PFI Standard ES-48

|Denotes Revision (Revised December 2013)

RANDOM EXAMINATION

Prepared by
Pipe Fabrication Institute Engineering Committee

All PFI Standards are advisory only. There is no

agreement to adhere to any PFI Standard and their
use by anyone is entirely voluntary.

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PIPE FABRICATION INSTITUTE

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 PFI Standard ES-48
|Denotes Revision (Revised December 2013)

Random Examination
Expectations, Guidelines and Methodology

1. Scope welds in a piping system containing 100 welds

are examined and accepted using random
1.1. Codes and specifications often require that welds radiography, the remaining 90 welds may
be subjected to spot or random radiography, contain rejectable flaws that would have been
ultrasonic or other examination methods. The disclosed if additional welds had been
purpose of this standard is to: radiographed. If all rejectable weld flaws must
be eliminated from a given piping system, then
1.1.1. Examine the expectations, effectiveness and examination of 100% of the welds in that system
limitations of random examination. must be performed1. More simply put, to insure
1.1.2. Identify common industry practices and that welds are free of rejectable flaws, 100% of
methods for specifying random examination. those welds must be examined, repaired as
necessary and then reexamined.
1.1.3. Provide guidance in establishing and
defining the size of a lot to be subjected to 3.2. Random examination of welds is an effective
random examination, focusing on the ASME quality control tool when properly implemented.
B31.3 use of the terms “lot” and “kind of
item.” 3.2.1. When random examination is used to check
2. Definitions the quality of the welder’s work, that
examination provides feedback to the welder
2.1. Commonly used extents of examination are showing that the work is or is not
defined as follows: satisfactory. If the work is not satisfactory,
the welder and/or the welding supervisor can
2.1.1. Random examination: complete take corrective steps to improve weld quality
examination of a percentage of a specified in subsequent work; such steps can include
kind of item in a designated lot of piping the full range of changes from increased
attention, to initial fit-up, to replacement of
2.1.2. Spot examination: a specified partial
the welder. This will improve the quality of
examination of a weld or specified group of
subsequent welds.
welds (e.g. 1 six inch spot in each 50 feet of
weld by a particular welder) 3.2.2. For this process to work properly, it is
critical that examinations be made, (and
2.1.3. Random spot examination: a specified
timely feedback provided to the welder),
partial examination of a percentage of a
contemporaneously with the work being
specified kind of item in a designated lot of
done. The sooner the welder learns that his
piping
weld requires repair, the sooner he can take
2.1.4. This standard uses the term ”random corrective action.
examination” to represent all examination
methods such as radiography and ultrasonic
or other examination that may be used in
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order to avoid excessive repetition of these

inspection method names throughout this
standard.
3. Expectations, effectiveness and limitations
of random examination
3.1. Random examination of welds in a piping
system will not ensure that all the welds in that
system will be of the same quality level as the 1
welds that were examined. For example, if 10 See ASME B31.3 para. 344.1.3, footnote 3 and ASME section
VIII Div 1, UW-52 footnote.

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 PFI Standard ES-48
|Denotes Revision (Revised December 2013)

