Professional Documents
Culture Documents
:
Shell Oil Products US Revision Date:
Martinez Refinery
Positive Material Reviewed:
Turnaround Department Identification, Proper Material Approved:
Page 1 of 27
Assurance & Control (PMAC)
CONTENTS
1.0 PURPOSE
2.0 SCOPE
This document sets requirements for verification of the chemistry, for alloy
materials at SMR, which can be used for new construction or for maintenance
repair/replacement of existing parts. This document was developed from the
Shell EGGS 2GS-55 specification. This site-specific procedure varies from
2GS-55 in the following areas:
(Ref: 6.1) SMR requires the alloy component supplier to perform the PMI at their
warehouse even for material supplied to pipe fabricators outside of SMR, unless
otherwise arranged by the person requesting/ordering the material.
(Ref: 6.2) SMR requires full or 100% PMI verification of all alloys used for
pressure retaining parts, including stainless steels, unless otherwise specified.
3.0 APPLICATION
4.0 DEFINITIONS
QA Quality Assurance
5.0 REFERENCES
This document is revised from Original C(F)-15. Any future revisions to C(F)-15
should be considered for this procedure as well.
6.0 REQUIREMENTS
After verification of alloy chemistry and that it matches the alloy indicated by the
ASTM markings, the component shall be marked to designate that the
components chemistry was checked per Subsection 6.7.
(a) For continuity in the SMR PMI program, all pressure retaining alloy (not
carbon steel or cast iron) components listed in Attachment-A shall have 100% of
the parts verified unless otherwise specified. This includes 100% verification of
the alloy welds joining these components.
(b) For longitudinally welded pipe and fittings in which filler metal is added as a
part of their fabrication, a random sampling will be performed on the longitudinal
welds. The requirements for this random sampling are also contained in
Attachment-A notes.
(c) Ten percent (10%) random sampling shall be performed on alloy non-
pressure retaining parts if the failure of the part could affect the structural integrity
of the equipment or piping system. Or if the failure could cause an equipment
reliability problem. Examples of non-pressure retaining parts that should be
randomly sampled include:
(e) Alloy studs generally will not require verification unless they are for a very
specific high temperature service or for a specific corrosive service inside of
pressure equipment. SMR will specify when verification on bolts will be required.
How to verify and how to mark will be agreed upon with the supplier on a
case-by-case basis.
(f) It is recommended that one alloy electrode or wire sample from each lot of
weld rod to be used should be positively identified. The remainder of the lot
(g) Unless otherwise specified by SMR, the following parts shall not be subject
to PMI:
(a) Materials suppliers, shop fabricators and field constructors or their PMI
subcontractors shall produce a PMI program in writing and submit it to the
purchaser for approval.
(c) Implementation of a PMI program shall not release the supplier from the
responsibility of furnishing the specified materials.
(d) SMR shall be notified of parts that are improperly marked from the
manufacturer and the action plan that the supplier or fabricator has for dealing
with these in order to assure properly marked materials in the future.
(e) Conflicts between this procedure, Shell EGGS and other related documents
such as drawings or purchase orders shall be brought to the attention of the
purchaser prior to any action by the supplier, shop fabricator, or field constructor.
6.4. Examination
(a) The machine used for metal alloy analysis shall be able to determine the
percentage, by weight, of elements in accordance with Table I of 2GS55, which is
contained in this procedure as Attachment-B. The examination shall prove that
the material contains the proper range of elements to meet the requirements of
the applicable ASME or ASTM specification for which the material was specified
in the procurement documents.
(b) Unless otherwise specified or approved, examination shall be carried out with
portable x-ray fluorescence or optical emission alloy analyzers such as:
(c) If approved by the purchaser, examination may be carried out with analytical
laboratory methods such as x-ray emission spectrometry, optical spectroscopy, or
wet chemical analysis.
(d) Examination shall not be carried out with chemical spot testing or methods
that use eddy current, triboelectric testing, or thermoelectric tests.
(e) Unless otherwise approved by the purchaser, examination method shall not
damage the component or equipment being examined.
(b) Rejected material shall be replaced with acceptable material at no cost to the
purchaser.
(c) The supplier, shop fabricator, or field fabricator shall submit, in writing to the
purchaser, an explanation for the rejected material that identifies the root cause,
and a plan for corrective action.
(d) When components are tested by 10% random sampling and an item is
rejected:
1. 100% of the remaining components from which the sample was taken
shall be examined.
2. 100% of the components from the next delivery from the supplier of the
rejected material shall be examined.
