POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

DOCUMENT DISTRIBUTION
Copy Hard Electronic
Name
No. Copy Copy

00 Document Control

01 Team Onshore

02 Team Offshore

03 Team quality

04 Team Contracts

05

06

07

08

09

10

NOTICE

All information contained with this document has been classified by INPEX as
Business - Unrestricted and must only be used in accordance with that
classification. Any use contrary to this document's classification may expose the
recipient and subsequent user(s) to legal action. If you are unsure of restrictions on
use imposed by the classification of this document you must refer to the INPEX
Information Security Classification Directive or seek clarification from INPEX.

Uncontrolled when printed.

ii
 POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

TABLE OF CONTENTS
1 INTRODUCTION ................................................................................................. 1
1.1 Purpose ............................................................................................................... 1
1.2 Scope................................................................................................................... 1
1.3 Abbreviations ....................................................................................................... 1
1.4 Definitions ............................................................................................................ 1
2 REQUIREMENTS................................................................................................ 2
2.1 Extent of PMI ....................................................................................................... 2
2.2 Test Procedure .................................................................................................... 2
2.2.1 Shop Fabrication PMI Form................................................................................. 2
2.2.2 Field Fabrication PMI Form ................................................................................. 3
2.3 Examination Methods and Instruments ............................................................... 3
2.4 Operators............................................................................................................. 3
2.5 Acceptance Criteria and Rejection ...................................................................... 4
2.5.1 Acceptance Criteria ............................................................................................. 4
2.5.2 Rejection.............................................................................................................. 4
2.6 Marking and Recording ....................................................................................... 4

TABLE OF APPENDICES
APPENDIX A: Extent of PMI During Shop/Field Fabrication ................................................. 5
APPENDIX B: Example Shop Fabrication PMI Report.......................................................... 8
APPENDIX C: Example Field Fabrication PMI Report........................................................... 9

iii
 POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

1 INTRODUCTION

1.1 Purpose

Positive Material Identification (PMI) is used to ensure that the nominal chemical
composition of metals conform to the material grades specified. This minimizes the
potential for failure of equipment and components.

This specification describes minimum requirements and the extent for PMI to be
performed by Contractors, Vendors, Suppliers and their subcontractors (hereafter
collectively referred to as Contractor) to ensure that the nominal composition of the
materials specified have been correctly supplied and used as intended. If more
stringent requirements are specified in other project specifications or technical
documents those shall be applied.

Contractors standard processes and procedures for PMI shall be submitted for
Company review and acceptance.

1.2 Scope

This specification applies to areas of “critical” fabrication, procured equipment,

fabricated equipment and piping components for use in the Ichthys project facilities
that are fabricated from alloy steels including austenitic, duplex/super duplex
materials and nickel based alloys.

Where Contractor and Company representative agree that PMI is not warranted for
a specific scope of work, or should be reduced from those specified herein, then the
requirements of this specification may be waived subject to the authorised approval
of a Technical Deviation Request as outlined in “Change / Deviation Management
Requirements” specification C065-AG-SPC-0001.

1.3 Abbreviations

Abbreviation Definition of Abbreviation

PMI Positive Material Identification

1.4 Definitions

Term Definition of Term

Alloy Material whose specification contains measurable quantities of alloying

elements, i.e., steels containing more than 0.5% alloying elements

Material Material specification which defines chemical and mechanical properties of a

Specification particular material form as specified in the material requisition (e.g. ASTM)

Shop Fabrication Covers all works performed under equipment procurement orders

Field Fabrication Covers all works performed at module/assembly fabrication,

construction and commissioning sites

Document No.: C075-AQ-SPC-0006 Page 1 of 9

Security Classification: Business - Unrestricted
Revision: 3
Date: 13/10/2010
 POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

2 REQUIREMENTS

2.1 Extent of PMI

PMI shall be performed on pressure containing alloy materials and all associated
welds in accordance with Appendix A.

Non pressure containing alloy materials and all associated welds that are in contact
with a process medium, eg vessel internals, filter baskets, bar tees etc will be
treated the same as a pressure containing material.

Where identified as a requirement, PMI of materials as described in 1.2 shall be

performed for each heat, supplier and type, and documented by Contractor at
receipt of bulk materials and on receipt of completed equipment or assembled parts.

