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Employer Doc. No.

NSRP Contractor Doc. No.


Complex Project Nghi Son Refinery and Petrochemical S-000-1670-0007V
Limited Liability Company
Nghi Son, Vietnam Rev. A Page 1 of 20

Employer Contract No.: , Contractor JOB Code: 0-6495-20 Date: 03/DEC/13

Positive Materials Identification (PMI) of Alloy Materials

during Site Fabrication and Erection

Unit No.:000

Unit Abbreviation.: Not Applicable

Document Class: X

Issue Purpose For Review

Rev Date Page Description Prep'd Chk'd App'd

A 03/DEC/13 All First issue K.K H.I Y.O.

Operation Centre JOB Code: Operation Centre Doc. No.:


Responsible Company Prepared by Checked by Approved by
JVD K. Kiba H. Ishiga Y. Ogawa

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Employer Doc. No.
NSRP Complex Project Rev. A

Title: Positive Materials Identification (PMI) of Alloy Materials Contractor Doc. No.
Page 2 of 20
During Site Fabrication and Erection S-000-1670-0007V

CONTENTS
1 SCOPE ..................................................................................................................................................3
2 DEFINITIONS ........................................................................................................................................4
3 PMI EXAMINATION ..............................................................................................................................5
3.1 General ..................................................................................................................................................5
3.2 Methods of PMI Examination .................................................................................................................5
3.3 Location, Timing and Extent of PMI Examination..................................................................................7
3.4 Acceptance Criteria ...............................................................................................................................7
3.5 Identification of Acceptable Materials ....................................................................................................8
3.6 Rejected Materials .................................................................................................................................8
3.7 Recording and Documentation ..............................................................................................................9
TABLE 1 - EXTENT OF PMI - MATERIALS RECEIVED WITH NO PMI MARKINGS ...................................10
TABLE 2 - EXTENT OF PMI - INSTALLED MATERIALS AND WELDS .......................................................12
TABLE 3 - ELEMENTS TO BE DETERMINED DURING PMI ........................................................................13
TABLE 4 - REQUIREMENTS FOR SAMPLE PMI ..........................................................................................14
ATTACHMENT A - PMI REPORT FORM - ALLOY BULK MATERIALS .......................................................15
ATTACHMENT B - PMI REPORT FORM - SITE MADE WELDMENTS ........................................................17
ATTACHMENT C: FLOW CHART-1 ...............................................................................................................19
ATTACHMENT D: FLOW CHART-2 ...............................................................................................................20

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Employer Doc. No.
NSRP Complex Project Rev. A

Title: Positive Materials Identification (PMI) of Alloy Materials Contractor Doc. No.
Page 3 of 20
During Site Fabrication and Erection S-000-1670-0007V

1 SCOPE

This specification defines the minimum Positive Material Identification (PMI)


requirements to be performed at fabrication yards and the construction site on
alloy, pressure retaining piping materials and welds. It shall apply to both PMI on
receipt of materials at the fabrication yard or construction site, as appropriate, and
PMI on final installed piping materials and welds.

PMI shall be performed on all pressure retaining components, including piping


items, valves, welds, bolting and gaskets, up to, and including the first instrument
block valve.

The following items shall not be subject to PMI unless specifically defined:
 Valve gates, stem and trim, internal bellows seals;
 Gaskets other than solid metal or metallic jacketed types (e.g. spiral wound
gaskets);
 Carbon steel items in any service.
 Austenitic stainless steel in non-hazardous services (eg air or non-sour
water in category D fluid service).
 Machinery lube oil, cooling water and steam piping.

Where materials are to be supplied by Employer, it shall be the responsibility of


the Contractor’s Material Controller to ensure that PMI, as defined in this
specification, has been performed on receipt of the alloy bulk materials and verify
that all 'free-issue' material is as specified on the 'Material Issue Request' form.

Where materials are to be supplied by the Contractor, it shall be the responsibility


of the Contractor to ensure that PMI, as defined in this specification, has been
performed on receipt of the alloy bulk materials, and on all final installed piping
materials and welds, and verify that all material is as specified on the relevant
piping isometrics and bill-of-materials.

