Overview of Piping
In every processing facility, you have feedstock and product that need to get from point A to point B. Piping is the vehicle that moves these liquids and gasses through a refinery or chemical processing plant. They can be made of steel, cast iron, copper, plastic, or other materials depending on the environment and materials being transported. Segments of pipe are often joined together using either bolted flanges or by welding pipes together. The major difference between piping and pipelines is that pipelines transport materials long distances between separate facilities or for distribution. Piping on the other hand is made to transport gasses and fluids, such as water or chemicals, within a single facility.[1]
There are several standards and recommended practices that apply to piping systems, including but not limited to:
- API 570, Piping Inspection Code - Inspection, Repair, Alteration and Rerating of In-Service Piping Systems, which provides guidance on how to determine which piping systems are most susceptible to CUI.
- API RP 574, Inspection Practices for Piping System Components, which discusses inspection practices for piping, tubing, valves, and fittings.
- API RP 578 - Material Verification for New and Existing Alloy Piping, which provides guidelines for a material and quality assurance system to verify that the composition of the alloy components of a piping system are consistent with the specified construction materials.
- API RP 583, Corrosion Under Insulation and Fireproofing, which covers the design, maintenance, inspection, and mitigation practices to address external CUI as it applies to pressure vessels, piping, storage tanks, and spheres.
- ASME PCC-2 - Repair of Pressure Equipment and Piping, which provides methods for repairing equipment and piping within the scope of ASME Pressure Technology Codes and Standards after it has been placed into service.
- ASTM STP 880, Corrosion of Metals Under Thermal Insulation, which provides information on corrosion problems that can occur on thermally insulated plant equipment and piping components if the insulation becomes wet.
References
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Field hardness tests can provide valuable information when evaluating piping and pressure vessel anomalies. This article summarizes laboratory examinations designed to gain a better understanding of UCI hardness test results taken in the field.
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This article describes the construction of corrosion-resistant fiber reinforced polymer (FRP), commonly used for pressure vessels and piping in the chemical processing industry, and the practices used for inspecting corrosion-resistant barriers.
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The health of piping and piping supports is critical to processing facilities, however there are very few facilities where a documented inspection program exists for spring supports. This article outlines some issues surrounding spring supports
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Partner Content
InVista is a lightweight, hand-held ultrasonic in-line inspection tool (intelligent pig) capable of detecting pipeline wall loss and corrosion in unpiggable or difficult-to-inspect pipelines. The pipeline geometry inspection data captured by the...
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BlogOctober 17, 2019 By PinnacleART
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May/June 2019 Inspectioneering JournalBy Ryan Baggett at Pro-Surve Technical Services
While planning methods for thickness data acquisition in any Inspection Data Management Program, PRT should be considered as a cost-efficient, effective way to increase the value of your program for small bore piping or any other suitable situation.
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January/February 2019 Inspectioneering JournalBy Qasem Fandem at Saudi Aramco
Welding imperfections vary in impact from being acceptable to requiring repair. It is important to ensure the quality of welds using NDT and to ensure the strength of the entire piping system with hydrotesting.
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January/February 2019 Inspectioneering JournalBy Greg Garic at Stress Engineering Services, Inc.
The distinction between primary and secondary loads is certainly important in analysis of pressure systems. But this distinction is also important for plant operations and reliability engineers to keep in mind when dealing with day-to-day problems.
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May/June 2018 Inspectioneering JournalBy Chad Patschke, CPSA at Ethos Mechanical Integrity Solutions
According to API 570, facilities must have a mechanical integrity program in place for critical check valves. But what criteria determines whether or not a check valve is critical in your process? How should check valves be inspected and by whom?
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Developing a Fitness for Service Approach for Reduced Toughness Carbon Steel Piping, Flanges & FittingsMay/June 2018 Inspectioneering JournalBy Ralph E. King P.E. at Stress Engineering Services Inc., John Norris, P.E. at Stress Engineering Services, Dr. Kannan Subramanian, Ph. D., P.E. at Stress Engineering Services Inc., and Daniel Ayewah, P.E. at Stress Engineering Services Inc.
There is concern in the industry over recent findings of reduced toughness fittings and flanges at risk of brittle fracture. This article provides an overview; possible contributors; measures taken to address; and a proposed FFS approach to address...