6.6. DOCUMENTATION
(b) The inspection report shall indicate the following as a minimum for each
inspection lot examined:
Supplier/Fabricator/Manufacturer name
Mill test certificate number and heat number, if applicable
Method of examination (laboratory or field analyzer)
Type of analyzer used if applicable
Inspection lot size and number of pieces or items examined
Number and type of each component inspected, rejected, and
reasons for rejection; corrective action taken
Weight percentage of elements, if required
(c) Completed inspection reports along with associated mill test certificates shall
be transmitted to the purchaser.
(d) Documentation associated with the PMI program shall be available for audit
by the purchaser for a period of one year after the material/equipment is
supplied.
(e) The basic intent is for the responsible PEI inspector, rotating equipment
inspector, or instrument inspector to review the PMI verification test results that
are submitted for the various types of equipment manufactured. This is done to
assure that the correct materials are being supplied and that the alloy analyzer
appears to have been working correctly. In addition the inspector can get a feel
as to the adequacy of the suppliers, fabricators, and contractors PMI program.
6.7.1. General
(a) The marking requirements of this procedure are the same as those in Shell
EGGS 2 GS-55 except that a color code has been provided for marking lengths
of pipe, bar stock or any other desired components.
(b) Components on which PMI tests are performed shall be identified with a PMI
stamp, material identification codes, and green spot (paint or sticker).
(d) Pressure equipment subject to PMI examination shall have a PMI stamp on
the nameplate.
(e) All piping components shall have PMI stamp, material identification code, and
green spot. Welds shall have a PMI stamp on a flat spot ground on the weld with
an adjacent green spot on the pipe material. For smaller welds, the PMI can be
stamped on the adjacent material with an arrow pointing toward the weld tested.
(f) Lengths of pipe, bar stock or other items that are normally cut to make final
assemblies for pressure retaining parts or components affecting reliability shall
have a color code along their entire length so that trace ability is readily
achievable in the field or shop. The colors shall be in accordance with the Pipe
Fabricators Institute ES-22 specification as shown in Attachment-C.
(g) Paints used for applying the colors and green spot shall have a chemical
composition that is not harmful to the alloy and does not contain zinc, aluminum,
lead, sulfur, or halogens.
(a) Letters "PMI" shall be stamped on each component PMI verified for chemical
analysis. Location of the stamp will be in accordance with drawing 2G55D1 from
Shell EGGS 2GS-55, reference copy shown in Attachment-D.
(b) The appropriate number code identifying the alloy of the component shall be
stamped below or adjacent to the "PMI" letters. The number code shall be
according to the table listed below for the various alloys.
(c) A green spot shall be applied next to the PMI and material code markings.
For materials that are painted, a green spot shall be applied after painting near
the PMI stamp. If the supplier or fabricator desires, a color code can be used to
circle the PMI markings. In the case of two color codes, the second color code
shall be a line under the circle in accordance with the drawing 2G55D1 from
Shell EGGS 2GS-55, reference copy shown in Attachment-D.
(d) PMI and number codes markings shall be 1/4" high minimum unless limited
by component size and shall be made with low stress steel stamps. Engraving
tools Or Electro-Chemical Etching may be used if approved by SMR or the
purchaser.
(e) High and low carbon stainless steel material shall be identified with the
letters "H/HT" and "L" respectively if the carbon content has been verified. HT
designates high carbon content with a special heat treatment process.
(a) Bulk pipe and heater tubes shall have the PMI Stamp, the Material Number
Code and the green spot applied at each end. Each time a piece is removed the
Material Number Code shall be reapplied on the appropriate piece(s) to maintain
verification.
(b) Application of codes to pipe fittings and valves shall conform to the drawing
2G55D1 from Shell EGGS 2GS-55, reference copy shown in Attachment-D.
(c) Shop fabricated pipe spools, heater coils and crossovers may have the PMI
Stamp and the Material Number Code applied at each end of the fabricated
spool. An arrow adjacent to the Number Code at each end will point towards the
other end of spool in order to depict the components covered by the stampings.
(d) Plates, including clad/overlaid plates, shall have the PMI stamp and the
Material Number Code applied at each corner. Pieces of plate removed shall
also have the Material Number Code transferred so that verification can be
maintained.
(e) Heat exchanger tubes shall have the color code applied at each end. Heat
exchanger tubes do not require stamping.
6.8. Compliance
The person responsible for pressure equipment Quality Assurance will audit
these requirements at least once every three years.
7.0 RESPONSIBILITIES
The materials supplier is responsible for developing a written PMI program for
SMR approval. Including a re-submission of the document when changes to it
occur, either from an internal change or a change made from revisions to this
procedure.