The Subcontractor shall submit a PMI procedure for Contractor’s review. The

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Title: Positive Materials Identification (PMI) of Alloy Materials Contractor Doc. No.
Page 4 of 20
During Site Fabrication and Erection S-000-1670-0007V

procedure shall provide for the right of the Inspector to audit examinations, and
perform, or have performed by others, random PMI examinations as required.
These random examinations may, or may not, include units from the
Subcontractor's sample.

PMI shall be stated as a separate quality control activity on the Subcontractor's


quality plan.

2 DEFINITIONS

Alloy: All non-carbon steel, including but not limited to, Cr-Mo
steels, austenitic, ferritic, martensitic and duplex stainless
steels, nickel and copper alloys, titanium.

Bulk Material: Material purchased in bulk where individual items are not
allocated a unique tag number (e.g. random pipe lengths,
tubes, valves, fittings, flanges, bolting, non-process strainers)

Lot: All units from a common heat of material presented for


inspection against a single purchase order item. In the case
of valves, or similar items, where bodies/bonnets/covers may
be from different heats, the Lot shall consist of all units with
the same combination of heat numbers for pressure
containing components.

Sample: One, or more, units selected at random from the Lot which
are to be examined to determine acceptability of the Lot.

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Title: Positive Materials Identification (PMI) of Alloy Materials Contractor Doc. No.
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During Site Fabrication and Erection S-000-1670-0007V

3 PMI EXAMINATION

3.1 General

3.1.1 PMI examination of alloy materials and welds is independent of any certification,
markings or colour coding that may exist and is aimed at verifying that, where alloy
materials are specified in the purchase order, or piping isometrics, only the correctly
specified alloy grades are installed.

3.1.2 On receipt of materials, the Subcontractor shall ensure that all alloy material is
quarantined in a material reception area pending verification of the identification
markings, colour coding, material certificates and prior PMI certification and
marking. Alloy material in quarantine shall be available for visual examination by the
Inspector.

3.1.3 The Subcontractor shall identify all alloy materials and maintain full traceability of all
alloy materials.

3.1.4 The Subcontractor shall ensure that all alloy materials are segregated and stored in
separately identified locations to prevent the mixing of different alloy specifications
or alloy material with carbon steel.

3.2 Methods of PMI Examination

3.2.1 The method used for PMI shall provide a qualitative determination of the critical
alloy elements in accordance with Table 3, without interpretation by the PMI
operator.

3.2.2 The following methods/instruments are acceptable:

(i) Niton XL-800 series multi-element analyser (XRF)


Texas Nuclear Analyser Models 9266/9277
Spectroport

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Title: Positive Materials Identification (PMI) of Alloy Materials Contractor Doc. No.
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Spectrotest 'F'
Metorex X-met 2000/3000
Metorex Arc-Met
(ii) Wet chemical analysis or other laboratory methods.

3.2.3 The use of a manual portable optical spectroscope requiring visual interpretation of
the presence and intensities of diffracted spectral lines (e.g.: ‘Metascop’) is not
acceptable.

3.2.4 All PMI instruments shall have been serviced within a 6 month period of the time of
use to verify the suitability of batteries, sources etc. The date of the last service
shall be stated on the pro-forma PMI Report Forms (Attachments A & B).

3.2.5 All PMI instruments shall be calibrated, in accordance with the instrument
manufacturer's recommendation, at the start of each working shift as a minimum.

3.2.6 Certified samples, with full traceability, of "known" alloy materials shall be available
for use as a random spot check on the instrument calibration. These samples are in
addition to any manufacturer's standard calibration sample.

3.2.7 Surfaces to be examined shall be prepared by light grinding or abrasive paper and
solvent cleaning. Evidence of 'arc burn' on process fluid contact surfaces resulting
from the examination shall be removed by light grinding or abrasive paper. All arc
burn’ marks shall be removed from Cr-Mo low alloy steels.

