API RP 578-2018 Guidelines for a Material Verification Program (MVP) for New and Existing Assets (Third Edition).pdf

1、Guidelines for a Material Verification Program (MVP) for New and Existing AssetsAPI RECOMMENDED PRACTICE 578THIRD EDITION, FEBRUARY 2018Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local,state, and federal laws and regulati

2、ons should be reviewed.Neither API nor any of APIs employees, subcontractors, consultants, committees, or other assignees make anywarranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of theinformation contained herein, or assume any liabili

3、ty or responsibility for any use, or the results of such use, of anyinformation or process disclosed in this publication. Neither API nor any of APIs employees, subcontractors,consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.API pu

4、blications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure theaccuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, orguarantee in connection with this publication and hereby expressly disclaim

5、s any liability or responsibility for loss ordamage resulting from its use or for the violation of any authorities having jurisdiction with which this publication mayconflict.API publications are published to facilitate the broad availability of proven, sound engineering and operatingpractices. Thes

6、e publications are not intended to obviate the need for applying sound engineering judgmentregarding when and where these publications should be utilized. The formulation and publication of API publicationsis not intended in any way to inhibit anyone from using any other practices.Any manufacturer m

7、arking equipment or materials in conformance with the marking requirements of an API standardis solely responsible for complying with all the applicable requirements of that standard. API does not represent,warrant, or guarantee that such products do in fact conform to the applicable API standard.Cl

8、assified areas may vary depending on the location, conditions, equipment, and substances involved in any givensituation. Users of this recommended practice should consult with the appropriate authorities having jurisdiction.Users of this recommended practice should not rely exclusively on the inform

9、ation contained in this document. Soundbusiness, scientific, engineering, and safety judgment should be used in employing the information contained herein.API is not undertaking the meet the duties of employers, manufacturers, or suppliers to warn and properly train andequip their employees, and oth

10、ers exposed, concerning health and safety risks and precautions, nor undertaking theirobligations to comply with authorities having jurisdiction.Information concerning safety and health risks and proper precautions with respect to particular materials andconditions should be obtained from the employ

11、er, the manufacturer, or supplier of that material, or the material safetydata sheet.Work sites and equipment operations may differ. Users are solely responsible for assessing their specific equipmentand premises in determining the appropriateness of applying the recommended practice. At all times u

12、sers shouldemploy sound business, scientific, engineering, and judgment safety when using this recommended practice.All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or

13、otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005.Copyright 2018 American Petroleum InstituteForewordNothing contained in any API publication is to be construed as granting any right, by implication

14、 or otherwise, for themanufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anythingcontained in the publication be construed as insuring anyone against liability for infringement of letters patents.Shall: As used in a standard, “shall” denotes a mi

15、nimum requirement in order to conform to the specification.Should: As used in a standard, “should” denotes a recommendation or that which is advised but not required in orderto conform to the specification.May: As used in a standard, “may” denotes a course of action permissible within the limits of

16、a standard.Can: As used in a standard, “can” denotes a statement of possibility or capability.This document was produced under API standardization procedures that ensure appropriate notification andparticipation in the developmental process and is designated as an API standard. Questions concerning

17、theinterpretation of the content of this publication or comments and questions concerning the procedures under whichthis publication was developed should be directed in writing to the Director of Standards, American PetroleumInstitute, 1220 L Street, NW, Washington, D.C. 20005. Requests for permissi

18、on to reproduce or translate all or anypart of the material published herein should also be addressed to the director.Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-timeextension of up to two years may be added to this review cycle. Statu

19、s of the publication can be ascertained from theAPI Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is publishedannually and updated quarterly by API, 1220 L Street, NW, Washington, D.C. 20005.Suggested revisions are invited and should be submitted to the

20、Standards Department, API, 1220 L Street, NW,Washington, D.C. 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1 Purpose . . . . . . . . . .

21、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 About this Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3 Supe

22、rsedes Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Normative References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23、. . 13 Terms, Definitions, and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24、 . . . . . . . . 23.2 Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Considerations and General Concerns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25、. . . . . . . . . . . . 44.1 Carbon Steel Substitutions in Low-alloy Steel Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2 Alloy Substitutions for Carbon Steel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26、 . . . 44.3 Stainless Steel and Nonferrous Substitutions Within High-alloy Systems. . . . . . . . . . . . . . . . . . . . . . . 44.4 Residual Elements in Carbon Steels in Hydrofluoric Acid Alkylation Units . . . . . . . . . . . . . . . . . . . . . . 44.5 Process Units Susceptible to Sulfidation . .

27、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.6 Gasket Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.7 Refractory Installation Systems (Anch

28、ors). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Material Verification Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 General. . . . . . . . . . . . . . . . . .

29、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 Asset Components Included in a Material Verification Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 Mill Test Reports and Usage in an MVP . . . . .

30、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.4 Roles and Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.5 New Construction MVP. . . . . . . . . . . . . .

31、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65.6 Existing Installed Assets MVP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.7 MVP as an Element of Maintenance Systems

32、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 PMI Methodology and Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.1 General. . . . . . . . . . . . . . . . . . . . . . . . . .

33、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.2 MVP Test Method Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.3 PMI Procedure . . . . . . . . . . . . . .

34、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.4 Personnel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.5 Chemical Analysis Techni

35、ques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106.6 Sorting Analysis Techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.7 Spectrometer Technology

36、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.8 Safety Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Evaluation

37、 of Testing Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147.1 Material Acceptance Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147.2 Follow-u

38、p PMI after Discovery of a Nonconformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 Materials Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148.1 Identification

39、Process. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148.2 Color Coding/Marking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158.3 M

40、arking of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 Documentation and Recordkeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159.1 Shop

41、and Field PMI Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159.2 New and Existing Equipment or System Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159.3 PMI Records . . . . . . . . . .

42、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15vContentsPageAnnex A (informative) Statistical Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Bibliography. .

43、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18viGuidelines for a Material Verification Program (MVP) for New and Existing Assets 1 Scope 1.1 Purpose The purpose of this recommended practice (RP

44、) is to provide guidelines for an owner/user to develop and implement a material verification program (MVP) as part of an asset integrity program. The MVP uses positive material identification and other methods to verify that the nominal composition of an asset, an asset component, or weldment withi

45、n the pressure envelope is consistent with the selected or specified construction materials. A well-designed and well-implemented MVP is an important management system used to minimize the potential for release of hazardous substances due to nonconforming materials of construction. 1.2 About this Do

46、cument This recommended practice provides the guidelines for material verification programs involving ferrous and nonferrous alloys during the construction, installation, maintenance, and inspection of new and existing process equipment. It applies to metallic materials purchased for use either dire

47、ctly by the owner/user or indirectly through distributors, fabricators, or contractors, and includes the supply, fabrication, and installation of these materials. This recommended practice is applicable to all refining and petrochemical industries, and may be applied in other industries and or busin

48、esses at the discretion of the owner/user. It is intended to be applied by any owner/user wishing to verify and/or validate that the materials of construction received, fabricated, and/or installed are in accordance with material and/or company specification(s). 1.3 Supersedes Notice This version of

49、 API RP 578 (third edition) supersedes and wholly replaces the second edition (2010) of API RP 578 (Material Verification Program for New and Existing Alloy Piping Systems). The third edition contains many of the same paragraphs and language of the second edition, but it has been revised, reformatted, and re-visualized into a more encompassing document for all types of assets that may have an applicable material verification program. 2 Normative References There are no documents considered to be normative for the application of this document. A bibliography can be found at the end of thi