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TABLE OF CONTENTS

1.0 SCOPE

2.0 REFERENCE DOCUMENTS

3.0 INTRODUCTION

4.0 DEFINITIONS

5.0 PROCEDURE
5.1 Standard Format for Thickness Monitoring Plans
5.2 Thickness Monitoring Inspection Intervals
5.3 Determination of TMLs for Piping
Table 5.3.1 Thickness Monitoring for Uniform Corrosion
Table 5.3.2 Thickness Monitoring for Localized Corrosion

6.0 DOCUMENTATION

ATTACHMENTS
Attachment 3.2.1: Typical Piping Standard For Tml Test Point Locations
Attachment 3.2.2: Uniform Corrosive Service – Standard Inspection Level
Attachment 3.2.3: Uniform Corrosive Service - Medium And High Inspection Levels Localized
Corrosive Service - Standard Inspection Level
Attachment 3.2.4 A: Localized Corrosive Service – Medium And High Inspection Levels TML/Test
Points -- ELL
Attachment 3.2.4 B: Localized Corrosive Service – Medium And High Inspection Levels Tml/Test
Points -- Tee 1
Attachment 3.2.4 C: Localized Corrosive Service – Medium And High Inspection Levels Tml/Test
Points -- Tee 2
Attachment 3.2.4 D: Localized Corrosive Service – Medium And High Inspection Levels Tml/Test
Points -- Tee 3
Attachment 3.2.4 E: Localized Corrosive Service

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1.0 SCOPE
This procedure provides the requirements for a piping thickness monitoring program. It establishes the
minimum number and location of initial thickness measurement locations (TMLs) for piping which has not
been exempted from corrosion rate monitoring, thickness verification, or remaining life determination based
on metal loss. This procedure does not include requirements for stagnant zones, dead legs, injection/mix
points, corrosion under insulation or corrosion at small pipe connections (vents and drains).

2.0 REFERENCE DOCUMENTS

GIP 3.1 Thickness Monitoring General Requirements

API 570 American Petroleum Institute, Piping Inspection Code

ExxonMobil Maintenance Practices Piping Equipment Strategy Development (PESD)

Manual (TMEE 062): 4-44-1 RP

ExxonMobil Maintenance Practices Equipment Degradation Documents (EDD)

Manual (TMEE 062): Section 7

ExxonMobil Chemicals Construction Materials Manual

ExxonMobil Refining Construction Materials Manual

ExxonMobil Piping Maintenance Guide (TMEE010)

3.0 INTRODUCTION

Thickness measurements must be obtained on piping systems in order To establish corrosion rates for
inspection interval and determine retirement. Determining the appropriate quantity and locations for the
thickness measurements can be problematic.

This document has been developed to help identify the optimal selection of thickness measurement
locations (TMLs) on piping. TMLs are used for monitoring degradation modes associated with metal loss.

Proper selection and location of TMLs is crucial to mitigating the risk caused by degradation modes
associated with metal loss.

4.0 DEFINITIONS

Piping Inspection Drawing Line sketches of a piping circuit that shows all fittings, reducers,
flanges, valves, small piping connections and supports. Additional
information may include process streams, temperatures, and materials
of construction.

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Typically drawings are three (3) dimensional (isometric) but can be a

two (2) dimensional plan.

Piping Circuit A group of piping components exposed to similar corrosive

environments and operating conditions, that also has a similar design.

Complex process units or piping systems are divided into piping

circuits to manage the necessary inspections, calculations, and record
keeping.

Soil-To-Air Interface An area in which external corrosion may occur on partially buried pipe.
(See API 570)

Straight Run of Pipe Straight section of pipe between two fittings (elbows, tees, valves, etc.)
that is at least 10 feet long or 20 times the diameter, whichever is less.

Test Points Area(s) at a TML typically defined by a circle having a diameter not
greater than 2 inches for a line diameter not exceeding 10 inches, or
not greater than 3 inches for larger lines.

Thickness readings should be averaged within the area. A test point

shall be within a thickness measurement location.

Thickness Measurement Designated areas on piping, where periodic thickness measurements

Locations (TMLs) are conducted at test points.

Thickness Reading A specific measurement taken within a test point.

Turbulent Point Any section of piping where turbulence is enhanced. This may occur at
or downstream of an orifice, reducer, tee, control valve, or pump
discharge.