4. Specifying Random Examination “Random Radiography and acceptance criteria

shall be in accordance with the requirements of
4.1. The method and extent of examination and ASME B31.3, paragraph 341.4.1(b).
acceptance criteria to be applied must be clearly Acceptance criteria shall be in accordance with
defined in the standard or specification and be Table 341.3.2, Normal Fluid Service, with
agreed upon prior to the start of work. This is progressive sampling in accordance with
standard industry practice that is well established paragraph 341.3.4.”
in various welding standards such as the ASME
B31 Code for Pressure Piping, ASME Section
5. Defining Random Examination when
VIII, Unfired Pressure Vessels, and the AWS
D1.1, Structural Welding Code - Steel. For ASME B31.3 is applicable
example, ASME B31.1, paragraph 136.3.1, 5.1. The following are important points to recognize
specifies: when ASME B31.3, Process Piping, is the
applicable Code.
“The degree of examination and the acceptance
standards beyond the requirements of this Code 5.1.1. For Normal Fluid Service piping, Paragraph
shall be a matter of prior agreement between 341.4.1(b) requires that not less than 5% of
the manufacturer, fabricator or erector and the circumferential butt and miter groove welds
Owner.” be examined fully by random radiography or
by random ultrasonic examination. Normal
4.2. When performing random examination, the Fluid Service is the applicable fluid service
method of examination (e.g., radiography in category unless another Fluid Service
accordance with ASME Section V, Article 2) Category (e.g., Category D, Category M,
and the acceptance criteria (e.g., ASME B31.1, Severe cyclic, etc) or a greater extent of
paragraph 136.4.5) are straightforward and examination is specified for a system by the
simple to define in the contract documents. engineer in the contract documents.

4.3. When random examination is specified, the 5.1.1.1. Random Examination is to be performed
extent of random examination must be clearly on a lot basis. Once the percentage of
defined in the contract documents. Random welds in a lot are examined and accepted
examination can be applied to: and the welds representing the work of
each welder in that lot have been
4.3.1. Circumferential butt and miter welds on a examined and accepted, all remaining
project. welds in that lot (i.e., those that were not
examined) are Code-acceptable provided
4.3.2. Circumferential butt and miter welds within they are visually acceptable and pass
specific line classes or systems on a project, hydrostatic testing. See paragraph
4.3.3. Circumferential butt and miter welds within 341.3.1.
particular parts of systems (e.g., high- 5.1.1.2. Since B31.3 places responsibility for
pressure parts of a steam system) performing examination on the
4.3.4. Circumferential butt and miter welds in Fabricator or Contractor who is doing the
specific locations (e.g., piping inside welding, lot selection is the prerogative
buildings) of the Fabricator or Contractor in the
absence of arrangements in which a lot is
4.3.5. Other schemes that satisfy the Owner or his established by contract. B31.3 recognizes
engineer. that lot selection can be a source of
4.3.6. Volumetric examination is not normally dispute and suggests2 that the quantity or
applied to nozzle or branch connection extent of a designated lot should be
welds or to fillet welds. established by agreement between the
contracting parties before the start of
4.4. When the purchaser wishes to impose additional work. See Section 6 for various methods
random examination, and the applicable code of defining a lot.
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does not specify random examination, the

following is recommended for inclusion in the
purchaser’s specification:
2
See paragraph 344.1.3, footnote 2.

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 PFI Standard ES-48
|Denotes Revision (Revised December 2013)

5.1.1.3. Since B31.3 places responsibility for lots, and more than one welding process may be
performing examination on the included in a lot.
Fabricator or Contractor who is doing the
welding, lot definition is the prerogative 6.3. In defining a lot, the fabricator/contractor should
of the Fabricator or Contractor in the consider the following:
absence of contractual arrangements in
which a lot is established by contract. 6.3.1. The lots should be of a size that can be
easily managed. Small lots may result in
5.1.2. The welds to be examined must include the
increased cost because paperwork will
work product of each welder, whose welds
increase and the total number of welds
are part of any designated lot, but B31.3
examined on the project will increase
does not require that the given percentage of
beyond the percentage required. Conversely,
each welder’s work within a lot be
large lots lead to increased risk when
examined.
progressive sampling is required.
5.1.3. When a weld is rejected, B31.3 paragraph
6.3.2. Welds should be examined shortly after the
341.3.4 requires “progressive sampling” of
required lot size has been achieved in order
other welds made by the welder who made
to obtain the desired effect on the quality of
the defective weld. Welds made by other
the work.
welders within the lot that have either been
examined and accepted or have not been 6.3.3. It may be necessary to examine the initial
examined would not be subject to welds made within each lot prior to the
progressive sampling. completion of all the welds within that lot, to
provide timely feedback.
5.2. Should the purchaser or his representative
demand additional nondestructive examination 6.3.4. The results obtained in examination of one
within a lot after that lot of welds has been lot should not be considered in the
accepted, such additional examination is outside evaluation or extent of examination applied
the provisions of B31.3. Defects found by this to any other lot.
additional examination shall be repaired and the
6.3.5. A tracking method that clearly documents
weld re-examined. The cost of any additional
welds in each lot should be established.
examination, and any subsequent repairs and re-
examination, shall be the responsibility of the 6.3.6. Welds selected for each lot must fall into the

