P4049N 0000 DE00 SPC 0006 Project Specification for PMI

Kuwait National Petroleum Company (K.S.C.) New Refinery Project Project Specification for Positive Material Identification (PMI)

Am end m ent en t His t o r y Revision

Date

Reason Reason for Revision

R1

26.Feb.14

AMEC has prepared this this document based upon document document P4001NRP.00.10. P4001NRP.00.10.10.001 10.001 Rev D

0

06.May.14 06.May.14

Updated Updated in line line with Client Comments.

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Table of Cont ents 1.0

SCOPE ................................................................................................................................................... 4

2.0

DEFINITIONS ......................................................................................................................................... 4

3.0

GENERAL .............................................................................................................................................. 5

4.0

VERIFICATION METHODS A ND RESPONSIBIL ITY ........................................................................... 6

5.0

EXTENT OF VERIFICATION ................................................................................................................. 7

6.0

CONTROLS FOR CARB ON STEEL MA TERIALS ............................................................................... 9

7.0

PMI VERIFICATION ACTIVITIES ........................................................................................................ 10

8.0

PMI A CCEPTANCE CRITERIA ........................................................................................................... 10

9.0

IDENTIFICATION ................................................................................................................................. 11

10.0

QUALIFICATIONS OF PROCEDURES AND PERSONNEL .............................................................. 12

11.0

RETAINED DOCUMENTATION .......................................................................................................... 12

12.0

PMI INSPECTION/ANAL YSIS REPORT ............................................................................................. 12

13.0

STANDARDS A ND CODE INDEX ....................................................................................................... 12

14.0

AL LOY COMPLIANCE TESTING ........................................................................................................ 13

Tables TABLE 1 - ALLOY BY CHEMISTRY (PMI) REFERENCE ................................................................................ 13 TABLE 2 - ALLOY COMPONENTS PMI TEST FREQUENCY ......................................................................... 15 TABLE 3 - PMI FOR INSTRUMENTATION COMPONENTS ........................................................................... 18 TABLE 4 - ALLOY ELEMENTS REQUIRED FOR ALLOY VERIFICATION (AV) ............................................. 19 TABLE 5 - MATERIAL IDENTIFICATION CODES ........................................................................................... 21

Figures FIGURE 1 - PMI REPORT FORM ..................................................................................................................... 22 FIGURE 2 - LOCATION OF PMI IDENTIFICATION MARKS FOR PIPING (EXAMPLES) .............................. 23

Ap pend ices Append ix A

Abbreviations ........................................................................................................................... 24

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1.0

SCOPE

1.1

This Project Specification replaces Shell DEP 31.10.00.10-Gen.(February 2011) Positive Material Identification (PMI) Program for the purposes of the NRP project. The specification requirements include qualification of procedures and personnel, extent of verification, and verification marking and reporting.

1.2

Positive Material Identification (PMI) is a procedure used to verify that the nominal composition of alloy components and consumables is consistent with the selected or specified construction materials.

1.3

This Specification applies to “alloy material” as defined in paragraph 2.1 of this Specification. All alloy materials purchased and/or used in fabrication by the Supplier and any Sub-Suppliers and included in the scope of supply as defined in the Contractor’s P.O. shall be covered by these requirements.

1.4

Under no circumstances is this procedure to be used as a substitute for normal traceability procedures (e.g., Mill Test Reports, etc.) employed by Supplier as required by governing Codes and regulations. Mill Test Reports shall be obtained and provided to the Contractor as required by the base specification.

2.0

DEFINITIONS

2.1

Al lo y Materials in this specification are generally defined as all materials having a "P" number greater than 1, as defined in ASME Section IX, (QW-422) and includes any materials that contain alloying elements such as chromium, nickel or molybdenum that are intentionally added to enhance the mechanical or physical properties and/or corrosion resistance. The term alloy includes special grades of carbon steel such as low temperature (LT) and sour service grades. Aluminum (P-21 through P-25) is exempt from the requirements of this specification.

2.2

The Contractor is the party which carries out all or part of the design, engineering, procurement, construction, commissioning or management of a project or operation of a facility. The Principal may undertake all or part of the duties of the Contractor.

2.3

The Supplier (refers to Manufacturer/Fabricator/Supplier) is the party which manufactures or supplies equipment, materials and services to perform the duties specified by the Contractor.

2.4

The Principal is the party which initiates the Project and ultimately pays for its design and construction. The Principal will generally specify the technical requirement. The Principal may also include an agent “Third Party Inspection Agency (TPIA)” or consultant to act for, and on behalf of, the Principal.

2.5

With the exception of fasteners, an inspection lot is a group of components from the same heat number or heat treatment batch from which a sample is drawn. For fasteners, a lot is a group of similar components in terms of alloy type and size.

2.6

A traceable mill certificate (and other test certificates as required by Project Specifications) is a document that permits each component to be identified according to the original heat or material from which it was produced (see also 2.12). Material certificates shall be legible and comply with ISO 10474 or EN 10204 and the language used shall include English. Other languages are acceptable provided that these are accompanied by an endorsed, stamped and dated English translation of the original certificate to the satisfaction of the Contractor.

2.6.1

Certificates for final products (such as welded fittings) shall include certification of the base material and a copy of the welding procedure qualification applied. If the Manufacturer of a semi-finished product and the Supplier of the base material are not the same, the certificate shall consist of two documents covering both stages of the manufacturing process.

2.6.2

Certificates issued by material stockists or agents are not acceptable.

2.7

Representative Sampling is PMI testing of a sample, consisting of one or more pieces or components selected at random from an inspection lot, which will be examined to determine acceptability of the inspection lot.

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2.8

The word shall indicates a requirement.

2.9

The word should indicates a recommendation.

2.10

Bulks include flanges, fittings, valves, pipe, tubing, fasteners and instrumentation components.

2.11

PMI stamping on an item indicates Positive Material Identification has been done on that item.

2.12

A Mill Test Report (material test report), is a document verification that the material is of a certain grade. The report must identify the source of the material and include the chemical composition and physical properties of the material as originally produced by the mill or foundry, including documentation of all test results required by the material specification. The material must bear a heat number or some other kind of cross reference marking to positively identify that the report refers to that cast or heat of material. A traceable mill certificate as noted in 2.6 above is a special form of material test report and required for all pressure containment equipment.

