PDRP-8440-SP-0015_Rev_F1.pdf

PARADIP REFINERY PROJECT SPECIFIC STANDARDS

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POSITIVE MATERIALS IDENTIFICATION

(PMI) AT SUPPLIER WORK PDRP-8440-SP-0015

PAGE : 2 of 18 REV : F1

DSN 1867

CONTENTS

SECTION SUBJECT 1.0 SCOPE ................................................................................................. 3 2.0 REFERENCED STANDARDS ............................................................. 4 3.0 DEFINITIONS....................................................................................... 4 4.0 PMI EXAMINATION ............................................................................. 4 4.1 General ................................................................................................ 4 4.2 Methods of PMI Examination............................................................. 5 4.3 Location, Timing and extent of PMI Examination............................ 6 4.4 Acceptance Criteria and Identification of Acceptable Materials .... 7 4.5 Rejected Materials .............................................................................. 7 4.6 Recording and Documentation ......................................................... 7 ATTACHMENTS ATTACHMENT A: PMI REPORT FORM - SHOP MADE WELDMENTS………………..19


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DSN 1867

1.0 SCOPE

1.1 This Standard defines the minimum Positive Material Identification (PMI) requirements to be performed at the Supplier's works, on all alloy materials, as defined herein, for equipment items allocated a unique tag number. This shall include, but not be limited to, the following items:

• Machinery (e.g. pumps, compressors, blowers)

• Pressure Vessels

• Heat Exchangers (e.g. shell & tube, air cooled, double pipe & multitube)

• Fired Heaters

• Special Piping Items

• Package Equipment

• In-line instruments (e.g. instrument control & relief valves, thermowells, orifice plates).

• Consumables (such as electrodes)

1.2 PMI shall be performed on all pressure retaining components, attachments, welds, bolting and gaskets to the extent defined in Table 1. The following items shall not be subject to PMI unless deemed critical in nature and specifically defined in the material requisition:

(i) Machinery rotating elements;

(ii) Valve gates, stem and trim;

(iii) Gaskets other than solid metal or metallic jacketed types (e.g. spiral wound gaskets);

(iv) Metallic insulation covering.

(v) Machinery lube oil, cooling water and steam piping

(vi) Carbon steel items

1.3 PMI, as defined in this Standard, is the responsibility of the Supplier of the equipment, even when the manufacture of the equipment is subcontracted.

1.4 The Supplier, or nominated sub-supplier if applicable, shall submit a PMI procedure for IOCL’s review in accordance with PDRP-8440-SP-0009. The procedure shall provide for the right of the Inspector to audit examinations.


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DSN 1867

2.0 REFERENCED STANDARDS

PDRP-8440-SP-0009 Submission of Welding and manufacturing Procedures for Review

API RP-578 Material verification programme for new and existing alloy piping system

3.0 DEFINITIONS

Inspector: IOCL’s or IOCL's appointed inspector.

Sub-contractor: Any sub-supplier or sub-contractor of any tier on whom the supplier has directly or indirectly placed a sub-order.

Supplier: Any party on whom an order is placed for the supply of equipment allocated a unique tag number.

Alloy: All non-carbon steel, including, but not limited to, Cr-Mo steels, austenitic, ferritic, matensitic and duplex stainless steels, nickel and copper based alloys, titanium alloys.

Tag Number: A unique identification number, allocated to an individual equipment item

Lot: All units from a common heat of material presented for inspection against a single purchase order item. In the case of valves, or similar items, where bodies/bonnets/covers may be from different heats, the Lot shall consist of all units with the same combination of heat numbers for pressure containing components.

Sample: One, or more, units selected at random from the Lot which are to be examined to determine acceptability of the Lot.

4.0 PMI EXAMINATION

4.1 General 4.1.1 PMI examination of alloy materials and welds is independent of any

certification, markings or colour coding that may exist and is aimed at verifying that, where alloy materials are specified, only the correct alloy grades are installed.


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4.1.2 Upon receipt at the Supplier's works, or nominated sub-supplier's works if applicable, all alloy material shall be quarantined in a material reception area pending verification of the identification markings, any colour coding, materials certificates and, where applicable, preceding PMI records. Alloy material in quarantine shall be available for visual examination by the Inspector.

