PL | Saudi Q Tech LTD Co (GENERAL PROCEDURE PROCEDURE FOR POSITIVE MATERIAL IDENTIFICATION oc, 8 GTECHOC-NOT-013 Revo Date 251062013 Page tf SAUDI Q-TECH LTD CO. GENERAL PROCEDURE NOT & INSPECTION SERVICES Of. CONTROLL PROCEDURE FOR POSITIVE MATERIAL IDENTIFICATION OL: MASTER COPY Q.TECH-QC-NDT-013 26082013 Issued for approval Date Deseripton af Revision Prepared Approved ‘This document popesty of SAUDI G-TECH who wil safeguard sgh according to the ell and pena prewsions of te lawSaudi ech LTD Co, Deen QTECH-ACNDT-O18 CGNERAL PROGEOURE ev.01 | Date 2ecanore PROCEDURE FOR x POSITIVE MATERIAL IDENTIFICATION Peat ISSUE & REVISION STATUS sw | Revisea pate | Dee. No. Rev No. Change Reference Remarks 1 | maveaoie | aTecnacnoros | co = : 2 | 2eoscors | arecHacnoreis | oi $ Reference documanis SWE POTS ae Eaton OTECHGENDTOS | OF Tr Records nl Regan CTehOCRER OTS PU1X Saud TechLAD Co, GENERAL PROCEDURE PROCEDURE FOR POSITIVE MATERIAL IDENTIFICATION (Doe. Q.TECHOC-NOT.013 Rev.c1 ate 261082019 Poge Sof tt INDEX 1 Scope. 4 2 Conflicts and Deviations. sensei 4 3__ References, 4 4__Definitons. 5 5 Responsibilities... & 6__ Extent of Verification, 6 T__ Procedures, z B Methods... 7 9 Acceptance Criteria. 8 40 Rejection Procedures. 8 11__Records and Reports, aint 10 12 Inspection sass eee 10 13 Marking and Colour Coding, : u }| Suu tech LTD Co, Doe. 8 TECH GO-NDT-O18 ‘GENERAL PROCEDURE. Rev 01 Cate 28082013 | ech PROCEDURE FOR ee s POSITIVE MATERIAL IDENTIFICATION Page sof 4 44 42 13 a @ (3) a © 14 15 16 SCOPE This standard covers the requirements for positive material identification (Ml) oF ASME 631.3, ASME 831.4, and ASME B31.8 pressure-containing alley material components and other piping or equipment where specified in the SAMS catalog description, SAMSS, or purchase order. Pressure-containing flange bolting, welds, weld overlays and cladding are included. The intent of this standard is to minimize the potential for occurrence of leaks and ruptures in the covered systems. The requirements in this standard shall apply to PMI of both new components and repair or replacement ‘components. The requirements apply to plant, shop, and field fabrication. Unless specifically required in the purchase order or subcontractor requisition, the following components and materials are exempt from PMI Non-pressure components. Pressure and non-pressure components from carbon steel or cast irons. Filler metal for \wolding carbon stool is also exempt from PMI, Rotating equipment internals, and associated seal, lube oil, cooling water and steam ‘equipment and piping. Valve internals. Piping components in ASME B31.3 Category D Service or equivalent. If specified in a project design document, purchase order, or Client catalogue description, PMI is required for operationally important non-pressure components. Also, PMI of replacement components shall be required, This standard [s intended to ensure that the nominal composition of the alloy components and associated welds have been correctly supplied and installed as specified The testing methods outlined in this, standard are not intended to establish the complete conformance of a material to the material ‘specifications, PM testing shall be performed at 2 point in time that ensures proper alloy materials have been used in the fabrication of an identifiable assembly. Usually this is during fabrication or immediately prior to fabrication. Although manufacturing quality control is an important issue, testing performed by a manufacturer or suppiier of raw material or loose components is not considered to be PMI testing ‘Whore applicable, this entire standard shall be attached to and made a part of purchase orders. Retroactive PMI testing of existing systems and stocked materials shall be performed upon the recommendation of a Risk-Based Assessment Team, of if eecommended by the Consulting Services. Department, or by decision of the piant manager. During or subsequent to the engineering review of a project proposal, to preclude alloy substitutions selected PMI requirements may be adopted for certain carbon stee! components and Weldments by agreement of the proponent organization and the Consulting Services Department, Factors to be considered include wet, sour service, the potential for mixing of carbon steel and alloy components and filler metals at the job site, the potential for catastrophic failure, and other related provisions in the project