PROCEDURE FOR PMI TESTING

PROCEDURE FOR PMI TESTING

Page 1 of 9
CONTENTS

DESCRIPTION PAGE
COVER SHEET
CONTENTS 2

1.0 AIM / SCOPE 3

2.0 DEFINITIONS 3

3.0 REFERENCES 3

4.0 SAFETY 3
5.0 PERSONNEL 4
6.0 EQUIPMENT 4

7.0 EQUIPMENT CALIBRATION AND VALIDATION 5

8.0 VERIFICATION COVERAGE 5

9.0 PREPARATION 6

PROCEDURE 7

11 .0 EVALUATION 7

12.0 ACCEPTANCE CRITERIA 7

13.0 REJECTION PROCEDURE 8

14.0 MARKING 9

15.0 REPORTING 10
PMI REPORT FORMAT SAMPLE 10
1.0 AIM SCOPE
1.1 This procedure establishes the minimum requirements for identification of metallic
materials, also referred to as Alloy Verification (Positive Material Identification - PMI).
1.2 The aim of the identification of material shall be to ensure that the nominal material
composition is as supplied and complies with purchase order and I or design requirements.
1.3 This procedure shall be used to perform Positive Material Identification (PMI) .

1.4 Considering safety issues involved in placing the OES PMI equipment at elevated locations,
the usage of the same will be limited to ground level work or limited to those elevations
where it can be safely lifted and placed.

2.0 DEFINITIONS
a) Material Verification - Verifying the composition of metallic elements against known data.

b) Material Identification - Investigating unknown or unidentified metallic materials.

c) Material Sorting Comparing and sorting material against a reference sample analysis for
which analyser is programmed.

d) AV - Alloy Verification

e) PMI - Positive material identification is the determination / verification whether the nominal
material composition is as specified.

f) OES - Optical Emission Spectrometer

g) Client — with whom Cooperheat has a direct contractual agreement

3.0 REFERENCES
The following documents shall be referred to in conjunction with this procedure:

ASME Section ll. Material Specification

ASTM E-353, Chemical Analysis of Stainless, Heat Resisting, Maraging and Other Similar
Chromium, Nickel — Iron Alloys
ASTM E-354, Chemical Analysis of High-Temperature, Electrical, Magnetic and Other Similar,
Nickel and Cobalt Alloys
ASTM A-751, Method Practices and Terminology for Chemical Analysis of Steel Products
SAEP 1 160-2011 , Tracking & Reporting of Welding, NDT and Pressure testing for Capital projects.

4.0 SAFETY

4.1 Only trained personnel shall use this equipment.

4.2 As this procedure involves the use of an electrically operated I x-ray producing portable
equipments care should be exercised due to the possible hazards of using them in humid and
other adverse operating conditions. Safe operation and emergency requirement shall be
carried out in accordance with the respective equipment operations manual

4.3 Direct viewing of the arc or x-ray should be avoided to protect the eyes from damaging ultraviolet
rays and x-ray radiation.
5.0 PERSONNEL
PMI technician shall have been trained to use the equipment in accordance with this
procedure. Personnel training shall include Radiation Safety (as per equipment manufacturer's
instructions), Instrument operation, instrument limitations, basic knowledge in metallurgy and
standards related to steel manufacture.

Only trained, qualified and experienced personnel shall undertake the operation and
interpretation of recorded results to ensure that both the procedure and the work are
implemented correctly in order to identify 1 verify the nominal material compositions.
Operator records meeting the minimum requirements of training, qualification and experience
shall be submitted for Company approval.

the PMI technician shall demonstrate his working knowledge to operate the PMI equipment on
a representative sample of the alloy material and PMI technicians training record shall be
offered to review. The PMI technician shall have knowledge about all aspects of PMI test
methods and the operation of PMI test equipment used on the job.

6.0 EQUIPMENT

6.1 OES - Optical Emission Spectrometer equipment shall be used when Carbon has to be
verified as per the inspection request from the client / owner.
XRF - X-Ray Fluorescence equipment shall be used when element lighter than Sulphur has
NOT to be verified as per the inspection request from the client owner.

