most common CS pipe materials
A53 & A106 574: 4.1.1.1
Repair - Maximum allowed SMYS for pipe if fillet-welded patch is installed
40,000 psi 570: 8.1.4.1
Test - Maximum stress allowed during a pressure test
90% of SMYS 570: 5.8 Note
Test - pH of water needed to reduce likelihood of MIC (bugs)
> 10 pH 570: 5.8.1
Corrosion - Typical external corrosion rate for dry rural environments
Corrosion - Typical external corrosion rate for inland locations with moderate rain & humidity
1-3 mpy 571: 4.3.2.3.c
Corrosion - Possible external corrosion rate for industrial environments with acid or sulfur compounds
5-10 mpy 571: 4.3.2.3.b
Corrosion - Possible external corrosion rate for marine environments
20 mpy 571: 4.3.2.3.b
NDE - Limits of RT Film Density of weld as compared to IQI
-15 to +30% ASME V: T-282.2.a.1
Design - Mill Tolerance of Seamless Pipe
-12.5% 574: 4.1.1.3
Pipe Class - % of H2S in process to classify as Class 1 Pipe
Equal to or > 3% 570: 6.3.4.2.c
NDE - % of welds to RT when fabricating Normal Service Pipe
5% B31.3: 341.4.1.b.1
NDE - % of welds to VT when fabricating Normal Service Pipe
5% B31.3: 341.4.1.a.2
NDE - % of welds to Brinnell after PWHT in furnace (if BHN are required)
10% B31.3: 331.1.7.a
NDE - Overlap with a UT scan, % of transducer diameter
10% 574: 10.2.1.4.3
AI - Amount of time inspector must be involved in inspection activities - required to maintain API 570 certification
20% 570: A.3.2
Mtls - Amount of nickel required for a material to be considered a nickel alloy
> 30% 571: 3.1.15
NDE - % of welds to Brinnell after local PWHT (if BHN is reqd)
100% B31.3: 331.1.7.a
NDE - % of Visual & RT required when fabricating Severe Cyclic Pipe
100% B31.3: 341.4.3.a.1/b
Testing - Pneumatic test pressure, % of design pressure
110% B31.3: 345.5.4
Testing - Leak test pressure of underground pipe, % of operating pressure
110% 570: 9.3.7
PRV - Maximum set pressure for thermal relief valves, % of design pressure
120% B31.3: 322.6.3.b.2
Document Owner/User must have that is following API 570
QA/Repair Manual 570: 4.3.1.1
Document required for each piping system
Inspection Plan 570: 5.1.1.1
Document required when changes are made to hardware or process
MOC 570: 4.3.1.2
Document required when Owner audits inspection program
Tracking System 570: 5.13
Document required of Examiner’s Employer
Certification Records 570: 4.3.5.3
Document required for each PRD Repair Organization
QA Manual 570: 6.7.2
Document required concerning personnel at PRD Repair Organization
Training Program 570: 6.7.2
Records maintain by Repair Organization and available to the inspector
WPS(s) & WPQ(s) 570: 8.2.2
Another Record that the Owner/User must maintain # 1
Insp Iso’s 570: 7.6.6
Another Record that the Owner/User must maintain # 2
Track Repairs Recommendations 570: 7.7
Another Record that the Owner/User must maintain # 3
External Inspections 570: 7.8
Another Record that the Owner/User must maintain # 4
Track Temporary Repairs 570: 7.9
Another Record that the Owner/User must maintain # 5
Deferrals 570: 7.10
API 578 provides guidelines for a material assurance system to verify:
All alloy materials. 1.0
The material verification program specified by API 578 covers:
Only pressure-containing components. 1.0
An alloy material is any metallic material that contains alloying elements thatare added:
To improve either mechanical properties or corrosion resistance. 3.1
An inspection lot includes:
all materials from a common source, of the same material type and same heat. 3.4
For construction and repair activities a written material verification program should be established by the:
Owner/User. 4.1
The material verification program should cover PMI testing of materials:
In existing piping systems and during construction, repairs andalterations of piping systems. 4.1
During repairs, random PMI sampling of new components is most appropriatefor:
low-risk piping systems. 4.1
Who has the responsibility to determine the extent of PMI performed?
Owner/User 4.1
During construction the Owner should consider 100% PMI of new components on:
high-risk piping systems. 4.1
Usually substituting an alloy for carbon steel does not cause a problem. But hardenable alloys may cause failure in some carbon steel systems. Which of the following process services would substituting an alloy for carbon steelnot result in a potential problem.
Benzene 4.1.1
Who is responsible to assure that the material verification program meets the guidelines of API 578?
Owner/User 4.2.1
Who is responsibility to verify the adequacy of the material verification program that is performed by material suppliers?
Owner/User 4.2.2
Who has the responsibility to review and approve the adequacy of the PMI program used by fabricators?