Quality Pian, CONFLICTS AND DEVIATIONS Any conflicts between this standard and other applicable Client Specifications, or industry standards, ‘codes, and forms shall be resolved in writing by the Client Representative through the Client Engineering Department. REFERENCE DOCUMENTS The selection of material and equipment, and the design, construction, maintenance, and repair of equipment and facies covered by this standard shall comply with the latest ecition of the references listed below, unless othenwvise nated, American Petroleum Institute APIRP 578 Material Verification Program for New and Existing Alloy Piping Systems, 2010 Bdttion American Society of Mechanical Engineers ASME Boiler and Pressure Vessel Code Section I: Parts A, Band C, 2013 ASME B16,20 Spiral-Wound Gaskets, latest Kaition, 2012| Saudi @-TechLTD Co Deen ATECHACHOTOIS | ‘GENERAL PROCEDURE -——_—, ——_ —| T Rev. 1 Date 260072013 lech PROCEDURE FOR free erect eee x POSITIVE MATERIAL IDENTIFICATION Agosern | ASME B31.3 Chemical Plant and Petroleum Refinery Piping, 2012 Edition ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids, 2012 Edition ASME B31.8 Gas Transmission and Distribution Piping Systems 2012 Edition I American Society for Testing and Materials ASTM A193 Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service, latest Edition ASTM A751 Standard Methods Practices and Terminology for Chemical | Analysis of Steel Products, latest Edition 4 DEFINITIONS Alloy Material: Any metal (including filler metals for welding alloy materials) containing alloying elements such as chromium, nickel, or molybdenum, that are intentionally added to enhance mechanical or physical properties andlor corrosion resistance. Does not include high-strength lovealloy | (microalloyed) steels and Impact-tested carbon steels, PMI: Positive Material identification ~ Verification that the nominal chemical composition of an alloy material is as specified and ordered. The term applies to programs, processes, procedures, and tests in accordance with this standard, PM Testing: Any physical evaluation or test of a material, meeting the requirements of this standard, to confirm that the material which has been or will be placed into service is consistent with the selected or specified alloy material Equipment Manufacturer: The company responsible for the plant or shop manufacturing of pressured equipment that is within the scope of this standard, | Fabricator: The company, organization, or agency responsible for the shop or feld fabrication or assembly of piping and pressured equipment within the scope of this standard. Material Specifications: ASME Section Il, Parts A, B and C, or the relevant ASTM, or any other material specification required Nonpressure Components: Items that are not part of the pressure containing envelope, and, therefore, do not affect the pressure retaining capacity of pressured components. | Pressure-Containing Components; Product forms used for the fabrication of pressured piping and equipment, including but not limited to: shells, heads, tubesheets, nozzles, tubes, flange boting, gaskets, forgings, flanges, individual pipe lengths and ftings such as tees, elbows, reducers, and special pipe components, valve bodies and bonnets, bodies of pressure-containing instruments, pressure-containing welds, weld overlays and cladding, expansion joints and bellows Glient inspector: The person or company authorized by the Client Inspection Department to verity Implementation of the requirements of this standard, | 5 RESPONSIBILITIES 5. For all new projects, Project Management or their designated representative shall be responsible for Insuring that proper PMI programs and procedures are developed and PMI testing is performed by the Equipment Manufacturer or the Fabricator, as applicable, prior to equipment installation and start-up. Project Management is normally supported by Project Inspection and Vendor Inspection, 52 For maintenance and refurbishment activities, the applicable plantifacllty manager or his designated | representative shall be responsible for insuring that PMI programs and procedures have been developed and Pil testing is performed prior to equipment start-up,Saudi Q-Tech LID Ce, ee n QTECH-OC-NOT-O13 GENERAL PROCEDURE ireeieeeeee aera ac Rev. 01 Date 260872013 lech PROCEDURE FOR - & POSITIVE MATERIAL IDENTIFICATION Page Sof 14 ‘Commentary Note: Refinenes and large plants should acquire their own equipment for PMI testing. The Inspection Department has the capability for providing some PldI testing support. For large maintenance projects, a focal Saudi Aramco approved vendor of Pll services can be retained, 6 EXTENT OF VERIFICATION 6.4 The PMI program covers alloy material, pressure-containing components in shop and field fabricated equipment and piping (both base metal and welds) and materials used for repair or replacement of pressure containing components. 