REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL-BENZENE <> A SKIKDA ALGERIE

CT-EPC/017/SH/EPM/RPC-X/2023

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

2

1

0

23/10/2024

24/07/2024

24/04/2024

IFD - Issued for Design

G. Mancuso

F. Barsanti

F. Laurenzi

IFD - Issued for Design

G. Mancuso

F. Barsanti

F. Laurenzi

IFA - Issued for Approval

G. Mancuso

F. Scazzosi

F. Laurenzi

Issue

Date

Reason for Issue - Revision Description

Prepared

Checked

Approved

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

CONTENTS:

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1 PURPOSE … 3

1.1 GENERAL … 3

1.2 MATERIALS SUBJECT TO PMI/MVP: … 3

1.3 COMPONENTS SUBJECT TO PMI/MVP: … 3

1.4

ITEMS SUBJECT TO PMI/MVP: … 4

2 REFERENCE DOCUMENTS … 4

2.1

INTERNATIONAL STANDARDS … 4

2.2 ORDER OF PRECEDENCE… 5

3 ACRONYMS AND DEFINITIONS … 5

4 PMI WRITTEN PROCEDURE … 6

5 MATERIAL VERIFICATION PROGRAM (MVP) ACTIVITIES… 7

6 EXTENT, LOCATIONS AND TIMING OF PMI … 7

6.1 FOR ALL ITEMS, LISTED IN SUB-CLAUSE 1.4, POINTS I, II, III, IV, VII. THIS SUB-CLAUSE IS APPLICABLE ALSO TO POINT VIII WHEN PART OF A VENDOR PACKAGE OR SKID SUPPLY 7

6.1.1 COMPONENTS: … 8

RANDOM EXAMINATION PER INSPECTION LOT IS ALLOWED, FOR THE FOLLOWING

FOR ALL ITEMS, LISTED IN SUB-CLAUSE 1.4, POINT V WHEN RELEVANT TO

6.2 INSTRUMENT MATERIAL REQUISITION OR WHEN RELEVANT TO LOSE MATERIAL SUPPLY AS PART OF VENDOR PACKAGE SCOPE OF WORK … 8

6.2.1 MATERIAL AND/OR COMPONENTS … 9

RANDOM EXAMINATION PER INSPECTION LOT IS ALLOWED, FOR THE FOLLOWING

FOR ALL ITEMS, LISTED IN SUB-CLAUSE 1.4, POINT VI WHEN RELEVANT TO PIPING

6.3 MATERIAL REQUISITION OR WHEN RELEVANT TO LOSE PIPING MATERIAL SUPPLY AS PART OF VENDOR PACKAGE SCOPE OF WORK … 9

6.3.1 RANDOM EXAMINATION PER INSPECTION LOT IS ALLOWED, FOR MATERIAL AND/OR COMPONENTS … 9

FOR ALL ITEMS, LISTED IN SUB-CLAUSE 1.4, POINT VIII, WHEN RELEVANT TO SUB-

6.4 CONTACTOR SCOPE OF WORK … 10

6.4.1 WELDING CONSUMABLES: … 10

7 ACCEPTABLE METHOD(S) AND ACCEPTANCE CRITERIA OF PMI … 11

7.1

FOR ALLOY MATERIALS … 11

8 NON-CONFORMANCES … 13

9 PERSONNEL PERFORMING PMI TESTING … 14

10

11

IDENTIFICATION OF COMPONENTS FOR PMI VERIFICATION … 14

RECORDS … 15

APPENDIX 1 - ALLOYING ELEMENTS REQUIRED FOR PMI … 17

APPENDIX 2 - COLOUR CODING FOR MATERIAL IDENTIFICATION … 19

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1

PURPOSE

1.1 GENERAL

This document provides the requirements for Positive Material Identification (PMI) to verify and/or validate that the materials of construction are in accordance with selected or specified Material Specification(s). The requirements specified in present document are fully in compliance with or additional to the ones provided in the Owner document. Every modification which may result less stringent or conservative than the requirement in the Owner standard shall require previously written approval from Owner. The elements covered by this specification are the followings: a) Materials, components and assembled items subject to PMI b) Extent of PMI c) Locations and timing for PMI d) Acceptable method(s) of PMI e) Verification results acceptance criteria f) Process for managing material non-conformities g) Qualification requirements for personnel performing PMI testing h) Identification of components on which PMI has been performed i) Material traceability during fabrication, including transfer of identification markings j) Method of documenting items that are acceptable for service

1.2 MATERIALS SUBJECT TO PMI/MVP:

a) PMI testing shall be performed for all alloy steel materials listed in Appendix-1, except in case of

austenitic stainless steel type 304

b) MVP is requested for the following special grades of carbon steel materials:

1. where Hydrogen Induced Cracking (HIC) resistant material are specified
2. where materials for Wet Hydrogen Sulphide (H2S) services with maximum hardness levels

are specified

3. where low temperature enhanced mechanical properties are specified (i.e impact tested

material, LTCS)

1.3 COMPONENTS SUBJECT TO PMI/MVP:

a) Pressure containing components (or fluid containing in case of tank and silos) b) Components directly welded on to the pressure containing parts, including relevant attaching

welds, cladding and clad resorting/weld overlay

c) Non-pressure retaining bundle components (baffles, tie-rods, seal strips) d) Non-pressure retaining components of pressure vessels (tray components, downcomers,

distributor pipes, reactor bed internals)

Impellers

e) Refractory anchors f) g) Bolting components except ASTM A193 grade B7(stud) and B8 (nut) h) Spiral wound gaskets other than 304 stainless steel grade

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i) Solid metal, metal jacketed & ring-type joint gaskets j) Welds and welding consumables

1.4

ITEMS SUBJECT TO PMI/MVP:

i.

