RNP DCU Plant Project

CB&I s.r.o. Brno, NIS a.d., Novi Sad,

Czech Republic Serbia

Document Title: Positive Material Identification (PMI) of Alloys

Unit Code: General for all units

Document No: 172784-00-PR-SP-00002

CB&I Contract No: 172784 and 222121

Issued for Construction 2 15-Dec-17 MUrsu MHR MHR

Issued for Design 1 05-Jan-17 JLAS MHR MHR
Issued for Design 0 09-Dec-16 JLAS MHR MHR
Revision Descriptions Rev Date Originator Checker Approver

Page 1 of 14

"THIS DOCUMENT IS THE PROPERTY OF CHICAGO BRIDGE & IRON COMPANY (CB&I). IT MAY CONTAIN INFORMATION
DESCRIBING TECHNOLOGY OWNED BY CB&I AND DEEMED TO BE COMMERCIALLY SENSITIVE. IT IS TO BE USED ONLY IN
CONNECTION WITH WORK PERFORMED BY CB&I. REPRODUCTION IN WHOLE OR IN PART FOR ANY PURPOSE OTHER THAN
WORK PERFORMED BY CB&I IS FORBIDDEN EXCEPT BY EXPRESS WRITTEN PERMISSION OF CB&I. IT IS TO BE
SAFEGUARDED AGAINST BOTH DELIBERATE AND INADVERTENT DISCLOSURE TO ANY THIRD PARTY."
 RNP DCU Plant Project (WP1)
Document Title: Document No. Rev:
Positive Material Identification (PMI) of Alloys 172784-00-PR-SP-00002 2

Table of Contents
Contents Page

1.0 INTRODUCTION .......................................................................................................................................3

1.1 Purpose ..........................................................................................................................................3
1.2 Scope ..............................................................................................................................................3
2.0 REFERENCES ..........................................................................................................................................3
2.1 Codes and Standards ...................................................................................................................3
3.0 DEFINITIONS ............................................................................................................................................4
4.0 IDENTIFICATION ......................................................................................................................................5
5.0 SPECIFIC REQUIREMENTS ....................................................................................................................6
5.1 Acceptance Criteria.......................................................................................................................6
5.2 Non-Conformance .........................................................................................................................6
6.0 TEST EQUIPMENT ...................................................................................................................................7
7.0 DOCUMENTATION ...................................................................................................................................8
8.0 MISCELLANEOUS....................................................................................................................................9
9.0 APPENDICES............................................................................................................................................9
APPENDIX 9.1 ALLOY ELEMENTS REQUIRED FOR PMI INSPECTION..................................................... 10
APPENDIX 9.2 EXTENT OF PMI TEST REQUIREMENTS (NOTE 14) .......................................................... 12

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 RNP DCU Plant Project (WP1)
Document Title: Document No. Rev:
Positive Material Identification (PMI) of Alloys 172784-00-PR-SP-00002 2

1.0 INTRODUCTION

1.1 Purpose
This Specification is to provide the means to prevent a mix-up of materials and welds. The specification
covers the basic requirements for establishing a Positive Material Identification (PMI) procedure for
alloys which are required to be verified to meet the minimum chemical requirements. The procedure
will be used by the Supplier at Supplier’s facilities and at construction sites.

1.2 Scope
Alloys in hydrogen services or in high pressure services will always mandate a requirement for PMI/AV
in order to avoid catastrophic failure in the event of unintended materials being supplied. Other alloy
applications will require decision on application based on the cost-benefit or inconvenience of any
potential failure where the wrong material might be used during installation or fabrication.

2.0 REFERENCES
The following documents are referenced herein and form part of the technical requirements. Additional
documents, when applicable, will be listed in the Requisition. Current editions of the industry standards
including all mandatory addenda in effect at the time of the order shall apply unless otherwise
indicated.

