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QUALITY CONTROL PROCEDURE

SUBJECT PROCEDURE No. REVISION NO. DATE OF FIRST ISSUE POSITIVE MATERIAL IDENTIFICATION AMSYCO 40001/01 00 October 20, 2012

DISTRIBUTION OF CONTROL COPIES


PROJECT CONTRACT SADARA, Mixed Feed Cracker (MFC) Project 6600027129 (IK)

COPY # 1 COPY # 2 COPY # 3

Daelim Saudi Arabia Co. Ltd. N/A N/A

REVISION

DATE

Procedure No. First Issue Date Revision No. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION

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TABLE OF CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. SCOPE REFERENCES DEFINITIONS RESPONSIBILITIES EQUIPMENT EXTENT OF VERIFICATION PROCEDURE ACCEPTANCE CRITERIA REJECTION PROCEDURES

10. REPORTING 11. MARKING AND COLOR CODING

APPENDIX
REPORT FORM

Procedure No. First Issue Date Revision No. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION 1. Scope

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This procedure sets forth the minimum requirements to be followed when using the Portable Metal Analyzer, for identification of materials used on the Projects (applicable to plants, shop and field fabrication) and the reporting of results. The requirements in this procedure shall apply to PMI of both new components and repair or replacement components. This procedure is intended to ensure that the nominal composition of the alloy components and associated welds have been correctly supplied and installed as specified. The testing methods outlined in this procedure are not intended to establish the complete conformance of a material to the material specifications. PMI testing shall be performed at a point in time that ensures proper alloy materials have been used in the fabrication of an identifiable assembly. Usually this is during fabrication or immediately prior to fabrication.

2. References ASME Boiler & Pressure Vessel Code Section II: Parts A, B and C (2010 ed., 11 a.) ASME B31.1 ASME B31.3 ASME B31.4 ASME B31.8 ASME B16.20 ASTM A193/11a. ASTM A751/11 API RP-578/10 Power Piping (2010 ed.) Process Piping (2010 ed.) Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids (2009 ed.) Gas Transmission and Distributing Piping Systems (2010 ed.) Metallic gaskets for Pipe Flanges: Ring Joints, Spiral-Wound Gaskets and Jacketed Standard Specification for Alloy-Steel and Stainless Steel Bolting materials for High-Temperature and High-Pressure Service Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel Products. Material Verification Program for New and Existing Alloy Piping Systems

SADARA (RTIP) Standards: RT8S-4001-61 Positive Material Identification Saudi Aramco Standards: SAES-A-206 Positive Material Identification (July 2007) 00-SAIP-07 175-320300 PFI ES-22 Positive Material Identification Requirements Inspection Requirements: Positive Material Identification Recommended Practice for color coding of Piping Materials

SpectroTEST Operation Manual NITON XLt, XL2-980 Series Users Guide

Procedure No. First Issue Date Revision No. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION 3. Definitions

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Alloy Steel: Any steel (including filler metals for welding alloy materials) that contains specified quantities of elements, such as Chromium, Nickel or Molybdenum, that are added to enhance mechanical or physical properties, and/or corrosion resistance. Alloy steels and stainless steels comprise ASME P-Nos. 3 through 11, or equivalent. PMI: Positive Material Identification determination that the nominal chemical composition of a mechanical component is as specified and ordered. PMI Testing: Any physical evaluation or test of a material, meeting the requirements of this standard, to confirm that the material which has been or will be placed into service is consistent with the selected or specified alloy material. Equipment Manufacturer: The company responsible for the plant or shop manufacturing of pressured equipment that is within the scope of this standard. Fabricator: The company, organization, or agency responsible for the shop or field fabrication or assembly of piping and pressured equipment within the scope of this standard. Material Specifications: ASME Section II, Parts A, B and C, or the relevant ASTM, or any other material specification required. Nonferrous Alloys: Metals that are not iron-based, including Nickel alloys and other corrosion-resistant alloys. ASME P-No. 21 and higher, or equivalent. Nonpressure Components: Items that are not part of the pressure containing envelope, and, therefore, do not affect the pressure retaining capacity of pressured components. Pressure-Containing Components and Parts: Product forms used for the fabrication of pressured piping and equipment, including but not limited to: shells, heads, tubesheets, nozzles, tubes, stud bolts/nuts, gaskets, forging, flanges, pipe and fittings such as tees, elbows, reducers, and special pipe components, valves (body and bonnets), and alloy welds joining pressure parts to non-pressure parts. Project Inspector: The person or company authorized by the Project Inspection Department to verify implementation of the requirements of this procedure and Project Specifications.

