JA00-03-AD-00004 Specification for Positive Material Identification

CONTRACT NO:

NO. OF DOC. SHEETS

NSBU-064101

18

DOCUMENT NO:

REV:

JA00-03-AD-00004

C2

CONOCOPHILLIPS PETROLEUM COMPANY U.K. LIMITED

J-BLOCK OU DOCUMENT TITLE:

JASMINE DEVELOPMENT PROJECT Specification for Positive Material Identification

Facility Code

System Code

Area Code

Discipline Code

SDRL Code

Document Type

JA00

99

N/A

AD

N/A

37

C2

Issued for Use

DM

04/03/11

RD

04/03/11

NT

04/03/11

A2

Issued for IDC/ICR

DM

11/02/11

RD

11/02/11

NT

11/02/11

C1

Approved for Detailed Design (AFD)

KM

15/03/10

RD

15/03/10

NT

15/03/10

A1

Issued for IDC/ICR

KM

02/11/09

RD

02/11/09

TW

02/11/09

REV

ISSUE OR REVISION DESCRIPTION

ORIG BY

DATE

CHKD BY

DATE

APPD BY

DATE

MC

14/03/11

CLIENT ACCEPT

DATE

Specification for Positive Material Identification

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REVISION CHANGE NOTICES Rev

Location of Change

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Brief Description of Change

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Specification for Positive Material Identification

CONTENTS 1.0

INTRODUCTION 1.1 PROJECT BACKGROUND 1.2 DEFINITIONS 1.3 ABBREVIATIONS 1.4 REFERENCED DOCUMENTS 1.5 UNITS OF MEASUREMENT

7 7 7 7 8 8

2.0

GENERAL 2.1 PURPOSE 2.2 SCOPE 2.3 RESPONSIBILITIES

9 9 9 9

3.0

EXTENT 3.1 GENERAL 3.2 FABRICATION 3.3 WELDS

10 10 10 11

4.0

TEST REQUIREMENTS 4.1 METHODS AND EQUIPMENT 4.2 TESTING PROCEDURES 4.3 PERSONNEL QUALIFICATION

11 11 12 12

5.0

MARKING AND ACCEPTANCE/REJECTION 5.1 MARKING 5.2 ALLOY ACCEPTANCE 5.3 REJECTED MATERIAL

13 13 13 13

6.0

DOCUMENTATION OF PMI TESTING RESULTS

13

APPENDICES APPENDIX 1 PMI REPORT FORM APPENDIX 2 ALLOYING ELEMENTS

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1.0

INTRODUCTION

1.1

PROJECT BACKGROUND The Jasmine field is located in blocks 30/6 and 30/7a in the UK sector of the Central North Sea, about 240 km south-east of Aberdeen, in the ConocoPhillips operated J-Block Area. The Jasmine development will utilise the existing processing capacity on the Judy Platform. The J-Block Area currently comprises three fields: Judy, Joanne and Jade. The Judy Platform currently serves as a hub for petroleum operations from production wells situated on the Judy Platform, fluids from the Joanne subsea manifold and fluids from the Jade normally-unmanned Wellhead Platform. The combined gases leaving Judy are exported to the Central Area Transportation System (CATS) to Teesside, UK. Oil is exported to the NORPIPE system to Teesside, UK. The Jasmine Development comprises the following:

1.2

1.3



Jasmine Wellhead Platform (JWHP)



Jasmine Accommodation and Utility Platform (JLQ), bridge linked to the Jasmine Wellhead Platform (JWHP)



Judy Riser and Separation Platform with additional Judy well slots (JRP), bridge linked to the existing Judy Platform



Multi-phase pipeline from Jasmine Wellhead Platform to the Judy Riser Platform

DEFINITIONS COMPANY

ConocoPhillips Petroleum Company UK Limited

CONTRACTOR

WorleyParsons Europe Limited

PURCHASER

ConocoPhillips Petroleum Company UK Limited

SUPPLIER

A company identified in a Purchase Order to supply or fabricate equipment and/or materials and technical data pertaining thereto.

