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
outline in this procedure is 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. References
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

3. 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.
.
The Trained PMI Personnel shall calibrate and/or verify the test equipment performance in
accordance with manufacturers recommendations. The equipment shall be calibrated at intervals of
12 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. Equipment
5.1. PMI-OES Equipment
Oxford smart pro
.Oxford Master Pro
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.

The principle of the analysis method of PMI-OES portable metal analyzer is optical emission
Spectroscopy

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

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.

PMI-OES 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.

6. Extent of Verification
6.1. 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.
6.2. 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 steels Chromium, Nickel and Molybdenum
Low and High carbon stainless steels Chromium, Nickel, Molybdenum, and Carbon
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 in P.O.

6.4. 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.
Each alloy type or grade Each heat of metal or part used shall be
tested.
Low carbon grades of stainless
steels including dual certified
grades or alloys that may be
sensitized by welding.
Each heat of metal or part used shall be
tested.
Fired heaters/Fired boilers Each alloy type or grade
Shop and Field fabricated pressure
components and welds which are wholly
or partly outside of the casing plate or
header box, unless otherwise noted in
the P.O.
In addition, 5% of the pressure
containing components and tube sheets
which are inside the casing plates.
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.
Each alloy type or grade
Parts shall be 10% random sampled
and tested. If improper materials are
discovered, all parts shall be tested.
Welding Filler Metal Each alloy type or grade Each batch or lot of filler metal shall be
tested.
Mechanical Rotating Equipment
(pumps, compressors, expanders,
turbines, etc.)
Each alloy type or grade 100% of pressure retaining 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 testers name.
Part Metal Specified Test Required
Factory assembled instruments and
also parts of minor equipment
contacting the process stream,
including all orifice plates and
welds, if any.
Each alloy type or grade All components contacting the process
shall be tested.
Instruments, Pressure Relief Valves
(PRV), etc. Each alloy type or grade
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, the
chamber and head of each 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 testers name.
Part Metal Specified Test Required
Pipes, Pipe Fittings, slipblinds, and
thermowells, including lap rings,
flange gasket faces and metallic
alloy gaskets.
Alloy type or grade Each heat of metal contacting the
process stream shall be tested.
Low carbon grades of stainless
steels or alloys that may be
sensitized by welding
Each heat of metal or part used shall be
tested.
All valve bodies and stems; the ball
and plug in valves 1 and larger;
the flapper in check valves; the disc
in butterfly valves; bolts and nuts
holding flapper and disks.
Alloy type or grade All parts not having an embossed
identification shall be tested.
Screwed pipe, nipples, fittings,
process-wetted components of
gaskets.
Alloy type or grade Each heat of metal or part used shall be
tested.
Welding Filler Metal: in cases where
PMI testing of the completed welds
is not possible because of
geometry, PMI testing of filler metal
lots and visual inspection of
electrodes as described in Para 6.7
is an acceptable substitute for
testing of the completed weld.
Alloy type or grade Each batch or lot of filler metal shall be
tested.
Welds, Weld Overlays, and
Cladding Alloy type or grade 100% PMI
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:

6.6.1. One test for each pressure-containing component. If an assembly contains a number of
components (parts), one test is required for each component (part).
6.6.2. One test for each pressure-containing weld and weld repair, plus filler metal testing.
6.7. PMI Testing of Welding Consumables
6.7.1. In 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.
6.7.2. PMI 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.
Note: some weld rods have the alloying elements contained in the flux, and do not meet the
alloy specification until welded.

6.7.3. 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 6.7.1 and 6.7.2 is an acceptable substitute for testing of the
completed weld.

6.8. Exemptions:
6.8.1. Unless specifically required in the project, the following components and materials are
exempt from PMI:
a. Non-pressure components
b. Components made from carbon steel or cast iron and filler metal for welding carbon steel
c. Rotating equipment internals and associated seal, lube oil, cooling water and steam
equipment and piping
d. Valve internals (trim)
e. Piping components in ASME B31.3 Category D Service or equivalent
f. All instrumentation provided with isolation valves.

7. Procedure

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).

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.

8. 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.

9. 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. Reporting
10.1. A 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.
10.2. As 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.
10.3. All the hard copy of computer printouts shall be attached along with the PMI Reports.
10.4. The PMI Report shall be reviewed by the Client Inspector prior to final acceptance.
11. Marking and Color Coding
11.1. Verification 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 a
certified low-stress stamp. 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:
11.1.3.1. Pipe: one mark, 75 mm from one end on the outer surface of the pipe.
11.1.3.2. Welds: adjacent to the welders mark on the weld.
11.1.3.3. Fittings and Forgings: adjacent to the manufacturers marking.
11.1.3.4. Valves: adjacent to the manufacturers markings on bodies and other pressure parts.
11.1.3.5. Plates: 75 mm from one edge, adjacent to the heat numbers.
11.1.3.6. Castings: adjacent to the manufacturers markings and heat numbers.
11.1.3.7. Tubes: stenciled, 300 mm from each end.
Procedure No. : AMSYCO 400-01/01
First Issue Date : October 20, 2012
Revision No. : 00
Revision Date : NIL
Title: POSITIVE MATERIAL IDENTIFICATION Page 10 of 12
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 Sellers 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 manufacturers markings
required by ASTM or other specifications. Permanent manufacturers 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. In particular, paints shall
be free of lead, sulfur, zinc, cadmium, mercury, chlorine, and other halogens.
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.
11.2.8. Spiral-wound gaskets shall be color coded in accordance with ASME B16.20. Sheet type
gaskets do not require color coding.
11.2.9. Pipe and Fittings: each length of pipe and fitting shall have a 5 mm or larger stripe running
full length. One inch NPS and smaller may have a 3 mm stripe running full length.
11.2.10. Valves: when required, stripe across the body from flange to flange or end to end.
11.2.11. Flanges: when required, stripe across edge to hub.
11.2.12. Bolting: when required, stripe around the midpoint of each bolt or stud.
11.2.13. Plate, sheet and strip: stripe on surface near two perpendicular edges for entire length.
11.2.14. Tubes and Bars: stripe entire length.

12. Safety
12.1. The instrument shall be operated in a dry environment.
12.2. The instrument must be secured if operated on an uneven surface.
12.3. Avoid looking directly into the light arc.
12.4. Attention 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.
12.5. Avoid 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.
12.6. The electrical source must be turned off while changing the electrode on the probe.
12.7. The 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.
12.8. Though 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.