Inspection, Repair, Alteration, and Rerating of In-Service

Piping Systems

API 570
ENG. HESHAM ISMAIL
API 570 03

 Piping Inspection Code: In-service Inspection,

Rating, Repair, and Alteration of Piping Systems

ENG. HESHAM SEDDIK

 04
 Coverage :
 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
 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

ENG. HESHAM SEDDIK

Included Fluid Services 05
 API 570 applies to piping systems for process fluids,
hydrocarbons, and similar flammable or toxic fluid services,
such as the following:
 raw, intermediate, and finished petroleum and chemical
products;
 catalyst lines;
 hydrogen, natural gas, fuel gas, and flare systems;
 sour water and hazardous waste streams;
 hazardous fluid services;
 cryogenic fluids such as: liquid N2, H2, O2, and air;
 high-pressure gases greater than 150 psig such as:
gaseous He, H2, O2, and N2 ENG. HESHAM SEDDIK
Fitness-For-Service (FFS) and Risk-
Based Inspection (RBI) 06

 evaluating in-service damage of pressure

containing piping components.
 This inspection Code also recognizes RBI concepts
for determining inspection intervals or due dates
and strategies.

ENG. HESHAM SEDDIK

3- Terms, Definitions, 07
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.
The following are not considered alterations: comparable or duplicate replacements and
replacements in kind.
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/user of piping
systems that are used only by the owner/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/user.
ENG. HESHAM SEDDIK
Terms, Definitions, 08
Construction code
 The code or standard to which the piping system
was originally built (e.g. ASME B31.3).
Corrosion allowance
 Material thickness in excess of the minimum
required thickness to allow for metal loss (e.g.
corrosion or erosion) during the service life of the
piping component.

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4
Owner/User Inspection
Organization

ENG. HESHAM SEDDIK

Responsibilities 10
An owner/user organization
is responsible for developing, documenting, implementing, executing, and assessing piping
inspection systems and inspection procedures .
Piping Engineer
The piping engineer is responsible to the owner/user for activities involving design,
engineering review, rating, analysis,
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.
Authorized Piping Inspector
the designated authorized piping inspector shall be responsible to the owner/user for
determining that the requirements of API 570 on inspection, examination, quality assurance
and testing are met. ENG. HESHAM SEDDIK
Responsibilities 11
Examiners
The examiner's employer shall maintain certification records of the
examiners employed, including dates and results of personnel
qualifications. These records shall be available to the inspector.
Other Personnel
Operating, maintenance, engineering (process and mechanical) or
other personnel who have special knowledge or expertise related to
particular piping systems shall be responsible for timely notification to
the inspector and/or engineer

ENG. HESHAM SEDDIK

 12

5
Inspection, Examination, and
Pressure Testing Practices

ENG. HESHAM SEDDIK

Minimum Contents of an Inspection Plan 14
 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.
The plan should:
a) define the type(s) of inspection needed, (e.g. internal, external, on-stream ,nonintrusive);
b) identify the next inspection date for each inspection type;
c) describe the inspection methods and NDE techniques;
d) describe the extent and locations of inspection and NDE at CMLs;
e) describe the surface cleaning requirements needed for inspection and examinations for each
type of inspection;
f) describe the requirements of any needed pressure test (e.g. type of test, test pressure, test
temperature, and duration);
g) describe any required repairs if known or previously planned before the upcoming inspection.
h) describe the types of damage anticipated or experienced in the piping systems;
i) define the location of the expected damage;
j) define any special access and preparation needed. ENG. HESHAM SEDDIK
RBI 15
Probability Assessment
 shall be based on all forms of damage that could
reasonably be expected to affect equipment in any
particular service.
 effectiveness of the inspection practices, tools, and
techniques used for finding the potential damage
mechanisms
Consequence Assessment
 the potential l 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.) ENG. HESHAM SEDDIK
Areas Of Deterioration For Piping
Systems 18
 Each owner/user shall provide specific attention to the need for inspection of piping systems
that are susceptible to the following specific types and areas of deterioration:
a) injection points and mixing points,
b) deadlegs,
c) CUI including ECSCC inspection,
d) Soil-to-air interfaces and soil corrosion of buried piping,
e) service specific and localized corrosion,
f) erosion and corrosion/erosion,
g) environmental cracking,
h) corrosion beneath linings and deposits,
i) fatigue cracking,
j) creep cracking,
k) freeze damage,
l) contact point corrosion. ENG. HESHAM SEDDIK
 19

