Piping External Visual Inspection Procedure

Piping External Visual Inspection Procedure 1.0 PURPOSE This Piping Inspection Procedure outlines the requirements for the inspection, testing, and maintenance of piping system components as established by recognized and generally accepted good engineering practices. It provides directions to determine the physical condition of the pipe in a piping circuit and to identify signs of deterioration. 2.0 SCOPE This procedure applies to above ground piping as defined by API 570, Piping Inspection Code - Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems, that is in, adjacent to, or connected to processes that contains toxic, reactive, flammable, or explosive chemical as described in OSHA 29 CFR 1910.119. The following types of piping system components are included: • Pipe • Fittings • Flanges • Gaskets • Valves • Supports 3.0 RESPONSIBILITY 3.1 The data collector selects a piping circuit from the tracking list, which is not marked complete in the datasheet column, gathers the data, and prepares the Piping Data Sheets. 3.2 The API 570 Inspector is responsible for performing the external inspection of piping according to this procedure, preparing the Inspection Report, and assisting the Site Supervisor with the analysis of the results. 3.3 The Level II certified Technician is responsible for performing all required NDE according to the NDE Inspection Procedures, preparing the NDE report, and assisting the Site Supervisor with the analysis of the results. 3.4 The Site Supervisor is responsible for performing the final analysis of the inspection results, managing the documentation after the activities have been completed and nonconformances resolved, and sending all information to the Data Entry Clerk and ACAD assigned person (if drawings were made or revised). 4.0 DEFINITIONS Data sheet - a standard form for entering design and operating information about an equipment item. A blank data sheet, which identifies the necessary data, is included with each Inspection Procedures Defect - An imperfection of a type or magnitude exceeding the acceptable criteria. Deficiency - Any nonconformance, which must be corrected either now or later. Deficiency Tracking Report - The periodic report, which gives the status of all deficiency correction work orders, which have been entered into the Maintenance Data Management System. Indication - A response or evidence resulting from the application of a nondestructive evaluation technique. In-Service - Piping systems that have been placed in operation, as opposed to new construction prior to being placed into service. Inspection Procedure - Documents, which describe the method for developing and carrying out Inspections specific to each type of equipment. An Inspection Procedure gives the certified Inspector(s) the steps, information, and safety requirements needed to perform the Inspection task Maintenance Data Management System - The electronic system for managing the Mechanical Integrity Program. It contains the data from the equipment files, tracks scheduled activities, and correction of deficiencies.

Nonconformance - Any inspection activity result that either exceeds the established acceptance criteria or has clearly changed from the last time the inspection was performed. Nonconformance Report - The report, which identifies inspection activity results, which do not meet the acceptance criteria or have deviated from the prior activity. These nonconformances require evaluation. This report is initiated by the Inspector(s) who discovered the issue. The Mechanical Integrity Program Site Supervisor reviews the report and issues it to the Host Company Representative for evaluation. Pipe - A pressure-tight cylinder used to convey a fluid or to transmit a fluid Piping Circuit - A section of piping that has all points exposed to an environment of similar corrosivity and that is of similar design conditions and construction material. Complex process units or piping systems are divided into piping circuits to manage the necessary inspections, calculations, and record keeping. Piping Engineer - Individuals or organizations acceptable to the owner or user who are knowledgeable and experienced in the engineering disciplines associated with evaluating mechanical and material characteristics affecting the integrity and reliability of piping components and systems. Piping System - An assembly of interconnected piping that is subject to the same set or sets of design conditions and is used to convey or otherwise affect fluid flows. Piping systems also include pipe-supporting elements but not support structures. 5.0 PROCEDURE 5.1 Identify all the piping systems, which are covered by the Mechanical Integrity System. 5.2 Gather the following documentation for the piping systems: • P&IDs • Piping specifications • Operating data • Piping isometric drawings if available If piping data is unavailable or questionable, field measurements will be used to verify the required information. 5.3 Divide the piping systems into piping circuits. Assign each piping circuit a unique number that will be used for identification in the piping inspection program. This circuit number should identify the location in the facility and the type of process. The circuit should be in sequential number. 5.4 Prepare a Piping Data Sheet for each piping circuit. A sample data sheet is shown in Attachment A. 5.5 Once the Piping Data Sheet is complete, the assigned Inspector will identify potential problems with each piping circuit. The assigned Inspector will select the appropriate inspection, test, and maintenance activities to be performed and complete the Inspection and Testing Plan Worksheet. 5.6 The assigned Inspector will locate the circuit in the field and will observe all the plant safety regulations and appropriate safe work practices. The Inspector will have all the proper tools and equipment. An example of some of the special tools and equipment necessary for the inspection are: • Thin-bladed knife • Pointed scraper • Flashlight • Inspection mirror • Steel rule • Wire brush 5.7 Use the Inspection and Testing Plan Worksheet to determine what needs to be inspected. Use Attachment B inspection checklist to document the visual inspection. Do not limit the inspection to the items listed on the checklist, but include other inspections, which may be necessary because of the design or operation of the piping circuit.

5.8 The assigned Inspector will correct the drawings and P&ID’s during the inspection activity and create new field sketches if there are none in the circuit folder. 5.9 Recommend additional inspection as needed to define the condition of areas of concern. Typical inspection techniques may include: • Ultrasonic testing • Liquid penetrant testing • Magnetic particle testing • Radiographic testing 5.10 Review the inspection activity results per the Code, standard, or acceptance criteria and refer any nonconformances that require evaluation to the Site Supervisor. 5.11 Send the completed inspection documentation results to the Site Supervisor for review. 5.12 After the Site Supervisor reviews the results of the inspection, the documentation will be sent to the Data Entry Clerk to enter the information into the Maintenance Data Management System. The original inspection report with UT data will be stored in the equipment files. The electronic copy of the inspection report with UT data will be printed and also stored in the equipment file folder until each inspection activity on the tracking list is signed off as complete. 5.13 The drawings from the circuit package will be given to the ACAD assigned person, who will create or revise the drawing. The original drawings with UT data will be stored in the equipment files. The electronic copy of the inspection report with UT data will be printed and also stored in the equipment file folder until each inspection activity on the tracking list is signed off as complete. 5.14 Once all the necessary work is completed for the selected piece of equipment, the equipment file folder will be sent to the master file at the Host Company. 6.0 REFERENCES OSHA 29 CFR 1910.119 Process Safety Management of Highly Hazardous Chemicals API 570 Piping Inspection Code Inspection, Repair, Alteration, and Rerating of InService Piping Systems ANSI/ASME B31.3 Chemical Plant and Petroleum Refinery Piping ANSI/ASME B31G Remaining Strength of Corroded Pipelines