POSITIVE MATERIAL IDENTIFICATION

PROCEDURE
 TABLE OF CONTENTS

1. SCOPE

2. REFERENCES

3. DEFINITIONS

4. RESPONSIBILITIES

5. EQUIPMENT

6. EXTENT OF VERIFICATION

7. PROCEDURE

8. ACCEPTANCE CRITERIA

9. REJECTION PROCEDURES

10. REPORTING

11. MARKING AND COLOR CODING

APPENDIX

REPORT FORM
1.0 Scope

This procedure sets forth the minimum requirements to be followed when using the Portable Metal
Analyzer, for identification of materials used on the Projects (applicable to plants, shop and field
fabrication) and the reporting of results. The requirements in this procedure shall apply to PMI of both
new components and repair or replacement components.

This procedure is 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 procedure are not intended to establish the complete conformance of a material to the
material specifications.

PMI testing shall be performed at a 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.

2.0 Reference

ASME Boiler & Pressure Vessel Code Section II: Parts A, B and C (2010 ed., 11 a.)

ASME B31.1 Power Piping (2010 ed.)

ASME B31.3 Process Piping (2010 ed.)

ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids (2009
ed.)

ASME B31.8 Gas Transmission and Distributing Piping Systems (2010 ed.)

ASME B16.20 Metallic gaskets for Pipe Flanges: Ring Joints, Spiral-Wound Gaskets and
Jacketed

ASTM A193/11a. Standard Specification for Alloy-Steel and Stainless Steel Bolting materials for
High-Temperature and High-Pressure Service

ASTM A751/11 Standard Test Methods, Practices, and Terminology for Chemical Analysis of Steel
Products.

API RP-578/10 Material Verification Program for New and Existing Alloy Piping Systems

NITON XLt, XL2-980 Series User’s Guide

3.0 Definitions

Alloy Steel: Any steel (including filler metals for welding alloy materials) that contains specified
quantities of elements, such as Chromium, Nickel or Molybdenum, that are added to enhance
mechanical or physical properties, and/or corrosion resistance. Alloy steels and stainless steels
comprise ASME P-Nos. 3 through 11, or equivalent.

PMI: Positive Material Identification – determination that the nominal chemical composition of a
mechanical component is as specified and ordered.

PMI 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 field fabrication or
assembly of piping and pressured equipment within the scope of this standard.

Material Specifications: ASME Section II, Parts A, B and C, or the relevant ASTM, or any other
material specification required.

Nonferrous Alloys: Metals that are not iron-based, including Nickel alloys and other corrosion-
resistant alloys. ASME P-No. 21 and higher, or equivalent.

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 and Parts: Product forms used for the fabrication of pressured
piping and equipment, including but not limited to: shells, heads, tubesheets, nozzles, tubes, stud
bolts/nuts, gaskets, forging, flanges, pipe and fittings such as tees, elbows, reducers, and special pipe
components, valves (body and bonnets), and alloy welds joining pressure parts to non-pressure parts.

Project Inspector: The person or company authorized by the Project Inspection Department to verify
implementation of the requirements of this procedure and Project Specifications.

4.0 Personnel Qualification & Equipment Calibration

Trained personnel shall be responsible for operating the Metal Analyzer in accordance with the
approved procedure in order to verify the nominal compositions of the alloy pressure containing
components, interpreting and recording the results. Prior to commencing PMI, the operators shall be
qualified to operate equipment on a representative sample of the alloy materials with 100% correct
assessment as the performance criteria. Evidence of training, qualification and experience shall be
provided for review and approval before start of work. Records of examination will be completed 48
hours after testing occurs and will be maintained as required by the projects requirements.

The Trained PMI Personnel shall calibrate and/or verify the test equipment performance in accordance
with manufacturer’s recommendations. The equipment shall be calibrated at intervals of six (06)
months by verification using certified standards samples or by the equipment manufacturer. When the
inspector doubts the reliability of the measurement, he may request for re-calibration of the instrument
on shorter periods.
5.0 Equipment

5.1. PMI Equipment

5.1.1 NITON XLt, XL2-980 (XRF Analyzer)

5.2 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.