NOTE:
Brittle fracture is not normally mitigated by inspection but the
owner/users should be aware of the potential for brittle fracture for
some materials of construction

ENG. HESHAM SEDDIK

General Types Of Inspection And Surveillance 20
a) internal visual inspection,
b) on-stream inspection,
c) thickness measurement inspection,
d) various NDE examinations,
 guided wave examination
e) external visual inspection,
f) vibrating piping inspection,
g) supplemental inspection.
 radiography and/or thermography to check for fouling or internal
plugging ENG. HESHAM SEDDIK
 External inspection

External inspections are also intended to find conditions that compromise the
integrity of the
• coating
• insulation covering,
• the supporting structures
• misalignment, vibration, and leakage.
• attachments ( pipe supports, shoes, hangers, instrument, and small
branch connections).
• External piping inspections may include CUI inspections
 CML Monitoring

• The minimum measured thickness at a CML can be located by ultrasonic scanning or

profile radiography. Electromagnetic techniques also can be used to identify thin areas that
may then be measured by UT or radiography
• When accomplished with UT, scanning consists of taking several thickness measurements
at the CML searching for localized thinning. The thinnest reading or an average of several
measurement readings taken within the area of a examination point shall be recorded and
used to calculate corrosion rates, remaining life, and the next inspection date
• thickness measurements should include measurements at each of the four quadrants on pipe
and fittings, with special attention to the inside and outside radius of elbows and tees where
corrosion/erosion could increase corrosion rates.
Other NDE Techniques For Piping Systems 21
a) Magnetic particle examination for cracks and other linear discontinuities that extend to the surface of the material
in ferromagnetic materials
b) Liquid penetrant examination for disclosing cracks, porosity, or pin holes that extend to the surface of the material
and for outlining other surface imperfections, especially in nonmagnetic materials.
c) RT for detecting internal imperfections such as porosity, weld slag inclusions, cracks, and thickness of
components.
d) Ultrasonic flaw detection for detecting internal and surface breaking cracks and other elongated discontinuities
e) Alternating current flux leakage examination technique for detecting surface-breaking cracks and elongated
discontinuities.
f) Eddy current examination for detecting localized metal loss, cracks, and elongated discontinuities
g) Field metallographic replication for identifying metallurgical changes.
h) Acoustic emission examination for detecting structurally significant defects
i)Thermography for determining temperature of components, blockages
j)Leak testing for detecting through-thickness defects
K)Guided wave examination for the detection of metal loss ENG. HESHAM SEDDIK
Mixing Point Inspection 22

 Mixing points are locations in piping systems where two or more

different streams meet
 Allpotentially problematic (subject to corrosion or cracking) mixing
points should be identified and reviewed to determine if these areas
have an increased rate of degradation

ENG. HESHAM SEDDIK

Injection Point Inspection 23
 the recommended upstream
limit of the injection point circuit
is a minimum of 12 in. (300
mm) or three pipe diameters
upstream of the injection point,
whichever is greater.
 The recommended
downstream limit of the injection
point circuit is the second
change in flow direction past
the injection point, or 25 ft (7.6
m) beyond the first change in
flow direction, whichever is less
Setting Inspection Intervals Without The Use
Of Rbi 24