Static equipment (vessel, drum, absorber, stripper, condenser, tower, reactor, strainer, silencer, ejector, heat exchanger, air cooler heat exchanger, plate heat exchanger, etc.) Storage tanks and silos

ii. iii. Rotating equipment (compressor, pump, turbine)1 Package equipment (furnace, boiler, heater) iv. Instruments v. ➢ Flow nozzles ➢ Flow meters ➢ Control valves ➢ Orifice flanges ➢ Temperature instruments/thermowells ➢ Analyzer probes ➢ Restriction orifice multi-steps ➢ Venturi tubes ➢ Pitot tubes ➢ Pressure relieving equipment’s Piping bulk materials ➢ Pipes, fittings & flanges2 ➢ Valves (body, bonnet & steam)3 ➢ Discs and spacers ➢ Solid gaskets ➢ Bolt and nuts ➢ reinforcement pads and pads for attachments Itemized piping components, relevant to Material Requisitions series “XH-MR-9XX’ Piping spools

vi.

vii. viii.

2

REFERENCE DOCUMENTS

2.1

INTERNATIONAL STANDARDS

Number

Title

ASME Section II Part C

ASME Boiler and Pressure Vessel Code - ed. 2023 - Specifications for Welding Rods, Electrodes, and Filler Metals

API RP 578

Material Verification Program for New and Existing Assets - ed. 4th (2023)

1 Internals components (except impeller) of rotating equipment are excluded from PMI testing - see sub-clause 1.3 2 Steam tracing components are excluded from PMI testing 3 Internals components of valves are excluded from PMI testing - see sub-clause 1.3

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

2.2 ORDER OF PRECEDENCE

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Requirements due to local authority regulations (if any) shall be also complies with and will prevail on this specification.

3

ACRONYMS AND DEFINITIONS

The following terms used in this document have the meaning defined below:

COMPANY/OWNER

SONATRACH

CONTRACTOR

Tecnimont S.p.A, part of the Maire Tecnimont Group

CONTRACT

PROJECT

LICENSOR

means the agreement signed between OWNER and CONTRACTOR

means Linear Alkyl Benzene (LAB)

means the technology providers who entered in License Agreements with COMPANY, to grant COMPANY access to technical information and intellectual property rights related to the technology processes.

VENDOR/SUPPLIER

means the equipment/component/item supplier

Sub-Contactor

Referred to the company appointed for piping fabrication and erection.

Material Verification Program (MVP)

Positive Material Identification (PMI)

Mill Test Certificate (MTC)

Alloy

It covers the procedures and administrative methods to verify that the Alloy Material of Construction is in accordance with selected or specified type/grade, and that such materials are properly analyzed and marked to indicate that. It includes material traceability to source as part of the process.

It is a physical test on material, which provide a quantitative information that is sufficient to verify the nominal alloy composition. PMI testing is not considered a substitute for required material test reports listing chemical composition, since it is not intended to establish certification of a material to a particular Material Specification

It is a quality assurance document used in the steelmaking industry that certifies a material’s compliance with appropriate standards, including physical and chemical specifications, and applicable dimensions. Material test certificates are not to be considered PMI testing

Includes any materials (including welding filler materials) that contain alloying elements such as chromium, nickel or molybdenum that are intentionally added to enhance the mechanical or physical properties and/or corrosion resistance. Alloy can be ferrous or nonferrous

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

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Heat

Inspection Lot

Representative Sample

Random

Standard Reference Materials

Weld button (button)

Pressure containing components

Non-Pressure containing components

Material Specification

Low Temperature Carbon Steel (LTCS)

Traceability

The amount of a given material produced from a single finishing furnace melt and therefore has consistent chemical and physical properties.

Lot is a group of items or materials of the same type from a common source from which a sample is to be drawn for examination. An inspection lot does not include items from more than one heat.

Is one or more items selected at random from the inspection lot that are to be examined to determine the acceptability of the inspection lot.

Selection process by which choices are made in an arbitrary and unbiased manner

It is the sample materials for which laboratory chemical analysis data are available and are used in demonstrating test instrument accuracy and reliability

It is a sample of welding filler material deposited on relevant base metal in order to provide basis for PMI of the filler

Components acting as pressure envelope or boundary, and prevent the fluid from being released to the environmental. Examples include, but not limited to, product forms used for the fabrication of pressured piping and equipment such as shells, heads, tube- sheets, nozzles, tubes, forgings, flanges, individual pipe length and fittings (tees, elbows, reducers, etc.), valve bodies and bonnets, expansion joints and bellows

Components which are not part of the pressure retaining envelope. ASME Section II, Parts A, B and C, or the relevant ASTM, or any other material specification Carbon steel material conforming to Material Specification, requesting impact test properties It is the ability to match an installed component to its source

Notes: The word “shall” is to be understood as a mandatory requirement. The word “should” is to be understood as strongly recommended. The word “may” is to be understood as an action to be undertaken at the Contractor’s discretion.

