Api578 my self study notes

Material Verification Program for New and Existing Alloy Piping Systems API RECOMMENDED PRACTICE 578 2013- My exam preparation Notes 新建和在职石油化工中设施-合金管道系统,材料验证

Charlie Chong/ Fion Zhang

API578

Contents 1 Scope 2 Normative References 3 Definitions 4 Extent of Verification 4.1 General 4.2 New Construction Quality Assurance (QA) Material Verification Program 4.3 Material Verification Program for Existing Piping Systems 4.4 Material Verification Program as an Element of Maintenance Systems 5. Material Verification Program Test Methods 5.1 Material Verification Program Test Method Objectives 5.2 PMI Test Methods 5.3 Equipment Calibration 5.4 Equipment Precision 5.5 Personnel Qualifications 5.6 Safety Issues

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6 Evaluation of PMI Test Results 6.1 Material Acceptance Methods 6.2 Dissimilar Metal Welds and Weld Overlays 6.3 Follow-up PMI Testing after Discovery of a Nonconformity 7 Marking and Recordkeeping 7.1 Materials Identification Process 7.2 Material Certifications 7.3 Shop and Field PMI Test Documentation 7.4 New and Existing Piping System Documentation 7.5 PMI Test Records 7.6 PMI Test Procedures 7.7 Traceability to Field Components

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There will be about 5 questions from this document on the API 570 exam

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1 Scope 范围

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1 Scope čŒƒĺ›´ 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.

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Key Words: 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.

这个建议RP578的做法的目的质量保证体系的指导方针用于 确认承压管道或组件的 ”合金的标称成分” , 符合选定或指定的建筑 材料规格, 达到最小化潜在的有毒, 有害液体或蒸气, 灾难性释放.

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API578 RP 指导目的是确保设备新建,维修,改造时不会用错 建材, 而不是确切的确定材料符合规格要求.

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Key Words:

Alloy components within the pressure envelope 适用压力包络线范围内的合金组件 / 受压合金组件

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Key Words:

RP 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 ASME B31.3和API 570覆盖黑色金属和有色金属

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Key Words:

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. 不具体涉及碳钢组件-除非轻微/微量合金元素对组件的耐腐蚀性作 为关键因素.

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API578 Applicable: construction, installation, maintenance, and inspection of new and existing process piping systems covered by the ASME B31.3 and API 570 piping codes

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This RP provides the guidelines for material control and material verification programs on ferrous and nonferrous alloys

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.

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API578 Section 1:  覆盖 ASME B31.3 和 API 570黑色金属和有色金属  适用受压范围内的合金组件  不具体涉及碳钢组件-除非轻微/微量合金元素对组件的耐 腐蚀性作为关键因素.

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2 Normative References 规范性引用文件

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2 Normative References 规范性引用文件         

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 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 ASME B31.3, Process Piping CSB Chemical Safety Board Bulletin 2005-04-B, “Positive Material Verification: Prevent Errors During Alloy Steel Systems Maintenance” NACE Paper No 03651, “Specification for Carbon Steel Materials for Hydrofluoric Acid Alkylation Units” PFI ES22, Recommended Practice for Color Coding of Piping Materials

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3 Definitions

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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.

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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.

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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 材料制造商 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.

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3.9 material supplier 材料供应商 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.

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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.

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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.

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4 Extent of Verification 验证程度

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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.

For higher-risk systems, the owner/user should consider the need for employing a higher percentage of examination (up to 100 %) rather than random sampling which may be more appropriate for lower-risk systems. Inadvertent material substitution problems tend to be sporadic; therefore, small sample sizes may not locate all inadvertent alloy substitutions. The owner/user should also consider the need to conduct examinations after fabrication is complete, to ensure that incorrect substitutions did not occur at the work site.

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4 Extent of Verification 验证程度 4.1 General 大纲 这里提了三次 Owner/User  建立的一种书面材料验证程序覆盖新建, 在职, 维修,改 造, 新建后复查是业主/用户的责任.  规定验证的程度(%)和类型也是业主/用户的责任  材料替换的问题往往是零星,小样本抽样验证可能无法 找到所有问题.

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4.1.1 Alloy Substitutions in Carbon Steel Systems 碳钢合金中的替换 When determining the need to perform material verification on carbon steel systems, the owner/user should evaluate the effect that the process stream could have on substituted alloy materials. In some cases, the substitution of hardenable alloy materials in carbon steel piping systems resulted in failure and loss of containment. Examples of such systems include wet hydrogen sulfide (H2S), hydrofluoric acid (HF), and sulfuric acid (H2S04) services.

当考虑对碳钢系统材料 PMI 时, 用户/业主应评估工艺流程对碳 钢合金材料的影响

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4.2 New Construction Quality Assurance (QA) Material Verification Program 新施工PMI质量保证 确保验证程序是按照RP要求-责任是业主/用户 This section covers alloy piping during fabrication either in the shop or in the field prior to the items being placed into service and is restricted to the pressure-containing boundaries. 此RP受限制于压力的含边界的管道与其组件

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4.2.1 Roles and Responsibilities 角色和职责 A material verification program for piping systems may involve participation of several groups within the operating plant or the shop of a contractor, vendor, or fabricator. When establishing a material verification program, consideration should be given to the roles and responsibilities that each group has within the specific organization. These roles and responsibilities should be clearly defined and documented. Within the operating plant, this can include those groups responsible for purchasing, engineering, warehousing /receiving, operations, reliability, maintenance, and inspection. It is the responsibility of the owner/user or designee to determine the extent of examination required and to verify that the implementation and conduct of the material verification program is properly performed in accordance with this RP. It is also the responsibility of the owner/user to verify that the alloy materials subsequently placed into service are as specified, and that the documentation of the material verification program is in accordance with this RP.

确保PMI验证程序按照RP要 求-是业主/用户责任 Fion Zhang/ Charlie Chong

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管道系统的材料验 证程序可能涉及几 组单位或地点,比如 ; 承建方, 供应方, 储 存商或建造方在不 同的地点执行PMI 检验。

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4.2.2 Material Verification Test Procedure Review When PMI testing is performed by the material supplier or third-party agency, the owner/user or designee should review and approve the adequacy of the material verification program and testing procedure of the fabricator or material supplier prior to testing.

4.2.3 Scheduling of Material Verification Testing PMI testing should be performed at the point in time that ensures that proper alloy materials have been used in the fabrication of an identifiable assembly.

当PMI由材料供应商或第三方机构进行测试, 业主/用户应当应审查和批准与 确保程序和测试程序符合RP要求 PMI应当在适当的时间进行.

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4.2.4 Mill Test Report Mill test reports should not be considered a substitute for a PMI test.

However, mill test reports are an important part of an overall material quality assurance program.

材质证书虽然是整体材料的质量保证计划的重要组成部 分但不能作为替代的PMI测试的根据.

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4.2.5 Components Covered in a Material Verification Program Examples of pressure-containing components that make up fabricated piping systems that are covered by this RP include: a) pipe lengths; b) pipe fittings, such as tees, elbows, reducers, special pipe components, blinds and plugs; c) flanges; d) special forgings; e) process valves (including control valves) and relief valves; f) pressure-containing welds; g) instruments (all pressure containing parts); h) weld overlays or cladding; i) bolting; j) expansion joints and bellows; k) gaskets.

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4.2.6 PMI Testing of Welding Consumables 焊材测试 When welding is conducted, one electrode or wire sample from each lot or package of alloy weld rod should be positively identified. The remainder of the lot should be compared to the sample to verify that the markings of the wires/electrodes are correct. Some weld rods have the alloying elements contained in the flux, and do not meet the alloy specification until welded. PMI testing of weld metal (e.g. deposited weld metal or undiluted weld “buttons”) is a permissible alternative to PMI testing of an electrode or wire sample provided it is conducted immediately prior to welding or during the welding process.

