API RP 578
MODULE 6 : Part 1
API RP 578 : Guidelines for a Material Verification Program
(MVP) for New and Existing Assets, 4rd Edition , February 2023
This entire recommended practice (RP) is to be studied for API 570 Piping Inspector program. As there are no tables or charts in this recommended practice, most of the questions will be on closed book exam.
We will go through the headings of this RP and will not down the important points. Please note that you have to read the entire original document for a clear understanding on this topic.
Purpose
- This is a
recommended practice (RP) and is for owner/operator
- The RP is a supporting document for development of asset integrity program
MVP (material verification program) uses
- positive material identification
(PMI)
- other testing methods
- administrative methods
There are many methods adopted for material verification program and PMI is only one of them.
- MVP, minimize the potential for release
of hazardous substances due to nonconforming materials of construction.
If you receive a material lacking any identification marks indicating the Material of Construction (MOC), this recommended practice provides guidelines for identifying such items. Even if you receive a material with proper identification, you still need to verify whether the specified specifications (suppose You want to do a sampling verification of the received material) are accurate. In such cases, you can refer to the guidelines outlined in API 578
It is to be noted that this code uses the words "asset, asset component, weldment or any tested item" and not pipe, elbow, plate etc.
About this Document
- ferrous and nonferrous alloys are only addressed by this RP.
- During construction, installation and maintenance this document can be applied.
- This RP is used for the Inspection of new and existing process
equipment.
Two commonly used terms are "In-service inspection" and "new construction." Certain codes, standards, and recommended practices are applicable to either in-service inspection or new construction exclusively, while others can be utilized for both purposes. It is important to take note of the applicability specified in each document. For example, API 578 can be employed for both in-service inspection and new construction, whereas API 570 is specifically designed for in-service inspection only.
- Metallic materials purchased for use
either directly by the owner/operator or indirectly through distributors,
fabricators, or contractors, and includes the supply, fabrication, and
installation of these materials.
-Applicable to all refining and
petrochemical industries
-May be applied in other industries and or
businesses at the discretion of the owner/operator
-To verify and/or validate the
materials of construction
Definitions
The definitions are arranged for a detailed unterstanding of the terms used.
Alloy Material:
- Any metallic material
- Welding filler wire is also alloy material
- Alloy elements such as Cr, Ni and Mo are intentionally added
- To enhance mechanical or physical properties and/or corrosion resistance
- Alloys may be ferrous or nonferrous
Carbon steels are not considered alloys in this document
Asset: Equipment owned by a company that is either directly or indirectly involved with the manufacturing process.
A pump is an asset which is directly involved in the manufacturing process. A PMI machine is an asset which is not directly involved in the manufactuirng process.
Distributor: A warehousing supplier for
manufacturers or suppliers of materials or components.
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.
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.
What is the difference between a
distributor and material supplier?
A distributor supplies materials or components to material manufacturer.
A Material manufacturer makes the product/item
That Product/Item is supplied by the material supplies.
There can be a confusion in the terminology for distributor and material supplier. Have a through understanding to avoid confusion in the concepts.
Fabricator: An organization that
utilizes the materials of construction affected by this recommended practice in
order to create an asset.
What is the difference between Material
manufacturer and fabricator?
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. A inspection lot does not include items from more than one heat.
Lot Size: The number of items available in the inspection lot at the time a representative sample is selected.
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.
Extent of examination: The specified percentage of the number of
items to be examined in an inspection lot. That means number of representative samples to be selected.
Heat: A batch of metal made at the same time,
able to be traced from its original constituents and manufacturing process.
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. A inspection lot does not include items from more than one heat.
Definition of the inspection lot is repeated here to understand the difference with 'Heat'.
Definition of the inspection lot is repeated here to understand the difference with 'Heat'.
Mill test report (MTR): A quality assurance document used in the
steelmaking industry that certifies a material’s compliance with appropriate
standards, including physical and chemical specifications, and applicable
dimensions. The MTR also includes a date of production and testing, and may
include notation about method of fabrication.
PMI gives either qualitative or
quantitative information that is sufficient to verify the composition.
Weld button (button): A sample of welding
filler material deposited on relevant base metal in order to provide basis for
PMI of the filler.
 |
| Weld Button of an Electrode |
Acronyms
LOQ: Limit of quantitation
PFI: Pipe Fabrication Institute
PIP: Process Industry Practices
This blog is not a replacement for the training provided by authorized partners/experienced institutions nor this blog guarantee success in API exams. This blog is the outcome of the approach followed by the author for the preparation of API exams.
Disclaimer: Photos are taken from different websites. If this violates any copyright rules this will be removed. Please inform me if any of the photos or contents violate copyright rules. (through 13hareesh13@gmail.com). This blog is meant for educational purposes only. If it is used for any other means without the written consent from the author, the author will not be responsible. The author does not guarantee the accuracy of the data used in this blog. All the information, data, photo/image, calculations presented in this blog should be used at the sole risk of the user. The blogger is not liable or responsible in any way for any damage, losses or costs arising from the use of the blog for any purpose whatsoever or whosoever it may be. The blog is to be used at your sole risk and responsibility.
Comments
Post a Comment