CHAPTER 2

API 574

Inspection of Piping, Tubing

and Flanges

API Recommended Practice 574

Second Edition, June 1998

Chapter 2 - API 574 (Dec 2008) 1

 Inspection Practices for
Piping System Components

Foreword

This recommended practice is based on the accumulated knowledge and

experience of engineers and other personnel in the petroleum industry

1. Scope

API 574 covers the inspection practices for piping, tubing, valves (other than
control valves), and fittings used in petroleum refineries and chemical plants.

2. References

3. Definitions

3.1 ASME B31.3:

Abbreviation for ASME/ANSI B31.3, Process Piping, published by the American
Society of Mechanical Engineers. ASME B31.3 is written for design and
construction of piping systems. However, most of the technical requirements on
design, welding, examination, and materials also can be applied in the inspection,
rerating, repair, and alteration of operating piping systems. When ASME B31.3
cannot be followed because of its new construction coverage, such as revised or
new material specifications, inspection requirements, certain heat treatments, and
pressure tests, the piping engineer/inspector shall be guided by API 570 in lieu of
strict conformance with ASME B31.3. As an example of intent, the term
"principles" of ASME B 31.3 has been employed in API 570 rather than the phrase
"in accordance with" ASME B31.3.

3.2 CUI:
Corrosion under insulation, which includes stress corrosion cracking under
insulation.

3.3 deadlegs:
Components of a piping system that normally have no significant flow. Examples
include blanked branches, lines with normally closed block valves, lines which
have one end blanked, pressurized dummy support legs, stagnate control valve
bypass piping, spare pump piping, level bridles, relief valve inlet and outlet header
piping, pump trim bypass lines, high point vents, sample points, drains, bleeders,
and instrument connections.

3.4 defect:
In NDE usage, a defect is an imperfection of a type or magnitude exceeding the
acceptable criteria.

3.5 design temperature:

The temperature at which, under the coincident pressure, the greatest thickness
or highest rating of a piping system component is required. It is equivalent to the
design temperature, as defined in ASME B31.3 and other code sections, and is
subject to the same rules relating to allowances for variations of pressure or
temperature or both. Different components in the same piping system or circuit
may have different design temperatures. In establishing this temperature,

Chapter 2 - API 574 (Dec 2008) 2

 consideration shall be given to process fluid temperatures, ambient temperatures,
heating/cooling media temperatures and insulation.

3.6 imperfection:
Flaws or other discontinuities rioted during inspection that may be subject to
acceptance criteria on engineering/ inspection analysis.

3.7 injection points:

Locations where relatively small quantities of materials are injected into process
streams to control chemistry or other process variables. Injection points do not
include the locations where two process streams join (mixing tees). Examples of
injection points include chlorine in reformers, water injection in overhead systems,
polysulfide injection in catalytic cracking wet gas, anti-foam injections, inhibitors,
and neutralizers.

3.8 in-service:
Refers to piping systems that have been placed in operation as opposed to new
construction prior to being placed in service.

3.9 inspector:
An authorized piping inspector.

3.10 jurisdiction:
A legally constituted government administration that may adopt rules relating to
piping systems.

3.11 mixing tees:

A component that combines two process streams of differing composition and/or
temperature.

3.12 NDE:
Nondestructive examination.

3.13 NPS:
Nominal pipe size (followed, when appropriate, by the specific size designation
number without an inch symbol).

3.14 on-stream:
Piping containing any amount of process fluid.

3.15 owner-user:
An operator of piping systems who exercises control over the operation,
engineering, inspection, repair, alteration, testing, and rerating of those piping
systems.

3.16 PT:
Liquid penetrant testing.

3.17 pipe:
A pressure-tight cylinder used to convey a fluid or to transmit a fluid pressure,
ordinarily designated "pipe" in applicable material specifications. (Materials
designated "tube" or "tubing" in the specifications are treated as pipe when
intended for pressure service.)

