Inspection Procedure

01-SAIP-01 19 August 2009

Small Nipple Inspection Program
Document Responsibility: Inspection Engineering Standards Committee

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Purpose.......................................................... 2
3 Safety............................................................. 2
4 References..................................................... 2
5 Definitions and Abbreviations........................ 4
6 Inspection Procedure Steps........................... 6
7 Inspection Intervals........................................ 7
8 Inspection Methods........................................ 9
9 Acceptance and Rejection Criteria............... 10
10 Repairs......................................................... 11
11 Documentation............................................. 12

Appendix – I........................................................ 12
Appendix – II....................................................... 13

Previous Issue: 5 February 2008 Next Planned Update: TBD

Revised paragraphs are indicated in the right margin Page 1 of 17
Primary contact: Kakpovbia, Anthony E. on 966-3-8747226

Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-01
Issue Date: 19 August 2009
Next Planned Update: TBD Small Nipple Inspection Program

1 Scope

1.1 This Saudi Aramco Inspection Procedure (SAIP) establishes the inspection
requirements of in service (existing) small pipe nipples of up to 1-½ inch NPS
within existing facilities. This procedure applies primarily to piping in
hydrocarbon service but can be applied to other services as well.

1.2 Nondestructive Testing (NDT) should be performed only by individuals

certified to level I or II in accordance with SAEP-1140 or SAEP-1142.

2 Purpose

This SAIP is intended to assist the Plant and Equipment (PE) Inspectors of Operations
Engineering Units in their selection, on stream evaluation, and tracking of existing
nipple condition.

3 Safety

3.1 Radiographic examination personnel safety should be per SAEP-1143 para. 3.

3.2 All pressure testing should be in compliance with GI-0002.102, "Pressure

Testing Safely".

4 References

The following standards were used in the preparation of this procedure and should be
carefully reviewed by the inspectors. All references should be the latest issued revision
or edition.

4.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

SAEP-20 Equipment Inspection Schedule
SAEP-302 Instructions for Obtaining a Waiver of a
Mandatory Saudi Aramco Engineering
Requirement
SAEP-1140 Qualification and Certification of Saudi Aramco
NDT Personnel
SAEP-1141 Industrial Radiation Safety
SAEP-1142 Qualification and Certification of Non-Saudi
Aramco NDT Personnel
SAEP-1143 Radiographic Examination

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-01
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SAEP-1144 Magnetic Particle Examination of Welds and

Components
SAEP-1145 Liquid Penetrant Examination of Welds and
Components

Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-A-206 Positive Material Identification
SAES-L-310 Design of Plant Piping
SAES-W-011 Welding Requirements for On-Plot Piping

Saudi Aramco Standard Drawing

AB-036521 Bracing Detail on Small Connection

Saudi Aramco General Instructions

GI-0002.102 Pressure Testing Safely
GI-0150.003 Radiation Safety

Saudi Aramco Inspection Procedures

00-SAIP-07 Positive Material Identification Requirements
01-SAIP-02 Retirement Thickness of In-Plant Piping

4.2 Industry Codes and Standards

American Society of Mechanical Engineers

ASME SEC V Nondestructive Examination
ASME B 31.1 Power Piping
ASME B 31.3 Chemical Plants and Petroleum Refinery Piping
ASME B 31.4 Liquid Transportation System for Hydrocarbon,
LPG, Anhydrous Ammonia, & Alcohol
ASME B 31.8 Gas Transmissions and Distribution Piping
System

American Petroleum Institute

API RP 570 Piping Inspection Code
API RP 578 Material Verification

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-01
Issue Date: 19 August 2009
Next Planned Update: TBD Small Nipple Inspection Program

5 Definitions and Abbreviations

Nipple: A pipe nipple is a small bore pipe attached to a main header by welding.
The attachment may be by use of a welding boss or proprietary fitting/valve welded to
the pipe header.

Alloy Material: Any metallic material (including welding filler materials) that contains
alloying elements such as chromium, nickel, or molybdenum, which are added to
enhance mechanical or physical properties and/or corrosion resistance.

Fabrication: The preparation of piping and small connection for assembly, including
cutting, threading, grooving, forming, bending and joining of components into
subassemblies.

Face of the weld: The exposed surface of a weld on the side from which the welding
was done.

