TGP-15 Pmi & Pmac

Procedure TGP-15 Revision No.
:
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 7.0 RESPONSIBILITIES

2.0 SCOPE 8.0 TRAINING
3.0 APPLICATION 9.0 DOCUMENTS
4.0 DEFINITIONS 10.0 RECORDS
5.0 REFERENCES 11.0 ATTACHMENTS
6.0 REQUIREMENTS 12.0 REVISION HISTORY
1.0 PURPOSE
The purpose of this procedure is to establish the requirements for positive

material identification within the Shell Martinez Refinery (SMR).
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.
(Ref: 6.3) Requirements for suppliers and PMI subcontractors, submission of

program for approval and notification process on non-conformances.
(Ref: 6.4) Requirements for examination equipment.
Uncontrolled when printed

Procedure TGP-15 Revision No.:
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(Ref: 6.5) Handling of rejected material.
(Ref: 6.6) Documentation requirements.
(Ref: 6.7) Identification codes, stamping, painting, marking, etc.
(Ref: 6.8) Compliance requirements.
(Attachment F) Proper Material Assurance and Control (PMAC); this is a form of

PMI where tagging is used on spools removed during large turnaround activities.
3.0 APPLICATION
This procedure applies to Positive Material Identification (PMI) practices within

the Shell Martinez Refinery. This procedure does not apply to any other Shell
location.
4.0 DEFINITIONS
CBT Computer Based Training
EGGS Engineering Guides & General Specifications
EQ-TYP Equipment Type
IGP Inspection Guidelines and Procedures
PEE Pressure Equipment Engineer
PEI Pressure Equipment Integrity
PMI - Positive Materials Identification, specifically the identification of alloy

chemistry.
QA Quality Assurance
SMR Shell Martinez Refinery

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Supplier When used in the context of supplying documentation, the term

supplier shall mean the organization responsible for doing the PMI validation, this
most often will be the materials supplier, but could be the fabricator, etc.
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.
The following documents provide additional information and/or practices to better

understand the PMI process:
Shell EGGS 2 GS-55 Positive Materials Identification for Alloys

API Recommended Practice 578, PMI and Construction Material
QA
Shell Best Practice and Guidelines INSP-05 for Alloy Material
Control and Handling of Piping.
Design and Engineering Practice DEP 31.10.00.10-Gen, Material
Traceability and Positive Material Identification
Pipe Fabrication Institute (PFI) Standard ES-22, Recommended
practice for color coding of piping materials
SMR IGP 18.0 Audits (specifically 18.27)
6.0 REQUIREMENTS
6.1. Basic Requirements

The chemistry of all incoming pressure retaining alloy materials shall be verified
using an alloy analyzer. The material supplier shall do this verification unless
otherwise arranged by the project engineer or engineering field person
responsible for the maintenance work. Materials that will be shipped directly to
SMR without going through the warehouse of SMRs preferred materials supplier
shall have the material verified on site. Fabricated pipe arriving at SMR shall
have the alloy materials verified at the fabricators shop or from his material
supplier.

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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.
6.2. Parts Subject to PMI and Amount of PMI
(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:
Vessel internals such as trays, bubble caps, and distributors

Exchanger baffles and tube supports
Furnace tubesheets and tube supports
(d) Internal alloy components on rotating equipment such as impellers, turbine

shafts and turbine blades require PMI only if specifically designated by SMR in
purchasing documents.
(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

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should be compared to the sample to ensure that the color-coding and

identification of the wires/electrodes are correct. PMI verification shall also be
conducted in the shop or field on deposited weld metal for all pressure retaining
welds, except for tube-to-tubesheet welds, which are dependant on access,
(g) Unless otherwise specified by SMR, the following parts shall not be subject
to PMI:
All grades of carbon steel

Internal valve parts
Equipment made of alloy solely to maintain purity of the process
product
Internal machinery parts made of 304 or 316 stainless steel
Threaded pipe, fittings and valves made of brass, bronze, 304 or
316 stainless steel
Instrumentation orifice plates
Tubing and tubing fittings
Electrical components
Auxiliary equipment such as machinery lube oil systems, seal pots
and steam turbine gland vacuum systems
6.3. PMI Program
(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.
(b) PMI program shall include, at a minimum, details on the following:
Type of analyzer to be used

Calibration procedure of analyzers and calibration frequency
Qualification of personnel performing PMI
Analyzer functional check using a representative sample(s) of the
material subject to PMI. Representative sample shall be a reference
material standard.