Additional areas include the outlets of tanks, pressure vessels, or

exchangers.

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5.0 PROCEDURE

5.1 Standard Format for Thickness Monitoring Plans

Each site shall have a piping thickness monitoring plan documented in the Unit Inspection Plan that
may be stored in hard copy or electronically. The plan should contain the following elements:
§ Flow diagram of pipe circuit
§ Pipe line identification classification
§ API line classification and/or corrosion classification (Uniform, Localized)
§ Inspection drawings showing TMLs and test points, dead legs, stagnant zones, injection
points, and mix points
§ Log listing the thickness measured at each test point during thickness monitoring
inspection, the date of the inspection, and name of the inspector
§ Documentation on lines exempt from thickness monitoring
§ Schedule for thickness monitoring inspections

5.2 Thickness Monitoring Inspection Intervals

Piping thickness monitoring inspection intervals shall be established using the risk-based approach
described in the Piping Equipment Strategy (TMEE 062 Sec 4-44-1) Document or in accordance
with piping inspection codes recognized by local jurisdiction (e.g. API 570 Piping Inspection Code).

5.3 Determination of TMLs for Piping

5.3.1 Each piping circuit shall be categorized into one of two general classifications based on the
extent of corrosion.

5.3.1.1 Uniform corrosive service (regardless of corrosion rates) as described in EDDs 7,

11, 32, 34 and 44 such as:
§ Low temperature hydrocarbon (<500° F/260° C)
§ High temperature sulfidizing environments
§ Elevated temperature H2/H2S

5.3.1.2 Localized corrosive services as described in EDDs 7, 12, 15, 16, 21, 35, 45, 46, 47,
48, 49 & 50. Some examples include:
§ Acid gas lines where local heat sinks such as piping supports or
vents/drains may cause some condensation,
§ Rich Amine systems where pressure drop at control valve stations may
cause acid gas break out,
§ Fuel Gas lines ahead of knock out pots where water may drop out and
cause problems at low points.

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§ H2SO4 alkylation piping at high velocity or turbulent areas

§ Dew point conditions resulting in mixed phase hydrocarbon/sour water
§ Hot rich (from lean-rich exchangers to regenerator) or hot lean (from
regenerator to lean-rich exchangers) MEA
§ Naphthenic acid corrosion
5.3.2 Determine the Number of Thickness Measurement Locations
5.3.2.1 Uniform corrosive service
§ TMLs shall be located per Table 5.3.1
§ The inspection level will be determined through the application of the
Piping Equipment Strategy Development (PESD) Process.
§ If API 570 is used instead of the PESD, the Standard Inspection Level shall
be used.

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Table 5.3.1
Thickness Monitoring for Uniform Corrosion

Inspection
Description
Level
§ TML's located on 50% of components including a representative number of
fittings and straight runs.
§ A minimum of 4 test points in a band around the pipe (or UT scanning non-
High insulated pipe) or radiography at each TML in two planes. (Att. 3.2.3)
§ Corrosion rate should be estimated using a statistical approach.

§ TML's located on 10% of components including a representative number of

fittings and straight runs.
§ A minimum of 4 test points in a band around the pipe or one radiograph at each
Medium TML in 2 planes. (Att. 3.2.3)
§ Corrosion rate should be estimated using a statistical approach.

§ TML's located on 10% of components including a representative number of

fittings and straight runs.
Standard
§ A minimum of 1 test point or one radiograph at each TML. (Att. 3.2.2)

5.3.2.2 Localized corrosion services

§ TMLs shall be located per Table 5.3.2.
§ The inspection level will be determined through the application of the
Piping Equipment Strategy Development (PESD) Process.
§ If API 570 is utilized instead of the PESD, the Medium Inspection Level
shall be used.