SHALL

Indicates a mandatory action

SHOULD

Indicates a preferred course of action

MAY

Indicates one acceptable course of action

ABBREVIATIONS CoP

ConocoPhillips

CS

Carbon Steel

PMI

Positive Material Identification

QA

Quality Assurance

TMCP

Thermo-mechanical Controlled Processed

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Specification for Positive Material Identification

1.4

1.5

REFERENCED DOCUMENTS CPMS-MAT-EP-006

-

Alloy Verification / Positive Material Identification for Shop and Field Requirements (ConocoPhillips standard)

ASTM E62

-

Standard Test Methods for Chemical Analysis of Copper and Copper Alloys (Photometric Methods)

ASTM E322

-

Standard Test Method for X-Ray Emission Spectrometric Analysis of Low-Alloy Steels and Cast Irons

ASTM E350

-

Standard Test Methods for Chemical Analysis of Carbon Steel, Low-Alloy Steel, Silicon Electrical Steel, Ingot Iron, and Wrought Iron

ASTM E353

-

Standard Test Methods for Chemical Analysis of Stainless, Heat-Resisting, Maraging, and Other Similar ChromiumNickel-Iron Alloys

ASTM E354

-

Standard Test Methods for Chemical Analysis of HighTemperature, Electrical, Magnetic, and Other Similar Iron, Nickel, and Cobalt Alloys

ASTM E478

-

Standard Test Methods for Chemical Analysis of Copper Alloys

ASTM E572

-

Standard Test Method for Analysis of Stainless and Alloy Steels by X-ray Fluorescence Spectrometry

UNITS OF MEASUREMENT The SI system of units shall be used on all nameplates, project documents, drawings and calculations with the exception of pipe nominal diameters, associated flange sizes, and flange bolting, which shall be in inches and pressures in bars. Any other units required for specific process measurements will be defined in the equipment specifications or data sheets. PARAMETER

UNIT

ACCEPTABLE ALTERNATIVES

Length

m

mm

Weight

kg

tonne

Time

second

minute; hour; day

Area

m

2

cm2

Volume

m3

litre

Temperature

8

O

C

K

Electrical Potential

V

mV

Electrical Current

A

mA

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Specification for Positive Material Identification

2.0

GENERAL

2.1

PURPOSE This document defines the requirements for positive material identification (PMI) for all equipment, piping and instrumentation including those items supplied as part of a skid package and also for bulk piping items. PMI shall ensure that the specified alloy materials are supplied and/or have been used for all the components of a finished assembly or equipment. This WorleyParsons general standard has been amended to align with the requirements of CPMS-MAT-EP-006.

2.2

SCOPE PMI shall be carried out for all alloy materials (i.e. austenitic, duplex and super-duplex stainless steels, nickel alloys), non-ferrous alloys (i.e. cupro-nickels, titanium alloys) and low alloy steels (i.e. CrMo steels and 3½Ni, 5Ni steels). Carbon steel, carbon-manganese steels, TMCP steels or micro-alloyed steels shall not require PMI testing. PMI shall be performed through all stages of fabrication (shop and site) and when there is a risk of material mix-ups occurring such as during transportation or stockage. This may result in individual items being subject to PMI at several occasions. PMI shall be applied during shop fabrication and during site fabrication for field assembled items. Where required by this specification PMI shall also be carried out on welds. PMI shall be applied in addition to the manufacturer’s/supplier’s overall quality assurance requirements for materials and shall not be used as a replacement or substitute for Certified Material Test Reports and other QA requirements. The extent of PMI is defined in Section 3. PMI testing may be performed prior to post weld heat treatment if required. All tested items shall be marked in accordance with Section 5 and a report form issued, refer to Section 6.

