Engineering Standard SAES-A-206 9 April 2020 Positive Material Identification Document Responsibility: Materials Engineering Standards Committee Contents Summary of Changes .............................................. 2 1 Scope ................................................................. 4 2 Conflicts and Deviations ..................................... 4 3 References ......................................................... 4 4 Terminology........................................................ 5 5 Requirements ..................................................... 6 6 Responsibilities .................................................. 8 7 Verification Coverage ......................................... 8 8 Methods ........................................................... 12 9 Acceptance Criteria .......................................... 13 10 Rejection Procedures ....................................... 13 11 Records and Reports ....................................... 14 12 Marking and Color Coding ................................ 15 Document History .................................................. 18 Previous Revision: 5 May 2019 Contact: MUAILISM Next Revision: 5 May 2024 Page 1 of 18 ©Saudi Aramco 2020. 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Saudi Aramco: Company General Use Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 SAES-A-206 Positive Material Identification Summary of Changes Paragraph Change Type 1 1 Modification 2 1.1 Modification/Addition 3 1.2 Addition Clarified the purpose of the standard. 4 1.3 Addition Clarified the scope of application of this standard. 5 1.4 Addition Clarified the end users intended under the scope of this SAES. 6 1.5 Addition Emphasis on MTRs, marking and traceability. 7 3 Deletion Removed reference to SAES-W-019 8 4 Addition Added “Responsible Inspection Organization”. 9 4 Deletion Removed “SAMS: Saudi Aramco Material System”. 10 5.1.1 Deletion Deleted but the requirements were indicated in the scope, paragraph 1.3 and 1.4. 11 5.1.2 Deletion Deleted but the requirements were indicated in the scope, paragraph 1.5. 12 5.1.1 Addition Emphasis on QC, conformance testing and traceability. 13 5.1.3 Addition Control of welding procedure. 14 5.1.4 Deletion No CSD recommendation is required to conduct retroactive PMI testing. 15 5.2.1 Exceptions Modification 16 5.2.1 Note Editorial 17 5.2.2 Editorial 18 6.1 / 6.2 Modification 19 6.3 Addition Responsible Inspection Organization responsibilities. 20 6.4 Addition Manufacturer responsibilities. 21 6.5 Addition PMI application responsibilities. Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Technical Change Scope was re-arranged and clarified. Added “operationally-important components” Replaced the Materials Engineering Committee review by quality control requirements. Spelled out SSC. - Corrected “SAMS” to read “SAMSS”. Added “175-Form”. Replaced “representative” with “Responsible Inspection Organization”. Page 2 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 SAES-A-206 Positive Material Identification Paragraph Change Type Technical Change 22 6.6 Addition Saudi Aramco Inspector responsibilities. 23 6.7 Addition Manufacturer PMI operators training responsibilities. 24 7.1 Modification Added “Operationally-Important Components”. - 25 Modification Table 1 - Moved all alloy requirements to table 2. Added requirements for internally cladded components. Added API 570 “Class 3” Services”. Added “ASME B31.3 Category D Service”. Re-write the table to maintain standard terminology. Added examples. Added clarifications. Added Ferritic and Martensitic SS. Added clarification for Aluminum Alloys. Added clarification for Copper Alloys. Removed registered alloy names from the note section. 26 Table 2 Modification 27 7.6 Modification 28 8 Deletion 29 9.2 Modification/ Editorial 30 9.4 Deletion 31 9.5 Modification 32 13 Deletion 33 14 Modification Renumbered the whole section from 14 to 13. 34 14.1.3 Modification Deleted the material selection requirements for 300 series stainless as this is irrelevant to this standard. 