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CONSTRUCTION SPECIFICATION
POSITIVE MATERIAL IDENTIFICATION ( P M I )
AT CONSTRUCTION SITES
FOR
NITROGEN PACKAGE
FOR
HINDUSTAN PETROLEUM CORPORATION LTD.
VISAKH REFINERY

DHT PROJECT
TEIL JOB NO. : 6261
DOCUMENT NO. : P - 101

16.04.2009

For Bid Enquiry

Rev.
no.

Issue Date

Description

UCM

PRK

Prepared by Checked by Approved by

TOYO ENGINEERING INDIA LIMITED

MUMBAI

SSV

INDIA

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Sheet 2 of 13

Revision History
Rev.

Date

16.04.2009

Description
For Bid Enquiry

< Security Level 2 >

POSITIVE MATERIAL
IDENTIFICATION ( P M I )
AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 3 of 13

HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

TABLE OF CONTENTS
DESCRIPTION

CLAUSE NO.

PAGE NO.

1.0

SCOPE

2.0

DEFINITION

3.0

SPECIFIC APPLICABILITY

4.0

REFERANCES

5.0

GENERAL REQUIREMENTS

6.0

EXTENT OF PMI

10

7.0

PMI IN WARE HOUSE

10

8.0

PMI OF PIPING AND HEATER COIL

COMPONENTS

10

9.0

TESTING METHODOLOGY

11

10.0

CALIBRATION

11

11.0

PERSONEL QUALIFICATION

11

12.0

ACCEPTANCE CRITERIA

11

13.0

REJECTION CRITERIA

12

14.0

DOCUMENTATION

12

ATTACHMENT - A

13

< Security Level 2 >

POSITIVE MATERIAL
IDENTIFICATION ( P M I )
HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 4 of 13

1.0

SCOPE

1.1

This specification applies to metallic alloy materials used in piping, heater coils,
storage tanks, vessels, column, etc. at construction sites. PMI is to be carried
out on OWNER supplied material as well on material purchased by the LSTK
contractor.

1.2

This specification covers the procedures and methods to be used to assure that
the chemical composition of alloy materials confirms to the material specification
as specified in purchase documents / contract using Alloy Analyzers.

1.3

Any deviation from this specification must be approved by OWNER / PMC in the
prescribed format.

1.4

Carbon steels except Low Temperature Carbon Steel (LTCS) are excluded from
the scope of this specification.

1.5

Actual alloy verification application shall be controlled and coordinated by PMI

agency appointed by LSTK.

1.6

Alloy verification shall be performed by the inspector of the LSTK or appointed

agency sub contracted by the LSTK

1.7

The inspector who is instructed by the PMI Agency shall perform alloy
verification tests to ensure that verified material is traceable to the order and
any required material documentation.

1.8

The PMI tests shall be performed in accordance with the approved procedure
by qualified personnel at the point, which ensure the correct material has been
used.

1.9

The alloy verification procedures, including complete descriptions of the

methods, equipment to be used, and personnel qualification procedure shall be
established for providing consisting and accurate results if conduct of any
verification is unacceptable or if any material has been incorrectly identified, all
further tests shall not be performed until the problem is corrected.

< Security Level 2 >

POSITIVE MATERIAL
IDENTIFICATION ( P M I )
HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 5 of 13

2.0

DEFINITIONS

2.1

POSITIVE MATERIAL IDENTIFICATION (PMI).

The term Positive Material Identification (PMI) refers to determination /
verification of alloy type or its composition using portable or mobile
spectrometer / XRF alloy analyzer.
Chemical spot checking, resistively testing, eddy current testing,
electromagnetic alloy sorting, turboelectric testing thermoelectric testing shall
not be considered as PMI for the purpose of this specification.

3.0

SPECIFIC APPLICABILITY

3.1

The following items require PMI unless specifically exempted through a Waiver /
Deviation permit by OWNER / PMC.
All welds performed at construction job site
A)
B)

C)

Where accessible, the alloy verification of welds shall preferably be

made on the process side of the weld.
For welds made by the GTAW, SMAW or other processed not using
continuous wire electrodes, a minimum of one alloy verification
analysis shall be made for each FIVE METER (5M) of individual weld
length,
For individual pressure-containing welds made by the SAW process or
other approved process using continuous wire electrode, a minimum of
one alloy verification analysis shall be made on each weld on the
individual.
Repair welds.

