cic api 570 ( 8 )api-578

Cairo Inspection Company

Eng. Ibrahim Eldesoky

ASNT –NDT-LEVEL III

ASME AUTHORIZED INSPECTOR

8

2Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky

The purpose of RP 578 is to provide

guidelines for a material and QA system to

verify the composition and alloy components

within the piping system are consistent with

the specified construction materials to

minimize the potential for release of toxic or

hazardous liquids or vapors.


RP 578 also provides guidelines for material

control and material verification programs on

ferrous and non-ferrous alloys of new and

existing systems specifically covered by B 31.3

(New Process Piping) and API 570 (In Service

inspection) during:

Construction

Installation

Maintenance

Inspection


RP 578 applies to metallic alloy materials

purchased for use:

Directly by the owner.

Indirectly through vendors, fabricators, or

contractors.

Includes the supply, fabrication and erection of

these materials.


1.2 Alloy Substitutions in Carbon Steel

Systems

When determining if carbon steel systems

require material verification, the owner/user

should consider what effect the process

stream could have on a substituted alloy

material.

Substitutions of hardenable alloy materials in

carbon steel systems have resulted in failure

and loss of containment.


Examples:

Wet H2S

Hydrofluoric acid

And sulfuric acid


1.3 Roles and ResponsibilitiesConsideration should be given to the roles and

responsibilities that each group involved in the material

verification program has. Groups within the operating plant

or shops of contractors, vendors or fabricators should have

roles and responsibilities clearly defined and documented.

Groups can include:

Purchasing

Engineering

Warehousing/receiving

Operations

Reliability

Maintenance

Inspection


2.0 References

Refer to the listed referenced

publications in Section 2.

3.0 Definitions

Refer to section 3 for definitions

related to Material Verification

Programs.


4.0 Extent of Verification

4.1 General

The owner/user should establish a written

material verification program indicating the

extent and type of PMI testing to be conducted

during construction of:

New piping systems

Retroactively on existing piping systems

Maintenance and repair

Alterations


A. The owner/user should consider

performing a high percentage of

examinations for higher-risk systems.

B. Lower risk-systems could have random

sampling performed.

C. Material substitution problems tend to

be random and small sampling may not

locate all substitutions.


4.2 New Construction Q/A Material

Verification Program

Covers shop and field fabrication of

alloy pipe.

Prior to being put into service.

Is restricted to pressure containing

boundaries.


4.2.1 ResponsibilitiesThe owner/user or designee is responsible for:

A. Determining the extent of examination

needed.

B. Verify implementation and conduct of the

program is performed in accordance with RP

578.

C. Verify that alloy materials placed into service

are as specified.

D. Documentation of the material program is in

accordance with this recommended practice.


4.2.2 Material Verification Test

Procedure ReviewWhen PMI testing is performed by the

material supplier or third-party agency; the

owner/user should review and approve the

adequacy of the material verification

program and testing procedure of the

fabricator or material supplier prior to

testing.


4.2.3 Scheduling of Material

Verification TestingPMI testing should be conducted at a time

that ensures that proper alloy materials have

been used in the fabrication of an

identifiable assembly.

4.2.4 Mill Test ReportAlthough this is an important part of a

material QA program, MTRs should not be

considered a substitute for PMI testing.


4.2.5 Components Covered in a Material

Verification Program

Examples:a. pipe lengths

b. pipe fittings

c. flanges

d. special forgings

e. processes valves and RVs

f. instruments

h. weld overlays or cladding

i. bolting

j. expansion joints and bellows


4.2.6 PMI Testing of Welding Consumables

Should PMI one electrode or wire sample

form each lot or package of alloy weld rods.

Should compare remainder of the lot to

sample to verify markings are correct.

Because of alloying elements in flux, PMI testing

of weld metal is an acceptable alternative

provided it is conducted immediately after

welding or during the welding process.


4.2.6.1 Longitudinal Pipe and Fitting Welds

Should receive random PMI of the base

metal and weld metal.

4.2.6.2 Autogenous welds

If required, it only necessary to test the base

metals.

4.2.7 PMI testing of Components Supplied

by a Distributor

A higher degree of PMI testing should be

performed due to the potential for material

mix-ups.


4.3 Material Verification Program For

Existing Piping Systems

Section covers alloy piping in service where

material verification programs were not in

accordance with 4.2

Material verification is limited to

pressure containing components and

attachments welds.


4.3.1 Responsibilities

The owner/user is responsible for:

Determining if a retroactive material

verification program is required for existing

piping systems.

Prioritizing the piping systems to receive

retroactive PMI testing.

Determining the extent of PMI testing

required.


4.3.2 Prioritizing piping systems for retroactive

PMI Testing

When determining if retroactive PMI testing is

necessary, the owner/user should consider the

following:

a. likelihood of material mix up

b. consequence of a failure

c. reason for alloy specification

d. related historical data- non-conformance report

Owner/user should establish a methodology for

prioritizing PMI testing. Methodology may be based

on a qualitative or quantitative risk analysis.


4.3.2.1 Carbon Steel Substitutions in Low Alloy

Steel Systems.

Historically, low alloy steel has the greatest number

of material non-conformances with serious

consequences.

4.3.2.2 Other Factors to Consider When

Prioritizing Piping Systems

Site specific or experienced-based factors should

be considered when prioritizing piping systems.

Factor to consider:

A. Constructions and maintenance practices.

B. Reasons for the alloy specification


4.3.3 Component Prioritization FactorsPiping components may have a higher likelihood or

inadvertent substitutions of a non-specific material.