2.13

Non-Destructive Test methods involve surface analysis techniques requiring only surface preparation and with no resulting adverse damage to the original sample integrity. These usually involve hand-held non-intrusive instruments of varying sophistication with direct recordable readouts.

2.14

Destructi ve Testing or wet analysis techniques require the removal of material by machining or grinding or the sacrifice of items representative of the lot and sent to a registered laboratory for spark, electron beam, nuclear or liquid chemical analysis.

3.0

GENERAL

3.1

PMI required by this specification is the responsibility of the Supplier and the Contractor as described in Section 4.0 and shall be carried out in the presence of the Principal's representative at his discretion. Contractor shall develop a Project PMI Program based on, but not limited to, this Specification.

3.2

For items requiring PMI by destructive tests or wet analysis, it is the Supplier's responsibility to provide samples for checking the chemistry as outlined in this specification. The Supplier shall have samples removed in the presence of the Contractor’s representative unless this requirement is waived by the Principal on a case-by-case basis.

3.3

This Specification requires PMI to be carried out at a time which ensures that proper materials are being used in the fabrication of an identifiable assembly (e.g., a pipe length welded into a spool, or a nozzle welded into a vessel, etc.). All PMI records are to be traceable to a material source and heat number. The Supplier shall demonstrate traceability at anytime. This will require the results to be incorporated into fabrication logs.

3.4

When traceability of a lot cannot be established back to a heat number, mill certification or other positive means of identification, then that lot of items, regardless of quantity, shall be examined 100%.

3.5

The representative sample for bulks (other than covered in Table 2) shall be:

3.5.1

One hundred percent (100%) for a lot of five (5) pieces or less;

3.5.2

The greater of five (5) pieces or 5% for a lot of five (5) to two hundred (200) pieces; and

3.5.3

The greater of ten (10) pieces or 3% for a lot greater than two hundred (200) pieces. If any piece from a representative sample is found to be unacceptable, each piece of that lot shall be examined.

3.6

When a lot is found to contain unacceptable pieces, 100% of the next two lots from the same Supplier and/or Sub-Supplier shall be examined. If both lots are acceptable, or when two successive lots are acceptable, the representative sampling frequency given in paragraph 3.5 of this Specification may be resumed.

3.7

Materials with no alloy type identification (i.e., permanent marking) cannot be PMI tested on a representative basis.

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3.8

Where items are rejected after verification, all remaining pieces of the same item from a particular Supplier shall be verified. Rejected items shall be returned to the original source of supply at no cost to the Contractor or Principal.

3.9

Verification of the weld seam alloy should be on the "wetted" (process) side of the fabrication if possible.

3.10

A material compatible solvent such as acetone should be used in cleaning of tools and sample surfaces prior to obtaining samples for destructive testing.

3.11

Test locations for non-destructive PMI testing shall be ground or otherwise prepared to the proper surface finish as specified by the analyzer device manufacturer.

3.12

Mill test reports shall not be considered as a substitute for PMI testing; however, mill test reports are an important part of an overall material quality program.

4.0

VERIFICATION METHODS AND RESPONSIBIL ITY

4.1

The state-of-the-art PMI machines can detect carbon plus elements in the periodic table from atomic number 12 (carbon) through atomic number 92 (uranium); low concentrations of certain elements are not detectable. Consequently, there are alloy materials which require destructive or wet laboratory analysis and they are identified in Table 1 - Alloy Material PMI Requirements. All PMI equipment to be used on the Project shall be calibrated in accordance to the requirements of API RP578, paragraph. 5.3.

4.2

Non-destructive and destructive tests by the Supplier(s) used for verification shall be capable of identifying the material qualitatively as an alloy. Typical test equipment for non-destructive testing is listed below: (a)

Metorex Arc-Met 930, 900 or 8000

(b)

Texas Nuclear Analyzer Model 9266

(c)

Texas Nuclear Analyzer Model 9277-XR

(d)

Columbia Scientific X-Met

(e)

X-Met 3000TXR

The Supplier shall submit a PMI procedure including the manufacturer and model number of any proposed PMI analyzer to the Contractor for acceptance prior to use. 4.3

For destructive testing, a sample from each heat of materials shall be forwarded to a laboratory. The name of the laboratory must be submitted to the Contractor for approval prior to forwarding the samples.

4.3.1

The sample shall be tagged with the Contractor’s purchase order number and item tag number. Upon receipt, the Supplier shall submit the results of the analysis to the Contractor for review.

4.3.2

Where destructive sampling of unique items is economically prohibitive, the Supplier(s) shall obtain the Contractor's permission to submit material test reports and non-destructive PMI test results to the Contractor in lieu of destructive testing. In such cases the Contractor must obtain approval from the Principal before proceeding.

4.4

The Supplier PMI Program shall provide for review and comment a PMI Program that complies with the requirements of this Specification, and as specified by the Contractor. The PMI Program shall consist of two basic elements:

4.4.1

A PMI Execution Plan which shall include the following minimum definitions and detail: 

“Who” is responsible for implementing the Program



“What” components and materials will be PMI inspected.



“When” items will be PMI inspected.



“Where” items will be PMI inspected.



“How” the Principal’s requirements for marking and documentation will be met.

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Kuwait National Petroleum Company (K.S.C.) New Refinery Project Project Specification for Positive Material Identification (PMI) 

4.4.2

Qualifications of the PMI technicians, including training and experience.

A PMI Procedure which shall consist of the following minimum definitions and detail: 

The PMI equipment to be used.



The equipment calibration requirements, including pre- and post-examination checks for equipment accuracy against known samples traceable to a recognized National Standard.



The PMI acceptance and rejection criteria.



The critical elements to be verified for each alloy type tested.



The methods employed for PMI testing, marking, and controlling of materials examined prior to use in fabrication.



The PMI and PMIV marking requirements, including methods, timing, and locations.



The documentation and traceability methods used for both accepted and rejected materials.