4.1.3 The Supplier, or nominated sub-supplier, shall identify all incoming alloy materials and maintain full traceability of all alloy materials, including all off-cuts. Transfer of identification marks shall be undertaken prior to cutting to ensure maintenance of identification on off-cuts.

4.1.4 The Supplier, or nominated sub-supplier if applicable, shall ensure that all alloy materials are segregated and stored in separately identified locations to prevent the mixing of different alloy specifications or alloy material with carbon steel. Non ferro-magnetic materials shall be segregated at all times from ferro-magnetic materials.

4.1.5 The Supplier, or nominated sub-supplier, shall have in place a programme for the control, disbursement and collection of welding consumables. This programme shall ensure that the correct welding consumables are employed for each weld.

4.1.6 PMI shall be subject to sample witness inspection by the Inspector. The Inspector may perform, or have performed by others, random PMI examinations, which may or may not, include those made by the Supplier or sub-supplier.

4.2 Methods of PMI Examination 4.2.1 The method used for PMI shall provide a quantitative and recordable

determination of the critical alloy elements in accordance with Table 2, without interpretation by the PMI operator.

4.2.2 The following methods/instruments are acceptable:

(i) Texas Nuclear Analyser Models 9266/9277

Spectroport

Spectrotest `F'

Niton XL-800 series multi-element analyser (XRF)

Metorex X-Met 2000/3000

Metorex Arc-Met

(ii) Wet chemical analysis or other laboratory methods.

(iii) Portable optical spectroscope (Metascope), subject to the operator passing a qualification test on 'unidentified' material, witnessed by the Inspector, and the procedure specifically approved by the IOCL in writing.


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DSN 1867

(iv) Chemical spot tests, magnets, alloy sorters and methods other than specified in clause no. 4.2.2 are not acceptable for PMI.

4.2.3 All PMI instruments shall have been serviced within a 6 month period of the time of use to verify the suitability of batteries, sources etc. The date of the last service shall be stated on the pro-forma PMI Report Form (Attachment A)

4.2.4 All PMI instruments shall be calibrated, in accordance with the instrument manufacturer's recommendation, at the start of each working shift as a minimum.

4.2.5 Ring Type Joint (RTJ) gaskets (rings) shall only be inspected by using portable X-ray fluorescence instruments.

4.2.6 Certified samples, with full traceability, of "known" alloy materials shall be available for use as a random spot check on the instrument calibration. These samples are in addition to any standard manufacturer's calibration sample.

4.2.7 Surfaces to be examined shall be prepared by light grinding or abrasive paper and solvent cleaning. Evidence of 'arc burn' resulting from the examination shall be removed by light grinding or abrasive paper.

4.2.8 It is advised, but not mandatory, that PMI activities be sub-contracted to an independent PMI sub-contractor, to ensure that experienced, qualified PMI operators are employed. In all cases, whether PMI activities are sub-contracted or performed in-house, records showing qualification and experience of PMI operators shall be available for inspection by the Inspector.

4.3 Location, Timing and extent of PMI Examination 4.3.1 All incoming alloy materials shall be subject to 'spot' PMI on a 5% sample

basis per Lot, minimum, to ensure that the Supplier's, or nominated sub-supplier's, material control procedures are functioning correctly.

4.3.2 PMI shall be performed on the components to the extent stated in Table 1, after the components have been built into the completed equipment item, or a readily identifiable sub-assembly, but before any post weld heat treatment (PWHT) or painting/insulation activities.

4.3.3 PMI shall, in principle, be performed at the Supplier's works. If the Supplier sub-contracts part of the manufacture, PMI shall be performed either at the appropriate sub-supplier's works, subject to the IOCL’s approval, or on the sub-assemblies on arrival at the Supplier's works and prior to incorporation into the main assembly. Where a sub-assembly requires PWHT at the sub-suppliers, PMI shall be performed at the sub-suppliers.

4.3.4 PMI shall be stated as a separate quality control activity on the Supplier's,or nominated sub-supplier's, quality plan.

4.3.5 Where a particular constituent of the alloy composition cannot be determined by the PMI instrument employed (e.g. carbon content in austenitic stainless steels, minor alloying elements in grades of titanium), the instrument shall be


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used to verify the major alloy constituents of the material and traceable material test certificates used to verify the remainder.

