Pmi
Content
Inspection Procedure
00-SAIP-07 Positive Material Identification Requirements Document Responsibility: Inspection Engineering Standards Committee 19 August 2009
Saudi Aramco DeskTop Standards
Table of Contents 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Scope............................................................. 2 Purpose.......................................................... 2 References..................................................... 2 Definitions....................................................... 3 Responsibilities.............................................. 3 Instrument for PMI Analysis........................... 3 Personal Qualifications.................................. 4 Positive Material Identification General Requirements........................... 4 Alloy Items Subject to PMI............................. 5 Extent of Verification...................................... 5 Elements for Verification................................ 5 Acceptance Criteria........................................ 5 Re-Verification / Rejection Criteria................. 5 Marking and Color Coding............................. 6 Reporting and Documentation....................... 6
Attachment I – PMI Report Form.......................... 7 Attachment II – PMI Log Sheet............................ 8 Attachment III – Color Code for Material Identification........................................... 9 Attachment IV – PMI Procedure Flow Chart...... 10
Previous Issue: 5 July 2008 Next Planned Update: TBD Revised paragraphs are indicated in the right margin Primary contact: Kakpovbia, Anthony E. on 966-3-8747226
Copyright©Saudi Aramco 2009. All rights reserved.
Page 1 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
1
Scope 1.1 1.2 1.3 This SAIP provides functional guidance for Plant Inspectors performing Positive Material Identification (PMI) in all Saudi Aramco Facilities. This SAIP also instructs the assigned Saudi Aramco Inspector, on color coding of PMI verified materials, reporting and documentation. This SAIP does not include PMI requirements for the following: As per SAES-A-206 Paragraph 1.3.
2
Purpose The purpose of this SAIP is to ensure that the nominal composition of the materials specified has been correctly supplied and installed in the fabricated equipment or piping. Also, it ensures that the correct welding by testing the welds has been performed.
Commentary Note: PMI is a testing method which is independent of any material certification, mill test reports and marking or color coding of materials.
3
References All references defined in SAES-A-206 section 3 plus the following: 3.1 Saudi Aramco References Saudi Aramco Form SA 2093-ENG Equipment Inspection Record-General
Saudi Aramco Inspection Procedure 00-SAIP-12 3.2 Industry Codes and Standards American Society of Mechanical Engineers ASME SEC VIII Boiler and Pressure Vessel Code Equipment Deficiency Reports
Page 2 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
American Society for Testing Materials ASTM E353 Chemical Analysis of Stainless, Heat-Resisting, Maraging, and other Similar ChromiumNickel-Iron Alloys
Pipe Fabrication Institute PFI ES-42 Positive Material Identification of Piping Components Using Portable X-Ray Emission Type Test Equipment
4
Definitions All definitions of SAES-A-206 apply with the following addition or changes: Saudi Aramco Inspector: The person authorized by the Saudi Aramco responsible inspection unit to verify implementation of the requirements of this SAIP and SAES-A-206. Construction Organization: The organization responsible for fabrication, installation or repair of the alloy material in the field (e.g., maintenance organizations). PMI Instrument Operator: Trained technician assigned by Plant Inspection Unit supervisor to operate the PMI testing machine and record the PMI testing result.
5
Responsibilities The Assigned Inspector shall verify that the proper color coding and PMI tests are conducted and that the installed materials are of the specified metallurgy. In case a discrepancy is found, the inspector shall initiate an Equipment Deficiency Report (EDR) and ensure that the requirements of this SAIP and SAES-A-206 are satisfied.
6
Instrument for PMI Analysis 6.1 6.2 Instruments for performing the PMI analysis of weld and the base metals is as stated by SAES-A-206. Both method and frequency of calibration and standardization shall be based upon equipment manufacturer's recommendations. Records shall be maintained for the checks and the date of calibration noted in the PMI report (Attachment-I). When the inspector doubts the reliability of the measurement, he may calibrate the instrument on shorter periods (e.g., on weekly basis or before every use).
6.3
Page 3 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
6.4
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. (Attachment-I)
6.5
7
Personal Qualifications The person(s) performing the PMI test should be knowledgeable about all aspects of operation of PMI test equipment and the PMI test method used. Qualification of the person performing the PMI test, including training and experience, should be documented and submitted for review and approval by the responsible inspection unit. Personnel shall be trained, tested, and certified to: a) b) c) Safely use the PMI analyzers(s) (i.e., electrical arcing, X-Ray emission or chemical testing methods). Properly apply material specification such as ASTM and ASME. Fully understand the PMI requirements, including the verification method to be used, the period during fabrication when verification will be conducted, and the method of marking and color coding verified material and segregation and reporting non-compliant material.