2.1 Codes and Standards

API 578
ASME Section II, Part A
ASME Section II, Part B
ASME Section II, Part C
ASME Section IX
ASTM A193 / A193M
Material Verification Program for New and Existing Alloy Piping
Systems
Materials: Ferrous Material Specifications
Materials: Nonferrous Material Specifications
Materials: Specifications for Welding Rods, Electrodes and Filler
Metals
Welding and Brazing Qualifications
Standard Specification for Alloy-Steel and Stainless Steel
Bolting Materials for High Temperature or High Pressure Service
and Other Special Purpose Applications

ASTM A194/A194M Standard Specification for Carbon and Alloy Steel Nuts for Bolts
for High Pressure or High temperature Service, or Both

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Document Title: Document No. Rev:
Positive Material Identification (PMI) of Alloys 172784-00-PR-SP-00002 2

3.0 DEFINITIONS

Term Definition
Alloy Metallic materials that contain alloying elements, such as
chromium, nickel, or molybdenum, which are intentionally added
or used to enhance mechanical or physical properties and / or
corrosion resistance. The term “Alloy” is to include materials such
as non-ferrous grades including aluminium, cupro-nickels and
titanium or similar.
Alloy Verification (AV) Is interchangeably the same or equivalent procedure for PMI and
extends to the process of performing PMI. For the remainder of
this specification only PMI will be used.
Purchaser Means NIS a.d., Novi Sad, Serbia.
Contractor Means any private or public entity engaged and nominated by
the Purchaser to provide technical monitoring and supervision of
procurement, design, manufacturing and supply of equipment
and or entity responsible for Engineering and design,
Procurement, Construction and (Pre-) Commissioning of the
Project.
Carbon Steel Steel conforming to ASME Section IX and P-Number 1 shall be
considered carbon steel.
Contract Documents Contract Documents shall be understood to mean the contract or
subcontract along with its attachments and references.
Inspection Lot A group of like items from a single manufacturer from which a
random inspection sample is taken for testing.
Lot Size Number of pieces available in the inspection lot at the time a
random inspection sample is selected.
Manufacturer The vendor or supplier from which the Seller/Subcontractor buys
parts and/or materials.
Owner The Owner is defined as the ultimate user of the equipment or
piping.
Positive Material Identification A procedure used to verify that a metallic component used in a
(PMI) design meets the specified alloy material.
Random Inspection Sample One or more items selected at random, which shall represent the
general chemistry of the inspection lot.
Referee Examination Any questionable results which do not positively identify a
material examined, shall be re-examined by an alternate means
which can properly characterize the specified alloy.
Seller The party with whom the contract / subcontract is placed, as
shown on the face of the contract / subcontract.
Stock Material or equipment supplied from or stored within a common
source or area.
Supplier Seller or Manufacturer contracted to fabricate or supply an item
or service for the design, construction, operation and or testing of
an item or facility.

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Document Title: Document No. Rev:
Positive Material Identification (PMI) of Alloys 172784-00-PR-SP-00002 2

4.0 IDENTIFICATION
Mandatory PMI shall be included in accordance with the appropriate sections of this specification for
the following materials and typical equipment:

1 1 1
 Chromium-Molybdenum alloys (1 /4Cr- /2Mo, 5Cr- /2Mo, 9Cr-1Mo)
 Transfer line from Delayed Coker Heater (Stainless steel 347H)
1 1
 Coke drums material (1 /4Cr- /2Mo + 410S)
 Duplex Stainless Steels
 Alloy 825
 Stainless Steel 304(L), Stainless Steel 316(L) and Stainless Steel 410S Clad
 Other materials when PMI is specifically specified in project documents (such as
datasheet, requisition documents)

Elements of these alloys required for PMI inspection are listed in Appendix 9.1. Extent of PMI test
requirements is listed in Appendix 9.2.

PMI shall be performed at the point of application at a time which ensures that proper materials have
been used in the fabrication of an identifiable assembly (such as pipe lengths welded into spools or
plates welded into pressure vessels).

PMI, as defined in this document, is the responsibility of the Supplier, even when the supply of the alloy
bulk materials is subcontracted.

Upon completion of fabrication or prior to release for shipment, PMI test documentation shall be made
available to the Contractor’s Inspector. The documentation shall demonstrate that PMI has been
performed on individual plates, pipe, fittings, valve bodies and all other components that were used to
fabricate items listed in Appendix 9.2. Permanent marking shall only be applied when specified in the
Contract Specification. Drawings or weld maps shall be used to identify where PMI test was conducted,
which corresponds to the PMI report.

