Batam Training Institute

Material Inspection
Its code and standard
By : HSB

CONTENT

z Material
M t i l classification
l ifi ti
z Properties of materials
z Codes and specifications definition
z Codes comparison
z Project
j specifications
p comparison
p
z Material Inspection

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MATERIAL CLASSIFICATION

Common material to be used in offshore industries are:

z Carbon Steel-standard (ASTM/API/BS-EN/AS)

z Stainless Steel (austenitic and Duplex SS)

z Copper Nickel (EEMUA 144,145,146)Æ 90Cu-10Ni

z Nickel Base alloy (very rare)

z Others (Timber
(Timber, Grating
Grating, Neoprene etc )

MATERIAL CLASSIFICATIONS

z Carbon Steel Material

z Alloy of iron and carbon,
carbon usually containing 00.2
2 – 1.5
15
percent carbon, often with other constituents such as
manganese, chromium, nickel, molybdenum, copper,
tungsten, cobalt or silicon , depending on the desired
properties and widely used as a structural materials
z Classification, Designations, and specifications for
steels:
z Classification According to Composition
z Classification According to Strength
z Classification According to Shape, finish processing, and
Quality Descriptors

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MATERIAL CLASSIFICATION

z Classified by composition as follows:

z Low-carbon steels contain up to 0.30% C
z Medium-carbon steels are similar to low-carbon steels except that the
carbon ranges from 0.30 to 0.60% and the manganese from 0.60 to 1.65%.
z High-carbon steels contain from 0.60 to 1.00% C with manganese
contents ranging from 0.30 to 0.90%.
z Ultrahigh-carbon steels are experimental alloys containing 1.25 to 2.0% C

Classification According to Strength

Yield Strengths
Plain Carbon ASTM A36, JIS SS400,
Generally below
Steel API 5LB
40ksi
HSLA (High Strength
Low Alloy)
High Strength 40ksi up to 80ksi Microalloyed HSLA
Structural TMCP
steel
Yield strength above A517 Q+T
80Ksi HSLA 80; HSLA 100
All Q+T ;
Ultra High
Min Yield Strength High Alloy steel
Strength
200 Ksi Low carbon Maraging
Steels
Steel

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Classification According to Shape, finish

processing, and Quality Descriptors

z Shape/Product form : Plate, Bar, angles, channels,

hexagon, square.
z Finishing process : Hot rolled, cold-rolled, annealed,
normalized, Quench and Tempered.
z Coating Process such as Hot dip galvanizing, electrolitic
galvanizing (zinc-coating).
z Pi i Component:
Piping C t Pipe,
Pi Flange,
Fl Elbow,
Elb Weldolet,
W ld l t
Nippoflange, Valve.

MATERIAL CLASSIFICATION

z Carbon Steel Elements affect:

z Carbon, as carbon content increases, hardenability and
tensile strength increase and ductility and weld ability
decrease.
z Manganese, increases hardenability and strength.
z Sulfur, increases the machinability of steels, reduces
transverse ductility, impact toughness, and weldability.
z Silicon increases strength and hardness
Silicon,
z Phosphorus, increases strength and hardness, reduces
ductility and impact.
z Copper, improves atmospheric corrosion resistance

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MATERIAL CLASSIFICATION

z Stainless Steels are typically divided into four categories:

z M t
Martensitic
iti stainless
t i l steels,
t l typified
t ifi d b
by AISI ttypes
410/420/440 contain about 12% Cr and 0.1% C in its basic
composition, leading to a fully martensitic structure at room
temperature.
z Ferritic stainless steels contain larger amounts of Cr which
stabilise the ferritic structure.
z Austenitic stainless steels, such as AISI type 304 typically
contain 18% Cr and 8% Ni which stabilises the austenitic
structure The large susbtitutional content depresses the
structure.
martensitic transformation temperatures well below 0 C.
z Duplex stainless steels, whose microstructure is
approximately made up of 50/50 ferrite/austenite

MATERIAL CLASSIFICATION

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AISI C Si Mn
Cr Ni Mo Ti Nb Al V
grade max. max. max.
301 0.15 1 2 16-18 6-8
302 0.15 1 2 17-19 8-10
17.5-
304
0.08 1 2 20 8-10.5

310 0.25 1.5 2 24-26 19-22

316 0.08 1 2 16-18 10-14 2.0-3.0

5x
321 %C
0.08 1 2 17-19 9-12 min.
10 x
347 %C
0.08 1 2 17-19 9-13 min.

