[8015-0151-SECL-00-000-QC-PP-00105_00] PMI Procedure

West Qurna Field 2nd Phase Project

(Early Oil Phase) DOC. TITLE Positive Material Identification Procedure Page 2 of 13 Rev. 00 DOC NO. 8015-0151-SECL-00-000-QC-PP-00105 Job. No. SO2476

TABLE OF CONTENTS

1 INTRODUCTION ..................................................................................................................... 3 2 SCOPE .................................................................................................................................... 3 3 PURPOSE ............................................................................................................................... 3 4 REFERENCE .......................................................................................................................... 3 5 DEFINITIONS ......................................................................................................................... 4 6 PERSONNEL QUALIFICATION ............................................................................................. 4 7 GENERAL ............................................................................................................................... 4

7.1 INSTRUMENT ......................................................................................................................................... 5 7.2 SHOP AND FIELD TESTING ...................................................................................................................... 5 7.3 EXTENT OF TESTING .............................................................................................................................. 6

8 SAFETY .................................................................................................................................. 8 9 ACCEPTANCE CRITERIA...................................................................................................... 8

9.1 REJECTION CRITERIA ............................................................................................................................. 9 10 PMI TEST REPORT .............................................................................................................. 10 11 APPENDIX ............................................................................................................................ 10

APPENDIX A REPORT FORMAT APPENDIX B REQUIRED ALLOY ELEMENTS



1 INTRODUCTION

This procedure is developed to cover the Positive Material Identification (hereinafter PMI) requirements for West Qurna Field 2nd Phase Project Site.

2 SCOPE

This procedure covers the positive materials identification (hereinafter referred to as PMI) requirement for low alloy steel (1 1/4Cr-1/2Mo, etc.), stainless steel (ANSI 316, 316L, 317L, etc.) and nickel alloys used for equipment and piping systems. This procedure shall be used as a guide for performing PMI test using x-ray tube type potable alloy analyzer. This procedure may also be applied for PMI on stainless steel and alloy steels other than those listed in this procedure when so required by project specifications.

3 PURPOSE

The purpose of PMI is to ensure that the nominal composition of the material specified has been correctly supplied and documented.

The nominal composition required by the applicable code and/or specification shall be used to assess the acceptability of the material tested.

Certified material test reports (including those certified by a third party) are not to be considered as a substitute for PMI, and vice versa.

4 REFERENCE

ASME Sec.II Part A : 2010 ASME Sec.II Part B : 2010 ASME Sec.II Part C : 2010 8015-0151-SECL-00-000-PQ-SP-00001 Procedure for Positive Alloy Material

Identification of Equipment and Piping.

8015-0151-SECL-00-000-QC-SP-00004 General Construction Specification for Piping



5 DEFINITIONS

Terms included in this procedure are defined as follows; Company Lukoil Oil Company (Lukoil) Contractor Samsung Engineering Co., Ltd (SECL) Manufacturer / Vendor the supplier of equipment and support services for a

particular piece of equipment / package Pipe Fabricator The party which fabricates pipe spools whether in the shop

or field. PMI Positive Materials Identification PMI operator the person who perform PMI test with PMI instrument Alloy Material any ferrous or nickel alloy material that is not carbon steel Equipment mechanical equipment such as vessels, heat exchangers,

pumps, compressors, heaters, etc Piping System shop-fabricated pipe-spools, field-fabricated pipe-spools,

field-fabricated random-run piping, and equipment piping

(including furnace coils), instrumentation CRA is referred to as Corrosion Resistant Alloy

6 PERSONNEL QUALIFICATION

Personnel who perform this test shall be trained by instrument manufacture or the person who accredited by instrument manufacture. Those trained by accredited person shall have a record of training, education and examinations as given by accredited person. Further- all PMI operators will carry a card certificate or other certificate which identify them as PMI operators though training, experience and education.

7 GENERAL

Equipment and piping components requiring PMI testing shall be noted on the applicable project documents (such specifications, code requirements etc.). In case of any discrepancy, COMPANYs interpretation shall prevail. In general terms however, all metallic materials except carbon steel, and non ferrous materials, shall be subjected to PMI testing, as defined in section 7.3.

