Update on API Inspection Documents

Ray Konet Director Fixed Equipment Reliability Valero Energy Corporation

Outline
API Committee Organization
Inspection Subcommittee (SCI) Current Document Activity Recent New Editions API 570

API RP 572
API RP 574 API RP 576 API RP 578 API RP 580

API Committee Organization

Committee on Refinery Equipment Fitness-for-Service (STD 579) Task Group

Aboveground Storage Tank

Corrosion & Materials

Piping & Valves

Inspection

Electrical Equipment

Mechanical Equipment

Heat Transfer Equipment

Instrument & Control Systems

Pressure Relieving Systems

API Committee Organization

Subcommittee Inspection

Inspection Codes Task Group

Manufacturers and Contractors Task Group RP 581 Task Group

NDE Task Group

Individual Certification Program Task Group

RP Task Groups

API Standards Development Process

API is accredited by the American National Standards Institute (ANSI) Regular program audits Open and transparent process All comments and objections must be considered

API Standards Development Process

Developed by consensus (does not mean unanimity) Balance between owner operators and manufacturers/contractors API corporate membership is not a requirement for participation on API standardization committees

Committee Membership
Be technically proficient/involved in the inspection field related to pressure equipment, NDE techniques, and related subjects
Attend two committee meetings per year Participate on committee business such as standards revisions and technical inquiries

Have the support of company management to participate

Inspection Subcommittee Documents

Whole suite of standards and RPs covering fixed equipment inspection Pressure vessels Piping Pressure Relief Devices Boilers and fired heaters Tanks Risk-Based Inspection RPs for activities involving inspection Welding and Metallurgy Positive Material Identification Corrosion under insulation Coming RPs supporting reliability of fixed equipment Integrity Operating Windows Coming Pressure Equipment Incident Investigation - Coming

Inspection Subcommittee Documents

API 510 Pressure Vessel Inspection Code 10th edition in process API 570 Piping Inspection Code 3rd edition 2009 RP 571 Damage Mechanisms Inspection guidance for mechanisms in process RP 572 Inspection Practices for Pressure Vessels 3rd edition 2009 RP 573 Inspection of Fired Boilers and Heaters 3rd edition in process RP 574 Inspection Practices for Piping System Components 3rd edition 2009 RP 575 Inspection of Atmospheric and Low Pressure Storage Tanks 3rd edition in process

Inspection Subcommittee Documents

RP 576 RP 577 RP 578
RP 580 RP 581 RP 583 RP 584 RP 585

Inspection of Pressure Relieving Devices 3rd edition 2009 Welding Inspection and Metallurgy 2nd Edition in process Material Verification Program for New and Existing Alloy Piping Systems 2nd Edition 2009 Risk Based Inspection 2nd Edition 2009 Risk Based Inspection Technology 2nd Edition 2008 Corrosion Under Insulation New document in development Integrity Operating Windows New document in development Pressure Equipment Incident Investigations New document in development

API 570 PIPING INSPECTION CODE 3RD EDITION

Significant rewrite Consistency with API 510 9th edition

API 570 PIPING INSPECTION CODE 3RD EDITION

FRP piping included into scope of document Specifically recognizes fitness-for-service and RBI within scope of the document Definitions were significantly expanded for clarity Added section of application of management of change Expanded responsibilities of the inspector to expand scope of inspection where findings dictate and notify owner-user of nonconformances. Added responsibilities to new group Examiners. Added responsibilities for operating, maintenance, engineering and other personnel.

API 570 PIPING INSPECTION CODE 3RD EDITION

Added section on development and contents of an Inspection Plan Eliminated special emphasis requirements (e.g. soilto-air) except for injection points. Now located in API RP 574. Define eight types of inspection and surveillance Created new paragraph on Inspection Organization Audits Defined a new Class 4 piping Created a new section on Pressure relieving devices identical to API 510. Significantly expanded the documentation section and added reference to inspection deferral.

