Meridium RBI-580 Inspection Strategies - Q12016

RBI 580 Inspection Strategies
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Revision History
Revision Date Author Description

0 10/11/2011 Michael Warren Draft
1 6/1/2012 Michael Warren Published
2 4/2/2013 Michael Warren Updated
3 2013 Michael Warren Updated per 3.5.1
4 12/15/2014 Mike Taylor Updated per 3.6.0.2
5 10/01/2016 Vipin Nair Updated to RBI 580 Inspection strategies
document for sharing with customers
Table of Contents
TABLE OF CONTENTS .............................................................................................................. 3

1 GUIDELINES FOR ESTABLISHING INDIVIDUAL INSPECTION CONFIDENCE............................. 4
2 INTERNAL CORROSION STRATEGY RULES FOR VESSELS, EXCHANGERS, AND TANKS (APPENDIX B)
6
3 SUBSTITUTING NON-INTRUSIVE INSPECTIONS IN-LIEU OF INTRUSIVE INSPECTION ........... 23
4 INTERNAL CORROSION STRATEGY RULE SET FOR AIR COOLED HEAT EXCHANGERS (APPENDIX D)
24
5 INTERNAL CORROSION STRATEGY RULE SET FOR PIPING (APPENDIX E) ............................. 46
6 EXTERNAL AND CUI STRATEGY RULE SETS FOR VESSELS, EXCHANGERS, TANKS AND PIPING
(APPENDIX F) ....................................................................................................................... 69
7 ENVIRONMENTAL CRACKING STRATEGY RULE SETS FOR VESSELS, EXCHANGERS, TANKS, AND
PIPING (APPENDIX G) ........................................................................................................... 97
8 CORROSION AND CRACKING STRATEGY RULE SETS EXCHANGER BUNDLES / TUBES (APPENDIX H)
130
9 PLATE CORROSION AND WELD CRACKING STRATEGY RULE SETS FOR STORAGE TANK BOTTOMS
(APPENDIX I) ..................................................................................................................... 150
10 PRD STRATEGIES ......................................................................................................... 158
1 Guidelines for Establishing Individual Inspection Confidence
The Individual Inspection Confidence (IIC) represents the degree of confidence that an inspection for a particular damage
mechanism will indentify it and be able to accurately measure its rate. Likewise the Aggregate Inspection Confidence (AIC)
represents the sum total confidence of all the inspections performed for particular damage mechanism as to how effective
they were in finding the damage mechanism and measuring its rate. The Aggregate Number of Inspections is total number
of past inspections at an Aggregate Inspection Confidence (AIC).
The Aggregate Inspection Confidence (AIC) is based on historical evidence accumulated from a review of
past inspection documentation and/or information obtained from discussions with plant personnel. In
most cases the analyst will be considering multiple past inspection records. Per API-581 no more than 6 of
the most recent inspections are required to provide the best information.
For each Degradation Mechanism the Meridium RBI methodology requires the Aggregate Number of
Inspections along with the Aggregate Inspection Confidence (AIC) in order to perform the risk assessment.
In order to obtain an Aggregate Inspection Confidence (AIC) and an Aggregate Number of Inspections for
each damage mechanism, each individual inspection needs to be assigned an Individual Inspection
Confidence (IIC). This is accomplished by comparing the type and extent of inspection to that provided in
the Strategy Rule Sets in the appendices directly following. Appendices B – G provide these guidelines for
determining the confidence for individual inspection scopes per degradation mechanism.
Aggregate Inspection Confidence (AIC) can be ascertained in terms of the number of the highest Individual Inspection
Confidence (IIC) assigned to those past inspections. The table below outlines the inspection confidence equivalency.
This table is the primary tool that is used for performing this roll up.
Inspection Confidence Equivalence
3 Highs (H) = 1 Very High (VH)

3 Mediums (M) = 1 High (H)
3 Lows (L) = 1 Medium (M)
For example, let’s consider that we have 3 internal inspections and they have already had their individual inspection
confidences assigned as follows:
 1 VH
 1H
 1M
Following the rule of 3’s, the Aggregate Inspection Confidence (AIC) would be assigned as a Very High (VH) level since
the highest Individual Inspection Confidence (IIC) considered was a Very High (VH). Using the triangular figure below,
we would then equivocate the number of lower confidence inspections to the assigned Aggregate Inspection
Confidence (AIC) of VH as follows:
1VH
3H
9M
27 L
 1 VH = 1VH
 1 H = 1/3 VH
 1 M = 1/9 VH
Therefore the equivalent number of VH inspections = 1 + 1/3 + 1/9 = 1 4/9 VH. Since the ar/t table from API-581 only
uses integers, the 1 4/9 should be rounded down to the nearest whole number and for this example that is 1.
Therefore the Aggregate Inspection Confidence (AIC) would be assigned VH and Aggregate Number of Inspections
would be calculated to be 1.
2 Internal Corrosion Strategy Rules for Vessels, Exchangers, and Tanks (Appendix B)
Internal Corrosion Inspection Priority Categories referenced in the Tables below are based on the Risk Matrix given in Fig 1
of this document. Table 1 below provides a list of the recommended inspection frequencies and minimum confidences by
risk level (Inspection Priority). Table 2 provides a list of the Intrusive Inspection Methods and Scopes of Work per each
minimum Inspection confidence level. Table 2 will always be used to specify inspection method and extent unless the rules
are satisfied in Appendix C for the allowance of Non-Intrusive Inspection methods. Table 3 provides a list of those Non-
Intrusive Inspection Methods and Extents.
Table 1 – Recommended Inspection Frequency and Confidence

Internal Corrosion Recommended Inspection Intrusive Inspection Non -Intrusive
1
Inspection Priority Frequency (Years) Recommended Inspection Inspection
Category Confidence Recommended
Inspection Confidence
1–5 5 Very High High
6 – 12 10 Very High High
13 – 19 15 High High
20 – 25 20 Medium Medium
1. These intervals are applicable provided corrosion half life is not exceeded
Table 2 – Intrusive Inspection Method and Scope vs. Confidence- Int. Corrosion
Inspection Method and Scope Options for General, Localized, or Pitting Corrosion
Confidence
Very – High 100% Visual Coverage of the entire internal surface area of the vessel. This includes the internal
visual examination of all nozzles, man-ways, and supports/appurtenances.
The Inspector must be an API Authorized Pressure Vessel or Tank Inspector according to API 510 or
API 653. These credentials need to be verified prior to the start of work.
The inspection should return the following minimum information:

 Damage Rate
o Corrosion/Pitting Rate
 Damage Extent
o Was damage found? - Good description of the damaged area and its location and
dimensions
 Proper documentation of the inspection technique used
o Enough to repeat it.
 Inspection Extent
o Good description of the total amount of the asset examined as a percentage.
 Inspection Confidence
o A gradation on how likely the inspection performed found the damage mechanism
it was intended to find.
High 50% Visual Coverage of the entire internal surface area of the vessel. This includes the internal visual
examination of 50% of the nozzles, man-ways, and supports/appurtenances.
 Damage Rate
 Damage Extent
dimensions
Medium 25% Visual Coverage of the entire internal surface area of the vessel. This includes the internal visual

 Damage Rate
 Damage Extent
dimensions
Table 3 – Non-Intrusive Inspection Method and Scope vs. Confidence- Int. Corrosion
Inspection Method and Scope Options for General Corrosion Only
Confidence
Very – High N/A
High 4 UT readings per head, 8 readings per shell course/band, 1 reading on 50% of nozzles (Min. 1 Inlet
and 1 Outlet nozzle).
The Inspector must hold certifications for UT examination that conform to ASNT SNT-TC-1A. These
credentials need to be verified prior to the start of work.

 Damage Rate
o Corrosion Rate
 Damage Extent
o Was damage found? - Good description of the damaged area including CML
locations and dimensions
o The total number of the CML’s examined and their descriptions.
Medium 2 UT readings per head, 4 UT readings per shell course/band,
1 reading on 50% of nozzles (Min. 1 Inlet and 1 Outlet nozzle).

 Damage Rate
o Corrosion Rate
 Damage Extent
Low N/A
The above strategy tables apply to those vessels directly inspected that have only General Internal Corrosion. Vessels that
are grouped using the rules for similar service and are not directly inspected, need to discount the confidence of the
inspection in the above tables by 1 level when recalculating risk. Example, performing a Low confidence inspection on the
represented vessel would require that no credit be given in number or confidence of inspections to those vessels not
inspected.
Internal Corrosion Strategy Rules for Pressure Vessels, Shell and Tube Heat
Exchangers Channels and Shells, Double Pipe Heat Exchangers Outer Pipe, and
Tank Shells
Internal Corrosion Internal Corrosion Internal Corrosion Internal Corrosion

Inspection Priority Inspection Priority Inspection Priority Inspection Priority
1-5 6 - 12 13 - 19 20 - 25
Nonintrusive Nonintrusive Nonintrusive

No No Yes
Req. Met? Yes No Req. Met? Yes Req. Met?
Half Life < Half Life < Half Life < Half Life < Half Life < Half Life <
Half Life < 5 yrs
10yrs 10yrs 15yrs 15yrs 20yrs 20yrs
No Yes No Yes No Yes No Yes
No Yes No Yes No Yes
LC09 LC10 LC11 LC111 LC12 LC121 LC13 LC131 LC14 LC141 LC15 LC151 LC16 LC161
Gen Gen Gen Gen Gen Gen Gen Gen

Corr? Corr? Corr? Corr? Corr? Corr? Corr? Corr?
Yes Yes Yes Yes Yes Yes Yes Yes
LC091 LC101 LC112 LC113 LC1132 LC133 LC152 LC153

Inspection Priority 13 -
Inspection Priority 1 - 5 Inspection Priority 6 - 12 19 Inspection Priority 20 - 25
No non-intrusive
inspection in lieu of
intrusive inspection POF category for Int. POF category for Int. POF category for Int. Corr.
allowed. Corr. must be a 4 or 5 Corr. must be a 3, 4, or 5 must be a 3, 4, or 5
1 very high confidence
2 very high confidence intrusive inspections in
intrusive inspections in the last 5 years
the last 10 years confirming that general Can be eliminated at any
confirming that general corrosion is the only time provided that general
corrosion is the only degradation corrosion is the only
degradation mechanism. mechanism. degradation mechanism.*
Corr. Rate < .127mm/yr Corr. Rate < .127mm/yr Corr. Rate < .127mm/yr or
or .005in/yr or .005in/yr .005in/yr
Key process variables Key process variables Key process variables have
have not changed over have not changed over not changed over the time
the time period. the time period. period.
Non Intrusive Criteria that must be met for Non Intrusive inspection in lieu of Intrusive inspection
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval
RECOMMENDED INSPECTION SCOPE
100% Visual Coverage of the entire internal surface area of the vessel. This includes the internal visual
examination of all nozzles, man-ways, and supports/appurtenances.
The Inspector must be an API Authorized Pressure Vessel or Tank Inspector according to API 510 or API
High Int Cor Risk- Half Life Not Governing
653. These credentials need to be verified prior to the start of work.

