QUALITY CONTROL PROCEDURESUBJECT PROCEDURE No. REVISION NO. DATE OF FIRST ISSUE POSITIVE MATERIAL IDENTIFICATION AMSYCO 400–01/01 00 October 20, 2012 DISTRIBUTION OF CONTROL COPIES PROJECT CONTRACT SADARA, Mixed Feed Cracker (MFC) Project 6600027129 (IK) COPY # 1 COPY # 2 COPY # 3 Daelim Saudi Arabia Co. Ltd. N/A N/A REVISION DATE 3. 7. 6. 8. 4.Procedure No. MARKING AND COLOR CODING APPENDIX REPORT FORM . 2012 00 NIL Page 1 of 12 TABLE OF CONTENTS 1. 2. SCOPE REFERENCES DEFINITIONS RESPONSIBILITIES EQUIPMENT EXTENT OF VERIFICATION PROCEDURE ACCEPTANCE CRITERIA REJECTION PROCEDURES 10. REPORTING 11. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION : : : : AMSYCO 400-01/01 October 20. First Issue Date Revision No. 9. 5. The requirements in this procedure shall apply to PMI of both new components and repair or replacement components.1 ASME B31. References ASME Boiler & Pressure Vessel Code Section II: Parts A. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION 1.) Gas Transmission and Distributing Piping Systems (2010 ed. ASTM A751/11 API RP-578/10 Power Piping (2010 ed.) Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids (2009 ed.) ASME B31. B and C (2010 ed.. The testing methods outlined in this procedure are not intended to establish the complete conformance of a material to the material specifications. shop and field fabrication) and the reporting of results.) Metallic gaskets for Pipe Flanges: Ring Joints. 2012 00 NIL Page 2 of 12 This procedure sets forth the minimum requirements to be followed when using the Portable Metal Analyzer. XL2-980 Series User’s Guide .Procedure No.20 ASTM A193/11a. Usually this is during fabrication or immediately prior to fabrication. 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. for identification of materials used on the Projects (applicable to plants. Spiral-Wound Gaskets and Jacketed Standard Specification for Alloy-Steel and Stainless Steel Bolting materials for High-Temperature and High-Pressure Service Standard Test Methods. 11 a. and Terminology for Chemical Analysis of Steel Products. Material Verification Program for New and Existing Alloy Piping Systems SADARA (RTIP) Standards: RT8S-4001-61 Positive Material Identification Saudi Aramco Standards: SAES-A-206 Positive Material Identification (July 2007) 00-SAIP-07 175-320300 PFI ES-22 Positive Material Identification Requirements Inspection Requirements: Positive Material Identification Recommended Practice for color coding of Piping Materials SpectroTEST Operation Manual NITON XLt. Scope : : : : AMSYCO 400-01/01 October 20. 2.8 ASME B16.4 ASME B31.) Process Piping (2010 ed.3 ASME B31. Practices. 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. First Issue Date Revision No. 3 through 11. 4. or any other material specification required. 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. Pressure-Containing Components and Parts: Product forms used for the fabrication of pressured piping and equipment. and/or corrosion resistance. reducers. Nonferrous Alloys: Metals that are not iron-based. that are added to enhance mechanical or physical properties. the operators shall be qualified to operate equipment on a representative sample of the alloy materials with 100% correct assessment as the performance criteria. . B and C. stud bolts/nuts. or the relevant ASTM. The Trained PMI Personnel shall calibrate and/or verify the test equipment performance in accordance with manufacturer’s recommendations. do not affect the pressure retaining capacity of pressured components. tubes. interpreting and recording the results. flanges. organization. 2012 00 NIL Page 3 of 12 Alloy Steel: Any steel (including filler metals for welding alloy materials) that contains specified quantities of elements. forging. meeting the requirements of this standard. PMI Testing: Any physical evaluation or test of a material. and alloy welds joining pressure parts to non-pressure parts. When the inspector doubts the reliability of the measurement. valves (body and bonnets). Project Inspector: The person or company authorized by the Project Inspection Department to verify implementation of the requirements of this procedure and Project Specifications. including but not limited to: shells. 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. PMI: Positive Material Identification – determination that the nominal chemical composition of a mechanical component is as specified and ordered. heads. and. to confirm that the material which has been or will be placed into service is consistent with the selected or specified alloy material. he may request for re-calibration of the instrument on shorter periods. therefore. 21 and higher. elbows. including Nickel alloys and other corrosion-resistant alloys. First Issue Date Revision No. ASME P-No. Definitions : : : : AMSYCO 400-01/01 October 20. The equipment shall be calibrated at intervals of six (06) months by verification using certified standards samples or by the equipment manufacturer. or equivalent. pipe and fittings such as tees. Alloy steels and stainless steels comprise ASME P-Nos. Parts A. such as Chromium. gaskets. tubesheets. or equivalent. Nickel or Molybdenum. 