ENG. HESHAM SEDDIK

Piping Service Classes 25
 Class 1
 Services with the highest potential of resulting in an immediate emergency
 Flammable services that can auto-refrigerate and lead to brittle fracture
 Hydrogen sulfide (greater than 3 % weight) in a gaseous stream.
 Flammable services operating above their auto-ignition temperature.
 Class 2
 on-site hydrocarbons that will slowly vaporize during release such as those
operating below the boiling point but above the flash point,
 on-site hydrogen, fuel gas, and natural gas,
 on-site strong acids and caustics.
ENG. HESHAM SEDDIK
Piping Service Classes 26
 Class 3
 Services that are either flammable but do not significantly vaporize when they leak
 tank farm piping;
 Class 4
 Services that are essentially nonflammable and nontoxic
 steam and steam condensate;
 air;
 nitrogen;
 water, including boiler feed water or stripped sour water;

ENG. HESHAM SEDDIK

SBP 27

 SBP that is secondary process piping has different

minimum requirements depending upon service
classification. Class 1 and 2 secondary SBP shall be
inspected to the same requirements as primary
process piping.
 Inspection of Class 3 and Class 4 secondary SBP is
optional at the owner-users discretion depending
upon reliability and risk

ENG. HESHAM SEDDIK

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7
Inspection Data Evaluation, Analysis, And
Recording

ENG. HESHAM SEDDIK

Corrosion Rate Determination 29

ENG. HESHAM SEDDIK

Remaining Life Calculations 30

ENG. HESHAM SEDDIK

Newly Installed Piping Systems Or
Changes In Service 31
 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 probable rate of corrosion
from which the remaining wall thickness at the time of the next inspection can be estimated.
 a) A corrosion rate for a piping circuit may be calculated from data collected by the owner/user
on piping systems of similar material in comparable service and comparable operating
conditions.
 b) If data for the same or similar service are not available, a corrosion rate for a piping circuit
may be estimated from the owner/user's experience or from published data on piping systems
in comparable service.
 c) If the probable corrosion rate cannot be determined by either method listed in 7.3a) or 7.3b),
the initial thickness measurement determinations shall be made after no more than three
months of service by using nondestructive thickness measurements of the piping system.
Corrosion monitoring devices, such as corrosion coupons or corrosion probes, may be useful in
establishing the timing of these thickness measurements. Subsequent measurements shall be
made after appropriate intervals until the corrosion rate is established. ENG. HESHAM SEDDIK
 32

8
Repairs, Alterations, and Rerating of Piping
Systems

ENG. HESHAM SEDDIK

Temporary Repairs 33

ENG. HESHAM SEDDIK

Permanent Repairs 34
 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:
a) full-penetration groove welds are provided;
b) for Class 1 and Class 2 piping systems, the welds shall be
100 % radiographed or ultrasonically tested using NDE
procedures that are approved by the inspector;
c) patches may be any shape but shall have rounded corners [1
in. (25 mm) minimum radius]. ENG. HESHAM SEDDIK
 35

Inspection Practices for Piping

System Components
Downstream Segment

API RECOMMENDED PRACTICE 574

ENG. HESHAM SEDDIK

Scope 36

 Thisrecommended practice (RP) supplements

API 570 by providing piping inspectors with
information that can improve skill and increase
basic knowledge and practices

ENG. HESHAM SEDDIK

Terms, Definitions 37

small-bore piping SBP

Pipe or pipe components that are less than or
equal to NPS 2.

ENG. HESHAM SEDDIK

Allowable Tolerances In Pipe Diameter 38

 The actual thickness of seamless piping can vary from its nominal
thickness by a manufacturing tolerance of as much as 12.5 %.
 The under tolerance for welded piping is 0.01 in. (0.25 mm). Cast
piping has a thickness tolerance of +1/16 in. (1.6 mm) and –0 in.
(0 mm)
 Castiron piping is generally used for nonhazardous service, such
as water; it is generally not recommended for pressurized
hydrocarbon service.
ENG. HESHAM SEDDIK
Allowable Tolerances In Pipe
Diameter 39

