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Pipe Inspection Methods & Tests

Pipe Inspections

third party pipes inspectionPipes Inspection

Pipe inspection verifies that newly manufactured pipes are fit for their intended purpose, capable of safely handling operational demands and compliant with applicable standards and specifications. Every pipe entering an oil and gas facility, power plant, or chemical processing plant must pass a defined set of tests before acceptance.

Why Inspection Matters

ReasonBenefit
Safety assuranceDetects hazards before catastrophic failures
Regulatory complianceMeets industry codes; avoids fines and shutdowns
System reliabilityIdentifies issues before they escalate
Performance verificationConfirms design flow rates and pressure ratings
Lifecycle extensionEarly defect detection reduces maintenance costs
Contractual obligationSatisfies purchase order and project specification requirements

Standard Inspections per ASME/API

CategoryTestsWhat’s Checked
VisualSurface inspectionDents, scratches, laminations, weld seam integrity, straightness, roundness
DimensionalOD, ID, WT, lengthCompliance with ASME B36.10/B36.19 tolerances
NDTRT, UT, MPI, DPIInternal flaws, weld defects, surface cracks
MechanicalTensile, Charpy, hardnessStrength, toughness, wear resistance
MetallurgicalChemical analysis, microstructureAlloy composition, grain size
PressureHydrostatic testLeak-tightness at design pressure
MarkingStencil/stamp verificationManufacturer, grade, size, heat number
DocumentationMTC reviewEN 10204 certification with all test results

Inspection Scope: Full vs. Sample

ApproachTestsFrequency
100% inspectionVisual, dimensional, UT for wall thickness, hydrostaticEvery pipe
Sample inspectionTensile, Charpy impact, chemical analysis, microstructurePer heat/batch

Sampling rates are defined by applicable standards (API, ASTM, ASME). For critical applications or high-spec orders, sample testing frequency may increase, or every pipe may be tested. Sampling rates can be negotiated with the client.

Pipe inspection verifies compliance with standards across five areas: visual (surface defects), dimensional (OD, ID, WT, length), metallurgical (chemical composition, microstructure), mechanical (tensile, impact, hardness), and pressure (hydrostatic testing). For critical applications, define witness and hold points in the Inspection Test Plan before the order is placed; not after.

Mill Inspection vs Third-Party vs Site Inspection

Pipe inspection occurs at three distinct locations, each with a different scope and purpose.

Mill Inspection (Manufacturer QC)

Mill inspection is performed by the pipe manufacturer’s own quality control department as part of the standard production process. The mill’s QC team follows internal procedures based on the applicable product standard (API 5L, ASTM A106, ASTM A312, etc.) and the customer purchase order.

Mill inspection covers:

  • Raw material verification (incoming steel plate, billet, or coil)
  • In-process checks during forming and welding
  • Heat treatment verification (temperature, soak time, cooling rate)
  • All required mechanical and chemical testing
  • Final visual and dimensional inspection
  • Hydrostatic testing
  • Marking and documentation

Third-Party Inspection (TPI)

Independent inspection agencies (Lloyd’s, SGS, DNV, Bureau Veritas, Cotecna, TUV) provide impartial verification for critical applications. The third-party inspector works on behalf of the buyer, witnessing tests and reviewing documentation at the manufacturer’s facility.

ScenarioWhy Third-Party
High-stakes applicationsOil & gas, nuclear, where failure consequences are severe
Regulatory requirementsSome jurisdictions mandate independent verification
Contract specificationsClient or project manager stipulates third-party witness
CertificationASME, API stamps require independent verification
International tradeBuilds trust across borders; facilitates customs clearance
Specialized expertiseTesting capabilities manufacturer lacks in-house

Site (Receiving) Inspection

Site inspection is performed when pipes arrive at the fabrication yard, construction site, or warehouse. It serves as the final quality gate before pipes enter the piping system.

CheckPurpose
Visual inspectionDetect transport damage (dents, scratches, bent ends, coating damage)
Dimensional spot-checkVerify OD, WT, and length against PO
Marking verificationConfirm stencils match MTC and purchase order
MTC reviewVerify all test results meet specification requirements
PMI (if required)Positive Material Identification confirms alloy composition
Quantity countReconcile delivered quantity against packing list

Inspection Stages: Pre-Production to Shipping

Pipe manufacturing inspection follows four stages, each with defined activities and checkpoints.