Chapter 2 - API 574 (Dec 2008) 3

3.18 piping circuit:
Complex process units or piping systems are divided into piping circuits to
manage the necessary inspections, calculations, and record keeping. A piping
circuit is a section of piping of which all points are exposed to an environment of
similar corrosivity and which is of similar design conditions and construction
material. When establishing the boundary of a particular piping circuit, the
Inspector may also size it to provide a practical package for record keeping and
performing field inspection.

3.19 piping engineer:

One or more persons or organizations acceptable to the owner-user who are
knowledgeable and experienced in the engineering disciplines associated with
evaluating mechanical and material characteristics which affect the integrity and
reliability of piping components and systems. The piping engineer, by consulting
with appropriate specialists, should be regarded as a composite of all entities
necessary to properly address a technical requirement.

3.20 piping system:

An assembly of interconnected piping, subject to the same set or sets of design
conditions, used to convey, distribute, mix, separate, discharge, meter, control, or
snub fluid flows. Piping system also includes pipe-supporting elements, but does
not include support structures, such as building frames, bents, and foundations.

3.21 PWHT:
Post weld heat treatment.

3.22 repair:
A repair is the work necessary to restore a piping system to a condition suitable
for safe operation at the design conditions. If any of the restorative changes result
in a change of design temperature or pressure, the requirements for rerating also
shall be satisfied. Any welding, cutting, or grinding operation on a pressure-
containing piping component not specifically considered an alteration is
considered a repair.

3.23 rerating:
A change in either or both the design temperature or the maximum allowable
working pressure of a piping system. A rerating may consist of an increase,
decrease, or a combination. Derating below original design conditions is a means
to provide increased corrosion allowance.

3.24 small bore piping (SBP):

Less than or equal to NPS2.

3.25 soil-to-air (S/A) interface:

An area in which external corrosion may occur on partially buried pipe. 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 inches (30 cm) below to 6 inches (15 cm) above the soil surface. Pipe
running parallel with the soil surface that contacts the soil is included.

3.26 spools:
A section of piping encompassed by flanges or other connecting fittings, such as
unions.

Chapter 2 - API 574 (Dec 2008) 4

3.27 temper embrittlement:
A loss of ductility and notch toughness in susceptible low-alloy steels (e.g., 1¼
Cr and 2¼ Cr) due to prolonged exposure to high temperature service between
700º to 107º F (371ºC to 577ºC).

3.28 thickness measurement locations (TMLs):

Designated areas on piping systems where periodic inspections and thickness
measurements are conducted.

3.29 WFMT or WFMPT:

Wet fluorescent magnetic particle testing.

4. Piping Components

4.1 PIPING

Piping can be made from any material that can be rolled and welded, cast, or
drawn through dies to form a tubular section. The difference from traditional
thickness designations and schedules is indicated. Small bore piping (NPS 2
pipe size and less) is also included. See Table 1 for nominal sizes.

ASTM A53 and A106 piping materials are used most commonly in the
petrochemical industry. Piping of a nominal size > 16” is made by rolling plates
to size and welding the seam. Steel piping is manufactured to standard
dimensions in NPS up to 48”. Pipe wall thickness is given schedule number up to
36” For NPS 12” and smaller, the size refers to the internal diameter of standard
schedule (Sch 40). For NPS 14” and larger, the size refers to the outside
diameter.

The actual thickness of seamless piping may vary from its nominal thickness by
a manufacturing tolerance of 12.5%. Cast iron piping is generally not
recommended for pressurized hydrocarbon services. The standards and sizes
for cast iron are differred from those for welded and seamless piping.

4.2 TUBING

Tubing is generally seamlessly drawn. General information about tubing.

Tubing is mainly used for heat exchangers, instrument piping, steam tracing, etc.
the stated size is the actual outside diameter.

4.3 VALVES

The basic types of valves are gate, globe, plug, ball, diaphragm, butterfly, check,
and slide valves. See Figures 1 - 8 for cross section view of each of theses
valves. All of Section 4.3 is general basic information about valves.

4.4 FITTINGS

Fittings are used to connect pipe sections and change the direction of flow or
allow the flow in a piping run to be diverted or added to. The basic types of pipe
fittings, cast, forged, seamlessly drawn, or formed and welded. Fittings may be
flanged, socket-welded, butt welded or threaded. See Figures 9 - 16 for cross
section view of each of theses fittings. All of Section 4.4 and 4.5 is general basic
information about pipe fittings.