35 14.1.5 Editorial Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Added “Special”. All requirements in section 8 “procedures” were reviewed and moved to section 6 “responsibilities”. - Clarification about PMI testing techniques. - Commentary note was added. - 9.2.1 XRF. - 9.2.2 OES. - Arranged requirements. Eliminate confusion. Editorial change to match API RB 578 terminology. All requirements in section 13 “inspection” were reviewed and moved to section 6 “responsibilities”. New paragraph number for an existing requirement. Page 3 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 1 SAES-A-206 Positive Material Identification Scope This standard defines the minimum mandatory requirements for positive material identification (PMI) of pressure-retaining alloys and operationally-important components. This includes, but not limited to, pipes, fittings, flanges, bolting, welds, weld overlays and cladding. It aims to minimize the risk of component failure and release of hazardous/toxic liquids and vapors. The requirements in this standard are intended to: a) Ensure that the nominal composition of the alloy components and associated welds have been correctly supplied and installed as specified. b) Prevent mix-up of materials and/or welding consumables during dispatching by manufacturers and during fabrication or assembly at the shop or site. c) Be an integrated part of a Quality Control (QC) system by manufacturers, fabricators, construction contractors and maintenance activities. The requirements in this standard shall apply to both new, repair or replacement alloy components. The requirements in this standard shall apply to materials and equipment manufacturers, shop and field fabrication and plant maintenance activities. The testing methods outlined in this standard are not intended to establish the complete conformance of a material to its specification. Also, it is not intended to replace or substitute the original material or welding consumable Material Test Records (MTR). Unidentified pressure retaining alloys or critical components that are not marked, untraceable or without MTR shall not be covered by this standard. Where applicable, this standard shall be attached to and made a part of invitations to bid and purchase orders. Note: Although this document addresses PMI requirements for pressure-retaining alloy material components, provisions are also given for carbon steels and non-pressure alloy material/operationally-important components under certain conditions. 2 Conflicts and Deviations Any conflicts between this document and other applicable Mandatory Saudi Aramco Engineering Requirements (MSAERs) shall be addressed to the EK&RD Coordinator. Any deviation from the requirements herein shall follow internal company procedure SAEP-302. 3 References The selection of materials, design, construction, maintenance, and repair of plant equipment covered by this standard shall comply with the latest edition of the references listed below, unless otherwise noted. Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 4 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 3.1 SAES-A-206 Positive Material Identification Saudi Aramco Documents Saudi Aramco Engineering Procedures SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering Requirement Saudi Aramco Engineering Standards SAES-W-014 Weld Overlays and Welding of Clad Materials Saudi Aramco Inspection & Testing Requirements 175-320300 3.2 Positive Material Identification (PMI) Industry Codes and Standards American Society of Mechanical Engineers ASME SEC II ASME B16.20 Boiler and Pressure Vessel Code Section II: Parts A, B and C Metallic Gaskets for Pipe Flanges: Ring-Joint, Spiral-Wound, and Jacketed ASME B31.3 Process Piping American Society for Testing and Materials ASTM A193 Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for High-Temperature Service ASTM A751 Standard Methods, Practices and Terminology for Chemical Analysis of Steel Products Pipe Fabrication Institute PFI ES-22 Recommended Practice for Color Coding of Piping Materials 4 Terminology 4.1 Acronyms PWHT PMI SAMSS 4.2 Post-Weld Heat Treatment Positive Material Identification Saudi Aramco Materials System Specification Definitions Alloy Material: Any metal (including filler metals for welding alloy materials) containing alloying elements such as chromium, nickel, or molybdenum that are intentionally added to enhance mechanical or physical properties and/or corrosion resistance. Alloy materials do not include high-strength microalloyed steels and impacttested carbon steels. Manufacturer: The company responsible for the plant or shop manufacturing of pressured equipment or commodities that are within the scope of this standard. Fabricator: The company, organization or agency responsible for the shop and/or field fabrication or assembly of piping and pressured equipment within the scope of this standard. Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 5 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 SAES-A-206 Positive Material Identification Lot: Same batch of particular components - the same supplier, type of component, size, rating, material, etc. and from the same shipment. Material Specifications: ASME SEC II, Parts A, B and C, or the relevant ASTM, or any other material specification. Nonpressure Components: Items that are not part of the pressure-retaining envelope and, therefore, do not affect the pressure retaining capacity of pressured components. PWHT: Post-Weld Heat Treatment PMI: Positive Material Identification – Verification that the nominal chemical composition of an alloy material is as specified and ordered. The term applies to programs, processes, procedures and tests in accordance with this standard. PMI Testing: Any physical evaluation or test of a material, meeting the requirements of this standard, to confirm that the material which has been or will be placed into service is consistent with the selected or specified alloy material. Pressure-Retaining Components: Components acting as pressure envelope or boundary; breach of this envelope or boundary would lead to loss of containment and discharge of process fluids. Examples include, but not limited to, product forms used for the fabrication of pressured piping and equipment such as shells, heads, tubesheets, nozzles, tubes, flange bolting, some types of gaskets, forgings, flanges, individual pipe lengths and fittings (tees, elbows, reducers, special pipe components), drains, vents, plugs, valve bodies and bonnets, pressure relief/safety valves, pressure-retaining welds, pump casings, weld overlays/cladding, expansion joints, bellows, injection quills and thermowells. Saudi Aramco Inspector: The person or company authorized by Saudi Aramco Inspection Department to verify implementation of the requirements of this standard. Responsible Inspection Organization: The entity that is authorized by Saudi Aramco and is responsible to carry out inspection activities including the implementation of the requirements of this standard. This could include SA Operation Inspection, SA Project Inspection, SA Vendor Inspection or an authorized third party inspection representative. 5 Requirements 5.1 General Requirements 5.1.1 5.1.2 5.1.3 Manufacturing quality control (QC) is an important requirement. This includes conformance testing and materials traceability to be controlled by the manufacturer or supplier of raw material or loose components. PMI and QC are not substitutional, yet they complete each other. PMI testing shall be performed at a point in time that ensures proper alloy materials have been used in the fabrication of an identifiable assembly. Usually, this is during fabrication or immediately prior to fabrication. MTRs and welding with an approved welding procedure shall not be considered as alternatives to PMI testing and the requirements of this standard. Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 6 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 SAES-A-206 Positive Material Identification Note: Construction and fabrication quality control is vital and PMI is a very important part of total quality control. 5.2 Exemptions 5.2.1 Unless specifically required in the purchase order or material catalog description or SAMSS, the following components and materials are exempt from PMI: 1. Non-pressure components 2. Components made from carbon steel or cast iron and filler metal for welding carbon steel, except as noted below. Exceptions: During the engineering review of a project proposal, to preclude alloy substitutions, selected PMI requirements may be adopted for certain carbon steel components and weldments by special quality control requirements. Factors to be considered include the following: • Wet sour service • The potential for mixing of carbon steel and alloy components and filler metals at the job site • The potential for catastrophic failure • Other related provisions in the project Quality Plan Note: Incorrect installation of low-alloy materials or welds in place of carbon steels in components in wet sour service has been experienced. As these components are not in principle subject to PWHT, there is the potential for high hardness levels in the low-alloy material with the subsequent risk of Sulfide Stress Cracking. 3. 4. 5. 6. 7. 8. 9. Rotating equipment internals and auxiliary/associated seal/lube oil/cooling water/steam equipment and piping. Piping components in ASME B31.3 Category D Service or equivalent. Instrumentation tubing, instrumentation fittings and all instrumentation fitted with isolation double block and bleed valves. Heat tracing tubing Steam traps Strainers API 570 Class 3 Services: a. Services that are flammable but do not significantly vaporize when they leak and are not located in high-activity areas. b. Services that are potentially harmful to human tissue but are located in remote areas. c. Examples of Class 3 service include but are not necessarily limited to those containing the following: i. Distillate and product lines to and from storage and loading ii. Tank farm piping iii. Off-site acids and caustics Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 7 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 5.2.2 SAES-A-206 Positive Material Identification When specified in a project design document, purchase order, SAMSS or 175Form, PMI shall be required for operationally-important non-pressure components. Note: Examples of important non-pressure components could include, but not be limited to, column trays (refer Section 7.2), internal attachment welds, valve internals or trim, thermowells and certain load-bearing supports, e.g. fired heater tube supports/tubesheets/hangers. 