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organization requiring the additional same percentage of examination.
examination. Approval of the customer’s
contracting officer may be required for increases 6.4. Some lot definitions are show below.
in the extent of examination since such
examination would usually be compensable 6.4.1. Daily: All the welds completed by all
changes to the contract. welders, and are accepted by visual
examination on any day shall be considered
a lot. The number of welds to be examined
6. Establishing a Lot shall be calculated based on the size of the
6.1. Contract requirements for establishing lots or for lot and the percentage of welds that are
selection of welds to be examined should be required to be examined.
agreed upon by the contracting parties. When the
purchaser will be responsible for selection of the 6.4.2. Daily Multiple lots: All the welds
random welds in a lot, the purchaser’s completed by all welders, and accepted by
representative will need to be readily available to visual examination on any day shall be
avoid impeding work flow. The process of broken up into separate lots and each lot
selection should also be included in such examined individually (e.g., 65 welds are
agreement, (e.g., select from the list of welds in a completed in a day; if the lot size is 20, those
lot, select the weld(s) after visual examination, 65 welds shall be separated into 4 lots of a
etc.) convenient sizes of 20 or fewer and the
welds to be examined shall be selected from
6.2. The welds in a lot do not need to be of the same each lot). If the required number of welds to
material, thickness or size. Butt welds and miter achieve the required lot size has not been
welds do not need to be segregated into different obtained, the welds that have been
completed each day shall be considered a lot.

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 PFI Standard ES-48
|Denotes Revision (Revised December 2013)

6.4.3. By Welder: Only the welds of a single 6.4.9. Welds along a run until the required
welder are included in the lot. When the number is reached. Field work only. Not
welds made by a welder achieve the required suitable for sizes and wall thicknesses where
lot size, that group of welds shall be achieving a lot of a particular size takes an
considered a lot. Since more than one extended period of time.
welder may make a weld, that weld shall be
6.5. Shipping of Lots: For shop fabrication, no item
included only in one welder’s lot.
in a lot shall be shipped before the required
6.4.4. Truck Load: All welds on all of the examination of that lot is completed and that lot
assemblies to be loaded on a single truck has been accepted.
shipment may be considered a lot.
Acceptance of the whole lot should be 7. Documentation of Sampling
completed prior to loading the truck.
7.1. Welds making up lots should be documented
6.4.5. All Welds on a Job: All the welds on a job concurrently with the progress of fabrication.
may be considered a lot. This option should Joints should be logged as final visual inspection
not be selected unless the project is very is completed for each spool piece or as erection
small. welds are made. Any form of tracking and
6.4.6. Spool Grouping: Each project shall be documenting lots is acceptable provided:
subdivided into "lots" as required for
convenience and flow of work through the 7.1.1. The welds which make up the lot are clearly
shop. The "lot" may consist of different identified
piping systems with the same percentage 7.1.2. The number of welds from each welder is
requirements for random radiography. Only clearly identified
piping with the same radiographic
percentage requirements (e.g. 5% and 20% 7.1.3. The weld(s) selected for examination are
systems) should be included in the same clearly identified
"lot". 7.1.4. All of the requirements for initial selection
6.4.7. All the Welds in a Piping System or Line: and progressive selection have been met.
When drawings identify the customer’s
piping system, all welds in each system can
be considered a lot. Another alternative is to
choose lots by line or group of lines. This
option is generally only suitable for field
welding. In a shop environment, this method
is discouraged because it increases costs due
to impeded work flow, added material
handling and delayed delivery.
6.4.8. All Welds in a Room or other Easily-defined
Space: Field work only.

