150201.pdf

PETRONAS TECHNICAL STANDARDS

Positive Material Identification (PMI)

PTS 15.02.01 November 2016

© 2016 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.


POSITIVE MATERIAL IDENTIFICATION (PMI)

Page 2 of 18

FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge, experience and best practices of the PETRONAS group supplementing National and International standards where appropriate. The key objective of PTS is to ensure standard technical practic e across the PETRONAS group. Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes all phases of work activities. Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of work, goods and services meet the required design and engineering standards. In the case where specific

requirements

are

not

covered

in

the

PTS,

it

is

the

responsibility

of

the

Contractors/manufacturers/suppliers to propose other proven or internationally established standards or practices of the same level of quality and integrity as reflected in the PTS. In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall ensure accuracy and completeness of the PTS used for the intended design and engineering requirement and shall inform the Owner for any conflicting requirement with other international codes and technical standards before start of any work. PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or otherwise) or be disclosed by users to any company or person whomsoever, without the prior written consent of PETRONAS. The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to PETRONAS that this requirement is met.

PTS 15.02.01 POSITIVE MATERIAL IDENTIFICATION (PMI)

November 2016 Page 3 of 18

ANNOUNCEMENT

Please be informed that the entire PTS inventory is currently undergoing transformation exercise from 2013 - 2015 which includes revision to numbering system, format and content. As part of this change, the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and where required make reference to other PTS in its revised numbering to ensure consistency. Users are requested to refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For further inquiries, contact PTS administrator at [email protected]



Table of Contents 1.0

2.0

3.0

INTRODUCTION ..................................................................................................... 5 1.1

SCOPE .............................................................................................................................. 5

1.2

GLOSSARY OF TERM ........................................................................................................ 5

1.3

SUMMARY OF CHANGES ................................................................................................. 6

TECHNICAL REQUIREMENTS ................................................................................... 7 2.1

EXTEND OF PMI ............................................................................................................... 7

2.2

LOCATION AND TIMING OF PMI ..................................................................................... 7

2.3

INSTRUMENTATION ........................................................................................................ 7

2.4

TESTING PROCEDURE ...................................................................................................... 8

2.5

OPERATOR QUALIFICATION ............................................................................................ 8

2.6

ACCEPTANCE CRITERIA.................................................................................................... 9

2.7

IDENTIFICATION .............................................................................................................. 9

2.8

DOCUMENTATION ........................................................................................................ 10

BIBLIOGRAPHY .................................................................................................... 12

APPENDIX 1

: ALLOY IDENTIFICATION CHECKLIST ....................................................... 13

APPENDIX 2

: ELEMENTS TO BE DETERMINED DURING PMI ........................................... 15

APPENDIX 3

: EXTEND OF PMI – INSTALLED MATERIALS AND WELDS .............................. 16

APPENDIX 4 : BASE MATERIAL AND WELD FILLER METAL COMPOSITION REQUIREMENTS (WT %) .................................................................................................. 17



1.0

INTRODUCTION

This PETRONAS Technical Standards (PTS) provides the minimum technical requirements for Positive Material Identification for materials for all pressure equipment, piping, pipe fittings and weldments. This PTS was developed to ensure integrity of the equipment for the desired range of operations. This PTS also incorporates PETRONAS lesson learnt and best practices. 1.1

SCOPE

1.1.1

This PTS specifies the requirements of PMI for Low Temperature Carbon Steel, Low Alloy and Alloy materials and fabricated assemblies at all stage of manufacturing and fabrication for onshore and offshore facilities. PMI of non-pressure retaining components, if there is a significant risk, may be specified in the project specification.

1.1.2

Carbon Steel is excluded from this PTS.

1.2

GLOSSARY OF TERM

1.2.1

General Definition of Terms & Abbreviations Refer to PTS 00.01.03 for PTS Requirements, General Definition Of Terms, Abbreviations & Reading Guide.

1.2.2

Specific Definition of Terms No

Term

Definition

1

Inspector

Person who execute and evaluate PMI results.

2

Lot

Prescribed quantity of material that is made to the same specified size and specified wall thickness, by the same material-manufacturing process, from the same heat and under the same material manufacturing.

3

PMI

A method used to verify both the type of material and chemical composition of designated items as specified in this specification or the purchase order Table 1: Specific Definition of Terms



1.2.3

Specific Abbreviations No

Abbreviation

Description

1

LTCS

Low Temperature Carbon Steel

2

PMI

Positive Material Identification Table 2: Specific Abbreviations

1.3

SUMMARY OF CHANGES

This PTS 15.02.01 (November 2016) replaces PTS 15.02.01 (October 2013).



