DOW RESTRICTED - For internal use only Material Verification for Piping Positive Material...

DOW RESTRICTED - For internal use only

Material Verification for Piping

Positive Material Identification in Texas Operations

MyLearning Course Code 281258

PMI For Texas Operations \ MyLearning 281258

M. Stepien September 2010 DOW RESTRICTED - For internal use only

Introduction

• The intent of Positive Material Identification (PMI) for pipe systems is to reduce the likelihood of process safety risks by verifying that the installation of alloy and low alloy steel piping materials is consistent with engineering specifications.

• This discipline applies to Maintenance, Small Projects Construction Group (SPCG), and Engineering Solutions Construction.

You were invited to this training because your role has responsibilities in the PMI process.



Desired Outcomes

In this session we will; 1. Explain what Positive Material Identification for piping (PMI) is.2. Explain why we’re formalizing a PMI process.3. Provide an overview of the PMI process.4. Review role responsibilities.5. Review process steps.6. Review next steps.



TXO Operating Discipline Development Team

Sponsors• Wayne Muil, Site Maintenance Leader• Dave Rizzo, Engineering Solutions Construction Leader

Team• David Barber, Maintenance Technology Center• Mike Groth, Engineering Solutions• Gary Parker, Site Maintenance• Donny Stamps, Site Maintenance• Mike Stepien, Site Reliability



Dow’s Corporate Loss Prevention Principles indicate that we will use appropriate materials in our piping systems such that risks are managed.

• Our Process Safety efforts continue this thought through the Global Mechanical Integrity Safety Standard (GMISS) stating the use of proper materials in our piping systems.

• General guidance for verification of proper material usage follows the API recommended practice 578.

• EMETL Specification G8S-5002-03 Material Verification Program - Piping

Material Verification Program - Piping



Why add another requirement?Events

Exxon Coker – substitution of material resulted in Coker fire and fatalities

BP Texas City – wrong material re-installed resulted in major fire and equipment damage

Dow Chlor-Alkali Events (~$7MM impact)• Freeport ($600M replacement & 60MM lbs AC loss)• Plaquemine (EH&S incident (PS) & 12MM lbs AC loss)

Marsh Limited Insurance Audit Feedback (April 2008)

“We would therefore recommend that the site amends its material identification procedures (typically only depending on mill certificate checks) to include physical verification sampling of key alloys arriving at the warehouse and/ or the construction field.”



• The installation of alloy and low alloy steel piping materials shall be verified to be consistent with engineering specifications.

• This process applies to installation of new piping and work on existing piping.

• Pipe • Pipe Fittings (tees, elbows, reducers, blinds, plugs, stub ends, and

special pipe components)• Flanges, for lap joint stub ends, both the ring flange and piping

stub end will be analyzed.• Welds and consumables (electrodes & filler metal)• Special forgings• Process valve bodies (including control valves) and relief devices• Expansion joints and bellows

Scope

Material Verification Program - Piping



How was the PMI level established?

Business Tech Centers (using criteria in G8S-4001-65) determined Positive Material Identification (PMI) Inspection Levels;

• Level 1 – Sampling• Level 2 – Full Finished• Level 3 – Full in Process

Note: These inspection levels will be explained later in this presentation



(5) Considering (1) – (4) is more verification needed?

(4) Business Risk – LOPC or Reactive Chemical

(3) NFPA (Fire) Hazard Rating 3 or greater

(2) GMISS hazard class assigned or corrosive substance?

(1) Alloy or Low Alloy Steel Pipe Spec?

IF YES, the Business Tech Center:1. Determines the required inspection level.

2. Adds a standard note to the pipe spec.

IF No, no change.



What was the result of PMI criteria application?

The Impact

Out of ~1570 total pipe specs in CPPS, 700 are alloy pipe specs and of those 148 have Level 1 – 3 requirements (to-date)

Inspection Level Table (example on next page)



Material Verification Log Example

Some Level 3 Inspection Levels for Chlor Alkali



Chlor Alkali Example

PMI Inspection Level Note



Material Verification Inspection Requirements

Level 1 - Sampling• PMI by X-ray fluorescence or spark OES* for 25% of welds …• At least 1 test of each welder• At least 2 tests per pipe weld• A nonconformance will escalate testing coverage …• Piping removed and reinstalled must be PMI tested for verification

or labeled appropriately in the field

Technologies with L1 Requirements Identified include (but not limited to) Chlorinated Organics, Chlorohydrin Oxides & Glycols, Energy Systems, Hydrocarbons, Polycarbonate, Polyethylene, Polypropylene

* Optical Emission Spectrometer




Level 2 – Full Finished• PMI by X-ray fluorescence or spark OES for 100% of finished

welds …• Four readings 90 degrees apart for 3” NPS and larger, 2” and

less require 2 tests per weld• Piping removed and reinstalled must be PMI tested for

verification or labeled appropriately in the field

Technologies with L2 Requirements Identified include (but not limited to) Contract Manufacturing, EDC/VCM, Chlorinated Organics, Specialty Alkanolamines, Environmental, Energy Systems, Hydrocarbons, Styrene Monomers




Level 3 – Full in Process• PMI by X-ray fluorescence or spark OES for 100% of root passes …• Root pass tests will require 1 test per nominal inch …• Only 1 material shall be in the welder’s possession and tested.• Piping removed and reinstalled must be PMI tested for verification or

labeled appropriately in the field

Technologies with L3 Requirements Identified include (but not limited to) Chlor Alkali, EDV/VCM, Chlorinated Organics, Specialty Alkanolamines, Environmental, Polycarbonate, Styrene Polymers



Piping repairs must be requested against the

proper Equipment Group, Pipe Spec, Equipment ID

P01 Piping (Non Hazardous)

P02 Classified Piping

I80 Control Valves

P72 Valves

Maintenance Example for Executing Positive Material Identification

Continued on next slide



Plan for the required PMI

Level


Continued on next slide



Fabricate/Test or Repair/Test per PMI Level

Qualified Inspector1. Confirms testing2. QC DocumentationProvided by the PMI Technician




TXO Operating Discipline for Positive Material Identification

L3G (Level 3 Geographic) Texas Operations document

Positive Material Identification for Piping in Texas Operations

In this session we will review;

1. Role Responsibilities

2. Process steps for Maintenance, Engineering Solutions / Small Projects Construction Group

3. Measurements

4. Gap Resolution


What does success look like?



Weld Map (and Component Map)



PMI Inspection Report



X-RAY FLUORECSCENCE ANALYZERUsed for majority of PMI inspections 40 TO 50 Kv x-ray tube or < 50 mCi source



• Number of readings determined by pipe size

• PMI of root required for level 3

PMI OF PIPE WELD



Results Display

• Gives composition and alloy match

• Results data logged



Next Steps

1. DAS’s to focus on role specific tasks in Network meetings.

2. Review and acknowledge MOC Number: 11111112010110001, Positive Material identification for Piping in Texas Operations.

3. Complete My Learning Course 281258 in December.

4. Positive Material Identification in-effect on January 1, 2011.


Questions?

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