INTERNAL VISUAL INSPECTION

- Damage Rate
- Corrosion/Pitting Rate
- Damage Extent
LC09
60
- Was damage found? - Good description of the damaged area and its location and dimensions
- Proper documentation of the inspection technique used
- Enough to repeat it.
- Inspection Extent
- Good description of the total amount of the asset examined as a percentage.
- Inspection Confidence
- A gradation on how likely the inspection performed found the damage mechanism it was intended to
find.
Visual Coverage of the entire internal surface area of the vessel. This includes the internal visual
Calculated remaining half life from NDE data.

 Damage Rate
High Int Cor Risk- Half Life Governing
 Damage Extent
 Was damage found?
o Good description of the damaged area and its location and dimensions
LC10

 Good description of the total amount of the asset examined as a percentage.
o A gradation on how likely the inspection performed found the damage mechanism it
was intended to find.
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval
4 UT readings per head, 8 readings per shell course/band, 1 reading on 50% of nozzles (Min. 1 Inlet and
High Int Cor Risk- Half Life Not Governing with additional
1 Outlet nozzle).
ULTRASONIC THICKNESS TESTING
UT for General Corrosion only.

 Damage Rate
o Corrosion Rate
LC091
 Damage Extent
60
High Int Cor Risk- Half Life Governing with additional UT
1 Outlet nozzle).
for General Corrosion only.

 Damage Rate
o Corrosion Rate
LC101
 Damage Extent
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval
Med High Int Cor Risk- Half Life Not Governing. Intrusive

 Damage Rate
Inspection Required.
 Damage Extent
LC11
120
dimensions
Med High Int Cor Risk- Half Life Governing. Intrusive Inspection


 Damage Rate
 Damage Extent
Required.
LC111
dimensions
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval
1 Outlet nozzle).
Inspection Required with additional UT for General

 Damage Rate
Corrosion only.
o Corrosion Rate
LC112
120
 Damage Extent
1 Outlet nozzle).
Med High Int Cor Risk- Half Life Governing. Intrusive

 Damage Rate
Corrosion only.
o Corrosion Rate
LC113
 Damage Extent
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval
1 Outlet nozzle).
Med High Int Cor Risk- Half Life Not Governing. Non
ULTRASONIC THICKNESS TESTINGI

Intrusive Inspection.
 Damage Rate
o Corrosion Rate
LC12
120
 Damage Extent
Med High Int Cor Risk- Half Life Governing. Non Intrusive
1 Outlet nozzle).

 Damage Rate
Inspection.
o Corrosion Rate
LC121
 Damage Extent
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval
Med Int Cor Risk- Half Life Not Governing. Intrusive

 Damage Rate
LC13
180
 Damage Extent
dimensions
Med Int Cor Risk- Half Life Governing. Intrusive Inspection


 Damage Rate
Required.
LC131
 Damage Extent
dimensions
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval
1 Outlet nozzle).

 Damage Rate
Corrosion only.
o Corrosion Rate
LC132
180
 Damage Extent
Required with additional UT for General Corrosion only.
1 Outlet nozzle).

 Damage Rate
o Corrosion Rate
LC133
 Damage Extent
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval
Med Int Cor Risk- Half Life Not Governing. Non Intrusive
1 Outlet nozzle).
ULTRASONIC THICKNESS TESTINGI

 Damage Rate
Inspection.
o Corrosion Rate
LC14
180
 Damage Extent
1 Outlet nozzle).
Med Int Cor Risk- Half Life Governing. Non Intrusive

 Damage Rate
Inspection.
o Corrosion Rate
LC141
 Damage Extent
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval
examination of the same percentage of the nozzles, man-ways, and supports/appurtenances.
Low Int Cor Risk- Half Life Not Governing. Intrusive

 Damage Rate
LC15
240
 Damage Extent
dimensions
Low Int Cor Risk- Half Life Governing. Intrusive Inspection
examination of the same percentage of the nozzles, man-ways, and supports/appurtenances.


 Damage Rate
Required.
LC151
 Damage Extent
dimensions
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval
2 UT readings per head, 4 UT readings per shell course/band,

Low Int Cor Risk- Half Life Not Governing. Intrusive

 Damage Rate
Corrosion only.
o Corrosion Rate
LC152
240
 Damage Extent


 Damage Rate
o Corrosion Rate
LC153
 Damage Extent
Strategy Management
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
Interval

Low Int Cor Risk- Half Life Not Governing. Non Intrusive

 Damage Rate
Inspection.
o Corrosion Rate
LC16
240
 Damage Extent
Low Int Cor Risk- Half Life Governing. Non Intrusive

 Damage Rate
Inspection.
o Corrosion Rate
LC161
 Damage Extent
3 Substituting Non-Intrusive Inspections In-Lieu of Intrusive Inspection
In order to perform a non-intrusive inspection in lieu of an intrusive inspection for Internal Corrosion, the conditions listed
in the table below must be satisfied for the particular risk ranking of the RBI Component
Internal Corrosion Risk Internal Corrosion Criteria

Ranking Probability Category
High Never Acceptable
Medium High (Inspection 4 or 5 2 very high confidence intrusive inspections in the last
Priority 6 – 12) 10 years confirming that general corrosion is the only
degradation mechanism, a corrosion rate of less than
or equal to 0.005in/yr, key process variables have not
changed.*
Medium(Inspection 3, 4, or 5 1 very high confidence intrusive inspections in the last
Priority 13 – 19) 5 years confirming that general corrosion is the only
degradation mechanism, a corrosion rate of less than
or equal to 0.005in/yr, key process variables have not
changed.*
Low (Inspection Priority 20 3,4,5 Can be eliminated at any time provided that general
– 25) corrosion is the only degradation mechanism with a
corrosion rate of less than or equal to 0.005in/yr, key
process variables have not changed.*
*Air Cooled Heat Exchangers have the addition requirement that the Header Box and Tube materials must have the same
corrosion characteristics.
As an example if a Risk Assessment results in a an Internal Corrosion Risk Ranking of Medium High, a Non Intrusive
Inspection can be performed In-Lieu of Intrusive Inspection if all the following conditions are met:
 Internal Corrosion Probability Category is 4 or 5 (low likelihood of failure).
 Equipment has more than 10 years of acceptable service
 There has been no appreciable impact due to CPP (Critical Process Variable) Excursions.
 Data collected from past Inspections have confirmed that the only degradation mechanism is general corrosion.
Localized and/or pitting corrosion does not qualify.
 Corrosion rate is less than 0.005in/yr.
4 Internal Corrosion Strategy Rule Set for Air Cooled Heat Exchangers (Appendix D)
Internal Corrosion Inspection Priority Categories referenced in the Tables below are based on the Risk Matrix
given in Fig 1 of this document. Table 1 below provides a list of the recommended inspection frequencies and
minimum confidences by risk level (Inspection Priority). Table 2 provides a list of the Intrusive Inspection
Methods and Scopes of Work per each minimum Inspection confidence level. Table 2 will always be used to
specify inspection method and extent unless the rules are satisfied in Appendix C for the allowance of Non-
Intrusive Inspection methods. Table 3 provides a list of those Non-Intrusive Inspection Methods and Extents.

Internal Corrosion Recommended Intrusive Inspection Non-Intrusive Inspection
Inspection Priority Inspection Frequency Recommended Inspection Recommended Inspection
Category (Years)1 Confidence Confidence2
1–5 5 Very High High
6 – 12 10 Very High High
13 – 19 15 High High
20 – 25 20 Medium Medium
2. Air Cooled Heat Exchangers have the addition requirement that the Header Box and Tube materials must
have the same corrosion characteristics.
Table 2 – Intrusive Inspection Method and Scope vs. Confidence- Int. Corrosion
Confidence Method and Scope Options for General, Localized, or Pitting Corrosion
Minimum of 100% of the header plugs removed or complete end plate removal for partial
internal visual inspection of the header box followed immediately with a tube examination by
EC, RFEC, and backed up by IRIS Inspection in the same percentage.
The Technician must hold certifications for EC, RFEC, and/or IRIS examination that conform to
ASNT SNT-TC-1A. These credentials need to be verified prior to the start of work as a
minimum with best practice dictating that the Technician and Instrument be qualified to
work by demonstration examination on the user’s equipment.

 Damage Extent
o Was damage found? - Good description of the damaged area including
mapped out tube-sheet locations and dimensions, distance from the tube-
sheet to the indication, type of indication, and % wall loss or wall penetration.
 Proper documentation of the type/s and inspection technique/s used
o Enough to repeat it including serial numbers of the equipment.
o Including a description of the amount of the header box and tube-sheet
visually inspected and the total number of the tubes examined and their
Very – High locations on a tube-sheet map.
o A gradation on how likely the inspection performed found the damage
mechanism it was intended to find.
EC, RFEC, and/or IRIS Inspection in the same percentage.
work by demonstration examination.

 Damage Extent
locations on a tube-sheet map.
High mechanism it was intended to find..
EC, RFEC, and/or IRIS Inspection in the same percentage.
work by demonstration examination.

 Damage Extent
Medium  Inspection Extent
Low N/A
Table 3 – Non-Intrusive Inspection Method and Scope vs. Confidence- Int. Corrosion
Confidence Method and Scope Options for General Corrosion Only with Header Box and Tube Material
Corrosion Characteristics the same. The tube corrosion rate will be inferred from the header
box UT.
Very – High N/A
High 8 UT readings per header box, 1 reading on 50% of nozzles (Min. 1 Inlet and 1 Outlet nozzle).
The Inspector must hold certifications for UT examination that conform to ASNT SNT-TC-1A.
These credentials need to be verified prior to the start of work.

