Material Verification Program for New and Existing Alloy Piping Systems
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<strong>Material</strong> <strong>Verification</strong> <strong>Program</strong> <strong>for</strong> <strong>New</strong><br />
<strong>and</strong> <strong>Existing</strong> <strong>Alloy</strong> <strong>Piping</strong> <strong>Systems</strong><br />
API RECOMMENDED PRACTICE 578<br />
2013- My exam preparation Notes<br />
新 建 和 在 职 石 油 化 工 中 设 施 - 合 金 管 道 系 统 , 材 料 验 证<br />
Charlie Chong/ Fion Zhang
Contents<br />
API578<br />
1 Scope<br />
2 Normative References<br />
3 Definitions<br />
4 Extent of <strong>Verification</strong><br />
4.1 General<br />
4.2 <strong>New</strong> Construction Quality Assurance (QA) <strong>Material</strong> <strong>Verification</strong><br />
<strong>Program</strong><br />
4.3 <strong>Material</strong> <strong>Verification</strong> <strong>Program</strong> <strong>for</strong> <strong>Existing</strong> <strong>Piping</strong> <strong>Systems</strong><br />
4.4 <strong>Material</strong> <strong>Verification</strong> <strong>Program</strong> as an Element of Maintenance<br />
<strong>Systems</strong><br />
5. <strong>Material</strong> <strong>Verification</strong> <strong>Program</strong> Test Methods<br />
5.1 <strong>Material</strong> <strong>Verification</strong> <strong>Program</strong> Test Method Objectives<br />
5.2 PMI Test Methods<br />
5.3 Equipment Calibration<br />
5.4 Equipment Precision<br />
5.5 Personnel Qualifications<br />
5.6 Safety Issues<br />
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6 Evaluation of PMI Test Results<br />
6.1 <strong>Material</strong> Acceptance Methods 6.2 Dissimilar Metal Welds <strong>and</strong> Weld<br />
Overlays<br />
6.3 Follow-up PMI Testing after Discovery of a Noncon<strong>for</strong>mity<br />
7 Marking <strong>and</strong> Recordkeeping<br />
7.1 <strong>Material</strong>s Identification Process<br />
7.2 <strong>Material</strong> Certifications<br />
7.3 Shop <strong>and</strong> Field PMI Test Documentation<br />
7.4 <strong>New</strong> <strong>and</strong> <strong>Existing</strong> <strong>Piping</strong> System Documentation<br />
7.5 PMI Test Records<br />
7.6 PMI Test Procedures<br />
7.7 Traceability to Field Components<br />
API578<br />
Fion Zhang/ Charlie Chong
There will be about 5 questions from this document on the API 570 exam<br />
API578<br />
Fion Zhang/ Charlie Chong
Fion Zhang/ Charlie Chong<br />
API578
1 Scope 范 围<br />
API578<br />
Fion Zhang/ Charlie Chong
API578<br />
1 Scope 范 围<br />
The purpose of this recommended practice (RP) is to provide the guidelines <strong>for</strong> a<br />
material <strong>and</strong> quality assurance system to verify that the nominal composition of<br />
alloy components within the pressure envelope of a piping system is consistent<br />
with the selected or specified construction materials to minimize the potential <strong>for</strong><br />
catastrophic release of toxic or hazardous liquids or vapors. This RP provides the<br />
guidelines <strong>for</strong> material control <strong>and</strong> material verification programs on ferrous <strong>and</strong><br />
nonferrous alloys during the construction, installation, maintenance, <strong>and</strong> inspection of<br />
new <strong>and</strong> existing process piping systems covered by the ASME B31.3 <strong>and</strong> API 570<br />
piping codes. This RP applies to metallic alloy materials purchased <strong>for</strong> use either<br />
directly by the owner/user or indirectly through vendors, fabricators, or contractors <strong>and</strong><br />
includes the supply, fabrication, <strong>and</strong> erection of these materials. Carbon steel<br />
components specified in new or existing piping systems are not specifically<br />
covered under the scope of this document unless minor/trace alloying elements<br />
are critical to component corrosion resistance or similar degradation.<br />
Fion Zhang/ Charlie Chong
API578<br />
Key Words:<br />
The purpose of this recommended practice (RP) is to provide the guidelines <strong>for</strong> a<br />
material <strong>and</strong> quality assurance system to verify that the nominal composition of<br />
alloy components within the pressure envelope of a piping system is consistent<br />
with the selected or specified construction materials to minimize the potential <strong>for</strong><br />
catastrophic release of toxic or hazardous liquids or vapors.<br />
这 个 建 议 RP578 的 做 法 的 目 的 质 量 保 证 体 系 的 指 导 方 针 用 于<br />
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<br />
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 .<br />
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API578<br />
API578 RP 指 导 目 的 是 确 保 设 备 新 建 , 维 修 , 改 造 时 不 会 用 错<br />
建 材 , 而 不 是 确 切 的 确 定 材 料 符 合 规 格 要 求 .<br />
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API578
API578<br />
Key Words:<br />
<strong>Alloy</strong> components within the pressure envelope<br />
适 用 压 力 包 络 线 范 围 内 的 合 金 组 件 / 受 压 合 金 组 件<br />
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API578<br />
Key Words:<br />
RP On ferrous <strong>and</strong> nonferrous alloys during the construction,<br />
installation, maintenance, <strong>and</strong> inspection of new <strong>and</strong> existing<br />
process piping systems covered by the ASME B31.3 <strong>and</strong> API<br />
570<br />
ASME B31.3 和 API 570 覆 盖 黑 色 金 属 和 有 色 金 属<br />
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API578<br />
Key Words:<br />
Carbon steel components specified in new or existing piping<br />
systems are not specifically covered under the scope of this<br />
document unless minor/trace alloying elements are critical to<br />
component corrosion resistance or similar degradation.<br />
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<br />
为 关 键 因 素 .<br />
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API578 Applicable: construction,<br />
installation, maintenance, <strong>and</strong><br />
inspection of new <strong>and</strong> existing<br />
process piping systems covered<br />
by the ASME B31.3 <strong>and</strong> API 570<br />
piping codes<br />
API578<br />
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API578<br />
This RP provides<br />
the guidelines <strong>for</strong><br />
material control <strong>and</strong><br />
material verification<br />
programs on ferrous<br />
<strong>and</strong> nonferrous<br />
alloys<br />
Carbon steel components specified in new or existing piping systems are<br />
not specifically covered under the scope of this document unless<br />
minor/trace alloying elements are critical to component corrosion resistance<br />
or similar degradation.<br />
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API578
API578<br />
API578 Section 1:<br />
• 覆 盖 ASME B31.3 和 API 570 黑 色 金 属 和 有 色 金 属<br />
• 适 用 受 压 范 围 内 的 合 金 组 件<br />
• 不 具 体 涉 及 碳 钢 组 件 - 除 非 轻 微 / 微 量 合 金 元 素 对 组 件 的 耐<br />
腐 蚀 性 作 为 关 键 因 素 .<br />
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API578<br />
2 Normative References 规 范 性 引 用 文 件<br />
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API578<br />
2 Normative References 规 范 性 引 用 文 件<br />
• API 570, <strong>Piping</strong> Inspection Code: Inspection, Repair, <strong>and</strong> Rerating of In-service <strong>Piping</strong> <strong>Systems</strong><br />
• API Publ 581, Risk-Based Inspection—Base Resource Document<br />
• API RP 571, Damage Mechanisms Affecting Fixed Equipment In the Refining Industry<br />
• API RP 939-C, Guidelines <strong>for</strong> Avoiding Sulfidation Corrosion Failures in Oil Refineries<br />
• ASME Boiler <strong>and</strong> Pressure Vessel Code: Section II, <strong>Material</strong> Specifications Part A, Ferrous<br />
<strong>Material</strong>s Part B, Nonferrous <strong>Material</strong>s Part C, Welding Rods, Electrodes, <strong>and</strong> Filler Metals<br />
• ASME B31.3, Process <strong>Piping</strong><br />
• CSB Chemical Safety Board Bulletin 2005-04-B, “Positive <strong>Material</strong> <strong>Verification</strong>: Prevent Errors<br />
During <strong>Alloy</strong> Steel <strong>Systems</strong> Maintenance”<br />
• NACE Paper No 03651, “Specification <strong>for</strong> Carbon Steel <strong>Material</strong>s <strong>for</strong> Hydrofluoric Acid<br />
Alkylation Units”<br />
• PFI ES22, Recommended Practice <strong>for</strong> Color Coding of <strong>Piping</strong> <strong>Material</strong>s<br />
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3 Definitions<br />
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3.1<br />
alloy material<br />
Any metallic material (including welding filler materials) that contain alloying elements<br />
that are intentionally added to enhance mechanical or physical properties <strong>and</strong> corrosion<br />
resistance, or a combination thereof (e.g. Chromium, Nickel, or Molybdenum).<br />
API578<br />
3.2<br />
distributor<br />
A warehousing supplier <strong>for</strong> one or more manufacturers or suppliers of alloy materials or<br />
components.<br />
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3.3<br />
fabricator<br />
One who fabricates piping systems or portions of a piping system as defined by ASME<br />
B31.3.<br />
API578<br />
3.4<br />
inspection lot<br />
A group of items or materials of the same type from a common source from which a<br />
sample is to be drawn <strong>for</strong> examination.<br />
NOTE An inspection lot does not include items from more than one heat.<br />
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3.5<br />
level of examination<br />
The specified percentage of the number of components (or weldments when specified)<br />
to be examined in an inspection lot.<br />
3.6<br />
lot size<br />
The number of items available in the inspection lot at the time a representative sample<br />
is selected.<br />
3.7<br />
material manufacturer 材 料 制 造 商<br />
An organization that per<strong>for</strong>ms or supervises <strong>and</strong> directly controls one or more of the<br />
operations that affect the chemical composition or mechanical properties of a metallic<br />
material.<br />
3.8<br />
material noncon<strong>for</strong>mance<br />
A positive material identification (PMI) test result that is not consistent with the selected<br />
or specified alloy.<br />
API578<br />
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3.9<br />
material supplier 材 料 供 应 商<br />
An organization that supplies material furnished <strong>and</strong> certified by a material<br />
manufacturer, but does not per<strong>for</strong>m any operation intended to alter the material<br />
properties required by the applicable material specification.<br />
3.10<br />
material verification program<br />
A documented quality assurance procedure used to assess metallic alloy materials<br />
(including weldments <strong>and</strong> attachments where specified) to verify con<strong>for</strong>mance with<br />
the selected or specified alloy material designated by the owner/user.<br />
NOTE This program may include a description of methods <strong>for</strong> alloy material testing,<br />
physical component marking, <strong>and</strong> program<br />
record-keeping.<br />
API578<br />
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3.11<br />
mill test report<br />
A certified document that permits each component to be identified according to the<br />
original heat of material from which it was produced <strong>and</strong> identifies the applicable<br />
material specification (including documentation of all test results required by the<br />
material specification).<br />
3.12<br />
owner/user<br />
An owner or user of piping systems who exercises control over the operation,<br />
engineering, inspection, repair, alteration, testing, <strong>and</strong> rerating of those piping<br />
systems.<br />
3.13<br />
positive material identification (PMI) testing<br />
Any physical evaluation or test of a material to confirm that the material which has<br />
been or will be placed into service is consistent with the selected or specified alloy<br />
material designated by the owner/user. These evaluations or tests may provide<br />
either qualitative or quantitative in<strong>for</strong>mation that is sufficient to verify the nominal<br />
alloy composition.<br />
API578<br />
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3.14<br />
pressure-containing components<br />
Items that <strong>for</strong>m the pressure-containing envelope of the piping system.<br />
3.15<br />
r<strong>and</strong>om<br />
Selection process by which choices are made in an arbitrary <strong>and</strong> unbiased manner.<br />
3.16<br />
representative sample<br />
One or more items selected at r<strong>and</strong>om from the inspection lot that are to be examined to<br />