5.3 The principle of the analysis method of SPECTRO’s portable metal analyzer is optical emission
spectroscopy and NITON XLt analyzer is x-ray fluorescence (XRF)

5.4 The equipment shall be always re-calibrated at the job site if the readings observed are abnormal
due to severe temperature fluctuations or any other adverse site conditions. Analyzed samples with
reference to the job shall be made available for cross-reference and calibration and witnessed by the
inspector.

5.5 As an alternative, in accordance with one of the methods of ASTM A751 a chemical analysis of
samples cut out from the pieces requiring PMI may be used to check for the alloying elements
required by this procedure.

5.6 If sample removal is used, a written procedure for identification and traceability to original material is
required. This procedure shall be reviewed/approved by the Project Engineer and Project Inspection
Department.

5.7 Both inside and outside weld surfaces shall be tested where accessible. PMI testing of welds shall be
done after removal of slag and/or oxide from the weld surface. Surface shall be clean bare metal,
free of grease or oil as specified by the instrument manufacturer. A light grinding or power brushing
is sufficient in probe seating area if not bare metal.

6.0 Extent of Verification

6.6 The PMI program covers alloy material, pressure-containing components in shop and field fabricated
equipment and piping (base metal, welds and cladding) and materials used for repair or replacement
of pressure containing components.

6.6 The elements of the basic alloy materials to be verified shall be in accordance with Table 1, as below:

Basic Alloy Elements to be verified

Carbon-Molybdenum
Manganese-Molybdenum, and Chromium, Molybdenum and Vanadium
Chromium-Molybdenum steels
Nickel Steels Nickel
Regular carbon grade stainless Chromium, Nickel and Molybdenum
steels
Low and High carbon stainless Chromium, Nickel, Molybdenum, and Carbon
steels
Stabilized stainless steels Chromium, Nickel, Molybdenum, Titanium and Niobium
Nickel-based alloys Nickel, Iron, Copper, Chromium, Molybdenum, Tungsten,
Vanadium
Copper-based alloys Copper, Zinc, and other elements specified

6.6 For alloys not covered in Paragraph 6.5, the Supervisor of the Project shall be consulted.
6.6 100% PMI testing (each component and weld is tested) shall be performed on all pressure
components and weld of alloy materials, within the scope of this standard.

6.4.1 Major Equipment

Part Metal Specified Testing Requirements

Vessel shells, heads, tube
sheets, nozzles,
downcomers, wires, tray
support rings, any other
items assembled by welding
including heat exchanger
tubes to be welded to the
tubesheet.
Fired heaters/Fired boilers
Parts that are not to be
welded, such as nuts, bolts,
support posts, etc., including
tray decks, thermowells and
heat exchanger tubes that
will not be welded to the tube
sheet.
Welding Filler Metal
Mechanical Rotating
Equipment (pumps,
compressors, expanders,
turbines, etc.)
Each heat of metal or part used
Each alloy type or grade
shall be tested.
Low carbon grades of
stainless steels including
dual certified grades or Each heat of metal or part used
alloys that may be shall be tested.
sensitized by welding.
Shop and Field fabricated
pressure components and welds
which are wholly or partly
outside of the casing plate or
header box, unless otherwise
Each alloy type or grade
noted in the P.O.
In addition, 5% of the pressure
containing components and tube
sheets which are inside the
casing plates.
Parts shall be 10% random
sampled and tested. If improper
Each alloy type or grade
materials are discovered, all
parts shall be tested.
Each batch or lot of filler metal
Each alloy type or grade
shall be tested.
100% of pressure retaining
Each alloy type or grade components exposed to the
process shall be verified.

6.4.2. Minor Equipment and Instruments

When identified with the notation “PMI check for xxxx” alloy on the P&ID, PMI as given in the below
table shall be conducted. For internal process wetted components in instruments and control valves, a
parts list should be made. The list should contain the components name or part number, the material
of construction, the method of testing, and tester’s name.

Part Metal Specified Test Required

Factory assembled
instruments and also parts of
minor equipment contacting All components contacting the
Each alloy type or grade
the process stream, including process shall be tested.
all orifice plates and welds, if
any.
 For control valves, the body and
bonnet of each control valve shall
be verified. For flow meters, the
pressure containing portions of
each inset type flow meter shall
be verified.
For displacers and float switches,
Instruments, Pressure Relief
Each alloy type or grade the chamber and head of each
Valves (PRV), etc.
displacer and switch shall be
verified.
The PRV rupture discs, and
pressure containing portions of
any instrument through which the
process fluid flows shall be
verified.

