api 578 positive material identification pmi

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N. Al-Khirdaji, AZTech Sr. Consultant 1

5.2 API 578 Positive Material Identification (PMI)

• Objectives and methodologies (e.g. X-Ray Fluorescence and Optical Emission Spectroscopy)

– ASTM- E1916 – Pipe Fabricator Institute PFI-ES42 – API 578 – MSS SP-137-2007 – Material Test Reports

Positive Material Identification (PMI) Testing

• Any physical evaluation or test of a material to confirm that the material which has been or will beconfirm that the material which has been or will be placed into service is consistent with the selected or specified alloy material designated by the owner/user.

• These evaluations or tests may provide qualitative or quantitative information that is sufficient to verify the nominal alloy compositionnominal alloy composition.

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Positive Material Identification (PMI)

• It is critically important for workers in inspection, safety and maintenance departments in refineriessafety, and maintenance departments in refineries, petrochemical, process, power and other industrial plants to prevent the accidents that can occur as a result of the installation of incorrect or out-of-specification metal alloy parts.

• With Positive Material Identification (PMI) the alloyWith Positive Material Identification (PMI) the alloy composition and so, the identity of materials can be determined/verified.


• As a result of a series of accidents resulting from material mix ups many companies havefrom material mix-ups, many companies have instituted stringent Positive Material Identification (PMI) programs.

• Industry organization has also worked to develop guidelines to assure that the nominal compositions of all alloy components in acompositions of all alloy components in a process system are consistent with design specification.

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OSHA Regulations and PMI 1/2

• Inspection Scheduling by OSHA: All Refineries –Section E 10Section E-10– It should be noted that both PMI and proper OPERATOR

TRAINING programs are QUESTIONS that the Compliance Safety and Health Officer (CSHO) will address to the Owner/Operator as to compliance with their Process Safety Management (PSM) program. D h l h l i i i– Does the employer ensure that replacement piping is suitable for its process application? Yes, No, N/A

OSHA Regulations and PMI 2/2

• If no, possible violations include:– The employer did not follow Recognized And Generally p y f g z y

Accepted Good Engineering Practice (RAGAGEP) when it failed to conduct Positive Material Identification (PMI) testing to ensure that construction materials of replacement/repaired piping were adequate for process conditions. Examples RAGAGEP for PMI testing for existing piping systems include but is not limited to,

• API RP 578, Material Verification Program for New and Existing Alloy Piping Systems, Section 4.3, and

• CSB, Safety Bulletin – Positive Material Verification: Prevent Errors During Alloy Steel Systems Maintenance, BP Texas City, TX Refinery Fire;

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Recognized And Generally Accepted Good Engineering Practice (RAGAGEP)

• “Recognized And Generally Accepted Good Engineering Practice” (RAGAGEP) - areEngineering Practice (RAGAGEP) are engineering, operation, or maintenance activities based on established codes, standards, published technical reports or recommended practices (RP) or a similar document.

• RAGAGEPs detail generally approved ways to perform specific engineering inspection orperform specific engineering, inspection or mechanical integrity activities, such as fabricating a vessel, inspecting a storage tank, or servicing a relief valve

Regulatory Compliance Positive Material Identification (PMI)

• Does the employer ensure that replacement piping is suitable for its process application? p pp– Yes, No, N/A

• If no, possible violations include:– The employer did not follow RAGAGEP when it failed to

conduct Positive material identification (PMI) testing to ensure that construction materials of replacement/repaired piping were adequate for process conditions (An example RAGAGEP for PMI testing for existing piping systemsRAGAGEP for PMI testing for existing piping systems includes but is not limited to, API RP 578, Material Verification Program for New and Existing Alloy Piping Systems, Section 4.3), and CSB, Safety Bulletin – Positive Material Verification: Prevent Errors During Alloy Steel Systems Maintenance, BP Texas City, TX Refinery Fire);

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Approximate Hardness of Steel By the File Test