3.1.1

All pressure containing piping components including welds, Thermowells

instrument manifolds, RTJ gaskets, fasteners etc.

3.1.2

Tubular products used in the fabrication of heaters.

3.1.3

Pressure containing instrument housings (e.g. gauge glass housings, and

orifice meter tubes).

3.1.4

Internal metallic linings / cladding and weld overlay, done at Site, used for
protection against corrosive environments.

3.1.5

Tubing.

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POSITIVE MATERIAL
IDENTIFICATION ( P M I )
AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 6 of 13

HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

3.1.6

Stud, bolts and nuts of ASTM A-193/A-194 Specification etc.

3.1.7

Parts which have been alloy verified at the fabricators shops with sufficient
marking and records are the exceptions unless PMI Agency instructs otherwise.

3.1.8

Plate and pipe material to be used as pressure-containing parts may be alloy

verified prior to cutting at construction job site provided the transferred marking
properly identify the subsequent components with heat/lot traceability and alloy
verification status.

3.1.9

For LTCS piping and other pressure containing components intended for
service at 29C or colder, traceable mill certificates shall be used to verify
notch toughness and chemical composition for each component.
Documentation of compliance as per this specification shall be included in the
permanent inspection records.

3.1.10

All pressure containing welds.

3.1.11

Any other components or materials specifically designated for PMI on the

purchase order / contract.

3.2

EXCLUSIONS
The following items are exempted unless specifically designated for PMI in the
purchase order / contract.

3.2.1

Gaskets (spiral wound or carbon steel only).

3.2.2

Internal instrument parts.

3.2.3

Internal machinery parts.

3.2.4

Internal non pressure containing baffles, tray, clips, supports, pall-rings,

support rings etc.

3.2.5

Electrical components.

3.2.6

Non pressure containing welds, including seal welds, piping supports welds,
structural parts.

3.2.7

Internal valve components.

3.2.8

Compression type ferrules and fittings for use with inch (19mm) outside
diameter and smaller tubing.

< Security Level 2 >

POSITIVE MATERIAL
IDENTIFICATION ( P M I )
HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

4.0

AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 7 of 13

REFERENCES
American Society of Mechanical Engineers (ASME) BPV Code Section II Part
A, B.C.and D.
ASME B 31.3 American Society for Testing and Materials (ASTM): As
applicable.
Material Verification Program for New and Existing Alloy Piping Systems: API
RP 578.
Any other material specification referenced by the Purchase Order / Contract.

5.0

GENERAL REQUIREMENTS

5.1

The LSTK contractor shall submit a procedure for PMI to comply with the
requirements of this Specification. Approval of PMI procedure shall be obtained
prior to commencing fabrication/ erection as the case may be.

5.2

Tabulation of tested items must be keyed to as-built drawings and Mill

Certification Document-Stampings through the use of reference numbers. One
(1) copy of test results shall be provided to Owner as part of the as-built
document.

5.3

PMI test results must conform to purchase documents, be properly identified to

the applicable Specifications such as Piping Material Specification, ASME,
ASTM, BS and Colour coded as required by contract Specifications.
Upon receipt, purchased materials or equipment that has been subject to PMI
by the vendor shall be examined by the
LSTK CONTRACTOR. This
examination shall include verification of stamping, marking and records of PMI
per this specification.
After installation but prior to hydrostatic testing/painting/insulation, the LSTK
contractor shall examine all components requiring PMI for proper compliance to
this specification. A record of this final check as specified below shall be
submitted to OWNER / PMC and made part of the permanent inspection
records.

5.4

The test methods outlined in this specification are intended to identify the
nominal composition of alloy materials. These test methods are not intended to
establish the conformance of a material to a particular alloy specification.

< Security Level 2 >

POSITIVE MATERIAL
IDENTIFICATION ( P M I )
HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 8 of 13

5.5

PMI shall not be considering as a substitute for required mill test reports listing
chemical composition. In addition, mill test reports shall not be considered as
confirming alloy verification.

5.6

The PMI activity shall be included in the overall quality plan and Inspection &
Test Plan for warehouse and fabrication / erection. The LSTK contractor shall
submit to OWNER / PMC, a procedure for PMI to comply with the requirements
of this specification. Approval of PMI procedure shall be obtained from OWNER
/ PMC prior to commencement of fabrication / erection as the case may be.

5.7

A copy of daily PMI records shall be submitted to OWNER / PMC.

5.8

MARKING

5.8.1

Marking methods.

