API570 Training Book PDF

API 570 - PIPING INSPECTOR COURSE
CONTENTS
PROGRAM SCHEDULE, BENCH MARK QUIZ
PART I - CERTIFICATION INFORMATION FROM API.
PART II - GUIDELINES FOR CLEARING API 570 EXAMINATION
PART III - OVERVIEW OF PIPING DESIGN AND CONSTRUCTION

(ASME B 31.3 CODE-2010 EDITION)
PART IV - OVERVIEW OF PIPING INSPECTION CODE

(API 570 CODE-2009 EDITION)
PART V - CASE STUDIES ILLUSTRATING USE OF CODE RULES
PART VI - WPSJPQR REVIEW CASE STUDIES
PART VII - DAILY EXAMINATIONS FOR API 570 COURSE
PART VIII- IMPORTANT SUMMARY POINTS
PART IX - ADDITIONAL INFORMATION
PART X - QUESTION BANK FOR API 570 PREPARATORY COURSE
2
PROGRAM SCHEDULE
I DAY-l
Bench-mark Quiz
Introduction to API 570 certification
ASME B 31.3 Scope and applicability
~ervice/Fluid Classification
Joint Quality Factors
Allowable stresses
Design for Internal Pressure
Design of permanent blanks
Impact testing for Low temperature service
Acceptance of Impact test results
Welding requirements-Preheat Temperatures
PostWeldHeat Treatment
Hardness Testing after PWHT
Practice Questions on ASME B 31.3
I DAY-2
Inspection and testing

N on Destructive Examination Requirements
Acceptance Criteria
Leak testing-Hydrostatic
Leak testing-Pneumatic
Precautions during Pneumatic test
Service leak test
Thermal Expansion of Piping-Table C1
Overview of B16.5
ASME B16.5, Pipe Flanges and Flanged Fittings
Scope
Pressure Temperature Ratings
Materials
Dimensions
System pressure Test
Practice Questions on ASME B 31.3 and B 16.5
I DAY-3.
Scope of API 570

Definitions.
Owner / user inspection organization
API authorized piping inspector qualification and certification
Inspection and testing practices.
Risk-based inspection
Preparation for inspection
Inspection for specific types of corrosion and cracking
Types of inspection and surveillance
Thickness measurement locations
Thickness measurement methods
Inspection of welds in-service
Inspection of flanged joints.
I DAY-4.
Frequency and extent of inspection

Piping service classes
Inspection intervals
Extent of visual external and cui inspections
Inspection data evaluation, analysis, and recording
Corrosion rate determination
Maximum allowable working pressure determination
Repairs, alterations, and rerating of piping systems
Welding and hot tapping.
Inspection of buried piping
Types and methods of inspection
Frequency and extent of inspection
Repairs to buried systems
Overview of API 574 Inspection of piping, tubing, valves, and fittings
I DAY-S.
ASME boiler and pressure vessel code, Sec.IX

Review of a WPS and PQR
Determine if WPS and PQR are in compliance with ASME Sec. IX.
Essential and Nonessential Variables
Determine that the number and type of mechanical tests are correct tests,
Determine whether the results are acceptable.
ASME Section V, nondestructive examination
Article I, general requirements:
Article 2, radiographic examination
I DAY-6.
Article 6, liquid penetrant examination

Article 7, magnetic particle examination (yoke and prod techniques only):
Article 9, visual examination:
Article 10, leak testing
API RP 571, Damage mechanisms in the Refining Industry
Brittle Fracture
Thermal Fatigue
Erosion/ Erosion Corrosion
Mechanical Fatigue
Vibration Induced Fatigue
Atmospheric Corrosion
Corrosion Under Insulation (CUI)
Boiler Water Condensate Corrosion
Flue Gas Dew Point Corrosion
Microbiological Induced Corrosion (MIC)
Soil Corrosion
Sulfidation
Chloride Stress Corrosion Cracking (ClSCC)
Caustic Stress corrosion Cracking (Caustic Embrittlement)
High Temperature Hydrogen Attack (HTTA)
I DAY-7.
Overview of API RP 577, Welding Inspection and Metallurgy

Overview of API Recommended Practice 578 - Material Verification program for New
and Existing Alloy piping Systems
Punch Points for all Codes and Mock Up Examination
.ICP BODY OF KNOWLEDGE
API-570 AUTHORIZED PIPING INSPECTOR

CERTIFICATION EXAMINATION
July 2012 (Replaces August 2010)
API Authorized Piping Inspectors must have a broad knowledge base relating to maintenance, inspection, alteration and
repair of in-service metallic piping systems. The API Authorized Piping Inspector Certification Examination is designed
to determine if applicants have such knowledge.
The examination consists of two parts. The closed book part tests the candidate on knowledge and tasks requiring everyday
working knowledge of API Standard 570 and the applicable reference documents . The open book portion of the
examination requires the use of more detailed information that the inspector is expected to be able to find in the
documents, but would not normally be committed to memory.
REFERENCE PUBLICA nONS:
A. API Publications:
( ... . :,
API Standard 570 - Inspection, Repair, Alteration, and Rerating ofIn-Service Piping Systems
API RP 571, Damage mechanisms Affecting Fixed equipment in the Refining Industry
API Recommended Practice 574 - Inspection Practices for Piping System Components
API RP 577, Welding Inspection and Metallurgy
API Recommended Practice 578 - Material Verification Program for New and Existing Alloy Piping Systems
B. ASME (American Society of Mechanical Engineers) Publications:.
Boiler and Pressure Vessel Code:
Section V, Nondestructive Examination, and
Section IX, Welding and brazing Qualifications
BI6.5, Pipe Flanges and Flanged Fittings
B31 .3, Process Piping
Note: Refer to the Publications Effectivity Sheet in the application package for a list of specific editions, addenda, and
supplements of the referenced publications that are effective for your examination date.
The following is the list of specific topics in which an API certified Piping Inspector should be knowledgeable.
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I. CALCULATIONS FOR EVALUATING THICKNESS MEASUREMENTS, INSPECTION INTERVALS,
AND PIPING INTEGRITY
A. Code calculation questions will be oriented toward existing in-service piping, not new piping. API Authorized Piping
Inspectors should be able to check and perform calculations relative to in-service deterioration, repairs, rerates, or
alterations, such as those included in the following eight categories.
Note: Candidates are expected to understand the SI units (metric system) and the US customary units (inches,
feet, PSI, etc.) and to use both system formulas.
I. CORROSION RATES AND INSPECTION INTERVALS
The Inspector should be able to understand inspection data and determine the thickness measurement and visual
external inspection intervals.
The Inspector must be able to calculate:
a) Corrosion Rates (API-570, Par. 7.1)

b) Remaining Service Life (API-570, Par., 7.1.1)
c) Inspection Interval (API-570, Par., 6.3.3 & Table 2)
The formulas for performing the above calculations and rules for setting the inspection intervals may be "closed-book"
during the exam.
2. WELD JOINT QUALITY FACTORS AND CASTING QUALITY FACTORS
The inspector should be able to determine the weld joint quality factor "Ej" of a longitudinal pipe weld joint. The
inspector should be able to determine:
a) Casting Quality factor, Ec from B31.3, 312.3 and A-1A

b) Weld Joint Quality factors from ASl\1E B31.3 302.3.4 and A-lBy
c) Increased Joint Quality Factors by performing supplemental NDE from ASl\1E B31.3 Table 302.3.4;
Determining weld joint quality factor may be part of an internal pressure problem since the joint factor Ej is used in the
formulas for determining required thickness or internal design pressure.
3. INTERNAL PRESSURE / MINIMUM THICKNESS OF PIPE!
The inspector should be able to determine:
a) The minimum required thickness or pressure design thickness of a straight pipe section for a intemal
pressure only (ASl\1E B31.3 ~ection 304.l.l and 304.1.2);
b) The minimum required thickness of a permanent blank for a given design pressure (ASME B31.3 Section
304.5.3);
c) The "MA WP" of corroded pipe, compensating for expected corrosion loss at the next inspection (API 570,
Par., 7.2)
The inspector should also be able to compensate for the corrosion allowance. (Add or subtract based on requirements
from the exam problem). .
4. PRESSURE TESTING
The inspector should be able to:
a) Demonstrate knowledge concerning hydrostatic leak testing (ASl\1E B31.3 Section 345.4)
b) Demonstrate knowledge concerning pneumatic leak testing (ASl\1E B31.3 Section 345.5)
c) Calculate a hydrostatic or pneumatic leak test pressure (ASl\1E B31.3 Sections 345.4, 345.5)
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5. IMPACT TESTING -\(
The inspector should be able to:
a) Determine the minimum metal temperature of a material, which is exempt from impact testing (ASME
B31.3, Section 323.2.2, Figure 323.2.2A & Table A-I).
b) Determine the minimum required charpy V-notch impact values of a given material. (ASME B31.3,
Section 323.3, Table 323.3.5)
6. PREHEATING AND HEAT TREA TMENT REQUIREMENTS
The inspector should be able to determine which weld sizes require preheating and/or heat treatment. The inspector
also should be able to:
a) Determine what is the required or recommended preheat temperature (ASME B31.3, Section 330 & Table
330.1.1).
b) Determine the governing thickness, holding time, holding temperature, and maximum Brinell hardness for
heat treatment applications (ASME B31.3, Section 331 & Table 331.1.1).
7. THERMAL EXPANSION
The inspector should be able to determine the total thermal expansion of a material between temperatures (ASME
B31.3, Appendix C, Table C-l).
8. MINIMUM WALL THICKNESS & WORKING PRESSURES FOR FLANGES
The inspector should be able to determine the minimum wall thickness and working pressure requirements for flanges.
The inspector should also be able to:
a) Determine the working pressure and minimum/maximum system hydrostatic test pressure for a flange of specified
material and temperature (ASME BI6.5, Par. 2.5 & Table lA & Tables 2-1.1 through 2-3.17).
b) Determine the minimum dimensions of a given flange (ASME B 16.5 Tables 7 through 22).
c) Determine maximum working pressure of a flange when given the design temperature, flange material and flange
class.
d) Determine maximum temperature of a flange when given the design pressure, flange material and flange class.
e) Determine most cost effective flange when given the design pressure, design temperature, and flange material.
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9. MINIMUM REQUIRED THICKNESS OF A PERMANENT BLANK (ASME B31.3, Par. 304.5.3)
B. The following are the ASME B31.3 code engineering requirements that are excluded from the examination and
that the API Authorized Piping Inspectors will NOT be expected to know for the purposes of certification testing.
1. 302 Design criteria - (All except for 302.3.3 Casting Quality Factor, E e, and 302.3.4, Weld Joint
Quality Factor, Ej )
2. 304.1.3 Straight Pipe Under External Pressure
3. 304.2 Curved and Mitered Segments of Pipe
4. 304.3 Branch Connections
5. 304.4 Closures
6. 304.5 Pressure Design of Flanges & Blanks (All except 304.5.3, Blanks)
7. 304.6 Reducers
8. 304.7 Pressure Design of Other Components
9. 315 Tubing Joints
10.316 Caulked Joints
11. 317 Soldered and Brazed Joints
12. 318 SpecialJoints
13.319.4 Flexibility Analysis
14.319.5 Reactions
15. 319.6 Calculation of Movements
16. 319.7 Means of Increasing Flexibility
17. 322.3 Instrument Piping
18. Chap. VII Nonmetallic Piping and Piping Lined With Nonmetals
19. Chap. VIII Piping for Category M Fluid Service
20. Chap. IX High Pressure Piping
21. App.B Stress Tables and Allowable Pressure Tables for Nonmetals
22. App. D Flexibility and Stress Intensification Factors
23. App.E Reference Standards
24. App. G Safeguarding
25. App. H Sample Calculations for Branch Reinforcement
26. App. J Nomenclature
27. App. K Allowable Stresses for High Pressure Piping
28. App. X Metallic Bellows Expansion Joints
29. App. Z Preparation of Technical Inquiries
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II. WELDING PROCEDURE AND QUALIFICATION EVALVATION
A. ASME BOILER AND PRESSURE VESSEL CODE, SECTION IX
The inspector should have the knowledge and skills required to review a Procedure Qualification Record and a Welding
Procedure Specification and to be able to determine the following:
a) Determine if procedure and qualification records are in compliance with applicable ASME Boiler and Pressure
Vessel Code and any additional requirements of API-570. The weld procedure review will include:
One Weld Procedure Specification (WPS); and
One Procedure Qualific(ltion Record (PQR). .
a) Determine if all required essentia:J and non-essential variables have been properly addressed. (Supplemental
essential variables will not be a part of the WPSIPQR)
b) Determine that the number and type of mechanical tests that are listed on PQR are the proper tests, and whether the
results are acceptable.
WELD PROCEDURE REVIEW MAY INCLUDE SMA W, GTAW, GMAW, OR SAW, WITH THE FOLLOWING
LIMITATIONS:
a) No more than one process will be included on a single WPS or PQR and the WPS to be reviewed will be supported
by a single PQR.
b) Filler metals will be limited to one-per-process for SMAW, GTAW, GMAW, or SAW
c) The PQR will be the supporting PQR for the WPS.
d) Base metals will be limited to PI, P3, P4, P5, and P8.
e) Dissimilar base metal joints, and dissimilar thicknesses of base metals will be excluded.
f) Special weld processes such as corrosion-resistant weld metal overlay, hard-facing overlay, and dissimilar metal
welds with buttering of ferritic member will be excluded.
g) For PI, P3; P4, and P5, for the purpose of the examination the lower transition temperature will be 1330 0 F and the
upper transformation temperature will be 1600ilp.
B. ASME B31.3
The inspector should be familiar with and understand the general rules for welding in ASME B31.3, Chapter V such as:
a) Typical joints and definitions

b) Weld sizes
c) Restrictions on joints
d) Maximum allowable reinforcement
e) Inspection requirements
f) Preheating and Heat Treatment
C. API Standard 570

The inspector should be familiar with and understand any rules for welding in API-570. Any rules for welding given in API-
570 shall take precedence over those covering the same areas in ASME, B31.3.
Note: "Editorial" and non-technical requirements for the welding subject matter, the candidate is to be tested on, are
excluded. This includes items such as the revision level of the WPS, company name, WPS number and date, and name
of testing lab. However, the API Authorized Piping Inspector should know that the PQR must be signed and dated.
D. The inspector shall be familiar with all the requirements of and information in API RP 577.
570_bokyev7-10-12_final.docx 5
III. NONDESTRUCTIVE EXAMINATION
1. ASME Section y, Nondestructive Examination
NOTE: The examination will cover only the main body of each referenced Article, except as noted.
A. Article 1, General Requirements:

The inspector should be familiar with and understand;
a) The Scope of Section Y,

b) Rules for use of Section Y as a referenced Code,
c) Responsibilities of the Owner / User, and of subcontractors,
d) Calibration,
e) Definitions of "inspection" and examination"
f) Record keeping requirements,
B. Article 2, Radiographic Examination:

a) The Scope of Article 2 and general requirements,

b) The rules for radiography as typically applied on butt welded seams such as, but not limited to:
Required marking
Type, selection, number, and placement ofIQI's,
Allowable density and density ranges
Control of backscatter radiation
c) Records
C. Article 6, Liquid Penetrant Examination (Including mandatory appendices II and III):
The inspector should be familiar with and understand the general rules for applying and using the liquid penetrant
method, including but not limited to the following:
a) The Scope of Article 6,

b) General requirements such as but not limited to:
Procedures
Contaminants
Techniques
Examination
Interpretation
Documentation and record keeping
E. Article 7, Magnetic Particle Examination (Yoke and Prod techniques only):

The inspector should be familiar with and understand the general rules for applying and using the magnetic particle
method including, but not limited to the following:
a) The Scope of Article 7,

Procedures
Techniques (Yoke and Prod only)
Calibration
Examination
Interpretation
c) Documentation and record keeping
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F. Article 9, Visual Examination:
The inspector should be familiar with and understand the general rules for applying and using the visual examination
method including, but not limited to the following:
a) The scope of Article 9,

Procedures
Physical requirements
Procedure/technique
Evaluation
G. Article 10, Leak Testing (Including Mandatory appendix 1 Bubble Test -Direct Pressure Technique):
The inspector should be familiar with and understand the general rules for applying and using the leak testing method
including, but not limited to the following:
a) The scope of Article 10,

b) General requirements such as but not limited to :
Procedures
Equipment
Calibration
Test
Evaluation
H. Article 23, Ultrasonic Standards, Section SE-797 only - Standard practice for measuring thickness by manual ultrasonic
pulse-echo contact method:
1) The Scope of Article 23, Section SE-797,

2) The general rules for applying and using the Ultrasonic method
3) The specific procedures for Ultrasonic thickness measurement as contained in paragraph 7.
2. ASME B31.3 and API-570: General nondestructive examination requirements:
ASME B31.3: The inspector should be familiar with and understand the general rules for NDE (Chapter VI).
API Standard 570
The inspector should be familiar with and understand the general rules for NDE in API-570.

IV. PRACTICAL KNOWLEDGE - GENERAL
A. The following topics may be covered:
1. Organization and Certification Requirements.

2. Types and Definitions of Maintenance Inspections.
3. Welding on Piping
4. Corrosion and Minimum Thickness Evaluation.
S. Estimated Remaining Life.
6. Inspection Interval Determination and Issues Affecting Intervals.
7. Maintenance Inspection Safety Practices.
8. Inspection Records and Reports.
9. Repairs/ Alterations/Reratings to Piping.
10. Rerating Piping.
11. Pressure Testing After Repairs, Alterations, or Rerating
12. Pressure Temperature Ratings
l3. Markings
14. Materials
15. Dimensions
16. Test
17. Limiting Dimensions of Gaskets
18. Methods for Establishing Pressure-Temperature Ratings
19. Methods of performing positive material identification and related record keeping.
More information relative to each of the categories is contained in section "V. PRACTICAL KNOWLEDGE - SPECIFIC"
where each reference publication applicable for study for the examination has been listed with relevant topics that may
be covered on the examination.

V. PRACTICAL KNOWLEDGE - SPECIFIC
API-570, Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems - the entire document is
subject to testing
API RP 571, Damage mechanisms Affecting Fixed equipment in the Refining Industry
ATTN: Examination questions will be based on the following portions of the document only:
o Par. 3 - Definitions
o 4.2.7 - Brittle Fracture
o 4.2.9 - Thermal Fatigue
o 4.2.14 - ErosionlErosion Corrosion
o 4.2.16 - Mechanical Fatigue
o 4.2.17 - Vibration-Induced Fatigue
o 4.3.l - Galvanic Corrosion
o 4.3.2 - Atmospheric Corrosion
o 4.3.3 - Corrosion Under Insulation (CUI)
o 4.3.5 - Boiler Water Condensate Corrosion
o 4.3.7 - Flue Gas Dew Point Corrosion
o 4.3.8 - Microbiological Induced Corrosion (MlC)
o 4.3.9 - Soil Corrosion
o 4.4.2 - Sulfidation
o 4.5.l - Chloride Stress Corrosion Cracking (CI-SCC)
o 4.5.3 - Caustic Stress corrosion Cracking (Caustic Embrittlement)
o 5.1.3.1 - High Temperature Hydrogen Attack (HTTA)
API RP-574, Inspection of Piping, Tubing, Valves, and Fittings - the entire document is subject to testing
API RP 577, Welding Inspection and Metallurgy - the entire document is subject to testing
API Recommended Practice 578 - Material Verification program for New and Existing Alloy piping Systems
- the entire document is subject to testing
ASME B16.5, Pipe Flanges and Flanged Fittings
o Scope
o Pressure Temperature Ratings
o Markings
o Materials
o Dimensions
o Test
o Limiting Dimensions of Gaskets
o Methods for Establishing Pressure-Temperature Ratings
570 bok rev7-10-12 fina1.docx 9

API 570 Exam Publications Effectivity Sheet
FOR: December 5, 2012 and June 5, 2013 and September 25, 2013
Listed below are the effective editions of the publications required for this exam for the date(s) shown above.
Please be advised that API and ASME documents and publications are copyrighted materials. Reproducing
these documents without API permission is illegal. If exam proctors determine that your documents are
illegal copies, the illegal documents will be confiscated from you prior to the exam.
API Standard 570, Piping Inspection Code: Inspection, Repair, Alteration, and Rerating ofIn-Service Piping
Systems, 3rd Edition, November 2009.
API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment in the Refining Industry,
2nd EDITION, April 2011.
ATTENTION: Only the following sections / mechanisms from RP 571 are included on the exam:
Section 3 - Terms (Definitions)
Mechanisms:
Par. 4.2.7 Brittle Fracture
4.2.9 Thermal Fatigue
4.2.14 ErosionlErosion Corrosion
4.2.16 Mechanical Fatigue
4.2 .17 Vibration-Induced Fatigue
4.3 .1 Galvanic Corrosion
4.3 .2 Atmospheric Corrosion
4.3 .3 Corrosion Under Insulation (CUI)
4.3.5 Boiler Water Condensate Corrosion
4.3 .7 Flue Gas Dew Point Corrosion
4.3.8 Microbiologically Induced Corrosion (MIC)
4.3.9 Soil Corrosion
4.4.2 Sulfidation
4.5 .1 Chloride Stress Corrosion Cracking (Cl-SCC)
4.5.3 Caustic Stress corrosion Cracking (Caustic Embrittlement)
5.1.3.1 High Temperature Hydrogen Attack (HTTA)
API Recommended Practice 574, Inspection Practices for Piping System Components, 3rd Edition, Nov. 2009.
API Recommended Practice 577, Welding Inspection and Metallurgy, 1st edition, October 2004.
(
API Recommended Practice 578, Material Verification Program for New and Existing Alloy Piping Systems, 2nd
Edition, March 2010.
American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel Code, 2010 Edition, w/2011
Addendum, July 2011
i. Section V, Nondestructive Examination, Articles 1,2, 6, 7, 9, 10, and 23 (Section SE-797 only).
ii. Section IX, Welding and Brazing Qualifications, Welding only
American Society of Mechanical Engineers (AS ME)

B16.5, Pipe Flanges and Flanged Fittings, 2009 Edition
B31.3, Process Piping, 2010 Edition
Please ensure you obtain authorized documents from one of API's redistributors:
Techstreet: www.techstreet.com; Phone: 1-800-699-9277
ms Documents: www.global.ihs.com ; Phone: 1-800-854-7179
570- EffSheet2012-2013 - 072312
General Information and Qualification Requirements
1. Introduction
The American Petroleum Institute (API) initiated a Pressure Vessel Inspector Certification Program to
improve management control of process unit operation, repair, and maintenance; reduce the potential for
inspection delays resulting from regulatory requirements; and provide a continued high level of safety
through the use of inspectors specialized in process equipment. The program promotes self-regulation and
establishes a uniform national program that will assist state and local governments in pressure vessel
. regulations.
2. Qualification Requirements
1. You must be employed by or under contract to an authorized inspection agency or owner/user

agency as defined in API 510.
2. You must have one of the following combinations of education and experience:
Minimum
Education Experience
Required
ISkills
Supervision or performance of
BS or higher in
inspection activities as described in
engineering 11Y'" API 510
Design, construction, repair,

2-year degree or operation, or inspection of pressure
certificate in engineering 2 years vessels, of which one year must be in
or technology supervision performance of
inspection activities.

operation, or inspection of pressure
High school diploma or
3 years vessels, of which one year must be in
equivalent
supervision performance of
inspection activities.

( operation, or inspection of pressure
None 5 or more years vessels, of which one year must be in
supervision performance of
inspection activities
3. Methods to Become API 510 Certified
1. Successful completion of National Board of Boiler and Pressure Vessel Inspectors Commission
exam or Certificate of Competency.
Applicants who have successfully passed the written examination for the National Board of Boiler
and Pressure Vessel Inspectors are eligible for API 510 certification without taking API test. Please
fill out the application package for API 510 certification, including the Employment Reference Form,
and provide the appropriate documentation cited in the Application Form to confirm your
qualifications.
2. Written Examination under API Standard 510
If an applicant does not qualify under the National Board Commission, he/she must be certified by
written examination.
Examination Information
1. API examination consists of 150 multiple-choice questions with an open and closed book
sections. The examination is administered by participating members of the National
Board of Boiler and Pressure Vessel Inspectors and by the Professional Examination
Service (PES). Total length of examination is 8 hours. Individual jurisdictions may
charge a sitting fee to take the examination in their jurisdiction. Please contact the
jurisdiction you select for an exact amount. There is no additional sitting fee at the
locations where examination is administered by PES.
2. If you pass the examination, and all sections of your application are complete, you will be
certified and receive a wallet card and a certificate approximately 3 months after the
examination date.
3. API grants each applicant three consecutive attempts during the I8-month period to sit
and pass the test, starting with the first exam administration the applicant registers for. If
you fail the examination on your first attempt, you may retake it twice. If you fail to
appear for the test, it will still count as an official attempt.
4. If you do not pass the examination on the first attempt, you need to submit a $50.00
rescheduling fee. If you do not pass it on the second attempt, you must also submit an
updated Employment Reference form. If the candidate is unsuccessful on the third
attempt, a new application must be submitted with a new application fee.
5. Examination results will be mailed to you approximately 8 weeks after you have taken
the exam. DO NOT call API, PES, or your jurisdiction for examination results; these
results WILL NOT be given over the telephone.
What to Bring to the Exam
o No.2 pencils;
o A non-programmable calculator (a calculator with only simple functions); .
o The applicable API and ASME reference publications. Please note: highlighting,
underlining, page tabs, and notes written in margins of the code books are
acceptable. However, loose pages inserted in the code books are not acceptable.
Note: API and ASME publications are copyrighted material. Photocopies of
( publications are not permitted at the exam;
o Your examination site confirmation letter;
o A picture ID (i.e. driver's license).
Step-by-step certification process
Please complete the following steps in order to get certified:
1. Check out minimum qualification requirements for your chosen certification program , and confirm
your eligibility for certification.
2. Review API's testing and certification policies.
3. Determine the most convenient location, test date and application deadline for your chosen
program .
4. Download the application for your program or request the application package to be sent to you via
mail.
5. Fill out your application completely.
6. Mail your application, supporting documentation and payment to API by the deadline indicated.
7. Download the Body of Knowledge for your chosen program .
8. Obtain necessary technical documents and publications. Effective publication dates are listed in the
application package.
9. Prepare for examination. Training programs are optional and not provided by API.
10. Take the examination.
510 examination sample items
SAMPLE API-510 Exam Items
The items below are examples of what an exam item might look like. If yOU have guestions about an item or
disagree with the answer. please email us at inspector@api.org and we will forward to one of our subject
matter experts.
Correct Answer: 4
A. The nondestructive examination method to be used for a particular inspection should

be determined by the:
1. availability of certified NDE examiners.

2. length of time since the last inspection.
3. age of the component to be inspected.
4. type, location, and orientation of the expected
flaws.
Correct Answer: 3
B. In planning for an internal inspection of a vessel that has contained

acidic corrodents, what type and location of corrosion would you expect
to find on the vessel shell, away from the welds?
1. Hydrogen blistering in the vapor space

2. Hydrogen embrittlement in the vapor space
3. Hydrogen blistering near the liquid level
4. Hydrogen embritllement below the liquid level
Correct Answer: 1
C. A pressure vessel is scheduled for pneumatic testing using the

methodology of ASME Code, Section VIII , Division 1, with the maximum
0
allowable working pressure = 635 psig at 375 F. The vessel is
constructed of SA-516 Gr. 65 material and is neither enameled nor
0
lined. The test metal temperature will be a minimum of 50 F, per the
owner's specifications. How many pressurization steps are needed to
achieve the minimum required test pressure, and at what minimum
( pressure will the visual examination be performed?
1. 6 steps; 635 psig

2.6 steps; 793.75 psig
3. 9 steps; 635 psig
4. 9 steps; 793.75 psig
Correct Answer: 4
D. The principal reason for inspecting a pressure relief device is to

determine:
1. the remaining life.

2. the spring coil diameter.
3. the body thickness.
4. if it is functioning properly.
Correct Answer: 1
E. A pressure vessel has been in service for 12 years and has a history
of corrosion over its service life. The original thickness was 1.9375
inches; the current thickness is 1.405 inches. What is the corrosion rate
for this vessel?
1.0.044 inch per year

2. 0.089 inch per year
Correct Answer: 3
F. What can be done to extend the life of a vessel with a corroded area
in the shell plate 6 inches from the weld, a joint efficiency of less than 1,
and a corrosion thickness currently near the minimum required
thickness?
1 . Recalculate t minimum for current operating

conditions using E < 1.
2. Recalculate t minimum for current operating
conditions using E = 1.
3. Recalculate t minimum for design conditions using
E = 1.
4. Monitor the thickness during the run.
Correct Answer: 2
G. Temporary repairs to pressure vessels:
1. must be replaced with permanent repairs during the

next scheduled shutdown.
2. may remain in place for long periods if approved by

the pressure vessel engineer.
3. may remain in place for long periods if approved by

the API-authorized pressure vessel inspector.
4. may remain in place permanently if approved by

the pressure vessel engineer and the API authorized
pressure vessel inspector.
[M$fiI!Wi! ij f
Correct Answer: 2
H. Who must be consulted before the repair of a crack at a discontinuity

where stress concentrations may be serious?
1. The owner-user
2. The pressure vessel engineer
3. The National Board inspector
4. The vessel manufacturer
Correct Answer: 4
I. The WPS and the PQR are used to determine:
1. if the welder is able to deposit sound weld metal.

2. if the welder is able to operate welding equipment.
3. the welder's ability to produce welds that are
radiographically free of defects.
4. if a weldment has the required properties for the
intended application.
Correct Answer: 3
J. In a certain arc welding process, coalescence of metals is produced

by an arc between a tungsten electrode and the work, and shielding is
obtained from a gas or gas mixture. Both pressure and filler metal may
or may not be used. This process is called:
1. FCAW
2. GMAW
3.GTAW
4. SAW
API 570- PIPING INSPECTOR PREPARATORY COURSE
(VOLUME-I)
Part-2
GUIDELINES FOR CLEARING

API 570 CERTIFICATION EXAMINATION
API 570 CERTIFICATION FOR IN-SERVICE INSPECTION
GUIDELINES FOR CLEARING API 570 EXAMINATION

SUCCESSFULLY
INTRODUCTION
Process plant piping systems are typically designed, fabricated, installed,

inspected, and tested in accordance with ASME B31.3, Process Piping.
Unfortunately, piping systems cannot just be installed, placed into
operation, and forgotten. They must be periodically inspected to ensure
that they have sufficient structural integrity and remain safe for continued
operation.
Repairs may be necessary to correct deterioration.
Alterations are often required when physical changes must be made to a
piping system.
It may be necessary to rerate systems to new design conditions.
API 570, Piping Inspection Code, covers inspection, repair, alteration, and
rerating procedures for metallic piping systems after they have been
placed into service. This course provides an overview of API 570
requirements
The corrosion may cause thinning, pitting or cracking of pipe wall. The internal
pressure will tend to bulge the piping at the corroded locations, releasing the
explosive or toxic contents resulting in serious consequences to the plant,
personnel and the people at large. It is therefore essential that during the planned
shutdowns, the degradation and damages inflicted to the Piping should be
monitored and evaluated so as to arrive at the '3R' decisions. i.e. "Run-Repair-
Replace" decisions.
More specifically, this course describes the essentials of what to inspect, where to
inspect, how much to inspect and what to accept so as to evaluate the safety and
mechanical integrity of in-service Piping. The course also covers methods of
repair, alteration, re-rating and replacements of affected Piping.
The APr Courses provide the participants the guidelines and methodology of
carrying out inspection of in-service" equipments. It also provides techniques
fI
for the assessment of the wear and tear of the equipments as well as to measure
de-gradation and damages caused to the process equipments due to the process
conditions.
COURSE OBJECTIVES
This examination preparation course is designed to prepare the participant to

successfully sit for the API-570 exam. Through your concentrated effort, and the
material provided in this course, you should have sufficient information to pass
the examination.
The majority of the classroom study will focus on the Body of Knowledge. The
goal, is to obtain a perfect score. Therefore please take your daily classroom
activity and assigned homework seriously.
The material contained in this manual is to be thoroughly studied and practiced

prior to attending the course. The math examples and practice problems are
based on the types of questions given on the API -570 exam. Through the use of
these examples, you will be exposed to many of the formulas used during the
course.
The Examination
The certification examination has 150 multiple-choice questions. Each

question has four possible answers.
A few of the multiple-choice questions will require you to perform a
calculation. You will need to perform the calculation and then pick the
correct answer.
Each question is multiple choice questions with given 4 possible choices.
Only one is the correct choice.
The candidate has to pick-up the correct choice and indicate the same on
separate answer sheet.
The answer sheet along with the question paper should be returned back
to the Supervisor.
The correct answer is to be indicated by blackening (filling) the relevant
circle by a pencil.
There is no set passing percentage. However a score of about 95 to 105 out
of 150 is a good estimate of passing score
The test is divided into two sections! a closed-book section and an open-book
section. The closed-book examination includes such questions which the
inspector is normally expected to know without referring the Codes! i.e.! the
questions are II awareness level questions. Whenever you find a very definitive
ll
or quantitative statement in body of the Code! a closed book question may be

expected on it. Thus! the basic requirements of a code! specific liDO!! and
IIDON!T" statements! important quantified statements! important definitions and
well-known inspection principles will constitute such questions.
Where the student is required to refer to the diagrams or formulas or tables or

graphs and curves from the Codes! it will always be an "open-book!! question.
All calculation oriented questions will normally be open-book" type. The Code
/I
information which is not short and crisp, (i.e., large paragraphs, several
,
(
descriptive statements clubbed together) will normally be asked in "open-book"

part. Here the participant is expected not to remember the information but
should know where to find it in the body of the Code.
No reference material of any kind will be permitted during the closed book
portion; some examining proctors may permit language translation dictionaries.
There will be some common knowledge mathematical questions on the practical
portion of the exam - remember to have your calculator available for this part of
the exam.
WEIGHTAGE OF MARKS
You have only a limited amount of time to study, so you need to invest your time
where you can get the MAXIMUM return! Approximately 50% of the test
questions are directly from API 570. So, that's your priority! For every hour spent
studying the other publications, spend 2 hours studying API 570.
There will be about 75 test questions directly from API 570 .This document is
about 40 pages, that averages almost 2 questions per page. The remaining 65
questions will come from the 600+ pages contained in the other documents.
That's only 1 question for every 10 pages.
Following distribution scheme will help the participant to decide how much
time he should spend for each document during preparation.
Note: The weightage indicated is approximate and for guidance only.

A . API Publications:
API 570, Piping Inspection Code ........................................... 50 %

API RP 571, Damage Mechanisms ........................................... .5 %
API RP 574, Recommended practice. Inspection of Piping ........... 4 %
API RP 578, Material verification Program .................................. 3 %
API RP 577, Welding Inspection and Metallurgy ........................ 3 %
B. ASME Publications:
Section V, Nondestructive Examination ................................. 7 %

ASME B 31.1 Process piping code ......................................... 20 %
ASME B 16.5 Flanges and flanged fittings ............................... 3%
Section IX, Welding and Brazing Qualifications ........................7 %
(VOLUME-I)
Part-3
Overview of Piping Design and Construction

(ASME B 31.3 Code-2010 Edition)
CHAPTER 1. INTRODUCTION TO PIPING CODES
1) GENERAL ASME Piping Codes give stipulations and guidelines for the
design, materials, manufacture and testing of pressure Piping.
These are issued by the American Society of Mechanical
Engineers, New York.
It is a LIVE code and is revised and updated periodically by
issuing new editions and addenda. It keeps pace with time and
is responsive to the questions from its users.
2) APPLICABILITY The editions and addenda become applicable after six months
from date of issue. However, for old contracts still in execution,
the old applicable edition and addenda are valid till the
completion of contract! up to start-up.
3) CODE INTERPRETATION : ASME issue written replies know as "Interpretations" to.

the inquiries concerning technical aspects of the code .and are
sent to "Edition - subscribers" as up-date service.
4) CODE CASES ASME committee meets regularly to consider proposed additions

and revisions to the code. At the same time it may formulate
code cases to clarify' Intent' of existing requirements. These
are published as code-Cases. It is published along with new
editions and supplements are automatically sent to
subscribers of code case book till new edition is published.
5) SALIENT FEATURES OF ASME CODES:

Every ASME Code starts with specifying the scope of the code in terms of capacity, size
and pressure and other limitations if any. It also deals with and the battery limits and the
areas of code jurisdictions.
The Codes categorize and classify acceptable grades for materials of construction, for
specific applications covered by the codes. The codes also identify and categorize
various methods of construction / fabrication.
The codes specify the required N.D.T. and other inspections. They also specify accept /
reject criteria.
What is most important about the ASME Code is that they are user friendly, and keep
pace with changing technologies and new materials. No wonder - the users and the
Manufactures world over have adopted the ASME codes whole heartedly.
The participants are advised to refer the actual code clauses and extract information
from the latest codes applicable. ASME code is even evolving document and one has to
refer to the latest applicable edition and addenda.
PRESSURE PIPING CODES - 8 31 :
The ASME 831 Code for Pressure Piping consists of a number of individually published
Sections.
Rules for each Section have been developed considering the need for application of
specific requirements for various types of pressure piping. Application considered for
e.ach Code Section inclu.de
831.1 Power piping: Piping typically found in electric power generating stations, in
industrial and institutional plants, geothermal heating systems, and central and district
heating and cooling systems;
831.3 Process Piping: Piping typically found in petroleum refineries, chemical,

pharmaceutical, textile, paper, semiconductor, and cryogenic plants, and related
processing plants and terminals;
831.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids:
transporting products which are predominately liquid between plants and terminals and
within terminals, pumping, and metering stations;
831.5 Refrigeration Piping: Piping for refrigerants and secondary coolants;
831.8 Gas Transportation and Distribution Piping Systems: piping transporting

products which are predominately gas between sources and terminals. Including
compressor, regulating, and metering stations; and gas gathering pipelines.
831.9 8uilding Services Piping: piping typically found in industrial, institutional,

commercial, and public buildings, and in multi-unit residences, which does not require
range of sizes, pressures, and temperatures covered in B31.1;
831.11 Slurry Transportation Piping Systems: piping transporting aqueous slurries

between plants and terminals, and within terminals, pumping, and regulating stations.
It is the owners responsibility to select the code Section which almost nearly applies to a
proposed piping installation. Factors to be considered by the owner include limitations of
the Code Section; jurisdictional requirements; and the applicability of other codes and
standards. All applicable requirements of the selected Code Section shall be met .For
some installations, more than one Code Section may apply to different parts of the
installation.
CHAPTER - 2. OVERWIEW OF ASME 8 3'1.3
1.1 GENERAL
The Code sets forth engineering requirements deemed necessary for safe design
and construction of pressure piping.
Unless agreement is specifically made between contracting parties to use

another issue, or the regulatory body having jurisdiction imposes the use of
another issue, the latest Edition and Addenda issued at least 6 months prior to
the original contract date for the first phase of activity covering a piping
installation shall be the governing document for all design, materials, fabrication
erection, examination, and testing for the piping until the completion of the work
and initial operation.
1.2 SCOPE
Rules for the Process Piping Code Section B 31.3 have been developed
considering piping typically found in petroleum refineries; chemical,
pharmaceutical, textile, paper; semiconductor, and cryogenic plants; and related
processing plants storage facilities and terminals within the property limits. The
code is therefore often referred as Refineries and Plant piping code
This Code prescribes requirements for materials and components, design,

fabrication, assembly, erection, examination, inspection, and testing of piping.
1.3 DEFINITIONS
1.3,1 Chemical plant: an industrial plant for the manufacture or processing of

chemicals, or of raw materials or intermediates for such chemicals. A
chemical plant may include supporting and service facilities, such as
storage, utility, and waste treatment units.
1.3.2 Fluid service : a general term concerning the application of a piping
system, considering the combination of fluid properties, operating
conditions, and other factors which establish the basis for design of the
piping system. See Appendix M.
a. Category 0 Fluid Service a fluid service in which all the

following apply :
1. the fluid handled is nonflammable, nontoxic, and not

damaging to human tissues as defined in para 300.2 ;
2. the design gage pressure does not exceed 1035 kPA (150
psi) ; and
3. the design temperature is from -29 C (-20 F) through
186 C (366 F)
b. Category M Fluid Service : a fluid service in which the potential

for personnel exposure is judged to be significant and in which a
single exposure to a very small quantity of a toxic fluid, caused by
leakage, can produce serious irreversible harm to persons on
breathing or bodily contact, even when prompt restorative
measures are taken.
c. High Pressure Fluid Service: a fluid service for which the

owner specifies the use of Chapter IX for piping design and
construction; see also para. K300
d. Normal Fluid Service : a fluid service pertaining to most piping

covered by this Code, i.e. not subject to the rules for Category 0,
Category M, or High Pressure Fluid Service.
Fluid Service Categories
Normal Fluid Service Pertains to most piping covered by the Code and
includes piping not classified within the other fluid
services listed below [300.2].
Service in which the fluid is nonflammable, nontoxic,

Category D Service and not damaging to human tissue; the design
pressure does not exceed 150 psig (1030 kPag); and
the design temperature is from -20F (-29C) TO
366F (186C)[300.2].
Service in which a single exposure to a very small

Category M Service
quantity of toxic fluid can produce serious irreversible
harm on breathing or body contact, even when prompt
restorative measures are taken [300.2].
Service which applies when designated by the owner,

High Pressure (K) Service typically for pressures in excess of that allowed by
ASME 816.5 Class 2500 rating, for the specified
design temperature and material group mk300(a)].
CHAPTER - 3. DESIGN OF PIPING COMPONENTS
1.1 DESIGN CONDITIONS
This paragraph defines the temperatures, pressures, and forces applicable to

the design of piping, and states the considerations that shall be given to
various effects and their consequent loadings.
1.1.1 Design Pressure :

The design pressure of each component in a piping system shall be not
less than the pressure at the most severe condition of coincident internal
or external pressure and temperature (minimum or maximum) expected
during service.
1.1.2 Design Temperature :

The design temperature of each component in a piping system is the
temperature at which, under the coincident pressure, the greatest
thickness or highest component rating is required.
1.1.3 Design Minimum Temperature :

The design minimum temperature is the lowest component temperature
expected in service.
1.1.4 Bases for Design Stresses
1. the lower of one-third of SMTS and one-third of tensile strength at

temperature;
2. the lower of two-third of SMYS and two - thirds of yield strength at
temperature;
2.2 WELD JOINT QUALITY FACTOR, EJ
Basic Quality Factors. The weld joint quality factors Ej tabulated in Table A-1 B
are basic factors for straight or spiral longitudinal welded joints for pressure-
containing components as shown in Table 302.3.4
Increased Quality Factors. Table 302.3.4 also indicates higher joint quality
factors which may be substituted for those in Table A-1 B for certain kinds of
welds if additional examination is performed beyond that required by the product
specification.
2.3 WELD JOINT STRENGTH REDUCTION FACTOR, W :
The factor shall be taken as 1.0 at temperatures of 510 deg C and below, and
0.5 at 815 deg C for all materials. The strength factor shall be interpolated for
intermediate values.
2.3 PRESSURE DESIGN OF COMPONENTS:
2.3.1 Straight Pipe
The required thickness of straight sections of pipe shall be determined in

accordance with following equation.
tm = t + c
The Nominal thickness T for the pipe selected considering manufacturer's

minus tolerance, shall be not less than t m .
The following nomenclature is used in the equations for pressure design

of straight pipe.
= minimum required thickness, including mechanical,

corrosion, and erosion allowances.
t = pressure design thickness.
c = plus corrosion and erosion allowances.
T = Nominal pipe wall thickness
P = internal design gage pressure.
0 = outside diameter of pipe
E = quality factor from Table A-1A or A-1 B
S = stress value of materials.
y = coefficient from Table 304.1.1, valid for t < 0/6 and for
materials shown. The value of Y may be interpolated for
intermediate temperatures.
W = weld joint strength reduction factor.
Straight Pipe Under Internal Pressure:
For t < 0/6, the internal pressure design thickness for straight pipe shall
be not less than that calculated in accordance with Eq. (3a) :
PO
t =
2(SEW + PY)
Straight Pipe Under External Pressure:
To determine wall thickness and stiffening requirements for straight pipe under
external pressure, the procedure outlined in the BPV code, Section VIII Division
1, UG-28 through UG-30 shall be followed, using as the design length L, the
running centerline length between any two sections stiffened in accordance with
UG-29.
2.3.2 Blanks
The minimum required thickness of a permanent blank (representative
configurations shown in Fig. 304.5.3) shall be calculated in accordance
with Eq. (15)
=
.y
+C16SEW
where-
dg = inside diameter of gasket
E = same as defined earlier.
p = design gage pressure
S = same as defined earlier
c = sum of allowances defined earlier.
W = weld joint strength reduction factor.