6.2 The following equipment or similar equipment shall be used, as may be available:

6.2.1 Optical Emission Spectrometer (OES)

a) Spectro Analytical 'Spectroport' Alloy Analyser works on the principle of Optical
Emission Spectrograph (OES).

b) Belec Optical Emission Spectrometer (OES) works on the principle of Spark Emission
Spectroscopy.

Note: OES equipment may be used to check for the required elements including
carbon. A hot work permit may be required before using this equipment. Any burn
damage resulting from the usage of emission spectrograph shall be removed by
grinding.

6.22 X-Ray Fluorescence (XRF)

a) Niton Corporation 'XLt 800' Alloy Analyser works on the principle of X-Ray
Fluorescence (XRF).

b) Innov-X Systems 'Alpha 2000' Alloy Analyser works on the principle of X-Ray
Fluorescence (XRF) or similar equipment.
Note: Because of inherent limitation of XRF, it js not possible to detect all elements.
Elements fighter than Sulphur cannot be detected using portable XRF equipment.
Therefore, this technique shall not be used to detect Carbon.

7.0 EQUIPMENT CALIBRATION AND VALIDATION

a) The equipment shall be calibrated or verified as specified in the equipment operation
manual. The equipment shall be calibrated once in a year.
b) The equipment shall be set up with the standard samples in accordance with procedure
given by the manufacturer.

c) Verification of calibration shall be carried out on a standard calibration sample,

representative of the base metal / weld being tested. The calibration verification shall be
done at the beginning of each shift or whenever there is change in material to be tested.
8.0 VERIFICATlON COVERAGE
8.1 The PMI programme shall cover alloy materials and materials as per the project I TP and as
given in the written PMI request. Client shall follow the NDT Matrix and line class list for PMI.

8.2 PMI of weld material shall be performed in the same manner as for the adjacent base metal.
PMI testing of welds shall be done after removal of slag and/or oxide from the weld surface.

In 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 may be acceptable.

8.3 The required number of PMI tests shall be in accordance Table-I .

a) One sample for each pipe spool component.
b) One sample for any component that makes up part of the pressure boundary.
c) For non-pressure components, ten (10) samples or 10% of total, whichever is greater,
from each heat or lot.
d) One sample for each pressure boundary weld and for all welds between non-pressure
parts and pressure parts.
e) When welding of alloy materials is conductedJ one electrode or wire sample from
each lot of filler metal shall be positively identified.

8.4 The elements of the basic alloy materials to be verified shall be in accordance with the
Table shown below;

TABLE

Basic Alloy Elements to be verified

Carbon-Molybdenum,
ManganeseMolybdenum,
Chromium-
Mol bdenum-Vanadium steels
Regular Carbon grade Stainless
Steels
Low and High Carbon Stainless
Steels
Stabilised Stainless Steel
Nickel-based alloys
Chromium, Molybdenum and Vanadium
and
Chromium, Nickel and Molybdenum
Chromium, Nickel, Molybdenum and Carbon
Chromium, Nickel, Molybdenum, Titanium and
Niobium
Nickel, Iron, Copper, .Chromium, Molybdenum,
Tungsten, Vanadium and Copper as applicable

Note: Nickel base alloys also include "Hast alloys", "Inconels", "Alloy20",
Monel etc. For Copper alloys PMI verification is not required.
 8.5 For alloys not covered in the Table, the Client shall obtain written instructions from the
owner. Dissimilar Metal Weld PMI results from base and weld metals shall be submitted by
Client to the Materials Engineering Unit of ME&CCD/CSD foe evaluation and approval

8.6 PMI Testing of Welding Consumables

PMI testing of welding consumables shall be done as per Client's requirement as

follows

One consumable from lot Shall be PMI-tested- The remainder of the

lot shall be compared to the identified consumable to verify that the
makings of the electrodes / wires are correct.
PMI testing of weld metal (e.g., deposited or undiluted weld ) is an
acceptable altemative to PMI testing of an electrode or wire
sample provided it is conducted immediately prior to welding or
during the welding process.