E 1250 0.1 0.5 6 15 10 0.25

20/25-
Nb 0.05 1 1 20 25 0.7
A 286 0.05 1 1 15 26 1.2 ~1.9 ~0.18 ~0.25
254SM 18.5- 17.5-
O 0.02 0.8 1 20.5 18.5 6-6.5 ~1.9 ~0.18 ~0.25

MATERIAL
CLASSIFICATION

z Such as 2304 and 2205 (these designations indicate compositions of

23% chromium, 4% nickel and 22% chromium, 5% nickel but both
grades contain further minor alloying additions) have microstructures
comprising a mixture of austenite and ferrite
z Resistant to stress corrosion cracking,
z The toughness is superior to that of the ferritic steels but inferior to
that of the austenitic steels,
z The strength is greater than that of the (annealed) austenitic steels, by
a factor of about two.
z In addition the duplex steels have general corrosion resistances equal
to or better than 304 and 316, and in general their pitting corrosion
resistances are superior to 316.
z They suffer reduced toughness below about –50°C and after exposure
above 300°C, so are only used between these temperatures.

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Austenite
Ferrite

Duplex Microstructure

MATERIAL CLASSIFICATION
z Copper Nickel (Cu Ni)
z Some of the better known copper nickel alloys include:
z Copper with 10% nickel
z Copper
C with
ith 30% nickel
i k l
z Copper with 25% nickel with 0.05-0.4% manganese
z Copper with 45% nickel (also known as constantan)
z All copper nickel alloys consist of only one phase as the
copper nickel binary system exhibits complete solid
solubility.
z Properties Copper 90/10 and Copper 70/30:
z Outstanding resistance to corrosion, particularly sea
water
z 70/30 is stronger and has superior resistance to
impingement corrosion
z Good resistance to biofouling, with the 90/10 alloy being
slightly superior compared to the 70/30 alloy

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MATERIAL CLASSIFICATION

z Nickel Base Alloys

z Ni k l alloys
Nickel ll are used
d extensively
t i l b because off th
their
i corrosion
i
resistance, high temperature strength and their special
magnetic and thermal expansion properties.
z The major alloy types that are used are:
z Iron-Nickel-Chromium alloys

z Stainless Steels

z Copper-Nickel alloys and Nickel-Copper alloys

z Nickel-Chromium and Nickel-Chromium-Iron alloys

z Low Expansion Alloys

z Magnetic Alloys

MATERIAL CLASSIFICATION
z Nickel Chromium Base Alloys

UNS No Al Cr Co Fe Mo Ni Nb+Ta Ti W

N10276 15.5 5.5 16 57 3.8

N06600 15.5 8 76

N06625 21.5 9 61 3.6

N08800 21 46 32.5

N07718 0.5 19 18.5 3 52.5 5.1

N07090 1.5 19.5 16.5 60 2.5

This group of alloys are frequently sold under trade name specifications but most are listed in
the Unified Numbering System. Common trade names are HASTELLOY, INCOLOY, INCONEL,
NICROFER, and NIMONIC,

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MATERIAL CLASSIFICATION

z Trade Names and Owners of Nickel Alloys

z HASTELLOY is a registered trade name of Haynes Intl
Intl.
z INCOLOY, INCONEL, MONEL and NIMONIC are registered
trade names of the INCO family of companies.
z INVAR is a registered trademark of Imphy S.A.
z MU-METAL is a registered trademark of Telcon Metals Ltd
z NICORROS and NICROFER are registered tradenames of Krupp
UM GmbH

PROPERTIES OF MATERIALS
(METALS)

¾ Mechanical Properties – those that reveal the

elastic and inelastic behavior when force is applied
applied.
They are:
1) Ultimate Tensile Strength
2) Yield Strength
3) Elongation
4) Modulus of Elasticity
5) Compressive Strength
6) Shear Strength
7) Fatigue Strength
8) Impact Strength
9) Hardness

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PROPERTIES OF MATERIALS
(METALS)

¾ Physical
Ph i l Properties
P ti – those
th th
thatt other
th ththan
mechanical and chemical that describe the nature of
the metal. They are:
¾ Density – Mass per unit volume.
¾ Electrical conductivity – Measure of materials ability to
conduct an electric current.
¾ Thermal conductivity – Heat moves through a material at
specific rate
rate.
¾ Thermal expansion – The tendency of material to increase in
volume.
¾ Melting temperature – The temperature at which the
substance change from solid to liquid.