62 One hundred percent PMI testing (each component and weld is tested) shall be performed on all pressure ‘components and welds of alloy materials, within the scope of this standard, with the following exceptions: Exceptions: (1) Tubes for shell and tube and air-cooled heat exchangers and for fired process heaters and boilers: 10 tubes or 10%, whichever is greater, from every heat number shall bo ‘chosen at random and tested prior to the installation of tubes into tubesheets. Also note the rejection procedures in Section 10, (2) This testing requency shall elso apply to any replacement tubes for equipment listed in 6.2(1). (Alloy flange bolting may be verified by random 2% PMI testing if he project Quality Plan ‘contains speaife provisions for color coding, segregation, and visual inspection that are acceptable to Project Inspection and the proponent organization. The project inspector may implement up to 100% PMI testing of alloy botting any time he determines that other quality procedures are not adequate or are not being observed, 6.3 PMI testing of weld material shall be performed in the same manner as for the adjacent base metal 64 The required number of PMI tests shall be as follows: (1) One test for each pressure-containing component. If an assembly contains a number of components (parts), one test is required for each component (part) (2) One test for each pressure-containing weld and wold repair, plus filer metal testing (Para. 6.7) Commentary Note: A strict filer metal control program is vital. Generaily, only the proper welding electrodes for the current welding should be allowed at the welding site. 6.5 The elements of the basic alloy materials to be verified shall be in accordance with Table 4 Table 1 Basie Aloy Tiements tobe Veried Case MyBaona, Mangoneee Mo}ederun, and Chromium and Molybdenum hrm Maybeoram stool Nekel aol Nika Rogier carbon ade sainess sols | Chromium, Nickel, and Nolbdenurm Low corbon staniss stele trou, Nika, Mojedenu and Carbon Slubizd tints stool ‘Shremian, Nikal, Molden, Tianiun facpietea each "fick, ron, Copper, Chromium, and ‘| Nickel-based alloys Molybdenum, ‘Copper, Zinc, and other elements specified in eee purchase ofder or SAMS catalog descriptionSaudi Q-Tech LID Co, Doe. n QTECH-GC-NDT-O13 oN BROCEDURE Revo1 | oaeasoen0%e een pRoceouRe FOR POSITIVE MATERIAL IDENTIFICATION peataitt 68 For aloys not covered in Paragraph 65, the Supervisor of the Materials Engineering Unit of MESCCDICSD shall be consulted 6.7 __ PMI Testing of Welding Consumables 6.7.4 Inaddtion to the PMI testing of completed pressure-containing welds, when welding of alloy materials is conducted, one electrode of wire sample trom each lt of filler metal shall be positively identified The remainder ofthe lt shall be compared to the identified rod to verly that the markings of the wires/electrodes are correct. 6.72. PMI testing of weld metal (¢.g., deposited or undiluted weld buttons") is an acceptable alternative to PMI testing of an electrode or wire sample provided itis conducted immediately prior to welding or during the welding process, Commentary Note: ‘Some weld rods have the alloying elements contained inthe tlux, and do not meet the alloy specification until welded. 6.7.3. Incases where PMI testing of the completed weld Is nat possible because of geometry (e.g., small fillet welds and narrow root beads), PM| testing of filer metal lots and visual inspection of electrodes as desoribed in 6.7.1 and 6.7.2 is an aopeptable substitute for testing of the completed weld. 7 PROCEDURES 7A The Equipment Manufacturer or the Fabricator, as applicable, shal implement a written PM Procedure, covering testing and reporting, which shal be mace available to the Saudi Aramco Inspector for review, acceptance, and verification of implementation. 