2.3

RESPONSIBILITIES It is the responsibility of the SUPPLIER to perform the PMI and/or to ensure it is performed by other sub-suppliers in accordance with this specification. For material and components where PMI was undertaken by others, the SUPPLIER is responsible for confirming that PMI was performed by the checking of markings on components and inspecting PMI reports on assembled items. The SUPPLIER shall submit a PMI procedure to the COMPANY for review prior to commencing the work. In-house PMI procedures employed by material suppliers, manufacturers and other sub-suppliers shall be subject to COMPANY review. The SUPPLIER shall review the sub-supplier PMI procedures to ensure they meet the requirements of this specification before submitting them for COMPANY review. Final acceptance by the COMPANY of any material, equipment or pipe spool etc shall require PMI in accordance with this specification. PMI may be witnessed or confirmed by independent testing by the COMPANY or a third party inspector.

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3.0

EXTENT

3.1

GENERAL PMI testing should be carried out at a time and location that enables simple corrective action should it be necessary to replace materials (i.e. during procurement and subassembly). However, for bulk piping components this does not negate the requirement of testing after fabrication. The minimum sampling frequency for PMI is defined below, for items/components represented by a heat, lot or batch the indicated percentage shall be selected randomly.

3.2

FABRICATION

3.2.1

Equipment Equipment includes vessels, columns, burners, pumps, tanks, heat exchanger air coolers, heaters, piping components, instruments and accessories, skid mounted equipment and associated piping. PMI testing shall be performed following assembly and prior to coating and may be performed prior to post weld heat treatment. All pressure containing, alloy material shall be subject to PMI as follows: 1. 2. 3.

4.

5. 3.2.2

All plate material, 100 % Items fabricated from material not previously alloy verified, 100% All alloy material, pressure-containing piping components (includes pipe or tube used for heater coils and instrumentation components) used for the fabrication of equipment, 100 % 10% of alloy bolting including L7/B7 grade bolts, or 1% if the bolting can be proven as originating from a previously alloy verified batch. Galvanised bolting need not be tested at equipment fabrication stage see 3.2.3. Welds as per Clause 3.3

Shop and field fabricated pipe spools On receipt of all materials the SUPPLIER shall check that PMI has been carried out before dispatch from the stockist or manufacturer as per Clause 3.2.3. If any material has not been subjected to PMI the SUPPLIER shall conduct PMI on receipt of the materials to the same extent described in Clause 3.2.3. Following fabrication all pressure retaining items shall be subject to alloy PMI as follows: 1. All alloy piping, piping components such as valves (bodies only), nozzles, flanges, fittings, couplings, instrument tubing and instrument components etc for the main process streams shall be subjected to 100% PMI testing. All other piping and instrument systems shall be subject to 5% testing per batch/heat/lot with a minimum of 4 lengths being tested. The pipe must be positively identified as belonging to the batch/heat/lot throughout fabrication. 2. Pipe that cannot be proven as originating from an alloy verified batch shall be 100% tested. 3. Piping components that cannot be proven as originating from an alloy verified batch shall be 100% tested. 4. 10% of alloy bolting including L7/B7 grade bolts, or 1% if the bolting can be proven as originating from a previously alloy verified batch. Galvanised bolting need not be tested at spool fabrication stage see Clause 3.2.3. 5. Welds as per Clause 3.3

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Specification for Positive Material Identification

3.2.3

Bulk piping components, bolting and bulk instruments All SUPPLIERS of alloy pipe and piping components (including valves, o-lets, flanges, fittings, couplings, etc), instrument tubing and instrument components, whether they be manufactures or stockists, shall operate a PMI system which provides 100% PMI inspection of all alloy piping components immediately prior to dispatch to the COMPANY or any of its sub-suppliers. Manufactures of alloy valves shall perform PMI on all pressure retaining components (bodies, bonnets or covers, balls, gates, discs) during valve assembly. Low alloy steel bolts, studs and nuts purchased for spool fabrication and structural fabrications shall be subject to 1% testing, prior to galvanising, by the manufacturer per alloy batch/heat/lot with a minimum of 4 items or pieces being tested. Alloy bolting which is not galvanised shall be subjected to PMI to same extent before dispatch.

3.3

WELDS PMI of weld metal shall be carried out on both SUPPLIER fabricated items and site fabricated items. Pressure-containing butt welds in equipment and piping made with alloy welding consumables shall be PMI tested in accordance with the following: 1. 2. 3. 4. 5.

6.

7.