determine acceptability of the inspection lot.<br />
3.17<br />
st<strong>and</strong>ard reference materials<br />
Sample materials <strong>for</strong> which laboratory chemical analysis data are available <strong>and</strong> are used<br />
in demonstrating test instrument accuracy <strong>and</strong> reliability.<br />
API578<br />
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4 Extent of <strong>Verification</strong> 验 证 程 度<br />
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API578<br />
4 Extent of <strong>Verification</strong><br />
4.1 General<br />
The owner/user should establish a written material verification program indicating<br />
the extent <strong>and</strong> type of PMI testing to be conducted during the construction of new<br />
piping systems, retroactively on existing piping systems, <strong>and</strong> during the<br />
maintenance, repair, or alteration of existing piping systems.<br />
For higher-risk systems, the owner/user should consider the need <strong>for</strong> employing a<br />
higher percentage of examination (up to 100 %) rather than r<strong>and</strong>om sampling<br />
which may be more appropriate <strong>for</strong> lower-risk systems. Inadvertent material<br />
substitution problems tend to be sporadic; there<strong>for</strong>e, small sample sizes may not<br />
locate all inadvertent alloy substitutions. The owner/user should also consider the<br />
need to conduct examinations after fabrication is complete, to ensure that<br />
incorrect substitutions did not occur at the work site.<br />
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API578<br />
4 Extent of <strong>Verification</strong> 验 证 程 度<br />
4.1 General 大 纲<br />
这 里 提 了 三 次 Owner/User<br />
• 建 立 的 一 种 书 面 材 料 验 证 程 序 覆 盖 新 建 , 在 职 , 维 修 , 改<br />
造 , 新 建 后 复 查 是 业 主 / 用 户 的 责 任 .<br />
• 规 定 验 证 的 程 度 (%) 和 类 型 也 是 业 主 / 用 户 的 责 任<br />
• 材 料 替 换 的 问 题 往 往 是 零 星 , 小 样 本 抽 样 验 证 可 能 无 法<br />
找 到 所 有 问 题 .<br />
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API578<br />
4.1.1 <strong>Alloy</strong> Substitutions in Carbon Steel <strong>Systems</strong> 碳 钢 合 金 中 的 替 换<br />
When determining the need to per<strong>for</strong>m material verification on carbon steel<br />
systems, the owner/user should evaluate the effect that the process stream could<br />
have on substituted alloy materials. In some cases, the substitution of<br />
hardenable alloy materials in carbon steel piping systems resulted in failure <strong>and</strong><br />
loss of containment. Examples of such systems include wet hydrogen sulfide (H 2<br />
S),<br />
hydrofluoric acid (HF), <strong>and</strong> sulfuric acid (H 2<br />
S0 4<br />
) services.<br />
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<br />
钢 合 金 材 料 的 影 响<br />
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API578<br />
4.2 <strong>New</strong> Construction Quality Assurance (QA) <strong>Material</strong> <strong>Verification</strong><br />
<strong>Program</strong> 新 施 工 PMI 质 量 保 证<br />
确 保 验 证 程 序 是 按 照 RP 要 求 - 责 任 是 业 主 / 用 户<br />
This section covers alloy piping during fabrication either in the shop or in the<br />
field prior to the items being placed into service <strong>and</strong> is restricted to the<br />
pressure-containing boundaries.<br />
此 RP 受 限 制 于 压 力 的 含 边 界 的 管 道 与 其 组 件<br />
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API578<br />
4.2.1 Roles <strong>and</strong> Responsibilities 角 色 和 职 责<br />
A material verification program <strong>for</strong> piping systems may involve participation of<br />
several groups within the operating plant or the shop of a contractor, vendor, or<br />
fabricator. When establishing a material verification program, consideration should<br />
be given to the roles <strong>and</strong> responsibilities that each group has within the specific<br />
organization. These roles <strong>and</strong> responsibilities should be clearly defined <strong>and</strong><br />
documented. Within the operating plant, this can include those groups responsible<br />
<strong>for</strong> purchasing, engineering, warehousing /receiving, operations, reliability,<br />
maintenance, <strong>and</strong> inspection. It is the responsibility of the owner/user or designee to<br />
determine the extent of examination required <strong>and</strong> to verify that the implementation<br />
<strong>and</strong> conduct of the material verification program is properly per<strong>for</strong>med in accordance<br />
with this RP. It is also the responsibility of the owner/user to verify that the alloy<br />
materials subsequently placed into service are as specified, <strong>and</strong> that the<br />
documentation of the material verification program is in accordance with this RP.<br />
确 保 PMI 验 证 程 序 按 照 RP 要<br />
求 - 是 业 主 / 用 户 责 任<br />
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API578<br />
管 道 系 统 的 材 料 验<br />
证 程 序 可 能 涉 及 几<br />
组 单 位 或 地 点 , 比 如<br />
;<br />
承 建 方 , 供 应 方 , 储<br />
存 商 或 建 造 方 在 不<br />
同 的 地 点 执 行 PMI<br />
检 验 。<br />
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4.2.2 <strong>Material</strong> <strong>Verification</strong> Test Procedure Review<br />
When PMI testing is per<strong>for</strong>med by the material supplier or third-party agency, the<br />
owner/user or designee should review <strong>and</strong> approve the adequacy of the material<br />
verification program <strong>and</strong> testing procedure of the fabricator or<br />
material supplier prior to testing.<br />
4.2.3 Scheduling of <strong>Material</strong> <strong>Verification</strong> Testing<br />
PMI testing should be per<strong>for</strong>med at the point in time that ensures that proper alloy<br />
materials have been used in the fabrication of an identifiable assembly.<br />
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<br />
确 保 程 序 和 测 试 程 序 符 合 RP 要 求<br />
PMI 应 当 在 适 当 的 时 间 进 行 .<br />
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API578<br />
4.2.4 Mill Test Report<br />
Mill test reports should not be considered a substitute <strong>for</strong> a PMI test.<br />
However, mill test reports are an important part of an overall material<br />
quality assurance program.<br />
材 质 证 书 虽 然 是 整 体 材 料 的 质 量 保 证 计 划 的 重 要 组 成 部<br />
分 但 不 能 作 为 替 代 的 PMI 测 试 的 根 据 .<br />
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API578<br />
4.2.5 Components Covered in a <strong>Material</strong> <strong>Verification</strong> <strong>Program</strong><br />
Examples of pressure-containing components that make up fabricated piping<br />
systems that are covered by this RP include:<br />
a) pipe lengths;<br />
b) pipe fittings, such as tees, elbows, reducers, special pipe components, blinds <strong>and</strong><br />
plugs;<br />
c) flanges;<br />
d) special <strong>for</strong>gings;<br />
e) process valves (including control valves) <strong>and</strong> relief valves;<br />
f) pressure-containing welds;<br />
g) instruments (all pressure containing parts);<br />
h) weld overlays or cladding;<br />
i) bolting;<br />
j) expansion joints <strong>and</strong> bellows;<br />
k) gaskets.<br />
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4.2.6 PMI Testing of Welding Consumables 焊 材 测 试<br />
When welding is conducted, one electrode or wire sample from each lot or<br />
package of alloy weld rod should be positively identified. The remainder of the<br />
lot should be compared to the sample to verify that the markings of the<br />
wires/electrodes are correct. Some weld rods have the alloying elements<br />
contained in the flux, <strong>and</strong> do not meet the alloy specification until welded. PMI<br />
testing of weld metal (e.g. deposited weld metal or undiluted weld “buttons”) is<br />
a permissible alternative to PMI testing of an electrode or wire sample provided<br />
it is conducted immediately prior to welding or during the welding process.<br />
API578<br />
• 从 每 批 或 ” 包 裹 ” 合 金 焊 材 , 一 支 焊 条 或 金 属 丝 样 品 取 样 做 PMI<br />
测 试 .<br />
• 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<br />
稀 释 焊 接 “ 按 钮 ”) 的 PMI 测 试 (2013 June)<br />
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4.2.6.1 Longitudinal Pipe <strong>and</strong> Fitting Welds<br />
Where there is reason to suspect problems, longitudinally welded alloy pipe <strong>and</strong><br />
fittings should receive r<strong>and</strong>om PMI testing verification of the base metal <strong>and</strong> weld<br />
metal.<br />
4.2.6.2 Autogenous Welds<br />
If the owner/user determines that material verification testing is required on<br />
autogenous-welded (with no added filler metal) alloy pipe or fittings, it is necessary to<br />
conduct testing on only the base metal.<br />
4.2.7 PMI Testing of Components Supplied by a Distributor<br />
A higher degree of PMI testing verification should be conducted on alloy material<br />
supplied by stocking distributors due to the potential <strong>for</strong> material mix-ups as a result<br />
of h<strong>and</strong>ling.<br />
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Longitudinal Pipe <strong>and</strong> Fitting Welds 直 缝 钢 管 及 管 件 的 焊 缝<br />
API578<br />
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自 体 焊 缝<br />
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stocking distributors 材 料 存 库 商<br />
A higher degree of PMI<br />
testing verification should<br />
be conducted on alloy<br />
material supplied by<br />
stocking distributors due to<br />
the potential <strong>for</strong> material<br />
mix-ups as a result of<br />
h<strong>and</strong>ling.<br />
对 材 料 存 库 商 提 供 的 受<br />
压 管 道 与 配 件 应 当 采 取<br />
较 高 PMI 测 试 验 证 因 潜 在<br />
的 材 料 混 乱 .<br />
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API578<br />
API578 Section 4.2: 新 建 设 的 设 备 ( 小 结 )<br />
• 确 保 PMI 验 证 程 序 按 照 RP 要 求 - 是 业 主 / 用 户 责 任 .<br />
• 实 际 的 PMI 操 作 工 作 可 以 是 项 目 任 何 参 与 方 或 在 地 点 执 行 .<br />
• 应 当 及 时 的 执 行 PMI 检 测 .<br />
• 只 适 用 受 压 管 道 与 相 关 组 件 .<br />
• Section 4.2.5 提 示 , 法 兰 垫 圈 (gasket) 与 螺 栓 (bolting) 定 义 为 受 压 组 件 .<br />
Fion Zhang/ Charlie Chong
4.3 <strong>Material</strong> <strong>Verification</strong> <strong>Program</strong> <strong>for</strong> <strong>Existing</strong> <strong>Piping</strong> <strong>Systems</strong><br />
4.3.1 General<br />
This section covers alloy piping systems that are already in service where the<br />
material verification program procedures <strong>for</strong> the construction were not in<br />
accordance with 4.2. <strong>Material</strong> verification is limited to the pressure containing<br />
components <strong>and</strong> their attachment welds. It is important to recognize that previous<br />
maintenance activities, as well as new construction practices, may influence the<br />
likelihood of inadvertent materials substitutions.<br />
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4.3.2 Responsibilities<br />
The owner/user is responsible <strong>for</strong> determining if a retroactive material verification<br />
program is appropriate <strong>for</strong> each existing piping system, <strong>for</strong> prioritizing the piping<br />
systems to receive retroactive PMI testing, <strong>and</strong> <strong>for</strong> determining the extent of PMI<br />
testing required.<br />
Section 4.3 是 关 于 在 职 管 道 在 新 建 时<br />
PMI 没 完 全 按 照 4.2 要 求 执 行 的 检 测 .<br />
应 当 考 虑 的 有 , 维 修 与 改 造 的 材 料 替<br />
代 的 可 能 性 . 4.3.2 再 一 次 重 申 业 主 /<br />
用 户 的 全 部 职 责 .<br />
Fion Zhang/ Charlie Chong
4.3.3 Prioritizing <strong>Piping</strong> <strong>Systems</strong> <strong>for</strong> Retroactive PMI Testing<br />
If the owner/user elects to prioritize piping systems <strong>for</strong> the material verification program<br />
or needs to determine whether PMI testing is needed at all, the owner/user should<br />
consider the following.<br />
如 业 主 / 用 户 对 管 道 系 统 PMI 优 先 次 序 时 , 以 下 为 考 虑 因 素 ;<br />
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a) Likelihood of a material mix-up during previous project <strong>and</strong> maintenance activities. A<br />
key factor is the effectiveness of the material verification program at the time of these<br />
activities. 以 前 的 项 目 和 维 护 活 动 期 间 的 材 料 混 合 的 可 能 性<br />
b) Consequences of a failure. Some factors to be considered include flammability, fire<br />
potential, toxicity, proximity to other equipment or community, temperature, pressure,<br />
mode of failure, <strong>and</strong> size of release. 出 现 故 障 的 后 果<br />
c) Reason <strong>for</strong> alloy specification (i.e. corrosion resistance or product purity). 合 金 规 范 的<br />
原 因<br />
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d) Historical data relating to inadvertent material substitutions. This may be related to<br />
previous experience with material noncon<strong>for</strong>mities in the process unit or within the<br />
operating plant. 有 关 意 外 的 材 料 替 代 的 历 史 数 据<br />