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CODES and SPECIFICATIONS

z Webster’s Third International Dictionary (1969) defines the

terms as follows:
z Code: ”A set of rules of procedure and standards of
materials designed to secure uniformity and to protect the
public interest in such matters as building construction and
public health, established usually by a public agency.”
z Standard: ”Something that is established by authority,
custom or general consent as a model or example to be
followed.”
z Rule: ”An accepted procedure, custom, or habit having the
force of a regulation.”
z Specification: “A detailed, precise, explicit, presentation (as
by numbers, description, or working drawing) of something
or a plan or proposal of something.”

CODES and SPECIFICATIONS

z Organizations that write codes:

z AWS S (American
( Welding Society),
S ) this organization writes codes ffor
welding buildings and bridges, prepare specifications for welding
electrodes, rods, fluxes, welder qualification & Inspection of weld. “
z ASME (American Society of Mechanical Engineer), the boiler and
pressure vessel committee of the ASME establishes standards and
rules of safety for the design, construction and inspection of boilers
and other pressure vessels.” pressure vessel and boiler
z ASTM (American Society for Testing Materials), this national technical
society has numerous committees, each of which issues regulations
and standards in a prescribed field of materials application
application. (i
(i.e
e
construction materials and the methods of testing)’Pengujian material,
sampling frekuensi,

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CODES and SPECIFICATIONS

z API (American Petroleum Institute): Preferred practices

governing the design and fabrication of welded equipment and
structures used in the petroleum industry are issued by the API.
(widely used for overland-pipelines)
z AISC (American Institute of Steel Construction): This trade
organization issues specifications for the design, fabrication, ad
erection of structural steel for buildings.
z Other codes: British Standard (BS), DNV, EEMUA, ABS etc

APPLICATION COVERED BY CODES:

z Pressure Vessel, Piping, Water Pipelines, Field welded storage
tanks, aircraft fabrication, ship construction etc

CODES and SPECIFICATIONS

z ASTM Vol. 01.01 Steel-Piping, Tubing, Fitting

z ASTM Vol. 01.02 Ferrous Castings,
g , Ferroalloys
y
z ASTM Vol. 01.03 Steel-Plate, Strip, Wire
z ASTM Vol. 01.04 Steel-Structural, Reinforcing, Pressure Vessel,
Railway
z ASTM Vol. 01.05 Steel-Bars, Forgings, Bearings, Chain, Springs
z ASTM Vol. 01.06 Coated Steel Product
z ASTM Vol. 01.07 Ship Building
z ASTM Vol. 02.01 Copper and Copper Alloys
z ASTM Vol. 02.03 Electrical Conductors

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CODES and SPECIFICATIONS

z ABS Notice No.1 Rules for Building and Classing

z ABS Steel Vessels Notices and General Information 2005
z ABS Steel Vessels Part 1 – Classification, Testing and Surveys
z ABS Steel Vessels Part 2 – Materials and Welding
z ABS Steel Vessels Part 3 – Hull Construction ad Equipment
z ABS Steel Vessels Part 4 – Machinery Equipment and Systems
z ABS Steel Vessels Part 5 – Specialized Vessels and Services.
z ABS Steel Vessels Part 5, Sect.4 – Vessels Intended to Carry
Liquefied Gases and Chemical Cargoes in Bulk.