3.2.8 It is advised, but not mandatory, that PMI activities be sub-contracted to an


Independent PMI Subcontractor, to ensure that experienced, qualified PMI
operators are employed. In all cases, whether PMI activities are sub-contracted or
performed in-house, only qualified operators shall perform PMI and records
showing qualification and experience of PMI operators shall be available for
inspection by the Inspector.

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Title: Positive Materials Identification (PMI) of Alloy Materials Contractor Doc. No.
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During Site Fabrication and Erection S-000-1670-0007V

3.3 Location, Timing and Extent of PMI Examination

3.3.1 On receipt, materials which have been subject to a previous 100% PMI examination
and for which there is supporting PMI marking and certification, shall, in principle,
be accepted for receiving inspection without further PMI checks. Spot PMI checks
may be performed on materials subject to a previous sample PMI examination to
ensure that material control procedures are operating correctly.

3.3.2 For materials which have not been subject to a previous PMI examination, or for
which there is no, or insufficient, PMI marking and certification, PMI shall be
performed on all such materials on receipt to the extent stated in Table 1 prior to
receiving inspection.
For materials which are too small or thin diameter to have marking of previous PMI
Examination, and pressure retaining welds, PMI is performed as per Attachment-C
and Attachment-D.

3.3.3 All installed alloy bulk materials and welds shall be subject to PMI examination in
the final 'as-installed' condition, but prior to insulation or painting, to the extent
stated in Table 2.

3.3.4 Where a particular constituent of the alloy composition cannot be determined by the
PMI instrument employed (e.g. carbon content in austenitic stainless steels, minor
alloying elements in grades of titanium), the instrument shall be used to verify the
major alloy constituents of the material and traceable material test certificates used
to verify the remainder.

3.4 Acceptance Criteria

3.4.1 The analysed concentration of alloy elements as determined by PMI examination


shall be within the specified level or range in the applicable material specification
(e.g. ASME or ASTM), or for weld metal ASME Section II Part C, with an additional
margin of 10% on the minimum and maximum specified limits.

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Title: Positive Materials Identification (PMI) of Alloy Materials Contractor Doc. No.
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During Site Fabrication and Erection S-000-1670-0007V

3.5 Identification of Acceptable Materials

3.5.1 Contractor’s Material Controller, or Subcontractor if applicable, shall verify


agreement between the material requisition, purchase order, identification
markings, colour coding, applicable material test reports and the results of the PMI
examination prior to receiving inspection.

3.5.2 If the colour coding on bulk piping materials has been obliterated, the Subcontractor
shall ensure that this is corrected, subject to PMI verification, prior to receiving
inspection.

3.5.3 For materials subject to receipt PMI examination in accordance with para. 3.3.2 and
Table 1, acceptable materials shall be marked by means of a low-stress (dot,
vibratory or 'U' type) hard stamp or indelible, non-deleterious ink or paint (i.e. free of
low melting point metals such as zinc, lead, copper etc.), at or adjacent to each PMI
sample point on each component or weld. For 'sensitive' materials such as thin walled
pipe etc., identification shall be by indelible, non-deleterious ink or paint.

3.5.4 The Subcontractor shall verify agreement between the piping isometric bill-of material
and the results of the PMI examination on the as-installed piping materials
and welds.

3.5.5 For installed materials and welds subject to PMI examination in accordance with
para. 3.3.3 and Table 2, acceptable materials shall be marked by means of a low
stress (dot, vibratory or 'U' type) hard stamp or indelible, non-deleterious ink or paint
(i.e. free of low melting point metals such as zinc, lead, copper etc.), at or adjacent
to each PMI sample point on each component or weld.

3.6 Rejected Materials

3.6.1 Whenever material is identified as rejected, the material shall be suitably marked
with a red "X" using indelible, non-deleterious ink or paint, or a red "Rejected" label.

3.6.2 Where a rejection is identified during receipt PMI examination, a discrepancy report
shall be raised by the Subcontractor. Where a rejection is identified during
installation, the Subcontractor shall advise Contractor.