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Table 5.3.2
Thickness Monitoring for Localized Corrosion
Inspection Description
Level
• TMLs located on 50% of components including a representative number of fittings and
straight runs
• PLUS - TMLs located at 100% of any additional areas suspected of experiencing
accelerated corrosion. For example, locations where flow is disrupted, or where
condensation could occur.
• For the TMLs, test points should be taken per Attachments 3.2.4A-E or, in lieu of test
points, one radiograph in each of two planes should be taken at each TML. The
readings or radiographs should be directed at the expected areas of corrosion (i.e. the
High extrados of and elbow for erosion-related corrosion, or the bottom of a pipe for under-
deposit corrosion.
• Until the presence or absence of localized corrosion has been confirmed and located,
automated scanning UT or close-grid UT measurements also should be considered as
an inspection method.
• Corrosion rate and remaining life should be calculated using an advanced statistical
(1)
approach after the areas of accelerated corrosion have been located

• TMLs located on 10% of components including a representative number of fittings and

straight runs
• PLUS - TMLs located at 50% of any additional areas suspected of experiencing
accelerated corrosion For example locations where flow is disrupted, or where
condensation could occur.
• For the TMLs, test points should be taken per Attachments 3.2.4A-E or, in lieu of test
points, one radiograph in each of two planes should be taken at each TML. The
Medium readings or radiographs should be directed at the expected areas of corrosion (i.e. the
extrados of an elbow for erosion-related corrosion, or the bottom of a pipe for under-
deposit corrosion.
• Until the presence or absence of localized corrosion has been confirmed and located,
scanning UT, scrubbing UT or close-grid UT measurements also should be considered
as an inspection method.
• Corrosion rate and remaining life should be calculated using a more sophisticated
(2)
approach than that used for the standard level of inspection after the areas of
accelerated corrosion have been located.
• TMLs located on 10 % of components including a representative number of fittings
and straight runs
• PLUS - TMLs located at 10% of any additional areas suspected of experiencing
accelerated corrosion, for example, locations where flow is disrupted, or where
Standard condensation could occur.
• For the TMLs, test points should be taken per Attachment 3.2.3 or, in lieu of test
points, one radiograph may be taken at the TML. The readings or radiographs should
be directed at the expected areas of corrosion (i.e. the extrados of an elbow for
erosion-related corrosion, or the bottom of a pipe for under-deposit corrosion).
• Corrosion rate and remaining life can be calculated using point to point analysis after
the areas of accelerated corrosion have been located.
(1)
Extreme Value Analysis (EVA) type approach or that approved by EMRE or CORE
(2)
For example: linear regression analysis on point to point
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5.3.2.3 Every effort should be made to understand the nature and the critical areas of
corrosion for localized corrosive services. TMLs should be planned accordingly -
both to find the critical areas, if possible, and to monitor their status. This might
include additional test points around the circumference of the pipe, more frequent
TMLs along the length, a TML grid in various or suspect locations, additional TMLs
in potential areas (e.g. only along the bottom or at the liquid/vapor interface), or
other areas, and might include alternate NDE methods.
5.3.2.4 When a large amount of data is needed to evaluate piping subjected to localized
corrosive services and to manage the costs and time associated with this extent of
inspection, it may be appropriate to consider the following:
§ Use of UT scanning to evaluate the entire area followed by grid mapping of
only the thin locations.
§ Use of radiography to complement or at times replace UT
§ Use of external MFL/EMAT.
5.3.2.5 Once a corrosion pattern has been established, and the minimum thickness area
identified for future monitoring, the requirement for TML grids or area inspection by
RT or UT scanning may be adjusted to focus on that specific area.
5.3.2.6 It is expected that this approach will apply to most localized corrosive services.
However, it should be emphasized that there may be some unique circumstances
in which the corrosion is so highly localized (e.g. pitting corrosion) that the
corrosion rate can not be predicted with confidence. In such cases, use of this
procedure may not be appropriate. Some examples may include:
§ Acid services where velocities exceed recommended limits for the material
§ Lines containing naphthenic acid exceeding recommended TAN/TRS and
velocity limits
§ Lines with two-phase flow where turbulence effects can produce extremely
high local corrosion rates.
It should be noted that localized corrosion does not mean pitting. Pitting should be
considered unpredictable unless special evaluation/analysis proves differently.
5.3.3 Locating TMLs
5.3.3.1 The location of TMLs shall consider the potential for localized corrosion and service
specific corrosion as well as actual corrosion history. To minimize costs, ease of
access should be considered in the location of TMLs but only if it does not
compromise the quality of the thickness data and the ability to properly monitor the
progress of the identified degradation. Other considerations include:
§ Locations representative of the typical line sizes and conditions found in
the circuit.
§ Locations where the direction of fluid flow is changed, e.g., at or
immediately downstream (two times the pipe diameter) of an elbow
§ Locations before and after a change in line size
§ Dead legs and stagnant zones
§ The heat-affected zones of welds, especially dissimilar materials
§ Mix points and injection points

