QA/QC Department

I. Training Objectives
II. Terms & Definitions
III. Codes & Standards/Specifications Required
for Inspections
IV. QC Tools Required for Inspections
V. Inspection Flow Process
VI. Piping Inspections General Requirements
VII.Documents Required for Inspections (i.e. RFI,
DFIR, DWIR, QCIR, etc.)
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To be familiarized in the usage of PMI pistol type
(NITON XLT) equipment.
To identify alloy/stainless steel requirements on
welds deposits and base metal components.

To identified correct usage of filler wires/electrodes

on the deposited welds after welding process.

To ensure that the nominal material composition is

as supplied and complies with P.O. and/or design
requirements.

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Verifying the composition of metallic elements
against known data.

Investigating unknown or unidentified metallic

materials.

Are metallic materials that contain alloying elements,

such as chromium, nickel or molybdenum, which are
intentionally added or used to enhance mechanical
or physical properties and/or corrosion resistance.
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ASME Sec II, Parts A, B and C, or the relevant ASTM, or
any other material specification required e.g. DIN, BS,
EN and ISO.

Steel that contains specified quantities of elements

such as, chromium, nickel or molybdenum that are
added to enhance mechanical properties, and/or
corrosion resistance. Low alloy are those materials with
chromium contents of 11% or less. Percentages greater
than 11 are classified as high alloy.
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Steel having no specified minimum quantity for alloying element
(other than commonly accepted amounts of manganese, silicon
and copper) and containing only an incidental amount of any
element other than carbon, copper, sulfur and phosphorous.
Steel containing traces of vanadium or columbium, added to
increase the strength, and shall be considered carbon steel.

Metals that are not iron-based, including nickel alloys

and other corrosion-resistant alloys such as ASME P No.
21 and higher or equivalent.
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Static or non-moving internals that are not part of the
pressure containing boundary.

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Part A – Ferrous Material Specifications
Part B – Non-ferrous Material Specifications
Part C – Specifications for Welding Electrodes &
Filler Metals

Power Piping

Process Piping

Alloy Analyzer User’s Guide

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 Material verification for alloy quality
assurance and alloy quality control
(alloy QA/QC) are critical to product
safety. The potential for material
mix-ups and the need for
traceability are a concern at every
step in the manufacturing process:

Primary metal production

Metal service center
Component fabrication
Final product assembly

Wrong or out-of-specification metal

alloys can lead to premature and
potentially catastrophic part failures
that can be expensive, damaging to
your reputation, and, sometimes,
PMI ANALYZER result in loss of life.
(NITON XLT 800 SERIES)

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Press rubber button Θ & hold to switch on.

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Press the screen to log on.

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Press “YES” to proceed.

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Enter password “1234E”.

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Press “Utilities”

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Press “Calibrate”

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Choose “Calibrate touch Screen” and follow the cursor

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Press “Return”

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The choices

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Choose “Return” and you will see the choices

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Choose “Test” & press “”Data Entry”

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Verify “Calibration coin”

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After verification of calibration coin, choose “NAV” &
press “Data Entry”

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On the screen you will see the columns for data entry

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Press the box at the right side of screen with Dots

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After completion of data input, wear the hand strap
while holding the machine

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Press and hold the trigger for 20 seconds or until the
machine beep.

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The readings of alloying elements, type of material &
elements percentage

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Scroll up & down to see the complete list of elements

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Press “NAV” for other choices or “Exit” to end the
verifications

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To end the activity press “Log Off” and hold rubber
button to shutdown

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For safety factor never point the machine into
yourself or to anyone while the x-ray is on.

Always secure the machine by wearing the hand

strap while in use to avoid potential drop.

Turn over the machine to the encoder for print

out of the reports, (QC will review the reports).

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 PMI testing to be applied
for equipment and piping
components made from
alloyed/stainless steel
materials including weld
metal if specified, in-
process or pressure-
containing parts for any
ARCC PSFP and Field
projects.
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PMI testing shall be performed when the materials
to be received at Lay down and then it shall be
performed at shop and field.
One hundred percent alloy verification shall be
performed on all pressure components and welds
of alloy materials.

Alloy verification of weld material shall be

performed in the same manner as for the
adjacent base metal.