CHAPTER - 4. PIPING MATERIALS
Generic Description
Classification of materials by generic description involves the grouping of materials into

broad categories according to certain attributes such as general composition,
mechanical properties, product form, or end use.
Material Requirements of 831.3
Materials considerations are specifically covered in 831.3 Chapter III, but there are also
material references in many other chapters. In fact, after stating the obvious in the first
sentences of Chapter III (that "limitations and required qualifications for materials are
based on their inherent properties") [323], 831.3 continues by referring back to 300(d) in
Chapter 1.
Materials and Specifications [323.1]
831.3 classifies materials as listed, unlisted, unknown, or reclaimed, and places

conditions on the used of such materials.
In most cases, Code users deal with listed materials. These may be considered as
materials, which are "pre-qualified" for Code use based on inherent properties and listed
in 831.3 Tables A-1 and A-2. For pressure design purposes, the Code provides stress
values for the listed materials as a function of temperature (since mechanical behavior is
temperature dependent). However, the suitability of a particular material for a particular
fluid service is beyond the scope of the Code. A materials specialist should be
consulted to ensure correct materials selection for a fluid service.
Temperature Limitations [323.2]
831.3 recognizes that material properties and behavior in service are temperature
dependent. A significant portion of b31.3 Chapter III deals with temperature limitations
for materials, in particular lower temperature limits where impact testing may apply. The
Code also imposes cautionary and restrictive temperature limits in Tables A-1 and A-2,
and requires designers to verify that materials are suitable for service throughout the
operating temperature range
Upper Temperature Limits [323.2.1]
Upper temperature limits for listed limited materials are the maximum temperatures for
which a stress value or rating is shown directly in or referenced by the Code. The Code
may also provide notes to the stress value tables, precautionary information in Appendix
F, and lor restrictions within the text of Code. For example, from Table A-1, the upper
temperature limit for ASTM A 106 Grade 8 pipe is 11 OOF even though there are two
notes pertaining to use of the material above 800F and 900F, respectively.
Lower Temperature Limits and Impact Testing [323.2.21
Lower temperature limits for materials are established as a means of controlling risk of
brittle fracture. Terms frequently used in lower temperature limit discussions include
notch sensitivity, impact testing, Charpy testing, and notch brittleness.
For must Code users, the basic question to be answered is: "Do I need to use impact
tested mater'ialsl,1,; answering the question can be complex and convoluted; however, the
basic steps to determining the answer are listed below and are discussed in detail in the
following paragraphs.
a. Select the design minimum temperature for the piping. This may involve process
engineering and or heat transfer specialists, and consideration of ambient
temperature effects.
b. Obtain the minimum permissible temperature for the proposed piping materials
according to 831.3 rules.
a. Follow the instructions of 831.3 to determine whether impact tests are required
(e.g., Table 323.2.2).
b. If impact tests are required, consult the additional requirements of 831.3 regarding
impact test methods and acceptance criteria.
Common Code Paragraphs Relating to Notch Toughness and Low Temperature

Requirements
For the convenience of users of the guide, several clauses and tables applicable to
831.3 impact testing requirement are listed in Table below.
831.3 Clauses and Tables Applicable to Impact Testing
Clause or Table Description
301.3.1 Design Minimum Temperature

323.1 Materials and Specifications
Fig. 323.2.2A Minimum Temperatures Without Impact Testing
323.2 Temperature Limitations
323.2.2 Lower Temperature Limits, Listed Materials
323.3 Impact Testing Methods and Acceptance Criteria
323.3.3 Test Specimens
Table 323.3.5 Minimum Required Charpy V-Notch Impact Values
CHAPTER - 5. FABRICATION AND ERECTION
Introduction
ASME 831.3 gives exhaustive requirements for the fabrication, assembly, and erection
of piping systems. These terms are defined by as follows.
a. Fabrication is the preparation of piping for assembly, including cutting, threading,

grooving, forming, bending, and joining of components into subassemblies.
Fabrication may be performed in the shop or in the field.
b. Assembly is the joining together of two or more piping components by bolting,

welding, bonding, screwing, brazing, soldering, cementing, or use of packing
devices as specified by the engineering design.
c. Erection is the complete installation of a piping system in the locations and on the
supports designated by the engineering design, including any field assembly,
fabrication, examination, inspection, and testing of the system as required by the
code.
Welding
831.3 provides welding guidance in the areas of:

a. responsibility [328.1],
b. qualifications[328.2], and
c. technical and workmanship criteria [328.3 through 328.6].
Welding Qualification [328.2]
Although the qualification exemptions discussed above may be used, normally the
employer is required to conduct welding qualifications. 831.3 controls the details of
welding qualifications by referencing:
a. ASME Section IX[328.2.1 (a)],
b. Supplementary technical requirements
c. Requirements for qualification records
8y external reference to ASME Section IX, the 831.3 Code takes advantage of a general
working document governing welding qualifications for the entire ASME Code. Topics in
the following paragraphs, which address welding variables listed in ASME Section IX,
are indicated by the "QW" prefix to clause numbers.
Pre-heating:
a. 831.3 defines preheating as the application of heat to the base metal immediately
before or during a forming, welding, or cutting process [300.2]. This definition has a
slightly broader scope than the definition provided in ASME Section IX QW - 492.
831.3 also states that preheat is used, along with heat treatment to minimize the
detrimental effects of high temperature and severe thermal gradients inherent in
welding [330.1].
From a practical welding perspective, the method of heating is not generally an issue as
long as the correct preheat temperature is achieved, with the heat uniformly applied
throughout the full thickness and circumference of the joint. In some cases, the use of
oxyacetylene torches is prohibited by owner specifications due to the intensity of the
heat source and the risk of local damage to the base metal or weld metal if the heat is
concentrated at one location.
831.3 requires that the preheat temperature be checked to ensure that the temperature
specified by the WPS is obtained prior to and during welding
a. Temperature indicating crayons, thermocouple pyrometers, or other suitable means

shall be used to measure temperature, [330.1.3(a)]
b. The preheat zone shall extend at least 1 inch beyond each edge of the weld.
Heat Treatment [331]
Heat treatment is used to minimize certain detrimental effects associated with welding,
bending and forming processes [331]. Depending on the nature of each process,
attendant high temperatures, severe thermal gradients, and/or severe metal forming.
operations (cold work) can result in dramatic loss of toughness, reduction of ductility,
increased hardness, and/or high residual stresses. In turn, these can lead to premature,
unexpected, and potentially catastrophic failures caused by brittle fracture, fatigue
cracking, stress corrosion cracking, and/or hydrogen embrittlement.
831.3 provides basic heat treatment practices suitable for most welding, bending, and
forming operations. One should confirm that proposed heat treatment cycles are capable
of satisfying maximum hardness restrictions. Confirmation would
Heat treatments listed in 831.3 table 331.1.1 are best described as stress relieving heat
treatments, since the primary purpose of the treatment is the reduction of residual
stresses due to welding, forming, or bending operations. Such treatment may also result
in improved ductility, lower hardness (note that 831.3 does impose some hardness
restrictions), better toughness, and reduced distortion during subsequent machining
operations ..
Heat Treatment Requirements
331.1.1 imposes the following heat treatment requirements:

a. Heat treatment shall be in accordance with the material groupings and thickness
ranges in Table 331.1.1
b. Heat treatment to be used after production welding shall be specified in the WPS
and shall be used in qualifying the welding procedure.
c. The engineering design shall specify the examination and/or other production
quality controls (not less than the requirements of 831.3) to ensure that the final
welds are of adequate quality.
d. Heat treatment for bending and forming shall be in accordance with 332.4.
Equipment and Methods of Heat Treatment
831.3 does not impose limitations on heating equipment and methods. It only indicates
that the heating method must provide the required metal temperature, metal temperature
uniformity, and temperature control, and then lists methods which may be used for
heating including furnace, local flame heating, electric resistance, electric induction, and
exothermic chemical reaction [ 331.1.4].
Heating methods used for heat treatment may be classified in terms of the facility used
for heat-treating and the energy source. Facilities can be discussed in terms of local heat
treatment and furnace heat treatment.
a. Local heat treatment involves the heating of a small band of metal. Normally the
band being heat-treated is stationary, but in some manufacturing operations, the
band moves. Examples of moving bands include in-line-tempering operations used
during manufacture of quenched and tempered pipe and local heating operations
used in the manufacture of induction bends.
b. Furnace heat treatment generally involves placing the item to be heat treated inside
a permanent furnace operated by a fabrication shop or commercial heat treater.
However, it is possible to construct temporary heat treatment facilities (e.g., at the
job site), which may range from simple ad hoc insulated box constructions to
complex portable furnaces.
Heating and Cooling Rates [331.1.4]
831.3 does not impose restrictions on heating and cooling rates [331.1.4]. ASME .
Section VIII, Division 1, UCS-56 requirements are frequently applied, but there are
causes where insulation and coils are ripped off immediately after the soak period. In the
stress relieving business, time is money, especially if the heat treater is working by the
weld or lump sum. So, if heating and cooling rates need to be controlled, it should be
stated in specifications or other contract documents.
Hardness Tests [331.1.4]
Hardness tests of production welds and of hot bent and hot-formed piping are intended
to verify satisfactory heat treatment. Hardness limits apply to the weld and to the heat
affected zone (HAZ) tested as close as practicable to the edge of the weld.
a. Where a hardness limit is specified in Table 331.1.1, at least 10% of welds, hot
bends, and hot formed components in each furnace heat treated batch and 100% of
those locally heat treated shall be tested.
b. When dissimilar metals are joined by welding, the hardness limits specified for the
. base and welding materials in Table 331.1.1 shall be met for each material.
The code does not discuss many of the technical details necessary to give an accurate
and representative appraisal of production weld harness. Consequently, owner
specifications are recommended for guidance on applying this simple but often misused
and abused test method. Owner specifications should consider the size of hardness
indentations relative to the size of weld zones to be measured, surface preparation of
. the weld, methods for locating the zones of interest, and training requirements for
hardness testing personnel.
CHAPTER - 6 INSPECTION, TESTING
Inspection of Piping:
The code distinguishes between Examination (see para. 341) and Inspection. Inspection
applies to functions performed for the owner, by the owner's inspector or the inspector
delegate. References in this code to the "Inspector" are to the owner's inspector or the
inspector delegate.
It is owner's responsibility, exercised through the inspector, to verify that all required
examinations and testing have been completed and to inspect the piping to the extent
necessary to his satisfaction to confirm all applicable examinations required by code and
by the engineering Design.
The owner's Inspector shall be designated by the owner and shall be the owner, an
employee of the owner, an employee of an engineering or scientific organization,
or of a recognized insurance or inspection company acting as the owner's agent
The owner's Inspector shall have not less than 10 years experience in the design,
fabrication, or inspection of industrial pressure piping
It is a right of the inspector delegated by code that the inspector shall have access to
any place where work concerned with piping fabrication, installation is being performed.
This includes manufactures, fabrications, assembly, erection, examination and testing of
piping. He shall have right to audit any examination, examination methods, qualification
of personnel carrying examinations and review of records.
Inspector shall be the owner, employee of the owner, employee of the inspection
organization. Inspector shall not represent nor be the employee of piping manufacturer,
fabricator or erector.
Inspector shall have engineering degree and at least 5 years relevant experience.
Examination
Examination applies to functions performed for the manufacturer, fabricator of piping

system. Inspection does not relive the manufacture, fabricator or erector of the
responsibility for
Providing material, components and workmanship in accordance with the

requirement of the code.
Performing all required examinations and
Preparing all necessary records of all examinations and testing.
Examination Requirements
Code has specified various minimum required examinations to be carried out for
checking of the quality achieved. Code also specifies acceptance criteria for all these
various examination results. Code suggests the remedies over the defects find outs and
specifies the repairs and re-examinations (double of the originally specified) of that
repaired component. Code has specified very systematic approach to carry out the
examinations so as to maintain the minimum expected quality.
Code has specified minimum requirements of following examinations:
Visual Examinations: At least following shall be examined in accordance with para.

344.2
Sufficient materials and components, randomly selected are confirming to

the specifications and free from defects,
At least 5% of work of each welder is examined,
100% of fabrication of longitudinal welds at site,
Random examination of threaded assemblies. All threaded joints which
will be pneumatically tested, shall be examined,
Random examination of alignment of weld joints, flange joints during
erection,
Examination of erected piping to the satisfaction of engineering
requirements.
Other examinations:
Not less than 5% of circumferential butt and miter groove weld shall be examined fully by
random radiography in accordance with para 344.5 or by random ultrasonic
examinations in accordance with para 344.6. Weld shall be selected in such a way that
each welder's production welding is covered. They shall be selected to maximize
coverage of intersections with the longitudinal joints. At least 38 mm (1 ~ in) of
longitudinal weld shall be examined.
Testing of Piping System.
After completion of construction in all aspects and before first run (commissioning) it is
mandatory to test the systems for design conditions. Code has made pressure test
mandatory for all piping installations with water. In case hydrates is not possible, one
can opt for pneumatic test.
Code has recommended test pressure as 1.5 times design pressure and also suggested
to use temperature correction factor. For pneumatic test the test pressu(e factor is 1.1
and temperature correction factor is optional for owner.
System shall be tested at least for 10 minutes at test temperature. No evidence of any
kind of leak shall be noticed. During pneumatic test code identifies the hazard involved in
the energy stored system and has suggested carrying out test stage wise.
The record of all tests, examinations and inspection shall be maintain for at least for five
years.
(VOLUME-I)
Part-4
Overview of In-Service Piping Inspection Code

(API 570 Code-2009 Edition)
1
PIPING INSPECTION AS PER API 570.
1. INTRODUCTION TO API-570
1.1 SCOPE
1.1.1 Coverage
API 570 covers inspection, repair, alteration, and rerating procedures for metallic piping
systems that have been in service.
Repair ; The work necessary to restore a piping system to a condition suitable for safe
operation at the design condition.
Alterations : A physical change in any component that has design implications

affecting the pressure containing capability or flexibility of a piping system beyond the
scope of its design.
Rerating : A change in either or both the design temperature or the maximum

allowable working pressure of a piping system. A rerating may consist of an increase, a
decrease, or a combination of both. Rerating below original design conditions is a
means to provide increased corrosion allowance.
1.1.2 LIMITATIONS:
API 570 shall not be used as a substitute for the original construction requirements
governing a piping system before it is placed in service.
1.2 SPECIFIC APPLICATIONS
1.2.1 Included Fluid Services
a. API 570 applies to piping systems for process fluids, hydrocarbons, and
similar flammable or toxic fluid services.
1.2.2 Excluded or Optional Piping Systems :
The fluid services and classes of piping systems listed below are excluded from the specific
requirements of API 570 but may be included at the owner's or user's (owner/user's) option.
a. Fluid services that are excluded or optional include the following.
1. Hazardous fluid services below threshold limits, as defined by jurisdictional

regulations.
2. Water (including fire protection systems) , steam, steam-condensate, boiler
feed water, and Category D fluid services, as defined in ASME B 31.3
2
2. DEFINITIONS
2.1 APPLICABLE CODE :
The code, code section, or other recognized and generally accepted engineering
standard or practice to which the piping system was built or which is deemed by the
owner or user or the piping engineer to be most appropriate for the situation, including
but not limited to the latest edition of ASME B 31.3
2.2 AUTHORIZED INSPECTION AGENCY
Defined as any of the following. :
a. The inspection organization of the jurisdiction in which the piping system is used.
b. The inspection organization of an insurance company that is licensed or

registered to write insurance for piping systems.
c. An owner or user of piping systems who maintains an inspection organization for

activities relating only to his equipment and not for piping systems intended for
sale or resale.
d. An independent inspection organization employed by or under contract to the

owner or user of piping systems that are used only by the owner or user and not
for sale or resale.
e. An independent inspection organization licensed or recognized by the jurisdiction
in which the piping system is used and employed by or under contract to the
owner or user.
2~3 AUTHORIZED PIPIN~ INSPECTOR :
An employee of an authorized inspection agency who is qualified and certified to perform

the functions specified in API 570. A nondestructive (NDE) examiner is not required to
be an authorized piping inspector. Whenever the term inspector is used in API 570, it
refers to an authorized piping inspector.
2.4 AUXILLARY PIPING:
Instrument and machinery piping, typically small-bore secondary process piping that can
be isolated from primary piping systems. Examples include flush lines, seal oil lines,
analyzer lines, balance lines, buffer gas lines, drains and vents.
2.5 CUI:
Corrosion under insulation, including stress corrosion cracking under insulation.
2.6 DEAD LEGS :
3
Components of a piping system that normally have no significant flow. Examples
include the following : blanked branches, lines with normally closed block valves, lines
with one end blanked, pressurized dummy support legs, stagnant control valve bypass
piping, spare pump piping, etc
2.7 DEFECT:
An imperfection of a type or magnitude exceeding the acceptable criteria.
2.8 EXAMINER:
A person who assists the [nspector by performing specific nondestructive examination

(NDE) on piping system components but does not evaluate the results of those
examinations in accordance with API 570, unless specifically trained and authorized to
do so by the owner or user. The examiner need not be qualified in accordance with API
570.
2.9 HOLD POINT
A point in the repair or alteration process beyond which work may not proceed until the
required inspection has been performed and documented.
2.10 IMPERFECTIONS:
Flaws or other discontinuities noted during inspection that may be subject to acceptance
criteria during an engineering and inspection analysis.
2.11 INDICATION:
A response or evidence resulting from the application of a nondestructive evaluation

technique.
2.12 INJECTION POINT
Locations where relatively small quantities of materials are injected into process streams
to control chemistry or other process variables. Injection points do not include locations
where two process streams join.
2.13 IN-SERVICE:
Refers to piping systems that have been placed in operation, as opposed to new
construction prior to being placed in service.
2.14 INSPECTOR:
An authorized piping inspector.
2.15 LEVEL BRIDLE :
A level gauge glass piping assembly attached to a vessel.
4
2.16 MAXIMUM ALLOWABLE WORKING PRESSURE (MAWP)
The maximum internal pressure permitted in the piping system for continued operation at
the most severe condition of coincident internal or external pressure and temperature
(maximum and minimum) expected during service. It is the same as the design
pressure, as defined in ASME B 31.3 and other code sections, and is subject to the
same rules relating to allowances for variations of pressure or temperature or both.
2.17 ON-STREAM:
Piping containing any amount of process fluid.
2.18 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.
2.19 PRIMARY PROCESS PIPING:
Process piping in normal, active service that cannot be valved off or, if it were valved off,
would significantly affect unit operability. Primary process piping normally includes all
process piping greater than NPS 2.
2.20 REPAIR ORGANIZATION
Any of the following:
a. An owner or user of piping systems who repairs or alters his or her own
equipment in accordance with API 570.
b. A contractor whose qualifications are acceptable to the owner or user of piping
systems and who make~JepairsQralterations,in accordance with API 570. .
c. One who is authorized by, acceptable to, or otherwise not prohibited by the
jurisdiction and who makes repairs in accordance with API 570.
2.21 SECONDARY PROCESS PIPING :
Small-bore (less than or equal to NPS 2) process piping downstream of normally closed
block valves.
2.22 SMALL-BORE PIPING (SBP)
Piping that is less than or equal to NPS 2.
2.23 SOIL-TO AIR (S/A) INTERFACE :
An area in which external corrosion may occur on partially buried pipe. The zone of the
corrosion will vary depending on factors such as moisture, oxygen content of the soil,
and operating temperature. The zone generally is considered to be from 12 inches (305
5
mm) below to 6 inches (150 mm) above the soil surface. Pipe running parallel with the
soil surface that contacts the soil is included. .
2.24 SPOOL:
A section of piping encompassed by fianges or other connecting fittings such as unions.
2.25 TEMPER EMBRITTLEMENT :
A loss of ductility and notch toughness in susceptible low-alloy steels, such as 1 14 Cr

and 2 14 Cr, due to prolonged exposure to high-temperature service [700 F-1070F
(370C-575C) ]
2.26 TEMPORARY REPAIRS :
Repairs made to piping systems in order to restore sufficient integrity to continue safe
operation until permanent repairs can be scheduled and accomplished within a time
period acceptable to the inspector or piping engineer.
2.27 TEST POINT :
An area defined by a circle having a diameter not greater than 2 inches (50 mm) for a
line diameter not exceeding 10 inches (250 mm) or not greater than 3 inches (75 mm)
for larger lines. Thickness readings may be averaged within this area. A test point shall
be within a thickness measurement location.
2.28 THICKNESS MEASUREMENT LOCATIONS (TMLs)
Designated areas on piping systems where periodic inspections and thickness

measurement's are conducted.
2.29 WFMT:
Wet fluorescent magnetic -particle testing.
6
3. INSPECTION AND TESTING PRACTICES
1. ~. RISK.BASED INSPECTION (RBI)
RBI is identifying and evaluating potential degradation consequence of which may be a

risk of creation of unsafe conditions (for plant, process, people) and! or likely failure of
component.
RBI involves following essential elements:
Expected type of degradation. ely areas affected i.e. identifying the most prone areas
and possible locations, Measurement of degradation i.e. quantifying the amount of
degradation.
Assessment and evaluation i.e. analysis of degradation ( Likelihood of failure)
Assessment and evaluation of possible consequences.
Above all effectiveness of inspection practices, tools techniques employed have a

great bearing of success of RBI program.
2. PREPARATION:
Prior to actual inspection proper preparation and safety precautions are essential
particularly if components are to be inspected internally. This essentially involves
Isolating and segregating the piping system, installing blanks (blids) etc.
Removal of harmful liquids, gases, vapors, flushing out and purging to bring down
residual content to safe leveJs.
Obtain suitable permissions to work i.e. cold work permit (CWP), Hotwork Permits
(HWP) etc.
Protective equipment, clothing, masking as required.
Safety equipments shall be subject 0 operating facilities safety requirements. (e. g.

electrical requirements, flame arrester etc.)
3. INSPECTION FOR SPECIFIC TYPES OF CORROSION AND CRACKING:
Each owner! user should provide specific attention to the need for inspection of piping
system that are susceptible to the following specific types & areas of deterioration:
a. Injection points.
b. Oeadlegs.
c. Corrosion under insulation ( CUI ).
d. Soil-to-air (S!A ) interfaces.
7
e. Services specific & localized corrosion.
f. Erosion &c orrosion/erosion.
g. Environmental cracking.
h. Corrosion beneath linings & deposits.
i. Fatigue cracking.
j. Creep cracking.
k. Brittle fracture.
I. Freeze damage.
3.1 Injection Points: Injection points are sometimes subject to accelerated or localized
corrosion.
When designating an injection point circuit for the purposes of inspection, the
recommended upstream limit of the injection point circuit is a minimum of 12 inches
(300) or three pipe diameters upstream of the injection point, whichever is greater. The
recommended downstream limit of the injection point circuit is the seconed change in
flow direction past the injection point, or 25 feet (7.6 m) beyond the first change in flow
direction, whichever is less. In some cases, it may be more appropriate to extend this
circuit to the next piece of pressure equipment.
The preferred methods of inspecting injection points are radiography and/or ultrasonics,
as appropriate, to establish the minimum thickness at each TML.
During periodiC scheduled inspections, more extensive inspection should be applied to

an area beginning 12 inches (300 mm) upstream of the injection nozzle and continuing
for at least ten pipe diameters downstream of the injection point. Additionally, measure
and record the thickness at all TMLs within the injection point circuit.
3.2 Oeadlegs : The corrosion rate in dead legs can vary significantly from the adjacent active
piping. The inspector should monitor wall thickness on selected dead legs, including both
the stagnant end and at the connection to an active line. In hot piping systems, the high-
point area may corrode due to convective currents set up in the deadlegs. Consideration
should be given to removing dead legs that serve no further process purpose.
3.3. Corrosion Under Insulation : External inspection of insulated piping systems should
include a review of the integrity of the insulation system for conditions that cold lead to
corrosion under insulation (CUI) and for signs of ongoing CUI. Sources of moisture may
include rain, water leaks, condensation and deluge systems. The most common forms of
CUI are localized corrosion of carbon steel and chloride stress corrosion cracking of
austenitic stainless steels.
3.4 Insulated Piping Systems Susceptible to CUI : Certain areas and types of piping
systems are potentially more susceptible to CUI, including the following:
a. Areas exposed to mist overspray from cooling water towers.

b. Areas exposed to steam vents.
c. Areas exposed to deluge systems
d. Areas subject to process spills, ingress of moisture, or acid vapors.
8
e. Carbon steel piping systems, including those insulated for personnel protection,
operation between 25 F- 250 F (-4C-120 C).
f. Carbon steel piping systems that normally operate in-service above 250 F
(120C) but are in intermittent service.
g. Deadlegs and attachments that protrude from insulated piping and operate at a
different temperature than the operating temperature of the active line.
h. Austenitic stainless steel piping systems operating 1500 F- 400 F (65C-204C).
(These systems are susceptible to chloride cracking. )
i. Vibrating piping systems that have a tendency to inflict damage to insulation
jacketing providing a path for water ingress.
j. Steam traced piping systems that may experience tracing leaks, especially at
tubing fitting beneath the insulation.
k. Piping systems with deteriorated coatings and/or wrappings.
3.5 Soil-to-Air Interface: Soil-to-air (S/A) interfaces for buried piping without adequate
cathodic protection shall be included in scheduled external piping inspections.)
Thickness measurements and excavation may be required to assess whether the corrosion
is localized to the S/A interface or extends to the buried system.
Thickness readings at S/A interfaces may expose the metal and accelerate corrosion if
coatings and wrappings are not properly restored.
If the buried piping is uncoated at grade, consideration should be given to excavating 6

inches to 12 inches (150 mm to 300 mm) deep to assess the potential for hidden
damage.
3.7 Service Specific & Localized Corrosion: Examples of Service Specific & Localized
Corrosion are::
Dew point corrosion in condensing streams.
Mixed grades of carbon steel piping in hot corrosive oil service (450 deg F [230
deg]C) or higher temperature & sulfur content in the oil greater than 0.5 percent by
weight.
Non silicon kiled steel pipe, such as A-53 & API 5L, may corrode at higher rates than
does silicon killed steel pipe, such as A-106 especially in high -temperature sulfidic
environments.
3.6 Erosion & corrosionl erosion: Erosion can be defined as the removal of surface
material by the action of numerous individual impacts of solid or liquid particles. It can
be characterized by grooves, rounded holes, waves, & vallys in a directional pattern.
Erosion usually occurs in areas of turbulent flow, such as at change of direction in a
piping system or downstream of control valves where vaporization may take place.
3.7 Erosion damage is usually increased in streams with large quantities of solid or liquid
particles flowing at high velocities. A combination of corrosion & erosion (
corrosion/erosion )results in significantly greater metal loss than can be expected from
corrosion occurs at high velocity & high turbulence areas.
9
3.9 Environmental Cracking: Piping system construction materials are normally selected
to resist the various forms of stress corrosion cracking (SCC). However, some piping
system may be susceptible to environmental cracking due to upset process conditions,
CUI unanticipated condensation, or exposure to wet hydrogen sulfide or carbonates.
Examples of environmental cracking include:
a. Chloride SCC of austenitic stainless steels due to moisture &

chlorides under insulation, under deposits, under gaskets, or in crevices.
b. Caustic SCC ( sometimes known as caustic embrittlement ).
c. Scc in environments where wet hydrogen sulfide exists, such as systems'
containing sour water.
d. Hydrogen blistering & hydrogen induced cracking ( HIC ) damage.
10
4. SPECIFIC AREAS OF INSPECTION
4.1 CORROSION BENEATH LININGS AND DEPOSITS :
If external or internal coatings, refractory linings, and corrosion-resistant linings are in

good condition and there is no reason to suspect a deteriorated condition behind them, it
is usually not necessary to remove them for inspection of the piping system.
The linings should be inspected for separation, breaks, holes, and blisters. If any of
these conditions are noted, it may be necessary to remove portions of the internal lining
to investigate the effectiveness of the lining and the. condition of the metal piping
beneath the lining.
Corrosion beneath refractory linings can result in separation and bulging of the
refractory. If bulging or separation of the refractory lining is detected, portions of the
refractory may be removed to permit inspection of the piping beneath the refractory.
4.2. FATIGUE CRACKING :
Fatigue cracking of piping systems may result from excessive cyclic stresses that are
often well below the static yield strength of the material. Excessive piping system
vibration (such as machine or flow-induced vibrations) also can cause high-cycle fatigue
damage.
Fatigue cracking can typically be first detected at points of high-stress intensification

such as branch connections. Locations where metals having different coefficients of
thermal expansion are joined by welding may be susceptible to thermal fatigue.
Preferred NDE methods of detecting fatigue cracking include liquid-penetrant testing
(PT) or magnetic-particle testing (MT).
4:2.12 CREEPCRAGKING :
Creep is dependent on time, temperature, and stress. Cracking is accelerated by creep

and fatigue interaction when operating conditions in the creep range are cycle. If
excessive temperatures are encountered, mechanical property and microstructural
changes in metals also may take place.
NDE methods of detecting creep cracking include liquid-penetrant testing, magnetic-

particle testing, ultrasonic testing, radiographic testing, and in-situ metallography.
Acoustic emission testing also may be used to detect the presence of cracks that are
activated by test pressures or stresses generated during the test.
4.2.13 BRITTLE FRACTURE :
Carbon low-alloy, and other ferritic steels may be susceptible to brittle failure at or below
ambient temperatures. Brittle fracture usually is not a concern with relatively thinwall
piping. Most brittle fractures have occurred on the first application of a particular stress
11
level (that is, the first hydrotest or overload) unless critical defects are introduced during
service. The potential for a brittle failure shall be considered when rehydrotesting.
4.2.14 FREEZE DAMAGE:
At subfreezing temperatures, water and aqueous solutions in piping systems may freeze
and cause failure because of the expansion of these materials. After unexpectedly
severe freezing weather, it is important to check for freeze damage to exposed piping
components before the system thaws. If rupture has occurred, leakage may be
temporarily prevented by the frozen fluid. Low points, riplegs, and deadlegs of piping
systems containing water should be carefully examined for damage.
4.3 TYPES OF INSPECTION AND SURVEILLANCE :
Different types of inspection and surveillance are appropriate depending on the

circumstances and the piping system. These include the following :
a. Internal visual inspection.

b. Thickness measurement inspection.
c. External visual inspection.
d. Vibrating piping inspection
e. Supplemental inspection.
4.3.1 INTERNAL VISUAL INSPECTION
Internal visual inspections are not normally performed on piping. When possible and
practical, internal visual inspections may be scheduled for systems such as large-
diameter transfer lines, ducts, or other large-diameter piping systems. Such inspections
are similar in nature to pressure vessel inspections and should be conducted with
methods and procedures similar to those outlined in API 510.
4.3.2 THICKNESS MEASUREMENT INSPECTION :
A thickness measurement inspection is performed to determine the internal condition

and remaining thickness of the piping components. Thickness measurements may be
obtained when the piping system is in or out of operation and shall be performed by the
inspector or examiner.
4.3.3 EXTERNAL VISUAL INSPECTION
In addition to these scheduled external inspections that are documented in inspection

records, it is beneficial for personnel who frequent the area to report deterioration or
changes to the inspector.
4.3.4 SUPPLEMENTAL INSPECTION
Other inspections may be scheduled as appropriate or necessary. Examples of such

inspections include periodic use of radiography and/or thermography to check for fouling
or internal plugging, thermography to check for hot spots in refractory lined systems, or
inspection for environmental cracking. Acoustic emission, acoustic leak detection, and
thermography can be used or remote leak detection and surveillance. Ultrasonics
and/or radiography can be used for detecting localized corrosion.
12
4.4 THICKNESS MEASUREMENT LOCATIONS :
Thickness measurement locations (TML's) are specific areas along the piping circuit where
inspections are to be made. The nature of the TML varies according to its location in the
piping system. The selection of TML's shall consider the potential for localized corrosion
and service-specific corrosion as described in 5.3
4.5 THICKNESS MEASUREMENT METHODS :
Ultrasonic thickness measuring instruments usually are the most accurate mean for
obtaining thickness measurements on installed pipe larger than NPS 1. Radiographic
profile techniques are preferred for pipe diameters of NPS 1 and smaller. Radiographic
profile techniques may be used for locating areas to be measured, particularly in insulted
systems or where non-uniform or localized corrosion is suspected.
When piping systems are out of service, thickness measurements may be taken through
openings using calipers. Calipers are useful in determining approximate thicknesses of
castings, forgings, and valve bodies, as well as pit depth approximations from CUI on
pipe.
Pit depth measuring devices also may be used to determine the depth of localized metal
loss.
4.6 PRESSURE TESTING OF PIPING SYSTEMS
Pressure tests are not normally conducted as part of a routine inspection. Exceptions to
this include requirements of local jurisdictions, after welded alterations or when specified
by the inspector or piping engineer. When they are conducted, pressure tests shall be
performed in accordance with the requirements of ASME B 31.3
Upon completion of the pressure test, pressure relief devices of the proper settings and
other appurtenanees removed or made iiloperable during the pressure test shall be
reinstalled or reactivated.
4.7 MATERIAL VERIFICATIONS AND TRACEABILTY
During repairs or alterations of low- to high alloy piping systems, the inspector shall
verify the installation of the correct new materials. At the discretion of the owner/user or
the inspector, this verification can be either by 100 percent checking or testing in certain
critical situations or by sampling a percentage of the materials.
4.8 INSPECTION OF VALVES:
Normally, thickness measurements are not routinely taken on valves in piping circuits.
The body of a valve is normally thicker than other piping components for design reasons.
13
Critical check valves should be visually and internally inspected to ensure that they will
stop flow reversals.
The normal visual inspection method should include
a. Checking to insure that the flapper is free to move, as required, without excessive
looseness from wear.
b. The flapper stop should not have excessive wear. This will minimize the likelihood
that the flapper will move past the top dead central position and remain in an open
position when the check valve is mounted in a vertical position.
c. The flapper nut should be secured to the flapper bolt to avoid backing off in service.
4.9 INSPECTION OF WELDS IN- SERVICE :
Inspection for piping weld quality is normally accomplished as a part of the requirements
for new construction, repairs, or alterations.
4.10 INSPECTION OF FLANGED JOINTS:
The markings on a representative sample of newly installed fasteners and gaskets

should be examined to determine whether they meet the material specification. The
markings are identified in the applicable ASME and ASTM standards. Questionable
fasteners should be verified or renewed.
Fasteners should extend completely through their nuts. Any fastener failing to do so is
considered acceptably engaged if the lack of complete engagement is not more than
one thread.
14
5. FREQUENCY AND EXTENT OF INSPECTION
5.1 GENERAL:
The frequency and extent of inspection piping circuits depend on the forms of
degradation that can affect the piping and consequence of a piping failure.
Inspection strategy based on likelihood and consequence of failure, is referred to as risk-

based inspection. Piping classification scheme in Section given below is based on the
consequence of a failure. The classification is used to establish frequency and extent of
inspection.
5.2 PIPING SERVICE CLASSES
5.2.1 CLASS 1 :
Services with the heist potential of resulting in an immediate emergency if a leak were to
occur are in Class 1. Such an emergency may be safety or environmental in nature.
Examples of Class1 piping include, following :
a. Pressurized services that may rapidly vaporize during release, creating vapors
that may collect and form an explosive mixture, such as C2, C3 and C4
( LPG) streams.
b. Hydrogen sulfide (greater than 3 percent weight) in a gaseous stream.
c. Anhydrous hydrogen chloride.
d. Hydrofluoric acid.
e. Piping over or adjacent to water and piping over public through ways.
5.2.2 CLASS 2 :
Services not included in other classes are in Class 2. This classification includes the
majority of unit process piping and selected off-site piping. Typical examples of these
services include those containing the following:
a. On-site hydrocarbons that will slowly vaporize during release.

b. Hydrogen, fuel gas and natural gas
c. On-site strong acids and caustics.
5.2.3 CLASS 3 :
Services that are flammable but do not significantly vaporize when they leak and are not
located in high activity areas are in Class 3.
a. On site hydrocarbons that will not significantly vaporize during release.

b. Distillate and product lines to and from storage and loading.
c. Off-site acids and caustics.
15
5.3 INSPECTION INTERVALS :
Thickness measurements should be scheduled based on the calculation of not more

than half the remaining life determined from corrosion rates indicated or at the
maximum intervals suggested in Table 6-1, whichever is shorter.
5.4 EXTENT OF VISUAL EXTERNAL AND CUI INSPECTIONS :
External visual inspections, including inspections for corrosion under inSUlation (CUI),
should be conducted at maximum intervals listed in Table 6-1 to evaluate external
condition of paint and coating systems, to check for external corrosion, and to check for
other forms of deterioration.
Following the external visual inspection of susceptible systems, additional examination is

required for the inspection of CUI. The extent and type of the additional CUI inspection
are listed in Table 6-2. NDE inspection for CUI should also be conducted as listed in
Table 6-2 at suspect locations of 5.3.3.1
Piping systems that are known to have a remaining life of over 10 years or that are
adequately protected against external corrosion need not be included for the NDE
inspection recommended in Table 6-2
5.5 EXTENT OF THICKNESS MEASUREMENT INSPECTION
To satisfy inspection interval requirements, each thickness measurement inspection

should obtain thickness readings on a representative sampling of TMLs on each circuit.
This sampling also must include TMLs with the earliest renewal date as of the previous
inspection. The more TMLs measured for each circuit, the more accurately the next
inspection date will be projected.
5.6 EXTENT OF SMALL-BORE, AUXILIARY PIPING, AND THREADED - CONNECTIONS