File Reaction Brinell Hardness Type of SteelFile Reaction Brinell Hardness Type of SteelFile bites easily into metal 100 BHN Mild SteelFile bites into metal with pressure

200 BHN Medium carbon steel

File does not bite into metal except with extreme pressure

300 BHN High carbon steelHigh alloy steel

Metal can only be filed with 400 BHN Unhardened tool steelMetal can only be filed with difficulty

400 BHN Unhardened tool steel

File will mark metal but metal is almost as hard as the file and filing is impractical

500 BHN Hardened tool steel

Metal is harder than file 600+ BHN

Metal Identification – Spark Test

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PMI Standards • ASTM E1916

Standard Guide for Identification and/or Segregation of Mixed Lots of MetalsMetalsAmerican Society of Testing Material /1997 , reaffirmed 2004

• MSS SP-137-2007 - Quality Standard for Positive Material Identification of Metal Valves, Flanges, Fittings, and Other Piping Components Edition: 1st Manufacturers Standardization Society / 01-May-2007 This Standard Practice provides methods and acceptance standards forThis Standard Practice provides methods and acceptance standards for Positive Material Identification (PMI) of metal flanges, fittings, valves, and pressure boundary parts of valves and other piping components.

• PFI ES42 - Standard for Positive Material Identification of Piping Components Using Portable X-Ray Emission Type Test Equipment Pipe Fabrication Institute / 01-Oct-1996

PMI Standards

• API R P 578Material Verification Program for New and Existing Alloy Piping SystemsAmerican Petroleum Institute / May 1999

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PMI Standards – API RP 578SCOPE• This recommended practice provides the guidelines forThis recommended practice provides the guidelines for

material control and material verification programs on ferrous and nonferrous alloys during the construction, installation, maintenance, and inspection of new and existing process piping systems covered by the ASME B31.3 and API 570 piping codes.

• This practice applies to metallic alloy materials purchased for use either directly by the owner/user or indirectly throughuse either directly by the owner/user or indirectly through vendors, fabricators, or contractors and includes the supply, fabrication, and erection of these materials.

• Carbon steel components specified in new or existing piping systems are not specifically covered under the scope of this document.

PMI Standards – API RP 578ROLES AND RESPONSIBILITIES• A material verification program for piping systems mayA material verification program for piping systems may

involve participation of several groups within the operating plant or the shop of a contractor, vendor, or fabricator.

• When establishing a material verification program, consideration should be given to the roles and responsibilities that each group has within the specific organization.

• These roles and responsibilities should be clearly defined and d d Wi hi h i l hi i l d hdocumented. Within the operating plant, this can include those groups responsible for purchasing, engineering, warehousing/receiving, operations, reliability, maintenance, and inspection

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PMI Standards – API RP 578

• Carbon Steel Substitutions in Low Alloy Steel SystemsSystems– In determining the likelihood of material nonconformances,

it is worth noting that historically the greatest number of material nonconformances with serious consequences have involved carbon steel components in low alloy steel

– (e.g., 1 ¼ Cr– ½ Mo, 2 ¼ Cr–1 Mo, 5 Cr– ½ Mo, 9 Cr–1 M ) i i Th h b l i l fMo) piping systems. There have been relatively fewer nonconformances in stainless steel and nonferrous (e.g. Monel, Inconel) systems because of appearance and weldability issues.

PMI Standards – API RP 578

• Alloy Substitutions In Carbon Steel SystemsWh d t i i th d t f t i l ifi ti– When determining the need to perform material verification on carbon steel systems, the owner/user should evaluate the effect that the process stream could have on substituted alloy materials.