 Damage Rate
o Corrosion Rate
 Damage Extent
Medium 4 UT readings on each header box, 1 reading on 50% of nozzles (Min. of 1 outlet and 1 inlet
nozzle).
The Inspector must hold certifications for UT examination that conform to ASNT SNT-TC-1A.

 Damage Rate
o Corrosion Rate
 Damage Extent
Low N/A
Internal Corrosion Strategy Rules for Air Cooled Heat Exchangers
Internal Corrosion Internal Corrosion Internal Corrosion Internal Corrosion

1-5 6 - 12 13 - 19 20 - 25
Nonintrusive Nonintrusive Nonintrusive

No No Yes
Req. Met? Yes No Req. Met? Yes Req. Met?
Half Life < 5 yrs
10yrs 10yrs 15yrs 15yrs 20yrs 20yrs
LC17 LC171 LC18 LC181 LC19 LC191 LC20 LC201 LC21 LC211 LC22 LC221 LC23 LC231
Gen Gen Gen Gen Gen Gen Gen Gen

Corr? Corr? Corr? Corr? Corr? Corr? Corr? Corr?
Yes Yes Yes Yes Yes Yes Yes Yes

Non Intrusive Criteria that must be met for Non Intrusive inspection in lieu of Intrusive inspection
Inspection Priority 1 -
5 Inspection Priority 6 - 12 Inspection Priority 13 - 19 Inspection Priority 20 - 25
No non-intrusive
inspection in lieu of
intrusive inspection POF category for Int. Corr. POF category for Int. Corr. POF category for Int. Corr.
allowed. must be a 4 or 5 must be a 3, 4, or 5 must be a 3, 4, or 5
2 very high confidence
intrusive inspections in 1 very high confidence
the last 10 years intrusive inspections in the Can be eliminated at any
confirming that general last 5 years confirming that time provided that
corrosion is the only general corrosion is the general corrosion is the
degradation mechanism. only degradation only degradation
Air Cooled Heat mechanism. Air Cooled mechanism. Air Cooled
Exchangers have the Heat Exchangers have the Heat Exchangers have the
addition requirement that addition requirement that addition requirement that
the Header Box and Tube the Header Box and Tube the Header Box and Tube
materials must have the materials must have the materials must have the
same corrosion same corrosion same corrosion
characteristics. characteristics. characteristics.
Corr. Rate < .127mm/yr or Corr. Rate < .127mm/yr or Corr. Rate < .127mm/yr or
.005in/yr .005in/yr .005in/yr
Key process variables Key process variables have Key process variables
have not changed over not changed over the time have not changed over
the time period. period. the time period.
INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Minimum of 100% of the header plugs removed or complete end plate removal
for partial internal visual inspection of the header box followed immediately with
a tube examination by EC, RFEC, and backed up by IRIS Inspection in the same
percentage.
The Technician must hold certifications for EC, RFEC, and/or IRIS examination that
conform to ASNT SNT-TC-1A. These credentials need to be verified prior to the
High Int Cor Risk- Half Life Not Governing
start of work as a minimum with best practice dictating that the Technician and
Instrument be qualified to work by demonstration examination on the user’s
equipment.

 Damage Extent
LC17
60
o Was damage found? - Good description of the damaged area

including mapped out tube-sheet locations and dimensions,
distance from the tube-sheet to the indication, type of indication,
and % wall loss or wall penetration.
o Including a description of the amount of the header box and tube-
sheet visually inspected and the total number of the tubes
examined and their locations on a tube-sheet map.
o A gradation on how likely the inspection performed found the
damage mechanism it was intended to find.
INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
percentage.

High Int Cor Risk- Half Life Governing

equipment.

 Damage Extent
LC171

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
8 UT readings per header box, 1 reading on 50% of nozzles (Min. 1 Inlet and 1
High Int Cor Risk- Half Life Not Governing with additional
Outlet nozzle).
The Inspector must hold certifications for UT examination that conform to ASNT
SNT-TC-1A. These credentials need to be verified prior to the start of work.
UT for General Corrosion only.

 Damage Rate
o Corrosion Rate
LC172
 Damage Extent
60

including CML locations and dimensions
High Int Cor Risk- Half Life Governing with additional UT
Outlet nozzle).
for General Corrosion only.

 Damage Rate
o Corrosion Rate
LC173
 Damage Extent
INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Med High Int Cor Risk- Half Life Not Governing. Intrusive Inspection Required.
percentage.
equipment.

 Damage Extent
LC18
120

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Med High Int Cor Risk- Half Life Governing. Intrusive Inspection Required.
percentage.

equipment.

 Damage Extent
LC181

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Outlet nozzle).
only. TESTING

 Damage Rate
THICKNESS
o Corrosion Rate
LC182
Corrosion
120
 Damage Extent
ULTRASONIC

Outlet nozzle).
Med High Int Cor Risk- Half Life Governing. Intrusive
only. TESTING

 Damage Rate
THICKNESS
o Corrosion Rate
LC183
Corrosion
 Damage Extent
ULTRASONIC

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Outlet nozzle).
Med High Int Cor Risk- Half Life Not Governing. Non

Intrusive Inspection.
 Damage Rate
o Corrosion Rate
LC19
120
 Damage Extent
Med High Int Cor Risk- Half Life Governing. Non Intrusive
Outlet nozzle).

 Damage Rate
Inspection.
o Corrosion Rate
LC191
 Damage Extent
INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Minimum of 70% of the header plugs removed or complete end plate removal for
Med Int Cor Risk- Half Life Not Governing. Intrusive Inspection Required.
partial internal visual inspection of the header box followed immediately with a
tube examination by EC, RFEC, and/or IRIS Inspection in the same percentage.
Instrument be qualified to work by demonstration examination.

 Damage Extent
LC20
180

damage mechanism it was intended to find..
INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Med Int Cor Risk- Half Life Governing. Intrusive Inspection Required.


 Damage Extent
LC201

damage mechanism it was intended to find..
INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Outlet nozzle).
only. TESTING

 Damage Rate
THICKNESS
o Corrosion Rate
LC202
Corrosion
180
 Damage Extent
ULTRASONIC

Outlet nozzle).

 Damage Rate
o Corrosion Rate
LC203
 Damage Extent
INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Med Int Cor Risk- Half Life Not Governing. Non Intrusive
Outlet nozzle).

 Damage Rate
Inspection.
o Corrosion Rate
LC21
180
 Damage Extent
Outlet nozzle).
Med Int Cor Risk- Half Life Governing. Non Intrusive

 Damage Rate
Inspection.
o Corrosion Rate
LC211
 Damage Extent
INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Low Int Cor Risk- Half Life Not Governing. Intrusive Inspection Required.

 Damage Extent
LC22
240

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Low Int Cor Risk- Half Life Governing. Intrusive Inspection Required.


 Damage Extent
LC221

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
Low Int Cor Risk- Half Life Not Governing. Intrusive Inspection Required with
additional UT for General Corrosion only.

 Damage Extent
LC22
240

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)
4 UT readings on each header box, 1 reading on 50% of nozzles (Min. of 1 outlet

and 1 inlet nozzle).


 Damage Rate
o Corrosion Rate
LC223
 Damage Extent
Low Int Cor Risk- Half Life Not Governing. Non Intrusive

 Damage Rate
Inspection.
o Corrosion Rate
LC23
240
 Damage Extent
INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
Task Type ID
DESRIPTION
LOGIC CASE
(months)

Low Int Cor Risk- Half Life Governing. Non Intrusive

 Damage Rate
Inspection.
o Corrosion Rate
LC231
 Damage Extent
5 Internal Corrosion Strategy Rule Set for Piping (Appendix E)
risk level (Inspection Priority). Table 2 provides a list of the Inspection Methods and Scopes of Work for general or localized
internal corrosion with predictable locations for each minimum Inspection Confidence level. Table 3 provides a list of the
Inspection Methods and Scopes of Work for localized or pitting internal corrosion which is not predictable for each
minimum Inspection Confidence level.
Table 1 – Recommended Percentage, Frequency, and Confidence

Internal Pitting or General and Pitting or General and Recommended
Corrosion Localized Predictable Localized Predictable Confidence
Inspection Unpredictable Localized Unpredictable Localized
Priority Percentage of Percentage of Recommended Recommended
Category Representative Representative Frequency (Years)1 Frequency (Years)1
Piping Circuits (%) Piping Circuits (%)
2,3 2,3
1–5 100 50 3 5 High

6 – 12 50 25 5 7.5 High
13 – 19 25 10 7.5 10 Medium
20 – 25 10 5 10 15 Low
1. These intervals are applicable providing corrosion half life is not exceeded
2. For Internal Corrosion, all piping in a Unit can be grouped by Inspection Priority and then by Wall Ratio. The grouping
allows one or a small number of piping circuits to represent a larger population of piping. When selecting
representative circuits from each Inspection Priority and Wall Ratio, select the piping circuits with the highest
Inspection Priority first and those that have the same Inspection Priority are to be decided by wall ratio.
3. 100 percent (%) of Injection Circuits require inspection. The number of assigned CML’s shall be defined per API 570.
The recommended upstream limit of the injection circuit is a minimum of 12 inches or three (3) pipe diameters
upstream of the injection point, whichever is larger. The recommended downstream limit is the second change in flow
direction after the injection point or 25 feet beyond the first change in flow direction, whichever is less. In some cases,
it may be more appropriate to extend this circuit to the next piece of pressure equipment.
Table 2 – Piping Inspection Method and Scope vs. Confidence- General or Localized Predictable Internal Corrosion
Inspection Method and Scope Options for General and Predictable Localized
Confidence
Very – High N/A
High Inspect a minimum of 50% of the assigned CML’s locations. Assigned CML’s are defined by a
combination of:
Inspection/Failure History – First assign to all locations with known corrosion problems and or
failures regardless of access requirements.
 Turbulent Flow Areas – Then assign to 50% of all tees, elbows, changes of direction, and
straight run mid points.
 Every injection point CML shall be defined per API-570 and inspected.
 Access requirements need to be considered as part of the assignment process.
 Locations that require external support, such as scaffolding to allow access, should be
avoided unless the location is one with known corrosion problems or failures.
Recommend using Profile RT as the primary method for monitoring when piping its diameter is 10”
or less, otherwise use External UT. If UT is used in place of RT, then discount the “Confidence” one
(1) level.
The Inspector must hold certifications for RT or UT examination that conform to ASNT SNT-TC-1A.