PMI shall be performed at receipt inspection stage or during the appropriate

manufacture or fabrication stages to ensure that only verified materials have been
used in fabrication and final assembly of items. Where contractor takes receipt of
packaged equipment that includes alloy materials, the contractor shall perform a
random 10% PMI verification check.

The chosen method of PMI shall not damage or leave un-repairable damage to the
material being tested.

An alternative to the physical PMI checking may be offered by the Contractor for
Company approval.

2.2 Test Procedure

Contractor shall submit a PMI procedure addressing all test equipment, testing
methods, operators, marking and blank test report forms.

2.2.1 Shop Fabrication PMI Form

The PMI form for Shop Fabrication (see Appendix B for an example) shall contain
the following information as a minimum:

• Name of Supplier/Vendor
• P.O./Contract number
• Item number and name of the fabricated equipment and piping
• Location where the test was undertaken
• Date of examination
• Name and signature of examiner
• PMI method/instrument used
• Listing of items with reference to the fabrication drawings/ spool drawings
• Type of alloy examined
• Conclusion (i.e., “Accept” or “Reject”)
• Mill certificate / heat number

Document No.: C075-AQ-SPC-0006 Page 2 of 9

Security Classification: Business - Unrestricted
Revision: 3
Date: 13/10/2010
 POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

• Number of pieces, items examined

A hard copy print out of the test result should be attached to the report.

2.2.2 Field Fabrication PMI Form

The PMI form for Field Fabrication (see Appendix C for an example) shall contain
the following information as a minimum:

• Name of Contractor/Subcontractor
• Contract number
• Location where the test was undertaken
• Date of examination
• Name and signature of examiner
• PMI method/instrument used
• Listing of items with reference to the fabrication drawings/ spool drawings
• Type of alloy examined
• Acceptance Criteria
• Conclusion (i.e., “Accept” or “Reject”)
A hard copy print out of the test result should be attached to the report.

2.3 Examination Methods and Instruments

• Portable X-ray fluorescence spectrometers with direct reading of alloy grade

or composition in the applicable range are generally acceptable.
• Portable arc-emission spectrometers with direct reading of alloy grade or
composition in the applicable range are generally acceptable.
• Fixed laboratory optical emission spectrometers may also be used where it
can be demonstrated that “cut off” samples are adequately traceable to the
original heat and batch.

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

2.4 Operators

Contractor shall submit qualification certificates of PMI operators demonstrating

ability and experience with the PMI equipment and testing procedure.

Document No.: C075-AQ-SPC-0006 Page 3 of 9

Security Classification: Business - Unrestricted
Revision: 3
Date: 13/10/2010
 POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

2.5 Acceptance Criteria and Rejection

2.5.1 Acceptance Criteria

Materials verified in accordance with this specification shall record the amounts of
alloying elements as specified in material specification data sheets and electrode
consumable supplier data sheets for as-deposited weld metal.

2.5.2 Rejection

Whenever material is identified as incorrect, the option is given to perform a more

accurate test (e.g. wet chemical analysis) to verify the material composition or to
reject the material. Where any material is found to be unacceptable after re-test it
shall be rejected including other materials from the same batch, heat or type.
Rejected material shall be suitably marked and segregated. The marking shall spoil
any existing marking or colour-coding to prevent accidental supply of the rejected
item.

If a weld fails PMI, remaining welds in the piece of equipment or piping shall receive
PMI. Additionally, other equipment or components being fabricated by that same
Contractor using the same welding procedure qualification in the same shop or field
location shall be reviewed for need of additional PMI. The required actions shall be
approved by Company.

2.6 Marking and Recording

"AV" (Alloy Verified) shall be marked by the PMI operator with a suitable marker
near the weld when the weld and both sides of base metal are PMI tested and
accepted, or onto the component for non-welded part. Any markers used for
identification shall not contain any substances detrimental to the corrosion resistant
materials.

All PMI results ("Accept" or "Reject") shall be recorded for each weld and
component subjected to PMI.

