Document No.

GIS 36-103
Applicability Group
Date 30 August 2006

Guidance on Industry Standard for

Positive Materials Identification (PMI) for
Pressure Vessels, Piping, and other
Components

GIS 36-103

BP GROUP
ENGINEERING TECHNICAL PRACTICES
30 August 2006 GIS 36-103
Guidance on Industry Standard for
Positive Materials Identification (PMI) for Pressure Vessels, Piping, and other Components

Foreword

This revision of Engineering Technical Practice (ETP) BP GIS 36-103 consists of clarifications
throughout the document. This Guidance on Industry Standard (GIS) is based on parts of heritage
documents from the merged BP companies as follows:

Amoco
A MM-TEST-PMI-G Metallic Materials—Test—Positive Material Identification—Guide.
A MM-TEST-PMI-S Metallic Materials—Test—Positive Material Identification—
Specification.

BP OUS
RP 20-1-4 PMI.

Copyright  2006, BP Group. All rights reserved. The information contained in this
document is subject to the terms and conditions of the agreement or contract under which
the document was supplied to the recipient’s organization. None of the information
contained in this document shall be disclosed outside the recipient’s own organization
without the prior written permission of Director of Engineering, BP Group, unless the
terms of such agreement or contract expressly allow.

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30 August 2006 GIS 36-103
Guidance on Industry Standard for
Positive Materials Identification (PMI) for Pressure Vessels, Piping, and other Components

Table of Contents
Page
Foreword ........................................................................................................................................ 2
1. Scope .................................................................................................................................... 4
2. Normative references............................................................................................................. 4
3. Terms and definitions............................................................................................................. 4
4. Symbols and abbreviations .................................................................................................... 5
5. PMI Personnel ....................................................................................................................... 6
6. General considerations .......................................................................................................... 6
7. Requirements ........................................................................................................................ 7
8. Custom and specialty engineered equipment and parts......................................................... 8
9. Field fabricated equipment and parts ..................................................................................... 8
10. Field piping ............................................................................................................................ 9
Bibliography .................................................................................................................................. 10

List of Tables

Table 1 - PMI examination requirements for shop fabricated equipment ......................................... 9

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30 August 2006 GIS 36-103
Guidance on Industry Standard for
Positive Materials Identification (PMI) for Pressure Vessels, Piping, and other Components

1. Scope

a. This GIS defines requirements for PMI of materials purchased for use either directly by the
owner or indirectly by fabricators or material suppliers. PMI includes verification of the
chemical composition of metals and visual examination of the manufacturer’s stamping
and MTR of materials and parts for construction or fabrication of pressure vessels, piping,
engineered equipment, and components. These include exchangers, vessels, pumps,
compressors, furnaces, pipe spools, pipe fittings, valves, pressure relief devices, instrument
control devices, welds, welding consumables, spiral wound and RTJ gaskets, claddings,
weld overlays, studs, bolts, nuts, elastomers, non-metallic materials, etc.
b. This GIS does not cover PMI requirements for existing or in-service engineered equipment
and components.
c. Any deviation from this GIS shall be brought to the attention of a BP Materials Engineer.
PMI is used to insure that the nominal chemical compositions of metals and non-
metallic components, which affect the pressure envelope of pressure containing
equipment and reliability of all equipment, conform to the materials specified. This
minimizes the potential for premature problems or failure of equipment and
components.
If only one type of high-alloy material is used and a good paper trail back to the
initial supplier/s is maintained, PMI generally is not needed because the potential of
mixing other types of alloy steel materials is remote. Paper trails are the customary
approach for verification of non-metallic materials. The need for specifying PMI
should be based on principle of total cost of ownership (TCO); refer to GP 36-10 for
guidelines of TCO.

2. Normative references

The following normative documents contain requirements that, through reference in this text,
constitute requirements of this technical practice. For the purpose of this document, only information
related to materials selection and application is intended for reference. For dated references,
subsequent amendments to, or revisions of, any of these publications do not apply. Parties to
agreements based on this technical practice are encouraged to investigate the possibility of applying
the most recent editions of the normative documents indicated below. For undated references, the
latest edition of the normative document referred to applies.

American Society of Mechanical Engineers (ASME)

ASME B31.3 Process Piping.