Chapter 2 - API 574 (Dec 2008) 5

4.5 PIPE-JOINING METHODS

Commonly used for piping joining methods are welding, threading and flanging.

 Welded joints – Butt-welded joints, socket-welded joints.

 Welded branch connections – Most piping failures occur at pipe-to-pipe
welded branch connection due to higher than normal stresses and
unsupported valves, vibration and thermal expansion.
 Threaded joints – generally limited to non-critical services and for NPS 2”
and smaller.
 Flanged joints – common types are welding neck, slip-on, threaded, blind,
lap joint and socket-welded.
 Tubing joints – can be joined by welding, soldering or brazing.

5. Reasons For Inspection

5.1 General

The primary purpose of inspection is to achieve the desired quality assurance

and ensure plant safety and reliability.

5.2 Safety

Basic information about common sense piping safety.

5.3 Reliability and efficient operation

An added benefit to having a regular inspection program, is that it creates a data

bank of information regarding the physical condition of equipment and the rate
and causes of deterioration. The user can then establish effective preventative
maintenance schedules. This effort should result in reduced maintenance costs
and more reliable and efficient operations.

5.4 Regulatory Requirements

Federal, state, and local statutes and regulations may apply to piping installation
and inspection.

6. Inspecting for Deterioration In Piping

Aboveground piping is subject to atmospheric corrosion; buried piping is subject

to soil corrosion. See Figures 17, 18, 19, 20 and 23 for illustrations of corrosion
and eroding of piping.

6.1 GENERAL

Petrochemical piping, by nature, often carries highly corrosive materials, it is

suggested API IRE Chapter 11, Conditions Causing Deterioration or Failures, be
reviewed for causes of deterioration.

6.2 CORROSION MONITORING OF PROCESS PIPING

The most frequent reason for replacing piping is from thinning due to corrosion.
A good monitoring system is imperative. Things to consider when establishing a
corrosion-monitoring plan:

Chapter 2 - API 574 (Dec 2008) 6

 a. Classifying the piping accordance with API 570
b. Categorizing the piping into circuits of similar corrosion behavior.
c. Identifying susceptible locations where accelerated corrosion is expected.
d. Accessibility of the TML for monitoring.

6.2.1 Piping Circuits

The basic factors of pipe wall corrosion are listed. As well as, suggestions for
breaking piping systems into circuits, see figure 21 for an example

6.2.2 Identifying locations susceptible to accelerated corrosion

Corrosion rates are normally increased at areas where increased flow velocity
and turbulent flow is presence. Areas in elbows, reducers, mixing Tee, control
valves and orifices are vulnerable to higher corrosion rate.

6.2.3 Piping Classifications

Factors to consider when classifying piping are, toxicity, volatility, combustibility,

location of the piping with respect to personnel and other equipment, and
experience and history.

6.2.4 Accessibility of the TMLs

Accessibility for the areas of inspection should be considered when assigning

TMLs.

6.3 inspection for specific types of corrosion and cracking

General information about the following subjects are found in the rest of this
section:

a. Injection points.
b. Deadlegs.
c. Corrosion under insulation (CUI).
d. Soil-to-air interfaces.
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. Brittle fracture.
l. Freeze damage.
m. Corrosion at support points.
n. Dew Point Corrosion.

7. Frequency and Time of Inspection

7.1 General

The frequency and time of inspection should be determined by the following

conditions:

a. The severity of service. (Piping classification)

b. The degree of risk. (Likelihood and consequence of a failure)
c. The amount of corrosion allowance remaining.

Chapter 2 - API 574 (Dec 2008) 7

 d. The historical data available.
e. Regulatory requirements.

7.2 Inspection while equipment is operating

Many other conditions in piping systems should be determined while the

equipment is operating. On-stream inspection can reduce downtime by the
following means:

a. Extending process runs and preventing some unscheduled shutdowns.

b. Permitting fabrication of replacement piping before a shutdown.
c. Eliminating unnecessary work and reducing personnel requirements.
d. Aiding maintenance planning to reduce surges in work load.