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. Evidence of training. qualification and experience shall be provided for review and approval before start of work. Prior to commencing PMI. nozzles. Nonpressure Components: Items that are not part of the pressure containing envelope.Procedure No. and special pipe components. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION 3. Records of examination will be completed the same day as testing occurs and will be maintained as required by the projects requirements. 5. 6.2.O. Zinc. First Issue Date Revision No. Analyzed samples with reference to the job shall be made available for cross-reference and calibration and witnessed by the inspector. Molybdenum and Vanadium Nickel Chromium. PMI Equipment 5. Both inside and outside weld surfaces shall be tested where accessible.3. a written procedure for identification and traceability to original material is required.6.1. Molybdenum.2. Molybdenum. 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. Copper. XL2-980 (XRF Analyzer) : : : : AMSYCO 400-01/01 October 20. SPECTROTEST 5. 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. 6. 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. NITON XLt. 5.2. 5. The elements of the basic alloy materials to be verified shall be in accordance with Table 1. 6.7. Titanium and Niobium Nickel. 2012 00 NIL Page 4 of 12 5. pressure-containing components in shop and field fabricated equipment and piping (base metal. and Chromium-Molybdenum steels Nickel Steels Regular carbon grade stainless steels Low and High carbon stainless steels Stabilized stainless steels Nickel-based alloys Copper-based alloys Elements to be verified Chromium. 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. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION 5. as below: Basic Alloy Carbon-Molybdenum Manganese-Molybdenum. 5. free of grease or oil as specified by the instrument manufacturer. Nickel and Molybdenum Chromium. Tungsten. 5.1.1. As an alternative. This procedure shall be reviewed/approved by the Project Engineer and Project Inspection Department. and other elements specified in P. The PMI program covers alloy material. Chromium. Equipment 5.1. and Carbon Chromium. Molybdenum. the Supervisor of the Materials Engineering Unit of the Project shall be consulted. Nickel. welds and cladding) and materials used for repair or replacement of pressure containing components.3. For alloys not covered in Paragraph 6.4. Extent of Verification 6. . If sample removal is used.5. Nickel.Procedure No. PMI testing of welds shall be done after removal of slag and/or oxide from the weld surface. Surface shall be clean bare metal. Vanadium Copper. Iron.1. if any. wires. expanders. bolts. Each alloy type or grade Instruments. etc. tube sheets. all parts shall be tested. and pressure containing portions of any instrument through which the process fluid flows shall be verified. For flow meters. and tester’s name. Welding Filler Metal Mechanical Rotating Equipment (pumps.4.) Each alloy type or grade Each alloy type or grade Each alloy type or grade 6. such as nuts. the material of construction. 6. the chamber and head of each displacer and switch shall be verified. Each alloy type or grade . Fired heaters/Fired boilers Each alloy type or grade Parts that are not to be welded. Minor Equipment and Instruments When identified with the notation “PMI check for xxxx” alloy on the P&ID. etc. the body and bonnet of each control valve shall be verified. thermowells and heat exchanger tubes that will not be welded to the tube sheet. heads. 2012 00 NIL Page 5 of 12 6. any other items assembled by welding including heat exchanger tubes to be welded to the tubesheet. For displacers and float switches. compressors. including all orifice plates and welds. Each heat of metal or part used shall be tested. turbines. Parts shall be 10% random sampled and tested. within the scope of this standard.O.4. tray support rings.Procedure No. 100% PMI testing (each component and weld is tested) shall be performed on all pressure components and weld of alloy materials. For control valves. Each batch or lot of filler metal shall be tested. downcomers.2. The PRV rupture discs. The list should contain the components name or part number.. including tray decks. support posts. Testing Requirements Each heat of metal or part used shall be tested. If improper materials are discovered.4. Metal Specified Test Required All components contacting the process shall be tested. 5% of the pressure containing components and tube sheets which are inside the casing plates. Metal Specified Each alloy type or grade Low carbon grades of stainless steels including dual certified grades or alloys that may be sensitized by welding. nozzles. First Issue Date Revision No. etc. a parts list should be made. Major Equipment Part Vessel shells. 100% of pressure retaining components exposed to the process shall be verified. unless otherwise noted in the P.1. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION : : : : AMSYCO 400-01/01 October 20. Pressure Relief Valves (PRV). In addition. Part Factory assembled instruments and also parts of minor equipment contacting the process stream. the pressure containing portions of each inset type flow meter shall be verified. Shop and Field fabricated pressure components and welds which are wholly or partly outside of the casing plate or header box. PMI as given in the below table shall be conducted. For internal process wetted components in instruments and control valves. the method of testing. 