INSPECTIONS :
5.6.1 SMALL BORE PIPING INSPECTION
Small bore piping (SBP) that is primary process piping should be inspected in
accordance with all the requirements of this document. .
SBP that is secondary process piping has different minimum requirements

depending upon service classification. Class1 secondary SBP shall be inspected
to the same requirements as primary process piping. Inspection of Class2 and
Class 3 secondary SBP is optional. SBP deadlegs (such das level bridles) in
Class 2 and Class 3 systems should be inspected where corrosion has been
experienced or is anticipated.
5.6.2 AUXILIARY PIPING DDDDlNSPECTION
Inspection of secondary, auxiliary SBP associated with instruments and machinery

is optional.
16
TABLE 6-1 RECOMMENDED MAXIMUM INSPECTION INTERVALS
Types of Circuit Thickness Visual External

Measurements
Class 1 5~ears 5~ears
Class 2 10 years 5 years
Class 3 10 years 10years
Injection points 3 years By Class
Soil-to-air interfaces ---- By Class
TABLE 6-2 RECOMMENDED EXTENT OF CUI INSPECTION

FOLLOWING VISUAL INSPECTION
Approximate Amount of CUI

Approximate Amount of Followup Inspection by NDE at Suspect
Examination with NDE or Insulation Areas ( 5.3.3.2 ) on Piping Systems within
Removal at Areas with Susceptible Temperature
Damaged Insulation Ranges ( 5.3.3.2 e.f.h )
Pipe Class
1 75% 50%
2 50% 33%
3 25% 10%
17
6. INSPECTION DATA EVALUATION
6.1 CORROSION RATE DETERMINATION
6.1.1 REMAINING LIFE CALCULATIONS:
The dreaming life of the piping system shall be calculated from the following formula
tactual _ t minimum
Remaining life (years) = -----------------------------
Corrosion rate
[inches (mm) per year]
where:
tactual = the actual minimum thickness, in inches (mm),determined at the

time of inspection as specified 5.6
t minimum = the minimum required thickness, in inches (mm) for the limiting
section or zone.
The long term (L.T.) corrosion rate of piping circuits shall be calculated from the
following formula :
Corrosion rate (L.T.) = t initial _ t last .
time (years) between last

and initial inspections
The short term (S.T.) corrosion rate of piping circuits shall be calculated from the
following formula:
Corrosion rate (S.T.) = t previous _ t last
time (years) between last

and previous inspections
Long term and short term corrosion rates should be compared to see which results in the
shortest remaining life.
6.1.2 EXISTING PIPING SYSTEMS
Corrosion rates shall be calculated on either a short term or a long term basis. For the
short term calculation, readings from the two most recent inspections shall be used. For
the long term calculation, wall thicknesses from the most recent and initial (or nominal)
inspections shall be used. In most cases, the higher of these two rates should be used
to estimate remaining life and so set the next inspection interval.
If calculations indicate that an inaccurate rate of corrosion has been assumed, the rate
to be used for the next period shall be adjusted to agree with the actual rate found.
18
6.2 MAXIMUM ALLOWABLE DWORKING PRESSURE DETERMINATION :
a. The maximum allowable working pressure (MAWP) for the continued use of
piping systems shall be established using the applicable code.
For unknown materials, computations may be made assuming the lowest grade material
and joint efficiency in the applicable code. When the MAWP is recalculated, the wall
thickness used in these computations shall be the actual thickness as determined by
inspection (see definition) minus twice the estimated corrosion loss before the date of
the next inspection.
6.3 MINIMUM REQUIRED THICKNESS DETERMINATION
The minimum required pipe wall thickness, or retirement thickness, shall be based on
pressure, mechanical, and structural considerations using the appropriate design
formulas and code allowable stress.
6.4 REPORTING AND RECORDS FOR PIPING SYSTEM INSPECTION
The owner/user shall maintain appropriate permanent and progressive records of each
piping system covered by API 570. These records shall contain pertinent data such as
piping system service; classification; identification numbers; inspection intervals; and
documents necessary to record the name of the individual performing the testing, the
date, the types of testing, the results of thickness measurements and other tests,
inspections, repairs (temporary and permanent), alterations, or rerating.
19
7. REPAIRS, ALTERATIONS, RERATING
7.1 REPAIRS AND ALTERATIONS:
The principles of ASME 831.3 or the code to which the piping system was built shall be
followed.
7.1.1 AUTHORIZATION
All repair and alteration work must be done by a repair organization as defined in
Section 3 and must be authorized by the inspector prior to its commencement.
Authorization for alteration work to a piping system may not be given without prior
consultation with, and approval by, the piping engineer. The inspector will designate any
inspection hold points required during the repair or alteration sequence. The inspector
may give prior general authorization for limited or routine repairs and procedures,
provided the inspector is satisfied with the competency of the repair organization.
7.1.2 APPROVAL:
All proposed methods of design, execution, materials, welding procedures, examination,

and testing must be approved by the inspector or by the piping engineer, as appropriate.
Owner/user approval of on stream welding is required.
Welding repairs of cracks that occurred in service should not be attempted without prior
consultation with the piping engineer in order to identify and correct the cause of the
cracking. Examples are cracks suspected of being caused by vibration, thermal cycling,
thermal expansion problems, and environmental cracking.
The inspector shall approve all repair and alteration work at designated hold points and
after the repairs and alterations have been satisfactorily completed in accordance with
the requirements of API 570
7.1.3 WELDING REPAIRS (DDINCLUDING ONOSTREAM)
7.1.3.1 TEMPORARY REPAIRS:
For temporary repairs, including on steam, a full encirclement welded split sleeve or
box type enclosure designed by the piping engineer may be applied over the damaged
or corroded area. Longitudinal cracks shall not be repaired in this manner unless the
piping engineer has determined that cracks would not be expected to propagate from
under the sleeve. In some cases, the piping engineer will need to consult with a
fracture analyst.
If the repair area is localized (for example, pitting or pinholes) and the specified
minimum yield strength (SMYS) of the pipe is not more than 40,000 psig (275,800
kPa), a temporary repair may be made by fillet welding a properly designed split
coupling or plate patch over the pitted area (See 7.2.3 for design considerations and
Appendix C for an example) The material for the repair shall match the base metal
unless approved by the piping engineer.
20
For minor leaks, properly designed enclosures may be welded over the leak while the
piping system is in service, provided the inspector is satisfied that adequate thickness
remains in the vicinity of the weld and the piping component can withstand welding
without the likelihood of further material damage, such as form caustic service.
Temporary repairs should be removed and replaced with a suitable permanent repair
at the next available maintenance opportunity. Temporary repairs may remain in place
for a longer period of time only if approved and documented by the piping engineer.
7.1.3.2 PERMANENT REPAIRS:
Repairs to defects found in piping components may be made by preparing a welding

groove that completely removes the defect and then filling the groove with weld metal
deposited din accordance with 7.2
Corroded areas may be restored with weld metal deposited din accordance with 7.2
Surface irregularities and contamination shall be removed before welding. Appropriate
NDE methods shall be applied after completion of the weld.
If it is feasible to take the piping system out of service, the defective area may be
removed by cutting out a cylindrical section and replacing it with a piping component that
meets the applicable code.
Insert patches (flush patches) may be used to repair damaged or corroded areas if the
following requirements are met :
o Full penetration groove welds are provided.

o For Class 1 and Class 2 piping systems, the welds shall be
o 100 percent radio-graphed or ultrasonically tested
o Patches may be any shape but shall have rounded corners (1 inch radius)
7.1.4 NON-WELDING REPAIRS (ON STREAM) :
Temporary repairs of locally thinned sections or circumferential linear defects may be

made on stream by installing a properly designed and fabricated bolted leak clamp. The
design shall inClude control of axial thrust loads if the piping component being clamped
is (or may become) insufficient to control pressure thrust. The effect of clamping
(crushing) forces on the component also shall be considered.
7.2 WELDING AND HOT TAPPING :
All repair and alteration welding shall be done in accordance with the principles of ASME
B 31.3 or the code to which the piping system was built.
Any welding conducted on piping components in operation must be done in accordance

with API Publ 2201. The inspector shall use as a minimum the' Suggested Hot Tap
Checklist" contained in API Publication 2201 for hot tapping performed on piping
components.
7.2.2 PERHEATING AND POSTWELD HEAT TREATMENT
21
7.2.2.1 PREHEATING:
Preheating to not less that 300F (150C) may be considered as an alternative to

postweld heat treatment (PWHT) for alterations or repairs of piping systems initially
postweld heat heated as a code requirement. This applies to piping constructed of
the P-1 steels listed in ASME B31.3. P-3 steels, with the exception of Mn-Mo steels,
also may receive the 300F(1500C)
Piping systems constructed of other steel initially requIring PWHT normally are
postweld heat treated if alterations or repairs involving pressure retaining welding are
performed. The use of the preheat alternative requires consultation with the piping
engineer who should consider the potential for environmental cracking and whether
the welding procedure will provide adequate toughness. Examples of situations where
this alternative could be considered include seal welds, weld metal buildup of thin
area, and welding support clips.
7.2.3 DESIGN:
Butt joints shall be full penetration groove welds.
Piping components shall be replaced when repair is likely to be inadequate. New

connections and replacement s shall be designed and fabricated according to the
principles of the applicable code. The design of temporary enclosures and repairs shall
be approved by the piping engineer. .
7.2.4 MATERIALS:
The materials used in making repairs or alterations shall be of known weldable quality,
shall conform to the applicable code, and shall be compatible with the original materials.
For material verification requirements see 4.8
7.2.5 NON-DESTRUCTIVE EXAMINATION :
Acceptance of a welded repair or alteration shall include NDE in accordance with the
applicable code and the owner/user's specification, unless otherwise specified in API
570
7.2.6 PRESSURE TESTING
After welding is completed, pressure test in accordance with 4.7 shall be performed if
practical and deemed necessary by the inspector. Pressure tests are normally required
after alterations and major repairs. When a pressure test is not necessary or practical,
NDE shall be utilized in lieu of a pressure test. Substituting special procedures for a
pressure test after an alteration or repair may b e done only after consultation with the
inspector and the piping engineer.
When it is not practical to perform a pressure test of a final closure weld that joins a new
or replacement section of piping to an existing system, all of the following requirements
shall be satisfied :
22
a. Any final closure butt-weld shall be of 100 percent radiographic quality;
OR angle beam ultrasonics flaw detection may be used, provided the appropriate
acceptance criteria have been established.
b. MT or PT shall be performed on the root pass and the completed weld for
butt-welds and on the completed weld for fillet welds.
7.3 RERATING
Rerating piping systems by changing the temperature rating or the MAWP may be
done only after all of the following requirements have been met :
a. Calculations are performed by the piping engineer or the inspector.
b. All ratings shall be established in accordance with the requirements of the code to
which the piping system was built or by computation using the appropriate
methods in the latest edition of the applicable code.
c. Current inspection records verify that th~ piping system is satisfactory for the
proposed service conditions and that the appropriate corrosion allowance is
provided.
d. Rerated piping systems shall be leak tested in accordance with the code to which
the piping system was built or the latest edition of the applicable code for the new
service conditions, unless documented records indicate a previous leak test was
performed at greater than or equal to the test pressure for the new condition.
c. The piping system is checked to affirm that the required pressure relieving devices
are present, are set at the appropriate pressure, and have the appropriate
capacity at set pressure.
f. The piping system rerating is acceptable to the inspector or piping engineer.
g. All piping components in the system (such as valves, flanges, bolts, gaskets,
packing, and expansion joints) are adequate for the new combination of pressure
and temperature.
j. A decrease in minimum operating temperature is justified by impact test results, if

required by the applicable code.
23
8. INSPECTION OF BURIED PIPING
Inspection of buried process piping is different from other process piping inspection because
significant external deterioration can be caused by corrosive soil conditions.
Since the inspection is hindered by the inaccessibility of the affected areas of the piping, the
inspection of buried piping is treated in a separate section of API 570.
8.1 TYPES AND METHODS OF INSPECTION
8.1.1 Above Grade Visual Surveillance :
Indications of leaks in buried piping may include a change in the surface contour of the
ground, discoloration of the soil, softening of paving asphalt, pool formation, bubbling
water puddles, or noticeable odor. Surveying the route of buried piping is one method of
identifying problem areas.
8.1.2 Close Interval Potential Survey
The close interval potential survey performed at ground level over the buried pipe can be
used to locate active corrosion points on the pipe's surface.
Corrosion cells can form on both bare and coated pipe where the bare steel contacts the
soil. Since the potential at the area of corrosion will be measurably different from an
adjacent area on the pipe, the location of the corrosion activity can be determined by this
survey technique.
8.1.3 Pipe Coating Holiday Survey
The pipe coating holiday survey can be used to locate coating defects on buried coated
pipes, and it can be used on newly constructed pipe systems to ensure that the coating
is intact and holiday free. More often it is used to evaluate coating serviceability for
buried piping that has been in service for an extended period of time.
8.1.4 Soil Resistivity :
Corrosion of bare or poorly coated piping is often caused by a mixture of different soils in
contact with the pipe surface. The corrosiveness of the soils can be determined by a
measurement of the soil resistivity.
Lower levels of resistivity are relatively more corrosive than higher levels, especially in
areas where the pipe is exposed to significant changers in soil resistivity.
8.1.5 Cathodic Protection Monitoring :
Cathodically protected buried piping should be monitored regularly to assure adequate

levels of protection.
24
8.1.6 Inspection Methods :
Several inspection methods are available. Some methods can indicate the external or
wall condition of the piping, whereas other methods indicate only the internal condition.
Examples are as follows :
o Intelligent pigging. This method involves the movement of a device (pig)

through the piping either while it is in service or after it has been removed from
service. Several types of devices are available employing different methods of
inspection.
o Video cameras. Television cameras are available that cana be inserted into
the piping. These cameras may provide visual inspection information on the
internal conditionof the line.
o Excavation. In many cases, the only available inspection method that can be
performed is unearthing the piping in order to visually inspect the external
condition of the piping and to evaluate its thickness and internal condition.
8.2 FREQUENCY AND EXTENT OF INSPECTION
8.2.1 Above-Grade Visual Surveillance :
The owner/ user should, at approximately 6 month intervals survey the surface
conditions on and adjacent to each pipeline path.
8.2.2 Pipe to Soil Potential Survey :
A close interval potential survey on a cathodically protected line may be used to verify
that the buried piping has a protective potential throughout its length. For poorly coated
pipes where cathodic protection potentials are inconsistent, the survey may be
conducted at 5 year intervals for verification of continuous corrosion control.
8.2.3 Pipe Coating Holiday Survey :
The frequency of pipe coating holiday surveys is usually based on indications that other
forms of corrosion control are ineffective. For example, on a coated pipe where there is
gradual loss of cathodic protection potentials or an external corrosion leak occurs at a
coating defect, a pipe coating holiday survey may be used to evaluate the coating.
8.2.4 Soil Corrosivity :
For piping buried in lengths greater than 100 feet ( 30 m ) and not cathodically protected,
evaluations of soil corrosivity should be performed at 5 year intervals. Soil resistivity
measurements may be used for relative classification of the soil corrosivity.
25
8.2.5 Cathodic Protection :
If the piping is cathodically protected, the system should be monitored at intervals in

accordance with Section 10 of NACE RP0169 or Section 11 of API RP 651.
8.2.6 External and Internal Inspection Intervals :
The external condition of buried piping that is not cathodically protected should be
determined by either pigging, which can measure wall thickness or by excavating
according to the frequency given in Table 9-1. Significant external corrosion detected by
pigging or by other means may require excavation and evaluation even if the piping is
cathodically protected.
If inspection reveals damaged coating or corroded piping, additional piping shall be

excavated until the extent of the condition is identified. If the average wall thickness is at
or below retirement thickness, it shall be repaired or replaced.
8.2.7 Leak Testing Intervals:
An alternative or supplement t'O inspection is leak testing with liquid at a pressure atleast
10 percent greater than maximum operating pressure at intervals one-half the length of
those shown in Table 9-1 for piping not cathodically protected and at the same intervals
as shown in Table 9-1 for cathodically protected piping. The leak test should be
maintained for a period of 8 hours.
Four hours after the initial pressurization of the piping system, the pressure should be
noted and, if necessary, the line repressurized to original test pressure and isolated from
. the pressure source.
If, during the remainder of the test period, the pressure decreases more than 5 percent,
the piping should be visually inspected externally and! or inspected internally to find the
leak and assess the extent of corrosion. Sonic measurements may be helpful in locating
leaks during leak testing.
Buried piping also may be surveyed for integrity by using temperature-corrected

volumetric or pressure test methods.
Table 9-1 Frequency of Inspection for Buried Piping

Without Effective Cathodic Protection
Soil Resistivity( ohm-cm ) Inspection Interval ( years)

< 2,000 5
2,000 to 10,000 10
> 10,000 15
Other alternative .Ieak test methods involve acoustic emission examination and the
addition of a tracer fluid to the pressurized line ( such as helium or sulfur hexafloride). If
the tracer is added to the service fluid, the owner! user shall confirm suitability for
process and product.
26
8.3 REPAIRS TO BURIED PIPING SYSTEMS
8.3.1 Repairs to Coatings :
Any coating removed for inspection shall be renewed and inspected appropriately.
In addition, coating repairs may be tested using a high voltage holiday detector. The detector
voltage shall be adjusted to the appropriate value for the coating material and thickness. Any
holidays found shall be repaired and retested.
8.3.2 Clamp Repairs :
If piping leaks are clamped and reburied, the location of the clamp shall be logged in the
inspection record and may be surface marked.
Both the marker and the record shall note the date of installation and the location of the
clamp. All clamps shall be considered temporary. The piping should be permanently
repaired at the first opportunity.
******
27
(VOLUME-I)
Part-5
Case studies illustrating use of code rules for
API 570- PIPING INSPECTORS

CODE CALCULATIONS
(Thickness Determination)
Exercise-I.
Determine the Pressure design thickness and minimum required thickness for a piping
with the following design conditions: Take W=l.
Design Pressure = 500 psig
Design Temperature = 650 degrees F

Pipes to be used = A 53 gr. B Electric Resistance Welded (ERW)
Pipe size =NPS6
Corrosion Allowance = 0.125 inch

CODE CALCULATIONS
Exercise-I. (SOLUTION)
1. Pressure Design thickness, t = PD / 2 (SE + PY)
Here, P = 500 psig

D= 6. 625 (Ref. table in API 574 )
S= 17,000 psi Table A-I (ASME B 31.3)
E= 0.85 Table A-IB (ASME B 31.3)
Y= 0.4 Table 304.1.1 (ASME B 31.3)
Now, t = 500 x 6.625/ 2 (17,000 xO.85 + 500 x 0.4)
= 0.115 inch
Thus, Pressure Design thickness = 0.115 inch
NowMin. Required thickness tm =t + c.

Min~Required thickness = 0.115 inch + 0.125 inch
Min. Required thickness = 0.240 inch
CODE CALCULATIONS
Exercise-2.
Determine the Pressure design thickness and minimum required thickness fot a piping
with the following design conditions:

Design Temperature = 700 degrees F
Pipes to be used = A 106 gr. C (Seamless)
Pipe size = NPS 12
Corrosion Allowance = 0.1 inch

CODE CALCULATIONS
Exercise-2. (SOLUTION)
1. Pressure Design thickness, t = PD /2 (SE + PY)
Here, P = 800 psig

D= 12.75 (Ref. table in API 574 )
S= 19,200 psi Table A-l (ASME B 31.3)
E=1.0 Table A-1B (ASME B 31.3)
Y= 0.4 Table 304.1.1 (ASME B 31.3)
Now, t = 800 x 12.75/ 2 (19,000 x 1 + 800 x 0.4)
= 0.268 inch
Thus, Pressure Design thickness = 0.268 inch
Now Min. Required thickness tin =t+ c.

Min. Required thickness = 0.268 inch + 0.1 inch
Min. Required thickness = 0.368 inch
CODE CALCULATIONS
(Thickness of Permanent Blank )
Exercise-3.
Find Minimum required Thickness of a seamless Permanent Blank to be inserted

at a flanged joint for the following piping:
Blank Material Safe Stress = 16,800 psig
Corrosion Allowance= 0.0625 inch
Gasket Internal Diameter = 8.0"

CODE CALCULATIONS
Min required thk for permanent blank
Tm _ d ~ 3 P + C
- g 16 SE
P = 250psig
C = 0.625 inch
S = 16800 psig
E =1.0
Dg=8 inch
Key-in the values in above formula
Minimum reguiredthickness = 0.422 inch +0.0625 inch
Minimum required thickness = 0.4845 inch

CODE CALCULATIONS
( Impact testing requirements)
Exercise-4.
Q.l A Piping system is to be constructed using 12.7mm (0.50 inch) thick pipes.
Pipe specification is A 106 Grade A (de-oxidised). Design minimum
temperature is 0 deg.C ( 32 0 F). Will you require impact testing ,?-S per
ASME B 31.3?
Q. 2 If the Design minimum temperature in Q. 1 above is changed to -40 deg.C

( -40 0 F). Will impact testing be required?
Q. 3 If the Design minimum temperature in Q. 1 above is changed to -29 deg.C

( - 20 0 F). Will impact testing be required?
Q.4 If all conditions in Q. 1 above are same except that we now use 30 mm
thick pipe. Will you specify impact test?
Q.5 Impact testing was conducted on A 106 Grade A pipes. Using 3 specimen.
Test impact values reported were:
Specimen 1: 16 ft Ib
Is impact test acceptable?
Q.6 If pipe material is changed to A 333 Grade I, and Design minimum

temperature is (-40 deg F) the impact test be required?
CODE CALCULATIONS
(Impact testing requirements)
1) In this example Curve B will apply. Referring to Pig 323.2.2A, the point is
clearly above the curve, hence Impact Testing is not required.
2) Now the point lies clearly below the curve. Impact testing is required.
3) Now the point lies very close to the curve. Decision whether point is
above or below is difficult. Go to table 323.2.2A . We see that point will be
below the curve. Impact testing is required.
4) Now the Point is clearly below curve.

Impact test required.
5) Required Average for 3 specimen = 13 ft Ib
Actual average obtained = 16 + 15 + 11 42 =14ft1b

3 3
Average obtained ,14 ftlb > 13 ft lb ....... OK

Only one specimen has gone below the 13 ftlb
Its value must be more than 10 ftlb. And its actual value =11 ftlb.
11 > 10ft/ b -----------------0 K
Both criteria of Average & minimum are satisfied - Test is accepted.
6) Not required. Go to Table A.1. This material can be used without impact
testing up to (_50 P).
0
CODE CALCULATIONS
( Pressure testing requirements)
Exercise-5.
Following information is taken from data sheet for a Piping system.

Design Pr = 150 psi.
Stress value of the pipes at design temperature = 18000 psi
Stress value at test temperature = 19800 psi
Calculate the following

Q.l Hydrostatic Test Pressure
Q.2 Pneumatic Test Pressure
Q.3 Max. Relief value set Pressure for Pneumatic Test
Q.4 Firststage pressure for Pneumatic Test
Q.5 Inspection pressure at which leak check shall be performed for Pneumatic
Test
CODE CALCULATIONS
( Pressure testing requirements)
Exercise-5. (SOL UTION)
1) Hydrostatic Test Pr = 1.5 X Design pressure X Stress ratio

= 1.5 X 150 X 19800/18000
= 1.5 x 150 x 1.1
= 247.5 psi
2) Pneumatic Test Pr = 1.1 x Design pressure

= 1.1 x 150
= 165 psi
3) Max. Relief Value set Pro = 1.1 X Pneumatic Test Pr

= 1.1 x 165
= 181.5 psi
4) First stage pressure for Pneumatic is smaller of 50% of test pro or 25 psi
= Smaller of 165/2 or 25 psi
= 25 psi.
5) Inspection Pressure = Design pressure = 150 psi

CODE CALCULATIONS
(Pre-heating teperatures)
Exercise-6.
Determine if pre-heating is required in following cases and if required, provide

minimum pre-heat temperature
Q.1 All pipes A 106 Gr B pipes ,NPS 10, Sch SO
Q.2. A 106 Gr B pipes, NPS 12, Sch 80 pipe welded to NPS 12 Sch 160 pipe
(Ambient temperature at plant site = -SOC)
Q.3 All pipes A 335 Grade 12, NPS 10 Sch 40
Q.4 A 335 Grade P12 pipes NPS 10, Sch SO pipes welded to A 335 Grade P5
pipes NPS 10, Sch SO
CODE CALCULATIONS
( Pre-heating teperatures )
Exercise-:-6. ( SOLUTION)
1) Solution to Q.l
For AI06 Gr.B pipes P no. is 1
Tensile strength is 60000 psi
Thickness for NPS 10 sch 80 is 0.594 inch
From table 330.1.1 Preheat temp. = 50 deg F recommended
2) Solution to Q.2
For A106 Gr.B pipes P no. is 1

Thickness for NPS 12 sch 80 is 0.688 inch. And Preheat temp= 50 deg
F recommended
For NPS 12 sch 160 thickness is 1.312 in. and Preheat temp. = 175 deg
F recommended
Higher preheat temperature = 175 deg F recommended
But welding is to be done with ambient temperature = -SoC
Hence Preheat temp. = 175deg F Required
3) For A 335 Gr.12 pipes, the P no. is 4.

From table 330.1.1 Preheat temp. = 300 deg F Required.
4) For A 335 Gr.12 pipes P no. is 4. and For A 335 Gr.P5, the P no. is 5B
For P noA, Preheat temp= 300 deg F required
For P no.5B, Preheat temp= 350 deg F required
Use higher Preheat temp. = 350 deg F. Required.
CODE CALCULATIONS
( PWHT Requirments )
Exercise-7.
Find out whether PWHT is required in following cases and if required,
provide minimum PWHT temperature, time and Brinell hardness. There is no
Service related PWHT requirement.
Q.l All pipes A 106 Gr B pipes ,NPS 10, Sch 80
Q.2 All pipes A 335 Grade 12, NPS 10 Sch 80
Q.3 All pipes A 335 Grade P5, NPS 10 Sch 80

CODE CALCULATIONS
( PWHT Requirments )
Exercise-7. (SOL UTION)
1) Solution to Q.l
For AI06 Cr.B pipes P no. is 1

Thickness for NPS 10 sch 80 is 0.594 inch
From table 331.1.1 PWHT Not required
2) Solution to Q.2
For A 335 Cr.12 pipes. the P no. is 4.

Thickness for NPS 10 sch 80 is 0.594 inch.
From table 331.1.1 PWHT is required
PWHT temp. = 1300 - 1375 deg F
Holding time = 2 hours
Brinell hard ness = 225 Maximum
3) Solution to Q.3
For A 335 Cr.P5 pipes. the P no. is 5B.

Thickness for NPS 10 sch 80 is 0.594 inch.
From table 331.1.1 PWHT is required
PWHT temp. = 1300 -1400 deg F
Holding time = 2 hours
Brinell hard ness = 241 Maximum
CODE CALCULATIONS
( Thermal Expansion of Pipes)
Exercise-8.
1. Estimate the total length after heating if a 200 feet long, A 106 Gr.B pipe was
heated from 70 deg.F to 800 deg.F
2. Estimate the contraction in above pipe if it was cooled from atmospheric

.temperature 70 deg.F to a low temperature -300 deg.F
3. What will be the total length after heating if a 280 feet long pipe was heated from
70 deg.F to 975 deg.F. Out of250 feet length, 150 feet was Carbon Steel and 130
feet was Austenitic Stainless steel ( 18Cr-8Ni)
CODE CALCULATIONS
( Thermal Expansion of Pipes)
Exercise-8.( SOLUTION)
1) Go to Table C-1 of ASME B 31.3

Thermal expansion for 100 feet = 6.7 inch
For 200 feet the expansion = 13.4 inch
Total length after heating = 200 feet + 13.4 inch = 201 feet and 1.4 inch
Total length after heating =20 1 feet and 1.4 inch

Thermal contraction (negative expansion) expansion for 100 feet = 2.24 inch
For 200 feet the contraction = 4.48 inch

For Carbon steel, Thermal expansion for 100 feet = 8.62 inch
For 150 feet Carbon steel pipe the expansion = 12.93 inch
For Stainless Steel, Thermal expansion for 100 feet = 11.14 inch
For Stainless Steel, Thermal expansion for 130 feet = 1.3 X 11.14 = 14.48 inch
Total expansion after heating = 27.41 inch
Total length after heating = 280 feet + 27.41 = 282 feet and 3.41 inch
Total length after heating =282 feet and 3.414 inch
CODE CALCULATIONS
Selection of ASME B 16.5 flanges
(Question)
1. Choose correct flange class for design pressure = 600psi and

temperature = 600 deg. F. Material of construction AI05.
2. Choose correct flange class for design pressure = 600psi and

temperature = 600 deg. F. Material of construction Al82 Gr. Fl.
3. If flange (MOC - Al82 Gr. F2, Class 400) is to be used up to maximum

400deg. F, what is maximum pressure we can use it for?
4. If flange Al82 Gr. F2, Class 400 is to be used up to 650psi pressure,

what is maximum temperature it can be used?
CODE CALCULATIONS
Selection of ASME B 16.5 flanges
(Answer)
1. Go to page 4 table A1. For material A105, refer pressure-temperature

table number F2-1.1, page 118.
For 600deg. F and pressure = 600psi, Class 400 flange will be OK.
2. Go to page 4 table A1. For material A182 Gr. F1, refer pressure-
temperature table number F2-1.5, page 122.
For 600deg. F and pressure = 600psi, Class 300 flange will be OK.
3. From table F2-1.7, page 123, A182 Gr. F2, Class 400 flange can be used
up to 940psi pressure for temperature of 400 deg. F.
4. From table F2-1.7, page 123, A182 Gr. F2, Class 400 flange can be used
up to 850 deg. F temperature for pressure of 650psi.
CODE CALCULATIONS
(Numerical Examples in API 570 Code)
Exercise"':9.
(A) Following information is available from Pipe data sheet & inspection
records for a classl Piping in service. The service in unchanged from 2002
& will continue.
Initial thickness = 1.2 inch (1992 May)

First shutdown inspection thickness = 1.1 inch (1997 May)
Second shutdown inspection thickness = 1.05 inch (2002 May)
Current inspection thickness = 0.9 inch (2007 May)
Required thickness = 0.60 inch
Calculate following:
1. Long term corrosion rate
2. Short term corrosion rate
3. ,. What corrosion rate is to be considered of for Remaining life calculation?
4. Calculate Remaining Life.
5. What are nexfmaximum Thickness measurement & External inspection
intervals?
(B) A fillet patch is to be installed on a Pipe with ID = 8 inch & minimum

required thickness for the patch to be welded is 1/2 ". What should be
minimum toe to toe distance from a similarly welded existing patch?
. (C) Estimate the maximum permitted Thickness measurement & External

inspection intervals for following 5 Piping systems. No RBI is performed.
1. Class 1 piping, Remaining life = 14 years
4. Injection points in Class 1 piping, Remaining life = 8 years
5. Injection points in Class 3 piping, Remaining life = 22 years
(D) A Class 1 Piping was inspected for thickness measurement. Actual

thickness was found to be 0.86 inch. Next thickness inspection interval is
5 years. Corrosion rate = 10 mpy. What value of thickness should be
used in MAWP calculation?
CODE CALCULATIONS
(Numerical Examples in API 570 Code)
Exercise-9 (SOLUTION).
(Solution for A)
t initial = 1.2 inch (May 1992)
t previous = 1.05 inch (May 2002)
tactual = 0.9 inch (May 2007)
t required = 0.60 inch
1) Corrosion rate (L.T.) = t initial- tactual

No. of years between t initial & tactual
= 1.2 -0.9
15
= 0.020" jyear = 20 mpy
2) Corrosion rate (S.T.) = t previous - tactual

No. of years betn t previous & tactual
1.05 -0.9
5
= 0.030" /year = 30 mpy
3) S.T. rate reflects current process used S.T. Corrosion rate (30 mpy)
for remaining life calculation.
4) Remaining life = (t actual- t required)/ Corrosion rate
0.9-0.60
0.030
10 years
(5) Next Thickness inspection = Lower of (1/2 x 10) or 5 years

= 5 years
External inspection = 5 years
( Solution B) Spacing (s) = v'DT. Here, D= 8 inch

= v'8X1l2
s = 2 inches.
(Solution C ) 1. For Class 1 piping:

Max. Thickness measurement Interval = Lower of 1/2 (RL) or 5 years
= Lower of V2 x 14 or 5 years
= 5 years.
External = years.
Similarly for other Piping calculation can be done
2. Class 2 piping: Thk. measurement = 8 years, External = 5 years
3. Class 3 piping: Thk. measurement = 10 years, External = 10 years
4. Injection points in Class 1 piping = Lower of V2 (RL) or 3 years

= Lower of V2 x 8 or 3 years
Thk. measurement Interval = 3 years
External by class (classl) = 5 years.
5. Injection points in Class 3 piping = Lower of 1/2 (R.L) or 3 years
= Low~r of 1/2 x 8 or 3 years
Thk. measurement Interval = 3 years
External by class (class 3) = 10 years.
(Solution D) Thickness (t) = tactual- 2 (C.R x Interval)

0.86 - 2 (0.010 x 5)
0.86 -0.1 = 0.76 inch
(VOLUME-I)
Part- 6
WPS/PQR Review Case studies

Review of WPS/PQR (Road Map)
Start at Front side ofPQR.
~DO the P, F & A Nos. match Withl

mtl. Spec No & filler A WS No.
Go to back side ofPQR.Are the (Q W 140)

No results for tcnsile, and bend tcsts
stated.
lyes
No For tensile tcst are qty of
specimen, area and unit (QW - 45l. 1)
strcss calculation right
lYes
No
Is location of failure stated
R
11 lYes
h lill;! ,!,," ~ ,I (QW 153)
~
SMTS of base metal
Yes
E Hwas break ~I
weld metal
~No
Is the WPS supported by No Is unit stress 2:
PQR. Does WPS show No If--- 95%ofSMTS (QW -153)
---:l
reference No. of the J of base metal
supporting PQR
Yes I
1 Yes
Yes
No I Is bend test Qty, type
stated and correct I (QW - 451.1
Has PQR been revised ~
E ~Yes
lNa No
No
Is the result stated & OK I (QW -1 63)
I Is PQR signed and dated ~ {, Yes
lYes No Are result.s for tou)Fl (QW _ 17 2)
I test (If any) OK
Accept for C J,Yes
detailed Place WPS & PQR side by side
review
1
Go to tables as follows
T SMAW -QW253
SAW -QW254
No Check WPS/PQR for QW 402 to
QW 410 for the following
WPS: EV, NEV, PQR: EV,
Are the documents OK?
1
If the welder is to be qualified on the
~ basis ofPQR. Is his IdentifYing code.
Position of welding recorded on PQR.?
Accept
20 Welding DocUIllentation Forms Chapter 2
QW-483 SUGGESTED FORMAT FOR PROCEDURE QUALIFICATION RECORDS (PQR)

(See QW-200.2, Section IX, ASME Boiler and Pressure Vessel Code)
Record Actual Conditions Used to Weld Test Coupon.
Company Name X y Z COl ~t{-dICJl.J

Procedure Qualification Record No. p& ~ 12 COL I a II Date '2..6 - 2 ~ 2007-
WPSNo. \A-IPS/:l&"p/o 24 ~r 'I
Welcling Process(e~) 7 5M AV..J
Types (Manual, Automatic, Semi-Auto.) M A H U"-,,,A.~'______________________
JOINTS (QW-402)
Groove Design of Test

(For combination qualifications, the weld metal thickness shall be recorded for each filler metal or process used.)
BASE METALS (QW-403) POSTWELD HEAT TREATMENT (QW-4071

Material Spec_ 5 A. 5 (G 4"(
GO Temperature iI - N
Type or Grade Te _______~cl~.~_~.---------------
Other _ _ _ _ _ _~~_~~_ _ _ _ _ _ _ _ _ _ _ __
__
P-No. 1 to P-No. -_J~---;---;-----
Thickness of Test Coupon 0 -75 iKc.h-
Diameter of Test Coupon _ _ __
Other _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
GAS (QW-40S)
Percent Composition
Gas(es) (Mixture) Flow Rate
Shielcling
1-==-=-=:-::-:=::-:-::-::-:-::-:::--:------------- Trailing
FILLER IVJ:ETALS (QW-404) Backing
SFA Specification S FA :5. \
AWS Specification ---I:t;;--i7'-'Ou--l-'!<O&------- ELECTRICAL CHARACTERISTICS (QW-409)
Filler Metul F-ND. ------:2-&--------- Cunent ---.>:D!::-'-c=------------------
Weld Metal Analysis A-No. --,::-,........;11------- Polarity ----=--'R""'-'P~_______::__:______:,___---
Size of Filler Metal -1't/1::"".-',---,.~S~fl.';..,.=--------- Amps. SO, IQ 0 Volts 2..'3, 9> 2
Other _ _ _ _ _ _ _ "'_ _--'="'-'~'__ _ _ _ _ __ Tungsten Electrode Size _ _ _ _ _ _ _ _ _ _ _ _ __
Other _____________________________________
Weld Metal Thickness
POSITION (QW-405) TECHNIQUE (QW-410l

rosition of Groove _ _ _---"1:......::Ci-"--_ _ _ _ _ _ __ Travel Speed 4-6 t'\I\(h/m,,~
Weld ProgTession(Uphill, Downhill) _ _~~_ _ __ String or Weave Bead S l'jV'j f
other _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Oscillation - - - - - - - - - - - - , . - - - : - - - r - - ; - ; - ; - ; - ,
Multipass or Single Pass (per side) .sin! leo /lYi.. pk_
ttl
Single or Multiple Electrodes $. f""j ',.,
PREHEAT (QW-406) Other _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ____
Preheat Temp
Interpass Temp _ _ _ _ _ _- _ _ _ _ _ _ __
other _ _ _ _ _ _ _ _~_ _ _ _ _ _ _ _ __
Figure 2.2 QW-483 Form - Nonmandatory Appendix B (Page 10f2)
CASTI Guidebool, to ASME Section IX - Welding Qualifications - Third Edition

Chapter 2 Welding Documentation Forms 21
QW 483 (Back)
PQRNo.l'81 R/'l.oo+ /611
Tensile Test (QW150)
Ultimate Ultimate Type of
Specimen Total Load Unit Stress Failure &
No. Width Thickness Area lb psi Location
TeJ\si\~~1 I c'746 It
W,,-:l'-'l;'~
"\f\\S\ \e. Q;.I Q; '74 (/' . . . . . 'Bei.JE.- ii:fM
j .
GuidedBend Tests (QW160)
Type anel. Figure No. Result
Ftc~ r3J2Jl\~.~ . 1
.f~~ B~ ':J.
R.e6t-~~:1
R.';~t- ~-E.JII\! - l.
Toughness Tests (QW-170)

Specimen Notch Specimen Test Impact Values Drop Weight
Break
No. Location Size Temp. FtILs I % Shear :Mils (YIN)
...... 1 I I ..... f''''' ... ,........... .

