AD204-600-G-08012_R0_PMI Procedure

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ADMA‐OPCO Document No. AD204‐600‐G‐08012

Contractor Document No. AD204‐600‐G‐08012

ADMA‐OPCO Contract No. 160597 Budget Ref.

Project Ind. Area Section Sub Section Number Revision Volume

204 600 G SPC 08012 0 1 of 1

SATAH AL RAZBOOT (SARB) FIELD DEVELOPMENT PROJECT

‐ PACKAGE 4 EPC WORK

SPECIFICATION FOR PMI (POSITIVE MATERIAL IDENTIFICATION)

0 19‐Dec‐13 Issued for Construction S.K.PARK H.S.KIM T.H.KIM

B 13‐Dec‐13 Issued for Approval S.K.PARK H.S.KIM T.H.KIM

A 11‐Oct‐13 Issued for Client Comments S.K.PARK H.S.KIM T.H.KIM

Rev Date Description Prepared

By Checked

By Approved

By

SPECIFICATION FOR PMI

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REVISION LOG

REV. NO. REV. DATE REVISED

PAGE REVISION DESCRIPTION

A 11-OCT-13 - Issued for Client Comments

B 11-DEC-13 Incorporate with COMPANY Comments 0 19-DEC-13 Incorporate with COMPANY Comments


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TABLE OF CONTENTS

1. INTRODUCTION .......................................................................................................... 4

1.1 Purpose ........................................................................................................................ 4

1.2 Scope ............................................................................................................................ 4

2. ABBREVIATIONS AND DEFINITIONS ........................................................................ 4

2.1 Abbreviation .................................................................................................................. 4

2.2 Definition ....................................................................................................................... 4

3. REFERENCE DOCUMENTS ........................................................................................ 5

3.1 Reference documents ................................................................................................... 5

3.2 Document precedence .................................................................................................. 6

3.3 Specification Deviation/Concession Control ................................................................. 6

4. REQUIREMENTs ......................................................................................................... 6

4.1 General ......................................................................................................................... 6

4.2 Personnel qualification .................................................................................................. 7

4.3 PMI procedure .............................................................................................................. 7

4.4 Extent of verification for PMI ......................................................................................... 7

4.5 Exception of PMI ........................................................................................................... 8

4.6 Acceptance criteria ....................................................................................................... 8

4.7 Identification .................................................................................................................. 8

5. TEST RESULT CONTROL ........................................................................................... 9

5.1 Rejection Criteria .......................................................................................................... 9

5.2 Rejected Materials ........................................................................................................ 9

6. TABLES ....................................................................................................................... 9


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1. INTRODUCTION

1.1 Purpose

The purpose of specification is to ensure that composition of the alloy materials specified has been correctly supplied, used, and documented for fabrication and installation work at EPC Contractor / Subcontractors yards or Suppliers premises for the PROJECT.

1.2 Scope

This specification includes verification of the chemical composition of alloy metals and visual examination of the manufacturer’s stamping and MTR of materials and parts for construction or fabrication of pressure vessels, piping, engineered equipment, and components.

2. ABBREVIATIONS AND DEFINITIONS

2.1 Abbreviation

PQM Project Quality Manager

QC Quality Control

QA Quality Assurance

PMI Positive Material Identification

MTR Material Test Report

NCR Non-conforming Report

2.2 Definition

PROJECT Satah Al RazBoot (SARB) Field Development Project- Package 4 EPC Work

COMPANY Abu Dhabi Marine Operation Company

CONTRACTOR Hyundai Engineering & Construction Co., Ltd

SUBCONTRACTOR whom any part of the WORKS has been subcontracted by CONTRACTOR

SUPPLIER who is providing GOODS (including any Purchase Orders assigned by COMPANY to CONTRACTOR)

Alloy Material Any metals other than carbon steel, cast or ductile iron, copper, and copper alloys.


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Heat The primary melt of a metal: this generally determines the chemistry unless the heat or portions of the heat undergo additional treating or refining. In that case, PMI chemistry is required of the altered product.

Lot or batch A quantity of the same or similar made in a grouping, for example made at similar time, using the same source components (such as steel from the same heat), and/or with same manufacturing process.

Positive material

identification

Verification of chemical composition of metals using an X-ray emission analyzer, an optical emission spectrometer, or similar COMPANY approved device for verification of alloy content in metallic materials. Verification of nonmetals typically uses a “paper trial” that provides a reference to the original lot, batch, mix, or similar manufacturing reference.