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March/April 2018 Inspectioneering JournalBy Ibrahim Kodssi at Independent Consultant, and Houssam Sabry at ADNOC LNG
Implementing RBI for process piping can be a very tedious and lengthy exercise, especially for major process plants with thousands of feet of interconnected piping. This article shares the experience of ADNOC LNG following a structured RBI approach...
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January/February 2018 Inspectioneering JournalBy Neil Burns at Stress Engineering Services
The actions you take immediately after a failure are critical in understanding the cause and appropriate steps to remedy the problem. However, the wrong moves might prevent you from getting the answers you need.
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July/August 2017 Inspectioneering JournalBy Richard B. Eckert at DNV GL, and Dr. Kathy Buckingham at DNV GL
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May/June 2017 Inspectioneering JournalBy Ryan Myers at PinnacleART, and Brian Marino at PinnacleART
Effective condition monitoring location selection is a key component of a best-in-class mechanical integrity program. Learn how moving beyond traditional qualitative approaches to optimized CML selection can reduce risk and maximize the value of...
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March/April 2017 Inspectioneering JournalBy Vibha Zaman, P.E. at Asset Optimization Consultants, and Leomar Penuela at Asset Optimization Consultants
This article discusses the use of the RBI methodology supplemented by a well-designed IOW program to assess and manage aging in fixed equipment and piping in hydrogen generation units.
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January/February 2017 Inspectioneering JournalBy Israel D. Martinez at ORPIC
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November/December 2016 Inspectioneering JournalBy Adam Gardner at PinnacleART
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November/December 2016 Inspectioneering JournalBy Nolan L. Miller at SASOL North America
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My Pipes are Corroding! When Should I Repair? Getting the Answers You Need for Maintaining Pipeline IntegrityNovember/December 2016 Inspectioneering JournalBy Michael Turnquist at Quest Integrity Group
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July/August 2016 Inspectioneering JournalBy Mark Geisenhoff at Flint Hills Resources, Jonathan D. Dobis at The Equity Engineering Group, Inc., Phillip E. Prueter at The Equity Engineering Group, Inc., and Dr. Michael S. Cayard at Flint Hills Resources
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July/August 2016 Inspectioneering JournalBy Ralph E. King P.E. at Stress Engineering Services Inc., and Jacob Manuel, P.E. at Stress Engineering Services, Inc.
An overview of process piping vibration and evaluating piping systems in vibration service to reduce harmful vibrations.
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Online Article
Updated editions of both API 570 and API RP 580 were recently released by the American Petroleum Institute.
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Insights Into Fixed Equipment Vibration – How a Piping System Was Affected by Flow-Induced VibrationNovember/December 2015 Inspectioneering JournalBy Paolo Torrado at Engineering and Inspection Services, LLC., and Dr. Reza Azizian at Engineering & Inspection Services, LLC
Excessive vibration is a problem frequently encountered in industrial plants and their peripheral equipment, including piping systems, pressure vessels, and steel structures. Long term excessive vibration can lead to fatigue crack propagation and...
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September/October 2015 Inspectioneering JournalBy Harold Marburger at Dunn Heat Exchangers
This article is Part II of a three-part series that explores the various methods, benefits, challenges and solutions to efficiently and effectively clean heat exchangers, both onsite and offsite.
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In-Place Pipe Support Load Testing & Hanger Surveys – Part of a Best in Class Fitness-for-Service ProgramJuly/August 2015 Inspectioneering JournalBy Joe Frey, PE at Stress Engineering, Inc., Lange Kimball at Stress Engineering Services, and Britt Bettell at Stress Engineering Services
This article introduces portions of a “Best-In-Class” Fitness-for-Service (FFS) program that includes the performance of regular visual inspections of pipe supports and hangers, coupled with in-situ load testing of suspect supports. This...
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May/June 2015 Inspectioneering JournalBy David A. Hunter at Neptune Research, Inc.
In recent years, the growing use of composite repair systems for the rehabilitation of piping systems in the refining and chemical industries has increased the need for associated technologies for their manufacturing, installation, and inspection....
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January/February 2015 Inspectioneering JournalBy Pamela Hamblin at Thielsch Engineering, Inc.
