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This content provides you with a sample positive material identification procedure. This PMI test procedure must be modified based your project specification. This procedure has been prepared for industrial plant construction project and contains both shop and site inspections.
1. Introduction
The XXX company has been contracted by the xxx to conduct the EPC for XXX Project. This Project includes offshore facilities, platform and undersea pipelines, and onshore facilities for the processing of the reservoir fluid.
2. Project Overview
XXX
3. General
3.1 Scope
This procedure prescribes the requirements for the positive material identification (PMI) for vessels and piping to verify that alloy materials are of acceptable chemical composition independent of any certificate and marking that may exist, and to assure that correct alloy materials are used at the places where intended. “AV” low stress stamp will be applied for the marking.
3.2 Definition of Contracting Parties
Company: XXX
Contractor: XXX
Vendor: Company who will supply and/or manufacture equipment and/or materials under Purchase Order issued by Contractor
Inspector: Inspector dispatched by Contractor/Company or inspector of third party inspection agency designated by Contractor
EPCC: Engineering, Procurement, Construction & Commissioning
SBM: Single Buoy Mooring
PMI: Positive Material Identification
3.3 Referenced Documents
This Procedure shall be read in conjunction with the following Documents:
XXX Project Quality Plan
XXX General Requirements for Welded Fabrication
XXX Specification, Design and Fabrication of Pressure Vessels
XXX Steel Piping Fabrication
XXX General Work Procedure for Welding
XXX Non Destructive Testing Procedure
XXX Site Material Approval Procedure
ASME B31.3 Process Piping
ASME Section II Part C Materials
DINEN 10204 Metallic products – Types of inspection documents
ASTM E 1476 Standard Guide for Metals Identification, Grade Verification, and Sorting
ASTM E 572 Standard Test Method for Analysis of Stainless and Alloy Steels by X-ray Fluorescence Spectrometr
ASTM E 322 Standard Test Method for X-Ray Emission Spectrometric Analysis of Low- Alloy Steels and Cast Irons
4. Extent of PMI
4.1 Materials
4.1.1 This procedure shall be applied to the following low alloy / Stainless Steel / high alloy materials, i.e.:
1) Low alloy steel containing more than 1 Cr – 0.5 Mo and/or 3.5 Ni
2) Type 316/316L stainless steel
3) Type 321/347 stainless steel
4) 11-13% Cr (Type 410/410S/40S)
5) Nickel Alloy such as INCONEL&HASTELLOY
6) Cooper Nickel Alloy
7) Aluminum -Bronze
8) Titanium
9) Other materials as mentioned in table 1.
Examination of the base materials to be carried out. Elements to be determined during PMI shall be as per Table.1.
4.2 Positive Material Identification Extent of Examination
4.2.1 This procedure shall be applied to the pressure containing parts of following items including welded joints and components (plates, forgings, nozzle(pipe), flanges, internal lining, tubes etc.) to the pressure containing parts of Pressure Vessels and Piping mentioned below para.1 and 2, respectively:
Also it shall be applied to the similar part in the package units.
1) Equipment
a) Pressure vessels, such as reactors, towers, drums, heat exchangers, air cooled heat exchangers
b) Fired heaters (only heater coils)
2) Piping
a) Pipes
b) Fittings
c) Flanges
d) Valves
The welded joints and components shall be tested after fabrication. For PMI test of tagged items, mill certificates shall cover all bulk items and components before fabrication.
All parts that are tested in the fabricated form should be 100% verified.
5. Sampling Procedure
5.1 Positive Material Identification (PMI) of Equipment at Vendor’s Shop
The vendor shall perform PMI examination of the finish weld on the one point of each joint inside and outside for all weld joints. When access is not possible to the inside weld and/or weld size is small, examination of the outside of a weld only shall be acceptable.
5.2 PMI of Piping Bulk Materials at Vendor’s Shop
5.2.1 The vendor shall perform PMI examination of all samples chosen at random from an inspection batch. Unless otherwise specified, inspection will be carried out at random for at least 1 (one) per each heat, minimum 3 points on each length of examined pipe to be carried out.
5.2.2 If any item from sample is found to be unacceptable, all remainder of that batch and two subsequent inspection batches shall be performed 20% PMI examination.
