New and Revised Editions of API Standards Just Published

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June 2, 2014 By John Reynolds at Intertek

Three new API standards have been published, and one has been revised and updated to a new edition. The standards are described in this post.

API RP 583 Corrosion Under Insulation and Fireproofing, First Edition

cuiThis recommended practice (RP) covers the design, maintenance, inspection, and mitigation practices to address external corrosion under insulation (CUI) and corrosion under fireproofing (CUF). The document discusses the external corrosion of carbon and low alloy steels under insulation and fireproofing and the external chloride stress corrosion cracking (ECSCC) of austenitic and duplex stainless steels under insulation.  The purpose of this RP is to:

  • help owner/users understand the complexity of the many CUI/CUF issues;
  • provide owner/users with understanding on the advantages and limitations of the various nondestructive examination methods used to identify CUI and CUF damage;
  • provide owner/users with an approach to risk assessment (i.e. likelihood of failure and consequence of failure) for CUI and CUF damage; and
  • provide owner/users guidance on how to design, install, and maintain insulation systems to avoid CUI and CUF damage.

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API RP 584 Integrity Operating Windows, First Edition

The purpose of this RP is to explain the importance of Integrity Operating Windows (IOW’s) for process safety management and to guide users in how to establish and implement an IOW program for refining and petrochemical process facilities for the express purpose of avoiding unexpected equipment degradation that could lead to loss of containment.  This RP outlines the essential elements in defining, monitoring and maintaining IOW’s as a vital component of integrity management (materials degradation control) and assisting in the inspection planning process, including Risk Based Inspection (RBI).  Other Process Safety systems may be affected by or involved with the IOW program, including management of change (MOC), process safety information (PSI), and training. It is not the intent of this document to provide a complete list of specific IOW’s or operating variables that might need IOW’s for the numerous types of hydrocarbon process units in the industry (though some generic examples are provided in the text and in Appendix A); but rather to provide the user with information and guidance on the work process for development and implementation of IOW’s to help strengthen the Mechanical Integrity (MI) program for each process unit. The scope of this RP covers:

  • Definitions of IOW’s and related terminology,
  • Creating and establishing IOW’s,
  • Data and information typically needed to establish IOW’s,
  • Descriptions of the various types of IOW’s needed for process units,
  • Risk ranking IOW’s,
  • Documenting and implementing IOW’s,
  • Monitoring and measuring process variables within established IOW’s
  • Communication of IOW exceedances,
  • Reviewing, changing and updating IOW’s,
  • Integrating IOW’s with other risk management practices,
  • Roles and responsibilities in the IOW work process, and
  • Knowledge transfer to affected personnel.

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API RP 585 Investigation of Pressure Equipment Integrity Incidents, First Edition

The purpose of this recommended practice (RP) is to provide owners/users with practices for developing, implementing, sustaining, and enhancing an investigation program for pressure equipment integrity (PEI) incidents. This RP describes characteristics of how an effective investigation could be structured so organizations can learn from PEI incidents. This RP is not intended to define or supplement criteria for compliance with regulatory requirements for which companies already have defined investigation processes in place. Rather, API RP 585 provides a specific focus on investigating PEI failures that are precursors to potential incidents that could have significant impact on safety, health, and environment.

Significant mechanical integrity incidents are rarely the result of one isolated issue; there are almost always less severe precursors to a major failure. These precursors are frequently called near misses when they are found. Additionally, this document highlights the value in recognizing these precursor occurrences and promotes investigating them to determine the immediate, contributing, and root causes. If these precursor occurrences are uncovered, investigated, and the contributing and root causes are resolved, then major catastrophic failures of pressure equipment could be minimized or prevented.

The investigation principles and concepts that are presented in this RP are specifically targeted for application to process pressure equipment in the refining and petrochemical industry but could be applied to other equipment at the discretion of the owner/user. The following examples are the types of equipment considered to be within the scope of this document.

  • Pressure vessels—all pressure-containing components.
  • Piping—pipe and piping components (valves, expansion joints, sight glasses).
  • Storage tanks—atmospheric, low pressure, and pressurized.
  • Rotating equipment—pump and compressor cases and associated pressure-containing piping and pressure vessels, excluding seals.
  • Boilers and heaters—pressurized components.
  • Heat exchangers—shells, heads, channels, and pressure-containing components and tube bundles.
  • Pressure-relief devices.
  • Structural systems—integral to supporting pressure-containing systems.
  • Cooling water towers.
  • Stacks and flares.

 

API 510 Pressure Vessel Inspection Code, Tenth Edition

The tenth edition of API 510 includes many changes and improved coverage of important issues governing inspection, repair and maintenance of pressure vessels in the petroleum and petrochemical industry.  Some of the more significant revisions include:

  • New section on Management of Change
  • New section on Integrity Operating Windows with reference to the new API RP 584
  • New section on Deferral of Inspection Due Dates
  • New section on Review and Deferral of Inspection Repair Recommendations
  • Several revisions to sections detailing responsibilities of various operating site personnel associated with pressure vessel mechanical integrity
  • New section on Inspection Organization Audits
  • New section on Vessels in Cyclic Service
  • Updates on inspection planning for pressure vessels
  • Updates to the section on CUI inspection with reference to the new API RP 583 on CUI/CUF
  • New section on Operator Surveillance of pressure vessels in service
  • New section on the Inspection of Shell and Tube Heat Exchangers
  • Additional guidance on selection and placement of CML’s, including when to use more or when fewer CML’s may be needed.
  • Several updates to the section on pressure testing of PV’s
  • Expanded coverage of the section on Inspection and Repair of Flange Joints
  • Changes to the section on RBI, including the need to be in compliance with API RP 580
  • Significant new guidance on inspection of PV’s in same service
  • Significant new guidance on evaluating the corrosion rate in corroded areas of PV’s
  • Revised guidance on temporary repairs, especially filet welded patches
  • Multiple new references to API STD 579-1/ASME FFS-1 for fitness-for-service analysis
  • Numerous additional references to other documents that are now considered indispensible for the application of API 510, including the sister document RP 572 on Inspection Practices for PV’s, RP 571 on Damage Mechanisms for PV’s and ASME PCC-2 on Repair and Testing of Pressure Equipment
  • Numerous new and revised definitions of terms associated with PV inspection and repair

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Interested in reading more about the topics covered above and dozens more? Click the button below to download a free copy of John Reynold's updated and revised 101 Essential Elements in a Pressure Equipment Integrity Management Program guide. Many new elements are being added each month; get the latest copy now!


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