6.4.3. Valves and Piping

When required, valves and piping shall be checked as in below table. For internal process wetted
components in control valves, a parts list should be made by the fabricator. The list should contain the
components name or part number, the material of construction, the method of testing, and the tester’s
name.

Part Metal Specified Test Required

Each heat of metal contacting the
Pipes, Pipe Fittings, Alloy type or grade
process stream shall be tested.
slipblinds, and thermowells,
Low carbon grades of
including lap rings, flange
stainless steels or alloys Each heat of metal or part used
gasket faces and metallic
that may be sensitized by shall be tested.
alloy gaskets.
welding
All valve bodies and stems;
the ball and plug in valves
1½” and larger; the flapper in
All parts not having an embossed
check valves; the disc in Alloy type or grade
identification shall be tested.
butterfly valves; bolts and
nuts holding flapper and
disks.
Screwed pipe, nipples,
Each heat of metal or part used
fittings, process-wetted Alloy type or grade
shall be tested.
components of gaskets.
Welding Filler Metal: in
cases where PMI testing of
the completed welds is not
possible because of
geometry, PMI testing of filler
Each batch or lot of filler metal
metal lots and visual Alloy type or grade
shall be tested.
inspection of electrodes as
described in Para 6.7 is an
acceptable substitute for
testing of the completed
weld.
Welds, Weld Overlays, and
Alloy type or grade 100% PMI
Cladding
6.5 PMI testing of weld material shall be performed in the same manner as for the adjacent base metal.

6.6 The required number of PMI tests shall be as follows:

6.6.1One test for each pressure-containing component. If an assembly contains a number of components
(parts), one test is required for each component (part).
6.6.2One test for each pressure-containing weld and weld repair, plus filler metal testing.

6.7 PMI Testing of Welding Consumables

6.7.1In addition to the PMI testing of completed pressure-containing welds, when welding of alloy
materials is conducted, one electrode or wire sample from each lot of filler metal shall be positively
identified. The remainder of the lot shall be compared to the identified rod to verify that markings of
the wires/electrodes are correct. Failure of PMI on consumable will result in rejection of whole lot
consumable.

6.7.2PMI testing of weld metal (e.g., deposited or undiluted weld “buttons”) is an acceptable alternative to
PMI testing of an electrode or wire sample provided it is conducted immediately prior to welding or
during the welding process.

6.7.3In cases where PMI testing of the completed weld is not possible because of geometry (e.g., small
fillet welds and narrow root beads), PMI testing of filler metal lots and visual inspection of electrodes
as described in 6.7.1 and 6.7.2 is an acceptable substitute for testing of the completed weld.

6.8 Exemptions:
6.8.1Unless specifically required in the project, the following components and materials are exempt from
PMI:

 Non-pressure components
 Components made from carbon steel or cast iron and filler metal for welding carbon steel
 Rotating equipment internals and associated seal, lube oil, cooling water and steam equipment and
piping
 Valve internals (trim)
 Piping components in ASME B31.3 Category D Service or equivalent
 All instrumentation provided with isolation valves.

7.0 Procedure

Elements lighter than Sulfur cannot be detected by the X-ray emission analysis due to inherent
limitations. Therefore, this technique cannot differentiate between Carbon levels within a given alloy
family, eg., they cannot determine the difference between stainless steel grades such as 304L, 304
and 304H. An optical emission spectroscope may be used to check for all the required elements,
including Carbon.

7.1 For Spectro TEST

The metallic surface to be tested shall be free from all extraneous materials such as scale, rust, dirt,
grease, etc. which may interfere with the testing. All surfaces to be examined shall be prepared by light
grinding to ensure good surface contact. Ferritic base materials and areas of weld to be tested can be
prepared with a mini-disk grinder; however excessive removal could reduce the effective material
thickness beyond permissible limits.
 The equipment shall be connected to the power source after ensuring the correct voltage. The
electrode shall be checked for its cleanliness and sharp tip; otherwise the electrode shall be properly
cleaned or replaced. The basic electrode is copper, which is used for all analysis, however for
identification of copper in metallic material, a silver electrode shall be used in place of the copper
electrode.