Filler material: The material to be added in making metallic or nonmetallic joints.

Fillet weld: A weld of approximately triangular cross section joining two surfaces
approximately at right angles to each other in a lap joint, tee joint, or corner joint.

Crack: A fracture type discontinuity characterized by a sharp tip and high ratio of
length to width to opening displacement.

Lack of fusion: A weld discontinuity in which fusion did not occur between weld
metal and base metal or adjoining weld beads.

Incomplete Penetration: The weld beads unable to fill the weld bevel groove.

Porosity: Cavity type discontinuities formed by gas entrapment during solidification of

the weld metal.

Rounded Indications: Indications with a maximum length of three times the width or
less on the radiograph.

Aligned Indications: A sequence of four (4) or more rounded indications should be

considered aligned.

Leg Length: is the thickness of a fillet weld, excluding any allowable reinforcement
measured through the leg.

tm: Minimum thickness required (t) is equal to the design thickness as calculated by
the applicable ASME Code B31.3 formula.

Hydrocarbon Services: Process streams of liquid or gaseous hydrocarbon (HC)

materials, or HC streams that may contain phenols, carbon dioxide, and ammonia.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-01
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Category "D" Fluid Service: A fluid service in which all the following apply:
1) The fluid handled is nonflammable, non toxic, and not damaging to human tissues
as defined in ASME B31.3 paragraph 300.2.
2) The design gage pressure does not exceed 150 psi (1030 kpa)
3) The design temperature is from -20°F (-29°C) through 366°F (180°C)

Low-Chrome Alloy Steels: Alloy materials with nominal chromium contents of 1% to

5% chrome.

Repair: The work necessary to restore a nipple to a condition suitable for safe
operation at the design conditions, without any deviation from the original
configuration.

Abbreviations:
ADIP Amino-Di-IsoPropanol
DEA Di Ethanol Amine
DGA Di Glycol Amine
HAZ Heat Affected Zone
HC Hydrocarbon
MEA Mono Ethanol Amine
MSAER Mandatory SA Engineering Requirements
MT Magnetic Particle Testing
NDT Non Destructive Testing
P&ID Piping and Instrumentation Drawings
PFD Process Flow Diagram
PMI Positive Material Identification
PT Penetrant Testing
PWHT Post Weld Heat Treatment
RT Radiography Testing
RTFI Radiographic Film Interpretation
TEG Tri Ethylene Glycol
UT Ultrasonic Testing
VT Visual Inspection

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-01
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6 Inspection Procedure Steps

6.1 Piping Categorization

6.1.1 A piping circuit will usually start and end at individual pieces of
equipment and includes all lines of similar metallurgy and corrosion rate,
same service, and design temperature and pressure. P&IDs or PFDs
should be marked to designate to which corrosion circuit each line
corresponds and line designation tables should be prepared for each unit.

6.1.2 Circuits should be categorized according to the corrosion (as described in

6.1.4), vibration and consequence of failure of the process fluid they
handle.

6.1.3 The consequences of failure should be based on the potential safety and
environment effect when leak occur. Accordingly, the three (3) classes
of the piping are as follow:

6.1.3.1 Class 1

Services with the highest potential of resulting in an immediate

emergency if a leak were to occur. Those include the
following:
 Vibrating service at all operating temperatures including
cryogenic service
 Chemical injection points
 Hydrocarbons services that are significantly vaporize when
they leak
 Hydrogen sulfide (greater than 3 percent weight) in a
gaseous services
 Hyrdrofluic acid
 Anhydrous hydrogen chloride

6.1.3.2 Class 2

Services not included in class 1 or class 3. Typical examples

of these services include those containing the following:
 Hydrocarbons that will slowly vaporize during releases
including those operations below flash point
 On -site caustic and acids

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-01
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6.1.3.3 Class 3

Hydrocarbons that will not significantly vaporize during

releases including those operations below flash point and are
not located in high –activity area. Those include the
followings:
 Off –site caustics and acids
 Category –D services
 Services that are potentially harmful to human tissues

6.2 Corrosion Categories

Table -1 show the three (03) corrosion categories based on the corrosion rate:

Table 1 – Corrosion Category

Category Criteria
A Corrosive Service 150 to 350 µm/a (6 to 14 mpy)
B Mild Corrosive Service 75 to 125 µm/a (3 to 5 mpy)
C Low Corrosive Service Less than 75 µm/a (3 mpy)

7 Inspection Intervals

7.1 The matrix shown in figure -1 shall be used to determine the maximum
inspection intervals based on piping class and corrosion category as described in
6.1.

