Guidelines for a Material Verification Program (MVP) for New and Existing Assets

API RECOMMENDED PRACTICE 578 THIRD EDITION, FEBRUARY 2018

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Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manufacturer, or supplier of that material, or the material safety data sheet.

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Foreword

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Contents

Page

1. Scope 1

   1. Purpose 1

   2. About this Document 1

   3. Supersedes Notice 1

2. Normative References 1

3. Terms, Definitions, and Acronyms 2

   1. Definitions 2

   2. Acronyms 3

4. Considerations and General Concerns 4

   1. Carbon Steel Substitutions in Low-alloy Steel Systems 4

   2. Alloy Substitutions for Carbon Steel. 4

   3. Stainless Steel and Nonferrous Substitutions Within High-alloy Systems 4

   4. Residual Elements in Carbon Steels in Hydrofluoric Acid Alkylation Units 4

   5. Process Units Susceptible to Sulfidation 4

   6. Gasket Materials 5

   7. Refractory Installation Systems (Anchors) 5

5. Material Verification Programs 5

   1. General 5

   2. Asset Components Included in a Material Verification Program 5

   3. Mill Test Reports and Usage in an MVP 6

   4. Roles and Responsibilities 6

   5. New Construction MVP 6

   6. Existing Installed Assets MVP 7

   7. MVP as an Element of Maintenance Systems 8

6. PMI Methodology and Technology 10

   1. General 10

   2. MVP Test Method Objectives 10

   3. PMI Procedure 10

   4. Personnel Qualifications 10

   5. Chemical Analysis Techniques 10

   6. Sorting Analysis Techniques 11

   7. Spectrometer Technology 11

   8. Safety Issues 13

7. Evaluation of Testing Results 14

   1. Material Acceptance Methods 14

   2. Follow-up PMI after Discovery of a Nonconformity 14

8. Materials Identification 14

   1. Identification Process 14

   2. Color Coding/Marking 15

   3. Marking of Components 15

9. Documentation and Recordkeeping 15

   1. Shop and Field PMI Documentation 15

   2. New and Existing Equipment or System Documentation 15

   3. PMI Records 15

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Contents

Page

Annex A (informative) Statistical Terminology 17

Bibliography 18

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Guidelines for a Material Verification Program (MVP) for New and Existing Assets

1. Scope

   
   

   1. Purpose

      
      

      The purpose of this recommended practice (RP) is to provide guidelines for an owner/user to develop and implement a material verification program (MVP) as part of an asset integrity program. The MVP uses positive material identification and other methods to verify that the nominal composition of an asset, an asset component, or weldment within the pressure envelope is consistent with the selected or specified construction materials.

      
      

      A well-designed and well-implemented MVP is an important management system used to minimize the potential for release of hazardous substances due to nonconforming materials of construction.

      
      

   2. About this Document

      
      

      This recommended practice provides the guidelines for material verification programs involving ferrous and nonferrous alloys during the construction, installation, maintenance, and inspection of new and existing process equipment. It applies to metallic materials purchased for use either directly by the owner/user or indirectly through distributors, fabricators, or contractors, and includes the supply, fabrication, and installation of these materials.

      
      

      This recommended practice is applicable to all refining and petrochemical industries, and may be applied in other industries and or businesses at the discretion of the owner/user. It is intended to be applied by any owner/user wishing to verify and/or validate that the materials of construction received, fabricated, and/or installed are in accordance with material and/or company specification(s).

      
      

   3. Supersedes Notice

      
      

      This version of API RP 578 (third edition) supersedes and wholly replaces the second edition (2010) of API RP 578 (Material Verification Program for New and Existing Alloy Piping Systems). The third edition contains many of the same paragraphs and language of the second edition, but it has been revised, reformatted, and re-visualized into a more encompassing document for all types of assets that may have an applicable material verification program.

      
      

2. Normative References

   
   

   There are no documents considered to be normative for the application of this document. A bibliography can be found at the end of this document.

   
   

3. Terms, Definitions, and Acronyms

   
   

   1. Definitions

3.1.1

alloy material

Any metallic material (including welding filler materials) that contains alloying elements, such as chromium, nickel, or molybdenum, that are intentionally added to enhance mechanical or physical properties and/or corrosion resistance. Alloys may be ferrous or nonferrous.