CODES and SPECIFICATIONS

z API 2W
Specification for Steel Plates for Offshore Structures, produced
by (TMCP)
z API 2H
Specification for Carbon Manganese Steel Plate for Offshore
Platforms Tubular Joints

z API 2Y
Specification for Steel Plates, Quenched and Tempered, for
Offshore Structures
z API 2Z
Recommendation Practice for Preproduction Qualification for
Steel Plates for Offshore Struct.
z API 5L – Specification for line pipe

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CODES and SPECIFICATIONS

(British/Europe/AUS)
z BS EN 10225
W ld bl structural
Weldable t t l steels
t l ffor fifixed
d offshore
ff h structure-
t t
technical delivery conditions : S355, S420, S460 ,..
z AS 1163 - Structural steel hollow section

z AS/NZS 3679.2 1-Structural Steel - Welded Sections

z AS/NZS 3678-Structural Steel – Hot rolled plates,

floorplates & slabs

TECHNICAL RECOMMENDATION
BEFORE PURCHASE MATERIAL

z Size, special condition

z Chemical composition—ASTM/AISI/API based
chemical composition
z Quality of product : mechanical property, additional
requirement; type of processing, NDT
z Quantitative requirement, allowable ranges of
composition and all necessary physical and
mechanical properties that characterize the material
material,
test methods reference
z Special tolerance, surface preparation, edge and
finish, packaging, loading and transport condition

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CODES COMPARISON

No Description AWS D1.1 ASME IX API 1104

code use for weldingg

boiler, pressure vessels
specification
code use for and process/power
1 Application for pipelines and
structural welding. piping in accordance
riser piping.
with related
ANSI/ASME codes.

2 Revision 2 years 3 years 5 years

Base metal
B t l iis assigned
i d
with P. No. and S. No.
based on the Base metal is
grouping based on its
strength levels and grouped in
3 Grouping nominal chemical
welding accordance with its
composition, weldability
characteristics. yield strength.
and mechanical
properties.

CODES COMPARISON

No Description AWS D1.1 ASME IX API 1104

List of P-No could be Grouping could be
Material grouping is
Material found in Table found in Section
4 li t d iin AWS D1
listed D1.1
1
Classification 5.4.2.2 in API 1104
table 3.1. QW/QB 422 in ASME IX. latest edition.
Group I materials:
A36, 53 Gr. B, API 5L
Gr. B
P1 materials: A-53 Gr. Group I
Group II materials:
B, A106 Gr. B, A333 Gr. materials: API 5L
API 2W Gr. 50/50T,
6, A350 LF2… Gr. B, API 5L X42
API 2H Gr. 50, API 2Y
P8 materials: A312 TP Group II
Type
yp of Gr. 50,, ABS EH 36
5 316(L) A240 TP 304
316(L), 304, materials:
t i l API 5L
material Group III materials:
A358 TP 304L X56, API 5L X60
API 2W/2Y Gr. 60,
P10H materials: A790 Group III
ASTM A572 Gr. 60
S31803, A182 F51 materials: API 5L
Group IV materials:
X65, API 5L X70
ASTM A709 Gr.
HPS70W

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Mill Certificates

z The mill certificates certifies that the material in that lot is

as described.
described It is where the chemical composition of
metal and mechanical properties of metal is
documented.
z Certification of material EN 10204 ( 2.1; 2.2; 3.1B ; 3.2)

2.1 /2.2 Æ Certificate of Compliance

p (CoC)
( )
3.1 Æ QA/QC Department
3.2 Æ Third Party (ABS/DNV/BV/LR)

Typical Project Specifications for

Structural Steel

DESCRIPTION Requirement

Type Type 1, 2, 3, 4

ASTM A6
General Requirement
Certification EN 10204
S1, S3, S4, S5, S8, S11
(API 2W) Type 1

CE and Pcm CE=0.45 ; Pcm = 0.23

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Typical Project Specifications for

Structural Steel
DESCRIPTION Requirement

Primary Steel
S Fine grain practice Total Al Min.
0.020%

Acid Open Heart or Bessemer

Steel Making Process Not Acceptable

Electric Resistance welded not for primary,

(ERW) Secondary Dia<12" (9.5mm)

Marking,Traceability 

Typical Project Specs Piping Process

DESCRIPTION Requirement
DSS (Duplex Stainless Steel)
SS ((Austenitic stainless Steel))
CS (Carbon Steel)
Material LTCS (low Temp. Carbon Steel)

Carbon Steel
CE = 0.43 ; PCM = 0.23
(A234-WPB
ERW not acceptable
, A105-N, A106B)

Low Temp Carbon Steel test Temp -46°C

(A350LF2, A333Gr6, Impact value : 40J(ave) ; 28 (ind)
A420WPL6) Or ANSI B31.3

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Typical Project Specs Piping Process