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If different from the requirements of this procedure or if necessary

to clarify, the program shall also include:
Identification of equipment items that are to be subjected to
PMI
Type of materials and percent to be subjected to PMI
Sequence of PMI during production or fabrication
Acceptance/rejection criteria.
Handling and storage of incoming material
Handling, segregation, and storage of accepted material
Handling, segregation, and disposition of rejected material
Material identification codes for accepted material
(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:
Texas Nuclear 9200, 9266, or 9277 Analyzer

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Outokumpu X-Met 840 or 880

Spectro Spectrosport
Outokumpu Arcmet 900 or 930
(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.
6.5. Rejected Material
(a) Rejected material shall be identified by markings and segregated from

acceptable materials.
(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.
If either of these samplings rejects components then

deliveries from this supplier will be suspended until corrected.
(or)

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If both of these samplings are okay then the established

representative sampling process can be started again.
6.6. DOCUMENTATION
(a) Results of examinations for PMI shall be recorded on an approved report

form. The PMI inspection report shown on Drawing 2G55D2 from Shell EGGS
2GS-55 included in Attachment-E, is an approved form. The supplier or
fabricator can use their own report form as long as the information contained is
the same as required in this report and is approved as part of the their PMI
program.
(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.

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6.7. Identification Codes
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).
(c) Material identification codes specified in the procedure are required in

addition to identification codes required by applicable regulations such as ASTM.
(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.
6.7.2. Letter And Number Codes
(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.

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(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.
(f) The following is the number code for alloys:
ALLOY NUMBER CODE

1-1/4Cr 1/2Mo 1 CR
2-1/4Cr 1Mo 2 CR
5Cr 1/2Mo 5 CR
9Cr 1Mo 9 CR
304, 304L, 304H 304, 304L, 304H

316, 316L, 316H 316, 316L, 316H
317, 317L 317, 317L
321, 321H 321, 321H
347, 347H 347, 347H
410, 410S 410, 410S
430 430
Alloy 2205 2205
Alloy 20 20
Hastelloy C-22 C22
Hastelloy C-276 276
Inconel 625 625
Incoloy 800, 800H, 800HT 800, 800H, 800HT
Incoloy 825 825
Inconel 600 600
Monel 400 400

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6.7.3. Application Of Codes
(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.
(f) Complete items of equipment, such as heat exchangers or vessels, shall

have the PMI stamp and the basic Material Code for the vessel Shell and heads
applied on the nameplate. This certifies that all pressure-retaining components
meet the PMI requirements.
6.7.4. Color Code
Attachment-C contains a sub list of the Pipe Fabricators Institute ES-22

Recommended Practice for Color Coding of Piping Materials, for materials used
in SMR. This color code is recommended for components requiring color coding
in this procedure.

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6.8. Compliance
Designated representatives of the PEI Department will audit suppliers, fabricators

and maintenance activities at SMR at least once every three years for
compliance with the requirements of this procedure.
The person responsible for pressure equipment Quality Assurance will audit
these requirements at least once every three years.
7.0 RESPONSIBILITIES
7.1. Materials Supplier
The materials supplier is responsible for implementing SMRs requirements perre

this Procedure.
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.
7.2. Project Engineer (PE) and Construction Coordinator (CC)
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).
7.3. PEI Inspector
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

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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.
7.4. PEI/MPO QA Inspector
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.
In addition the PEI/MPO QA Inspector has many of the same responsibilities as

the PEI Inspector when reviewing work in the field, material in the MPO yard and
QC documentation when received.
7.5. FABRICATOR (Field or Shop)
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.

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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.
7.6. Maintenance Planner and/or Team Leader
The maintenance planner and/or team leader is responsible for assuring

materials, that the received materials are in accordance with the packing slip and
that the packing slip is in accordance with what was ordered. That the materials
have been validated by the use of a PMI stamp, material code stamp and green
dot are present or that the material color coding is correct. In addition that
certified test reports have been provided with the material.
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.
7.7. Rotating Equipment Inspector
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.
7.8. Crafts Person (Instrument Techs, Machinists, Pipe-Fitters and Welders)
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.