4. Personnel Qualification & Equipment Calibration Trained personnel shall be responsible for operating the Metal Analyzer in accordance with the approved procedure in order to verify the nominal compositions of the alloy pressure containing components, interpreting and recording the results. Prior to commencing PMI, the operators shall be qualified to operate equipment on a representative sample of the alloy materials with 100% correct assessment as the performance criteria. Evidence of training, qualification and experience shall be provided for review and approval before start of work. Records of examination will be completed the same day as testing occurs and will be maintained as required by the projects requirements. The Trained PMI Personnel shall calibrate and/or verify the test equipment performance in accordance with manufacturers recommendations. The equipment shall be calibrated at intervals of six (06) months by verification using certified standards samples or by the equipment manufacturer. When the inspector doubts the reliability of the measurement, he may request for re-calibration of the instrument on shorter periods.

Procedure No. First Issue Date Revision No. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION 5. Equipment 5.1. PMI Equipment 5.1.1. SPECTROTEST 5.1.2. NITON XLt, XL2-980 (XRF Analyzer)

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5.2. The instruments and methods used shall be suitable for identifying the material by quantitative measurement of the major alloying elements required in the applicable material specification or welding procedure specification. 5.3. The principle of the analysis method of SPECTROs portable metal analyzer is optical emission spectroscopy and NITON XLt analyzer is x-ray fluorescence (XRF) 5.4. The equipment shall be always re-calibrated at the job site if the readings observed are abnormal due to severe temperature fluctuations or any other adverse site conditions. Analyzed samples with reference to the job shall be made available for cross-reference and calibration and witnessed by the inspector. 5.5. As an alternative, in accordance with one of the methods of ASTM A751 a chemical analysis of samples cut out from the pieces requiring PMI may be used to check for the alloying elements required by this procedure. 5.6. If sample removal is used, a written procedure for identification and traceability to original material is required. This procedure shall be reviewed/approved by the Project Engineer and Project Inspection Department. 5.7. Both inside and outside weld surfaces shall be tested where accessible. PMI testing of welds shall be done after removal of slag and/or oxide from the weld surface. Surface shall be clean bare metal, free of grease or oil as specified by the instrument manufacturer.

6. Extent of Verification 6.1. The PMI program covers alloy material, pressure-containing components in shop and field fabricated equipment and piping (base metal, welds and cladding) and materials used for repair or replacement of pressure containing components. 6.2. The elements of the basic alloy materials to be verified shall be in accordance with Table 1, as below: Basic Alloy
Carbon-Molybdenum Manganese-Molybdenum, and Chromium-Molybdenum steels Nickel Steels Regular carbon grade stainless steels Low and High carbon stainless steels Stabilized stainless steels Nickel-based alloys Copper-based alloys

Elements to be verified
Chromium, Molybdenum and Vanadium Nickel Chromium, Nickel and Molybdenum Chromium, Nickel, Molybdenum, and Carbon Chromium, Nickel, Molybdenum, Titanium and Niobium Nickel, Iron, Copper, Chromium, Molybdenum, Tungsten, Vanadium Copper, Zinc, and other elements specified in P.O.

6.3. For alloys not covered in Paragraph 6.5, the Supervisor of the Materials Engineering Unit of the Project shall be consulted.

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6.4. 100% PMI testing (each component and weld is tested) shall be performed on all pressure components and weld of alloy materials, within the scope of this standard. 6.4.1. Major Equipment
Part Vessel shells, heads, tube sheets, nozzles, downcomers, wires, tray support rings, any other items assembled by welding including heat exchanger tubes to be welded to the tubesheet. Metal Specified Each alloy type or grade Low carbon grades of stainless steels including dual certified grades or alloys that may be sensitized by welding. Testing Requirements Each heat of metal or part used shall be tested. Each heat of metal or part used shall be tested. Shop and Field fabricated pressure components and welds which are wholly or partly outside of the casing plate or header box, unless otherwise noted in the P.O. In addition, 5% of the pressure containing components and tube sheets which are inside the casing plates. Parts shall be 10% random sampled and tested. If improper materials are discovered, all parts shall be tested. Each batch or lot of filler metal shall be tested. 100% of pressure retaining components exposed to the process shall be verified.

Fired heaters/Fired boilers

Each alloy type or grade

Parts that are not to be welded, such as nuts, bolts, support posts, etc., including tray decks, thermowells and heat exchanger tubes that will not be welded to the tube sheet. Welding Filler Metal Mechanical Rotating Equipment (pumps, compressors, expanders, turbines, etc.)