 从每批或”包裹”合金焊材, 一支焊条或金属丝样品取样做PMI 测试.  如焊剂化学成分对焊肉有影响,可做焊缝金属(熔敷金属或非 稀释焊接“按钮”)的PMI测试 (2013 June)

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4.2.6.1 Longitudinal Pipe and Fitting Welds Where there is reason to suspect problems, longitudinally welded alloy pipe and fittings should receive random PMI testing verification of the base metal and weld metal.

4.2.6.2 Autogenous Welds If the owner/user determines that material verification testing is required on autogenous-welded (with no added filler metal) alloy pipe or fittings, it is necessary to conduct testing on only the base metal.

4.2.7 PMI Testing of Components Supplied by a Distributor A higher degree of PMI testing verification should be conducted on alloy material supplied by stocking distributors due to the potential for material mix-ups as a result of handling.

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Longitudinal Pipe and Fitting Welds 直缝钢管及管件的焊缝

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自体焊缝

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stocking distributors 材料存库商 A higher degree of PMI testing verification should be conducted on alloy material supplied by stocking distributors due to the potential for material mix-ups as a result of handling. 对材料存库商提供的受 压管道与配件应当采取 较高PMI测试验证因潜在 的材料混乱.

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API578 Section 4.2: 新建设的设备(小结)     

确保PMI验证程序按照RP要求-是业主/用户责任. 实际的PMI操作工作可以是项目任何参与方或在地点执行. 应当及时的执行PMI检测. 只适用受压管道与相关组件.

Section 4.2.5 提示, 法兰垫圈(gasket)与螺栓(bolting)定义为受压组件.

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4.3 Material Verification Program for Existing Piping Systems 4.3.1 General This section covers alloy piping systems that are already in service where the material verification program procedures for the construction were not in accordance with 4.2. Material verification is limited to the pressure containing components and their attachment welds. It is important to recognize that previous maintenance activities, as well as new construction practices, may influence the likelihood of inadvertent materials substitutions.

4.3.2 Responsibilities The owner/user is responsible for determining if a retroactive material verification program is appropriate for each existing piping system, for prioritizing the piping systems to receive retroactive PMI testing, and for determining the extent of PMI testing required.

Section 4.3 是关于在职管道在新建时 PMI没完全按照 4.2 要求执行的检测. 应当考虑的有, 维修与改造的材料替 代的可能性. 4.3.2 再一次重申业主/ 用户的全部职责.

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4.3.3 Prioritizing Piping Systems for Retroactive PMI Testing If the owner/user elects to prioritize piping systems for the material verification program or needs to determine whether PMI testing is needed at all, the owner/user should consider the following.

如业主/用户对 管道系统PMI优先次序时, 以下为考虑因素; a) Likelihood of a material mix-up during previous project and maintenance activities. A key factor is the effectiveness of the material verification program at the time of these activities.以前的项目和维护活动期间的材料混合的可能性 b) Consequences of a failure. Some factors to be considered include flammability, fire potential, toxicity, proximity to other equipment or community, temperature, pressure, mode of failure, and size of release.出现故障的后果 c) Reason for alloy specification (i.e. corrosion resistance or product purity).合金规范的 原因

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d) Historical data relating to inadvertent material substitutions. This may be related to previous experience with material nonconformities in the process unit or within the operating plant.有关意外的材料替代的历史数据 Taken together, these factors can be used to determine the risk associated with possible material non-conformances in a piping system. The owner/user should establish a methodology for estimating the relative priority for PMI testing of various piping circuits within a given unit. This methodology may be based on qualitative or quantitative risk analysis. API 581 discusses several risk-based approaches and the factors that should be considered when conducting a risk analysis such as material, service conditions, service fluid, and mode of failure. 上述几个考虑因素可以用来评估管道系统中可能因为材料不符合带来的相关风险, 从而 定义管道系统PMI优先次序. API581定性或定量的风险分析方法也可以作为评估手段.

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在考虑出现故障的后果时,这里没考虑出现故障的概率, 这有差异与常规 API580风险 分析做法 14. The lead inspector (owner/user) has decided to prioritize existing piping systems in the crude unit for PMI testing. Which is a consideration for prioritization?

A. How lucky he feels.

B. Likelihood of Failure C. Consequence of failure D. Both A and B

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API 581 discusses several riskbased approaches and the factors that should be considered when conducting a risk analysis such as material, service conditions, service fluid, and mode of failure.

API581定性或定量的风险分析方法也 可以作为评估手段.

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4.3.3.1 Carbon Steel Substitutions in Low Alloy Steel Systems In determining the likelihood of material non-conformances, it is worth noting that historically the greatest number of material non-conformances with serious consequences have involved carbon steel components in low alloy steel (e.g. 1 ¼ Cr– ½ Mo, 2 ¼ Cr–1 Mo, 5 Cr– ½ Mo, 9 Cr–1 Mo) piping systems. There have been fewer non-conformances in stainless steel and nonferrous (e.g. Monel, Inconel) systems because of appearance and weldability issues.

4.3.3.2 Residual Elements In Carbon Steels In Hydrofluoric Acid Alkylation Units 氢氟酸烷基化装置 Carbon steels in some specific locations in HF acid service have been reported to suffer increased corrosion rates based on the residual elements (RE) (i.e. C, Ni, Cr, and Cu) in the steels, and is discussed in API 751. PMI methods can be used to assess the potential for enhanced corrosion in HF service. Consideration should be given to the ability of the PMI method to detect the various elemental concentrations.

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API571/ 5.1.1.6 Hydrofluoric (HF) Acid Corrosion

In carbon steel, residual elements ( %C, %Cu, %Ni, %Cr) may accelerate corrosion in certain parts of the unit but industry recommended guidelines have not been formally developed. Some users limit the total Residual Element (RE) content to 0.20% maximum, where RE= %Cu + %Ni +%Cr. See Figure 5-5.

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It is worth noting that historically the greatest number of material nonconformances with serious consequences have involved carbon steel components in low alloy steel

因普通碳钢和低合金钢的外观一致,这导致 绝大多数的材 料不符合造成重大后果.

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4.3.3.3 Gasket Materials垫片材料 Incorrect gasket materials in incompatible service may cause premature failings. The main principles outlined in this document can be applied to gasket materials. The owner/user is required to ascertain the potential material variations and select analytical methods capable of providing the required data. The actual test procedures can be more detailed due to the geometric structure of the gasket materials.

4.3.3.4 Process Units Susceptible To Sulfidation.容易硫化工艺装置 Carbon steels with low silicon (< 0.10 %) content can corrode at an accelerated rate when exposed to hydrogen-free sulfidation conditions. These phenomena are discussed more extensively in AP 571 and API 939-C. Owner/users with assets at risk from this type of degradation should consider the risks and the requirements to apply PMI control in order to determine Silicon levels and the extent to which the material may corrode.

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Sulfidation

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4.3.3.5 Other Factors to Consider When Prioritizing Piping Systems Site-specific or experienced-based factors should be considered when prioritizing piping systems. Factors to consider include the following. a) Construction and maintenance practices. In assessing the likelihood of material non-conformances, the owner/user should also consider the materials handling, material control, and any PMI testing procedures followed during construction of the process unit. Process-unit maintenance procedures are also important. Process units in which rigorous procedures for material verification are used would be expected to have a lower likelihood of nonconformances. 前期的投入与检测范围. b) Reason for the alloy specification. In some cases, alloys are used in piping systems for reasons other than corrosion resistance or structural integrity. In these cases, the structural integrity of the system would not be harmed by material non-conformances. A material verification program may not be necessary in these systems. An example would be stainless steel lube oil systems in which stainless steel is used for maintaining oil purity. 合金规格的目 的.

