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API-U Approved Training Course for API RP 578

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Guidelines and Application Procedures
for API RP 578

Class Dates
Learning Objectives
Course Agenda
who is this for?
Why Is it important?

Positive Material Identification (PMI) Using XRF, OES and LIBS Technologies

Guidelines and Application Procedures
for API RP 578

Class Dates
December 14 – 15, 2022 $1,250 API Member $1,750 Non-Member
February 15 – 16, 2023 $1,250 API Member $1,750 Non-Member
April 19 – 20, 2023 $1,250 API Member $1,750 Non-Member
June 21 – 22, 2023 $1,250 API Member $1,750 Non-Member
August 16 – 17, 2023 $1,250 API Member $1,750 Non-Member
October 18 – 19, 2023 $1,250 API Member $1,750 Non-Member
December 13 – 14, 2023 $1,250 API Member $1,750 Non-Member
Private Classes Upon Request – Call for Information and Availability

Learning Objectives


  1. Understand and apply API Recommended Practice 578 Positive Material Identification (PMI) Guidelines.
  2. Explain How OSHA Instruction-CLP 03-00-004 Nation Emphasis Program (NEP) Applies to Their Industry.
  3. Better Understanding of OSHA CPL-02-02-045. Process Safety Management (PSM) 29CFR1910.119 With Proper Material Verification Program and Training.
  4. Practical PMI Applications Using XRF/OES & LIBS Technologies.
  5. Technical Understanding of How XRF Technology Works.
  6. Technical Understanding of How OES & LIBS Technology Works.
  7. Recognize Safe Practices Utilizing XRF Technology. Radiation Safety Understanding How “As Low As Reasonably Achievable” (ALARA) can be Attained.
  8. Applying “Recognized And Generally Accepted Good Engineering Practices”(RAGAGEP) for Inspection of Material, Warehouse Material Identification Through Positive Material Identification PMI XRF/OES/LIBS Analysis.

Course Agenda

Day 1

8:00 AM

Introduction / Arrival

  • Why should this course be given?
  • Purpose of Course

8:30 AM

Through Understanding of API RP 578

  • Scope of Course
  • Industry References
  • Terms and Definitions
  • Extent of Material Verification Program

10:00 AM

BREAK

10:15 AM

Explain Use “Material Verification Program” Test Methods: XRF

  • Introduction and History
  • How It All Works
  • Limits of Detection (LOD)

12:00 PM

LUNCH

1:00 PM

Explain Use of “Material Verification Program” Test Methods: OES & LIBS

  • Introduction and History
  • How It All Works
  • Laboratory XRF / OES Analysis

3:00 PM

BREAK

3:15 PM

  • Safety Issue: “Radiation Safety”
  • Field Evaluation Sample Preparation
  • Proper Marking, Record Keeping and Reports

4:00 PM

Review

  • Review and Testing on Academic Material of API RP 578

4:30 PM

“Open Book” Written Exam

Course material is designed to verify the understanding of material as stated in the Course Objectives.

5:00 PM

End of Day 1

Day 2

8:00 AM

Introduction / Arrival

  • Review Test Results on Academic Material
  • Review XRF / OES / LIBS Operation Procedures

8:30 AM

Application of Proper PMI Testing Procedures: Using XRF Technology (Hands-On)

  • Application
  • Demonstration
  • Preparation

10:00 AM

BREAK

10:15 AM

Application of Proper PMI Testing Procedures: Using OES / LIBS Technology (Hands-On)

  • Application
  • Demonstration
  • Preparation

12:00 PM

LUNCH

1:00 PM

Review and Testing with XRF / OES / LIBS

  • Analysis on Different Alloy Samples with XRF
  • Analysis on Different Alloy Samples with OES
  • Analysis on Different Alloy Samples with LIBS

3:00 PM

BREAK

3:15 PM

Conclusion

  • Continue Alloy Analysis XRF / OES / LIBS
  • Review Test Results and Questions
  • Issue Grades Pass / Fail

4:00 PM

Review

  • Review and Testing on Academic Material of API RP 578

4:30 PM

“Open Book” Written Exam

Course material is designed to verify the understanding of material as stated in the Course Objectives.

5:00 PM

End of Day 1

Day 3 (Optional)

8:00 AM

Hands-On Proficiency Lab and / or Field Testing

10:00 AM

BREAK

10:15 AM

Hands-On Proficiency Lab and / or Field Testing

12:00 PM

LUNCH

1:00 PM

Hands-On Proficiency Lab and / or Field Testing

3:00 PM

BREAK

3:15 PM

Hands-On Proficiency Lab and / or Field Testing

5:00 PM

End of Day 1

Who should attend the course?