 Damage Rate
o Corrosion Rate
 Damage Extent
If damage is found, continue testing likely locations by doubling the percentage until no further
damage is seen.
Medium Inspect a minimum of 25% of the assigned CML’s locations. If CML’s have not been previously
defined then locations should be determined by a combination of:
(1) level.

 Damage Rate
o Corrosion Rate
 Damage Extent
damage is seen.
Low Inspect a minimum of 10% of the assigned CML’s locations. If CML’s have not been previously
(1) level.
These credentials need to be verified prior to the start of work. The inspection should return the
following minimum information:
 Damage Rate
o Corrosion Rate
 Damage Extent
damage is seen.
Table 3 – Piping Inspection Method and Scope vs. Confidence- Pitting or Localized Unpredictable Internal Corrosion
Confidence Method and Scope Options for Unpredictable Localized and Pitting Corrosion
Very – High N/A
High Inspect a minimum of 100% of the assigned CML’s locations. If CML’s have not been previously
or less, otherwise use External Shear wave UT, Phased Array or Smart Pigging.

 Damage Rate
o Corrosion Rate
 Damage Extent
Medium Inspect a minimum of 50% of the assigned CML’s locations. If CML’s have not been previously
 Damage Rate
o Corrosion Rate
 Damage Extent
damage is seen.
Low Inspect a minimum of 25% of the assigned CML’s locations. If CML’s have not been previously
 Damage Rate
o Corrosion Rate
 Damage Extent
damage is seen.
Internal Corrosion
for Piping
Internal Corrosion Internal Corrosion

Inspection Priority Inspection Priority
6 - 12 20 - 25
General or Loc. General or Loc.

No Predictable? Yes No Predictable? Yes
Internal Corrosion Internal Corrosion

Half Life < Half Life < Half Life <
Inspection Priority Half Life < 5yrs Inspection Priority
7.5yrs 10yrs 15yrs
1-5 13 - 19

General or Loc. General or Loc.
No Predictable? Yes No Predictable? Yes
Half Life < Half Life <

Half Life < 3yrs Half Life < 5yrs
7.5yrs 10yrs
RBI Strategy Rule Sets Page 52 of 161

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)
Inspect a minimum of 100% of the assigned CML’s locations.
Assign CML’s to be defined by a combination of:
Inspection/Failure History – First assign to all locations with known corrosion

problems and or failures regardless of access requirements.
 Turbulent Flow Areas – Then assign to 100% of all tees, elbows, changes
High Int. Cor. Risk- Pitting or Localized - Half Life Not Governing.
of direction, and straight run mid points.

 Access requirements need to be considered as part of the assignment
process.
 Locations that require external support, such as scaffolding to allow
access, should be avoided unless the location is one with known corrosion
problems or failures.
RADIOGRAPHIC TESTING
Recommend using Profile RT as the primary method for monitoring when piping
its diameter is 10” or less, otherwise use External Shear wave UT, Phased Array or
LC24
36
Smart Pigging.
The Inspector must hold certifications for RT or UT examination that conform to

ASNT SNT-TC-1A. These credentials need to be verified prior to the start of work.

 Damage Rate
o Corrosion Rate
 Damage Extent

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)
Inspect a minimum of 100% of the assigned CML’s locations.

High Int. Cor. Risk- Pitting or Localized - Half Life Governing.
process.
LC241
Smart Pigging.


 Damage Rate
o Corrosion Rate
 Damage Extent

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)
Inspect 100% of the assigned CML locations.

 Turbulent Flow Areas – Then assign to 50% of all tees, elbows, changes of
direction, and straight run mid points.
High Int. Cor. Risk- General - Half Life Not Governing.
process.
its diameter is 10” or less, otherwise use External UT. If UT is used in place of RT,
then discount the “Confidence” one (1) level.
LC25
60


 Damage Rate
o Corrosion Rate
 Damage Extent
If damage is found, continue testing likely locations by doubling the percentage

until no further damage is seen.

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

process.
High Int. Cor. Risk- General - Half Life Governing.

LC251


 Damage Rate
o Corrosion Rate
 Damage Extent


INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

Med-High Int. Cor. Risk- Pitting or Localized - Half Life Not Governing.
process.
LC26
60
Smart Pigging.


 Damage Rate
o Corrosion Rate
 Damage Extent

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

Med-High Int. Cor. Risk- Pitting or Localized - Half Life Governing.

process.
LC261
Smart Pigging.


 Damage Rate
o Corrosion Rate
 Damage Extent

INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

Med-High Int. Cor. Risk- General - Half Life Not Governing
process.
LC27
84


 Damage Rate
o Corrosion Rate
 Damage Extent


INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

Med-High Int. Cor. Risk- General - Half Life Governing.
process.
LC271


 Damage Rate
o Corrosion Rate
 Damage Extent


INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)
Assign CML’s to be defined by a combination of::

Med Int. Cor. Risk- Pitting or Localized - Half Life Not Governing.
process.
Smart Pigging.
LC28
84

 Damage Rate
o Corrosion Rate
 Damage Extent


INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

Med Int. Cor. Risk- Pitting or Localized - Half Life Governing.

process.

Smart Pigging.
LC281

 Damage Rate
o Corrosion Rate
 Damage Extent


INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

Med Int. Cor. Risk- General - Half Life Not Governing
process.
LC29
120


 Damage Rate
o Corrosion Rate
 Damage Extent


INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

process.
Med Int. Cor. Risk- General - Half Life Governing.

LC291


 Damage Rate
o Corrosion Rate
 Damage Extent


INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

Low Int. Cor. Risk- Pitting or Localized - Half Life Not Governing.
process.
Smart Pigging.
LC30
120

 Damage Rate
o Corrosion Rate
 Damage Extent


INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)
I Inspect 100% of the assigned CML locations.

Low Int. Cor. Risk- Pitting or Localized - Half Life Governing.

process.

Smart Pigging.
LC301

 Damage Rate
o Corrosion Rate
 Damage Extent


INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

Low Int. Cor. Risk- General - Half Life Not Governing
process.
LC31
160

 Damage Rate
o Corrosion Rate
 Damage Extent


INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)

process.
Low Int. Cor. Risk- General - Half Life Governing.

LC311

 Damage Rate
o Corrosion Rate
 Damage Extent


6 External and CUI Strategy Rule Sets For Vessels, Exchangers, Tanks and Piping (Appendix F)
External Degradation and CUI Inspection Priority Categories referenced in the Tables below are based on the Risk Matrix
given in Fig 1 of this document. External Degradation inspection is accomplished in two parts. One is for all equipment,
insulated or not, and that recommended technique is external visual inspection. The other part is only for insulated
equipment and the recommended techniques are stripping of insulation accompanied by external visual inspection and/or
using NDT such as RT to look at the surface. These two inspections/parts are separate events and this appendix provides
strategy rules for both. Table 1 below provides a list of the recommended inspection frequencies and minimum
confidences by risk level (Inspection Priority) for both external visual inspection and the CUI inspection. Table 2 provides a
list of the Inspection Methods and Scopes of Work for external visual inspection for both insulated and non-insulated
equipment. Table 3 provides a list of the Inspection Methods and Scopes of Work for CUI inspection for each minimum
Inspection Confidence level.

External Percentage of Recommended Recommended Recommended Recommended
Corrosion Representative Frequency Frequency CUI Confidence for all Confidence for all
Inspection for CUI Inspection of External Visual for all Equipment Equipment Types Equipment Types
Category of all Equipment for all Equipment Types (Years)1 External Visual CUI Inspection
Types Types Coverage
(%)3 (Years)1
1–5 50% 3 5 Very – High/ High
Medium4
6 – 12 25% 5 10 Very – High/ High
Medium4
13 – 19 10% 7 15 Very – High/ Medium
Medium4
20 – 25 N/A2 10 N/A2 Very – High/ Low
Medium4
1. These intervals are applicable provided corrosion half life is not exceeded.
2. Pressure Vessels, Tanks excluding floors, and Piping with a Low Criticality rating for CUI will not be inspected unless the
external visual inspection identifies a condition that indicates significant CUI is occurring on the vessel.
3. For CUI, all Pressure Vessels, Tanks, and Piping in a Unit can be grouped by Equipment Type, Criticality Rating, and then
by operating temperature range. The grouping allows one or a small number of piping circuits to represent a larger
population of piping. The temperature range groupings in degrees F are [0 - 75], [75 - 150], [150 - 200], [200 – 300] and
[300 - 350]. When choosing representative components from each criticality rating and temperature range, select the
piping circuits with the highest likelihood for CUI and those that may have damaged or wet insulation or other
indications of external corrosion from the external visual inspection checklist.
4. Confidence taken when performing a visual external inspection on insulated equipment.
Table 2 – Inspection Method and Scope vs. Confidence- External Inspection Pressure Vessels, Tanks, & Piping
Inspection Method and Scope Options for insulated and non-insulated
Confidence
Very – High/ 100% External Visual of the entire outer surface noting any discontinuities. Per API 510, external
Medium inspections are performed to check the condition of:
 The outside surface of the vessel,
 Insulation systems,

 Painting and coating systems,
 Supports and associated structure;
and to check for:
 Leakage,
 Hot spots,
 Vibration,
 The allowance for expansion and the general alignment of the vessel on its supports.
During the external inspection, particular attention should be given to welds used to attach
components (e.g. reinforcement plates, and clips) for cracking or other defects. Any signs of leakage
should be investigated so that the sources can be established. Normally, weep holes in reinforcing
plates should remain open to provide visual evidence of leakage as well as to prevent pressure build-
up behind the reinforcing plate.
If the Pressure Vessel, Tank, or Piping is insulated, please make certain to note the number of:
 barrier penetrations
 termination of insulation
 damaged insulation
 insulation support rings
For piping specifically note the number of vertical changes of direction.
The Inspector must be an API Authorized Pressure Vessel, Piping, or Tank Inspector according to API
510, 570, or 653. These credentials need to be verified prior to the start of work.

 Damage Rate
 Damage Extent
dimensions
If the equipment is insulated use the “Confidence” in red.

