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Cairo Inspection Company
Eng. Ibrahim Eldesoky
ASNT –NDT-LEVEL III ASME AUTHORIZED INSPECTOR

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.

Cairo Inspection Company (CIC)

Www. CIC-Egypt.com

Eng. Ibrahim Eldesoky

2

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

Cairo Inspection Company (CIC)

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Eng. Ibrahim Eldesoky

3

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.

Cairo Inspection Company (CIC)

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Eng. Ibrahim Eldesoky

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com Eng.2 Alloy Substitutions in Carbon Steel Systems When determining if carbon steel systems require material verification. CIC-Egypt. Substitutions of hardenable alloy materials in carbon steel systems have resulted in failure and loss of containment.1. the owner/user should consider what effect the process stream could have on a substituted alloy material. Ibrahim Eldesoky 5 . Cairo Inspection Company (CIC) Www.

CIC-Egypt.com Eng.Examples: Wet H2S Hydrofluoric acid And sulfuric acid Cairo Inspection Company (CIC) Www. Ibrahim Eldesoky 6 .

CIC-Egypt. vendors or fabricators should have roles and responsibilities clearly defined and documented. Groups within the operating plant or shops of contractors. Ibrahim Eldesoky 7 .com Eng. Groups can include:  Purchasing  Engineering  Warehousing/receiving  Operations  Reliability  Maintenance  Inspection Cairo Inspection Company (CIC) Www.1.3 Roles and Responsibilities Consideration should be given to the roles and responsibilities that each group involved in the material verification program has.

CIC-Egypt.2.com Eng. Ibrahim Eldesoky 8 .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. Cairo Inspection Company (CIC) Www.

com Eng.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 Cairo Inspection Company (CIC) Www. CIC-Egypt. Ibrahim Eldesoky 9 .0 Extent of Verification 4.

Lower risk-systems could have random sampling performed.A.com Eng. Cairo Inspection Company (CIC) Www. Ibrahim Eldesoky 10 . Material substitution problems tend to be random and small sampling may not locate all substitutions. CIC-Egypt. C. The owner/user should consider performing a high percentage of examinations for higher-risk systems. B.

Ibrahim Eldesoky 11 .com Eng.  Is restricted to pressure containing boundaries.  Prior to being put into service. Cairo Inspection Company (CIC) Www. CIC-Egypt.4.2 New Construction Q/A Material Verification Program Covers shop and field fabrication of alloy pipe.

CIC-Egypt. B.com Eng.1 Responsibilities The owner/user or designee is responsible for: A. Documentation of the material program is in accordance with this recommended practice. Cairo Inspection Company (CIC) Www. Ibrahim Eldesoky 12 . Determining the extent of examination needed.2. Verify implementation and conduct of the program is performed in accordance with RP 578. C. D. Verify that alloy materials placed into service are as specified.4.

CIC-Egypt.2 Material Verification Test Procedure Review When PMI testing is performed by the material supplier or third-party agency.4.2.com Eng. 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. Cairo Inspection Company (CIC) Www. Ibrahim Eldesoky 13 .

com Eng. Cairo Inspection Company (CIC) Www.3 Scheduling of Material Verification Testing PMI testing should be conducted at a time that ensures that proper alloy materials have been used in the fabrication of an identifiable assembly. Ibrahim Eldesoky 14 .4 Mill Test Report Although this is an important part of a material QA program. MTRs should not be considered a substitute for PMI testing.4.2. 4.2. CIC-Egypt.

special forgings e. bolting j.4.com Eng. Ibrahim Eldesoky 15 . CIC-Egypt. pipe fittings c. pipe lengths b. instruments h. processes valves and RVs f. flanges d. weld overlays or cladding i.5 Components Covered in a Material Verification Program Examples: a. expansion joints and bellows Cairo Inspection Company (CIC) Www.2.

4. Ibrahim Eldesoky 16 .2.com Eng.  Should compare remainder of the lot to sample to verify markings are correct. PMI testing of weld metal is an acceptable alternative provided it is conducted immediately after welding or during the welding process.6 PMI Testing of Welding Consumables  Should PMI one electrode or wire sample form each lot or package of alloy weld rods. CIC-Egypt. Cairo Inspection Company (CIC) Www. Because of alloying elements in flux.