Each alloy type or grade

Each alloy type or grade Each alloy type or grade

6.4.2. Minor Equipment and Instruments When identified with the notation PMI check for xxxx alloy on the P&ID, PMI as given in the below table shall be conducted. For internal process wetted components in instruments and control valves, a parts list should be made. The list should contain the components name or part number, the material of construction, the method of testing, and testers name.
Part Factory assembled instruments and also parts of minor equipment contacting the process stream, including all orifice plates and welds, if any. Metal Specified Test Required All components contacting the process shall be tested. For control valves, the body and bonnet of each control valve shall be verified. For flow meters, the pressure containing portions of each inset type flow meter shall be verified. For displacers and float switches, the chamber and head of each displacer and switch shall be verified. The PRV rupture discs, and pressure containing portions of any instrument through which the process fluid flows shall be verified.

Each alloy type or grade

Instruments, Pressure Relief Valves (PRV), etc.

Each alloy type or grade

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6.4.3. Valves and Piping When required, valves and piping shall be checked as in below table. For internal process wetted components in control valves, a parts list should be made by the fabricator. The list should contain the components name or part number, the material of construction, the method of testing, and the testers name.
Part Pipes, Pipe Fittings, slipblinds, and thermowells, including lap rings, flange gasket faces and metallic alloy gaskets. All valve bodies and stems; the ball and plug in valves 1 and larger; the flapper in check valves; the disc in butterfly valves; bolts and nuts holding flapper and disks. Screwed pipe, nipples, fittings, process-wetted components of gaskets. Welding Filler Metal: in cases where PMI testing of the completed welds is not possible because of geometry, PMI testing of filler metal lots and visual inspection of electrodes as described in Para 6.7 is an acceptable substitute for testing of the completed weld. Welds, Weld Overlays, and Cladding Metal Specified Alloy type or grade Low carbon grades of stainless steels or alloys that may be sensitized by welding Test Required Each heat of metal contacting the process stream shall be tested. Each heat of metal or part used shall be tested.

Alloy type or grade

All parts not having an embossed identification shall be tested.

Alloy type or grade

Each heat of metal or part used shall be tested.

Alloy type or grade

Each batch or lot of filler metal shall be tested.

Alloy type or grade

100% PMI

6.5. PMI testing of weld material shall be performed in the same manner as for the adjacent base metal. 6.6. The required number of PMI tests shall be as follows: 6.6.1. One test for each pressure-containing component. If an assembly contains a number of components (parts), one test is required for each component (part). 6.6.2. One test for each pressure-containing weld and weld repair, plus filler metal testing. 6.7. PMI Testing of Welding Consumables 6.7.1. In addition to the PMI testing of completed pressure-containing welds, when welding of alloy materials is conducted, one electrode or wire sample from each lot of filler metal shall be positively identified. The remainder of the lot shall be compared to the identified rod to verify that markings of the wires/electrodes are correct. Failure of PMI on consumable will result in rejection of whole lot consumable. 6.7.2. PMI testing of weld metal (e.g., deposited or undiluted weld buttons) is an acceptable alternative to PMI testing of an electrode or wire sample provided it is conducted immediately prior to welding or during the welding process. Note: some weld rods have the alloying elements contained in the flux, and do not meet the alloy specification until welded.

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6.7.3. In cases where PMI testing of the completed weld is not possible because of geometry (e.g., small fillet welds and narrow root beads), PMI testing of filler metal lots and visual inspection of electrodes as described in 6.7.1 and 6.7.2 is an acceptable substitute for testing of the completed weld. 6.8. Exemptions: 6.8.1. Unless specifically required in the project, the following components and materials are exempt from PMI: a. Non-pressure components b. Components made from carbon steel or cast iron and filler metal for welding carbon steel c. Rotating equipment internals and associated seal, lube oil, cooling water and steam equipment and piping d. Valve internals (trim) e. Piping components in ASME B31.3 Category D Service or equivalent f. All instrumentation provided with isolation valves.