ENG. HESHAM SEDDIK

 40

ENG. HESHAM SEDDIK

Tubing 41
 With the exception of heater, boiler, and exchanger tubes, tubing
is similar to piping, but is manufactured in many Ods and wall
thicknesses. Tubing is generally seamless, but can be welded.
Its stated size is the actual OD rather than NPS.
 [ASTM B88 tubing, which is often used for steam tracing, is an
exception in that its size designation is 1/8 in. (3.2 mm) less than
the actual OD.]
 Tubingis usually made in small diameters and is mainly used for
heat exchangers, instrument piping, lubricating oil services,
steam tracing, and similar services.
ENG. HESHAM SEDDIK
Reasons For Inspection 42

 The primary purposes of inspection are to identify active

deterioration mechanisms and to specify repair, replacement, or
future inspections for affected piping. These purposes require
developing information about the physical condition of the piping,
the causes of any deterioration, and the rate of deterioration. By
developing a database of inspection history,
 Theseactions should result in increased operating safety,
reduced maintenance costs,

ENG. HESHAM SEDDIK

Piping Circuits 43
 A number of factors can affect the rate and nature of pipe wall corrosion. They
include, but are not limited to, the following items:
a) piping metallurgy;
b) process fluid and its phase (e.g. gas, liquid, two phase, solid);
c) flow velocity;
d) temperature;
e) pressure;
f) changes in temperature, velocity, pressure, direction, phase, metallurgy, or pipe cross section;
g) injection of water or chemicals;
h) process fluid contaminants;
i) mixing of two or more streams;
j) piping external conditions, including coating/painting, insulation, and soil conditions, as
applicable;
k) stagnant flow areas (e.g. dead-legs). ENG. HESHAM SEDDIK
 59

ARTICLE 9
VISUAL EXAMINATION
T-910

ENG. HESHAM SEDDIK

WRITTEN PROCEDURE REQUIREMENTS 60
 Requirements: Visual examinations shall be performed in
accordance with a written procedure.
 Procedure Qualification: When procedure qualification is
specified by the referencing Code Section, a change of a
requirement in Table T-921 identified as an essential
variable.
 EQUIPMENT : Equipment used for visual examination
techniques, for example, direct, remote,
 DIRECT VISUAL EXAMINATION: Direct visual
examination may usually be made when access is
sufficient to place the eye within 24 in. (600 mm) of the
surface to be examined and at an angle not less than 30
deg to the surface to be examined
ENG. HESHAM SEDDIK
 61

ENG. HESHAM SEDDIK

REPORT OF EXAMINATION 62
 A written report of the examination shall contain the following
information:
(a) the date of the examination
(b) procedure identification and revision used
(c) technique used
(d) results of the examination
(e) examination personnel identity, and, when required by the referencing
Code Section, qualification level
(f) identification of the part or component examined
ENG. HESHAM SEDDIK
 71

ENG. HESHAM SEDDIK

 Fluid Service: 72
(a) Category D 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)
(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
ENG. HESHAM SEDDIK
Hydrostatic Leak Test 81
 the hydrostatic test pressure at any point in a metallic piping system shall be as
follows:
(a) not less than 1.5 times the design pressure.
(b) when the design temperature is greater than the test temperature, the minimum test
pressure, at the point the maximum calculated value of PT is the minimum test gage
pressure.

ENG. HESHAM SEDDIK

 75

ENG. HESHAM SEDDIK

 76

ENG. HESHAM SEDDIK

Hydrostatic Test Of Piping With Vessels
As A System 82
(a) Where the test pressure of piping attached to a vessel is the same as or less than
the test pressure for the vessel, the piping may be tested with the vessel at the
piping test pressure.