8.7 PMI Testing of Weld Overlay and Clad Materials

The final weld overlay surface shall have the chemical composition checking prior to
final PWHT or Hydro test. The chemistry may be tested using portable X-ray
fluorescence equipment (XRF equipment) instead of Spectrograph equipment.
All elements specified for the deposit chemistry shall be analyzed and reported, except
for Carbon when using the X-ray fluorescence method. The analysis method and
accuracy limits for each element shall be submitted to Owner inspector for review and
approval.

The frequency of Chemical composition analysis shall be as follows:

a) Automatic Welding — One analysis for each overlay area or Clad joint.
Separate analysis shall be made for each heat/batch of Filler metal or
Electrode.

b) Manual Welding — One analysis for each 1 meter square of area or one
analysis at interval of 2 meter or less for overlay restoration of clad joints.

9.0 PREPARATION
The metallic surface to be tested shall be free from all extraneous materials such as scale,
welding flux, slag, grease, rust, dirt, etc. which may interfere with the testing,

if necessary, light filing shall be done to ensure good surface contact of the electrode of the
Spectroport equipment.

Only stainless steel brasses, ceramic (glass) beads, iron-free grit or stainless steel grit shall be
used to mechanically clean the overlay surfaces.

10.0 PROCEDURE
10.1 Optical Emission Spectrometer (OES)
The Spectroport Equipment shall be set, verified and operated in accordance with the
manufacturer instructions.
 a) The Spectroport equipment shall be connected to power source after ensuring
compatible voltage. The electrode shall be checked for cleanliness and having
sharp tip, otherwise the electrode shall be properly cleaned or replaced. The
basic electrode copper, which is suitable for most analysis; however for
identification of copper in metallic material, a silver electrode shall replace the
copper electrode,
b) In the case of Spectroport the electrode shall make contact with the metallic
material to strike an arc and then the readings obtained shall be stored; the print
out shall give the permanent record of the readings.

c) Programme options as per Client requirement, such as identification, verification or

sorting shall be selected.

10.2 X-Ray Fluorescence (XRF)

The XRF equipment shall be set* verified and operated in accordance with the
manufacturer's instructions.

In the case of the battery powered Niton or similar equipment* the measurement
window shall be placed against the sample to be analysed and the trigger pulled
to get the analysis of the sample. The chemical composition obtained shall be
noted down in the appropriate report format.

b) Programme options as per Client requirement, such as identification, verification

or sorting shall be selected.

c) Display Requirement: On start-up, the screen will be replaced by the restart

screen which will count down from 9 to 0 in increments of 1 second. When restart
is complete the screen will be replaced by Logon screen. The operator needs to
enter the 4 digit security code followed by enter key to access the main menu.

d) Once in the main menu by selecting the utilities menu one can select the auto
calibrate option. Once auto calibration is complete one can go to the Mode menu
to select one of the test mode — Alloy, PB paint, Thin Sample, Bulk sample and
User definable modes. The Alloy mode is normally used and under this the
chemistry mode is selected and the verification sample is tested to ensure proper
identification.
e) From the main menu Test icon is selected to proceed with the test in the selected
measurement mode. Now the instrument is ready to take a measurement and
there are five (5) different methods of operation to take a sample measurement.
These methods are given below in increasing order of secure operation:

1. Trigger Only method

2. Trigger and Proximity Sensor method
3, Momentary Trigger Touch and Proximity Sensor method
4. Trigger and Interlock method
5. Trigger + Interlock + Proximity sensor method.
It is recommended to use the Trigger + Interlock + Proximity sensor method. When the proximity
sensor Is enabled, the shutter will open only when the window is pressed against the sample. The
X-Ray tube will operate only when both the Trigger and the Interlock are pressed simultaneously
and even if one is not pressed or released the X-Ray gets switched off/.

For Further information on the measurement modes refer to the Instruction manual of the
Equipment.