4.4 Acceptance Criteria and Identification of Acceptable Materials PMI acceptance criteria for materials/welding consumables/welds will be as per relevant codes/standards like ASTM/ASME/AWS etc.

Acceptable materials shall be marked by means of a low stress (dot, vibratory or 'U') hard stamp or indelible, non-deleterious ink or paint (i.e. free of low melting point metals such as zinc, lead, copper etc.), at or adjacent to each PMI sample point on each component or weld. For 'sensitive' materials such as gaskets, RTJ rings, thin-walled pipe etc., identification shall be by indelible, non-deleterious ink or paint.

4.5 Rejected Materials 4.5.1 Whenever material is identified as rejected, the material shall be suitably

marked with a red "X" using indelible, non-deleterious ink or paint.

4.5.2 Rejected material shall be segregated in a separate, designated area, to prevent their re-use.

4.5.3 Rejected weld metal shall be removed by suitable means and the excavation subject to a PMI check prior to repair. Alternatively, the weld shall be completely removed, the weld preparation re-made and surface non destructively examined, and re-welded. All repair welds shall be subject to PMI per Table 1, Section 11.

4.5.4 Where the rejection is identified by the Inspector, a rejection notice shall be issued by the Inspector. Where this rejection is identified by the Supplier's, or nominated sub-supplier's, quality control system, and the material is subsequently replaced with acceptable material, the Inspector shall identify this on the release notice and verify the corrective action undertaken.

4.5.5 The Supplier shall have the option of performing a more accurate analysis per para. 4.2.2(ii) on rejected material, at his own care and cost, to verify the composition of the rejected material.

4.5.6 The Supplier shall be responsible for replacing all rejected material with the correct specified material and performing PMI on this replacement material.

4.6 Recording and Documentation 4.6.1 PMI results, whether acceptable or rejectable, shall be reported on a PMI

Report Form (Attachment A). The Supplier may use his own form providing it includes all of the following data:

• Supplier's, or nominated sub-supplier's, name

• PMI sub-contractor's name and address, if applicable

• Purchase Order No. and Contract No.

• Equipment item no.


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• Location and date of PMI examination

• Description of method/ instrument used

• Instrument no. and date of last service

• List of equipment items with reference to fabrication drawings

• Results of PMI examination

• Type of alloy examined per location

• Conclusion

4.6.2 In addition to above, for complex equipment items (e.g. pressure vessels, heat exchangers), the report shall include a line drawing identifying, by number, each component and weld tested.

4.6.3 The PMI report shall be included in the Supplier's manufacturing data dossier.


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DSN 1867

TABLE 1: EXTENT OF PMI 1. Pressure Vessels and Shell and Tube Heat

Exchangers

Shell and head plates, including integral cladding on

plate materials: Each component part (1)

Nozzle pipes and fittings - if welded, weld shall be

examined in accordance with Section 11: Each component part (1)

Forgings, including nozzle and girth flanges: Each component part (1)

Major load bearing external and all internal

attachments, including alloy sections of support skirts, welded directly to the pressure retaining components:

Each component part (1)

Pressure retaining welds: Refer to Section 11

All attachment welds to the pressure retaining

components: Each weld per component part

Deposited weld overlay including clad restoring: Refer to Section 11

Floating head - if welded, weld shall be tested in

accordance with Section 11: Each component part (1)

Tubesheets: Each component part

Tubes: Sample basis per Table 3

Tube-to-tubesheet welds: Refer to Section 11

Bolting: Refer to Section 12

Gaskets: Refer to Section 13

Non-load bearing external attachments welded

directly to the pressure retaining components; internals, including trays, baffles, etc.:

PMI not required unless specifically defined in the material requisition

2. Air Cooled Heat Exchangers

Header plates: Each component part (1)


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DSN 1867

Nozzle pipes and fittings - if welded, weld shall be examined in accordance with Section 11:


Forgings, including nozzle flanges: Each component part (1)

Major load bearing external attachments, and pass

partition plates, welded directly to the pressure retaining components:


Pressure retaining welds: Refer to Section 11 All attachment welds to the pressure retaining