2.0

TECHNICAL REQUIREMENTS

2.1

EXTEND OF PMI

2.1.1

PMI shall (PSR) be carried out on 100% of critical items as shown in Appendix 1 of Alloy Verification Identification Checklist.

2.1.2

Batch sampling on a statistical basis should be avoided, unless checks are performed at the manufacturer where large numbers of identical items are purchased and where a minimum of clearly visible heat numbers is involved.

2.2

LOCATION AND TIMING OF PMI

2.2.1

PMI shall be performed on materials which have not been subjected to a previous PMI examination, or for which there is no, or insufficient, PMI marking and certification, to the extent stated in Appendix 2.

2.2.2

For materials received at site, materials which have been subjected to a previous 100% PMI examination and for which there is supporting PMI marking and certification, shall, in principle, be accepted for receiving i nspection without further PMI.

2.2.3

Spot PMI checks shall be performed on materials subject to a previous sample PMI examination to ensure that material control procedures are operating correctly.

2.2.4

All installed alloy bulk materials and welds shall be subjected to PMI examination in the final 'as-installed' condition, but prior to insulation or painting, to the extent stated in Appendix 3.

2.2.5

If the PMI instrument cannot determined a particular element of the al loy, the PMI instrument shall be used to determine the major elements of the alloy. A traceable material test certificate shall be used to verify the remainder elements of the alloy.

2.3

INSTRUMENTATION

2.3.1

The PMI method used shall provide a qualitative determination of the critical alloy without interpretation by the PMI operator.

2.3.2

The following methods/instruments are acceptable: i.

Instruments shall have a suitable X-Ray tube or Isotope source, with alloy verification, quantitative element analysis with permanent recording capabilities. The alloy analyser used shall be detailed in Contractor’s PMI procedure. The procedure shall include technical information with sufficient comprehensive data to establish acceptance within project requirements.

ii.

Wet chemical analysis or other laboratory methods. This may include the following methods: a) Gravimetric b) Titrimetric c) Colorimetric



2.3.3

Test equipment or method used for testing shall be such as defined in API 578. All PMI instruments shall have been serviced within a period of 6 months. The date of the last service shall be stated on the PMI Report Forms.

2.3.4

All PMI instruments shall have a valid calibration certificate, in accordance with the instrument manufacturer's recommendation. Calibration shall be checked at the start of each working shift as a minimum.

2.3.5

Certified calibration 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.

2.3.6

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

2.3.7

PMI activities shall be sub-contracted to an independent PMI sub-contractor, to ensure that experienced, qualified PMI operators are employed.

2.4

TESTING PROCEDURE

2.4.1

Testing shall be performed in accordance with written test procedure which have been submitted to Contractor and approved by Owner prior to start of fabrication.

2.4.2

Written test procedure shall contain, as a minimum, the following information:

2.5

2.5.1

i.

Name and manufacturer of equipment to be used, or Names of any proposed analytical laboratories which might be used

ii.

Description of equipment operating principle

iii.

Calibration records, procedure and frequency

iv.

Equipment accuracy

v.

Surface preparation, cleaning, sample removal (as applicable), temperature of use (minimum and maximum)

vi.

Marking method for typical components

vii.

Acceptance criteria

OPERATOR QUALIFICATION

The minimum qualification of a PMI operator shall be: i.

Has undergone training on the use of the PMI equipment

ii.

Has successfully pass the examination (if required) to verify capability;



2.6

iii.

Has the necessary interpretive skills essential with the used of the PMI equipment;

iv.

Has the ability to identify erroneous material by the nearest alloy type to assist in making decisions on acceptability;

v.

Has satisfactory work experience with references.

ACCEPTANCE CRITERIA

2.6.1

The PMI results shall fall within t he chemical composition requirements of the ASTM, AWS or other applicable material specification allowing for the accuracy of the instrument. Any questionable PMI result shall be re-analysed using the same or another instrument, after verification of proper surface preparation. Refer to Section 2.6.2, below, for materials and welds that failed to meet the requirements on the second analysis.

2.6.2

Materials, components, or welds which does not require 100% PMI, if found unacceptable and failed on the second analysis, all o ther materials, components, or welds (same heat, lot, etc.) represented by that failed item shall be considered suspect.