7.2 Chemical Injection Points shall be inspected at three (03) years maximum
inspection interval.

7.3 The maximum inspection intervals shall be 12 months when corrosion rate is
380 µm/a (15 mpy) or greater per SAEP-20.

7.4 Pipe nipples shall be inspected based on the class of the line and/or circuit in
which they are installed.

7.5 Subsequent pipe nipple inspection priorities should be adjusted based on

historical inspection findings and corrosion rate.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-01
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A 7 Years 6 Years 5 Years

Corrosion B 8 Years 7 Years 6 Years

Category

C 10 Years 8 Years 7 Years

3 2 1
Piping Class
Figure1 – Nipple Inspection Intervals Matrix

8 Inspection Methods

8.1 Radiography should be used to inspect all pipe nipples for I.D. /O.D corrosion
on piping including cryogenic service. If, during the inspection of existing
nipples or replacements, indications are found in welds, these indications should
be evaluated per acceptance/rejection criteria of Table's 2 and 4.

8.2 The radiographic technique for small diameter nipples and to measure side wall
thickness is shown in Appendices I & II.

8.3 Where questionable radiographs are produced, ultrasonic thickness (UT)

gauging of the pipe nipple should be used as comparison.
8.4 In addition to radiography, MPI or PT should used to inspect for cracks in
vibrating services or austenitic stainless steel welds. MT and PT techniques
shall meet the requirements of SAEP-1144 and SAEP-1145 respectively.
8.5 Visual inspection should be performed on all pipe nipple systems to determine
the need for replacement or repairs due to external corrosion, threads not
covered by seal weld, vibration fatigue or possibility of overloading of the
nipple. In cases where fatigue is suspected and radiography is not possible, then
liquid penetrant or magnetic particle inspection should be performed to
determine if cracking has been initiated.
Commentary Note:

Over loading is usually associated with over stressing of the pipe nipple welds
due to applied external forces such as people continuously using branch
connection as a step.

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Document Responsibility: Inspection Engineering Standards Committee 01-SAIP-01
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Next Planned Update: TBD Small Nipple Inspection Program

9 Acceptance and Rejection Criteria

Table 3 – Defect Acceptance Limits in Socket Weld Radiography

Cracks Lack of Fusion,
Lack of Penetration Porosity
(MPI , PT) Slag
Acceptable provided the fused
Length ≤ 0.4 x OD (note 1)
fillet leg and throat thickness ≤ 0.31 x "t" and
None Width ≤ 0.31 x "t" and
meet the minimum acceptable 0.040" (note 2)
0.040" (1 mm) (note 2)
value (note 3)

Notes:
1 In case of lack of fusion and slag defects, the calculation of the maximum acceptable limits (length) for each
pipe size are shown in Table 4 based on outside diameter.
2 The maximum permitted defect width shall be the lesser of 0.31 x "t" or 0.040" (1mm). "t" is the pressure
design thickness of the pipe.
3 The minimum fused leg length (Cx ) is 1.25 x "t" (from ASME B31.3 328.5.2.C). The minimum effective
throat thickness is 0.88 x "t". These are determined from radiography not physical measurement. "t" is the
pressure design thickness of the pipe.
4 Aligned defects shall be considered as one defect if the separation distance is less than the length of the
longer defect.

Table 4 – Maximum Defect Lengths for Pipe Sizes

Outside Diameter 0.4 x OD
Pipe Size NPS
(OD) (inches) (Inches)
½ 0.840 0.34
¾ 1.050 0.42
1 1.315 0.53
1½ 1.900 0.76

Table 5 – Acceptance Criteria for Other Characteristics

Existing Piping New Piping

Rejectable if gap is over 50% Rejectable if gap is over 50%
Gap in Socket Welding Boss of the socket depth or ¼" of the socket depth or 3/16"
whichever is less whichever is less
Rejectable if the corroded Rejectable if the corroded
Nipple Wall Thickness thickness is below "t" min. per thickness is below "t" plus the
design calculations corrosion allowance
Must meet applicable industrial
Fabrication Tolerances NA
standards

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10 Repairs

10.1 Calculated retirement thickness (t) code tm and structural minimum thickness
(which ever is greater) should be compared against original nipple thickness
from the line specification. The structural minimum retirement thickness for
carbon steel and chrome-moly alloy pipe nipples up to 1.5 NPS is 0.09 inch
(2.25 mm) per 01-SAIP-02.

