~
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ASubsidiary of Kuwait Petroleum CorporaUon
STANDARDS PUBLICATION
KOC STANDARD
FOR
POSITIVE MATERIAL IDENTIFICATION (PMI)
DOC NO: KOC-Q-015
STANDARDS TEAM
DOC. NO. KOC-Q-015
II
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~~'l..-.-).o~""':'oI_! o\~ktLtfy""KWN~e.IPO"fI*I
STANDARDS PUBLICATION
KOC STANDARD FOR POSITIVE MATERIAL IDENTIFICATION (PMI) DOC.NO. KOC-Q-015
STANDARDS TEAM
I
DOC. NO. KOC-Q-01S
Page 2 of 29
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II
KOC STANDARD
FOR
POSITIVE MATERIAL IDENTIFICATION (PMI)
DOC.NO. KOC-Q-015
ISSUING AUTHORITY:
STANDARDS TEAM
Rev.
29.07.12
Issued as Final KOC Standard
Date
Description
n
Task Force
(TF-Q/15 )
Prepared by Tel. No. 65434
Snr. Engr. Standards ~ Tel. No. 61407
~ . Tean Leader Standards '~1. No. 61896
Page 3 of 29
DOC.N
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TABLE OF CONTENTS
Page No.
FOREWORD
4
1.0
SCOPE
5
2.0
EXCEPTIONS
5
3.0
APPLICATIONS AND COVERAGE
5
4.0
CONFLICTS
6
5.0
TERMINOLOGY
6
5.1
Definitions
6
5.2
Abbreviations
8
6.0
REFERENCE STANDARDS, CODES AND SPECIFICATIONS
8
6.1
National/International Standards and Codes
9
6.2
KOC Standards and Recommended Practices
10
7.0
MATERIALS COVERED
10
8.0
IMPLEMENTATION AND RESPONSIBILITIES
10
9.0
EXTENT OF PMI TESTING
10
10.0
TIMING OF PMI
12
11.0
PMI TEST METHODS
13
12.0
ELEMENTS OF ALLOY MATERIALS TO BE VERIFIED
14
13.0
PMI PROCEDURE
14
14.0
PERSONNEL QUALIFICATIONS AND TRAINING
15
15.0
ACCEPTANCE CRITERIA
15
16.0
RETEST, RE..IECTION AND DISPOSITION OF RE.JECTED MATERIALS 16
17.0
MATERIAL MARKING, IDENTIFICATION AND TRACEABILITY
17
18.0
DOCUMENTATION
19
19.0
SAFETY
19
APPENDIX 1 : Typical Materials and Elements to be Analyzed
20-22
APPENDIX 2 : Typical Weld Metal I Consumable Alloy Elements
to be Analyzed
23
APPENDIX 3 : Typical Pressure Boundary Bolting Materials and
Elements to be Analyzed
25-26
APPENDIX 4: PMI Report
27
ACKNOWLEDGEMENT
28-29
1
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is commonly referred to as "Positive Material Verification of different alloys and Identification" (PMI). Various nondestructive solutions provide proper identifications various metal alloys (there are over 50,000 known based on their chemical composition. With specifications materials in the oil and industry becoming more specific, the for accurate PMI has been increasing over the past few years. During manufacturing and as arrive at a facility; they also to be quickly confirm that various components match the engineering requirements of a project. Improper verification materials could lead to faulty final product and potential injury to users. Similarly, as components are sourced from a global market; buyers, manufacturers and users must have a method of verifying what supplier sends is what they per requirements. PMI as such is an important tool to safeguard the safety of personnel and integrity of the facility. Therefore this KOC Standard was developed under the consensus of the KOC Standards Team KOC Standards Technical Committee This Standard is intended as the practice to be followed by the Contractor, Manufacturer, Vendor, Supplier and as of the quality assurance/quality control program and the endeavor. Feedback, comments or suggestions derived from the application of this encouraged and should be directed to:
are
The Team Leader (Standards)
(Chairman Standards Committee)
Industrial services Group,
9758,Ahmadi61008 State of Kuwait
Standards Technical Committee (STC) entrusted the preparation of this Standard Task Force No. TF-Q/15 conSisting of following members: Task Force Leader
Tel. 63693
Member
Tel. 61102
Insp. & Corr. (N&W) Team
Member
Tel. 61
Insp. & Corr. (S&E) Team
Member
Tel.61455
Member
Tel. 61768
Member
Tel. 65218
Mr. Mohd Emam 2
Mr. Mohd Aslam Imadi Mr. Ghassab AI-Ajmi Abul-Khair
5
Mr. A.K.Ghosh
6
Mr. Santosh Kumar
7
Mr. Sivasankaran
Team
Team Insp. & Corr. (S&E) Team Team
Member
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1.0 1.1
This KOC defines the mandatory requirements positive material identification (PMI) of alloy material components to supplied to KOC and are intended to be exposed to and/or environments, whether purchased directly by or indirectly through contractors, manufacturers, vendors, suppliers, engineering It is to ensure that the nominal composition of the alloy components and welds have been correctly supplied and installed as by KOC.
1.2
may include but not limited to forgings, castings, plates, sheets, valves, flanges, fittings, fasteners, springs, solid metal gaskets, overlays, expansion cladding, pressure internals and
1.3
KOC Standard applies to both new replacement/expansion of components of facility, plant, as for shop or field fabrication.
1.4
KOC Standard is applicable for the identification at the point of final during manufacturing or inspection or in process
1 In_C,I'>n,flf"I'>
1.6
and repair or or pipelines as well
Standard is also applicable for material verification programs to identify materials. test is intended
===::=:: for a manufacturer's
material grade identification only and does not report / (MTR/MTC) or a laboratory's
chemical analysis.