6 Responsibilities 6.1 For all new projects, Project Management or their designated Responsible Inspection Organization shall be responsible for ensuring that proper PMI scope, programs and procedures are developed per this standard and PMI testing is performed by the manufacturer, fabricator or contractor, as applicable, prior to equipment or piping installation and start-up. Project Management is normally supported by Project Inspection and Vendor Inspection. For existing facilities, the plant manager or his designated Responsible Inspection Organization, e.g., Plant Inspection, shall be responsible for ensuring that a PMI program is developed and implemented based on this standard. 6.2 Note: Facilities should acquire their own PMI equipment. For major PMI activities, local Saudi Aramco approved service providers may be contracted. 6.3 6.4 6.5 6.6 6.7 7 For applicable purchases, materials shall be subject to inspection by the Responsible Inspection Organization in accordance with Saudi Aramco Inspection & Testing Requirement 175-320300 and relevant SAMSS and 175-forms. The manufacturer or the fabricator, as applicable, shall implement a written PMI Procedure, covering testing and reporting, which shall be made available to the Saudi Aramco Inspector for review, acceptance and verification of implementation. The manufacturer or the fabricator, as applicable, shall ensure that PMI is performed prior to completion of fabrication, in the shop or at the site, for welds and for fieldassembled items not previously PMI-tested. The Saudi Aramco Inspector shall have the option to witness any or all of the PMI testing. The fabrication status schedule shall be submitted to Inspection two weeks before the fabrication. Each manufacturer and each fabricator shall use only trained, qualified and experienced operators to perform PMI activities. Operator records confirming such training, qualification and experience shall be made available for the representative inspection organization review and approval. Verification Coverage A listing of materials and components requiring PMI verification is given in Table 1. 7.1 The PMI program covers the following: • Alloy materials. Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 8 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 SAES-A-206 Positive Material Identification • 7.2 Shop and field-fabricated pressure-retaining components (base metal, welds, and cladding). • New materials used for repair or replacement of pressure-retaining components. • Operationally-important components. One hundred percent (100%) PMI testing shall be performed on all pressure components and welds of alloy materials, within the scope of this standard, with the following exceptions: Exceptions: 1) Tubes for shell/tube and air-cooled heat exchangers and fired steam boilers: 10 tubes or 10%, whichever is greater, from every heat number shall be selected at random and tested prior to installation. This testing frequency shall also apply to any replacement tubes. Note the rejection procedures in Section 11. 2) Alloy flange bolting may be verified by random 5% PMI testing if the project Quality Plan contains specific provisions for color coding, segregation and visual inspection that are acceptable to Project Inspection and the proponent organization. The project inspector may implement up to 100% PMI testing of alloy bolting any time he determines that other quality procedures are not adequate or are not being implemented. 3) For column trays and internals, PMI shall be performed on 10 trays/internals or 10% of each type, whichever is greater. For attachment welds associated with trays/internals, coverage shall be the same as trays/internals. For bolting associated with trays/internals, PMI shall be carried out on 2% of the bolting if the project Quality Plan contains specific provisions for color coding, segregation and visual inspection that are acceptable to Project Inspection and the proponent organization. The project inspector, at his discretion, may implement up to 100% PMI testing of alloy bolting any time he determines that other quality procedures are inadequate or are not being implemented. 