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在职管道与组件检测范围与优先次序时, 其他考虑因素;  前期的投入与检测深度  合金规格的目的

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4.3.4 Component Prioritization Factors 组件的优先次序因素 Based on experience, some types of piping system components can have a higher likelihood of inadvertent substitution of a non-specified material. This can provide a basis for prioritizing specific equipment in a given system or process unit.

Examples are:不慎替代的可能性较高受压组件有; a) warm-up and bypass lines on pumps or check valves;加热或旁路管道 b) small diameter piping systems, including welds, with a diameter less than or equal to 2 in. (50 mm);小直径的管道系统 c) valves and other removable devices such as rupture discs, spacer blinds, or ring joint gaskets; 可拆卸受压组件 d) thermowells; 承插式温度计 e) bolting; 螺栓 f) piping as a part of a packaged system; 成套管路系统 g) components without an ASTM stamp; 不带ASTM标记的组件 h) specific process systems with corrosion issues (e.g. residual elements in Carbon Steels in HF Acid service or high Silicon content in potential sulfidation conditions). 特定的腐蚀机理受压工艺系统

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API578 对以下两种损坏机理特别的描述: specific process systems with corrosion issues (e.g. residual elements in Carbon Steels in HF Acid service or high Silicon content in potential sulfidation conditions). 特定的腐蚀机理受压工艺系统

 Residual elements in Carbon Steels in HF Acid service氢氟酸 腐蚀机理

 Silicon content in potential sulfidation conditions 硫化腐蚀机理

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硫化腐蚀机理 当暴露于硫腐蚀碳素结构钢在低硅(< 0.10%)的情况下会加速腐蚀 Sulfidic corrosion of piping and equipment within the refining industry continues to be a significant cause of leaks and issues that can lead to early replacements, unplanned outages, and incidents potentially resulting in loss of property and injury to workers. Carbon steels with low silicon (<0.10%) content have been shown to corrode at an accelerated rate when exposed to sulfidation corrosion conditions1.

According to the American Petroleum Institute (API) Recommended Practice 939C (Guidelines for Avoiding Sulfidation Corrosion Failures in Oil Refineries), onethird of high-temperature sulfidic corrosion failures are the result of low silicon content in piping. API RP 939-C is a subcomponent of the larger API RP 578 (Material Verification Program for New and Existing Alloy Piping Systems) Positive Material Identification (PMI) program – the verification of correct alloy installation in all sulfidation surfaces, both proactive and reactive.

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4.3.5 Factors to Consider When Determining the Extent of PMI Testing 设定PMI测试的范围应当考虑因素 The owner/user should determine the extent of PMI testing. Factors to consider when determining the extent of PMI testing for an existing process unit include: a) Historical inspection and material verification program records, 历史记录 b) Number of plant modifications, 改造数次 c) Materials control during original construction and during modifications, 改造或 新建时对材料管理的有效性 d) Material verification program quality during construction and fabrication,改造或 新建时对材料PMI管理的有效性 e) Consequence of release,释放的后果 f) Likelihood of corrosion/degradation.腐蚀/降解的可能性

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API578 Section 4.3: 现有的管道系统的材料验证程序(小结)    

容易被硫化工艺装置- 碳钢 PMI考虑因素: Si (硅含量) 氢氟酸烷基化装置- 碳钢 PMI考虑因素: Re (残余成分) API581定性或定量的风险分析方法也可以作为评估手段.

4.3.5 列出 PMI 测试程度应当考虑的因素.

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4.4 Material Verification Program as an Element of Maintenance Systems The principles associated with materials verification as part of a new piping installation should also be applied to provide confidence that proper materials are being used as part of maintenance activities. The concepts noted previously in 4.2 and API 570 should be reviewed and applied as applicable to the maintenance function.

4.4.1 Responsibilities It is the responsibility of the owner/user to evaluate maintenance systems so that material verification programs can be designed and implemented to effectively support the mechanical integrity of alloy piping systems. The owner/user should establish a written procedure for the material verification program to be used for repair of piping systems during maintenance outages. This procedure should be documented by the owner/user.

确保在维修,改造时, 正确的材料运用是业主/用户的全职. 这包括维护合适的计 划与程序作为维护系统的因素.

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业主/用户职责: 业主/用户应当确保在维修,改造时, 正确的材料应用作 为维修/维护/改造管理系统的基本元素.

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4.4.2 Control of Incoming Materials and Warehousing 来料和仓储的控制 A material verification program should be directly applied to activities associated with receiving alloy materials into warehouse systems. PMI testing may be performed as part of this receiving function, or, when appropriate, may be performed at the supplier’s location as a condition of release for shipment. The material verification program that is adopted should provide for proper documentation and methods for indicating which materials have been tested and are approved for use.

The use of material verification program principles to check materials received into a warehouse system should be regarded as a quality assurance practice to minimize the potential for discovering an alloy material discrepancy during subsequent PMI testing.

PMI testing within the warehouse should not be regarded as an alternative to PMI testing of the fabricated piping system when testing is specified. ，制造管道系统 指定测试时, 仓库内的测试不能被视为作为一种替代

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PMI testing within the warehouse should not be regarded as an alternative to PMI testing of the fabricated piping system when testing is specified. ，当制造管道系统指定PMI测试时, 仓库内 的PMI测试不应该被视为作为一种替代.

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当制造管道系统指定PMI测试时, 仓库内的PMI测试不应该被视为作 为一种替代.

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当制造管道系统指定PMI测试时, 仓库内的PMI测试不应该被视为作 为一种替代.

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4.4.3 Maintenance Activities of Piping Systems 管路系统的维护活动 There are a number of in-service maintenance activities where material verification should be established. Temporary removal of spool pieces needs to be managed in such a way that material mix-ups cannot occur. Incidents have occurred when same size spool pieces have been removed during turnarounds and substituted into the wrong locations during installation. Consideration shall be given to a firm control system or a verification prior to reinstallation to prevent these incidences occurring. A process where a system of ‘tagging’ spools as they are removed to ensure correct replacement should be considered It is important that repair procedures include consideration of PMI testing as part of obtaining satisfactory alloy materials to be used for the repair. As appropriate, this may include any of the components noted in 4.2.5.

Much of this can be controlled through awareness of the issues at all levels within the repair process. Consulting with an inspector prior to commencement of work can ensure that systems, processes and activities are in place to ensure good material control.

当执行管路系统的维修/改造/维护 时, 错误的材料替代往往会发生,有 效的防备包括对临时管路执行”标 签管理”, 新建材料PMI测试等手段.

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5 Material Verification Program Test Methods 材料验证程序测试方法

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5.1 Material Verification Program Test Method Objectives The test methods outlined in this RP are intended to identify alloy materials and are not intended to establish the exact conformance of a material to a particular alloy specification. Depending on the test method selected, the PMI test method may identify the nominal composition of alloy materials. Identification of materials by visual stamps/ markings alone should not be considered as a substitute for PMI testing but may be an important component of an overall quality assurance program.

 此API578 RP的目的是识别合金材料, 而不是为了确定, 材料确切的符合特 定的合金化学成分和标准规格要求.  材料标记是材料管理重要部分,然而这不应当视为作为PMI测试的替代.

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API578 RP 指导目的是确保设备新建,维修,改造时不会用错 建材, 而不是确切的确定材料符合规格要求.

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5.2 PMI Test Methods PMI测试方法 5.2.1 General A variety of PMI test methods are available to determine the identity of alloy materials.