Certified Material Test Reports (including those certified by a third party) are not to be considered as a
substitute for PMI or vice versa.

When a random inspection sample has been accepted, each part in the inspection lot shall be marked
and segregated from materials waiting to be tested as outlined in the Seller’s PMI procedure. The
Seller is required to provide specific details of the marking system to be utilized, subject to the
Contractor’s review and written approval.

PMI inspection by the Contractor’s Inspector does not relieve the Seller of his responsibility to provide
and maintain an adequate quality control program.

Copies of all PMI test results shall be given to the Contractor’s Inspector for review, immediately upon
completion. The Seller’s PMI procedure shall indicate how permanent records of all PMI test results
shall be documented.

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Controls shall be outlined in the Seller’s PMI procedure to prevent the accidental use of any untested
materials and / or materials which have failed a PMI test.
PMI requirements on alternative materials shall be as per the originally specified material. When the
original specified material did not require PMI, the accepted alternative material also will not require
PMI.

PMI should be stated as a separate quality control activity on the Supplier’s or nominated sub-
supplier’s or manufacturer’s quality plan and inspection and test plan (ITP).

5.0 SPECIFIC REQUIREMENTS

PMI shall be conducted on all the pressure retaining components, including piping items valves welds
bolting and gaskets to the extent defined in Appendix 9.2 of the alloy groups listed in Appendix 9.1
unless specifically exempted in the Purchase Order.

5.1 Acceptance Criteria

Materials shall satisfy the controlling standard or specification (for example: ASTM or ASME IIA, IIB or
IIC composition requirements) unless agreed instrumentation limits differ as noted below.

Components or welds which are found to comply with the applicable material specification shall be
accepted. Acceptance or rejection shall take into account the accuracy of the portable testing
equipment used, as noted in the Seller’s approved PMI procedure. If alloy individual element
determinations for selected elements in Appendix 9.1, are outside of the range specified by the
applicable material standard, the component shall be rejected or a referee analysis shall be performed
in accordance with this specification.

All unacceptable materials shall be identified, marked, removed and replaced with the specified
materials.

5.2 Non-Conformance
Non-conforming items or welds shall be replaced immediately or re-analysed successfully at the
Seller’s expense. The Contractor shall be informed, in writing, of any non-conformances. The Seller’s
non-conformance report shall include a proposed corrective action plan.

If non-conforming components are detected within the lot, 100% examination of the inspection lot shall
be required.

All non-conforming components shall be removed and replaced. Rejected material shall be identified by
markings and segregated from acceptable material to prevent re-use.

Rejected material shall be replaced with acceptable material.

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Supplier, shop fabricator, or field fabricator shall submit, in writing to the Contractor, an explanation for
the rejected material that identifies the root cause, and a plan for corrective action. If an item from a
representative sample is rejected:

 100% of the remaining components from which the sample was taken shall be examined.
 100% of the components from the next delivery from the same manufacturer or supplier shall
be examined.

If no further components are rejected, the extent of examination shall return to that specified per the
Contract and the extent from the forgoing “Specific Requirements” or “Random Sampling” as originally
specified.

If referee examination becomes required, positive confirmation of identity shall be performed by

quantitative analysis. Quantitative analysis shall provide recordable, elemental composition results for
positive identification of alloying elements listed in Appendix 9.1. Alternatively an independent
laboratory analysis using any of the acceptable methods referenced in this specification may be
performed. The independent laboratory shall be approved in writing by the Contractor.

6.0 TEST EQUIPMENT

The equipment or methods used for this standard shall be able to positively identify and provide a
quantitative, recordable, elemental composition measurement of the alloying elements specified in
Appendix 9.1 “Alloy Elements Required for PMI Inspection”.

Testing shall be done as per the procedures outlined by the manufacturer of the alloy analyser being
used. Modification of these procedures must be approved by the Contractor. Each analyser shall be
calibrated according to the requirements of the manufacturer of the alloy analyser.

The person(s) performing the PMI shall demonstrate documented proof of their capabilities and
experience in performing PMI.

