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Beaumont Refinery
Maintenance Procedure
Safety and Failure to comply with industry codes and standards can have
Environmental
substantial safety and environmental consequences. The
Precautions
references and procedures outlined in this document establish
appropriate levels of quality control to ensure the mechanical
integrity of all process equipment containing alloy materials
References FEQA Manual Section 6.6 - Field Audit Procedures for
Materials Identification (PMI)
GP 18-12-01 Positive Material Verification
Definitions PMI - Positive Material Identification - In general, this term
refers to the program established to ensure all pressure-
containing alloy equipment meets the metallurgical
specifications.
PMI Verification -This is the action taken by an ExxonMobil
designated Inspector after installation.
Documentation and Work Management System
Records
FEQA Section 6.6 - PMI Audit Form
The Positive Material Identification (PMI) procedure applies to all alloy equipment components,
pressure containing equipment, and piping.
A refinery work order must be initiated and approved before installing or replacing alloy piping,
vessels, or other alloy equipment as defined in Attachment 1. Pertinent PMI information must be
included in the Refinery Work Request that includes but is not limited to the following:
1. Specific Process Location identifier
2. Piping Circuit and / or Equipment Class
3. Detailed Long" description of the work requested
All Work Requests that pertain to alloy material must have the PMI box highlighted to document
that the material needs PMI.
All alloy materials must be purchased through the refinery purchase requisition system. All alloy
materials must be received through Storehouse Receiving during normal working hours and must
be PMId and color-coded prior to installation. During off-hours and holidays the Mechanical
Execution Supervisor (FLS) in charge of the ongoing mechanical activities will receive alloy
materials and notify the PMI Group for PMI and color coding/ stamping. All Work Requests that
pertain to alloy require that a job step be initiated in the core step portion of the Work Request
which requires the PMI of material and the quality assurance (QA) for final PMIV. PMIV (final
verification of PMI) is performed by the QA Group and must occur after installation and prior to
putting the equipment into service. PMIV is also required prior to final MOC approval.
Responsibilities
Proprietor
The unit/area Process Operator (or Process Unit representative), or Project Coordinator are
responsible for the initiation of Work Requests and providing accurate alloy identification in the
Refinery Work Management system. Alloy selection for piping and valves must be identified from
the color-coded unit/area P&ID's. The process location identifier will determine other pressure
containing equipment (e.g. pumps and compressors, exchangers, vessels, etc.) alloy data through
the work management system. The Proprietor must identify specific process location, piping circuit,
yard number, equipment class, and other details in the long description of the work request.
Note: Alloy selection for piping and valves is to be identified from the color-coded unit/area P&ID's.
When alloy piping or equipment is fabricated by outside shops, the purchase order and or contract
shall clearly state that the PMI Group will verify all alloy components and materials. The PMI and
QA groups must be notified when work orders are issued to outside fabricators and must be issued
a copy of the construction drawings at time of construction.
Note: The PMI and QA groups will retain proper documentation for the completed alloy work for the
life of the alloy material (Per FEQA 6.6)
Security Guards
The Refinery Security Guards are to direct all alloy material deliveries to the storehouse on days
and to the Mechanical Execution Supervisor (FLS) in charge of the ongoing mechanical activities
on off shift and holidays.
Mechanical Execution Supervisor (FLS) in charge of off-shift work (off-hours and holidays)
The Mechanical Execution Supervisor (FLS) in charge of the ongoing off-shift mechanical activities
is responsible for receiving alloy material during off-hours and holidays and for notifying the PMI
Group for PMI identification. Additionally, the Machine Shop and the Weld Shop shall follow this
procedure for alloy pumps, seals, pump cases and alloy piping.
Note: The PMI Group shall only be called out on off shift when the Work Orders Priority is
either an A or a B that will be worked to completion. PMI will not respond to calls made
for convenience. An example of this scenario would be an alloy delivered on Friday night
because the delivery is late.
The QA Group will be notified through the Mechanical Group/QC, after the installation of the
material is complete, and must verify the alloy as correct before the equipment is placed in service.
Upon completion of PMIV, the QA Group will sign the PMI documentation forms and the
ExxonMobil PMI Final Verification Form (Attachment 2).
When the mechanical craftsman installs an alloy material, a representative of the craftsmen or the
Mechanical FLS notifies the Fabricator/Installer QC once the job is complete. The PMI Group will
be called as required to provide any final identification of unmarked materials. The QA Group shall
then be notified to perform PMIV. This PMIV step must be complete and documented prior to
MOC approval and prior to putting the equipment into service. If MOC is required, copies of the
completed QA/QC documents shall be included in the MOC documentation.
Note: All Fabrication Shops are responsible for following GP-18-12-01 on the control of welding
rods and the process of identifying welding rods prior to fabrication.
