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POSITIVE MATERIAL IDENTIFICATION

TESTING PROCEDURE

Document No: SAIC/NDT/PMI/01

Revision No : 00
Issue Date : 5/11/2020

Prepared By Reviewed By Approved By

Name
Designation
Sign & Date
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CONTENTS

01 PURPOSE 3

02 SCOPE 3

03 DEFINITIONS 3

04 REFERENCE DOCUMENTS 4

05 TERMS AND DEFINITIONS 4

06 TEST MATERIAL 5

07 TEST EQUPMENT 5

08 SURFACE PREPARATION 6

09 TEST PROCEDURE 6

10 ACCEPTANCE CRITERIA 7

11 SCHEDULING OF TESTS 8

12 REJECTION PROCEDURES 8

13 IDENTIFICATION and MARKING 8

14 RECORDS 9
DOCUMENTATION AND REPORTING OF TEST RESULTS
15 10
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1.0 PURPOSE

To define the scope and method of carrying out positive materials identification (PMI).This form
of testing is an effective way of determining the material types in terms of chemical
composition of metallic materials.

2.0 Scope
This procedure establishes the minimum requirements for identification of metallic materials,
also referred to as Alloy Verification (positive material identification - PMI). 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. The scope of this
document extends to performing PMI on the following items:
• Alloy Steel Pipes including clad pipes
• Alloy Steel Flanges and Forgings
• Alloy Steel Fittings including clad fittings
• Alloy Steel Fasteners
• Alloy cast and forged steel valves
• Alloy Steel instrumentation items (control valves, safety valves, etc.)
• Longitudinal vales and fitting welds
• Gaskets (for ring type joints)

3. DEFINITIONS
I. Material verification: Verifying the
composition of metallic elements against known
data.
II. Material identification: Investigating
unknown run identified metallic materials.
III. Material sorting: Comparing and sorting material gains
dereference sample analysis for which analyzers programmed.
IV. AV: alloys verification
V. PMI: Positive material identification is the determination when
VI. the nominal material composition is as specified.
VII. OES: Optical Emission Spectrometer
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4.0 References Documents

• ISO6955: Analytical Spectroscopy Methods-Vocabulary;
• ASTM E135:Standard Terminology Relating to Analytical Chemistry for Metals, Ores, and
Relate
• Materials;
• ASTM E322:Standard Test Method for X-Ray Emission Spectrometric Analysis of Low-Alloy
Steels.
• ASTME353:Chemical Analysis of Stainless, Heat Resisting, Managing and Other Similar
Chromium, Nickel-Iron Alloys
• ASTM E-354: Chemical Analysis of High-Temperature, Electrical ,Magnetic and Other
Similar, Nickel and Cobalt Alloys Cast Irons;
• ASTM E572:Standard Test Method for Analysis of Stainless and Alloy Steels by X-ray
Fluorescence.
• ASTMA-751:Method Practices and Terminology for Chemical Analysis of Steel Products
• SAES-A-206: Saudi Aramco Engineering Specification on Positive Material Identification
• Spectrometry;
• ASME II Part A (Ferrous Material Specification)
• ASME II Part C (Specification for Welding Rods, Electrodes and Filler Metals)
• X-MET 8000 Series Alloy Analyzer Operating Manual;
• Spectro test TXC02AlloyAnalyzer Operating Manual
• APIRP578 Material Verification Program for New and Existing Alloy Piping Systems.
•
• (All these reference document are applied in their last valid edition and/or revision.)

5. Terms and definitions

• Alloy Material: Any metal containing alloying elements such as chromium, nickel, or
molybdenum, that are intentionally added to enhance mechanical or physical properties
and/or corrosion resistance. Does not include high-strength low-alloy (micro alloyed) steels
and impact-tested carbon steels.
• PMI: Positive Material Identification -Verification that the nominal chemical composition
of an alloy material is as specified and ordered. The term applies to programs, processes,
procedures, and tests in accordance with this standard.
• 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
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consistent with the selected or specified alloy material