Taken together, these factors can be used to determine the risk associated with<br />
possible material non-con<strong>for</strong>mances in a piping system. The owner/user should<br />
establish a methodology <strong>for</strong> estimating the relative priority <strong>for</strong> PMI testing of various<br />
piping circuits within a given unit. This methodology may be based on qualitative or<br />
quantitative risk analysis. API 581 discusses several risk-based approaches <strong>and</strong> the<br />
factors that should be considered when conducting a risk analysis such as material,<br />
service conditions, service fluid, <strong>and</strong> mode of failure.<br />
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<br />
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 .<br />
Fion Zhang/ Charlie Chong
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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<br />
分 析 做 法<br />
14. The lead inspector (owner/user) has decided to prioritize existing piping<br />
systems in the crude unit <strong>for</strong> PMI testing. Which is a consideration <strong>for</strong> prioritization?<br />
A. How lucky he feels.<br />
B. Likelihood of Failure<br />
C. Consequence of failure<br />
D. Both A <strong>and</strong> B<br />
Fion Zhang/ Charlie Chong
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API 581 discusses several riskbased<br />
approaches <strong>and</strong> the factors<br />
that should be considered when<br />
conducting a risk analysis such as<br />
material, service conditions, service<br />
fluid, <strong>and</strong> mode of failure.<br />
API581 定 性 或 定 量 的 风 险 分 析 方 法 也<br />
可 以 作 为 评 估 手 段 .<br />
Fion Zhang/ Charlie Chong
4.3.3.1 Carbon Steel Substitutions in Low <strong>Alloy</strong> Steel <strong>Systems</strong><br />
In determining the likelihood of material non-con<strong>for</strong>mances, it is worth noting that<br />
historically the greatest number of material non-con<strong>for</strong>mances with serious<br />
consequences have involved carbon steel components in low alloy steel (e.g. 1 ¼<br />
Cr– ½ Mo, 2 ¼ Cr–1 Mo, 5 Cr– ½ Mo, 9 Cr–1 Mo) piping systems. There have been<br />
fewer non-con<strong>for</strong>mances in stainless steel <strong>and</strong> nonferrous (e.g. Monel, Inconel)<br />
systems because of appearance <strong>and</strong> weldability issues.<br />
4.3.3.2 Residual Elements In Carbon Steels In Hydrofluoric Acid Alkylation<br />
Units 氢 氟 酸 烷 基 化 装 置<br />
Carbon steels in some specific locations in HF acid service have been reported to<br />
suffer increased corrosion rates based on the residual elements (RE) (i.e. C, Ni, Cr,<br />
<strong>and</strong> Cu) in the steels, <strong>and</strong> is discussed in API 751. PMI methods can be used to<br />
assess the potential <strong>for</strong> enhanced corrosion in HF service. Consideration should be<br />
given to the ability of the PMI method to detect the various elemental concentrations.<br />
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Fion Zhang/ Charlie Chong
API571/ 5.1.1.6 Hydrofluoric (HF) Acid Corrosion<br />
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In carbon steel, residual<br />
elements ( %C, %Cu, %Ni,<br />
%Cr) may accelerate corrosion<br />
in certain parts of the unit but<br />
industry recommended<br />
guidelines have not been<br />
<strong>for</strong>mally developed. Some<br />
users limit the total Residual<br />
Element (RE) content to 0.20%<br />
maximum, where RE= %Cu +<br />
%Ni +%Cr. See Figure 5-5.<br />
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It is worth noting that historically the greatest number of material noncon<strong>for</strong>mances<br />
with serious consequences have involved carbon steel<br />
components in low alloy steel<br />
因 普 通 碳 钢 和 低 合 金 钢 的 外 观 一 致 , 这 导 致 绝 大 多 数 的 材<br />
料 不 符 合 造 成 重 大 后 果 .<br />
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Fion Zhang/ Charlie Chong<br />
API578
4.3.3.3 Gasket <strong>Material</strong>s 垫 片 材 料<br />
Incorrect gasket materials in incompatible service may cause premature failings. The<br />
main principles outlined in this document can be applied to gasket materials. The<br />
owner/user is required to ascertain the potential material variations <strong>and</strong> select<br />
analytical methods capable of providing the required data. The actual test procedures<br />
can be more detailed due to the geometric structure of the gasket materials.<br />
4.3.3.4 Process Units Susceptible To Sulfidation. 容 易 硫 化 工 艺 装 置<br />
Carbon steels with low silicon (< 0.10 %) content can corrode at an accelerated rate<br />
when exposed to hydrogen-free sulfidation conditions. These phenomena are<br />
discussed more extensively in AP 571 <strong>and</strong> API 939-C. Owner/users with assets at risk<br />
from this type of degradation should consider the risks <strong>and</strong> the requirements to apply<br />
PMI control in order to determine Silicon levels <strong>and</strong> the extent to which the material<br />
may corrode.<br />
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Sulfidation<br />
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4.3.3.5 Other Factors to Consider When Prioritizing <strong>Piping</strong> <strong>Systems</strong><br />
Site-specific or experienced-based factors should be considered when prioritizing<br />
piping systems. Factors to consider include the following.<br />
a) Construction <strong>and</strong> maintenance practices. In assessing the likelihood of<br />
material non-con<strong>for</strong>mances, the owner/user should also consider the materials<br />
h<strong>and</strong>ling, material control, <strong>and</strong> any PMI testing procedures followed during<br />
construction of the process unit. Process-unit maintenance procedures are<br />
also important. Process units in which rigorous procedures <strong>for</strong> material<br />
verification are used would be expected to have a lower likelihood of noncon<strong>for</strong>mances.<br />
前 期 的 投 入 与 检 测 范 围 .<br />
b) Reason <strong>for</strong> the alloy specification. In some cases, alloys are used in piping<br />
systems <strong>for</strong> reasons other than corrosion resistance or structural integrity. In<br />
these cases, the structural integrity of the system would not be harmed by<br />
material non-con<strong>for</strong>mances. A material verification program may not be<br />
necessary in these systems. An example would be stainless steel lube oil<br />
systems in which stainless steel is used <strong>for</strong> maintaining oil purity. 合 金 规 格 的 目<br />
的 .<br />
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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 ;<br />
• 前 期 的 投 入 与 检 测 深 度<br />
• 合 金 规 格 的 目 的<br />
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4.3.4 Component Prioritization Factors 组 件 的 优 先 次 序 因 素<br />
Based on experience, some types of piping system components can have a higher<br />
likelihood of inadvertent substitution of a non-specified material. This can provide<br />
a basis <strong>for</strong> prioritizing specific equipment in a given system or process unit.<br />
Examples are: 不 慎 替 代 的 可 能 性 较 高 受 压 组 件 有 ;<br />
a) warm-up <strong>and</strong> bypass lines on pumps or check valves; 加 热 或 旁 路 管 道<br />
b) small diameter piping systems, including welds, with a diameter less than or equal<br />
to 2 in. (50 mm); 小 直 径 的 管 道 系 统<br />
c) valves <strong>and</strong> other removable devices such as rupture discs, spacer blinds, or ring<br />
joint gaskets; 可 拆 卸 受 压 组 件<br />
d) thermowells; 承 插 式 温 度 计<br />
e) bolting; 螺 栓<br />
f) piping as a part of a packaged system; 成 套 管 路 系 统<br />
g) components without an ASTM stamp; 不 带 ASTM 标 记 的 组 件<br />
h) specific process systems with corrosion issues (e.g. residual elements in Carbon<br />
Steels in HF Acid service or high Silicon content in potential sulfidation conditions).<br />
特 定 的 腐 蚀 机 理 受 压 工 艺 系 统<br />
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Fion Zhang/ Charlie Chong
API578 对 以 下 两 种 损 坏 机 理 特 别 的 描 述 :<br />
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specific process systems with corrosion issues (e.g. residual elements in Carbon<br />
Steels in HF Acid service or high Silicon content in potential sulfidation conditions).<br />
特 定 的 腐 蚀 机 理 受 压 工 艺 系 统<br />
• Residual elements in Carbon Steels in HF Acid service 氢 氟 酸<br />
腐 蚀 机 理<br />
• Silicon content in potential sulfidation conditions<br />
硫 化 腐 蚀 机 理<br />
Fion Zhang/ Charlie Chong
API578<br />
硫 化 腐 蚀 机 理<br />
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<br />
Sulfidic corrosion of piping <strong>and</strong> equipment within the refining industry continues to<br />
be a significant cause of leaks <strong>and</strong> issues that can lead to early replacements,<br />
unplanned outages, <strong>and</strong> incidents potentially resulting in loss of property <strong>and</strong><br />
injury to workers. Carbon steels with low silicon (
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4.3.5 Factors to Consider When Determining the Extent of PMI Testing<br />
设 定 PMI 测 试 的 范 围 应 当 考 虑 因 素<br />
The owner/user should determine the extent of PMI testing. Factors to consider<br />
when determining the extent of PMI testing <strong>for</strong> an existing process unit include:<br />
a) Historical inspection <strong>and</strong> material verification program records, 历 史 记 录<br />
b) Number of plant modifications, 改 造 数 次<br />
c) <strong>Material</strong>s control during original construction <strong>and</strong> during modifications, 改 造 或<br />
新 建 时 对 材 料 管 理 的 有 效 性<br />
d) <strong>Material</strong> verification program quality during construction <strong>and</strong> fabrication, 改 造 或<br />
新 建 时 对 材 料 PMI 管 理 的 有 效 性<br />
e) Consequence of release, 释 放 的 后 果<br />
f) Likelihood of corrosion/degradation. 腐 蚀 / 降 解 的 可 能 性<br />
Fion Zhang/ Charlie Chong
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API578 Section 4.3:<br />
现 有 的 管 道 系 统 的 材 料 验 证 程 序 ( 小 结 )<br />
• 容 易 被 硫 化 工 艺 装 置 - 碳 钢 PMI 考 虑 因 素 : Si ( 硅 含 量 )<br />
• 氢 氟 酸 烷 基 化 装 置 - 碳 钢 PMI 考 虑 因 素 : Re ( 残 余 成 分 )<br />
• API581 定 性 或 定 量 的 风 险 分 析 方 法 也 可 以 作 为 评 估 手 段 .<br />
• 4.3.5 列 出 PMI 测 试 程 度 应 当 考 虑 的 因 素 .<br />
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4.4 <strong>Material</strong> <strong>Verification</strong> <strong>Program</strong> as an Element of Maintenance <strong>Systems</strong><br />
The principles associated with materials verification as part of a new piping installation<br />
should also be applied to provide confidence that proper materials are being used as<br />
part of maintenance activities. The concepts noted previously in 4.2 <strong>and</strong> API 570<br />
should be reviewed <strong>and</strong> applied as applicable to the maintenance function.<br />
4.4.1 Responsibilities<br />
It is the responsibility of the owner/user to evaluate maintenance systems so that<br />
material verification programs can be designed <strong>and</strong> implemented to effectively support<br />
the mechanical integrity of alloy piping systems. The owner/user should establish a<br />
written procedure <strong>for</strong> the material verification program to be used <strong>for</strong> repair of piping<br />
systems during maintenance outages. This procedure should be documented by the<br />
owner/user.<br />
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<br />
划 与 程 序 作 为 维 护 系 统 的 因 素 .<br />
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业 主 / 用 户 职 责 :<br />
业 主 / 用 户 应 当 确 保 在 维 修 , 改 造 时 , 正 确 的 材 料 应 用 作<br />
为 维 修 / 维 护 / 改 造 管 理 系 统 的 基 本 元 素 .<br />
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4.4.2 Control of Incoming <strong>Material</strong>s <strong>and</strong> Warehousing<br />
来 料 和 仓 储 的 控 制<br />
A material verification program should be directly applied to activities associated with<br />
receiving alloy materials into warehouse systems. PMI testing may be per<strong>for</strong>med as<br />
part of this receiving function, or, when appropriate, may be per<strong>for</strong>med at the supplier’s<br />
location as a condition of release <strong>for</strong> shipment. The material verification program that is<br />
adopted should provide <strong>for</strong> proper documentation <strong>and</strong> methods <strong>for</strong> indicating which<br />
materials have been tested <strong>and</strong> are approved <strong>for</strong> use.<br />
The use of material verification program principles to check materials received into a<br />
warehouse system should be regarded as a quality assurance practice to minimize the<br />
potential <strong>for</strong> discovering an alloy material discrepancy during subsequent PMI testing.<br />
PMI testing within the warehouse should not be regarded as an alternative to PMI<br />