For equipment and pipe spools, acceptance of alloy materials will be base on final PMI testing after fabrication in the field by the CONTRACTOR. Testing may be witnessed by the COMPANY. It is recommended that preliminary PMI testing be performed by the



VENDOR prior to final fabrication. VENDOR should state PMI programs in their quotations.

7.1 Instrument

7.1.1 PMI instrument used for PMI test shall be suitable for identifying the material by quantitative measurement of the major alloying elements required in the applicable material specification.

7.1.2 PMI instrument shall be x-ray tube type potable alloy analyzer (e.g. Thermo Scientific NITON series, Innov-X systems Alpha series or equivalent) approved by CONTRACTOR.

Following test equipment has been accepted and recommended. Portable X-ray fluorescence spectrometers with direct reading of alloy grade or composition, or portable arc or optical-emission spectroscopes with output in the form of visible light spectra will be generally acceptable as follows ; a. Texas Nuclear Analyzer b. Metallurgist XR, c. Nitton Series d. ARL Quantotest e. Spectrotest f. Baird Spectromobile g. Metorex X-Met Metal Master or Metorex Arc-Met h. Or equivalent authorized by CONTRACTOR

7.1.3 As a minimum, the PMI instrument verification shall be performed using certified master standards daily and/or each-use by PMI operator.

7.1.4 Certified master standards for daily and/or each-use verification shall be material similar in composition as the material being performed PMI test.

7.1.5 PMI instrument and certified master standard shall be calibrated by manufacturer or authorized laboratory annually during use.

7.1.6 The calibration shall be repeated after any repair and/or maintenance of the PMI instrument.

7.2 Shop and Field Testing

7.2.1 Shop fabricated equipment requiring PMI test shall have the verification testing performed in accordance with the project specification 8015-0151-SECL-00-000-PQ-



SP-00001 Procedure for Positive Alloy Material Identification of Equipment and Piping and the vendors dedicated procedure.

All shop fabricated pipe spools and welds requiring PMI test shall have verification testing performed in accordance with the project specification 8015-0151-SECL-00-000-PQ-SP-00001 Procedure for Positive Alloy Material Identification of Equipment and Piping and the vendors dedicated procedure.

7.2.2 Field welds shall be PMI tested in field in accordance with this procedure.

7.2.3 All bulk alloy materials shall be PMI tested upon receipt in the field and fabrication shop in accordance with its own procedure respectively.

7.2.4 CONTRACTOR shall have the right to witness the performance and to review PMI procedure.

7.3 Extent of Testing

7.3.1 Equipment

The PMI extent of the equipment will be covered by the project specification 8015-0151-SECL-00-000-PQ-SP-00001 Procedure for Positive Alloy Material Identification of Equipment and Piping and the vendors dedicated procedure.

7.3.2 Bulk Piping Component, Instrumentation and Bolting

(a) Bulk piping and instrumentation components are as follows:

Pipe Valve bodies and bonnets or covers Control and relief type valves, bodies, bonnets or covers as applicable Flanges (e.g. weldneck, slip-on, lap-joint, orifice, etc.) Fittings (e.g. socketweld, buttweld, etc.) Pressure blinds (e.g. spectacle, spacer, paddle blind, etc.) Strainers (e.g. Y-type, basket, etc.) Thermowells



Vent and drain caps Flow metrs (pressure-containing components) Level displacers and float switches (chambers and heads) Metallic Expansion Joints Other instrumentation with pressure-containing parts

(b) Bolting

1% of each alloy heat/lot of bolts/studs and nuts purchased for pressure retaining bolting for pipe fabrication with a minimum of four (4) pieces shall be

verified.

Pressure retaining fasteners for equipment items that require alloy verification shall be 10% alloy verified.

(c) For bulk piping components, instrumentation and bolting, PMI testing should be

carried out at such a time and location as to provide for simple corrective action

where erroneous materials are found or, even more advantageously, where

replacements are more easily available and can be substituted and retested (i.e.

during early stages of procurement and subassembly). The exact location and

timing of PMI testing of bulk piping components shall be determined by the

CONTRACTOR.