The equipment shall then be standardized with sample and procedures as given by the manufacturer.
After successful standardization the equipment shall be calibrated by checking the values of the
standard samples with reference to the job.

Programmed options as per client requirements, such as identification, verification or sorting may be
selected. Spark the electrode and store the readings and print the permanent record of the readings.
The readings obtained shall be compared and the results noted in the appropriate report format.

Direct viewing of the arc should be avoided to protect eyes from ultraviolet rays. Upon completion of
testing, the burn areas shall be cleaned/light grinding to remove the burn residue.

The compositions that need to be verified in the test report shall be in accordance with Table 1, Para
6.5 (which are in accordance with Para 4.0 of RT8S-4001-61 and Table 2 of Para 7.5 of SAES-W-
206).

7.2 For NITON XLt, XL2-980

Before beginning a test, ensure that the battery has sufficient charge. The analyzer and the battery
packs shall be stored in a cool place, away from direct sunlight. To ensure the reliability, durability, and
performance of the NITON XLt Analyzer, always keep the transparent Kapton window covering the
analysis clean with a cotton swab.

The analyzer shall never be pointed towards yourself or anyone else while the shutter is open to avoid
unnecessary radiation.

8.0 Acceptance Criteria

8.1 Materials shall contain the amount of alloying elements specified in the material specification.
Alloys, including castings, shall be acceptable if the alloying elements are each within 10% of
the specified range of values.

8.2 Welds with consumables that match, or nearly match, the base metal composition shall be
within ±12.5% of the ranges allowed in ASME Section IIC for each element.

8.3 For dissimilar metal alloy welds (other than weld overlays), the effects of dilution from the
different base metals and the filler metal shall be taken into account for determining the
nominal as deposited weld metal composition.

8.4 For weld overlays, the chemistry on the surface of overlays shall be in accordance with the
following:

8.4.1 The weld deposit chemistry shall be specified in the engineering design. Where a
nominal alloy designation for the overlay or cladding is listed (e.g., 316L), then
the overlay deposit shall meet the equivalent filler metal composition
requirements unless otherwise specified or exempted in this procedure.

8.4.2 The cladding restoration portion of weld joints between clad materials or
attaching clad materials shall meet the requirements for weld overlays.
 8.4.3 PMI test report shall be reviewed prior to any Post Weld Heat Treatment,
Painting, Insulation or Hydrotest and made part of the hydrotest package
supporting document.

9.0 Rejection Procedures

9.1 If the PMI testing results fall outside the acceptable range using the testing method described
in Section 7, the Equipment Manufacturer or the Fabricator, as applicable, has the option to
conduct a 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 to the
Client Inspector. The results of the more accurate test method or independent chemical
analysis shall govern.

9.2 If any component or weld is found unacceptable, it shall be replaced and the replacement
shall be alloy verified in accordance with this procedure.

9.3 Procedures shall be in place to ensure that rejected components are segregated and properly
identified to prevent reuse.

9.4 Where one of the tubes for heat exchangers, and boilers is found unacceptable, all remaining
tubes required of the particular alloy shall be tested for the individual equipment. This also
applies to the weld metals.

9.5 All rejected tubes shall be replaced and 100% of the replacement tubes shall be subjected to
PMI testing in accordance with this procedure.

10.0 Reporting

10.1A detailed PMI map of the equipment being fabricated shall be supplied by the fabricator.
The map shall show the alloy material specification of each alloy component and the extent
of PMI required in accordance with the requirements of project specifications.

10.2As a minimum, the report shall include:

Report number, Client/Contractor name, Project, Location, Material under Examination,
Identification of Materials for all components and welds, Material Verification, Results, Name
and Signature of the Operator with date of testing.

10.3All the hard copy of computer printouts shall be attached along with the PMI Reports.

10.4The PMI Report shall be reviewed by the Client Inspector prior to final acceptance.

11.0 Marking and Color Coding

11.1Verification Marking

11.1.1 Paint marking shall be done with the letters ‘PMI’ using a water insoluble material that
contains no harmful substance, such as metallic pigments, lead, zinc, sulfur, mercury,
chlorides or other halogens, which would attack or harmfully affect austenitic or nickel alloy
steels at ambient or elevated temperature.
 11.1.2. All components and welds that are found to be unacceptable during verification shall be
marked with a circled red “X” pending resolution in accordance with Section 9.

