1515 050 SPC 0009 - Pmi
1515 050 SPC 0009 - Pmi
1515 050 SPC 0009 - Pmi
Santos Specification
Table of contents:
FOREWORD ......................................................................................................................... 2
1 SCOPE ...................................................................................................................... 3
1.1 Purpose .......................................................................................................... 3
1.2 Structure ......................................................................................................... 3
1.3 Application ...................................................................................................... 3
2 REFERENCES AND DEFINITIONS .......................................................................... 3
2.1 References ..................................................................................................... 3
2.2 Definitions....................................................................................................... 3
3 PART 1 - PMI REQUIREMENTS PERFORMED BY SANTOS .................................. 4
3.1 Roles and Responsibilities .............................................................................. 4
3.2 Santos PMI Levels .......................................................................................... 4
4 PART 2 - PMI REQUIREMENTS PERFORMED BY CONTRACTOR AND
SUPPLIERS .............................................................................................................. 5
4.1 Roles and Responsibilities .............................................................................. 5
4.2 Verification Methods ....................................................................................... 5
4.3 Verification Samples ....................................................................................... 6
4.4 PMI Acceptance Criteria ................................................................................. 9
4.5 PMI Identification .......................................................................................... 11
4.6 PMI Documentation ...................................................................................... 12
5 REVISION NOTES................................................................................................... 12
6 APPENDICES.......................................................................................................... 13
FOREWORD
Santos Engineering Standards apply to all Santos facilities and are based on
Australian Regulations and Standards. When applied outside of Australia, Local Regulations,
Codes of Practice and Environmental Regulations shall take precedence.
The Santos Engineering Standards are generated, implemented and reviewed in accordance
with the Santos Engineering Management Standards (EMS).
Use of this Santos Engineering Standard is MANDATORY. If any part of this Standard
appears inadequate, unsuitable or not cost effective, consult with the Custodian to agree a
suitable solution. This may result in a revision to the Standard.
Deviations from Santos Engineering Standards shall be approved in writing via the Santos
Engineering Standards Waiver process. Approval of waivers is vested in the Santos Chief
Facilities Engineer or his delegate.
1 SCOPE
1.1 Purpose
The purpose of this Specification is to direct the performance of assurance activities that
ensure Positive Material Identification (PMI).
1.2 Structure
This Specification is structured in two parts to permit its application for internal Santos PMI
and for PMI actions performed by Suppliers:
Part 1 - Santos PMI Actions
Part 2 - Supplier PMI Actions.
1.3 Application
This Specification applies to all project and maintenance activities that result in a physical
change within the pressure envelope of pressure equipment that processes hydrocarbons or
hazardous fluids within Santos operated assets. It includes the activities of both Santos and
its Contractors and Suppliers and applies across materials destined for immediate use and
inventory. Types of materials covered are:
Metal alloys
Welding consumables and weldments
Plastics and rubber components
Structural composites
Metallic gaskets.
2.1 References
American Petroleum Institute (API):
API RP578 Material Verification Program for New and Existing Alloy Piping
Systems.
Australian Standards:
AS/NZS 3992:1998 Pressure equipment - Welding and brazing qualification
AS 4037:1999 Pressure equipment - Examination and testing.
To view current individual Australian Standards click on this Santos link
Australian Standards.
2.2 Definitions
Refer to Appendix A.
4.3.1 General
Samples taken for destructive testing shall be removed by the Supplier in the presence of the
Contractor’s representative unless this requirement is waived in writing by the Principal on a
case by case basis.
PMI is to be carried out at a time which ensures that proper materials are being used in the
fabrication of an identifiable assembly (e.g. a pipe length welded into a spool, or a nozzle
welded into a vessel, etc.).
All PMI records are to be traceable to a material source and heat number and the Supplier
shall demonstrate traceability at any time. The results shall be incorporated into fabrication
logs/manufacturer’s data records.
The Supplier shall ensure that all materials are segregated and stored in separate identified
locations to prevent the mix-up of materials of different alloy specifications or alloy material
with carbon steel. Non-ferro-magnetic materials shall be segregated at all times from ferro-
magnetic materials.