7.3 Inspection while equipment is shut down

Piping can often be inspected internally during outages.

8. Safety Precautions and Preparatory Work

8.1 Safety precautions

This section outlines some generic, extremely basic safety precautions which are
probably inferior to your own safety department requirements.

8.2 Preparatory Work

This section should be titled:

“The Common Sense Guide to Advance Shut Down Work”.
And contains no new or extremely useful information.

9. Inspection Tools

See Table 2, page 30 of API 574.

10. Inspection Procedures

10.1 Inspection while equipment is operating

10.1.1 Visual Inspection

External visual inspection should focus on pain coating breakdown, check for
sign of misalignment, vibration, leakage and build-up of corrosion product at pipe
support areas.

[Link] Leaks

Leaks can be safety or fire hazards, and always result in economic loss.
Temporary or permanent repairs can often be made while the lines are in
service.

[Link] Misalignment

Piping should be inspected for misalignment. Pipe dislodged from supports,

vessel wall deformation, pipe supports out of plumb, excessive replacement of
bearings, etc., shifting of base plates, foundation damage, cracks in connecting

Chapter 2 - API 574 (Dec 2008) 8

 flanges, expansion joints not performing properly, are all indications of
misalignment.

[Link] Supports

Supports are shoes, hangers, and braces, and should be visually inspected for
problems.

[Link] Vibration

Vibrating or swaying piping should be inspected for cracks, at points of restraint,

usually in the areas of anchors, or where small bore pipe is attached to the main
line.

[Link] External Corrosion

Defects in the protective coatings and insulation will permit moisture to contact
the piping. This can result in corrosion and metal loss.

[Link] Accumulations of Corrosive Liquids

Some liquids are corrosive to steel piping, spills should be cleaned up or

neutralized.

[Link] Hot Spots

Operating piping at higher than design limits may cause bulging, even to the
point of failure. Investigation of these areas is essential.

10.1.2 Thickness Measurements

[Link] Ultrasonic Inspection

with emphasis on high temperature readings.
UT digital thickness gauges are mentioned.

[Link] Radiographic Inspection

Wall shot or radiographic profile radiography is discussed in this section, as to

the use of the technique, no information about how the technique is performed.

10.1.3 Other On-stream Inspections

This section mentions "new" methods of inspection; halogen leak detectors,

magnetic induction, real-time radiography, neutron radiography, thermography,
etc.

10.2 INSPECTION WHILE EQUIPMENT IS SHUTDOWN

10.2.1 Visual Inspection

[Link] Corrosion, Erosion and Fouling

Borescopes are used to inspect piping internally.

Chapter 2 - API 574 (Dec 2008) 9

[Link] Cracks

Inspect the susceptible locations, construction tack welds at other than pressure
welds, heat affected areas joining welds, and points of restraint or excessive
strain. Include locations that are subject to stress-corrosion cracking, hydrogen
cracking, and caustic or amine embrittlement, as well as exposed threads.

[Link] Gasket Faces of Flanges

General inspection.

[Link] Valves

Inspection techniques for gate valves including the valves being dismantled at
specified intervals.

[Link] Joints

Flanged Joints,
Welded Joints,
Threads Joints,
Clamped Joints

All the listed joints should be inspected, the basic technique is visual examination.

[Link] Misalignment

Misalignment is caused by:

a. Inadequate provision for expansion.
b. Broken or defective anchors or guides.
c. Excessive friction on sliding saddles, indicating a lack of lubrication or a need
for rollers.
d. Broken rollers or rollers that cannot turn because of corrosion or lack of
lubrication.
e. Broken or improperly adjusted hangers.
f. Hangers that are too short and thus limit movement or cause lifting of the pipe.
g. Excessive operating temperature

[Link] Vibration

Vibrating or swaying piping should be inspected for cracks, at points of restraint,

usually in the areas of anchors, or where small bore pipe is attached to the main
line.

[Link] Hot Spots

The outer surface of piping in high-temperature service – about 427 degree C and
above should be checked for creep or deformation with time under stress.

