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    API RP 578-2010 Material Verification Program for New and Existing Alloy Piping Systems (Second Edition)《现有合金管道系统的材料核查程序.第2版》.pdf

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    API RP 578-2010 Material Verification Program for New and Existing Alloy Piping Systems (Second Edition)《现有合金管道系统的材料核查程序.第2版》.pdf

    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

    2、 necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.Neither API nor any of APIs employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, eithe

    3、r express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication. Neither API nor any of APIs employees,

    4、subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in

    5、them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this public

    6、ation may conflict.API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are not intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized.

    7、 The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable

    8、 requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.Users of this RP should not rely exclusively on the information contained in this document. Sound business, scientific, engineering, and safety judgment

    9、should be used in employing the information contained herein. API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obliga

    10、tions to comply with authorities having jurisdiction.Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet.All ri

    11、ghts 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 otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Str

    12、eet, NW, Washington, DC 20005.Copyright 2010 American Petroleum InstituteForewordNothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither s

    13、hould anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.Shall: As used in a standard, “shall” denotes a minimum requirement in order to conform to the specification.Should: As used in a standard, “should” denotes a recommendati

    14、on or that which is advised but not required in order to conform to the specification. This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the in

    15、terpretation of the content of this publication or comments and questions concerning the procedures under which this publication was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to

    16、 reproduce or translate all or any part 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-time extension of up to two years may be added to this review cycle. Status o

    17、f the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005.Suggested revisions are invited and should be submitted to the Standards Department, API

    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


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