3. REFERENCE DOCUMENTS

3.1 Reference documents

American Society of Mechanical Engineering (ASME)

ASTM E80 Chemical Analysis of Steel, Cast Iron, Open Health Iron, and Wrought Iron

ASTM E212 Spectrographic Analysis of Carbon and Low Alloy Steel by the Rod to Rod Technique

ASTM E322 X-ray Emission Spectrometric Analysis of Low Alloy Steel and Cast Iron

ASTM E327 Optic Emission Spectrometric Analysis of Stainless Type 18-8 Steel by the Point to Plane Technique

ASTM E350 Chemical Analysis of Carbon Steel, Low Alloy Steel, Silicon Electrical Steel, Ingot Iron, and Wrought Iron

ASTM E352 Chemical Analysis of Tool Steel and Other similar Medium and High Alloy Steel

ASTM E527 Numbering Metal and Alloys (UNS)

ASTM E572 X-ray Emission Spectrometric Analysis of Stainless Steel

BP

BP GIS 36-103 Guidance on Industry Standard for Positive Material


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Identification (PMI) for Pressure Vessels, Piping and other Components

BP GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld overlay, and Limited Loose Lining of Pressure Vessels and Components.

3.2 Document precedence

It shall be the CONTRACTOR’S responsibility to be, or to become, knowledgeable of the requirements of the referenced Codes and Standards.

The CONTRACTOR shall notify the COMPANY of any apparent conflict between this specification, the related data sheets, the Codes and Standards and any other specifications noted herein. Resolution and/or interpretation precedence shall be obtained from the COMPANY in writing before proceeding with the design/manufacture.

In case of conflict, the order of precedence shall be:

Statutory legislation and regulation inclusive of ADNOC standards and codes of practices

Project Specifications

ADMA-OPCO Standard Engineering and HSE Documents

BP Recommended Practices and Specifications for Engineering

International Codes and Standards

3.3 Specification Deviation/Concession Control

Any technical deviations to the purchase order and its attachments including, but not limited to, the Project Design Specifications shall be sought by the CONTRACTOR only through CONCESSION REQUEST format. CONCESSION REQUESTS require COMPANY’s review/approval, prior to the proposed technical changes being implemented. Technical changes implemented prior to COMPANY approval are subject to rejection.

4. REQUIREMENTs

4.1 General

PMI results shall match the chemistry requirements of the material specified, or its approved equivalent, for the component being tested.

PMI testing is required for any ferrous or nickel alloy material other than carbon steel

Unless otherwise noted in contract document, non-ferrous materials (copper alloys, aluminium, etc.) other than nickel alloys do not require PMI testing.

PMI testing may be performed prior to post weld heat treatment


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All alloy materials and welds should satisfy the extent of PMI testing and results requirements before hydro test

4.2 Personnel qualification

Personnel performing examinations shall be knowledgeable of all aspects of the PMI program and of the operation of PMI equipment

Qualification of the personnel performing PMI, including training and experience, shall be the responsibility of the equipment/component Supplier or Vendor/Contractor. Verification of their qualifications shall be provided to Company upon request

In case if PMI personnel is qualified by Vendor / Contractor, PMI personnel shall meet following requirement, as minimum

Experience in operation of instrument (3 years or Petrochemical and Gas Plant)

Familiar with capabilities of instrument

Interpretation ability about result displayed

On completing the formal course of instruction and practical application satisfactorily, PMI Operator will be certified by Project Quality Manager or his designee. And Certificate will be issued.

4.3 PMI procedure

PMI procedure shall be approved by COMPANY before beginning work or supplying components and shall include the following as a minimum:

Description of testing equipment, minimum personnel qualification, calibration verification, and required surface preparation.

Description of the item, the number of items in each heat or lot/batch, and the total number of items subject to PMI.

Materials specification and heat or lot/batch number of materials or welding consumables

Description of marking and recording method and handling of rejected items.

PMI procedure should specify the type of equipment which is acceptable to perform the testing and its calibration frequency.

Vendor/Supplier/Fabricator PMI procedure will include “PMI report format”

4.4 Extent of verification for PMI

PMI shall be carried out in accordance with the extent shown in “Table 1. Extent of PMI”

When an approved method of analysis is used, the alloy verified shall contain the amounts of alloying elements mentioned in “Table 2. Alloy Elements Required for PMI Testing”.


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Selection of samples will be random where extent is percentage, the TPA will be given opportunity to select samples.

4.5 Exception of PMI

All the alloy materials within the following standard manufactured equipment packages do not required PMI testing:

Gas Turbines, within the enclosure package and gear boxes

Diesel engines(for firewater pumps and generators), and gear boxes

Potable water maker packages including evaporator, condenser, UV sterilization, re-mineralization system, filter, strainers and pipe/fittings

Air compressor packages

Instrument air dryer and filter packages

Nitrogen generator packages

Sewage treatment packages

Electro-chlorination packages

Rotating backwash filter packages

Chemical injection pumps

Diesel pumps

Methanol pumps

HVAC equipment

Electrical and instrument equipment

4.6 Acceptance criteria

All materials shall comply with the requirements of applicable material specification.