2.0 Standard does not apply for: a. Carbon steel (group
),
iron and filler
for welding carbon
b. Electrical equipment. 3.0
APPLICATIONS AND COVERAGE
3.1
This Standard shall used to verify that composition of alloy components to be to either pressure or conditions are with the specified construction materials in order to minimize the nl"'!fonT'I<:i disastrous release toxic or hazardous liquids or vapours. PMI or alloy verification is intended to be an component of an assurance program. It is not intended to substitute for any other material identification or programs. For (L) grade content shall be
suitable Refer to clause 11
DOC. NO. KOC-Q-015
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final installation as
3.4
It is intended that PMI shall performed as practical to ensure installation of the proper
3.5
Where there are different requirements within publications, codes, and standards, the more
or with referenced shall applied.
3.6
The testing techniques addressed in this establish the complete conformance of a ...... "'ro..'
are not aimed to to its specification.
4.0
CONFLICTS In the event of conflict(s) between Standard and the standards, codes, specifications referred herein or in technical/commercial requirements drawings, forms, and other contract specified in the purchase order, data agreements, etc.; the subject shall brought to the attention of the Controlling Team for resolution by KOC Inspection & Corrosion Teams. Until the resolution is officially made in writing by KOC, the most stringent requirement shall govern.
5.0
TERMINOLOGY
5.1
Definitions For the purpose of
following definitions shall apply:
Alloy Material
Any metallic material (including welding filler materials) that as Chromium, Nickel or Molybdenum, which are intentionally added to enhance or physical properties and/or corrosion This shall indude all materials classified as group higher (as defined in ASME IX, QW/QB-422), all as1"I"'~'fQrI produced using consumables of group A-2 higher (as defined in ASME IX, QW-442) and all bolting other than carbon steel or conforming to ASTM B7, B7M, and B16.
Accessible
Means no disassembly for inspection is required.
Assembled
Items previously assembled that are selected from existing inventory.
Bulk Material
Material purchased in bulk where individual items are not a unique tag number (e.g. random pipe valves, fittings, flanges, bolting, "'l'\r,_I"I"I'\(',,,<><> etc.).
Buyer
KOC
Disassembled
Component parts (manufactured or selected from inventory) that have not yet been assembled,
or
its designated etc.
agent,
supplier,
REV. 1
from a single manufacturer or supplier a heat from which the inspection is An inspection lot will not contain more heat number. up
case of valves, or similar items, where I covers may be from different of all units with the same combination
Inspection Sample
or more items selected at random which the general chemistry of the inspection lot
Material Program
A documented quality assurance procedure used to assess alloy materials (including and with the attachments where specified) to vertfy ~Qi'''''ft:>l''I or specified alloy material by KOe.
Verification
Mill Stockist
A distributor or warehousing supplier for one or more of a material or component.
Mill Test or Certificate (MTRlMTC)
A certifiable report from the showing the composition, mechanical properties, heat treatment, and testing required on the material for the purchase order or compliance wi1h the requirements Dllc:aDle industry material, or both.
Positive Material Identification (PMI)
An examination procedure used to material grade/type and nominal chemistry of the alloying elements.
Reference Standard
A material sample that has by a laboratory in accordance with the with instrumentation that is American Society for Testing of Materials (ASTM).
Sample
One, or more, units selected at random from the Lot which are to be examined to determine acceptability of the Lot A term used to method of positive material to point out the fact that, identification. term is while the field use of PMI instrumentation is capable of precision analysis, measurements are not being carried out under controlled environmental conditions, and therefore, are not ,..orT'T',....... Any person or firm contracted to manufacture, fabricate or supply an item or to services incidental to design, of components or facilities construction, operation, or designated
Fluorescence (known also as Emission Analysis)
A method of energy strength material. Each QiQltnQlnt energy strength are measured and " .... rY'l .... ·!:Ir.o'rt
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positive material identification that detects and quantifies the of in a material. It utilizes the fact that each element has a different unique of atomic structure that when subjected to the energy, will emit a pattern of light colors or wavelengths along the spectrum. Since no two elements emit the same 1"1<:111'0'1"1 of lines, can be Since. light is proportional to the quanttty of the i in the material, the concentration of the can and material Components acting as pressure envelope or boundary. Breach this envelope or boundary would lead to loss process containment and discharge include, but not limited to, product forms used for the fabrication of pressured piping and equipment shells, heads, tube-sheets, nozzles, tubes, flange Qa~;kets, forgings, flanges, individual lengths fittings pipe components), (tees, el bo\NS , reducers, weld bodies bonnets, pressure-retaining overlays/cladding, expansion jonts and bellows.
5.2
Abbreviations AV
Verified Alloy
CRA
Corrosion Resistant Alloy
KOC
Kuwait Oil Company
MTR/MTC
Material Test .... <;;or..
MRB
Manufacturing Record Book
NDT
Non-Destructive Testing
NCR
Non Conformance Report
PMI
_n';;:"".,,;:>
rI". /
Material
Certificate
Material Identification
Pressure . . . . ';II""T\I Valve
The latest editions/revisions form an integral part of this
the following Standards, Standard.
and Specifications
-Q-015
6.1
Page 9 of 29
REV. 1
National/International Standards and Codes API RP 578
Material Verification Program for New and Existing Alloy Piping Systems
API RP 582
Welding Guidelines for the Chemical, Oil, and Gas Industries
ASME Section II, Part A
Materials-Part A: Ferrous Materials Specifications.
ASME Section II, Part B
Materials-Part-B: Specifications.
ASME Section II, Part C
Materials Part C: Specifications for Welding Rods, Electrodes and Filler Metals.