(b) Where the test pressure of the piping exceeds the vessel test pressure, and it is
not considered practicable to isolate the piping from the vessel, the piping and the
vessel may be tested together at the vessel test pressure, provided the owner
approves and the vessel test pressure is not less than 77% of the piping test pressure
calculated ENG. HESHAM SEDDIK
Pneumatic Leak Test 83
 Precautions.
Pneumatic testing involves the hazard of released energy stored in compressed
gas. Particular care must therefore be taken to minimize the chance of brittle failure
during a pneumatic leak test.
 Pressure Relief Device.
A pressure relief device shall be provided, having a set pressure not higher than
the test pressure plus the lesser of 345 kPa (50 psi) or 10% of the test pressure.
 Test Fluid.
The gas used as test fluid, if not air, shall be nonflammable and nontoxic.
 Test Pressure.
The test pressure shall be 110% of design pressure.
ENG. HESHAM SEDDIK
Procedure 84

The pressure shall be gradually increased until a gage pressure which is

the lesser of one-half the test pressure or 170 kPa (25 psi) is attained, at
which time a preliminary check shall be made, including examination of
joints in accordance with para. 341.4.1(a). Thereafter, the pressure shall
be gradually increased in steps until the test pressure is reached, holding
the pressure at each step long enough to equalize piping strains. The
pressure shall then be reduced to the design pressure before examining
for leakage in accordance with para. 345.2.2(a).
ENG. HESHAM SEDDIK
Alternative Leak Test 85
 which have not been subjected to hydrostatic or pneumatic leak tests
in accordance with this Code, shall be examined as follows:
(a) Circumferential, longitudinal, and spiral groove welds shall be 100%
radiographed in accordance with para. 344.5 or 100% ultrasonically
examined in accordance with para. 344.6.
 (b) All
welds, including structural attachment welds, not covered in (a)
above, shall be examined using the liquid penetrant method (para.
344.4) or, for magnetic materials, the magnetic particle method (para.
344.3).

ENG. HESHAM SEDDIK

P-NUMBER ASSIGNMENT TO BASE
METALS 86
 Base metals are assigned P-numbers in ASME Section IX to reduce the number of welding
procedure qualifications required. For ferrous base metals having specified impact test
requirements, group numbers within P-numbers are assigned. These assignments are
based on comparable base metal characteristics such as composition, weldability, and
mechanical properties. Table 1 lists the assignments of base metal to P-numbers
 87

ENG. HESHAM SEDDIK

F-number Assignment To Filler
Metals 88
 Electrodes and welding rods are assigned F-numbers to reduce the
number of welding procedure and performance qualifications. The F-
number groupings are based essentially on their usability characteristics,
which fundamentally determine the ability of welders to make satisfactory
welds with a given process and filler metal.
AWS CLASSIFICATION OF FILLER METALS
An AWS classification number identifies electrodes and welding rods.

ENG. HESHAM SEDDIK

A-NUMBER 89
 To minimize the number of welding procedure
qualifications, steel and steel alloy filler metals are also
grouped according to their A-number. The A-number
grouping in ASME Section IX, Table QW-442 is based on
the chemical composition of the deposited weld metal

Welder performance qualification expires if the welding process is not

used during a six-month period.