4) For fired heater tube supports/tubesheets/hangers, PMI shall be performed on 10% basis of each heat number for each size and type of these components. 5) For fittings and flanges, PMI shall be performed on 10% basis on each heat number for each size and type of these components. 7.3 7.4 PMI testing of weld metal shall be subjected to the same coverage as for the base material. The required number of PMI tests shall be as follows: 1) One test for each pressure-retaining component. If an assembly contains a number of components (parts), one test is required for each component (part). 2) One test for each pressure-retaining weld and weld repair, in addition to filler metal testing (Paragraph 7.7). Note: A strict filler metal control program is vital. Only the proper welding rods for the current welding shall be allowed at the welding site. Table 1: Positive Material Identification Program # Item 1 Alloy Pipes, Flanges, Fittings Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Verification Required Reference Sections Yes 4, 7.2 Page 9 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 # Item SAES-A-206 Positive Material Identification Verification Required Reference Sections 2 Internally Cladded Pipes, Flanges And Fittings Yes 4, 7.2 3 Alloy Valves and Pressure Relief/Safety Valves (Bodies, Bonnets and Internals/Trim) Yes 4, 5.2.2, 7.2 4 Alloy Pump Casings Yes 4, 7.2 5 Alloy Drains, Vents, Plugs Yes 4, 7.2 6 Instrumentation No 5.2.1 Spiral-wound No 4 Ring Joint (Pressure Energized) Yes 4 9 Flexitallic No 4 10 Metal Clad Yes 4 7 8 Gaskets 11 Bolting Yes 4, 7.2 12 Vessels, Heat Exchangers, Forgings Yes 4, 7.2 13 Chemical Injection Quills Yes 4, 7.2 14 Thermowells Yes 4, 7.2 15 Furnace Tube/Supports/Hangers/Tubesheets/Fittings Yes 4, 5.2.2, 7.2 16 Column Trays/Internals Yes 7.2 17 Strainers No 5.2.1 18 Steam Traps No 5.2.1 19 Heat Tracing Tubing No 5.2.1 20 API 570 “Class 3” Services No 5.2 21 ASME B31.3 Category D Service No 5.2 7.5 The elements of the basic alloy materials to be verified shall be in accordance with Table 2. Table 2: Elements to be verified for Basic Alloys Basic Alloy Carbon Steels Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Elements to be Verified Usually no PMI is required with the exception of the cases shown in paragraph 5.2.1 Page 10 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 SAES-A-206 Positive Material Identification Chrome-Molybdenum Materials e.g. Gr11, Gr22… Gr 9. Cr and Mo. Chrome-Molybdenum-Vanadium Materials e.g. Gr. 22v Cr, Mo and V. Ferritic and Martensitic Stainless Steels e.g. 405, 410, and 13 Cr. Cr only. Austenitic Stainless Steels and Duplex Stainless Steels. e.g. 304, 316, 317, Nitronic-50, XM-19, 904L, 6MO, 2205, 2507… etc. Cr, Ni and Mo. Carbon shall be verified if low, high carbon grade or dual grade was specified, such as 316L, 316H or 316/316L. Stabilized Stainless Steels e.g. 321 and 347. Cr, Ni, Mo, and Ti or Nb (Cb). Nickel-based Alloys and other HighAlloys e.g. Alloys 400, 600, 800, 825, 625, C4, C22 and C276. Ni, Cr, Mo, V, Nb (Cb), Cu and W. Carbon shall be verified if special carbon grade was specified, such as alloy 800H or 800HT. Hard-facing Chromium, Nickel, Cobalt, Tungsten, and Iron Aluminum Alloys Usually no PMI is required. Only if critical application or to prevent potential mix-up. Copper Alloys Usually no PMI is required. Only if critical application or to prevent potential mix-up. 7.6 For special alloys not listed in Table 2, the Chairman of the Materials Engineering Standards Committee shall be consulted. 7.7 PMI Testing of Welding Consumables 7.7.1 7.7.2 7.7.3 Electrodes shall be properly stored and segregated in the store, shop or ovens to avoid mix-up. Separate ovens are required for different welding consumable types. The fabricator shall ensure that adequate inventory control is established to account for all consumables checked-out. One consumable from each lot shall be PMI-tested. The remainder of the lot shall be compared to the identified consumable to verify that the markings of the electrodes/wires are correct. PMI testing of weld metal (e.g., deposited or undiluted weld “buttons”) is an acceptable alternative to PMI testing of an electrode or wire sample provided it is conducted immediately prior to welding or during the welding process. Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 11 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 SAES-A-206 Positive Material Identification Note: Some weld rods have the alloying elements contained in the flux, and do not meet the alloy specification until welded. 