4

PMI WRITTEN PROCEDURE

A written procedure shall be defined by Vendor/Sub-Contactor (as applicable) as a specified series of actions, acts, or operations that have to be implemented in a specific order to continuously obtain the same PMI results under the same circumstances. It shall include a sequence of activities, tasks, steps, decisions, calculations and processes, that when undertaken in the sequence prescribed will produce the desired PMI analysis.

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This written procedure, in compliance with the requirements of this specification, shall be submitted by Vendor/Sub-Contactor (as applicable) for Contactor’s review, prior to the start of fabrication. It shall contain, as a minimum, the following information: a) Description of method and equipment operating principle b) Name and manufacturer of equipment to be used c) Calibration requirements d) Condition of testing surface e) Schedule showing when PMI will be performed during fabrication cycle f) Procedure steps in detail g) Procedure to follow when identification results are inconclusive (alloy type is not determinable) h) Analyzer manufacturer’s safety operating and emergency procedures i) Personnel qualification procedures, along with PMI operator’s training record or experience

certificate

j) Acceptance criteria k) Identification requirements l) Documentation requirements., along with forms for PMI record and PMI map

5

MATERIAL VERIFICATION PROGRAM (MVP) ACTIVITIES

MVP verification shall be performed by matching heat numbers of components to the mill test reports. Materials involved in MVP should be stored and fabricated in an area separated from regular grade carbon steel in order to avoid mixing of materials and welding electrodes. When traceability of a material heat number cannot be established back to the mill certification or other positive means of identity, that material heat number, regardless of quantity, shall be rejected. After satisfactory MVP, all items (listed in the above sub-clause 1.4 point vi4) shall be marked with color coding by Vendor, according to clause 10 prior to dispatch. PMI testing is not required for material listed in the sub-clause 1.2 b).

6

EXTENT, LOCATIONS AND TIMING OF PMI

6.1

FOR ALL ITEMS, LISTED IN SUB-CLAUSE 1.4, POINTS I, II, III, IV, VII. THIS SUB- CLAUSE IS APPLICABLE ALSO TO POINT VIII WHEN PART OF A VENDOR PACKAGE OR SKID SUPPLY

Except as indicated in sub-clause 6.1.1, 100% PMI is required for all materials, components and welds listed in sub-clauses 1.2 and 1.3, as follow:

1. One test for each component
2. One test for each weld or once for every 3.0 meters of weld length, whichever is most, and

specifically: i. Double side welds shall be tested both inside and outside ii. Single side weld shall be sampled on the “process” side where this is not possible the weld

cap on the outer side maybe tested

iii. Each weld repair

4 When relevant to Piping Material Requisition or when relevant to lose piping material supply as part of Vendor Package scope of work

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3. Weld overlays, for large deposit shall be sampled once per 0.5m² of clad areas, smaller areas (i.e

<0.5m²) shall be tested once per clad item

4. Weld back cladding shall be tested once per back clad seam
5. Welding Consumables:

i. PMI shall be performed also on welding materials (wire, rod, and electrodes) before consuming in welded joints. At least one welding electrode, bare or reel-wire shall be randomly selected from each lot (identical heat number, type, size, grade, etc.) for PMI testing ii. PMI testing of weld metal (e.g. deposited or undiluted weld “buttons”) is an acceptable alternative to PMI testing of an electrode, bar, or reel-wire sample provided it is conducted immediately prior to welding or during the welding process. Buttons shall be in accordance with ASME II Part C SFA-5.4 clause 9.3

iii. The remainder of the lot shall be compared to the identified consumable to verify that the

markings of the electrodes/wires are correct

verifications

PMI shall be performed (and certified) by Vendor at his shop after assembly but prior to dispatch. Only components for which the PMI is not feasible after assembly shall be examined before their installations. All testing/painting/insulation (whichever is applicable before) or other special processing if required. Results of all PMI shall be noted by Vendor on as-built drawings, or NDE maps, to track both the PMI test results and the PMI test locations. Items shall not be shipped until all PMI has been completed, documented, and approved by the purchaser.

shall be performed prior

treatment or hydrostatic

to any heat

6.1.1 RANDOM EXAMINATION PER INSPECTION LOT IS ALLOWED, FOR THE

FOLLOWING COMPONENTS:

a) Heat exchanger/air cooler/heater/boiler tubes: 10% (minimum 10 tubes) in each heat in each

bundle

b) Plates heat exchanger: 10% (minimum 10 plates) in each heat in each assembly c) Non-pressure retaining bundle components (e.g. baffles, tie-rods, seal strips, etc.): 5% d) Non-pressure retaining components of pressure vessels (e.g. tray components, downcomers,

distributor pipes, reactor bed internals, etc.): 5%

e) Refractory anchors: 0.5% (rounded up to the next whole number) of each component style,

component size, metallurgy

f) Bolting components except ASTM A193 grade B7 (stud) and B8 (nut): 2% per heat (10% by

inspection lot without heat traceability)

g) Spiral wound gaskets when the windings or ID ring are alloys other than 304: 5%

