pmi procedure tracebilty matrial

JOB No. DOC. No. Rev.

0-5151-20 S-900-1540-201 0

DATE 5 - Jan - 2012 SHEET 1 OF 11

PREPD S. Kuritsubo

CHKD T. Kiyama

APP'D Y. Kawase

REV. Date Page DESCRIPTION PRED CHKD APPD0 05 Jan 2012 All Issued for Information S. Kuritsubo T. Kiyama Y. Kawase

REQUIREMENTS OF MATERIAL CERTIFICATION &TRACEABILITY AND POSITIVE MATERIAL IDENTIFICATION

FOR CONSTRUCTION WORK

DONGGI SENORO LNG PROJECT

FOR INFORMATION

DSLNG Project Job No. : 0-5151-20Requirements of Material Certification & Traceability and Positive Material Identification for Construction Work

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Contents1 GENERAL ..................................................................................................................................... 3

1.1 Scope ............................................................................................................................................. 31.2 Purpose .......................................................................................................................................... 31.3 Objective ........................................................................................................................................ 3

2 ABBREVIATION AND DEFINITION.............................................................................................33 REFERENCES..............................................................................................................................44 MATRIAL CERTIFICATION, MARKING AND TRACEABILITY ................................................. 4

4.1 General Requirement for Certification of Materials........................................................................... 44.2 Type of Certificates ......................................................................................................................... 44.3 Contents of Certificate..................................................................................................................... 44.4 Certification Selection ..................................................................................................................... 5

5 MATERIAL TRACEBILITY........................................................................................................... 65.1 Tagged Items.................................................................................................................................. 65.2 Piping Bulk Materials....................................................................................................................... 65.3 Identification ................................................................................................................................... 7

6 POSITIVE MATERIAL IDNETIFICATION (PMI) .......................................................................... 76.1 Extent of PMI testing....................................................................................................................... 76.2 Exemption of PMI............................................................................................................................ 76.3 Test Procedure ............................................................................................................................... 86.4 Acceptable PMI Equipment ............................................................................................................. 86.5 Elements to be Verified................................................................................................................... 96.6 Qualification of PMI Operators ........................................................................................................ 96.7 Acceptance Criteria......................................................................................................................... 96.8 Retest and Nonconformity of PMI.................................................................................................... 96.9 Marking and Identification of PMI .................................................................................................. 106.10 Record.......................................................................................................................................... 10

Attachment-1 : Scope and Extent of PMI in Construction Phase..................................................... 11Attachment-2 : Identification Elements of PMI.................................................................................. 11


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1 GENERAL

1.1 Scope

This specification describes Requirements for certification, marking and material traceability for equipment and

piping components in process or pressure containing duty to be applied for field fabrication and installation and

Requirements of Positive Material Identification (PMI) for construction work. PMIis applicable to metallic alloy material components except carbon steel used in Donggi-Senoro LNG (DSLNG) Project.

1.2 Purpose

The purpose of this procedure is: To define the requirement of scope, extent and procedure of certification, marking ,

material traceability and PMI To handle tested materials and documentation requirements for PMI.

1.3 Objective

The objective of this procedure is to ensure that PMI will be done by Subcontractor certainly and collect material are used for

construction work at job site. To maintain the appropriate material installation as per the applicable standard and

drawing by Subcontractor

2 ABBREVIATION AND DEFINITION

Owner: PT. Donggi Senoro LNGContractor: PT.JGC Indonesia and JGC Corporation Consortium (JIND/JGC)Subcontractor: The person, firm or corporation to whom the Order is issuedFQCM: Field QC ManagerPMI Positive Material IdentificationTagged Items Equipment allocated a unique tag number or spool

number i.e., tanks, vessels, rotating equipment,packaged units, fabricated pipe spools, control valves,relief valves, and any other items listed in equipmentlist or instrument schedule

Bulk Items Piping materials purchased in bulk by the Contractorwhere individual items are not allocated a unique tagnumber.e.g.) plate, pipe, tube, valves, fittings, traps andstrainers, other castings and forgings

In-Line Instrument

Instruments and components mounted in pressurepiping or equipment. Typical examples are controlvalves, turbine meters, orifice plates and flanges,thermowells(Note : safety valve and level gauge are classified aspiping material)

Off-Line Instrument

Instruments and components connected to pressurepiping or equipment via small block valves. Typical


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examples are transmitters, pressure gauges, analyzersampling systems

ITP: Inspection and Test PlanNDE Non-Destructive ExaminationNCR: Nonconformity Report

3 REFERENCES

S-900-1540-002 Project Quality Control Procedure for Construction Work (Construction Phase)

S-900-1540-101 Quality Control Requirements to Subcontractor S-900-1540-102 Nonconformity Control Procedure EN10204 : Metallic Products-Types of Inspection Documents

4 MATRIAL CERTIFICATION, MARKING AND TRACEABILITY

4.1 General Requirement for Certification of Materials

(1) The language used within material certificates should be English. Certificates inother languages are acceptable provided that they are accompanied by Englishtranslation of the contents.(2) Certificates shall be complete, unambiguous and legible over the full contents andcare should be taken so that copies present a full and clear reproduction.