Attachments
Attachment 1, Guidelines for Positive Material Identification
Requirements
***END OF PROCEDURE***
Attachment 1
GUIDELINES FOR POSITIVE MATERIAL IDENTIFICATION REQUIREMENTS
Scope: The following outlines minimum PMI requirements for various equipment located in the
Beaumont Refinery. It is a guide for requirements on NEW equipment; however, if there is
question as to the identity of an existing material, a request for PMI inspection should be made.
The inspector has the right to require additional PMI inspection if there is reason to believe that
improper materials have been installed or received.
Piping, piping components, valves, expansion joints, heater tubes and pressure vessels:
100% PMI required, inspection will stamp, and color-code all alloys. For clad vessels, the
inspector will perform PMI of the cladding. New alloy vessels also require PMI of all nozzles,
nipples, heads, etc.
Welds: Pressure containing alloy welds, which can physically be analyzed, are to be tested and
marked. Welding rod control is established as a part of welding quality control procedures. If welds
can not be analyzed due to geometry or other limitations, deposit of weld metals by lot and heat
shall be analyzed in lieu of in-situ analysis or the weld should be tested with another method
approved by owner's representative. All weld deposit analyses shall be documented with
appropriate equipment or piping PMI documentation.
Bolting: Inspection will perform random PMI on bolting as it is received at the warehouse. The
inspector will verify proper markings (B-8, B-16, etc.) on a representative sampling basis as
defined in GP-18-12-01 version 1 and random visual verification of markings in the field will be
performed as part of a QA/QC inspection. The inspector will not stamp, nor color code bolting, and
an inspector WILL NOT be called out on off shift to perform PMI on bolting materials. Per GP 18-
12-01 the minimum sample size is 100 percent for a lot of 5 pieces or less, or 5 percent for a lot of
5 to 200 pieces, and the greater of 10 pieces, or 3 percent for a lot greater than 200 pieces.
Spiral wound gaskets: Inspection will not perform PMI on spiral wound gaskets, but will accept
the color coding from the manufacturer. 100% visual verification of color-coding is part of the
QA/QC inspection.
Jacketed gaskets (for exchangers): 100% PMI will be performed on critical jacketed gaskets.
Critical is defined as when an exchangers gasket joint is process to process as opposed to
process to cooling water. Stamping is not required, however, color-coding IS required. PMI is not
required on brass-jacketed gaskets. Typical gaskets requiring PMI are 4-6 Cr and 300 series
stainless steel.
RTJ gaskets: Inspection will perform 100% PMI on all RTJ gaskets and color-code accordingly.
No stamping required.
Instrument Tubing: PMI not required on standard 316 SS tubing or fittings (storehouse stock
items.)
GUIDELINES: continued
New Pump Cases: Inspection will perform100% PMI on all alloy pump cases and installed plugs
or nipples. Stamping and color coding is required and dismantling the equipment to allow PMI on
internal parts (e.g., impeller, etc.) is not required provided required documentation is available for
review.
Existing pumps require special PMI consideration. When an existing alloy pump is pulled and
overhauled in the shop, the pump shall be delivered to the field with bull plugs installed where
small bore piping will be installed in the field. In some cases, these plugs may not be removed in
the field. Where equipment cases and the plug metallurgy are not an exact match (e.g., a cast
CA6NM pump case may have a 410 ss plug) the bull plugs must be solid in construction and be of
sufficient alloy composition to resist the service requirements.
NOTE: Some pump cases are carbon steel with ss weld overlay (e.g., FCC main column bottoms,
etc.) In these applications, the plugs will be required to have the same resistance as the overlay.
Materials Engineer should be consulted if there is a question regarding proper plug materials. A
final, field PMI check to alloy pump cases shall be made as part of a QA/QC inspection prior to the
alloy pump returning to service.
Pump Impellers: PMI inspection required for all new purchases of alloy pump impellers.
Pump Shafts: 100 % PMI required on alloy shaft material stored in the machine shop. Continuous
color coding and stamping the end of the shaft is required, including all 4140 material.
Exchanger Tubing: Inspection will perform PMI testing on alloy exchanger tubing based on
representative sample size per GP 18-12-01. It may be possible to perform PMI on the embedded
tubes by accessing the tube ends. No stamping is required except on the tube sheet and random
color-coding is required. On assembled complete exchangers, PMI must be completed at the
vendor shop prior to assembly.
Relief Valve Internals: 100% PMI is required on all relief valve alloy internal parts purchased for
use by our shop in the rebuilding or repair of relief valves. Relief valves that are rebuilt by an
outside shop shall have PMI performed as part of the shops PMI program. Disassembly of relief
valves for the purpose of PMI is NOT required provided supporting documentation is submitted.
Vessel Internals (Trays / non-pressure -containing parts: Inspection will perform random PMI
on trays at a minimum of 10% unless the supplier provides a documented PMI program to ensure
conformance of components to the specified composition. This program may include segregation
procedures for tested material, marking, and small percentage random sampling.
Attachment 2