7.7.4 In cases where PMI testing of the completed weld is not possible because of geometry (e.g., small fillet welds and narrow root beads), PMI testing of filler metal lots and visual inspection of electrodes as described in 7.7.2 and 7.7.3 is an acceptable substitute for testing of the completed weld. 8 Methods 8.1 The instruments and methods used for PMI testing 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. PMI testing techniques include: 8.2.1 The primary acceptable method is X-ray emission analysis, also known as Xray fluorescence (XRF) analysis with a calibrated portable instrument. Because of inherent limitations of some XRF analyzers, it is not possible to detect all elements. Elements lighter than sulfur (S) cannot be detected by these tools. Therefore, this technique cannot be used to detect carbon (C). 8.2 Note: XRF technique cannot distinguish between low/high carbon stainless steels grades; e.g. 316, 316L and 316H stainless steel grades. Unintentional mix-up and weld joining between these alloys could result in sensitization in the 316 or 316H grades that could lead to failure of the component and leak or loss of containment. 8.2.2 8.3 8.4 8.5 An optical emission spectrograph (OES) may be used to check for all the required elements, including carbon. This technique is almost capable of identifying and conform any alloy nominal composition. This is the recommended technique to confirm the carbon content in stainless steels. Any burn damage resulting from the usage of the emission spectrograph shall be removed by grinding. A hot work permit may be required before using this equipment. 8.2.3 Laser-Induced Breakdown Spectroscopy (LIBS) is not an approved PMI option by this standard. As an alternative, a chemical analysis of samples cut out from the pieces requiring PMI, in accordance with one of the methods in ASTM A751, may be used to check for the alloying elements required by this standard. Prior to commencing PMI testing, instrument operators shall be qualified to operate approved equipment on a representative sample of the alloy materials with 100% correct assessment as the performance criteria. The instrument operator shall work from a written procedure and shall have been trained to use the instrument in accordance with that procedure. Training shall be documented. The person(s) performing PMI testing shall calibrate and/or verify the test equipment performance as specified by the equipment manufacturer. Calibration/verification shall be carried out using certified standards of the same alloy family. The PMI test procedure shall specify the frequency interval for this calibration/verification. If calibration procedures are not provided by the equipment manufacturer, they shall be established by Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 12 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 8.6 8.7 8.8 SAES-A-206 Positive Material Identification the owner/user. Typically, these procedures shall include calibration/verification using certified standards. If sample removal is used, a written procedure for identification and traceability to original material is required. Both inside and outside weld surfaces shall be tested where accessible. PMI testing of welds shall be done after removal of slag and/or oxide from the weld surface. See also 7.7.3. The surface to be analyzed shall be clean bare metal, free of grease or oil, with a surface finish as specified by the instrument manufacturer. Note: Generally a fresh 60 grit finish and flat surface are required for optical emission spectrometry, while no minimum surface finish is required for portable XRF analysis, only that the surface be clean bare metal. 9 Acceptance Criteria 9.1 For acceptance, it must be demonstrated that materials contain the amounts of alloying elements within the standard ASTM/ASME chemistry ranges. Alloys shall be acceptable if the alloying elements are each within ±10% of the specified range of values. Welds with consumables that match, or nearly match, the base metal composition shall be within ±12.5% of the ranges given in ASME SEC IIC for each element. For weld overlays, the chemistry on the surface of overlays shall be in accordance with SAES-W-014. For dissimilar metal alloy welds (other than weld overlays), the effects of dilution from the different base metals and the filler metal shall be taken into account for determining the nominal as-deposited weld metal composition. 