6.2

FOR ALL ITEMS, LISTED IN SUB-CLAUSE 1.4, POINT V WHEN RELEVANT TO INSTRUMENT MATERIAL REQUISITION OR WHEN RELEVANT TO LOSE MATERIAL SUPPLY AS PART OF VENDOR PACKAGE SCOPE OF WORK

Except as indicated in sub-clause 6.2.1, 100% PMI is required for all materials, components and welds listed in sub-clauses 1.2 and 1.3, as follow:

1. One test for each item
2. One test for each weld and weld repair

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3. Welding Consumables:

i. PMI shall be performed also on welding materials (wire, rod, and electrodes) before consuming in welded joints. At least one welding electrode or bare wire shall be randomly selected from each lot (identical heat number, type, size, grade, etc.) for PMI testing

ii. 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. Buttons shall be in accordance with ASME II Part C SFA-5.4 clause 9.3

iii. The remainder of the lot shall be compared to the identified consumable to verify that the

markings of the electrodes/wires are correct

verifications

PMI shall be performed (and certified) by Vendor at his shop after assembly but prior to dispatch. Only components for which the PMI is not feasible after assembly shall be examined before their installations. All testing/painting/insulation (whichever is applicable before) or other special processing if required. Results of all PMIs shall be noted by Vendor on as-built drawings, or NDE maps, to track both the PMI test results and the PMI test locations. Items shall not be shipped until all PMI has been completed, documented, and approved by the purchaser.

shall be performed prior

treatment or hydrostatic

to any heat

6.2.1 RANDOM EXAMINATION PER INSPECTION LOT IS ALLOWED, FOR THE

FOLLOWING MATERIAL AND/OR COMPONENTS

a) Bolting components except ASTM A193 grade B7 (stud) and B8 (nut): 2% per heat (10% by

inspection lot without heat traceability)

b) Spiral wound gaskets when the windings or ID ring are alloys other than 304: 5%

6.3

FOR ALL ITEMS, LISTED IN SUB-CLAUSE 1.4, POINT VI WHEN RELEVANT TO PIPING MATERIAL REQUISITION OR WHEN RELEVANT TO LOSE PIPING MATERIAL SUPPLY AS PART OF VENDOR PACKAGE SCOPE OF WORK

Except as indicated in sub-clause 6.3.1, 10% PMI is required for all materials, components and welds listed in sub-clauses 1.2 and 1.3 as follow: a) One test for each item (note: items which are longitudinally welded shall have the welds PMI

verified by testing both welds and base metal)

b) PMI shall be performed (and certified) by Vendor at his shop after assembly but prior to dispatch c) Results of all PMIs shall be recorded by Vendor

All positively verified material shall be marked by color coding by Vendor prior to dispatch, according to clause 10. Items shall not be shipped until all PMI and color coding has been completed, documented, and approved by Contactor.

6.3.1 RANDOM EXAMINATION PER INSPECTION LOT IS ALLOWED, FOR MATERIAL

AND/OR COMPONENTS

a) Bolting components except ASTM A193 grade B7 (stud) and B8 (nut): 2% per heat (10% by

inspection lot without heat traceability)

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b) Spiral wound gaskets when the windings or ID ring are alloys other than 304: 5%

6.4

FOR ALL ITEMS, LISTED IN SUB-CLAUSE 1.4, POINT VIII, WHEN RELEVANT TO SUB-CONTACTOR SCOPE OF WORK

100% PMI shall be performed by Sub-Contractor, for all materials, welds and welding consumables of materials listed in sub-clause 1.2. Any PMI check for welding joint shall be 3 readings (base material 1, weld deposit, base material 2) as follow: a) One test for each weld and weld repair b) Total two readings on base materials, one for each side of weld

6.4.1 WELDING CONSUMABLES:

a) PMI shall be performed also on welding materials (wire, rod, and electrodes) before consuming in welded joints. At least one welding electrode or bare wire shall be randomly selected from each lot (identical heat number, type, size, grade, etc.) for PMI testing

b) 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. Buttons shall be in accordance with ASME II Part C SFA-5.4 clause 9.3

c) The remainder of the lot shall be compared to the identified consumable to verify that the

markings of the electrodes/wires are correct

d) After PMI the represented welding materials shall be color coded according to clause 10. If not

otherwise accepted5, color coding shall match the appropriate base metal

100% PMI is required for also all flanged Item (e.g. valve, steam trap, blind, spacer, etc.). All PMI shall be noted by Sub-Contractor on NDE map or register, to track the welds that were tested and test results. Only color-coded components (as per sub-clause 6.3) and welding materials (as per this clause) shall be used for spool fabrication and piping erection. If the components could not be identified through their color coding (or marking) after prefabrication or erection, the components shall be submitted for PMI examination at Sub-Contactor cost and care. Prefabricated pipe spools shall be PMI verified at shop before spool dispatch to painting or site, but in any case, prior to any heat treatment (whichever is applicable before). For piping field welding activities PMI shall be performed prior to any heat treatment or hydrostatic testing (whichever is applicable before). To ensure material traceability the following shall be documented by Sub-Contactor in fully implemented and auditable fabrication and/or construction procedures: a) The heat numbers and color coding on completed piping spools shall be 100% verified prior to

release of the spools for painting and/or field installation

b) The heat numbers shall be copied onto the relevant shop fabrication isometric/weld map, written

on a tag applied to the spool, or hard stamped (when permitted)

c) Verification of heat numbers and heat number transfer shall be included as an inspection point on

the piping Inspection and Test Plan (ITP)

d) The heat number transfer shall be transferred before materials are cut e) Verification in the field that the components have been installed per requirements