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The crafts person is responsible for reporting non-conformance issues to there

immediate supervision so that a proper follow up can be done.
8.0 TRAINING
8.1. Computer Based Training (CBT)
The primary method of training will be through the CBT system. It will consist of
two levels
Initial or Awareness Training

Detailed refresher training
8.1.1. Initial Training
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

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Foreman
Supervisors
8.1.2. Detailed Refresher Training
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
Martinez Projects Organization
Central Maintenance Department (CMD) - SMR Crafts:
Welders
Pipe Fitters
Machinists
Instrument Techs
Operating Departments:
Team leaders
Foreman
9.0 DOCUMENTS
The Pressure Equipment Integrity Manager or his/her designee shall maintain

this procedure. This procedure shall be managed in accordance with A (A)-19,
Procedures Management. This procedure shall be reviewed every three years,
and as often as necessary to ensure that it is current and accurate.

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10.0 RECORDS
10.1. Required Records

Record Type/Name Maintained At Maintained By (Name/Dept.) Retention Period
(Location)
PMI Report Supplier & N/A 1-year
(ref Attachment-E) SMR Resp Dept Varies
PMI Audit SMR PEI Department 3-years????
(ref - IGP 18.27)
10.2. Records Control
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
Attachment A: Positive Materials Identification For Alloys

Attachment B: Alloy Elements Required For PMI Inspection
Attachment C: PFI ES-22 Color Code System For Materials Identification
Attachment D: Copy of 2G55D1 from EGGS (reference only)
Attachment E: Copy of 2G55D2 from EGGS (reference only)
Attachment F: Turnaround Proper Material Assurance & Control (PMAC)

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12.0 REVISION HISTORY

Responsible
Revision No. Effective Date Description of Revision Appv. By
Person
0 2-1-09
Approvals
Procedure Number: TGP-15
Date of Revision:
Next Revision Due: 08/31/2011
Approvals: Name Signature Date

Revised: /s/
Reviewed: J. K. Brown /s/
Approved: /s/

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Attachment A: Positive Materials Identification for Alloys
MATERIAL EXTENT OF PMI

PIPING
PIPE ALL - 100%
FITTINGS ALL - 100%
VALVES (4) ALL - 100%
WELDED PIPE AND FITTINGS WITH FILLER METAL ADDED (7)
HEAT EXCHANGERS, BOILERS, FIRED HEATERS
HEATER TUBES ALL - 100%
HEAT EXCHANGER TUBES 1% (1)
HEAT EXCHANGER TUBESHEETS ALL - 100%
FITTINGS ALL - 100%
EXPANSION JOINTS ALL - 100%
CHANNELS ALL - 100%
PIPE ALL - 100%
FURNACE TUBE HANGERS ALL - 100%
FURNACE TUBE SUPPORTS ALL - 100%
EXCHANGER CLADDING ALL - 100%
EXCHANGER BAFFLES, TIE RODS 10%
PRESSURE RETAINING COMPONENTS OF PRESSURE VESSELS
SHELL AND HEADS ALL - 100%
NOZZLES, FITTINGS AND FLANGES ALL - 100%
CLADDING ALL - 100%
NON PRESSURE RETAINING PARTS
TRAYS, BUBBLE CAPS, DISTRIBUTORS, ETC. 10%
PRESSURE RETAINING COMPONENTS OF MACHINERY
PUMP OR COMPRESSOR CASING ALL - 100%
INSTRUMENTATION
LEVEL BRIDLES, GLASSES, FLOAT CHAMBERS ALL - 100%
FLOW NOZZLE, FLOW METERS, VENTURIS ALL - 100%
CONTROL VALVE (4) ALL - 100%
THERMOWELLS (8) ALL - 100%
ALLOY BOLTS FOR HIGH TEMP OR FOR CORROSIVE SERVICE (2)
WELDING
WELDS (PRESSURE EQUIPMENT) ALL - 100% (3)(5)(6)
WELDS (REPAIRS) ALL - 100% (3)(5)(6)
WELDS (PIPING) ALL - 100% (3)
WELDS OVERLAY ALL - 100% (5)(6)
PRESSURE RELIEVING EQUIPMENT
BELLOWS ALL - 100%
BODY ALL - 100%
BONNET ALL - 100%

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Attachment A (Cont): Positive Materials Identification for Alloys
1. 1% representative sample of the total number of tubes.