9.2 9.3 9.4 10 Rejection Procedures 10.1 If the PMI testing results fall outside the acceptable range using a method described in Section 9, the manufacturer or the fabricator, as applicable, has the option to conduct a more accurate analysis at his own expense to determine the component acceptance such as obtaining a chemical analysis performed by an independent testing laboratory. The alternative test method or independent laboratory must be acceptable to the Saudi Aramco Inspector. The results of the more accurate test method or independent chemical analysis shall govern. If any component or weld is found unacceptable, it shall be replaced and the replacement shall be alloy verified in accordance with this standard. Procedures shall be in place to ensure that rejected components are segregated and properly identified by color-coding to prevent reuse. If one of the tubes for heat exchangers and boilers is found unacceptable, all remaining tubes of the particular alloy shall be tested for the individual equipment. This also applies to the weld metal. All rejected tubes shall be replaced and 100% of the replacement tubes shall be PMItested in accordance with this standard. 10.2 10.3 10.4 10.5 Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 13 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 11 Records and Reports 11.1 Shop Fabrication Records 11.1.1 11.1.2 11.1.3 11.1.4 11.1.5 11.2 Positive Material Identification A detailed recording/logging procedure shall be prepared by the manufacturer or shop fabricator. The log shall identify each component and weld corresponding to an individual equipment item or piping spool and shall include the equipment or spool number and purchase order number. The log shall identify all components and welds that have been alloy-verified and the results of testing. Test results shall include measured percentages of alloying elements for components that were accepted or rejected. The manufacturer shall prepare a detailed PMI map of the pressured equipment or commodity being fabricated. The map shall show the alloy material specification of each alloy component and the extent of PMI required in accordance with this standard. Field Fabrication Records 11.2.1 11.2.2 11.2.3 11.3 SAES-A-206 At least two weeks prior to the commencement of fabrication, the field fabricator shall establish and present to the Saudi Aramco Inspector for review the proposed testing, logging, identification and final installation procedures for all components requiring PMI testing onsite (such as fabricated pressured equipment, piping, valves and welds). Shop-fabricated alloy pressure equipment or piping assemblies that have been alloy verified by the shop fabricator need not be re-verified in the field. However, the field fabricator shall have available, for review, the shop fabricator's report of PMI testing. Material certificates are not allowable substitutes for PMI testing reports. The field fabricator shall prepare a detailed PMI map of the piping and other commodities being fabricated. The map shall show the alloy material specification of each alloy component and the extent of PMI required in accordance with this standard. Final Report 11.3.1 11.3.2 Prior to final acceptance of alloy pressured equipment or piping, the manufacturer or fabricator, as applicable, shall prepare a complete PMI Testing Report containing all relevant data. For pressured equipment, the PMI Testing Report shall be included as part of the Equipment Data Book and the QA/QC Dossier. The PMI Testing Report shall be reviewed by the Saudi Aramco Inspector prior to final acceptance. An example template for this report is given in Table 3. Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 14 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 12 Marking and Color Coding 12.1 Verification Marking 12.1.1 12.1.2 12.1.3 12.1.4 12.1.5 12.2 SAES-A-206 Positive Material Identification Paint marking shall be done with water-insoluble material that contains no substances that harmfully affect the metal at ambient or elevated temperatures. In particular, the marking material shall be free of lead, sulfur, zinc, cadmium, mercury, chlorine or other halogens. All components and welds that are found unacceptable shall be marked immediately with a circled red “X” pending resolution in accordance with Section 11. All verified materials with an acceptable analysis shall be marked with the letters “PMI” using a certified low-stress stamp (these use a series of rounded dots or a rounded indenter to form the letters). Alternatively, a vibrating “pencil” may be used. The marking shall be placed as follows: Pipe: One mark, 75 mm from one end on the outer surface of the pipe. This marking shall be in addition to the requirements of PFI ES-22. Welds: Adjacent to the welder's mark on the weld. Welds on tubes for heat transfer equipment shall be marked by either stenciling or vibro-etching on the tubesheet. Fittings