The primary methods include (1) portable X-ray fluorescence便携式X射线荧光, (2) portable optical emission spectroscopy便携式发射光谱, and (3) laboratory chemical analysis实验室化学分析. A description of several test methods is listed below.

In addition to these methods, there are a variety of alloy sorting techniques that may be appropriate for the purposes of this RP including magnetic testing 磁力检测 to differentiate between ferritic and austenitic materials. It is important that users verify what the objectives and accuracies are required from the PMI tool they wish to use. All of the tools have benefits and limitations on the elements they can or cannot detect, in addition to the accuracy and ability to differentiate between different material grades which have only slight variations in alloying elements.

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5.2.2 Portable X-ray Fluorescence 便携式X射线荧光 There are several variants of portable X-ray fluorescence (XRF) spectrometers available. The principle of operation is that one or more gamma ray or X-ray sources are used to generate a beam of low energy radiation to excite the material under analysis. The material under analysis then emits a characteristic radiation spectrum which can be analyzed both qualitatively and quantitatively to determine which elements are present and in what quantity. The results of this analysis can be reported in either or both of the following formats. a) as a match against one of many reference spectra stored in the instrument, i.e. 316 stainless steel or 5 Cr – 1⁄2 Mo steel; b) each element present is reported as a percentage.

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Because of the inherent limitations of the technique it is not possible to detect all elements. XRF analyzers are capable of detecting elements from Ti to U in the periodic tables. This may exclude some of the important elements in carbon steels such as C, Si, and S. In addition many analyzers are sold with basic element packages so it is important to decide exactly what elemental analysis is required and select an appropriate instrument.

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XRF method 便携式X射线荧光

http://inspectioneering.com/content/2013-0301/3226/xrf-inspection-of-piping-syste http://www.squareoneinspection. com/XRF_Drywall.html

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Portable X-ray Fluorescence 便携式X射线荧光

Limitation:限制因素 This may exclude some of the important elements in carbon steels such as C, Si, and S.

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5.2.3 Portable Optical Emission Spectrometry 便携式发射光谱 An electric arc stimulates atoms in the test sample to emit a characteristic spectrum of light for each element in the sample. The combined light spectra from different elements are passed through a light guide to the optical analyzer. In the analyzer, the light is dispersed into its spectral components, and then measured and evaluated against stored calibration curves. These devices fall into two groups;

the first being a light portable and operator evaluated device that can typically identify up to 16 elements but depends upon operator evaluation of a light spectra.

These devices do not directly indicate alloy grade or composition, but produce an output in the form of visible light spectra that permits semi qualitative alloy identification The technique is also sensitive to operator skill and experience.

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The second group are field portable laboratory grade analyzers. These were originally difficult to use due to their size and weight. Modern units are now available weighing only 33 lbs including small Argon cylinders. Some operate in a pure arc mode for routine PMI applications and the more sophisticated units have a spark mode allowing laboratory quality analysis. The significant advantage of these instruments is the expansion of elements that can be analyzed including C. These more advanced instruments are also not subject to operator interpretation. Similar to X-ray fluorescence devices, results can be reported in either a spectral match or elemental percentage mode. As these techniques generate arcs and sparks a potential ignition source occurs therefore prior to use of this technique in the field, a review should be conducted to determine if gas testing and hot work permits are required.

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Principle:原理 XRF 便携式X射线荧光 The principle of operation is that one or more gamma

ray or X-ray

sources γ射线或X射线源 are used to generate a beam of low energy radiation to excite the material under analysis. The material under analysis then emits a characteristic radiation spectrum 特征辐射谱.

---------------------------------------------------------------------------Portable Optical Emission Spectrometry 便携式发射光谱 An electric arc stimulates电弧刺激 atoms in the test sample to emit a characteristic spectrum of light 光谱光 for each element in the sample.

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35. How do portable X-Ray Fluorescence PMI tools work? a. Radiation waves excite the materials and the material emits a different spectrum of radiation that can be analyzed. b. Radiation waves excite the materials and the material emits a different spectrum of light that can be analyzed. c. Sound waves excite the materials and the material emits a different spectrum of radiation that can be analyzed. d. Sound waves excite the materials and the material emits a different spectrum of light that can be analyzed.

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5.2.4 Chemical Laboratory Chemical Analysis 化学实验室, 化学分析 Owner/user-approved material analysis laboratories using; (1) X-ray emission spectrometry, X射线发射光谱法 (2) optical emission spectrometry光发射光谱法, or (3) wet chemical analysis 湿化学分析 can provide the most accurate analytical results for all elements. The accuracy is typically much higher than is normally needed for PMI testing. Laboratory analysis may involve the removal of significant amounts of material, and is typically slower than field PMI test techniques.

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5.2.5 Other Qualitative Tests 其他定性测试

5.2.5.1 Chemical Spot Testing 点式化学抽查测试 The chemical spot test is typically accomplished by electrochemically removing a minute amount of surface metal and depositing it onto moistened filter paper. Reagents dropped onto the paper produce distinct colors that are indicative of the presence of specific elements in the sample tested. Chemical spot testing is much slower than the other field PMI test methods and interpretation is subjective.

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5.2.5.2 Resistivity Testing 电阻率的测试 The principle employed in the test method is known as the Seebeck Effect, or thermoelectric principle. A heated junction of dissimilar metal is created when the heated probe [300oF (150oC)] and the metal being tested are in contact with each other. The voltage generated at this junction is representative of the chemistry and crystalline structure of the metal being tested. Every alloy of a given crystalline structure will generate the same voltage regardless of the geometry or size of the piece being tested or the pressure applied. By references to known standards, these instruments are capable of sorting and identifying a wide range of ferrous and nonferrous materials. Alloy sorters have not proved to be consistently capable of sorting low alloy (< 5 % Cr) and austenitic stainless steels.

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5.2.5.2 Resistivity Testing 电阻率的测试

Limitation:限制因素 Alloy sorters have not proved to be consistently capable of sorting low alloy (< 5 % Cr) and austenitic stainless steels.

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5.2.5.3 Other Techniques 其他技术 Techniques such as;    

Eddy-current sorters涡流分拣 , Electromagnetic alloy sorters电磁合金分拣, Triboelectric testing devices 静电测试 (e.g. ferrite meters), and Thermoelectric tests热电测试

are qualitative定性 and as such may only be appropriate for limited sorting applications and not for specific alloy identification.

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5.3 Equipment Calibration 设备校订 The person performing the PMI testing should calibrate and/or verify the test equipment performance as specified by the equipment manufacturer. The PMI test procedure should provide the frequency interval for this calibration/ verification. If calibration procedures are not provided by the equipment manufacturer, they should be established by the owner/user. Typically, these procedures should include calibration/verification using certified standards.

   

设备操作员应当及时的校订设备 按照设备提供商指定的程序, 验证与校订PMI设备. 在缺乏设备商提供程序情况, 业主/用户应当开发校订程序 一般校订程序包括用认证试块对比.

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5.4 Equipment Precision 设备精密度 The precision of the test equipment should be consistent with the established test objectives (see 5.1). When component composition is desired, the owner/user should establish the acceptable precision and repeatability. The accuracy and the method in which accuracy is determined needs to be understood. For example, in some tools, the sensitivity may be dependent upon how long you conduct the test in order to improve signal averaging algorithms. Failure to understand these issues may produce inaccurate results.

测试设备的精度应符合既定的测试目标 (如 5.1) 当需要合金材料的成分组成时, 业主/用户应建立可接受的精度和 可重复性

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API578 RP 指导目的是确保设备新建,维修,改造时不会用错 建材, 而不是确切的确定材料符合规格要求. (这里重复是提醒此RP不能作为项目材料验收程序, 引用规范根据)

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5.5 Personnel Qualifications 人员资格 The person(s) performing the PMI test should be knowledgeable about all aspects of operation of PMI test equipment and the PMI test method used. Qualifications of the person performing the PMI test, including training and experience, should be submitted for review and approval by the owner/user. Owner/users should ensure that personnel using testing devices are adequately trained not only in the specific instrument but also in the alloys they will be examining. In some cases for critical application a formal documented program and some form of testing of personnel may be required. The higher the degree of operator analysis the more important this aspect of the whole procedure becomes.