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Title: Positive Materials Identification (PMI) of Alloy Materials Contractor Doc. No.
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3.6.3 Rejected material found on receipt PMI examination shall be segregated in a


separate, designated area, to prevent re-use. A more accurate analysis may be
performed to verify the composition of the rejected material or, alternatively, the
material shall be replaced. Rejected material found during erection PMI examination
shall be removed and replaced.

3.6.4 Rejected weld metal shall be removed by suitable means and the excavation
subject to a PMI check prior to repair. Alternatively, the weld shall be completely
removed, the weld preparation re-made and surface non destructively examined,
and re-welded. All repair welds shall be subject to PMI per Table 2, Section 2.

3.7 Recording and Documentation

3.7.1 PMI results for materials subject to receipt PMI examination, whether acceptable or
rejectable, shall be reported on a PMI Report Form (Attachment A).
3.7.2 PMI results for as-installed piping materials and welds, whether acceptable or
rejectable, shall be reported on a PMI Report Form (Attachment B). The
Subcontractor may use his own form providing it includes all the following data:

Subcontractor's Name
PMI Subcontractor's name and address, if applicable
Subcontract number
Isometric number
Location and date of PMI examination
Description of method/instrument used
Instrument no. and date of last service
Results of PMI examination
Type of alloy examined per isometric
Conclusion

3.7.3 The PMI report for as-installed PMI examination shall be included in the final piping
isometric records.

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Title: Positive Materials Identification (PMI) of Alloy Materials Contractor Doc. No.
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During Site Fabrication and Erection S-000-1670-0007V

TABLE 1 - EXTENT OF PMI - MATERIALS RECEIVED WITH NO PMI MARKINGS

Section 1. Piping Bulk Materials

Random length seamless and ERW pipe: Each component part

Random length fusion welded pipe (ERW Each component base


pipe excluded): material part (1). Refer to
Section 2 below for tests on
welds

Forged fittings (e.g. flanges, branch fittings, Each component part


weldolets, blinds, plugs, etc.):

Seamless and ERW pipe fittings: Each component part


Fusion welded pipe fittings: Each component base
material part (1). Refer to
Section 2 below for tests on
welds

Valves, including body, bonnet, plugs, Each pressure retaining


vents, drains etc.: component part. Refer to
Section 2 below for tests on
welds & Section 3 for tests on
bolting.

Permanent strainers, traps, including blind Each pressure retaining


flanges, plugs etc.: component part. Refer to
Section 2 for tests on welds
and Section 3 for tests on
bolting.

Section 2. Pressure Retaining Welds

Circumferential welds, including valve body- Each weld, with 1 test per
to-flange and valve body-to-bonnet welds: weld seam for automatic and
semi-automatic welding
processes, and 1 test per
weld seam and 1 test per
450mm weld length thereafter
for manual welding
processes(2)

Repair welds: 1 test on excavated weld to


ensure incorrect material fully
removed; thereafter 1 test per
450mm repair weld length

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Title: Positive Materials Identification (PMI) of Alloy Materials Contractor Doc. No.
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TABLE 1 - EXTENT OF PMI - MATERIALS RECEIVED WITH NO PMI MARKINGS (CONT.)

Section 3. Bolting

Valve bonnet bolting for flange rating Classes Sample basis per Table 4
<900

Valve bonnet bolting for flange rating Classes Each bolt and nut

External pressure retaining bolting for flange Sample basis per Table 4
rating Classes <900

External pressure retaining bolting for flange Each nut and bolt
rating Classes

External pressure retaining bolting for flange Each nut and bolt
rating Classes

Section 4. Gaskets

Solid metal or jacketed metallic gaskets for Each gasket


flange rating Classes

Alloy rings associated with ring-type joints (RTJs) Each ring

Gaskets other than above PMI not required unless


specifically stated

Notes:
(1) PMI on these components may be undertaken in conjunction with PMI of the
deposited weld metal per Note (2).

(2) For all welds, PMI shall be performed on the completed weld capping pass (both
internal and external, where access permits) and the base material on either side.

