1、Material Verification Program for New and Existing Alloy Piping Systems API RECOMMENDED PRACTICE 578 SECOND EDITION, MARCH 2010Material Verification Program for New and Existing Alloy Piping SystemsDownstream SegmentAPI RECOMMENDED PRACTICE 578 SECOND EDITION, MARCH 2010Special NotesAPI publications
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18、, 1220 L Street, NW, Washington, DC 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Normative References. . . . . . . . . . . . . . .
19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Extent of Verifica
20、tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21、 . . . . . . . . . 34.2 New Construction Quality Assurance (QA) Material Verification Program . . . . . . . . . . . . . . . . . . . . . . . . . 44.3 Material Verification Program for Existing Piping Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.4 Material Ver
22、ification Program as an Element of Maintenance Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Material Verification Program Test Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.1 Material Verification Program Test Met
23、hod Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85.2 PMI Test Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.3 Equipment Calibration . . . . .
24、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105.4 Equipment Precision. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105.5 Person
25、nel Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105.6 Safety Issues . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26、 . . . . . . . . . 116 Evaluation of PMI Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.1 Material Acceptance Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27、. . . . . . . . . . . . . . . 116.2 Dissimilar Metal Welds and Weld Overlays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.3 Follow-up PMI Testing after Discovery of a Nonconformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28、 . . . . . . 117 Marking and Recordkeeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117.1 Materials Identification Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29、. . . . . . . . . . . . 117.2 Material Certifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127.3 Shop and Field PMI Test Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30、 . . . . . . . . . . . . . . . . . . 127.4 New and Existing Piping System Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127.5 PMI Test Records. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31、. . . . . . . . . . . . . . . . . . . . . . 127.6 PMI Test Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137.7 Traceability to Field Components . . . . . . . . . . . . . . . . . . . . . . . . . . .
32、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13vMaterial Verification Program for New and Existing Alloy Piping Systems1 ScopeThe purpose of this recommended practice (RP) is to provide the guidelines for a material and quality assurance system to verify that the nominal compositio
33、n of alloy components within the pressure envelope of a piping system is consistent with the selected or specified construction materials to minimize the potential for catastrophic release of toxic or hazardous liquids or vapors.This RP provides the guidelines for material control and material verif
34、ication programs on ferrous and nonferrous alloys during the construction, installation, maintenance, and inspection of new and existing process piping systems covered by the ASME B31.3 and API 570 piping codes. This RP applies to metallic alloy materials purchased for use either directly by the own
35、er/user or indirectly through vendors, fabricators, or contractors and includes the supply, fabrication, and erection of these materials. Carbon steel components specified in new or existing piping systems are not specifically covered under the scope of this document unless minor/trace alloying elem
36、ents are critical to component corrosion resistance or similar degradation.2 Normative ReferencesThe following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenc
37、ed document (including any amendments) applies.API 570, Piping Inspection Code: Inspection, Repair, and Rerating of In-service Piping SystemsAPI Publ 581, Risk-Based InspectionBase Resource DocumentAPI RP 571, Damage Mechanisms Affecting Fixed Equipment In the Refining IndustryAPI RP 939-C, Guidelin
38、es for Avoiding Sulfidation Corrosion Failures in Oil RefineriesASME1Boiler and Pressure Vessel Code: Section II, Material Specifications Part A, Ferrous Materials Part B, Nonferrous Materials Part C, Welding Rods, Electrodes, and Filler MetalsASME B31.3, Process PipingCSB2Chemical Safety Board Bull
39、etin 2005-04-B, “Positive Material Verification: Prevent Errors During Alloy Steel Systems Maintenance”NACE3Paper No 03651, “Specification for Carbon Steel Materials for Hydrofluoric Acid Alkylation Units”PFI4ES22, Recommended Practice for Color Coding of Piping Materials1ASME International, 3 Park
40、Avenue, New York, New York 10016-5990, www.asme.org.2U.S. Chemical Safety and Hazard Investigation Board, Office of Prevention, Outreach, and Policy, 2175 K Street NW, Suite 400, Washington, D.C. 20037-1848, 202-261-7600, www.csb.gov. Most CSB publications are posted on, and can be downloaded from t
41、he CSB web site, http:/www.csb.gov/safety_publications/docs/SB-Nitrogen-6-11-03.pdf.13NACE International (formerly the National Association of Corrosion Engineers), 1440 South Creek Drive, Houston, Texas 77218-8340, www.nace.org.4Pipe Fabrication Institute, 511 Avenue of the Americas, #601, New York
42、, New York 10011. www.pfi-institute.org.2 API PUBLICATION 5783 Definitions3.1alloy materialAny metallic material (including welding filler materials) that contain alloying elements that are intentionally added to enhance mechanical or physical properties and corrosion resistance, or a combination th
43、ereof (e.g. Chromium, Nickel, or Molybdenum).3.2distributorA warehousing supplier for one or more manufacturers or suppliers of alloy materials or components.3.3fabricatorOne who fabricates piping systems or portions of a piping system as defined by ASME B31.3.3.4inspection lotA group of items or ma
44、terials of the same type from a common source from which a sample is to be drawn for examination. NOTE An inspection lot does not include items from more than one heat.3.5level of examinationThe specified percentage of the number of components (or weldments when specified) to be examined in an inspe
45、ction lot.3.6lot sizeThe number of items available in the inspection lot at the time a representative sample is selected.3.7material manufacturerAn organization that performs or supervises and directly controls one or more of the operations that affect the chemical composition or mechanical properti
46、es of a metallic material.3.8material nonconformanceA positive material identification (PMI) test result that is not consistent with the selected or specified alloy.3.9material supplierAn organization that supplies material furnished and certified by a material manufacturer, but does not perform any
47、 operation intended to alter the material properties required by the applicable material specification.3.10material verification programA documented quality assurance procedure used to assess metallic alloy materials (including weldments and attachments where specified) to verify conformance with th
48、e selected or specified alloy material designated by the owner/user. NOTE This program may include a description of methods for alloy material testing, physical component marking, and program record-keeping.MATERIAL VERIFICATION PROGRAM FOR NEW AND EXISTING ALLOY PIPING SYSTEMS 33.11mill test report
49、A certified document that permits each component to be identified according to the original heat of material from which it was produced and identifies the applicable material specification (including documentation of all test results required by the material specification).3.12owner/userAn owner or user of piping systems who exercises control over the operation, engineering, inspection, repair, alteration, testing, and rerating of those piping systems.3.13positive material identification (PMI) testingAny physical evaluation or test of a material to confirm that the material which has
