12 Elements of a Highly Effective Piping Inspection Program

Introduction

Observations over the last 20 years in addressing integrity management issues related to both equipment and associated piping have revealed the following issues when addressing piping:

• Many owner-operators do not have a formal piping inspection program, or if one exists, its processes only meet minimum standards.
• Program technical requirements are not clearly defined or have changed over time.
• Required front-end tasks are not fully addressed.
• Assessment and implementation of work processes are not optimal.
• Sustainment programs are absent and lack long-term follow-through.

The objective of this article is to present a detailed process for developing a cost-effective piping inspection program, outlining its content and scope. The program presented consists of 12 elements addressed through a combination of recommended procedures and guidelines. The program elements presented are based on a combination of experience, a review of API 570, API RP 574, and concepts from API 580 and API RP 581.

Why a Piping Inspection Program is Needed

The observations listed in the introduction provide some reasons an effective piping inspection program is needed. Without planning, engineering, and management control, piping inspections, even if conducted in a timely and repeatable manner, can be ineffective. This can also lead to the misapplication of corrosion monitoring locations (CMLs), either through incorrect placement or excessive assignment of CMLs, which drives up inspection costs, as the cost of a single CML measurement can exceed $3,000. Another reason is that piping system failures are relatively common when compared to other assets, and they often result in high-consequence events. Furthermore, a growing number of regulatory bodies are mandating a certain level of formal piping programs.