Instrumentation
Control Valve (8) 100% 5%
Inline Instruments (11) 100% 5% (1)
Notes:
1. 10% of all the components shall be examined. Components to be examined shall be selected by
the Principal or Contractor. If any given component has fewer than 10 items but more than 5, one
shall be examined. If 5 or less, all items shall be examined.
2. 5% representative sample of the total number of tubes from each heat, lot and material
specification of tubes.
3. 5% of bolts supplied in bulk or 2 bolts per box, and per heat and lot, whichever is the greater, shall
be examined. If lot size is less than 5, all are to be examined. Bolts to be examined shall be
randomly selected by the Principal or Contractor.
4. One examination per heat of material.
5. One spot on every cap pass of every pressure retaining weld.
6. This classification does not include carbon steel pipelines designed to AS 2885.
7. One spot on one cap pass per weld process specification per spool of piping shall be examined in
accordance with Table 2.
8. Valve body and hood only. However PMI testing of non-standard trim upgrades using high alloy
material such as alloy 400 trim is recommended in the modification workshop.
9. One analysis per WPS shall be taken at the base filler material and/or overlaid weld on each major
longitudinal and circumferential weld seam. For nozzles lined with alloy weld metal overlay, one
analysis per nozzle is required. For sleeve lined nozzles, one analysis for the flange face overlay
and of the shell tie-in overlay is required. One analysis is also required for the alloy weld overlay
covering a base metal weld and joining the cladding of clad plates. In cases of inaccessibility, a
test sample may be welded for analysis. A test sample shall be welded for each welding process
and for each heat and lot of filler materials.
One analysis is required on each fabricated head. The analysis shall meet the same composition
limits as the corresponding base plate and clad materials except that carbon maximum of 0.045%
is acceptable in a deposit joining L grade austenitic stainless steel cladding.
For alloy air cooler header boxes, one analysis for each welding process used for long seams, end
plates and nozzles is required.
10. Analysis of the base filler metal and/or alloy weld overlay shall be made at a location determined
by the Principal or Contractor’s inspector. If overlay has been applied for corrosion protection, the
analysis shall be performed at half the minimum specified thickness as qualified in the welding
process specifications. If the function of the overlay is to ensure product purity only, the sample
shall be taken at the surface. Chemical composition at the designated depth shall meet the
minimum composition requirements for the weld overlay alloy applied.
11. Includes venturis (external portion only), level bridles, Coriolis meter, magnetic level, displacer and
other instruments installed in-line pressure retaining service. Only the accessible welds are to be
tested in the field. Insertion type instruments such as thermowells, annubars, capacitance probes,
FCI flow meters are exempt because of the low stress level and standard stainless construction.
Insertion type instruments of alloys higher than stainless require PMI. Excludes items that are not
pressure retaining or not in-line instruments (downstream of the primary block valve) such as
pressure transmitters.
12. Bi-metallic joints. The Principal or Contractor shall be contacted prior to performing PMI on any
dissimilar / bimetallic joints.
Notes:
1. Test to be chosen based on the reason the liner has been applied. Eg, corrosion resistance.
2. Consider resin burn off techniques for establishing the fibre volume in a composite.
3. Consider tensile tests.
4. Consider compositional tests.
5. Consider tear tests.
Notes:
1. Carbon content; <0.035% for “L” Grades
2. Carbon content: 0.08%.Maximun for “Standard” (not “L” or “H” Grades)
3. Carbon content: 0.04% - 0.10% for “H” Grades
4. Carbon content: 0.08% Maximum; Titanium content: 5 times Carbon Minimum to 0.07% Maximum
5. Carbon content: 0.04% - 0.10%; Columbium (Niobium) content: 8 times Carbon Minimum to 1.0%
Maximum
6. The analysis of phosphorus and tin shall meet the following weight percent limits:
7. P 0.012%, and Sn 0.015%; (P+Sn) < 0.020. J-Factor = 150 max.(See note (14) below)
8. Ti; 0.15 - 0.60%
9. Co; 1.0% Maximum, Iron content: 2.0% maximum
10. Iron content: 6.0% - 10.0%
11. Iron content: 2.5% Maximum
12. Ti; 0.60 - 1.2%
13. Co; 2.5% Maximum, W; 3.0 - 4.5%
14. Iron content; 5.0% Maximum, Co; 1.0% Maximum, Ti; 0.40% Maximum
15. J-Factor = (Si+Mn)x(P+Sn)x10exp4 shall not exceed 100. (Si, Mn, P, Sn:wt%)
This specification does not allow for percentage non-conformance. If any piece from a sample
population is found to be unacceptable then the remainder of that lot shall be verified by performing a
100% examination.