I i
.,.
1 1
r
....... . .......
... I I
I
I I ......
..............
. "'j
I
I
I. I I
I
I
....
i I I
J i
Comments: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
..
FilletWeld Test (QW.180)
Result Satisfactory: Yes _ _ _ No _ _ __ Penetration into Parent Metal: Yes No _ _ ___
Macro Results __________________________________________________
Other Tests
T}~eofTest _______________________________________________
DepositAnalysis _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Other _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _. ________________________________
I.... f"11"
Welder'sName H::t\.)'
f',,,
~ v,'1"Ic..OY'. Clock No, Stamp No, N ! 2....
Tests conducted by: bJ A-l \ 0 l:-i p... L T i;. ST Laboratory Test No. H,. H I I" I
I
We certify that the statements in this record are correct and that the test welds were prepared, welded, and tested in
accordance with the requirements of Section IX of the ASME Code,
Manufacturer -r-=----------,.,.----'--'....q';;#'''-----
..., .J::>I\ V IDS ""1"11-\
Date 2.6-'2.-2007'". By xyz. CoRj?oRf\"TION
metail of record of tests are illustrati\'e only and may be modified to confonn to the t\ e and number of tests re uired by the Code.)
Figure 2.2 QW483 Form Nonmandatory Appendix B (Page 2 of2)
CAST1 Guidebook to ASAfE Section IX Welding Quali(u;ations . Third Edition
:'!I<~""'------
18 Welding Documentation Forms Chapter 2
QW-482 SUGGESTED FORMAT FOR WELDING PROCEDURE SPECIFICATIONS (WPS)

(See QW-200.1, Section IX, ASME Boiler and Pressure Vessel Code)
Company N ame_X"-'--y-'--'Z"'--....,.."'=L..!...f~'-"'-~=:;--'--_=-~ By: --'.D=:=:-c:."'t~,;'-i:..=----'''''''-'-2.!..!..O.J'-----''-=.=.'-'':fp....u'~~~~

"-"-'-"'1'-="-"-'--P'~ate al2'7 -1. ~ 2..60
ate _~~_ _ __
r.
Welding Process( es) S'f".1AW Type(s) _ _ _ _ML"-~"'CJ!N~\)~~::L.:L.!=._ _ _ _ _ _ __
(Automatic, Manual, Machine. or SemiAu to!
JOINTS (QW-402) Details

JointDesign I~<?.Y
As. Vesse...l Drwj .
Backing ( y e s ) _ _ _ _ _ _ _ (No).c.V"
_ _ _ _ _ _ __
Backing Material (Type) _ _ _ _LN"'"'A""-'-'_______
(Refer to both backing and retainers.)
o Metal o Nonfusing Metal

o Nonmetallic o Other
Sketches, Production Drawings, Weld Symbols or Written

Description should show the general arrangement of the parts
to be welded. Where applicable, the root spacing and the detaiis
of weld groove may be specified.
(At the option of the Mfgr., sketches may be attached to illustrate

t=SZ=lI)
t ---I I-t- (~cA . I
joint design, weld layers and bead sequence, e.g., for notch
toughness procedures, for multiple process procedures. etc.)
Ro..V''j E!.. of 'II\'<::.k.M$S ~'_ ~
"BA.SE METALS (QW-403l

P-No. 1. Group No. to P-No. _ _~i,,- _____
Group No. _____________
OR
Specification type and grade _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
to Specification type and grade _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _.
OR
Chern. Analysis and Mech. Prop. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
to Chem. Analysis and Mech. Prop. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Thickness Range: I, "
2.~----- Fillet _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Base Metal: Groove----"TI'T__t+.l.O-'--_..
Other ._ _ _ _ _ _ _-_' ...(;=-_ _ _ _ __
"'FILLER METALS (QW-404)

Spec. No. (SFA) _$..lJEl....CA'---..S<-....I'--___
AWS No. (Class)
F-No. 2.
A-No.
Size of Filler Metals
Weld Metal
Thickness Range: I II 1/
Groove TC: to 2...:
Fillet
Electrode-Flux (Class)
Flux Trade Name
Consumable Insert _ _ _ _ _ _ _ _ __
Other
~'E:lch base metal-filler metal combination should bB recorded inciiyidually.
Figure 2.1 QW-482 Form - Nonmandatory AppendixB (Page 1 of2)
CAST! Guidebooh to ASME Section IX - Welding Qualifications - Third Edition

Chapter 2 Welding Documentation Fonus 19
QW-482 (Back)
'IN P!:I2.a of- } O:;",I!, 0
WPS No. f Rev.
POSITIONS (QW-405) POSTWELD HEAT TREATMENT IQW-407)

Position(s) of Groove 1 C:r ) 2..u.,Ct, 4G Temperature Range R e.qtW' V<!..&
Welding Progression: Up Down - - - - Time Range A:. s pe ~ C/;' d. Ie
\
Position(s) of Fillet
PREHEAT (QW-406) GAS (QW-408)

Preheat Temp. Min. \oot>F Percent Composition
Interpass Temp. IvIax. Gas(es) 1~Ii..,ture) Flow Rate
Preheat Maintenance Shielding
(Continuous or special heating where applicable should be recorded) Trailing
Backing
ELECTRICAL CHARACTERISTICS (QW-409)

RP
Current AC or DC
A.mps (Range)
P
eoD-c.. R.
Polarity
13 (? A.~volts (Range)
L>\mps and volts range should be recor,ded for ea electrode
2,b- 3'.1/
size, position. and thickness, etc. This information may be
listed in a tabular form similar to that shown beloW'.~
Tungsten Electrode Size and Type _______~!~~~P\.-l_.____________________________________________

(Pure Tungsten, 2O/C Thoriated, etc.)
Mode of Meta! Transfer for GMAW N'jI..
(Spray arc, short t.:ircuiting arc) etc.)
Electrode Wire Feed Speed Range NA.
I
TECHNIQUE (QW-410)
String or Weave Bead ~h,\\~
Orifice or Gas Cup Size
Irjtial and Interpass Cleaning (Brushing, Grinding, etc.!
Method of Back Gouging

Oscillation
Contact Tube to work Distance
MUltiple or Single Pass (per side)
Multiple or single Electrodes
Travel speed (Range)
Peening
Other
Weld ! Filler Metal I

Type
Current
Amp. -v~oli..
Travel
Spted
i. Other
(e.g.; R2marks!Go:u...mcnts) He: Vlire
I Process I I Range
Layer(s) Class Dia. Polar. Range I Range Addition. Technique, Torch Angle, Etc.!
Rmt ~tU.s ISM/>,w 2.b-2.a 14.'i"L~ . -

\ I,
~7018
e: il>c.ltP e,~1.2.8 I [1'1'-\1\
All o+t-.-e.....t
va.ss=.1 $1 ,"-.\1\.1
I I ! I) I
E:. 7618 ~ . Dc.Il...P '10- ,~, 2.9 :, ... 1 L.;-'!~!Il' -'-
1
j
.32..: ,
i
i
i I
!
1
i i
t
i I
I !
j i
,
i
Figure 2.1 QW-482 Form - Nonmandatory Appendix B (Page 2 0[2)
CAST! Guidebook to ASME Section IX - Welding Qualifications - Third Edition

Mistakes in WPSjPQR Documentation.
PQRREVIEW:
A. PQRj2oo7jOll (Front side):
1. Check P,F and A Nos ....... P NO.1 is OK, F No. should be 4 instead of 2,. A No.
OK
B. PQR (Back Side)
1. No. of Tensile Test Specimen=2 ...OK. But result offirst tensile

specimen(W.Mjracture)is not accepted. Second specimen is OK
2. Bend tests specimen Nos. = 4 ... 0K, Test results also OK, but specimen tested
are wrong. They must be 4 side bendsfor Test coupon thickness=0.75 inch.
WPSREVIEW:
C. WPSj 2oo7j24(Front side)
Check P.No , F No, A No. Change F No. to agree with PQR ( change F no. to 4)
Base metal thickness range shall be= 3/16 inch to 1112 inch.
Weld metal thickness range shall be = 0 to 1 112 inch.
D. WPS (Back side)
Min. Preheat shall be 120 deg.F

PWHT shall be NiL.since PQR is without PWHT.
Volume -1
PART 7
DAILY EXAMINATIONS FOR

API 570 COURSE
API 570 Preparatory training course
QUIZ DAY 1 (OPEN BOOK)

Note: Choose only one alternative which you think is most appropriate.
1. Pneumatic test is to be conducted using ASME 31.3 methodology on

piping having Design pr = 200 psig. Which of the following meet the
methodology of ASME B 31.3 as regards test prJ inspection prJ and safety
valve pressure respectively:
a. 250 psig, 200 psig, 275 psig respectively

b. 220 psig, 200 psig, 240 psig respectively
c. 220 psig, 220 psig, 242 psig respectively
d. None of the above
2. A piping is to be pneumatically tested at test pr = 80 psig. What will the

pressure at which a preliminary leak check shall be performed?
a. 40 psig
b. 20 psig
c. 25 psig
d. 80 psig
3. Pre-heating, whenever specified is:
a. Applicable to strength welds and not for tack welds

b. Strength welds and seal welds only
c. Strength welds, tack welds and seal welds
d. Strength welds only
4. For pressure testing of piping systems, which of the following

statement(s) are correct?
a. Hazard of released energy is higher in case of hydrostatic test since

Hydrostatic pressure is 50% higher than design pr while pneumatic
pressure is only 10% higher.
b. For hydrotesting water alone can be used.
c. Pneumatic test shall be conducted only if hydrostatic test is
impracticable.
d. a and c above
5. A 106 gr B pipe after installation, required Hydrostatic leak test. Following data
is presented Design pr = 300 psi, Design temp = 500F. Considering stress at
design as well as ambient temperature, determine correct hydrotest pressure if
test is carried out at ambient conditions.
a. 450 psi
b. 476 psi
c. 330 psi
d. 375 psi
6. Calculate pneumatic test pressure for above piping considering stress

correction.
a. 349 psi
b. 396 psi
c. 408 psi
d. 330 psi
7. PWHT is required for all thicknesses of piping over 1/2 inch for which
of the following materials?
a. P Nos. 1 and 2
b. PNos.1 and 3
c. PNos.2and3
d. P Nos. 4 and 5
8. Code B 31.3 recommends and mandates min, required pre-heat temp, for
welding of pipes. When do the recommendations become mandatory?
a. At ambient temperature above 0 deg C

b. At ambient temperature above 10 deg C
c. At ambient temperature below 10 deg C
d. At ambient temperature below 0 deg C
9. Code B 31.3 requires standard mill tolerance to be added to calculated

pipe thickness. The standard negative mill - tolerance as percentage of
nominal thickness is:
a. 10%
b. 15%
c. 121/2%
d. None of these
10. For 8" ND Sch 40 and 8" ND Sch 80 pipes,
a. ID for both pipes will be same

b. aD for both pipes will be same
c. IDs and ODs for both pipes will be different
d. Average pipe diameters for both will be same
- .
11. NPS 12, Sch 80 and Sch 160 pipes (M.O.C = A 106 gr B) are to be used at -100 C.
Determine whether,
a. Both pipes require impact testing

b. Only Sch 160 will require impact test but Sch 80 would be exempt.
c. Both would be exempt
d. Sch 80 would require but Sch 160 will be exempt.
12. In a certain arc welding process, coalescence of metals is produced

by an arc between a tungsten electrode and the work, and
shielding is obtained from a gas or gas mixture. Filler metal
mayor may not be used. This process is called:
a. FCAW
b. GMAW
c. GTAW
d. SAW
13. API 570 gives rules for:
a. Inspection Repairs and alteration of metallic pipes only

b. Repairs and alteration of metallic & non-metallic pipes.
c. In-service inspection of metallic & non-metallic pipes.
d. All of above.
14 In austentic stainless steel piping system operates between temperatures

of - 500 F and 350 0 F .The temperature of installation was 100 oF. The
approximate values of minimum expansion and contraction range for
sliding support installed at 150 ft from the anchored end will respectively
be:
a.2.4 inch and 4.3 inch

b.4.3 inch and 2.4 inch
c.l.9 inch and 4.8 inch
d.None of the above
15. Identify incorrect statement! s:
a. In impact test exemption curves, curve D represents better toughness material

than curve B
b. curve C represents more brittle material than Curve B
c. Fully de-oxidized steels are tougher than non-deoxidized materials
d. a andc
ANSWERS
Q.NO. ANSWER
1 B
2 C
3 C
4 C
5 B
6 A
7 D
8 D
9 C
10 B
11 B
12 C
13 A
14 B
15 D
QUIZ DAY 2 (CLOSED BOOK)
N ate: Choose only one alternative which you think is most appropriate.
1. Which of the following is true of "deadlegs" in a piping system?
a. NDT cannot be done on deadlegs

b. A portion of the piping which has fallen out of the test system
c. The corrosion rate can very significantly from adjacent piping
2. Which of the following is a description of a "repair organization"?
a. An owner or user of piping systems who repairs or alters his or her own
equipment in accordance with API 570
b. A contractor whose qualifications are acceptable to the owner or user of
piping systems and who makes repairs or alterations according to API 570
c. One who is authorized by, acceptable to, or otherwise not prohibited by the
jurisdiction and who makes repairs or alterations according to API 570
d. All of the above
3. What does the acronym CUI represent?
a. Cracking Under Insulation

b. Covered Under Insurance
c. Corrosion Under Insulation
d. Corrosion Under Inspection
4. Repair on piping system would
a. Restore piping to intended design conditions

b. Change the design conditions
. c. Require re-rating to be carried out
5. Which of the following best describes auxiliary piping?
a. Any piping which is extra to the main piping run can be considered as
auxiliary piping.
b. Instrument and machinery piping, typically small bore secondary process
piping that can be isolated from primary piping system.
c. Any piping which is less than 1.0 inch N.B
d. All of the above
6. Post weld heat treatment is carried out:

a. To increase Hardness
b. To increase Tensile strength
c. To release locked-up stresses in the weld and improve ductility
7. In case of piping requiring PWHT Pressure test is conducted
a. Before PWHT
b. After PWHT and before painting
c. After PWHT and painting
d. Anytime is okay
8. Basic construction code referred in API 570 is
a. ASME Sec. VIII DN 1

b. ASME Sec. IX
c. ASME B 31.1
d. ASME B 31.3
9. Which of the following defines the term hold point?
a. A pipe hanger that utilizes springs and sliding shoes to accommodate

expansion and contraction .
b. A dog welded onto piping and used to align joints prior to welding
c. A point beyond which work may not proceed until inspections have
been performed and documented
d. A trunnion, gimbat or sliding shoe used for piping support systems
10. Which of the following changes on a piping could be termed as an alteration?

a. Addition of a reinforced nozzle of size equal to an existing nozzle
b. Addition of a nozzle not requiring reinforcement
c. Any change that effect the pressure containing capacity of the piping beyond
the scope of items described in existing data reports
d. Only"b" and c"1/
11. API 570 was developed for the petroleum refining and chemical process industries.
a. It shall be used for all piping systems.

b. It may be used, where practical, for any piping system.
c. It can be used, where necessary, for power piping.
d. It may not be used unless agreed to by all parties.
12. The preferred medium for a pressure test is _ _ _ _.

a) Steam
b) Air
c) Water
d) Hydrocarbon
13. Identify dead legs" from the following.

II
a. Broken or damaged pipe supports

b. Spare pump piping
c. Both of above
d. None of above
14. In API-510, the term "RBI" means:
a. Repairing Before Inspection

b. Report Based Inspection
c. Repair Based Inspection
d. Risk Based Inspection
15. SI A interface is taken as zone which is:

a. 12 inches above soil
b. 12 inches below soil
c. 12 inches below and 6 inches above soil
d. a and b above
16. Part of piping installation exhibiting similar corrosivity and similar

design conditions is called:
a. Piping system
b. Piping Spool
c. Piping Circuit
d. N one of the above
17. What is the minimum time that a leak test must be maintained as per B 31.3?
a. 60 minutes
b. 45 minutes
c. 30 minutes
d. 10 minutes
18. "CML" in API 570 means:
a. Condition monitoring line

b. Condition measuring location
c. Condition monitoring location
19. Performing impact test requires testing of a set of:
a. Three specimen
b. At least two specimen
c. Minimum three specimen
d. Maximum three specimen
20. Hot tapping is best described by statement:
a. It is technique of heating the pipe to specified temperature and gently tapping

with lIb. rounded hammer to detect thinning of pipe wall
b. It is technique of providing a tapping connection while pipe system is in
operation
c. It is technique of fixing a water tap on hot water lines for use during winter
d. It is an act of using the tap and die for threading the pipe when the pipe is hot
ANSWER KEY
Q. ANS.
1 C
2 D
3 C
4 A
5 B
6 C
7 B
8 D
9 C
10 C
11 B
12 C
13 B
14 D
15 C
16 C
17 D
18 C
19 A
20 B
1. The recommended downstream limit of circuit of an injection point is a

minimum of:
a) Second change in flow direction past the injection point, or 25 feet

beyond the first change in flow direction whichever is less
b) Second change in flow direction past the injection point, or 25 feet
beyond the first change in flow direction whichever is greater
c) Second change in flow direction past the injection point, or 25 inches
beyond the first change in flow direction whichever is less
d) Second change in flow direction past the injection point, or 25 inches
beyond the first change in flow direction whichever is greater
2. For external inspections for potential corrosion under insulation (CUI) on

Class 1 systems, the examination should include at least percent
of all suspect areas and percent of all areas of damaged
insulation:
a) 50,75
b) 50,33
c) 75,50
d) 25,10
3. For Class 2 piping, the extent of CUI inspections on a system operating at

- 45F will be (as a minimum) of:
a) 75 % of damaged areas, 50 % of suspect areas

b) 50 % of suspect areas, 33 % of damaged areas
c) 33 % damaged areas, 50 % of suspect areas
d) None of the above
4. In the Barlow formula for determining pipe thickness, the term'S" stands for:
a. Internal design gage pressure of the pipe in psi

b. Pressure design strength for internal pressure, in inches
c. Allowable unit stress at the design temperature, in psi
d. Maximum strain at the average operating temperature, in psi
5. Determine the linear expansion (in/100 ft) of a carbon steel pipe between 70
degrees F and 450 degrees F.
a. 3.04" per 100 ft

b. 3.39" per 100 ft
c. 2.93" per 100 ft
d. 3.16" per 100 ft
6: A 20' long carbon steel pipe is heated uniformly to 450 degrees F. from 70
degrees F. Determine it~ length after heating.
a. 20.052'
b. 20.263'
c. 20.210'
d. 20.250'
7. As per API 570, in case of normal uniform corrosion, compared to other

piping. The thickness measurements on valves:
e. Must be routinely taken at same frequency while inspecting, other

piping components as valve thickness is less than other piping
components
f. Must be routinely taken at twice the frequency as other piping
components as valves are very critical components and essential for
reliable operation.
g. Are not routinely taken unless unusual corrosion pattern and thinning
is observed during servicing and repair.
h. Are routinely at twice the frequency of other components because

valves are more expensive items compared to rest of the piping and
must be more frequently checked.
8. The UT thickness measurements. for pipes at elevated temperatures, the

readings generally are corrected using thickness correction tables, because the
readings are normally
a. Higher than actual thickness

b. Lower than actual thickness
c. Temperature has no effect on the UT readings
d. Whether readings will be higher or lower depends on the UT
examiner's skill
9. Certain areas and types of piping systems are potentially more susceptible to corrosion
under insulation. Which of the items listed is not susceptible to CUI?
a) Areas exposed to mist over-spray from cooling water towers

b) Carbon steel piping systems that normally operate in-service above
250 degrees but are in intermittent service
c) Deadlegs and attachments that protrude from insulated piping
d) Carbon steel piping systems, operating between 250 degrees F and
600 degrees F
10. Environmental cracking of austenite stainless steels is caused many times by:
a) Exposing areas to high-velocity and high-turbulence streams

b) Excessive cyclic stresses that are often very low
c) Exposure to chlorides from salt water, wash-up water, etc.
d) Creep of the material by long time exposure to high temperature and
stress
ANSWERS
Q.NO. ANSWER
1 A
2 A
3 D
4 C
5 D
6 A
7 C
8 A
9 D
10 C
5. Which document gives the methodology for RBI?
a. API579
b. API570
c. API580
d. API574
6. "Pipe to soil potential survey" for poorly coated pipes (or where cathodic
protection is not reliable) should be conducted at intervals of:
a. Five years
b. Three years
c. Ten years
d. Six years
7. In pressure decay method for testing under ground pipe, the acceptance criteria
is that pressure decrease :
a. shall not exceed 15 %

b. shall not exceed 5 %
c. shall not exceed 10%
d. shall not exceed 1 %
8. In pressure-decay method for testing underground pipes, minimum leak test

pressure is % of maximum operating pressure.
a. 150%
b. 50%
c. 110%
d. 125%
5. Marker chemical (tracer) is used for testing the underground pipes for the
purpose of:
a. Checking internal smoothness of pipe

b. Checking strength and ductility of piping material
c. Checking the diameter of underground pipe
d. Detecting and locating the leaks in the pipe line
6. Except for the class 4500 valves, the valve wall thickness is times the
thickness of a simple cylinder designed for a stress of psi for similar
pressure and temperature.
a. 1.1 times and 7000 psi

b. 1.5 times and 15000 psi
c. 1.25 times and 15000 psi
d. 1.5 times and 7000 psi
7. The retirement thickness of valves and flanged fittings can be computed using
formula for pipes by using:
a. Factor of 1.5 and the stress = 15000 psi

b. Factor of 1.25 and stress = 7000 psi
c. Factor of 1.5 and allowable stress as per ASME B 31.3
d. Factor of 1.5 and stress = 7000 psi
8. Temporary repairs of locally thinned sections or circumferential linear defects

may be made on-stream by installing a properly designed and fabricated bolte<:i
leak clamp. What would this activity be termed as?
a. Welding repair (on-stream)

b. Permanent repair .
c. Non-welding repair (on-stream)
d. Hot tapping
9. Following inspection data is available for a piping circuit.
Minimum required thickness = 0.422 in

Actual thickness measured = 0.512 in
Long term corrosion rate = 0.018 in / year
Remaining life for this circuit will be:
a. 5.0 years
b. 4.5 years
c. 6.0 years
d. Data is insufficient to calculate remaining life
10. Piping classifications (class I, 2, 3) in API 570 will respectively mean:
a. Low, medium and high pressure pipes

b. High, medium, low pressure pipes
c. Low, medium, high level of inspection to be performed
d. High, medium, low level of inspection to be performed
11. Inspection records contain the following information for a particular thickness
measurement location (TML) in a return bend:
I Thickness I I Year I
0.500 II 0
0.425 II 5
0.400 II 10
On the basis of the information above, the long-term corrosion rate for the
location is:
a. 11/2 mils per year

b. 5 mils per year
c. 10 mils per year
d. 100 mils per year
12. For thickness measurement of pipes NPSl and smaller. NDT technique
employed would be:
a. Ultrasonic teclmique
b. Radiographic profile technique
c. Anyone is OK
d. None are OK
13. If probable corrosion rates can not be determined on-stream determinations shall
be made approximately
a. 6 months of service
b. 3 months of service
c. 1 month of service
14. Thickness monitoring during periodic measurements is taken at:
a. Same TMLS as used in previous inspection and approaching

retirement thickness
b. New TMLS only
c. Either same or new are okay
d. Depends on opinion of inspector
15. For calculating MAWP of Piping Circuit which is put in service the
wall thickness used in computations is:
a. Actual thickness as determined by inspection.
b. Actual thickness minus the estimated corrosion loss before the
date of next inspection
c. Actual thickness minus twice the estimated corrosion loss before
the date of next inspection
16. Table 6-2 of API 570 standard gives extent of CUI inspection following the visual
inspection, which is applicable to:
a. Entire insulated area

b. Areas with damaged insulation
c. Suspect areas within susceptible temperature
d. bandc
17. As per API 570 for .bolted flanged joints, bolts and nuts are considered as
acceptably engaged if the lack of complete engagement is:
a. Not more than two threads

b. Not more than one thread
c. Bolts and nuts are engaged at least 50% of threads in the nuts
d. Bolts shall completely extend through nuts
18. When an RBI assessment is used to increase inspection intervals, the

assessment shall be conducted on Class 1 systems at a maximum interval
of years
a. 5
b. 10
c. 15
d. 3
19. Class 3 piping is described as being in services
a. With the highest potential of resulting in an immediate

emergency if a leak occurs
b. That is flammable but do not significantly vaporizes when they leak
and are not located in high-activity areas
c. That is flammable and slowly vaporize if leak occurs
d. That is not in classes 1 and 2.
20. Thickness measurement inspection on Class 1 piping should be
scheduled based on the calculation of not more than
a. One half the remaining life determined from corrosion rates or

the maximum interval of 5 years whichever is shorter.
b. . One half the remaining life determined from corrosion rates or
5 years, whichever is longer
c. One fourth the remaining life determined from corrosion rates or
the maximum interval of 10 years whichever is shorter.
d. One quarter the remaining life determined from corrosion rates or 5
years, whichever is longer
ANSWERS
Q.NO. ANSWER
1 C
2 A
3 B
4 C
5 D
6 D
7 C
8 C
9 A
10 D
11 C
12 B
13 B
14 A
15 C
16 D
17 B
18 A
19 B
20 A
QUIZ FINAL (CLOSED BOOK)
1. Which of the following statement is correct?
a. Soil resistivity is a measure of resistance offered by soil to drilling

operation for oil exploration and it has no connection with corrosivity
of soil.
b. Lower soil resistivity indicates less corrosive soil.
c. Soil resistivity has nothing to do with corrosiveness of soil because soil
corrosion depends on the amount of corrosive chemicals present in the
soil.
d. Higher soil resistivity indicates less corrosive soil.
2. The shall be responsible to the owner-user for determining that

the requirements of API 570 for inspection, examination, and testing are met.
a) Piping Engineer
b) Inspector
c) Repair Organisation
d) Operating Personnel
3. Which of the following are some of the mandatory requirements for re-rating a
piping system?
a. Calculations must be performed by the piping engineer or the inspector.

b. Current inspection records shall be reviewed to verify that the piping system
is satisfactory for the proposed service conditions and that the appropriate
corrosion allowance has been provided.
c. The piping system is checked to affirm that the required pressure relieving
devices are present, are set at the appropriate pressure and have the
appropriate capacity at the set pressure.
d. All of the above
4. After completion of alterations a pressure test is/will:
a. Normally required
b. Not required at all
c. Depend on opinion of piping inspector
d. Only a" and c" above
/I /I
5. Name a part of a piping system that thickness measurements are not

normally routinely taken:
a) Elbows
b) Expansion loops
c) Tees
d) Valves
6. Pressure decay method is:
a. A technique adopted for checking the leakage in above ground piping

b. A technique used for checking leakage in underground piping
c. A technique used for calibration of pressure gauges
d. A technique used for releasing the overpressure in piping
7. Which of the following are areas on piping systems which are susceptible to CUI
during the range of 25F to 250F:
a. All the area which is below insulation

b. Insulated areas below steam vents
c. Insulated piping exposed to cooling tower mist
d. ub" and c" above
U
8. Listed below are several examples of piping system. Which is class I piping
for flammable fluids?
a) Readily vaporizing on leakage

b) Slowly vaporizing on leakage
c) No significant vaporization
d) All of above
9. Which of the following documents referenced in API 570 addresses hot tapping?
a. API 2201
b. API 574
c. ASMEB31 G
10. The preferred method for inspecting piping coating is:
a. Visual inspection only

b. Holiday detection
c. M.P. Check
d. D.P. Check
11. For which of the following, the approval from piping engineer is not mandatory:
a. Changing the damaged flange to a new flange of same rating and material
b Alteration on piping changing a nozzle size from one not requiring
reinforcement pad to the one requiring reinforcement pad
c. For both a and b
d. For none of the above
12. Fillet welded patches (lap patches) shall be designed by:
a) An engineer expert in corrosion

b) The inspector
c) The piping engineer
d) The repair organization
13. For a project involving piping welding at site by 10 welders, (with only one
qualified welder) procedure and 9 welders were to be qualified. In this case,
. identify correct statement from the following:
a. 9 welders qualification must be performed before procedure
qualification.
b. 9 welders qualification should be performed after procedure
qualification is carried out using qualified welder.
c. Out of Welder qualification and procedure qualification, anything can
be performed before.
d. .Welder qualification and procedure qualification must be performed
simultaneously, without waiting for the test results.
14. Guided bend test represents:
a. Ductility of weld
b. Strength of weld
c. Soundness of weld
d. Both soundness and ductility of weld
15. All positions of groove welds are qualified by
a. Pipe positions IG and 5G

b. Pipe positions 2G and 5G
c. Pipe position 5G and 3G
16. According to ASME Sec. IX, a welder for SMAW can be qualified by following
minimum tests (for IG pipe position):
a. 1 tensile and 2 bend tests

b. 2 bend tests
c. 2 tensile tests and 1 bend tests
d. 1 tensile and 1 radiography
17. Identify incorrect statement from following
a. A welder performing procedure test is also qualified in that position.

b. Supplementary essential variables become essential variables when
impact test is specified.
c. For procedure qualification, the test can be performed in any position
as the position is not essential variable for procedure qualification.
d. A 3G welder qualified in SMAW process can be employed for TIG
welding also in that position.
18. Procedure Qualification Record is a document which can be revised time to .

time.
a. True
b. False
c. Depends on company policy
d. Depends on client of the company
19. Use of Radiography is made for:
a. Performance qualification only

b. Procedure qualification only
c. Both a and b
d. Use of radiography is not permitted by ASME Sec. IX.
20. When dial-type indicating and recording pressure gauges are used to
monitor leak testing, the maximum gauge range shall not exceed which
multiple of the expected test pressure?
a. 11/2 times
b. 21/2 times
c. 3 times
d. 4 times
21. A radiographic technique in which radiation passed through two walls and both the
walls are viewed on the same radiograph (double wall, double image - ellipse) the
limitation for the outside diameter is:
a. 3-1/2"
b. 2"
c. 4"
d. Any diameter possible
22. Following data is available to compute remaining life of a piping circuit:
Minimum required thickness = 0.422 in
Actual thickness measured = 0.512 in
Corrosion rate = 0.018 in / year
Remaining life for this circuit will be:
a. 5.0 years
b. 4.5 years
c. 6.0 years
d. None of above
23. Common locations which are susceptible to CUI on the insulated piping are:
e. All penetrations or breaches in the insulation jacketing such as vents, drains,

piping hangers
f. Termination of insulation at flanges
g. All insulated bends and elbows
h. a and b above
24. The accuracy of magnetizing equipment that is equipped with an ammeter shall be
verified:
a. Each year
b. Each two years
c. When possible
d. Every 6 months
25. The WPS and the PQR are used to determine:
a. If the welder is able to deposit sound weld metaL

b. If the welder is able to operate welding equipment.
c. The welder's ability to produce welds that are radiographically free of
defects.
d. If a weldment has the required properties for the intended application
(strength, ductility)
26. Which of the following penetrant system is generally considered least

sensitive?
a. Water-washable - visible dye.

b. Solvent removable - visible dye.
c. Water-washable - fluorescent dye.
d. Post-emulsification - visible dye.
27. As soon as possible after completing an inspection, the Inspector should:
a. Review the inspection records and schedule the next

inspection
b. Always require a hydrotest
c. Sign all RT records
d. Notify the Piping Engineer
28. The nondestructive examination method to be used for a particular

inspection should be determined by the:
a. Availability of certified NDE examiners.

b. Length of time since the last inspection.
c. Age of the component to be inspected ..
d. Type, location, and orientation of the expected flaws.
29. To verify satisfactory PWHT the test conducted is:
a. Radiography
b. Ultrasonic
c. Hardness survey
d. N one of above
30. In visual testing for qualifying the procedure, a defect of which minimum
width shall be used:
a. 1/16"
b. 1/8"
c. 1/32"
d. N one of the above
31. Visual examiner should pass Jaeger J-1 check:
a. Annually
b. Six monthly
c. Once in 3 years
32. The pressure gauges for leak testing shall be calibrated as an ASME Sec. V
requirement, at least:
a. Every six months

b. Everyone year
c. Every three years
33. It is decided to carryout a surface NDT for austenitic S.S. pipe welds. Choose the
best combination.
a. Penetrant testing with Halogen free developer

b. Penetrant testing with any aqueous developer
c. Magnetic particle testing with wet particles
d. Magnetic particle testing with dry particles
34. In ultrasonic testing, for thickness measurement on corroded surface, use:
a. CRT read out

b. Digital read out
c. Any of above
d. None of above.
35. An example of service-specific corrosion is:
a) Corrosion under insulation in areas exposed to steam vents

b) Unanticipated acid or caustic carryover from processes into non-
alloyed piping
c) Corrosion in deadlegs
d) Corrosion of underground piping at soil-to-air interface
36. When a pressure test is not necessary or practical, what shall be utilised in
lieu of a pressure test?
a) PMI Testing
b) Non-destructive examination
c) Vacuum visual examination
d) Hammer Testing
37. For which of the following can yoke technique be used?
a. Sub-surface cracks
b. Surface cracks
c. Both a and b
d.None of a or b
38. The pipe welding test position in which the pipe is horizontal and rotated so that
welding takes place at or near the top is designated as?
a. 2G
b. 5G
c. 3G
d. 1G
39. API 578 gives rules for Alloy Verification for:
a. Carbon steel piping material for olcl. or new piping

b. Alloy steel piping materials, for old or new piping
c. Carbon steel materials used for old piping only
d. Alloy steels used for old piping only
40. For thickness measurement of pipes NPS 1 and smaller, NDT technique
employed would be:
e. Ultrasonic technique
f. Radiographic profile technique
g. Anyone is okay.
h. None are okay.
41. API 578 requires at least _ _ _ _ electrodes to be PMI tested from each box.
a. One
b. Two
c. Minimum 10%
d. All
42. Which of the following make pipe system most susceptible to CUI?
a. Painted pipes operating at 1500 F

b. Insulated pipes operating at 1500 F
c. Projections, penetrations in a"
If
d. Projections, penetrations in lib"
43.Freeze damage can occur in case of which of the following fluids:
a. Water only
b. Oil only
c. Water and aqueous solutions
44. For calculating MA WP of Piping Circuit which is put in service the wall thickness
used in computations is:
e. Actual thickness as determined by inspection.

f. Actual thickness minus the estimated corrosion loss before the
date of next inspection
g. Actual thickness minus twice the estimated corrosion loss before
the date of next inspection
h. None of the above
45. When checking Titanium materials for cracks using PT methods only liquid
penetrants:
a. with low or no nitrides should be used

b. with low or no carbides should be used
c. with high or medium chlorides should be used
d. with low or no chlorides should be used
46. As per API 570 for bolted flanged joints, bolts and nuts are considered as acceptably
engaged if the lack of complete engagement is:
e. Not more than two threads

f. Not more than one thread
g. Bolts and nuts are engaged at least 50% of threads in the nuts
h. Bolts shall completely extend through nuts
47. Inspection of piping systems is carried out for purpose of:
a. Safety
b. Reliability of operation
c. Regulatory requirements
d. All of above
48. For a typical "injection point pipe circuit" starts upstream of injection point
from a distance of
a. 3 times pipe diameter or 12 inches which ever is greater

b. 2 times pipe diameter or 12 inches which ever is greater
c. Fixed 12 inches irrespective of pipe diameter
d. 3 times pipe diameter or 12 inches whichever is smaller
49. For MT examination by Prod technique the spacing between prods shall be between:
a. 4 inches to 12 inches
b. 4 inches to 10 inches
c. 3 inches to 10 inches
d. 3 inches to 8 inches
50. API 578 Material Verification can be applied for:
a. New and in-service carbon steel piping

b. New and in-service alloy piping
c. Only in service carbon steel piping
d. Only for in-service alloy piping
QUIZ FINAL (CLOSED BOOK)
ANSWER KEY
Q. ANS. REFERENCE Q. ANS. REFERENCE

1 D API 570,9.1.4 29 C ASME B 31.3, 331.1.7
2 B API 570, 4.3.4 30 C ASME V, T-921.3
3 D API 570, 8.3 31 A ASME V, T-923
4 A API 570, 8.2.6 32 B ASME V, T-I061 (a)
5 D API 570, 5.9 33 A ASME V, II-642 (p. 128.1)
6 B API 570, 9.2.7 34 A ASME V, SE-797, 8.8
7 D API 570,5.3.3.1 . 35 B API 570, 5.3.5
8 A API 570, 6.2.1 36 B API 570,8.2.6
9 A API 570, Section 2 37 B ASME V, 755.1
10 B API 570, 9.1.3 38 D ASME IX, Fig. QW-461.4
11 A API 570, 8.1.1 39 B API 578,1.1
12 C API 570, 8.2.3, Para. 4 40 B API 570, 5.6, Para. 1
13 B ASME IX, QW-300.2 41 A API578,4.2.6
14 D ASME IX, QW-141.2 42 D API 570, 5.3.3.1
15 B ASME IX, QW-461.9 43 C API 570,5.3.12
16 B ASME IX, QW-302.3 44 C API 570,7.2
17 D ASME IX, QW-301.2 45 D ASME V, II-642 (p. 128.1)
18 B ASME IX, QW-200.2 (c) 46 B API 570,5.11 (Para. 2)
19 A ASME IX, QW-142 47 D API 574,5.1
20 D ASME V, T-I031 48 A API 570, 5.3.1
21 A ASME V, T-271.2 (b) 49 D ASME V, T-752.3
22 A API 570,7.1.1 50 B API 578, 1.1
23 D API 570,5.3.3.2
24 A ASME V, T-761.1 (b)
25 D ASME IX, Introduction
26 A Experience & Knowledge
27 A API 570, 6.3
28 D ASME V, Table A-110
QUIZ FINAL (OPEN BOOK)
1. The following data is presented for a class 2 pipe,
Thickness = 0.36 inch (after inspection)

Corrosion rate = 10 mpy
Remaining life = 16 years
Whenis the next thickness measurement inspection due?
a. After 8 years
b. After 5 years
c. After 10 years
2. Please calculate remaining corrosion allowance for piping in Question 1 above.
a. 0.20 inch
b. 0.28 inch
c. 0.12 inch
d. 0.16 inch
3. When will be the next inspection schedule from now on for external inspection for
. . Ql?
plpem ..
a. 10 years
b. 8 years
c. 5 years
d. none of the above
4. The pipe in Q.l above has an insulated area of 200 sq. ft., which is exposed to
susceptible temperature and mist spray of cooling tower. According to API 570, how
much of minimum area is recommended for NDT survey for CUI during external
inspection?
a. 100 square feet

b. 50 square feet
c. 66 square feet
d. 150 square feet
5. A PQR is to be qualified using 5/8 inch thick test coupon. It can qualify thickness:
a. 1/8// to 1-1/4//
b. 1/16/1 to 5/8/1
c. 1/16/1 to 1-1/4/1
6. The recommended minimum development time (Penetrant Testing) allowed for a

material made of high temperature alloy is:
a. 5 min
b. 10 min
c. 7 min
d. 6 min
7. A radiograph was having density near the penetrameter equal to 3.0. Hence the
acceptable density range of the radiograph is:
a. 1.7 to 4
b. 2.55 to 3.9
c. 2.0 to 4.0
8. For piping buried in soil with resistivity of 5000-ohm cm and not cathodically
protected, evaluations of pipe thickness should be performed at:
a. 10 year interval
b. 5 year interval
c. 3 year interval
9. For a certain Natural gas piping system, which is in operation for 16 years, it is
estimated that it has remaining life of 12 years. Considering the stipulation of API
570, which of the following will determine maximum interval for next proposed
date for thickness measurement examination and visual examination?
a. 6 years and 5 years respectively

b. 3 years and 10 years respectively
c. 10 years and 5 years respectively
d. 6 years and 6 years respectively
10. An Inspector finds incomplete penetration of 2mm in a radiograph of a girth weld of

normal fluid service piping 12 mm thick. Can he accept as per ASME B31.3?
a. If the incomplete penetration is greater than 1 mm, reject.

b. If the incomplete penetration is more than 1 mm but still less than
0.2 times pipe thickness, accept.
c. Depends on opinion of inspector
d. Radiograph again and then decide on acceptance.
11. You are planning for the Hydro-test of a piping with Hydro test pressure
40Kg/cm2g. The calibrated test gauges available with you are 0-50 Kg/cm2g, 0-100
Kg/cm2g, 1-150 Kg/cm2g and 0-200 Kg/cm2g. Which two gauges are acceptable for
this test?
a. 0-100 Kg/ cm2g and 0-150 Kg/ cm2g

b. 0-50 Kg/ cm2g and 0-100 Kg/ cm2g
c. 0-100 Kg/ cm2g and 0-200 Kg/ cm2g
d. 0-50 Kg/ cm2g and 0-200 Kg/ cm2g
12. What would you expect to happen if you were taking VT readings on piping
that was operated higher than 200 degrees F?
a. The thickness readings could be lower.

b. The thickness readings would not be influenced.
c. The thickness readings could be about 1 % higher for each 100 degrees
F rise of temperature.
d. The thickness readings may pe higher or lower depending on
couplant.
13. A welded part is to be radiographed and is I" thick, with 1/8" reinforcement. What
ASTM wire set IQI should be used on these radiographs if a source side technique is
used?
a. SetA
b. SetB
c. SetC
d. Set D
14. The document referenced in API 570 for determining "fitness for service" of piping
system is:
i. API 579
j. API 574
k. ASME B 31.1
1. None of the above
15. During impact testing of A 106 grB (Deoxidised) and A53 grB pipes (non-
deoxidised), following absorbed energy values in ft-Ib were observed:
A 106 grB 12.5, 13.5 , 12

A53 grB : 11,11.5,9
Your assessment is:
a. Both AI06 and A53 are acceptable

b. Both AI06 and A 53 shall be rejected
c. Only A53 grB can be accepted
d. Only 106 grB shall be accepted
16. A PQR test was made on A 106 grade C pipe. This will qualify which of the following
sets of materials:
a. A 106 gr B, A36, A 182 Fl

b. A lOS, A516 gr 60, A516 gr 70
c. 515 gr 70, A 285 gr C, A 335 P 11
d. None of the above set is fully qualified by this PQR.
17. Carbon percentage cannot be detected by x-ray fluroscence method because

this method cannot detect materials:
a. Lighter than sulpher

b. Heavier than sulpher
c. Black in color
d. Which are radioactive
18. When a PT test cannot be conducted between 10-52 degree C (50 degrees F - 125
degrees F) what must be done, as per ASME Sec. V?
a. A new procedure must be qualified using suitable penetrant materials.

b. The surface must be re-cleaned.
c. The test cannot be conducted.
d. Use the dwell time for penetrant and developer as per Table in Article 6 of
ASMESec. V.
19. A piping system isto be pneumatically pressure tested. Its Design Pressure is 160
psig. The first stage pressuration, the test pressure and inspection pressure
respectively will be:
a. 80 psi, 176 psi, 160 psi

b. 25 psi, 200 psi, 176psi
c. 25 psi, 176 psi, 160 psi
d. none of above
20. Select suitable Hole type (source side) penetrameter for following weld joint:
A full penetration butt made between plates 7/8" thick,

Weld reinforcement = 1/8 inch.
Weld is Also Provided backing Strip of thickness=1j 4inch
a. No 20
b. No 25
c. No 30
21. If type of penetrameter in above question is changed to wire type what shall be the
wire designation (wire decimeter in inch)?
e. 0.025 (No. 10)
f. 0.016 (No.8)
g. 0.032 (No. 11)
h. None of the above
22. For steel plates and welds to be checked by LPI, what shall be the penetration time
for penetrant?
a. 10 min for weld, 5 min for plate

b. 5 min for both .
c. 10 min for both
d. 5 min for weld, 10 min for plate
23. After applying the developer the examiner checked four welds for surface defects
after following period, weld A - after 5 minute, weld B after 10 minutes, weld C was
checked after 30 minutes and welds Dafter 65 minutes. Which of the welds were
checked wrongly?
a. Weld A and B
b. Weld C and D
c. Weld D only
d. WeldA and D
24. In a certain PQR for SMAW, the electrodes used for all passes were of AWS
classification (E 7018). Corresponding WPS also showed filler materials as E
7018. Now the manufacturer proposes to change the filler material in WPS to
E 7015. Will you ask manufacturer to:
a. Qualify new PQR with E 7015 electrodes.

b. Revise only WPS showing the change from E 7018 to E 7015 and submit
WPS as a new revision.
c. Revise only the PQR document showing the change and resubmit for
approval.
d. Revise both WPS and PQR showing the change and resubmit for approval.
25. Actual thickness measured at a TML was 0.4 inch. The corrosion rate is 10 mpy.If
next planned thickness inspection is after 6 years, what thickness will be used for
MAWP calculation?
a. 0.4 inch
b. 0.34 inch
c. 0.28 inch
26. Estimated rate of Sulphidation corrosion for a crude handing equipment due to
sulpher content of 0.5% (by weight) at 600 0F is 10 mpy. What will be the corrosion
rate if sulpher content is 1.0% by weight?
a. 10 mpy approximately
b. 12 mpy approximately
c. 15 mpy approximately
d. 20 mpy approximately
27. Suggest suitable construction materials for caustic service having 40% NaOH
concentration (by weight) operating at 240 0P
a. Carbon st~el with PWHT

b. Carbon Steel, but PWHT is not required
c. Carbon steels with quenched and tempering treatment
d. Consider Use of Nickel alloys.
28. To avoid HTHA, sugge~t suitable materials of construction for hydrogen service
with partial pressure of hydrogen = 1500psi, and temperature = 800 0P
a. Carbon steel
b. 1.25 Cr - 0.5 Mo
c. 2.25 Cr - 1 Mo
d. 1 Cr - 0.5 Mo
29. In typical refinery service, PWHT of 2.25 Cr -1 Mo steel is generally required if

hardness values in base metal and HAZ is
a. Higher than 241 Brinell

b. Lower than 241 Brinell
c. Higher than 225 Brinell
d. Lower than 225 Brinell
30. While observing radiographic film for weld with SMAW process showed indication
of following description. "A localized darker density with fuzzy edges in the center
of the width of weld image." This indication most likely represents:
a. Excessive penetration
b. Lack of penetration
c. Cluster porosity
d. Burn through
QUIZ FINAL (OPEN BOOK)

SOLUTION
Q.l Remaining life = 16 years

Thickness measurement interval = 1/2 remaining life or 10 years -use lower
(Ref.: API 570:6.3 and Table 6-1)
Answer: a (Ref.: 7.1.1 of API 570)
Q.2 Remaining c.A. = Remaining life x Corrosion rate

= 16 x 10
= 160 mils say 0.16"
Answer: d (Ref: 7.1.1 of API 570)
Q.3 Answer: c (Ref.: Table 6-1)
Q.4 Answer: c (Ref.: Table 6-2)
Q.5 Answer: d (Ref.: ASME Sec. IX, Table 451.1)

Qualified thickness is 3/16" to 1 W'
Q.6 Table in Art. 6 of ASME Sec. V shows development time of 10 ririnutes for all
materials.
Answer:b
Q.7 ASME Sec. V, Art. 2. Density variation in -15% to +30%
Answer:b
Q.8 Ref.: Table 9-1 of API 570
Answer: a
Q.9 Natural gas is Class 2 fluid (Ref.: 6.2.2 of API 570)

Refer Table 6-1 of API 570
Answer: a
Q.I0 Refer Table 341.3.2, pages 77 and 78 from ASME B31.3

Incomplete penetration permitted is)mm for letter liB" for normal fluid, girth weld.
Answer: a
Q.ll Refer ASME Sec. V (Leak Testing - Art. 10). The range for pressure
gauges is:
oto 1 Y2 times (minimum range)

oto 4 times (maximum range)
for given example,
o- 60 (minimum) and 0 - 160 maximum

Answer: a
Q.12 Refer SE-797 from Section V.