5 As per Sub-Contractor quality procedure(s)

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In fact, material traceability by Sub-Contactor shall include the following controls at both the fabrication and construction sites:

➢ Step 1: Material certification and identification:

Upon material receipt, the Sub-Contractor shall verify that materials are properly marked and match the certificates.

➢ Step 2: Strict separate material storage based on material grade:

Following PMI and color coding, the materials shall be stored by material grade. The Sub- Contractor shall be responsible for segregating unexamined and/or rejected items and assuring that they are properly identified to prevent their unauthorized use.

➢ Step 3: Issue of Materials:

Controls for the issue and tracking of materials and components and welding consumables. Materials required for construction/fabrication purposes shall be supplied from their storage area by means of a materials issue voucher which clearly identifies the required material grade and for which construction/fabrication item it is required. It shall include the control and traceability of surplus materials, rejected materials, as well as the return and/or replacement.

➢ Step 4: Strict separation of material grades:

At the construction/fabrication site materials grades shall be kept strictly separate and identifiable until such time as the fabricated item is complete and the likelihood of rogue materials being substituted is minimized. It includes controls during fabrication, such as the segregation of materials, materials traceability and identification including matching of heat numbers to MTRs.

7

ACCEPTABLE METHOD(S) AND ACCEPTANCE CRITERIA OF PMI

7.1

FOR ALLOY MATERIALS

Instruments or methods used for PMI testing shall be able to provide quantitative, recordable, elemental composition results for alloying elements present listed in Appendix-1. The elements listed in Appendix-1 are to be considered as the minimum element determination for PMI testing. Materials shall contain the amount of alloying elements specified in the applicable ASME/ASTM specification, as follow:

➢ Alloy components and alloy welding filler materials shall be acceptable under this specification if each of the requested alloy elements is detected to have a value no less than 10% below the minimum value nor more than 10% above the maximum value specified by the governing material specification.

➢ Deposited production weld metal deposits shall be within +/- 12.5% of the ranges allowed by ASME Section II Part C for each requested alloy element. (note: acceptance criteria for dissimilar metal alloy welds shall be such that the weld meets the chemical composition requirements as agreed upon between Vendor/Sub-Contractor and Contractor. The effects of dilution during deposition should be taken into account for deposited/diluted weld metal)

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PMI testing shall be conducted using one of the following devices suitable for the elements to be determined as required in Appendix-1, having the sensitivity to detect these alloying elements in the above specified ranges.

a) Use of quantitative, portable X-ray fluorescence analyzers: It includes also instruments with advancements in XRF technology, such as 50KV, X-ray tubes, and silica drift detectors (SDD), which allow the user to detect light elements down to very low concentrations in steel substrates. For example, the latest generation of handheld X-ray fluorescence analyzers now measure light elements (Mg, Al, Si, P, and S) to very low limits of detection and can provide for field measurement of silicon in steel down to very low concentrations. However, to get this near-laboratory-quality measurement, significant care regarding surface preparation and cleanliness is required, as contamination of the prepared surface can lead to inaccurate results. Most comports are exposed to environments that promote surface pollution and contamination, which can interfere with the analysis. Typically, a small test area is prepared with a portable grinding disk (60 to 80 grit, minimum zirconium aluminum oxide disposable abrasive disk) to properly clean the sample location prior to analysis. The inherent limitations of the technique mean it is not possible to detect all elements. XRF analyzers are capable of detecting elements from magnesium (Mg) to Uranium (U) in the periodic tables. This excludes some elements, such as carbon and boron. The user should be aware of potential radiation exposure hazards when operating an XRF device. The user is expected to observe local jurisdictional requirements that govern radiation safety, and consult the manufacturer’s instructions for safe operation.

b) Use of portable optical emission analyzers: These devices fall into two acceptable groups:

i. Field-portable, laboratory grade analyzers. These were originally difficult to use due to their size and weight; however, modern units are now available that can be considered lightweight, including the small argon cylinders required for operation. Some of these analyzers operate in a pure arc mode for routine PMI applications, while the more sophisticated units have a spark mode allowing laboratory quality analysis. The significant advantage of these instruments is the expansion of elements that can be analyzed, including carbon. Another advantage of these advanced instruments is that they are not subject to operator interpretation. As these techniques generate arcs and sparks, a potential ignition source occurs during their operation; therefore, prior to use of this technique in the field, a review shall be conducted in order to determine if gas testing and hot work permits are required. Evidence of Arc burn resulting from examination shall be removed by light grinding or abrasive paper. No permanent marks, which are injurious to the usage of product in service, are acceptable