操作人员没有特定的学会资格要求,但必须对相关的PMI设备和测试的合金材 料有充分的认识. 相关人员的资质与培训资料必须提供给业主/用户审核.

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5.6 Safety Issues 安全问题 The specific requirements for each PMI test technique should be clearly reviewed as to the amount of mechanical preparation. Consideration should be given to the anticipated thickness of the sample before mechanical methods are used to prepare the sample. In addition, considerations for electrical arcing and “hot spots” should be considered as well as appropriate electrical and hot work permits. Chemical spot testing involves the use of a variety of chemicals.

Appropriate safety precautions should be taken when handling these chemicals.

关注的因素有:  作为表面处理剩余厚度  PMI测试时电弧考虑  热工证  湿化学实验牵涉的化学品危害等

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6 Evaluation of PMI Test Results 测试结果评价

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6.1 Material Acceptance Methods 材料验收方法 The owner/user may elect any one of the following methods of material acceptance. a) Materials can be confirmed to contain the nominal amounts of alloying elements specified in the relevant materials specification (e.g. ASME Section II or ASTM specifications). 标称成分 b) Materials can be classified through a qualitative sorting technique (see 5.2.4) to establish the conformance with the intended material. 定性归类法 c) When PMI testing indicates alloying elements are outside the ranges indicated in the material specification, the owner/user may still choose to allow the use of the tested materials in situations where a person knowledgeable of the appropriate damage mechanisms confirms that the material will perform satisfactorily in the service. 标称成分,让步接收. d) If testing using one of the portable or qualitative analysis methods (see 5.2.1 or 5.2.2) leads to the potential rejection of a component, a more accurate analysis may be used to determine component acceptance (see 5.2.3). 用更准确分析方 法作为接收条件.

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6.1 Material Acceptance Methods 材料验收方法 业主/用户可以选择任何材料验收的下列方法之一

a) b) c) d)

标称成分 定性归类法 标称成分超出规范时让步接收.(在考虑损坏机理/材料合理性下) 当怀疑有不合格项时可疑用更准确分析方法作为接收条件.

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6.2 Dissimilar Metal Welds and Weld Overlays 异种金属对接焊和堆焊 Results from testing dissimilar metal welds should take into account the effects of dilution, which occurs during weld deposition. The owner/user should establish the minimum compositional requirements of the as-deposited weld metal necessary for the intended service. 考虑:稀释的影响 6.3 Follow-up PMI Testing after Discovery of a Nonconformity 不合格项跟踪 If any one of a representative sample is rejected, all items of that inspection lot should be considered suspect. A more extensive inspection of the remaining lot should be considered. 如抽样PMI不合格, 该检验批的所有项目应被可疑项.对其余项应考虑广泛的检查.

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7 Marking and Recordkeeping 标记和记录保存

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7.1 Materials Identification Process 材料识别过程 Alloy materials should be identified by their alloy designation or nominal composition.

Examples of some acceptable identification methods are: a) color coding by alloy,颜色编码 b) a low-stress stamp marking indicating that the test has been performed, 低应力钢印 c) documentation showing both the PMI test results and the PMI test locations. 文档 记录PMI测试结果与位置 Test locations should be shown on appropriate drawings so that each test site can be traceable to the fabricated piping components.

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7.1.1 Color Coding/Marking 颜色编码/标记 If the material verification program procedure established by the owner/user requires a visual identification such as color coding or marking, the owner/user should maintain a record of the alloy material/color code combinations. Pipe Fabrication Institute (PFI) Standard ES22 is an example of one such system.

Materials identification by color coding is not a substitute for permanent manufacturers’ markings required by applicable ASTM or other materials specifications.

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7.1.2 Marking of Components If the owner/user’s documentation process requires physical marking of piping components, it should specify one of the following. a) Whether or not the marking system should remain legible for the expected life of the component without deterioration due to corrosion or elevated temperature. b) Whether or not the marking system is only temporary to facilitate proper handling and identification from the point of PMI testing to final installation. This marking can be semi permanent paint applied to each item. The markers should not contain additives such as metallic pigments (Al, Pb, or Zn), sulfur or chlorides. 标记不应含有金属颜料的添加剂，例如 (Al, Pb, or Zn), sulfur or chlorides.

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7.2 Material Certifications 材料认证 Material certifications, mill test reports, or certificates of compliance should not be considered a substitute for PMI testing, but may be an important part of an overall quality assurance program. 材料证书不能作为PMI测试的替代.

7.3 Shop and Field PMI Test Documentation 车间和现场PMI测试文档 Those individuals performing PMI testing should obtain and follow the PMI test procedure approved by the owner/ user. This procedure should cover the technique used, equipment calibration, the qualification requirements of PMI test personnel, the testing methodology, and documentation requirements. When documentation, such as drawings, is used in lieu of physical marking, the documentation should allow the owner/user to identify which components were tested.现场PMI测试文档应当依照批准程序执行.

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7.4 New and Existing Piping System Documentation 新的和现有的管道系统文档 When PMI testing is conducted on new or existing piping systems, records of the results should be kept as long as the piping system exists in its original location.

If a piping system or a portion of a piping system that has not received material verification is relocated, the owner/user should consider the need for PMI testing prior to placing the relocated components into service.

文件保留多久?  只要管道系统应保持在其原始位置, 相关的PMI文档应当保留.  如管道系统被移动,业主/用户应当考虑搬迁组件重新运作前是否需要PMI 测试

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7.5 PMI Test Records 测试记录内容 Typical PMI test records should contain the following. a) Reference to the PMI test procedures used.参考文献/程序 b) Date of testing.测试日期 c) Test instrument identification number or serial number where appropriate.测试仪 器识别号码 d) Name of each person and company performing the tests. 操作人员/单位 e) Results of the tests.测试结果 f) Basis and action for resolving and documenting PMI test nonconformances including those that have been left in service.解决和记录的依据和行动 g) Documentation of the criteria used for prioritization of piping systems and extent of PMI testing performed. Alternately, the owner/user may choose to include this within the written material verification procedure. When included in the owner/user’s written material verification procedure, the date and edition number of the written procedure should be documented in the test record.用于管道系统的 优先级的标准文档/验收标准根据等.

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7.6 PMI Test Procedures 测试程序 The PMI test procedure should include the techniques used, equipment calibration elements, the qualification requirements for PMI test personnel, the testing methodology, acceptance criteria and the documentation requirements.

7.7 Traceability to Field Components 可追溯性 The information listed in 7.5 should be reported in such a manner that they are traceable to the point of installation.

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1. API 578 provides guidelines for a quality assurance system to verify: a. b. c. d.

all materials. b. all alloy materials. c. only non-ferrous materials. d. only high-alloy materials.

3. An alloy material is any metallic material that contains alloying elements that are added: a. only to improve mechanical properties. b. only to improve corrosion resistance. c. to improve either mechanical properties or improve corrosion resistance

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5. An inspection lot includes: a. b. c. d.

all materials from same supplier. all materials included on the same purchase order. all materials of the same material type (i.e. 316 SS) all materials of the same material type from the same supplier and heat.

6. A documented material verification program should be established by the: a. b. c. d.

Authorized inspector.

Owner/User.

Repair organization.

Engineering organization.