Stage 1: Pre-Production

ActivityDetails
ITP review and approvalAgree on inspection and test plan with all parties
Raw material certificatesVerify incoming steel (plate, billet, coil) MTCs
Chemical analysisConfirm heat analysis meets grade requirements
Welding procedure reviewApprove WPS/PQR for welded pipe production
Calibration recordsVerify all testing equipment is calibrated and current

Stage 2: In-Process

ActivityDetails
Forming verificationMonitor pipe forming (piercing, rolling, or plate bending)
Welding monitoringVerify weld parameters match approved WPS
Heat treatment witnessConfirm temperature, hold time, and cooling method
In-process NDTUT of weld seam, lamination check on plate
Dimensional spot-checksOD, WT at intervals during production run

Stage 3: Final Inspection

ActivityDetails
Visual inspection (100%)Every pipe checked for surface defects
Dimensional inspection (100%)OD, WT, length, straightness, end prep on every pipe
NDT (as required)Full-body UT, weld seam RT/UT per specification
Hydrostatic test (100%)Every pipe pressure-tested
Mechanical testing (per heat)Tensile, impact, hardness on sample pipes
Marking verificationStencils match specification and PO requirements
MTC preparationCompile all test results into certificate

Stage 4: Shipping Inspection

ActivityDetails
Coating/protectionVerify end caps, coating, corrosion inhibitor applied
Bundle/crate inspectionProper stacking, dunnage, and securing
Packing list verificationQuantity, sizes, heat numbers match documentation
Loading supervisionPrevent handling damage during truck/vessel loading

Types of Pipe Inspections

Visual Inspection (VI)

HFW PipesHFW Pipes

Visual inspection is the first step in any inspection regime: quick, cost-effective, and often sufficient to identify obvious defects requiring further investigation.

AspectWhat’s Checked
Surface conditionCracks, dents, scratches, laminations, tears
Weld qualityUniformity, porosity, undercut, incomplete penetration
Coating/insulationIntegrity of protective coatings
MarkingsGrade, size, manufacturer, heat number
DeformationBends, bulges, ovality

Tools: Flashlights, mirrors, magnifying glasses, borescopes/cameras for internal inspection.

Limitations: Surface defects only; VI cannot detect subsurface or internal flaws. ASME/API/ASTM define acceptable defect criteria.

Dimensional Inspection

caliber for pipes inspection

Dimensional inspection verifies pipe geometry against ASME B36.10/B36.19 or API 5L tolerances.

DimensionWhy It MattersTolerance Source
ODFit with fittings, flanges, equipmentASME B36.10/B36.19, API 5L
IDFlow capacity and resistanceCalculated from OD and WT
Wall thicknessPressure rating, mechanical strengthASME B36.10/B36.19, API 5L
LengthLogistics, installation planningPer order specification
StraightnessAlignment and connection integrity~1 mm/m typical; ASTM A312M: 3.2 mm/3 m for SS
OvalityConnection sealing, flow characteristicsPer applicable standard
End preparationWeld bevel angle and root face dimensionsASME B16.25 (37.5 deg standard bevel)
End squarenessProper fit-up during field weldingPer applicable standard

Measurement tools: Calipers, micrometers, UT (wall thickness), laser scanning (roundness/straightness), tape measures (length), bevel gauges (end prep), pi tapes (circumferential OD).

Mechanical Testing

Mechanical testing permanently alters samples to determine material behavior under extreme conditions. Results are documented in Mill Test Certificates.

TestWhat’s MeasuredApplication
TensileYield strength, tensile strength, elongation, reduction of areaAll pipes
Hardness (Rockwell, Brinell, Vickers)Resistance to indentationAll pipes; max 22 HRC for sour service (NACE MR0175)
Impact (Charpy V-notch)Toughness at specified temperatureLow-temp service, API 5L PSL2, critical applications
BendDuctility, weld qualityWelded pipes (transverse guided bend)
FlatteningDuctility, soundness of weld and base metalSeamless and welded pipes
Drop weight tear (DWTT)Fracture propagation resistanceLarge-diameter pipeline (API 5L, high grades)

Tensile Testing

Tensile testing is the most fundamental mechanical test. A machined specimen is pulled to failure to measure:

  • Yield strength (Rt0.5 or Fy): Stress at which permanent deformation begins
  • Ultimate tensile strength (Rm or Fu): Maximum stress before necking
  • Elongation (A%): Ductility measure, expressed as percentage of original length at fracture
  • Reduction of area (Z%): Cross-section reduction at fracture point

Specimens are taken longitudinally (body) and transversely (weld) per the applicable standard. API 5L PSL2 requires both body and weld transverse tensile tests.

