MAJNOON CPF 2 PROJECT

COMMENTS RESPONSE SHEET (CRS) FOR VENDOR/SUB-CONTRACTOR

Document Title : SITE POSITIVE MATERIAL IDENTIFICATION TESTING PROCEDURE Company Job No. : BOC 1561

Discipline : MECHANICAL Petrofac Job No. : JI-2042

Document No. : MGP1-CP2-KMS-QA-6050-0003

STATUS
Serial No. Page No. / Section Rev. COMPANY/ CONTRACTOR COMMENT VENDOR/SUBCONTRACTOR RESPONSE CONTRACTOR RESOLUTION COMPANY RESOLUTION
(Open /Close)

CONTRACTOR

NO COMMENT

COMPANY

1 Page 10 / Section - 15 007 NO COMMENT ITR Revised to Revision 2 Agreed Agreed Closed

VENDOR / SUB-CONTRACTOR CONTRACTOR COMPANY

Prepared By: Ameer Razzaq Noor Date:

Date: 26-Jul-2022 Approved By: Date: Approved By:
Signature:

Approved By: Ameer Razzaq Noor Date:

Date: 26-Jul-2022 Signature: Date: Signature:
Signature:
 MAJNOON CPF 2 PROJECT

SUBCONTRACTOR DOCUMENT REVIEW

SHEET

Contract Number: JI-2042-03-002

SUBCONTRACTOR Name: KHAERAT MSK AL IRAQ FOR OIL SERVICES

Contract Title Name: ME&I Works of MAJNOON CPF-2 Project

Document Number: MGP1-CP2-KMS-QA-6050-0003

Project № Plant Code Originator Discipline Doc Sequence Sheet No.
Code Code Type No. (Optional)
MGP1 CP2 KMS QA 6050 0003 N/A
Document Description: SITE POSITIVE MATERIAL IDENTIFICATION TESTING
PROCEDURE
Revision: 007
Review Status: APP

Review Code and Status

Code 1 Accepted – Up-rev and Resubmit with applicable document lifecycle status code
Revise and Resubmit –Incorporate Comments, Up-Rev & Resubmit at the next document lifecycle
Code 2 status code – Work May Proceed
Rejected– Address highlighted deficiencies, Up-Rev and Resubmit at the next document lifecycle
Code 3 status code – Work May not proceed

Code 4 Review Not Required – Do not resubmit

Code 5 Cancelled or Superseded

Code 6 Information

Date: Name: Sign:

Note: This sheet shall be the 1st cover page of all A3 & A4 documents. This block will also form part of the A3 drawing
template.
 MAJNOON CPF 2 PROJECT

SITE POSITIVE MATERIAL IDENTIFICATION TESTING PROCEDURE

007 Approved for Use 26-Jul-2022 AB AR OD AS

DOCUMENT TITLE:
006 Approved for Use 30-Apr-2021 AB AR OD AS
Issued for
005 Approval
19-Mar-2021 AB AR OD AS
SITE POSITIVE MATERIAL IDENTIFICATION
Issued for TESTING PROCEDURE
004 Approval
22-Dec-2020 AB AR OD AS
Issued for
003 Approval
18-Oct-2020 AB AR AH AS
Issued for
002 Approval
11-Sep-2020 AB AR AH AS DOC. SIZE: A4 DOC. CATEGORY: R PAGE 1 OF 14 REV.
COMPANY JOB
001 Issued for Review 05-Sep-2020 AB AR AH AS NO. BOC 1561 DOC. NO.:
007
REV. DESCRIPTION DATE PRPD CHKD APPD APPD JOB. NO.: JI-2042 MGP1-CP2-KMS-QA-6050-0003
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HOLD LIST

Hold
Para. Description of Hold
No.
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TABLE OF CONTENTS

1  INTRODUCTION ................................................................................................................ 4 

2  SCOPE .................................................................................................................................... 4 

3  PURPOSE .............................................................................................................................. 4 

4  REFERENCES ...................................................................................................................... 4 

5  DEFINITION AND ABBREVIATIONS ............................................................................. 5 

6  PERSONAL............................................................................................................................ 5 

7  EQUIPMENT ........................................................................................................................ 5 

8  PROCEDURE ........................................................................................................................ 6 

9  EXTENT OF EXAMINATION ........................................................................................... 7 

10  ALLOYING ELEMENTS REQUIRED FOR PMI ............................................................. 7 

11  MATERIAL MARKING AFTER PMI EXAMINATION .................................................... 7 

12  PMI ACCEPTANCE AND REJECTION ............................................................................ 7 

13  REPORTING ......................................................................................................................... 8 

14  HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENT ................................. 9 

15  ATTACHMENTS ................................................................................................................ 10 

Daily PMI Report ..............................................................................................................................10 

SPECTROPORT PXC01 PORTABLE ARC/SPARK OES METALS ANALYZER The
for Positive Material Identification (PMI) ......................................................................................11 
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1 INTRODUCTION

This procedure specifies the requirements of Positive Material Identification (PMI) for the
components/welds/weld consumables in material other than CS & LTCS by Khaerat MSK Al-Iraq
for MAJNOON CPF 2 PROJECT.