• Material Specifications: ASME Section II, Parts A, Band C, or the relevant ASTM, or any
other material specification required.
• Non-Pressure Components: Items that are not part of the pressure-containing envelops, and
therefore, do not affect pressure retaining capacity of piping
• Pressure Product Components and Parts: Product forms used for the fabrication f
pressured piping, including but not limited to: forgings, 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.
• Pressure Piping: Piping whose design pressure is 100 Kpa (15 Psig) and above.
6. TEST MATERIAL
• Personnel performing PMI shall have a minimum training of 8 hours in understanding of the
operation & application of the PMI equipment and the underlying the principles.
• Prior to commencing PMI testing, instrument operators shall be qualified to operate
approved equipment on a representative sample of the alloy materials with 100% correct
assessment as the performance criteria. The instrument operator shall work to a written
procedure and shall have been trained to use the instrument in accordance with that
procedure. Training shall be documented.
• If sample removal is used, a written procedure for identification and traceability to original
material is required.
7. TEST EQUIPMENT
• The primary acceptable method is X-ray emission analysis, also known as X-ray fluorescence
(XRF) analysis with a calibrated portable instrument such as HITACHI X-MET8000 Series,
Alpha Series.
• Standard calibration blocks have been provided with the equipment. Every time the
machine is switched on the equipment calibration verification shall be carried out using
standard alloy samples that are representative of the material to be tested, prior to first
reading being taken and whenever there is a significant change of the material to be
tested.
• In addition to the manufacturer's standard calibration samples, certified samples with the
traceability of "known" material shall be made available for a random (spot) check.
• The date of the latest calibration of the instrument shall be stated in the PMI report.
• Because of inherent limitations of XRF, it is not possible to detect all elements. Elements
lighter than sulfur (S) cannot be detected using portable X-ray fluorescence
spectrometers. Therefore, this technique cannot be used to detect carbon (C).
• The person(s) performing PMI testing shall calibrate and or verify the test equipment
performance as
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• Specified by the equipment manufacturer. Calibration shall be carried out on a standard

calibration alloy sample, representative of the base material/weld being tested. The PMI
test procedure shall specify the frequency interval for this calibration/ verification. If
calibration procedures are not provided by the equipment manufacturer, they shall be
established by the owner/user. Typically these procedures shall include calibration
/verification using certified standards

8. SURFACE PREPARATION

PMI testing of welds shall be done after removal of slag and/or oxide from the weld surface. The
surface of material to be analyzed shall be clean and free from paint, rust and debris. Generally
a fresh 60 grit finish is required for the Arc Spark type instrument and the clean bare metal
surface required for XRF INNOV-X system equipment's. For Arc/Spark instrument, the small arc
burn created by the analysis technique shall be removed by lightly abrading the surface after
test.

9. TEST PROCEDURE
• The PMI program covers alloy material, pressure-containing components
in shop equipment and piping (both base metal and welds) and materials
used for repair pressure containing components.
• PMI testing of weld material shall be performed in the same manner as
for the adjacent base metal.
• The required number of PMI tests shall be as follows:-
a. One test components (parts), one test is required for each component (part).
b. One test for each pressure-containing weld and weld repair, plus filler metal testing.
• The elements of the basic alloy materials to be verified shall in accord a nee with Table 1
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• PMI Testing of Welding Consumables

a. Electrodes shall be properly stored and segregated in the store, shop, or up. Separate
ovens are required for different welding consumable types. The Fabricator shall ensure that
adequate inventory control is established to account for all consumables checked out.
b. One consumable from each lot shall be PM I-tested. The remainder of the lot shall be
compared to the identified consumable to verify that the markings of the electrodes/wires
are correct.
c. PMI testing of weld metal is an acceptable alternative to PMI testing of an electrode or wire
d. sample provided it is conducted immediately prior to welding or during the welding process.
e. 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 as described in b. and c. is an acceptable substitute for testing of
the completed weld.
10. ACCEPTANCE CRITERIA
• For acceptance, it must be demonstrated that materials contain the amounts of alloying
elements shown in the material specification. Alloys shall be acceptable if the alloying elements
are each within ±10% of the specified range of values.
• 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.
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• For weld overlays, the chemistry on the surface of overlays shall be in accordance with SAES W -
014.
• For dissimilar metal alloy welds (other than weld overlays), the effect of dilution from the
different base metals and the filler metal shall be taken in to account for determining the
nominal as-deposited weld metal composition.

11. SCHEDULING OF TESTS

• PMI when specified shall be performed any time prior to, during fabrication for pressure
components and that alloy verification of welds is completed prior to shipment to ensure proper
materials have been used in the fabrication of an assembly.
• Weld metal PMI shall be performed prior to any PWHT, radiography or other NOE and or
surface coating.
• Weld metal PMI will be performed on the final deposited pass.
• Material test reports will not be considered as an acceptable positive material identification and
alloy verification shall not be considered as a substitute for the required materials test reports.