4.5

All Sub-Suppliers of the Supplier shall be covered by the Supplier’s PMI Program, and any instructions or requirements included in this Specification that are applicable to the Supplier shall also be applicable to any Sub-Supplier.

4.6

The Supplier shall not proceed with any PMI activities prior to receiving the Contractor’s prior approval to the Supplier’s PMI Program.

4.7

Where accessible, welds shall be examined on both the inside and outside surfaces, based on the sampling frequencies shown in paragraph 5.3 of this Specification. Where applicable, base metal welds shall be examined prior to the application of weld overlay or back cladding. The Supplier shall map all PMI tests of welds and weld repairs and include the PMI mapping in the final documentation.

4.8

Performance of PMI by non-destructive and destructive methods on shop/field fabricated alloy pipe, plate and weld consumables for materials being received directly from supply sources is to be performed by the Contractor in the same manner as described in paragraph 4.2. Shop/field fabrication material provided by a Supplier shall be positive material identified by the Supplier prior to erection in the field.

5.0

EXTENT OF VERIFICATION

5.1

During fabrication , vessels, heat exchangers, rotating equipment and shop/field fabricated piping including weld overlaid surfaces (stainless steel or other alloys) shall be subjected to PMI. Sampling is to be representative of each welding process used.

5.2

The following alloy materials specifically require PMI testing: 

Shell and head plates



Nozzle and manway forgings



Nozzle necks (pipe or plate)



Special forgings (shell rings or skirt-head-shell “Y”-forgings)



Rotating Equipment Components (i.e. casing, barrel, shaft, impellers, etc.).

Each individual pressure containing component shall be PMI tested. Multiple components (plates, pipes, flanges, nozzles, fittings, etc.) manufactured from the same heat of material, ingot, or base forging shall be individually tested. 5.3

All pressure containing welds shall be tested at the following testing frequency.

5.3.1

Category A and B Weld Seams per ASME VIII, UW-3 

Automatic welding: one sample per seam for seams less than 15 m in length; two samples per seam for seams greater than 15 m in length.



Manual welding: two samples per seam for seams less than 15 m in length; four samples per

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seam for seams greater than 15 m in length. 5.3.2

5.3.3

Category C and D Weld Seams per ASME VIII, UW-3 

Automatic welding: one sample per seam.



Manual welding: one sample per seam.

Piping Welding 

5.3.4

Weld Repairs 

5.3.5

Each weld in fabricated piping shall be subject to a minimum of one sample. Circumferential welds in piping 600 mm or larger nominal size shall be subject to a minimum of two samples.

One sample for every 600 mm of repair length, minimum 1 sample per repair.

Weld Overlay and Back Cladding Analysis of the weld overlay and back cladding material shall be performed to verify the specified alloy chemical composition and that the degree of alloy dilution is acceptable at the designated depth. This analysis shall include: 

If the function of the overlay is corrosion protection, a volumetric or surface analysis shall be completed at a minimum depth of 1.5 mm below the process-contacted surface.



If the function of the overlay is to assure product purity only, the sample shall be taken at a minimum depth of 1 mm.



In cases of in-accessibility a weld test sample should be completed for analysis, and tested. The test sample shall be welded for each welding process and for each heat and lot of filler materials.



5% of all weld overlaid surfaces



5% of all clad surfaces



5% of butt welds of clad restoration material

5.4

Any other components or materials specifically designated for 100% PMI testing in the Contractor’s P.O.

5.5

Welding Consumables Prior to use in fabrication, all alloy consumables (including those for both pressure containing and non-pressure containing welds) shall be PMI examined at the following frequency. 

Each heat of bare wire (for GMAW and GTAW);



Each lot of electrodes (for SMAW and FCAW); and



Each heat of wire / batch of flux combination (for SAW).

PMI testing of consumables shall be performed on a sample weld pad, typically welded in accordance with ASME Section II Part C (2013), SFA 5.4, paragraph 9.3. 5.6

Alloy stud fasteners shall be examined per paragraph 3.5 of this Specification.

5.7

The following items are exempt from PMI testing unless otherwise specified in the Contractor’s Purchase Order: 

All grades of carbon steel for use in normal refinery and chemical plant service. Refer to section 6.0 for Controls for Carbon Steel Materials in specialty services, such as low temperature (LT), sour service, HFA service, etc.



Internal valve components that are standard from the Manufacturer Note:



High alloy valve trim upgrades that are performed in a valve modification shop are included as part of the incoming goods QA program.

All standard cast 304 and 316 stainless steel valves, control valves and machinery components, although for services where the molybdenum content is critical, such as

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naphthenic acid services, 316 SS components shall be tested. 

Internal parts of machinery and pumps made of type 304, 316 stainless steel or brass.



Instrumentation, such as orifice plates, venturi internals; and secondary (e.g., that are downstream of primary block valves) tubing and components that are made from 304, 304L, 316 and 316L stainless steel or copper.



All cast brass valves.



Auxiliary equipment such as machinery lube oil systems, hydraulic systems, steam tracing and steam turbine gland vacuum systems.



Standard (304 stainless steel) spiral wound gasket materials, however higher alloy spiral wound gasket materials do require PMI testing based on the Table 2 minimum requirements.



Non-pressure process internals.



Non-pressure containing welds.

6.0

CONTROLS FOR CARBON STEEL MATERIALS

6.1

Carbon steel for use in general refinery and chemical plant service does not normally require PMI controls or testing. However, for some services, micro alloying, restricted chemistries and/or heat treatment of carbon steel material may be specified to ensure that equipment will perform suitably in-service. Refer to NACE Standard MR0103:2012; Materials Resistant to Sulphide Stress Cracking in Corrosive Petroleum Refining Environments.

6.2

PMI testing/Material verification of carbon steels shall be applied in the following services: 

Sour service and hydrofluoric acid service - carbon steel materials and B7M bolting where HIC resistant material or maximum hardness levels are specified.



Hydrofluoric acid service (e.g., Hydrofluoric Alkylation) - carbon steel materials with restricted carbon content and residual elements requirements.



Service where silicon (Si) content is critical to corrosion resistance (e.g., carbon steels with low silicon may corrode at an accelerated rate when exposed to hydrogen-free sulfidic conditions).



