Positive Material ldentification

(PMl) as it Relates to Pressure

Vessels
by
1yrki Iuominen
Oxford lnstruments
Content
- What is PMl
- How metals are analyzed: XRF vs. OE5
- Pros, cons and limitations of both techniques
- Where and by who PMl is typically done,
what is measured
- Review and typical features of analyzers on
the markets
- 5ummary and conclusions
What is Positive Material
ldentification (PMl) (1/3)
- PMl refers to the identification and analysis
of metal alloys based on their elemental
composition
- Measurement results are shown
either in form of elemental
concentration in percentage and/or
by specific alloy name.
- PMl is a typically field testing method,
occasionally in office/lab environment
- Analyzers are portable/mobile
Example of a typical analysis
- PMl is a non-destructive testing (NDI) technique to
accept or reject the material used - not to adjust its
properties in the process
- Iypically used to
- Verify that alloy used is correct
- Grade name is what supposed to be and/or
- Alloy has the expected concentrations of elements (Ihis
requirement might be set stronger than the actual
grade requirement.)
- Verify possible impurities (unwanted elements)
- PMl is done due to
- Local/national laws and regulations like the A5IM/A5ME
code or Pressure Equipment Directive (PED) in EU
- Companies' internal policies requires it because of
quality and/or safety reasons
What is Positive Material
ldentification (PMl) (2/3)
What is Positive Material
ldentification (PMl) (3/3)
Date: 4/8/06


6.0 PROCEDURE
6.1 Instruments may be used in an assay or grade mode. The accuracy of the instrument shall
be checked by measurement against a known standard of each alloy type. Measured
values shall be within 10 percent of the actual alloy content of the standard.
6.2 Instruments may be used in an assay or grade mode, when approved by Owner's
Engineer. Follow-up analysis is required when alloy identification does not comply with
the specified alloy.
6.3 All material to be tested shall be cleaned of any oil, grease, or dirt. The part shall be
sanded to remove any mill scale, surface oxides or residual debris and to ensure that the
readings obtained are representative of the base metal. No wire brush shall be used. The
sandpaper shall be changed any time the material type is changed. Testing will then be
performed and the major alloy elements shown in table 1 shall be recorded. If the
material is not listed in Table 1 then the elements listed in ASME Boiler & Pressure
Vessel Code, Section II, Part A, B or C shall be used, or as specified by the customer.

7.0 ACCEPTANCE/REJECTION CRITERIA
7.1 The acceptance/rejection criteria will be per the ASME Boiler & Pressure Vessel Code,
Section II, Parts A, B, & C, unless otherwise specified by the customer.
7.2 For all materials requiring PMI, acceptance criteria shall be as follows:
7.3 Assay or grade mode: the measured value of alloying elements shall be within 10 percent
of the specified level or range in the applicable materials standards (example: for 5 Cr,
where the allowable range is 46 percent, the measured value shall fall within the range
3.6 to 6.6 percent). Requirements for minor alloying elements are defined in Table 1
notes.
7.4 Assay or grade mode examination: the instrument shall confirm that alloys comply with
the specified standard, within the accuracy given in Section 5, Item (1).
7.5 Test results shall conform to purchase documents and be properly identified to the
applicable materials specifications. When required by the specification or drawings,
materials shall be color coded in accordance with Owner's Specification, and/or marked
per Section 6, of this Practice.
7.6 For weld metal PMI testing, or joints of similar base metals with matching filler, the
acceptance criteria are based on the requirements of ASME Section II, Part C (ASME
SEC II C

8.0 STAMPING AND MARKING
8.1 All stamping and marking and/or color coding of the material shall be performed in
accordance with the customers specification.
8.2 When heat treatment is performed after material verification, the identification marking
and/or color coding shall be recognizable after such heat treatments. If the marking is
unrecognizable, PMI testing shall be repeated.
8.3 Items which do not meet the PMI acceptance criteria shall be red tagged as HOLD and
controlled in accordance with the non-conformances section of the PSI QA manual.
An example of a internal PMl procedure


Table 1: Identification Elements

Materials Identification Elements Materials Identification Elements
C -
1
/2 Mo Mo Alloy 20Cb-3 C**, Cr, Ni, Mo, Cb, Cu
1 Cr -
1
/2 Mo Cr, Mo Brass, Admiralty Sn
1
1
/4 Cr -
1
/2 Mo Cr, Mo Brass, Naval Sn
2
1
/4 Cr Mo Cr, Mo Brass, Aluminum Zn, Al
5 Cr -
1
/2 Mo Cr, Mo 90/10 Cu/Ni Cu, Ni
7 Cr -
1
/2 Mo Cr, Mo 70/30 Cu/Ni Cu, Ni
9 Cr - 1 Mo Cr, Mo Alloy 400 Ni, Cu
12 Cr (Type 405/410S) C**, Cr Titanium Grades 1 and 2 Ti
12 Cr (Type 410) Cr Grade 12 Ti Ti, Mo**, Ni**
17 Cr (Type 430) Cr Grade 16 Ti Ti, Pd**
25 Cr (Type 446) Cr Grade 26 Ti Ti, Ru
304 Cr, Ni Alloy 182 Ni, Cr
304L C**, Cr , Ni Alloy 600 Ni, Cr
304H C**, Cr, Ni Alloy 625 Ni, Cr, Mo, Cb, Ti
309L C**, Cr, Ni Alloy 800 Ni, Cr, Al, Ti
309 CbL C**, Cr, Ni, Cb Alloy 825 Ni, Cr, Mo, Cu, Ti
310 Cr, Ni AISI 4140 C**, Cr
316/317 Cr, Ni, Mo AISI 4340 C**, Cr, Ni
316L/317L C**, Cr, Ni, Mo Alloy 2205 Cr, Ni, Mo
321 Cr, Ni, Ti Alloy 2507 Cr, Ni, Mo
347 Cr, Ni, Cb 3.5, 5 and 9 Ni Ni
Hastelloy C276 Ni, Cr, Mo, W