– In some cases, the substitution of hardenable alloy materials in carbon steel piping systems resulted in failure and loss of containment Examples of such systems includeand loss of containment. Examples of such systems include wet hydrogen sulfide (H2S), hydrofluoric acid (HF), and sulfuric acid (H2S04) services

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PMI Standards – API RP 578• Some Highlights

– PMI Testing of Welding Consumables - When welding is g W g C W gconducted, one electrode or wire sample from each lot or package of alloy weld rod should be positively identified. The remainder of the lot should be compared to the sample to verify that the markings of the wires/electrodes are correct

– Maintenance Repairs of Piping Systems - It is important that repair procedures include consideration of PMI testing as part of obtaining satisfactory alloy materials to be usedas part of obtaining satisfactory alloy materials to be used for the repair

– Material Certifications - Material certifications, mill test reports, or Certificates of Compliance should not be considered a substitute for PMI testing, but may be an important part of an overall quality assurance program


• Positive Material Identification (PMI) is one f th i li d d t tiof the more specialized non-destructive

testing (NDT) methods. • There are two methods for PMI:

1. The XRF-principle (x-ray fluorescence)2 Optical emission systems (OES) also called2. Optical emission systems (OES), also called

arc/spark

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PMI Methods - XRF

1. The X-Ray Fluorescence Technique XRFXRF i t t k b i l t• XRF instruments work by exposing a sample to a beam of X-rays. – The atoms of the sample absorb energy from the X-

rays, become temporarily excited and then emit secondary X-rays.

– Each chemical element emits X-rays at a unique y qenergy. By measuring intensity and characteristic energy of the emitted X-rays, an XRF analyzer can provide qualitative and quantitative analysis regarding the composition of the material being tested.

PMI Methods - OES2. The Optical Emission Spectroscopy Technique OES• In the OES technique atoms also are excited; however• In the OES technique, atoms also are excited; however,

the excitation energy comes from a spark formed between sample and electrode. – The energy of the spark causes the electrons in the sample to

emit light, which is converted into a spectral pattern. – By measuring the intensity of the peaks in this spectrum, the

OES analyzer can produce qualitative and quantitative analysis f th t i l itiof the material composition.

• Although OES is considered a non-destructive testing method, the spark does leave a small burn on the sample surface

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PMI Methods - OESOptical Emission Spectrography – A spark is released that vaporizes a very small portion of the sample (withoutthat vaporizes a very small portion of the sample (without impairing its functionality).

The analyzer optically measures the atoms in the

d d t i thvapor and determines the components of the material.

“Spectro” metal analyzer

XRF Excitation ModelX-ray fluorescence (XRF) spectrometry is an elemental analysis technique with broad application in science and industry. XRF is based on the principle that individual atoms, when excited by an external energy source, emit X-ray photons of a characteristic energy or wavelength.

The identification of elements by X-ray methods is possible due to the characteristic radiation emitted from the inner electronic shells of the atoms under certain conditions.

h i d f di iThe emitted quanta of radiation are X-ray photons whose specific energies permit the identification of their source atoms.

By counting the number of photons of each energy emitted from a sample, the elements present may be identified and quantified.

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Optical Emission Analyzer

Optical Emission analyzer designed to identify all the key elements in metals -especially where highest accuracy and/or the analysis of light elements like C, p y g y y g ,Al, S, P, Mg, Si is needed and when sorting low alloys and aluminums. Ideal, for example, for separation of 316 H (>0.04% C) and 316 L (<0.03% C).

ARC-MET 8000 Optical Emission Analyzer.

Case Study 1 – Chlorine Transfer Hose Failure

– On August 14, 2002, a 1-inch transfer line ruptured during a railcar offloading operation atruptured during a railcar offloading operation at DPC Enterprises in Festus, Missouri and released 48,000 pounds of Chlorine into neighboring area.

– Safety Bulletin from U.S. Chemical Safety and Hazard Investigation Board (CSB)-Chlorine Transfer Hose Failure due to improper materialTransfer Hose Failure due to improper material braid construction (i.e.,316L and not the recommended braid of Hastelloy C-276).