Low temperature (LT) service – where carbon steel with enhanced low temperature properties (e.g., impact tested material) is specified.



Any other specific applications where carbon steel chemistry or properties are critical to avoid failure and loss of containment.

6.3

Carbon steel components above shall be verified by matching heat numbers of components to certified test certificates. Validation of this requirement shall be included in the PMI report (section 12).

6.4

Additional testing requirements for components above may include:

6.5



Hydrogen Induced Cracking (HIC) sensitivity tests to NACE MR0103.



Impact toughness testing of base materials and welded coupons



The use of specialty PMI testing equipment such as portable optical emission spectroscopy devices to measure elements such as carbon, silicon, and other trace elements.

The Contractor shall specify when PMI testing or Material verification is required for carbon steels in other services at the bid stage. LT carbon steel shall be fabricated in a separate area from carbon steel in order to avoid mixing of component materials and electrodes. Colour codes shall be applied when carbon steel and LT carbon steel piping are handled concurrently.

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7.0

PMI VERIFICATION ACTIVITIES

7.1

Non-destructive PMI shall be performed by the Supplier or a Contractor approved third party, contracted by the Supplier. The Supplier shall certify that all PMI tests have been performed in accordance with API RP578 and this specification, and that all PMI testing has been performed at a point which will ensure the correct material was used in actual fabrication.

7.2

The Principal reserves the right to establish an Inspection Hold Point for each fabricated item just prior to surface preparation and painting. The Hold Point shall be used to verify that the correct materials, including deposited weld metal, and colour coding were used prior to the loss of material identity marking during surface preparation.

7.3

The Hold Point verification shall also include a review of the PMI Analysis Reports and a random spot check performed by the Supplier and witnessed by a Third Party Inspection Agency (TPIA), Consultant or Contractor to act for and on behalf of the Principal.

7.4

The Contractor shall be contacted prior to performing PMI on any dissimilar/bimetallic joints. The Supplier shall test both sides of the dissimilar weld and the consumable as a separate coupon. The Supplier shall demonstrate sufficient control of consumables and meet the ASME IIC deposition requirements.

8.0

PMI ACCEPTANCE CRITERIA

8.1

When quantitative, multi-element analysis is required, material components shall contain the amounts of alloying elements specified in Table 1 - Alloy Material PMI Requirements. Testing of material not included in Table 1 requirements shall comply with ASTM/ASME material specifications and Table 4.

8.2

The results of weld metal PMI shall meet the requirements of ASME Section II, Part C. Analysis need only be performed for those elements specified in Table 4 for comparable base materials.

8.3

If the PMI test results fall outside of the acceptable ranges, the item will be rejected.

8.4

This specification does not allow for percentage non-conformance. If any piece from a random sample is found to be unacceptable, then the remainder of that lot shall be verified by performing a 100% examination. If incorrect materials are shipped to the job-site, back-charge procedures will be initiated against the Supplier.

8.5

All rejected materials shall be isolated in a "HOLD" or “Quarantined” area, tagged "REJECTED", and a Non-conformance Report initiated by the Supplier for Contractor and Principal acceptance.

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9.0

IDENTIFICATION

9.1

After PMI has been successfully completed, each item piece shall be marked to identify the alloy type (i.e., PMI 1¼ Cr or PMI 316). The preferred marking methods are low stress stamps or vibra-etch. Other marking methods require the Principal’s agreement and authorization. Where colour coding is used, all practices should be in accordance with Pipe Fabrication Institute Standard ES-22, although BS 381C may be accepted with the Principal’s agreement. Cut lengths of pipe from PMI examined material are to have PMI markings transferred to all pieces. This marking is in addition to those normally required by applicable codes(s) or other job specifications.

9.2

Items which cannot accommodate this identification shall be individually tagged with the above 8.1 identification placed on tags.

9.3

Ink or paint shall be of a type whose chemistry (e.g., halide free) will not be detrimental to the material being identified and of an "indelible" type or other which is not easily removed. Using a low stress stamp or other marking must be approved by Contractor.

9.4

PMI marking shall be placed as follows: 

Pipe shall have two marks, 180 degrees apart, 75 mm from each end of each length for a total of four marks on the outer surface of the pipe.



Where representative sampling is allowed, pieces may be PMI tested upon receipt and those pieces tested shall be marked per 8.1 above. Items from the same lot that are not tested shall be marked PMI.



Weld marks shall be placed adjacent to the welder’s mark, directly on the weld.



Fittings and forgings shall be marked adjacent to the component manufacturer’s markings.



Plates shall be marked adjacent to the heat numbers.



Fasteners shall be marked on one end.



Nuts shall be marked on one flat

Notes:

1.

2.

Paint shall not be applied, in any circumstances, to the following: (a)

inside surfaces of pipe, flanges or fittings;

(b)

threads;

(c)

weld bevels;

(d)

symbols or markings which would obliterate identification;

(e)

gasket seating surface.

Colour codes shall be applied when carbon steel and LT carbon steel are handled concurrently.

9.5

Other items shall have each piece identified a sufficient number of times and at different locations to insure visibility of identification during the fabrication or erection cycle.

9.6

When heat treatment is performed after material verification, the identification markings shall be recognizable after the heat treatment.

9.7

The Supplier shall provide a “Quality Assurance Warehousing Procedure” for review by Contractor and Principal. The Procedure shall address controls established to prevent the inadvertent use of materials failing to pass examinations or those incorrectly identified (see paragraph 8.5).

9.8

As outlined in this specification, the Contractor will witness at his discretion the required examinations and application of the identification marks. This is not to be treated as an Inspection Hold Point by the Supplier. This will assure the Contractor that alloy materials have already received the necessary examinations and are acceptable.

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10.0

QUAL IFICATIONS OF PROCEDURES AND PERSONNEL

10.1

The party performing PMI shall submit a written procedure conforming to this specification for the Contractor review and written approval.

10.2

The written procedure shall include complete description(s) of methods and equipment to be used, the time in fabrication cycle when PMI will be carried out and the working method used to identify that PMI has been carried out.