Test point locations shall be selected by the SUPPLIER. Welds shall be tested on the process-exposed side where feasible. Weld overlay and cladding restoration weld shall always be tested on the process-exposed side. For site fabricated pipe spools all welds shall be subject to PMI testing - one test per weld. For welded pipe and fittings all welds shall be subject to PMI testing - one test per weld. For fabricated equipment 100% of pressure welds shall be subject to PMI testing; circumferential and longitudinal seam welds shall be tested at a minimum frequency of one test per 5 metres of weld length. All weld overlay shall be subject to PMI testing at a frequency of one test per 2 square metres; the test locations shall include areas from all weld methods. Vessels shall have a minimum of 5 tests per vessel including at least one nozzle. Cladding restoration welds shall be PMI tested at a minimum frequency of one test per 5 metres of weld length.

4.0

TEST REQUIREMENTS

4.1

METHODS AND EQUIPMENT PMI test methods shall use one of the following methods:  X-ray fluorescence  Optical emission spectrometry X-ray spectrometry shall comply with the applicable ASTM method: ASTM E322 or ASTM E572.

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Specification for Positive Material Identification

Test equipment shall comply with the following requirements:  capable of providing quantitative, recordable, elemental composition results for positive identification of the alloying elements present  hand-portable or mobile  subject to COMPANY approval Should laboratory chemical analysis be proposed the means of sample identification and traceability to the original material shall be reviewed by COMPANY prior to testing. Chemical analysis shall comply with one of the following ASTM methods:, ASTM E62, ASTM E350, ASTM E353, ASTM E354 or ASTM E478.

4.2

TESTING PROCEDURES Testing shall be performed in accordance with written operating procedures which have been submitted for COMPANY review prior to the start of fabrication. Operating procedures shall ensure tests are performed in accordance with this specification. Written operating procedures shall contain, as a minimum, the following information: 1.

Type of equipment/component/item to be examined and the percentage examination required. 2. Identify the PMI test equipment to be used including make, model and manufacturer. 3. Description of equipment operating principle the elements that are analyzed and any elements that cannot be analyzed. 4. Calibration procedure and frequency. 5. Marking method for typical components. 6. Acceptance criteria. 7. Procedure steps in detail. 8. Procedure to follow when identification results are inconclusive (alloy type is unknown). 9. Radiation Safety Operating and Emergency Procedures, if applicable. 10. Statement of operating personnel competency for the PMI techniques. The COMPANY may choose to have a third party inspector present to witness or perform additional PMI testing.

4.3

PERSONNEL QUALIFICATION PMI procedures shall contain a statement of personnel competency or qualification by training and experience in the techniques of material identification by one or more of the methods listed in Clause 4.1. The COMPANY has the right to reject personnel considered un-qualified.

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5.0

MARKING AND ACCEPTANCE/REJECTION

5.1

MARKING Immediately following PMI examination, all items shall be clearly marked to show whether the analysis of the item is acceptable or is subject to rejection/quarantine. This marking shall remain until subsequent coating or insulation is applied. Marking shall be done with a water insoluble material that contains no harmful substances such as metallic pigments, sulphur and chlorides. The method of marking and the symbols to be used shall require prior COMPANY approval. The use of die stamping shall not be permitted. All marking materials shall be certified not to contain components which may have a deleterious effect on the performance of the component in service.

5.2

ALLOY ACCEPTANCE Unless otherwise noted, a portable alloy analyzer “match” of material is accepted as verification of an alloy material. However, if a clear match is not made then the alloying elements specified in Appendix 2 shall be quantified by PMI testing and the results included with the PMI Report Form. All materials shall comply with the chemical composition requirements of the applicable material standards and any additional project specifications. Test results outside the required range shall be cause for rejection. If any one of the major alloying elements is outside the range specified by the applicable material standard, the alloy content must be reported to COMPANY for acceptance or rejection. One re-test per item only shall be permitted. Rejected material may be sent for laboratory analysis and the results submitted for COMPANY review. The SUPPLIER shall identify, mark and remove all unacceptable materials. If any material/item or weld from a representative percentage sample is found to be unacceptable then all material/items belonging to the same heat/batch/lot number or all welds shall be subject to 100% PMI testing.