11.1.3. All verified materials with acceptable analysis may be marked with the letters ‘PMI’ using
an acceptable low-stress stamp/marking. The marking (stamping) shall be in accordance
with procedures and specifications, and shall not have a negative effect on the material.
The marking shall be placed as follows:

11.1.1.1 Pipe: one mark, 75 mm from one end on the outer surface of the pipe.
11.1.1.2 Welds: adjacent to the welder’s mark on the weld.
11.1.1.3 Fittings and Forgings: adjacent to the manufacturers marking.
11.1.1.4 Valves: adjacent to the manufacturer’s markings on bodies and other pressure
parts.
11.1.1.5 Plates: 75 mm from one edge, adjacent to the heat numbers.
11.1.1.6 Castings: adjacent to the manufacturer’s markings and heat numbers.
11.1.1.7 Tubes: stenciled, 300 mm from each end.

11.1.4 If the material or item is too light, too small, or cannot otherwise be stamped, vibro-etching
or color-coding shall be applied in conjunction with Seller’s standards and the requirements
of Para 9.2.1 and noted on the alloy verification reports.

11.1.5 Where heat treatment is performed after alloy verification, the identification marking must
be recognizable after heat treatment. PMI markings shall be transferred when a plate or
pipe is cut.

11.2 Color Coding

11.2.1 The color coding system for material identification described herein is intended to
help prevent fabricators from using incorrect alloy material. The principal purpose of
color coding is visual identification during storage and after the components has
been cut for fabrication.

11.2.2 Color coding is not a substitute for PMI testing or other permanent manufacturer’s
markings required by ASTM or other specifications. Permanent manufacturer’s
markings shall not be obscured by color coding.

11.2.3 Color coding may be done by the material manufacturer or material supplier. Color
coding need not be retained after painting.

11.2.4 Prior to coding, surfaces shall be clean and free of dirt, 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.

11.2.5 Each component shall be coded in accordance PFI ES-22 and Para 14 of 00-SAIP-
07, and shall have painted characters indicating the specification number of the
material if it is not permanently marked or tagged according to the applicable material
specification.

11.2.6 Valves, flanges, and fittings do not require color coding if these components are
permanently stamped or tagged by the manufacturer. If the materials are not easily
 legible, valves, flanges, and fittings shall be coded with a stripe of 5 mm minimum
width. The color coding on valves should indicate the valve body material.

11.2.7 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.

11.2.7 Spiral-wound gaskets shall be color coded in accordance with ASME B16.20. Sheet
type gaskets do not require color coding.

11.2.8 Pipe and Fittings: each length of pipe and fitting shall have a 5 mm or larger stripe
running full length.

11.2.9 Valves: when required, stripe across the body from flange to flange or end to end.

11.2.10 Flanges: when required, stripe across edge to hub.

11.2.11 Bolting: when required, stripe around the midpoint of each bolt or stud.

11.2.12 Plate, sheet and strip: stripe on surface near two perpendicular edges for entire
length.

11.2.13 Tubes and Bars: stripe entire length.

12.0 Safety

12.1The instrument shall be operated in a dry environment.

12.2The instrument must be secured if operated on an uneven surface.

12.3Avoid looking directly into the light arc.

12.4Attention will be paid on compliance with all electrical connections. The instrument may only
be operated on power outlets with a circuit breaker or ground fault breaker.

12.5Avoid simultaneous contact between the instrument and electrically conductive components,
other instruments, machinery, etc. Such contact may lead to a small electrical voltage due to
unfavorable potential ratios between grounded wires from different supplies or between
grounded wires and the instrument housing.

12.6The electrical source must be turned off while changing the electrode on the probe.

12.7The NITON XLt Analyzer contains an x-ray tube, which emits no radiation unless the user
turns the x-ray tube on. When the x-ray tube is ON and the shutter is open, as during a
measurement, the analyzer emits a directed radiation beam at the front and top-front of the
analyzer. There is negligible radiation at the handle of the analyzer.

12.8Though NITON XLt was designed to be safe as possible, it is strongly recommended that all
precautions are taken to insure safety for the operator and others around.