testing of the fabricated piping system when testing is specified. , 制 造 管 道 系 统<br />
指 定 测 试 时 , 仓 库 内 的 测 试 不 能 被 视 为 作 为 一 种 替 代<br />
API578<br />
Fion Zhang/ Charlie Chong
API578<br />
PMI testing within the warehouse should not be regarded as an<br />
alternative to PMI testing of the fabricated piping system when<br />
testing is specified. , 当 制 造 管 道 系 统 指 定 PMI 测 试 时 , 仓 库 内<br />
的 PMI 测 试 不 应 该 被 视 为 作 为 一 种 替 代 .<br />
Fion Zhang/ Charlie Chong
API578<br />
当 制 造 管 道 系 统 指 定 PMI 测 试 时 ,<br />
仓 库 内 的 PMI 测 试 不 应 该 被 视 为 作<br />
为 一 种 替 代 .<br />
Fion Zhang/ Charlie Chong
API578<br />
当 制 造 管 道 系 统 指 定 PMI 测 试 时 ,<br />
仓 库 内 的 PMI 测 试 不 应 该 被 视 为 作<br />
为 一 种 替 代 .<br />
Fion Zhang/ Charlie Chong
4.4.3 Maintenance Activities of <strong>Piping</strong> <strong>Systems</strong> 管 路 系 统 的 维 护 活 动<br />
There are a number of in-service maintenance activities where material verification<br />
should be established. Temporary removal of spool pieces needs to be managed in<br />
such a way that material mix-ups cannot occur. Incidents have occurred when same<br />
size spool pieces have been removed during turnarounds <strong>and</strong> substituted into the<br />
wrong locations during installation. Consideration shall be given to a firm control<br />
system or a verification prior to reinstallation to prevent these incidences occurring. A<br />
process where a system of ‘tagging’ spools as they are removed to ensure correct<br />
replacement should be considered It is important that repair procedures include<br />
consideration of PMI testing as part of obtaining satisfactory alloy materials to be used<br />
<strong>for</strong> the repair. As appropriate, this may include any of the components noted in 4.2.5.<br />
Much of this can be controlled through awareness of the issues at all levels within the<br />
repair process. Consulting with an inspector prior to commencement of work can<br />
ensure that systems, processes <strong>and</strong> activities are in place to ensure good material<br />
control.<br />
API578<br />
当 执 行 管 路 系 统 的 维 修 / 改 造 / 维 护<br />
时 , 错 误 的 材 料 替 代 往 往 会 发 生 , 有<br />
效 的 防 备 包 括 对 临 时 管 路 执 行 ” 标<br />
签 管 理 ”, 新 建 材 料 PMI 测 试 等 手 段 .<br />
Fion Zhang/ Charlie Chong
API578<br />
5 <strong>Material</strong> <strong>Verification</strong> <strong>Program</strong> Test Methods<br />
材 料 验 证 程 序 测 试 方 法<br />
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5.1 <strong>Material</strong> <strong>Verification</strong> <strong>Program</strong> Test Method Objectives<br />
The test methods outlined in this RP are intended to identify alloy materials <strong>and</strong> are<br />
not intended to establish the exact con<strong>for</strong>mance of a material to a particular alloy<br />
specification. Depending on the test method selected, the PMI test method may<br />
identify the nominal composition of alloy materials. Identification of materials by<br />
visual stamps/ markings alone should not be considered as a substitute <strong>for</strong> PMI<br />
testing but may be an important component of an overall quality assurance<br />
program.<br />
• 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<br />
定 的 合 金 化 学 成 分 和 标 准 规 格 要 求 .<br />
• 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 .<br />
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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<br />
建 材 , 而 不 是 确 切 的 确 定 材 料 符 合 规 格 要 求 .<br />
Fion Zhang/ Charlie Chong
5.2 PMI Test Methods PMI 测 试 方 法<br />
5.2.1 General<br />
A variety of PMI test methods are available to determine the identity of alloy materials.<br />
The primary methods include (1) portable X-ray fluorescence 便 携 式 X 射 线 荧 光 , (2)<br />
portable optical emission spectroscopy 便 携 式 发 射 光 谱 , <strong>and</strong> (3) laboratory chemical<br />
analysis 实 验 室 化 学 分 析 . A description of several test methods is listed below.<br />
In addition to these methods, there are a variety of alloy sorting techniques that may be<br />
appropriate <strong>for</strong> the purposes of this RP including magnetic testing 磁 力 检 测 to<br />
differentiate between ferritic <strong>and</strong> austenitic materials. It is important that users verify<br />
what the objectives <strong>and</strong> accuracies are required from the PMI tool they wish to use. All<br />
of the tools have benefits <strong>and</strong> limitations on the elements they can or cannot detect, in<br />
addition to the accuracy <strong>and</strong> ability to differentiate between different material grades<br />
which have only slight variations in alloying elements.<br />
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5.2.2 Portable X-ray Fluorescence 便 携 式 X 射 线 荧 光<br />
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There are several variants of portable X-ray fluorescence (XRF) spectrometers<br />
available. The principle of operation is that one or more gamma ray or X-ray sources<br />
are used to generate a beam of low energy radiation to excite the material under<br />
analysis. The material under analysis then emits a characteristic radiation spectrum<br />
which can be analyzed both qualitatively <strong>and</strong> quantitatively to determine which<br />
elements are present <strong>and</strong> in what quantity. The results of this analysis can be<br />
reported in either or both of the following <strong>for</strong>mats.<br />
a) as a match against one of many reference spectra stored in the instrument, i.e. 316<br />
stainless steel or 5 Cr – 1⁄2 Mo steel;<br />
b) each element present is reported as a percentage.<br />
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Because of the inherent limitations of the technique it is not possible to detect all<br />
elements. XRF analyzers are capable of detecting elements from Ti to U in the<br />
periodic tables. This may exclude some of the important elements in carbon steels<br />
such as C, Si, <strong>and</strong> S. In addition many analyzers are sold with basic element<br />
packages so it is important to decide exactly what elemental analysis is required <strong>and</strong><br />
select an appropriate instrument.<br />
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XRF method 便 携 式 X 射 线 荧 光<br />
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http://inspectioneering.com/content/2013-03-<br />
01/3226/xrf-inspection-of-piping-syste<br />
http://www.squareoneinspection.<br />
com/XRF_Drywall.html<br />
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Portable X-ray Fluorescence 便 携 式 X 射 线 荧 光<br />
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Limitation: 限 制 因 素<br />
This may exclude some of the important elements in carbon steels such as<br />
C, Si, <strong>and</strong> S.<br />
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5.2.3 Portable Optical Emission Spectrometry 便 携 式 发 射 光 谱<br />
An electric arc stimulates atoms in the test sample to emit a characteristic spectrum<br />
of light <strong>for</strong> each element in the sample. The combined light spectra from different<br />
elements are passed through a light guide to the optical analyzer. In the analyzer,<br />
the light is dispersed into its spectral components, <strong>and</strong> then measured <strong>and</strong> evaluated<br />
against stored calibration curves. These devices fall into two groups;<br />
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the first being a light portable <strong>and</strong> operator evaluated device that can typically<br />
identify up to 16 elements but depends upon operator evaluation of a light spectra.<br />
These devices do not directly indicate alloy grade or composition, but produce an<br />
output in the <strong>for</strong>m of visible light spectra that permits semi qualitative alloy<br />
identification The technique is also sensitive to operator skill <strong>and</strong> experience.<br />
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The second group are field portable laboratory grade analyzers. These were<br />
originally difficult to use due to their size <strong>and</strong> weight. Modern units are now available<br />
weighing only 33 lbs including small Argon cylinders. Some operate in a pure arc mode<br />
<strong>for</strong> routine PMI applications <strong>and</strong> the more sophisticated units have a spark mode<br />
allowing laboratory quality analysis. The significant advantage of these instruments is<br />
the expansion of elements that can be analyzed including C. These more advanced<br />
instruments are also not subject to operator interpretation. Similar to X-ray<br />
fluorescence devices, results can be reported in either a spectral match or elemental<br />
percentage mode. As these techniques generate arcs <strong>and</strong> sparks a potential ignition<br />
source occurs there<strong>for</strong>e prior to use of this technique in the field, a review should be<br />
conducted to determine if gas testing <strong>and</strong> hot work permits are required.<br />
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Principle: 原 理<br />
XRF 便 携 式 X 射 线 荧 光<br />
The principle of operation is that one or more gamma ray or X-ray<br />
sources γ 射 线 或 X 射 线 源 are used to generate a beam of low energy<br />
radiation to excite the material under analysis. The material under<br />
analysis then emits a characteristic radiation<br />
spectrum 特 征 辐 射 谱 .<br />
----------------------------------------------------------------------------<br />
Portable Optical Emission Spectrometry 便 携 式 发 射 光 谱<br />
An electric arc stimulates 电 弧 刺 激 atoms in the test sample to emit<br />
a characteristic spectrum of light 光 谱 光 <strong>for</strong> each element in the<br />
sample.<br />
Fion Zhang/ Charlie Chong
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35. How do portable X-Ray Fluorescence PMI tools work?<br />
a. Radiation waves excite the materials <strong>and</strong> the material emits a different spectrum<br />
of radiation that can be analyzed.<br />
b. Radiation waves excite the materials <strong>and</strong> the material emits a different spectrum<br />
of light that can be analyzed.<br />
c. Sound waves excite the materials <strong>and</strong> the material emits a different spectrum of<br />
radiation that can be analyzed.<br />
d. Sound waves excite the materials <strong>and</strong> the material emits a different spectrum of<br />
light that can be analyzed.<br />
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5.2.4 Chemical Laboratory Chemical Analysis 化 学 实 验 室 , 化 学 分 析<br />
Owner/user-approved material analysis laboratories using;<br />
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(1) X-ray emission spectrometry, X 射 线 发 射 光 谱 法<br />
(2) optical emission spectrometry 光 发 射 光 谱 法 , or<br />
(3) wet chemical analysis 湿 化 学 分 析<br />
can provide the most accurate analytical<br />
results <strong>for</strong> all elements. The accuracy is<br />
typically much higher than is normally<br />
needed <strong>for</strong> PMI testing. Laboratory analysis<br />
may involve the removal of significant<br />
amounts of material, <strong>and</strong> is typically slower<br />
than field PMI test techniques.<br />
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5.2.5 Other Qualitative Tests 其 他 定 性 测 试<br />
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5.2.5.1 Chemical Spot Testing 点 式 化 学 抽 查 测 试<br />
The chemical spot test is typically accomplished by electrochemically removing a minute<br />
amount of surface metal <strong>and</strong> depositing it onto moistened filter paper. Reagents dropped<br />
onto the paper produce distinct colors that are indicative of the presence of specific<br />
elements in the sample tested. Chemical spot testing is much slower than the other field<br />
PMI test methods <strong>and</strong> interpretation is subjective.<br />
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5.2.5.2 Resistivity Testing 电 阻 率 的 测 试<br />
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The principle employed in the test method is known as the Seebeck Effect, or<br />
thermoelectric principle. A heated junction of dissimilar metal is created when the<br />
heated probe [300 o F (150 o C)] <strong>and</strong> the metal being tested are in contact with each<br />
other. The voltage generated at this junction is representative of the chemistry<br />
<strong>and</strong> crystalline structure of the metal being tested. Every alloy of a given<br />
crystalline structure will generate the same voltage regardless of the geometry or<br />
size of the piece being tested or the pressure applied. By references to known<br />
st<strong>and</strong>ards, these instruments are capable of sorting <strong>and</strong> identifying a wide range<br />
of ferrous <strong>and</strong> nonferrous materials. <strong>Alloy</strong> sorters have not proved to be<br />