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TABLE 2 - EXTENT OF PMI - INSTALLED MATERIALS AND WELDS

Section 1. Piping Bulk Materials

Piping, flanges, branch fittings etc. welded into Each component base material
line: part, undertaken in conjunction
with PMI of weld per Section 2.

Flanged or screwed valves, fittings (e.g. Each component base material


plugs),strainers,filters etc. installed into line: part. Only body shall be tested
on valves

Section 2. Pressure Retaining Welds

Circumferential welds: Each weld, with 1 test per weld


seam for automatic and semiautomatic
welding processes,
and 1 test per weld seam and 1
test per 450mm weld length
thereafter for manual welding
processes (1)

Attachment welds: Each weld per component part


(1)

Note:
(1) For all welds, PMI shall be performed on completed weld capping pass and the base
material on either side. Where carbon steel base material is welded to an alloy base
material with an alloy weld metal, the carbon steel base material is exempt from PMI.
Where carbon steel base material is welded to an alloy base material with a carbon steel
weld metal, the carbon steel base material and the carbon steel weld metal are exempt
from PMI.

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TABLE 3 - ELEMENTS TO BE DETERMINED DURING PMI

MATERIALS (1) ELEMENTS TO BE DETERMINED


1 Cr - 0.5 Mo Cr, Mo,
1.25 Cr - 0.5 Mo Cr, Mo,
2.25 Cr - 1 Mo Cr, Mo,
2.25 Cr - 1 Mo-V Cr, Mo, V
5 Cr - 0.5 Mo Cr, Mo,
9 Cr - 1 Mo Cr, Mo,
9 Cr - 1 Mo-V Cr, Mo, V

12 Cr (Type 410S/405) Cr
12 Cr Cr
17 Cr Cr
304 (L/H) Cr, Ni,
310 Cr, Ni,
309 (L) Cr, Ni, Mo,
309 Nb Cr, Ni, Mo, Nb(Cb),
316 (L) Cr, Ni, Mo,
321 Cr, Ni, Ti,
347 Cr, Ni, Nb(Cb),
31803 Duplex Stainless Steel Cr, Ni, Mo
Inconel 182/82 Ni, Cr
Inconel 625 Ni, Cr, Mo, Nb(Cb) + Ta
Inconel 600 Ni, Cr
Incoloy 800 Cr, Ni, Al, Ti, Cu
Incoloy 825 Cr, Ni, Mo, Ti

Admiralty Brass Cu, Sn, As


Aluminium Brass Cu, Al, Zn
Cupro-nickel (70-30) Cu, Ni
Cupro-nickel (90-10) Cu, Ni
Monel 400 Cu, Ni
Titanium Ti

Note:
(1) List of materials is not exhaustive, and shall not be construed as limiting the alloy materials
subject to PMI.

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TABLE 4 - REQUIREMENTS FOR SAMPLE PMI

Number of Units in a Lot Representative Sample

1 -5 100% of all units

6 - 200 5 units or 5%, whichever is greater

≥200 10 units or 3%, whichever is greater

Notes:
(1) If all units of the representative Sample are acceptable, the inspection Lot shall be
acceptable.
(2) If any unit from the representative Sample is found to be unacceptable, the remainder of
that Lot shall be examined 100%. If the remainder of the Lot is found acceptable, the
sampling technique in Table 4 shall be resumed. The unacceptable unit(s) shall be
replaced and the replacements examined 100%.
(3) If a Lot is found unacceptable, the next two Lots, of the same material product and from
the same source, shall be examined 100%. If both Lots are acceptable, the sampling
technique in Table 4 shall be resumed.
(4) If any of the Lots examined in (3) above is found unacceptable, the remaining material
product from the same source shall be examined 100%. Any unacceptable unit(s) shall be
replaced and the replacements examined 100%.
(5) When the material markings are incomplete, preventing positive correlation between the
material requisition, purchase order and a material test certificate, the materials shall be
rejected.