Refer paragraph no. 8.
Answer: c
Q.13 Refer Art. 2, ASME Sec. V.

IQI is on source side.
We need wire no. 9 for thickness=1"
Wire no. 9 will be in Set B.
Answer:b
Q.14 Ref. Section 2 of API 570 Page 2-1
Answer: a
Q.1S For deoxidized steel (A106 grB, T.5 == 60,000 psi)

Average required = 13 ft Ib, min 10 ft lb for one.
For non-deoxidised steel (A53 grB, T.5 = 60,000 psi)
Average required 10 ftjlb and min for one = 7 ft lb
12.5 + 13.5 + 12
Average for A106 grB = = 12.5 < 13
3
11 + 11.5 + 9
Average for A53 grB = = 10.5> 10 ft lb
3
Minimum for one = 9 > 7 ft lb
Answer: c (Ref.: ASME B31.3, page 54)
Q.16 A 106 grC pipe belongs to P No.1 material. So it will qualify only P No.1 materials.
A lOS, A 516 gr60 and A516 gr70 are P No.1 materials.
Refer Table QW-422 from ASME Sec. IX.
Answer:b
Q.17 Refer API RP 578, paragraph 5.2.1
Answer: a
Q.18 Refer dwell time table in Art. 6, ASME Sec. V.

See the note below the table.
Answer: a
Q.19 Refer ASME B31.3, Page 86, 345.5
Answer: c
Q.20 Refer ASME Sec. V, Art. 2

Refer Table for selection of IQI
Required IQlis No. 25.
Answer: b
Q.21 Refer ASME Sec . V, Art. 2.

Required wire is no. 9.
Answer: d
Q.22 Refer dwell time in Art. 6 of ASME Sec. V.
Answer: d
Q.23 Refer Art. 6, ASME Sec. V - Interpretation

Interpretation shall be between 7 mins to 60 mins
Answer: d
Q.24 Refer ASMB Sec. IX - Table for F Nos.
B7018 and B70I8 are both F No. = 4
So same PQR is OK. Only revise WPS.
Answer:b
Q.25 Refer API 570 Page 7-2 for MAWP thickness used shall be Actual Thickness minus
twice the corrosion loss up to next inspection.
0.4 - 2 x 0.01 x 6 = 0.28 inch
Answer: c
Q.26. Refer to API 571 Fig. 4 - 66.
Answer is: B
Answer is: D
Answer is: C
Q.29. Refer to API 577 Table 11.
Answer is: A
Q.30. Refer to Radiographic Film, Figure 38, API 577.
Answer is: D
Volume -1
PART 8
IMPORTANT SUMMARY POINTS

FOR API 570 COURSE
IMPORTANT SUMMARY POINTS FOR API 570 COURSE
Points From API 570 Code - Edition 2009
CHAPTER -1. Scope of API 570
1) API 570 covers inspection, rating, repair, and alteration procedures for metallic
and fiberglass reinforced plastic (FRP) piping systems and their associated
pressure relieving devices that have been placed in service.
2) The intent of this code is to specify the in-service inspection and condition-
monitoring program that is needed to determine the integrity of piping.
3) API 570 was developed for the petroleum refining and chemical process
industries but may be used, where practical, for any piping system.
4) API 570 shall not be used as a substitute for the original construction
requirements governing a piping system before it is placed in service;
5) API 570 shall not be used in conflict with any prevailing regulatory requirements.
Ifthe requirements ofthis code are more stringent than the regulatory
requirements, then the requirements ofthis code shall govern.
6) The extruded, generally homogenous non-metallics, such as high and low-

density polyethylene are excluded.
7) The fluid services and classes of piping systems listed below are optional with
regard to the requirements of API 570.
hazardous fluid services below threshold limits, as defined by jurisdictional
regulations;
water (including fire protection systems), steam, steam-condensate, boiler
feed water, and Category D fluid services, as defined in ASME B31.3.
Other classes of piping systems that are optional are those that are
exempted from the applicable process piping construction code.
8) This inspection code recognizes Fitness-For-Service concepts for evaluating in-

service damage of pressure containing components. API 579 provides detailed
assessment procedures
9) This inspection code recognizes RBI concepts for determining inspection

intervals. API 580 provides guidelines for conducting a risk-based assessment.
CHAPTER - 2. Normative References
The following referenced documents are important to remember
API Publication SiD, Pressure Vessel Inspection Code: Maintenance Inspection, Rating,
Repair, and Alteration
API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment in the
Refining Industry
API Recommended Practice 574, Inspection Practices for Piping System Components
API Recommended Practice 576, Inspection of Pressure-relieving Devices
API Recommended Practice 577, Welding Inspection and Metallurgy
API Recommended Practice 578, Material Verification Program for New and Existing
Piping Systems
API Standard 579-1/ASME FFS-l, Fitness-for-service
API Recommended Practice 580, Risk-based Inspection
API Recommended Practice 581, Risk-based Inspection Technology
API Publication 2201, Safe Hot Tapping Practices in the Petroleum and Petrochemical
Industries
CHAPTER - 3. Terms, Definitions, Acronyms, and Abbreviations
1. alteration
A physical change in any component that has design implications affecting the
pressure containing capability or flexibility of a piping system beyond the scope of its
original design.
2. authorized inspection agency

Defined as any of the following:
a) the inspection organization of the jurisdiction in which the piping system
is used,
b) the inspection organization of an insurance company that is licensed to
write insurance for piping systems,
c) an owner or user of piping systems who maintains an inspection
organization for activities relating only to his piping systems
d) an independent inspection organization employed by or under contract
to the owner or user of piping systems that are used only by the owner or
user
e) an independent inspection organization licensed or recognized by the
jurisdiction and employed by or under contract to the owner or user.
3. authorized piping inspector

An employee of an authorized inspection agency who is qualified and certified to
perform the functions specified in API 570.
4. auxiliary piping
Instrument and machinery piping, typically small-bore secondary process piping that
can be isolated from primary piping systems.
5. condition monitoring locations CMLs

Designated areas on piping systems where periodic examinations are conducted.
6. corrosion barrier
The corrosion allowance in FRP equipment typically an interior layer which is
specified as necessary to provide the best overall resistance to chemical attack.
7. corrosion specialist
A person who is knowledgeable and experienced in the specific process chemistries,
corrosion degradation mechanisms, materials selection, corrosion mitigation
methods, corrosion monitoring techniques etc.
8. deadlegs
Components of a piping system that normally have no significant flow like bypass
piping, spare pump piping.
9. examination point (recording point,measurement point,test point)

An area within a CML defined by a circle having a diameter not greater than 2 in. (50
mm) for a pipe diameter up to 10 in. (250 mmL or not greater than 3 in. (75 mm) for
larger lines
10. examiner
A person who assists the inspector by performing specific NDE on piping system
components but does not evaluate the results of those examinations in accordance
with API 570, unless specifically trained and authorized to do so by the owner or
user.
11. Fitness-For-Service evaluation

A methodology whereby flaws and other deterioration/damage contained within
piping systems are assessed in order to determine the structural integrity of the
piping for continued service.
12. FRP specialist

A person acceptable to the owner/user who is knowledgeable and experienced in
FRPs concerning the process chemistries, degradation mechanisms, materials
selection, failure mechanisms, fabrication methods etc.
13. hold point

A point in the repair or alteration process beyond which work may not proceed until
the required inspection has been performed and documented.
14. in service
Piping systems placed in operation (installed).
NOTE: Does not include piping systems that are still under construction or in
transport to the site prior to being placed in service or piping systems that have
been retired.
Piping systems that are not currently in operation due to an outage of the process,
turnaround, or other maintenance activity are still considered to be "in service./J
15. in-service inspection

All inspection activities associated with piping after it has been initially placed in
service, but before it has been retired.
16. inspection
The externat internat or on-stream evaluation (or any combination of the three) of
piping condition conducted by the authorized inspector or his/her designee.
17. minimum required thickness
The thickness without corrosion allowance based on the appropriate design code
calculations that consider pressure, mechanical and structural loadings.
18. off-site piping

Piping systems not included within the plot boundary limits of a process unit, such as,
a hydrocracker, an ethylene cracker or a crude unit.EXAMPLE Tank farm piping and
other lower consequence piping outside the limits of the process unit.
19. on-site piping

Piping systems included within the plot limits of process units, such as, a
hydrocracker, an ethylene cracker, or a crude unit.
20. on-stream
A condition where in-service piping systems have not been prepared for an internal
inspection.
21. on-stream inspection

An inspection performed from the outside of piping systems while they are on-
stream using NDE procedures
22. piping circuit

A section of piping that is exposed to a process environment of similar corrosivity or
and is of similar design conditions and construction material.
23. piping system

An assembly of interconnected'piping circuits that are subject to the same set or
sets of design conditions
24. positive material identification ,PMI

Any physical evaluation or test of a material to confirm that the material is
consistent with the specified alloy material
25. primary process piping

Process piping in norma" active service that cannot be valved off or, if it were valved
off, would significantly affect unit operability. Primary process piping normally
includes most process piping greater than NPS 2, and typically does not include small
bore or auxiliary process piping (see also secondary process piping).
26. renewal
Activity that discards an existing component, fitting, or portion of a piping circuit and .
replaces it with new or existing spare materials of the same or better qualities as the
original piping components.
27. repair
The work necessary to restore a piping system to a condition suitable for safe
operation at the design conditions
28. repair organization

Any of the following:
a) an owner or user of piping systems who repairs or alters his or her own
equipment in accordance with API 570,
b) a contractor whose qualifications are acceptable to the owner or user of
piping systems and who makes repairs or alterations in accordance with
API 570,
c) one who is authorized by, acceptable to, or otherwise not prohibited by
the jurisdiction and who makes repairs in accordance with API 570.
29. rating
Calculations to establish pressures and temperatures appropriate for a piping
system, including design pressure/temperature, MAWP, structural minimums,
required thicknesses, etc.
30. rerating
A change in the design temperature, design pressure Qr the MAWP of a piping
system (sometimes called rating). A rerating may consist of an increase, a decrease,
or a combination of both.
31. risk-based inspection, RBI

A risk assessment and risk management process which considers both the
probability of failure and consequence of failure
32. secondary process piping

Process piping, often SBP downstream of block valves that can be closed without
significantly affecting the process unit operability.
33. small-bore piping, SBP

Piping that is less than or equal to NPS 2.
34. soil-to-air interface, SI A

An area in which external corrosion may occur on partially buried pipe.
The zone generally is considered to be from 12 in. (305 mm) below to 6 in. (150 mm)
above the soil surface.
35. temporary repairs

Repairs made to piping systems in order to restore sufficient integrity to continue
safe operation until permanent repairs can be scheduled
Important Acronyms, and Abbreviations
CML condition monitoring location
CUI corrosion under insulation,
MOC management of change
MAWP maximum allowable working pressure
MDR manufacturer's data reports
MT magnetic-particle technique
MTR material test report
NDE nondestructive examination
NPS nominal pipe size
PQR procedure qualification record
SMYS specified minimum yield strength
WPS welding procedure specification

CHAPTER - 4. Owner/User Inspection Organization
1. An owner/user of piping systems shall bear ultimate responsibility for all aspects
covered in API 570
2. Moe
The owner/user is also responsible for implementing an effective MOe process that
will review and control changes to the process and to the hardware.
3. Piping Engineer
The piping engineer is responsible to the owner/user for activities involving design,
engineering review, analysis, or evaluation of piping systems covered by API 570.
4. Repair Organization
All repairs and alterations shall be performed by a repair organization. The repair
organization shall be responsible to the owner/user and shall provide the materials,
equipment, quality control, and workmanship necessary to repair the piping systems
in accordance with the requirements of API 570.
5. Authorized Piping Inspector

When inspections, repairs, or alterations are being conducted on piping
systems, an authorized piping inspector shal be responsible to the
owner/user for determining that the requirements of API 570 Inspection
and testing are met.
The inspector is also responsible for extending the scope of the
inspection (with appropriate consultation with engineers/specialists),
where justified ..
All NDT examination results shall be evaluated and accepted by the
authorized piping inspector.
6. Examiners
The examiner shall perform the NDE in accordance with job requirements.
7. Other Personnel
Operating, maintenance, engineering or other personnel shall be responsible for
timely notification to the inspector or engineer of any issues that may affect piping
integrity or any unusual conditions that may develop (e.g. noises, leaks, vibration, etc.).
CHAPTER - 5. Inspection, Examination, and Pressure Testing Practices
5.1 Inspection Plans

The inspection plan shall be developed by the inspector and/or engineer.
A corrosion specialist should be consulted when developing the inspection plan

for piping systems that operate at elevated temperatures [above 750 of (400C)]
and piping systems that operate below the ductile-to-brittle transition
temperature.
The inspection plan should consider present or possible types of damage

mechanisms. The methods and the extent of NDE shall be specified
Minimum Contents of an Inspection Plan

The inspection plan shall contain the inspection tasks and schedule required to
monitor identified damage mechanisms and assure the pressure integrity of the
piping systems.
5.2 RBI
RBI can be used to determine inspection intervals and the type and extent of
future inspection/examinations.
RBI assessment it shall include a systematic evaluation of both the probability

and the associated consequence of failure, in accordance with API 580. API 581
details an RBI methodology
Identifying and evaluating potential damage mechanisms, current equipment

condition and the effectivenes5 of the pastinspections are important steps in
assessing the probability o(piping failure
Probability Assessment
The probability assessment shall be in accordance with API 580 and shall be
based on all forms of damage that can be expected to affect equipment
Additionally, the effectiveness of the inspection practices, tools, and techniques

used for finding the potential damage mechanisms shall be evaluated.
Consequence Assessment
The consequence assessment shall consider the potential incidents that may
occur as a result of fluid release, the size of a potential release, and the type of a
potential release (includes explosion, fire, or toxic exposure.)
Frequency of RBI Assessments

When RBI assessments are used to set equipment inspection intervals, the
assessment shall be updated after each equipment inspection and each time
process or hardware changes are made
5.3 Preparation for Inspection

Safety Regulations issued by Occupational Safety and Health Administration
(OSHA) and in addition, the owner/user's safety procedures shall be reviewed
and followed.
Piping Entry
Prior to entering large piping, the piping shall be isolated from all sources of
liquids, gases, vapors, electricity, and other sources of energy.
The piping system should be drained, purged, cleaned, ventilated, gas tested and
locked out/tagged out before it is entered.
Records Review
Before performing any of the required inspections, inspectors shall familiarize
themselves with prior history of the piping system for which they are responsible.
In particular, they should review the piping system's prior inspection results,
prior repairs, current inspection plan, and/or other similar service inspections.
5.4 Inspection for Damage, Deterioration and Failure

The damage in equipment is dependent upon its material of construction, design,
construction, and operating conditions.
The inspector should be familiar with these damage mechanisms associated

with the equipment being inspected
5.5 General Types of Inspection and Surveillance
Internal Visual Inspection

Internal visual inspections are not normally performed on piping.
It may be scheduled for large diameter piping systems.
Such inspections are similar to pressure vessel inspections and should be

conducted with methods similar to those outlined in API 510 and API 574.
On-stream Inspection
All on-stream inspections should be conducted by either an inspector or
examiner.
All on-stream inspection work performed by an examiner shall be authorized and

approved by the inspector.
The inspection may include several NDE techniques to check various damages.
Thickness Measurement Inspection

Thickness measurements shall be obtained by the inspector or the examiner at
the direction of the inspector.
Normally thickness measurements are taken while the piping is on-stream.
The inspector should consult with a corrosion specialist when the short-term
corrosion rate changes significantly from the previous identified rate to
determine the cause.
External Visual Inspection

An external visual inspection is performed to determine the condition of the
outside ofthe piping, insulation system, painting, and coating systems, and to
check for signs of misalignment, vibration, and leakage.
External piping inspections may be made when the piping system is in-service.
The periodic external inspection should normally be conducted by the inspector,

but qualified operating or maintenance personnel also may conduct external
inspections, when acceptable to the inspector.
External Inspection of Buried Equipment

Buried piping shall be inspected to determine its external surface condition.
The external inspection interval shall be based on corrosion rate information

obtained from various sources like test coupons, buried piping in similar
circumstances; or from the results of cathodic protection surveys.
CUI Inspection
Inspection for CUI shall be considered for externally-insulated piping with
possibility of moisture ingress and susceptible temperature range {Carbon steel
piping operating between 10 OF (-12C} and 350 OF (175 C)}.
CUI inspections may be conducted as part of the external inspection.
If CUI damage is found during spot checks, the inspector should inspect other
susceptible areas on the equipment.
Vibrating Piping and Line Movement Surveillance

Operating personnel should report vibrating or swaying piping to engineering or
inspection personnel for assessment. Evidence of significant line movements
that could have resulted from liquid hammer, or process upsets.
periodic MT or PT should be considered to check for the onset of fatigue cracking .

Branch connections should receive special attention particularly unbraced small
bore piping connected to vibrating pipe.
Supplemental Inspection
Other Supplemental inspections may be scheduled as appropriate or necessary.
-~
Examples of such inspe.ctions include thermography to check for hot spots in

refractory lined systems, acoustic leak detection etc
Injection'Point Inspection
The recommended upstream limit ofthe injection point circuit is a minimum of
12 in. (300 mm) or three pipe diameters whichever is greater. The recommended
downstream limit the second change in flow direction, or 25 ft (7.6 m) beyond
the first change whichever is less.
The preferred methods of inspecting injection points are radiography and/or UT,
as appropriate
During periodic scheduled inspections, more extensive inspection should be

applied to an area beginning 12 in.(300 mm) upstream of the injection nozzle
and continuing for at least ten pipe diameters downstream of the injection point.
5.6 CMLs
CMLs are specific areas along the piping circuit where inspections are to be made.
Examples of different types of CMLs include locations for thickness
measurement, locations for stress cracking examinations, locations for CUI and
locations for high temperature hydrogen attack examinations.
CML Monitoring
Each piping system shall be monitored at CMLs.
CMLs should be distributed appropriately throughout each piping circuit.
The thinnest reading or an average of several measurement readings taken

within the area of a examination point shall be recorded
CMLs should be marked on inspection drawings and on the piping system to

allow repetitive measurements at the same CMLs.
CML Selection
A decision on the type, number and location of the CMLs should consider results
from previous inspections, corrosion and damage that are expected
Every CML should have one or more examination points identified by:
locations marked on un-insulated pipe using paint stencils, or stickers;
holes cut in the insulation and plugged with covers;
isometrics or documents showing CMLs
Corrosion specialists should be consulted about the appropriate placement and

number of CMLs for piping systems susceptible to localized corrosion or cracking
5.7 Condition Monitoring Methods

UTand RT
UT is most common method for thickness monitoring.
. Radiographic profile techniques are preferred for pipe diameters of NPS 1 and
smaller. Radiographic profile techniques may be used, in insulated systems or
where localized corrosion is suspected.
When ultrasonic measurements are taken above 150 of (65C), measurements

should be adjusted by the appropriate temperature correction factor.
5.8 Pressure Testing of Piping Systems-General

Pressure tests are not normally conducted as part of a routine inspection.
When they are conducted (if required by inspector or by jurisdiction), pressure

tests shall be performed inaccordancewiththe requirements of ASME B31.3.
Lower pressure tests, which are used only for tightness of piping systems, may
be conducted at pressures designated by the owner/user.
The owner/user is cautioned to avoid exceeding 90 % of the SMYS for the

material
Test Fluid
The test fluid should be water unless there is the possibility of damage due to
freezing. such case, another suitable nontoxic liquid may be used.
Piping fabricated of or having components of 300 series stainless steel should be

hydro tested with water having a total chloride content of less than 50 ppm.
For sensitized austenitic stainless steel piping use alkaline-water solution for
pressure testing
Pneumatic Pressure Tests

A pneumatic (or hydropneumatic) pressure test may be used when it is
impracticable to hydrostatically test due to temperature, structural, or process
limitations.
Test Temperature and Brittle Fracture Considerations
At ambient temperatures, carbon, low-alloy, and other steels, including high
alloy steels embrittled by service exposure, may be susceptible to brittle failure.
The potential for a brittle failure shall be evaluated by an engineer prior to

hydrostatic or pneumatic testing.
To minimize the risk of brittle fracture during a pressure test, the metal
temperature should be maintained at least 30 of (17C) above the MDMT for
piping that is more than 2 in. (5 cm) thick, and 10 of (6C) above the MDMT for
piping that have a thickness of 2 in. (5 cm) or less.
Precautions and Procedures

During a pressure test, where the test pressure will exceed the set pressure of
the pressure relieve valve on a piping system, the pressure relief valve or valves
should be removed or blanked for the duration of the test.
As alternative, each valve disk shall be held down by a suitably designed test
clamp.
The application of an additional load to the valve spring by turning the adjusting
screw is prohibited.
A close visual inspection of piping components should not be performed until

the equipment pressure is at or below the MAWP.
Pressure Testing Alternatives

Appropriate NDE shall be specified and conducted when a pressure test is not
performed after a major repair or alteration.
Substituting NDE procedures for a pressure test after an alteration is allowed

only afterthe engineer and inspector have approved the substitution.
5.9 Material Verification and Traceability

During repairs or alterations to alloy material piping systems, the inspector shall
verify that the installation of new materials is consistent with the specified
material.
PMI testing can be accomplished by the inspector or the examiner with the use
of suitable methods as described in API 578.
5.10 Inspection of Valves

Normally, thickness measurements are not routinely taken on valves since the
body of a valve is normally thicker than other piping components for design
reasons.
When valve body and/or closure pressure tests are performed after servicing,
they should be conduCted in accordance with API 598.
Critical check valves should be visually and internally inspected to ensure that
they will stop flow reversals.
5.11 In-service Inspection of Welds

Inspection for piping welds is normally accomplished as a part ofthe
requirements for new construction, repairs, or alterations.
Due to the different capabilities various NDE methods to find flaws, it is a good
practice to specify the types of NDE during original fabrication that the owner-
user plans to apply during in-service inspections.
5.12 Inspection of Flanged Joints

If flanges are significantly bent or distorted, their markings and thicknesses
should be checked against engineering requirements before taking corrective
action.
Flange fasteners snoulCf be examinedvisually for corrosion and thread

engagement. Fasteners should be fully engaged. Any fastener failing to do so is
considered acceptably engaged if the lack of complete engagement is not more
than one thread.
5.13 Inspection Organization Audits

Each owner/user organization should be audited periodically to determine ifthe
authorized inspection agency is meeting the requirements of this inspection
code.
The audit team should typically be from another owner/user plant site or from a
third party experienced in refining and/or petrochemical process plant
inspection
CHAPTER - 6. Interval/Frequency and Extent of Inspection
6.1 General
Scheduled inspections of Piping Systems shall be conducted on or before their
due date or be considered overdue for inspection.
Inspections that have been risk assessed and found to have acceptable risk for
an extension of the due date are not considered overdue until the end of the
documented extension period.
The appropriate inspection shall provide the information necessary to determine

that Piping is safe to operate until the next scheduled inspection.
6.2 Inspection During Installation and Service Changes
Piping Installation
Piping shall be inspected in accordance with code of construction requirements
at the time of installation.
This installation inspection should document base-line thickness measurements

to be used as initial thickness readings for corrosion rate calculations in lieu of
nominal thickness data in specifications, and design datasheetsjdrawings.
Piping Service Change

If both the ownership and the location of the piping are changed, the piping shall
be inspected before it is reused.
The allowable service conditions and the inspection interval shall be established
for the new service.
6.3 Piping Inspection Planning
The piping classification scheme in 6.3.4 is based on the consequence of a failure.

The classification is used to establish frequency and extent of inspection.
RBI for Inspection Planning

An RBI assessment may be used to increase or decrease the inspection limits
described in Table 2. Similarly, the extent of inspection may be increased or
decreased beyond the targets in Table 3, by an RBI assessment.
When used to increase inspection interval limits or the extent of inspection, RBI
assessments shall be shall be reviewed and approved by a piping engineer and
authorized piping inspector at intervals not to exceed limits in Table 2, or more
often if warranted by process, equipment, or consequence changes.
Inspection Intervals
The owner/user or the inspector shall establish inspection intervals
Thickness measurements should be scheduled at intervals that do not exceed

the lesser of one half the remaining life or the maximum intervals recommended
in Table 2.
Table 2 contains recommended maximum inspection intervals for Classes 1, 2

and 3 of piping services. Maximum intervals for Class 4 piping are left to the
determination of the owne-r/user.
Piping Service Classes
Class 1
Services with the highest potential of resulting in an immediate emergency if a
. leak were to occur are in Class 1.
Fluids that can rapidly vaporize during release, are class 1 ( such as C2, C3, and
C4 streams).
Fluids that rapidly vaporize are those with boiling temperatures below 50 OF
(10C)
Class 2
Services not included in other Classes are in Class 2. This classification includes
the majority of unit process piping
On-site hydrocarbon fluids tnat will slowly vaporize during release are class 2
Class 3
Hydrocarbon Fluids that do not significantly vaporize during release are class 3
Services that are potentially harmful but are located in remote areas may be
included in this class.
Class 4
Services that are essentially nonflammable and nontoxic are in Class 4, as are
most utility services. Inspection of Class 4 piping is optional.
6.4 Extent of Visual External and CUI Inspections

External visual inspections, including inspections for CUI, should be conducted at
maximum intervals listed in Table 2
Alternatively, external visual inspection intervals can be established by using a
valid RBI assessment conducted in accordance with API 580.
Following the external visual inspection of susceptible systems, additional

examination is required for the inspection of CUI. The extent and type of the
additional CUI inspection are listed in Table 3.
Piping systems that are known to have a remaining life of over 10 years or that
are adequately protected against external corrosion ne'ed not be included for the
NDE inspection recommended in Table 3.
6.5 Extent of Thickness Measurement Inspection

To satisfy inspection interval requirements, thickness measurement inspection
should obtain thickness readings on a representative sampling of CMLs on each
circuit
This sampling also shall include CMLs with the earliest renewal date as of the
previous inspection.
6.6 Extent of Small-bore, Auxiliary Piping, and Threaded-connections Inspections

SBP Inspection
SBP that is primary process piping should be inspected in accordance with all the
requirements ofthis document.
SBP that is secondary process piping
Class 1 secondary SBP shall be inspected as primary process piping.
Inspection of Class 2 and Class 3 secondary SBP is optional.
Inspection of auxiliary SBP is optional
6.7 Inspection and Maintenance of Pressure-relieving Devices (PROs)
PRDs should be inspected, tested, and maintained in accordance with API 576 .
Unless documented experience and/or an RBI assessment indicates that a longer

interval is acceptable, test and inspection intervals for pressure-relieving devices
in typical process services should not exceed:
o five years for typical process services, and
o 10 years for clean (nonfouling) and noncorrosive services.
Table 2-Recommended Maximum Inspection Intervals
Type of Circuit Thickness Measurements Visual External
Class 1 Five years Five years
Class 2 10 years Five years
Class 3 10 years 10years
Class 4 Optional Optional
Injection points a Three years By class
S/A b By class
Table 3-Recommended Extent of CUI Inspection Following Visual Inspection

Approximate Amount of CUI Inspection
by NDE at Suspect Areas on Piping
Pipe Class Approximate Amount of Follow-up Examination Systems within Susceptible
with NDE or Insulation Removal at Areas with Temperature Ranges as indicated in API
Damaged Insulation 574
75% 50%
2 50% 33%
3 25% 10 %
4 Optional Optional
CHAPTER- 7. Inspection Data Evaluation l Analysis l and Recording
7.1 Remaining Life Calculations

The remaining life of the piping system shall be calculated from the following formula:
tactual- trequired
Rem ai n in g Iife (yea rs) = ------------------------------------------------------
corrosion rate [inches (mm) per year]
where,
tactual is the actual thickness, measured at the time of inspection.
trequired is the required thickness, at the same location as the tactual
Corrosion Rates Calculations
The corrosion rates of piping circuits shall be calculated from the following formula:
tinitial- tactual
Corrosioon rate (LT) = ---------------------------------------------------------
time (years) between tinitial and tactual
The 5T corrosion rate of piping circuits shall be calculated from the following formula:
tprevious - tactual
Corrosioon rate (5T) = --------------------------------------------------------------
time (years) between tprevious and tactual
where
tinitial is the thickness, at initial installation
. tprevious is the thickness, at the same location as tactual measured during previous
inspection.
LT and 5T corrosion rates should be compared. The authorized inspector, in

consultation with a corrosion specialist, shall select the corrosion rate that
best reflects the current process.
Corrosion Rates for Newly Installed Piping Systems or Changes in Service
For new piping systems and piping systems for which service conditions are
being changed, one of the following methods shall be employed to determine
the rate of corrosion
o A corrosion rate for a piping circuit may be calculated from data collected
by the owner/user on piping systems of similar service an~ comparable
operating conditions.
o If data for the same or similar service are not available, a corrosion rate
from the published data on piping systems in comparable service.
o If the probable corrosion rate cannot be determined by either a) or b),

the initial thickness measurement shall be made after no more than
three months of service.
Inaccurate Corrosion rates for Existing Piping Systems

If calculations indicate that an inaccurate rate of corrosion has been assumed,
the rate to be used for the next period shall be adjusted to agree with the actual
rate found.
7.2 MAWP Determination

The MAWP for the continued use of piping systems shall be established using the
applicable code.
For unknown materials, computations may be made assuming the lowest grade
material and joint efficiency in the applicable code.
When the MAWP is recalculated, the wall thickness used in these computations
shall be the actual thickness determined by inspection minus twice the
estimated corrosion loss before the date of the next inspection
7.3 Required Thickness Determination

The required thickness of a pipe shall be the greater of the pressure design
thickness or the structural minimum thickness.
7.4 Assessment of Inspection Findings
Pressure containing components found to have degradation that could affect
their load carrying capability shall be evaluated for continued service.
Fitness-For-Service techniques, such as those documented in API 579-1/ASME

FFS-l, may be used for this evaluation.
7.S Piping Stress Analysis
Piping stress analysis to assess system flexibility and support adequacy is not
normally performed as part of a piping inspection.
7.6 Reporting and Records for Piping System Inspection
Permanent and Progressive Records
Piping system owners and users shall maintain permanent and progressive
records of their piping systems and pressure-relieving devices. Permanent
records will be maintained throughout the service life of each piping system.
Types of Piping Records

Piping system and pressure-relieving device records shall contain four types of
information pertinent to mechanical integrity as follows.
Fabrication, Construction and Design Information to the Extent Available-For

example, MDRs, MTRs, WPS/PQR, design data, design calculations, NDE records,
pressure-relieving device sizing calculations and construction drawings.
Inspection History-inspection reports ( internat external, thickness

measurementsL the name of the person who performed the inspection
description of the inspection and/or examination performed, and the results of
the inspection and/or examination.
Repair, Alteration, and Re-rating Information
Fitness-For-Service Assessment Documentation
7.7 Inspection Recommendations for Repair or Replacement

A list of repair or replacement recommendations that impact piping integrity is
required and shall be kept updated.
7.8 Inspection Records for External Inspections

Results of external piping system inspections shall be documented. A narrative
or checklist format is recommended
7.9 Piping Failure and Leak Reports

Leaks and failures in piping that occur as a result of corrosion, cracking or
mechanical damage shall be reported and recorded to the owner-user.
Causes of leaks and failures in piping systems shall be investigated

7.10 Inspection Deferral or Interval Revision
Any piping circuit not inspected within the established interval is considered
overdue for inspection,
A deferral is appropriate when the piping circuit's current interval is still

considered to be correct given the available data but an extension of the
inspection date based on a documented risk analysis process is acceptable to the
inspector.
Temporary extensions of piping inspection due dates and shall not be considered
inspection interval revisions.
An inspection interval revision is appropriate when review ofthe piping

condition and history indicates that the current inspection interval was set too
conservatively
CHAPTER-8. Repairs, Alterations, and Rerating of Piping Systems
8.1.2 Authorization
All repair and alteration work shall be authorized by the inspector prior to its
commencement. Authorization for alteration work may not be given without
prior consultation with, and" approval by, the piping engineer.
The inspector will designate any inspection hold points required during the
repair or alteration sequence.
The inspector may give prior general authorization for limited or routine repairs
and procedures, provided the inspector is satisfied with the competency of the
repair organization.
Approval
All proposed methods of execution of repair and alteration work, materials,
welding procedures, examination, and testing shall be approved by the inspector
or by the piping engineer, as appropriate.
Owner/user approval of on-stream welding is required.
Welding repairs of cracks that occurred in-service should not be attempted

without prior consultation with the piping engineer in order to identify and
correct the cause ofthe cracking. ]
The inspector shall approve all repair and alteration work at deSignated hold
points and after the repairs and alterations have been satisfactorily completed.
8.1.4 Welding Repairs (Including On-stream)

8.1.4.1 Temporary Repairs
For temporary repairs, a full encirclement sleeve may be applied over the
damaged or area ..
If the repair area is localized and the specified minimum yield strength of the
pipe is not more than 40,000 psi a temporary repair may be made by fillet
welding a split coupling or plate patch over the pitted area.
A fillet-welded patch shall not be installed on an existing fillet-welded patch.
When installing a fillet-welded patch adjacent to an existing fillet-welded patch,

the distance between them (the toe to toe) shall not be less than:
d= 4 vRT
where,
d = the minimum distance between the adjacent fillet weld attachments,
R = the inside radius
t =the minimum required thickness of the fillet welded patch
Temporary repairs should be removed and replaced with a suitable permanent

repair at the next available maintenance opportunity.
Temporary repairs may remain in place for if approved by the piping engineer.
Permanent Repairs
Repairs may be made by preparing a welding groove to remove the defect and
then filling the groove with weld metal
Corroded areas may be restored with weld metal deposited in accordance
The defective area may be removed by cutting out a cylindrical section and
replacing it with a piping component
Insert patches (flush patches) may be used to repair damaged or corroded areas
if the following requirements are met:
o Full-penetration groove welds are provided.
o For Class 1 and Class 2 piping systems, the. welds shall be 100 percent
radiographed or ultrasonically tested.
o Patches may be any shape but shall have rounded corners 1 inch radius
The bolted clamp, nonmetallic composite wrap, metallic and epoxy wraps, are
considered as non-welded temporary repairs. These can be installed on-stream.
Any welding conducted on~ piping components in operation must be done in

accordance with API Publ 2201.
The repair organization shall use welders and welding procedures qualified in
accordance with the code to which the piping was built.
o Preheating to not less than 300F (150C) may be considered as an

alternative to PWHT for repairs initially PWHT'd pipes constructed of the
P-l steels and P-3 steels,{except Mn-Mo steels}.
o Local PWHT may be substituted for 360-degree banding on local repairs

under certain precautions
o Butt joints for repairs shall be full-penetration groove welds
o The temporary repairs shall be approved by the piping engineer.