5.3 Positive Material Identification of Welded Joints at Site
5.3.1 After installation on the final location at site, the color code marked on the piping systems shall be checked and recorded by the Construction Contractor.
5.3.2 Finished groove weld in alloy piping system shall be examined on the one point of each joint for 5% groove weld joint.
5.3.3 Finished groove weld of alloy equipment assembled at Site shall be examined on the 5% random basis for all welded joints.
5.4 PMI of Components at Site
PMI of equipment is not required at site since PMI examination of these items shall be done at Vendor’s shop, but for piping components such as pipes, fittings & flanges, material traceability shall be performed in accordance with the document No. XXX Procedure for Heat Number Traceability for Piping Material.
If material traceability has not been done properly, PMI is required for such part of piping compounded at site.
Also for PMI of deposited weld metal at site, refer to Method Statement for Positive Material Identification – XXX.
6. Positive Material Identification Examination Method
6.1 Instruments used to perform PMI shall conform to one of following:
6.1.1 Portable X-ray emission or fluorescence spectrometers with direct reading of alloy grade or composition in the applicable range, such as “Texas Nuclear 9266” or META scope or equivalent.
6.1.2 Molybdenum in type 316 and 316L stainless steel may be checked with reagent.
6.2 The traces of PMI examination shall be taken off not to adversely affect the end use of items.
6.3 Reagent shall be washed off with water not to adversely affect to the end use of items and corrosion.
6.4 The construction contractor shall submit the PMI examination procedures which include following:
6.4.1 Equipment to be used
6.4.2 Washing of reagent
6.4.3 Control sheet of examination
6.4.4 Report form
7. Positive Matreial Identification Acceptance Criteria
Alloy elements specified in chemical composition of materials shall be detected at the PMI examination. Acceptance criteria range for all the project material to be tabulated as per related standard. Acceptable range shall include the tolerance of the measuring equipment, which is provided with manual by equipment’s maker
8. Color Code
8.1 For piping bulk materials, all items in an inspection batch shall be marked color code by the vendor. The color-coding for pipes shall be marked whole length of pipes after acceptance has been made.
9. Records
9.1 The vendor or the Construction contractor shall record the results of examination on a report form which indicates following as a minimum:
9.1.1 Item number of equipment, name of piping bulk material or welding joint number of piping systems
9.1.2 Material specification number and grade
9.1.3 Mill certification number
9.1.4 Inspection batch size
9.1.5 Number of items examined
9.1.6 Chemical composition detected
9.1.7 Measuring equipment used for examination with type, model, etc.
9.1.8 Signature and date of the representative of the supplier or the Construction Contractor
9.1.9 Calibration certificate of the positive material identification equipment
9.1.10 PMI report shall be as per DIN 50049 or BS/EN 10204 type 3.1C or 3.2. (In the meantime, PMI shall be witnessed by Company according to inspection and test plan enclosed in the Material Requisition).
9.1.11 PMI performed by the Vendor shall be presented to the Company/Contractor’s inspector for his review and will be compiled into Manufacturer’s Data Records at the completion of fabrication or manufacturing.