High N/A
Medium N/A
Low N/A

Table 3 – Inspection Method and Scope vs. Confidence- CUI Inspection Pressure Vessels, Tanks, & Piping
Inspection Method and Scope Options for CUI Inspection with and without Insulation Removal.
Confidence
Very – High N/A
High Profile RT may be used for piping 10” or less in diameter, otherwise strip and visually examine a
minimum of 50% of:
 termination of insulation,
 damaged insulation,
 insulation support rings,
 the number of vertical changes of direction identified as damaged for piping only
If damage is found, continue stripping likely locations by doubling the percentage until no further
damage is seen.
510, 570, or 653 for the visual inspection or must hold certifications for RT examination that conform to

 Damage Rate
 Damage Extent
dimensions
Medium Profile RT may be used for piping 10” or less in diameter, otherwise strip and visually examine a
minimum of 25% of the barrier penetrations:
 larger than 10” diameter and smaller penetrations that are not properly sealed,
If damage is found continue stripping likely locations by doubling the percentage until no further
damage is seen.

 Damage Rate

 Damage Extent
dimensions
Low Profile RT may be used for piping 10” or less in diameter, otherwise strip and visually examine a
minimum of 10% of the barrier penetrations:
 larger than 10” diameter and smaller penetrations that are not properly sealed,
 insulation support rings, and
If damage is found continue stripping likely locations by doubling the percentage until no further
damage is seen.

 Damage Rate
 Damage Extent
dimensions

External Degradation For Pressure Vessels, Shell and Tube Heat Exchangers Channels
and Shells, Double Pipe Heat Exchangers Outer Pipe, Tank Shells and Roofs, and
Piping
External External External External

Degradation Degradation Degradation Degradation
1-5 6 - 12 13 - 19 20 - 25
Insulated? Insulated? Insulated? Insulated?

No Yes No Yes No Yes No
Yes
Half Life < Half Life < Half Life < Half Life < Half Life < Insulation
10yrs 10yrs 10yrs 15yrs 15yrs Damage?
No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes
LC32 LC321 LC33 LC34 LC35 LC351 LC36 LC37 LC38 LC381 LC39 LC40 LC41 LC411 LC42 LC421
LC331 LC341 LC361 LC371 LC391 LC401

Logic Case ID
Logic Case
Description
Task Type ID
Recommended
Inspection
RBI Strategy Rule Sets

Interval
Page 74 of 161
Recommended Inspection Scope
100% External Visual of the entire outer surface noting any discontinuities. Per API 510,
external inspections are performed to check the condition of:
and to check for:
 Leakage,
 Hot spots,
 Vibration,
 The allowance for expansion and the general alignment of the vessel on
Strategy for High Risk – Non-Insulated – Half Life Not Governing
its supports.
During the external inspection, particular attention should be given to welds used to
attach components (e.g. reinforcement plates, and clips) for cracking or other defects. Any
signs of leakage should be investigated so that the sources can be established. Normally,
EXTERNAL VISUAL - NON-INSULATED ASSET
weep holes in reinforcing plates should remain open to provide visual evidence of leakage
as well as to prevent pressure build-up behind the reinforcing plate.
If the Pressure Vessel, Tank, or Piping is insulated, please make certain to note the
number of:
LC32
60

The Inspector must be an API Authorized Pressure Vessel, Piping, or Tank Inspector
according to API 510, 570, or 653. These credentials need to be verified prior to the start of
work.
 Damage Rate
 Damage Extent
o Was damage found? - Good description of the damaged area and its
location and dimensions
o Good description of the total amount of the asset examined as a
percentage.

NON-
remaining half
Non-Insulated
life from NDE

Strategy for
INSULATED

High Risk –
Calculated
Governing
EXTERNAL
– Half- Life

LC321
ASSET
data.
VISUAL


Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval
and to check for:

 Leakage,
 Hot spots,
 Vibration,
its supports.
number of:

work.
 Damage Rate
 Damage Extent
percentage.

and to check for:
 Leakage,
 Hot spots,
 Vibration,
its supports.
Strategy for High Risk – Insulated – Half Life Not Governing
EXTERNAL VISUAL - INSULATED ASSET

number of:
LC33
60

work.
 Damage Rate
 Damage Extent
percentage.

Profile RT may be used for piping 10” or less in diameter, otherwise strip and visually
Half Life Not
Strategy for
examine a minimum of 50% of:

CUI –
High Risk –
Governing
Insulated
LC331
60

Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval
 the number of vertical changes of direction identified as damaged for

piping only
If damage is found, continue stripping likely locations by doubling the percentage until no
further damage is seen.
according to API 510, 570, or 653 for the visual inspection or must hold certifications for RT
examination that conform to ASNT SNT-TC-1A. These credentials need to be verified prior
to the start of work.

 Damage Rate
 Damage Extent
percentage.

and to check for:
 Leakage,
 Hot spots,
 Vibration,
its supports.
Strategy for High Risk – Insulated – Half Life Governing

number of:
LC34

work.

 Damage Rate
 Damage Extent
percentage.

Strategy for
CUI –
High Risk –
Calculated
Governing
remaining
from NDE
Half Life

Insulated
half life
LC341
data.

Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval

piping only
 Damage Rate
 Damage Extent
percentage.

and to check for:
 Leakage,
 Hot spots,
 Vibration,
Strategy for Med-High Risk – Non-Insulated – Half Life Not Governing
its supports.
number of:
LC35
120

work.
 Damage Rate
 Damage Extent
percentage.

- NON-
Med-High Risk
half
life from NDE
Strategy for
INSULATED

–
Calculated
Governing
EXTERNAL
Half Life
Insulated
– Non-

LC351
ASSET
remaining
data.
VISUAL


Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval
and to check for:

 Leakage,
 Hot spots,
 Vibration,
its supports.
number of:

work.
 Damage Rate
 Damage Extent
percentage.

and to check for:
 Leakage,
 Hot spots,
 Vibration,
Strategy for Med-High Risk – Insulated – Half Life Not Governing
its supports.

number of:
LC36
120

work.
 Damage Rate
 Damage Extent
percentage.

Med-High Risk
CUI –
Half Life Not
Strategy for

Governing
– Insulated
LC361
120

Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval

piping only

 Damage Rate
 Damage Extent
percentage.

and to check for:
 Leakage,
 Hot spots,
 Vibration,
its supports.
Strategy for Med-High Risk – Insulated – Half Life Governing

number of:
LC37

work.
 Damage Rate
 Damage Extent
percentage.

Med-High Risk
remaining half
life from NDE
CUI –
Strategy for

Calculated
Governing
– Insulated
Half Life
LC371
data.

Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval

piping only

 Damage Rate
 Damage Extent
percentage.

and to check for:
 Leakage,
 Hot spots,
 Vibration,
Strategy for Med Risk – Non-Insulated – Half Life Not Governing
its supports.
number of:
LC38
180

work.
 Damage Rate
 Damage Extent
percentage.

NON-
remaining half
Non-Insulated
life from NDE

Strategy for
INSULATED

Med Risk –
Calculated
Governing
EXTERNAL
– Half- Life

LC381
ASSET
data.
VISUAL


Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval
and to check for:

 Leakage,
 Hot spots,
 Vibration,
its supports.
number of:

work.
 Damage Rate
 Damage Extent
percentage.

and to check for:
 Leakage,
 Hot spots,
 Vibration,
its supports.
Strategy for Med Risk – Insulated – Half Life Not Governing

number of:
LC39
180

work.
 Damage Rate
 Damage Extent
percentage.

Half Life Not
Strategy for
CUI –
Med Risk –
examine a minimum of 25% of the barrier penetrations:

Governing
Insulated
LC391
 larger than 10” diameter and smaller penetrations that are not properly
180
sealed,

Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval

piping only
If damage is found continue stripping likely locations by doubling the percentage until no
 Damage Rate
 Damage Extent
percentage.

and to check for:
 Leakage,
 Hot spots,
 Vibration,
its supports.
Strategy for Med Risk – Insulated – Half Life Governing

number of:
LC40

work.
 Damage Rate
 Damage Extent
percentage.

Life Governing
Risk- Internal –
Env Crack
Possible – Half
Strategy for
CUI –
Med Risk –

Governing
No Entry
Half Life
Insulated
LC401
sealed,
High

Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval

piping only

 Damage Rate
 Damage Extent
percentage.

and to check for:
 Leakage,
 Hot spots,
 Vibration,
Strategy for Low Risk – Non-Insulated – Half Life Not Governing
its supports.
number of:
LC41
240

work.
 Damage Rate
 Damage Extent
percentage.

NON-
remaining half
Non-Insulated
life from NDE

Strategy for
INSULATED

Calculated
Governing
Low Risk –
EXTERNAL
– Half- Life

LC411
ASSET
data.
VISUAL


Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval
and to check for:

 Leakage,
 Hot spots,
 Vibration,
its supports.
number of:

work.
 Damage Rate
 Damage Extent
percentage.

and to check for:
 Leakage,
 Hot spots,
 Vibration,
its supports.
Strategy for Med Risk – Insulated – Half Life Not Governing

number of:
LC42
240

work.
 Damage Rate
 Damage Extent
percentage.

Recommended
Logic Case ID
Task Type ID
Description
Inspection
Logic Case
Interval
As Required – If external visual inspection identifies a condition that indicates significant

sealed,
 insulation support rings, and
Strategy for Low Risk – Insulated – As Required
piping only
CUI is occurring on the vessel.
LC421
CUI

 Damage Rate
 Damage Extent
percentage.