Examples are:

a. warm up and bypass lines on pumps or check

valves.

b. small diameter piping systems.

c. valves and other removable devices

d. thermowells

e. bolting

f. piping as apart of a packaged system

g. components without an ASTM stamp


4.3.4 Factors to Consider when Determining

the Extent of PMI testing

a. Historical inspection material verification

records.

b. Number of plant modifications.

c. Material control during original fabrication.

d. Material verification program during

construction and fabrication.

e. Consequence of release.

f. Likelihood of corrosion/degradation.


4.4 Material Verification Program as Element

of Maintenance Systems

Concepts in 4.2 and API 570 should be reviewed

and applied as applicable.

4.4.1 Responsibilities

It is the owner/user’s responsibility to verify

programs are designed and implemented to

support the MI of alloy piping.

A material verification procedure should also

be written to address the repair of piping

systems during maintenance outages.


4.4.2 Control of Incoming Materials and

Warehousing

PMI testing can be as part of receiving function

or performed at the supplier’s location (as a

condition of release for shipment).

Material verification in the warehouse should be

regarded as a QA practice to minimize potential

discrepancies during subsequent PMI testing

but should not be regarded as an alternative to

PMI testing of fabricated systems when

required.


4.4.3 Maintenance Repairs of Piping

Systems

Important to consider PMI testing of

the repair materials.


5.1 Material Verification Program Test Method

Objectives

Methods of RP 578 are intended to ID alloy

materials and not intended to establish the exact

conformance of material to a particular spec.

Depending on the test method used, PMI

testing may identify the nominal composition of

the material.

ID of materials by visual stamps/markings

alone should not be considered a substitute for

PMI testing.


5.2 PMI Test Methods

Portable x- ray fluorescence

portable optical emission spectroscopy

laboratory chemical analysis

There are also alloy-sorting techniques may

be appropriate. These techniques can

include magnetic testing to differentiate

between ferritic and austenitic.

Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky 29

5.2.1 Portable X-ray Fluorescence

5.2.2 Portable Optical Emission Spectrometry

5.2.3 Chemical Laboratory Chemical Analysis

5.2.4 Other Qualitative Tests

5.2.4.1 Chemical Spot Testing

5.2.4.2 Resistivity Testing

5.2.4.3 Other Techniques


5.3 Equipment Calibration

Calibrate or verify the test equipment as

specified by the equipment manufacturer

PMI test procedure should provide frequency

interval.

If the manufacturer does not provide

calibration procedures, the owner/user should

establish them.

Procedures should include calibration

verification using certified standards.


5.4 Equipment Precision

Should be consistent with established

test objectives (see 5.1).

When composition is required, the

owner/user should establish the

acceptable precision and repeatability.


5.6 Safety Issues

Should consider electrical arching and

hot spots.

Consider appropriate electrical and hot

work permits.

Take safety precautions when handling

chemicals used in chemical spot testing.


6.0 Evaluation of PMI Test Results

6.1 Material Acceptance Methods

Confirmation of materials by the use of

relevant material specifications (e.g.

ASME Sec II or ASTM).

Materials can be classified through

qualitative sorting techniques.


When PMI testing indicates alloying elements

are outside the material specification ranges,

the owner/ user can choose to allow the use of

the materials provide a knowledgeable person

confirms that the material will perform

satisfactorily in the service.

If portable or qualitative PMI testing leads to

a potential rejection, a more accurate analysis

may be used to determine component

acceptance.


6.2 Dissimilar Metal Welds And Weld Overlays

When testing dissimilar welds, consider the

effects of dilution, which occurs during, weld

deposition.

6.3 Follow-Up PMI Testing After Discovery Of A

Nonconformity

If a representative sample is rejected, all of that

lot should be considered suspect and more

extensive inspection should be conducted of the

remaining lot.


7 Marking and Record-keeping

7.1 Materials Identification Process

Acceptable examples:

a. Color coding by alloy

b. Stamp marking

c. Documentation of PMI results and

test locations


7.1.1 Color Coding/Marker

If visual identification (color coding or marking)

is required by the material verification program,

records of the alloy material/ color-code

combinations should be maintained by the

owner/user.

Color-coding is not a substitute for permanent

manufacturers markings required by ASTM or

other material specs.


7.1.2 Marking or Components

Documentation process should specify one of

the following:

If the marking system is to remain for the

expected life of the component.

the marking system is only to be

temporary.


7.2 Material Certifications.

Should not be considered a substitute

for PMI testing.

7.3 Shop And Field PMI Test

Documentation


7.4 New And Existing Piping System

Documentation

Records of results for PMI testing should

be kept as long as the piping system exists

in its original location.

Should consider PMI testing prior to

placing relocated components into service

for piping that has no records of material

verification


7.5 PMI Test Records

Test records should contain:

a. Reference to the PMI test procedure(s)

used.

b. Date of testing.

c. Test instruments identification number or

serial number (where appropriate)


d. Name of each person and company

performing the test.

e. Results of the test.

f. Basis and action for resolving and

documenting PMI test including those that

have been left in service.

g. Documentation of the criteria used for

prioritization of piping systems and the extent

of PMI testing performed.


7.6 PMI Test ProceduresShould include:

Techniques used

Equipment calibration

Qualification requirements for PMI

test performed

The testing methodology

Documentation requirements


7.7 Traceability To Field Components

The information in 7.5 should be reported

in such a manner that they are traceable to

the point of installation.

cic api 570 ( 8 )api-578

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