(3) Certificates shall be dated and signed by an authorized person, whose name andposition shall be indicated on the document.

(4) For Tagged Items, the certificates shall cover all components used in themanufacture of Tagged Item.

4.2 Type of Certificates

4.2.1 Type A (Certificate of Compliance)

This is a certificate issued by the manufacturing or processing works and signed by aperson responsible for quality, stating that the material supplied complies with thatspecified in the purchase order requirements

4.2.2 Type B (Material Test Certificate)

This is a certificate issued by the manufacturers or process works quality departmentconfirming that the product supplied corresponds with the specified requirements.Certification shall be based on tests carried out on the material of the product itself or on test samples of the material in accordance with the material specification and thepurchase order requirement. Testing must have been carried out by a testing center which is independent of the production section of the manufacturing works

4.3 Contents of Certificate

Type A and B certificates shall contain the following information:


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(1) Name of material manufacturer identification number of certificate and its date ofissue

(2) Material specification (including class, grade and heat treatment condition, whereapplicable

(3) Dimensions and quantity covered

(4) Name, job title and signature of person authorizing the certificate

(5) Such supplementary or additional information as may be required by the purchaseorder

Additionally, Type B certificates shall contain the following information:

(1) Purchase order number

(2) Material manufacturers work order number

(3) Material charge number, batch number, heat/lot number or other references required to demonstrate that the testing and inspection has been performed on the required number of test units

(4) Test and inspection results

4.4 Certification Selection

The required type of certificate listed below for equipment and piping shall be theminimum requirement. When local regulation, the other applicable Project ,Specification data sheet, and/or requisition specify more stringent or specific requirement, it shall prevail

4.4.1 Tank

Type B certificate shall be required for bottom/shell plates and shell openings for API 650 tanks, and bottom/shell/roof plates and shell/roof openings for API 620 tanks. Inaddition, any 9% nickel materials including non-pressure parts for LNG storage tank shall be Type B.

For piping bulk materials and instruments procured by LNG Tank subcontractor, thematerial certification requirements as specified in Subsections 4.4.2 and 4.4.3 shall apply.

4.4.2 Piping Bulk Materials Procured by Subcontractor

(1) Pipe, Fitting, Flange and BoltingType B certificate shall be required for pipe/fit-tings/flange and stud bolting forpressure retaining parts

(2) ValvesType B certificate shall be required for body/bonnet/cover and Type A certificate shall be required for closure member (gate/wedge, disc, ball, and plug), stem, seat and bolting

(3) Piping Specialties


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Type B certificate for pressure parts and Type A certificate for internal parts andbolting shall be required

4.4.3 Instruments Procures by Subcontractor

(1) For In-Line Instruments, the same certification requirements as for piping shall berequired as follows Instrument Valves

Type B certificate for body/bonnet/cover and Type A certificate for closuremember, stem, seat and bolting.

Other In-Line InstrumentsType B certificate for pressure retaining envelope and Type A certificate forbolting.Example: Level switch, displacer, thermowell, turbine meter, orifice flange and

plate, ventury tube, rota meter, annuber, pitot tube, etc.

(2) For Off-Line Instruments and their connections to pressure piping system, no material certification is required provided facilities are foreseen to block these instruments and connections of the piping systemExample: Analyzer sampling system, controller, pressure and differential

pressure transmitter, pressure gauge, pressure switch, etc.For instrument bulk material to be used for Off-Line Instrument connections such as instrument tubing, etc., and conduit pipe, junction box, etc., material certificate is not required except that special high alloy tubing other than 300 series S/S, such as Monel etc., (if applied) shall require Type A certificate

5 MATERIAL TRACEBILITY

When a Type B certificate is specified for Tagged Items or Bulk Items, materials shall be traceable to the material certificate after assembly, at the time of final inspection atSubcontractors shop before shipping

5.1 Tagged Items

Each completed Tagged Item at Subcontractors shop shall be identifiable and traceable by tag number and accompanied Subcontractors Manufacturing Reports.For field assembled tanks, the following traceability requirements shall apply:(1) API 620/650 Tanks

Shell, shell opening and annular bottom plate materials shall be traceable back to the material certificate after assembly with as-built sketch

(2) API 620 App. LNG Tanks:All primary components shall be traceable back to the material certificate afterassembly with as-built sketch. Shell and annular bottom plate materials for outertank to be also traceable back to the material certificate with as-built sketch.