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PMI TestingThe elements of the basic alloy materials to be verified should be in accordance with Table below:

Chromium Nickel Molybdenum and CarbonLow carbon stainless steelsChromium, Nickel, and Molybdenum Regular carbon grade stainless steels Nickel Nickel steels

Chromium and Molybdenum Carbon-Molybdenum, ManganeseMolybdenum, and ChromiumMolybdenum steels

Elements to be Verified Basic Alloy

Copper, Zinc, and other elements specified inpurchase order or SAMS catalog description Copper-based alloys

Nickel, Iron, Copper, Chromium, andMolybdenum Nickel-based alloys

Chromium, Nickel, Molybdenum, Titanium andNiobium Stabilized stainless steels

Chromium, Nickel, Molybdenum, and Carbon Low-carbon stainless steels

X-Ray Fluorescence (XRF) AnalyzerWhen an electron beam of high energy strikes a material, one of the results of the interaction is the emission of photons which have a broad continuum of energies. This radiation, called bremsstrahlung.

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Component Identification

• The ASME B31.3 Code requires random i ti f t i l d t texamination of materials and components to

ensure conformance to listed specifications and standards.

• B31.3 also requires these materials to be free from defects.from defects.

• Component standards and specifications have various marking requirements.

Material Verification AndTraceability

• During repairs or alterations alloy material piping systems WHERE THE ALLOY MATERIAL ISsystems, WHERE THE ALLOY MATERIAL IS REQUIRED TO MAINTAIN PRESSURE CONTAINMENT, the inspector shall verify that the installation of new materials is consistent with the selected or specified construction materials.

• This material verification program should be consistent with API RP 578 Material Verificationconsistent with API RP 578, Material Verification Program for New and Existing Alloy Piping Systems.

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Case Study 1: Failure of A Slurry Recycle Line in a Delayed Coker – Canada 1984

• Failure of a slurry recycle line in a delayed coker unit in Canada in 1984. The line was specified to be NPS 6, schedule 40 ASTM A 335 grade P5 (UNS K41545) seamless pipe having a nominal composition of 5% chromium and ½% molybdenum.

• The line contained oil with sulfur compounds and coke particles at a temperature of 705 °F (374 °C) and a pressure of 240 psig (1 66 MPa)and a pressure of 240 psig (1.66 MPa).

• The line split longitudinally, showering the unit with hot oil and causing a fire to spread through the unit resulting in a half dozen additional pipe failures


The fire was traced to the rupture of a 16-in. (406-mm) long section of carbon steel, shown in Figure, that had been welded into the line approximately fi i l

The carbon steel section had a thickness of only 0.090 to 0.125 in. (2.3 to 3.2 mm) prior to the failure while the adjacent pipe was between 0.250 and 0.260 in. (6.4 to 6.6 mm) thick.

five years previously.

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Figure below is a longitudinal metallographic section of one of the girth welds at the end of the carbon steel section illustrating thegirth welds at the end of the carbon steel section illustrating the abrupt change in wall thickness between the carbon steel section and the adjacent 5% chromium steel pipe and weld.

Safety Bulletin - U.S. Chemical Safety and Hazard Investigation Board (CSB)Positive Material Verification: Prevent Errors During Alloy Steel Systems Maintenance

• The U.S. Chemical Safety and Hazard Investigation Board (CSB) issues this Safety Bulletin to focus attention on process equipment configuration control and positive material verification of critical alloy steel piping components. The CSB e e d th t the efi i et he i l d

Alloy Steel Systems Maintenance

• The CSB recommends that the refining, petrochemical, and chemical industries review material verification programs to ensure that maintenance procedures include sufficient controls and positive material identification (PMI) testing to prevent improper material substitutions in hazardous process systems.

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Case Study 2: Material Verification Error

• On July 28, 2005, the BP Texas City refinery i d j fi i th R idexperienced a major fire in the Resid

Hydrotreater Unit (RHU) that caused a reported $30 million in property damage.

• One employee sustained a minor injury during the emergency unit shutdown and there werethe emergency unit shutdown and there were no fatalities.