3. First Issue Date Revision No.6. plus filler metal testing.1.7 is an acceptable substitute for testing of the completed weld. Alloy type or grade Each batch or lot of filler metal shall be tested.. One test for each pressure-containing component. Valves and Piping When required.g. 6. Pipe Fittings.4. If an assembly contains a number of components (parts).6. PMI testing of weld material shall be performed in the same manner as for the adjacent base metal.Procedure No. a parts list should be made by the fabricator. All valve bodies and stems. and thermowells. flange gasket faces and metallic alloy gaskets. Alloy type or grade All parts not having an embossed identification shall be tested. when welding of alloy materials is conducted. PMI testing of weld metal (e. the flapper in check valves. The required number of PMI tests shall be as follows: 6. nipples. 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. 2012 00 NIL Page 6 of 12 6. the ball and plug in valves 1½” and larger. 6.7. bolts and nuts holding flapper and disks.5. Part Pipes. Welding Filler Metal: in cases where PMI testing of the completed welds is not possible because of geometry. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION : : : : AMSYCO 400-01/01 October 20.7. slipblinds. PMI Testing of Welding Consumables 6. In addition to the PMI testing of completed pressure-containing welds. one electrode or wire sample from each lot of filler metal shall be positively identified. Each heat of metal or part used shall be tested. Welds.2.2. fittings. The remainder of the lot shall be compared to the identified rod to verify that markings of the wires/electrodes are correct. Weld Overlays. PMI testing of filler metal lots and visual inspection of electrodes as described in Para 6.7. Note: some weld rods have the alloying elements contained in the flux. Alloy type or grade 100% PMI 6. . valves and piping shall be checked as in below table. process-wetted components of gaskets. Alloy type or grade Each heat of metal or part used shall be tested. One test for each pressure-containing weld and weld repair. 6. the material of construction. The list should contain the components name or part number. 6. and Cladding Metal Specified Alloy type or grade Low carbon grades of stainless steels or alloys that may be sensitized by welding Test Required Each heat of metal contacting the process stream shall be tested. including lap rings. and the tester’s name. the method of testing. and do not meet the alloy specification until welded.6.1. Failure of PMI on consumable will result in rejection of whole lot consumable. the disc in butterfly valves. For internal process wetted components in control valves. Screwed pipe. one test is required for each component (part). grease. Therefore. An optical emission spectroscope may be used to check for all the required elements. which is used for all analysis. Non-pressure components b.7. In cases where PMI testing of the completed weld is not possible because of geometry (e. the burn areas shall be cleaned/light grinding to remove the burn residue. Valve internals (trim) e. The compositions that need to be verified in the test report shall be in accordance with Table 1.7. All instrumentation provided with isolation valves. verification or sorting may be selected. however for identification of copper in metallic material.3. All surfaces to be examined shall be prepared by light grinding to ensure good surface contact. . 304 and 304H.0 of RT8S-4001-61 and Table 2 of Para 7. Spark the electrode and store the readings and print the permanent record of the readings. Unless specifically required in the project. which may interfere with the testing. a silver electrode shall be used in place of the copper electrode. they cannot determine the difference between stainless steel grades such as 304L. Rotating equipment internals and associated seal. eg. The equipment shall then be standardized with sample and procedures as given by the manufacturer. lube oil.8. etc.5 of SAES-W-206). Ferritic base materials and areas of weld to be tested can be prepared with a mini-disk grinder.3 Category D Service or equivalent f.1 and 6.g. 2012 00 NIL Page 7 of 12 6. cooling water and steam equipment and piping d.1. this technique cannot differentiate between Carbon levels within a given alloy family. Programmed options as per client requirements. rust. Upon completion of testing. including Carbon. The electrode shall be checked for its cleanliness and sharp tip. First Issue Date Revision No. PMI testing of filler metal lots and visual inspection of electrodes as described in 6..5 (which are in accordance with Para 4. otherwise the electrode shall be properly cleaned or replaced. such as identification. The equipment shall be connected to the power source after ensuring the correct voltage. 