ii. Laser-induced breakdown spectroscopy (LIBS), in which an atomic emission spectroscopy technique uses highly energetic laser pulses. The laser is focused to form plasma, which atomizes and excites samples. Plasma light emissions provide the spectral signature of chemical composition for practically any material. When calibrated for metal analysis, LIBS can provide quantitative information to determine which elements are present and in what quantity. Considerable progress has been made during the past few years in LIBS technology. Handheld LIBS metal analyzers are becoming available that can provide fast in situ chemical analysis with appropriate precision and detection limits. The significant advantage of LIBS technology is its wide element range. In principle, LIBS can detect all elements, limited by the power of the laser as well as the sensitivity and wavelength range of the spectrograph and detector. The LIBS technology also can provide low-level carbon analysis, which, in principle, enables LIBS to positively identify a wide range of ferrous alloys.

This document is property of Tecnimont S.p.A. and cannot be used by others for any purpose, without prior written consent

POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000002

SHEET 13 / 21

ISSUE 2

This technique generates a laser during operation, which is a potential ignition source. Therefore, before using this technique in the field, a review shall be conducted in order to determine if gas testing and hot work permits are required.

The specific device (manufacturer, model number) shall be identified within the submitted PMI procedure. The surfaces to be examined shall be prepared and cleaned by suitable means before PMI so that surface be free from grease, oil, paint or oxides. Testing shall be done after proper surface cleaning and other requirements as outlined by the manufacturer of the portable alloy analyzer. Each analyzer shall be calibrated according to Manufacturer requirements. At the beginning and end of each shift, the instrument shall be checked at least three times against a Standard Reference Materials of the same alloy family to be inspected during the shift, using the method to be used during the shift. This check shall be performed under environmental conditions similar to the test location. Analytical laboratories using X-ray fluorescence spectrometry, optical spectroscopy, or wet chemical analysis may be used for verification in cases where PMI testing using one of the above portable qualitative analysis methods leads to the potential rejection of a component.

8

NON-CONFORMANCES

If PMI/MVP result does not comply with acceptance criteria specified, the relevant item shall be rejected, and the following actions shall be taken by Vendor/Sub-Contactor (as applicable): a) a non-conformance report (NCR) per the project quality procedures shall be issued b) a corrective action plan shall be issued for the Contactor’s acceptance, and in particular,

i. Vendor/Sub-Contactor (as applicable) shall be responsible for replacing the weld with the

correct specified welds and for performing PMI on all replacement welds.

ii. Vendor shall be responsible for replacing the components with the correct specified material

and for performing PMI on all replacement components.

In addition to the above, if an item from a representative sample is rejected, the following additional testing shall be carried out by Vendor’s expense: ➢ Examine 100% of the remaining components/welds of the lot from which the sample was taken ➢ Examine 100% of next lot from the same Vendor ➢ Return the level of examination to the originally specified level if examination of the next lot does

not identify any similar non-conformance

c) 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.

d) If the PMI test results fall outside the acceptable range, using the instruments and method described in clause 7, Vendor/Sub-Contactor (as applicable) may obtain a quantitative check analysis performed by an independent testing laboratory, at his own expense. If no method is referenced in the applicable materials standard, an appropriate method of chemical analysis, as specified in API RP 578 para 6.5.1, shall be used. Results of this analysis shall govern.

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000002

SHEET 14 / 21

ISSUE 2

9

PERSONNEL PERFORMING PMI TESTING

Personnel performing PMI tests shall have sufficient training, knowledge and experience in related fields to operate the testing equipment and to make proper evaluations on the acceptability of the materials tested. PMI operator shall be trained, tested, and certified to: a) Safely use the PMI analyzer(s) b) Properly apply material specifications such as ASTM and ASME Operator training, qualification and experience record issued by employer of operator shall be attached to PMI procedure prepared by Vendor/ Sub-Contractor for Contractor’s review.

10

IDENTIFICATION OF COMPONENTS FOR PMI VERIFICATION

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. As requested by sub-clauses 6.1, 6.2, 6.3 and 6.4, upon satisfactory completion of PMI, Vendor/Sub-Contactor shall show the test result on appropriate drawing/map so that each test site and result can be traceable. Upon satisfactory completion of PMI, Vendor shall apply color coding on all components of relevant inspection lot. Identification by color coding is not a substitute for other permanent manufacturer’s marking, as is required by applicable ASTM or other piping material specifications. When heat treatment is performed, the identification marking and color coding shall be recognizable after such heat treatments.

Paints for color coding shall be selected such that: ➢ They shall not cause degradation to the base material (e.g., no zinc-containing paint/marker on stainless steel base material, no chloride-containing paint/marker on stainless steel base material) ➢ They shall not contain undesirable substances such as chlorides, fluorides, sulfur, and low melting

point metals

➢ They shall have a life of at least one year in exposed outdoor weather conditions Note: in case of component (e.g. bulk valves) are supplied/provided with primer coat, paint shall be compatible for the primer used

Appendix-2 provides the color code to be adopted. The color shall be applied as per following table:

Pipe

Fittings

Flanges

Each length of pipe shall be painted over the entire length with a 12 mm (0.5 in) to a 40 mm (1.6 in) wide stripe, depending on the pipe size.

a) Each socket weld fitting, swage or pipe nipple shall be dabbed with a spot of paint 12 mm (0.5 in) to 25 mm (1 in) in diameter. b) The entire length of each butt weld fitting shall be painted on the outside surface with a 12 mm (0.5 in) to 40 mm (1.6 in) wide stripe, depending on size.