Impact Testing (Charpy V-Notch)

Charpy testing measures the energy a material absorbs before fracturing at a specific temperature. A notched specimen is struck by a pendulum, and the absorbed energy (Joules) is recorded.

StandardTypical Test TemperatureMinimum Energy
API 5L PSL2Per supplementary requirement or 0 deg C defaultGrade-dependent (e.g., 27 J min for body, 20 J min for weld)
ASTM A333 Gr.6-46 deg C18 J average
ASTM A106Not mandatory (unless specified)Per PO requirement
NACE MR0175Service temperaturePer applicable part of ISO 15156

Hardness Testing

Hardness is measured using Vickers (HV), Brinell (HBW), or Rockwell (HRC) methods. Hardness values verify that heat treatment achieved the correct microstructure and are critical for sour service compliance.

MaterialMax HardnessStandard
Carbon steel (sour service)22 HRC / 248 HBW / 250 HV10NACE MR0175 / ISO 15156
API 5L PSL2 (most grades)250 HV10API 5L Table 6
Duplex SS36 HRC (typical)ASTM A789/A790
Austenitic SS22 HRC (sour) / no limit (sweet)NACE MR0175 / ASTM A312

Chemical Analysis

Chemical analysis verifies that the steel composition matches the specified grade. Two levels of analysis exist:

TypeSample SourceWhen
Heat (ladle) analysisMolten steel during castingSteel mill provides with MTC
Product analysisFinished pipe specimenMandatory for API 5L PSL2; optional for PSL1

Key elements checked include carbon (C), manganese (Mn), phosphorus (P), sulfur (S), silicon (Si), chromium (Cr), nickel (Ni), molybdenum (Mo), vanadium (V), niobium (Nb), titanium (Ti), copper (Cu), nitrogen (N), and boron (B). The carbon equivalent (CE) is calculated to predict weldability.

CE FormulaApplicationMax CE (typical)
CE(IIW) = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/15API 5L (C > 0.12%)0.43 for X65 PSL2
CE(Pcm) = C + Si/30 + (Mn+Cu+Cr)/20 + Ni/60 + Mo/15 + V/10 + 5BAPI 5L (C <= 0.12%)0.25 for X65 PSL2

Metallurgical Inspection

metallurgical inspection

Metallurgical inspection evaluates material properties and microstructure to verify compliance with specifications and detect defects that could cause in-service failures.

Micro-Metallurgical Tests

TestPurposeApplication
Chemical composition (OES, XRF)Verify alloy matches specified gradeAll materials
Ferrite contentBalance of phases for strength/corrosion resistanceDuplex, austenitic SS
HIC testingResistance to hydrogen-induced crackingSour service (H2S environments)
SSC testingResistance to sulfide stress corrosion crackingSour service
Grain sizeAffects strength, toughness, creep resistanceAll steels
IGC testing (ASTM A262)Resistance to intergranular corrosionStainless steels

Macro-Metallurgical Analysis

Macro examination uses low magnification (up to 100x) or naked eye to assess:

AspectWhat’s Examined
Weld qualityDiscontinuities, misalignment, incomplete penetration
Heat treatmentUniformity of grain structure across treated zones
Grain structureSize and distribution (affects mechanical properties)
DefectsCracks, porosity, slag inclusions, laminations
CorrosionExternal/internal attack patterns (service pipes)

Techniques: Visual inspection, stereomicroscopy, chemical etching (reveals weld zones, HAZ, grain boundaries), photographic documentation.

Surface Condition and Defect Acceptance Criteria

Pipe surface quality is governed by the applicable product standard. Defects that exceed acceptance criteria must be repaired (by grinding) or the pipe must be rejected.

Defect TypeAcceptance Criteria (Typical)
DentsDepth <= 6.35 mm and length <= 50% of OD (API 5L)
Scratches / gougesRemaining WT above minimum; no sharp-bottomed defects
LaminationsNot acceptable at pipe ends (within 100 mm); body laminations per standard
CracksNot acceptable; any crack is cause for rejection
Hard spotsNot acceptable per API 5L (PSL2: max 35 HRC)
Weld defectsPer applicable NDT acceptance criteria (ASME, API)
Arc strikesNot acceptable on pressure-containing surfaces; must be ground and NDE verified

Destructive Testing

hardness testing (destructive pipe testing)

Destructive testing permanently alters samples to determine material behavior under extreme conditions. Results are documented in Mill Test Certificates.