10.3

It shall also include qualifications of personnel (in accordance to API RP578, paragraph 5.5 and this specification), who will be responsible for performing PMI examinations.

11.0

RETAINED DOCUMENTATION

11.1

The Quality Records and other forms and reports identified in and required by this specification shall be maintained by the Supplier and copies made available to the Contractor and Principal upon request.

12.0

PMI INSPECTION/ANALYSIS REPORT

12.1

The Supplier shall report destructive and non-destructive PMI/Inspection/Analysis Report results to the Contractor and include PMI test reports in the final Code Data Package. See Figure 1 for the PMI report form.

13.0

STANDARDS AND CODE INDEX Standards or Code

Descriptio n or Title

API RP578: 2010

Material Verification Program for New and Existing Alloy Piping Systems

ASME Section II Pt C: 2013

Materials Part C-Specifications for Welding Rods Electrodes and Filler Metals

ASME Section IX: 2013

Qualification Standard for Welding and Brazing Procedures, Welders, Brazers and Welding and Brazing Operators

ASME Section VIII: 2013

Boiler and Pressure Vessel Code (BPVC), Section VIII, Division 1.

ASTM A193

Standard Specification for Alloy-Steel and Stainless Steel Bolting for High Temperature or High Pressure Service and Other Special Purpose Applications

BSI BS 381C

British Standard Colour Charts

BSI BS 10204: 2004

Metallic products — Types of inspection documents.

ISO 10474: 2013

Steel and Steel Products - Inspection Documents.

NACE MR0103: 2012

Materials Resistant to Sulfide Stress Cracking in Corrosive Petroleum Refining Environments

Pipe Fabrication Institute ES-22

Recommended Practice for Colour Coding of Piping Materials

Shell DEP 31.10.00.10-Gen. (February 2011)

Positive Material Identification (PMI) Program

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14.0

AL LOY COMPLIA NCE TESTING

14.1

Where quantitative, multi-element analysis is required, materials and components shall contain the amounts of alloying elements specified in the following tables and as per the notes below: 

Alloy identification by nominal chemistry measurement shall be as per Table 1 where applicable. Where “Destructive” testing is indicated, laboratory analysis will be necessary.



The extent of PMI required shall either be “Standard” or “Full” in accordance with Table 2 and Table 3.



Table 2 defines the percentage of components subject to PMI for all items other than instrumentation.



Table 3 applies to instrumentation.



In case of conflict with other requirements, these tables are to be applied by preference.



For all grades of type 304 stainless steel (i.e., 304L, 304, and 304H), the extent of PMI shall be “Standard” and subject to requirements in the notes of Table 2 and 3.



For services where the addition of alloying agents may adversely affect the material properties in service, such as molybdenum content in phenol services, 304 SS components shall be tested in accordance with “Full”.



For all other alloy materials including all grades of Type 316 stainless steel, the extent of PMI shall be “Full” for both wrought base material and welds and subject to requirements in the notes in Table 2 and 3.



Refer to (5.8) for materials and components excluded from PMI testing. Implementation of an alternative PMI Program that defines the extent of PMI based on risk may be permitted, subject to the approval of the Principal.

TABLE 1 - ALLOY BY CHEMISTRY (PMI) REFERENCE Alloy

Ni

Cr

Mo

Others

Destructive

304

8.0 - 11.0

18.0 - 20.0

304 (Special Chemistry)

8.0 - 11.0

18.0 - 20.0

316

10.0 – 14.0

16.0 – 18.0

2.0 –3.0

316 (Special Chemistry)

10.0 - 14.0

16.0 - 18.0

2.0 – 3.0

317

11.0 - 15.0

18.0 - 20.0

3.0 - 4.0

321

9.0 -13.0

17.0 - 20.0

(C and Ti) (4)

No If Arc-Met 930, 900 or 8000

347

9.0 - 13.0

17.0 - 20.0

(Cb/Nb)

No

347H

9.0 - 13.0

17.0 - 20.0

(C, Cb/Nb) (5)

No If Arc-Met 930, 900 or 8000

No (1) (2) (3) (C only)

No If Arc-Met 930, 900 or 8000 No

(1) & (3) (C only)

No If Arc-Met 930, 900 or 8000 No

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Page 13 of 24


Alloy

Ni

Cr

Mo

1¼ Cr - ½ Mo (Standard) 2¼ Cr - 1 Mo (Standard)

- 1.50

0.44 - 0.65

No

1.90 - 2.60

0.87 - 1.13

No

1¼ Cr - ½ Mo (Special Chemistry) 2¼ Cr –1 Mo (Special Chemistry) 5Cr 9Cr 12Cr Duplex 2205 Super Duplex 2507

- 1.50

0.44 - 0.65

1.90 - 2.60

0.87 - 1.13 0.45 - 0.65 0.90 - 1.10

4.6 - 6.5 6.0 - 8.0

4.0 - 6.0 8.0 - 10.0 11.5 - 13.5 21.0 - 23.0 24.0 - 26.0

Incoloy 800 Incoloy 825

30.0 - 35.0 38.0 - 46.0

19.0 - 23.0 19.5 - 23.5

Hastelloy B-2 Hastelloy C-276

65.0 min. Bal.

Inconel 600 Inconel 625

72.0 min. 58.0 min.

Monel 400

63.0 min.

Alloy 20

36.5 – 38.0

Notes:

Others

Destructive

Si; 0.50 – 0.80 Si; 0.50 Max

Yes (P and Sn) (6) Yes (P and Sn) (14) No No No No No No

2.5 - 3.5

(7) (11)

No No

1.0 max. 14.5 – 16.5

26.0 - 30.0 15.0 – 17.0

(8) (12)

No No

14.0 - 17.0 20.0 – 23.0

1.0% Max. 8.0 – 10.0

(9) (13)

No No

2.0% Max.

Cu-28.0 to 34.0; Fe-2.5 Max. (10)

No

2.0 – 3.0

Cu 3.0 - 4.0 Mn 1.0 - 2.0

No

2.5 - 3.5 3.0 - 5.0

19.0- 21.0

For Table 1:

(Numbers in parentheses refer to the following notes) (1)

Carbon content: <0.035% for “L” Grades.