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November/December 2014 Inspectioneering JournalBy Rajesh Bose at BP, and Terry M. Webb at BP
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BlogDecember 8, 2014 By Nick Schmoyer at Inspectioneering
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BlogJanuary 6, 2014 By Nick Schmoyer at Inspectioneering
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Small Bore Piping Inspection Programs: How a serious incident and investigation led to a best practiceNovember/December 2013 Inspectioneering JournalBy Anthony J. Rutkowski at A.J. Rutkowski, LLC, and Anthony M. Damron at The Equity Engineering Group, Inc.
Small bore piping is present in many variations throughout numerous industries. This article will address an incident involving a small bore piping failure that occurred on a 140,000 BPD crude distillation unit in the refining industry.
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September/October 2013 Inspectioneering JournalBy Matthew Green at Neptune Research, Inc.
Composite repair systems can be a great option for owner/ operators to extend the life of their assets without disrupting operations.
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September/October 2013 Inspectioneering JournalBy A.C. Gysbers at The Equity Engineering Group, Inc.
This article is the fifth of a series of articles that will focus on one critical sub process within a PEIP that is key in managing the integrity of process piping; Thickness Monitoring Programs for Internal Corrosion.
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July/August 2013 Inspectioneering JournalBy James R. Widrig at Quest Integrity
Inspection and fitness-for-service assessments of critical in-plant piping systems are a concern for the chemical industry. This presents a potentially insurmountable task and discovery of a number of areas where the condition is at risk.
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May/June 2013 Inspectioneering JournalBy A.C. Gysbers at The Equity Engineering Group, Inc.
Piping failures still represent a frustrating and ongoing problem for processing plants. Failures are still commonly reported and contribute to large losses. In the author’s experience, piping represents the highest percentage of fixed equipment...
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A Discussion on the Piping Thickness Management Process: Data Collection with Ultrasonics and RadiographyJanuary/February 2013 Inspectioneering JournalBy A.C. Gysbers at The Equity Engineering Group, Inc.
This article is the third of a series of articles that will focus on one critical sub process within a PEIP that is key in managing the integrity of process piping: thickness monitoring programs for internal corrosion. These articles will discuss...
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November/December 2012 Inspectioneering JournalBy A.C. Gysbers at The Equity Engineering Group, Inc.
Piping failures still represent a frustrating and ongoing problem for processing plants. Failures are still commonly reported and contribute to large losses. In the author’s experience, piping represents the highest percentage of fixed equipment...
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September/October 2012 Inspectioneering JournalBy Peter Carter, PhD, PE at Stress Engineering, Inc., Joe Frey, PE at Stress Engineering, Inc., and Mike Guillot, PhD, PE at Stress Engineering, Inc.
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September/October 2012 Inspectioneering JournalBy A.C. Gysbers at The Equity Engineering Group, Inc.
Piping failures still represent a frustrating and ongoing problem for processing plants (example in Figure 1). Failures are commonly reported and contribute to large losses. As well per the author’s experience, piping still represents the highest...
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September/October 2012 Inspectioneering JournalBy Richard D. Roberts at Quest Integrity Group
The refining industry has applied ultrasonic-based intelligent pigging to inspect serpentine coils in fired heaters since the 1990s. Today, thousands of serpentine coils in fired heaters are inspected annually at process facilities around the globe.
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May/June 2012 Inspectioneering JournalBy Clay Goudy at GE Industrial Solutions
A self-propelled in-line inspection tool tested at Electric Power Research Institute and utilized in Europe can traverse a complex piping configuration and discriminate areas of metal loss. This tool is becoming available to inspect traditionally...
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September/October 2011 Inspectioneering JournalBy Greg Alvarado at Inspectioneering Journal
Leaks or spills over the life of nuclear power plant operation can lead to undesirable consequences. The nuclear industry’s GroundwaterProtectionInitiativeandthelessonslearnedand experiences gained from implementing groundwater protection...
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July/August 2010 Inspectioneering JournalBy Craig Emslie BSc at Sonomatic Ltd., and Karen Gibson at Sonomatic Ltd.
Inspection intervals for equipment have in the past been defined in a prescriptive manner. However, industry is now embracing the Risk Based Inspection (RBI) approach which in contrast prioritises inspections based on an assessment of the risk to...
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January/February 2007 Inspectioneering Journal
NACE International has approved two highly anticipated standards dedicated to the control of internal pipeline corrosion.