Analyser instruments and methods used for PMI examination shall be approved by Contractor.
Acceptability for approval shall be based on the following principles:

 Portable X-ray fluorescent spectrometers with direct reading of alloy grade or composition in
the applicable range are acceptable.
 Portable arc-emission spectrometers with direct reading of alloy grade or composition in the
applicable range are acceptable.
 Portable arc-emission spectroscopes with output in the form of visible light spectra are
acceptable after approval of the contractor.

Other methods, such as spectrographic or wet chemical analysis of sample drillings shall not be used
unless specifically approved by Contractor for a particular application. Magnetic and electromagnetic
testing are not acceptable for PMI.

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Document Title: Document No. Rev:
Positive Material Identification (PMI) of Alloys 172784-00-PR-SP-00002 2

7.0 DOCUMENTATION
Inspection Report - A signed and dated record for documenting the PMI examination shall be provided
to the owner/user. Fabricated items with multiple components and welds shall include a map showing
the location of each test:

 Each component PMI tested by the manufacturer.

 Each piece of equipment, by item number, PMI tested by the Shop Fabricator, including a test
location map.
 Each pipe line, by line number and pipe spec, including the spool or fabrication drawing,
showing the test locations by the Shop/Field Fabricator or Field Constructor.

Results of examinations for PMI shall be recorded on a PMI Inspection Report, which includes all of the
elements required to be verified by Appendix 9.1, and all additional data as required by this
Specification. Reports downloaded from the alloy analyser are acceptable as an attachment to a PMI
Inspection Report.

Inspection report shall indicate the following, as a minimum, for each inspection lot examined:

a) Manufacturer/fabricator name.
b) Date(s) of testing.
c) Purchase Order/ Contract reference number.
d) Reference to the PMI test procedure(s) used.
e) Name of person and company performing the test.
f) Material manufacturer, mill test certificate number heat, and lot number if applicable.
g) Material specification.
h) Type of alloy examined per item.
i) Description of the material marking if applicable.
j) Type of test instrument and test instrument identification number or serial number where
appropriate.
k) Inspection lot size and number of pieces or items examined.
l) Number and type of each component inspected, rejected, and reasons for rejection and the
corrective action taken.
m) Results of the test and resolution of non-conformance material.

All of the above information and inspection reports shall be transmitted to the owner/user.

Inspection reports shall become part of the permanent record and included in the final data package or
equipment/piping file folders.

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Document Title: Document No. Rev:
Positive Material Identification (PMI) of Alloys 172784-00-PR-SP-00002 2

8.0 MISCELLANEOUS
Documentation associated with the PMI program shall be available for audit by the Contractor for a
period of three years after the material/equipment is supplied.

9.0 APPENDICES

Appendix 9.1 Alloy Elements Required for PMI Inspection

Appendix 9.2 Extent of PMI Test Requirements

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Document Title: Document No. Rev:
Positive Material Identification (PMI) of Alloys 172784-00-PR-SP-00002 2

APPENDIX 9.1 ALLOY ELEMENTS REQUIRED FOR PMI INSPECTION

ALLOY Cr Ni Mo Cb/Nb Ti Cu Co Al Zn Sn Pd V
1Cr-1/2Mo x x
1-1/4Cr-1/2Mo x x
2-1/4Cr-1Mo x x
2-1/4Cr-1Mo-.25V x x x
5Cr-1/2Mo x x
9Cr-1Mo x x
9Cr-1Mo-V x x x
13Cr-4Ni x x
13Cr-4Ni/CA6NM x x x
12Cr/CA15 x x
2-1/2Ni x
3-1/2Ni x
5-Ni x
9-Ni x
304/304L/304H (note 1) x x
308/308L x x
309/309L x x
310S/310H (note 1 and 3) x x
316/316L/316H (note 1) x x x
317/317L x x x
321/321H (note 1) x x x
347/347H (note 1) x x x
410 x x
410S x x
430 x x
Alloy 2205 x x x
CD4MCu x x x x
Alloy 2507 UNS32750 x x x x
Zeron 100 UNS32760 x x x x
Alloy 20 x x x x x
6 Moly Stainless Steel Alloys x x x
Alloy C-276 x x x