2.6.3

The failed materials could be handled in the following: i.

Scrapping/ removing all materials, components, or weld represented by the test piece (all of that heat, lot, etc.) and replacing with new components or filler metals, or

ii.

Performing 100% examination of the remainder of the represented materials, components, or welds, and replacing each item that fails the PMI check, or

iii.

Verifying correct chemistry by laboratory chemical analysis

2.6.4

Allowance for dilution should be c onsidered for PMI on welds joining dissimilar base materials. Acceptable composition ranges for commonly used combinations of base material and weld filler metals are depicted in Appendix 4.

2.6.5

Should the suspected PMI results are verified by laboratory analysis, the laboratory analysis data shall be used and recorded.

2.7

IDENTIFICATION

2.7.1

All materials whether fabricated or loose that have passed PMI shall be marked. Marking shall be durable and long lasting throughout the life of the project.

2.7.2

Acceptable materials shall be marked “ PMI” by means of a low-stress (dot, vibratory or 'U' type) 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 thin-walled pipe etc., identification shall be by indelible, non-deleterious ink or paint. Height of marking shall be at least 6mm.

2.7.3

Marking materials shall not cause corrosion or other harmful effects. Minimum requirements for marking materials are as follows;



i.

The total chloride content shall not exceed 200ppm.

ii.

The total sulphur content shall not exceed 400ppm.

iii.

The total of low melting point metals such as lead, zinc, cooper, tin, antimony, and mercury shall not exceed 1%. From this total mercury shall not exceed 50 ppm.

2.7.4

Rejected material on receiving inspection shall be clearly marked as “DO NOT USE-PMI FAILED”, segregated in a separate, designated area, to prevent re-use. Rejected material found during construction shall be removed and replaced.

2.7.5

Rejected weld metal shall be removed by suitable means and the excavation shall be subjected to a PMI check prior to repair. Alternatively, the weld shall be completely removed, the weld preparation re-made and surface NDT, and re-welded. All repair welds shall be subjected to PMI. Welding, repair welding and NDT requirements shall follow PTS 15.10.06.

2.8

DOCUMENTATION

2.8.1

PMI results shall be reported in a PMI report form. The form as a minimum shall contain the following data; i.

Project/ PO No

ii.

PMI report no

iii.

Material manufacturer, material test record number, heat number and lot number, as applicable

iv.

Material and grade including material certificate and transfer record, as applicable

v.

PMI procedure

vi.

Name of PMI inspector

vii.

Contractor's name

viii.

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

ix.

Location and date of PMI examination

x.

Description of test method

xi.

PMI instrument name, serial number, last calibratio n date and last service date

xii.

Type of alloy examined per isometric

xiii.

Isometric number



2.8.2

xiv.

Equipment tag number or pipe spool number (PO No. For bulk items) for the specific piece tested

xv.

Quantitative analysis results for relevant elements (Results of elements)

xvi.

Conclusion (Results of Test (Pass/Fail))

The PMI report shall be included in the final piping isometric records or equipment final documentation records.



3.0

BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically designated by date, the latest edition of each Standards/Publications shall be used, together with any supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS

Index to PTS

PTS 00.01.01

PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide

PTS 00.01.03

Pressure Vessels

PTS 12.20.01

Weldable Martensitic Stainless Steel Line Pipe (Amendments/Supplements To API Spec 5LC)

PTS 15.10.06

INTERNATIONAL STANDARDS

API Material Verification Program for New and Existing Alloy Piping Systems

API RP 578:2ndEdition 2010

ASTM Materials Handbook

Vol. 03.05 & 0306

ASME Boiler & Pressure Vessel Code

Section II A, B & C



APPENDIX 1

: ALLOY IDENTIFICATION CHECKLIST

Alloy Identification Checklist Component

Extent

Pressure retaining parts

100 %

Pressure retaining welds - Shell - Heads - Nozzles - Fittings - Flanges - CRA lined or clad components

100% 100% 100% 100% 100% 100%

Welding - Welding consumables - Welds (pressure equipment) - Welds (repairs) - Welds (piping) - Attachment welds to pressure parts Load bearing attachments (as clips for platform and pipe support) Fired heaters, boilers and heat exchanger - Heater tubes - Heat exchanger tubes - Tubesheets - Fittings - Solid/ jacketed gaskets - Expansion joints - Channels - Pipe - Furnace tube hangers - Furnace tube supports - Air Cooled Heat Exchanger Header Plugs and Gaskets - Corrosion resistant Alloy (CRA) lined or clad components Clad/weld overlay - Nozzle - Shell course - Head - Clad restoring Internals - Tray - Distributors, nozzles, piping, supporting beams