A short discussion of areas over heated on piping is discussed. No mention of

thermal photography.

10.2.2 Thickness Measurements

UT digital thickness gauges are mentioned with emphasis on high temperature

readings and the use of radiography on nipple thickness.

Chapter 2 - API 574 (Dec 2008) 10

10.2.3 Pressure Tests

Pressure tests are leak tests and may be used on the following:
a. Underground lines and other inaccessible piping.
b. Water and other non-hazardous utility lines.
c. Long oil transfer lines in areas where a leak or spill would not be hazardous
to personnel or harmful to the environment.
d. Complicated manifold systems.
e. Small piping and tubing systems.
f. All systems, after a chemical cleaning operation.

Do not over pressure the system! For service testing of Category D piping
systems, ASME B31.3 limits the gauge pressure to 150 psi.

Various fluids may be used for pressure testing:

a. Water with or without an inhibitor, freezing-point depressant, or wetting agent.

b. Liquid products normally carried in the system, if non-toxic or flammable.
c. Stream
d. Air, carbon dioxide, nitrogen, helium, or another inert gas

Salt water can create problems like pitting and corrosion.

Pneumatic tests should be conducted strictly in accordance with ASME B 31.3.

10.2.4 Hammer Testing

Hammer testing is an old method of testing piping systems, do not use the
hammer on cast iron and stress-relieved lines in caustic and corrosive service.

10.2.5 Inspection of Piping Welds

Refer to API 570, Section 3.10 which will reference ASME B 31.3 for weld quality.

10.3 INSPECTION OF UNDERGROUND PIPING

Basic information about buried piping, referencing several NACE documents.

10.3.1 Types and Methods of Inspection and Testing

[Link] Above-Grade Visual Surveillance

Extremely basic information about leaking underground piping.

[Link] Close-Interval Potential Survey

This type of survey is used to locate corrosion cells, galvanic anodes, stray
currents, coating problems, underground contacts, areas of low pipe-to-soil
potentials and other cathodic protection problems.

[Link] Holiday Pipe Coating Survey

Basically, a measurement is taken and compared to other areas of the system,

coated as opposed to non-coated piping, will give different corrosion rates and
readings.

Chapter 2 - API 574 (Dec 2008) 11

[Link] Soil Resistivity Testing

The Wenner method, the soil bar and soil box methods are discussed. Basically,
each method measures a voltage drop, caused by a known current flow, across a
measured volume of soil. The resistance factor is used in a formula to determine
the resistivity of the soil.

[Link] Cathodic Protection Monitoring

Refer to NACE RP0169 and Section 11 of API Recommended Practice 651.

10.3.2 Inspection Methods

1) Intelligent Pigging
2) Video Cameras
3) Excavation

10.3.3 Leak Testing

The basic methods of leak testing underground piping are briefly described in this
section. The methods are:
1. Pressure decay method.
2. Volume in / volume out method.
3. Single-point volumetric methods.
4. A marker chemical (tracer) method.
5. Acoustic emission method.

10.4 Inspection of new construction

10.4.1 General

Must meet the requirements of ASME B 31.3.

10.4.2 Inspection of Materials

Materials should be checked for conformance with the codes and specifications
that are appropriate for the plant. Checks should be made using material test kits
or a nuclear alloy analyzer, (PMI).

10.4.3 Deviations

No comment.

11 Determination of Retirement Thickness

11.1 Piping

All formulas and data for determining the required wall thickness for piping are
found in ASME B 31.3. ASME B 31.3 also takes into consideration the following:

a. Corrosion.
b. Threads
c. Stresses caused by mechanical loading, hydraulic surge pressure thermal
expansion and other conditions.

Chapter 2 - API 574 (Dec 2008) 12

 The Barlow formula:

The Barlow formula can be used provided that the value is less than D/6, or P/SE
is not greater than 0.385". The Barlow formula is as follows:

PD
t
2SE

Where:
t = pressure design thickness for internal pressure, in inches
P = Internal design gauge pressure of the pipe, in pounds per square inch
D = outside diameter of the pipe, in inches
S = allowable unit stress at the design temperature, in psi
E = longitudinal joint efficiency.