ASME B16.34
Valves Flanged, Threaded and Welding End
ANSI/ASQ Z1.4
Sampling Procedures and Tables for Inspection by Attributes
ASTM A751
Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products
ASTM E1476
Standard Guide for Metals Identification, Grade Verification, and Sorting
ASTM A 960
Standard Specification for Common Requirements for Wrought Steel Piping Fittings
ASTM A 961
Nonferrous
Materials
Standard Specification for Common Requirements for Steel Flanges, Forged Fittings, Valves, and Parts for Piping Applications
ASTM A 962
Standard Specification for Common Requirements for Bolting Intended for Use at Any Temperature from Cryogenic to the Creep Range
MSS SP137
Quality Standard for Positive Material Identification of Metal Valves, Flanges, Fittings, and Other Piping Components
PFI-ES-22
Pipe Fabrication Institute-Recommended Practice for Color Coding of Piping Materials
PFI-ES-42
Pipe Fabrication Institute - Standard for Positive Material Identification of Piping Components Using Portable X-Ray Emission Type Test Equipment
DOC. NO. KOC-Q-015 6.2
7.0
Il
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II
KOC Standards and Recommended Practices KOC-MP-010
KOC Standard for Piping Material Classes
KOC-MP-026
KOC Standard for Colour Coding of Pipes and Fittings for Material Identification
KOC-Q-014
KOC Standard for QAlQC Requirements for Projects
MATERIALS COVERED PMI testing shall be performed on all new alloy material components that may be exposed to pressure and/or process environments. PMI shall be performed on all new alloy material components and welds comprising the pressure envelope and on all equipment internals that may be exposed to the process environment. Testing shall be performed in the "completed" or "as-welded" condition.
8.0
IMPLEMENTATION AND RESPONSIBILITIES
8.1
It shall be the responsibility of the Engineering Project Teams to ensure that the requirements of this Standard are implemented on KOC projects where this Standard is adopted .
8.2
PMI is not a substitute for required MTR's and, alternatively, the availability of an MTR does not relieve the requirement for PMI testing .
8.3
Contractors, manufacturers, vendors, suppliers and stockists shall provide for KOC review and approval a complete PMI program as part of its Quality Manuals. The program shall ensure that requirements of this KOC Standard are incorporated and implemented correctly and at the appointed time.
8.4
For existing KOC facilities, the Inspection & Corrosion Teams are responsible for ensuring that a PMI program is developed and implemented.
9.0
EXTENT OF PMI TESTING
9.1
PMI Test Program
9.1 .1
PMI program shall cover the following components
9.1.2
a.
Alloy materials.
b.
Shop and field fabricated pressure-retaining components which include the base metals, the welds, cladding and weld overlays.
c.
Materials used components.
for
repairing
or
replacement
of
pressure-retaining
PMI testing shall be performed on the external surface of the component or weld , and if possible the surface to be exposed to pressure or the process conditions.
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9.2
100% PMI Testing
9.2.1
The 100% PMI testing shall consist of a minimum of one (1) test point for:
9.2.2
a.
Each component such as plate, pipe, pipe fittings, forging, casting, pipe nipple, solid metal gaskets, etc.
b.
Every 25ft2 (2 .32 m2) of weld overlay regardless of heat number.
c.
Each weld or weld seam and when either of these exceeds 48" (1.22 m) in length , this shall include one (1) additional test point for every 48" (1.22 m) of weld length.
d.
All repair welds shall be 100% tested.
The 100% PMI testing is required on each of the following items; a.
All equipment and components that comprise the pressure envelope or that may be exposed to the process environment, such as pressure vessels, storage tanks, boilers, heat exchangers or fired/indirect heaters including all welds unless specifically exempted in clause 9.3.3 below. This includes all plate, pipe, fired/indirect heater tubes, heads, tube sheets, fittings, forgings, nozzles, nipples, solid metal gaskets (this applies to ring joint only) and flanges as well as all internal components.
b.
All pressure piping components of fabricated pipe spools and all accessible welds, both shop and field including tie-ins. This includes all pipes, pipe fittings such as elbows, tees, reducers, o-Iets, plugs, blinds, special components, flanges, nipples and valve bodies and bonnets.
Note: No PMI is required for pipe spool materials if this material has already been subjected to a PMI check and as such marked and identified, by the Vendor, with a rubber or steel PMI stamp as per clause 17.0 (Marking) of this Standard. c.
All process equipment and components that may be exposed to pressure or to the process environment such as pumps and compressors. This includes the casings, covers , impellers and shafts. Equipment internals shall be tested at the vendor shop during fabrication or assembly.
d.
Components that may be exposed to pressure or service such as thermowells, vortex meters, control valves, level bridles, level controls, orifice plates or PSV's.
e.
Instruments that may be exposed to service including all internal metallic linings, cladding or weld overlay including clad restoration welds.
f.
Flare tips.
DOC. NO. KOC-Q-01S 9.2.3
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Random PMI Testing a. Random PMI in lieu of 100% PMI is acceptable only where specified in clauses 9.2.3 (b) & (c) of this Standard. b. Random PMI requires a representative sample of the inspection lot. The sampling for inspection shall be undertaken as per Table (2) of this Standard. c. Random PMI shall be made in the following cases . Where there is a conflict with Table (2), the most stringent shall be applied. (i) Tubes for Shell & Tube exchangers, air coolers and boiler tubes (Ten tubes or 5% whichever greater from each heat number) shall be selected for testing . (ii) Heat exchanger tube to tube sheet seal welds (5% of the welds made by each operator or machine per shift) (iii) Plates for the Plate & Frame heat exchangers (Ten plates or 5% whichever greater from each heat number) (iv) Pipe components purchased directly from the manufacturing mill (5% from each heat) (v) Pipe components purchased from stockists (10% from each heat) (vi) Alloy fasteners, bolts and nuts (2% from each vendor). KOC may request up to 100% in case marking and/or quality program is not properly implemented . (vii) Vessel internals such as distributors, nozzles, piping and trays (viii) Valve parts such as seats, gates, balls, stems , flappers and body bolts (5% of each component /valve type/valve size) (ix) Mechanical Seal Parts (shaft, Stationary Face, Rotary Face, Bellow, Spring Retainer, Spring, Drive Shell, Drive Ring). One (1) test on each part for minimum of one (1) mechanical seal from the same vendor.
10.0
TIMING OF PMI
10.1
Final PMI shall be performed upon completion of fabrication or assembly but prior to hydro-testing or packaging for delivery. PMI of completed equipment and materials shall not be postponed to be made (partially or in full) upon arrival at KOC construction sites.
10.2
Where identically sized equipment or piping with differing metallurgies are installed, field PMI is required .