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7. The material verification program should cover PMI testing of materials: a. during construction of piping systems. b. in existing piping systems. c. during repairs and alterations of piping systems. d. in existing piping systems and during construction, repairs and alterations of piping systems.

8. Random sampling is most appropriate for: a. low-risk systems. b. low alloy systems. c. stainless steel systems. d. ferritic steel systems.

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9. Who has the responsibility to determine the extent of PMI performed? a. b. c. d.

Authorized inspector Owner/User Repair organization Engineering organization.

10. Who has the responsibility to verify that the material verification program is properly implemented? a. b. c. d.

Authorized inspector Owner/User Repair organization Engineering organization

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11. Who has the responsibility to review and approve the adequacy of the PMI program used by fabricators and material suppliers? a. Authorized inspector b. Owner/User c. Repair organization d. Engineering organization

12. A mill test report: a. eliminates the need for further material verification. b. is a report showing material discrepancies. c. is an important part of the material qualify assurance program. d. is issued by the owner upon receipt of materials.

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13. The material verification program specified by API 578 covers: a. only pressure-containing components b. only pipe, and fittings. c. only pipe, fittings, and welds. d. pressure-containing and non-pressure containing components.

14. During alloy welding: a. one electrode from each box should be sampled. b. two electrodes from each box should be sampled. c. one electrode from each lot should be sampled. d. two electrodes from each lot should be sampled.

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15. If alloy element(s) are contained in the flux of a welding electrode, PMI testing: a. is not necessary. b. is not necessary provided appropriate documentation is provided by the supplier. c. could be conducted on any of the production welds. d. could be conducted on a weld button prior to production welds.

16. New longitudinal welded alloyed pipe should: a. never be used. b. be used only if the Quality Factor is 1.0. c. receive random PMI testing of weld and base metal. d. receive 100% PMI testing of weld and base metal.

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17. Who has the responsibility to determine the extent of PMI testing required on existing piping systems? a. Authorized inspector b. Owner/User c. Repair organization d. Engineering organization

19. Incorrect substitution of carbon steel is most likely to be found in: a. chrome steels. b. stainless steels. c. any ferritic steel. d. any non-ferrous.

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20. Which of the following piping components is most likely to have a substitution with the wrong material? a. A 20â&#x20AC;&#x2122; length of 6 NPS pipe b. Weld-neck flange c. Expansion joint d. Bolting

21. Which of the following piping components is most likely to have a substitution with the wrong material? a. A 10â&#x20AC;&#x2122; length of 6 NPS 316L SS pipe b. 6 NPS Gate valve c. 4 NPS Monel elbow d. Slip-on flange

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22. Who has the responsibility to determine the extent of PMI testing required during repairs and alterations of piping systems? a. Authorized inspector b. Owner/User c. Repair organization d. Engineering organization 23. PMI testing at the warehouse is: a. done by only checking material stampings. b. accomplished by the Authorized Inspector. c. not important since materials will be checked during fabrication. d. not an important part of the material verification program. e. not a substitute for PMI testing required during fabrication.

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24. Identification of materials by visual stamps or markings: a. is not an important part of the material verification program. b. is not a substitute for PMI testing. c. is important only on high alloy materials. d. should only be done by inspectors.

25. PMI tools that use X-Ray fluorescence can not detect: a. carbon content. b. chrome content. c. iron content. d. molybdenum content.

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26. How does Portable Optical Emission Spectrometry determine the elements in a material? a. An electric arc causes a spectrum of light to be emitted from the tested material.

The light is analyzed. b. X-rays striking the material cause a spectrum of x-rays to be emitted from the tested material. The x-rays are analyzed. c. Specific chemicals deposited on the tested material cause a spectrum of colors to be emitted. The colors are analyzed. d. The surface is polished and etched. A replication is preformed and is analyzed with a microscope.

27. PMI testing equipment should be: a. calibrated every 4 hrs. b. calibrated as specified by the manufacturer. c. used only by the manufacturerâ&#x20AC;&#x2122;s personnel. d. used by owner/user personnel.

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28. All personnel performing PMI tests should be: a. qualified by national exam. b. qualified by the owner/user. c. knowledgeable about the operation of the PMI test equipment. d. knowledgeable about the operation of the plant where the PMI is conducted.

29. An alloy weld overlay is applied to carbon steel base metal. Who has the responsibility to establish the minimum alloy requirements of the as-deposited weld metal? a. Authorized inspector b. Owner/User c. Repair organization d. Engineering organization

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30. What is the appropriate action to take when an incorrect material is located during a PMI sampling of new materials. a. Inspect 2 more items from the inspection lot. b. Inspect 50% of the items from the inspection lot. c. Inspect 100% of the items from the inspection lot. d. Inspection all items supplied by that manufacturer.

31. Marking pens should not contain chlorides or: a. Carbon. b. Chrome. c. Oxides. d. Sulfur.

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Answers: 1. b. all alloy materials.

3. c. to improve either mechanical properties or improve corrosion resistance 5. d. all materials of the same material type from the same supplier and heat 6. b. Owner/User 7. d. in existing piping systems and during construction, repairs and alterations 8. a. low-risk systems 9. b. Owner/User 10. b. Owner/User 11. b. Owner/User 12. c. is an important part of the material qualify assurance program 13. a. only pressure-containing components 14. c. on electrode from each lot should be sampled 15. d. could be conducted on a weld button prior to production welds 16. c. receive random PMI testing of weld and base metal 17. b. Owner/User

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19. a. chrome steel 20. d. bolting 21. b. Valve 22. b. Owner/User 23. e. not a substitute for PMI testing required during fabrication.

24. b. is not a substitute for PMI testing 25. a. carbon content 26. a. an electrode arc causes a spectrum of light to be emitted from the tested material.

The light is analyzed.

27. b. calibrated as specified by the manufacturer 28. c. knowledgeable about the operation of the PMI test equipment 29. b. Owner/User 30. c. inspect 100% of the items from the inspection lot / 31. d. sulfur

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1. API 578 provides guidelines for a material assurance system to verify: a. all materials. b. all alloy materials. c. only non-ferrous materials. d. only high-alloy materials.

2. The material verification program specified by API 578 covers: a. only pressure-containing components. b. only pipe, and fittings. c. only pipe, fittings, and welds. d. pressure-containing and non-pressure containing components.

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3. An alloy material is any metallic material that contains alloying elements that are added: a. only to improve mechanical properties. b. only to improve corrosion resistance. c. to improve either mechanical properties or corrosion resistance.

4. An inspection lot includes: a. all materials from a common source. b. all materials included on the same purchase order. c. all materials of the same material type (i.e. 316 SS) d. all materials from a common source, of the same material type and same heat.

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5. For construction and repair activities a written material verification program should be established by the: a. API 570 Authorized Inspector. b. Engineering Organization. c. Owner/User. d. Repair Organization.

6. The material verification program should cover PMI testing of materials: a. during construction of piping systems. b. in existing piping systems. c. during repairs and alterations of piping systems. d. in existing piping systems and during construction, repairs and alterations of piping systems.

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7. During repairs, random PMI sampling of new components is most appropriate for: a. low-risk piping systems. b. low alloy piping systems. c. stainless steel piping systems. d. ferritic steel piping systems. e. all piping systems.

8. Who has the responsibility to determine the extent of PMI performed? a. API 570 Authorized Inspector b. Owner/User c. Piping Engineer d. Repair Organization

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9. During construction the Owner should consider 100% PMI of new components on: a. all piping systems. b. all alloys above P-5. c. exotic alloys. d. high-risk piping systems.