Owner/User 4.2.2
A mill test report:
Is an important part of the material qualify assurance program. 4.2.4
During construction, which of the following alloy components does not need to be covered by a material verification program?
Bolts, expansion joints, gaskets, and pressure containing welds need to be checked. 4.2.5
During alloy welding:
One electrode from each lot or package should be identified. 4.2.6
If alloy element(s) are contained in the flux of a welding electrode, PMI testing:
Could be conducted on a “weld button” prior to production welds. 4.2.6
New longitudinal welded alloyed pipe should:
Receive random PMI testing of weld and base metal if there is a reason to suspect problems. 4.2.6.1
PMI of autogenous welds is:
Not required if the base metal was PMI tested. 4.2.6.2
Who has the responsibility to determine the extent of PMI testing required on existing piping systems?
Owner/User 4.3.2
When prioritizing the need for PMI on existing piping systems, which of the following is not a factor to consider?
Age of the facility. 4.3.3
Incorrect substitution of carbon steel is most likely to be found in:
Chrome systems. 4.3.3.1
Which residual element in a carbon steel system has not caused increased corrosion rates in HF acid piping system?
Fe 4.3.3.2
Low silicon carbon steel can corrode rapidly when exposed to:
Hydrogen-free sulfidation. 4.3.3.4
Carbon steel can corrode rapidly in hydrogen-free sulfidation when the silicon content in carbon steel is:
The owner decides to conduct PMI testing on some existing piping systems. Which of the following is a major factor in prioritizing the pipe?
The effectiveness of the construction & maintenance practices. 4.3.3.5
Which of the following piping components is most likely to have a substitution with the wrong material?
Bolting. 4.3.4
Which of the following piping components is most likely to have a substitution with the wrong material?
6 NPS Gate valve. 4.3.4
Who has the responsibility to determine the extent of PMI testing required during repairs and alterations of piping systems?
Owner/User. 4.4.1
Who has the responsibility to evaluate the effectiveness of a PMI program during repairs and alterations?
Owner/User. 4.4.1
During repairs and alterations the Owner should:
Have a written procedure describing their PMI program. 4.4.1
PMI testing at the warehouse is:
Not a substitute for PMI testing required during fabrication. 4.4.2
In the petrochemical industry, one common material mix-up problem occurs:
When temporarily removing spool pieces. 4.4.3
Identification of materials by visual stamps or markings:
Is not a substitute for PMI testing. 5.1
How do portable X-Ray Fluorescence PMI tools work?
Radiation waves excite the materials and the material emits adifferent spectrum of radiation that can be analyzed. 5.2.2
PMI tools that use X-Ray fluorescence can not detect:
carbon. 5.2.2
How does Portable Optical Emission Spectrometry determine the elements in a material?
An electric arc causes a spectrum of light to be emitted from the tested material. The light is analyzed. 5.2.3
Chemical spot testing:
Removes a small amount of surface metal that is placed in a filter paper. Small droplets of reagents are used on the sample and different colors indicated different materials. 5.2.5.1
PMI tools that use Resistivity Testing are not always able to sort:
Low chromes and 300 series stainless steels. 5.2.5.2
PMI testing equipment should be:
Calibrated as specified by the manufacturer. 5.3
All personnel performing PMI tests should be:
Knowledgeable about the operation of the PMI test equipment. 5.5
Qualifications for personnel performing PMI testing should be submitted and reviewed by:
The Owner/User. 5,5
When PMI testing indicates that an alloy is outside the range allowed on the material spec, the component can:
Be used if accepted by the Owner/User following an assessment. 6.1c
An alloy weld overlay is applied to carbon steel base metal. What will occur?
Dilution. 6.2
An alloy weld overlay is applied to carbon steel base metal. Who has the responsibility to establish the minimum alloy requirements of the asdeposited weld metal?
Owner/User. 6.2
What is the appropriate action to take when an incorrect material is located during a PMI sampling of an inspection lot?
A more extensive inspection of the lot should be considered. 6.3
A color code system for pipe is specified by:
PFI ES22. 7.1.1
Identification of materials by color coding:
Is not a substitute for PMI testing. 7.1.1
Which of the following is not required when the owner’s PMI system requires physical marking of components?