consistently capable of sorting low alloy (< 5 % Cr) <strong>and</strong> austenitic stainless steels.<br />
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5.2.5.2 Resistivity Testing 电 阻 率 的 测 试<br />
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Limitation: 限 制 因 素<br />
<strong>Alloy</strong> sorters have not proved to be consistently capable of sorting low alloy (< 5<br />
% Cr) <strong>and</strong> austenitic stainless steels.<br />
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5.2.5.3 Other Techniques 其 他 技 术<br />
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Techniques such as;<br />
• Eddy-current sorters 涡 流 分 拣 ,<br />
• Electromagnetic alloy sorters 电 磁 合 金 分 拣 ,<br />
• Triboelectric testing devices 静 电 测 试 (e.g. ferrite meters), <strong>and</strong><br />
• Thermoelectric tests 热 电 测 试<br />
are qualitative 定 性 <strong>and</strong> as such may only be appropriate <strong>for</strong> limited sorting<br />
applications <strong>and</strong> not <strong>for</strong> specific alloy identification.<br />
ferrite meters<br />
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5.3 Equipment Calibration 设 备 校 订<br />
The person per<strong>for</strong>ming the PMI testing should calibrate <strong>and</strong>/or verify the test<br />
equipment per<strong>for</strong>mance as specified by the equipment manufacturer. The<br />
PMI test procedure should provide the frequency interval <strong>for</strong> this calibration/<br />
verification. If calibration procedures are not provided by the equipment<br />
manufacturer, they should be established by the owner/user. Typically, these<br />
procedures should include calibration/verification using certified st<strong>and</strong>ards.<br />
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• 设 备 操 作 员 应 当 及 时 的 校 订 设 备<br />
• 按 照 设 备 提 供 商 指 定 的 程 序 , 验 证 与 校 订 PMI 设 备 .<br />
• 在 缺 乏 设 备 商 提 供 程 序 情 况 , 业 主 / 用 户 应 当 开 发 校 订 程 序<br />
• 一 般 校 订 程 序 包 括 用 认 证 试 块 对 比 .<br />
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5.4 Equipment Precision 设 备 精 密 度<br />
The precision of the test equipment should be consistent with the established test<br />
objectives (see 5.1). When component composition is desired, the owner/user<br />
should establish the acceptable precision <strong>and</strong> repeatability. The accuracy <strong>and</strong><br />
the method in which accuracy is determined needs to be understood. For example,<br />
in some tools, the sensitivity may be dependent upon how long you conduct the test<br />
in order to improve signal averaging algorithms. Failure to underst<strong>and</strong> these issues<br />
may produce inaccurate results.<br />
测 试 设 备 的 精 度 应 符 合 既 定 的 测 试 目 标 ( 如 5.1)<br />
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<br />
可 重 复 性<br />
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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<br />
建 材 , 而 不 是 确 切 的 确 定 材 料 符 合 规 格 要 求 .<br />
( 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 )<br />
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5.5 Personnel Qualifications 人 员 资 格<br />
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The person(s) per<strong>for</strong>ming the PMI test should be knowledgeable about all aspects of<br />
operation of PMI test equipment <strong>and</strong> the PMI test method used. Qualifications of the<br />
person per<strong>for</strong>ming the PMI test, including training <strong>and</strong> experience, should be<br />
submitted <strong>for</strong> review <strong>and</strong> approval by the owner/user. Owner/users should ensure<br />
that personnel using testing devices are adequately trained not only in the specific<br />
instrument but also in the alloys they will be examining. In some cases <strong>for</strong> critical<br />
application a <strong>for</strong>mal documented program <strong>and</strong> some <strong>for</strong>m of testing of personnel<br />
may be required. The higher the degree of operator analysis the more important this<br />
aspect of the whole procedure becomes.<br />
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<br />
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 .<br />
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5.6 Safety Issues 安 全 问 题<br />
The specific requirements <strong>for</strong> each PMI test technique should be clearly reviewed as<br />
to the amount of mechanical preparation. Consideration should be given to the<br />
anticipated thickness of the sample be<strong>for</strong>e mechanical methods are used to<br />
prepare the sample. In addition, considerations <strong>for</strong> electrical arcing <strong>and</strong> “hot<br />
spots” should be considered as well as appropriate electrical <strong>and</strong> hot work<br />
permits. Chemical spot testing involves the use of a variety of chemicals.<br />
Appropriate safety precautions should be taken when h<strong>and</strong>ling these chemicals.<br />
关 注 的 因 素 有 :<br />
• 作 为 表 面 处 理 剩 余 厚 度<br />
• PMI 测 试 时 电 弧 考 虑<br />
• 热 工 证<br />
• 湿 化 学 实 验 牵 涉 的 化 学 品 危 害 等<br />
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6 Evaluation of PMI Test Results<br />
测 试 结 果 评 价<br />
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6.1 <strong>Material</strong> Acceptance Methods 材 料 验 收 方 法<br />
The owner/user may elect any one of the following methods of material acceptance.<br />
a) <strong>Material</strong>s can be confirmed to contain the nominal amounts of alloying elements<br />
specified in the relevant materials specification (e.g. ASME Section II or ASTM<br />
specifications). 标 称 成 分<br />
b) <strong>Material</strong>s can be classified through a qualitative sorting technique (see 5.2.4) to<br />
establish the con<strong>for</strong>mance with the intended material.<br />
定 性 归 类 法<br />
c) When PMI testing indicates alloying elements are outside the ranges indicated<br />
in the material specification, the owner/user may still choose to allow the use of<br />
the tested materials in situations where a person knowledgeable of the<br />
appropriate damage mechanisms confirms that the material will per<strong>for</strong>m<br />
satisfactorily in the service. 标 称 成 分 , 让 步 接 收 .<br />
d) If testing using one of the portable or qualitative analysis methods (see 5.2.1 or<br />
5.2.2) leads to the potential rejection of a component, a more accurate analysis<br />
may be used to determine component acceptance (see 5.2.3). 用 更 准 确 分 析 方<br />
法 作 为 接 收 条 件 .<br />
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6.1 <strong>Material</strong> Acceptance Methods 材 料 验 收 方 法<br />
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业 主 / 用 户 可 以 选 择 任 何 材 料 验 收 的 下 列 方 法 之 一<br />
a) 标 称 成 分<br />
b) 定 性 归 类 法<br />
c) 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 )<br />
d) 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 .<br />
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6.2 Dissimilar Metal Welds <strong>and</strong> Weld Overlays<br />
异 种 金 属 对 接 焊 和 堆 焊<br />
Results from testing dissimilar metal welds should take into account the effects of<br />
dilution, which occurs during weld deposition. The owner/user should establish the<br />
minimum compositional requirements of the as-deposited weld metal necessary <strong>for</strong><br />
the intended service.<br />
考 虑 : 稀 释 的 影 响<br />
6.3 Follow-up PMI Testing after Discovery of a Noncon<strong>for</strong>mity<br />
不 合 格 项 跟 踪<br />
If any one of a representative sample is rejected, all items of that inspection lot<br />
should be considered suspect. A more extensive inspection of the remaining lot<br />
should be considered.<br />
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 .<br />
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7 Marking <strong>and</strong> Recordkeeping<br />
标 记 和 记 录 保 存<br />
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7.1 <strong>Material</strong>s Identification Process 材 料 识 别 过 程<br />
<strong>Alloy</strong> materials should be identified by their alloy designation or nominal composition.<br />
Examples of some acceptable identification methods are:<br />
a) color coding by alloy, 颜 色 编 码<br />
b) a low-stress stamp marking indicating that the test has been per<strong>for</strong>med,<br />
低 应 力 钢 印<br />
c) documentation showing both the PMI test results <strong>and</strong> the PMI test locations. 文 档<br />
记 录 PMI 测 试 结 果 与 位 置<br />
Test locations should be shown on appropriate drawings so that each test site can be<br />
traceable to the fabricated piping components.<br />
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7.1.1 Color Coding/Marking 颜 色 编 码 / 标 记<br />
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If the material verification program procedure established by the owner/user<br />
requires a visual identification such as color coding or marking, the owner/user<br />
should maintain a record of the alloy material/color code combinations. Pipe<br />
Fabrication Institute (PFI) St<strong>and</strong>ard ES22 is an example of one such system.<br />
<strong>Material</strong>s identification by color coding is not a substitute <strong>for</strong> permanent<br />
manufacturers’ markings required by applicable ASTM or other materials<br />
specifications.<br />
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7.1.2 Marking of Components<br />
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If the owner/user’s documentation process requires physical marking of piping<br />
components, it should specify one of the following.<br />
a) Whether or not the marking system should remain legible <strong>for</strong> the expected life of<br />
the component without deterioration due to corrosion or elevated temperature.<br />
b) Whether or not the marking system is only temporary to facilitate proper<br />
h<strong>and</strong>ling <strong>and</strong> identification from the point of PMI testing to final installation. This<br />
marking can be semi permanent paint applied to each item. The markers should<br />
not contain additives such as metallic pigments (Al, Pb, or Zn), sulfur or<br />
chlorides.<br />
标 记 不 应 含 有 金 属 颜 料 的 添 加 剂 , 例 如 (Al, Pb, or Zn), sulfur or chlorides.<br />
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7.2 <strong>Material</strong> Certifications 材 料 认 证<br />
<strong>Material</strong> certifications, mill test reports, or certificates of compliance should not be<br />
considered a substitute <strong>for</strong> PMI testing, but may be an important part of an overall<br />
quality assurance program.<br />
材 料 证 书 不 能 作 为 PMI 测 试 的 替 代 .<br />
7.3 Shop <strong>and</strong> Field PMI Test Documentation 车 间 和 现 场 PMI 测 试 文 档<br />
Those individuals per<strong>for</strong>ming PMI testing should obtain <strong>and</strong> follow the PMI test<br />
procedure approved by the owner/ user. This procedure should cover the<br />
technique used, equipment calibration, the qualification requirements of PMI test<br />
personnel, the testing methodology, <strong>and</strong> documentation requirements. When<br />
documentation, such as drawings, is used in lieu of physical marking, the<br />
documentation should allow the owner/user to identify which components were<br />
tested. 现 场 PMI 测 试 文 档 应 当 依 照 批 准 程 序 执 行 .<br />
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7.4 <strong>New</strong> <strong>and</strong> <strong>Existing</strong> <strong>Piping</strong> System Documentation<br />
新 的 和 现 有 的 管 道 系 统 文 档<br />
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When PMI testing is conducted on new or existing piping systems, records of the<br />
results should be kept as long as the piping system exists in its original location.<br />
If a piping system or a portion of a piping system that has not received material<br />
verification is relocated, the owner/user should consider the need <strong>for</strong> PMI testing<br />
prior to placing the relocated components into service.<br />
文 件 保 留 多 久 ?<br />
• 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 .<br />
• 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<br />
测 试<br />
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7.5 PMI Test Records 测 试 记 录 内 容<br />
Typical PMI test records should contain the following.<br />
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a) Reference to the PMI test procedures used. 参 考 文 献 / 程 序<br />
b) Date of testing. 测 试 日 期<br />
c) Test instrument identification number or serial number where appropriate. 测 试 仪<br />
器 识 别 号 码<br />
d) Name of each person <strong>and</strong> company per<strong>for</strong>ming the tests. 操 作 人 员 / 单 位<br />
e) Results of the tests. 测 试 结 果<br />
f) Basis <strong>and</strong> action <strong>for</strong> resolving <strong>and</strong> documenting PMI test noncon<strong>for</strong>mances<br />