7.2. The Equipment Manufacturer or he Fabricator, as applicable, shall ensure that Pll Is performed prior to completion of fabrication in the shop or atthe sie, for welds and for ield-assembled items not previously positively identified 7.3. The Client Inspector shall have the option to witness any of allof the PMl testing. The fabrication status schedile shal be submited to Inspection two weeks before the fabrication 74 PMI testing shall not be considered as a substitute forthe required materials test reports. 715 Material test reports and welding with an approved welding procedure shall not be considered as alternatives to PMI testing and the requirements of this standard. 7.8 Each Equipment Manufacturer and each Fabricator shall use only trained, qualified, and experienced operators to perform PMI activites, Operator records attesting to such taining, qualification and experience shall be avallable for Cilent Inspector for review and approval 8 METHODS 8.1 The instruments and methods used shall be suitable for identifying the material by quantitative measurement of the major alloying elements required in the applicable material specification or welding procedure specification, 82 The primary acceptable method is X-ray emission analysis, also known as X-ray fluorescence (XRF) analysis with a calibrated portable instrument. See also API RP 578 Para, 6.2.1 Because of inherent limitations of XRF, itis not possible to detect all elements. Elements lighter than sulfur (S) can not be detected using portable X-ray fluorescence spectrometers, Therefore, this technique can not be used to detect carbon (C) An optical emission spectrograph may be used to check for all the required elements, including carbon. Ail burn damage shall be removed by grinding. See also API RP 578 Para. 5.2.2. 83 As an allemative, a chemical analysis of samples cut out from the pieces requiring PMI, in accordance vith one of the methods in ASTM A751, may be used to check for the alloying elements required by this standard. 84 Additional PMI testing techniques as listed in API RP 578 will be considered for use upon written request to the Company or Buyor Representative, who shall follow internal company procedure, 85 Prior to commencing PMI testing, instrument operators shall be qualiied to operate approved equipment on a representative sample of the alloy materials with 100% correct assessment as the performance ctiteria. The instrument operator shall work to a written procedure and shall have beenSalk Q-Fech 1D Co, oe. O.TECHOC-NOT-O13 PROCEDURE FOR POSITIVE MATERIAL IDENTIFICATION Page 8 of 1 GENERAL PROCEDURE Rev.01 Date 2510872013 ech trained to use the instrument in accordance with that procedure, Training shall be documented, 86 — The person(s) performing the PMI testing shall calibrate andlor verify the test equipment performance 28 specified by the equipment manufacturer. The Pll test procedure shall specify the frequency interval for this calibration / verification. If calibration procedures are not provided by the equipment manufacturer, they shall be established by the owner/user. Typically, these procedures shall include calibration/verification using certified standards, 87 If sample removal is used, a written procedute for Identification and traceability to original material is required, 88 Both inside and outside weld surfaces shall be tested where accessible, PM testing of welds shall be done after removal of slag andlor oxide from the weld surface, See also 6.7.3, &9 The surface to be analyzed shall be clean bare metal, free of grease or oll, with a eurface finish as specified by the instrument manufacturer. Commentary Note: Gonerally a fresh 60 grit finish and flat surface are required for the optical emission ‘spectrograph, while no minimum surface finish is required for portable XRF analysis, only that tho surface be clean bare metal. 9 ACCEPTANCE CRITERIA 94 For acceptance, it must be demonstrated that materials contain the amounts of alloying elements shown in the material specification. Alloys hall be acceptable Ifthe alloying elements are each within 10% of the specified range of values. 9.2 Welds with consumables that match, or nearly mateh, the base metal composition shall be within 12.5% of the ranges allowed in ASME Section IIC for each element. 