Table.1 Elements to be determined during PMI
| Materials (1) | Elements to be determined |
|---|---|
| 1% Cr, 0.5% Mo | Cr, Mo |
| 1.25% Cr, 0.5% Mo | Cr, Mo |
| 2.25% Cr, 1.0% Mo | Cr, Mo |
| 9% Cr, 1% Mo | Cr, Mo |
| 11-13% Cr (Type 410/410S/40S) | Cr |
| 304 (L) | Cr, Ni, Mo, Nb(Cb), Ti |
| 310 | Cr, Ni, Mo, Nb(Cb), Ti |
| 309 (L) | Cr, Ni, Mo, Nb(Cb), Ti |
| 309 Nb | Cr, Ni, Mo, Nb(Cb), Ti |
| 316 (L) | Cr, Ni, Mo, Nb(Cb), Ti |
| 321 | Cr, Ni, Ti, Nb(Cb) |
| 347 | Cr, Ni, Nb(Cb), Ti |
| Alloy 600 | Cr, Ni, Mo, Nb(Cb) + Ta |
| Alloy 625 | Cr, Ni |
| Alloy 800/800H | Cr, Ni, Al, Ti, Cu |
| AWS A5.11 ENiCrFe-2 | Cr, Ni, Nb(Cb) + Ta |
| AWS A5.11 ENiCrFe-3 | Cr, Ni, Nb(Cb) + Ta |
| AWS A5.14 ERNiCr-3 | Cr, Ni, Nb(Cb) + Ta |
| 2205 Duplex | Cr, Ni, Mo |
| Admiralty Brass | Cu, Sn, As |
| Aluminium Brass | Cu, Al, Zn |
| Cupro-nickel (70-30) | Cu, NI |
| Cupro-nickel (90-10) | Cu, Ni |
| Monel 400 | Cu, Ni |
| Titanium | Ti |
Executive Summary & Industrial Inspection Scope
In demanding industrial environments across Oil, Gas, Petrochemical, Offshore, and Heavy Process Infrastructure, rigorous compliance with ISO 9001 / ASME / API is essential to ensure operational integrity, personnel safety, and compliance with statutory regulatory frameworks. This technical specification provides QA/QC managers, procurement engineers, welding inspectors, and third-party inspection (TPI) agencies with an authoritative, field-tested guideline for “Positive Material Identification Procedure”.
Ensuring compliance regarding positive material identification procedure minimizes the risk of catastrophic asset failures, costly unscheduled shutdowns, and supplier non-conformances. The following technical sections delineate the scope of inspection, mandatory verification protocols, acceptance criteria, documentation deliverables, and root cause mitigation strategies.
Governing International Engineering Codes & Specifications
Verification and validation of Positive Material Identification Procedure must strictly conform to the latest editions of the following international engineering codes and project specifications:
• **Primary Standard Reference:** ISO 9001 / ASME / API
• **Quality Management & Inspection Systems:** ISO 9001:2015 & ISO/IEC 17020 (Requirements for the operation of various types of bodies performing inspection)
• **Material Compliance & Traceability:** EN 10204 Type 3.1 / 3.2 Inspection Certificates for metallic and non-metallic pressure-retaining components
• **Personnel Qualification:** ASNT SNT-TC-1A / ISO 9712 for NDT personnel, CSWIP 3.1 / AWS CWI for welding inspection, and NACE / AMPP Level 2/3 for coating and corrosion personnel
• **Statutory & Health Safety Directives:** ASME Boiler & Pressure Vessel Code (BPVC), API Standards, OSHA, and regional local authority regulations.
Step-by-Step Quality Control & Inspection Procedure
The execution of quality surveillance for Positive Material Identification Procedure is structured across four progressive QA/QC intervention phases:
Stage 1: Pre-Inspection & Engineering Document Review (Review Point – R)
Prior to commencement of any physical activities or manufacturing operations related to Positive Material Identification Procedure, the contractor or vendor must submit all technical submittals to the Owner or TPI agency for formal review and approval.
- Verification of approved Inspection and Test Plan (ITP) identifying all Hold (H), Witness (W), Review (R), and Surveillance (S) intervention points.
- Cross-examination of Material Test Reports (MTR / Mill Certificates) against standard design specifications (ISO 9001 / ASME / API).
- Review and approval of specific Procedure Qualification Records (PQR), Welding Procedure Specifications (WPS), or calibration certificates.
- Verification that all measurement instruments, gauges, and NDT equipment hold valid calibration certificates from ISO/IEC 17025 accredited calibration laboratories (within 6 to 12 months validity).
Stage 2: In-Process Witnessing & Fabrication Control (Witness / Hold Point – W/H)
During the active execution phase, the certified inspector performs physical surveillance to ensure strict adherence to certified drawings, manufacturing procedures, and code tolerances.
- Verification of material traceability (heat number, heat treatment lot, plate number) transferred accurately onto fabricated components.
- Dimensional verification and visual inspection using calibrated gauges, micrometer depth dials, or laser alignment systems.
- Monitoring ambient environmental parameters (relative humidity, dew point, substrate temperature) when applying surface treatments, welding preheat, or pressure testing.
- Witnessing non-destructive examination (RT, UT, MT, PT, PMI) at specified percentages according to project critical rating and code requirements.