7.2 is an acceptable substitute for testing of the completed weld. Direct viewing of the arc should be avoided to protect eyes from ultraviolet rays. After successful standardization the equipment shall be calibrated by checking the values of the standard samples with reference to the job.7.. The basic electrode is copper. Piping components in ASME B31. Para 6. Procedure Elements lighter than Sulfur cannot be detected by the X-ray emission analysis due to inherent limitations. For Spectro TEST The metallic surface to be tested shall be free from all extraneous materials such as scale. however excessive removal could reduce the effective material thickness beyond permissible limits. The readings obtained shall be compared and the results noted in the appropriate report format. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION : : : : AMSYCO 400-01/01 October 20.8. the following components and materials are exempt from PMI: a. 6.Procedure No. dirt. Components made from carbon steel or cast iron and filler metal for welding carbon steel c. Exemptions: 6. small fillet welds and narrow root beads). 9. the Equipment Manufacturer or the Fabricator. For weld overlays. The results of the more accurate test method or independent chemical analysis shall govern.1.5. XL2-980 Before beginning a test. The analyzer and the battery packs shall be stored in a cool place. or nearly match. The alternative test method or independent laboratory must be acceptable to the Client Inspector. then the overlay deposit shall meet the equivalent filler metal composition requirements unless otherwise specified or exempted in this procedure. Alloys.3. If any component or weld is found unacceptable.4.4.5% of the ranges allowed in ASME Section IIC for each element. ensure that the battery has sufficient charge. 316L). For dissimilar metal alloy welds (other than weld overlays). 9. shall be acceptable if the alloying elements are each within 10% of the specified range of values. the base metal composition shall be within ±12.2. The cladding restoration portion of weld joints between clad materials or attaching clad materials shall meet the requirements for weld overlays. The analyzer shall never be pointed towards yourself or anyone else while the shutter is open to avoid unnecessary radiation. as applicable.2. .3. 8. Welds with consumables that match.2. 8. Insulation or Hydrotest and made part of the hydrotest package supporting document. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION : : : : AMSYCO 400-01/01 October 20. 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. To ensure the reliability. Materials shall contain the amount of alloying elements specified in the material specification.1. Procedures shall be in place to ensure that rejected components are segregated and properly identified to prevent reuse. Where a nominal alloy designation for the overlay or cladding is listed (e. 8. the chemistry on the surface of overlays shall be in accordance with the following: 8. Painting. 2012 00 NIL Page 8 of 12 For NITON XLt.4. 8.. including castings. The weld deposit chemistry shall be specified in the engineering design.1. 8. it shall be replaced and the replacement shall be alloy verified in accordance with this procedure. 8. always keep the transparent Kapton window covering the analysis clean with a cotton swab. durability. and performance of the NITON XLt Analyzer.Procedure No.g. PMI test report shall be reviewed prior to any Post Weld Heat Treatment. away from direct sunlight. Rejection Procedures 9. If the PMI testing results fall outside the acceptable range using the testing method described in Section 7. the effects of dilution from the different base metals and the filler metal shall be taken into account for determining the nominal asdeposited weld metal composition. Acceptance Criteria 8. First Issue Date Revision No. 9. 10.4. the report shall include: Report number.5. chlorides or other halogens. 10. 11. such as metallic pigments.2. Results. 10.1. Tubes: stenciled. Paint marking shall be done with the letters ‘PMI’ using a water insoluble material that contains no harmful substance.3. sulfur. 11. Location. 11. Verification Marking 11.4.1. A detailed PMI map of the equipment being fabricated shall be supplied by the fabricator. mercury.3.1. zinc.3.5. 300 mm from each end. Castings: adjacent to the manufacturer’s markings and heat numbers. Where one of the tubes for heat exchangers. Welds: adjacent to the welders mark on the weld. Material Verification. Name and Signature of the Operator with date of testing. 9. 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.1.2. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION : : : : AMSYCO 400-01/01 October 20. 75 mm from one end on the outer surface of the pipe. The PMI Report shall be reviewed by the Client Inspector prior to final acceptance. 2012 00 NIL Page 9 of 12 9.1. Valves: adjacent to the manufacturer’s markings on bodies and other pressure parts.6. This also applies to the weld metals. all remaining tubes required of the particular alloy shall be tested for the individual equipment.3. 11.3.1.Procedure No.1.3.1.1. 11. 11. 11. As a minimum. Material under Examination. and shall not have a negative effect on the material.2. and boilers is found unacceptable. 11. Fittings and Forgings: adjacent to the manufacturers marking. lead. adjacent to the heat numbers. 