Metallic pipe for which t > D/6 or P/SE > 0.385 requires special consideration.

11.2 Valves and flanged fittings

Refer to ASME B16.34 for minimum valve wall thickness.

12 Records

12.1 General

Records should be kept in a detailed and orderly manner. These records will help
in evaluating replacement or repair intervals.

12.2 Sketches

Sketches have important functions:

a. They identify particular piping systems in terms of location, size, material

specification, general process flow, and service conditions.
b. They inform the mechanical department of points to be opened for visual
inspection and parts that require replacement or repair.
c. They serve as field data sheets on which can be recorded the locations of
thickness measurements, serious corrosion, and sections requiring immediate
replacement. These data can be transferred to continuous records at a later
date.
d. They assist at future inspections in determining locations that urgently require
examination.

12.3 Numbering systems

Use any convenient means.

12.4 Thickness data

A record of thickness data may provide a means of corrosion or erosion rates for
the piping system. See Figure 34 for an example of sketches and thickness data.

12.5 Review of records

General information about when to review records.

Chapter 2 - API 574 (Dec 2008) 13

 API 574
Quiz

1. API 574 covers inspection of:

A. new construction
B. new tank construction
C. piping
D. vessels

2. Cast iron pipe can be joined by:

A. welding
B. compression
C. epoxy resin
D. bell and spigot

3. The primary purpose of inspection is to achieve the desired quality assurance and:

A. ensure plant safety

B. supply the necessary paperwork for outside audits
C. complicate maintenance activities
D. create an avenue for dismissing craftsmen

4. Ultrasonic thickness readings at areas with surface temperatures above ______ are
normally higher than actual thickness.

A. 100ºF
B. 200ºF
C. 300ºF
D. 212ºF

5. Flame detectors used to indicate a furnace or boiler fire may give erroneous indications
on control panels during:

A. Welding or related repairs on piping.

B. Piping alterations in the shop.
C. Ultrasonic inspection.
D. Radiographic inspection.

6. Leaks in a threaded joint may be caused by:

A. Back-welding the fitting.

B. Lack of thread lubricant.
C. Under-pressuring the part.
D. Changing the direction of flow in the piping system.

7. A leaking threaded joint should not be tightened while the system is in service under
pressure because:

A. The craftsman should not be near the threaded connection.

B. Rust or corrosion might be holding the pressure.
C. The joint might be unscrewed.
D. A crack in a thread root might fail.

Chapter 2 - API 574 (Dec 2008) 14

8. During a pressure test, care should be taken not to:

A. Allow any inert gas into the system.

B. Use water in the system.
C. Overpressure the system.
D. Underpressure the system.

9. Which of the following tests should not be used on cast iron piping:

A. Radiographic test
B. Leak test
C. Ultrasonic test
D. Hammer test

10. The details of inspection of in-service piping are provided in:

A. ASME IX
B. ASME B31.3
C. API 570
D. ASME B 16.5a

PD
11. t is the formula for:
2SE

A. Required Piping Thickness

B. Maximum Piping Thickness
C. Maximum Piping Thickness
D. Average Piping Thickness

12. API RP 574 is a:

A. Code
B. Standard
C. Specification
D. Recommended Practice

13. During the manufacturing of tubing, the tubing may be welded, but is generally:

A. Riveted.
B. Seamlessly drawn.
C. Wire drawn.
D. Forged.

14. A globe valve is commonly used to:

A. Prevent back flow.

B. Allow full flow.
C. Stop all flow.
D. Regulate fluid flow.

15. A check valve is commonly used to:

A. Prevent back flow.

B. Allow full flow.
C. Stop all flow.
D. Regulate fluid flow.

Chapter 2 - API 574 (Dec 2008) 15

 API 574 Quiz

Answer Key

1. C
2. D
3. A
4. B
5. D
6. B
7. D
8. C
9. D
10. C
11. A
12. D
13. B
14. D
15. A

Chapter 2 - API 574 (Dec 2008) 16