7.3.3 Shop and Field Fabricated Pipe Spools

(a) PMI testing of completed shop fabricated pipe spools shall be conducted prior to

shipping to construction site. Testing shall include the components listed in

paragraph 0 (a). A report format shall be completed for this testing. The completed

pipe spools shall be subjected to PMI testing by the CONTRACTOR on a random

sample basis upon receipt at the construction site. A report form is not required for

this testing.

(b) For field fabricated spools the pipe components shall be subjected to PMI testing by

the CONTRACTOR on a random sample basis upon receipt at the construction site.

After fabrication (or spool layout at the start of fabrication) the spool shall be

subjected to 10% PMI testing. A report shall be completed for this testing.



7.3.4 Welds

Pressure-containing butt-welds in equipment and piping made with alloy welding consumables shall be PMI tested in accordance with the following guidelines:

(a) Selection of the test point locations to be examined shall be made by

CONTRACTOR.

(b) For piping, 10% of welds per completed pipe spool shall be PMI tested.

(c) For fabricated equipment, 10% of pressure welds shall be PMI tested.

8 SAFETY

Any personnel using PMI instrument shall be given a safety orientation by radiation safety officer prior to operation. The safety orientations will include as a minimum, the following: (1) Radiation safety for radiation type PMI instrument and emergency procedure in case

of malfunction or unit damage during field usage (2) Operation of radiation type PMI instrument toward any part of the human body can

be injurious.

Radiation safety officer shall periodically audit field usage of PMI instrument in compliance with safety procedure.

9 ACCEPTANCE CRITERIA

Materials shall contain the amount of alloying elements specified in ASME Sec.II Part A and ASME Sec.II Part B or equivalent ASTM specifications for low alloy, alloy and CRA ferrous and nonferrous.

Welding electrodes and wires shall meet the requirements for alloying element specified in ASME Sec.II Part C. Alloys, including castings, shall conform to the minimum and maximum values permitted by the material specification.

Deposited weld metal or undiluted weld metal deposits shall be within the ranges specified by ASME Sec.II Part C for each element.

Acceptance criteria for dissimilar metal alloy welds shall be such that the weld at least meets the nominal chemical composition requirements. The effects of dilution during deposition shall be taken into account for deposited (diluted) weld metal in a test



specimen welded and witnessed by the COMPANY prior to production PMI testing of dissimilar weld metal welds.

For weld metal overlay, the weld metal composition shall meet the requirements of elements specified in ASME Sec.II Part C.

Components shall comply with the requirements of the applicable material specification or the project data sheet. As a minimum, the main elements listed in APPENDIX-I shall be indicated. Unless otherwise noted, PMI instrument match of material is accepted as verification of an alloy material. Some tolerances on the specified limits may be accepted due to the limitation of potable PMI instrument.

9.1 Rejection Criteria

9.1.1 If any of the major alloying elements are below the range specified by the applicable material standard or a portable analyzer indicates an incorrect match or no match, the component shall be rejected or a laboratory analysis may be performed at no additional cost to the COMPANY. The laboratory analysis will determine acceptance or rejection of the material.

9.1.2 If any of the major alloying elements are greater than the range specified by the applicable material standard, the alloy content must be reported to CONTRACTOR for acceptance or rejection.

9.1.3 The MANUFACTURER or PIPE FABRICATOR shall identify, mark and remove all unacceptable material.

9.1.4 If any material component or weld is found to be unacceptable, all other represented materials, components, or welds shall be considered suspect. When the examined items representing a lot (spot examination) are found unacceptable, the next two components or lots from the same supplier shall be examined 100%. If both additional components and lots are acceptable, the represented components are accepted and the sampling (spot) percentage of PMI examination can be resumed.

9.1.5 If any materials components or weld is found to be unacceptable in the extended examination, all the represented materials shall be considered suspect.

9.1.6 Material, items, and welds that are found to be unacceptable during PMI testing shall be marked immediately with water insoluble paint / ink, circled red cross as non conforming materials and segregated from acceptable materials to prevent their unauthorized reuse.



10 PMI TEST REPORT

Results of all final testing shall be recorded on report format (see Attachment.1). Report format shall indicate for each equipment item, pipe spool component or representative percentage sample tested, the following information: (a) VENDORs mill certification number

(b) Material heat number

(c) Representative percentage sample size and number for item(s) tested (welds or

heat exchanger tubes)

(d) A statement (under Testing Results Table, Appendix-I) that the material has been

tested and identified

Test report shall be kept to identify each component that has been alloy-verified and shall include the results of the testing.