(2)

Carbon content: 0.04% - 0.06%.

(3)

Carbon content: 0.04% - 0.10% for “H” Grades.

(4)

Carbon content: 0.08% Maximum; Titanium content: 5 times Carbon Minimum to 0.07% Maximum.

(5)

Carbon content: 0.04% - 0.10%; Columbium (Niobium) content: 8 times Carbon Minimum to 1.0% Maximum.

(6)

The analysis of phosphorus and tin shall meet the following weight percent limits: P 0.012% and Sn  0.015%; (P+Sn) < 0.020. J-Factor = 150 max. (See note (14) below)

(7)

Ti: 0.15 - 0.60%.

(8)

Co: 1.0% Maximum; Iron content: 2.0% maximum.

(9)

Iron content: 6.0% - 10.0%.

(10)

Iron content: 2.5% Maximum.

(11)

Ti: 0.60% – 1.2%.

(12)

Co: 2.5% Maximum; W: 3.0 - 4.5%.

(13)

Iron content: 5.0% Maximum; Co: 1.0% Maximum; Ti: 0.40% Maximum.

(14)

J-Factor = (Si+Mn) x (P+Sn) x 10 shall not exceed 100. (Si, Mn, P, Sn: wt%)

4

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

Page 14 of 24


TABLE 2 - ALLOY COMPONENTS PMI TEST FREQUENCY Material

Full

Standard

Pipe (14)

ALL - 100 %

10 % (1,12)

Corrosion resistant Alloy (CRA) lined or clad pipe

ALL - 100 %

10 % (1,12)

Fittings (14)

ALL - 100 %

10 % (1,12)

Valves (7,14)

ALL - 100 %

10 % (1,12)

Expansion Joints and special items

ALL - 100 %

10 % (1,12)

Heater tubes (14)

ALL - 100 %

10 %(1)

Heat exchanger tubes

1 % (2)

1 % (2, 12)

Tubesheets (14)

ALL - 100 %

10 % (4, 12)

Fittings (14)

ALL - 100 %

10 % (1, 12)

Solid or jacketed gaskets

ALL - 100 %

10 % (1)

Expansion joints

ALL - 100 %

10 % (4)

Non-pressure retaining bundles: Baffles, tie-rods, seal strips, etc

10 % (1)

10 % (1, 12)

Channels (14)

ALL - 100 %

10 % (4, 12)

Pipe(14)

ALL - 100 %

10 % (1, 12)

Furnace tube hangers

ALL - 100 %

10 % (1)

Furnace tube supports

ALL - 100 %

10 % (1)

Air Cooled Heat Exchanger Header Plugs and Gasket

ALL- 100%

10% (1)

Corrosion resistant Alloy (CRA) linedor clad components

ALL - 100 %

10 % (1,12)

Shell (14)

ALL- 100 %

10 %(4, 12)

Heads (14)

ALL - 100 %

10 %(4, 12)

Nozzles (14)

ALL- 100 %

10 %(1, 12)

Fittings (14)

ALL - 100 %

10 %(1, 12)

Flanges (14)

ALL- 100 %

10 %(1, 12)

Corrosion resistant Alloy (CRA) lined or clad components (14)

ALL - 100 %

10 %(1,12)

10 %(1)

10 %(1)

Pump casing (14)

ALL- 100 %

100 %

Compressor casing (14)

ALL- 100 %

100 %

ALL - 100%

10 %(1)

Piping

Heat exchangers, boilers, fired heaters

Pressure retaining components of pressure vessels

Non-pressure retaining components of pressure vessels Tray components, downcomers, reactor bed internals Pressure retaining components of machinery

Instrumentation Control valve (7, 14)

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

Page 15 of 24


Material

Full

Standard

ALL - 100%

10 %(1)

ASTM A193 bolts above B7/B7M (12) only

5 %(3)(13)

5 %(3)

Non-standard spiral wound gaskets (>304 SS)

5 %(11)

5 % (11)

solid metal, metal jacketed, ring-type joint gaskets

ALL - 100 %

10 %(1)

Welds (pressure equipment)

ALL- 100 %(5)

5 % (8,9,10,12)

Weld (repairs)

ALL- 100 %(5)

5 %(8,9,10, 12)

Welds (piping)

ALL- 100 %(5)

5 %(6,8,10,12)

Weld overlay

ALL- 100 %(8,9,10)

5 %(6,8,9,10,12)

Bellows

ALL- 100 %

100 %

Body (14)

ALL - 100 %

100%

Bonnet (14)

ALL - 100 %

100%

Rupture disc (14)

ALL - 100 %

100 %

In-line instruments (14) Bulk material

Welding

Pressure relieving equipment

Notes:

1.

10 % of all the components purchased shall be examined. Components to be examined shall be selected by the purchaser. If any given sample of components has fewer than 10 items, one item shall be examined.

2.

1 % representative sample of the total number of tubes from each heat, lot and material specification of tubes.

3.

5 % of bolts supplied in bulk or two bolts per box, and per heat and lot, whichever is greater, shall be examined. Bolts to be examined shall be selected randomly by the purchaser.

4.

One examination per heat of material

5.

One spot on every cap pass of every pressure retaining weld shall be examined in accordance with Table 2.

6.

One spot on one cap pass per weld procedure per spool of piping shall be examined in accordance with Table 2.

7.

Valve body and bonnet only. However PMI testing of non-standard trim upgrades using high alloy material such as alloy 400 trim is recommended in the modification shop. Internal bonnets as found on “power seal” type valves are considered internal components as they typically cannot be accessed by PMI analyzers.

8.

Analysis of the weld overlay shall be performed to verify the specified alloy chemical composition and that the degree of alloy dilution is acceptable at the designated depth. This analysis shall include: 

If the function of the overlay is corrosion protection, a volumetric or surface analysis shall be completed at a minimum depth of 1.5 mm (0.060 inch) below the process-contacted surface.



If the function of the overlay is to assure product purity only, the sample shall be taken at a minimum depth of 1 mm (0.040 inch).

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

Page 16 of 24

Kuwait National Petroleum Company (K.S.C.) New Refinery Project Project Specification for Positive Material Identification (PMI) 

9.

