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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.

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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

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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.

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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

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1.3 Roles and Responsibilities

Consideration 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
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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.

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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

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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.

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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.

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4.2.1 Responsibilities
The 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.
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4.2.2 Material Verification Test Procedure Review

When 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.

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4.2.3 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.

4.2.4 Mill Test Report

Although this is an important part of a material QA program, MTRs should not be considered a substitute for PMI testing.

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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

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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.

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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.
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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.

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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.

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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.
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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
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4.3.3 Component Prioritization Factors

Piping 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
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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.

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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/users 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.
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4.4.2 Control of Incoming Materials and Warehousing

PMI testing can be as part of receiving function or performed at the suppliers 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.
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4.4.3 Maintenance Repairs of Piping Systems Important to consider PMI testing of

the repair materials.

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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.
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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.

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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.

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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.

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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.

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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.

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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.

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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 Procedures

Should 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.

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