Each lot before welding 100% 100% 100% 5% 5%

100% 5% each lot 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%

One reading for each Two readings for each One reading for each 100% 100% of incoming goods/5% after fabrication 100% of welds and components



Alloy Identification Checklist Component

Extent

Bulk material - Bolting - Gaskets

10% per lot (5 minimum per lot) 100% for ring type joint/10% for kamprofile

Pressure relieving equipment - Bellows - Body - Bonnet - Rupture disc

100% 100% 100% 100%

Alloy Identification Checklist Instrumentation Components

Extent

Orifice Plate

100% (321SS, 347SS, all chrome alloys and high nickel alloy)

Thermowell, other type insertion type instruments and positive displacement meters

10% (304/304L and 316/316L SS) 100% (321SS, 347SS, all chrome alloys and high nickel alloy)

Instrument tubing including insertion type


Control valve

100% (321SS, 347SS, all chrome alloys, high nickel alloy and all Custom Cast)

Valve trim


Displacer, magnetic level gauge and level chamber


Coriolis meters


Fabricated meter runs and fabricated 100% (321SS, 347SS, all chrome alloys and venturies (pressure retaining parts only) high nickel alloy)



APPENDIX 2

: ELEMENTS TO BE DETERMINED DURING PMI Materials

Elements To Be Determined

1Cr – 0.5Mo 1.25Cr – 0.5Mo 2.25Cr – 1Mo 5Cr – 0.5Mo 9Cr – 1Mo 2.25Cr - 1Mo - 0.25V

Cr, Mo, Cr, Mo, Cr, Mo, Cr, Mo, Cr, Mo, Cr,Mo,

12Cr (Type 410S/ 405) 12Cr 17Cr

Cr, Ni, Ti, Al Cr, Ni, Ti, Al Cr, Ni, Ti, Al

304 (L) 304 304 (H) 310 309 (L) 309 Nb 316 (L) 321 347

Cr, Ni, (C if specified in equipment data sheet) Cr, Ni C, Cr, Ni Cr, Ni, Mo, Nb(Cb), Ti (C if specified in equipment data sheet) Cr, Ni, Mo, Nb(Cb), Ti (C if specified in equipment data sheet) Cr, Ni, Mo, Nb(Cb), Ti (C if specified in equipment data sheet) Cr, Ni, Mo, (C if specified in equipment data sheet) Cr, Ni, Ti, Nb(Cb) (C if specified in equipment data sheet) Cr, Ni, Nb(Cb), Ti (C if specified in equipment data sheet)

Inconel 182/ 82 Inconel 625 Inconel 600 Incoloy 800 Incoloy 825 Admiralty Brass Aluminum Brass Cupro-Nickel (70-30) Cupro-Nickel (90-10) Monel 400 Titanium

Ni, Cr Ni, Cr, Mo, Nb(Cb) + Ta Ni, Cr Cr, Ni, Al, Ti, Cu Cr, Ni, Mo, Ti Cu, Sn, As Cu, Al, Zn Cu, Ni Cu, Ni Cu, Ni Ti

NOTE(S): List of materials is not exhaustive, and shall not be construed as limiting the alloy materials subject to PMI. Remark: For verification of minor elements e.g. low carbon in stainless steel type 304L or 410S , Contractor shal l specify identific ation methods and propose to Technical Authority for approval.



APPENDIX 3 No

1.

: EXTEND OF PMI – INSTALLED MATERIALS AND WELDS Material Type

Piping Bulk Materials

Materials and Welds

Piping, flanges, branch fittings etc. welded into line:

Flanged valves, fittings (e.g. plugs), strainers, filters etc. installed into line: 2.

Pressure Retaining Welds

Circumferential welds

Attachment welds

Description

Each component base material part, undertaken in conjunction with PMI of weld per Section 2.2 Each component base material part. Only body shall be tested on valves Each weld, with 1 test per weld seam for automatic and semiautomatic welding processes, and 1 test per weld seam and 1 test per 450mm weld length thereafter for manual welding processes (1) Each weld per component part (1)

NOTE(S): 1. For all welds, PMI shall be performed on completed weld capping pass and the base material on either side. Where carbon steel base material is welded to an alloy base material with an alloy weld metal, the carbon steel base material is exempted from PMI. Where carbon steel base material is welded to an alloy base material with a carbon steel weld metal, the carbon steel base material and the carbon steel weld metal are exempted from PMI.