Stage 3: Final Acceptance, Pressure/Performance Testing & Marking (Hold Point – H)
The culminating milestone where the fully assembled or completed item is subjected to definitive acceptance tests in the presence of the Owner’s Third-Party Inspector (TPI).
- Execution of pressure proof tests (Hydrostatic at 1.3x to 1.5x MAWP or Pneumatic test) with dual calibrated pressure gauges and temperature recorders.
- Full visual inspection of completed surfaces, welds, protective coatings, and flange contact faces for absence of mechanical damage or code defects.
- Validation of permanent stamping, low-stress die markings, nameplate data verification, and barcoding in strict conformity with project specs.
- Clearing all open punch-list items, non-conformance reports (NCRs), and concession requests prior to issuance of the release note.
Stage 4: Packing, Preservation & Inspection Release (Inspection Release Certificate – IRC)
Ensuring the inspected equipment is adequately protected against atmospheric corrosion, mechanical shock, and marine transit degradation.
- Inspection of rust preventative coatings, desiccant bags, flange face blind protectors, and vapor corrosion inhibitor (VCI) packaging.
- Verification of heavy-lift sea fastening lugs, center-of-gravity markings, and export crating compliance (ISPM 15 wooden crating).
- Compilation and signing of the final Inspection Release Certificate (IRC / Shipping Release) and manufacturer data dossier (MDR).
Technical Acceptance Criteria & Tolerances Matrix
All measurements and physical characteristics must comply with the engineering tolerances and acceptance thresholds tabulated below:
| Inspection Parameter / Test Item | Applicable Standard & Clause | Permissible Tolerance / Acceptance Limit | Verification Method | Intervention Type |
|---|---|---|---|---|
| Material Chemical & Mechanical Verification | ISO 9001 / ASME / API / EN 10204 3.1 | 100% compliance with minimum tensile, yield, elongation, and impact values (Charpy V-Notch at design temp) | Optical Emission Spectrometry (OES) / MTR Verification | Review (R) |
| Visual & Dimensional Tolerances | ISO 9001 / ASME / API / Project Specs | Zero cracks, lack of fusion, severe pitting; dimensional tolerances within ±1.0mm to ±3.0mm per code drawings | Calibrated Vernier, Bridge Cam, Depth Micrometer | Witness (W) |
| Non-Destructive Examination (NDT) | ASME Sec V / ASNT SNT-TC-1A | 100% compliant with code acceptance criteria; zero planar defects or unpermitted volumetric indications | Radiographic (RT) / Ultrasonic (UT) / Magnetic Particle (MT) | Hold (H) |
| Pressure / Proof Testing (Hydrostatic) | ISO 9001 / ASME / API / ASME Sec VIII | Test pressure maintained for minimum 30 to 60 mins; zero pressure drop, zero leakage or visible sweating | Dual calibrated Bourdon pressure gauges + Chart Recorder | Hold (H) |
| Surface Prep & Protective Coating Quality | SSPC-SP / NACE / ISO 8501 | Surface profile 50 – 75 µm; Dry Film Thickness (DFT) within 80/20 rule of specified nominal thickness | Replica Tape (ASTM D4417) & Magnetic Gauge (SSPC-PA 2) | Witness (W) |
| Nameplate & Final Preservation Verification | API / ASME / Client Specs | 316L SS nameplate securely affixed with correct design code, MAWP, design temp, and national board stamping | Physical visual check & VCI preservation verification | Hold (H) |
Mandatory QA/QC Dossier & Inspection Deliverables
Prior to the final issuance of the Inspection Release Certificate (IRC), the contractor and vendor must compile and submit the verified manufacturer data record containing:
- Approved Inspection & Test Plan (ITP) with sign-off stamps by Contractor, Client, and TPI.
- Material Test Reports (MTR / Mill Test Certificates EN 10204 Type 3.1 or 3.2).
- Certified Welding Procedure Specifications (WPS), Procedure Qualification Records (PQR), and Welder Performance Qualifications (WPQ).
- Calibration Certificates for all test instruments and measuring equipment (NABL / ISO 17025 accredited).
- Non-Destructive Examination Reports (RT, UT, MT, PT, PMI, Ferrite Content) evaluated by Level II/III inspectors.