8
Positive Material Identification General Requirements 8.1 When PMI testing is performed by the material supplier or third-party agency, the Company should review and approve the adequacy of the material PMI program and testing procedure of the fabricator or material supplier prior to testing. PMI shall be conducted before any post weld heat treatment, hydro test, painting or insulation of any equipment or piping. The area to be tested shall be solvent cleaned to remove any grease/oil/paint. Surface (base metal and welds) to be examined shall be prepared by light grinding to remove any rust/scale as per manufacturer's recommendations. Weld surface of overlay or clad restoration shall be prepared by removing 2-3 mm of weld metal. The PMI test report shall be reviewed prior to hydro test and made part of the hydro test package supporting documents.
8.2 8.3 8.4 8.5 8.6
Page 4 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
8.7
The responsible inspection unit shall audit the PMI test program to ensure its effective functionality. The Operation Inspection Division of the Inspection Department can be contacted for assistance.
9
Alloy Items Subject to PMI The following components shall be subject to PMI testing in accordance with this procedure. Plates (heads, shells, tube sheets, etc) and internals such as trays if required by the purchase order Forgings Flanges Pipe and fittings such as tees, elbows, reducers, and special pipe components Valves (body and bonnet) internals as per SAES-A-206 Thermowells Furnace tubes and fittings Casings for pumps, compressors, turbines Alloy welds joining pressure parts to pressure parts Heat exchanger tubes Metallic alloy gaskets
10
Extent of Verification As per SAES-A-206.
11
Elements for Verification As per SAES-A-206.
12
Acceptance Criteria As per SAES-A-206.
13
Re-Verification / Rejection Criteria As per SAES-A-206.
Page 5 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
14
Marking and Color Coding As per SAES-A-206 and Attachment III.
15
Reporting and Documentation 15.1 15.2 15.3 The PMI report form (Attachment-I) shall be completely filled out by the assigned inspector/technician for each PMI analysis. A log shall be maintained (see form in Attachment-II) to identify each component that has been alloy verified and the results. The Report should be part of the permanent Equipment Inspection Record.
Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document and reissued with editorial changes.
19 August 2009
Page 6 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
Attachment I – PMI Report Form
Request No. POSITIVE MATERIAL IDENTIFICATION REPORT Date: / / Location of Test:
Plant/P.O.: Equipment/Line No.: Item Type:( weld, valve, pipe, etc.) Type of Instrument Used: Model: Serial No.: Date of Calibration: Analysis Result:
Equipment /Line No. P.O.& Line item SubItem
Report No.: Sheet ______of________ Drawing No: (e.g., Equipment or ISO) Item Description: (Manufacturer & Heat #)
Elements for verification C Cr Ni Mo Nb
Result of Analysis Accept Reject Pending chemical analysis
Color code (Refer to 00-SAIP-07) Attachment III and PFI ES-22)
This is to certify that the above materials verification is done in accordance with the requirement of SAES-A-206 and the above alloying element percentages were evaluated in accordance with the criteria stated in the above-mentioned standard and this SAIP procedure. The items above were also color coded/marked in accordance with above two documents.
PMI Operator /Plant Inspector
Date
Signature
Verified by Inspector (Name &ID#)
Date
Page 7 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
Attachment II – PMI Log Sheet
LOG NO. Plant/P.O. # Equipment/ Line# Item Description PMI Report No.& Date Remarks
Page 8 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
Attachment III – Color Code for Material Identification
Material Low Alloy Materials 7 Cr-1/2 Mo Steel Nickel Based Alloys Copper based Alloys 90-10 Cu-Ni 70-30 Cu-Ni Note: B111 B111 C70600 C71500 1 solid green 1 solid red A335 GR. P7 S50300 2 solid green Common Designation UNS Designation Color of Stripe(s)
Any product manufactured by welding shall have an additional white stripe. Any additional alloy material not included in this table or PFI ES-22 shall be referred to the Operations Inspection Division of the Inspection Department for obtaining a Color Code.
