cic api 570 ( 8 )api-578
TRANSCRIPT
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.
3Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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
4Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
5Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
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Examples:
Wet H2S
Hydrofluoric acid
And sulfuric acid
7Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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
8Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
9Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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
10Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
11Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
12Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
13Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
14Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
15Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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
16Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
17Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
18Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
19Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
20Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
21Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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
22Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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
23Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
24Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
25Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
26Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
4.4.3 Maintenance Repairs of Piping
Systems
Important to consider PMI testing of
the repair materials.
27Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
28Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
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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
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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.
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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.
32Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
33Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
34Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
35Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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.
36Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky
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
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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.
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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.
Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. Ibrahim Eldesoky 39
7.2 Material Certifications.
Should not be considered a substitute
for PMI testing.
7.3 Shop And Field PMI Test
Documentation
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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
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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)
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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.
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7.6 PMI Test ProceduresShould include:
Techniques used
Equipment calibration
Qualification requirements for PMI
test performed
The testing methodology
Documentation requirements
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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.