Tubes and header plugs: Each tube and plug

Tube-to-header welds: Refer to Section 11 Bolting: Refer to Section 12 Gaskets: Refer to Section 13 Non-load bearing external attachments welded

directly to the pressure retaining components: PMI not required unless specifically defined in the material requisition

3. Double Pipe and Multitube Exchangers

External alloy piping, bends, nozzles, flanges: Each component part (1)

Tubes: Sample basis per Table 3 Pressure retaining welds: Refer to Section 11 All attachment welds to the pressure retaining


Bolting: Refer to Section 12 below Gaskets: Refer to Section 13 below Non-load bearing, minor internal and external

attachments welded directly to the pressure retaining components:

PMI not required unless specifically defined in the material requisition

4. Plate Exchangers


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DSN 1867

Plates: Sample basis per Table 3


Bolting: Refer to Section 12 5. Machinery

All pressure retaining components, including

auxiliary process fluid piping, valves etc.: Each component part


All attachment welds to the pressure retaining


Bolting: Refer to Section 12 Gaskets: Refer to Section 13

Machinery internal rotating elements, lube oil,

cooling water and steam piping: PMI not required unless specifically defined in the material requisition

6. Valves

All pressure retaining components, including bodies, bonnets, plugs, vents, bleeds, drains etc.:

Each component part




Valve gates, stems, trim, internal bellows seals: PMI not required unless

specifically defined in the material requisition

7. Package Equipment

Individual vessels, exchangers, valves, machinery

etc.: Refer to individual sections above

Piping, fittings, forgings including flanges: Each component part (1)



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DSN 1867


Gaskets: Refer to Section 13 Instruments: Refer to Section 10

8. Fired Heaters

All pressure retaining tubes, bends, fittings, flanges

etc.: Each component part (1)

Manifolds, (longitudinal welds shall be examined in

accordance with Section 11): Each component part (1)

Pressure retaining manifold and coil welds: Refer to Section 11



9. Special Piping Items

All pressure retaining components, including piping, fittings, forgings including flanges, castings:





10 Instruments up to, and including, the first block valve

Control and relief valves: Refer to Section 6 above

Thermowells, orifice flanges, orifice plates etc.: Each component part (1)




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DSN 1867

Gaskets: Refer to Section 13 11. Pressure Retaining Welds

Circumferential welds, including nozzle pipe-to-

flange welds, and nozzle-to-shell/head welds; Longitudinal welds (3):

Each weld, with 1 test per weld seam for automatic and semi-automatic welding processes, and 1 test per 450mm weld length for manual welding processes (2)

Weld overlay, including clad restoring: 1 test per square metre, or part thereof, minimum

Tube-to-tubesheet and tube-to-header welds: 10% of welds for ≤200 tubes; 5% of welds for >200 tubes, with maximum of 50 welds tested.

Repair welds: 1 test on excavated weld to ensure incorrect material fully removed; thereafter 1 test per 450mm repair weld length

12. Bolting

External pressure retaining bolting for flange rating Classes <900:

Sample basis per Table 3

External pressure retaining bolting for flange rating Classes >=900:

Each bolt and nut

Valve bonnet bolting for flange rating Classes <900: Sample basis per table 3

Valve bonnet bolting for flange rating Classes

>=900: Each bolt and nut

Internal bolting: Sample basis per Table 3

13. Gaskets


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Notes:

(1) PMI on these components may be undertaken in conjunction with PMI of the deposited weld metal per Note 2.

(2) For all welds, PMI shall be performed on the completed weld capping pass

(both internal and external, where access permits) and the base material on either side.

(3) For longitudinally welded bulk pipe and fittings where no evidence exists

that PMI was performed at the source of supply, PMI shall be performed to the extent stated for longitudinal welds made by the Supplier, or nominated sub-supplier.

