Guidelines and Application Procedures For API 578 PMI Final
Guidelines and Application Procedures For API 578 PMI Final
Guidelines and Application Procedures For API 578 PMI Final
Presented on : March 6, 2012 Presented by : Don Mears-Oil & Gas Industry Consultant & Trainer
API/TPCP -0118
Presentation Outline:
Introduction New Construction- QA/MVP Programs Existing Piping Systems ( Retro-Active PMI ) Programs PMI Field Testing Methods ( XRF or OES ) Technologies Control of Incoming Materials & Warehouse Elements of Maintenance Systems for PMI Recording & Reporting PMI Test Results Conclusion ( Questions & Answers )
Dr. Moure-Eraso with USA Chemical Safety Board (CSB) urges companies to take action to prevent accidents, including:
Implement a robust mechanical integrity programs with an emphasis on thorough inspections of critical equipment Monitor process safety performance using appropriate leading and lagging indicators to measure process safety before major accidents occur Maintain an open and trusting safety culture where near-misses and loss of containment incidents are reported and investigated
Aerial view of the damaged heat exchangers following the April 2, 2010 fire
Introduction: Why Did OSHA Establish the National Emphasis Program (NEP) Program in USA?
Occupational Safety and Health Administration (OSHA) Acts
Process Safety Management (PSM) 1910-119-Highly Hazardous Chemicals (HHC) 2/24/1992 (Regulation) Refinery National Emphasis Program (NEP) CPL 03-00-004 6/7/2007 (Enforcement) Chemical National Emphasis Program (NEP) 09-06 (CPL 02) Notice Pilot NEP 7/27/2009 (Enforcement) Standard-API-570-Piping Inspection Code Standard-API-510-Pressure Vessel Inspection Code Standard-API-653-Storage Tank Inspection Code Recommended Practice-API RP-578-Material Verification Program-MVP/PMI Recommended Practice-API 571 HF Corrosion in CS Pipes ( REs, Cr, Cu, Ni ) Recommended Practice-API 939-C-Guidelines for Avoiding Sulfidation, & Retro-Active PMI, 7.1.4&5
Understanding HOW, WHY, & APPLYING: API 578 PMI Guidelines and Applications Proper Training and Refresher Training Needed Data Management Software- Now Required for PMI (PCMS, Ultra-Pipe, Meridian, Solid PMI)
New Construction: Do Not Rely Solely on Supplier Material Test Reports (MTRS)
Experience has shown that you cannot rely on material test reports (MTRS) alone; there can be significant errors. One customer site survey revealed as much as 40% of material test reports (MTRS) did not match actual chemistry. They also tend to loose the reports. They get separated from the existing material.
New Construction: PMI Cycle Overview- Renewed & Now Required Emphasis
Residual Elements found in Carbon Steel (i.e. Cr, Cu, NI, V, Ti) MTRs Normally do not test for these Elements and should not be in the Carbon Steel ! But They Are There!!!
Programs :
Priority for API RP 578 2nd Edition High Temperature Sulfidic Corrosion - API RP 939-C
Process Units Susceptible to Sulfidation:
Carbon Steels with low silicon (0.10%) content can corrode at an accelerated rate Assets at risk from this type of degradation should apply PMI control to determine Silicon levels. (Retro-Active PMI is suggested and to follow API 578.) See API 571 and API RP 939-C See Section 7.1.4 & 5
HF Alkylation Unit Retro -Active PMI for Residual Elements in Carbon Steel API 571
Cons:
Cons:
Report New Construction Report Existing Piping Report Date: Shop Ref No. Item Tag No. Performed By:
Reading No
Material Description
Grade of Material
Traceability to Field Components; the information listed in PMI Test Records should be reported in such a manner that they are traceable to the point of installation.
Remarks
Heat No.
Accept
Reject
The best way to tie the Report Documentation to the field PI&D or ISO drawings, is to mark the drawings ( Electronically or Manually) and enter this (drawing number) in the XRF/OES Analyzer. It is strongly suggested that you keep both paper and electronic files on this documentation.
Enter data into Analyzer
PMI PMI
PMI
Interface with Data Management Software (i.e. PCMS, Ultra-Pipe, Meridian, Solid AIM & RBI Software)
Conclusion :
Introduction New Construction- QA/MVP Programs Existing Piping Systems ( Retro-Active PMI ) Programs PMI Field Testing Methods ( XRF or OES ) Technologies Control of Incoming Materials & Warehouse Elements of Maintenance Systems for PMI Recording & Reporting PMI Test Results Conclusion ( Questions & Answers )
API/TPCP -0118