5.8.1.1

Principally the marking shall be done by certified low stress stamp.

5.8.1.2

If the material or item is too light, too small, or can not otherwise be stamped,
vibro-etching or color coding shall be applied in conjunction with the Vendors
standards and the requirements of the above paragraph and noted on the alloy
verification reports.

5.8.1.3

Marking material used for Color Coding, Tubes, and Rejected Components.
a.

The marking material shall be a water insoluble material that contains no

harmful substance, such as metallic pigments, sulphur, or chlorides, which
would attack, or harmfully affect austenitic or nickel alloy steel at ambient or
elevated temperature.

b.

The analysis of marking material shall be confirmed.

These markings are in addition to markings required by other Codes/

Specification/ Technical notes.
5.8.2

Failed Components.

5.8.2.1.

Materials, items and welds which are found to be unacceptable during

verification testing shall be immediately marked with a red R pending
resolution.
Marking material for failed components shall meet the requirements of marking
materials in Para 5.8.1.3

5.8.2.2.

< Security Level 2 >

POSITIVE MATERIAL
IDENTIFICATION ( P M I )
AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 9 of 13

HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

5.8.3

Accepted Components.

5.8.3.1.

All verified materials with acceptable analysis shall be marked with the letters A
appropriate using certified low-stress stamp or other acceptable methods.

5.8.3.2.

The marking shall be placed as follows:

a.
b.
c.
d.
e.
f.
g.

Pipe: two marks, 180 degrees apart, 75mm (3 in) from each and of each
length on the outer surface of the pipe.
Welds: Adjacent to the welders mark on the weld.
Fittings and forgings: Adjacent to the Vendors marking.
Valves adjacent to the Vendors marking on bodies and other pressure
parts.
Plates: adjacent to the heat number.
Casting: adjacent to the manufacturers marking and number.
Tubes for heat transfer service: stenciled, not stamped, on each end.

5.8.4

If the alloy verification test results fall outside of the acceptance criteria, then the
following shall be done by PMI Agency,

5.8.4.1

Obtain a quantitative check analysis performed by an independent test

laboratory using the applicable method referenced by the material specification.
If no method is referenced, an appropriate standard chemical analysis method
shall be used.

5.8.4.2

Find other corrective action plan.

5.8.5

All items of the type in question or all similarly identified materials of that lot or
shipment shall not be accepted pending results of the independent tests. If the
test results of the Independent laboratory tests are not within the acceptable
range of the ASTM or other applicable material specification, the material shall
be rejected.

5.8.6

Owner supplied material / Free Issue Material:

Records signed by LSTK contractor and duly certified by OWNER / PMC.

5.8.7

LSTK contractor supplied material:

Records signed by LSTK contractor and certified by and approved third party
inspection agency.

5.9

After acceptance, all components shall be marked with a suitable paint mark.
Marking must be permanent and readily visible. These markings are in addition
to markings required by other codes/specifications/Technical Notes.

< Security Level 2 >

POSITIVE MATERIAL
IDENTIFICATION ( P M I )
AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 10 of 13

HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

5.10

Controls shall be established to keep the non confirming items identified till
proper resolution of non conformity.

5.11

OWNER / PMC shall have the right to witness the performance of any PMI test.

6.0

EXTENT OF PMI
PMI shall be done on each component (100 percent PMI inspection) including
welds, unless specifically exempted by OWNER / PMC.
However, all non pressure containing parts (such as pipe supports) and studs,
bolts, nuts and washers shall require random PMI of 10% of each lot. For each
nonconformity detected, the extent of PMI shall double.

7.0

PMI IN WAREHOUSE
PMI testing to be performed as part of the receiving inspection at warehouse.
The extent of PMI shall be as specified in 6.0. However, if PMI testing has been
carried out at vendor / manufactures shop and relevant certified records and
correlation with incoming material is available, PMI testing at warehouse need
not be done.
PMI testing within the warehouse shall not be regarded as and alternative to
PMI testing of the installed system.
Alloys verified by an approved analysis method shall contain the amount of alloy
elements within the ranges permitted by the material specification increased by
the tolerance of the equipment or method used.

8.0

PMI OF PIPING AND HEATER COIL COMPONENTS

PMI testing (irrespective of PMI done at earlier stages) shall be carried out
when piping loops/heater coils have been cleared for hydrostatic testing by
OWNER / PMC. Hydrostatic testing shall be carried out only when non
confirming components have been replaced with conforming components and
subsequent Non Destructive Testing. Post Weld Heat-Treatment. Hardness
checking etc. as required by specifications has been completed. PMI records
shall form a part of piping/heater inspection records. LSTK contractor shall
demonstrate to PMC that each & every component of the piping system and
heater coils has been subjected to PMI.