7 Environmental Cracking Strategy Rule Sets For Vessels, Exchangers, Tanks, and Piping (Appendix
G)
Environmental Cracking Inspection Priority Categories referenced in the Tables below are based on the Risk Matrix given in
Fig 1 of this document. This strategy covers both internal and external cracking degradation mechanisms. Table 1 below
provides a list of the recommended inspection frequencies and minimum confidences by risk level (Inspection Priority).
Table 2 provides a list of the Recommended Inspection Methods and Scopes of Work per each minimum Inspection
Confidence level when internal access is possible. Table 2 is also the preferred method and scope for all types of external
cracking. Table 3 provides a list of the Optional Inspection Methods and Scopes of Work per each minimum Inspection
Confidence level when access is not available to the internal surface.
Table 1 – Recommended Frequency and Confidence

Environmental Cracking Recommended Inspection Recommended Confidence
Inspection Category Frequency (Years)1
1–5 3 High
6 – 12 5 Medium
13 – 19 10 Low
2
20 – 25 (15) (Low)2
1. If cracking is identified, remaining life has to be evaluated and this information must be used to set inspection
frequency.
2. Vessels with Low Criticality rating for environmental cracking will not be inspected unless the internal visual
inspection of the equipment item or inspections performed on equipment in similar service identify a
condition that indicates cracking is occurring in the vessel.
Table 2 – Recommended Inspection Method and Scope vs. Confidence- MT or PT

Inspection Method and Scope for Internal and External Environmental Cracking when access is available (entry is
Confidence possible).
Very – High N/A
High Use MT or PT to examine 50% of all potential cracking locations. Location categories for examination
should include:
 pressure-containing welds (category A, B, & D welds), especially tee sections where
longitudinal welds end at circumferential welds and circumferential shell to tubesheet welds,
 if access permits category C welds [weld categories defined by ASME Section VIII],
 where non-pressure components are attached by welding to pressure retaining components,
 tank critical zone welds especially the bottom to shell weld and
 any locations identified by the visual inspection, drawings or Degradation Mechanisms study,
 pipe supports that a attached by welding,
 joint welds on elbows, tees, and bends that have high external tension loading due to lack of
support or where the fluid flow may provide swirling and chloride deposition.
 pipe dead legs and normally closed bypasses where the normal operating temperature could
be lower than the process and fall into the correct temperature range for external SCC.
Magnetic Particle Testing (MT) shall be performed to a written procedure that is in accordance with
ASME Section V, Article 7 along with internal visual inspection. Surface prep by cleaning the area to be
inspected in accordance with SSPC-6 at least 1 inch beyond the heat affected zone on both sides of all
joints to be inspected. Acceptance criteria shall be in accordance with ASME Section VIII, Appendix 6,
in accordance with the applicable construction code, or in accordance with Owner User specifications.

Penetrant Testing (PT) shall be performed to a written procedure that is in accordance with ASME
Section V, Article 6 along with internal visual inspection. Surface prep by cleaning the area to be
If damage is found continue inspecting likely locations by doubling the percentage until no further
damage is seen.
Method chosen for the inspection may be dictated by the material of construction, for instance MT is
not applicable for austenitic stainless steel materials.
The Inspector must hold certifications for MT or PT examination that conform to ASNT SNT-TC-1A.

 Damage Rate
o Corrosion Rate
 Damage Extent
o Was damage found? - Good description of the damaged area including CML locations
and dimensions
Medium Use MT or PT to examine 25% of all potential cracking locations. Location categories for examination
should include:
support or where the fluid flow may provide swirling and chloride disposition.

damage is seen.
 Damage Rate
o Corrosion Rate
 Damage Extent
and dimensions
Low Use MT or PT to examine 10% of all potential cracking locations. Location categories for examination
should include:

damage is seen.
 Damage Rate
o Corrosion Rate
 Damage Extent
and dimensions

Table 3 – Optional Inspection Method and Scope vs. Confidence- External UT Shearwave
Inspection Method and Scope Options for Internal Environmental Cracking only when access is not available
Confidence (entry is not possible).
Very – High N/A
High Use UT shear wave to examine 100% of all potential cracking locations. Location categories for
examination should include:
UT shear wave shall be performed per a written procedure that is in accordance with ASME Section V,
Article V. Acceptance criteria shall be in accordance with ASME Section VIII, Appendix 12, in
accordance to the applicable construction code, or in accordance with Owner User specifications.
The Inspector must hold certifications for UT shear wave examination that conform to ASNT SNT-TC-
1A. These credentials need to be verified prior to the start of work.

 Damage Rate
o Corrosion Rate
 Damage Extent
and dimensions
Medium Use UT Shearwave to examine 50% of all potential cracking locations. Location categories for

damage is seen.

 Damage Rate
o Corrosion Rate
 Damage Extent
and dimensions
Low Use UT shear wave to examine 25% of all potential cracking locations. Location categories for
damage is seen.

 Damage Rate
o Corrosion Rate
 Damage Extent
and dimensions

Environmental Cracking Strategy Rule Sets For Pressure
Vessels, Shell and Tube Heat Exchangers Channel and Shells,
Double Pipe Heat Exchangers Outer Pipe, Tank Shells and
Bottoms, and Piping
Environmental Environmental Environmental Environmental

Cracking Cracking Cracking Cracking
1-5 6 - 12 13 - 19 20 - 25
Yes Yes Yes Yes
Is Entry Is Entry Is Entry Evidence of

Yes Yes Yes LC59 No
Possible? Possible? Possible? Cracking?
No No No
Yes
PT or MT PT or MT PT or MT Is Entry
No
No Access? No Access? No Access? Possible? Yes
Yes Yes Yes
Half Life < Half Life < Half Life < Half Life < PT or MT
Half Life < 3yrs Half Life < 5yrs Half Life < 5yrs Half Life < 5yrs Half Life < 5yrs Half Life < 5yrs
10yrs 10yrs 10yrs 15yrs Access?
No Yes
No
No No Yes No No No No No
Yes No Yes Yes Yes Yes No Yes Yes
Yes Yes
Half Life < Half Life <
15yrs 15yrs
LC44 LC441 LC45 LC451 LC46 LC461 LC49 LC491 LC50 LC501 LC51 LC511 LC54 LC541 LC55 LC551 LC56 LC561 LC60 LC601
Yes No Yes
No
LC61 LC611 LC62 LC621

ENVIRONMENTAL CRACKING INSPECTION STRATEGY DETAILS
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Use UT shear wave to examine 100% of all potential cracking locations. Location categories for
- pressure-containing welds (category A, B, & D welds), especially tee sections where longitudinal
welds end at circumferential welds and circumferential shell to tubesheet welds,
- if access permits category C welds [weld categories defined by ASME Section VIII],
- where non-pressure components are attached by welding to pressure retaining components,
High Env Crack Risk- Internal – No Entry Possible – Half Life Not Governing
- tank critical zone welds especially the bottom to shell weld and
- any locations identified by the visual inspection, drawings or Degradation Mechanisms study,
- pipe supports that a attached by welding,
- joint welds on elbows, tees, and bends that have high external tension loading due to lack of
- pipe dead legs and normally closed bypasses where the normal operating temperature could be
ULTRASONIC SHEAR WAVE TESTING
lower than the process and fall into the correct temperature range for external SCC.
UT shear wave shall be performed per a written procedure that is in accordance with ASME Section
V, Article V. Acceptance criteria shall be in accordance with ASME Section VIII, Appendix 12, in
LC44
36
The Inspector must hold certifications for UT shear wave examination that conforms to ASNT SNT-
TC-1A. These credentials need to be verified prior to the start of work.

- Damage Rate
- Corrosion Rate
- Damage Extent
- Was damage found? - Good description of the damaged area including CML locations and
dimensions
- Inspection Extent
- The total number of the CML’s examined and their descriptions.
- A gradation on how likely the inspection performed found the damage mechanism it was intended
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
High Env Crack Risk- Internal – No Entry Possible – Half Life Governing
LC441

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
High Env Crack Risk- Internal – Entry Possible – No PT or MT Access - Half Life Not Governing

LC45
36

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
High Env Crack Risk- Internal – Entry Possible – No PT or MT Access - Half Life Governing
LC451

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
Use MT or PT to examine 50% of all potential cracking locations. Location categories for
High Env Crack Risk- Internal – Entry Possible – PT or MT Access - Half Life Not Governing
ASME Section V, Article 7 along with internal visual inspection. Surface prep by cleaning the area to
be inspected in accordance with SSPC-6 at least 1 inch beyond the heat affected zone on both sides
of all joints to be inspected. Acceptance criteria shall be in accordance with ASME Section VIII,
MAGNETIC PARTICLE OR PENETRANT TESTING
Appendix 6, in accordance with the applicable construction code, or in accordance with Owner User
specifications.
inspected in accordance with SSPC-6 at least 1 inch beyond the heat affected zone on both sides of
all joints to be inspected. Acceptance criteria shall be in accordance with ASME Section VIII,
LC46
36
specifications.
damage is seen.
Method chosen for the inspection may be dictated by the material of construction, for instance MT
is not applicable for austenitic stainless steel materials.

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
High Env Crack Risk- Internal – Entry Possible – PT or MT Access - Half Life Governing
specifications.
LC461
specifications.
damage is seen.

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Med. High Env Crack Risk- Internal – No Entry Possible – Half Life Not Governing

LC49
60

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Med. High Env Crack Risk- Internal – No Entry Possible – Half Life Governing

LC491

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Med. High Env Crack Risk- Internal – Entry Possible – No PT or MT Access - Half Life Not Governing
LC50
60

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Med. High Env Crack Risk- Internal – Entry Possible – No PT or MT Access - Half Life Governing

LC501

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
Med. High Env Crack Risk- Internal – Entry Possible – PT or MT Access - Half Life Not Governing
specifications.
LC51
60
specifications.
damage is seen.

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
Med. High Env Crack Risk- Internal – Entry Possible – PT or MT Access - Half Life Governing
specifications.
LC511
specifications.
damage is seen.

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Use UT Shearwave to examine 50% of all potential cracking locations. Location categories for
Med. Env Crack Risk- Internal – No Entry Possible – Half Life Not Governing
LC54
120
The Inspector must hold certifications for UT shear wave examination that conform to ASNT SNT-

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Med Env Crack Risk- Internal – No Entry Possible – Half Life Governing
LC541

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Med Env Crack Risk- Internal – Entry Possible – No PT or MT Access - Half Life Not Governing

LC55
120

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Med Env Crack Risk- Internal – Entry Possible – No PT or MT Access - Half Life Governing
LC551

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Med Env Crack Risk- Internal – Entry Possible – PT or MT Access - Half Life Not Governing
specifications.
LC56
120
specifications.
damage is seen.
- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Med Env Crack Risk- Internal – Entry Possible – PT or MT Access - Half Life Governing
specifications.
LC561
specifications.
damage is seen.
- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Low Env Crack Risk- Internal – No Entry Possible – Half Life Not Governing
LC60
180
damage is seen.

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Low Env Crack Risk- Internal – No Entry Possible – Half Life Governing

LC601
damage is seen.

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Low Env Crack Risk- Internal – Entry Possible – No PT or MT Access - Half Life Not Governing
LC61
180
damage is seen.