Page 9 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
Attachment IV – PMI Procedure Flow Chart
Page 10 of 10
00-SAIP-07 Positive Material Identification Requirements Document Responsibility: Inspection Engineering Standards Committee 19 August 2009
Saudi Aramco DeskTop Standards
Table of Contents 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Scope............................................................. 2 Purpose.......................................................... 2 References..................................................... 2 Definitions....................................................... 3 Responsibilities.............................................. 3 Instrument for PMI Analysis........................... 3 Personal Qualifications.................................. 4 Positive Material Identification General Requirements........................... 4 Alloy Items Subject to PMI............................. 5 Extent of Verification...................................... 5 Elements for Verification................................ 5 Acceptance Criteria........................................ 5 Re-Verification / Rejection Criteria................. 5 Marking and Color Coding............................. 6 Reporting and Documentation....................... 6
Attachment I – PMI Report Form.......................... 7 Attachment II – PMI Log Sheet............................ 8 Attachment III – Color Code for Material Identification........................................... 9 Attachment IV – PMI Procedure Flow Chart...... 10
Previous Issue: 5 July 2008 Next Planned Update: TBD Revised paragraphs are indicated in the right margin Primary contact: Kakpovbia, Anthony E. on 966-3-8747226
Copyright©Saudi Aramco 2009. All rights reserved.
Page 1 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
1
Scope 1.1 1.2 1.3 This SAIP provides functional guidance for Plant Inspectors performing Positive Material Identification (PMI) in all Saudi Aramco Facilities. This SAIP also instructs the assigned Saudi Aramco Inspector, on color coding of PMI verified materials, reporting and documentation. This SAIP does not include PMI requirements for the following: As per SAES-A-206 Paragraph 1.3.
2
Purpose The purpose of this SAIP is to ensure that the nominal composition of the materials specified has been correctly supplied and installed in the fabricated equipment or piping. Also, it ensures that the correct welding by testing the welds has been performed.
Commentary Note: PMI is a testing method which is independent of any material certification, mill test reports and marking or color coding of materials.
3
References All references defined in SAES-A-206 section 3 plus the following: 3.1 Saudi Aramco References Saudi Aramco Form SA 2093-ENG Equipment Inspection Record-General
Saudi Aramco Inspection Procedure 00-SAIP-12 3.2 Industry Codes and Standards American Society of Mechanical Engineers ASME SEC VIII Boiler and Pressure Vessel Code Equipment Deficiency Reports
Page 2 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
American Society for Testing Materials ASTM E353 Chemical Analysis of Stainless, Heat-Resisting, Maraging, and other Similar ChromiumNickel-Iron Alloys
Pipe Fabrication Institute PFI ES-42 Positive Material Identification of Piping Components Using Portable X-Ray Emission Type Test Equipment
4
Definitions All definitions of SAES-A-206 apply with the following addition or changes: Saudi Aramco Inspector: The person authorized by the Saudi Aramco responsible inspection unit to verify implementation of the requirements of this SAIP and SAES-A-206. Construction Organization: The organization responsible for fabrication, installation or repair of the alloy material in the field (e.g., maintenance organizations). PMI Instrument Operator: Trained technician assigned by Plant Inspection Unit supervisor to operate the PMI testing machine and record the PMI testing result.
5
Responsibilities The Assigned Inspector shall verify that the proper color coding and PMI tests are conducted and that the installed materials are of the specified metallurgy. In case a discrepancy is found, the inspector shall initiate an Equipment Deficiency Report (EDR) and ensure that the requirements of this SAIP and SAES-A-206 are satisfied.
6
Instrument for PMI Analysis 6.1 6.2 Instruments for performing the PMI analysis of weld and the base metals is as stated by SAES-A-206. Both method and frequency of calibration and standardization shall be based upon equipment manufacturer's recommendations. Records shall be maintained for the checks and the date of calibration noted in the PMI report (Attachment-I). When the inspector doubts the reliability of the measurement, he may calibrate the instrument on shorter periods (e.g., on weekly basis or before every use).
6.3
Page 3 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
6.4
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. (Attachment-I)
6.5
7
Personal Qualifications The person(s) performing the PMI test should be knowledgeable about all aspects of operation of PMI test equipment and the PMI test method used. Qualification of the person performing the PMI test, including training and experience, should be documented and submitted for review and approval by the responsible inspection unit. Personnel shall be trained, tested, and certified to: a) b) c) Safely use the PMI analyzers(s) (i.e., electrical arcing, X-Ray emission or chemical testing methods). Properly apply material specification such as ASTM and ASME. Fully understand the PMI requirements, including the verification method to be used, the period during fabrication when verification will be conducted, and the method of marking and color coding verified material and segregation and reporting non-compliant material.