The name of individual doing the marking. 7.1.1 / 7.1.2
Marking pens should not contain chlorides or:
Sulfur. 7.1.2b
When PMI testing is conducted on a new piping system, the documentation of the PMI results should be kept:
Until piping system is removed/scrapped. 7.4
Overall responsibility for complying with API 570 4.1
O
Responsible for developing &implementing a QA insp/repair mgmt system 4.3.1.1
O
Responsible for implementing an effective MOC process 4.3.1.2
O
Responsible for QC during repairs or alterations 4.3.3
Repair Organization
Assure owner - testing, inspection & examination activities meet Code 4.3.4
I
Evaluate and accept NDE examination results 4.3.4
I
Maintain certification records of NDE examiners 4.3.5.3
Exam Employer
Develop an inspection plan for a piping system 5.1.1.1
And / Or I E
Also involved in making inspection plans for pipe that operates >750 oF 5.1.1.1
CS
Choose to conduct RBI assessments 5.2
0
Get familiar with prior inspection data & repairs prior to inspections 5.3.5
I
Get familiar w/ operating conditions & potential damage mech of pipe system 5.4.1.2
I
Perform On-stream inspections 5.5.2
Or I Tech
Perform Thickness Inspection 5.5.3
Or I Tech
Assure individuals taking thickness measurements are trained and qualified 5.5.3
O
Determine cause if short-term corrosion rate varies significantly 5.5.3
And I CS
Perform External Inspection 5.5.4
Or I Qualified Other
Involved if the # of CML’s will be significantly reduced or eliminated 5.6.2
CS
Select or adjust the # of CMLs 5.6.3
I
Select CMLs for pipe systems subject to localized corrosion or cracking 5.6.3
CS
Determine need for non-thickness NDE techniques. Inspector consults w/: 5.7.2
Or E CS
Determine surface prep for NDE exam. Inspector made need to consult with: 5.7.3
GURU
Perform UT flaw detection for finding linear flaws 5.7.4
QUTE
Determine pressure for leak tests (non-code tests) 5.8
O
Prior to hydrotest determine if structure will support weight 5.8
E
Determine risk of brittle fracture prior to performing a pressure test 5.8.3
E
Approve substituting NDE for a pressure test 5.8.5
And I E
Perform UT as a substitute for a pressure test 5.8.5
QUTE
Verify that new alloy material during repairs & alteration meet specifications 5.9
I
When verifying new materials, determine the sampling percentage 5.9
O
PMI new materials during repairs & alterations 5.9
Or I Tech
If incorrect mat’l found in existing pipe, determine amount of further verification 5.9
I
Determine if PMI program is needed for existing facilities 5.9
O
Determine date to replace incorrect mat’ls found during PMI survey 5.9
And I O CS
Periodically inspect components found during PMI survey that are wrong mat’ls 5.9
I
Determine if crack-like weld flaws are the result of original weld fabrication 5.11
I
Assess crack-like flaws and environmental cracking 5.11
Or E CS
Assess preferential weld corrosion 5.11
I
Perform audit of owner/users to assure compliance with 570 5.13
Competent
Make corrections based on the audit of owner/users piping program 5.13
Owner’s AIA
Review and approve RBI assessments 6.3.2
And I E
Determine the inspection intervals 6.3.3
Or I O
Maintain a record of process fluid classification 6.3.4.1
O
PRD’s tested and repaired 6.7.1
Exp. Repair Org
Determine the inspection intervals for PRDs 6.7.3.1
Or I E Qualified Other
Select corrosion rate that best reflects conditions 7.1.1
And I CS
Maintain piping records 7.6.1
O
Review and approval an interval deferral 7.10
I
Revise an existing interval and document basis for change 7.10
I
Revise an existing interval that has unusual degradation issues. Inspector and: 7.10
Or E CS
Perform piping repairs 8.1.2
Repair Org
Authorize all repairs 8.1.2
I
Authorize all alterations 8.1.2
And I E
Designate hold points for repairs and alterations 8.1.2
I
Provide general authorization for limited or routine repairs 8.1.2
I
Approve all proposed methods of design, materials, WPSs, NDE & testing 8.1.3
Or I E
Approve use of on-stream welding 8.1.3
O
Approve repair welding of cracks 8.1.3
E
Approve all repair and alteration work at hold points 8.1.3
I
Approve all repair and alteration work at completion of work 8.1.3
I
Design temporary repairs 8.1.4.1
E
Determine longitudinal cracks won’t grow beyond a FW patch 8.1.4.1
E
Approve using lap patches with a material different than the pipe 8.1.4.1
E
Determine that wall thickness is adequate for on-stream welding 8.1.4.1
I
Allow temporary welded repairs to remain in place past “next opportunity” 8.1.4.1
E
Allow temp leak sealing devices to remain in place past “next opportunity” 8.1.5
E
Review leak sealing procedures 8.1.5
Or I E
Maintain record of qualified WPS’s and WPQ’s 8.2.2
Repair Org
Allow exceptions to required preheat temperature for temporary repairs 8.2.3.2
E
Check preheat temperature when using Preheat in lieu of PWHT 8.2.3.2
I
Review the use of Preheat in lieu of PWHT 8.2.3.2
E
Exceptions to PWHT on temporary repairs 8.2.3.3
E
Review the use of a local PWHT in lieu of a full encirclement PWHT 8.2.3.3
E
Determine whether a pressure test is needed after repairs 8.2.7
I
Approve substituting NDE in lieu of a pressure test 8.2.7
And I E
Perform rerating calcs 8.3
Or I E