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Document Title: Document No. Rev:
Positive Material Identification (PMI) of Alloys 172784-00-PR-SP-00002 2

APPENDIX 9.1 ALLOY ELEMENTS REQUIRED FOR PMI INSPECTION

ALLOY Cr Ni Mo Cb/Nb Ti Cu Co Al Zn Sn Pd V
Alloy 400 UNS N04400 x x
Alloy 600 x x
Alloy 625 and 625LCF x x x x x
Alloy 800 x x x x x
Alloy 825 x x x x x
90/10 CuNi x x
70/30 CuNi x x
Admiralty Brass x x x
Naval Brass x x x
Al-Brass x x x
Al-Bronze x x x
Stellites x x x
Titanium Gr 2 x
Titanium Gr 7 x
Titanium Gr 12 x x x
Titanium Gr 16 x x

Notes:
1. Where specified/applied in high temperature service per Code, all austenitic H-grades require analysis of
Carbon Content for conformance with the Material Specification. Since “sorting” cannot be accomplished by
XRF techniques, portable OES or spark techniques (for example, see Oxford Instruments PMI-Master Pro”)
shall be employed; or drillings for wet-lab analysis can be substituted. Since “L”-grades do not represent
Code required design (e.g., potential liabilities as in the case of “H”-grades) nor are these a potential
catastrophic mix-up event and therefore do not require sorting (including where defined within pressure
boundary weldments).

2. The list of materials is not exhaustive and shall not be considered as limiting the alloy metals subject to
PMI. For alloy materials not covered in the table, the Supplier shall seek Contractor approval for elements
to be analysed.

3. Additional check for Si may be required when the difference between 310S and 304H is essential.

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Document Title: Document No. Rev:
Positive Material Identification (PMI) of Alloys 172784-00-PR-SP-00002 2

APPENDIX 9.2 EXTENT OF PMI TEST REQUIREMENTS (NOTE 14)

Unless otherwise specified in project documents (datasheet, requisition documents) due to the equipment
criticality the following table shall be considered as minimum extent of PMI test requirements:

Shop (1), Field

EQUIPMENT: Numbers in parenthesis “( )” refer to notes.
(3), (7) (4)
Pressure Containing external components for Pressure Vessels, Tanks and Heat
100% N/A
Exchangers
Pressure containing internal heads, flanges, plates, forgings, nozzles (pipe), internal
100% N/A
linings
Pressure containing forgings such as nozzles, flanges and “olets” 100% N/A
Fired heater tubes 100% N/A
Pressure containing castings or fabricated casings for pumps, compressors, steam
100% N/A
turbines, combustion turbines, turbo-expanders and other process equipment
Expansion Joints (all pressure containing components) 100% N/A
10%
Piping valves 10%
(9)
Automated control and on-off valves (13) 10% N/A
Pressure relief valves (13) 10% N/A
Piping welds (10) 10% 10%
Instrumentation: Pressure containing housing for ASME Class 600 or higher (13) 5% N/A
Thermowells (13) 5% N/A
Alloy Piping and piping components 5% N/A
Bulk Piping Components 5% 5%
Tubes, tube sheets and other internal alloy pressure containing parts for vessels,
5% 1% (8)
exchangers, condensers and boilers (11)
Shop fabricated spools (pipe, pipe fittings, flanges) (5) 5% N/A
Alloy Bolting (11) (6) 1%
Pressure Containing Welds including vessels and exchangers (12) 5% N/A
Socket Welds 5% 1%
RTJ ring gaskets 5% 5%

Notes:
1. 100% PMI (this means PMI for every plate, forging, nozzle, pipe, weld etc. on one (1) spot, as applied in,
for example, a pressure vessel).
2. Unless otherwise specified, the random (noted as less than 100%) number of pieces for inspection shall be
the greater of X1 or X2 where:

X 1  R  100 or N if N  X1
X2  R N
Where: R the % which is less than 100% noted in the above table
N  total number of pieces

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Document Title: Document No. Rev:
Positive Material Identification (PMI) of Alloys 172784-00-PR-SP-00002 2

APPENDIX 9.2 EXTENT OF PMI TEST REQUIREMENTS

Example 1:
A shop fabricated heat exchanger with alloy components consisting of two tubesheets,
4700 tubes (of the same heat lot), two nozzle necks and two nozzle flanges. The above
table specifies a random 5% PMI for internal pressure components and 100% for external
components.