2. CIC-Egypt.6.2. 4. it only necessary to test the base metals. 4. Cairo Inspection Company (CIC) Www.4. Ibrahim Eldesoky 17 .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.1 Longitudinal Pipe and Fitting Welds Should receive random PMI of the base metal and weld metal.2 Autogenous welds If required.6.2.com Eng.

com Eng. Cairo Inspection Company (CIC) Www.2  Material verification is limited to pressure containing components and attachments welds.4. Ibrahim Eldesoky 18 .3 Material Verification Program For Existing Piping Systems Section covers alloy piping in service where material verification programs were not in accordance with 4. CIC-Egypt.

CIC-Egypt.4.  Prioritizing the piping systems to receive retroactive PMI testing.  Determining the extent of PMI testing required. Ibrahim Eldesoky 19 .com Eng. Cairo Inspection Company (CIC) Www.3.1 Responsibilities The owner/user is responsible for:  Determining if a retroactive material verification program is required for existing piping systems.

the owner/user should consider the following: a. CIC-Egypt.3.non-conformance report Owner/user should establish a methodology for prioritizing PMI testing. reason for alloy specification d. Methodology may be based on a qualitative or quantitative risk analysis. consequence of a failure c. related historical data.4. Ibrahim Eldesoky 20 . Cairo Inspection Company (CIC) Www.com Eng. likelihood of material mix up b.2 Prioritizing piping systems for retroactive PMI Testing When determining if retroactive PMI testing is necessary.

com Eng.1 Carbon Steel Substitutions in Low Alloy Steel Systems. Ibrahim Eldesoky 21 . Constructions and maintenance practices.2 Other Factors to Consider When Prioritizing Piping Systems Site specific or experienced-based factors should be considered when prioritizing piping systems. B. Historically. Reasons for the alloy specification Cairo Inspection Company (CIC) Www.3.3. CIC-Egypt. low alloy steel has the greatest number of material non-conformances with serious consequences. 4.2. Factor to consider: A.4.2.

c. thermowells e.3.com Eng. Examples are: a. valves and other removable devices d. small diameter piping systems. warm up and bypass lines on pumps or check valves. piping as apart of a packaged system g.3 Component Prioritization Factors Piping components may have a higher likelihood or inadvertent substitutions of a non-specific material. bolting f. CIC-Egypt.4. Ibrahim Eldesoky 22 . components without an ASTM stamp Cairo Inspection Company (CIC) Www. b.

3. Likelihood of corrosion/degradation. Ibrahim Eldesoky 23 .4 Factors to Consider when Determining the Extent of PMI testing a. c. e. Material verification program during construction and fabrication.4. Number of plant modifications. Cairo Inspection Company (CIC) Www. CIC-Egypt. f. Consequence of release. Historical inspection material verification records. b. d.com Eng. Material control during original fabrication.

Ibrahim Eldesoky 24 . 4.1 Responsibilities It is the owner/user’s responsibility to verify programs are designed and implemented to support the MI of alloy piping.2 and API 570 should be reviewed and applied as applicable. CIC-Egypt.4.com Eng. Cairo Inspection Company (CIC) Www.4 Material Verification Program as Element of Maintenance Systems Concepts in 4.4. A material verification procedure should also be written to address the repair of piping systems during maintenance outages.

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). CIC-Egypt. Cairo Inspection Company (CIC) Www. Ibrahim Eldesoky 25 .com Eng.4. 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.

Ibrahim Eldesoky 26 .4. Cairo Inspection Company (CIC) Www.com Eng.3 Maintenance Repairs of Piping Systems  Important to consider PMI testing of the repair materials.4. CIC-Egypt.

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. Ibrahim Eldesoky 27 .5. CIC-Egypt. Cairo Inspection Company (CIC) Www.com Eng. ID of materials by visual stamps/markings alone should not be considered a substitute for PMI testing. PMI testing may identify the nominal composition of the material. Depending on the test method used.

2 PMI Test Methods Portable x.5. These techniques can include magnetic testing to differentiate between ferritic and austenitic.ray fluorescence portable optical emission spectroscopy laboratory chemical analysis There are also alloy-sorting techniques may be appropriate. CIC-Egypt. Cairo Inspection Company (CIC) Www. Ibrahim Eldesoky 28 .com Eng.

3 Chemical Laboratory Chemical Analysis 5.4 Other Qualitative Tests 5.4.3 Other Techniques Cairo Inspection Company (CIC) Www.2 Resistivity Testing 5.4.2.com Eng.2.2.2.2 Portable Optical Emission Spectrometry 5.1 Portable X-ray Fluorescence 5.4.2.1 Chemical Spot Testing 5. Ibrahim Eldesoky 29 . CIC-Egypt.5.2.2.