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10. Usually substituting an alloy for carbon steel does not cause a problem. But hardenable alloys may cause failure in some carbon steel systems. Which of the following process services would substituting an alloy for carbon steel not result in a potential problem. a. Benzene b. Hydrofluoric acid (HF) c. Sulfuric acid d. Wet hydrogen sulfide 11. Who is responsible to assure that the material verification program meets the guidelines of API 578? a. Authorized Inspector b. Examiner c. Owner/User d. Piping Engineer

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12. Who is responsibility to verify the adequacy of the material verification program that is performed by material suppliers? a. API PMI Specialist b. Authorized Inspector c. Piping Engineer d. Owner/User 13. Who has the responsibility to review and approve the adequacy of the PMI program used by fabricators? a. API 570 Authorized Inspector b. API 578 Certified Inspector c. Engineering Organization d. Owner/User e. Repair Organization

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14. A mill test report: a. eliminates the need for further material verification. b. is a report showing material discrepancies. c. is an important part of the material qualify assurance program. d. is issued by the owner upon receipt of materials.

15. During construction, which of the following alloy components does not need to be covered by a material verification program? a. Bolts b. Expansion Joints c. Gaskets d. Pressure containing welds e. All the above components need to be checked

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16. During alloy welding: a. one electrode from each pallet should be identified. b. two electrodes from each pallet should be identified. c. one electrode from each lot or package should be identified. d. two electrodes from each lot or package should be identified.

17. If alloy element(s) are contained in the flux of a welding electrode, PMI testing: a. is not necessary. b. is not necessary provided appropriate documentation is provided by the supplier. c. could be conducted on any of the production welds. d. could be conducted on a â&#x20AC;&#x153;weld buttonâ&#x20AC;? prior to production welds.

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18. New longitudinal welded alloyed pipe should: a. never be used. b. always receive random PMI testing of weld and base metal. c. receive random PMI testing of weld and base metal if there is a reason to suspect problems. d. always receive 100% PMI testing of weld and base metal.

19. PMI of autogenous welds is: a. always required. b. never required. c. not required if the weld rod was PMI tested. d. not required if the base metal was PMI tested.

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20. Who has the responsibility to determine the extent of PMI testing required on existing piping systems? a. API Authorized Inspector b. Engineering Organization c. Owner/User d. Repair Organization 21. When prioritizing the need for PMI on existing piping systems, which of the following is not a factor to consider? a. Age of the facility b. Consequence of failure c. Likelihood of failure d. Plant experience with inadvertent material substitutions e. Reason for the alloy

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22. Incorrect substitution of carbon steel is most likely to be found in: a. chrome systems. b. stainless systems. c. any ferritic systems. d. any non-ferrous systems.

23. Which residual element in a carbon steel system has not caused increased corrosion rates in HF acid piping system? a. C b. Cr c. Cu d. Fe e. Ni

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24. Low silicon carbon steel can corrode rapidly when exposed to: a. hydrogen-free sulfidation. b. hydrogen-rich sulfidation. c. hydrogen-free oxidation. d. hydrogen-rich oxidation.

25. Carbon steel can corrode rapidly in hydrogen-free sulfidation when the silicon content in carbon steel is: a. < 0.10%. b. > 0.10%. c. < 0.25%. d. > 0.25%.

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26. The owner decides to conduct PMI testing on some existing piping systems.

Which of the following is a major factor in prioritizing the pipe? a. The effectiveness of the construction & maintenance practices b. The effectiveness of the inspection practices c. Age of the unit d. Line size 27. Which of the following piping components is most likely to have a substitution with the wrong material? a. A 20â&#x20AC;&#x2122; length of 6 NPS pipe b. Weld-neck flange c. Expansion joint d. Bolting

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28. Which of the following piping components is most likely to have a substitution with the wrong material? a. A 10â&#x20AC;&#x2122; length of 6 NPS 316L SS pipe b. 6 NPS Gate valve c. 4 NPS Monel elbow d. Slip-on flange 29. Who has the responsibility to determine the extent of PMI testing required during repairs and alterations of piping systems? a. API 578 Authorized Inspector b. Engineering Organization c. Owner/User d. Repair Organization

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30. Who has the responsibility to evaluate the effectiveness of a PMI program during repairs and alterations? a. API Authorized Inspector b. Examiner c. Owner/User d. Piping Engineer e. Repair Organization 31. During repairs and alterations the Owner should: a. use NACE certified examiners. b. have a written procedure describing their PMI program. c. PMI test 100% of all materials. d. PMI test 100% of all alloy materials.

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32. PMI testing at the warehouse is: a. done by only checking material stampings. b. accomplished by the Authorized Inspector. c. not important since materials will be checked during fabrication. d. not an important part of the material verification program. e. not a substitute for PMI testing required during fabrication.

33. In the petrochemical industry, one common material mix-up problem occurs: a. when temporarily removing spool pieces. b. when sending pumps out for repair. c. by using carbon steel in a 300 series stainless steel system. d. by using 300 series stainless steel in a carbon steel system.

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34. Identification of materials by visual stamps or markings: a. is not an important part of the material verification program. b. is not a substitute for PMI testing. c. is important only on high alloy materials. d. should only be done by inspectors.

35. How do portable X-Ray Fluorescence PMI tools work? a. Radiation waves excite the materials and the material emits a different spectrum of radiation that can be analyzed. b. Radiation waves excite the materials and the material emits a different spectrum of light that can be analyzed. c. Sound waves excite the materials and the material emits a different spectrum of radiation that can be analyzed. d. Sound waves excite the materials and the material emits a different spectrum of light that can be analyzed.

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36. PMI tools that use X-Ray fluorescence can not detect: a. carbon. b. chrome. c. iron. d. molybdenum.

37. How does Portable Optical Emission Spectrometry determine the elements in a material? a. An electric arc causes a spectrum of light to be emitted from the tested material.

The light is analyzed. b. An electric arc causes a spectrum of radiation to be emitted from the tested material. The radiation is analyzed. c. X-rays striking the material cause a spectrum of radiation to be emitted from the tested material. The radiation is analyzed. d. Specific chemicals deposited on the tested material cause a spectrum of colors to be emitted. The colors are analyzed. e. The surface is polished and etched. A replication is preformed and is analyzed with a microscope.

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38. Chemical spot testing: a. is the fastest PMI technique. b. provides an accurate way to determine the percentage of the types of metals in the material. c. uses droplets of acids or caustics that are placed on the component. Different colors indicated different materials. d. removes a small amount of surface metal that is placed in a filter paper. Small droplets of reagents are used on the sample and different colors indicated different materials.

39. PMI tools that use Resistivity Testing are not always able to sort: a. low chromes. b. high chromes. c. 300 series stainless steels. d. 400 series stainless steels. e. low chromes and 300 series stainless steels. f. high chromes and 400 series stainless steels.

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40. PMI testing equipment should be: a. calibrated every 4 hrs. b. calibrated as specified by the manufacturer. c. used only by the manufacturerâ&#x20AC;&#x2122;s personnel. d. used by owner/user personnel.

41. All personnel performing PMI tests should be: a. qualified by national exam. b. qualified by the owner/user. c. knowledgeable about the operation of the PMI test equipment. d. knowledgeable about the operation of the plant where the PMI is conducted.

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42. Qualifications for personnel performing PMI testing should be submitted and reviewed by: a. API. b. ASNT. c. the Authorized Inspection. d. the Owner/User. e. the Piping Engineer.

43. When PMI testing indicates that an alloy is outside the range allowed on the material spec, the component can: a. never be used. b. be used if the alloy percentages exceed requirements. c. be used in low risk piping systems. d. be used if accepted by the Owner/User following an assessment.