ENG. HESHAM SEDDIK

90
 Corrosion Under Insulation Inspection
• Inspection for CUI shall be considered for externally-insulated carbon and
low alloy piping operating between 10 °F (–12 °C) and 350 °F (175 °C).
• If CUI damage is found during spot checks, the inspector should inspect
other susceptible areas on the piping.
• external insulation may appear to be in good condition, CUI damage may
still be occurring. real time radiography can help to determine if any scale
is present behind the insulation without removal.
• Other techniques such as profile radiography, Pulsed Eddy Current and
Guided Wave Examination can help to locate damage.
Corrosion Under Insulation Inspection
Pressure Testing of Piping Systems
• Pressure tests are not normally conducted as part of a routine inspection.
• after welded alterations, buried piping or when specified by the inspector or piping
engineer.
• pressure tests of individual components/sections can be performed in lieu of entire
circuit.
• An engineer should be consulted when a pressure test of piping
components/sections is to be performed (including use of isolation devices) to
ensure it is suitable for the intended purpose.
• When a pressure test is required, it shall be conducted after any heat treatment.
• Before applying a hydrostatic test, the supporting structures and foundation design
should be reviewed by an engineer to ensure that they are suitable for the
hydrostatic load.
Test Fluid
• The test fluid should be water.
• there is the possibility of damage due to freezing.
• In either case, another suitable nontoxic liquid may be used. If the
liquid is flammable, its flash point shall be at least 120 °F (49 °C) or
greater.
• austenitic stainless steel should be hydrotested with a solution made
up of potable water (see note), de-ionized/de-mineralized water or
steam condensate having a total chloride concentration (not free
chlorine concentration) of less than 50 ppm.
• Potable water with 250 parts per million maximum chloride, sanitized
with chlorine or ozone.
 Test Temperature and Brittle Fracture
Considerations
• To minimize the risk of brittle fracture during a pressure test, the metal
temperature should be maintained at least
• 3 °F (17 °C) above the MDMT for piping that is more than 2 in. (5 cm) thick,
and
• 10 °F (6 °C) above the MDMT for piping that have a thickness of 2 in. (5 cm) or
less.
• The test temperature need not exceed 120 °F (50 °C) unless there is
information on the brittle characteristics of the piping construction material
indicating a higher test temperature is needed.
PRD Testing and Inspection Intervals
• Pressure-relieving devices shall be tested and inspected at intervals
that are frequent enough to verify that the valves perform reliably.
• test and inspection intervals for pressure-relieving devices in typical
process services should not exceed:
a) 5 years for typical process services, and
b) 10 years for clean (non-fouling) and noncorrosive services.
 Non welding Repairs (On-stream)
• Temporary repairs of locally thinned sections or circumferential linear defects
may be made on-stream.
• bolted clamp, non metallic composite wrap, metallic and epoxy wraps, or other
non-welded applied temporary repair.
• temporary leak sealing and leak dissipating devices, (e.g., wire wrapping,
mechanical clamps, etc) including temporary repairs on valves, shall be
removed and appropriate actions taken to restore the original integrity of the
piping system. The inspector and/or piping engineer shall be involved in
determining repair methods and procedures. Temporary leak sealing and leak
dissipating devices may remain in place for a longer period of time only if
approved and documented by the piping engineer.
 Inspection of Buried Piping
• soil-to-air interface S/A
• An area where increased external corrosion can occur on partially buried
pipe and where buried piping begins to extend above ground.
• The zone of the corrosion will vary depending on factors such as moisture,
oxygen content of the soil and the operating temperature. The zone
generally is considered to be from 12 in. (30 cm) below to 6 in. (15 cm)
above the soil surface. Pipe running parallel with the soil surface that
contacts the soil is included.
Inspection of Buried Piping
• excavation is required only if there is evidence of coating or wrapping
damage. If the buried piping is uncoated at grade, consideration
should be given to excavating 6 in. (150 mm) to 12 in. (300 mm) deep
to assess the potential for hidden damage. Alternately, specialized UT
techniques such as guided wave can be used to screen areas for more
detailed evaluation.
Leak Testing Intervals
• An alternative or supplement to inspection is leak testing with liquid at a pressure
at least 10 % greater than maximum operating pressure at intervals one-half the
length of those shown in Table 4 for piping not cathodically protected and at the
same intervals as shown in Table 4 for cathodically protected piping.
• The leak test should be maintained for a period of eight (8) hours.
• Four hours after the initial pressurization of the piping system.
• during the remainder of the test period, the pressure decreases more than 5 %,
the piping should be visually inspected externally and/or inspected internally to
find the leak and assess the extent of corrosion.
Service tests
• Service tests and/or lower pressure tests, which are used only for
• tightness of piping systems, may be conducted at pressures
designated by the owner/user.
• For service testing of Category D piping systems, ASME B31.3 limits
the gage pressure to 150 psi (1034.2 kPa).
 ARTICLE 10
LEAK TESTING
• GAGES
Gage Range. When dial indicating and recording pressure gage(s) are
used in leak testing, they should preferably have the dial(s) graduated
over a range of approximately double the intended maximum pressure,
but in no case shall the range be less than 1 1/2 nor more than four
times that pressure.
• TEST SEQUENCE
It is recommended that leak testing be performed before hydrostatic or
hydropneumatic testing.
API 577 Hardness level
welder performance (WPQ). 01