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January/February 2006 Inspectioneering JournalBy John Reynolds at Intertek
After a pressure equipment or piping failure, it’s not uncommon to find out during the failure analysis part of the investigation that the failure initiated at a welding flaw of some sort.
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March/April 2005 Inspectioneering JournalBy Bob Stakenborghs, P.E. at Evisive Inc.
Once the microwave inspection method was determined to be capable of providing reliable and meaningful inspection results for defects located on the exterior, interior, and interior surfaces of non-metallic components, potential industry...
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September/October 2004 Inspectioneering JournalBy Julian Speck at TWI Ltd., and Peter Mudge at Pi Ltd.
The impetus for the development of LRUT is that ultrasonic thickness checks for corrosion, erosion, etc. are localised, in that they only measure the thickness of the area under the UT transducer.
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May/June 2003 Inspectioneering JournalBy John Reynolds at Intertek
Next year, the API Inspector Recertification Program (ICP) will be recertifying inspectors who have held their API certifications for more than 6 years. Things have changed this time though, and inspectors will be required to pass a short exam...
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March/April 2003 Inspectioneering JournalBy Dr. Nand K. Gupta at Omega International Technology, Inc.
During the past two years, a new High Resolution Gamma Ray Detector Array System to detect and measure small corrosion pits in real-time in the inservice piping in process industries, has been in development. This High Resolution Gamma Ray...
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July/August 2003 Inspectioneering JournalBy John Reynolds at Intertek
This failure mechanism is unfortunately all too common in our industry. It's also known as stress rupture, and it is usually entirely preventable by proper maintenance and operating procedures. It occurs when equipment, piping or furnace tubes...
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January/February 2001 Inspectioneering JournalBy Paul K. Davidson at WIS, Inc., David Silverling at Tubular Ultrasound, L.P., and Jason Hicks at Tubular Ultrasound, L.P.
This article describes a new inspection technology for rapid, on-stream,quantitative examinations of piping under support areas. This portable production system has been in commercial operation in the major U.S. Gulf Coast refineries for the past...
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January/February 2001 Inspectioneering JournalBy John Reynolds at Intertek
Part 5 of this article continues to outline the 101 essential elements that need to be in place, and functioning well, to effectively and efficiently, preserve and protect the reliability and integrity of pressure equipment (vessels, exchangers,...
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101 Essential Elements in a Pressure Equipment Integrity Management Program for the Hydrocarbon Process Industry Part 2July/August 2000 Inspectioneering JournalBy John Reynolds at Intertek
This paper outlines the 101 essential elements that need to be in place, and functioning well, to effectively and efficiently, preserve and protect the reliability and integrity of pressure equipment (vessels, exchangers, furnaces, boilers, piping,...
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May/June 1999 Inspectioneering JournalBy Paul K. Davidson at WIS, Inc.
EMATs (Electromagnetic Acoustic Transducers) have been used for over six years for field service inspection of in-service piping. Recent advances in technology have allowed us to inspect new types of on-stream piping.
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January/February 1999 Inspectioneering JournalBy Joseph E. Pascente at Lixi, Inc.
One of the greatest challenges facing many of refining, fossil power, and pulp and paper industries is: How to effectively examine their insulated piping?
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November/December 1998 Inspectioneering JournalBy Michael Twomey at CONAM Inspection Inc., and Jay N. Rothbart at Conam Inspection Inc.
We have been asked many times by existing and prospective users of PCMS (a computerized, inspection database management system), how many TMLs (Thickness Management Locations) should be installed per piping circuit. These inquiries must be addressed...
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September/October 1997 Inspectioneering JournalBy John Reynolds at Intertek
This is the fourth in a series of articles on piping inspection that I'm writing for the Journal. One of the previous ones dealt with improving thickness data taking accuracy with digital ultrasonic methods. This article is a "sister article" that...
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May/June 1997 Inspectioneering JournalBy John Reynolds at Intertek
In the Jan/Feb issue of the IJ, I mentioned how important the Management of Change (MOC) process is when it comes to maintaining safe, leak-free piping systems; stating that we in the inspection business cannot do it alone; that is, we taint the...
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March/April 1997 Inspectioneering JournalBy John Reynolds at Intertek
This is the second in a series of articles on piping inspection. In the last article, I enumerated four inspection issues that I believe contribute to inadequate piping mechanical integrity in the hydrocarbon process industry.