In cases of in-accessibility a weld test sample should be completed for analysis, and tested as above. The test sample shall be welded for each welding process and for each heat and lot of filler materials.

One analysis per weld procedure shall be taken of the base filler material and/or overlay finished weld per note 8 (e.g., covering a base metal weld or joining the cladding of clad plates) on each major longitudinal and circumferential weld seam. Refer to the requirements for the following specific components: 

Nozzles: For nozzles and components lined with alloy weld metal overlay, one analysis per nozzle is required. For sleeve lined nozzles, one analysis for the flange face overlay and of the shell tie-in overlay is required.



Alloy Air Cooler Header Boxes: one analysis for each welding procedure used for long seams, end plates, and nozzles is required.



Machined components: the PMI analysis shall be completed on the finished machined components.

10. Analysis of the base filler metal and/or final closure weld seams of internally clad or weld overlaid components shall be made at location determined by the purchaser's designated Inspector. 11. 5 % of spiral wound gaskets shall be tested when the windings or ID ring are higher alloy than 304 SS. The PMI shall be of the area at the ends where there is no filler or if provided, the ID ring. 12. Equipment and piping fabricated of alloy material solely to maintain product purity is subject to 10% PMI including welds, with the exception of 304, 304L, 304H or 316, 316L, 316 H, unless otherwise specified by the Principal. 13. 100% of B7M bolting for HFA and sour service (if applicable) shall be tested for hardness as a part of the PMI program. 14. Carbon steel and Alloy 400 intended for Hydrofluoric Acid service requires “Full” testing.

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

Page 17 of 24


TABLE 3 - PMI FOR INSTRUMENTATION COMPONENTS Instrum ents

No PMI *

Orifice plate

304/304L and 316/316L SS

Thermowell, other type insertion type instruments and positive displacement meters (analyzer probes, FCI meters and vortex meters)

10 % PMI

100 % PMI Higher alloy (2)

304/304L and Higher alloy (1, 2) 316/316L SS

Instrument tubing including insertion type

304/304L and 316/316L SS

Higher alloy (1, 2)

Control valve

Cast 316 SS bulk produced CV

Higher alloy (2) or all Custom Cast

Valve trim

Standard trim from the manufacturer

High alloy trim upgrades at valve modification shops

Displacer, magnetic level gauges and 304/304L and level chamber 316/316L SS components and welds

Higher alloy (1,2)

Coriolis meters

304/304L and 316/316L SS components and welds

Higher alloy (1,2)

Fabricated meter runs and fabricated 304/304L and venturis (pressure retaining parts only) 316/316L SS components and welds

Higher alloy (1,2)

Notes:

1.

Includes venturies (external portion only), level bridles, Coriolis meter, magnetic level, displacer and other instruments installed in-line pressure retaining service upstream of the primary block valve. Only the accessible welds are to be tested in the field. Insertion type instruments such as thermowells, annubars, capacitance probes, FCI flow meters are exempt because of the low stress level and standard stainless construction. Insertion type instruments of alloys higher than 304/316 austenitic stainless require PMI. Excludes items that are not pressure retaining or not in-line instruments (downstream of the primary block valve), such as pressure transmitters.

2.

Higher alloy is 321SS, 347SS, all chrome alloys and high nickel alloy.

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

Page 18 of 24


TABLE 4 - ALLOY ELEMENTS REQUIRED FOR ALLOY VERIFICATION (AV) The individual alloy elements listed in Table 4 shall be evaluated during PMI testing, based on the specified alloy grade. Reference shall also be made to Table 1 for specific alloy chemistry. Chemical element All oy

C

Cr

Ni

Mo

Nb

Ti

Cu

Co

Al

Zn

Sn

Pd

V

AISI 8630

X

X

X

AISI 8620

X

X

X

AISI 4130

X

X

1Cr–½Mo

X

X

1¼Cr–½Mo

X

X

Yes (P & Sn) (6)

2¼Cr–1Mo

X

X

Yes (P & Sn) (14)

2¼Cr–1Mo–¼V

X

X

5Cr–½Mo

X

X

9Cr –1Mo V

X

X

X

9Cr-1Mo V (mod)

X

X

X

13Cr–4Ni

X

X

X

Table 1 Ref

Yes (P & Sn) (14) Yes Yes

13Cr–4Ni /CA6NM

X

X

X

12Cr/CA15

X

X

X

304(1)

X

X

308

X

X

309(1)

X

X

310(1)

X

X

316(1)

X

X

X

Yes (1,3)

317(1)

X

X

X

Yes

321(1)

X

X

347(1)

X

X

410(2)

X

X

430

X

X

Alloy 2205 (Duplex)

X

X

X

Alloy 2507 (SDSS)

X

X

X

SMO 254

X

X

X

F6NM

X

X

X

CD4Mcu

X

X

X

Alloy 20

X

X

X

6 Mo Alloys

X

X

X

Alloy C-276

X

X

X

X

Yes (Cu,W) (12)

Alloy B2

X

X

X

X

Yes (Co,Fe) (8)

X

Yes (Cu,Fe,Co) (10)

Alloy 400(5) Alloy 600

X X

X

X X

X

Yes Yes (1,2,3,4)

X

Yes (C&Ti) (4)

X

Yes (C,Nb) (5) X

X

Yes

X X

X

X

X

Yes (Fe) (9)

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

Page 19 of 24


All oy

C

Cr

Ni

Mo

Nb

Ti

Alloy 625

X

X

X

X

X

Alloy 625 LCF

X

X

X

X

X

Alloy 800

X

X

Alloy 825

X

X

X

Cu

Sn

Pd

V

Table 1 Ref

Yes (Ti) (7)

X

Yes (Ti) (11)

X

70/30 CuNi

X

X

X

Zn

X

X

X

Al

Yes (Fe,Co,Ti) (13)

90/10 CuNi

Stellites

Co

X

304L(1,6)

X

X

X

Yes (1,2,3,4)

304H(1)

X

X

X

Yes (1,2,3,4)

308L(1,6)

X

X

X

309L(1,6)

X

X

X

410S(2)

X

X

X

316H

X

X

X

X

Yes (1,3)

316L(1,6)

X

X

X

X

Yes (1,3)

316H(1)

X

X

X

X

Yes (1,3)

317L (6)

X

X

X

X

Yes

321H(1)

X

X

X

347H(1)

X

X

X

X

X

X

Yes (C&Ti) (4)

X

Yes (C,Nb) (5)

Tantalum(3) Titanium Gr 2

X

Titanium Gr 7

X

Titanium Gr12

X

Titanium Gr 16

X

X

Zirconium(3) Admiralty brass

X

X

X

Naval brass

X

X

X

CS in HFA Service (4)

Notes:

X

X

X

X

1.