• A welder may be qualified by radiography of a test coupon or of an

initial production weld or by bend tests of a test coupon. Some end
users and codes limit or restrict the use of radiography for this purpose
such as radiography is not allowed for GMAW-S by ASME Section IX.
• If radiographic exam is used for qualification, the minimum length of
coupon to be examined is 6 in. (152.4 mm), and includes the entire weld
circumference for pipe coupons. Coupons are required to pass visual
examination and physical testing,
• Welder performance qualification expires if the welding process is not
used during a six-month period.

ENG. HESHAM ISMAIL

WELDER RETESTS 02

• Immediate Retest Using Visual Examination. When the qualification

coupon has failed the visual examination
• the welder shall make two consecutive test coupons for each position
which he has failed, all of which shall pass the visual examination
requirements. The examiner may select one of the successful test
coupons from each set of retest coupons which pass the visual
examination for conducting the mechanical testing.

ENG. HESHAM ISMAIL

Immediate Retest Using 03
Volumetric NDE.

(a) For welders and welding operators the retest shall be to examine
two 6 in. (150 mm) plate coupons;
for pipe, to examine two or more pipe coupons of the same diameter
for a total of 12 in. (300 mm) of weld, which shall include the entire
weld circumference for pipe or pipes (for small diameter pipe the total
number of consecutively made test coupons need not exceed eight).

ENG. HESHAM ISMAIL

failed the production weld 04

• b) At the option of the organization, the welder who as failed the

production weld alternative test may be retested by examining additional
weld areas equal to twice the required length or number of pipe
circumferences of the same or consecutively made production weld(s)
specified
• If this length of weld passes the test, the welder is qualified and the area
of weld on which he had previously failed the test shall be repaired by him
or another qualified welder.
• If this length does not meet the examination standards, the welder has
failed the retest and all of the production welds made by this welder shall
be examined completely and repaired by a qualified welder

ENG. HESHAM ISMAIL

Grade, Type, and Class
• the terms Grade, Type, and Class are generally defined as follows:
• Grade : is used to describe chemical composition
• Type : is used to define the deoxidation practice
• Class : is used to indicate other characteristics such as strength level
or surface finish.
• the ASTM standards, these terms were adopted and used to identify a
particular metal within a metal standard and used without any strict
definition. 
Materials classification P/T/TP/F
• Another use of ASTM grade designators is found in pipe, tube, and forging products,
•
* (P) refers to pipe
Example: (A335 Grade P22).
•
* (T) refers to tube.
Example:(A213M Grade T22)
•
* (TP) may refer to tube or pipe. 
Example:(A312 Grade TP304)
•
* (F) refers to forging.
Example:(A 336 Class F22)
Tack welds
• Tack welds at the root of the joint shall be made with filler metal
equivalent to that used in the root pass.
• Tack welds shall be made by a qualified welder or welding operator.
Tack welds shall be fused with the root pass weld, except that those
that have cracked shall be removed.
TYPES OF EXAMINATION
• Definitions. The following terms apply to any type of examination:
• 100% examination: complete examination of all of a specified kind of
item in a designated lot of piping
• random examination :complete examination of a percentage of a
specified kind of item in a designated lot of piping
• spot examination: a specified partial examination of each of a
specified kind of item in a designated lot of piping
• random spot examination: a specified partial examination of a
percentage of a specified kind of item in a designated lot of piping
THANK
YOU
ENG. HESHAM SEDDIK