The outer peripheral edge of each flange shall be painted with a spot of paint on the outer surface.

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000002

SHEET 15 / 21

ISSUE 2

Valves

Bolts

Nuts

a) Each welded or flangeless (wafer type) valve shall be dabbed with a spot of paint 12 mm (0.5 in) to 25 mm (1 in) in diameter. b) Each flanged valve shall be dabbed with a spot of paint 12 mm (0.5 in) to 25 mm (1 in) in diameter on the top side of one flange. c) For flanges thicker than 25 mm (1 in), the width of the band may be limited to 25 mm (1 in).

Each stud bolt shall be dabbed with a spot of paint on each end.

On one of external flat surfaces.

Welding Materials On one of the ends

General Notes: a) If two colours are required, the above length are to be intended for each marking. b) The pipes that are sand/shot blasted and primed on site and then stored again in the warehouse shall be marked after primer application with the same procedures aforementioned

The marking is applied directly, by brush and/or spray painting. Paint shall not be applied, in any circumstances, to the following: ➢ Threads ➢ Weld Bevels ➢ Symbols or markings which would obliterate identification ➢ Gasket seating surface

Persons responsible for reading/applying the colors shall be confirmed as being able to distinguish the difference between the colors being used (i.e. not be color-blind).

11

RECORDS

In addition to requirements of clause 9, for each PMI executed, record(s) of PMI results shall be provided by Vendor/Sub-Contactor (as applicable) to Contactor as part of the final (as-built) documentation. PMI output shall include the compilation of auditable material traceability records. The following information shall be included in PMI record6 (as minimum):

1. Report No.
2. Project name
3. Purchase Order No.
4. Reference to PMI procedure used
5. Item No. / Description
6. Location where PMI performed such as weld, base metal, shell head etc.
7. Material specification / type such as ASTM A240 Type 316 etc. with acceptance criteria
8. Material Manufacturer/Supplier, MTR number, heat number and lot number, as applicable

6 For activities relevant to sub-clause 6.4, Sub-Contactor shall refer to PMI forms attached to “Steel Piping Works - Site Inspection Plan Doc No 4439-XH-PQ”

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000002

SHEET 16 / 21

ISSUE 2

9. Inspection lot size and number of pieces examined
10. PMI inspection date
11. Type and brand name of instrument, including test instrument identification number or serial

number

12. Measured Chemical elements such as Cr, Ni, Mo etc.
13. Measured Chemical element values (%)
14. Result of PMI (Accept or reject)
15. Name & signature who carried our PMI
16. Name & signature who endorsed the PMI result

In addition to the above, for fabricated or assembled items, results of all PMI shall be noted on as- built drawings, spool sheets, or isometrics, to track the components that were tested and test results.

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000002

SHEET 17 / 21

ISSUE 2

APPENDIX 1 - ALLOYING ELEMENTS REQUIRED FOR PMI

Material

UNS No.

C

Cr

Ni Mo Cb Ti

Cu W

Al

V

Zn Fe

1-1/4 Cr, 1/2 Mo

2-1/4 Cr, 1 Mo

5 Cr, 1/2 Mo

9 Cr, 1 Mo

9 Cr, 1 Mo, 0.2V

K11597

K21590

K41545

K90941

K90901

9 Cr, 1/2 Mo, 0.2V 2W

K92460

12 Cr, 4 Ni

308

309

310

316

317

321

347

304L*

308L*

309L*

316L*

317L*

304H*

316H*

321H*

347H*

405

410

410S

430

Duplex

Super Duplex

S41500

S30800

S30900

S31000

S31600

S31700

S32100

S34700

S30403

S30883

S30983

S31603

S31703

S30409

S31609

S32109

S34709

S40500

S41000

S41008

S43000

S31803 S32205

S32750 S32760

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X#

X#

X#

X#

X

X

X

X

X@

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000002

SHEET 18 / 21

ISSUE 2

Material

UNS No.

C

Cr

Ni Mo Cb Ti

Cu W

Al

V

Zn Fe

6 Mo Alloys

Alloy B-2

Alloy C-22

Alloy C-276

Alloy 20

Alloy 600

Alloy 625

Alloy 800

Alloy 825

Alloy 400

AL-6XN

904L

90/10 CuNi

70/30 CuNi

Titanium

Naval brass

Notes:

N08367 / N08925

N10665

N06022

N10276

N0S020

N06600

N06625

N0S800

N0S825

N04400

N0S367

N0S904

C70600

C71500

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

• For low and high carbon grade of SS, there must be a traceable mill certificate showing carbon content and carbon content shall be verified during PMI testing; in particular:

➢ For low carbon (“L”) grade material, measurement of carbon content is not necessary in case of exclusively use of dual grade material (e.g. 316/316L) and no high carbon (“H”) grade material is part of scope of work of Fabricator

➢ For high carbon (“H”) grade material, measurement of carbon content cannot be waived.