BP
GIS 36-107 Guidance on Industry Standard for Integral Cladding, Weld Overlay, and
Limited Loose Lining of Pressure Vessels and Components.

3. Terms and definitions

Alloy materials
Any metals other than carbon steel, cast or ductile iron, copper, and copper alloys.

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30 August 2006 GIS 36-103
Guidance on Industry Standard for
Positive Materials Identification (PMI) for Pressure Vessels, Piping, and other Components

Fabricator or vendor
The recipient of a purchase order for the supply of fabricated equipment or of components such as
valves, fittings, instruments, pumps, etc. The fabricator or vendor generally receives raw materials and
goods from the material supplier.

Heat
The primary melt of a metal: this generally determines the chemistry unless the heat or portions of the
heat undergo additional treating or refining. In that case, PMI chemistry is required of the altered
product.

Inspector
A BP appointed engineer or inspector.

Lot or batch
A quantity of the same or similar items made in a grouping, for example made at similar time, using
the same source components (such as steel from the same heat), and/or with same manufacturing
process.

Materials supplier
The recipient of a purchase order for the supply of raw materials and goods direct to BP or to a
fabricator or vendor.

Material test report

A document, or documents, issued by the materials supplier to document the satisfactory results of the
tests, examinations, repairs, or treatments performed as required by the material specification, such as
ASTM, ASME, DIN, JIS, etc. Supplementary or special requirements specified in the purchase
documents shall also be included on the MTR.

Positive material identification

Verification of chemical composition of metals using an X-ray emission analyzer, an optical emission
spectrometer, or similar BP approved device for verification of alloy content in metallic materials.
Verification of nonmetals typically uses a “paper trail” that provides a reference to the original lot,
batch, mix, or similar manufacturing reference.

Random examination
Random examination per this GIS shall include PMI examination of an entire inspection lot.

Spot examination
Spot examination per this GIS shall include PMI examination of a defined minimum percentage of
components that are not stamped with the correct stamp and/or colour coded. In addition PMI
examination shall be performed on any item designated by the Inspector.

4. Symbols and abbreviations

MTR material test report

NCR non-compliance record

PMI positive materials identification

SCC stress corrosion cracking

TCO total cost-of-ownership

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30 August 2006 GIS 36-103
Guidance on Industry Standard for
Positive Materials Identification (PMI) for Pressure Vessels, Piping, and other Components

QC/QA quality control/quality assurance

5. PMI Personnel

a. Personnel performing examinations shall be knowledgeable of all aspects of the PMI

program and of the operation of PMI equipment.
b. Qualification of the personnel performing PMI, including training and experience, shall be
the responsibility of the equipment or component supplier. Verification of their
qualifications shall be provided to BP upon request.
c. The personnel qualification documentation shall be maintained as follows:
1. Fabricator and vendor: The fabricator/vendor’s inspection or QC/QA department shall
retain all qualifications records.
2. Material supplier: The material supplier’s inspection or QC/QA department shall
retain all qualification records.
3. BP: BP shall retain all qualification records of BP personnel responsible for PMI.
d. If at any time, in the judgement of the inspector or BP, the assigned personnel do not
appear to be qualified to perform PMI examinations in accordance with the agreed
procedures, BP reserves the right to prohibit those personnel from performing further
examinations. In addition, BP may require re-examinations of materials previously tested
and accepted by the personnel in question.

6. General considerations

a. PMI results shall match the requirements of the material specified, or its approved
equivalent, for the component being tested.
b. Unless otherwise stated by BP, compliance with this GIS is the responsibility of the
fabricator or vendor and/or materials supplier(s).
c. The PMI procedure shall be approved by BP before beginning work or supplying
components and shall include a description of testing equipment, minimum personnel
requirements, calibration verification, and required surface preparation.
d. A BP inspector or a designated BP representative shall be provided documentation of PMI
procedures and PMI results required in this GIS.
e. All equipment, piping, and components shall meet the requirements of this GIS unless BP
provides prior agreement of waiver.
1. Equipment, piping, or components not meeting the requirements of this GIS shall be
rejected, quarantined, and entered into an NCR system of the fabricator/vendor or
material supplier as appropriate for disposition.
2. Non-compliance shall be reported to BP.
f. Any raw material or fabricated item purchased with PMI requirements that cannot be
traced to a PMI report, heat number, and/or MTR shall be rejected and placed in a holding
area pending a PMI examination.
1. PMI examination shall be at the fabricator’s, vendor’s, or material supplier’s cost.
2. Upon discovery of a second item not traceable to a PMI report and MTR, a deficiency
notice shall be written by the inspector and presented to the fabricator, vendor, or
material supplier, and BP.
g. If samples needed for analysis are cut from a component, the repair procedure shall be
approved by BP.
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30 August 2006 GIS 36-103
Guidance on Industry Standard for
Positive Materials Identification (PMI) for Pressure Vessels, Piping, and other Components