All rejected materials shall be isolated in a "HOLD" area, tagged "REJECTED", and a Non-
conformance Report initiated by the Supplier.
Other items shall have each piece identified a sufficient number of times and at
different locations to ensure visibility of identification during the fabrication or erection
cycle.
When heat treatment is performed after material verification, the identification markings shall
be recognizable after the heat treatment.
The Supplier shall implement controls to prevent the inadvertent use of materials failing to
pass examinations or those incorrectly identified.
5 REVISION NOTES
Revision 1
This standard was previously TIMS document [1515-50-S-009-0].
Revision 1 reflects the migration of Santos engineering documentation from The Technical
Information Management Systems (TIMS) to myPlant OP during 2014. No technical update
changes have been made to this standard but where possible the update has addressed:
Compliance with the new Santos naming conventions
Links, including Redirect documents, to Santos Intranet, Extranet and external web
sites
Keyword replacements (eg. replace TIMS with myPlant)
Inclusion of reference to the Santos Engineering Management Standards (EMS)
which were launched in 2014.
Revision 0
First Issue
Prepared D Gillott, Santos Feb 2014
Reviewed Colin Beasley, Principal Engineer - Integrity Feb 2014
Approved Michael McCarthy, Chief Facilities Engineer Feb 2014
6 APPENDICES
Appendix A Definitions
APPENDIX A DEFINITIONS
Alloy Materials
Alloy materials are metal materials having a "P" number greater than 1, as defined in ASME
Section IX, QW-422. (These are also cross referenced in AS 3992:1998 Table 5.3 and AS
4037:1999 Table 2.1).
Bulks
Bulks include flanges, fittings, valves, pipe, tubing fasteners and instrumentation components
which are generally delivered in large lots with or without individual identification.
Contractor
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
Inspection Lot
An inspection lot is a group of components from the same heat number or heat treatment
batch from which a sample is drawn. For fasteners, a lot is a group of similar components in
terms of alloy type and size.
Manufacturer
See Supplier.
National Standards
A National Standard is a standard that describes the methods for conducting a test that has
been issued by an independent national authority such as Australian Standards, ASTM, ISO,
ASME or similar.
PMI (marking)
“PMI” marking on an item indicates PMI Verification has been performed on at least one
other item from the representative sample (i.e., the item stamped “PMI” is one on which PMI
Verification has not been performed).
PMI Procedure
A PMI procedure shall consist of the following minimum information:
The PMI equipment to be used;
The equipment calibration requirements, including pre- and post-examination checks
for equipment accuracy against known samples traceable to a National Standard;
The critical elements to be verified for each alloy type tested;
The PMI acceptance and rejection criteria;
The methods employed for PMI testing, marking, and controlling of materials
examined prior to use in fabrication;
The PMI and PMIV marking requirements, including methods, timing, and locations;
and
The documentation and traceability methods used for both accepted and rejected
materials
PMIV (marking)
“PMIV” marking on an item indicates Positive Material Identification Verification has been
done on that individual item.
Principal
The Principal is the party, generally being Santos Ltd, which initiates the Project and
ultimately pays for its design and construction. The Principal will generally specify the
technical requirement. The Principal may also include an agent “Third Party Inspection
Agency (TPIA)” or consultant to act for, and on behalf of, the Principal.
Representative Sampling
Representative Sampling is PMI testing of a sample, consisting of one or more pieces or
components selected at random from an inspection lot, which will be examined to determine
acceptability of the inspection lot.
Shall
The word 'Shall' indicates a requirement.
Should
The word 'Should' indicates a recommendation.
Supplier
The Supplier (refers to Manufacturer or Supplier) is the party which manufactures or supplies
equipment, materials and services to perform the duties specified by the Contractor.
WPS
A Weld Process Specification.
XRF
X-Ray fluorescence, including XRF analyser, being a device for measuring metal
composition using X-ray fluorescence analysis.