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Low Env Crack Risk- Internal – Entry Possible – No PT or MT Access - Half Life Governing

LC611
damage is seen.

- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Low Env Crack Risk- Internal – Entry Possible – PT or MT Access - Half Life Not Governing
specifications.
LC62
180
specifications.
damage is seen.
- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
INTERVAL (Months)
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
Low Env Crack Risk- Internal – Entry Possible – PT or MT Access - Half Life Governing
specifications.
LC621
specifications.
damage is seen.
- Damage Rate
- Corrosion Rate
- Damage Extent
dimensions
- Inspection Extent
to find.
8 Corrosion and Cracking Strategy Rule Sets Exchanger Bundles / Tubes (Appendix H)
Inspection Priority Categories referenced in the Tables below are based on the Risk Matrix given in Fig 1 of this document.
This strategy covers both internal corrosion and cracking degradation mechanisms. Table 1 below provides a list of the
recommended inspection frequencies and minimum confidences by risk level (Inspection Priority). Table 2 provides a list of
the Recommended Inspection Methods and Scopes of Work per each minimum Inspection Confidence level. Table 3
provides a list of the Optional Inspection Methods and Scopes of Work per each minimum Inspection Confidence level.
Table 3 will only be used for internal environmental cracking when access is not available to the internal surface.
Table 1 – Recommended Frequency and Confidence

Inspection Priority Recommended Recommended
Category Frequency (Years)1 Confidence
1–5 5 High
6 – 12 7.5 Medium
13 – 19 10 Low
20 – 25 15 Low
2. For Bundle and Inner Pipe Corrosion, all bundles and inner pipes in a Unit can be grouped by Component Type,
Inspection Priority, and then by Wall Ratio. The grouping allows one or a small number of components to represent a
larger population. When selecting representative components from each Component Type, Inspection Priority, and
Wall Ratio, select the piping circuits with the highest Inspection Priority first and those that have the same Inspection
Priority are to be decided by wall ratio.
Table 2 – Inspection Method and Scope vs. Confidence for

S&T Heat Exchanger Tube Bundle
Confidence Method and Scope Options for General Corrosion and Cracking
Very – High N/A
High 100% Visual Examination of the tube sheets with PT examination of the identified problem areas and
tube testing (ECT, IRIS) on 100 % of the tubes with follow-up on any indications.
joints to be inspected. Acceptance criteria shall be in accordance with ASME Section VIII, Appendix 8, in
accordance with the applicable construction code, or in accordance with Owner User specifications.
damage is seen.
The Inspector must be an API Authorized Pressure Vessel, Piping, or Tank Inspector according to API 510
for the visual inspection and/or must hold certifications for PT, ECT, and/or IRIS examination that
conform to ASNT SNT-TC-1A. These credentials need to be verified prior to the start of work.

 Damage Extent
o Was damage found? - Good description of the damaged area including mapped out
tube-sheet locations and dimensions, distance from the tube-sheet to the indication,
type of indication, and % wall loss or wall penetration.
o Including a description of the amount of the header box and tube-sheet visually
inspected and the total number of the tubes examined and their locations on a tube-
sheet map.
Medium 100% Visual Examination of the tube sheets with PT examination of the identified problem areas and

 Damage Extent
sheet map.
If damage is found, continue testing likely locations by doubling the percentage until no further damage
is seen.
Low 100% Visual Examination of the tube sheets with PT examination of the identified problem areas and

 Damage Extent
sheet map.
If damage is found, continue testing likely locations by doubling the percentage until no further damage
is seen.
Table 3 – Inspection Method and Scope vs. Confidence for
Double Pipe Exchanger Inner Pipe
Confidence Method and Scope Options for General Corrosion and Cracking
Very – High N/A
High 100% Visual Examination of the inner tube sealing surface with testing (ECT, IRIS) performed
on the inner pipe straight runs followed by profile RT of the return bend/s and inlet nozzles
with calculated exposure time set to reveal the inner tube only.
according to API 510 for the visual inspection and/or must hold certifications for RT, ECT,
and IRIS examination that conform to ASNT SNT-TC-1A. These credentials need to be
verified prior to the start of work.

 Damage Extent
sheet to the indication, type of indication, and % wall loss or wall
penetration.
Medium 100% Visual Examination of the inner tube sealing surface with testing (ECT, IRIS) performed
on the inner pipe straight runs followed by profile RT of the inlet nozzles with calculated
exposure time set to reveal the inner tube only.
according to API 510 for the visual inspection and/or must hold certifications for RT, ECT,
and IRIS examination that conform to ASNT SNT-TC-1A. These credentials need to be
verified prior to the start of work.

 Damage Extent
sheet to the indication, type of indication, and % wall loss or wall
penetration.
Low Profile RT on the inner pipe straight runs with calculated exposure time set to reveal the
inner tube only.
The Inspector must hold certifications for RT examination that conform to ASNT SNT-TC-1A.

 Damage Rate
 Damage Extent
percentage.
Corrosion and Cracking Strategy Rule Sets for Shell &
Tube Exchanger-Bundle and Double Pipe Exchanger
Inner Pipe
Corrosion Corrosion Corrosion Corrosion

1-5 6 - 12 13 - 19 20 - 25
Bundle or Inner Bundle or Inner Bundle or Inner Bundle or Inner

Bundle Pipe? Inner Pipe Bundle Pipe? Inner Pipe Bundle Pipe? Inner Pipe Bundle Pipe? Inner Pipe
7.5yrs 7.5yrs 10yrs 10yrs 15yrs 15yrs
No Yes No Yes No Yes No Yes No Yes No Yes No Yes No Yes
LC65 LC651 LC66 LC661 LC67 LC671 LC68 LC681 LC69 LC691 L70 LC701 LC71 LC711 LC72 LC721
HEAT EXCHANGER BUNDLE AND AIR COOLED EXCHANGER TUBES STRATEGY DETAILS
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
100% Visual Examination of the tube sheets with PT examination of the identified
problem areas and tube testing (ECT, IRIS) on 100 % of the tubes with follow-up on
any indications.
Penetrant Testing (PT) shall be performed to a written procedure that is in

accordance with ASME Section V, Article 6 along with internal visual inspection.
Surface prep by cleaning the area to be inspected in accordance with SSPC-6 at least
1 inch beyond the heat affected zone on both sides of all joints to be inspected.
High Cor. Risk- Inner Pipe - Half Life Not Governing.
Acceptance criteria shall be in accordance with ASME Section VIII, Appendix 8, in

accordance with the applicable construction code, or in accordance with Owner User
EXCHANGER BUNDLE/TUBE INSPECTION
specifications.
If damage is found continue inspecting likely locations by doubling the percentage

LC65
60
according to API 510 for the visual inspection and/or must hold certifications for PT,
ECT, and/or IRIS examination that conform to ASNT SNT-TC-1A. These credentials
need to be verified prior to the start of work.

- Damage Extent
- Was damage found? - Good description of the damaged area including mapped out
- Proper documentation of the type/s and inspection technique/s used
- Enough to repeat it including serial numbers of the equipment.
- Inspection Extent
- Including a description of the amount of the tube-sheet visually inspected and the
total number of the tubes examined and their locations on a tube-sheet map.
- A gradation on how likely the inspection performed found the damage mechanism
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
any indications.

High Cor. Risk- Inner Pipe - Half Life Governing
specifications.
If damage is found continue inspecting likely locations by doubling the percentage

LC651
0

- Damage Extent
- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
100% Visual Examination of the inner tube sealing surface with testing (ECT, IRIS)
performed on the inner pipe straight runs followed by profile RT of the return bend/s
and inlet nozzles with calculated exposure time set to reveal the inner tube only.
Med. High Cor. Risk- Bundle - Half Life Not Governing
according to API 510 for the visual inspection and/or must hold certifications for RT,
ECT, and IRIS examination that conform to ASNT SNT-TC-1A. These credentials need
to be verified prior to the start of work.

- Damage Extent
LC66
60

- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
performed on the inner pipe straight runs followed by profile RT of the return bend/s
and inlet nozzles with calculated exposure time set to reveal the inner tube only.
Med. High Cor. Risk- Bundle - Half Life Governing

- Damage Extent
LC661

0

- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
any indications.

Med. High Cor. Risk- Inner Pipe - Half Life Not Governing
specifications.
LC67
90

- Damage Extent
- Inspection Extent
- Including a description of the amount of thetube-sheet visually inspected and the
If damage is found, continue testing likely locations by doubling the percentage until
no further damage is seen.
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
any indications.

Med. High Cor. Risk- Inner Pipe - Half Life Governing

specifications.
LC671

- Damage Extent
- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
performed on the inner pipe straight runs followed by profile RT of the inlet nozzles
Med. Cor. Risk- Bundle - Half Life Not Governing

- Damage Extent
LC68
90

- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
performed on the inner pipe straight runs followed by profile RT of the inlet nozzles
Med. Cor. Risk- Bundle - Half Life Governing

- Damage Extent
LC681
0

- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
any indications.

Med. Cor. Risk- Inner Pipe - Half Life Not Governing

specifications.
LC69
120

- Damage Extent
- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
any indications.

Med. Cor. Risk- Inner Pipe - Half Life Governing
specifications.
LC691

- Damage Extent
- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
Profile RT on the inner pipe straight runs with calculated exposure time set to reveal
the inner tube only.
Low Cor. Risk- Bundle - Half Life Not Governing
The Inspector must hold certifications for RT examination that conform to ASNT SNT-

- Damage Rate
- Damage Extent
LC70
120
- Was damage found? - Good description of the damaged area and its location and
dimensions
- Inspection Extent
Low Cor. Risk- Bundle - Half Life Governing

- Damage Rate
- Damage Extent
LC701
0
dimensions
- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
any indications.

Low Cor. Risk- Inner Pipe - Half Life Not Governing
specifications.
LC71
160

- Damage Extent
- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
any indications.

Low Cor. Risk- Inner Pipe - Half Life Governing
specifications.
LC711

- Damage Extent
- Inspection Extent
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
High Risk for Tank Bottoms – Half Life Not Governing

- Damage Rate
- Damage Extent
LC72
160
dimensions
- Inspection Extent
High Risk for Tank Bottoms – Half Life Governing

- Damage Rate
- Damage Extent
LC721
0
dimensions
- Inspection Extent
9 Plate Corrosion and Weld Cracking Strategy Rule Sets for Storage Tank Bottoms (Appendix I)
The Combined Inspection Priority Categories referenced in the Tables below are based on the Risk Matrix given in Fig 1 of
this document. Table 1 below provides a list of the recommended inspection frequencies and minimum confidences by risk
level (Inspection Priority). Table 2 provides a list of the Inspection Methods and Scopes of Work per each minimum
Inspection confidence level.