DESCRIPTION Requirement

Corrosion Test : ASTM G48

Hardness : 28HRC
DSS (Duplex Stainless PREN : 35
Steel) Nitrogen : 0.14 Min
UNS S31803
Impact value : 50J (ave); 40J(ind)
Ferrite content : 40-60 (BM); 30-55(WM)
Metalographic examination
PMI (Positive Material Identification)
Carbon Max : 0.03%
SS (Austenitic Mo Content Min : 2.2%
Stainless Steel) Corrosion test A262- Practice E
-A316/316L Dual Stamp
PMI (Positive Material Identification)

MATERIAL INSPECTION

z The Quality Control Department shall be

responsible for verifying and receiving
material certificate traceability and submitting
to the costumer in a timely manner.

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MATERIAL INSPECTION

z Parent materials and edge preparations

z I t d ti
Introduction
It should be kept in mind that many problems
associated with weld quality can be due to poor
edge preparation of the parent materials. Before any
welding is carried out, inspection and conformance
to the welding procedure requirements can prevent
the formation of imperfections during manufacture
manufacture.
z Furthermore, it is equally important that correct
welding consumables are used to ensure that the
required mechanical properties are met.

MATERIAL INSPECTION
Parent materials

z To ensure that the correct material grade or composition is used on the

project, it is necessary for the inspector to check 3 main areas:
z Size
z number of components for welding/to be joined (number off)
z thickness (abbreviated to 't')
z length (abbreviated to 'l')
z width (abbreviated to 'w')
z diameter (abbreviated to 'ø' for pipes)
z Type
z composition of material
or
z grade d off material
t i l
or
z tradename of material
z If the material is known, it is possible to assess the risk of cracking or other
types of defect common to a particular material type. For example, the
likelihood of, and susceptibility to, porosity in aluminium alloys.

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MATERIAL INSPECTION
z Condition
z surface condition: freedom from contaminants which
may affect welding or in-service operation, including -
z - mill-scale
mill scale remaining from material manufacture
z - protective coatings to inhibit corrosion during storage
z - oil, grease or paints
z distortion, due to poor storage or transportation of the
material
z inherent defects, including metallurgical imperfections
such as segregation bands or surface-breaking
i
imperfections
f ti such
h as llaps
z The heat treatment condition is also important. For
example, some steels can be supplied in the
normalised or quenched and tempered condition. This
can have an implication for the material's mechanical
properties and its weldability.

MATERIAL INSPECTION

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MATERIAL INSPECTION

z A great variety of materials may require to be inspected with a

view to satisfactory welding. The main topics in material
i
inspection
ti are SiSize, T
Type and d Condition.
C diti
z Specification.
It is not, in general, safe for the inspector to identify materials by
composition from a mill sheet, since very small variations or
additions to the metal may give rise to significant changes in
properties and weldability. However limited selectivity is
permissible, such as percentage carbon maximum etc. The
procedure is for the mill sheet to be submitted for approval and
then the inspector records and transfers the reference number
number.
z Supplier.
This can be found on the Goods Inwards documents or the
receipt documents, or occasionally on packaging or even marked
on the metal.

MATERIAL INSPECTION

z Quantity.
The quantity being inspected should always be
noted as well as the sample size if 100 % inspection
is not being employed.
z Size.
Sizes must be checked for secondary identification
as well as conformance.
conformance The inspector will
will, as
appropriate, be given tolerances on size that are
permissible. Check length, breadth, thickness and
diameter.

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MATERIAL INSPECTION
z Distortion.
A check is often required on the degree of distortion, i.e.
Flatness
Squareness
q
Straightness
Ovality
Consistent wall thickness

z Condition.
Rust, paint and grease on the surface of the metal are all
harmful to welding and must usually be removed, at least near to
the actual weld.
weld Guidance is normally given to the inspector
regarding acceptable levels or the treatment that is required. An
inspector should be alert to gradual changes, such as increased
corrosion. Carefully maintained specimens showing acceptable
conditions are often the best method. Heat treatment condition,
annealed, normalised etc., should all be recorded.