All 300 series stainless steel welds shall have the ferrite controlled between 4 % and 8 %. The ferrite testing shall be at the same frequency as required for PMI.

2.

0.5 % to 0.75 % max Ni in base material and <1.1 % Ni for weld deposits. 0.1 % to 0.3 % Al. 0.2 % to 0.5 % Ti.

3.

Check alloying elements meet the ASTM specification.

4.

C <0.18%, Cu+Ni+Cr<0.18%

5.

Alloy 400 weld consumables shall contain Ti<2.2%wt. and Fe<5%wt. in Hydrofluoric acid service.

6.

The weld analysis shall meet the same composition limits as the corresponding base plate and clad materials except that carbon maximum of 0.045 % is acceptable in a deposit joining L grade austenitic stainless steel cladding.

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

Page 20 of 24


TABLE 5 - MATERIAL IDENTIFICATION CODES Alloy

UNS No.

Material code

Alloy

UNS No.

Material code

1¼ Cr ½ Mo

K11597

1 CR

430

S43000

430

2¼ Cr 1 Mo

K21590

2 CR

Alloy 2205

S31803/32205

2205

2¼ Cr 1 Mo ¼ V

K31835

2CR V

Alloy 2507

S32750/32760

2507

5 Cr ½ Mo

K41545

5 CR

Alloy 20

N08020

20

9 Cr 1 Mo V

S50400

9 CR V

6 Mo Alloys

N08367 and N08925

6 Mo

13 Cr-4Ni, or CA6NM

J91540

CA6NM

Alloy B2

N10665

B2

12 Cr, or CA15

J91150

CA 15

Alloy C-276

N10276

276

304

S30400

304

Alloy 600

N06600

600

304L

S30403

304L

Alloy 625

N06625

625

304H

S30409

304H

Alloy 625LCF

N06626

626

308

S30408

308

Alloy 800

N08800

800

308L

S30883

308L

Alloy 825

N08825

825

309

S30900

309

90/10 CuNi

C70600

90/10

309L

S30983

309L

70/30 Cu/Ni

C71500

70/30

310

S31000

310

Alloy 400

N04400

400

316

S31600

316

Nickel 200

N02200

200

316L

S31603

316L

Titanium Gr 2

R50400

T-2

316H

S31609

316H

Titanium Gr 7

R52400

T-7

317

S31700

317

Titanium Gr 12

R53400

T-12

317L

S31703

317L

Titanium Gr 16

R52402

T-16

321

S32100

321

Zirconium 702

R60702

Z-702

321H

S32109

321H

Zirconium 705

R60705

Z-705

347

S34700

347

Tantalum

R05210

R05210

347H

S34709

347H

Tantalum 40 % Nb

R05240

R05240

410

S41000

410

Admiralty Brass

C44x00 x = 3,4 or 5

C44x00 x = 3,4 or 5

410S

S41008

410S

Naval Brass

C46x00 x = 5,6 or 7

C46x00 x = 5,6 or 7

405

S40500

405

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

Page 21 of 24


FIGURE 1 - PMI REPORT FORM PMI Request by:

Purchase Order Number

Signature: Date: PMI Performed by :

PMI Will Be / Was Performed At:

Signature: Date: Supplier/Manufacturer : EPC Contractor: Make

Test Instrument Used Item or Tag Number

Sample Size

Material

Mill Cert No.

Type

Heat No.

Serial No.

Last Calibration

Item Description

Remarks

Examination Results: Item or Tag Number

No. of Pieces Exam

No. of Pieces Accept

No. of Pieces Reject

Material Identified as:

Chemical Composition Percentage: C

Si

Cr

Mo

Ni

Mn

Ti

V

Fe

Co

Cu

Nb

W

Address of Supplier Responsible for Rejection(s): Additional Information: Manhours and Loss Incurred from Rejections, etc.: PMI Supervisor __________________________________________________________ Signature/Date

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

Page 22 of 24


FIGURE 2 - LOCATION OF PMI IDENTIFICATION MARKS FOR PIPING (EXAMPLES)

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

Page 23 of 24


Ap pend ix A

Abb reviatio ns

Abbreviation

Complete Term

AISI

American Iron and Steel Institute

API

American Petroleum Institute

ASME

American Society of Mechanical Engineers

ASTM

American Society for Testing and Materials

BS

British Standards

BSI

British Standards Institute

CRA

Corrosion Resistant Alloy

CS

Carbon Steel

CV

Control Valve

EN

European Norm

FCAW

Flux Cored Arc Welding

FCI

Fluid Components International

GMAW

Gas Metal Arc Welding

GTAW

Gas Tungsten Arc Welding

HFA

Hydrofluoric Acid

HIC

Hydrogen Induced Cracking

ID

Inside Diameter

ISO

International Standards Organisation

J-Factor

Temper Embrittlement Resistant Steel Factor - Watanabe et al

KNPC

Kuwait National Petroleum Company

LT

Low Temperature

NACE

National Association of Corrosion Engineers

NRP

New Refinery Project

PMI

Positive Material Identification

PMIV

Positive Material Identity Verification

PO

Purchase Order

SAW

Submerged Arc Welding

SDSS

Super Duplex Stainless Steel

SMAW

Shielded Metal Arc Welding

SS

Stainless Steel

TPIA

Third Party Inspection Agency

UNS

Unified Numbering System

P4049N-0000-DE00-SPC-0006_0 P4049NRP.00.10.10.001_A

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P4049N 0000 DE00 SPC 0006 Project Specification for PMI

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