5.3

REJECTED MATERIAL Materials, components and welds found to be incorrect shall be replaced by the SUPPLIER. PMI shall be performed on all replaced components and associated welds.

6.0

DOCUMENTATION OF PMI TESTING RESULTS Results of all final testing shall be recorded on report forms. See Appendix 1 as a typical example. Report forms shall indicate for each equipment item, pipe spool component or representative percentage sample tested, the following information: 1.

Material batch/heat/lot number.

2.

Representative percentage sample size and number for item(s) tested (welds or heat exchanger tubes).

3.

The specified alloy material.

4.

Alloy material type identified.

5.

If alloy match not possible then a quantitative elemental determination as per Appendix 2

The SUPPLIER shall provide PMI reports and material certifications to COMPANY when required by contract documents.

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Appendix 1 PMI Report Form POSITIVE MATERIAL IDENTIFICATION REPORT FORM PMI REQUESTED BY:

PURCHASE ORDER NUMBER

SIGNATURE: DATE: PMI PERFORMED BY:

PMI WILL BE/WAS PERFORMED AT:

SIGNATURE: DATE: ITEM

MILL

OR TAG

SAMPLE

TYPE OF

CERT.

HEAT

NUMBER

SIZE

MATERIAL

NUMBER

NUMBER

DESCRIPTION

TESTING RESULTS ITEM OR TAG NUMBER

NO. PIECES EXAM.

NO. PIECES ACCEPT.

NO. PIECES REJ.

MATERIAL IDENTIFIED AS

ADD’L NO. PIECES TESTED DUE TO REJ.

NO. PIECES ACCEPT.

NO. PIECES REJ.

TOTAL NO. REJ.

ADDRESS OF SUPPLIER RESPONSIBLE FOR REJECTION(S) ADDITIONAL INFORMATION MANHOURS AND LOSS INCURRED FROM REJECTIONS, ETC. PMI Supervisor : ……………………….

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(printed)

Signature/Date : ……………………………………..

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Appendix 2 Alloying Elements ALLOY ELEMENTS REQUIRED ALLOY Cr Ni Mo Cb 7 1 Cr - ¼ Mo x x 1¼ Cr - ½ Mo x x 2¼ Cr - ½ Mo x x 5 Cr - ½ Mo x x 7 Cr - ½ Mo x x 9 Cr - 1 Mo x x 304 x x 304L x x 304H x x 309 x x 316 x x x 316L x x x 317 x x x 321 x x 347 x x x 405 x 410 x 410S x 430 x 22 Cr Duplex x x x 25 Cr Super Duplex x x x Alloy 20 x x x x Hast C-276 x x x Alloy 600 x x Alloy 601 x x Alloy 625 x x x x Alloy 800 x x Alloy 825 x x x Monel 400 x RA 330 x x RA 333 x x x 4 2½ Ni / 3½ Ni x 5 Ni / 9 Ni x 70/30 CuNi x 90/10 CuNi x

FOR PMI INSPECTION Ti Cu Al C

3

Co

W

Fe

x1 x1

x1 x x2 x2 x2 x2

x x1

x x x x x x x

x

x x

See Notes

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Specification for Positive Material Identification

1.0

NOTES TO TABLE – APPENDIX 2 1. 2. 3.

4. 5. 6. 7.

18

Testing of C is not required unless specifically indicated on the data sheet or purchase documents. Testing of Ti will prevent unacceptable substitution with Grade 409. In the event that a generic alloy “match” by a portable alloy analyzer cannot be achieved then the following elements shall be quantitatively determined. Refer to Section 5 of this specification. A “match” by a portable alloy analyzer is acceptable; refer to Section 5 of this specification. If the portable analyzer is unable to provide the degree of accuracy for these lower nickel alloys the verification shall be by chemical analysis approved by the COMPANY. Alloy materials not listed shall be referred to the COMPANY for elemental requirements. L7/B7 bolts and nuts as per ASTMs A193/A194 respectively.

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