Case Study 2: Material Verification ErrorThe RHU incident investigation determined that an 8-inch diameter carbon steel elbow inadvertently installed in a high-pressure, high-temperature hydrogen line ruptured after operating for only 3 monthstemperature hydrogen line ruptured after operating for only 3 months. The escaping hydrogen gas from the ruptured elbow quickly ignited.

Carbon steel RHU heat exchanger outlet pipe (arrow) ruptured after operating only 3 months in high-temperature hydrogen service.

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• This incident occurred after a maintenance contractor accidentally switched a carbon steel elbow with anaccidentally switched a carbon steel elbow with an alloy steel elbow during a scheduled heat exchanger overhaul in February 2005.

• The alloy steel elbow was resistant to high temperature hydrogen attack (HTHA) but the carbon steel elbow was not Metallurgical analyses of thesteel elbow was not. Metallurgical analyses of the failed elbow concluded that HTHA severely weakened the carbon steel elbow.


Dimensionally identical piping elbows on RHU heat exchangers A and B.

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Ruptured 8-inch carbon steel pipe elbow pieces recovered after the fire

Case Study: Material Verification Error

RHU hydrogen heat exchanger piping material requirements.

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API RP 578: Material Verification Program for New and Existing Alloy Piping Systems

• Provides guidelines for a material quality assurance system to verify the consistency between the nominal composition of alloy

t ithi th l f i icomponents within the pressure envelop of a process piping system with the selected or specified construction materials to minimize the potential for catastrophic release of toxic or hazardous liquids or vapors.

• Presents material control and verification programs on ferrous and nonferrous alloys during construction, installation, maintenance, and inspection of new and existing process piping systems covered under the ASME B31.3 and API 570 codes.systems covered under the ASME B31.3 and API 570 codes.

• Applies to metallic alloy materials purchased for use by the owner/user or indirectly through vendors, fabricators, or contractors, and includes the supply, fabrication and erection of these materials.

• Carbon steel components specified in new or existing piping systems are not covered under the scope of this document.


• The ASME B31.3 Code requires random i ti f t i l d t texamination of materials and components to

ensure conformance to listed specifications and standards.

• B31.3 also requires these materials to be free from defects.from defects.

• Component standards and specifications have various marking requirements.

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Markings – Pipe

Pipe, Steel, Black and Hot-Dipped, Zinc Coated, Welded and

Title and Marking Requirements Standard

Seamless Carbon Steel Pipe for High-Temperature Service1. Marking requirements of A530/A530M 2. Heat Number 3. Hydro/NDE Marking

Seamless 1. Name of Brand of Manufacturer 2. Kind of Pipe (e.g. ERW B, XS) 3. Specification Number 4. Length

ASTM A53

y g4. “S” for supplementary requirements as specified (stress-relieved

annealed tubes, air underwater pressure test, and stabilizing heat treatment)

5. Length 6. Schedule Number 7. Weight on NPS 4 and larger

ASTM A106

Markings – Flanges & Flanged Fittings


Orifice Flanges Classes 300, 400, 600, 1500 and 25001 Fl h ll b k d i d b ASME B16 5

ASME B16.36

Pipe Flanges and Flanged Fittings1. Manufacturer’s Name or Trademark 2. ASTM Specification and Grade 3. Rating Class 4. “B16” 5. Size

ASME B16.5

1. Flanges shall be marked as required by ASME B16.5 2. For welding neck flanges only, the bore diameter shall be

marked.

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Markings – Fittings

Factory-Made Wrought Steel Buttwelding Fittings


Forged Fittings, Socket-Welding and Threaded1. Manufacturer’s Name or Trademark. 2 M t i l id tifi ti i d ith th i t ASTM

Factory Made Wrought Steel Buttwelding Fittings1. Manufacturer’s Name or Trademark2. Material and Product Identification (ASTM or ASME grade

symbol).3. “WP” in grade symbol.4. Schedule number or nominal wall thickness.5. NPS

ASME B16.9

2. Material identification in accordance with the appropriate ASTM. 3. Product conformance symbol, either “WP” or “B16”. 4. Class designation - 2000, 3000, 6000, or 9000. Where size and

shape do not permit all of the above markings, they may be omitted in the reverse order given above