7. Requirements

a. PMI procedure shall include the following as a minimum:

1. Description of testing equipment, minimum personnel qualifications, calibration
verification, and required surface preparation.
2. Description of the item, the number of items in each heat or lot/batch, and the total
number of items subject to PMI.
3. Materials specification and heat or lot/batch number of materials or welding
consumables.
b. Materials that have been PMI verified shall be marked and recorded.
1. Marking shall be done immediately after PMI either by low-stress (round bottomed)
stamps or paint marking each item. If item is too small for stamping or paint marking,
wire tagging or bagging shall be used.
2. If PMI materials are cut, marking shall be immediately applied to unmarked parts
where practical.
3. Paint used shall not contain additives that could have deleterious effects on alloy
material.
For example, halides (especially chlorides) in markers can lead to SCC of austenitic
stainless steels in some service environments.
c. Fabricators/vendors and/or materials suppliers shall verify accuracy of stamping/marking
and information on MTR by visually examining 100% of materials and parts received.
d. Fabricators/vendors and/or materials suppliers shall perform 10% PMI for each heat of
material received unless BP provides a waiver before start of work. Table 1 provides
guidelines for most common items.
An alternative to physically checking parts is for the fabricator/vendor or supplier to
maintain a QC/QA program that tracks a paper trail back to quality suppliers who
do PMI. BP must approve this option.. This option is particularly effective for high
alloy components purchased from industry leaders.
e. For equipment and components going into hydrogen service, ferritic materials for shop or
field fabrication shall receive 100% PMI.
f. If an item fails PMI, all remaining items from the affected heat and supplier shall receive
100% PMI. The additional PMI costs shall be the responsibility of the supplier.
g. If a weld fails PMI, remaining welds in the piece of equipment or piping shall receive PMI.
Additionally, other equipment or components being fabricated by that same contractor
using the same welding procedure qualification in the same shop or field location shall be
reviewed for need of additional PMI. The required actions shall be approved by BP.
h. Alloy studs, bolts, and nuts shall have appropriate stamping in addition to a MTR
i. Package labels of welding consumables shall be visually examined to confirm proper
material type for the work in question before opening.
j. PMI for non-metallic materials shall be accomplished by a qualified paper trail beginning
with the raw material supplier through the fabrication process.
Physical testing for PMI of non-metallic materials is very difficult and costly
because simple instrumentation applicable to field use is not available. Thus, the
most effective means of doing PMI is to create and maintain a detailed paper trail.
In addition, for some critical non-metallic materials, such as fiber-reinforced
plastics (FRP), mechanical property testing may be desirable. However, special
requirements of this nature should be handled on an individual job basis.
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30 August 2006 GIS 36-103
Guidance on Industry Standard for
Positive Materials Identification (PMI) for Pressure Vessels, Piping, and other Components

k. BP reserves right to witness and audit PMI.

8. Custom and specialty engineered equipment and parts

Some equipment is purchased primarily as manufactured standard. This can include

skid mounted or packaged units, specialty rotating equipment, such as compressors
and turbines, expansion bellows, rupture disks, and instrumentation. PMI is
important for this equipment, but may be difficult to verify because the equipment is
fabricated using in-house manufacturing procedures and is received fully assemble.
Some physical verification of PMI is desired where practical. However, an
acceptable in-house QC/QA program or a detailed paper trail can provide adequate
verification.
The manufacturer shall provide written procedures for in-house QC/QA for PMI; refer to appropriate
sub-clauses in clauses 5 and 7. If practical, the following shall also be required unless waived by BP:

a. Alloy parts of accessible pressure boundary of engineered equipment shall receive a

minimum 10% PMI after completion of equipment fabrication.
This requirement may be waived by BP after reviewing the manufacturer’s QC/QA
program.
b. Alloy parts of accessible pressure boundary of engineered equipment supplied by a
supplier not having a qualified QC/QA program as specified in appropriate sub-clauses of
clauses 5 and 7 shall receive 100% PMI after completion of equipment fabrication.