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The number of tests shall be as follows:
One test per each pipe spool is required. When the
pipe spool is made of more than one piping
components (components in contact with service
fluid), then only one test is required for every
identical piping component.
One test for each non-pressure part welded to a
pressure part is required.
One test per each weld is required for all pressure
boundary welds and for all welds between non-
pressure parts and pressure parts.
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 ELEMENTS
BASIC ALLOY
TO BE VERIFIED
Carbon – Molybdenum and
Molybdenum
Manganese – Molybdenum Steels
Chromium – Molybdenum Steels Chromium & Molybdenum
Regular Carbon Grade Stainless Steels Chromium, Nickel and Molybdenum
Nickel Steels Nickel
Chromium, Nickel, Molybdenum, Titanium
Low-Carbon Stainless Steels
& Niobium
Chromium, Nickel, Molybdenum, Titanium
Stabilized Stainless Steels
& Niobium
Nickel, Copper, Chromium and
Nickel-Based Alloys
Molybdenum
Other Alloys All major alloying elements
NOTES:
•For materials with basic alloys not covered, Customer shall be contacted.
•Finished welds of alloy materials in fabricator’s shop and at the work site shall be spot checked on a sample basis to determine if correct welding materials have been
used.
•Checks of unused welding rods are not satisfactory, since they do not represent the chemistry of the finished weld.

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The metallic surface to be tested shall be free from all extraneous materials such as
scale, greases, rust, dirt, etc. which would interfere with the testing.
Alloy verification to be performed prior to PWHT (if applicable) and also prior to
painting and pressure test.

The technique to be used to operate the instrument shall follow equipment

operation manual.

Following successful PMI examination and acceptance of the examined lot

(components in a lot or weld) shall be marked “AV (Alloy Verified)” and
examination date as shown below, using steel die stamp, vibrating pencil or
metal marking pens.
“AV” markings shall be applied beside material identification
markings or weld seams.
AV
“AV” marking of pipes for weld seams shall be applied beside a
DD/MM/YY weld seam and approximately 100mm from pipe end. “AV”
marking for materials shall also be applied beside a stencil such as
Example: 12/May/2004 material standard, heat no., etc. and approximately 300mm from
pipe end.

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Marking shall be done with water-insoluble material that contains no
harmful substances that would attack or harmfully affect the material at
ambient or elevated temperatures. The marking material shall be free of
lead, sulphur, zinc, cadmium, mercury, chlorine, or other halogens.
The verified alloy type, or characters indicating the material symbol,
could be marked by Contractor or Sub-Contractor on the material
adjacent to the AV mark using an approved ink marker.
Materials that failed to pass examinations or materials whose
identification does not have proper material identification does not have
proper PMI material designators shall be tagged until they are removed
or correct PMI examination is made and the material is properly
marked.
Any material received with no PMI identification shall be 100% PMI
tested and marked.
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Materials shall contain the amount of alloying elements specified in the
applicable material specification. Alloys, including castings, shall be
acceptable if the alloying elements are each within 10 percent (10 %) of
the specified range of values.

Deposited weld metal or undiluted weld metal deposits shall be ± 10.0

percent of the ranges allowed in ASME Section II Part C for each
element. Where non ASME Section II Part C consumables are used the
ranges shall be within ± 10.0 percent of the manufacturer’s specification

Acceptance criteria for dissimilar metal alloy welds shall be in

accordance with the welding consumable specified in the approved
welding procedure. The effects of dilution between the different base
metals and the filler metal shall be taken into account for determining
the nominal as-deposited weld metal composition.
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If any one item from a lot of material is rejected following
examination, the whole of Lot batch shall be 100 % examined.

If any component or weld is found unacceptable they shall be

replaced and the replaced component or weld alloy verified in
accordance with this procedure.

All materials rejected by PMI check, or with inadequate

documentation or marking shall be separated, marked “FAILED
PMI” and strictly quarantined pending investigation. Proven non-
compliant material shall be rejected and shall be removed from
fabrication or construction site. SR/NCR shall be issued for the
required corrective action.

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The report shall be a print out from the instrument with the following:
Client Name
Job Number
Technician’s Name
Project
Inspection Date
Grade Number
Heat Number
Results (Accept or Reject)
Remark(s), if any

All PMI results shall be documented daily and shall be registered as

appropriate. A table has to be constructed in which PMI percentage
as per line class / service has to be defined.

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QUALITY IS A LINE FUNCTION DO IT RIGHT THE FIRST TIME