10.2 Pipe nipples should be removed at the retirement thickness indicated in

paragraph 10.1. If the pipe nipple has not reached retirement thickness but
shows a reduction in original wall thickness, the corrosion rate and remaining
life should be calculated. The pipe nipples, which show a remaining life of less
than the normal inspection frequency outlined in Table 1 or the next T&I
inspection period, a temporary repairs (boxing) should be considered until
replacement during scheduled T&I. All pipe nipples that have been identified as
having the incorrect metallurgy for the piping system should be removed and
replaced regardless of the remaining wall thickness. All alloy replacement
nipples, valves and welds should be evaluated using an approved Positive
Material Identification (PMI) instrument before installation per SAES-A-206
using 00-SAIP-07 and API RP 578 as guides.

10.3 Those nipples which are not braced and subjected to vibration should be
adequately braced per SAES-L-310, paragraph 20.2.3 and Saudi Aramco
Standard Drawing AB-036521 to prevent future fatigue failure.

10.4 All repaired or replaced nipples should be radiographed and acceptance/

rejection criteria should be per Section 9.

10.5 All nipple repairs / replacement associated with MEA, DGA, TEG and ADIP
service piping should be Post Weld Heat Treated (PWHT) per SAES-W-011,
Section 13.0.

10.6 All low alloy steel material should be PWHT per SAES-W-011, Section 13.0.

10.7 All low alloy steel material should be radiographed and MT or PT inspected
after Post Weld Heat Treatment (PWHT) and acceptance/rejection criteria
should be per Section 9.

10.8 All piping associated with repaired or replaced nipple should be hydrostatically
tested per SIS requirements in accordance with SAES-A-004.

10.9 NDT in-lieu of hydrostatic test is not acceptable unless approved by the
responsible Plant Manager.

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10.10 If PWHT is a requirement of SAES-W-011, but is not feasible for any reason,
obtain an engineering waiver against the applicable MSAER per SAEP-302.

11 Documentation

11.1 All piping Nipples should be identified on each line in class 1-3 piping circuits.
These pipe nipples should be added to the OSI Program as additional
data/inspection points.

11.2 Thickness measured from the radiographic film image should be entered into the
OSI Program to track individual corrosion rates and remaining life of each pipe
nipple.

Revision Summary
19 August 2009 Revised the "Next Planned Update". Reaffirmed the contents of the document, and reissued
with editorial changes.

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Appendix – I

Radiographic Technique 90° Elbow

Radiographic Technique Tee

Notes:
1. SFD to be 12" with the source lined up in the middle.
2. Shoot with one MX & one AX type film, MX closest to the weld.
3. Only one weld per shot, with the number next to the weld on the pipe.
4. Use three times the pipe wall thickness fro the shot exposure time - MX film.

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Appendix – II

Profile Radiographic Technique for Pipe Wall Measurements

NDT Unit Procedure No. 32.60.2.001 Dated 2/28/96

1. Purpose

The purpose of this Operations Inspection Division Procedure is to define a

recommended method of performing Radiographic Corrosion Analysis using Profile
Radiography with a comparator reference.

2. Scope

This procedure should be applied to determine the pipe wall thickness using a reference
comparator on line and/or process piping with or without content and with or without
insulation. It is not intended to replace present methods of radiographically calculating
wall thickness, but to offer an alternate method with improved accuracy.

3. References

3.1 Saudi Aramco General Instruction GI-0150.003

3.2 Saudi Aramco General Instruction GI-0150.003, Supplement 8

3.3 Saudi Aramco Engineering Procedure SAEP-1141

3.4 Saudi Aramco Engineering Procedure SAEP-1143

4. Definitions

4.1 Profile Radiography - A tangential radiograph produced by alignment of the

radiographic technique such that the radiation passes through or adjacent to the
chord of the pipe producing an image of the ID and OD surfaces.