API RP 572 INSPECTION PRACTICES FOR PRESSURE VESSELS 3RD EDITION Consistency with API RP 574 rewrite Expanded educational material

API RP 572 INSPECTION PRACTICES FOR PRESSURE VESSELS 3RD EDITION

Title change to Inspection Practices from Inspection of Pressure Vessels Doubled the number of definitions including inspection plan, examination point, corrosion specialist. Incorporated philosophy that NDE is examination and pressure testing is testing. NDE is not testing. Added a section on inspection plans and RBI Deleted section on Alternative rules for Exploration and Production Vessels --- API 510 Code provides specific details

API RP 572 INSPECTION PRACTICES FOR PRESSURE VESSELS 3RD EDITION

Added over 50 pages of general education text and photos on operation of pressure vessels, types of trays, types of packing and associated inspection of those components. Added over 80 photos and figures to help visualize components and damage

API RP 574 INSPECTION PRACTICES FOR PIPING SYSTEM COMPONENTS 3RD EDITION Major update to provide greater detail behind code content and general inspection guidance

API RP 574 INSPECTION PRACTICES FOR PIPING SYSTEM COMPONENTS 3RD EDITION
Added section on development of an Inspection plan Incorporated fiber-reinforced plastic pipe into all sections detailing typical joints, damage mechanisms, inspection techniques Details on expansion joints and their inspection Provided guidance on establishing minimum required thickness and use of alert thickness for retirement Added safety considerations under new section on Investigation of Leaks.

API RP 574 INSPECTION PRACTICES FOR PIPING SYSTEM COMPONENTS 3RD EDITION
Added typical inspector activities related to repairs and alterations Expanded UT examination and thickness instrument considerations and limitations

API RP 576 INSPECTION OF PRESSURE RELIEVING DEVICES 3RD EDITION Technical update

API RP 576 INSPECTION OF PRESSURE RELIEVING DEVICES 3RD EDITION

Added cautionary notes on venting of the bellows to atmospheric pressure (open or closed system) for balanced bellow design valves to function properly. installing valves in the vertical position as other positions could have misalignment. Provided specific handling and installation guidance for rupture disks Added specific guidance for transporting pressure relief devices to the shop. Added recommendation to visually exam valves prior to any disassembly and cleaning.

API RP 578 MATERIAL VERIFICATION PROGRAM FOR NEW AND EXISTING ALLOY PIPING SYSTEMS 2ND EDITION Technical update

API RP 578 MATERIAL VERIFICATION PROGRAM FOR NEW AND EXISTING ALLOY PIPING SYSTEMS 2ND EDITION Added consideration of corrosion mechanisms affected by specific elements Residual elements in carbon steel in hydrofluoric acid alkylation units Process units with carbon steel susceptible to sulfidation (Si content) Added reference to consider testing of gasket materials

API RP 580 RISK BASED INSPECTION 2ND EDITION Significant revision to provide greater detail Incorporate lessons learned from ongoing implementation

API RP 580 RISK BASED INSPECTION 2ND EDITION

Added over 20 new definitions to reflect changes in other API codes Use of Damage mechanisms standardized replacing deterioration, and degradation. Emphasized that integrity operating windows and management of change are integral with a riskbased inspection plans. Enhanced the description of a quantitative risk assessment Provided a new section describing the key steps in a risk analysis.

API RP 580 RISK BASED INSPECTION 2ND EDITION Clarified difference between accuracy and precision associated with risk analysis. Recognized fitness-for-service as a component in achieving risk reduction Rewrote section on Damage Mechanisms and Failure Modes to more thoroughly reflect a work process of their assessment and use in a risk analysis Provides example frequencies for qualitative probability of failure categories (e.g. Low probability equates to <0.0001)

API RP 580 RISK BASED INSPECTION 2ND EDITION Provides examples for consequence categories cost ranges for economic categories Descriptions of safety, health, and environmental categories Added guidance steps and factors in determining the consequence of failure Added new section on potential pitfalls with RBI that could lead to less than adequate risk management results

Final Thoughts
Crack open the new editions to learn for yourself specific changes within the code and recommended practice---it might change how you do your business Give us feedback! --- Are we missing a subject?, Are the words clear or concise?, Is there an error? We need help! Participate on the committee or task groups

QUESTIONS?