2. Sampling requirements of special alloy studs or bolts for high temperature
service or for corrosive services should be decided upon between the supplier
and the purchaser. This applies to bolts with an alloy content higher than ASTM
A-193 B7 or B7M. Normally, 5% of bolts supplied in bulk or two bolts per box,
whichever is greater, shall be examined. Bolts to be examined shall be selected
randomly by the purchaser.
3. One spot on every cap pass of every pressure-retaining weld shall be examined
in accordance with Appendix 2. For small welds that are inaccessible by the PMI
machine, a weld button of undiluted weld metal next to the weld can be deposited
and PMID.
4. Test valve body and bonnet only - internal parts not required. If bonnet is welded
to body, test the weld also.
5. One spot on every cap pass of every pressure retaining welds hall be taken for
vessels made of alloy plates. For clad vessels, one analysis of the overlay weld
deposited at each of the major vessel seams shall be performed. For nozzles
lined with alloy weld metal overlay, one analysis per nozzle is required. For
sleeve-lined nozzles, one analysis each on the flange face overlay and the shell
tie-in overlay is required. For vessels overlaid with alloy, the alloy overlay shall
be tested at a frequency as called for in the appropriate EGGS specified for the
vessel or in separate specifications provided for the vessel.
The weld metal analysis shall meet the same composition limits as the
corresponding base plate and clad materials except that carbon maximum of
0.045% is acceptable in a deposit joining L grade austenitic stainless steel
cladding.
For alloy air cooler header boxes, one analysis for each welding procedure used
for long seams, end plates, and nozzles is required.
6. Analysis of the base filler metal and/or alloy weld overlay shall be made at a
location designated by purchasers inspector. If overlay has been applied for
corrosion protection, the analysis shall be performed at 1/2 the minimum
specified thickness as qualified in the welding procedures. If the function of the
overlay is to ensure product purity only, the sample shall be taken at the surface.
Chemical composition at the designated depth shall meet the minimum
composition requirements for the weld overlay alloy specified.

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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.

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Attachment B: Alloy Elements Required for PMI Inspection
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
308L*, 309, 309L*, 310 X X

316, 316L, 316H*, 317, 317L* X X X
321, 321H* X X X
347, 347H* X X X
904L X X X X
410, 410S X X** X** X**
430 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
Incoloy 800, 800H X X X

Incoloy 825 X X X X X
Inconel 600 X X X
Inconel 625 X X X 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
Admiralty Brass*** X X*** X***

Naval Brass X X*** X***
* Carbon Content to be verified for L & H grades if specified by purchaser
** Check to verify this element is not present
*** For elements not determinable with PMI analyzer, other chemical analysis methods must be considered in order to assure PMI verification

Martinez Refinery
Page 23 of 27
Attachment C: PFI ES-22 Color Code System - Materials Identification
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)

Martinez Refinery
Page 24 of 27
Attachment D: Copy of 2G55D1 from EGGS (Reference Only)

Revision No.: 4
Shell Oil Products US
Martinez Refinery Procedure C(F)-15 Revision Date: August 2008
Reviewed: C.L. Fisher
Department
Positive Material Identification Approved: S. Yuen
Page 25 of 27
Attachment E: Copy Of 2G55D2 From EGGS (Reference Only)
Uncontrolled when printed Compare printed copy to controlled

Copy on Shell Intranet prior to use
Revision No.: 4
Department
Page 26 of 27
Attachment F: T/A - Proper Material Assurance & Control (PMAC)
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.
Need to remove blind flange for line

cleaning
Blind flange removed for line cleaning
Blind flange re-installed 3

3
3 3
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

copy on Shell Intranet prior to use
Revision No.: 4
Department
Page 27 of 27
(PMAC) Unplanned or Additional Work