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44. An alloy weld overlay is applied to carbon steel base metal. What will occur? a. Cracking due to differential expansion rates b. Dilution c. Lack of Fusion d. Underbead cracking 45. An alloy weld overlay is applied to carbon steel base metal. Who has the responsibility to establish the minimum alloy requirements of the as deposited weld metal? a. API 570 Authorized Inspector b. Engineering Organization c. Owner/User d. Repair organization

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46. What is the appropriate action to take when an incorrect material is located during a PMI sampling of an inspection lot? a. Inspect 2 more items from the inspection lot. b. Inspect 50% of the items from the inspection lot. c. Inspect 100% of the items from the inspection lot. d. Inspection all items supplied by that manufacturer. e. A more extensive inspection of the lot should be considered.

47. A color code system for pipe is specified by: a. ASME B31.3. b. ASME 16.34. c. NACE 3389. d. PFI ES22.

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48. Identification of materials by color coding: a. is not an important part of the material verification program. b. is not a substitute for PMI testing. c. is important only on high alloy materials. d. should only be done by inspectors.

49. Which of the following is not required when the ownerâ&#x20AC;&#x2122;s PMI system requires physical marking of components? a. Whether the marking should remain legible for the componentâ&#x20AC;&#x2122;s life b. The name of individual doing the marking c. If colors are used, a description of color used for each alloy

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50. Marking pens should not contain chlorides or: a. Carbon. b. Chrome. c. Oxides. d. Sulfur.

51. When PMI testing is conducted on a new piping system, the documentation of the PMI results should be kept: a. until the piping system is operational. b. 1 year. c. until piping system is no longer in operation. d. until piping system is removed/scrapped. e. forever.

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1. RP 578 applies to _______________________________process piping systems covered by ASME B 31.3 and API 570 piping codes.

A. New B. Existing C. New and Existing D. None of the Above 2. RP 578 applies to ____________________________materials purchased directly or indirectly by the owner/user.

A. all materials B. metallic and non metallic C. metallic alloy D. all grades of monel

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3. Carbon steel components________________ under the Scope of RP 578.

A. are specifically covered.

B. are not specifically covered C. are optional D. none of the above 4. Any metallic material (including welding filler metals) that contains alloying elements such as chromium,nickel, or molybdenum, which are intentionally added to enhance mechanical or physical properties and/or corrosion resistance is called___________ A. A 53B pipe.

B. Austenitic material.

C. alloy material.

D. none of the above

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5. _____________________ is an organization that performs or services and directly controls one or more of the operations that affect the chemical composition or mechanical properties of a metallic material.

A. A material manufacturer B. A distributor C. A fabricator D. A owner/user 6. An organization that supplies materials 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 is a _____________.

A. distributor.

B. fabricator.

C. material supplier.

D. material manufacture.

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7. Who has the responsibility to determine the extent of examination required and to verify the material verification program is performed in accordance with RP 578?

A. engineer B. owner/user or designee C. Tim Schindler D. material supplier 8. Review and approval of the material verification program and testing procedure of the fabricator or material supplier should be done: A. Prior to PMI testing.

B. After PMI testing.

C. Any time prior to hydrotesting.

D. Both A and B.

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9. Mill Test Reports _________________considered a substitute for PMI testing.

A. and X-rays are B. should be C. should not be D. can be 10. Which of the following is an example of a pressure-containing component that makes up a fabricated piping system covered in the Material Verification Program?

A. Instruments B. dummy legs C. spring cans D. none of the above

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11. Verification of the alloy materials subsequently placed into service are as specified is a responsibility of: A. Authorized inspector B. Engineer C. Owner/User or designee D. None of the above 12. You have received a shipment of alloy electrodes and wire from your supplier. How much PMI testing should you perform?

A. Positively identify two electrodes or wire samples from each lot or package.

B. Positively identify one electrode or wire sample from each lot or package.

C. As determined by the owner/user D. No testing is required.

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13. A new section of seamed (longitudinal) alloy pipe is to be used for repairs and requires PMI testing, where should PMI testing be performed?

A. PMI the weld metal only.

B. PMI the base metal only.

C. PMI the base metal and weld metal D. No testing is required. You only need to verify the correct ASTM markings are on the pipe.

14. The lead inspector (owner/user) has decided to prioritize existing piping systems in the crude unit for PMI testing. Which is a consideration for prioritization?

A. How lucky he feels.

B. Likelihood of Failure C. Consequence of failure D. Both A and B

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15. The greatest Number of material non conformities with serious consequence have involved carbon steel components in ____________ A. non ferrous systems.

B. stainless steel systems.

C. low alloy systems.

D. non metallic systems.

16. _____________ should be considered when determining the extent of PMI testing for existing units.

A. The plant manufacturer B. The type of PMI equipment available C. The number of plant modifications D. The number of previous plant turnarounds

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17. Which is not an example of a component prioritization factor?

A. Warm-up and bypass lines on pumps or check valves.

B. Small diameter piping systems.

C. Components with ASTM stamp.

D. Components without an ASTM stamp.

18. Calibration and/or verification of the PMI test equipment should be performed: A. Before and after every use.

B. Once every quarter.

C. As determined by the AI. D. As specified the equipment manufacturer.

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19. If PMI equipment calibration/verification procedures are not provided by the equipment manufacturer,_________________ A. they should be established by the owner/user.

B. they should be established by the authorized inspector.

C. then equipment calibration is not required.

D. then a complete refund of the equipment should be obtained.

20. Personnel performing PMI testing should be: A. Trained by Tim Schindler.

B. Knowledgeable about all aspects of B31.3 and API 570.

C. Certified to ASME Sec V. D. Knowledgeable about all aspects of operation of PMI test equipment.

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21. What safety considerations are there when performing PMI testing? a. All PMI testing requires a hot work permit and a fire watch. b. Appropriate electrical permits, and hot work permits. c. Consider electrical arching and â&#x20AC;&#x153;hot spotsâ&#x20AC;?, appropriate electrical and hot work permits. d. Always test the Ground Fault interrupter.

22. What is an acceptable method of material acceptance? a. Materials can be classified through a qualitative sorting technique to establish the conformance with the intended material. b. Materials can be confirmed to contain nominal amounts of alloying elements specified in relevant materials specifications. c. Materials can be confirmed to contain nominal amounts of alloying elements specified in the written procedure. d. Both A and B

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23. You are the QA inspector of a new construction project and have been informed that some 5 Chrome fittings were PMI tested and the alloying elements are outside the ranges that allowed in the ASTM material specification, could these fittings still be used for your project? a. No, these fittings should be rejected and sent back to the supplier. b. Yes, provided they are higher than the specified ranges allowed by ASTM and a person knowledgeable of the appropriate damage mechanisms confirms that the materials will perform satisfactory in the service. c. Yes, provided a person knowledgeable of the appropriate damage mechanisms confirms that the materials will perform satisfactory in the service. d. Yes, proved the supplier signs off that the materials in question are acceptable.

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24. You are testing one representative fitting from a lot and find it rejectable, you should________.

A. consider the entire lot suspect and send it back to the supplier.

B. consider the entire lot suspect and conduct a more extensive inspection.

C. reject the bad fitting and assume the remainder of the lot is acceptable.

D. inform the manufacturer of his poor quality materials.

25. Material test reports should _______________ a. be considered a substitute for PMI testing as long as the project engineer signs off they are acceptable. b. be considered a substitute for PMI testing as long as metallurgists signs off they are acceptable. c. be considered a substitute for PMI testing when it is near the end of the project. d. not be considered a substitute for PMI testing.

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26. How long should records of PMI testing for new and existing piping systems be kept? a. Records should be kept as long as the piping system remains in the original location. b. Records should be kept until the next PMI survey is performed c. Records should be kept as long as the plant is not sold. d. None of the above.

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Chemical Laboratory Chemical Analysis

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Chemical Laboratory Chemical Analysis

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Chemical Laboratory Chemical Analysis

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