Document No.: C075-AQ-SPC-0006 Page 4 of 9

Security Classification: Business - Unrestricted
Revision: 3
Date: 13/10/2010
 POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

APPENDIX A: EXTENT OF PMI DURING SHOP/FIELD FABRICATION

(*) 10% unless reason for rejection then increase to 100% of that welder, material batch and/or component

Item Extent Notes

Subsea structures, umbilicals, Pressure Parts and welds 100%

risers and flowlines where CRA • Pressure containing alloy components and all associated welds.
materials are incorporated • 100% PMI of welds is defined as one location check of finished weld per each
continuous weld

Bolting materials 10% (*)

• An inspection lot is a group of the same alloy type and size

Pressure parts & welds 100%

• Pressure Vessels, Heat • Pressure containing alloy components and all associated welds after
Exchangers, Air fin Coolers, assembly.
Fired Heater and Boiler
• 100% PMI of welds is defined as 1 location check of finished weld per each
continuous weld
• PMI of welds shall include weld overlay unless wet chemical analysis by weld
deposit sampling is applied. Tube to tube sheet welds are exempted.
• PMI of heat exchanger tubes shall be 10% instead of 100%.
• Major alloy bolting require 10% PMI of each lot with minimum of 2 bolts.

Non pressure parts & welds in 10% (*) 10% per welder per longitudinal, circumferential and fillet welds
contact with pressure parts

Internals that are process 10% (*) 10% of all internals that are process wetted and/or located within the pressure
wetted and/or within the containing envelope, but not forming part of the pressure containing envelope.
pressure containing envelope
e.g. vessel trays

Rotating Equipment Pressure Casing & Weld 100%

• Pressure containing alloy components and all associated welds after

Document No.: C075-AQ-SPC-0006 Page 5 of 9

Security Classification: Business - Unrestricted
Revision: 3
Date: 13/10/2010
 POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

Item Extent Notes

assembly.
• 100% PMI of welds is defined as 1 location check of finished weld per each
continuous weld
• Major alloy bolting require 5% PMI of each lot with minimum of 2 bolts.

In-line Instruments Instrument Valves (control / 100%

relief valves etc) • Pressure containing alloy components and all associated welds after
assembly.
• 100% PMI of welds is defined as 1 location check of finished weld per each
continuous weld
• Major alloy bolting require 5% PMI of each lot with minimum of 2 bolts.

Other pressure containing parts 10% (*)

Pressure containing equipment, Pipe spools including fittings, 100%

piping & instrument in System flanges, subsea connectors & • Pressure containing alloy components and all associated welds after
equipment / Packaged unit and other pressure parts (except assembly.
Pre-fabricated Pipe Spools, Welds, Valves & Bolting Material) • 100% PMI of welds is defined as 1 location check of finished weld per each
Fittings and subsea spools(spool continuous weld
pieces and well jumpers).
Valves 10% (*)
• PMI of valves shall be applied to body, bonnet, cover and bolts of alloy
body/bonnet valves

Bolting Material 10% (*)

• An inspection lot is a group of the same alloy type and size.

Gaskets 10% (*)

Spiral wound and ring type joints (RTJ)

Storage Tanks Pressure Part & Weld 100%

• Pressure containing alloy components and all associated welds.
• 100% PMI of welds is defined as 1 location check of finished weld per each

Document No.: C075-AQ-SPC-0006 Page 6 of 9

Security Classification: Business - Unrestricted
Revision: 3
Date: 13/10/2010
 POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

Item Extent Notes

continuous weld
• For horizontal seam, 1 determination per every 10m length.

Field Installed Piping, Welds and Pressure Parts and Weld 100%
Fittings • Pressure containing alloy components and all associated welds.
• 100% PMI of welds is defined as 1 location check of finished weld per each
continuous weld

Document No.: C075-AQ-SPC-0006 Page 7 of 9

Security Classification: Business - Unrestricted
Revision: 3
Date: 13/10/2010
 POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

APPENDIX B: EXAMPLE SHOP FABRICATION PMI REPORT

Document No.: C075-AQ-SPC-0006 Page 8 of 9

Security Classification: Business - Unrestricted
Revision: 3
Date: 13/10/2010
 POSITIVE MATERIAL IDENTIFICATION FOR PROJECT EQUIPMENT AND MATERIALS

APPENDIX C: EXAMPLE FIELD FABRICATION PMI REPORT

Document No.: C075-AQ-SPC-0006 Page 9 of 9

Security Classification: Business - Unrestricted
Revision: 3
Date: 13/10/2010