5.2 Piping Bulk Materials

Prefabricated piping or assembled piping and bolting shall be traceable to the materialspecification, grade, size and schedule/ rating after assembly, at the time of finalinspection at Subcontractors shop.


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(1) At the time of receiving stage of piping bulk material at siteAll piping materials shall be identifiable by marking and/or color coding and shall be traceable to its material certificate. Receiving inspection by visual check of marking/ color coding/ overage/ shortage/ damage and confirmation of Inspection Release Notice for the received materials shall be carried out. Only accepted materials shall be issued for prefabrication and installation

(2) During and after prefabrication or installation of piping before piping system pressure test, all piping materials shall be controlled/identified by color coding (or piping spool ID number) and piping code number (or piping material spec. & size marking, such as TP316L, 2, sch.40). When cutting pipes, piping code number and/or equivalent marking shall be transferred and be identified (color code shall still remain) so that each pressure retaining piping material shall have the traceability to the material specification, grade, size and schedule/rating after assembly.

5.3 Identification

The Subcontractor shall maintain an identification procedure of all materials, parts andcomponents, including partially fabricated assemblies. The location and method of the identification shall not affect the function or quality of the item being identified.The procedure shall require that verification of correct identification of materials, parts and components be made and documented prior to release for fabrication, assembly,shipping or installation

6 POSITIVE MATERIAL IDNETIFICATION (PMI)

6.1 Extent of PMI testing

(1) PMI shall be performed on pressure containing alloy materials and all associated welds in accordance with Attachment-1 : Extent of PMI Field Fabrication and Attachment-2 : Elements of common alloys subject to PMI

.(2) PMI shall also be performed on completed equipment or assembled part of

equipment by the Subcontractor, at such a time as to ensure that only verifiedmaterials have been used in fabrication and final assembly of items.

(3) Components not accessible after assembly shall have PMI undertaken prior to assembly

6.2 Exemption of PMI

The following items / materials are exempted from PMI:

Aluminum and aluminum alloy Non-pressure containing parts of pressure vessels/heat exchanger internals Internal parts of valves, instruments and piping specialties Off-Line Instruments Instrument pneumatic tubing and fittings Tubing and fittings


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Air/drain traps, metallic flexible hoses, hose couplings B7, L7, B7M, L7M bolting All copper or copper alloy components exclusive to water service Austenitic stainless steel components for water/air/nitrogen/chemical/lube oil/seal oil

service Gaskets

6.3 Test Procedure

(1) PMI shall be performed in accordance with written Subcontractors PMI procedure approved by Contractor prior to the start of implementation. And testing shall also be performed according to the alloy analyzer Manufacturer's procedures. Any modification of such procedures shall be approved by Contractor

(2) PMI procedure shall ensure that tests are performed in accordance with this specification. Contractors inspector will confirm that Subcontractors implementation and conducting of the PMI program is in accordance with this procedure.

(3) Subcontractors PMI procedure shall contain, as a minimum, the following information; Name and Manufacturer of PMI equipment to be used. Description of equipment operating principle. Calibration procedure and frequency Qualification and training procedure of PMI operator PMI Marking method for typical components Acceptance criteria of PMI Procedure steps in detail.- Timing of PMI- PMI Elements of each material Segregation procedures for tested material Procedure to follow when identification results are inconclusive (alloy type is unknown). Radiation Safety Operating and Emergency Procedures, if applicable. Statement of operator competency for PMI techniques. Sample of PMI record or PMI record form

6.4 Acceptable PMI Equipment

(1) Portable X-ray fluorescence spectrometers with direct reading of alloy grade orcomposition in the applicable range are generally acceptable. TN Technologies(former Texas Nuclear) Model 9266 or 9277 and Metrex X-MET instruments areacceptable.

(2) Portable arc-emission spectrometers with direct reading of alloy grade or composition (former Texas Nuclear) Model 9266 or 9277 and Metrex X-METinstruments are acceptable (former Texas Nuclear) Model 9266 or 9277 and Metrex X-MET instruments are acceptable.Spectrotest instruments are acceptable.

(3) Portable arc-emission spectroscopes with output in the form of visible light spectra(e.g. Metascope) are generally acceptable, provided the competence of the PMIoperator is demonstrated and accepted by Contractor.


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(4) All materials shall be made good after examination e.g. by dressing out arc strikes.

