Positive Material Identification MP- 220

Beaumont Refinery
Maintenance Procedure

Positive Material Identification Approval: ___________________________

Mechanical Division Manager

Owner: Light Oils Routine Maintenance

Section Supervisor
Endorsed:___________________________
JH&SC Chairperson

Purpose The purpose of this procedure is to ensure the accurate

identification, procurement, handling and installation of all alloy
materials within the Beaumont Refinery and its off-site locations.

Primary Users with Process

Responsibilities
Mechanical
Engineering
Storehouse
Procurement

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

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Positive Material Identification MP- 220

Scope and Application

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.

Shift Team Supervisor (STS)

The Shift Team Supervisor reviews all the entered work orders each day and provides the required
edits. The STS meets with the Process SLS, PMC, & Area Planner daily to review the new Work
Orders for cost estimation and necessary corrections. The Work Orders are then released to the
PMC, canceled, or deemed requiring more information.

Process Mechanical Coordinator (PMC)

The responsibility of the Process Mechanical Coordinator is to verify that all of the information
generated by the Proprietor on the Work Request is correct. If alloy material is mandated, the PMC
must ensure the PMI field button is highlighted on the Work Request. The PMC must also verify
that Process location, piping circuit, yard number, equipment class, and material specification are
all correct. The PMC should consult with Engineering for any alloy related questions or concerns.
The PMC must provide accurate alloy identification in the Refinery Work Management System.

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Positive Material Identification MP- 220

Note: Alloy selection for piping and valves is to be identified from the color-coded unit/area P&ID's.

Planner or Project Coordinator

The Planner must review ALL work orders for PMI requirements. For work requests designated as
requiring PMI, a work order step must be created (i.e. Buyer's step) with a long description to
highlight the requirement for PMI & QA (PMIV). The job step must be scheduled such that the PMI
Group and the QA Group are notified for all PMI and final PMIV.

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)

Material Buyers (Material specialists, weld/machine shop/TA/RM/GEMS planners, etc.)

The Material buyer is responsible for the ordering of alloy material based on a Work Request or a
Construction Drawing (if a Fabrication Shop is used). The storehouse code 5000-222 must be
entered as the unloading point in the Account Assignment section of the requisition in SAP. All
alloyed material must have the delivery point designated as the storehouse and will be
delivered to Mechanical Execution Supervisor (FLS) in charge of the ongoing mechanical
activities should material be delivered on off shift. The final designation of the material (the job
site where the material will be installed) should be in the long description of the order form. Non-
stock alloy materials must be ordered through the refinery purchase requisition system. To ensure
identification of alloy materials, credit card purchase of alloy materials is not allowed.
Should a supplier be required to fill out a requisition, it is the responsibility of the Material Specialist
to make sure MP-220 is followed. Per GP-18-12-01 Revision 1, any and all alloy materials, or
fabricated pressure containing parts or welded components, must be accompanied with Material
Test Reports (MTRs) and complete fabricators Quality Control Package.

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.

Storehouse Receiving (during normal work hours)

The storehouse will process receipt of all materials and contact the PMI Group for confirmation and
identification of materials. After positive material identification, the storehouse will provide the alloy
materials to the job site or storehouse stock as appropriate. Material will only be released from the
storehouse upon acceptance of the material from PMI Group. (Note: With the exception of 316 SS
tubing and fittings, alloy materials are not allowed in satellite warehouses.)
Outside fabricated alloy items will be delivered to the storehouse where the PMI Group will PMI
them for the dispatch to the job site.

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.

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Positive Material Identification MP- 220

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.

PMI Group and QA Group

The PMI Group will perform PMI and provide color-code identification and/or PMI stamp on all alloy
material. The PMI Group will also issue a release of acceptance or rejection on all material PMI
identified. The PMI Group will also maintain documentation according to FEQA. 6.6. This
documentation includes point sheet information of alloy material and welds and final PMIV
signature. All documentation will be filed for the life of the alloy material.

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).

Note: The PMI Color-Code Chart is shown in Attachment 3

Mechanical Group: Execution FLS/Foreman/Craftsman

The Mechanical Group is responsible for receiving alloy material for the purpose of installation. The
Execution FLS/Foreman/ Craftsman will review the job for PMI requirements by referencing the
work order and/or construction drawings. The Execution FLS/Foreman/Craftsman is responsible
for ensuring the alloy material used on the job is correct before installation. This is done by
reviewing the Work Order, P&ID's, or construction drawings and comparing to the alloy color code
as marked on the equipment to be installed.

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.

Fabrication Shops: BMRF Weld Shop/Outside Shops

The Fabrication Shops are responsible for ensuring proper alloy material is used by referencing the
work order and/or the construction drawings. All alloy piping must have a CADD drawing before
fabrication. Equipment fabricated from alloy for product purity purposes, such as lube oil piping,
can be fabricated without CADD construction drawings. The Fabrication Shop will ensure that
alloy material is ordered through the SAP system and that alloy material is PMId before shipping to
the job site. The Fabrication shop will issue all NDE documentation with the completion of
fabricated material. All PMI identification shall be completed after post weld heat treatment and
prior to shipment. The PMI Group shall be notified when work orders are issued to Fabrication
Shops and a drawing issued to the PMI/QA Group at time of construction. The Fabrication Shop is
responsible for notifying the PMI Group for work done on all alloy equipment for the BMFR. The
outside fabricator Shop will notify PMI Group for PMI of material after NDE and prior to shipment of
material. The outside fabrication shop will see that all fabricated alloy items are delivered to the
storehouse where the PMI Group will identify them for dispatch to the job site.

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Positive Material Identification MP- 220

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

Attachment 2, Positive Material Identification Final

Verification Form

Attachment 3, Gasket Color Code Chart

***END OF PROCEDURE***

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Positive Material Identification MP- 220

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.)

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Positive Material Identification MP- 220

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 Heads: 100% PMI will be performed on pump heads

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.

Demister Pads: PMI is not required on demister pads.

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.

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Positive Material Identification MP- 220

Attachment 2

Positive Material Identification Final Verification Form

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Positive Material Identification MP- 220

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