Testing of Ti will prevent unacceptable substitution with Grade 409.

@ W measurement only for UNS S32760

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000002

SHEET 19 / 21

ISSUE 2

APPENDIX 2 - COLOUR CODING FOR MATERIAL IDENTIFICATION

MATERIAL

COLOUR FOR MARKING

RAL NUMBER

Carbon steel

None

Carbon steel for “Wet H2S service” (When “WET H2S” or “NACE” is specified in Purchaser’s commodity description)

One solid green

NA

6017

Carbon steel for “CS HIC resistance” (When “HIC” is specified in Purchaser’s commodity description)

One solid yellow, one solid green

1021/6017

Low Temperature Carbon Steel

One solid white

9010

Low Temperature Carbon Steel for “Wet H2S service” (When “WET H2S” or “NACE” is specified in Purchaser’s commodity description)

Low Temperature Carbon Steel for “LTCS HIC resistance” (When “HIC” is specified in Purchaser’s commodity description

C-½ Mo

1 Cr-1/2Mo

1¼ Cr-1/2Mo

2¼ Cr-1Mo

5 Cr-½ Mo

9 Cr-1Mo

One solid white, one solid green

9010/6017

One solid yellow, one solid white

1021/9010

One solid orange

2003

One solid orange, one solid blue

2003/5012

One solid yellow

One solid blue

1021

5012

One solid blue, one solid yellow

5012/1021

Two solids orange

2003/2003

9 Cr-1Mo-0.2V

One solid pink, one solid gray

3015/9007

9 Cr-1Mo -0.2V-2W

One solid green, one solid gray

6017/9007

Duplex

Super Duplex

One solid green, one solid black

6017/9005

One solid red, one solid green

3003/6017

Type 304/304L dual grade

One solid black

9005

Type 304/304L dual grade (When “NACE” is specified in Purchaser’s commodity description)

Type 304L

Type 304H

One solid brawn, one solid green

8001/6017

Two solids black

9005/9005

One intermittent black

Type 316/316L dual grade

One solid gray

Type 316/316L dual grade (When “NACE” is specified in Purchaser’s commodity description)

One solid brawn, one solid red

1021/3003

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9005

9007

POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000002

SHEET 20 / 21

ISSUE 2

MATERIAL

COLOUR FOR MARKING

RAL NUMBER

Type 316L

Type 316H

Type 321

Type 321H

Type 347

Type 347H

Type 904L

Alloy 20

Inconel 600

Inconel 625

Incoloy 800

Incoloy 825

Hastelloy B-2

Hastelloy C-276

Hastelloy C-22

Hastelloy G

Two solids gray

9007/9007

One intermittent gray

One solid pink

Two solid pink

One solid brawn

Two solid brawn

One solid red

9007

3015

3015/3015

1021

1021/1021

3003

One solid black, one solid blue

9005/5012

Two solid blue

5012/5012

One solid blue, one solid pink,

5012/3015

One solid black, one solid orange

9005/2003

One solid gray, one solid blue

9007/5012

One solid red, one solid orange

3003/2003

One solid red, one solid blue

3003/5012

Two solid red

3003/3003

One solid red, one solid yellow

3003/1021

Monel (alloy 400)

One solid black, one solid yellow

9005/1021

Cu-Ni

A193 B16-A194 4

A193 B8 Cl 2

A193 B7-A194 2H

A193 B7M-A194 2HM

A193 L7-A194 7

A193 L7M-A194 7M

Explanatory notes:

One solid gray, one solid red

9007/3003

Yellow

Green

None

Red

White

Blue

1021

6017

NA

3003

9010

5017

➢ CS is material grades such as A106 gr.B, A672 C65, A105, A234 WPB ,etc.

➢ LTCS is material grades such as A333 gr.6, A671 CC65, A35-LF2, A420 WPL6 , etc.

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POSITIVE MATERIAL IDENTIFICATION GENERAL SPECIFICATION

REALISATION EN EPC D’INSTALLATIONS DE PRODUCTION DE LINEAR-ALKYL- BENZENE <> A SKIKDA ALGERIE

TCM IDENTIFICATION CODE

4439-XZ-SG-000000002

SHEET 21 / 21

ISSUE 2

Spiral Wound Gasket

Winding / Filler Material

Outer Ring / Inner Ring

Colour

SS304L / Graphite

CS / SS316L

Green (1)

SS316L / Graphite

SS316L / SS316L

Green and dotted Red (2)

SS316L / Thermiculite 835

SS316L / SS316L

Green and dotted Black (2)

Monel / Graphite

321 / Graphite

Monel / -

321 / 321

Orange (1)

Turquoise (1)

UNS S31803 / Graphite

UNS S31803 / UNS S31803

Blu (3)

Full Face Gasket

Colour

None

Material

PTFE

Note:

1. As per ASME B16.20

2. Green background as per ASME B16.20 plus 4 red strip (25 mm width) 90 deg spaced

3. Custom colour

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Project: Q-32976 - Tecnmont SKIKDA Folder: Reference Documents