The materials used in making repairs or alterations shall be of known weldable
quality, shall conform to the applicable code
After welding is completed, a pressure test shall be performed if practical and

deemed necessary by the inspector.
o Pressure tests are normally required after alterations and major repairs
o When a pressure test is not necessary or practical, NDE shall be utilized in

lieu of a pressure test after consultation with the inspector and the piping
engineer.
Rerating:
Rerating piping systems can be done under following conditions
o Calculations are performed by the piping engineer or the inspector.

o All reratings shall be established in accordance with the requirements of
the applicable code.
o Current inspection records verify that the appropriate corrosion
allowance is provided.
o Rerated piping systems shall be leak tested unless a previous leak test
was performed at greater than or equal to the test pressure for the new
condition.
o Piping flexibility is adequate for design temperature changes.
o A decrease in minimum operating temperature is justified by impact test
results, if required by the applicable code.
CHAPTER 9-lnspection Of Buried Piping
Above-Grade Visual Surveillance by observing leaks change in the surface

contour of the ground, discoloration of the soil, pool formation etc. shall be
done at approximately 6-month intervals
The close-interval potential survey is performed at ground level over the buried
pipe to locate active corrosion of pipe's surface. For poorly coated pipes where
cathodic protection potentials are inconsistent, this survey is conducted at 5-
year intervals
The pipe coating holiday survey can be used to locate coating defects on buried
coated pipes
Measurements of soil resistivity should be performed using the Wenner Four-Pin

Method in accordance with ASTM G57.
For piping buried in lengths greater than 100 feet (30 m) and not cathodically
protected, evaluations of soil corrosivity should be performed at 5-year intervals
Cathodically protected buried piping should be monitored regularly as per NACE

RP0169 and Section 11 of API RP 651
Inspection Methods
Intelligent pigging. This method involves the movement of a device (pig) through the.
Five diameter bends are usually required since standard 90-degree elbows may not
pass a pig.
Video cameras. Television cameras are available that can be inserted into the piping.
These cameras may provide visual inspection information on the internal condition
of the line.
Excavation. In many cases, the only available inspection method that can be
performed is unearthing the piping in order to visually inspect the external condition
of the piping
The external condition of buried piping that is not cathodically protected should be
determined by either pigging, which can measure wall thickness, or by excavating
according to the frequency given in Table at the end (Table 9-1).
Leak Testing:
As alternative or supplement to inspection is leak testing with liquid at a
pressure at least 10 percent greater than maximum operating pressure
Intervals for above test are: one-half the length of those shown in Table 9-1 for
piping not cathodically protected and at the same intervals as shown in Table 9-1
for cathodically protected piping.
Table 9-1---Frequency of Inspection for Burled PJping

\,iVithout EffecUve Cathodic Protection
SoH Resisti ",ity {(J bm -em) Inspection Innerval (years)
< 2,000 5
2,000 to 1O,OnO 10
> 10,(JOO 15
The leak test should be maintained for a period of 8 hours. Four hours after the
initial pressurizationof the piping system, the pressure should be noted and, if
necessary,the line repressurized to original test pressure and isolated from the
pressure source. If, during the remainder of the test period, the pressure
decreases more than 5 percent, the piping should be visually inspected to find
the leak and assess the extent of corrosion.
Sonic measurements may be helpful in locating leaks during leak testing.
Buried piping also may be surveyed for integrity by using temperature-corrected

volumetric methods or by acoustic emission examination
If piping leaks are clamped and reburied, the location of the clamp shall be
logged in the inspection record (with the date of installation) also be surface
marked.
All clamps shall be considered temporary. The piping should be permanently

repaired at the first opportunity
AnnexA
Inspector Certification
An API 570 inspector certification will be issued when an applicant has successfully
passed the API 570 certification exam and satisfies at least one of the following:
o a Bachelor of Science degree in engineering or technology, plus one year

of experience in supervision of inspection activities or performance of
inspection activities as described in API 570;
o a two-year degree or certificate in engineering or technology, plus two

years of experience in the design, construction, repair, inspection, or
operation of piping systems, of which one year must be in supervision of
inspection activities or performance of inspection activities as described
in API 570;
o a high school diploma or equivalent, plus three years of experience in the

design, construction, repair, inspection, or operation of piping systems, of
which one year must be in supervision of inspection activities or
performance of inspection activities as described in API 570;
o a minimum of five years of experience in the design, construction, repair,

inspection, or operation of piping systems, of which one year must be in
supervision of inspection activities or performance of inspection activities
as described in API 570.
Recertification
o Recertification is required three years from the date of issuance of the
API 570 authorized piping inspector certificate. Recertification by written
examination will be required for authorized piping inspectors who have
not been actively engaged
o "Actively engaged as an authorized piping inspector" shall be defined as a

minimum of 20 % of time spent performing inspection activities or
supervision of inspection activities, or engineering support of inspection
activities, as described in the API 570, over the most recent three year
certification period.
o Once every other recertification period (every six years), inspectors

actively engaged as an authorized piping inspector shall demonstrate
knowledge of revisions to API 570 that were instituted during the
previous six years.
ASME 8 31.3 PROCESS PIPING CODE
1. ASME 8 31.3 piping is used for construction of new piping

installation and is applicable to all piping within the battery limits of
process plants (except power plants) and petroleum refinery.
2. Revised edition and addenda of ASME 8 31.3 Code may be used

from beginning with date of issue. But they become mandatory from
6 months after issue date.
3. Code statements with "shall" mean it is a mandatory requirement.

Code statements with "should" means it is a recommendation and
Code statements with "may" means it is a optional matter.
4. Code 831.3 classifies fluids as Category D (15 - 150 psi design

Pr.) Category M (toxic), and category K (high pressure).
5. The fluids which are not category D, M or K are called "Normal"

fluids.
6. Safe stress values shall be taken from Table A - 1A (stress table).
7. The material can be normally used up to the lower temperature

given in Min. Temp. Column of Table A - 1A (stress table).
8. It can not be used for lower temperature (if double line is to the left)
or higher temperature (if double line is to the right).
9. Table A-1 B of B 31.3 Code gives weld joint quality factor for
manufactured pipes. The factor can be increased for Electric
Fusion welded pipes by conducting additional radiography (spot or
full) as per Table 302.3.4.
10. Minimum Required Thickness (tm) for a pipe of outside diameter

(0) ,weld point factor (E) and made from material having safe
stress (8), Material co-efficient (Y), weld strength reduction factor
(W) and subjected to internal pressure (P) is given by:
PO
Min.Req.Thickness tm +C
2(8EW + PY)
where C::::: corrosion allowance.
11. The thickness calculated shall be corrected for 12.5% negative mill
tolerance.
12. Thickness of a permanent blank for the pipe is given by:
3P
---+C
16 SE
Where, dg::::: gasket inside diameter
13. Materials can be used up to given minimum temperature in table

A 1 (stress table) without impact testing.
14. For lower temperatures, go to Fig. 323.2.2. If temperature &

thickness combination point falls on or above the material curve
(Fig. 323.22), impact testing is NOT required. (If below the curve
- impact testing is required.)
15. To know which material is represented by which curve (Fig.
323.2.2, curves A, B, C, D), go to table A-1 (stress table).
16. Typically, Curve A materials are Most Brittle.
17. For impact testing, 3 specimens are required. If the average of 3

. specimens > = Required Average and value of only one
specimen is less than average but more than minimum for one
specimen - Accept.
is. If two specimens are below required average, or one specimen is

less than average but also less than minimum for one specimen -
Retest.
19.After retest all three must equal or exceed the average.
20. For joining unequal schedule pipe, tapering or step-slot shall be made
inside thicker pipe for weld fit-up.
21. For fillet weld, the throat of fillet weld is calculated as throat =0.707 size of
weld.
22.AII welding shall be done by qualifying procedures and welders according

to ASME Sec. IX.
23. Table 330.1.1 gives required and recommended pre-heat temperature.

Recommendation becomes requirement if ambient temp is <DoC.
24.ln dissimilar pipe joints higher temperature of the two is to be used

for pre-heating. The pre-heat zone shall extend at least one inch
beyond the edge of the weld.
25. Pre-heating, whenever specified ie applied to Strength welds, tack
welds and seal welds.
26. PWHT Table (331.1.1) gives temperature range, minimum holding time
and maximum hardness values.
27. PWHT conducted properly should reduce the hardness in weld and HAZ.
Code gives the maximum Brinell Hardness Values after PWHT .
28. Where a hardness limit is specified in Table 331.1.1, at least 10 % of

welds, hot bends, and hot formed components in each furnace heat
treated batch and 100% of those locally heat treated shall be tested for
hardness.
29.AII NDT (PT, RT, MT, VT, UT) shall be carried out according to
ASME Sec. V.
30. Acceptance criteria shall be as per Table 341.3.2.
31.lf two values are separated, by 'and' lower value becomes the acceptance
limit. If two values are separated by 'or' then higher value becomes the
acceptance lim it.
32.According to ASME B 31.3, Owner's inspector should have 10 years

minimum experience in the design, fabrication, or inspection of industrial
pressure piping.
33. After fabrication and inspection of piping, but before first operation,
hydrostatic pressure test shall be carried out on completed piping.
34. Only if hydrostatic test is not practicable, pneumatic test may be

conducted.
35. Test pressure in both cases shall be held for minimum 10 minutes.
36. Hydrostatic Pressure = 1.5 x Design Pressure x Stress Ratio
37 . Stress Rat 10 = -
Stress at test temperature (Ambient)
-----=-----'------'--
Stress at design temperature
38. Pneumatic Test Pressure = 1.1 x Design Pressure
39. Pneumatic Pressure should be initially raised up to 50% of test pressure

or 25 psi (whichever is less) and a preliminary check shall be made. After
preliminary check pressure can be increased slowly to reach up to test
pressure.
40.ln pneumatic leak test, final inspection pressure for leak check is Design
Pressure of the Piping System.
41. For category D fluids the leak testing at operating pressure can be
performed with the product itself directly.
42. For pressure testing of piping systems, pneumatic test should be

done using air but other non toxic gases may be used.
43. For hydro testing water should be used as testing medium but other
non toxic liquid may be used if water is not suitable due to
possibility of freezing or due to process reasons.
44. For pneumatic testing preferred medium is air but other non-toxic
gases also may be used
45. The inspection procedure records shall be retained for at least 5
years.
46. Thermal expansion and contraction for different temperatures is given in

Table C-1. This information is used to decide expansion and contraction
margins required for pipe supports and other purposes.
ASME B 16.5 PIPE FLANGES AND FLANGED FITTINGS
1. 8 16.5 Covers Flanges and flanged fittings with rating class designation 150.
300,400,600,900, 1500, and 2500 in sizes NPS 1/2 through NPS 24
2. ASME B 16.5 permits Blind flanges made from plates.
3. The System Hydrostatic Test pressure for flanges and flanged fittings is 1.5
times the pressure rating at 100 deg. F rounded to higher 25 psi.
4. For finding out the required flange class as per 816.5, first find out which table
(Pressure - Temperature rating table) to refer for that material. Flange rating
then can be read out from that table for given condition of design pressure and
design temperature.
5. Flanges are not required to be pressure tested. Each flanged fitting shall be
given a shell pressure test
6. The shell pressure test for flanged fittings shall be at a pressure no less than
1.5 times the 38C (100F) pressure rating rounded off to the next higher 1 bar
(25 psi) increment.
7. Flanged fittings shall be pressure tested for leak tightness using water. Other
test fluids may also be used if required. The test duration shall be:
Size Duration, sec
< NPS 2 60
NPS 21/2 to NPS 8 120
~NPS10 180
ASME - Sec. IX - welding Qualification Code
Note: Figures in parenthesis give reference cause in the code.
1. ASME Sec. IX gives requirement for Qualifying Procedures and

welders (QW 100).
2. For Procedure Qualifications a test coupon is welded and then

tested for strength (tension tests) and ductility (Bend tests) to
ensure that the weld has required properties (QW- 141).
3. In performance qualification we determine welder's ability to

produce sound welds by conducting either Bend tests or
Radiography. (QW 141, 142)
4. Tension test is passed if either of the following is satisfied.

a. If break is in weld metal is must be at strength above the
specified minimum tensile strength of Base metal.
b. If break is in base metal it must meet at least 95% of
minirrflJm tensile strength of Base metal. (QW 153). ('
5. Bend test (It may be Face bend, root bend or side bend) is
passed if test specimen does not show open discontinuity more
than 1/8 inch. (3 mm.) (QW 163).
6. Radiography for welder qualification shall meet acceptance

criteria of ASME Sec. IX (QW 191.2).
7. A PQR is a record of welding data used to weld test coupon. It

also contains test results on backside it can not be revised.
(QW 202.2)
8. A WPS is used to provide direction for making production welds.
It shall be within ranges qualified by P & R (QW 200.1)
9. A P & R support WPS as long as essential variables on both

are same.
10. For P & R test to pass it shall pars 2 tension tests and 4 bend
tests (QW 202).
11. Bend tests are 2 face Bend and 2 Root bends for coupon
thickness less than 3/4" (19 mm) and 4 side bend tests if
thickness is equal to greater than 3/4" (QW 451)
12. P Q R should also list P. No. (for parent metal) F.No. (for filler
metal) and A-No. (for weld metal) [QW-422, QW-432, QW-442].
13. For procedure qualification test coupon may be a plate or pipe.

plate qualities for pipe and vice versa (QW 211)
14. A procedure qualification in any position qualities the procedure

in all positions. (QW-203)
15. For welder qualification 2 bend tests or Radiography can be

used (Except for GMAW - 5 process) [QW - 452] and QW 304
16. for welder qualification position is important (QW - 461.9)

Qualification Test Position Qualified
1 G (flat) 1G
2 G (Horizontal) 1G, 2 G
3 G (Vertical) 1 G, 3 G
4 G (Overhead) 1 G, 4 G
5 G (Pipe fixed) 1 G, 3 G, 4 G, 5 G
6 G (Pipe at 45) All.
2 G and 5 G All.
17. For pipe positions 5 G and 6 G qualification 4 bend tests are
required and all must pass. (OW-452).
18. If a welder passes. procedure qualification test, be is also

qualified for performance in that position. (OW -301.2)
19. When welder is qualified by radiography for plate test

coupon, at least 6" length shall be examined by radiography
and for pipe, entire weld circumference shall be examined. (OW
- 302.2)
20. Performance qualification of a welder is affected if he does not

weld with a process for 6 months or more. If there is specific
reason to question his ability to make acceptable welds his
qualification for the welding he is doing shall be revoked. (OW-
322)
ASME Sec. V - Non destructive Examinations.
A. General:
1. ASME Sec. V. gives methods and requirements for conducting
NOT. It becomes applicable only if referred by the other
referencing codes.
2.. The user of Sec. V. Code is responsible for following.

a. Getting NOT personnel properly certified.
b. All NOT examinations require written procedures.
c. All NOT equipments shall be as per Sec. V.
d. Equipments shall be calibrated as required by Sec.V.
e. Records retention.
B. RT Examination:
3. For RT Examination, either hole type or wire type 101 shall be
used.
4. A radiograph is considered satisfactory, if it is within the density

limits and has required 101 image. For hole type 2 T hole and
for wire type the designated wire image shall be seen.
5. Density limitation:
2 to 4 for Gamma Rays.

18 to 4 for X rays.
Density variation permitted = +30% to - 15%
6. Selection of 101 is based on weld thickness plus the weld

reinforcement. Thickness of backing strip is excluded.
7. 101 is normally placed on Source side unless inaccessibility
prevents it. They 101 may be placed on Film side and a Lead
letter F shall be put adjacent to it.
8. Hole 101 may be placed on or near the weld. Wire IQI is placed
on the weld with wires perpendicular to the weld axis.
9. Double wall double image technique is suitable for pipes up to

3.5" 00.
10. Back scatter shall be avoided. If light image of Lead Letter - B .

is seen on dark background then the backscatter is excessive
and radiograph shall be rejected.
C. PT Examination.
11. For conducting PT on certain materials, the contaminants shall

be controlled as follows.
a. For Nickel and its alloy Sulpher content not to exceed
1 % of residue.
b. For Austenitic S.S. Duplex S.S. and Titanium content of
chlorine plus Florien shall not exceed 1 % of residue.
12. Two type of penetrates (visible and Fluorescent) can be used.

For excess penetrate removal 3 methods are used for visible
and fluorescent.
Water washable
Post Emulsifying.
Solvent Removable.
This results in total 6 techniques.
13. PT is normally conducted between temperatures 50 to 125 F

(10 to 52 C). For below or above this range special penitents
shall be used and the dwell time should be worked at using
quenched Aluminum blocks.
14. After applying the developer, interpretation shall be done within

10 to 60 minutes.
15. Intermixing of penetrate material from different families (Le .

. visible & fluorescent) or penetrate materials from different
manufacturers are not permitted.
D. MT Examination:
16. The Magnetic Particle Examination can be performed on
Ferromagnetic materials for finding surface and near surface
defects.
Drug or wet Iron powder and visible, or fluorescent powder is
used.
17. Prod Technique used Direct current. The distance between

prods shall be 3 inches to 8 inches. This is suitable for finding
surface and near surface defects.
18. Yoke technique is suitable for surface defects only and can use
A.C., D.C. or permanent magnet.
19. Ammeter on instrument shall be. calibrated annually by

comparing 3 current readings with a standard Ammeter, and
permitted tolerance is + 10% of full scale.
20. For yoke, the electromagnetic yokes shall be calibrated

annually by checking lifting power.
A.C. yoke shall lift 10 pounds (4.5 kg.)
D.C. yoke shall lift 40 pounds (18 kg.)
21. Lifting power of permanent magnet yoke shall be checked daily

prior to use by lifting 40 pounds (18 kg) weight.
22. Examination is performed in two perpendicular directions.
E. UT Examination:
23. Pulse - Echo contact method is used for finding thickness and
laminations.
24 In Direct contact (single element) method is not suitable for

smaller thickness hence delay line method is used which uses
a delay block to delay the echo.
25. In delay line, end of delay is made to coincide with Zero

thickness on CRT.
26. Dual Search units are also used using two crystals one for
sending pulse and other for receiving echo. On smaller
thickness this method results in vee-error which needs
correction.
27. For thick section measurement use of multiple echo technique

is made. The calibration block chosen is smaller thickness
which will permit standardizing the full-sweep distance to
adequate accuracy on CRT.
28. For measurement at nigh temperatures thickness correction. is

needed. A positive error of 1 % per 1000 F increase in results.
API RP 574 Inspection Practices for Piping System Components
1. The two most common carbon steel piping materials used in the
petrochemical industry are ASTM A53 and A 106.
2. A gate valve consists of a body that contains a gate that interrupts flow.
The gate valve is normally used in fully open or fully closed position.
3. Full ported gate valves shall be used on the pipelines which are to be
pigged.
4. A globe valve, which is commonly used to regulate fluid flow, consists of a

valve body that contains a circular disc that moves parallel to the disc axis
and contacts the seat.
5. A plug valve consists of a tapered or cylindrical plug fitted snugly into a

correspondingly shaped seat in the valve body. It is a quarter turn valve
which opens or closes by quarter turn of the spindle.
6. A diaphragm valve is a valve that contains a diaphragm made of a flexible

material that functions as both a closure and a seal. These valves are
used for low temperature corrosive service.
7. A butterfly valve consists of a disc mounted on a stem in the flow path of

process fluid.
8. A check valve is used to automatically prevent back flow. The most

common types of check valves are swing, lift-piston, ball, and spring-
loaded wafer check valves.
9. The primary purpose of inspection is to perform activities using
appropriate techniques to identify active deterioration mechanisms and to
specify repair, replacement, or future inspections for affected piping.
10. Proper Inspection leads to safety, continuity and reliability of the plant.
11. The major advantages of utilizing digital UT thickness instruments are

portability and low cost, but it is dependent on the operator's skill
12. Radiography has advantage of permanent record in the forrn of film. It can
be employed to check the thickness while insulation is intact.
13. Hotspots shall be inspected for oxidation loss and reduction of thickness.
Possibility of creep damage can be present if temperature during the
exposure was more than 800 deg. F.
14. Hammer Testing is used to locate thin spots by striking the hammer and
listening for the ringing sound by an experienced person.
15. Hammer testing shall not be performed on cast iron pipes, glass lined
pipes and stress relieved pipes. Hammer used shall be 1 lb. brass
hammer.
16. Retirement thickness is given by Barlow formula ( t=PD/2SE ). Thickness

should be adequate for structural rigidity. If inadequate the thickness
should be increased suitably.
17. Valves have complex shapes and also subject to closing stresses. These
stresses are difficult to calculate. Therefore, the thickness of valves and
flanged fittings is substantially greater than that of a simple cylinder.
18. Minimum valve wall thickness is 1.5 times (1.35 times for Class 4500) the
thickness of a simple cylinder designed for a stress of 7000 psi for valve
Classes 150-2500.
19. The formula for calculating the retirement thickness of pipe can be
adapted for valves and flanged fittings by using the factor of 1.5 and the
allowable stress for the material specified in ASME 831.3.
20. Standard mill under-tolerance on the pipes is 12.5% of nominal thickness.

API RP 571 - Damage Mechanisms
1. Brittle fracture is sudden fracture under stress due to loss of

ductility at low temperature, cracks are typically, sharp straight,
non-branchi ng.
2. Some reduction in possibility of brittle fracture may be achieved

by performing PWHT.
3. Fatigue is typically caused due to surface notch and cyclic

stresses. If cyclic stress are due to mechanical reasons
(rotating shaft, rapid change of pressure) it is Mechanical
Fatigue. If cyclic stresses are due to changes of temperature, it
is thermal fatigue. If surface notch is due to corrosion and cyclic
stresses are present it is corrosion Fatigue.
4. Thermal Fatigue cracks are dagger shaped and oxide filled.
5. Thermal fatigue is prevented by preventing stress concentration

and controlling thermal cycling.
6. Mechanical fatigue failure typically shows "Beach-mark" or

"clam shell" type concentric rings. Mechanical fatigue can be
prevented by avoiding stress concentration at surface.
7. Corrosion Fatigue can be prevented by using coatings or

inhibitors or by using more corrosion resistant materials.
8. Erosion-corrosion is damage that occurs when corrosion

contributes to erosion by removing protective scale due to the
combined action.
9. Erosion Corrosion increases with velocity, turbulence,
concentration of impacting medium size and hardness of
impacting particles.
10. Some methods to reduce Erosion-corrosion are

increasing pipe diameter to reduce velocity, using large radius
bends, increasing surface hardness, using corrosion-resistant
materials.
11. Atmospheric corrosion increases with high humidity

(marine environment) and atmospheric pollution (industrial
environment) and is best prevented by providing coating /
painting.
12. CUI is caused due to water trapped under insulation, for

carbon steel it may show scale formation and for S.S. it may
show pitting and cracking due to chloride stress corrosion
cracking.
13. CUI may be prevented by providing protective painting

and maintaining insulation is good condition to prevent the
moisture entry.
14. Boiler water corrosion is result of dissolved gases namely

oxygen and carbon di oxide.
15. Best method to reduce Boiler water corrosion is to use

de-aerator for Boiler feed water, monitoring presence of oxygen
and using oxygen scavangers like Hydrazine.
16. Chloride stress cracking corrosion is typically takes place

on Austenitic Stainless steel between 1500 to 400 0 F in chloride
environment.
17. Austenitic S.S. (300 Series) are most suceptible duplex
stainless steels are somewhat resistant and Nickel Alloys (more
than 40% Nickel) and almost immune.
18. For Hydro-testing of Austenitic S.S. Vessels and pipes

use water with low or free of chlorides (typically less than 50
ppm,)
19. Caustic Stress corrosion cracking typically takes place on

carbon steel adjacent to welds which are not stress relieved.
20. Higher temperature and higher caustic concentration

increases suceptibility.
21. Best method to prevent caustic stress corrosion cracking

is conducting PWHT of completed weld or use of Nickel alloys
should be considered.
22. Sulphidation of carbon and alloy steels typically takes

place above 500 0 F and increases with and sulpher
concentration increasing temperature.
23. Best method to prevent sulphidation is upgrading to

higher chromium alloys ..
24. High temperature Hydrogen attack (HTHA) takes place at

temperature above 400 0 F due to migration of atomic Hydrogen
which combines with carbide in carbon steels forming methane
gas, which can not diffuse out, collects at grain boundaries and
causes cracking.
25. Best method to avoid use of HTMA is select materials

using API RP 941 curves (Nelson curves). HTHA can be
detected by metallography.
26. Wet H 2S exposure causes 4 types of damages namely
Hydrogen blistering, Hydrogen induced cracking (HI C), Stress
Oriented Hydrogen induced cracking (SOHIC) and sulphide
stress corrosion cracking (SSC).
27. Hydrogen blistering takes place due to migration of

atomic hydrogen in steel and combining to term hydrogen
molecules which typically collect at voids, slags, porosity
causing Hydrogen pressure to build up and producing
Hydrogen Blister.
28. The Hydrogen blisters formed within steel at different

levels will grow and combine to form Hydrogen induced
cracking which typically has stepwise appearance.
29. The HIC cracks formed within HAZ will propagate rapidly
in perpendicular to surface due to loss of ductility to HAZ and
due to stress this is called SOHIC.
30. The Sulphide formed during the wet H2S exposure (Fe+
H 2S - FeS -+2H) causes cracking under combined action of
Sulphide and stress (which is caused due to internal pressure
in vessel) leading to SSC.
31. Best method to prevent wet H 2S damage is use of

controlled Hardness Steel (typically less than 22 HRC) and
steel with low percentage of Sulpher and Phosphorous
impurities (which reduces voids and porosity in steel).
32. SOHIC and SSC can also be reduced by performing

stress relieving of welds.
API RP 577 - Welding Inspection and Metallurgy.
1. Recordable indications means the indications recorded on data

sheet which need not exceed the rejection criteria.
2. Reportable indications means the indications which exceed the

rejection criteria. They should be recorded on data sheet and
also reported to appropriate authorities to get them rectified.
3. Any electrodes or fluxes that have become wet should be

discarded.
4. For visual examination the personnel are required to

demonstrate jagger J-1 eye test annually.
5. Direct Visual examination requires access to bring the eye

within 6" to 24" from the surface at an angle not less than 30.
6- Radiographic Film density is quantitative measure of film

blackening. Clear film has zero density. Exposed film that
allows 100/0 of light to pass has density =1. A
film density of 2, 3, 4 allows 1 %, 0.1 % and 0.01 % of light to

pars through the film respectively.
7. Straight beam techniques are used for thickness evaluation or

to check laminations. Shear wave (Angle beam) techniques are
employed for finding discontinuities in welds.
8. In UT, A-scan typically given pulse-echo display. B-scan shows
a cross-sectional view of the object and C-scan shows plan
view of object.
9. The HAZ is that portion of the base metal (adjacent to the weld)
that has not been melted but whose mechanical properties or
microstructure is altered due to heat of welding. For carbon
steels HAZ includes the regions heated to greater than 1350 F
(700 C).
10. The hardness values in HAZ for steels in Refinery service is

given in Table 11 (For Carbon steels it is 200 BHN) Hardness
in
11. "Weldability" is defined as capacity of the metal to be welded

under under the fabrication conditions imposed.
12. Weldability is measured by Carbon Equivalent (CE) formula.

CE= C + Mn + Cr + Mo + V + Si + Ni + Cu
6 5 15
13. Typically steels with CE less than 0.35% requires no preheating.

CE will CE of 0.35% to 0.55% requires preheating and CE
greater than 0.550/0 require both pre-heating and PWHT.
14. Simplest wel~bility tests are the strength and ductility test of
weld.
15. For qualifying welder on "GMAW - S" process bend tests shall
be used instead of Radiography.
API RP 578 Material Verification Program
1. The purpose of this recommended practice is to provide the guidelines for

a material and quality assurance system to verify that the nominal
composition of alloy components within the pressure envelope of a piping
system.
2. Carbon steel components specified in new or existing piping systems are

not specifically covered under the scope of this document.
3. A warehousing supplier is one who stocks and supplies materials from

one or more manufacturers or suppliers of alloy materials or components.
4. Inspection lot means materials of the same type from a common source
from which a sample is to be drawn for examination. An inspection lot
does not include items from more than one heat.
5. When welding is conducted, one electrode or wire sample from each lot or
package of alloy weldrod,s.hould be positively identified.
6. Longitudinally welded alloy pipe and fittings should receive random PMI
testing verification of the base metal and weld metal.
7. The primary methods include portable X-ray fluorescence, portable optical

emission spectroscopy, and laboratory chemical analysis.
a. Materials can be confirmed to contain the' nominal amounts of

alloying elements specified in the relevant materials specification.
b. Materials can be classified through a qualitative sorting technique
to establish the conformance with the intended material.
c. PMI testing is for deciding the ranges of alloying elements
d. If compositions are outside the ranges indicated in the material
specification, the owner/user shall decide suitability of the material
for intended use.
8. If anyone of a representative sample is rejected, all items of that

inspection lot should be considered suspect. A more extensive inspection
of the remaining lot should be considered.
9. Chemical laboratory testing usually gives more accurate results than

portable X-ray fluorescence, portable optical emission spectroscopy.
10. When PMI testing is conducted on new or existing piping systems, records
of the results should be kept as long as the piping system exists in its
original location.
(VOLUME-I)
Part-9
Additional Information
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CHARTS AND TABLES
C-l. Properties and Weights of Pipe -- Continued
Bend I
Nominal
Size
Weight
Designation
Aver- Mini-
age mum Inside
I
Cross-
Sectional :\lomcnt
1
Sec-
tioll
II Ch~r,,:('- Radiu
j of'
o
Weight of
Outside and/or Wall Wall Diam- 1\1 eta,1

j
of 1\10 d - I terlstlc
..' G Yra-
Pipe \Yater
Diam- Schedule Thick- Thick- eter Inertia Iper (Hilt :
eter Kumber ness ness Area ulus Bcnd hon
c= %t) I Radiu. "
inches
D
inr.he.,
t
I
inches
im
inches
d
square inches
A
inches'
1
Ibperft lbperft
illches 3
Z
11ft
h>R!
inches
r.
"'p U' U '
- - - 1 - - - 1 - - - - - - - - - - ..---+1---1---1. - - - 1- - - - -
I
Std. 40
5S' 0.065
lOS 0.109
40S 0.140
0.057
0.095
0.123
1.530
1.442
1.380
0.33
0.53
0.67
0.104
0.161
0.195
0.125
0.193
0.235
1.23
2.17
2.91
II 0.56
0.55
0.54
1.11
1.81
2.27
0.80
0.71
0.65
1;"'("
1.660 XS 80 80S 0.191 0.167 1.278 0.88 0.242 0.291 4.25 0.52 3.00 0.56
160 0.250 0.219 1.160 1.11 0.284 0.342 6.04 0.51 3.76 0.46
XXS 0.382 0.334 0.896 1.53 0.341 0.411 11.2 0.47 5.22 0.27
5f: 0.065 0.057 1.770 0.38 0.158 0.16t) 0.927 0.f5 1.27 1.07
IDS 0.109 0.095 1.682 0.61 0.24.7 0.2GO 1.63 0.63 2.0'! 0.96
:::~
Std. 40 401.' 0.145 0.127 1.610 O.SO 0.310 0.326 0.t)2 2.72 0.88
1%"
1.900 XS 80 80:::., 0.200 0.175 1.500 1.07 0.3\11 0.412 0.61 3.63 0.77
I
II
160 0.281 0.246 1.338 1,43 0.183 0.508 5.15 0.58 4.87 0.t)1
I":XS 0.400 0.350 LIDO 1.8[1 O.MS 0.5')8 8.53 0.41
I
0.55 0.41
-'-1, 5~ 00t)5 2.245 0.47 0.31D 0.205 0.5S5 082 I UiQ 1.72
10SI O.lO' 2.157 n.7S 0.499 0.420 1.02 0.80 2.61 L5S
2"
2.375
IStd. 4.0 408, 0.154
I
2.037 1.07 O.(itlG o "j>:a 1.50 I 0.79 3.65 1.45
I
I X'" SO SOS! 0.218 1.939 1.18 0.868 0.731 225 0.77 5.02
'X~:
1.28
160 I O.3~3 1.68'1 2.1P l.ll) 0.97\) 8.\1\' f 0.73 7A5 0.97
- - - - Ii
I 0.4:3Ii 1..503 2.Gii 1.31 1.10 5.57 I 0.70 n.03 0.77
IISt.(1. 40
.jS, 0083
10:3' 0.120
40::;1 0.203
2.70~
2.n:35 ,
2.4G!1
0.73
1.01
1.70
0.710
0.\188
1.53
0.494
0.1587
1.0:)
~:;~~,
1.37
II
0.(11)
0.\18
O.n,]
2.413
....D .]","'".:)
5.7\1
2 ..50
2.36
2.0S
'J~r
2.1.,~" .
2 ._{O i x S SO 80;;;1 0
'I 0:3;~
g-- I ., 2.323 1.93 1.34 0.02 7.t1G 1.84
1. ...'0 ,I
1
160 2.125 2.95 2.35 1,(H 2.SS 0.89 10.0 1.54
Ixxs 0.552 1.771 i 4.03 2.87 2.00 j 0.84 13.7 1.07
;~;
'''1
----I
1
5S1 0.083 3.334 0.89 1.30 0.741 1.21 3.7S
Std. 4.0
lOS' 0.120
40s1 0.215
.3.260
3.0c18
1.27
2.23
1.82
3.02
1.04
L72 0.%1
['
1.20
l.lLi 7.58
I 3.61
3.20
3"
3.500 XS so
160
80S 0.300
0.438
2.900
2.024
3.02
4.21
3.flO
5.04
2.2:3
2.88
1A1
2.21 1.14
1.0:1 I
10.;3
IL3
I V~Hi
2.:34
xxs 0.600 2.300 5.47 5.90 3.13 3.42 1.05 18.0 l.80
----
I 580 0.083 0.073 3.834 1.02 Ult) 0.U80 0.2(\0 1.39 3.47 5.00
lOS 0.12v 0.105 a.760 lAo 2.76 1.38 0.3Sa 1.37 4.!l7 4.81
3Y2" Stu. 40 408 0.226 O.lns 3.548 2.68' 4.79 2.39 0.71i2 1.:31 fLU 4.213
4.000 XS 80 808 0.318 0.278 3.364 3.G8 6.28 3.14 1.13 1.31 12 ..5 :3.8.'>
XXS 0.G3G 0.557 2.728 6.72 ti.85 4.(J;i ~.70 1.21 22.n 2.53
5S O.OS3 0.07:1 1.33-4 J.lD 2.81 1.2,:; 0.204 , UO 3.\12 tjAO

Wi'! O.:~()O
St.'.!. 40
O.l:!O
40:-:, 0.:::37
0.105
0.207
4.2130
4Jl21i
1.n5
3.17
a.!lG
7.23
1.7t'
0.21 I (Ui211
l.55
l.!il
:>.1;1
10.S
6.17
5.51
4"
4.500
;,,8 80 80:"1 0.:l37 ().2~1;) 1.41 [J.(\)
11.7
-1.27 O.(':3;~
1.27
J..JS
US
15.0
19.0
I 4.98
4.47
120 O.1=3S .>-t'2i 5.59 5.18
xxs
l()O I 0.;;:31 (I.-llif) :H38 (Uj2 ]:U 5.nO 1.C02 IA2 22 ..'i 4.02
_----.--------_ .._---_. - - - - - - -,- - - " - -

O.ti7J O.D!;O :~.152 8.10 15.3 n.7H 2.21 1.:37 27.;' 3.38
._ ... --- ... -_._.. -'~-'-.--. ---- . . . . ~---- ..--~-- ------ .... -
DESIGN OF PIPING SYSTEMS
C-l. Properties and Weights of Pipe - Continued

------ ---------c-------,---,-------,- - - - - - - ; - - - - - - , - - -
:\ominal \Yeight .-\ \'(~r l\Iilli-
Cross. i:l II Bt'nd Ii Ikdius I _ _ _
"_'e_ig..,..h_t_o_f_ _
Size Designation aj.!:c Inurn Inside Moment el'- Ch.irue- ,-
. Outside and/or \Yall \\" all Diam- Sectional
of
tion I,tPJlstlC
.. OJ
G"
Diam- Scherlul( Thi('k- Thick- eter Mci~tl lncrtia lIlod- ,'per l:nitl }r,l- Pipe Water
et.er Number Il(,"S ness I Area ulu~ D
0('11
d tlOU
inches
Ie = 'J/gt)
iuehe, I inches inches square ineh,,> i iIl('hcs 4 inches IHlidiu~
J ft iuc'hes w" lC u
D
1------1
t 1m d I .\ ' ---- ----
Z } , I? Tq lb per ft
Ib per ft.
____ 1_ _ _ _.1 _ _ __
5E, 0.109 0.095 5.345' 1.87 G.95 2.50 0.176 U)3 6.35 9.73
lOS 0.134 0.117 5.295 2.29 8,43 3.03 0.218 1.(12 7.77 9.53
Std, 40 40S 0.258 0.226 5.047 4.30 15,2 5.45 0.440 1.88 14.6 8.66
5" XS 80 80S 0.375 0.328 4.813 6.11 20.7 7.43 0.66Cl 1.84 20.8 7.88
5,563
120 0.500 0.438 4.563 7.95 25.7 9.25 0.936 1.80 27.0 7.09
160 0.(;25 0.547 4.313 9.70 30.0 10.8 1.23 L76 33.0 6.33
xxs 0.750 0.E55 4.063 11.3 33.6 12.1 1.55 1.72 38.6 5.62
51" 0.109 0.095 6.407 2.23 11.9 3.58 0.123 2.30 5.37 14.0
10:3! 0.134 0.117 6.357 2.73 14.4 4.35 0.153 2.30 9.29 13.7
Std. 40
(ll' I XS SO
40s1 0.280
80s1 0.432
0.245
0.378
6.065
5,761
5.58
8.40
28.1
40.5
8.50
12.2
0.334
0 ..')41
2.25
2.20
19.0
28.6
12.5
11.3
Ii 0.~li2 I 0.402
(td2.=) I
J20 5.501 I 10.7 49.6 15.0 0.735 2.15 36.4 10.3
. Ixxs HiO
i
0.d8
0.86'!
0.628
0.756
5.189 13.3
15.!}
5(1.0
66,3
17.8
20.0
0.~!8S
1.25
2.10
2.06
45.3
53.2
H.16
8.14
-._ .. --I 4. 897 1
5~1 O. J0, fl I 0. 005 1

10::- O.BS 0.130 I
8.407
8.329
2.\12
3.\14
2ti.5
35,4
13.13
8.21
0.072
O.o\!(1
3.01
3.00
9.91
1:3.-1
24.1
23,fj
1
20 i 0.250 1 0.219 i 8.125 6 ..')8 .57.7 13.'1 0.171 2.(16 22.4 22.5
;';'", 1
30 ! 0.277 0.242 I I 8.071 7.20 63.4 14.7 (Ll nl 2.% 24.7 22,2
,:3t(~.~ 40 .10.,,1 0.322 I 0.2821 7.\l81 8AO 72.5 16.8 0.224 2.\11 28.G 21.7
I .\:-'
,"0
<'n
Ov I.)
I 0.400
"0)1 r'.1.0-00.
0 ..
! 0.355
0 4~S I
."
7.813
7.(i25 1
10.5
12.S
88.8
lOG
20.G
24.5
O.2S!-I
0.3(i4
2.n
2.8S
35.6
43.4
20.S
HJ.8
I 100 I 0.5:13 0.519 I 7.439 15.0
I 121 28.1 O.H1 2.55 50.U 18.8
120 , 0.71S I 0.G28 I 17.8 141 32.0 O..lSI 2.S1 17.6

Ixxs lJO I 0.8~: I 0.7l~ !.
7. 189 1
7.001
0.7fitl I [i.Si5 1
10.9 154 35.G 0.I.i:39 2.7S
130.6
67.8 16.7
,n.Si:' 21.3 162 37.G O.l)!i9 2.70 72.4 16.1
HiO I (HOE; 0.7\13 I!
(\.SI3 1 22.0 IGG 38.5 0.730 2."j 74.7 15.8
II, I
fiS! 0.134 I 0.117 I 10A82 II 4.52 G3.7 lUi 0.0.:;7 3.75 15.2 37.4
1Of'! O.Hi5 , 0.1-14 I 10.420 5.4U 7(5.9 U.S 0071 3.74 18.7 36.9
20
30
I
().Z50
,,[ (j.30~
0.21 fl
0.2()~\
I 10.250
I 10.136
8.26
10.1
114
l:3S
21.2
25.6
0.10!l
0.135
3.71
3.W
28.0
34.2
35.7
34.9
Std. 40 40;::1 0,36;) 0.31.1 I 10.020 11,9 IG1 20.\! 0.103 3.G7 40.5 34.1
xs 60 80:01 0.500 0.438 I 9.750 1(",,] 212 39.1 0.228 3.fi3 54.7 32.3
10" so 0.593 0.519 ~1.5G4 18.0 245 '15.5 0.27G 3.fjO 64.3 31.1
lO.7S0 0.625 I 0.547 9.500 10.9 256 47.6 0.2\13 3 ..Sf! 67.5 30.7
100 0.718 0.628 9.314 22.li 286 53.2 0.342 3.56 76.9 2\).5
0.750 0.655 9.250 23.6 296 55.1 0.360 3.55 80.1 2\).1
120 0.8:~ I 0.~~8 9.0(\4 I 2\. 2 324 (;0.3 OA12 3 ..52 SQ.2 27.\1
0.8i0 O.,{.G !l.OOO I 27.1 33:3 1;2.0 OA:,1 :~.51 n2.3 27.~
I, 11(1
WO
I0.(\81 8.500
8.750 I
1.000
1.12ii
I n.Ri.,S ::lA7 3tU;
310
3li8
3fJU
(;8,4
74.3
0.505
O.:3S3 3A~1
104
lHi
2G.0
24.0
-_. --_--------__"_----__-_._-------_._P. __._---.. ______ .. __ .. _. _____ _
pg.4
CHARTS AND TABLES
C-l. Properties and Weights of Pipe - Continued
Xominal W~ight A"('r- Mini-