6.5 Elements to be Verified

(1) Elements of alloy materials and welds joining them shall be analyzed in accordance with Attachment-2 : Elements of common alloys subject to PMI.

(2) Where material type is not specified in Attchment-2, alloy elements to be verified by PMI testing shall be stipulated in the Subcontractors PMI testing procedure and be subject to approval of Contractor and Owner.

6.6 Qualification of PMI Operators

Subcontractors PMI operator shall be trained, qualified, and experienced to perform PMI activities. Operator training, qualification and experience record shall be submitted for Contractors approval.The PMI operator shall demonstrate their capabilities to the satisfaction of Contractor.

6.7 Acceptance Criteria

(1) Alloys elements verified in accordance with Attachment-2 shall be ranged between minimum and maximum (+/-) 12.5% of the amounts of alloying elements specified in each material Code/specification for quantitative analysis.

(2) For qualitative analysis (such as Metascope) existence of alloy elements shall be verified.

(3) The acceptance criteria for weld metals are based on the requirements of ASME SEC. II, Part C except for the those used for dissimilar welding

6.8 Retest and Nonconformity of PMI

6.8.1 Retest of PMI

If the PMI test results fall outside the acceptable range, using the standard instruments described in this Practice, Subcontractor may obtain a quantitative check analysis performed by an independent testing laboratory. If no method is referenced in the applicable materials standard, an appropriate method of chemical analysis, as specified in this Practice, shall be used. Results of this analysis shall govern

When the Nonconforming item is sampled from a lot, Subcontractor may conduct 100% examination for the remaining items of the lot to verify the acceptability of the remaining items

In any case, the next 2 lots from the same Supplier shall be examined on 100% basis.If the 2 lots contain an unsuccessful item /items, the examination on 100% basis shall be repeated for the next 2 lots.


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6.8.2 Nonconforming Item of PMI

If the PMI test results fall outside of the acceptable ranges, such item shall be rejected and will be regarded as Nonconforming item. Nonconforming items shall be dealt with in accordance with Nonconformity Control Procedure (S-900-1540-102)

(1) Whenever materials are identified as incorrect, a rejection note shall be issued indicating unacceptable materials have been supplied.

(2) Subcontractor shall be responsible for replacing the material with the correct specified material and for performing PMI on all replacement materials.

(3) Material rejected by PMI shall be marked to designate rejection using indelible ink or paint. The rejected items shall be held in a designated area to prohibit their re-use.

6.9 Marking and Identification of PMI

(1) "PMI shall be marked by the PMI operator with a suitable marker on base metal near the weld when the weld and both sides of base metal are PMI tested and accepted or onto the component for non-welded part.

(2) Any markers used for identification shall not contain any substances detrimental to the corrosion resistant materials on site

(3) If the material or item is too light, too small, or cannot otherwise be marked, colorcoding shall be applied in conjunction with Subcontractors standard with Contractors approval.

6.10 Record

All PMI test records shall be the following; have all required information including unique report number (Refer to Attachment-3) reviewed by Contractor and Owner with their signature encoded into QC data control system such as CMS and TOMAS in timely manner compiled by Subcontractor with traceability Submitted to Owner through Contractors review as final documentation


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Attachment-1 : Scope and Extent of PMI in Construction Phase

Items Extent Notes

LNGStorage

Tank

Pressure Parts& Weld 100%

- Pressure containing alloy components and allassociated weld after assembly.

- 100% PMI of welds is defined as 1 location check offinished weld per each continuous weld.

- For horizontal seam, 1 determination per every 10m length.

FiredHeater

Pressure Partsand Weld 100%

- When field assembly is required for furnace tube or boiler.

- Pressure containing alloy components and all associated welds after assembly. (Tube skin thermocouple and refractory anchor welds are exempted)


PipingMaterial

Bulk Valve(Non tagged

Valve)

5 % (beforeinstallation)

- PMI of valves shall be applied to the body, bonnet,cover of alloy valves.

- an Inspection lot is a group of the same valve type, size and rating.

Boltingmaterial

5 % (beforeinstallation)

- an Inspection lot is a group of the same alloy type and size

PipingSpecialties

(Tagged Item)N/A - To be performed by Vendor/Manufacturer

Pre-fabricatedand Field installed ping, welds (pipe,fitting, flange, etc)

100%(after

installation)

- Pressure containing alloy components and allassociated welds.


Attachment-2 : Identification Elements of PMI

Alloy Cr Ni Mo Cb Ti Cu Al Remarks304 / 304L / 304H / 308 / 309 / 310 Stainless Steel x x

316 / 316LStainless Steel x x x

9% Ni x