Combined Recommended Inspection Inspection Recommended Inspection
Inspection Priority Category Frequency (Years)1 Confidence
1–5 5 Very High
6 – 12 10 High
13 – 19 15 Medium
20 – 25 (20)2 (Medium)2
2. Tank Bottoms with Low Criticality rating will not be inspected unless inspections performed on tanks in similar service
identify a condition that indicates weld leaks or plate corrosion may be occurring in the tank.
Table 2 – Inspection Method and Scope vs. Confidence- Int. Corrosion

Very – High 100% Floor Scan with 100% Vacuum Box Testing of all weld seams.
The Inspector must be an API Authorized Tank Inspector according to API 653 for the visual
inspection and/or must hold certifications for MFL and LT examination that conform to ASNT SNT-

 Damage Rate
 Damage Extent
dimensions
High 100% Floor Scan with 50% Vacuum Box Testing of all weld seams. The 50% will include as a
minimum the entire shell to floor circumferential seam with the balance of the percentage specified
to be obtained from welds in the critical zone (12 to 18 inches from the shell) and any other weld
discontinuities visually observed.

 Damage Rate
 Damage Extent
dimensions
damage is seen.
Medium 100% Floor Scan with 25% Vacuum Box Testing of all weld seams. The25% will include as a minimum
the entire shell to floor circumferential seam with the balance of the percentage specified to be
obtained from welds in the critical zone (12 to 18 inches from the shell) and any other weld

 Damage Rate
 Damage Extent
dimensions
damage is seen.
Low N/A
Plate Corrosion and Weld Cracking Strategy
Rule Sets for Storage Tank Bottoms
Bottom Corrosion Bottom Corrosion Bottom Corrosion Bottom Corrosion

1-5 6 - 12 13 - 19 20 - 25
Half Life < 5 yrs Half Life < Half Life <
LC76
10yrs 15yrs
LC73 LC731 LC74 LC741 LC75 LC751

TANK BOTTOM STRATEGY DETAILS
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
100% Floor Scan with 100% Vacuum Box Testing of all weld seams. The 100% will include as a
minimum the entire shell to floor circumferential seam with the balance of the percentage specified to
be obtained from welds in the critical zone (12 to 18 inches from the shell) and any other weld
Med. High Risk for Tank Bottoms – Half Life Not Governing
The Inspector must be an API Authorized Tank Inspector according to API 653 for the visual inspection
and/or must hold certifications for MFL and LT examination that conform to ASNT SNT-TC-1A. These

 Damage Rate
FLOOR SCAN
LC73
 Damage Extent
60
dimensions
damage is seen.
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
100% Floor Scan with 100% Vacuum Box Testing of all weld seams. The 100% will include as a
minimum the entire shell to floor circumferential seam with the balance of the percentage specified to
be obtained from welds in the critical zone (12 to 18 inches from the shell) and any other weld
Med. High Risk for Tank Bottoms – Half Life Governing

 Damage Rate
FLOOR SCAN
LC731
 Damage Extent
dimensions
damage is seen.
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
100% Floor Scan with 50% Vacuum Box Testing of all weld seams. The 50% will include as a minimum
Med. Risk for Tank Bottoms – Half Life Not Governing

 Damage Rate
FLOOR SCAN
LC74
120
 Damage Extent
dimensions
damage is seen.
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL
100% Floor Scan with 50% Vacuum Box Testing of all weld seams. The50% will include as a minimum
Med. Risk for Tank Bottoms – Half Life Governing

 Damage Rate
FLOOR SCAN
LC741
 Damage Extent
dimensions
damage is seen.
Low Risk for Tank Bottoms – No Evidence of Cracking or Plate Corrosion

FLOOR SCAN
- Damage Rate
LC75
180
- Damage Extent
- Inspection Extent
find.
damage is seen.
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
INSPECTION
LOGIC CASE
INTERVAL

FLOOR SCAN
- Damage Rate
LC751
LC751
- Damage Extent
- Inspection Extent
find.
damage is seen.
LC76
LC76
N/A
N/A
No Inspection Required
10 PRD Strategies
risk level (Inspection Priority). Table 2 provides a list of the Inspection Methods and Scopes of Work for each minimum
Inspection Confidence level.

Internal Percentage of Recommended Recommended
Corrosion Representative Frequency Confidence
1
Inspection Piping Circuits (%) (Years)
2, 3
Priority
Category
1–5 100 1 High
6 – 12 50 2 High
13 – 19 25 3 Medium
20 – 25 10 5 Low
1. These intervals are applicable providing corrosion half life is not exceeded
2. For Internal Corrosion, all piping in a Unit can be grouped by Inspection Priority and then by Wall Ratio. The grouping
allows one or a small number of piping circuits to represent a larger population of piping. When selecting
representative circuits from each Inspection Priority and Wall Ratio, select the piping circuits with the highest
Inspection Priority first and those that have the same Inspection Priority are to be decided by wall ratio.
3. 100 percent (%) of Injection Circuits require inspection. The number of assigned CML’s shall be defined per API 570.
The recommended upstream limit of the injection circuit is a minimum of 12 inches or three (3) pipe diameters
upstream of the injection point, whichever is larger. The recommended downstream limit is the second change in flow
direction after the injection point or 25 feet beyond the first change in flow direction, whichever is less. In some cases,
it may be more appropriate to extend this circuit to the next piece of pressure equipment.
Table 2 – TBD
Inspection Method and Scope Options for Unpredictable Localized and Pitting Corrosion
Confidence
o
o
o
*
PRD Strategies
No Rupture Disk? Yes
Internal Corrosion Internal Corrosion Internal Corrosion Internal Corrosion Internal Corrosion
Inspection Priority No Inspection Priority No Inspection Priority Inspection Priority No Inspection Priority
1 - 12 13 - 19 20 - 25 1 - 19 20 - 25
PSV01 PSV02 PCV03 RD01 RD02
*
*
INSPECTION INTERVAL
RECOMMENDED
LOGIC CASE ID
DESCRIPTION
Task Type ID
LOGIC CASE
(Months)
A bench test should be performed on the PRV in the as received condition from the unit and the
POP TEST W/ VISUAL
initial leak pressure opening pressure and the reseat pressure Should be documented. The inlet
and outlet piping should be examined for signs of excessive plugging or fouling.
INSPECTION
PSV01
PSV01
A bench test should be performed, however, the PRD should cleaned or steamed out prior to the
POP TEST W/ VISUAL
bench test. Additionally, a visual inspection should be performed with detailed documentation of
the condition of the PRD internal components. An in-place test may be performed using the
INSPECTION
actual process fluid to pressurize the system where permitted by local jurisdiction.
PSV02
PSV02
A visual inspection may be performed without a pop test, with detailed documentation of the
condition of the PRD internal components. An in-place test may be performed where the actual
INSPECTION
VISUAL
process fluid was not used to pressurize the system where permitted by local jurisdiction.
PSV03
PSV03
The rupture disk is removed and visually inspected for damage or deformations.
INSPECTION
RD VISUAL
RD01
RD01
The space between the disk and the PRV is monitored for leakage in accordance with the ASME
Code and API RP 520 Part 2.
INSPECTION
RD VISUAL
RD02
RD02

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TABLE OF CONTENTS .............................................................................................................. 3

Inspection Confidence Equivalence

3 Highs (H) = 1 Very High (VH)

Table 1 – Recommended Inspection Frequency and Confidence

The inspection should return the following minimum information:

The inspection should return the following minimum information:

The inspection should return the following minimum information:

The inspection should return the following minimum information:

Internal Corrosion Internal Corrosion Internal Corrosion Internal Corrosion

Nonintrusive Nonintrusive Nonintrusive

Gen Gen Gen Gen Gen Gen Gen Gen

Yes Yes Yes Yes Yes Yes Yes Yes

LC091 LC101 LC112 LC113 LC1132 LC133 LC152 LC153

653. These credentials need to be verified prior to the start of work.

The inspection should return the following minimum information:

The inspection should return the following minimum information:

INTERNAL VISUAL INSPECTION

 Proper documentation of the inspection technique used

The inspection should return the following minimum information:

The inspection should return the following minimum information:

The inspection should return the following minimum information:

examination of all nozzles, man-ways, and supports/appurtenances.

653. These credentials need to be verified prior to the start of work.

The inspection should return the following minimum information:

The inspection should return the following minimum information:

Calculated remaining half life from NDE data.

The inspection should return the following minimum information:

The inspection should return the following minimum information:

The inspection should return the following minimum information:

The inspection should return the following minimum information:

examination of 50% of the nozzles, man-ways, and supports/appurtenances.

The inspection should return the following minimum information:

The inspection should return the following minimum information:

The inspection should return the following minimum information:

The inspection should return the following minimum information:

Calculated remaining half life from NDE data.

The inspection should return the following minimum information:

The inspection should return the following minimum information:

examination of the same percentage of the nozzles, man-ways, and supports/appurtenances.

The inspection should return the following minimum information:

2 UT readings per head, 4 UT readings per shell course/band,

The inspection should return the following minimum information:

1 reading on 50% of nozzles (Min. 1 Inlet and 1 Outlet nozzle).

The inspection should return the following minimum information:

2 UT readings per head, 4 UT readings per shell course/band,

1 reading on 50% of nozzles (Min. 1 Inlet and 1 Outlet nozzle).

The inspection should return the following minimum information:

Calculated remaining half life from NDE data.

The inspection should return the following minimum information:

Internal Corrosion Risk Internal Corrosion Criteria

Table 1 – Recommended Inspection Frequency and Confidence

The inspection should return the following minimum information:

The inspection should return the following minimum information:

The inspection should return the following minimum information:

The inspection should return the following minimum information:

The inspection should return the following minimum information:

Internal Corrosion Internal Corrosion Internal Corrosion Internal Corrosion

Nonintrusive Nonintrusive Nonintrusive

Gen Gen Gen Gen Gen Gen Gen Gen

Yes Yes Yes Yes Yes Yes Yes Yes