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10.3
Not all components or welds requiring PMI will be accessible for final PM!. It shall be the supplier's responsibility to ensure that all items requiring PMI are tested as specified at an appropriate time during the fabrication or assembly process. This will include such items as vessel internals and internal welding, valve internals, instruments, mechanical seals, pumps and other process equipment.
10.4
It is not the intent of this Standard that items be disassembled or that welds be excavated to perform PMI testing . The Contractor and KOC Project Quality Managers may review and approve vendor PMI programs to ensure that the intent of this Standard is fulfilled.
10.5
The KOC Project Quality Manager or his/her delegate has the right to witness any or all PMI testing and also spot check "as-installed" items in the field at any time during the life of the component. Any non-conformance shall be corrected by the supplier.
10.6
PMI testing at receiving is considered a critical component of an overall PMI program but shall not substitute for the final PMI as required in clause 10.1
10.7
PMI testing of welding consumables prior to use is considered a critical component of an overall PMI program but shall not substitute for finalized PMI required in clause 10.1 of this Standard.
11.0
PMI TEST METHODS
11.1
PMI shall be performed by one of the following quantitative methods (listed in order of preference): a. Portable X-Ray Fluorescence (XRF) known also as "X-Ray Emission Analysis", b. Optical Emission Spectrometry (OES), c. Wet Chemical Analysis.
11 .2
Due to the inherent limitations of portable XRF, elements lighter than sulphur (S) cannot be detected; therefore carbon (C) cannot be measured . The OES may be used to check for all the required elements including carbon (C). Hot work permit is required before using this method. Any burn damage caused by using OES instrument shall be removed by grinding.
11 .3
Qualitative methods of alloy sorting including electromagnetic (eddy current), thermoelectric, electrical resistivity, chemical spot testing , spark testing or triboelectric (Refer ASTM E1476) are not acceptable.
11.4
Alternatively, chemical analysis of samples cut out from the pieces requiring PMI , in accordance with one of the methods in ASTM A751, may be used to check for the alloying elements required by this Standard .
DOC. NO. KOC-Q-015 12.0
II
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ELEMENTS OF ALLOY MATERIALS TO BE VERIFIED The basic elements to be verified in the alloy material shall be as per Table 1. 3. 4 and 5 of this Standard as below. Table 1: Basic Alloys and Elements to be Verified (see also Table 3. 4, 5) Basic Alloy Elements to be Verified (1) C-Mo Steels Cr. Mo Mn-Mo Steels Cr-Mo Steels Stainless Steels (Normal carbon grades) Cr. Ni. Mo Stainless Steels (Low and high Carbon grades) Cr. Ni. Mo. C Stainless Steels (Stabilized) Cr. Ni. Mo. Ti . Nb Nickel-Based Alloys Ni. Fe. Cu. Cr. Mo Nickel Steels Ni Copper Based Alloys Cu. Zn. and other elements. Notes: Cr : Chromium. Ni : Nickel. Mo : Molybdenum. Ti : Titanium . Cu : Copper. W : Tungsten. V: Vanadium. Fe: Iron. Cb : Columbium (Also known as Nb. Niobium). Zn: Zinc
13.0
PMI PROCEDURE
13.1
The equipmenUmaterial supplier or third party agency performing PMI testing on behalf of KOC or KOC Contractors. shall submit their PMI testing procedure for review and approval by KOC prior to use. The procedure shall cover personnel qualifications. safety. calibration. testing requirements. material surface preparation . acceptance criteria. documentation requirements. performance. marking or stamping requirements and resolution of discrepancies. The procedure shall identify how the process will be controlled. particularly in a project environment where pipe spools may be fabricated at a fabricators shop. in the field and also where rework may occur. As a minimum. this Standard must be met.
13.2
Portable X-Ray Fluorescence units shall be calibrated daily at the start of each working shift and in conformance with the manufacturer's recommendations. using a known alloy test standard .
13.3
Implementation of a PMI program shall not release the supplier from the responsibility of furnishing the specified materials test certificates and documentation.
13.4
Sampling shall be based on the criteria provided in Table 2 of this Standard. Table 2: Sampling Basis Criteria
Number of Units in a Lot 1-5
Representative Sample 100% of all units
DOC. NO. KOC-Q-015
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6-200
5 units or 5%, whichever is greater
> 200
10 units or 3% whichever is greater
Notes: 1. If all units of the representative samples are acceptable, the inspection lot shall be acceptable. 2. If any unit from the representative Sample is found to be unacceptable, the remainder of that Lot shall be examined 100%. If the remainder of the Lot is found acceptable, the sampling technique in Table 2 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 2 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. When the material markings are incomplete, preventing positive correlation between the material requisition, purchase order and a material test certificate, the materials shall be rejected .
14.0
PERSONNEL QUALIFICATIONS AND TRAINING
14.1
Personnel performing PMI testing shall have previous proven ability with PMI and shall be qualified to the satisfaction of the KOC Inspection & Corrosion Teams who will review and approve the training and experience records. PMI technicians shall have the following qualifications: a. Proof of successful completion of an acceptable PMI training course, this course could be presented in-house, by the manufacturer or other institution but will generally be a minimum of one day in duration . b. Three months of documented experience performing PMI activity.
14.2
PMI operators shall ensure safe operation of the equipment.
14.3
PMI operators shall ensure PMI eqUipment is operated, calibrated and maintained in accordance with manufacturer's specifications and the submitted and approved PMI procedure.
15.0
ACCEPTANCE CRITERIA
15.1
The element specified in Tables 1, 3, 4 and 5 of this Standard shall be recorded on the PMI report.
15.2
All recorded elements shall meet the weight percentages of alloying elements as specified in the relevant ASME " or ASTM material specification. A summary of alloys commonly used by KOC is included in Tables 1, 3, 4 and 5 for reference. Alloys including castings shall be acceptable if the alloying elements are each within 10% of the specified range in the applicable materials standards (example : for 5% Cr, where the allowable range is 4-6 percent, the measured value shall fall within the range 3.6 to 6.6 percent).
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15.3
Materials including (Bolts and nuts) shall contain the amount of alloying specified in ASME Section IIA (or equivalent ASTM specification) for ferrous and ASME liB (or equivalent ASTM specification) for a nonferrous materials. Welding electrodes and wires shall contain within percent of the range of each alloying element as specified in ASME Section IIC.