The materials supplier is responsible for notifying SMR when PMI finds
components to be out of compliance with requirements. The notification must
include, a written explanation, root cause and a plan for correction. Reference
Subsection 6.5(d) for specific actions.
The materials supplier is responsible for documenting the PMI findings per the
requirements of Subsection 6.6 and submitting them back to the requestor for
approval.
The PE & CC are responsible for assuring that the required PMI this procedure
gets done at some-point in the project (reference Subsection 6.1).
The PEI Inspector is responsible for validating that the required PMI per this
procedure gets done on all (applicable) work generated as part of routine
maintenance, turnaround execution and PEI driven work for their area of
responsibility.
The PEI Inspector is responsible forto reviewing PMI reports for accuracy against
the requirements of this procedure.
The PEI Inspector is responsible for validating that the chemistry information is
correct and as specified for the application.
The PEI Inspector is responsible for auditing the PMI process to assure that the
required stamping and marking are being correctly applied per this procedure.
The PEI/MPO QA Inspector is responsible for auditing to assure that the required
PMI per this procedure is done correctly, using the audit form in PEI IGP 18.27.
The fabricator is responsible for assuring that the PMI is done in accordance with
requirements given to them, including meeting the requirements within this
procedure. That alloy materials added as part of the fabrication process
(typically this means deposited weld metal) are PMId. In addition that PMI is in
accordance with their QA manual and that the section of the QA manual on PMI
has been submitted to SMR for approval. Including a re-submission of the
document when changes to it occur, either from an internal change or a change
made from revisions to this procedure. Conflicts between requirements given
and the fabricators PMI program and/or this procedure shall be immediately
address and approval obtained from the PEI PEE.
The fabricator is responsible for notifying SMR when PMI finds components to be
out of compliance with requirements. The notification must include, a written
explanation, root cause and a plan for correction. Reference Subsection 6.5(d)
for specific actions.
The fabricator is responsible for documenting the PMI findings per the
requirements of Subsection 6.6 and submitting them back to the requestor for
approval.
If the Maintenance Planner and/or Team Leader are overseeing the fabrication of
alloy materials then they will be responsible for compliance to the same
requirements as the fabricator.
The rotating equipment inspector is responsible for assuring that alloy piping
associated with rotating equipment is PMI verified and marked at their next
scheduled machinery maintenance. This shall be documented in the equipment
file. After the initial PMI verification and marking, visual validations that the piping
components are correct shall be performed at each succeeding equipment
maintenance after piping re-assembly and documented as part of the final
inspection for completion of the maintenance for the piece of equipment.
The crafts person is responsible for having the right material for their job. They
shall validate the material stamping, that a PMI stamp, material code stamp and
green dot are present or that the material color-coding is correct. The crafts
person will also perform a final validation of the assembled work after final
installation.
Welders shall verify that they are using the correct filler material as defined by
the weld procedure. The welder will also perform a final validation of the
fabricated work prior to turnover.
8.0 TRAINING
The primary method of training will be through the CBT system. It will consist of
two levels
Initial training (as of this revision, this will be considered as new hires) will include
the following disciplines and crafts:
Materials Receiving
Contracts Procurement
Pressure Equipment Integrity
Martinez Projects Organization
Control Systems Engineering
Process Engineers
Central Maintenance Department (CMD) and Turnaround Planning
(TAP); Supervisors and Team Leaders, including the following SMR
Crafts:
Welders
Pipe Fitters
Machinists
Instrument Techs
Operating Departments:
Team leaders
Foreman
Supervisors
Detailed refresher training will be required for the following disciplines and crafts
on a yearly basis and at every (major revision) to 2GS-55 and/or this procedure:
Materials Receiving
Contracts Procurement
Pressure Equipment Integrity
Martinez Projects Organization
Central Maintenance Department (CMD) - SMR Crafts:
Welders
Pipe Fitters
Machinists
Instrument Techs
Operating Departments:
Team leaders
Foreman
9.0 DOCUMENTS
10.0 RECORDS
All records shall be controlled in accordance with the Shell Oil Products US and
Motiva- Records Management Program Manual and unique portions of the
applicable Pressure Equipment Integrity Department records control program.
11.0 ATTACHMENTS
0 2-1-09
Approvals
Procedure Number: TGP-15
Date of Revision:
Next Revision Due: 08/31/2011
7. For longitudinally welded pipe and fittings in which filler metal is added, a random
sampling will be performed on the welds as follows:
PMI verify 10% of each sample population or one PMI verification for each
200 ft length of total weld in the sample population, which ever is greater.