9. Field fabricated equipment and parts

a. A program shall be established for material handling in the field before field construction
work on BP facilities consisting of following:
1. Storage facilities to segregate materials and parts by alloy content.
2. Inventory control on materials and parts used.
3. Procedures for transferring material stamping or marking to unused portions of
materials and parts (such as plates, pipes, and studs) before returning to storage.
b. Materials and parts shall be ordered from suppliers meeting the QC/QA program as
specified in clauses 5 and 7. If this requirement is not met, alloy materials and parts shall
be furnished with MTRs and shall be subject to 10% PMI before use.
c. Additional tracking for welds shall be as follows:
1. A minimum of 10% of field welds shall receive PMI.
2. If at any time, the inspector discovers unidentified welding consumables being used
on materials subject to PMI examination, the welds in question shall immediately be
placed on hold until such time that positive identification can be established using the
criteria in this GIS.
3. If weld consumables packaging does not meet the appropriate requirements of
clause 7 the inspector may require PMI examination of the weld consumables before
welding. The PMI shall consist of one test on one electrode from each batch number
or filler wire from each heat number. The remainder of the consumables shall be
examined to determine that colour coding, identification, and heat number are correct
and traceable to PMI accepted materials.

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30 August 2006 GIS 36-103
Guidance on Industry Standard for
Positive Materials Identification (PMI) for Pressure Vessels, Piping, and other Components

10. Field piping

a. Field installations of alloy piping components shall receive 100% visual verification of
correct material stamping before painting or coating is applied and shall consist of:
1. Review of shop fabrication document(s) for evidence of shop verification of shop
fabricated components.
2. Review of correct material stamping or marking of field installed components
b. Unless otherwise specified, field verification of material identification need not include
utility piping and tubing for Class 300 and lower services.
c. Verification of pipe sections fabricated in a shop shall include:
1. Review of correct material stamping or marking after fabrication.
2. Sign off shop fabrication documents by person(s) performing visual examination
signifying correctness of materials used.
d. Visual verification of studs, bolts, and gaskets at time of assembly.
e. Welds of alloy piping components shall receive 10% PMI.
f. Welds of materials going into hydrogen or H2S service shall receive 10% PMI.

Table 1 – Common PMI examination requirements for components and fabricated equipment

Equipment Fabricator (1), (2)

Vessels and Heat Exchangers: plate, clad plate, strip 10% of each heat or lot
lining, forgings, nozzles (pipe), internals, tubes
Fabrication welds, including tube to tubesheet welds 10%
Weld overlay, back cladding Refer to GIS 36-107
Heaters and Boilers: tubes and tubesheets, other cast 10%
alloy pressure containing components
Heaters and Boilers: tube supports 10%
PSV and Piping Expansion Joints: Bellows elements 10%
Pipe, Pipe Fittings, Flanges 10%
Valves (3) 10%
Alloy Bolting (4) Random inspection of 10% of lots
Rotating Equipment: Pressure containing elements 10%
and BP specified internals
Instrumentation: Pressure containing housing 10%
NOTES:
1) The material supplier shall provide MTRs for equipment which contains materials that are subject to
PMI examination.
2) These percentages denote the minimum amount of PMI required unless BP approves a change in
writing. The Inspector reserves the right to carry out his own PMI examination activity in addition to
that specified as the Fabricator’s responsibility.
3) Unless otherwise specified by BP, PMI examination requirements for valves include the body,
bonnet, stem and a minimum of one out of every four bonnet bolts.
4) As defined in the ASME B31.3 Piping Code.

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30 August 2006 GIS 36-103
Guidance on Industry Standard for
Positive Materials Identification (PMI) for Pressure Vessels, Piping, and other Components

Bibliography

[1] GP 36-10 Guidance on Practice for Metallic Materials Selection.

[2] API RP 578 Material Verification Program for New and Existing Alloy Piping Systems.

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