2 SCOPE

The Scope of this Procedure to check chemical composition for materials such as austenic stainless
steel/ duplex stainless steel / Inconel / other low alloy steels specified in Project.
This procedure covers the extent of parts to be tested, requirements, acceptance/rejection criteria and
documentation of PMI.

3 PURPOSE

The purpose of this procedure is to describe how Positive Material Identification (PMI) will be carried
out by Sub Contractor for the above addressed Project. PMI is to ensure that correct material is
supplied & installed at correct places as required by requisition, drawing and data sheet.

4 REFERENCES

ASME Sec II Part C, Ed. 2019: Welding Rods, Electrodes and Filler Metals
ASME Sec IX, Ed. 2019: Welding and Brazing Qualification
ASME Sec V, Ed. 2019: Non-Destructive Examination
ASME B 31.3, Ed. 2018: Processing Piping
ASTM E 353, Edition 2017: Chemical Analysis of Stainless, Heat Resisting, Managing and
Other Similar Chromium, Nickel – Iron Alloys
ASTM E 354, Edition 2017: Chemical Analysis of High-Temperature, Electrical, Magnetic and
Other Similar, Nickel and Cobalt Alloys
ASTM E327: Test Method for Optical Emission Spectrometric Analysis of
Stainless-Steel Type 18-8 Steels by the Point – to –Plane Technique
ASTM E352: Methods for Chemical Analysis of Tools Steels and other similar
Medium and high Alloy steels
ASTM E572: Test Method for X-ray Emission Spectrometric Analysis of
Stainless Steel
ASTM A-751, Edition 2017: Method Practices and Terminology for Chemical Analysis of Steel
Products.
ASTM E478 Edition 2017: Chemical analysis of Copper alloys
ASTM E62 Edition 2007: Chemical analysis of Copper & Copper alloys
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API 578, Ed. 2018: Material Verification Program for New and Existing Alloy Piping
Systems
MGP1-CP2-PIL-QA-5733-1032: Inspection & Test Plan Site Fabrication, Erection & Testing of
Above Ground and Underground Piping
MGP1-CP2-PIL-QA-7739-0003: Specification for Welding
MGP1-CP2-PIL-MP-7739-0001: Purchase Specification for Piping Bulk Items
MGP1-CP2-PIL-QA-7739-0001: Specification for Positive Material Identification

5 DEFINITION AND ABBREVIATIONS

Company Basra Oil Company (BOC), Iraq

EPCM KBR
Contractor Petrofac International (UAE) Limited
Sub-Contractor KHAERAT MSK AL IRAQ (KMSK)
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials
API American Petroleum Institute
PMI Positive Material Identification
RFI Request for Inspection
AFC Approval for Construction
QA Quality assurance
QC Quality control

6 PERSONAL

 Personnel performing PMI testing shall have previous proven ability in PMI inspection. The
technicians shall have the following qualifications.
o Proof of successful completion of an acceptable PMI training course, this course could be
presented in- house the manufacturer or the other institution.
o Three months of documented experience performing PMI activity. PMI operator shall ensure
safe operation of the equipment.
 PMI Operator shall ensure PMI equipment is operated, calibrated and maintained in accordance
with manufacturer’s specifications and the submitted and approved PMI procedure.
 Records of PMI operator qualifications shall be maintained.

7 EQUIPMENT

 The analyzer equipment shall be approved by Contractor and EPCM.

 Optical emission technique shall not be used to thickness less than 2 mm.
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 Analyzed samples having relevance to the job shall be made available for Cross-reference and
calibration purposes.
 The equipment shall require re-calibration at the job site, if there is a difference in the readings.

8 PROCEDURE

The PMI shall be performed according to a written procedure that describes:

 The name & vendor of equipment to be used.
 Description of operation principle.
 Radiation safety operating and emergency procedures also operator qualification procedure.
 Preparation of test samples and calibration.
 Criteria for acceptance or rejection of components.
 Method of marking on inspected materials.
 Procedure to follow when identification results are inconclusive.
 Surface Preparation by Grinding or wiping the surface to remove paint, corrosion, scale, and
basic dirt is required on all samples, it shall be assured that the surface to be PMI tested is clean
– and free from any contamination that could influence on the PMI result.
 Documentation of test result (report Sample).
 Accuracy of the instrument, for each element to be analyzed, shall be indicated on the written
procedure.
 The measurement window shall be placed against the sample to be analyzed and the trigger
pulled to get the analysis of the sample. The chemical composition obtained shall be noted down
in the appropriate report format.
 The equipment shall be set up with the standard samples along with the procedure given by the
manufacturer.
 After successful standardization the equipment shall be calibrated by checking the values of the
standard material samples with reference to the job.
 Programming options as per Client requirement, such as identification, verification or sorting
shall be selected conditions.
 Machine calibration shall be done using standard test block, frequency on daily basis for each
material and grade.
 Instrument calibration certificates, standard reference sample and operator certificates shall be
furnished prior to testing.
 PMI shall be carried out on ASS & Alloy material (Base material and the weld metal) for
pressure retaining parts.
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9 EXTENT OF EXAMINATION

PMI program shall cover the following components.