15.4
all recorded elements shall meet the weight percentages of alloy elements specified in relevant ASME lie specification deposited weld metal. A summary of commonly used alloys is included in Table 4 for rotc,ron Deposited weld metal or undiluted weld metal deposits with consumables that match or nearly match the base metal composition shall be within 2.5% of the range allowed in ASME IIC for element.
1
Acceptance criteria for dissimilar metal alloy welds shall be such that the weld meets the chemical composition requirements. of dilution during deposition should be taken into account for deposited (diluted) weld metal.
1
weld overlays, the frequency of chemistry on the surface of overlays shall be verified as follows: a. For manual welding: One analysis every of heat number or one overlay restoration of clad joints.
(2.32 m2) of weld overlay for at intervals of 2 m or
b. For automatic welding: One analysis for each overlay area or clad joint. shall be made for each heat/batch of filler metal or electrode. c.
ferrite measurements shall made for austenitic welds 42re. The content shall be when design temperature checked in the as-welded condition. The Number shall between 3 number checks shall performed at the same and 10 FN. The frequency as specified in 15.6 (a) and (b).
d.
temperatures below 42re, the chemical analysis shall used to calculate ferrite content using the Delong diagram. If the ferrite content is not between 3 and 10 FN, then actual ferrite production piece and shall be between 3 measurements shall taken on and 10 FN.
15.7
Additional requirements, beyond the capability Inspection Engineer. carbon content may also
such as confirmation of actual carbon content (which is the KOe the XRF's), may be required at the request materials, other than (l) grades of stainless be confirmed by a review of MTR's.
16.0
RETEST, REJECTION AND DISPOSITION OF REJECTED MATERIALS
16.1
Materials, components or welds that are found to be unacceptable, shall be marked and segregated pending resolution by supplier's Quality Manager. Procedures shall in place ensure that rejected components are segregated and properly identified to prevent reuse.
I
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16.2
The supplier, vendor or contractor may retest any unacceptable component using the more accurate wet chemical analysis method including independent testing laboratory at his own cost and time. The results of this second test shall be considered final.
16.3
A "no-match" or no reading shall be deemed to be a NCR and treated accordingly.
16.4
KOC shall be notified of all rejects, the details of why the rejection occurred and the disposition of NCR.
16.5
Materials, cladded materials, weldments or weld overlays found by PMI to be unacceptable, shall be rejected and replaced with a component of correct specification (a changed component shall undergo a 100% PMI test) . The applicable NCR process shall be followed to determine the non-conformance causes and any preventative actions.
16.6
Where random PMI has been performed, one rejected component will reject the entire lot. Use of components from a rejected lot requires 100% PMI of the entire lot.
17.0
MATERIAL MARKING, IDENTIFICATION AND TRACEABILITY
17.1
Alloy materials are to be identified by their alloy designation (i.e. ASTM description) and nominal composition.
17.2
PMI does not relive the supplier of the colour coding requirements of KOC-MP 026, and KOC-MP-010 Pt.1 Standards.
17.3
PMI test locations shall be marked, preferably with a low-stress stamp; however, the supplier may mark the test location with a semi-permanent paint marker. The marker shall not contain additives such as aluminum , sulphur, chloride, lead or zinc which may be detrimental to the material, process and/or environment. For smaller items where marking is not possible, the KOC inspection engineer may accept other alternatives, such as color coding.
17.4
The supplier/fabricator shall submit PMI documentation for fabricated piping and equipment supplied. This documentation shall include all PMI test results and identify the general locations of all PMI tests. The PMI maps shall be on the same document as the weld maps.
17.5
With the exception of small bulk items, PMI test shall be traceable to each component and weld. Small bulk items include nuts, bolts, pipe nipples, pipe fittings, valves sized NPS2 and under, valve internals, and process equipment parts.
17.6
All materials that have been successfully tested shall be marked to indicate they are acceptable. If part of an inspection lot and all samples are acceptable, the entire lot shall be marked as acceptable.
Page 18 of 29
REV. 1
1
Materials, items, and welds that are found to be unacceptable during verification testing shall marked immediately with a circled red cross (X) pending resolution in accordance with clause 16.0 of this Standard.
1
letters All verified materials with an acceptable analysis shall be marked with "AV" using a certified low-stress stamp. PMI results shall be recorded in a report as per Appendix (4) of this Standard. The marking shall be placed as follows: each length Pipe: Two marks, 180 degrees apart, 75 mm (3 in.) from each end on the outer surface of the pipe. marking shall be in addition the requirements of KOC-MP-026 and Pipe Fabrication Institute Recommended Practice a. Welds: Adjacent to welder's mark on the weld. Welds on tubes in transfer service shall not stamped, but marked by either stenciling or vibro etching. b. Fittings and Forgings: Adjacent to the supplier's markings. c. Valves: Adjacent to the supplier's markings on bodies and other pressure parts. d. Plates: Adjacent
the
e. Castings: Adjacent to f.
numbers. supplier's markings and heat numbers.
Tubes for Heat Stenciled, not stamped, 300 mm (12 in.) from each end. The marking shall be done with a water-insoluble material that contains no harmful substance, such as metallic pigments [aluminum (AI), lead (Pb). and (Zn)]. sulfur, or chlorides, that would attack or harmfully affect austenitic or nickel alloy steels ambient or elevated temperatures. The sulfur and chloride content of water-insoluble materials shall be limited to one 29, percent or less as determined by ASTM Methods 0808 and respectively. The supplier shall submit an analysis of the marking material to the KOC to demonstrate, by chemical analysis history of that the marking meets the requirements.
g. Bolting: On one end. h. Nuts: On one flat. 1
If the material or item is too light, small, or cannot otherwise be stamped, vibro-etching or color coding shall be applied in conjunction with supplier's standards and noted on the alloy verification reports. When heat treating is performed after material verification, the identification marking must be after the heat treatments.