10. .1. Project.1.4. Identification of Materials for all components and welds. All rejected tubes shall be replaced and 100% of the replacement tubes shall be subjected to PMI testing in accordance with this procedure. All verified materials with acceptable analysis may be marked with the letters ‘PMI’ using a certified low-stress stamp.1. Plates: 75 mm from one edge. Pipe: one mark. 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. Reporting 10. The marking (stamping) shall be in accordance with procedures and specifications.3.7. 11.3. Marking and Color Coding 11. Client/Contractor name.1.3. The marking shall be placed as follows: 11.3.1. which would attack or harmfully affect austenitic or nickel alloy steels at ambient or elevated temperature. First Issue Date Revision No. All the hard copy of computer printouts shall be attached along with the PMI Reports. 4. and distinctive and shall not contain substances that would harmfully affect the material at ambient or elevated temperatures.10. and other halogens. Color coding is not a substitute for PMI testing or other permanent manufacturer’s markings required by ASTM or other specifications. Valves: when required. valves. mercury. 11. stripe around the midpoint of each bolt or stud. 11.2. 11. stripe across the body from flange to flange or end to end.20.2.8. Flanges: when required. 11. The principal purpose of color coding is visual identification during storage and after the components has been cut for fabrication. vibro-etching or color-coding shall be applied in conjunction with Seller’s standards and the requirements of Para 9. Color coding may be done by the material manufacturer or material supplier. Each component shall be coded in accordance PFI ES-22 and Para 14 of 00-SAIP-07.4. Where heat treatment is performed after alloy verification. 11. 11. loose scale. The color coding on valves should indicate the valve body material. Tubes and Bars: stripe entire length. 11.2. flanges. chlorine. 11. the identification marking must be recognizable after heat treatment.1. First Issue Date Revision No. In particular. If the materials are not easily legible.1.2. and fittings do not require color coding if these components are permanently stamped or tagged by the manufacturer. zinc. PMI markings shall be transferred when a plate or pipe is cut.2.2. 2012 00 NIL Page 10 of 12 11.5. Color Coding 11. 11.2.12. or cannot otherwise be stamped.1.2. Bolting: when required. Grade B7 stud bolts do not require color coding if the grade of the material is stamped on one end of each bolt.2. 11. Paints used for coding shall be durable.3.14. Permanent manufacturer’s markings shall not be obscured by color coding. Prior to coding. flanges.2.9.2. sulfur. stripe across edge to hub. Spiral-wound gaskets shall be color coded in accordance with ASME B16. 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. Sheet type gaskets do not require color coding. sheet and strip: stripe on surface near two perpendicular edges for entire length. Pipe and Fittings: each length of pipe and fitting shall have a 5 mm or larger stripe running full length. and fittings shall be coded with a stripe of 5 mm minimum width.Procedure No.2. 11. 11.6. 11. . too small. surfaces shall be clean and free of dirt.1 and noted on the alloy verification reports.2.13. 11.2. and oil.7. The color coding system for material identification described herein is intended to help prevent fabricators from using incorrect alloy material. cadmium. Plate. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION : : : : AMSYCO 400-01/01 October 20.2. ASTM A193. Valves. bright. If the material or item is too light. Color coding need not be retained after painting.2.5.2. paints shall be free of lead. One inch NPS and smaller may have a 3 mm stripe running full length.11. 11. 12. 12. First Issue Date Revision No. as during a measurement.8. 2012 00 NIL Page 11 of 12 12. The NITON XLt Analyzer contains an x-ray tube. The instrument shall be operated in a dry environment. 12. the analyzer emits a directed radiation beam at the front and top-front of the analyzer.1.Procedure No. etc. When the x-ray tube is ON and the shutter is open. Though NITON XLt was designed to be safe as possible. Attention will be paid on compliance with all electrical connections.2. Safety 12. which emits no radiation unless the user turns the x-ray tube on. Avoid simultaneous contact between the instrument and electrically conductive components. The instrument may only be operated on power outlets with a circuit breaker or ground fault breaker. other instruments. it is strongly recommended that all precautions are taken to insure safety for the operator and others around. 12.7. machinery.5. The electrical source must be turned off while changing the electrode on the probe. Avoid looking directly into the light arc.6. Revision Date Title: POSITIVE MATERIAL IDENTIFICATION 12.3.4. The instrument must be secured if operated on an uneven surface. There is negligible radiation at the handle of the analyzer. . 12. 12. 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. : : : : AMSYCO 400-01/01 October 20. First Issue Date Revision No. 2012 00 NIL Page 12 of 12 . Revision Date Title: POSITIVE MATERIAL IDENTIFICATION : : : : AMSYCO 400-01/01 October 20.Procedure No.