TestWhat’s MeasuredApplication
TensileYield strength, tensile strength, elongation, reduction of areaAll pipes
Hardness (Rockwell, Brinell, Vickers)Resistance to indentationAll pipes
Impact (Charpy, Izod)Toughness at specified temperatureLow-temp service, critical applications
BendDuctility, weld qualityWelded pipes
FlatteningDuctility, soundnessSeamless and welded pipes
BurstUltimate pressure resistanceDesign verification
Chemical analysisAlloy compositionAll pipes

Non-Destructive Testing (NDT)

NDT evaluates pipe properties without causing damage. See Non-Destructive Testing Types for detailed coverage of VI, LP, MP, UT, RT, and EC methods.

Hydrostatic Testing

Hydro Testing MachinePressure testing pump for hydrostatic tests

The hydrostatic test fills pipes with water and pressurizes above design pressure to verify strength and leak-tightness. See Hydrostatic Test for complete procedures and standards.

Marking and Traceability

Api pipes multiple markingApi pipes multiple marking

Marking inspection verifies that pipe stencils/stamps match specifications and enable full traceability from heat of steel to installed location.

Required Marking Elements

Marking ElementPurposeExample
ManufacturerSource identificationMill name or logo
Material gradeASTM/API specification complianceAPI 5L Gr. X65 PSL2
SizeNPS x Schedule or OD x WT12” x SCH 40 or 323.8 x 9.53
Heat numberTraceability to MTC and batchA7823
StandardApplicable specificationAPI 5L, ASTM A106, ASTM A312
Pipe typeManufacturing processS (seamless), E (ERW), L (LSAW)
Test pressureHydrostatic test pressure applied250 bar
TPI stampThird-party inspector verificationAgency logo/stamp

Marking Methods

MethodApplicationNotes
Stenciling (paint)Standard for most pipeWhite or yellow paint; must remain legible
Die stampingPipe ends, thick wall pipeLow-stress stamps only; not permitted on thin wall (< 4 mm)
Color codingGrade identification bandsSupplementary to stenciling
Labels/tagsBundled small-bore pipeMust be securely attached

Verification process: Visual inspection of markings, comparison against PO/MR specs, cross-reference with MTC, documentation of findings, and rectification of discrepancies.

Third-Party Inspection (TPI) and the Inspection Test Plan (ITP)

The Role of the Third-Party Inspector

The third-party inspector (TPI) acts as the buyer’s representative at the manufacturer’s facility. The TPI does not perform tests; the manufacturer’s lab performs testing while the TPI witnesses the process, verifies procedures, reviews results, and signs off on compliance.

Key TPI responsibilities:

  • Review and approve the Inspection Test Plan (ITP) before production
  • Witness tests at agreed hold and witness points
  • Verify calibration of testing equipment
  • Review MTCs and test reports for compliance
  • Issue inspection release notes (IRN) for shipment
  • Report non-conformances and verify corrective actions

Inspection Test Plan (ITP) Structure

The ITP is the master document governing all inspection activities. It is prepared by the manufacturer, reviewed by the TPI agency, and approved by the buyer before production begins.

ITP ColumnDescription
ActivityDescription of the inspection/test step
Reference standardApplicable code or specification
Acceptance criteriaPass/fail limits
ManufacturerQC activity level (Perform, Record, Certify)
TPIHold (H), Witness (W), Review (R), Monitor (M)
ClientHold (H), Witness (W), Review (R), Monitor (M)
Frequency100%, per heat, per lot, per shift

Hold, Witness, Review, and Monitor Points

CodeMeaningProduction Impact
H (Hold)Inspector must be present; work stops until releasedProduction halted until sign-off
W (Witness)Inspector invited; production continues if absent after notice24-48 hour notification typical
R (Review)Inspector reviews documentation after the factNo production delay
M (Monitor)Inspector monitors activity periodicallyNo production delay