1 10
When an alloy pipe or is cut after PMI testing and marking, the markings shall be transferred onto the unmarked section.
Page 19 of 29
DOC. NO. KOC-Q-015
Il
REV. 1
"
18.0
DOCUMENTATION
18.1
PMI test results shall be recorded on a PMI Report. As a minimum, the report shall contain the following: a. PMI Procedure number and revision. b. Inspection date c. Inspection location d. Inspection Agency e. Inspection Personnel f. PMI eqUipment, model number g. Date of calibration of the alloy analyzer h. KOC Project Number, KOC Contract Number, PO Number or other specific job reference Numbers i. Supplier Name (Contractor, manufacturer, fabricator, supplier, stockist) j . Material specification and traceability (heat number) k. Recorded element percentage by weight I. Name and signature of the PMI operator m. Name and Signature of the inspector to verify review and acceptance of results .
18.2
All elements with an atomic number of 16 or higher and listed in the material standard shall be recorded on the PMI Report.
18.3
The completed PMI report (Appendix-4) and documentation indicating test locations along with associated MTR's shall accompany the shipment for shop work. For all other works, MTR's and PMI reports shall be included in the appropriate job dossier (MRB).
19.0
SAFETY
19.1
The specific requirements for each PMI test technique shall be clearly reviewed as to the amount of mechanical preparation . Consideration shall be given to the anticipated thickness and temperature of the sample before mechanical methods are used to prepare the sample.
19.2
In addition, considerations for electrical arcing and "hot spots" shall be considered as well as appropriate electrical and hot work permits.
19.3
For the Portable X-Ray Fluorescence (XRF), Optical Emission Spectrometry (OES), X-Ray Emission Spectrometry, the PMI operator shall be trained and be fully familiar with the testing procedures and operation, instrument operation safety, radiation safety, State regulations and registration requirements, instrument power on/off, calibration and reference checking, sample handling, preparing, positioning, accessory tools needed, instrument features, modes, utilities, libraries, field entries, etc.
DOC. NO. KOC-Q-015 APPENDIX 1:
T~gical
Page 20 of 29
II
Materials and Elements to be
REV. 1
II Anal~zed
Appendix 1 (Table 3: Typical Materials and Elements to be Analyzed) (Extracted From MSS-SP-137)-This table is not an all-inclusive list of materials that require PMI ASME 816.34 Material Group Table 1
Major Elements
Grade
UNS No.
Cr
Ni
Mo
Cb
Ti
Cu
W
V
(1)
Y:. Cr - Y:. Mo.
K11547
C - Y:. Mo.
K11522
1Cr - Y:. Mo.
K11757
x
x
X
X x
1.9
1 Y. Cr, Y:. Mo
F11
K11597 K11789
X
X
1.10
2 Y. Cr, 1 Mo
F22
K21590
X
X
2 Y. Cr, 1 Mo-Y. V
K31835
x
x
3 Cr-1 Mo
K31545
X
X
1.17
5 Cr-Y:. Mo.
F5
S50200 K41545
x
x
1.14
9 Cr. 1 Mo
F9
K90941 K91560
X
X
1.15
9 Cr, 1 Mo, V
F91
K90901
X
X
S40500
X
X(3)
13 Cr (405) NA
13Cr, (410)
F6a
S41000
X
X(3)
NA
13 Cr, 4 Ni (415)
F6 NM
S41500
X
X
X
X
S30400 2.1/2 .3
18 Cr, 8 Ni
F304/LIH
(2)
S30403 S30409
308 ST ST
S 30800
X
X
309 ST ST
S 30900
X
X
X
X
X
X
X
X
S31600 2.2/2 .3
18 Cr, 8 Ni, 2 Mo
F316/LIH
(2)
S31603 S31609
2.2
19 Cr, 13 Ni, 3 Mo
F317/H
S31700 (2)
S31703
x
X
Fe
Page 21 of 29
DOC. NO. KOC-Q-015
I
REV. 1
II
"
Appendix 1 (Table 3: Typical Materials and Elements to be Analyzed) (Extracted From MSS-SP-137)-This table is not an all-inclusive list of materials that require PMI ASME 816.34 Material Group Table 1
Major Elements
Grade
UNS No.
Cr
Ni
Mo
Cb
Ti
Cu
W
V
Fe
(1)
2.4
18 Cr, 10 Ni, Ti
F321/H
2.5
18 Cr, 10 Ni, Cb
F347/H
2.6
23 Cr, 12 Ni
309H
2.7
25 Cr, 20 Ni
S32100
X
X
X
X
X
S30909
X
X
310
S31000
X
X
310H
S31009
X
X
430 st st
S43000
X
X(3)
16-8-2H ST ST.
S16800
X
X
X
X
X
X
(2)
S32109 S34700 (2)
S34709
X
2.8
22 Cr, 5 Ni, 3 Mo (2205 Duplex st st)
F51, F60, 2205, S32205
S31803
X
X
X
2.8
25 Cr, 7 Ni, 4 Mo
F53,2507
S32750
X
X
X
S31254
X
X
X
X
X
X
F44, 2.8
20 Cr, 18 Ni, 6 Mo
3.1
35 Ni, 35 Fe, 20 Cr, Cb,3 Cu, 2 Mo
Alloy 20
N08020
3.2
99 Ni
Alloy 200
N02200
X
3.4
67 Ni, 30 Cu
Alloy 400
N04400
X
3.5
72 Ni, 15 Cr, 8 Fe
Alloy 600
N06600
X
X
3.6
33 Ni, 42 Fe, 21 Cr
Alloy 800
N08800
X
X
3.7
65 Ni, 28 Mo, 2 Fe
8335
N10665
3.7
64 Ni, 29.5 Mo, 2 Cr, 2 Fe, 3 W
8335
N10675
Alloy 625
N06625
3.8
Alloy SMO
254
X
X
X X X
X
X
X
X
X
X
X
X
X X X
60 Ni, 22 Cr, 9 Mo, 3.5 Cb
X
X
X
-
DOC. NO. KOC-Q-015
Page 22 of 29
JI
-
-
REV. 1
I
Appendix 1 (Table 3: Typical Materials and Elements to be Analyzed) (Extracted From MSS-SP-137)-This table is not an all-inclusive list of materials that require PMI ASME 816.34 Material Group Table 1
Major Elements
Grade
UNS No.