Page 17 of 18

APPENDIX 4

: BASE MATERIAL AND WELD FILLER METAL COMPOSITION REQUIREMENTS (wt %)

Material

Cr

Ni

Mo

Cu

W

Notes

304L BM

18.0 – 20.0

8.0 – 12.0

---

---

---

308L WFM

19.5 – 22.0

9.0 – 11.0

0.75 max

---

---

E/ER308L & LT

304L Welds

18.0 – 22.0

8.0 – 12.0

0.75 max

---

---

NOTE 1

304L BM

18.0 – 20.0

8.0 – 12.0

---

---

---

316L BM

16.0 – 18.0

10.0 – 14.0

2.0 – 3.0

---

---

316L WFM

17.0 – 20.0

11.0 – 14.0

2.0 – 3.0

---

---

E/ER316L & LT

304L/316L Welds

16.0 – 20.0

8.0 – 14.0

3.0 max

---

---

NOTE 1

304L BM

18.0 – 20.0

8.0 – 12.0

---

---

---

316 BM

16.0 – 18.0

10.0 – 14.0

2.0 – 3.0

---

---

308L WFM

19.5 – 22.0

9.0 – 11.0

0.75 max

---

---

304L/316L Welds

16.0 – 22.0

8.0 – 14.0

3.0 max

---

---

304L BM

18.0 – 20.0

8.0 – 12.0

---

2.0 – 3.0

---

308L WFM

19.5 – 22.0

9.0 – 11.0

0.75 max

2.0 – 3.0

---

CD4MCu BM

24.5 26.5

4.75 – 6.0

1.75 – 2.25

2.75 – 3.25

---

304L/CD4MCu Welds

18.0 – 26.5

4.75 – 12.0

2.0 max

---

---

316L BM

16.0 – 18.0

10.0 -14.0

2.0 – 3.0

---

---

316L WFM

17.0 – 20.0

11.0 – 14.0

2.0 – 3.0

---

---

E/ER316L & LT

316L Welds

16.0 – 20.0

10.0 – 14.0

2.0 – 3.0

---

---

NOTE 1

316L BM

16.0 18.0

10.0 – 14.0

2.0 – 3.0

---

---

316L WFM

17.0 – 20.0

11.0 – 14.0

2.0 – 3.0

---

---

E/ER316L & LT

NOTE 1

E/ER316L & LT

NOTE 1

E/ER316L & LT



Page 18 of 18

Material

Cr

Ni

Mo

Cu

W

CD4MCu BM

24.5 – 26.5

4.75 – 6.0

1.75 – 2.25

2.75 – 3.25

---

316L/CD4MCu Welds

16.0 – 26.5

4.75 – 16.0

1.75 – 3.0

---

---

AL6XN BM

20.0 – 22.0

23.5 – 25.5

6.0 – 7.0

0.75 max

---

625 WFM

20.0 – 23.0

58.0 min

8.0 – 10.0

0.50 max

---

E/ERNiCrMo-3

AL6XN Welds

20.0 – 23.0

25.5 min

7.0- 10.0

0.75 max

---

NOTE 2

C-22 BM

20.0 – 22.5

Remainder

12.5 – 14.5

---

2.5 – 3.5

CD4MCu BM

24.5 – 26.5

4.75 – 6.0

1.75 – 2.25

2.75 – 3.25

---

C-22 WFM

20.0 – 22.5

Remainder

12.5 – 14.5

0.50 max

2.5 – 3.5

C-22/CD4MCu Welds

16.0 – 22.5

25.0 min

10.5 – 14.5

---

2.5 – 4.5

C-22 BM

20.0 – 22.5

Remainder

12.5 – 14.5

---

2.5 – 3.5

C-22 WFM

20.0 – 22.5

Remainder

12.5 – 14.5

0.50 max

2.5 – 3.5

E/ERNiCrMo-10

C-22 Welds

20.0 – 22.5

52.0 min

12.5 – 14.5

---

2.5 – 3.5

NOTE 1

BM: base metal; WFM: weld filler metal NOTE(S): 1. Acceptance is based on the combined base metal and WFM spec requirements.

2.

Acceptance is based on WFM spec and the expected amount of dilution for molybdenum.

Notes

NOTE 1

E/ERNiCrMo-10

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