8
Positive Material Identification General Requirements 8.1 When PMI testing is performed by the material supplier or third-party agency, the Company should review and approve the adequacy of the material PMI program and testing procedure of the fabricator or material supplier prior to testing. PMI shall be conducted before any post weld heat treatment, hydro test, painting or insulation of any equipment or piping. The area to be tested shall be solvent cleaned to remove any grease/oil/paint. Surface (base metal and welds) to be examined shall be prepared by light grinding to remove any rust/scale as per manufacturer's recommendations. Weld surface of overlay or clad restoration shall be prepared by removing 2-3 mm of weld metal. The PMI test report shall be reviewed prior to hydro test and made part of the hydro test package supporting documents.
8.2 8.3 8.4 8.5 8.6
Page 4 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
8.7
The responsible inspection unit shall audit the PMI test program to ensure its effective functionality. The Operation Inspection Division of the Inspection Department can be contacted for assistance.
9
Alloy Items Subject to PMI The following components shall be subject to PMI testing in accordance with this procedure. Plates (heads, shells, tube sheets, etc) and internals such as trays if required by the purchase order Forgings Flanges Pipe and fittings such as tees, elbows, reducers, and special pipe components Valves (body and bonnet) internals as per SAES-A-206 Thermowells Furnace tubes and fittings Casings for pumps, compressors, turbines Alloy welds joining pressure parts to pressure parts Heat exchanger tubes Metallic alloy gaskets
10
Extent of Verification As per SAES-A-206.
11
Elements for Verification As per SAES-A-206.
12
Acceptance Criteria As per SAES-A-206.
13
Re-Verification / Rejection Criteria As per SAES-A-206.
Page 5 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
14
Marking and Color Coding As per SAES-A-206 and Attachment III.
15
Reporting and Documentation 15.1 15.2 15.3 The PMI report form (Attachment-I) shall be completely filled out by the assigned inspector/technician for each PMI analysis. A log shall be maintained (see form in Attachment-II) to identify each component that has been alloy verified and the results. The Report should be part of the permanent Equipment Inspection Record.
Revision Summary Revised the "Next Planned Update". Reaffirmed the contents of the document and reissued with editorial changes.
19 August 2009
Page 6 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
Attachment I – PMI Report Form
Request No. POSITIVE MATERIAL IDENTIFICATION REPORT Date: / / Location of Test:
Plant/P.O.: Equipment/Line No.: Item Type:( weld, valve, pipe, etc.) Type of Instrument Used: Model: Serial No.: Date of Calibration: Analysis Result:
Equipment /Line No. P.O.& Line item SubItem
Report No.: Sheet ______of________ Drawing No: (e.g., Equipment or ISO) Item Description: (Manufacturer & Heat #)
Elements for verification C Cr Ni Mo Nb
Result of Analysis Accept Reject Pending chemical analysis
Color code (Refer to 00-SAIP-07) Attachment III and PFI ES-22)
This is to certify that the above materials verification is done in accordance with the requirement of SAES-A-206 and the above alloying element percentages were evaluated in accordance with the criteria stated in the above-mentioned standard and this SAIP procedure. The items above were also color coded/marked in accordance with above two documents.
PMI Operator /Plant Inspector
Date
Signature
Verified by Inspector (Name &ID#)
Date
Page 7 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
Attachment II – PMI Log Sheet
LOG NO. Plant/P.O. # Equipment/ Line# Item Description PMI Report No.& Date Remarks
Page 8 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
Attachment III – Color Code for Material Identification
Material Low Alloy Materials 7 Cr-1/2 Mo Steel Nickel Based Alloys Copper based Alloys 90-10 Cu-Ni 70-30 Cu-Ni Note: B111 B111 C70600 C71500 1 solid green 1 solid red A335 GR. P7 S50300 2 solid green Common Designation UNS Designation Color of Stripe(s)
Any product manufactured by welding shall have an additional white stripe. Any additional alloy material not included in this table or PFI ES-22 shall be referred to the Operations Inspection Division of the Inspection Department for obtaining a Color Code.
Page 9 of 10
Document Responsibility: Inspection Engineering Standards Committee 00-SAIP-07 Issue Date: 19 August 2009 Next Planned Update: TBD Positive Material Identification Requirements
Attachment IV – PMI Procedure Flow Chart
Page 10 of 10