including those that have been left in service. 解 决 和 记 录 的 依 据 和 行 动<br />
g) Documentation of the criteria used <strong>for</strong> prioritization of piping systems <strong>and</strong> extent<br />
of PMI testing per<strong>for</strong>med. Alternately, the owner/user may choose to include this<br />
within the written material verification procedure. When included in the<br />
owner/user’s written material verification procedure, the date <strong>and</strong> edition number<br />
of the written procedure should be documented in the test record. 用 于 管 道 系 统 的<br />
优 先 级 的 标 准 文 档 / 验 收 标 准 根 据 等 .<br />
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7.6 PMI Test Procedures 测 试 程 序<br />
The PMI test procedure should include the techniques used, equipment<br />
calibration elements, the qualification requirements <strong>for</strong> PMI test personnel, the<br />
testing methodology, acceptance criteria <strong>and</strong> the documentation requirements.<br />
7.7 Traceability to Field Components 可 追 溯 性<br />
The in<strong>for</strong>mation listed in 7.5 should be reported in such a manner that they are<br />
traceable to the point of installation.<br />
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1. API 578 provides guidelines <strong>for</strong> a quality assurance system to verify:<br />
a. all materials.<br />
b. b. all alloy materials.<br />
c. c. only non-ferrous materials.<br />
d. d. only high-alloy materials.<br />
3. An alloy material is any metallic material that contains alloying elements<br />
that are added:<br />
a. only to improve mechanical properties.<br />
b. only to improve corrosion resistance.<br />
c. to improve either mechanical properties or improve corrosion resistance<br />
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5. An inspection lot includes:<br />
a. all materials from same supplier.<br />
b. all materials included on the same purchase order.<br />
c. all materials of the same material type (i.e. 316 SS)<br />
d. all materials of the same material type from the same supplier <strong>and</strong> heat.<br />
6. A documented material verification program should be established by the:<br />
a. Authorized inspector.<br />
b. Owner/User.<br />
c. Repair organization.<br />
d. Engineering organization.<br />
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7. The material verification program should cover PMI testing of materials:<br />
a. during construction of piping systems.<br />
b. in existing piping systems.<br />
c. during repairs <strong>and</strong> alterations of piping systems.<br />
d. in existing piping systems <strong>and</strong> during construction, repairs <strong>and</strong> alterations of<br />
piping systems.<br />
8. R<strong>and</strong>om sampling is most appropriate <strong>for</strong>:<br />
a. low-risk systems.<br />
b. low alloy systems.<br />
c. stainless steel systems.<br />
d. ferritic steel systems.<br />
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9. Who has the responsibility to determine the extent of PMI per<strong>for</strong>med?<br />
a. Authorized inspector<br />
b. Owner/User<br />
c. Repair organization<br />
d. Engineering organization.<br />
10. Who has the responsibility to verify that the material verification program is<br />
properly implemented?<br />
a. Authorized inspector<br />
b. Owner/User<br />
c. Repair organization<br />
d. Engineering organization<br />
Fion Zhang/ Charlie Chong
API578<br />
11. Who has the responsibility to review <strong>and</strong> approve the adequacy of the PMI<br />
program used by fabricators <strong>and</strong> material suppliers?<br />
a. Authorized inspector<br />
b. Owner/User<br />
c. Repair organization<br />
d. Engineering organization<br />
12. A mill test report:<br />
a. eliminates the need <strong>for</strong> further material verification.<br />
b. is a report showing material discrepancies.<br />
c. is an important part of the material qualify assurance program.<br />
d. is issued by the owner upon receipt of materials.<br />
Fion Zhang/ Charlie Chong
API578<br />
13. The material verification program specified by API 578 covers:<br />
a. only pressure-containing components<br />
b. only pipe, <strong>and</strong> fittings.<br />
c. only pipe, fittings, <strong>and</strong> welds.<br />
d. pressure-containing <strong>and</strong> non-pressure containing components.<br />
14. During alloy welding:<br />
a. one electrode from each box should be sampled.<br />
b. two electrodes from each box should be sampled.<br />
c. one electrode from each lot should be sampled.<br />
d. two electrodes from each lot should be sampled.<br />
Fion Zhang/ Charlie Chong
15. If alloy element(s) are contained in the flux of a welding electrode, PMI testing:<br />
a. is not necessary.<br />
b. is not necessary provided appropriate documentation is provided by the supplier.<br />
c. could be conducted on any of the production welds.<br />
d. could be conducted on a weld button prior to production welds.<br />
API578<br />
16. <strong>New</strong> longitudinal welded alloyed pipe should:<br />
a. never be used.<br />
b. be used only if the Quality Factor is 1.0.<br />
c. receive r<strong>and</strong>om PMI testing of weld <strong>and</strong> base metal.<br />
d. receive 100% PMI testing of weld <strong>and</strong> base metal.<br />
Fion Zhang/ Charlie Chong
17. Who has the responsibility to determine the extent of PMI testing required on<br />
existing piping systems?<br />
a. Authorized inspector<br />
b. Owner/User<br />
c. Repair organization<br />
d. Engineering organization<br />
API578<br />
19. Incorrect substitution of carbon steel is most likely to be found in:<br />
a. chrome steels.<br />
b. stainless steels.<br />
c. any ferritic steel.<br />
d. any non-ferrous.<br />
Fion Zhang/ Charlie Chong
API578<br />
20. Which of the following piping components is most likely to have a substitution with the<br />
wrong material?<br />
a. A 20’ length of 6 NPS pipe<br />
b. Weld-neck flange<br />
c. Expansion joint<br />
d. Bolting<br />
21. Which of the following piping components is most likely to have a substitution with the<br />
wrong material?<br />
a. A 10’ length of 6 NPS 316L SS pipe<br />
b. 6 NPS Gate valve<br />
c. 4 NPS Monel elbow<br />
d. Slip-on flange<br />
Fion Zhang/ Charlie Chong
API578<br />
22. Who has the responsibility to determine the extent of PMI testing required during<br />
repairs <strong>and</strong> alterations of piping systems?<br />
a. Authorized inspector<br />
b. Owner/User<br />
c. Repair organization<br />
d. Engineering organization<br />
23. PMI testing at the warehouse is:<br />
a. done by only checking material stampings.<br />
b. accomplished by the Authorized Inspector.<br />
c. not important since materials will be checked during fabrication.<br />
d. not an important part of the material verification program.<br />
e. not a substitute <strong>for</strong> PMI testing required during fabrication.<br />
Fion Zhang/ Charlie Chong
API578<br />
24. Identification of materials by visual stamps or markings:<br />
a. is not an important part of the material verification program.<br />
b. is not a substitute <strong>for</strong> PMI testing.<br />
c. is important only on high alloy materials.<br />
d. should only be done by inspectors.<br />
25. PMI tools that use X-Ray fluorescence can not detect:<br />
a. carbon content.<br />
b. chrome content.<br />
c. iron content.<br />
d. molybdenum content.<br />
Fion Zhang/ Charlie Chong
26. How does Portable Optical Emission Spectrometry determine the elements in a<br />
material?<br />
a. An electric arc causes a spectrum of light to be emitted from the tested material.<br />
The light is analyzed.<br />
b. X-rays striking the material cause a spectrum of x-rays to be emitted from the<br />
tested material. The x-rays are analyzed.<br />
c. Specific chemicals deposited on the tested material cause a spectrum of colors to<br />
be emitted. The colors are analyzed.<br />
d. The surface is polished <strong>and</strong> etched. A replication is pre<strong>for</strong>med <strong>and</strong> is analyzed<br />
with a microscope.<br />
27. PMI testing equipment should be:<br />
a. calibrated every 4 hrs.<br />
b. calibrated as specified by the manufacturer.<br />
c. used only by the manufacturer’s personnel.<br />
d. used by owner/user personnel.<br />
API578<br />
Fion Zhang/ Charlie Chong
28. All personnel per<strong>for</strong>ming PMI tests should be:<br />
a. qualified by national exam.<br />
b. qualified by the owner/user.<br />
c. knowledgeable about the operation of the PMI test equipment.<br />
d. knowledgeable about the operation of the plant where the PMI is conducted.<br />
API578<br />
29. An alloy weld overlay is applied to carbon steel base metal. Who has the<br />
responsibility to establish the minimum alloy requirements of the as-deposited weld<br />
metal?<br />
a. Authorized inspector<br />
b. Owner/User<br />
c. Repair organization<br />
d. Engineering organization<br />
Fion Zhang/ Charlie Chong
30. What is the appropriate action to take when an incorrect material is located during<br />
a PMI sampling of new materials.<br />
a. Inspect 2 more items from the inspection lot.<br />
b. Inspect 50% of the items from the inspection lot.<br />
c. Inspect 100% of the items from the inspection lot.<br />
d. Inspection all items supplied by that manufacturer.<br />
API578<br />
31. Marking pens should not contain chlorides or:<br />
a. Carbon.<br />
b. Chrome.<br />
c. Oxides.<br />
d. Sulfur.<br />
Fion Zhang/ Charlie Chong
API578<br />
Answers:<br />
1. b. all alloy materials.<br />
3. c. to improve either mechanical properties or improve corrosion resistance<br />
5. d. all materials of the same material type from the same supplier <strong>and</strong> heat<br />
6. b. Owner/User<br />
7. d. in existing piping systems <strong>and</strong> during construction, repairs <strong>and</strong> alterations<br />
8. a. low-risk systems<br />
9. b. Owner/User<br />
10. b. Owner/User<br />
11. b. Owner/User<br />
12. c. is an important part of the material qualify assurance program<br />
13. a. only pressure-containing components<br />
14. c. on electrode from each lot should be sampled<br />
15. d. could be conducted on a weld button prior to production welds<br />
16. c. receive r<strong>and</strong>om PMI testing of weld <strong>and</strong> base metal<br />
17. b. Owner/User<br />
Fion Zhang/ Charlie Chong
19. a. chrome steel<br />
20. d. bolting<br />
21. b. Valve<br />
22. b. Owner/User<br />
23. e. not a substitute <strong>for</strong> PMI testing required during fabrication.<br />
24. b. is not a substitute <strong>for</strong> PMI testing<br />
25. a. carbon content<br />
26. a. an electrode arc causes a spectrum of light to be emitted from the tested material.<br />
The light is analyzed.<br />
27. b. calibrated as specified by the manufacturer<br />
28. c. knowledgeable about the operation of the PMI test equipment<br />
29. b. Owner/User<br />
30. c. inspect 100% of the items from the inspection lot / 31. d. sulfur<br />
API578<br />
Fion Zhang/ Charlie Chong
Fion Zhang/ Charlie Chong<br />
API578
API578<br />
1. API 578 provides guidelines <strong>for</strong> a material assurance system to verify:<br />
a. all materials.<br />
b. all alloy materials.<br />
c. only non-ferrous materials.<br />
d. only high-alloy materials.<br />
2. The material verification program specified by API 578 covers:<br />
a. only pressure-containing components.<br />
b. only pipe, <strong>and</strong> fittings.<br />
c. only pipe, fittings, <strong>and</strong> welds.<br />
d. pressure-containing <strong>and</strong> non-pressure containing components.<br />
Fion Zhang/ Charlie Chong
API578<br />
3. An alloy material is any metallic material that contains alloying elements that<br />
are added:<br />
a. only to improve mechanical properties.<br />
b. only to improve corrosion resistance.<br />
c. to improve either mechanical properties or corrosion resistance.<br />
4. An inspection lot includes:<br />
a. all materials from a common source.<br />
b. all materials included on the same purchase order.<br />
c. all materials of the same material type (i.e. 316 SS)<br />
d. all materials from a common source, of the same material type <strong>and</strong><br />
same heat.<br />
Fion Zhang/ Charlie Chong
API578<br />
5. For construction <strong>and</strong> repair activities a written material verification<br />
program should be established by the:<br />
a. API 570 Authorized Inspector.<br />
b. Engineering Organization.<br />
c. Owner/User.<br />
d. Repair Organization.<br />
6. The material verification program should cover PMI testing of materials:<br />
a. during construction of piping systems.<br />
b. in existing piping systems.<br />
c. during repairs <strong>and</strong> alterations of piping systems.<br />