Unless otherwise noted, a portable alloy analyzer “Match” of material is accepted as verification of an alloy material.

If a clear match is not made, then the alloying elements specified in attachment 2 for each individual alloy shall be verified by PMI testing and the results submitted to the Contractor.

The test results for welds including welding consumable shall be within the range specified by the applicable material standard _Table 3.

4.7 Identification

Materials that have been PMI verified shall be marked and recorded


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Marking shall be done immediately after PMI either by low-stress (round bottomed) stamps or paint marking each item. If item is too small for stamping or paint marking, wire tagging or bagging shall be used.

If PMI materials are cut, marking shall be immediately applied to unmarked parts where practical.

Paint used shall not contain additives that could have deleterious effects on alloy material. For example, halides (especially chlorides in markers can lead to SCC of austenitic stainless steels in some service environments.

5. TEST RESULT CONTROL

5.1 Rejection Criteria

If any of the major alloying elements are below the range specified in para. 4.6 or a portable analyzer indicates an incorrect match or “No match”

The component shall be rejected or laboratory analysis may be performed

The laboratory analysis will determine acceptance or rejection of the material

If any of the major alloying elements are greater than range specified in para. 4.6, the alloy content must be reported to COMPANY for acceptance or rejection

5.2 Rejected Materials

Rejected or Non-conforming materials and welds in shop and field fabricated pipe spools or equipment shall be marked (choose a method) isolated until it is replaced. Following replacement, PMI shall be conducted on all replaced components and/or new welds. If any piece, or weld from a representative percentage sample is found to be unacceptable, then the remainder of that material heat number or all welds on completed pipe spool or equipment item shall be verified by performing a 100% PMI testing When PMI results are non-conforming, NCR shall be generated by the Vendor / Supplier / Fabricator and reported along and disposition for COMPANY approval.

6. TABLES

Table 1. Extent of PMI

Table 2. Alloy Elements Required for PMI Testing

Table 3. Acceptable Range for PMI testing


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Table 1. Extent of PMI

Extent Elements of common alloys and weld metals

Equipment

a) 100%

All alloy pressure containing materials, except heat exchanger tubes

All alloy pressure containing components(includes pipe or tube for heated coils used for the fabrication of equipment

b) 10% per heat of material

All alloy heat exchanger tubes and non-pressure containing components

Bulk piping and tubing components

10% per heat or Lot

Pipe Valve bodies and bonnets or cover (including trim

and body/bonnet bolting) Control and relief type valves, bodies, bonnets or

covers as applicable (including trim and body/bonnet bolting)

Flanges (e.g. weldneck, slip-on, lap-joint, orifice, Hub connector, clamps, seal rings, etc.)

Fittings (e.g. buttweld, welded fittings, etc) Presssure blinds (e.g. spectacle, spacer, paddle

blind etc) Strainers (e.g. Y-type, basket, etc) Thermowells Vent and drain caps and plugs Metallic expansion joints In-line special piping items Instrument tubing and fittings Bolt/Nut/Stud

Shop & field fabricated pipe spools

100% Shop/field fabricated spool in alloy materials.

Welds 100% Pressure containing butt welds in equipment and piping made with alloy welding consumables

Gasket 10%

Note ; (1) If any piece from a random inspection sample is found to be unacceptable, each

piece of the lot shall be examined (2) Shop fabricated alloy equipment or assemblies that have been alloy verified in the

Supplier's shop need not be re-verified in the field unless field modification are required. For Field Welds alloy verification is required by PMI.

(3) Alloy studs, bolts and nuts shall have appropriate stamping in addition to a MTR (4) Package labels of welding consumables shall be visually examined to confirm

proper material type for the work during material receiving inspection followed by appropriate quality control to ensure the use of the correct consumable as per the WPS.

(5) PMI shall not be considered as a substitute for required mill test reports listing chemical composition. In addition, mill test reports shall not be considered as confirming alloy verification.


