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Calculations for Evaluating Thickness Measurements, Inspection Intervals, and Piping Integrity

- Corrosion Rates and Remaining Life

- Calculate average corrosion rate using initial and subsequent thickness readings (API 570, 7.1.2).

- Calculate short-term and long-term corrosion rates when multiple measurements exist.

- Determine remaining life based on current thickness, minimum required thickness, and corrosion rate (API 570, 7.2).

- Apply rules for corroded areas and local thin areas.



- Inspection Intervals

- Determine external visual inspection intervals and thickness measurement intervals for Class 1, 2, and 3 piping (API 570, 6.3.3 & Table 1).

- Understand factors influencing interval adjustments (e.g., corrosion rate trends, RBI if applicable).

- Set next inspection date based on remaining life and safety factors.



- Weld Joint Quality Factors (Ej) and Casting Quality Factors (Ec)

- Select weld joint quality factor Ej from ASME B31.3 Table A-1B for different weld types and joint efficiencies.

- Select casting quality factor Ec from ASME B31.3 Table A-1A.

- Increase joint quality factors (up to 1.0) by performing supplemental NDE as per ASME B31.3 Table 302.3.4 (e.g., 100% RT for seamless to welded transitions).



- Internal Pressure / Minimum Thickness Calculations

- Calculate pressure design thickness (minimum required thickness) for straight pipe under internal pressure (ASME B31.3, 304.1.1 and 304.1.2 formulas).

- Determine minimum thickness for permanent blanks (blanks, spectacle blinds) (ASME B31.3, 304.5.3).

- Calculate MAWP of corroded piping, including future corrosion allowance (API 570, 7.5).

- Adjust calculations for corrosion allowance addition/subtraction and mill tolerance.



- Pressure Testing Requirements

- Calculate hydrostatic leak test pressure (ASME B31.3, 345.4).

- Calculate pneumatic leak test pressure (ASME B31.3, 345.5).

- Understand test medium considerations, safety precautions, and acceptance criteria.



Welding and Brazing

- General Welding Requirements

- Understand ASME B31.3 Chapter V rules for welded joints, sizes, restrictions, reinforcement, preheating, PWHT, and inspection.

- Apply API 570 welding rules (which take precedence over B31.3 in conflicts for in-service work).



- Welding Processes, Inspection, and Metallurgy

- Identify common welding processes, advantages/disadvantages, and typical defects (API RP 577 – full coverage).

- Understand weld imperfection acceptance criteria and repair welding.



- Qualification Requirements

- Differentiate essential, nonessential, and supplementary essential variables for WPS/PQR (ASME Section IX).

- Review and qualify Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welder Performance Qualifications (WPQ/Welder Qualification).

- Understand welder continuity, retesting, and performance essential variables.



Nondestructive test (NDE)

- NDE Methods and Procedures

- Understand requirements and techniques for RT, UT, MT, PT, VT, and other methods (ASME BPVC Section V – Articles 1–10, mandatory appendices).

- Know personnel qualification and certification (ASNT SNT-TC-1A or equivalent referenced).

- Interpret NDE results, acceptance criteria, and documentation.



- Application to Piping

- Select appropriate NDE for weld joints, thickness measurements, and defect detection in in-service piping.



Inspection, Exam, and Pressure Testing Practices

- API 570 Core Rules

- Inspection types (external visual, thickness measurement, injection points, deadlegs, auxiliary piping).

- Frequency and extent of inspections (Class 1/2/3 piping).

- Data evaluation, recordkeeping, and CML (Condition Monitoring Location)/TML management.

- Repair, alteration, and rerating procedures (including authorization, documentation, and pressure testing after repairs).



- Piping System Components

- Inspection practices for pipe, valves, fittings, flanges, supports, and special components (API RP 574 – full coverage).

- Identify common degradation modes and inspection techniques for each component.



- Pressure-Relieving Devices

- Inspection, testing, and repair of PRDs (pressure relief valves, rupture disks) (API RP 576 – full coverage).



Material Verification Program

- PMI and Material Control

- Apply PMI techniques, extent, and acceptance criteria for new and existing assets (API RP 578 – full coverage).

- Understand alloy verification, positive material identification methods, and documentation.



Damage Mechanisms (from API RP 571 – specific mechanisms only)

- Common Mechanisms in Piping

- General/localized corrosion (atmospheric, galvanic, soil, microbiologically influenced – MIC).

- Corrosion under insulation (CUI), pitting, crevice corrosion.

- Erosion/erosion-corrosion.

- High-temperature mechanisms: sulfidation, high-temperature hydrogen attack (HTHA), carburization.

- Cracking mechanisms: chloride SCC, caustic cracking/embrittlement, amine cracking, sulfide stress cracking (SSC).

- Other: dew-point corrosion, boiler water/condensate corrosion, oxygen pitting, vibration-induced fatigue, mechanical fatigue.



- Critical Factors and Appearance

- Identify susceptible materials, environments, temperature/pressure ranges, and mitigation strategies for each mechanism.



Additional Supporting Topics

- Flanges and Bolting

- Flange ratings, dimensions, facing, and assembly practices (ASME B16.5).



- Repair Methods

- Post-construction repair techniques (ASME PCC-2 – relevant articles for piping repairs, e.g., welded sleeves, composite wraps).



- General Concepts

- Key terms: MAWP, CML/TML, injection point circuit, deadleg, rerating, alteration vs. repair, fitness-for-service basics.

- Buried piping inspection considerations.

- Overall application of codes to real-world in-service scenarios.

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