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§ Areas where condensation can form or solids can settle out (i.e., dead legs
or process stagnant zones)
§ Turbulent locations such as thermocouples, small connections, nozzle
intersections, orifice flanges, control valves, tees, pump or compressor
discharges, and outlets of pressure vessels
§ Accessibility to inspection
§ Locations on the downstream side of the direction of flow.
§ Older components in the circuit.
5.3.3.2 Attachment 3.2.1shows a typical standard for TML test point orientation on piping
components. Each site will have a standard orientation defined in the Site Quality
Assurance Manual or equivalent, and TMLs and test points shall be assigned
accordingly.
5.3.3.3 Attachments 3.2.2, 3.2.3 and 3.2.4 A to E provide guidance on location of TMLs
for fittings and tees for the two corrosion categories.
5.3.4 Data Quality and Evaluation
Thickness data must be reviewed for questionable readings and to confirm that the
thickness readings are appropriate. GIP 3.1, General Requirements for Thickness
Monitoring, should be followed to insure the quality of the data and consequent evaluation.

6.0 DOCUMENTATION
TMLs and test points shall be permanently documented on an appropriate drawing or sketch by TML/TP
point number. It is preferred for actual thickness data to be maintained electronically in a central inspection
database such as IDMS, MERIT or WTM. If electronic storage is not available, the hardcopies of the
thickness report shall be retained for the life of the equipment. In cases where UT scanning of the area or
RT is substituted for UT point readings the results should be documented and retained for corrosion rate
and remaining life calculations. See GIP 3.1 for specific guidelines on data/documentation requirements.

REVISION MEMO

DATE REV. # CHANGES MADE

7/04 0 Initial Release

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Attachment 3.2.1:
Typical Piping Standard For Tml Test Point Locations

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Attachment 3.2.2:
Uniform Corrosive Service –
Standard Inspection Level

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Attachment 3.2.3:
Uniform Corrosive Service - Medium And High Inspection Levels
Localized Corrosive Service - Standard Inspection Level

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Attachment 3.2.4 A:
Localized Corrosive Service –
Medium And High Inspection Levels TML/Test Points – ELL

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Attachment 3.2.4 B:
Localized Corrosive Service –
Medium And High Inspection Levels Tml/Test Points -- Tee 1
Applicable for all pipe to pipe Tee configurations

NOTE: FOR BRANCH CONNECTIONS MADE WITHOUT TEES, LOCATE BAND "C" ONE PIPE DIAMETER
FROM CENTERLINE OF BRANCH. LOCATE BAND "D" ONE HALF PIPE DIAMETER FROM "C". LOCATE
BAND "A" ONE PIPE DIAMETER FROM CENTERLINE OF PIPE. LOCATE BAND "B" ONE BRANCH
DIAMETER FROM "A".

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Attachment 3.2.4 C:
Localized Corrosive Service –
Medium And High Inspection Levels Tml/Test Points -- Tee 2
Applicable for all pipe to pipe Tee configurations

NOTE: FOR BRANCH CONNECTIONS MADE WITHOUT TEES, LOCATE BANDS EQUIDISTANT, ONE HALF
PIPE DIAMETER APART.

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Attachment 3.2.4 D:
Localized Corrosive Service –
Medium And High Inspection Levels Tml/Test Points -- Tee 3
Applicable for all pipe to pipe Tee configurations

NOTE: FOR BRANCH CONNECTIONS MADE WITHOUT TEES, LOCATE BANDS EQUIDISTANT, ONE HALF
PIPE DIAMETER APART.

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Attachment 3.2.4E:
Localized Corrosive Service
Medium And High Inspection Levels Tml/Test Points -- Tee 4
Applicable for all pipe to pipe Tee configurations

NOTE: FOR BRANCH CONNECTIONS MADE WITHOUT TEES, LOCATE BAND "B" ONE PIPE DIAMETER
FROM CENTERLINE OF PIPE. LOCATE BAND "C" ONE BRANCH DIAMETER FROM "B".

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