Cr
Ni
Mo
Cb
Ti
Cu
W
V
Fe
(1 )
42 Ni, 21.5 Cr,
3.8
Alloy 800
ND880D
X
X
Alloy 825
N08825
X
X
X
Alloy C276
N10276
X
X
X
X
cn
N06022
X
X
X
X
Alloy 904
N08904
X
X
X
Alloy AL6XN
N08367
X
X
X
Monel 400
N04400
Inconel617
N06617
X
X
HK-40
J94204
X
X
x
x
3 Mo, 2.3 Cu 54 Ni, 16 Mo,
3.8
15 Cr, 4 W 55 Ni, 21 Cr,
3.8
13.5 Mo, 3 W
3.11
44 Fe , 25 Ni, 21 Cr, 4 Mo, 1 Cu 46 Fe , 24 Ni,
3.12
21 Cr, 6 Mo
Alloy
(4)
HP
X
X
X
X
X
X X
Notes Reference Groups 1, 2 and 3 materials, Table 1, ASME 816.34 . "NA" denotes materials not listed in ASME 816.34. See Table 1, ASME 816.34 for other product forms not listed . KOC requires a carbon element verification to differentiate between the "H" grade and the "L" grade of austenitic stainless steel. Check to verify that this element is not present (other than trace amounts) . Mn shall be tested (1 .5 max. limit)
Cr: Chromium
Ni : Nickel
Mo : Molybdenum
Columbium Cb Niobium)
Ti : Titanium
Cu : Copper
W : Tungsten
V: Vanadium
(Also
l
known
Fe : Iron
as
Nb,
------,
Page 23 of 29 APPENDIX
REV. 1
Typical Weld Metal/Consumable Alloy Elements to be Analyzed
2 (Table 4: Typical Weld Metal I Consumable Alloy Element)
"'VTI'''I"'T,''n
This table is not an all-inclusive list of materials that require PMI
~.
Alloy
- Y:. Mo)
Other
UNS W17018 W51018
i
OAO-0.65
OAO-0.65
1.00-1.50
OAO-0.65
2.00-2.50
090-120
OAO
OA5-0.65
OAO
• 0.85-1.20
9.00-11.00 • 12,00-14.00 W31010 2.00-3,00
--"----' 3.00-4.00 Nb(2)
W3471 0
1.00
W41010
13.00-17.00 13.00-17.00
62,00 min. i
0.50-2.50
59,00 min.
21.00-23.50
0.50-3.00 !
, 550-7,50
• 55.0 max. I (includes Co)
8.00-10.00 Co
21.00-26.00
8.00-10.00 !
W84190
Nb(2)
62.00-69,00
W84002 W88021
Nb(2)
i
19,00-21,00
62,00-69.00 32.00-36.00
2,00-3.00
Nb(2)
1,00-2.50
DOC. NO. KOC-Q-01S
II
Page 24 of 29
II
REV. 1
Notes
(1) This Table is for reference only. For actual values, refer to the applicable ASME or ASTM Standards. (2) Nb may alternatively be reported as Nb+Ta (Nb may also be termed as Cb)
Cr : Chromium
Ni : Nickel
Mo : Molybdenum
Cb : Columbium (Also known as Nb, Niobium)
Ti : Titanium
Cu: Copper
W : Tungsten
V: Vanadium
I
Fe : Iron I Ta : Tantalum
Il
DOC. NO. KOC-Q-015
APPENDIX 3:
Page 25 of 29
REV. 1
II
T~~ical
Pressure Boundary Bolting Materials and Elements to be Analyzed
Appendix 3 (Table 5: Typical Pressure Boundary Bolting Materials and Elements to be Analyzed ASME B16.34 Bolting
Materials (Major Elements or Common Name)
Materials
(Extracted From MSS-SP-137)
UNS No.
Cr
Ni
Mo
Cb
Ti
Cu
W
V
Table 1 (1) A 193 B5
5 Cr, 'h Mo
S50100
X
A 193 86, 86X
13 Cr
S41000
X
A 193 B7 , B7M
1 Cr, 1/5 Mo
G41400
X
X
A193 B16
1 Cr, 'h Mo, }'4 V
K14072
X
X
A 193 B8, B8A
304 SS
S30400
X
A 193 B8C, B8CA
347 SS
S3700
X
A 193 B8M , B8MA
316 SS
S31600
X
X
X
A 193 B8R, B8RA
XM19
S209 10
X
X
X
A 193 B8P, B8PA
305 SS
S30500
X
X
A 193 B8T, B8TA
321 SS
S32100
X
X
A 193 B8MLCuN, B8MLCuNA
254 SMO
S32154
X
X
A 320 L7, L7M
1 Cr, 1/5 Mo
G41400
X
'h C, 1/5 Mo
K14510
A 194 Gr. 6 Nuts
13 Cr
S4100
X
A 194 Gr. 7, 7M Nuts
1 Cr, 1/5 Mo
G41400
X
X
A 194 Gr. 16 Nuts
1 Cr, 'h Mo, }'4 V
K14072
X
X
304 SS
S30400
X
X
316 SS
S31600
X
X
321 SS
S32100
X
X
A 194 Gr. 4 Nuts
(2)
X
X
X x
X
X
X
X X
X
X X
X
A 194, A 320 Gr. 8 Nuts
(2)
A 194, A 320 Gr. 8M Nuts
X
A 194, A 320 Gr. 8T Nuts
X
Page 26 of 29
DOC. NO. KOC..Q-015 A 320 Gr.
347 SS
REV. 1
. S34700
X
X
S63198
X
X
X
S66286
X
X
X
• BC Nuts
I A 453 Gr. 651
19
I A 453 Gr. 660
14 Cr, 24 Ni, 1 Mo
9 Ni, 1 Y, M 0, 1 W
A540
1 Cr, Y, Mo, % V
A 564 Gr. 630
17
B 335
4 Ni, 5 Cu
• 64 Ni, 29.5 Mo, 2 Cr, 2 Fe, 3 ,W Ni,42
, B 473
. B 574
!