12. REJECTION PROCEDURES

• If the PMI testing results fall outside the acceptable range using, 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 results of the more accurate test method
or independent chemical analysis shall govern.
• If any component or weld is found unacceptable, it shall be replaced, and the replacement shall
be alloy verified in accordance with this standard.
• Procedures shall be in place to ensure that rejected components are segregated and properly
identified to prevent reuse.
• If one of the tubes for heat exchangers and boilers is found unacceptable, all remaining tubes of
the alloy shall be tested for the individual equipment. This also applies to the weld metal.
• All rejected tubes shall be replaced and 100% of the replacement tubes shall be PM I-tested in
accordance with this standard.

13. IDENTIFICATION and MARKING

• Verification Marking
• 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.
• All components, and welds that are found unacceptable shall be marked immediately with a
circled red "X".
• All verified materials with an acceptable analysis shall be marked with the letters "PMI" using a
• Certified low-stress stamp or otherwise directed by Project Inspection. Marking shall be
adjacent to the manufacturer's marking
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• All verified materials with an acceptable analysis shall be marked with the letters "PMI" using a
certified low-stress stamp. The marking shall be placed as follows:-

I. Pipe: - One mark, 75 mm from one end on the outer surface of the
pipe. This marking shall be in addition to the requirements of PFI
ES-22 and Attachment 3 of 00-SAI P-07
II. Welds: - Adjacent to the welder's mark on the weld. (Welds on tubes
for heat transfer equipment shall be marked by either stenciling or vi
bro-etching on the tube sheet).
III. Fittings and Forgings: - Adjacent to the manufacturer's markings.
IV. Valves: - Adjacent to the valve manufacturer's markings on bodies
and other pressure parts.
V. Castings: - Adjacent to the casting manufacturer's markings and heat
numbers.
VI. Plates: - 75 mm from one edge, adjacent to manufacturer's
markings.
VII. Tubes: - Stenciled, 300 mm from each end.

• When heat treating is performed after PMI, the identification marking must be
recognizable after heat treatment. PMI markings shall be transferred when a plate or pipe
is cut.

14. RECORDS
1. Shop Fabrication Records: -.
 A detailed recording/logging procedure shall be prepared by the Equipment
Manufacturer or shop Fabricator.
 The log shall identify each component and weld corresponding to an individual
equipment item or piping spool and shall include the equipment or spool number
and purchase order number.
 The log shall identify all components and welds that have been alloy verified and the
results of testing.
 Test results shall include measured percentages of alloying elements
for components that were accepted or rejected.
 The Equipment Manufacturer shall prepare a detailed PMI map of the pressured
equipment being fabricated. The map shall show the alloy material specification of
each alloy component and the extent of PMI required in accordance with this
standard.
2. Field Fabrication Records
 At least two weeks prior to the commencement of fabrication, the field Fabricator
shall establish and present to the Saudi Aramco Inspector for review the proposed
testing, logging, identification, and final installation procedures for all components
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requiring PMI testing onsite (such as fabricated pressured equipment, piping, valves,
and welds).
 Shop-fabricated alloy pressure equipment or piping assemblies that have been alloy
verified by the shop Fabricator need not be re-verified in the field. However, the
field Fabricator shall have available, for review, the shop Fabricator's report of PMI
testing. Material certificates are not allowable substitutes for PMI testing reports.

 The field Fabricator shall prepare a detailed PMI map of the pressured equipment
being fabricated. The map shall show the alloy material specification of each alloy
component and the extent of PMI required in accordance with this standard.

15. DOCUMENTATION AND REPORTING OF TEST RESULTS

 Prior to final acceptance of alloy pressured equipment or piping, the Equipment Manufacturer
or the Fabricator, as applicable, shall prepare a complete PMI Testing Report containing all
relevant data. For pressured equipment, the PMI Testing Report shall be included as part of
the Equipment Data Book.
 The PMI Testing Report shall be reviewed by the Saudi Aramco Inspector prior to final
acceptance.
 Upon completion of PMI Testing the report will contain the
following information:
Client
Client Reference No
Part Identification
Date of Test
Report No
Procedure No, and Revision
Equipment used
Material type
Operator name and Signature.
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