9.3 Acceptance criteria for dissimilar metal alloy welds and weld overtays shall be in accordance with the welding coneumable specified in the approved welding procedure. The effects of dilution between the different base metals and the filer metal shall be taken into account for determining the nominal as- deposited weld metat composition 10 REJECTION PROCEDURES 410.1 If the PMI testing results fall oulside the acceptable range using @ method described in Section 8, the Equipment Manufacturer or the Fabricator, as applicable, has the option to conduct @ more accurate analysis at his own expense to determine the component acceptance such as obtaining a chemical analysis performed by an independent testing laboratory. The alternative test method or independent laboratory must be acceptable fo the Client Inspector. The results of the more accurate test ‘method or independent chemical analysis shall govern. 10.2 I any component or weld is found unacceptable, it shall be replaced and the replacement shall be alloy Verified In accordance with this standard, 40.3 Procedures shall be in place to ensure that rejected components are segregated and properly identified to prevent reuse. 10.4 Where one of the tubes for heat exchangers, fired process heaters, and boilers is found unacceptable, ail remaining tubes required of the particular alloy shall be tested for the individual equipment. 10.5 Allrejected tubes shall be replaced and 100% of the replacement tubes shall be subjected to PMl testing in accordance with this standard. 11 RECORDS AND REPORTS 11.4 Shop Fabrication Records 44.4.1 A detailed recording/iogging procedure shall be prepared by the Equipment Manufacturer or shop Fabricator. 14.4.2 The log shall identify each component and weld corresponding to an individual equipment item orSandi Teen LTD Ca One. n QTECHAG-NDT-OFS GENERAL PROCEDURE [rect | owe200s20%3 | ae PROCEDURE FOR POSITIVE MATERIAL IDENTIFICATION Page Sof 1 piping spool and shall include the equipment or spool number and purchase order number. 44.4.3 The log shall identify all components and welds that have been alloy verified and the results of testing. 11.1.4 Test results shall include measured percentages of alloying elements for components that were ‘accepted or rejected and for those components that were rejected but accepted based on independent chemical anaiysis. 11.4.5 The Equipment Manufacturer shall prepare a detailed Pil map of the pressured equipment being fabricated. The map shall show the allay material specttication of each alloy component and the, extent of Pil required in accordance with this standard. 11.2 _ Field Fabrication Records 11.2.1 At least two weeks prior to the commencement of fabrication, the field Fabricator shall estabilsh and. present to the Client Inspector for review the proposed testing, iogging, identification, and final installation procedures fr all components requiring PMI testing onsite (such as fabricated pressured equipment, piping, valves, and welds). 11.2.2 Shop-fabricated alloy pressure equipment or piping assemblies that have been alloy verified by the ‘shop Fabricator need not be re-verified in the field, However, the field Fabricator shall have available, for review, the shop Fabricator's report of PMI testing. Material certificates are not allowable substitutes, 11.2.3 The field Fabricator shall prepare a detailed Pll map of the pressured equipment being fabricated ‘The map shall show the alloy material specification of each alloy component and the extent of PMI ‘required In accordance with this standard 113 Final Report 14.3.4 Prior to final acceptance of alloy pressured equipment or piping, the Equipment Manufacturer or the Fabricator, as applicable, shall prepare a complete PMI Testing Report containing all relevant data, ( For pressured equipment, the PMll Testing Report shall be included as part of the Equipment Data Book 14.3.2 The PMll Testing Report shall be reviewed by the Client inspector prior to final acceptance. ‘See Attached PM Report Format : RP-Q.TECH-NDT-013-E 42 INSPECTION 42.4. The responsible Inspection Organization shall ensure and verify that alloy materials have been verified by PM testing as required. 42.2 During repairs of alterations of materials required to be PMI tested, the responsible Inspection Organization shall verify the correct compositions of the shop and field welds. 42.3 For applicable purchases, materials shall he subject to inspection by the Client Inspector in accordance: with Client Inspection Requirements. 