B 574
, B 637
21 Cr
35 Ni, 35 Fe, 20 Cr, Cb
N10675
Check Elements per Material Table 1A
' NOBBOO
Check Elements per Material Table 1A
!
N10276
Check Elements per Material Group Table 1A
per Material Group . N10276 • Check Elements Table 1A
I 54 Ni, 16 Mo, 15 Cr
55 Ni, 21 Cr, 13.5 Mo
N06022
Check Elements per Material Group 3.4, Table 1A
53 Ni, 19
No771B
Check Elements per Material Group Mo) Table 1A
19
Cb, Mo
Notes: (1) (2)
Reference 4 Materials, Table 1, ASME B16.34. Specific nut materials are listed; however, nuts may also be made from appropriate materials listed in Table 1A.
(+
Page 27 of 29
DOC. NO. KOC-Q-015
REV. 1
II
APPENDIX 4: PMI Report
Typical PMI Report Project # and Title ...... ... ..... . .
Sr. No: ... .. , .... .. .. .
Date: f f Location of Test: .. , .. .. ... ,. ,.. . Report No.: Sheet of
Plant: ..... ... . ...... ... ... '" C on tra ct # ... .. .. .. . Con t ra ct or. ...... .. P.O:.. ...... .. ..... . Drawing No: (e.g., Equipment or ISO) EquipmenULine No.: ..... . .. . .. ... ... . Item Type :( weld, valve, pipe, etc.)
Item Description: (Manufacturer & Heat #)
Type of Instrument Used: Model: Serial No.: Date of Calibration: PMI Procedure Applied : Analysis Result:
Main Item Sub (Equipment/Line Item No.lP.O.l Li ne item/etc.)
Elements for Verification (Add more columns as needed) C
Cr
Ni
Mo
Ti
Nb
Cu
Result of Analysis
Accept
Reject
Pending Chemical Analysis
Color Code (Refer to PFI ES-22)
This is to certify that the above materials verification is made in accordance with the requirement of KOC-Q-015 and the above alloying element percentages were evaluated in accordance with the criteria stated in the above-mentioned standard and the above stated PMI procedure. The items above were also colour coded/marked in accordance with the KOC Standard .
PMI Operator fPlant Inspector (Name) QNQC Manager (Name)
Date
Date
Signature
Signature
Verified by Inspector (Name &10#)
Date
REV. 1
Page 28 of 29 ACKNOWLEDGEMENT
This Standard has been approved by the Standards Technical Committee (STC) comprising of the following members:
Mr. Mr. Mr. Mr Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr. Mr.
Hamzah Ahmad Mohd Emam Kumar A. Unnikrishnan N. Ramanathan Daniel Pino Abdul R. AI-Shamari Haithem Aboughaith Gopal Murthy Mohd. Imadi G. Unnikrishnan Fahad AI Abdulla AI-Yousef .....".... '"'" .... Arthur
i
STC Chainnan Deputy Chainnan Secretary/Member
Member Member Member Member Member Member Member Member
The draft of this "KOC for Positive Identification (PM I)" had KOC User Teams for review and the responses were received from the following:
circulated to the
Team Leader HSE (TS)
Team Leader Insp. & Corr. (S&EK)
Team Leader Design
Team Leader Insp. & Corr. (N&WK)
Team Leader Construction MAJOR PROJECTS GROUPS (I & II)
HEALTH, SAFETY & ENVIRONMENT GROUP
Team Leader
Team Leader
Support
OPERATIONS GROUP (NK)
Team Leader
SUPPORT SVCS. GROUP (NK)
Tech. Svcs. (NK)
AHMADI SVCS. GROUP
OPERATIONS SUPPORT GROUP (S&EK)
Team Leader Project
Team leader Opns. Tech. Svcs. (S&EK)
Team Leader Utilities
Team Leader HSE (S&EK)
SECURITY & FIRE GROUP
SUPPORT SERVICES GROUP
Team Leader Fire
Team Leader General Projects
OPERATIONS GROUP (WK)
SUPPORT SVCS. GROUP (WK)
Team Leader Maintenance (WK)
Team Leader HSE (WK)
· NO. KOC-l..I-u·.::::1
REV. 1
Page 29 of 29
II
EXPORT AND MARINE OPNS. GROUP
TECHNiCAL SUPPORT GROUP- DRlG.
Team Leader Export Tech. Svcs.
Team Leader Drlg.& W/O Tech. Svcs.- I
Team Leader HSE (E & MO)
Team Leader Drlg.& W/O Tech. Svcs.- II
GAS MANAGEMENT GROUP
OPERATiONS GROUP (EK)
Team Leader Consumer Networks
Team Leader Maintenance (EK -II)
Team Leader Gas Opns. (S&EK) Team Leader Gas Maintenance Team Leader MSR (Gas) Team Leader HSE (Gas)
Task Force Responsible For This Standard The Standards Technical Committee (STC) entrusted the preparation of this Standard to the Task Force No. TF-Q/15 conmprising of the following members: 1
Mr. Mohd. Emam
Insp. & Corr. (S&E) Team
TF Leader
Tel. No. 63693
2
Mr. Mohd. Aslam Imadi
Design Team
Member
Tel. No. 61102
3
Mr. Ghassab AI-Ajmi
Insp. & Corr. (N&W) Team
Member
Tel. No. 61198
4
Mr. Sayed Abul-Khair
Insp. & Corr. (S&E) Team
Member
Tel. No ..61455
5
Mr. A. K. Ghosh
Design Team
Member
Tel. No. 61768
6
Mr. Santosh Kumar
Insp. & Corr. (S&E) Team
Member
Tel. No. 65218
7
Mr. Sivasankaran Gopakumar
General Projects Team
Member
Tel. No. 61388
8
Mr. Yaser Ai-Khayyat
OTS (WK) Team
Member
Tel. No. 20335