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 CURRENT INDEX OF 2014-2015
PFI STANDARDS & TECHNICAL BULLETINS
Engineering and Design
ES02 R13 Method of Dimensioning Piping Assemblies
ES07 R13 Minimum Length and Spacing for Welded Nozzles
ES16 R13 Access Holes, Bosses, and Plugs for Radiographic Inspection of Pipe Welds
ES26 R13 Welded Load Bearing Attachments to Pressure Retaining Piping Materials
ES36 R13 Branch Reinforcement Work Sheets.
ES36 R13 Branch Reinforcement Work Sheets – ELECTRONIC VERSION
ES40 RA10 Method of Dimensioning Grooved Piping Assemblies
ES44 R13 Drafting Practices Standard
Welding and Fabrication
ES01 R10 Internal Machining and Solid Machined Backing Rings For Circumferential Butt Welds
ES21 R10 Internal Machining and Fit-up of GTAW Root Pass Circumferential Butt Welds
ES24 R13 Pipe Bending Methods, Tolerances, Process and Material Requirements
ES35 RA03 Nonsymmetrical Bevels and Joint Configurations for Butt Welds
ES45 R13 Recommended Practice for Local Post-Weld Heat Treatment
ES47 R13 Welding of Internally Clad Piping
ES49 R13 Guidelines for Installation of Integrally Reinforced Branch Connection Fittings
Cleaning, Painting, and Shipping
ES05 R13 Cleaning of Fabricated Piping
ES29 R06 Internal Abrasive Blast Cleaning of Ferritic Piping Materials
ES31 RA04 Standard for Protection of Ends of Fabricated Piping Assemblies
ES34 R03 Temporary Painting/Coating of Fabricated Piping
ES37 RA10 Standard for Loading and Shipping of Piping Assemblies
Quality Control
ES03 R09 Fabricating Tolerances
ES11 R03 Permanent Marking on Piping Materials
ES22 R13 Recommended Practice for Color Coding of Piping Materials.
ES32 R13 Tool Calibration
ES39 RA10 Fabricating Tolerances for Grooved Piping Systems
ES41 RA03 Standard for Material Control and Traceability of Piping Components
ES43 RA13 Standard for Protection of Austenitic Stainless Steel and Nickel Alloy Materials
Examination and Testing
ES04 R13 Hydrostatic Testing of Fabricated Piping
ES20 R13 Wall Thickness Measurement by Ultrasonic Examination
ES27 R10 "Visual Examination" The Purpose, Meaning and Limitation of the Term
ES42 R05 Standard for Positive Material Identification of Piping Components using Portable X-Ray Emission Type Equipment
ES48 R13 Random Examination

Technical Bulletins
TB1 R13 Pressure - Temperature Ratings of Seamless Pipe Used in Power Plant Piping Systems - ELECTRONIC VERSION
TB3 R13 Guidelines Clarifying Relationships and Design Engineering Responsibilities Between Purchasers’ Engineers and Pipe Fabricator or Pipe
Fabricator or Pipe Fabricator Erector
TB5 R13 Information Required for the Bidding of Pipe Fabrication
TB7 R04 Guidelines for Fabrication and Installation of Stainless Steel High Purity Distribution Systems
TB8 R13 Recommended practice for the fabrication of polyvinylidene fluoride (PVDF) piping
TB9 R13 Customary Fitting, Forging, Plate and Bar Materials used with Pipe
ELECTRONIC VERSION

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 “1913 – 2013”
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PFI Standards and Technical Bulletins are published to serve proven needs of the pipe
fabricating industry at the design level and in actual shop operations. Hence, such needs
are continually considered and reviewed by the Engineering Committee of the Pipe
Fabrication Institute to provide recommended procedures, which have been demonstrated
by collective experiences to fulfill requirements in a manner for Code compliance.
However, as the PFI Standards are for minimum requirements the designer or fabricator
always has the option of specifying supplementary conditions in the form of requirements
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