API RP 578-2010 pdf download.Material Verification Program for New and Existing Alloy Piping Systems.
1 Scope The purpose of this recommended practice (RP) is to provide the guidelines for a material and quality assurance system to verify that the nominal composition 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 verification 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 owner/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 elements are critical to component corrosion resistance or similar degradation. 2 Normative References The 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 referenced document (including any amendments) applies. API 570, Piping Inspection Code: Inspection, Repair, and Rerating of In-service Piping Systems API Publ 581, Risk-Based Inspection—Base Resource Document API RP 571, Damage Mechanisms Affecting Fixed Equipment In the Refining Industry API RP 939-C, Guidelines for Avoiding Sulfidation Corrosion Failures in Oil Refineries ASME 1 Boiler and Pressure Vessel Code: Section II, Material Specifications Part A, Ferrous Materials Part B, Nonferrous Materials Part C, Welding Rods, Electrodes, and Filler Metals A
3 Definitions 3.1 alloy material Any 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 thereof (e.g. Chromium, Nickel, or Molybdenum). 3.2 distributor A warehousing supplier for one or more manufacturers or suppliers of alloy materials or components. 3.3 fabricator One who fabricates piping systems or portions of a piping system as defined by ASME B31.3. 3.4 inspection lot A group of items or materials 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. 3.5 level of examination The specified percentage of the number of components (or weldments when specified) to be examined in an inspection lot. 3.6 lot size The number of items available in the inspection lot at the time a representative sample is selected. 3.7 material manufacturer An organization that performs or supervises and directly controls one or more of the operations that affect the chemical composition or mechanical properties of a metallic material. 3.8 material nonconformance A positive material identification (PMI) test result that is not consistent with the selected or specified alloy. 3.9 material supplier An organization that supplies material furnished and certified by a material manufacturer, but does not perform any operation intended to alter the material properties required by the applicable material specification. 3.10 material verification program A documented quality assurance procedure used to assess metallic alloy materials (including weldments and attachments where specified) to verify conformance with the 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.
3.11 mill test report 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). 3.12 owner/user An owner or user of piping systems who exercises control over the operation, engineering, inspection, repair, alteration, testing, and rerating of those piping systems. 3.13 positive material identification (PMI) testing Any physical evaluation or test of a material to confirm that the material which has been or will be placed into service is consistent with the selected or specified alloy material designated by the owner/user. These evaluations or tests may provide either qualitative or quantitative information that is sufficient to verify the nominal alloy composition. 3.14 pressure-containing components Items that form the pressure-containing envelope of the piping system. 3.15 random Selection process by which choices are made in an arbitrary and unbiased manner. 3.16 representative sample One or more items selected at random from the inspection lot that are to be examined to determine acceptability of the inspection lot. 3.17 standard reference materials Sample materials for which laboratory chemical analysis data are available and are used in demonstrating test instrument accuracy and reliability. 4 Extent of Verification 4.1 General The owner/user should establish a written material verification program indicating the extent and type of PMI testing to be conducted during the construction of new piping systems, retroactively on existing piping systems, and during the maintenance, repair, or alteration of existing piping systems.