Pressure-containing butt welds in equipment and piping made with alloy welding consumables shall be
PMI tested in accordance with the following guidelines:
 Selection of the test point locations to be examined shall be made by CONTRACTOR/EPCM.
 Surface preparation:
The surface of the component subjected to the test shall be free from grease, oil, paint, and
oxides. The surface preparation shall be performed with a portable grinding machine or any
other suitable equipment and the same should represent the original surface of the component.
 The percentage of PMI test of completed weld should be according to piping material
specification or line list & as per Table-5 of Project Specification MGP1-CP2-PIL-QA-7739-
0001.
 PMI of Alloy welding consumable prior to welding shall be performed as per Table-5 of Project
specification MGP1-CP2-PIL-QA-7739-0001.

10 ALLOYING ELEMENTS REQUIRED FOR PMI

Alloy element verification shall be as per Table 1 of Specification MGP1-CP2-PIL-QA-7739-0001.

11 MATERIAL MARKING AFTER PMI EXAMINATION

 PMI test location shall be marked with a semi- permanent paint marker. The marker shall not
contain additives such as aluminum, Sulphur, chloride, lead or zinc. For smaller items color coding
may be accepted.
 Materials, welds that are found to be unacceptable during verification testing shall be marked
immediately with a circled red cross (X).
 All verified material with an acceptable analysis shall be marked with the letter “AV”. The marking
shall be placed as follows:
o Welds: Adjacent to the welder’s mark on the weld
o Cut lengths of pipe from PMI-tested material are to have PMI markings transferred to all pieces
by Sub-Contractor.

12 PMI ACCEPTANCE AND REJECTION

 All material shall comply with the requirements of the relevant material specification. Material
shall be verified to ensure the correct major alloying elements and correct percentage of each
element where applicable.
 For Weld deposits, all recorded elements shall meet the weight percentage of alloy elements
specified in the relevant ASME II C specifications for deposited weld metal. Deposited weld metal
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or undiluted weld metal deposit with consumables that match or nearly match the base metal
composition shall be the range allowed in ASME Sec IIC for each element.
 Welds, material that are found to be unacceptable, shall be marked and separated pending
resolution by Sub- Contractor Quality Manager. Procedure shall be in place for handling of
Non- Conformance products.
 If any of the major alloying elements are below the range specified by the applicable material
standard or a portable analyser indicates an incorrect match or “no match”, the component shall
be rejected.
 Any deviation of alloying elements or absence of alloying elements with respect to the required
material specification more that 10% shall be considered as Rejected.
 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.
 The Subcontractor shall identify, mark and remove all unacceptable materials.
 Not conforming materials shall be immediately marked with water insoluble paint/ink, circled
red cross (x) as non-conforming materials and segregated from acceptable materials, to prevent
their unauthorized use.
 Obtain a quantitative check analysis performed by an independent test laboratory using the
"referee" method referenced by the material specification. If no referee method is referenced, an
appropriate chemical analysis method specified in this procedure shall be used. Results of this
analysis shall govern.
 If an item from a representative sample is rejected:
o 100% of the remaining components from which the sample was taken shall be examined;
o If no further components are rejected in above, the extent of examination shall return to the
originally specified.
 If the test results of the independent laboratory tests are not within the acceptable range of the
ASME II C, ASTM or other applicable material specification, the material shall be rejected.

13 REPORTING

PMI Report having following information as minimum with attached PMI machine outputs.
 Client Name
 Company project No, Contract No, PO No
 PMI Report No
 Inspection date
 Procedure No / Revision No
 Item description
 Technician Name / Signature
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 Calibration Details
 Site / Location
 Project.
 PMI Instrument model
 Line / Heat Number, Joint/ weld number
 Element Percentage
 Material specification and traceability
 Name and signature of Operator
 Name and signature of inspector to verify review and acceptance of result.
 Acceptance / Rejection

14 HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENT

 Only trained personnel shall use PMI equipment.

 As this procedure involves the use of an electrically operated / X-ray producing portable
equipment, care should be exercised due to the possible hazards of using them in humid and other
adverse operating conditions. Safe operation and emergency requirement shall be carried out in
accordance with the respective equipment operations manual or user guides.
 Since it is an X-ray tube instrument the tube gets energized only once the trigger is activated.
 All back scattered ray will be absorbed by the machine itself.
 Direct viewing of the arc or X-ray should be avoided to protect the eyes from damaging ultraviolet
rays and X-ray radiation.
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15 ATTACHMENTS

Daily PMI Report

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SPECTROPORT PXC01 PORTABLE ARC/SPARK OES METALS ANALYZER The for

Positive Material Identification (PMI)
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