Tubesheets: 100% for both tubesheets since the number of tube sheets is less than
0.05100

Tubes: 0.05  4700  or 235 tubes assuming all are from the same heat lot.

Shell, Nozzle Necks and Flanges: 100% and comply with note 1.

Example 2:
1 1
Fabricated piping spools with 15 of carbon steel material, 50 of 1 /4Cr – /2Mo material and
35 of 304H material.

Carbon Steel piping spools: None

1 /4Cr – /2Mo piping spools: 0.05100  5 since this is greater than 0.05 50
1 1

304 H piping spools: 0.05100  5 since this is greater than 0.05 35

3. Extent shown is first verification. This may be at material supplier, fabrication shop or field.
4. Extent shown shall be considered as additional verification subsequent to verification at shop/supplier. The
extent of first verification at site (material purchased by Construction or field welding) shall be the same as
shown for "shop".
5. Provided the heat number can be identified throughout fabrication. If this condition does not satisfy, then
100% verification is required.
6. 1% of each alloy heat/lot of bolts/studs and nuts for structural fabrication and pressure retaining bolting for
pipe fabrication, and 10% pressure retaining fasteners for equipment shall be verified. ASTM A193-B16
bolts/studs shall be 10% alloy verified regardless of application.
7. The Supplier shall provide material certification for materials requiring alloy verification in accordance with
the Purchase Order requirements.
8. Applicable only if field is performing re-tubing. Not applicable for shop fabricated equipment.
9. Applicable only if random pieces are shipped to field for field assembly.
10. The following requirements shall be followed for random inspection of piping welds:
a) One test per WPS as a minimum.
b) Per welder, every first five (5) welds shall be tested.
c) Every batch (heat) of consumables shall be regarded as one lot.

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APPENDIX 9.2 EXTENT OF PMI TEST REQUIREMENTS

11. For items such as tubes, fasteners, bolts and nuts, a reduced random inspection sample shall normally be
acceptable, but requires prior written approval from the Contractor. If any piece from a random inspection
sample is found to be unacceptable, each piece of the lot shall be examined.

12. Pressure containing welds - minimum 5% of the quantity of as deposited welds from each Welding
Procedure Specification (weld cover pass only) for girth welds or longitudinal seams. This shall include one
test minimum for each WPS applied; and the first five (5) welds for each welder; each batch of
consumables shall be considered one lot. For Pressure Vessel longitudinal Seams this requirement to be
applied to each ten feet of a weld seam, or one check of each seam, if less than ten feet long.

13. Not applicable for non-hazardous fluids group 2 as specified by Pressure Equipment Directive (PED).

14. Exempt from PMI - The following components are exempt from PMI requirements, unless specifically
designated for PMI in the contract documents:

a) All components and welds manufactured from materials excluded from PMI (materials not
listed in Appendix 9.1).
b) Internal machinery parts.
c) Internal instrument parts, e.g., float/displacer, diaphragm.
d) Non-pressure retaining pressure vessel internals such as, baffles, trays, clips, supports, pall-
rings, support rings, etc.
e) Non-pressure retaining fired heater, heat exchanger and boiler internals such as, tube hangers,
tube supports, baffles, etc.
f) Non-pressure retaining welds.
g) Electrical components.
h) Internal valve components, e.g., plug, ball, disk, seat, stem and including bonnet bolts and
gaskets.
i) Spiral wound metallic gaskets.
j) Instrument tubing.
k) Compression type ferrules, fittings and components (e.g. valves, filters, etc.) for use with 3/4
inch outside diameter and smaller tubing.
l) Off line pressure and differential pressure instruments (including those equipped with
diaphragm seals).
m) Steam tracing, instrument air, seal oil, lube oil and hydraulic pipe and tubing.
n) Pressure containing instrument housings in alloy systems or housings with a design pressure
below ASME Class 600.
o) All B7/B7M bolts and 2H/2HM nuts.
p) All L7/L7M bolting

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