Cross- I Bend -' . Weight of
C""'''_I'"~'''
SC\,-
Size Designation age mum Inside Moment
Sectional tion
Ontside and/or 'Yall Wall Diam- of teristic GO
Metal lIlod-
Diam- Schedule Thirk- Thick- e(er Inertia per C ni t '~'ra- Pipe Water
Area ulnE Bend tlon
eter Number ne::;$ neg..;::
(= Yat)
inche..c;
D
Iinc~les inches inches
t.m d
II square inches
A
inches'
I
inches'
Z
Radius
lift
h/R
inches Wp lL'",
r. lb per ft lb per ft
------ ---
5S 0.165
lOS O.ISO
0.144
0.158
12.420
12.390
I 6.52
7.11
129
141
20.3
22.0
0.050
0.055
4.45 19.6 52.5
4.44 24.2 52.2
20 0.250 0.219 12.250 1 9.82 192 30.0 0.077 4.42 33.4 51.1
30 0.330 0.289 12.090 12.9 249 39.0 0.103 4.39 43.8 49.7
Std. 4013 0.375 0.328 12.000 14.6 279 43.8 0.118 4.38 49.6 49.0
40 0.406 0.355 11.9381 15.7 300 47.1 0.128 4.37 53.5 48.5
12/1 XS 80S 0.500 0,438 11.750 I 19.2 362 56.7 0.160 4.33 65.4 47.0
12.750 60 0.5li2 0,492 11.626 i 21.5 401 62.8 0.182 4.31 73.2 46.0
80
0.025
0.687
0.547
0.601
11.500
11.376
I 23.8
26.0
439
475
68.8 0.204 4.29 80.9 45.0
74.5 0.227 4.27 88.5 44.0
0.750 0.655 11.2.';0 1 2S.3 511 80.2 0.250 4.2.'i 96.2 43.0
100 0.843 I 0.738 11.064 31.5 5G2 88.1 0.28b I 4.22 107 41.6
I
0.875 0.76G ll.ooe ! 32.n 579 ~0.8 0.2)18 I 4.21 III 41.1
I 120 1.000 0.87.5 10.750 ! 3G.9 642 I 101 0.348 4.17 125 39.3
140 I i
J.l25 0.983 10.500 ! 41.1 701 110 00400 4.13 140 37.5
160 11.313 11.14(1 10.126 i ,),7.1 781 123 OASI 4.07 160 34.9
---- !
10 I 0.2.10 I 0.21 ~ 13.500 I 10.S 255 3il.5 0.004 4.S6 36.7 62.0
20 I 0.312 I 0.273 13.:375 I 13.4 315 4.'i.0 0.080 4.8,), 45.7 60.6
Std. 30
40
I 0375
! 0.438
I 0328
0.382
13.2;;0
13. 12.j
I IG.l
IS.7
373
42[1
.53.3
lol,4
0.007
0.114
4.82
4.80
M.6
63.4
59.7
58.6
I1 13.000 I
I
I XS 0.500 0.438 21.2 4S4 !lll.1 0.132 4.78 72.1 57.5
!
60 I 0.5i13 . 0.519 . 12.S14 I 25.0 5H2 80.3 0.158 4.74 84.9 55.9
11'1
1 0.~:5
0.517 12.750 I 2G.3 5S9 SU 0.168 4.73 Sll.3 55.3
14.000 SO 0.150 0.656 12.500 I 31.2 GS7 I \18.2 0.205 4.69 I ]23
106 53.1
1 0.875 O.7Gn 12.250 I 36.1 781
I
112 0.244 1.6.5 51.1
100 I 0.\137 0.820 12.125 I 38.4 825 118 0.264 4.63 131 50.0
120
1
i 1.093
I 0.956 H.3 930 133 151 47.5
11. 814 4.58
1 0. 315 1
140
11.2.'iO l.Ofl4 11.500 I 50.1 1030 147 0.369 4.53 170 45.0
100 1.406 1.230 55.6 1120 100 0..126 4.48 189 42.6
--- 11.1 88 1
10
I 0.312
0.250
0.219 15.500 12.4 384 48.0 0.048 --~
a.DI 42.1 81.7
20 0.273 15.376 15,4 474 59.3 O.OGI .5.55 52.3 80.5
Std. 30 0.375 0.328 15.250 18,4 562 70.3 0.074 5.53 52.6 79.1
XS 40 I 0.500 0.438 15.000 24.4 732 91.5 0.100 5..i8 82.8 76.5
0.625 0.547 14.750 30.2 894 112 0.127 5.44 103 74.1
lu"
GO I 0656
0.750
0.574
I 0.655
14.688
14.500
31.6
35 9
933
1050
117 0.134
0.155
5,43
5.10
108
122
73.4
71.5
!Ii 000 fA) , n 84B 1 0.73S 11314 I 40.1 l](iO 131
Wi 0.1711 ~.37 ]30 G9.7
I I O.Si.; /
I
J
070\i 14 2.;0 I 41l; , 11\;0 14\1 0.18i 5.36 141 on.l
HlO I 1 (nJ 0 (02 13 ~138 I ~S 5 11:r,0 J7l 0.221 5.29 W,) GO.I
I"~"~
.. I
J 10
I, 'W
Il.l(:~
._ (:) '0"
IlLl
1.258
'"1).n[J"'l
- -,
J3 121 II .")U.(l
I';"S
I J[,110
J7CO
] (I;')
220
0.2118
0.325
0.2;)
c
').li
,~
102
221
02.t)
,S~.6
--
11,0 J.Gr.;)
------- ---- - - - - - - - - - - -
1.:3(14 12.814 72.1
I lSr'O I 237 ---- -------.-----------
fl.l2 0.3(18
...
55.!l 215
.Po' J
IMPACT TESTING
pg.6
PIPE REPAIR CLAMPS FOR EMERGENCY REPAIR
pg.7
Studs & nuts / Test ports
in position
End thrust studs
End sealing
mechanism
H75016/2 P
H75016,,2P
pg.8
(VOLUME-I)
Part-10
QUESTION BANK FOR
API 570 PREPARATORY COURSE

Questions from API 570 Piping Inspection Code- 2009 Edition
(THIRD EDITION, NOVEMBER 2009)
Closed Book Questions
QUESTIONS FROM CHAPTER-l
1. API 570 covers inspection, rating, repair, and alteration procedures for which of the
following that have been placed in service
a. Metallic piping systems
b. Fiberglass reinforced plastic (FRP)
c. Associated pressure relieving devices
d. All of above
Ans: d. API 570 Para 1.1.1
2. The extruded, generally homogenous nonmetallics, such as high and low-density

polyethylene are:
a. Excluded from API 570
b. Included in API 570
c. Optional to include in API 570
d. Depends on the owner/user
Ans: a. API 570 Para 1.2
3. The intent of API 570 code is to specify -------------- that is needed to determine the
integrity of piping.
a. The in-service inspection program
b. Condition-monitoringprDgramfor in service piping.
c. Both the inspection and condition-monitoring program for in service piping.
d. The condition-monitoring program for both New and in service piping
Ans: c. API 570 Para 1.1.2
4. Which ofthe following is true?

a. API 570 shall not be used as a substitute for the original construction
requirements
b. It shall not be used in conflict with any prevailing regulatory requirements
c. If the requirements of API 570 code are more stringent than the regulatory
requirements, then the requirements of API 570 code shall govern
d. All of above are true

5. Fluid services that are optional to include in API 570 scope are:
a. Hazardous fluid services below threshold limits, as defined by jurisdictional
regulations;
b. Category D fluid services, as defined in ASME B31.3
c. Both a and b
d. None of a or b
Ans: c. API 570 Para 1.2.2 a
6. According to API 570, the Piping systems that are exempted from the applicable
process piping construction code are ----------- in scope of API 570 code
a. Included
b. Excluded
c. Optional
d. API 570 is silent on this aspect
Ans: c. API 570 Para 1.2.2 b
7. API 570 inspection code recognizes Fitness-For-Service concepts (API 579) for
evaluating in-service damage of:
a. Pressure containing parts as well as non-pressure parts
b. Pressure containing parts
c. Non-pressure parts
d. Use of API 579 is not recognized by API 570
Ans: b. API 570 Para 1.3

QUESTIONS FROM CHAPTER-2
1. Which of the following document is referenced in API 570 for: Material Verification
Program for New and Existing Piping Systems
a. API Recommended Practice 578,

b. API Recommended Practice 580,
c. API Recommended Practice 581,
d. API Publication 2201,
Ans: a. API 570 Para 2
2. Which of the following document is referenced in API 570 for: Fitness-for-service

c. API Publication 2201
d. API Standard 579-1/ASME FFS-1
Ans: d. API 570 Para 2
3. Which of the following document is referenced in API 570 for: Risk-based Inspection

c. API Publication 2201
d. API Recommended Practice 574,
Ans:b. API 570 Para 2
4. Which of the following document is referenced in API 570 for: Safe Hot Tapping
Practices in the Petroleum and Petrochemical Industries

b. API Publication 2201,
c. API Recommended Practice 571,
d. API Recommended Practice 580,
Ans: b. API 570 Para 2

1. For purposes of API 570 code,
a. Carbon steels are not considered as alloys,

b. Carbon steels are considered as alloy of Iron and carbon,
c. Depends on opinion of owner/user,
d. Depends on opinion of Authorized inspector
Ans: a. API 570 Para 3.1.1
2. Designated areas on piping systems where periodic examinations are conducted are
called.
a. Corrosion measuring locations

b. Corrosion monitoring locations
c. Condition monitoring locations
d. Examination locations
3. Which ofthe inspection agencies listed below is not an Authorised Inspection

Agency as defined in API 570.
a. Jurisdictional inspection organisation

b. Owner-user inspection organisation
c. ASTM inspection organisation
d. Independent inspection organisation
4. A person acceptable to the owner/user who is knowledgeable and experienced in the

specific process chemistries, corrosion degradation mechanisms, materials selection,
corrosion mitigation methods, corrosion monitoring techniques, and their impact on
piping systems is referred in API 570 as:
a. Corrosion specialist
b. Corrosion Expert
c. Corrosion Engineer
d. Piping Engineer

5. A defect is an imperfection of a type or magnitude exceeding the _ _ _- - criteria.
a. Non-specific
b. Imprecise
c. General
d. Acceptable
6. Which of the following piping can be called as "in service Piping systems".
a. Piping systems that are still under construction .

b. Piping systems that are in transport to the site prior to being placed in service
c. Piping systems that have been retired
d. Piping systems that are not currently in operation due to turnaround, or other
maintenance activity
7. Corrosion barrier is The corrosion allowance in -----------typically composed of an

inner surface and an interior layer which is specified as necessary to provide the best
overall resistance to chemical attack
a. Metallic equipment
b. FRP equipment
c. Any non-metallic equipment
d: None of these
Ans: b. API 570 Para 3.1.11
8. An examiner is a person who _____ the inspector
a. Supplants
b. Assists
c. Supervises
d. Directs
Ans. b. API 570 Para 3.1.22

9. Welding repairs that involve removal and replacement of large sections of piping
systems are called :
a. Major alteration
b. Major repairs
c. Routine repairs
d. Routine alterations
10. What is an imperfection?
a. It is a flaw or discontinuity noted during inspection that may be subject to

acceptance.
b. It is a defect noted during inspection that is unacceptable.
c. It is a weld flaw noted during an inspection that may be subject to repair
d. It is a blemish that is only cosmetic and acceptable under all conditions.
11. Which of the following is "off-site piping"
a. Piping systems associated with a hydro cracker,

b. Piping systems associated with an ethylene cracker
c. Both a and b .
d. Tank farm piping
12. Small-bore piping means
a. Piping that is less than NPS 2.

b. Piping that is less than or equal to NPS 2.
c. Piping that is less than or equal to NPS 3.
d. Piping that is less than NPS 3.

13. Hold point is a point in the repair or alteration process beyond which work may not
proceed until the has been performed and documented
a. PWHT required
b. Required inspection
c. RT required
d. Ultrasonic testing
14. Which of the following is NOT process piping

a. Piping located on pipe rack,
b. Piping located in tank farm,
c. Utility piping.
d. Tank farm piping and utility piping.
15. Calculations to establish pressures and temperatures appropriate for a piping system,
including design pressure/temperature, MAWP, structural minimums, required
thicknesses, etc. are called
a. Re-rating
b. Derating
c. Rating
d. Changed rating
Ans: c. API 570 Para3.1.80
16. is a response or evidence resulting from the application of a non-

destructive evaluation technique
a. Indication
b. Imperfection
c. Breach
d. Division

17. In API 570 code the Acronym PMI means
a. Primary material inspection

b. positive material identification
c. preliminary material identification
d. positive material inspection
Ans: b. API 570 Para 3.2
18. In API 570 code the Acronym CUI stands for:
a. Control unit inspector

b. Corrosion under insulation
c. Corrected unobtrusive inserts
d. Corroded underground installation
19. In API 570 code the Acronym MOC means
a. management of corrosion
b. measurement of corrosion
c. management of change
d. measurement of condition
Ans: c. API 570 Para 3.2
20. In API 570 code the Acronym SMYS means
a. Specified maximum yield strength

b. Specified measured yield strength
c. Sample monitored yield strength
d. Specified minimum yield strength
Ans: d. API 570 Para 3.2
21. In API 570 code the Acronym MDR means
a. Management data reports

b. Materials data reports
c. Material damage reports
d. Manufacturer's data reports

22. In API 570 code the Acronym MTR means
a. Material test report

b. Manufacturer's Test reports
c. Measurement thickness reports
d. Manufacturer's test record
Ans: a. API 570 Para 3.2

1. Who shall be responsible to the owner-user for determining that the requirements of
API 570 for inspection, examination, and testing are met.
a. Inspector
b. Repair Organisation
c. Operating Personnel
d. Piping Engineer
2. Who is responsible for implementing an effective MOC process that will review and
control changes to the process and to the hardware.
a. Authorized Piping Inspector

b. The owner/user
c. Piping Engineer
d. Repair Organization.
Ans: b. API 570 Para 4.3.1.2
3. Who bears overall responsibility for the control of piping system inspection programs,
inspection frequencies and maintenance of piping?
a. Authorised Piping Inspector

b. Jurisdiction
c. Contractor
d. Owner-user
Ans: d. API 570 Para 4.3.1.2
4. As per API 570, an authorized piping inspector shall have certain qualifications.
Which ofthe following is not acceptable qualification to become API 570 inspector.
a. High school education plus 3 years of experience in the design, construction,

repair, operation, or inspection of piping systems
b. Two year certificate in engineering or technology plus 2 years of experience in
the design, construction, repair, operation, or inspection of piping systems.
c. Four years of experience inspecting in-service piping systems
d. Degree in engineering plus one year experience in the design, construction, repair,
operation, or inspection of piping systems.
11
Ans: c. API 570 Annex A
. 5. "Actively engaged as an authorized piping inspector" shall be defined as

a minimum of -------------spent performing inspection activities or
supervision of inspection activities, or engineering support of inspection
activities, as described in the API 570, over the most recent three year
certification period.
a. 10 % of time
b, 20 % of time
c. 25 % of time
d. 50 % of time
Ans: b. API 570 Annex A
6. Once every other recertification period, inspectors actively engaged as an authorized

piping inspector shall demonstrate knowledge of revisions to API 570 that were instituted
during the previous----------.
a. Six years
b. Three years
c. Five years
d. Ten years
Ans: a. API 570 Annex A
12
1. The inspection plan shall be developed by:
a. The inspector
b. The inspector and/or engineer
c. The engineer
d. None of above
Ans: b API 570 Para 5.1.1.1
2. A corrosion specialist should be consulted when developing the inspection plan for
piping systems:
a. That operate at elevated temperatures[above 750 OF (400C)]

b. That operate below the ductile-to-brittle transition temperature
c. Both a and b
d. For each and every piping system
Ans: c API 570 Para 5.1.1.1
3. As per API 570, RBI can be used to determine
a. Inspection intervals
b. The type and extent of future inspection/examinations.
c. Both a and b
d. None of above
Ans: c. API 570 Para 5.2
4. In RBI assessment includes systematic evaluation of probability of piping failure and

the associated consequence of failure. In assessing the probability of piping failure
includes ientifying and evaluating:
a. Potential damage mechanisms,

b. Current equipment condition
c. The effectiveness of the past inspections
d. All of above
Ans: d API 570 Para 5.2
13
5. In RBI assessment includes systematic evaluation of probability of piping failure and
the associated consequence of failure. Consequence assessment shall consider In
assessing
a. The potential incidents that may occur as a result of fluid release,

b. The size of a potential release,
c. The type of a potential release (explosion, fire, or toxic exposure)
d. All of above
Ans: d API 570 Para 5.2.2
6. When RBI assessments are used to set equipment inspection intervals, the assessment
shall be updated after
a. Each time process or hardware changes are made

b. Each time the Inspection person is changed
c. Both a and b
d. Each time any RBI team member is changed
Ans: a API 570 Para 5.2.4
7. Safety precautions shall be included when preparing piping systems for inspection and
maintenance activities. One such organization issuing safety Regulations is "OSHA",
which means
a. Operational Safety and Health Administration (OSHA)

b. Occupational Safety and Health Administration (OSHA)
c. Operational Safety and Health Agency (OSHA)
d. Occupational Safety and Hazard Agency (OSHA)
Ans: b API 570 Para 5.3.1
8. Prior to entering large piping, the piping system shall be isolated from all sources of
liquids, gases, vapors. The piping system should be-------------- (Choose correct
Sequence from following)
a. Drained, gas tested, cleaned, purged, ventilated before it is entered

b. Drained, gas tested, purged, cleaned, ventilated before it is entered
c. Ventilated, gas tested purged, drained, cleaned before it is entered
14
d. Drained, purged, cleaned, ventilated, gas tested before it is entered.
9. Before performing any of the required inspections on piping system, inspectors should
reVIew:
a. The piping system's prior inspection results, prior repairs, current inspection plan
b. The piping system's Design calculations and drawings
c. The piping system's drawings and current inspection plan
d. The piping system's Stress analysis, flexibility calculations and inspection plan
10. Example of Subsurface cracking is:
a. Fatigue cracking
b. Caustic stress corrosion cracking
c. Hydrogen induced cracking
d. Chloride stress corrosion cracking
Ans: c API 570 Para 5.4.1.1 Table 1
11. Which of the following can result in General and local metal loss
a. Graphitization
b. Temper embrittlement
c. Sulfidation
d. a and b
Ans: c API 570 Para 5.4.1.1 Table 1
12. As per API 570, When possible and practical, internal visual inspections may be
scheduled for systems such as large-diameter piping systems. Such inspections should
be conducted with-----------
a. Methods and procedures similar to those outlined in API 510

b. Methods and procedures similar to those outlined in API 5 74
c. Methods and procedures similar to those outlined in API 510 and 574
d. Methods and procedures similar to those outlined in API 579
Ans: c API 570 Para 5.5.1
15
13. According to API 570, all on-stream inspections should be conducted by
a. Either an inspector or examiner.

b. Both inspector and examiner
c. Inspector
d. Examiner
14. All on-stream inspection work performed by an examiner shall be:
a. Approved by the inspector

b. Need not be approved by the inspector
c. Authorized and approved by the inspector
d. Depends on the opinion of i?spector
14. According to API 570, thickness measurements on piping systems are normally taken
while the piping is:
a. On-stream
b. Not in operation
c. Under maintenance
d. Empty and cleaned
15. What inspector should do when the short-term corrosion rate changes significantly
from the previous identified rate to determine the cause
a. Consult with a corrosion specialist

b. Consult with Piping Engineer
c. Consult with Design Engineer
d. Ignore the short-term corrosion rate and use long term corrosion rate
16
16. An inspection performed to determine the condition of the piping insulation system,
painting, and coating systems, and associated hardware; and to check for signs of
misaligmnent, vibration, and leakage is called-------------
a. Vibrating piping inspection

b. External Visual Inspection
c. Supplemental inspection
d. CUI Inspection
17. According to API 570, some welds in a piping system that has been subjected to
radiography according to ASME B31.3:
a. Will meet random radiograph requirements and will perform satisfactorily in-
service without a hydrotest
b. Will not meet random radiograph requirements, and will not perform
satisfactorily in-service even though hydrotested.
c. Will meet random radiograph requirements, and will not perform satisfactorily in-
service after a hydrotest
d. Will not meet random radiograph requirements, but will still perform
satisfactorily in-service after being hydro tested.
18. The periodic external inspection should normally be conducted by the inspector, but
may be conducted by----------------when acceptable to the inspector
a. Qualified maintenance personnel

b. Qualified operating personnel
c. Qualified operating or maintenance personnel
d. Inspector himself must conduct this inspection
19. For Carbon Steel piping Inspection for CUI shall be considered for externally-
insulated piping with possibility of moisture ingress and susceptible temperature
range, which is-------------
a. Between 10 OF (-12C) and 350 OF (175 C).
b. Between 25 OF (-4 C) and 250 OF (120 C).
c. Between 32 OF (0 C) and 212 OF (100C).
d. Between 10 OF (-12C) and 250 OF (120 C).
17
20. The recommended upstream limit of the injection point circuit

IS ....................
a. Up to length of three pipe diameters upstream

b. 12 in. (300 mm) upstream
c. 12 in. (300 mm) or three pipe diameters whichever is smaller
d. 12 in. (300 mm) or three pipe diameters whichever is greater
21. The recommended downstream limit ofthe injection point circuit is .................. .
a. Second change in flow direction, or 25 ft beyond the first change whichever is

more.
b. Second change in flow direction, or 25 ft beyond the first change whichever is
less
c. Second change in flow direction, or ten pipe diameters whichever is greater
d. Second change in flow direction, or ten pipe diameters whichever is less
22. During periodic scheduled inspections; more extensive inspection should be applied
to an area beginning ---------------------- upstream and continuing for at least --------
-----downstream of the injection point.
a. 12 in.(300 mm) upstream and at least ten pipe diameters downstream

b. Three pipe diameters upstream and at least ten pipe diameters downstream
c. 12 in.(300 mm) upstream and at least 25 ft downstream
d. 12 in.(300 mm) upstream and at least ten pipe diameters downstream
23. The preferred methods of inspecting injection points to establish the minimum
thickness at each TML are--------------
a. Radiography and Magnetic particle testing

b. PT orMT
18
c. Eddy current and UT
d. Radiography and/or UT
24. For thickness measurements on pipe diameters ofNPS 1 and smaller, preferred
technique is:.
a. Radiographic profile techniques

b. Magnrtic particle -Fluorescent particles
c. Fluorescent Liquid penetrant
d. Ultrasonic thickness measurements
25. Pressure tests are ------------ conducted as part of a routine inspection
a. Always
b. Not normally
c. Never
d. Usually
Ans: b API 570 Para 5.8
26. When a pressure test is required on in-service piping it -------------any heat treatment.
a. Shall be conducted after

b. Shall be conducted prior to
c. May be conducted after or before
. d. Depends on opinion of inspector
Ans: a API 570 Para 5.8
27. When a pressure test is required on in-service piping, API 570 has cautioned
the owner/user is to avoid --------------for the material at test temperature
a. Exceeding the SMYS

b. Exceeding 90 % ofthe SMYS
c. Exceeding the SMTS
d. Exceeding 90 % of the SMTS
19
28. To minimize the risk ofbritile fracture during a pressure test, the metal temperature
should be maintained at least --------- above the MDMT for piping that is more than
2 in. (5 cm) thick, and ------- above the MDMT for piping that have a thickness of2
in. (5 cm) or less.
a. 30 of and 10F respectively

b. 10F and 30 OF respectively
c. 17 of and 6 of respectively
d. 6 of and 17 of respectively
29. According to API 570, when a pressure test is not performed after a major repair or
alteration acceptable alternative is:.
a. Carry out Appropriate PWHT

b. Carry out Appropriate RBI studies
c. Carry out Appropriate Fitness for service assessments
d. Carry out AppropriateNDE
30. Substituting NDE procedures for a pressure test after an alteration is allowed only
after --------------- the substitution.
a. The engineer has approved

b. The inspector has approved
c. The engineer and inspector have approved
d. The engineer or inspector has approved
31. PMI testing can be accomplished by the ---------------with the use of suitable
methods as described in API 578.
a. Inspector
b. Examiner
c. Inspector and the examiner
d. Inspector or the examiner
20
32. Nonnally, thickness measurements -------------- on valves during scheduled
inspections.
a. Are routinely taken

b. Are not routinely taken
c .. Are usually taken
d. Are never taken
33. Fasteners should be fully engaged. Any fastener failing to do so is considered

acceptably engaged if--------------.
a. The lack of complete engagement is not more than two thread

b. The lack of complete engagement is not more than three thread
c. The lack of complete engagement is not more than half thread
d. The lack of complete engagement is not more than one thread
34. The audit team should typically be from ------------------ experienced in refining
and/or petrochemical process plant inspection
a. Another owner/user plant site or from a third party

b. Within the same plant site or from a third party
c. Another owner/user plant site
d .. From a third party
21
1. An RBI assessment may be used to ----------------the inspection intervals

described in API 570 ..
a. Increase
b. Decrease
c. Increase or decrease
d. None of these
2. Who establishes inspection interval for thickness measurements, external visual

inspections and for internal and supplemental inspections?
a. Piping engineer
b. Owner-user or the inspector
c. Chemical Engineer
d. Piping engineer and the jurisdiction
3. The classification in API 570 is used to establish frequency and extent of

inspection. The piping classification scheme in API 570 is based on----------
a. The consequence of afailure

b. The likelihood and consequence of a failure
c. The likelihood of a failure
d. The likelihood and consequence of a failure
Ans: a API 570 Para 6.3.4.1
4. Of the four classification of piping systems, which includes the majority of unit
processes and selected off-site piping?
a. Class 3
b. Class 4
c. Class 1
d. Class 2
Ans: d API 570 Para 6.3.4.3
22
5. Class 3 piping is described as being in services:
a. With the highest potential of resulting in an immediate emergency if a

leak occurs.
b. That are flammable but do not significantly vaporize when they leak
and are not located in high-activity areas
c. .That are not flammable and pose no significant risk to populated areas
d. That are not in classes 1 and 2.
Ans: b API 570 Para 6.3.4.4
6. The appropriate inspection shall provide the information necessary to determine that
Piping is safe to operate until--------------.
a. The Remaining life.

b. Next 10 years
c. The next scheduled inspection
d. Next 10 years or the Remaining life whichever is shorter.
Ans: c API 570 Para 6.1
7. Thickness measurement inspection should be scheduled based on the calculation of not

more than
a. One halfthe remaining life determined from corrosion rates or the

maximum interval of 5 years whichever is shorter.
b. One half the remaining life determined from corrosion rates or the
maximum interval allowed by API 570 in Table 2, whichever is
shorter
c. One fourth the remaining life determined from corrosion rates or the
maximum interval of 10 years whichever is shorter.
d. One quarter the remaining life determined from corrosion rates or the
maximum interval allowed by API 570 in Table 2, whichever is
shorter.
8. Table 2 of API 570 contains recommended maximum inspection intervals for Classes
1,2 and 3 of piping services. Maximum intervals for Class 4 piping are ------------------
23
a. Optional.
b. Same as class 3
c. Same as class 1
d. Same as class 2
Ans: a API 570-Table 2
9. Piping systems that are known to have a remaining life of over years or
that are protected against external corrosion need not have insulation removed for the
periodic external inspection.
a. 10
b. 15
c. 5
d. 20
10. If Piping Service is Changed then-------------shall be established for the new service.
a. The allowable service conditions

b. The inspection interval
c. The remaining life and the inspection interval
d. The allowable service conditions and the inspection interval
11. As per API 570, Services with the ------------------------ are in Class 1.
a. Highest potential of resulting in an immediate emergency if a leak were

to occur
b. Highest Inspection Interval as per Table 2 of API 670
c. Lowest potential of resulting in an immediate emergency if a leak were
to occur
d. Lowest remaining life
12. Identify correct statements from following
24
a. Fluids that can rapidly vaporize during release, are class l.
b. On-site hydrocarbon fluids that will slowly vaporize during release
are class 2
c. Hydrocarbon Fluids that do not significantly vaporize during release
are class 3
d. All of above
13. Identify correct statements from following
a. Services that are essentially nonflammable but may be toxic are in Class
4,
b. Services that are essentially flammable and nontoxic are in Class 4,
c. Services that are essentially nonflammable and nontoxic are in Class 4,
d. Services that are essentially flammable and toxic are in Class 4,
14. Pressure-relieving Devices PRDs should be inspected, tested, and maintained in

accordance with ............. .
a. API 579
b. API 578
c. API 577
d. API 576
15. As per API 570 , test and inspection intervals for pressure-relieving devices in typical
process services should not exceed:
a. 5 years for typical process services,

b. 10 years for clean (nonfouling) and noncorrosive services.
c. Both a and b
d. 10 years for all services
25
1. If LT and ST corrosion rates are showing different values, The authorized inspector,
in consultation with a corrosion specialist, shall select the corrosion rate that-------------
a. Is higher ofLT and ST corrosion rates

b. best reflects the current process.
c. Is lower of LT and ST corrosion rates
d. Is average of LT and ST corrosion rates
2. You have a new piping system that has just been installed. It is completely new and no
information exists to establish a corrosion rate. Also, infOlmation is no available on a
similar system. You decide to put the system in service and NDT it later to determine
the corrosion rate. How long do you allow the system to stay in service before you
take your first thickness readings?
a. 1 month
b. 3 months
c. 6 months
d. 12 months
3. When the MAWP is recalculated, the wall thickness used in these computations
shall be the actual thickness determined by inspection--~---------------
a. Minus the estimated corrosion loss before the date of the next
inspection
b. Plus the estimated corrosion loss before the date of the next inspection
c. Minus twice the estimated corrosion loss before the date of the next
inspection
d. Plus twice the estimated corrosion loss before the date of the next
inspection
4. Inspection deferral is appropriate when the piping circuit's current interval is still
considered to be correct given the available data but an extension of the inspection date
based on --------------
26
a. A documented stress analysis process is acceptable to the inspector
b. A documented risk analysis process is acceptable to the inspector
c. A documented flexibility analysis process is acceptable to the inspector
d. A documented both sress and flexibility analysis process is acceptable to
the inspector
Aus: b API 570 Para 7.10
5. If a piping system is made up of unknown materials and computations must be made to

determine the minimum thickness of the pipe, what can the inspector or the piping
engineer do establish the minimum thickness?
a. The lowest grade material and joint efficiency in the applicable code
may be assumed for calculations.
b. Samples must be taken from the piping and testing for maximum
tensile stress and yield strength will determine the allowable stress to
be used.
c. The piping made of the unknown material must be removed from
service and current piping of known material must be installed.
d. The piping of unknown material may be subjected to a hydrostatic
stress tests while having strain gages on it to determine its yield
strength and thus allowable stress.
Aus: a API 570 Para 7.2
6. As per API 570, Piping system and pressure-relieving device records shall contain
four types of information pertinent to mechanical integrity. Which ofthe following
is NOT part of these records.
a. Fabrication, Construction and Design Information to the Extent

Available
b. Inspection History-inspection reports
c. Repair, Alteration, and Re-rating Information
d. RBI documentation
Aus: d API 570 Para 7.8.2
7. The shall maintain appropriate permanent and progressive records of each

piping system covered by API 570.
27
b) Inspector
c) Piping system owners and users
d) Jurisdiction
e) Examiner
28
1. When making repairs and alterations to piping systems, the principles of ---------------
-------- shall be followed:
a. ASME B31.3
b. Code to which the piping system was built
c. Orb.
d. ASME B&PV Code
2. Repair and alteration work must be done by a repair organisation as defined in API
570 and must be authorised by the prior to its commencement:
a. Jurisdiction
b. Inspector
c. Owner-user
d. Examiner
3. Authorization for ------------------ to a piping system may not be given without

prior consultation with, and approval by, the piping engineer
a. Alteration work
b. Repair work
c. Any repair as well as alteration work
d. Replacement of any piping component
4. What type of repairs and procedures may the inspector give prior general
authorisation to continue (provided the inspector is satisfied with the competency
ofthe repair organisaton)?
a.. Major repairs and minor procedures

b. Limited or routine repairs and procedures
29
c. Alterations and re-ratings .
d. Minor re-ratings and alterations
5. Who approves all proposed methods of design, execution, materials, welding

procedures, examination and testing of in-service piping?
a. The jurisdiction or the piping engineer as appropriate

b. The analyst and the operator as appropriate
c.- The examiner and the piping programmer as appropriate
d. The inspector or the piping engineer as appropriate
6. Who must give approval for anyon-stream welding?
a. Owner-user
b. Jurisdiction
c. Examiner
d. Analyst
6. Temporary repairs should be removed and replaced with a suitable permanent

repair at the next available maintenance opportunity. Temporary repairs may
remain in place for a longer period of time only if approved and documented by
the----------. -
a. Examiner
h. piping engineer
c. Inspector
d. Corrosion engineer
30
7. What type of defect, should not be repaired by a full encirclement welded split
sleeve?
a. A longitudinal check
b. A circumferential crack
c. Pits that are one half through wall
d. General corrosion in the longitudinal direction.
8. If a repair area is localised (for example, pitting or pin-holes) and the specified
minimum yield strength (SMYS) of the pipe is not more than psi, a
temporary repair may be made by fillet welding a properly designed plate patch over
the pitted area:
a. 30,000 psi
b. 55,000 psi
c. 40,000 psi
d. 36,000 psi
9. Insert patches (flush patches) may be used to make permanent repairs. One of the
condition for making these is that :
a. Class 1 piping systems, the welds shall be 100 % radiographed or

ultrasonically tested
b. Class 2 piping systems, the welds shall be 100 % radiographed or
c. Class 3 piping systems, the welds shall be 100 % radiographed or
d. Class 1 and Class 2 piping systems, the welds shall be 100 % radiographed or
31
10. Insert patches may be used to repair damaged or corroded areas of pipe if several
requirements are met. One of these is that an insert patch shall have rounded
comers with minimum radii.
a. 0.375"
b. 0.50"
c. 0.75"
d. 1"
11. An inspector finds a pin-hole leak in a weld during an on-stream inspection of a

piping system. A permissible temporary repair is :-
a. The use of sealant of reputed brand to seal off the leak

b. The installation of a proper bolted leak clamp
c. Driving a wooden plug into the hole
d. Screwing a self tapping screw into the hole
12. Any welding conducted on piping components in operation must be done in

accordance with
a. API Publication 2201
b. API Standard 577
c. API Standard 579
d. ASME B31.3
13. For carrying out repairs by welding qualified welding procedures and welders have
to be used. Who ------------------shall maintain records of welding procedures and
welder performance qualifications.
a. Repair organization
b. Inspector
c. Owner-user
d. Examiner
32
14. The records of welding procedures and welder performance qualifications shall be
available to the inspector:
a. At the end of the job

b. After the start of welding
c. Following the start of welding .
d. Before the start of welding
15. Preheating to not less than OF may be considered as an alternative to

post weld heat treatment for alterations or repairs of piping (materials P No.1)
initially post weld heat treated as a code requirement.
a. 150
b. 200
c. 300
d. 350
16. Piping butt joints made during repairs shall be:
. a. Double fillet welds

b. Single fillet welds
c. Full-penetration groove welds with backing strip
d. Full-penetration groove welds
17. Fillet welded patches (weld-on patches) shall be designed by
a. An engineer
b. The inspector
c. The piping engineer
d. The repair organisation
33
18. As per API 570, pressure tests normally required----------
a. After alterations and any repair

b. After alterations and major repairs
c. After major and minor repairs
d. Aftereach inspection
19. When a pressure test is not necessary or practical, NDE shall be utilized in lieu of a
pressure test after consultation with --------------------
a. The inspector
b. Piping engineer.
c. The inspector and the piping engineer.
d. Corrosion specialist.
20. As per API 570, Rerating of piping systems can be done under certain conditions
which of the following is/are such conditionls for perfortning Rerating
a. Calculations are performed by the piping engineer or the inspector.

b. All reratings shall be established in accordance with the requirements
of the applicable code.
c. Current inspection records verify that the appropriate corrosion
allowance is provided.
d. All the above
21. As per API 570, Rerating of piping systems can be done under certain conditions
which ofthe following is/are such conditionls for performing Rerating
a. Rerated piping systems shall be leak tested unless a previous leak test was
done at greater than or equal to the test pressure for the new condition.
b. Full radiography of all butt welds must be performed.
c. PMI testing of piping systems shall be done
d. A and C above
34
1. For Inspection Of Buried Piping Above-Grade Visual Surveillance by observing leaks

change in the surface contour of the ground, discoloration of the soil, pool formation
etc. shall be done at approximately----------
a. 3-Itlonth intervals
b. 6-month intervals
c. Once a year
d. Once every 3 years
2. Corrosion cells can form on Buried pipes (both bare and coated pipe) where bare steel
contacts the soil. How can these cells be detected ?
a. Run an acoustic emission test on the piping

b. Visually survey the route of buried piping
c. Carry out a close-interval potential survey
d. Run an internal survey of the piping using a video camera
3. A pipe coating holiday survey is used to locate coating defects on coated pipes. More
often, it is used on buried pipeto--------------
a. Measure differences in electrical potential in corroded areas

b. Evaluate coating serviceability for buried piping that has been in-
service for along time.
c. Determine the leakage of service fluid in piping.
d. Evaluate the cathodic protection system
4. If an "smart" or "intelligent pigging" system is used to inspect buried piping, what

type of bends are usually required in the piping system?
a. Five diameter bends

b. Short radius elbows
c. Ten diameter bends
d. Three diameter bends
35
5. Measurements of soil resistivity should be performed using ---------------- in

accordance with ASTM G57.
a. Holiday detector
b. Intelligent pigging.
c. Boroscopes.
d. Wenner Four-Pin Method
6. For piping buried in lengths greater than 100 feet (30 m)and not cathodically
protected, evaluations of soil corrosivity should be performed at ---------
a. 3-year intervals half of remaining life whichever is shorter

b. 5-year intervals
c. 5-year or half of remaining life whichever is shorter
d. 3-year intervals
7. How often should poorly coated pipes withinconsistent cathodic protection potentials
have a pipe-to-soil potential survey made?
a. Yearly
b. Every 2 years
c. Every 3 years
d. Every 5 years
8. In Intelligent pigging inspection method (involving the insertion and travel of a

device through the piping) can be performed------------- .
a. While piping is in-service

b. While piping has been removed from service
c. Either while piping is in-service or after it has been removed from
service
36
d. Only on small bore piping
9. The external condition of buried piping that is ------------------should be determined

by either pigging, which can measure wall thickness, or by excavating according to
the frequency given in Table 5
a. Cathodically protected
b. Not painted and not cathodically protected
c. Painted and cathodically protected
d. Not cathodically protected
Ans: d API 570 Para 9.2.
10. An alternative or supplement to inspection of buried piping is leak testing with liquid
at a pressure at least % greater than the maximum operating pressure
a. 5
b. 25
c. 10
d. 50
11. In a certain leak test for a buried piping system, specified Leak test pressure was 200
psi and piping was pressurized to this pressure. Four hours after the initial
pressurization of the piping system, the pressure dropped to 285 psi . As per API
570, What should be done?
a. Pressure decrease is more than 5 %, Reject the test

b. Nothing is required. The loss of pressure is negligible accept the test.
c. The system should be re-pressurised to the original leak test
pressure, isolated from the pressure source, then pressure reduction
shall be observed.
d. Pipe should be drained and made empty. Stat a new the pressure test
agam.
37
12. If buried piping leaks are repaired by putting clamps and reburied What shall be done
as per API 570:
a. No further action is required unless the piping leaks again

b. The location and date of installation of the clamp shall be logged in the
inspection record for future corrective action at the first opportunity
c. The clamped line shall be pigged by intelligent pigging.
d. The clamped line shall be put back in service but the service pressure
shall be reduced to 80% of original pressure
38
Practice questions API-570 course
API 570 PRACTICE QUESTIONS

(OPEN BOOK)
1) A 18" O.D. pipe has a corroded area on it. What is the maximum size of a fillet
patch that may be used to repair the corroded area?
a. 3.5"
b. 9"
c. 6"
d. 6.5"
2) A 10' long carbon steel pipe is welded to a 10 '1ong 18-8 stainless pipe and is
heated uniformly to 475 degrees F from 70 degrees F. Determine its total
length after heating
a. 20.067'
b. 20.156'
c. 20.234'
d. 20.095'
3) A seamless NPS 10 pipe, ASTM A106 Grade B material operates at 750 psi
and 700 degrees F maximum. Considering only pressure design thickness,
what minimum thickness is required?
a. 0.244"
b. 0.200"
c. 0.282"
d. 0.173"
4) A seamless NPS 6, ASTM A106 Grade A pipe operates at 300 degrees F and
765 psi. The allowable stress is 16,000 psi. Using the Barlow equation,
determine the retirement thickness for these conditions
a. 0.446"
b. 0.332"
c. 0.231"
d. 0.158"
5) A seamless NPS 10 pipe, ASTM A106 Grade B material, operates at 750 psi
and 700 degrees F (maximum). The thickness of the pipe as determined by the
last inspection is 0.30". The pipe has been in service for 10 years. The original
39
thickness (measured when installed) was 0.365 11 Two years previous to the
0.30 11 measurement the thickness of the pipe was measured to be 0.3r.
Determine the greatest corrosion rate i.e. short or long term
a. 0.0050 inches per year

b. 0.0065 inches per year
c. 0.0100 inches per year
d. 0.0130 inches per year
40
ANSWER KEY - OPEN BOOK
1. API 570, APP

2. a B31.3, Table C-1
3. a B31.3,304.1.1
4. d B31.3304.1.1
5. b API 570,7.1 and 7.2
41
Practice Questions API-570 course
ASME B 31.3 PROCESS PIPING
Closed Book
Q1) Piping code to be adopted for process piping within a large fertilizer
factory will be:
(a) ASME B 31.1