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ATTACHMENT A - PMI REPORT FORM - ALLOY BULK MATERIALS

POSITIVE MATERIAL IDENTIFICATION (PMI) - Alloy Bulk Materials

PMI Report #________ Page______of________

Contract No: Vendor:


Order No: Vendor’s Ref No:
Requisition No: Sub-Vendor/Manufacturer:
Sub-Vendor/Manufacturer Ref No:

1. Description of Items

Item Type (as per requisition):


Material Colour Code:
Material Specification/Grade:

2. PMI Results
Requisition Requisition Number of Material test
Cast/Heat No. Accept/ Reject Date
Item No. Item No. Items Tested Certificate No.

Examination Location: PMI Inspector:-


Examination Date: Company:
Instrument Type/ID Number: Signature:
Date of Last Service: Date:
(include certificate) Stamp:

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ATTACHMENT A - PMI REPORT FORM - ALLOY BULK MATERIALS (CONT.)

POSITIVE MATERIAL IDENTIFICATION (PMI) - Alloy Bulk Materials

PMI Report #________ Page______of________

Requisition Number of Number of Material test


Cast/Heat No. Accept/ Reject Date
Item No. Items in Lot Items Tested Certificate No.

Examination Location: PMI Inspector:-


Examination Date: Company:
Instrument Type/ID Number: Signature:
Date of Last Service: Date:
(include certificate) Stamp:

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ATTACHMENT B - PMI REPORT FORM - SITE MADE WELDMENTS

POSITIVE MATERIAL IDENTIFICATION (PMI) - Site Made Weldments

PMI Report #________ Page______of________

Contract No: Subcontractor:


Isometric No.: PMI Subcontractor:
Area: Instrument Type/ID No.:
Material Type: Date of Last service:
(include certificate)

Weld No./Bulk Weld metal Base Matl. #1 Base Matl. #2 Insp.


Accept/ Reject Date
Fitting No. PMI Result PMI Result PMI Result. Initials

PMI Inspector: Contractor Approval:


Company: Signature/Stamp:
Signature/Stamp: Date:
Date:

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ATTACHMENT B - PMI REPORT FORM - SITE MADE WELDMENTS (CONT.)

POSITIVE MATERIAL IDENTIFICATION (PMI) - Site Made Weldments

PMI Report #________ Page______of________

Weld No./Bulk Weld metal Base Matl. #1 Base Matl. #2 Insp.


Accept/ Reject Date
Fitting No. PMI Result PMI Result PMI Result. Initials

PMI Inspector: Contractor Approval:


Company: Signature/Stamp:
Signature/Stamp: Date:
Date

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ATTACHMENT C: FLOW CHART-1

PMI examination Flow for thin diameter or small size materials

----- At Vendor Shop ---------------------------------------------------------------------------------------------


Bulk Materials

Spot PMI (Lot wise)

PMI results are acceptable

As Results of PMI (Packing at vendor shop )

1) To indicate traceable No. (Item No. and Lot No.) on representative


tag of banding or box and
2) PMI Certificate / Report are available.

Shipping

----- At Construction Site --------------------------------------------------------------------------------------

To confirm the results of PMI performed at vendor shop (Receiving


inspection at construction site)

A) Traceable No. on representative tag of banding or box and


B) PMI Certificate / Report are available.
C)

Are A) and B) PMI as receiving


available? No inspection is required as
per para. 3.3.2

Yes

No need to perform PMI as


receiving inspection.

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ATTACHMENT D: FLOW CHART-2


PMI examination Flow for pressure retaining welds

----- At Vendor Shop ---------------------------------------------------------------------------------------------


Pressure containing welds

PMI

PMI result is acceptable and PMI marking is done.

As Results of PMI (Packing at vendor shop)

1) PMI Certificate / Report is available at vendor shop


2) PMI marking for actual weld metal may disappear by painting
or grinding.

Shipping

----- At Construction Site --------------------------------------------------------------------------------------

To confirm the results of PMI performed at vendor shop (Receiving


inspection at construction site)

1) PMI Certificate / Report are available.

PMI as receiving inspection


Is PMI certificate / is required as per para.
report available? No
3.3.2

Yes

No need to perform PMI at


receiving inspection.

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