d. in existing piping systems <strong>and</strong> during construction, repairs <strong>and</strong><br />
alterations of piping systems.<br />
Fion Zhang/ Charlie Chong
API578<br />
7. During repairs, r<strong>and</strong>om PMI sampling of new components is most appropriate<br />
<strong>for</strong>:<br />
a. low-risk piping systems.<br />
b. low alloy piping systems.<br />
c. stainless steel piping systems.<br />
d. ferritic steel piping systems.<br />
e. all piping systems.<br />
8. Who has the responsibility to determine the extent of PMI per<strong>for</strong>med?<br />
a. API 570 Authorized Inspector<br />
b. Owner/User<br />
c. <strong>Piping</strong> Engineer<br />
d. Repair Organization<br />
Fion Zhang/ Charlie Chong
API578<br />
9. During construction the Owner should consider 100% PMI of new<br />
components on:<br />
a. all piping systems.<br />
b. all alloys above P-5.<br />
c. exotic alloys.<br />
d. high-risk piping systems.<br />
Fion Zhang/ Charlie Chong
API578<br />
10. Usually substituting an alloy <strong>for</strong> carbon steel does not cause a problem. But<br />
hardenable alloys may cause failure in some carbon steel systems. Which of<br />
the following process services would substituting an alloy <strong>for</strong> carbon steel<br />
not result in a potential problem.<br />
a. Benzene<br />
b. Hydrofluoric acid (HF)<br />
c. Sulfuric acid<br />
d. Wet hydrogen sulfide<br />
11. Who is responsible to assure that the material verification program meets<br />
the guidelines of API 578?<br />
a. Authorized Inspector<br />
b. Examiner<br />
c. Owner/User<br />
d. <strong>Piping</strong> Engineer<br />
Fion Zhang/ Charlie Chong
API578<br />
12. Who is responsibility to verify the adequacy of the material verification<br />
program that is per<strong>for</strong>med by material suppliers?<br />
a. API PMI Specialist<br />
b. Authorized Inspector<br />
c. <strong>Piping</strong> Engineer<br />
d. Owner/User<br />
13. Who has the responsibility to review <strong>and</strong> approve the adequacy of the PMI<br />
program used by fabricators?<br />
a. API 570 Authorized Inspector<br />
b. API 578 Certified Inspector<br />
c. Engineering Organization<br />
d. Owner/User<br />
e. Repair Organization<br />
Fion Zhang/ Charlie Chong
API578<br />
14. A mill test report:<br />
a. eliminates the need <strong>for</strong> further material verification.<br />
b. is a report showing material discrepancies.<br />
c. is an important part of the material qualify assurance program.<br />
d. is issued by the owner upon receipt of materials.<br />
15. During construction, which of the following alloy components does not need<br />
to be covered by a material verification program?<br />
a. Bolts<br />
b. Expansion Joints<br />
c. Gaskets<br />
d. Pressure containing welds<br />
e. All the above components need to be checked<br />
Fion Zhang/ Charlie Chong
API578<br />
16. During alloy welding:<br />
a. one electrode from each pallet should be identified.<br />
b. two electrodes from each pallet should be identified.<br />
c. one electrode from each lot or package should be identified.<br />
d. two electrodes from each lot or package should be identified.<br />
17. If alloy element(s) are contained in the flux of a welding electrode, PMI<br />
testing:<br />
a. is not necessary.<br />
b. is not necessary provided appropriate documentation is provided by<br />
the supplier.<br />
c. could be conducted on any of the production welds.<br />
d. could be conducted on a “weld button” prior to production welds.<br />
Fion Zhang/ Charlie Chong
API578<br />
18. <strong>New</strong> longitudinal welded alloyed pipe should:<br />
a. never be used.<br />
b. always receive r<strong>and</strong>om PMI testing of weld <strong>and</strong> base metal.<br />
c. receive r<strong>and</strong>om PMI testing of weld <strong>and</strong> base metal if there is a<br />
reason to suspect problems.<br />
d. always receive 100% PMI testing of weld <strong>and</strong> base metal.<br />
19. PMI of autogenous welds is:<br />
a. always required.<br />
b. never required.<br />
c. not required if the weld rod was PMI tested.<br />
d. not required if the base metal was PMI tested.<br />
Fion Zhang/ Charlie Chong
API578<br />
20. Who has the responsibility to determine the extent of PMI testing required<br />
on existing piping systems?<br />
a. API Authorized Inspector<br />
b. Engineering Organization<br />
c. Owner/User<br />
d. Repair Organization<br />
21. When prioritizing the need <strong>for</strong> PMI on existing piping systems, which of the<br />
following is not a factor to consider?<br />
a. Age of the facility<br />
b. Consequence of failure<br />
c. Likelihood of failure<br />
d. Plant experience with inadvertent material substitutions<br />
e. Reason <strong>for</strong> the alloy<br />
Fion Zhang/ Charlie Chong
API578<br />
22. Incorrect substitution of carbon steel is most likely to be found in:<br />
a. chrome systems.<br />
b. stainless systems.<br />
c. any ferritic systems.<br />
d. any non-ferrous systems.<br />
23. Which residual element in a carbon steel system has not caused increased<br />
corrosion rates in HF acid piping system?<br />
a. C<br />
b. Cr<br />
c. Cu<br />
d. Fe<br />
e. Ni<br />
Fion Zhang/ Charlie Chong
API578<br />
24. Low silicon carbon steel can corrode rapidly when exposed to:<br />
a. hydrogen-free sulfidation.<br />
b. hydrogen-rich sulfidation.<br />
c. hydrogen-free oxidation.<br />
d. hydrogen-rich oxidation.<br />
25. Carbon steel can corrode rapidly in hydrogen-free sulfidation when the<br />
silicon content in carbon steel is:<br />
a. < 0.10%.<br />
b. > 0.10%.<br />
c. < 0.25%.<br />
d. > 0.25%.<br />
Fion Zhang/ Charlie Chong
API578<br />
26. The owner decides to conduct PMI testing on some existing piping systems.<br />
Which of the following is a major factor in prioritizing the pipe?<br />
a. The effectiveness of the construction & maintenance practices<br />
b. The effectiveness of the inspection practices<br />
c. Age of the unit<br />
d. Line size<br />
27. Which of the following piping components is most likely to have a<br />
substitution with the wrong material?<br />
a. A 20’ length of 6 NPS pipe<br />
b. Weld-neck flange<br />
c. Expansion joint<br />
d. Bolting<br />
Fion Zhang/ Charlie Chong
API578<br />
28. Which of the following piping components is most likely to have a<br />
substitution with the wrong material?<br />
a. A 10’ length of 6 NPS 316L SS pipe<br />
b. 6 NPS Gate valve<br />
c. 4 NPS Monel elbow<br />
d. Slip-on flange<br />
29. Who has the responsibility to determine the extent of PMI testing required<br />
during repairs <strong>and</strong> alterations of piping systems?<br />
a. API 578 Authorized Inspector<br />
b. Engineering Organization<br />
c. Owner/User<br />
d. Repair Organization<br />
Fion Zhang/ Charlie Chong
API578<br />
30. Who has the responsibility to evaluate the effectiveness of a PMI program<br />
during repairs <strong>and</strong> alterations?<br />
a. API Authorized Inspector<br />
b. Examiner<br />
c. Owner/User<br />
d. <strong>Piping</strong> Engineer<br />
e. Repair Organization<br />
31. During repairs <strong>and</strong> alterations the Owner should:<br />
a. use NACE certified examiners.<br />
b. have a written procedure describing their PMI program.<br />
c. PMI test 100% of all materials.<br />
d. PMI test 100% of all alloy materials.<br />
Fion Zhang/ Charlie Chong
API578<br />
32. PMI testing at the warehouse is:<br />
a. done by only checking material stampings.<br />
b. accomplished by the Authorized Inspector.<br />
c. not important since materials will be checked during fabrication.<br />
d. not an important part of the material verification program.<br />
e. not a substitute <strong>for</strong> PMI testing required during fabrication.<br />
33. In the petrochemical industry, one common material mix-up problem occurs:<br />
a. when temporarily removing spool pieces.<br />
b. when sending pumps out <strong>for</strong> repair.<br />
c. by using carbon steel in a 300 series stainless steel system.<br />
d. by using 300 series stainless steel in a carbon steel system.<br />
Fion Zhang/ Charlie Chong
API578<br />
34. Identification of materials by visual stamps or markings:<br />
a. is not an important part of the material verification program.<br />
b. is not a substitute <strong>for</strong> PMI testing.<br />
c. is important only on high alloy materials.<br />
d. should only be done by inspectors.<br />
35. How do portable X-Ray Fluorescence PMI tools work?<br />
a. Radiation waves excite the materials <strong>and</strong> the material emits a different spectrum<br />
of radiation that can be analyzed.<br />
b. Radiation waves excite the materials <strong>and</strong> the material emits a different spectrum<br />
of light that can be analyzed.<br />
c. Sound waves excite the materials <strong>and</strong> the material emits a different spectrum of<br />
radiation that can be analyzed.<br />
d. Sound waves excite the materials <strong>and</strong> the material emits a different spectrum of<br />
light that can be analyzed.<br />
Fion Zhang/ Charlie Chong
36. PMI tools that use X-Ray fluorescence can not detect:<br />
a. carbon.<br />
b. chrome.<br />
c. iron.<br />
d. molybdenum.<br />
API578<br />
37. How does Portable Optical Emission Spectrometry determine the elements<br />
in a material?<br />
a. An electric arc causes a spectrum of light to be emitted from the tested material.<br />
The light is analyzed.<br />
b. An electric arc causes a spectrum of radiation to be emitted from the tested<br />
material. The radiation is analyzed.<br />
c. X-rays striking the material cause a spectrum of radiation to be emitted from the<br />
tested material. The radiation is analyzed.<br />
d. Specific chemicals deposited on the tested material cause a spectrum of colors to<br />
be emitted. The colors are analyzed.<br />
e. The surface is polished <strong>and</strong> etched. A replication is pre<strong>for</strong>med <strong>and</strong> is analyzed<br />
with a microscope.<br />
Fion Zhang/ Charlie Chong
38. Chemical spot testing:<br />
a. is the fastest PMI technique.<br />
b. provides an accurate way to determine the percentage of the types of metals in the<br />
material.<br />
c. uses droplets of acids or caustics that are placed on the component. Different colors<br />
indicated different materials.<br />
d. removes a small amount of surface metal that is placed in a filter paper. Small<br />
droplets of reagents are used on the sample <strong>and</strong> different colors indicated different<br />
materials.<br />
39. PMI tools that use Resistivity Testing are not always able to sort:<br />
a. low chromes.<br />
b. high chromes.<br />
c. 300 series stainless steels.<br />
d. 400 series stainless steels.<br />
e. low chromes <strong>and</strong> 300 series stainless steels.<br />
f. high chromes <strong>and</strong> 400 series stainless steels.<br />
API578<br />
Fion Zhang/ Charlie Chong
API578<br />
40. PMI testing equipment should be:<br />
a. calibrated every 4 hrs.<br />
b. calibrated as specified by the manufacturer.<br />
c. used only by the manufacturer’s personnel.<br />
d. used by owner/user personnel.<br />
41. All personnel per<strong>for</strong>ming PMI tests should be:<br />
a. qualified by national exam.<br />
b. qualified by the owner/user.<br />
c. knowledgeable about the operation of the PMI test equipment.<br />
d. knowledgeable about the operation of the plant where the PMI is conducted.<br />
Fion Zhang/ Charlie Chong
API578<br />
42. Qualifications <strong>for</strong> personnel per<strong>for</strong>ming PMI testing should be submitted<br />
<strong>and</strong> reviewed by:<br />
a. API.<br />
b. ASNT.<br />
c. the Authorized Inspection.<br />
d. the Owner/User.<br />
e. the <strong>Piping</strong> Engineer.<br />
43. When PMI testing indicates that an alloy is outside the range allowed on the<br />
material spec, the component can:<br />
a. never be used.<br />
b. be used if the alloy percentages exceed requirements.<br />
c. be used in low risk piping systems.<br />
d. be used if accepted by the Owner/User following an assessment.<br />
Fion Zhang/ Charlie Chong
API578<br />
44. An alloy weld overlay is applied to carbon steel base metal. What will occur?<br />
a. Cracking due to differential expansion rates<br />
b. Dilution<br />
c. Lack of Fusion<br />
d. Underbead cracking<br />
45. An alloy weld overlay is applied to carbon steel base metal. Who has the<br />
responsibility to establish the minimum alloy requirements of the as deposited<br />
weld metal?<br />
a. API 570 Authorized Inspector<br />
b. Engineering Organization<br />
c. Owner/User<br />
d. Repair organization<br />
Fion Zhang/ Charlie Chong
API578<br />
46. What is the appropriate action to take when an incorrect material is located<br />