ASME B16.11

Markings - Fasteners

Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service

Title and Marking RequirementsStandard

Specification for Carbon Steel Bolts and Studs1.Manufacturer’s identification mark. ASTM 307

Specification for Carbon and Alloy Steel Nuts for Bolts for High-Pressure and High-Temperature Service

1.Manufacturer’s identification mark. 2.Grade and process of manufacture (e.g. 8F indicates nuts that are hot-forged or

cold-forged)

ASTM 194

Temperature Service1.Grade or manufacturer’s identification symbols shall be applied to one end of studs

3/8” in diameter and larger and to the heads of bolts ¼ ” in diameter and larger. ASTM 193

Specification for Carbon and Alloy Steel Nuts1.Grades O, A, and B are not required to be marked unless identified as such by the

purchaser. 2.Grade D, DH, DH3 shall be marked with the symbol HX3 on one face. Heavy hex

nuts made to the requirements of DH3 are marked with HX3 on one face.3.Grades C, C3, D, DH, and DH3 and hex nuts made to the requirements of DH3,

are marked with the manufacturers symbol.

ASTM 563

2.All bolt heads, one end of studs 3/8” and larger, and whenever feasible studs less than 3/8”, shall be marked with a grade material.

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Metal AnalyzersPositive Material Identification (PMI) refers to the identification and analysis of various metal alloys based on their chemical composition in non-destructive testing (NDT). Measurement results are shown in the form of elemental concentration in percentage or by specific alloy name such as SS316L or Inconel 625. PMI is a field-testing method made possible by the portability of most PMI analyzers.

The two main technologies used for alloy

Innov-X Portable XRF Metal Analyzer

identification in PMI are:

X-ray Fluorescence (XRF), and

Optical Emission Spectroscopy (OES)

Spark Emission Spectrometer –PMI-MASTER SORT (Oxford)

The PMI-MASTER is a portable universal spectrometer for alloy sorting. The instrument provides a quick and precise analytical overview of all common materials with a Fe, Al, Cu, Ni, Ti and CO base.The instrument source works with a high-frequency spark in argon or a direct current arc in air. The respective excitation mode can be selected according toapplication and can be changed easily.

Depending upon the requirements, the instrument offers three different operationoffers three different operation modes; • sorting; • Grade ID; and • complete analysis of metals.

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CSB Bulletin – Failure Due to Improper Material

August 14, 2002, a 1-inch transfer line ruptured during a railcar offloading operationruptured during a railcar offloading operation at DPC Enterprises in Festus, Missouri and released 48,000 pounds of Chlorine into neighboring area.

Safety Bulletin from U.S. Chemical Safety and Hazard Investigation Board (CSB)-Chlorine Transfer Hose Failure due to improper material braid construction (i.e., 316L and not the recommended braid of Hastelloynot the recommended braid of Hastelloy C-276 as specified by DPC).

The CSB also recommended that the hose fabricator implement a materials’ verification procedure to improve quality and ensure that Hastelloy chlorine hoses are readily identifiable

Example: PMI on Type 304 SS Sample Using NITON XRF Analyzer

+/-20 Sec+/-5 SecCertSample: SS 304

0.050.130.100.140.13W 0.010.400.030.400.38Mo 0.141.800.301.811.73Mn 0.219.550.459.579.52Ni 0.1418.390.3218.3618.31Cr

304304Grade ID

NITON XRF instruments report a two-sigma precision along with the result for each element. This represents an error band of two standard deviations on either side of the result. The two sigma precision represents a 95 % confidence interval for the data. Note the precision, or +/- error band, is not an indication of accuracy, but a measurement of repeatability around a most probable value. Accuracy must be assessed by comparing the measured result and precision to known values from a reference standard.

api 578 positive material identification pmi

Documents

specified alloy material

material verification

alloy components

existing alloy piping

compliance safety

existing piping systems

process system

examples ragagep