Comparison of Tests by Pipe Specification

TestAPI 5L PSL1API 5L PSL2ASTM A106ASTM A312 (SS)ASTM A333 (Low-Temp)
Chemical (heat)RequiredRequiredRequiredRequiredRequired
Chemical (product)OptionalRequiredNot requiredNot requiredNot required
TensileRequiredRequiredRequiredRequiredRequired
Charpy impactNot requiredRequiredNot required (unless specified)Not required (unless specified)Required
HardnessNot requiredRequiredNot requiredNot requiredNot required (unless sour)
FlatteningRequired (welded)Required (welded)RequiredRequired (welded)Required
BendAlternative to flatteningAlternative to flatteningRequiredNot requiredRequired
HydrostaticRequiredRequiredRequiredRequired (or eddy current)Required
NDT (full body)Not requiredRequired (UT or EMI)Not required (unless specified)Not required (unless specified)Not required
NDT (weld seam)Required (welded)Required (welded)N/A (seamless)Required (welded)N/A (seamless)
DWTTNot requiredPer supplementary req.N/AN/AN/A

Standards Reference

StandardScope
API 5LLine pipe for oil and gas pipelines; covers grades, testing, tolerances
ASTM A530General requirements for carbon and alloy steel pipe, including supplementary requirements common to all ASTM pipe specifications
ASME B36.10Welded and seamless wrought steel pipe: standard dimensions and wall thicknesses
ASME B36.19Stainless steel pipe: dimensions and wall thicknesses
ASME B16.25Buttwelding ends; bevel dimensions for pipe and fittings
EN 10204Metallic products: types of inspection documents (MTC 2.1, 2.2, 3.1, 3.2)
ASME B31.3Process piping: inspection and examination requirements for installed piping
ASTM A370Standard test methods for mechanical testing of steel products
ASTM E23Standard test methods for notched bar impact testing (Charpy)
ISO 6892-1Metallic materials: tensile testing at ambient temperature
NACE MR0175 / ISO 15156Materials for use in H2S-containing environments (sour service)

Special End-User Requirements

End-users may specify requirements beyond standard ASME/API specifications. When present in a purchase order, these require tailored inspection procedures.

RequirementPurpose
Carbon equivalent (CE) limitConfirms weldability without preheat or PWHT
Low-temperature tensileVerifies strength at service temperature
Transverse tensileConfirms weld zone properties
Low-temperature impactCharpy testing at design minimum temperature
HIC/SSC resistanceSour service qualification (NACE MR0175)
Enhanced corrosion resistanceHigher Cr/Mo/Ni than standard grades
Ultra-low sulfurImproved toughness and weldability
Fine grain practiceMicrostructure control for toughness

Frequently Asked Questions

What is the difference between mill inspection and third-party inspection?

Mill inspection is performed by the manufacturer using in-house QC staff as part of standard production. Third-party inspection (TPI) is conducted by an independent agency (such as Lloyd's, SGS, DNV, or Bureau Veritas) hired by the buyer to witness and verify testing at the mill. TPI provides impartial confirmation that pipes meet purchase order specifications and results in an EN 10204 Type 3.2 certificate, the highest assurance level.

What tests are required for API 5L PSL2 pipe?

API 5L PSL2 requires: chemical analysis (product analysis mandatory), tensile testing (yield, UTS, elongation), Charpy V-notch impact testing at specified temperature, hardness testing (max 250 HV10 for most grades), hydrostatic test, full-body NDT (UT or EMI), dimensional inspection, and visual inspection. PSL2 has stricter limits on chemical composition, mandatory impact toughness, and carbon equivalent restrictions compared to PSL1.

What is an Inspection and Test Plan (ITP)?

An Inspection and Test Plan (ITP) is a document that lists every inspection and test activity for a manufacturing order. It specifies what is tested, the applicable standard, acceptance criteria, sampling frequency, and whether the activity is a Hold point (H), Witness point (W), Review point (R), or Monitor point (M). The ITP is agreed between buyer, manufacturer, and third-party inspector before production begins.

What are hold points and witness points in pipe inspection?

A Hold point (H) means production stops until the inspector is present, inspects, and formally releases the hold. Work cannot proceed without sign-off. A Witness point (W) means the inspector is invited to attend but production may continue if the inspector does not show up after reasonable notice. Hold points are used for critical activities like final inspection and hydrostatic testing; witness points for activities like heat treatment and in-process dimensional checks.

What pipe marking information is required by API 5L?

API 5L requires marking to include: manufacturer name or logo, specification (API 5L), PSL level (PSL1 or PSL2), grade (e.g. X65), pipe body type (S for seamless, E for ERW, L for LSAW), size (OD x WT), heat or lot number, and length. Additional markings may include test pressure, supplementary requirements, and third-party inspection stamps. Marking may be stenciled (paint) or die-stamped depending on wall thickness and client specification.

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