and Forgings: Adjacent to the manufacturer's markings. Valves: Adjacent to the valve manufacturer's markings on bodies and other pressure parts. Castings: Adjacent to the casting manufacturer's markings and heat numbers. Plates: 75 mm from one edge, adjacent to manufacturer's markings. Tubes: Stenciled, 300 mm from each end. When heat treating is performed after PMI, the identification marking must be recognizable after heat treatment. PMI markings shall be transferred to retain material identification when a plate or pipe is cut. The transfer of PMI markings shall be carried out prior to material cutting/separation. If this is not possible, then transfer shall be performed immediately after material cutting/separation. Color Coding 12.2.1 12.2.2 12.2.3 The color coding system for material identification described herein is intended to help prevent fabricators from using incorrect alloy material. The principal purpose of color coding is visual identification during storage and after the components have been cut for fabrication. Color coding is not a substitute for PMI testing or other permanent manufacturers' markings required by ASTM or other specifications. Permanent manufacturers' markings shall not be obscured by color coding. Color coding may be done by the material manufacturer or material supplier. Color coding need not be retained after painting. Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 15 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 12.2.4 12.2.5 12.2.6 12.2.7 12.2.8 12.2.9 12.2.10 12.2.11 12.2.12 12.2.13 12.2.14 SAES-A-206 Positive Material Identification Prior to coding, surfaces shall be clean and free of dirt, loose scale, grease and oil. Paints used for coding shall be durable, bright and distinctive, and shall not contain substances that would harmfully affect the material at ambient or elevated temperatures. In particular, paints shall be free of lead, sulfur, zinc, cadmium, mercury, chlorine, and other halogens. Each component shall be coded in accordance with PFI ES-22 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. Valves, flanges and fittings do not require color coding if these components are permanently stamped or tagged by the manufacturer. If the materials are not easily legible, valves, flanges and fittings shall be coded with a stripe of 5 mm minimum width. The color coding on valves should indicate the valve body material. ASTM A193 Grade B7 stud bolts do not require color coding if the grade of the material is stamped on one end of each bolt. Spiral-wound gaskets shall be color coded in accordance with ASME B16.20. Sheet type gaskets do not require color coding. Pipe and Fittings: Each length of pipe and fitting shall have a 5 mm or larger stripe running full length. One inch NPS and smaller may have a 3 mm stripe running full length. Valves: When required, stripe across the body from flange to flange or end to end. Flanges: When required, stripe across edge up to hub. Bolting: When required, stripe around the midpoint of each bolt or stud. Plate, Sheet, and Strip: Stripe on surface near two perpendicular edges for entire length. Tubes and Bars: Stripe entire length. Saudi Aramco: Company General Use ©Saudi Aramco 2020. All rights reserved. Saudi Aramco: Company General Use Page 16 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 SAES-A-206 Positive Material Identification Table 3: Positive Material Identification Record Sheet PURCHASE ORDER NO.: SUPPLIER OR PMI AGENCY: SAUDI ARAMCO DRAWING NO.: PMI PERFORMED BY (NAME & SIGNATURE): MANUFACTURER OR FABRICATOR’S DRAWING NO.: PMI APPROVED BY (NAME & SIGNATURE) LOCATION WHERE PMI PERFORMED: DATE: PMI ANALYZER MODEL & SERIAL NO.: ITEM NO. QTY LINE ITEM DESCRIPTION MTL. TYPE, SIZE, RATING HEAT NO. MATERIAL MARKED MATERIAL VERIFIED (PMI) PMI RESULTS ACCEPTANCE CRITERIA (MIN/MAX) QTY ACCEPT QTY REJECT REMARKS NOTES: 1. Record heat number only when traceability is required 2. Provide name, address and contact details of supplier for rejected material Page 17 of 18 Document Responsibility: Materials Engineering Standards Committee Publish Date: 9 April 2020 Next Revision: 5 May 2024 SAES-A-206 Positive Material Identification Document History 9 April 2020 5 May 2019 1 January 2018 5 May 2016 Editorial revision to remove reference and extend the next revision date as per the updated SAEP-301. Major revision. Clarify and detail the scope address the clients’ comments. Editorial revision to modify paragraph 9.4. Major revision. Enhanced content and improved clarity of the document. Incorporated all applicable comments from clients while maintaining some alignment to industry standards. Saudi Aramco: Company General Use Page 18 of 18