Analytical Training Consultants believes  that Material Verification and PMI is now industry driven  and nearly 100% required, so we have gone through the requirements of the API/TPCP ( stated above ) to provide you with the API RP 578 PMI Certification. As the graphic for the “PMI Process “below indicates : all groups from the foundry/producer to fabrication, warehouse, in service process, to scrap recycling, require Proper PMI analysis. Anyone and everyone involved with any of these processes need to be properly trained to perform qualified Material Verification through the  use of XRF and OES/LIBS technologies. The  Positive Material Identification (PMI) analysis is the only way to give assurance that the proper alloy is being used and will work according to design criteria.

All students enrolled in API 510, 570 classes, QA/QC inspectors, maintenance, stores, warehouse, inspection testing companies, fabrication shop, and reliability departments for oil and gas (Petrochemical and Refining) operations.

Why should the course be given?

PHMSA-Gas P/L Mega Rule

PHMSA proposed criteria that would require material properties verification for higher-risk locations through a new § 192.607; specifically, by adding requirements for the verification of pipeline material properties for existing onshore, steel, gas transmission pipelines that are located in HCAs or Class 3 or Class 4 locations.

The PHMSA Rules & Reg. Mega Rule 49 CFR 191 $196 Hi-Lited for MVP 1-30-2020 can be found here. I have Hi-Lited the important parts out of the 78 pages, ( starts on page 11 & 13 for Material Verification ) for the reader to get informed.

Material Chemistry Verification” for Pipeline Sector using XRF Technology. PMI seminar TransCanada by Don Mears on 7/9/2014.
Open PDF
PMI Seminar TransCanada Don Mears Presentation-7-9-6-2014
Open PDF
DoT Advisory Bulletin PHMSA-2009-0148
Open PDF
Keystone-XL-PHMSA-57-Special-Conditions
Open PDF
PHMSA-Low Chemistry report on 2009 Bulletin
September 9 thru 13 API organized the first API Beijing Conference. Don Mears was asked to present the API RP 578 (PMI) Program.
Open PDF
Presentation

On March 6, 2012, Don Mears presented below speech on Positive Material Identification (PMI) at the first API Singapore Conference.
Open PDF
Presentation

OSHA INSTRUCTION: Directive number CPL 03-00-004, effective June 7, 2007, which is the “Petroleum Refinery Process Safety Management Emphasis Program”.

“This instruction describes policies and procedures for implementing a National Emphasis Program (NEP) to reduce or eliminate the workplace hazards associated with the catastrophic release of highly hazardous chemicals at petroleum refineries”.

Open PDF
Presentation
Open PDF
Speech

Don Mears gave a speech at the API Inspector Summit, held in Galveston (TX), January 27-30, 2009 (click here to download this API summit speech) .

Executive Summary Chem NEP-2017 CPL 03-00-021

This instruction provides guidance to the Occupational Safety and Health Administration’s (OSHA’s) national, regional, area, and State Plan offices for implementing and conducting an NEP to reduce or eliminate workplace hazards associated with the catastrophic release of highly hazardous chemicals at facilities, including petroleum refineries, covered by OSHA’s Process Safety Management of Highly Hazardous Chemicals (PSM) standard, 29 CFR 1910.119. Both programmed and un-programmed inspections associated with this NEP will begin immediately in all regions.

Significant Changes

This instruction describes an updated initiative by OSHA. Under the previous related instructions, OSHA conducted inspections of facilities covered by OSHA’s PSM standard either through an instruction specific to petroleum refineries or an instruction related to all other PSM-covered chemical facilities excluding petroleum refineries. This instruction is applicable to all facilities, including petroleum refineries, covered by the PSM standard. NEP inspections conducted at petroleum refineries will be conducted in the same manner as NEP inspections conducted at all other facilities covered by this instruction.

Open PDF
OSHA Instruction
Safety Bulletin from U.S. Chemical Safety and Hazard Investigation Board (CSB)—BP Texas City

On July 28, 2005, 4 months after a devastating incident in the Isomerization (Isom) Unit that killed 15 workers and injured 180, the BP Texas City refinery experienced 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 were no fatalities.

Open PDF
BP Report
Safety Bulletin from U.S. Chemical Safety and Hazard Investigation Board (CSB) —Chlorine Transfer Hose Failure

Chlorine Transfer Hose Failure due to improper material braid construction (i.e., 316L and not the recommended braid of Hastelloy C-276). On August 14, 2002 a 1- inch transfer line ruptured during a railcar offloading operation at DPC Enterprises in Festus, Missouri and released 48,000 pounds of Chlorine into neighboring areas.

Open PDF
CSB Report
All the Reported and Unreported “Near Misses” the Oil and Gas Industry has Experienced.

Many give examples of this or have witnessed this happening. Because of either Luck, Proper PMI / Inspection, Training, or Recognized and Generally Accepted Good Engineering Practices (RAGAGEP) (i.e. API RP 578), we were able to apply these principles and stop the “Near Misses” from turning into catastrophe.

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281-702-6245
info@atc578.com

Mailing Address

29960 Pinto Lane
Waller, TX 77484

Hours of Operation

Monday - Friday 8 AM - 5 PM CST
Closed Saturday and Sunday

API-U Approved API RP 578 PMI Training Course

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