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January/February 1997 Inspectioneering JournalBy John Reynolds at Intertek
It's probably more important to those of us who don't have a brain tumor. Unfortunately, it's precisely because piping inspection is not neurosurgery that it's often done poorly, which can lead to significant impacts on process unit reliability, or...
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January/February 1997 Inspectioneering JournalBy Del Underwood at Det Norske Veritas
There are a number of terms to describe commonly experienced problem conditions with reciprocating compressors. One of the terms that I have always appreciated is the pendulum action of a large unsupported mass on the end of a vibrating pipe.
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May/June 1996 Inspectioneering JournalBy Del Underwood at Det Norske Veritas
This final issue on gusset problems will discuss why gussets are "stiffeners" rather than "strengtheners." The effective load bearing capacity of a member of given strength is based upon how large a cross-sectional area is carrying the load....
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January/February 1996 Inspectioneering JournalBy Del Underwood at Det Norske Veritas, and Tim Munsterman at Det Norske Veritas
Last issue, in keeping with the evaluation that "gussets are stiffeners, not strengtheners," we discussed welding around the ends of the gusset plate instead of just along the sides in order to reduce the stress concentration. A further improvement...
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September/October 1995 Inspectioneering JournalBy Del Underwood at Det Norske Veritas
A key to any piping evaluation program is to understand where problems can occur. Vibrating piping can propagate a crack relatively quickly. Have you ever installed gussets to stabilize a vibrating pipe situation only to find, shortly thereafter,...
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May/June 1995 Inspectioneering JournalBy Bob Browne at ERA Technology
For reason of economy, the hot reheat pipework in many US power plants is fabricated from seam-welded low chrome-moly carbon steel spools. Unlike girth butt welds, where the critical weldment microstructures can off-load stress to the stronger...
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Utilities' High Energy Piping Systems - Utility Industry's Application of Acoustic Emission Yields Measurable Improvement in Inspection Program Cost and Overall System IntegrityMarch/April 1995 Inspectioneering JournalBy Charles L. Foster at Pacific Gas & Electric
High energy piping (HEP) systems, main steam lines and hot reheat lines (typically low chrome molydbdenum steels), are susceptible to creep damage. Such damage can lead to leaks, and in extreme cases, catastrophic failure.
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Sponsored Video Published on June 26, 2019In this webinar, the presenters walk through a four step process to develop effective and efficient asset strategies for piping to optimize cost, refocus resources and reduce risk.
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Published on April 24, 2018The CSB has released an animation detailing the events leading up to the February 8, 2017 explosion at the Packaging Corporation of America's DeRidder, Louisiana, pulp and paper mill. The incident killed three contract workers and injured seven.
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Published on April 19, 2013The U.S. Chemical Safety Board releases an animation of the August, 2012 incident at Chevron's Richmond, CA refinery.
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NewsCSB, January 23, 2015
The U.S. Chemical Safety Board (CSB) will hold a public meeting on January 28, 2015, to present the third and final investigation report and safety recommendations from the August 6, 2012, crude unit fire that occurred at the Chevron Refinery in...
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NewsUS Chemical Safety Board, November 11, 2014
In its final Regulatory Report entitled "Regulatory Report: Chevron Richmond Refinery Pipe Rupture and Fire,” the U.S. Chemical Safety Board (CSB) proposes recommendations for substantial changes to the way refineries are regulated in...
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NewsUS Chemical Safety Board, April 10, 2014
A massive explosion and fire at the Silver Eagle Refinery on November 4, 2009, in Woods Cross, Utah, which damaged homes in a nearby neighborhood, was caused by a rupture in a pipe that had become dangerously thin from corrosion, the U.S. Chemical...
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Press ReleaseQuest Integrity, July 11, 2013
Quest Integrity Group introduces a new animation focused on the inspection and assessment of buried or inaccessible piping in nuclear facilities utilizing HYDRA™, an ultrasonic-based intelligent pigging technology.
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NewsFebruary 22, 2013
Chevron U.S.A. Inc. has reviewed Anamet, Inc.’s technical evaluation of the piping samples taken from the Chevron U.S.A. Richmond Refinery following the August 6, 2012 incident.
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