MATERIAL INSPECTION

z Defects.
In wrought products the most common defects are laps and
laminations (Also porosity and
segregation bands.) These will normally be subsurface so,
unless NDE is employed, only the edges of the plate, and
particularly cut edges, can be inspected. The lap/lamination will
appear as a narrow black line parallel to the surface.
z Storage.
p
After inspection and approval
pp for use it is essential that the metal
is stored in such a way as to maintain its good condition. Protect
from corrosion and mechanical damage

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MATERIAL INSPECTION
Parent material defects include:
Mechanical damage Lap

Lamination

Segregation line
Laminations are caused in the parent plate by the steel
making process
process, originating from ingot casting defects
defects.
Segregation bands occur in the centre of the plate and are
low melting point impurities such as sulphur and
phosphorous.
Laps are caused during rolling when overlapping metal does
not fuse to the base material.

MATERIAL INSPECTION

Plate Lamination

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Inspection of Raw Products

zForgings,
zCastings,
C ti
zExtrusions,
zetc.

MATERIAL INSPECTION

z Responsibilities
z Project Quality Supervisor
z Responsible for effective and timely execution of activities
defined in the project inspection and test plan.
z Liaise and responsible for material traceability activities to
ensure compliance with the procedure.
z Response to ensure the smooth flow of information and
coordination exist between QC inspector,Contractor and
verification body ( third party )

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Material Defect

MATERIAL INSPECTION

1 P91 failure in China - 3 fatalities

1.
z The material that failed was supplied by a company in Houston TX,
called S.M.A.N.T,who certified it as US pipe when it came from
questionable sources in China. These details have been confirmed by
the Bechtel QA Manager of Power. Bechtel China has also conducted
an investigation and the supply chain is ugly due to the extent of how
many agents, brokers, and mills are involved. The Chinese Government
has stepped in and has called for a formal
investigation. The Chinese Government has also banned Chinese
maded pipe
i for
f use ini major
j power plant
l critical
i i l applications.
li i Th
Thus ffar
there is evidence to support that over 30 plants contain similar or other
“fake pipe” all over China."

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Material Alert

Material Alert
Alloy Steel

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Material alert
Plate 30 mm. Crack on transverse direction

Defect on Material

Outside crack on new nuts have specific

stamp 660A - H

BSP/INS File No. 02

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Material Defect

Inside crack

All defected new nuts have specific stamp

660A - H

Material Defect
Pitted on channel

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Material defect
Laps

Material defect
Pitting

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Material defect
Rusty inner bore

Material defect
Heavy Rusty

7 4
e e
a a

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MATERIAL INSPECTION

z Responsibilities
z Chief Inspector
z Ensure allocated personnel have adequate
experience and are available in a timely
manner.
z Ensure material traceability records are
transmitted progressively to QC Certification.

MATERIAL INSPECTION

z Responsibilities
z Material Receiving Inspector
z Physically check received material according to
good receipt notes, purchase order and Customer
specification requirements.
z Ensure non-conformance : over, short and damage,
is raised and quarantine the material for non
compliance with purchase order and customer
specification
ifi ti requirement.
i t
z Ensure material certificates comply with project
specification and transmit progressively to material
certification.

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MATERIAL INSPECTION

z Responsibilities
z Field Inspector
z Verify material unique identity prior to cut on allocated
piece marked / spool number.
z Verify unique identity on material reference tables
(indices) to ensure material compliance with AFC /
ISO drawing and Customer requirements.
z Initiate and maintain traceability records and submit
progressively to QC Certification Department, for
inclusion in certification final dossier.

MATERIAL INSPECTION

z Responsibilities
z Material Inspector Certification
z Coordinating and progressively collecting document
from material receiving inspector/warehouse for
compilation.
z Generates material certificate records, obtain
customer and third party approval and generate
traceability reference table (indices) from approved
Material Certificate.

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MATERIAL TRACEABILITY SYSTEM

1. Material deliveries shall be inspected with

receiving inspection procedure and Traffic Material
Control & Warehousing procedure
2. Material traceability for secondary and non-
structural steels are traceable by batch reference.
3. Material traceability for pipe and fittings on lines
with a rating of 150psi and less are traceable by
Batch Reference
4. Materials found to be compliant with Purchase
order requirements shall be allocated a unique
number in accordance with following convention.

QUESTIONS

z What are three essential aspects to material inspection

that Inspector should consider
z What is the best NDT method to be used for the
detection of lamination in material
z What are the point of inspection when inspecting the
material condition and dimensions

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