@ “=. TOYO ENGINEERING INDIA LIMITED MBOP-DCU Project, Phase-lll, MRPL, Mangalore PROCEDURE FOR POSITIVE MATERIAL «| IDENTIFICATION TESTING DOCUMENT No. TOYO/MBOP/PMI/WP — 008 Rev. 0 PROJECT NAME. MBOP-6276-DCU Project, MRPL, Mangalore. CLIENT M/s. Mangalore Refinery and Petrochemicals Ltd. PMC M/s. Engineers India Limited. CONTRACTOR Toyo Engineering India Limited. ly, | =n) Rds | (Ny Fo [oar ta [inet trapno [CNRS p.runseat | WAU Ta | Frew) bate | Deserston | Pega” | Fei” eee eviewed by EIL & Bevewee Ronan Kumar aera Het its (FA /AGNE (C) Gorg.gs., i. A. ae, HTT lc, twAPL Site, Mangalore a, shReReevel griilvasan corarette Prefer sraeras Resident Construction Man~ge EIL, MAPL Phase Il Site Wangalore - 578 030i) ZToyvo ENGINEERING INDIA LIMITED PROCEDURE FOR POSITIVE MATERIAL | Doc. No. | TOYOMBOPIPMINIP-008 IDENTIFICATION TESTING a i secraow ~ PROJECT: MBOP-6276-DCU Project, Phase-tll, MRPL Page | 1 of 5 i CONTENTS: Page No: 1.0 SCOPE 2 20 REFERENCE DOCUMENTS 2 | > 30 PERSONNEL QUALIFICATION 2 1 4.0 EQUIPMENT 2-3 I 5.0 SPECIFIC APPLICABILITY 3 i 60 EXCLUSIONS 3 7.0 SURFACE PREPARATION 3 8.0 EXTENT OF PMI 3-4 | 9.0 PROCEDURE 4 10.0 ACCEPTANCE CRITERIA 4 i 110 NON CONFORMITIES 5 12.0 RECORDS 5 13.0 SAFETY 5 | | | a Aan? rer.air€ Hrerare /.R. Meshram aft, atic (fae) /St. Engineer (Mect) sé ere ume Sata. WES, ATS@tTovo ENGINEERING INDIA LIMITED PROCEDURE FOR POSITIVE MATERIAL Doc. No.: | TOYOMBOP/PMINVP-008 Rev. 0 IDENTIFICATION TESTING Date: 05.07.2010 PROJECT: | MBOP-6276-DCU Project, Phase-ll, MRPL__| Page 20f5 1.0 20 3.0 40 44 SCOPE ‘This covers requirements and procedure for PMI (Positive Material Identification) of AS (Alloy Steel) and SS (Stainless Steel) materials & weld joints of Piping System / pressure parts being constructed for Balance of Plant Delayed Coker Unit at MRPL (Mangalore Refinery and Petrochemicals Limited), Mangalore. This testing is carried out to assure that the basic chemical composition of alloy materials conforms to the material specification. REFERENCE DOCUMENTS The applicable codes and standards reference shall be: a) ASME Sec II Part A,B & C b) ASME B31.3 ©) EIL Specification No.: 6-82-0002 Rev. 1 dated 02-01-2007. In case of any conflict between this procedure and Ell. specification, the later shall govern. PERSONNEL QUALIFICATION ‘The operating personnel shall have experience in handling end operating the PMI instrument, The interpreting personnel shall have adequate knowledge of material specifications, grades, types, their properties and chemical composition, all aspects of operation of PMI equipment including the method of testing. Qualification / Experience documents of the person performing the PMI test including his training and experience shall be eubmitted to ElL / Owner for review and approval. EQUIPMENT The PMI equipment shall be a portable spectrometer / alloy analyzer. It shall be capable of analyzing and providing quantitative and recordable composition of material (including weld) that ‘contains alloying elements such as Chromium, Nickel, Molybdenum, and Vanadium and of any higher metallurgy which are intentionally added to enhance mechanical or physical properties or corrosion resistance. Portable X-ray Fluorescence (XRF) type analyzers such as Metorex X-Met 2000 or Met 5000 Metal Master or NITON II or equivalent shall be used for carrying out PMI. Identification of alloying elements, which distinguishes the material from other materials, will be sufficient. pare am. ABRET/M.R. Meshram rst ee nae 2 Gand.ge, ATLAS, EE, ER TS ey Site, Mangalore2toyo ENGINEERING INDIA LIMITED PROCEDURE FOR POSITIVE MATERIAL Dac, No. | TOYO/MBOP/PMIWP-008 Re IDENTIFICATION TESTING ev o | Date: 05.07.2010. PROJECT: | MBOPL6276-DCU Project Phase-ll, MRPL__| Page 30f5 42 5.0 6.0 