4.2 SFD - Source to Film Distance. For the purposes of this procedure, the
minimum source to film distance should be 3 times the outside diameter of the
pipe being radiographed.

4.3 Comparator - 1.000" carbon steel, nickel or chrome plated, spherical ball.

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5. Procedure

5.1 Radiation Safety

Handling and use of industrial radioactive isotopes should be in accordance with

the safety requirements of 00-SAIP-08 and GI-0150.003. Particular caution
should be applied due to the inherent long exposure times and/or use of
Cobalt60 when performing profile radiography.

5.2 Technique (Without Insulation)

Figure 1, provides a layout of the technique for the profile radiography of pipe
without insulation. Particular notice should be given to the orientation of the
source, and film in relation to the pipe and comparator. The source is to be placed
on a plane exactly level with the surface of the pipe and 90° (perpendicular) to the
film. With masking tape, the comparator is to be positioned such that it is exactly
on the radius of the pipe parallel with the film and 90° (perpendicular) to the
central direction of radiation (see paragraph 5.5, Note 2).

5.3 Technique (With Insulation)

Figure 2, provides a layout of the technique for the profile radiography of pipe
with insulation. Particular notice should be given to the orientation of the
source, and film in relation to the pipe and comparator. The source is to be
placed approximately mid point of the insulation and 90° (perpendicular) to the
film. With masking tape, the comparator is to be positioned such that it is
exactly on the radius of the pipe parallel with the film and perpendicular to the
central direction of radiation (see paragraph 5.5, Note 2).

5.4 Calculating Results

In either technique, measure comparator height film image and the film image of
the pipe wall thickness. Because of the geometric relationship of either
technique, the radiographic images will be an enlargement of the comparator
and pipe wall actual dimension. The comparator will provide a percentage of
image enlargement to serve as correction of the pipe wall image thickness.

Using a 1.00" comparator ball, the correction factor is the measured height of
the comparator and used as indicated in the following formula:

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Actual w.t. = image w.t. of pipe X Comparator actual w.t. / comparator image

Comparator
Image c

w Pipe wall image

actual w.t. = w * c actual /c

5.5 Technical Notes

Note-1: Position of the film is critical. As close as possible, the film is to be

held 90° (perpendicular) to the central beam of radiation as indicated in
either technique. Failure to hold the perpendicular position of the film
will cause the image of the comparator to appear oval and reduce
accuracy.

Note-2: Position of the source in relationship to the tangent of the pipe is

critical. Consider an imaginary radius line drawn from the center of
the pipe to the pipe O.D. surface. The imaginary line drawn must be
90° (perpendicular) to the central beam of radiation as indicated in
either technique. Position the ball off this imaginary line either too
close the film or too close to the source will result in an overlap of
images of the pipe wall and comparator reducing accuracy and increase
difficulty in taking measurements.

5.6 Technique Acceptance

The following technique acceptance criteria is based on empirically established

values.

Accuracy of this technique is dependent on adherence to the following technique

acceptance criteria.

5.6.1 Radiographic Quality as defined by SAEP-1143 for film density and film
artifacts should be applied. Film should not be less than 2.0 or greater
than 4.0 in density. Film should be free of film artifacts such as
watermarks, smudges, light leaks, etc. that would interfere with
interpretation. Given that this type of radiography is not to be used for

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weld quality examination, minor scratches or finger nail marks should

not be cause for rejection of the film.

Im a g e h

% O v a lity = w /h

5.6.2 Comparator Image - The image of the comparator should be round.

However, variations in the technique and in particular, the technique for
pipe with insulation will result in the comparator image being oval.
Ovality is determined by comparing the height and width of the
comparator image. A measured image height 7% greater than the
measured image width is an indication that the film was not properly
aligned 90° (perpendicular) to the central beam of radiation (see Note 1)
and must be radiographed again.

5.6.3 Comparator Image Enlargement - The maximum image enlargement of

the comparator should not exceed 20% (1.20"). A measured comparator
image greater than 1.20" is an indication that the SFD was insufficient.
To correct, increase the SFD in the technique and re-shoot. In the event
the enlargement exceeds 20%, the SFD may be increased to reduce the
image enlargement.

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Figure 1 – Technique without Insulation

Figure 2 – Technique with Insulation

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