7. Procedure Elements lighter than Sulfur cannot be detected by the X-ray emission analysis due to inherent limitations. Therefore, this technique cannot differentiate between Carbon levels within a given alloy family, eg., they cannot determine the difference between stainless steel grades such as 304L, 304 and 304H. An optical emission spectroscope may be used to check for all the required elements, including Carbon. For Spectro TEST The metallic surface to be tested shall be free from all extraneous materials such as scale, rust, dirt, grease, etc. which may interfere with the testing. All surfaces to be examined shall be prepared by light grinding to ensure good surface contact. Ferritic base materials and areas of weld to be tested can be prepared with a mini-disk grinder; however excessive removal could reduce the effective material thickness beyond permissible limits. The equipment shall be connected to the power source after ensuring the correct voltage. The electrode shall be checked for its cleanliness and sharp tip; otherwise the electrode shall be properly cleaned or replaced. The basic electrode is copper, which is used for all analysis, however for identification of copper in metallic material, a silver electrode shall be used in place of the copper electrode. The equipment shall then be standardized with sample and procedures as given by the manufacturer. After successful standardization the equipment shall be calibrated by checking the values of the standard samples with reference to the job. Programmed options as per client requirements, such as identification, verification or sorting may be selected. Spark the electrode and store the readings and print the permanent record of the readings. The readings obtained shall be compared and the results noted in the appropriate report format. Direct viewing of the arc should be avoided to protect eyes from ultraviolet rays. Upon completion of testing, the burn areas shall be cleaned/light grinding to remove the burn residue. The compositions that need to be verified in the test report shall be in accordance with Table 1, Para 6.5 (which are in accordance with Para 4.0 of RT8S-4001-61 and Table 2 of Para 7.5 of SAES-W-206).

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For NITON XLt, XL2-980 Before beginning a test, ensure that the battery has sufficient charge. The analyzer and the battery packs shall be stored in a cool place, away from direct sunlight. To ensure the reliability, durability, and performance of the NITON XLt Analyzer, always keep the transparent Kapton window covering the analysis clean with a cotton swab. The analyzer shall never be pointed towards yourself or anyone else while the shutter is open to avoid unnecessary radiation.

8. Acceptance Criteria 8.1. Materials shall contain the amount of alloying elements specified in the material specification. Alloys, including castings, shall be acceptable if the alloying elements are each within 10% of the specified range of values. 8.2. Welds with consumables that match, or nearly match, the base metal composition shall be within 12.5% of the ranges allowed in ASME Section IIC for each element. 8.3. For dissimilar metal alloy welds (other than weld overlays), the effects of dilution from the different base metals and the filler metal shall be taken into account for determining the nominal asdeposited weld metal composition. 8.4. For weld overlays, the chemistry on the surface of overlays shall be in accordance with the following: 8.4.1. The weld deposit chemistry shall be specified in the engineering design. Where a nominal alloy designation for the overlay or cladding is listed (e.g., 316L), then the overlay deposit shall meet the equivalent filler metal composition requirements unless otherwise specified or exempted in this procedure. 8.4.2. The cladding restoration portion of weld joints between clad materials or attaching clad materials shall meet the requirements for weld overlays. 8.5. PMI test report shall be reviewed prior to any Post Weld Heat Treatment, Painting, Insulation or Hydrotest and made part of the hydrotest package supporting document.

9. Rejection Procedures 9.1. If the PMI testing results fall outside the acceptable range using the testing method described in Section 7, the Equipment Manufacturer or the Fabricator, as applicable, has the option to conduct a more accurate analysis at his own expense to determine the component acceptance such as obtaining a chemical analysis performed by an independent testing laboratory. The alternative test method or independent laboratory must be acceptable to the Client Inspector. The results of the more accurate test method or independent chemical analysis shall govern. 9.2. If any component or weld is found unacceptable, it shall be replaced and the replacement shall be alloy verified in accordance with this procedure. 9.3. Procedures shall be in place to ensure that rejected components are segregated and properly identified to prevent reuse.

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9.4. Where one of the tubes for heat exchangers, and boilers is found unacceptable, all remaining tubes required of the particular alloy shall be tested for the individual equipment. This also applies to the weld metals. 9.5. All rejected tubes shall be replaced and 100% of the replacement tubes shall be subjected to PMI testing in accordance with this procedure.