5. Procedures should include calibration verification using certified standards. Ibrahim Eldesoky 30 .com Eng.3 Equipment Calibration Calibrate or verify the test equipment as specified by the equipment manufacturer PMI test procedure should provide frequency interval. Cairo Inspection Company (CIC) Www. the owner/user should establish them. If the manufacturer does not provide calibration procedures. CIC-Egypt.

Ibrahim Eldesoky 31 . Cairo Inspection Company (CIC) Www. CIC-Egypt.com Eng. When composition is required.5.1). the owner/user should establish the acceptable precision and repeatability.4 Equipment Precision Should be consistent with established test objectives (see 5.

CIC-Egypt. Cairo Inspection Company (CIC) Www.com Eng.5. Take safety precautions when handling chemicals used in chemical spot testing. Ibrahim Eldesoky 32 .6 Safety Issues Should consider electrical arching and hot spots. Consider appropriate electrical and hot work permits.

CIC-Egypt.6. Materials can be classified through qualitative sorting techniques. Ibrahim Eldesoky 33 .com Eng.1 Material Acceptance Methods Confirmation of materials by the use of relevant material specifications (e.0 Evaluation of PMI Test Results 6.g. Cairo Inspection Company (CIC) Www. ASME Sec II or ASTM).

com Eng. Ibrahim Eldesoky 34 . If portable or qualitative PMI testing leads to a potential rejection. Cairo Inspection Company (CIC) Www. 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. a more accurate analysis may be used to determine component acceptance. CIC-Egypt.When PMI testing indicates alloying elements are outside the material specification ranges.

CIC-Egypt. Ibrahim Eldesoky 35 . Cairo Inspection Company (CIC) Www.2 Dissimilar Metal Welds And Weld Overlays When testing dissimilar welds. all of that lot should be considered suspect and more extensive inspection should be conducted of the remaining lot. consider the effects of dilution. which occurs during.6.3 Follow-Up PMI Testing After Discovery Of A Nonconformity If a representative sample is rejected.com Eng. weld deposition. 6.

com Eng.1 Materials Identification Process Acceptable examples: a. Stamp marking c. Documentation of PMI results and test locations Cairo Inspection Company (CIC) Www. Ibrahim Eldesoky 36 .7 Marking and Record-keeping 7. Color coding by alloy b. CIC-Egypt.

1. CIC-Egypt.7. Cairo Inspection Company (CIC) Www. Ibrahim Eldesoky 37 .com Eng. Color-coding is not a substitute for permanent manufacturers markings required by ASTM or other material specs.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.

7. the marking system is only to be temporary.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. Cairo Inspection Company (CIC) Www.1. CIC-Egypt.com Eng. Ibrahim Eldesoky 38 .

CIC-Egypt.7. Should not be considered a substitute for PMI testing. 7.3 Shop And Field PMI Test Documentation Cairo Inspection Company (CIC) Www. Ibrahim Eldesoky 39 .com Eng.2 Material Certifications.

7.com Eng. Ibrahim Eldesoky 40 .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 Cairo Inspection Company (CIC) Www. CIC-Egypt.

com Eng. CIC-Egypt. Date of testing. c. Reference to the PMI test procedure(s) used. Ibrahim Eldesoky 41 . b.7. Test instruments identification number or serial number (where appropriate) Cairo Inspection Company (CIC) Www.5 PMI Test Records Test records should contain: a.

Results of the test. g. Name of each person and company performing the test. e.d. Ibrahim Eldesoky 42 .com Eng. Cairo Inspection Company (CIC) Www. Documentation of the criteria used for prioritization of piping systems and the extent of PMI testing performed. Basis and action for resolving and documenting PMI test including those that have been left in service. f. CIC-Egypt.

com Eng.7. Ibrahim Eldesoky 43 . CIC-Egypt.6 PMI Test Procedures Should include: Techniques used Equipment calibration Qualification requirements for PMI test performed The testing methodology Documentation requirements Cairo Inspection Company (CIC) Www.

7.5 should be reported in such a manner that they are traceable to the point of installation. Cairo Inspection Company (CIC) Www.7 Traceability To Field Components The information in 7. CIC-Egypt.com Eng. Ibrahim Eldesoky 44 .

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