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Table 2. Alloy Elements Required for PMI Testing

Alloy Cr Ni Mo Cb Ti Cu Al C Co W Fe

1¼Cr - ½Mo 1.00-1.50

0.44-0.65

2¼Cr - ½Mo 1.90-2.60

0.87-1.13

5Cr - ½Mo 4.00-6.00

0.45-0.65

9Cr - 1Mo 8.00-10.00

0.90-1.10

304 18.0-20.0

8.0-11.0

304L 18.0-20.0

8.0-13.0

x•

304H 18.0-20.0

8.0-11.0

x•

309 22.0-24.0

12.0-15.0

316 16.0-18.0

11.0-14.0

2.00-3.00

316L 16.0-18.0

10.0-14.0

2.00-3.00

x•

321 17.0-19.0

9.0-12.0

X**

347 17.0-19.0

9.0-13.0

A

Alloy 20 19.0-21.0

32.0-38.0

2.00-3.00

B 3.00-4.00

Hast C-276 14.5-16.5

C 15.0-17.0

2.5 Max

3.0-4.5

Alloy 600 14.0-17.0

72.0 Max

Alloy 601 21.0-25.0

58.0-63.0

1.0-1.7

Alloy 625 20.0-30.0

58.0 Min

8.0-10.0

3.15-4.15

0.40 0.40 Max

1.00 Max

Alloy 800 19.0-23.0

30.0-35.0

0.15-0.60

0.75 Max

0.15-0.60

Alloy 825 19.5-23.5

38.0-46.0

2.50-3.50

0.60-1.20

1.50-3.00

0.2

Monel 400 63.0 Min

28.0-34.0

9 Ni 18.0-21.0

8.0-11.0

0.50

Duplex 21.0-26.0

4.50-6.50

2.50-3.50

Super duplex

24.0-26.0

6.00-8.00

3.00-5.00

0.50 Max


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90-10 Cu Ni (C70600)

9.0-11.0

C

70-30 Cu Ni (C71500)

29.0-33.0

C

Titanium 98.825 Min

x• : Testing of C is only required when specifically indicated on the data sheet or purchase document x**: 5x(C+N) to 0.70 A: Contents shall be not less than 10 times the carbon content and not more than 1.00% B: Contents shall be not less than 8 times the carbon content and not more than 1.00% C: Remainder All values in weight percent based on ASTM


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Table 3. Acceptable Range for weld metal

Weld metal The amounts of alloy elements (%) Ni Cr Mo Other

1¼ Cr - ½ Mo(ER80S-B2,E8018-B2) 0.94-1.56 0.40-0.70

2¼ Cr - 1 Mo(ER90S-B3,E9018-B3)

1.88-2.62 0.85-1.15

5 Cr - ½ Mo(ER80S-B6,E8018-B6) Max. 0.50 4.0-6.0 0.44-0.65

9 Cr - 1 Mo(E80S-B8, E8018-B8)

0.40 8.0-9.5 0.85-1.05 Cb Max 0.06-

0.10 18Cr – 8Ni-Mo(ER304, E304-16)

8.0-12.0 18.0-20.0 C Max 0.08

18Cr – 8Ni-Mo(ER304H, 304H-16)

8.0-12.0 18.0-20.0 C 0.04-0.10

18Cr – 8Ni-Mo(ER304L, 304L-16)

8.0-12.0 18.0-20.0 C Max 0.03

18 Cr – 8 Ni - Mo(ER316-16, E316-16) 10.0-14.0 16.0-18.0 2.0-3.0 C Max 0.08

18 Cr – 8 Ni - Mo(ER316L-16, E316L-16) 10.0-14.0 16.0-18.0 2.0-3.0 C Max 0.03

18 Cr – 10 Ni(ER347,ER347-16)

9.0-13.0 17.0-20.0

25 Cr – 12 Ni(ER309,ER309-16)

12.0-15.0 22.0-24.0

Alloy 20(E(R)320LR) 32.0-38.0 19.0-21.0 2.0-3.0

C-276(E(R)NiCrMo-4) Remainder 14.5-16.5 15.0-17.0

Alloy 600(ERNiCr-3, ENiCrFe-3)

Min. 72.0 14.0-17.0

Alloy 601(ERNiCr-3, ENiCrCoMo-1)

58.0-63.0 21.0-25.0

Alloy 625(ENiCrMo-3, ERNiCrMo-3)

Min 58.0 20.0-23.0 8.0-10.0

Alloy 800(ENiCrFe-3, ERNiCr-3)

30.0-35.0 19.0-23.0

Alloy 825(ERNiCrMo-3, ENiCrMo-3)

38.0-46.0 19.5-23.5 2.5-3.5

9Ni (ENiCrMo-6) 8.4-9.6

Monel 400 (ENiCu-7) 62.0-69.0 Cu

Nickel(ENi-1) Min 92.0

Duplex(ER2209,E2209-17) 7.5-9.5 21.5-23.5 2.5-3.5

Super Duplex(ER2507, E2594-17)

6.0-8.0 24.0-26.0 3.0-5.0

CuNi 90/10(ERCuNi 90/10) 9.0-11.0 (Ni + Co)

Cu Min. 86.5

CuNi 70/30(ERCuNi 70/30) 29.0-33.0 (Ni + Co)

Cu Min. 65.0

AD204-600-G-08012_R0_PMI Procedure

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