10. Reporting 10.1. A detailed PMI map of the equipment being fabricated shall be supplied by the fabricator. The map shall show the alloy material specification of each alloy component and the extent of PMI required in accordance with the requirements of project specifications. 10.2. As a minimum, the report shall include: Report number, Client/Contractor name, Project, Location, Material under Examination, Identification of Materials for all components and welds, Material Verification, Results, Name and Signature of the Operator with date of testing. 10.3. All the hard copy of computer printouts shall be attached along with the PMI Reports. 10.4. The PMI Report shall be reviewed by the Client Inspector prior to final acceptance. 11. Marking and Color Coding 11.1. Verification Marking 11.1.1. Paint marking shall be done with the letters PMI using a water insoluble material that contains no harmful substance, such as metallic pigments, lead, zinc, sulfur, mercury, chlorides or other halogens, which would attack or harmfully affect austenitic or nickel alloy steels at ambient or elevated temperature. 11.1.2. All components and welds that are found to be unacceptable during verification shall be marked with a circled red X pending resolution in accordance with Section 9. 11.1.3. All verified materials with acceptable analysis may be marked with the letters PMI using a certified low-stress stamp. The marking (stamping) shall be in accordance with procedures and specifications, and shall not have a negative effect on the material. The marking shall be placed as follows: 11.1.3.1. 11.1.3.2. 11.1.3.3. 11.1.3.4. 11.1.3.5. 11.1.3.6. 11.1.3.7. Pipe: one mark, 75 mm from one end on the outer surface of the pipe. Welds: adjacent to the welders mark on the weld. Fittings and Forgings: adjacent to the manufacturers marking. Valves: adjacent to the manufacturers markings on bodies and other pressure parts. Plates: 75 mm from one edge, adjacent to the heat numbers. Castings: adjacent to the manufacturers markings and heat numbers. Tubes: stenciled, 300 mm from each end.

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11.1.4. If the material or item is too light, too small, or cannot otherwise be stamped, vibro-etching or color-coding shall be applied in conjunction with Sellers standards and the requirements of Para 9.2.1 and noted on the alloy verification reports. 11.1.5. Where heat treatment is performed after alloy verification, the identification marking must be recognizable after heat treatment. PMI markings shall be transferred when a plate or pipe is cut. 11.2. Color Coding 11.2.1. The color coding system for material identification described herein is intended to help prevent fabricators from using incorrect alloy material. The principal purpose of color coding is visual identification during storage and after the components has been cut for fabrication. 11.2.2. Color coding is not a substitute for PMI testing or other permanent manufacturers markings required by ASTM or other specifications. Permanent manufacturers markings shall not be obscured by color coding. 11.2.3. Color coding may be done by the material manufacturer or material supplier. Color coding need not be retained after painting. 11.2.4. Prior to coding, surfaces shall be clean and free of dirt, loose scale, and oil. Paints used for coding shall be durable, bright, and distinctive and shall not contain substances that would harmfully affect the material at ambient or elevated temperatures. In particular, paints shall be free of lead, sulfur, zinc, cadmium, mercury, chlorine, and other halogens. 11.2.5. Each component shall be coded in accordance PFI ES-22 and Para 14 of 00-SAIP-07, and shall have painted characters indicating the specification number of the material if it is not permanently marked or tagged according to the applicable material specification. 11.2.6. Valves, flanges, and fittings do not require color coding if these components are permanently stamped or tagged by the manufacturer. If the materials are not easily legible, valves, flanges, and fittings shall be coded with a stripe of 5 mm minimum width. The color coding on valves should indicate the valve body material. 11.2.7. ASTM A193, Grade B7 stud bolts do not require color coding if the grade of the material is stamped on one end of each bolt. 11.2.8. Spiral-wound gaskets shall be color coded in accordance with ASME B16.20. Sheet type gaskets do not require color coding. 11.2.9. Pipe and Fittings: each length of pipe and fitting shall have a 5 mm or larger stripe running full length. One inch NPS and smaller may have a 3 mm stripe running full length. 11.2.10. Valves: when required, stripe across the body from flange to flange or end to end. 11.2.11. Flanges: when required, stripe across edge to hub. 11.2.12. Bolting: when required, stripe around the midpoint of each bolt or stud. 11.2.13. Plate, sheet and strip: stripe on surface near two perpendicular edges for entire length. 11.2.14. Tubes and Bars: stripe entire length.

Procedure No. First Issue Date Revision No. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION 12. Safety 12.1. The instrument shall be operated in a dry environment. 12.2. The instrument must be secured if operated on an uneven surface. 12.3. Avoid looking directly into the light arc.

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12.4. Attention will be paid on compliance with all electrical connections. The instrument may only be operated on power outlets with a circuit breaker or ground fault breaker. 12.5. Avoid simultaneous contact between the instrument and electrically conductive components, other instruments, machinery, etc. Such contact may lead to a small electrical voltage due to unfavorable potential ratios between grounded wires from different supplies or between grounded wires and the instrument housing. 12.6. The electrical source must be turned off while changing the electrode on the probe. 12.7. The NITON XLt Analyzer contains an x-ray tube, which emits no radiation unless the user turns the x-ray tube on. When the x-ray tube is ON and the shutter is open, as during a measurement, the analyzer emits a directed radiation beam at the front and top-front of the analyzer. There is negligible radiation at the handle of the analyzer. 12.8. Though NITON XLt was designed to be safe as possible, it is strongly recommended that all precautions are taken to insure safety for the operator and others around.

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