11.0 EVALUATION
9.1 Sort mode may be used whenever different grades of the same material are mixed and
the aim shall be to separate one grade from other in a quick manner. This mode is
helpful in reclaiming valuable metals from scrap material.
 9.2 Material verification mode shall be selected whenever the chemical composition of
the job is to be verified. The chemical composition of the job shall be programmed into
the equipment and the result shall be verified.

12.0 ACCEPTANCE CRITERIA

a) For acceptance, it shall be demonstrated that materials contain the amount of alloying
elements shown in the material specification. Alloys shall be deemed acceptable if the
alloying elements are each within ten percent (10%) of the specified values.

b) Welds having consumable material content that matches, or nearly matches, the base
metal composition within approximately twelve and half percent (± 12.5%) of the
ranges allowed in ASME Section Il, Part C for each element.
c) Acceptance criteria for dissimilar metal alloy welds shall be in accordance with the
welding consumable material specified in the approved welding procedure. The effects
of dilution between the different base metals and the filler metal shall be taken into
account when determining the nominal as-deposited weld metal composition.

13.0 REJECTION PROCEDURE

a) If the PMI testing results fall outside the acceptable range, the Client has the option to
conduct a more accurate analysis to determine the component acceptance such as
obtaining a chemical analysis performed by an independent testing laboratory.
b) If any component or weld falls outside the acceptable range, it Shall be replaced and the
replacement shall be alloy verified.

c) Client shall ensure that rejected components are segregated and properly identified to
prevent reuse.

d) Where one of the selected items falls outside the acceptable range, all remaining
materials represented by such selected items shall be tested.

14.0 MARKING
All components and / or welds that are examined by PMI shall be marked by the Client (NSH)

14.1 Verification Marking

14.1.1 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, sulfur, zinc, cadmium, mercury, chlorine, or other halogens.
14.1.2 All components and welds that are found unacceptable shall be marked immediately with a
circled red "X" pending resolution in accordance with Section 11.
14.1.3 All verified materials with an acceptable analysis shall be marked with the letters "PMI" using a
certified low-stress stamp (these use a series of rounded dots or a rounded indenter to form
the letters).

Altematively , a vibrating "pencil" may be used. The marking shall be placed as follows:
Pipe: One mark, 75 mm from one end on the outer surface of the pipe.
Welds: Adjacent to the welders mark on the weld. (Welds on tubes for heat transfer equipment
shall be marked by either stenciling or vibro-etching on the tubesheet).
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 manufacturers markings and heat numbers.

Plates: 75 mm from one edge, adjacent to manufacturer's markings.

Tubes: Stenciled, 300 mm from each end.

 For 300-series stainless steel operating above 900+ (482 OC), consult with the Materials
Engineering Unit Supervisor of CSD (to guard against "strain aging" - unlikely to be encountered
in refinery processes).

14.1.4 When heat treating is performed after PMI, the identification marking must be
recognizable after heat treatment. PMI markings shall be transferred to retain material
identification when a plate or pipe is cut. The transfer of PMI markings shall be carried out
prior to material cutting/separation. If this is not possible, then transfer shall be performed
immediately after material cutting/separation.

14.2 Color Coding

14.2.1 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 have been cut for fabrication.

14.2.2 Color coding is not a substitute for PMI testing or other, permanent manufacturers' markings
required by ASTM or other specifications. Permanent manufacturers' markings shall not be
obscured by color coding.

15.0 REPORTING
15.1 PMI is to be integrated with the Weld ID system and data base as an element as per SAEP
1160 and the results shall be logged / reported / tracked accordingly by the Client.

15.2 The report if required by Client shall be taken directly from the 'Spectroport' Alloy
Analyser.
15.3 For X-Ray fluorescence equipment, .the PMI Report shall have the following information;

a) Client Name
b) Cooperheat Job Number
c) Technician Name
d) Site / Location
e) Project
f) Line I Heat Number
g) Weld Size
h) Element Percentage
i) Element Range
j) Grade Identification
k) Results