PRODUCTS SERVICES BLOG CONTACT

NOVEMBER 27, 2022 QUALITY

PROGRESSIVE WELD
SAMPLING
ASME B31.3 PROCESS PIPING PROGRESSIVE WELD SAMPLING
Progressive Sampling is the process of selecting cascading levels of additional samples as the
result of a rejected examination. Progressive sampling requirements can occur when working
within ASME B31.3 Process Piping and Section VIII Div. 1 Pressure Vessels when performing
random examinations. The focus of this article will be on ASME B31.3 Process Piping.

Random examinations are employed to sample work performed and determine the general
quality level of the tested population. This method has proven to be effective at maintaining
sufficient weld quality while minimizing the cost and schedule impact of examining every weld.

When performing required random examinations reveals a reject, the code requires that more
examinations be performed to determine if the initial reject represents other possible rejectable
quality issues; this is why the term “progressive” is used to define this process.

COMMON TERMINOLOGY & DEFINITIONS

ASME B31.3 paragraph 341.3.4 describes the additional examinations due to failure as
“Samples.” Standard terms used in the industry for these samples are also known as “Tracers” or
“Penalties.”

ASME B31.3 paragraph 344.1

100% examination: A complete examination of all a specified kind of item in a designated lot of
piping.

Random examination: complete examination of a percentage of a specified kind of item in a

designated lot of piping.

Spot examination: a specified partial examination of each of a specified kind of item in a

designated lot of piping, e.g., of part of the length of all shop-fabricated welds in a lot of
jacketed piping.

Random spot examination: a specified partial examination of a percentage of a specified kind of

item in a designated lot of piping.

Lot: A designated lot is that quantity of piping to be considered in applying the requirements for
examination in ASME B31.3. The quantity or extent of a designated lot should be established by
agreement between the contracting parties before the start of work. More than one kind of
designated lot may be established for different kinds of piping work. See Pipe Fabrication
Institute Standard ES-48, Random Examination, for examples of lot selection.

Random or Spot Examination Note: Random or spot examination will not ensure a fabrication
This websiteproduct
uses cookies to ensure you
of a prescribed get the
quality bestthroughout.
level experience on our website.
Items Learn more
not examined in a lot of piping Accept
 represented by such examination may contain defects that further examination could disclose.
PRODUCTS
Specifically, if all radiographically disclosable weld SERVICES
defects must be BLOG
eliminated from a lot of CONTACT
piping, 100% radiographic examination must be specified.

PROGRESSIVE SAMPLING SCOPE

B31.3 is written in such a way that progressive sampling due to rejects applies to all NDE
methods. In practice, most in the industry think of and focus on the RT or UT methods when
thinking about progressive sampling. This may be because the most common and sometimes the
only metrics kept and tracked for reject rates focus on RT or UT. So be familiar with the general
implementation within the industry and the customers you work with and what the code states
as requirements.

VT PRACTICES
It is common in the industry to perform 100% VT on all welds; this is a best practice and is highly
encouraged as the most effective and economical way to confirm adequate welding is taking
place. A careful reading of B31.3 para. 341.4 reveals that Category D & Normal Fluid Services
allow for random visual examination.

An alternate way to consider the practice of 100% VT is as follows. Consider that any “touch up,”
or “pick-up” repairs marked during VT are, in fact, initial rejections. With this being the case, the
welds are being rejected (and not tracked), and the rules of progressive sampling dictate that
other samples be made. This progressive sampling quickly puts all welders into a 100%
inspection requirement. You also need to be aware that customer specifications or in house
procedures or quality manuals may require the 100% VT practice.

ADDITIONAL SAMPLES - DEFINING “SAME KIND”

When a spot or random examination reveals a defect, two additional samples of the same kind
are required. One of the most common questions for those who find themselves involved in
selecting additional samples is how to apply the “same kind” requirements. Situations are so
diverse the Code has not provided much in the way of describing specifics, except in the case of
a couple of interpretations that have been issued. ASME code interpretations can be found
here: ASME Code Interpretations Link

This website uses cookies to ensure you get the best experience on our website. Learn more Accept
 When setting up projects it is important to know what the specifications, quality procedures, or
PRODUCTS
manuals may say pertaining to the definition of “same SERVICES
kind”, regularly BLOGwill notCONTACT
these resources
say anything, as it is very difficult to pre-define rules due to the diversity of scope and scenarios
to which this may apply. So the individual running the quality effort must decide what this means
as it applies to the situation. There is no Code requirement that the additional samples selected,
be approved by the customer, yet good advice would dictate that it be considered. On some
projects the contract or customer specifications may in fact state that the owner’s inspector
does review or approve the additional samples, so be sure to know what the contractual
documents state.

LOTS
ASME B31.3 includes the following definition footnotes in paragraph 344.1.3 Definitions.

Lot: A designated lot is that quantity of piping to be considered in applying the requirements for
examination in ASME B31.3. The quantity or extent of a designated lot should be established by
agreement between the contracting parties before the start of work. More than one kind of
designated lot may be established for different kinds of piping work. See Pipe Fabrication
Institute Standard ES-48, Random Examination, for examples of lot selection.

It also includes a note regarding the objectives of random examination as well as 100%
examination.

Random or Spot Examination Note: Random or spot examination will not ensure a fabrication
product of a prescribed quality level throughout. Items not examined in a lot of piping
represented by such examination may contain defects that further examination could disclose.
Specifically, if all radiographically disclosable weld defects must be eliminated from a lot of
piping, 100% radiographic examination must be specified.