(b) ASME B 31.3
(c) ASME B 31.4
(d) None of Above
Q2) Most of the fluids normally covered by B 31.3 code falls under
Category
a. Category M
b. Category K
c. Category D
d. Normal
Q3) The term 'Y' in pipe thickness formula in B 31.3 represents numerical
factor of value.
a.Which is more than 1 and depends on type of pipe materials and

design temperature?
b. Less than 1 and does not depend on materials & temp.
c. Less than 1, but depends on materials & temp.
d. More than 1, but does not depend on materials and design
temp.
Q4) Impact test is to be conducted with how many specimen for applying
acceptance criteria of ASME B 31.3
(a) 3 (b) All 5 (c) 2 (d) 4
Q5) ASME B31.3 applies to piping for all fluids except for which of the
below?
a. Tubes of fired heaters, plumbing lines.

b. Raw, intermediate and finished chemicals
c. Petroleum products, fluidized solids and refrigerants
d. Gas, steam, air, and water
42
Q6) As per ASME 31.3, the increased quality factors by conducting
additional NDT is permitted for:
a. ERWpipes
b. Seamless pipes
c. Electric fusion welded pipes
d. All types of pipes
Q7) The thickness formula t = PD /2 (SE +PY) What is the term E?
a. Weld Strength factor

b. Wind factor
c. Weld Quality factor
d. Weight factor of pipe
Q8) The Term'S' used in formula for calculating thickness of permanent

blinds as per 31.3 code, represents:
a. Safe stress Value of pipe materials

b. Safe stress value of blind materials
c. Lower of (a) and (b)
d. Higher a. and b.
Q9) ASME B 31.3 code is meant for new piping installations in:
a. Steam piping in Power stations

b. Piping in Refinery and process plants
c. Cross-country piping
d. Gas transmission piping
Q10) Identify incorrect statement/ s:
a. In impact test exemption curves, curve D

represents better toughness material than
curve B
b. Curve C represents more brittle material than
Curve B
c. Fully de-oxidized steels are tougher than non-
deoxidized materials
d. Both a and c
43
Q11) The requirements of the latest edition of ASME Code Section B 31.3 and
any subsequent Addenda become effective:
a. As soon as the latest edition is issued

b. Immediately from date of issue and all piping
installed per earlier editions must be upgraded to
latest edition/ addenda
c.After 6 months from date of issue
d. After 1 year from date of issue
Q12) Fluid service that is non-flammable, non-toxic, and not damaging to

human tissue and its gauge pressure does not exceed 150 psi and the design
temperature is form -20 degrees through 366F is known as a category
____ fluid.
a. D
b. C
c. M
d. N
Q13) A fluid service in which the potential for personnel exposure is judged to
be significant and in which a single exposure to a very small quantity of a
toxic fluid, caused by leakage, can produce serious irreversible harm to
persons on breathing or bodily contact, even when prompt restorative
measures are taken is known as a category fluid.
a. D
b. M
c. H
d. N
Q14) What type weld is considered to furnish no strength and is

only used to prevent leakage of threaded joints?
a. Tack weld
b. Seal weld
c. Fillet weld
d. Butt weld
Q15) In the equation tm = t + c, pick the correct definition of the value "tll.
44
a. Minimum required thickness, including mechanical,
corrosion, & erosion allowances
b. Pressure design thickness, as calculated for internal
pressure.
c. Nominal wall thickness (As per purchase
specification)
d. Minimum design temperature of the pipe
Q16) The theoretical throat of a fillet weld is = __ x the leg.

a. 0.707
b. 0.770
c. 1.414
d. 0.500
Q17) The pre-heat zone shall extend at least -----inch beyond the edge of the
weld.
a. 2inch b. 4 inch c. Half inch d. 1 inch
Q18) In ASME B 31.3, the term 'Unlisted materials' means:
a) Materials not listed by purchaser in the Data

Sheets
b) Materials of Unknown specifications.
c) Materials not listed in the code but meeting
. other published specification
d) Materials prohibited by code.
Q19) Impact testing is not required 1 Design Minimum temperature-Thickness

combination is-----------the material Curve
a) Above
b) Below
c) On or above
d) On or below
Q20) Choose correct statement: .
a) Curve A material is least brittle
45
b) Curve A material is most brittle
c) Curve D material is most brittle
d) Curve B material is most brittle
Q21) As per ASME B 31.3,the code used for Qualification of Welding Procedure
and welders is:
a) ASME Sec. IX
b) API 1104
c) Anyone of a or b above may be used.
d) Both a and b above must be used
Q22) Pre-heating, whenever specified is:
a) Applicable to strength welds and not for tack welds

b) Strength welds and seal welds only
c) Strength welds, tack welds and seal welds
d) Strength welds only
Q23) Performing impact test requires testing of a set of:
a. Three specimen
b. At least two specimen
c. Minimum three specimen
d. Maximum three specimen
Q24) Code ASME B 31.3 stipulates recommended and required pre-heat

temperatures for welding of pipes. When do you follow recommendations as
mandatory requirement?
a. Pipethk~r
b. Pipethk~%11
c. Ambient temp is less than OoC
d. None of above
Q25) If Two pipes different pre-heat requirements say tl and tz are to be welded,
the preheat for their joining shall be
46
b. Lower of tOl and t02
c. Average of tOl and t02
d. None of above
Q26) To have a safe Pressure Test of Piping which type of test will you
recommend?
a) Hydrostatic
b) Pneumatic
c) Either a or b both are equally safe.
d) Code does not accept a or b
Q27) VT, MT, PTi UT and RT shall be performed as specified in the:
a. ASME BPV Code, Section V

b. ASME BPV Code, Section IX
c. ASME BPV Code, Section VIII
d. ASME BPV Code, Section I
Q28) What is the only category fluid service that may be subject to an initial
service leak test?
a) Category M
b) Category D
c) Category N
d) Category K
Q29) What will be Hydrotest pressure for a piping system with design pr = 100
psig, and safe stress at design condition is 18,000 psi while safe stress at test
condition (ambient) is 19,800 psi?
a. 150 psig
b. 130 psig
c. 165 psig
d. N one of above
Q30) A piping is to be pneumatically tested at test pr = 80 psig. What will the

pressure at which a preliminary leak check shall be performed?
a. 40 psig
b. 20 psig
c. 25 psig
d. 80 psig
47
Q31) For pressure testing of piping systems, which of the following
statement(s) are correct?
a. Pneumatic test must be done using air only and no other

gas ..
b. For hydro testing water alone can be used and no other
liquid.
c. Pneumatic test shall be conducted only if hydrostatic test is
impracticable.
d. a and c above
Q32) According to ASME B 31.3 ,In case of fabricated piping Pressure test is
conducted
a. After fabrication but before examination

b. After Examinations are completed.
c. Before PWHT
d. Anytime is okay
Q33) What is the minimum time that a leak test must be maintained as per B
31.3?
a. 60 minutes
b. 45 minutes
c. 30 minutes
d. 10 minutes
Q34) According to ASME B31.3 how much minimum experience in the

design, fabrication, or inspection of industrial pressure piping
must a Owner's inspector have.
a. 10 years
b. 8 years
c. 6 years
d. 4 years
48
Q35) After PWHT, the hardness of weld and Heat affected Zone will generally -
a. Increase
b. May increase or reduce.
c. Remain unaffected.
d. Reduce.
49
Practice Questions API -570 course
Closed Book- Answer Key
Q.NO. ANSWER
1 B
2 D
3 C
4 A
5 A
6 C
7 C
8 B
9 B
10 B
11 C
12 A
13 B
14 B
15 B
16 D
17 a
18 a
19 b
.- -
20 d
21 b
22 c
23 b
24 d
25 a
26 a
27 a
28 b
29 d
30 b
31 c
32 b
33 d
34 a
35 d
50
Open Book
Ql) What is the longitudinal weld joint factor, Ej, for API 5L ERW (Electric
Resistance Welded) pipe?
a. 1.00
b. 0.95
c. 0.S5
d. 0.60
Q2) "S" is defined as the stress value for material from Table A-l of ASME
B31.3. Pick the value of "S" when the material is ASTM A335 Grade P5 and
the temperature is 950 degrees F.
a. llAOO psi
b. 10,600 psi
c. S,OOO psi
d. .20,00 psi
Q3) Select appropriate Y factor for Austenitic Stainless Steel pipes for Design
temperature of 630 deg. C.
a. 0.4 b.0.6 c.O.5 d.0.7
Q4) A Water piping with Design Pressure=lS0 psig and Design temperature=-
10 deg. F, will be classified as Fluid Service
a. D. b.M c. High Pressure d. Normal
Q5) If Design temperature in above question is changed to -30 deg.F what will
be the fluid service.
a. D. b.M c. High Pressure d. Normal
Q6) Water piping with Design Pressure=130 psig and Design temperature= -10
deg. F, will be classified as Fluid Service
51
a.D. b.M c. High Pressure d. Normal
Q7) NPS 12, Sch 80 and Sch 160 pipes (M.O.C = A 106 gr B) are to be used at (-100 C)
Determine whether,
a. Both pipes require impact testing

b. Only Sch 160 will require impact test but Sch
80 would be exempt.
c. Both would be exempt
d. Sch 80 would require but Sch 160 will be
exempt.
Q8) 6" NB Sch 40 pipe is selected for following conditions.

Design Pr = 360 psi
Design Temp. = 300 degrees F
M.O.C = A 53 gr B (ERW)
Corrosion Allowance = 2.0 mm
Assume standard mill tolerance
Your assessment is:
a. Pipe design meets code requirement

b. Pipe design does not meet code requirement
c. Depends on opinion of Piping Inspector
d. Depends on opinion of Piping Design Engineer
Q9) A flat plate (without joints) is used as permanent blank for flanged point
with gasket I.D = 200 mmDesign pro = 200 psi and safe stress value for plate
; ,i
is 18,000 psi, for given temperature of 2500 C What shall be the minimum
blank thickness from given options? Corrosion allowance is Nil code of
construction B 31.3.
a.8mm
b. 10mm
c. 12mm
d. 14mm
QI0) Maximum Brinell hardness observed (after PWHT) on

following three Joints was as follows:
Joint 1: P No.4, thk = 16 mm, Hardness = 240 HB

52
Your assessment is:
a) All joints are okay as per ASME B 31.3
b) Joint 2, and 3 are okay, joint 1 not okay
c) Only joint 1 is okay. Joint 2, and 3 are not
d) None of the above are correct answers.
Qll) An ASTM A53 Grade B pipe with a maximum wall thickness of 0.75/1 is
being considered for use in a cold service. What minimum temperature can it
be used and not have an impact test?
a. +20 degrees F
b. +15 degrees F
c. +10 degrees F
d. 0 degrees F
Q12) PWHT is required for all SMTS of piping over 1/2 inch for which of the
following materials?
a. P Nos. 1 and 2
b. P Nos. 1 and 3
c. PNos.2and3
d. PNos.4and5
Q13) A piping system has design pressure=200psig. The piping material has
allowable stress at design temperature=16000psi. It has allowable stress at test
temperature=17600 psi. Its minimum Hydro test pressure will be
a 300 psi b. 330 psi c.260 psi d. 220 psi.
Q14) A austenitic (18Cr-8Ni) stainless steel piping system operates between

temperatures of - 50 of and 350 of .The temperature of installation was 100 oF.
The approximate values of minimum expansion and contraction range for
sliding support installed at 150 ft from the anchored end will respectively be:
a. 2.4 inch and 4.3 inch

b. 4.3 inch and 2.4 inch
c. 1.9 inch and 4.8 inch
Q15) A radiograph taken on Girth weld of 12 mm thick piping in Normal fluid

service shows a slag inclusion of length= 8 mm . Is the individual slag length
acceptable as per ASME B 31.3?
a) Accept
53
b) Reject
c) Accept only if it is Stainless steel pipe
d) Reject only if it is Stainless steel pipe
Q16) A radiograph taken on Girth weld of 12 mrn thick piping in Severe Cyclic
condition shows a slag inclusion of length= 8 mrn . Is the slag length
acceptable as per ASME B 31.3?
a. Accept
b. Reject
c. Accept only if it is Stainless steel pipe
d. Reject only if it is Stainless steel pipe
Q17) PWHT is required for all SMTS of piping over % inch for
which of the following materials?
a. PNos.1 and 2
b. P Nos. 1 and 3
c. P Nos. 2 and 3
d. PNos.4and5
Q18) Piping system has design pressure=150 psig. Its Pneumatic test pressure
. will be
a 200 psi b. 230 psi c.165 psi d. 225 psi.
Q19) What will be the inspection pressure in above question
a 150 psi b. 200 psi c~165 psi d .. 225psi
Q20) ASME B 16.5 permits pipe flanges made from plates for which of the
following type?
a. Slip on type
b. Weld neck type
c. Blind flanges
d. None of above
Q21) Suitable Class for pipe flanges (AI05) for Design pr = 400 psi, design
temp = 4000F will be:
a) Class 600
b) Class 300
c) Class 400
54
d) None of the above
Q22) What will be the System Hydrostatic Test pressure for above flange.
a. 300psig
b. 1000psig
c. 1100psig
d. 1125 psig
Q23) A carbon steel ASTM A 106 Grade B material is being impact tested.
What is the minimum average energy requirement for this material
(average for 3 specimens-fully deoxidized steel)?
a. 7 ft-lbs
b. 10 ft-lbs
c. 13 ft-lbs
d. 15 ft-lbs
Q24) Where the design temperature of the system is the same as the
hydrostatic test temperature, the hydrostatic test pressure shall not be
less than: (Yield stress during hydrotest is not governing factor.)
a. 1.15 times design pressure

b. 1.1 times the design pressure
c. 1.25 times the operating pressure
d. 1.5 times the design pressure
Q25) A NPS 10 pipe made from ASTM A53 Grade B carbon steel is to be
checked for thickness (t). The pipe operates at 975 degrees F. Determine the
coefficient Y.
a. 0.4
b. 0.5
c. 0.6
. d. 0.7
Q26) You have a fluid that does not operate at high pressure. The fluid is not
toxic. The fluid is not flammable. Exposure to the fluid will not cause damage
to human tissue. The design gage pressure is 120 psi and the operating
temperature is 1000F. What category fluid service would you design?
a. Normal fluid service

b. Category D fluid service
55
c. Category M fluid service
d. High pressure fluid service
Q27) If a pneumatic Pressure test test is used, the test pressure shall be
_ _ _ _ % of design pressure.
a. 50
b. 150
c. 125
d. 110
Q28) Where a hardness limit is specified in Table 331.1.1, 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.
a. 5
b. 10
c. 15
d. 20
Q29) A 106 gr B pipe after installation, required pneumatic leak test.

Design pressure is = 300 psi. What is first stage pressure for
preliminary check and final inspection pressure for leak check?
a. 150 psi and 330 psi

b. 25 psi and 300 psi
c. 150 psi and 450 psi
d. 25 psi and 450 psi
56
ASME B31.3 PROCESS PIPING COURSE
Open Book Answer Key.
Q.NO. ANSWER
1 c
2 c
3 d
4 d
5 d
6 a
7 b
8 a
9 b
10 d
11 b
12 d
. 13 b
14 b
15 a
16 b
17 b
18 c
19 a
20 c
21 b
22 d
23 c
24 d
25 b
26 b
27 d
28 b
29 b
57
API-578 recommended practice
CLOSED BOOK
Ql) API 578 provides guidelines for a quality assurance system to verify:
a all metals.
b. all alloy materials.
c. non-ferrous materials.
d. For Carbon steels
Q2) An inspection lot includes:
a. all materials from same supplier.

b. all materials from same manufacturer.
c. all materials of the same material type but different heat numbers
d. all materials of the same material type and from the sameheat
numbers
Q3) Who has the responsibility to verify that the material verification program
is properly implemented?
a. Authorized inspector
b. Owner/User
c. Repair organization
d. Engineering organization
Q4) The material verification program specified by API 578 covers:

a. only new pressure-containing components
b. only old pipe, and fittings.
c. only old and new pipe, fittings, and welds.
d .. none of these
Q5) During alloy welding:
a. one electrode from each box should be sampled.

b. two electrodes from each box should be sampled.
c. one electrode from each lot should be sampled.
d. two electrodes from each lot should be sampled.
Q6) Who has the responsibility to determine the extent of PMI testing required
on existing piping systems?
58
a. Authorized inspector
b. Owner/User
c. Repair organization
d. Engineering organization
Q7) PMI tools that use X-Ray fluorescence can not detect:
a. carbon content.
b. chrome content.
c. iron content.
d. molybdenum content.
Q8) All personnel performing PMI tests should be:
a. qualified by ASNT exam.

b. qualified by the owner/user ..
c. knowledgeable about the operation of the PMI test equipment.
d. knowledgeable about the operation of the plant where the PMI is
conducted.
59
Api-578 recommended practice
CLOSED BOOK ANSWER KEY
1 b
2 d
3 b
4 c
5 a
6 b
7 a
8 c
60
ASME B 16.5
PRACTICE QUESTIONS - OPEN BOOK
1. The allowable pressure (in psig) on a 100F, Class 150 8"

flange made from A-182 Grade F2 material is:
a. 170
b.290
c. 300
d. 400
2. If a Class 1500 flange is to be made from A-182 F347

stainless steel and will be used at 280 psig with a carbon
content of 0.09%, at what maximum temperature can this
flange be used?
a. 1000 0 F
b. 1300 0 F
c. 1180 0 F
d. 2000 0 F
3. What is the maximum system hydrostatic test pressure

required for a Class 300 flange that is made from Group
1.10 material?
a. 1125 psig
b. 450 psig
c. 1000 psig
4. What is the maximum system hydrostatic test pressure

required for a Class 600 flange in a flanged joint made
from Group 3.5 material?
a. 2250 psi
b. 1500 psi
c. 1000 psi
61
ASME B 16.5
ANSWER KEY- OPEN BOOK
1. b
2. a
3. a
4. a
62
API 570 CERTIFICATION PREPARATORY COURSE
Practice Questions. ( Closed Book)
ASME Sec. V
1. Liquid penetrant inspection can find which type of discontinuity?
1. Internal cracking of welds.

2. Cracks open to the surface.
3. Subsurface porosity.
4. Laminations on the surfaces of plate.
Ans. 2. Ref. ASME V . T-620
2. Certification of contaminants shall be obtained for all PT materials used on
a. Carbon steels
b. Ferritic stainless steels
c. Austenitic stainless steels
Ans. 2. Ref. ASME V . T-640
3. The scope of the ASME Boiler and Pressure Vessel, Code, Section V includes:
A. NDE acceptance criteria

B. NDE metod and procedures to perform NDE
C. Extent of NDE (i.e. what welds to examine)
D. All of above
Ans. B. Ref. ASME V . T-110
63
4. For Ammeter calibration for Magnetising equipment, The allowable tolarence
is:
a. . 5%
a. + 10 %
b. + 15 %
d. . 20
Ans. b.. Ref. ASME V . T-761
5. The basic features section V focuses on for any NDT technique is
a. Qualification of personnel
b. Calibration of NDE equipments
c. Correct procedure for NDE
d. All of the above
Ans. c. Ref. ASME V. T-1TO
6. In the radiography, penetrameter is put on the job to :
a. Evaluate the image quality of the radiograph.

b. Measure the strength of the penetrating radiation.
c. Check the density of the radiograph.
d. All of above.
Ans. a. Ref. ASME V . T-640
64
7. Describe how a liquid penetrant examination should be performed in order to
detect discontinuities, which are open to the surface :-
(a) clean the part, apply the developer, apply the penetrant, remove excess
penetrant, inspect the part, clean the part;
(b) clean the part, apply the penetrant, remove excess penetrant, apply the
developer, inspect the part, clean the part;
(c) clean the part, apply the developer, apply the penetrant, inspect the part,
remove excess penetrant, clean the part;
(d) clean the part, apply the developer, apply the penetrant, inspect the part,
clean the part.
Ans: (b) Ref. : ASME Sec. V-T620
What it the minimum permitted density of radiographic film using an Iridium

source?
(a) 2.0; (b) 1.8; (c) 1.3; (d) 4.0
Ans. a. Ref. ASME V. T-282
8. When reviewing a radiograph, a light image of the letter B can be seen on the
film
(a) This is cause for rejection;

(b) This is not cause for rejection;
(c) This is the same as a light letter B
(d) An unusual safety hazard existed during the exposure.
Ans. a .. Ref. ASME V. T-284
9. The accuracy of a piece of magnetizing equipment that is equipped with an

ammeter shall be verified:
65
a. Each year
b. Each two years
c, When possible
d. Every 6 months
Ans. a .. Ref. ASME V . T-761
10. How shall Non-destrutive Examination Personnel be qualified?

d. To SNT-TC 1A
e. To CP-189
f. To referencing code requirements
g. To ACCP rules
Ans. a.. Ref. ASME V . T-284
11. For MT examination by Prod technique the spacing between prods shall be
between
a. 4 inch to 12 inch
b. 4 inch to 10 inch
c. 3 inch to 10 inch
d. 3 inch to 8 inch
Ans. d.. Ref. ASME V . T-752.3
13. What is the difference between an inspection and an examination per Section V of
the ASME Code?
a. Inspection performed AI
b. Examination performed by manufacturer's personnel
c. There is no difference between the two
d. Both a and b, above
66
Ans. d ... Ref. ASME V . T-170
14. In pulse -echo contact method, When does a considerable Vee - error will result
while measuring thickness?
a. Thickness measurement on thin sections using Dual Crystal probe

b. . Thickness measurement on thick sections using Dual Crystal probe
c. . Thickness measurement on thin sections using sinlgle Crystal probe
d. . Thickness measurement on thin sections using single Crystal probe
Ans. a .. Ref. ASME V . Art. 23. 7.3
15. In pulse -echo contact method which disply of UT results is recommended when
reflecting surface is rough.
a. CRT display
b. Direct Digital display
c. Any of a or b are OK
d. UT is prohibited when reflecting surface is rough
Ans. 8.. Ref. ASME V . Art. 23. 8.8
67
ASME Sec. IX
1. Essential variable on a welding procedure specification are :-
(a) those in which a change, as described in the specific variables, is considered to

affect the mechanical properties of the weldment;
(b) those in which a change, as described in the specific variables, is considered not to affect
the mechanical properties of the weldment;
(c) . both (a) and (b) above are essential variables
(d) They are applicable only if Impact testing of weld is specified.
ANS : (c) REF: Section IX, OW 251.2
2. The Heat Affected Zone is :-
(a) that portion of the base metal which has not been melted;
(b) whose mechanical properties or micro structures have been altered by the heat of
welding;
(c) is least likely to contain discontinuities;
(d) both (a) and (b) above.
ANS: (d) REF: Section IX, OW-492
3. A welder may deviate from the parameters specified in WPS if they are nonessential
variables :-
(a) Provided the change is documented on revised WPS;

(b) Provided the supporting POR is also revised;
68
(c) No;
(d) Nonessential variables only apply to PQRs
Ans. a REF: Section IX, QW-200.1
1. A welder is a qualified welder but gives consistently defective weld. What will be
your action as a Quality Control Manager?
Cut his salary to compensate your cost.

Remove him from your company
Discontinue him from the job and retrain and re-qualify him as per code
requirements.
d. Do not worry as anyway he is only going to repair his work.
Ans c. REF: Section IX, QW-322
5. Tensile test was carried out for qualifying a welding procedure (PQR). The specified
minimum tensile strength of the base metal is 70,000 psi. If the test specimen
breaks in parent metal (outside weld and fusion zone) and the tensile strength
calculated is 68,000 psi.
a. the test is acceptable

b. the test is rejected
c. the test is void and fresh test plate should be welded.
d. none of the above
Ans a. REF: Section IX, QW-151.1
6. A weld procedure is qualified in 1G position. This procedure can be used for welding
in positions
a. 1G
b. 2G
c. 4G
69
d. all of the above
Ans d. REF: Section IX, QW- 203
7. Guided bend test are used to determine the
a. ultimate tensile strength of the weld joint

b. degree of soundness of fillet welds
c. notch toughness of weldment
d. degree of soundness and ductility of groove weld joints
Ans d. REF: Section IX, QW- 141
8. When radiographic testing is used in place of bend tests in welder's performance

qualification on groove welds on plate, the minimum length of spot to be exposed
is :
6"
12"
15"
d. Radiography can not be used for welder qualification
Ans a. REF: Section IX, QW- 302.2
9. When a tensile specimen breaks in the base metal outside of the weld
or fusion line, the strength recorded may be at most __ below the
specified tensile and be accepted.
A. 3.5%
B. 0.5%
C. 5%
D. All of the above
Ans C. REF: Section IX, QW- 153
70
10. The basic purpose of testing a welder is to establish the welder's
a. Knowledge of welding requirements
b. Ability to deposit sound weld metal
c.. Mechanical ability to operate equipment
d.. General attitude toward welding inspectors
Ans b. REF: Section IX, QW- 100.2
11. What is the number of transverse guided bend tests required for
Performance Qualification in a 6G position?
a. 2 b. 3 c. 4 d. 6
Ans c. REF: Section IX, QW- 302.3
12. The procedure qualification test is used to determine:
a. The skill of the welder

b. That the proposed production weldment is capable of
having the required properties
c.. The corrosion-resistance of the proposed weldment
d.. None of the above
12. What period of inactivity from a given welding process

requires the welder to re-qualify in that process?
a. 3 months
b. 6 months
c. 9 months
d. 12 months
71
13. Groove weld test may be used for qualification of welders.
Which of the following shall be used for evaluation?
a. Only bend tests
b. Only radiography
c. Both radiography and bend tests
d. Either bend tests or radiography
Ans d. REF: Section IX, QW- 300.1
14. Under which of the following conditions can a welder be qualified

during production work?
a. A 6" length of the first production groove weld may be

qualified by radiography
b.. A bend test coupon may be cut from the first 12" length
of weld
c.. A macro examination may be taken from the first. 3" of
weld length
Ans a. REF: Section IX, QW- 300.1
72
Practice Questions. ( Open Book)
ASMESec. V
1. The recommended minimum development time allowed for a material made of high
temperature alloy is
a.5min
b. 10 min
c. 7 min
d. 60 min
Ans: b. Referance ASME Sec. V Art.6
2. What is the geometric unsharpness allowed as per code for a thickness of 2.0" (50.B
mm) as per code?
1. 0.020" ( 0.50Bmm)
2. 0.030" (.00.762mm)
3. 0.010 (O.254mm)
Ans: b. Referance ASME Sec. V Art.2, table 276
3. For steel plates and welds to be checked by LPI, what shall be the penetration time
for Penetrant
a) 10 min for weld, 5 min for plate

b) 5 min for both
c) 10 min for both
73
d) 5 min for weld, 10 min for plate
Ans: d. Referance ASME Sec. V Art.6
4. A 1" thickness butt weld has 0.125" acceptable reinforcement was radiographed.
The applicable plate type penetrameter on (Film side) and essential hole shall be
a. ASME 30 - 2T
b. ASME 25 - 2T
c. ASME 20 - 2T
d. ASME 30 - 4T
Ans: b. Referance ASME Sec. V Art2, table 276
5. What weight shall be used to check adequacy of lifting power of a permanent magnet yoke. ?
(a) 10 pounds (b) 20;pounds c) 30 pounds (d) 40 pounds.
Ans: d. Referance ASME Sec. V Art.7
6. When should a densitometer be calibrated as a minimum?
a. Annually
b. Every 90 days
c. Whenever it is turned on
d. As required by the Examiner
Ans: b. Referance ASME Sec. V Art.2
8. In puse -echo UT technique, calibration was done at 100 deg. F. Thickness

measurement at 700 deg. F showed trading of 50 mm. After temperature correction what
is correct thickness?
a. 48 mm
74
b. 47mm
c. 53mm
d. 52mm
Ans: b. Referance : ASME Sec. V Art.23, 8.5
9. What wire No. shall make image on the film If type of penetrameter ,is wire type which
was put source side . Nominal single wall thickness is 0.875 inch and
permissible reiforcement is 0.125 inch. (wire decimeter in inch)
1. 0.025 (No. 10)

2. 0.016 (No.8)
3. 0.020 (No.9)
Ans: 3. Referance : ASME Sec. V Art.2.

10. After applying the developer the examiner checked four welds by PT after
following period, weld A - 7 minutes, weld B - 15 minutes, weld C - 25 minutes
and welds 0 - 70 minutes. Which of the welds were checked with incorrect
interpretation time?
a. A and B
b. Band C
c. C and 0
d. Aand 0
Ans: d. Referance : ASME Sec. V Art.6
75
Practice Questions. ( Open Book)
ASME Sec. IX
1. A welder is decided to be qualified on his initial production weld on 1/4" thick

longitudinal seam of carbon steel shell. The first 6" length of the weld was
radiographed. The radiograph reveals slag length of 5 mm. Your decision
in this case will be
a. welder is not qualified .

b. welder is qualified since he meets acceptance criteria of ASME sec. VIII
Div.1
c. Data not adequate. In addition to radiography, bend tests are required.
d. Data not adequate. In addition to radiography, tension tests are required.
Ans: a. Referance : ASME Sec. IX, QW 191.2.1
2. In a certain PQR for SMAW, the electrodes used for all passes were of AWS
classification (E 7018). Corresponding WPS also showed filler materials as E
7018. Now the manufacturer proposes to change the filler material in WPS to E
7015. Will you ask manufacturer to:
a. Quality new PQR with E 7015 electrodes.

b. Revise only WPS showing the change from E 7018 to E
7015 and submit WPS as a new revision.
c. Revise only the PQR document showing the change and
resubmit for approval.
d. Revise both WPS and PQR showing the change and resubmit
76
for approval
Ans: b.. Referance : ASME Sec. IX, and Table QW-253.
3. What positions are necessary to qualify a welder for all position pipe
welding?
E. 3G and 4G
F. 2G and 5G
G. 3G and 1G
H. 4G and 5G
Ans: b. Referance : ASME Sec. IX, QW Table 461.9
4. The maximum preheat temperature decrease allowed without re-

qualification of a GMAW groove weld procedure is:
a 50F
b. 100F
c. 125F
d. 150F
Ans: b. Referance: ASME Sec. IX, table QW 355
2. The P numbers are assigned on the basis of
1. Hardness
2. Composition, weldability & mechanical properties
3. Ductility only
Ans: b. Referance : ASME Sec. IX, QW-420
77
6. A groove weld was made with 1 %" thickness plate with SMAW process for PQR
Qualification and the test were found acceptable. This PQR can be used up to a
maximum weld thickness of:
1. 1 %"
2. 2.5"
3. 8"
Ans: b. Reference: ASME Sec. IX, QW 451
7. A welder qualifies in the 3G position on a plate coupon, he is then qualified to weld in

the position(s) on NPS 6 pipe :-
(a) F, V;
(b) F only;
(c) F, V, 0;
(d) ALL
Ans: b. Referance : ASME Sec. IX, QW 461.9

8. A welder who gave procedure test in 3G position is also qualified for performance in
(a) 3Gand1G
(b)1Gonly
(c) None. Procedure does not qualify performane. (d) must requalify ( d) All
positions
Ans: a. Referance : ASME Sec. IX, QW 203
9. A welding procedure qualified on % inch thick plate can be used to weld groove welds
in materials from to :-
(a) 3/16 to 3/4; (b) 1/16 to 3/4;
78
(c) 3/8 to 3/4; (d) 1/16to 1/2.
Ans: d. Referance : ASME Sec. IX, OW 451.1
10. E7018 electrodes are classified as F number :-
a 1,
b 2,
c 4,
d 5.
Ans: c. - Reference: ASME Sec. IX, OW 432
79
QUESTIONS ON API RECOMMENDED PRACTICES
API RP 571 Damage Mechanisms:
0.1 Temper embrittlement typically takes place with which of the following materials:
a. Austenitic Stainless steels

b. Carbon Steels
c. Low alloy steels containing Chromium
d. Duplex Stainless Steels
Ans: c Reference: API RP 571 4.2.3
0.2 Brittle fracture typically takes place with which of the following materials:
a. Austenitic Stainless steels

b. Carbon Steels
c. Low alloy steels
d. Both band c
Ans: c Reference: API RP 571 4'.2.7
0.3 which of the following is true for Thermal fatigue:
a. It is caused due to Stress concentration and thermal cycling

b. It is caused at welds where materials with differing thermal exansion coefficint
are welded
c. They are Dagger shaped, oxide filled and initiate form the surface.
d. All of above.
Ans: d Reference: API RP 571 4.2.9
80
0.4 Erosion/Corrosion can be controlled by :
a. Increasing the pipe diameter to decrease velocity

b. Increasing surface hardness by using harder alloys or hard facing
c. Using corrosion resistant alloys
d. All of the above.
0.5 "Clam shell" type cracking failure is typically found in:
a. Mechanical fatigue.
b. Creep failure.
c. Stress corrosion cracks.
d. Hydrogen induced cracks.
Ans: a Reference: API RP 571 4.2.16
0.6 which of the following is true for Atmospheric corrosion
a. It increases in marine environment.

b. It causes environmental cracks in Carbon steels
c. It reduces in dry rural environment.
d. Only a and c
0.7. Cooling water corrosion increases with:
a. Increases with high flow velocity or turbulence.

b. Increases with stagnant or low velocity flow.
c. Increases with high dissolved oxygen
d. Only band c
81
0.8. The dissolved gases which cause Boiler water condensate corrosion are:
a. Oxygen and Hydrogen

b. Hydrogen and Carbon di oxide
c. Chlorine and Hydrogen
d. Oxygen and Hydrgen
o. 9 What construction material will you suggest where you are expecting serious
Sulphidation problem.
a. Upgrade to higher nickel alloys

b. Upgrade to higher chromium alloys
c. Upgrading to higher copper based alloys
d. All of the above.
Ans: b Reference: API RP 571 4.4.2
0.10 Characteristic of Chloride SCC in Austenitic S.S. is: Cracks which are:
a. Transgranular, branching and aggravated at elevated temperature

b. Intergranular and unidirectional (straight)
c. Independent of chloride content
Ans: a Reference: API RP 571 4.2.3
0.11 Identify the correct statement (s)
a. SSC is aggravated due to wet H2 S
82
b. Hydrogen blistering may occur on 1.0, 0.0, or any where within wall thickness of
the pressure vessel.
c. High hardness & High strength steels are more likely to undergo damage due to
wet H2 S compared to low strength/low hardness steels
d. All of the above are correct statements
Ans: c Reference: API RP 571 4.5.1
Q.12 High temperature hydrogen attack is typically due to
a. Methane gas formation.

b. Wet H2 S
c. Creep rupture
d. Presence of Nickel in alloy steels.
Ans: a Reference: API RP 571 5.1.3.1
83
QUESTIONS ON API RECOMMENDED PRACTICES
API RP 577- Welding and Metallurgy:
1. If Coated electrodes and fluxes become wet, What should be done.

a. Dry the Coated electrodes and carry out oven baking to ensure they are
completely dry before re-using
b. Dry the Fluxes and carry out oven baking to ensure they are completely dry
before re-using
c. Both a and b.
d. discard them
Ans: d Reference: API RP 577
2. A radiograph shows slag inclusion linear indication of length 19 mm. Acceptable

length is 12 mm. This indication can be classified as:
a Recordable indication
b Reportable indication
c both a and b
d None of above
Ans: c. Reference: APr RP 577
3. For carbon steel welding, Heat affected Zone typically means:
a. Zone adjacent to the weld which is not melted

b. Has its properties or microstructure altered
c. Was heated to more than 700 deg.F
d. All of above
84
4. A sub -surface terrace and step-like crack with basic orientation parallel to the
base metal surface caused by tensile stresses normal to thickness direction is
called
a. Lamination
b. Step-wise cracking
c. Lamellar tearing
d. Stress corrosion crack
Ans: c Reference: API RP 577
5. The "Slag inclusion" is typically not found in welding performed by
a. SMAW
b. c and d below
c GTAW
d GMAW
Ans: b Reference: API RP 577
6. Most applicable method for Performance qualification of welders as per

ASME Sec. IX for GMAW-S process is:
a. Radiography only
b. Bend tests only
c. Either radiography or bend tests
d. Both Radiography and bend tests
7. For direct visual examination, accessibility of eye shaH be:
a. within 6" - 24" with angle less than 30 with the surface
b. within 6"- 24"with angle not less than 30 with surface
c. within 24" with angle less than 30
85
d. beyond 24"with angle not less than 30
8. A perfectly clear radiography film indicates film density of
a.4 b. 1. c Zero d.2
Ans: c Reference: API RP 577

9. 8-scan In UT examination didplays::
a. cross-sectional elevation view of object scanned.

b. Plan view of object scanned
c. Pulse -Echo view
d. None of above
Ans: a Reference: API RP 577
10. Steels with CE greater than 0.55% typically require:
a. Preheating only
b. Pre-heating & PWHT
c. No preheating or PWHT
d. PWHTonly
11. Simplest Weldability tests are those that evaluate
a. Strength and Ductility of the weld

b. Strength and hardnedd of the weld
c. Strength and toughness of the weld
d. Toughness and Ductility of the weld
86
Ans: a Reference: API RP577
12. A method to assure that PWHT on the welds was performed satisfactorily is
to perform which of the following after PWHT
a. Hardness testing of weld & HAZ

b. Radiography of weld &HAZ
c. Calibrate Thermocouples
d. UT of weld & haz
Ans: a Reference: API RP 577
13. Among the following Welding processes, identify the one that has highest
me;tal deposition rate
a. all of below.
b. GTAWfoliowed by SMAW
c. GMAW
d. SAW
14. A welding process which allows welding to be done without adding filler
metal is
a. SMAw
b. GTAW
c. GMAW
d. FCAW

15. As hardness of Heat affected zone increases -------
a. Susceptibility of Hydrogen assisted Cracking increases.
87
b. Susceptibility of Hydrogen assisted Cracking decreases
c. Tensile Strength of the weld decreases
d. All of above"
Ans: a" Reference: API RP 577
88

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API 570 - PIPING INSPECTOR COURSE

PROGRAM SCHEDULE, BENCH MARK QUIZ

PART I - CERTIFICATION INFORMATION FROM API.

PART II - GUIDELINES FOR CLEARING API 570 EXAMINATION

PART III - OVERVIEW OF PIPING DESIGN AND CONSTRUCTION

PART IV - OVERVIEW OF PIPING INSPECTION CODE

PART V - CASE STUDIES ILLUSTRATING USE OF CODE RULES

PART VI - WPSJPQR REVIEW CASE STUDIES

PART VII - DAILY EXAMINATIONS FOR API 570 COURSE

PART VIII- IMPORTANT SUMMARY POINTS

PART IX - ADDITIONAL INFORMATION

PART X - QUESTION BANK FOR API 570 PREPARATORY COURSE

Inspection and testing

Scope of API 570

Frequency and extent of inspection

ASME boiler and pressure vessel code, Sec.IX

Article 6, liquid penetrant examination

Overview of API RP 577, Welding Inspection and Metallurgy

API-570 AUTHORIZED PIPING INSPECTOR

July 2012 (Replaces August 2010)

REFERENCE PUBLICA nONS:

API RP 577, Welding Inspection and Metallurgy

B. ASME (American Society of Mechanical Engineers) Publications:.

Boiler and Pressure Vessel Code:

Section V, Nondestructive Examination, and

Section IX, Welding and brazing Qualifications

BI6.5, Pipe Flanges and Flanged Fittings

B31 .3, Process Piping

570- bok- rev7-10-12- final.docx 1

I. CORROSION RATES AND INSPECTION INTERVALS

The Inspector must be able to calculate:

a) Corrosion Rates (API-570, Par. 7.1)

2. WELD JOINT QUALITY FACTORS AND CASTING QUALITY FACTORS

a) Casting Quality factor, Ec from B31.3, 312.3 and A-1A

3. INTERNAL PRESSURE / MINIMUM THICKNESS OF PIPE!

The inspector should be able to determine:

The inspector should be able to:

570- bok- rev7 -10-12- final.docx 2

The inspector should be able to:

6. PREHEATING AND HEAT TREA TMENT REQUIREMENTS

8. MINIMUM WALL THICKNESS & WORKING PRESSURES FOR FLANGES

570 bok rev7-10-12 fina1.docx 3

570- bok- rev7-10-12- finaI.docx 4

A. ASME BOILER AND PRESSURE VESSEL CODE, SECTION IX

a) Typical joints and definitions

C. API Standard 570

1. ASME Section y, Nondestructive Examination

A. Article 1, General Requirements:

a) The Scope of Section Y,

B. Article 2, Radiographic Examination:

a) The Scope of Article 2 and general requirements,

C. Article 6, Liquid Penetrant Examination (Including mandatory appendices II and III):

a) The Scope of Article 6,

E. Article 7, Magnetic Particle Examination (Yoke and Prod techniques only):

a) The Scope of Article 7,

570 bok- rev7-10-12- final.docx 6

a) The scope of Article 9,

a) The scope of Article 10,

1) The Scope of Article 23, Section SE-797,

2. ASME B31.3 and API-570: General nondestructive examination requirements:

570- bok- rev7-10-12- final.docx 7

A. The following topics may be covered:

1. Organization and Certification Requirements.