Maintenance foreman needing to remove pressure-retaining parts from a system that have no tags, are
responsible to contact their Q.C. / PMAC coordinator who will attach corresponding tags to the parts and
the locations from where the parts are to be removed. He/She is also responsible to assure that the parts
to be removed are logged in the Removed Equipment Log book.
TAG REMOVAL
Foremen and their crews are to leave both tags on the parts after the equipment is re-installed.
Blind flange 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.
REMOVED EQUIPMENT LOG BOOK

Parts removed from their systems will be logged and tracked in the Removed Equipment Log book. The
contractor Q.C. / PMAC coordinator is responsible to assure that all removed pressure-retaining parts are
properly tagged, identified in the log book, and signed off and dated when the part is removed and
installed. The Q.C. / PMAC coordinator is also responsible for final check, sign off and tag removal.
Tag # Item description Date Foreman Date Foreman PMI Designate Date
and location initials installed initials Required sign off
remo
ved
NEW / REPLACEMENT PRESSURE RETAINING PARTS

New / replacement pressure retaining parts will be tagged, logged and signed off the same as equipment
removed for maintenance, inspection or cleaning. Additionally, these parts will require PMI (see positive
material identification procedure) where applicable.
EQUIPMENT WITH ASSIGNED I.D. NUMBERS

Equipment with assigned numbers for specific locations (relief valves, control valves, exchanger
channels, etc.) are not required to be tagged and logged under this system, since they are covered and
controlled with T/A equipment sign off sheets.

copy on Shell Intranet prior to use

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Procedure TGP-15 Revision No.

1.0 PURPOSE 7.0 RESPONSIBILITIES

The purpose of this procedure is to establish the requirements for positive

(Ref: 6.3) Requirements for suppliers and PMI subcontractors, submission of

(Ref: 6.4) Requirements for examination equipment.

Uncontrolled when printed

(Ref: 6.5) Handling of rejected material.

(Ref: 6.6) Documentation requirements.

(Ref: 6.7) Identification codes, stamping, painting, marking, etc.

(Ref: 6.8) Compliance requirements.

(Attachment F) Proper Material Assurance and Control (PMAC); this is a form of

This procedure applies to Positive Material Identification (PMI) practices within

CBT Computer Based Training

EGGS Engineering Guides & General Specifications

EQ-TYP Equipment Type

IGP Inspection Guidelines and Procedures

PEE Pressure Equipment Engineer

PEI Pressure Equipment Integrity

PMI - Positive Materials Identification, specifically the identification of alloy

SMR Shell Martinez Refinery

Uncontrolled when printed

Supplier When used in the context of supplying documentation, the term

The following documents provide additional information and/or practices to better

Shell EGGS 2 GS-55 Positive Materials Identification for Alloys

6.1. Basic Requirements

Uncontrolled when printed

6.2. Parts Subject to PMI and Amount of PMI

Vessel internals such as trays, bubble caps, and distributors

(d) Internal alloy components on rotating equipment such as impellers, turbine

Uncontrolled when printed

should be compared to the sample to ensure that the color-coding and

All grades of carbon steel

6.3. PMI Program

(b) PMI program shall include, at a minimum, details on the following:

Type of analyzer to be used

Uncontrolled when printed

If different from the requirements of this procedure or if necessary

Texas Nuclear 9200, 9266, or 9277 Analyzer

Uncontrolled when printed

Outokumpu X-Met 840 or 880

6.5. Rejected Material

(a) Rejected material shall be identified by markings and segregated from

If either of these samplings rejects components then

Uncontrolled when printed

If both of these samplings are okay then the established

(a) Results of examinations for PMI shall be recorded on an approved report

Uncontrolled when printed

6.7. Identification Codes

(c) Material identification codes specified in the procedure are required in

6.7.2. Letter And Number Codes

Uncontrolled when printed

(f) The following is the number code for alloys:

ALLOY NUMBER CODE

304, 304L, 304H 304, 304L, 304H

Uncontrolled when printed

6.7.3. Application Of Codes

(f) Complete items of equipment, such as heat exchangers or vessels, shall

6.7.4. Color Code

Attachment-C contains a sub list of the Pipe Fabricators Institute ES-22

Uncontrolled when printed

Designated representatives of the PEI Department will audit suppliers, fabricators

7.1. Materials Supplier

The materials supplier is responsible for implementing SMRs requirements perre

308L, 309, 309L, 310 X X

Admiralty Brass* X X* X***