Notes to Table 1:
* Percentages shall be within 10 percent of the limits specified in the appropriate standards/specifications.
**Owner's Engineer shall specify identification methods for minor alloying elements (e.g., low carbon in Type
304L SS or Type 410S SS, minor alloying elements in various grades of titanium) Suitable methods for
identifying minor elements include: specialized laboratory instrumentation, suitable optical emission analyzers,
traceable mill certificates, or a combination of traceable mill certificates and chemical analysis using lower
measurement sensitivity.
What Iechniques are used on
portable PMl analyzers ?
- XRF based on X-Ray Fruorescence
- OE5 based Optical Emission 5pectroscopy
X-Ray Fluorescence (XRF)
- XRF works by exposing a
sample to be measured to a
beam of x-rays.
- Ihe atoms of the sample
absorb energy from the x-rays,
become temporarily excited and
then emit secondary x-rays.
- Each element emits x-rays at a
unique energy.
- By measuring the intensity and
characteristic energy of the
emitted x-rays, an XRF analyzer
can provide qualitative and
quantitative analysis.
Optical Emission 5pectroscopy (OE5)
- ln the OE5 atoms are also excited
- Excitation energy comes from a
spark formed between sample and
electrode
- Ihe energy of the spark causes the
electrons in the sample to emit light
- Ihis light is converted into spectral
pattern
- By measuring the intensity of the
peaks in this spectrum, the OE5
analyzer can produce qualitative and
quantitative analysis
XRF X-ray Fluorescence
OES Optical Emission Spectrometry
Element ranges of XRF and OE5 analyzers
Optical Emission vs. X-ray Fluorescence
on Mobile Analyzers
Calibration
Portability
Ease of Use
5ample 5urface Marking
5ample Preparation
5peed
Detection Limit
5ensitivity
Range
Fast
Moderate
(Few measurements required)
Yes
Yes, limited
Iypical weight of unit 20 - 25 kg
Unskilled Operator 5killed Operator
Ii and up
(Al, Mg, 5i, P, 5 possible w/limitations)
Good for light elements
(C, 5, P, Al, Mg, 5i)
Majors and Minors Majors, Minors and Iraces
Both empirical and fundamental
parameters (FP)
Empirical only
Iotally non-destructive
Yes
(5park causes burn mark)
Minimal
5ubstantial
(Clean/grinded surface required)
High (~1000 ppm) Low (~ 100 ppm)
XRF OE5
Optical Emission vs. X-ray Fluorescence
on Mobile Analyzers
ln brief main differences are
- XRF units are smaller and much easier to operate
- lf C, 5, P or B is needed, OE5 is the only choice
- XRF can sort major elements in Al alloys, for
analysis OE5 is the only choice. New detector
technogy is changing this currently
- XRF requires practically no sample prep
- OE5 requires always sample prep by grinding, air
sorting is an exception
Iypical measurements done in
PMl field
- ldentify alloy name, with or without carbon
- Verify composition
- Verify certain important values like
- Carbon equivalent C
eq
- 1-factor for temper embrittlement, base metal
- X-factor for temper embrittlement, weld
- PRE Pitting Resistance Equivalent
- FAC Flow Accelerated corrosion
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Document
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PowerPoint Presentation
Current analyzers on the markets
XRF Analyzers
- Only few major players on the markets
- Iypical "market price" ~U5 $30k
- 5mall size, light weight
- PDAs and Windows utilized
- Fast analysis, less than 5 sec
- Accuracy enough to identify grade
- Extensive libraries for alloy names
- Usage of X-ray isotopes diminishing
- Canada is an exception
- XRF units for light elements coming to
markets.
XRF Analyzers and light elements
- Light elements (Al, Mg, 5i, 5, P) can be
measured with some limitations
- Analyzers are either filled with
Helium or in "vacuum"
- Last year 5DD units were introduced; no
vacuum nor Helium fill
- "Real life" accuracy is typically 0.2 - 1
depending on element
- Main components; X-ray tube and
detector are significantly more fragile than on
standard analyzer
- Measurement times slightly longer; 10-20 sec
OE5 Analyzers
- Like in XRF, only few players on the
markets
- Iypical "market price" in U5D
- $28k for OE5 sorter
- $35-40k standard unit, no low carbon
- $45-55k to detect low carbon (L-grades
in 55)
- Much bigger and heavier than XRF
analyzers, weight typically 20-30kg
- 5eparate main unit and probe
- Results like in XRF; composition and
grade
- Accuracy down to 0.01 at best
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5ummary
- Need to PMl is increasing due to
- Need for better quality
- lncreased safety factors
- Global sourcing
- Analyzers are much smaller and user friendly
than before, does not require expert to use
- Accuracy and reliability has increased a lot in
last 5 years, especially on mobile XRF
- XRF is getting closer to OE5 analytically but
XRF does not detect carbon