The alloy analyzer shall be calibrated using known alloy standards for intended materials to be checked by PMI. Manufacturer's recommendation shall be followed in this regard. SPECIFIC APPLICABILITY The following items require PMI unless specifically exempted through a Wé by Owner, 4) All piping components ») Weld joints and attachments in direct contact with pipe ©) Plates 4) Tubing ©) All pressure containing piping components including, thermowells, instrument manifolds, fasteners, RTJ gaskets etc. J Deviation permit EXCLUSIONS ‘The following items are exempted unless specifically designated for PMI in the purchase order / contract: 2) Machinery parts b) Electrical components ©) _ Instrumentation components 4) _ Internal valve components ¢) _Intemal non-pressure containing baffles, trays, tray clips, supports, Support rings etc. f) Welds which are not integral with pressure parts like piping support welds & structural parts 7.0 SURFACE PREPARATION 8.0 a) Filing may be done on welds to expose fresh metal for getting better response from the instrument. ‘The contact area of the surface shall be dry, clean and free from dirt, grease, scale, powder, slag, spatter, etc., which may obscure / interfere with the examination. EXTENT OF PMI PMI shall be done on each component (100% PMI inspection) including welds, unless specifically ~ ‘exempted by EIL / Owner. pocee® a UH.oM. FaNTH/ MR. Meshram ‘aft afro (aifren) /Sr. Enaineer (Mech).@Toyo ENGINEERING INDIA LIMITED PROCEDURE FOR POSITIVE MATERIAL Doc. No.: | TOYO/MBOP/PMINP-008 Rev.: 0 IDENTIFICATION TESTING — Date: 05.07.2010 PROJECT: MBOP-6276-DCU Project, Phase-Ill, MRPL Page 40f5 b) _All-nen pressure parts such as pipe supports shall require 10% PMI (i.e. 1 out of 10 such ‘components). For each non conformity detected, the extent of PM shall double. ©) One stud & nut assembly for each flange joint shall require PMI. If any non conformity is detected, all studs & nuts in the particular piping loop shall require PML 9.0 PROCEDURE 9.1. PMI shall be carried out prior to Hydro / Pneumatic Testing. PMi certification shall be a part of NDT clearance of test loop / pack for testing. 9.2 Each component including weld to be examined shall be identified with unique test number and clearly marked in each drawing, 9.3 The identification details of the component / weld including the drawing no., line no., ete, shall be fed as input information to the analyzer (PMI instrument), 9.4 After ensuring the required surface preparation, the PMI analyzer shall be placed such that its probe is in proper contact with the surface of the spot / area to be examined. 9.5 After ensuring proper contact, the Instrument shall be triggered on so that the instrument will start analyzing the composition. 9.8 After obtaining the specification of the material examined as the output information from the analyzer, the instrument shall be triggered off, before moving to next component for testing Generally, 5 to 10 seconds exposure (ID-mode) is sufficient. 10.0 ACCEPTANCE CRITERIA 10.1 BASE METAL PMI test results showing presence of characteristic elements upto 10% less than the minimum specified value in the material specification and upto 10% more than the maximum specified value in the material specification shall be acceptable. 10.2. DEPOSITED WELD METAL For deposited weld metal between base metals of the same specification using matching ‘consumables, the recorded presence of characteristic elements upto 12.5% less than the minimum specified value in the welding consumables specification and upto 12.6% more than the maximum specified value in the welding consumable specification shall be acceptable. peti A var. Fbiera/M.n. Moshram AR, afc (ara). Enqnes Mecty piped yn panes UhaieaLerdeers