For example, 10 longitudinally welded pipes, each 20 ft long, requires PMI
verification of one pipe length (10% of the sample population)
For 10 longitudinally welded pipes, each 40 ft long, requires PMI verification
on two pipe lengths (400 ft/200 ft per test = 2 tests)
8. 300 series stainless steel thermowells to be used in carbon steel piping systems
need not be PMI verified as long as the process environment doesnt require the
alloy material for temperature and/or process flow erosion/corrosion resistance.
The PEI PEE and/or materials Engineer can verify this.
ALLOY Cr Ni Mo Cb Ti Cu Co Al Zn Sn Pd V
1Cr 1Mo V X X X
1-1/4Cr 1/2Mo X X
2-1/4Cr 1 Mo X X
2-1/4Cr 1Mo V X X X
5Cr 1/2 Mo X X
9Cr 1 Mo X X
13Cr 4Ni X X
304, 304L, 304H* X X
Alloy 2205 X X X
Alloy 20 Cb3 X X X X X
Hastelloy C-276, C-22 X X X
Hastelloy B X X
90/10 CuNi X X
70/30 CuNi X X
Monel 400 X X
Stellites X X X
Titanium X
Gr 2 X
Gr 7 X X***
Gr 12 X X X
ALLOY COLORS
1 Cr-1/2 Mo 1 solid orange, 1 solid blue
1-1/4 Cr-1/2Mo 1 solid yellow
2-1/4Cr- 1Mo 1 solid blue
5Cr-1/2Mo 1 solid blue, 1 solid yellow
9Cr-1/2 Mo 2 solid orange
Type 410 (12 Cr) 1 solid green, 1 solid red
304 1 solid black
304L 2 solid black
304H 1 intermittent black
309 1 solid black, 1 solid brown
310 1 solid green, 1 solid orange
316 1 solid gray
316L 2 solid gray
316H 1 intermittent gray
317 1 solid brown, 1 solid green
317L 1 solid brown, 1 solid red
321 1 solid pink
321H 2 solid pink
347 1 solid brown
347H 2 solid brown
Alloy 2205 * 1 solid brown, 1 solid yellow
Alloy 20Cb-3 (Carpenter-20) 1 solid black, 1 solid blue
Alloy 400 (Monel) 1 solid black, 1 solid yellow
Alloy B-2 (Hastelloy) 1 solid red, 1 solid orange
Alloy C-276 (Hastelloy) 1 solid red, 1 solid blue
Alloy C-22 (Hastelloy)
Alloy 600 (Inconel) 2 solid blue
Alloy 625 (Inconel) 1 solid blue, 1 solid pink
Alloy 800 (Inconel) 1 solid black, 1 solid orange
Alloy 800H (Incoloy) 1 solid gray, 1 solid red
Alloy 800HT (Incoloy) * 1 intermittent gray, 1 solid red
Alloy 825 (Incoloy) 1 solid gray, one 1 solid blue
* Alloy is not in ES-22, color code above selected by SMR
(Note This is a sub-list of the PFI Standard ES-22 for materials used in SMR)
BACKGROUND
In large maintenance projects (such as turnarounds) there is a risk for pressure retaining parts to be
installed in different locations from where they were removed or intended (many have same dimensions).
Since each process system has its own metallurgy requirements, the wrong metallurgy in a system could
lead to serious problems when the unit is brought back on line. It is maintenances responsibility to
assure that all pressure retaining parts removed during the turnaround are re-installed in the location /
system that they were removed from. With the amount of discrepancies found in audits, of operating
units, a turnaround procedure is needed to assure compliance. This procedure should also alleviate
some of the problems weve had with lost materials.
PROCEDURE
During T/As, pressure-retaining parts requiring removal will be color tagged and logged. A corresponding
tag (same number, different color) will be attached to the location from where the item was removed.
After maintenance, inspection or cleaning is complete the tagged pressure retaining parts are to be re-
installed in their original location identified by the corresponding tags. If the original item removed is lost
or misplaced its replacement will be required to go through the PMI (positive material identification)
process.
TAG INSTALLATION
Planned work
Pressure retaining parts (valves, piping, gauge glasses, blind flanges, etc.) identified for removal in the
turnaround plan will be tagged and logged by maintenance prior to feed outage
TAG REMOVAL
Foremen and their crews are to leave both tags on the parts after the equipment is re-installed.
3 3
The contractor Q.C. / PMAC coordinator designate will remove the tags using the Removed Equipment
Log book as a reference. Any discrepancies found by the designate will be required to go through the
PMI process.
Tag # Item description Date Foreman Date Foreman PMI Designate Date
and location initials installed initials Required sign off
remo
ved