13 MARKING AND COLOR CODING 13.1. Verification Marking 43.1.1 Paint marking shall be done with water-insoluble material that contains no substances that harmfully affect the metal at ambient or elevated temperatures. In particular, the marking material shall be free of lead, sulphur, zine, cadmium, mercury, chlorine, or other halogens. 13.1.2. All components, and welds that are found unacceptable shall be marked immediately wth a circled red "X” pending resolution in accordance with Seotion 10, 13.1.3 All verified materials with an acceptable analysis shall be marked with the jetters "PMI" using a cortified low-stress stamp. The marking shall be placed as follows: Pipe: One mark, 75 mm from one end on the outer surface of the pipe. This marking shall be in addition to the requirements of PFI ES-22. Welds: Adjacent to the wekder’s mark on the weld. (Welds on tubes for heat transfer equipment shall be ( marked by ether stenciling or vibro-etching on the tubeshoe!). Fittings and Forgings: Adjacent to the manufacturer's markings. Valves: Adjacent to the valve manufacturer's markings on bodies and other pressure parts. Castings: Adjacent to the casting manufacturer's markings and heat numbers,| Suudi Q-TeehLTD Co Deen aTecHacxoro:3s | GENERAL PROCEDURE | Rev.ct ate 281082013 4 Been | PROCEDURE FOR ees |____PostivenATERIA eFCaTIoN Page 100844 13.4.4 132 13.24 13.2.2 13.2.3 13.2.4 13.2.5 13.2.6 13.2.7 13.2.8 13.29 13.2.10 132.11 43.212 13.213 13.22.14 Plates: 75 mm from one edge, adjacent to manufacturer's markings. Tubes: Stenciled, 300 mm from each end ‘When heat treating is performed after Pil, the identification marking must be recognizable after heat treatment, PMI markings shall be transferred when a plate or pipe is cut Coton Gonna The colour coding system for material identiication described herein is intended to help prevent fabricators from using incorrect alloy matetial. The principal purpose of color cading is visual identification during storage end after the components have been cut for fabrication, Colour coding is not a substitute for PM testing or other, permanent manufacturers’ markings required by ASTM or other specifications. Permanent manufacturere! markings shall net be obscured by color coding Colour coding may be done by the material manufacturer of material supplier. Color coding need not be retained after painting, Prior to coding, surfaces shall be clean and free of dit, loose scale, and oil, Paints used for coding shall be durable, bright, and distinctive and shall not contain substances that would harmfully affect the ‘material at ambient or elevated temperatures. In particular, paints ehall be free of lead, sulfur, zine, cadmium, mercury, chlorine, and other halogens. Each component shall be coded in accordance PFI E'S-22, and shall have painted characters Indicating the specification number of the material iit is not permanently marked or tagged according to the applicable material specitication, Valves, flanges, and fittings do not require color coding if these components are permanently stamped ‘or tagged by the manufacturer. Ifthe materials are not easily legible, valves, flanges, and ftings shall be coded with a stripe of 5 mm minimum width. The color coding on vaives should indicate the valve body material ASTM A193, Grade B7 stud bolts do not require color coding If the grade of the material is stamped on one end of each bolt. Spiralavound gaskets shall be color coded in accordance with ASME 816.20. Sheet type gaskets do not require color coding, Pipe and Fittings: Each length of pipe and fitting shall have a 5 mm or larger stripe running full length. One inch NPS and smaller may have 2 3 mm stripe running full length Valves: When required, stripe actoss the body trom flange to flange or end to end Flanges: When required, stripe across edge up to hub. Bolting: When required, stripe around the midpoint of each bolt or stud. Plate, sheet, and strip: Stripe on surface near two perpendicular edges for entire length. ‘Tubes and Bars: Stripe entire lenath.eae Gorn area aon a saci) esses es rnoceaine ron x POSITIVE MATERIAL IDENTIFICATION. Rao Attached PMI Report Format : Q.TECH-QC-REP-013 PMI ecres caso ional Crean fot mreunsTED TV Toxo ise Das : . ee [v2 DEScHPTiGN OF COMOMENT KAMIGD: sisena arecCATON (Giyes feces tne trae te eect ered cult type ge OEE a surunactane cons/acGarancassrasnanoe | TsTING MAGI {38 £3 cceanoleats caamany vA Cua HOR: vas B snse 12 foe fh TT arene a a a (a a Sao Ta| mm [me ; 2 3 z 5 < : 5 : ji @ a w i we ® Ten Teta [ose i a = 7 — Soeur baa iat yaaete oe cea ati | oeelfte|eevea