- Heat Treatment & PWHT Time-Temperature Recorder Charts with thermocouple layout drawings.
- Hydrostatic / Pneumatic Pressure Proof Test Certificate with calibrated chart recorder logs.
- Surface Preparation and Protective Coating Inspection Reports (Daily environmental log, blast profile, DFT summary).
- Non-Conformance Report (NCR) and Concession Disposition Closeout Log.
- Official Inspection Release Certificate (IRC / Shipping Release Note) permitting packing and dispatch.
Common Non-Conformances & Field Mitigation Strategies
Based on extensive third-party inspection field records in oil & gas projects, the following deviations require heightened surveillance:
Defect / Hazard: Material Grade Substitution & Lack of Heat Traceability
Root Cause: Uncontrolled workshop storage, missing color coding, or unverified supplier sub-tier procurement without EN 10204 3.1 documentation.
Preventative Action: Enforce strict 100% Positive Material Identification (PMI) prior to cutting, and mandatory material receiving inspection with physical stamping cross-referenced to original mill test certificates.
Defect / Hazard: Out-of-Tolerance Fit-Up & Alignment Mismatch
Root Cause: Poor thermal cutting, thermal distortion from excessive preheat, or inadequate jigging and tacking arrangements.
Preventative Action: Establish a mandatory Witness/Hold point at joint fit-up before root pass deposition. Use calibrated Hi-Lo gauges to verify bevel angle, root face, and root gap according to the qualified WPS.
Defect / Hazard: Premature Coating Delamination & Blistering Under Film
Root Cause: Excessive soluble salt contamination (>20 mg/m²) left on the substrate, blast cleaning below dew point (<3°C above dew point), or oil/moisture in the blasting compressor air line.
Preventative Action: Perform Blotter Test (ASTM D4285) daily on compressed air, enforce Bresle patch chloride testing, and apply primer within 4 hours of abrasive blasting before rust blooming initiates.
Defect / Hazard: Pressure Drop During Final Hydrostatic Proof Testing
Root Cause: Micro-leakage through temporary test flange gaskets, entrapped air pockets inside vessel high points, or inadequate temperature stabilization.
Preventative Action: Ensure thorough venting at all high-point vents until bubble-free fluid emerges, allow minimum 15-minute temperature stabilization between filling medium and ambient metal, and torque all blind flanges with calibrated torque wrenches.
Frequently Asked Questions (FAQ)
Q: What are the mandatory qualifications for inspectors verifying Positive Material Identification Procedure?
A: Inspectors must hold recognized international certifications applicable to the discipline. For welding and fabrication: CSWIP 3.1/3.2, AWS CWI, or API 510/570 Source Inspector. For NDT: ISO 9712 or ASNT SNT-TC-1A Level II minimum. For coatings: NACE / AMPP Level 2 or FROSIO Level III. Additionally, the inspection agency must operate under an ISO/IEC 17020 accredited quality management system.
Q: How does PtroTek resolve non-conformances (NCRs) encountered during vendor surveillance?
A: When a deviation from certified drawings or ISO 9001 / ASME / API is detected, the inspector issues a formal Non-Conformance Report (NCR) within 24 hours. The vendor must submit a Root Cause Analysis (RCA) and proposed disposition (Rework, Repair, or Concession). Work on the affected component is halted (Hold Point) until the Owner’s engineering authority approves the disposition and a re-inspection confirms full compliance.
Q: What is the difference between Witness (W) and Hold (H) points in an Inspection & Test Plan (ITP)?
A: A Hold Point (H) is a mandatory milestone where fabrication or testing CANNOT proceed without the physical presence of the designated client or third-party inspector. Written clearance or stamping is strictly required. A Witness Point (W) requires prior notification (typically 24 to 48 hours) to the inspector; however, if the inspector fails to attend at the scheduled time, fabrication or testing may proceed with subsequent review of the test records.
Q: Can international clients review inspection reports and photos in real time?
A: Yes. PtroTek provides comprehensive Flash Reports issued within 24 hours of inspection completion, followed by detailed formal inspection reports accompanied by high-resolution calibrated photographic evidence, dimension logs, and signed vendor test records for complete global transparency.
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