during a PMI sampling of an inspection lot?<br />
a. Inspect 2 more items from the inspection lot.<br />
b. Inspect 50% of the items from the inspection lot.<br />
c. Inspect 100% of the items from the inspection lot.<br />
d. Inspection all items supplied by that manufacturer.<br />
e. A more extensive inspection of the lot should be considered.<br />
47. A color code system <strong>for</strong> pipe is specified by:<br />
a. ASME B31.3.<br />
b. ASME 16.34.<br />
c. NACE 3389.<br />
d. PFI ES22.<br />
Fion Zhang/ Charlie Chong
API578<br />
48. Identification of materials by color coding:<br />
a. is not an important part of the material verification program.<br />
b. is not a substitute <strong>for</strong> PMI testing.<br />
c. is important only on high alloy materials.<br />
d. should only be done by inspectors.<br />
49. Which of the following is not required when the owner’s PMI system<br />
requires physical marking of components?<br />
a. Whether the marking should remain legible <strong>for</strong> the component’s life<br />
b. The name of individual doing the marking<br />
c. If colors are used, a description of color used <strong>for</strong> each alloy<br />
Fion Zhang/ Charlie Chong
API578<br />
50. Marking pens should not contain chlorides or:<br />
a. Carbon.<br />
b. Chrome.<br />
c. Oxides.<br />
d. Sulfur.<br />
51. When PMI testing is conducted on a new piping system, the documentation<br />
of the PMI results should be kept:<br />
a. until the piping system is operational.<br />
b. 1 year.<br />
c. until piping system is no longer in operation.<br />
d. until piping system is removed/scrapped.<br />
e. <strong>for</strong>ever.<br />
Fion Zhang/ Charlie Chong
Fion Zhang/ Charlie Chong<br />
API578
Fion Zhang/ Charlie Chong<br />
API578
API578<br />
1. RP 578 applies to _______________________________process piping systems<br />
covered by ASME B 31.3 <strong>and</strong> API 570 piping codes.<br />
A. <strong>New</strong><br />
B. <strong>Existing</strong><br />
C. <strong>New</strong> <strong>and</strong> <strong>Existing</strong><br />
D. None of the Above<br />
2. RP 578 applies to ____________________________materials purchased directly<br />
or indirectly by the owner/user.<br />
A. all materials<br />
B. metallic <strong>and</strong> non metallic<br />
C. metallic alloy<br />
D. all grades of monel<br />
Fion Zhang/ Charlie Chong
API578<br />
3. Carbon steel components________________ under the Scope of RP 578.<br />
A. are specifically covered.<br />
B. are not specifically covered<br />
C. are optional<br />
D. none of the above<br />
4. Any metallic material (including welding filler metals) that contains alloying<br />
elements such as chromium,nickel, or molybdenum, which are intentionally added to<br />
enhance mechanical or physical properties <strong>and</strong>/or corrosion resistance is<br />
called___________<br />
A. A 53B pipe.<br />
B. Austenitic material.<br />
C. alloy material.<br />
D. none of the above<br />
Fion Zhang/ Charlie Chong
API578<br />
5. _____________________ is an organization that per<strong>for</strong>ms or services <strong>and</strong> directly<br />
controls one or more of the operations that affect the chemical composition or<br />
mechanical properties of a metallic material.<br />
A. A material manufacturer<br />
B. A distributor<br />
C. A fabricator<br />
D. A owner/user<br />
6. An organization that supplies materials furnished <strong>and</strong> certified by a material<br />
manufacturer, but does not per<strong>for</strong>m any operation intended to alter the material<br />
properties required by the applicable material specification is a _____________.<br />
A. distributor.<br />
B. fabricator.<br />
C. material supplier.<br />
D. material manufacture.<br />
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API578<br />
7. Who has the responsibility to determine the extent of examination required <strong>and</strong> to verify<br />
the material verification program is per<strong>for</strong>med in accordance with RP 578?<br />
A. engineer<br />
B. owner/user or designee<br />
C. Tim Schindler<br />
D. material supplier<br />
8. Review <strong>and</strong> approval of the material verification program <strong>and</strong> testing procedure of the<br />
fabricator or material supplier should be done:<br />
A. Prior to PMI testing.<br />
B. After PMI testing.<br />
C. Any time prior to hydrotesting.<br />
D. Both A <strong>and</strong> B.<br />
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API578<br />
9. Mill Test Reports _________________considered a substitute <strong>for</strong> PMI testing.<br />
A. <strong>and</strong> X-rays are<br />
B. should be<br />
C. should not be<br />
D. can be<br />
10. Which of the following is an example of a pressure-containing component that<br />
makes up a fabricated piping system covered in the <strong>Material</strong> <strong>Verification</strong> <strong>Program</strong>?<br />
A. Instruments<br />
B. dummy legs<br />
C. spring cans<br />
D. none of the above<br />
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API578<br />
11. <strong>Verification</strong> of the alloy materials subsequently placed into service are as specified is a<br />
responsibility of:<br />
A. Authorized inspector<br />
B. Engineer<br />
C. Owner/User or designee<br />
D. None of the above<br />
12. You have received a shipment of alloy electrodes <strong>and</strong> wire from your supplier. How<br />
much PMI testing should you per<strong>for</strong>m?<br />
A. Positively identify two electrodes or wire samples from each lot or package.<br />
B. Positively identify one electrode or wire sample from each lot or package.<br />
C. As determined by the owner/user<br />
D. No testing is required.<br />
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API578<br />
13. A new section of seamed (longitudinal) alloy pipe is to be used <strong>for</strong> repairs <strong>and</strong><br />
requires PMI testing, where should PMI testing be per<strong>for</strong>med?<br />
A. PMI the weld metal only.<br />
B. PMI the base metal only.<br />
C. PMI the base metal <strong>and</strong> weld metal<br />
D. No testing is required. You only need to verify the correct ASTM markings are on the<br />
pipe.<br />
14. The lead inspector (owner/user) has decided to prioritize existing piping systems in<br />
the crude unit <strong>for</strong> PMI testing. Which is a consideration <strong>for</strong> prioritization?<br />
A. How lucky he feels.<br />
B. Likelihood of Failure<br />
C. Consequence of failure<br />
D. Both A <strong>and</strong> B<br />
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15. The greatest Number of material non con<strong>for</strong>mities with serious consequence have<br />
involved carbon steel components in ____________<br />
A. non ferrous systems.<br />
B. stainless steel systems.<br />
C. low alloy systems.<br />
D. non metallic systems.<br />
16. _____________ should be considered when determining the extent of PMI testing<br />
<strong>for</strong> existing units.<br />
A. The plant manufacturer<br />
B. The type of PMI equipment available<br />
C. The number of plant modifications<br />
D. The number of previous plant turnarounds<br />
API578<br />
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API578<br />
17. Which is not an example of a component prioritization factor?<br />
A. Warm-up <strong>and</strong> bypass lines on pumps or check valves.<br />
B. Small diameter piping systems.<br />
C. Components with ASTM stamp.<br />
D. Components without an ASTM stamp.<br />
18. Calibration <strong>and</strong>/or verification of the PMI test equipment should be per<strong>for</strong>med:<br />
A. Be<strong>for</strong>e <strong>and</strong> after every use.<br />
B. Once every quarter.<br />
C. As determined by the AI.<br />
D. As specified the equipment manufacturer.<br />
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API578<br />
19. If PMI equipment calibration/verification procedures are not provided by the<br />
equipment manufacturer,_________________<br />
A. they should be established by the owner/user.<br />
B. they should be established by the authorized inspector.<br />
C. then equipment calibration is not required.<br />
D. then a complete refund of the equipment should be obtained.<br />
20. Personnel per<strong>for</strong>ming PMI testing should be:<br />
A. Trained by Tim Schindler.<br />
B. Knowledgeable about all aspects of B31.3 <strong>and</strong> API 570.<br />
C. Certified to ASME Sec V.<br />
D. Knowledgeable about all aspects of operation of PMI test equipment.<br />
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API578<br />
21. What safety considerations are there when per<strong>for</strong>ming PMI testing?<br />
a. All PMI testing requires a hot work permit <strong>and</strong> a fire watch.<br />
b. Appropriate electrical permits, <strong>and</strong> hot work permits.<br />
c. Consider electrical arching <strong>and</strong> “hot spots”, appropriate electrical <strong>and</strong> hot work<br />
permits.<br />
d. Always test the Ground Fault interrupter.<br />
22. What is an acceptable method of material acceptance?<br />
a. <strong>Material</strong>s can be classified through a qualitative sorting technique to establish the<br />
con<strong>for</strong>mance with the intended material.<br />
b. <strong>Material</strong>s can be confirmed to contain nominal amounts of alloying elements<br />
specified in relevant materials specifications.<br />
c. <strong>Material</strong>s can be confirmed to contain nominal amounts of alloying elements<br />
specified in the written procedure.<br />
d. Both A <strong>and</strong> B<br />
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API578<br />
23. You are the QA inspector of a new construction project <strong>and</strong> have been in<strong>for</strong>med that<br />
some 5 Chrome fittings were PMI tested <strong>and</strong> the alloying elements are outside the<br />
ranges that allowed in the ASTM material specification, could these fittings still be<br />
used <strong>for</strong> your project?<br />
a. No, these fittings should be rejected <strong>and</strong> sent back to the supplier.<br />
b. Yes, provided they are higher than the specified ranges allowed by ASTM <strong>and</strong> a<br />
person knowledgeable of the appropriate damage mechanisms confirms that the<br />
materials will per<strong>for</strong>m satisfactory in the service.<br />
c. Yes, provided a person knowledgeable of the appropriate damage mechanisms<br />
confirms that the materials will per<strong>for</strong>m satisfactory in the service.<br />
d. Yes, proved the supplier signs off that the materials in question are acceptable.<br />
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API578<br />
24. You are testing one representative fitting from a lot <strong>and</strong> find it rejectable, you<br />
should________.<br />
A. consider the entire lot suspect <strong>and</strong> send it back to the supplier.<br />
B. consider the entire lot suspect <strong>and</strong> conduct a more extensive inspection.<br />
C. reject the bad fitting <strong>and</strong> assume the remainder of the lot is acceptable.<br />
D. in<strong>for</strong>m the manufacturer of his poor quality materials.<br />
25. <strong>Material</strong> test reports should _______________<br />
a. be considered a substitute <strong>for</strong> PMI testing as long as the project engineer signs off<br />
they are acceptable.<br />
b. be considered a substitute <strong>for</strong> PMI testing as long as metallurgists signs off they are<br />
acceptable.<br />
c. be considered a substitute <strong>for</strong> PMI testing when it is near the end of the project.<br />
d. not be considered a substitute <strong>for</strong> PMI testing.<br />
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API578<br />
26. How long should records of PMI testing <strong>for</strong> new <strong>and</strong> existing piping systems be<br />
kept?<br />
a. Records should be kept as long as the piping system remains in the original<br />
location.<br />
b. Records should be kept until the next PMI survey is per<strong>for</strong>med<br />
c. Records should be kept as long as the plant is not sold.<br />
d. None of the above.<br />
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Fion Zhang/ Charlie Chong<br />
API578
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Chemical Laboratory Chemical<br />
Analysis<br />
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API578<br />
Chemical Laboratory Chemical Analysis<br />
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Chemical Laboratory<br />
Chemical Analysis<br />
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574-12<br />
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