< Security Level 2 >

POSITIVE MATERIAL
IDENTIFICATION ( P M I )
AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 11 of 13

HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

9.0

TESTING METHODOLOGY
In general, portable X-Ray Fluorescence (XRF) type analyzers such as Metorex
X-Met 2000 Metal Master or NITON II Alloy Analyzer or similar analyzer shall be
used for carrying out PMI. Identification of characteristic alloying element, which
distinguishes the material from other material, will be sufficient.
Testing shall be done after proper surface cleaning and other requirements
outlined by the manufacturer of the portable alloy analyzer. Modification, if any,
of these procedures must be approved by OWNER / PMC.

10.0

CALIBRATION

10.1

Instruments used for PMI shall have the sensitivity to detect the alloy elements
in the specified ranges. Instruments or methods used for examination shall be of
the type that will provide quantitative record-able elemental composition results
for positive identification of the alloy elements present.

10.2

Each alloy analyzer shall be calibrated using known alloy standards for intended
materials to be checked by PMI. Manufacturers recommendations shall be
followed in this regard.

10.3

OWNER / PMC shall review the procedure and qualification and witness sample
alloy verification tests to confirm that the procedures, equipment and personnel
are capable of providing consistent and accurate results.

11.0

PERSONNEL QUALIFICATION
The persons performing the PMI test should be knowledgeable about properties
of material, all aspects of operation of PMI equipment including the method of
testing. Qualification documents of the person performing the PMI test including
his training and experience shall be submitted to OWNER / PMC for review and
approval.

12.0

ACCEPTANCE CRITERIA

12.1

Material shall contain amount of characteristic alloying elements as specified in

respective material code/specification.

12.2

Deposited weld metal or undiluted weld metal deposits shall be within +/- 12.5%
of the ranges allowed by the welding consumable specification/code.

< Security Level 2 >

POSITIVE MATERIAL
IDENTIFICATION ( P M I )
AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 12 of 13

HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

13.0

REJECTION CRITERIA

13.1

If the PMI test results fall outside the acceptable range the LSTK contractor
shall obtain a quantitative check analysis performed by a laboratory acceptable
to OWNER / PMC for a complete chemical analysis. Results of this analysis
shall govern.

13.2

If any material component or weld is found unacceptable all other represented

materials (e.g. fasteners, supports) or weld shall be consider suspects. The
LSTK contractor has the following options

13.1.1

Scrapping all those represented materials and components and replacing with
new components or welds.

13.1.2

Performing 100% examination of the remainder of the represented materials/

components and replacing each item that fails the PMI check.

13.1.3

If the performance of any verification activity is unacceptable to OWNER / PMC

or if any material has been incorrectly identified all further tests shall be subject
to OWNER / PMC approval until the problem is corrected.

14.0

DOCUMENTATION

14.1

Printout from alloy analyzer, in original duly certified by the LSTK contractor
and the approved third party inspection agency for LSTK contractors supplied
material and OWNER / PMC for OWNERs supply materials.

14.2

PMI report shall be as per Attachment - A.

14.3

Basis and action for resolving and documenting PMI non conformances.

14.4

LSTK contractor shall demonstrate to OWNER / PMC that all components

requiring PMI have been subjected to PMI testing and accepted.

< Security Level 2 >

POSITIVE MATERIAL
IDENTIFICATION ( P M I )
AT CONSTRUCTION SITES

TOYO ENGINEERING INDIA LTD.

JOB NO. : 6261

DHT PROJECT

Sheet 13 of 13

HPCL, Visakh
ISSUED : 29.12.2008
DOC.No. P 101

ATTACHMENT - A
REPORT NO.:_______

POSITIVE MATERIAL IDENTIFICATION TEST REPORT

LSTK contractor _______________

Date. __________________

Project ___________________

Inspection Agency ________

Location _________________

PMI Equipment model ______

Line No. / ISO Drg. No.__________

Make & Serial No. _________

/ Heater No.

Sr. No.

Part Identification

Material As per Drg. /

spec

Material
PMI

as

per

_________________

________________

_______________

( LSTK CONTRACTOR)

(THIRD PARTY)

(OWNER / PMC)

Result