PROGRESSIVE SAMPLING
The following provides a step by step guide through the progressive sampling process. For
convenience, the terms “round” and “scenario” will be used to describe the cascading options
that occur when the progressive sampling yields defects; these are not used by B31.3.

When a random examination is performed and found to be acceptable, it is documented, the lot
for which it represents is satisfied or closed, and monitoring for the next Lot is set up.

FIRST ROUND REJECTION

This website uses cookies to ensure you get the best experience on our website. Learn more Accept
 When a random examination is rejected in the first round ASME B31.3 paragraph 341.3.4 (a)
PRODUCTS
states that two additional samples of the same kind, SERVICES
from the original designated BLOG
lot, shall beCONTACT
given the same type of examination (as the rejected sample).

Repairs or replacements of rejects and the ramifications of each option are detailed in ASME
B31.3 paragraph 341.3.3.

For documentation purposes, all documentation connected to this event needs to state or clarify
that these examinations are associated with the original reject. Best practice would also dictate
coordination with production that the welder in question be stopped from further welding and
placed on other duties until the process follows its course. Training and investigation are other
matters that should be performed, or at the very least considered at this point in the process.

SECOND ROUND
1. 2 Accepted: No more examinations are required for this lot.

2. 1 Accepted & 1 Rejected: The rejected sample requires 2 additional tracers

3. 2 Rejected: 4 additional tracers are required

THIRD ROUND
This website uses cookies to ensure you get the best experience on our website. Learn more Accept
 In the third round, any rejections will require that the entire lot be 100% examined.
PRODUCTS SERVICES BLOG CONTACT
1. All accepted: No more examinations required for this lot.

2. 1, 2, 3 or 4 Rejected: All items in Lot shall be

1. Repaired or replaced & fully reexamined per paragraph 341.3.4 (e)(1)

2. Fully examined and repaired or replaced as necessary and then fully reexamined per paragraph

341.3.4 (e)(2)

REPAIR OR REPLACE
Two options exist to address rejected welds; they can be repaired or replaced. B31.3 paragraph
341.3.3 addresses “Defective Components and Workmanship.”

Repair: Per B31.3 para. 341.3.3(a) When the defective item or work is repaired, the repaired
portion of the item or works shall be examined. The examination shall use the same methods
and acceptance criteria employed for the original examination.

So repair requires that the repair area be examined by the same original NDE method that was
used during the rejection.

DOUBLE JEOPARDY
Per B31.3 para. 341.3.4(f) progressive sampling does not apply to rejects of repairs or
replacements. Also see B31.3 interpretation 16-01 & 25-05.

PROGRESSIVE SAMPLING METRICS

Per ASME B31.3, not less than 5% of circumferential butt and miter groove welds shall be
examined fully by random radiography. The welds to be examined in each designated lot shall
include the work product of each welder or welding operator whose welds are part of the lot.
This website uses cookies to ensure you get the best experience on our website. Learn more Accept
 Customer specifications may require more due to a blanket requirement or due to special service
applications. PRODUCTS SERVICES BLOG CONTACT
To document that this requirement has been met, a running total should be kept. In calculating
this number, there are sometimes questions if accepted tracers can count towards satisfying
this total. Interpretation 16-05 question and reply #2 addresses this question and clarifies that
any accepted examinations which occur as a result of progressive sampling do not count
towards the required percentage.

REPRESENTED ITEMS
ASME B31.3 paragraph 341.3.4(e) reads as follows “if any of the items examined as required by
(c) above reveals a defect, all items represented by the progressive sampling shall be either”; it
then provides two approaches of performing repairs or replacements. The question arises as to
what the phrase “all items represented by the progressive sampling” refers to. The answer is
supplied in B31.3 interpretation 13-12, which is, “All items within the same designated lot.” So if a
welder has a reject that leads to enough rejects that they become exposed to the 100%
sampling criteria, it only applies to the lot which was represented by the original defect.

This emphasizes the need to have lots well defined before starting a project, as well as keeping
the random examinations very fresh on each welder so any possible quality issues don’t get too
far out of hand. Also remember a contractual specification or requirement can supersede the
restriction to only test within the defined lot, make sure this is well understood and that the
associated costs for progressive sampling outside of defined lots is understood by those in
charge of the budget.

SUMMARY
Progressive Sampling is the process of selecting cascading levels of additional samples as the
result of a rejected examination. The rules by which this is to be carried out is contained in ASME
This websiteB31.3
uses cookies
ProcesstoPiping
ensureand
you Section
get the best
VIII experience on our
Div. 1 Pressure Learnfor
website.each
Vessels, more
their respective scope. Accept
 Having a standardized process of documenting who has welded what, performing random
examinations promptly, to which welders lot do PRODUCTS SERVICES
random examinations belong, andBLOG CONTACT
a process to
document progressive samples if they were to occur can be very difficult to accomplish on
paper or in spreadsheets.

The complexity of managing welders, lots, and progressive sampling is a job best left to Fassen’s
welding QA/QC and project controls software program. Contact us if you would like to know
more.

DOWNLOAD THE PROGRESSIVE

WELD SAMPLING FLOWCHART

This website uses cookies to ensure you get the best experience on our website. Learn more Accept
 PRODUCTS SERVICES BLOG CONTACT

VIEW ALL

PRIVACY POLICY | TERMS OF SERVICE

© FASSEN INC 2021

This website uses cookies to ensure you get the best experience on our website. Learn more Accept