Solid metal or jacketed metallic gaskets for flange rating Classes >=900:

Each gasket

Alloy rings associated with ring-type joints (RTJ'): Each ring

Gaskets, other than above: PMI is not required


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TABLE 2: ELEMENTS TO BE DETERMINED DURING PMI

MATERIALS (1) ELEMENTS TO BE DETERMINED

1 Cr - 0.5 Mo 1.25 Cr - 0.5 Mo 2.25 Cr - 1 Mo 5 Cr - 0.5 Mo 9 Cr - 1 Mo

Cr, Mo, V Cr, Mo, V Cr, Mo, V Cr, Mo, V Cr, Mo, V

12 Cr (Type 410S/405) 12 Cr 17 Cr 304 (L) 310 309 (L) 309 Nb 316 (L) 321 347 Inconel 182/82 Inconel 625 Inconel 600 Incoloy 800 Incoloy 825

Cr Cr Cr Cr, Ni, Mo, Nb, Ti Cr, Ni, Mo, Nb, Ti Ni, Cr, Mo, Nb, Ti Cr, Ni, Nb, Ti, Mo Cr, Ni, Mo, Nb, Ti Cr, Ni, Ti, Nb Cr, Ni, Nb, Ti Ni, Cr Ni, Cr, Mo, Nb + Ta, Ti Ni, Cr Cr, Ni, Al, Ti, Cu Cr, Ni, Mo, Ti

Admiralty Brass Aluminium Brass Cupro-nickel (70-30) Cupro-nickel (90-10) Monel 400 Titanium

Cu, Sn, As Cu, Al, Zn Cu, Ni Cu, Ni Cu, Ni Ti

Note: (1) List of materials is not exhaustive, and shall not be construed as limiting

the alloy materials subject to PMI


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TABLE 3: REQUIREMENTS FOR SAMPLE PMI

Number of Units in a Lot Representative Sample

1 -5 100% of all units

6 - 199 5 units or 5%, whichever is greater

>=200 10 units or 3%, whichever is greater

Notes:

(1) If all units of the representative Sample are acceptable, the inspection Lot shall be acceptable.

(2) If any unit from the representative Sample is found to be unacceptable, the

remainder of the that Lot shall be examined 100%. If the remainder of the Lot is found acceptable, the sampling technique in Table 3 shall be resumed. The unacceptable unit(s) shall be replaced and the replacements examined 100%.

(3) If a Lot is found unacceptable, the next two Lots, of the same material

product and from the same source, shall be examined 100%. If both Lots are acceptable, the sampling technique in Table 3 shall be resumed.

(4) If any of the Lots examined in (3) above is found unacceptable, the

remaining material product from the same source shall be examined 100%. Any unacceptable unit(s) shall be replaced and the replacements examined 100%.

(5) Examination of 100% of the units is required when the materials are obtained from a Supplier's, or nominated sub-supplier's, in-house stock, or when markings are incomplete, preventing positive correlation with a material test certificate.


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ATTACHMENT A: PMI REPORT FORM - SHOP MADE WELDMENTS

POSITIVE MATERIAL IDENTIFICATION (PMI) - Shop Made Weldments

PMI Report #________ Page______of________

FW Contract No: Supplier: FW Order No: Supplier's Ref No: FW Requisition No: Sub-Supplier: Sub-Suppler Ref No: 1. Description of Equipment Item Description/Ref: Heat No: Drawing No: Certificate No: Drawing or Outline Sketch: (appended/not appended)

2. PMI Results

Alloy Content (Wt%) Weld No.

Weld metal PMI

Base Matl. #1 PMI Result

Base Matl. #2

PMI Result Cr Mo Ni V Nb Ti Cu

Accept/ Reject

Insp Initials

Date

Alloy content (wt%):

Examination Location: PMI Inspector: Examination Date: IOCL: Instrument Type/ID No.: Signature: Date of Last Service: Date: (include certificate) Stamp


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ATTACHMENT A: PMI REPORT FORM - SHOP MADE WELDMENTS (cont.)

POSITIVE MATERIAL IDENTIFICATION (PMI) - Shop Made Weldments

PMI Report #________ Page______of________

2. PMI Results

Alloy Content (Wt%) Weld No.

Weld metal PMI

Base Matl. #1 PMI Result

Base Matl. #2

PMI Result Cr Mo Ni V Nb Ti Cu

Accept/ Reject

Insp Initials

Date

Examination Location: PMI Inspector:- Examination Date: IOCL: Instrument Type/ID No.: Signature: Date of Last Service: Date: (include certificate) Stamp:

Documents

PDRP-8440-SP-0015_Rev_F1.pdf