Test results shall include: measured percentage of alloying elements, accepted, rejected, rejected but accepted based on dependent chemical analysis and etc.

Test report shall identify each component to an individual shop-fabricated equipment item, assembly, line number and etc.

All PMI reports shall include a copy of the material certification, when submittal is required by the CAONTRACT documents.

The MANUFACTURER/PIPE FABRICATOR shall provide PMI reports and material certifications to CONTRACTOR when required by contract document. Results of all PMI examinations shall be noted on as-built drawings, spool sheets, or isometrics.

11 APPENDIX

APPENDIX A REPORT FORMAT

APPENDIX B REQUIRED ALLOY ELEMENTS



APPENDIX-I. REQUIRED ALLOY ELEMENTS

ALLOY Cr Ni No Cb Ti Cu Al C Co W Fe1 1/4 Cr-1/2 Mo X X 2 1/4 Cr-1/2 Mo X X 5 Cr-1/2 Mo X X 7 Cr-1/2 Mo X X 9 Cr-1 Mo X X 304 X X 304L X X X* 304H X X X* 309 X X 316 X X X 316L X X X X* 317 X X X 321 X X X 347 X X X 405 X X# X 410 X X# 410S X X# X* 430 X X# Alloy 20 X X X X X Hast C-276 X X X X Alloy 600 X X Alloy 601 X X X Alloy 625 X X X X Alloy 800 X X X Alloy 825 X X X Monel 400 X X RA 330 X X RA 333 X X X X X 9 Ni X 70 / 30 CuNi X X 90 / 10 CuNi X X Note:

A potable alloy analyzer match is also acceptable per section 8.6 of this procedure

(*) : Carbon content could not be easily detectable by portable PMI instruments. Therefore, it is not

required to be checked unless otherwise so specified in the project specification or data sheets.

(#) : Testing of Ti will prevent unacceptable substitution with Grade 409.



APPENDIX-II. REPORT FORMAT

BASE METAL WELDMENT ELECTROD

MTR No. MATERIAL HEAT No.

S/N DWG No. JOINTNo. Cr Ni Mo Cu

ALLOY ELEMENTS ANALYZED

PURCHASE ORDER No. TEST ITEM / No.

CERTIFIED MASTER STANDARD VERIFICATION

VENDOR NAME TEST MATERIAL TYPE

ACC/REJ

MATERIAL

S/N

DUE DATE

VERIFICATIONCr Ni Mo

RESULT OF EXAMINATION

REMARK

PROCEDURE No. ACC. CRITERIA

NAME

POSITION

COMPANYPMI SUB-CONTRACTOR CONTRACTOR

PROJECT No./NAME DATE OF TEST

COMPANY NAME CONTRACTOR NAME

REQUEST No.

REPORT No.

PAGE No. 1 OF 2

(PMI SUB-CONTRACTOR LOGO)

TEST INSTRUMENT

DUE DATE

NITON

XLt-898

XRF

MANUFACTURER

MODEL NAME

S/N

TYPE

SIGNATURE/DATE


(Early Oil Phase)

POSITIVE MATERIAL IDENTIFICATIONEXAMINATION REPORT




(Early Oil Phase)

MAGNETIC PARTICLE EXAMINATION REPORT

WELDER MAT'L

IP: INCOMPLETE PENETRATION

R-UC: ROOT UNDER CUT SD: SURFACE DEFECT

DB: DEBRIS

LF: LACK OF FUSION

CR: CRACK

UC: UNDER CUTTINGDEFECT

CODERC: ROOT CONCAVITY

N: NONE

BT: BURN THROUGH

TI: TUNGSTEN INCLUSION

EP: EXCESS PENETRATIONPO: POROSITY

SI: SLAG INCLUSION

A

S/N LENGTH(mm) INTERPRETATIONSACC/REJ

(NDE SUB-CONTRACTOR LOGO)

REPORT No.

REQUEST No.

PAGE No. 2 OF 2

RESULT OF EXAMINATION

DWG No. JOINTNo.DIA

INCH SCH

[8015-0151-SECL-00-000-QC-PP-00105_00] PMI Procedure

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