DEP 31.10.00.10-Gen. - 2017
DEP 31.10.00.10-Gen. - 2017
DEP 31.10.00.10-Gen. - 2017
DEP 31.10.00.10-Gen.
February 2017
ECCN EAR99
DEM1
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PREFACE
DEP (Design and Engineering Practice) publications reflect the views, at the time of publication, of Shell Global Solutions
International B.V. (Shell GSI) and, in some cases, of other Shell Companies.
These views are based on the experience acquired during involvement with the design, construction, operation and
maintenance of processing units and facilities. Where deemed appropriate DEPs are based on, or reference international,
regional, national and industry standards.
The objective is to set the standard for good design and engineering practice to be applied by Shell companies in oil and
gas production, oil refining, gas handling, gasification, chemical processing, or any other such facility, and thereby to help
achieve maximum technical and economic benefit from standardization.
The information set forth in these publications is provided to Shell companies for their consideration and decision to
implement. This is of particular importance where DEPs may not cover every requirement or diversity of condition at each
locality. The system of DEPs is expected to be sufficiently flexible to allow individual Operating Units to adapt the
information set forth in DEPs to their own environment and requirements.
When Contractors or Manufacturers/Suppliers use DEPs, they shall be solely responsible for such use, including the
quality of their work and the attainment of the required design and engineering standards. In particular, for those
requirements not specifically covered, the Principal will typically expect them to follow those design and engineering
practices that will achieve at least the same level of integrity as reflected in the DEPs. If in doubt, the Contractor or
Manufacturer/Supplier shall, without detracting from his own responsibility, consult the Principal.
The right to obtain and to use DEPs is restricted, and is typically granted by Shell GSI (and in some cases by other Shell
Companies) under a Service Agreement or a License Agreement. This right is granted primarily to Shell companies and
other companies receiving technical advice and services from Shell GSI or another Shell Company. Consequently, three
categories of users of DEPs can be distinguished:
1) Operating Units having a Service Agreement with Shell GSI or another Shell Company. The use of DEPs by these
Operating Units is subject in all respects to the terms and conditions of the relevant Service Agreement.
2) Other parties who are authorised to use DEPs subject to appropriate contractual arrangements (whether as part of
a Service Agreement or otherwise).
3) Contractors/subcontractors and Manufacturers/Suppliers under a contract with users referred to under 1) or 2)
which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said
users comply with the relevant standards.
Subject to any particular terms and conditions as may be set forth in specific agreements with users, Shell GSI disclaims
any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person
whomsoever as a result of or in connection with the use, application or implementation of any DEP, combination of DEPs
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companies, that may issue DEPs or advise or require the use of DEPs.
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GSI may at any time require information satisfactory to them in order to ascertain how users implement this requirement.
All administrative queries should be directed to the DEP Administrator in Shell GSI.
TABLE OF CONTENTS
1. INTRODUCTION ........................................................................................................ 4
1.1 SCOPE ....................................................................................................................... 4
1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS ......... 4
1.3 DEFINITIONS ............................................................................................................. 4
1.4 CROSS-REFERENCES ............................................................................................. 6
1.5 SUMMARY OF MAIN CHANGES............................................................................... 6
1.6 COMMENTS ON THIS DEP ....................................................................................... 7
1.7 DUAL UNITS............................................................................................................... 7
1.8 NON NORMATIVE TEXT (COMMENTARY) .............................................................. 7
2. GENERAL .................................................................................................................. 8
3. MATERIAL CONTROL AND VERIFICATION PROGRAMME MAIN
ELEMENTS ................................................................................................................ 8
4. MATERIAL VERIFICATION ....................................................................................... 9
4.1 ALLOY COMPONENTS AND ALLOY WELDS SUBJECT TO PMI ........................... 9
4.2 WELDING CONSUMABLE CONTROL AND VERIFICATION ................................... 9
4.3 CARBON STEEL COMPONENTS SUBJECT TO MATERIAL VERIFICATION ...... 10
4.4 ALTERNATE PMI PROGRAMS ............................................................................... 10
4.5 ALLOYING ELEMENTS REQUIRED TO BE EVALUATED DURING PMI .............. 10
4.6 MATERIALS AND COMPONENTS NOT SUBJECT TO PMI .................................. 11
4.7 TIMING AND LOCATION OF PMI/VERIFICATION CHECKS ................................. 11
4.8 GENERAL REQUIREMENTS FOR MATERIAL CERTIFICATIONS........................ 11
5. EXAMINATION EQUIPMENT/TEST METHOD ....................................................... 12
6. MATERIAL IDENTIFICATION ................................................................................. 12
6.1 TRACEABILITY ........................................................................................................ 12
6.2 MARKING ................................................................................................................. 13
6.3 COLOUR CODING ................................................................................................... 13
6.4 COMPONENT IDENTIFICATION ............................................................................. 14
6.5 REJECTED MATERIAL ............................................................................................ 14
7. PMI INSPECTION REPORT .................................................................................... 15
8. REFERENCES ......................................................................................................... 16
APPENDICES
APPENDIX A COMPONENTS SUBJECT TO PMI............................................................... 17
APPENDIX B PMI FOR INSTRUMENTATION COMPONENTS .......................................... 20
APPENDIX C ALLOYING ELEMENTS REQUIRED FOR PMI ............................................ 21
APPENDIX D MATERIAL IDENTIFICATION CODES ......................................................... 23
APPENDIX E LOCATION OF PMI IDENTIFICATION MARKS FOR PIPING
(EXAMPLES)................................................................................................... 24
APPENDIX F PIPING COMPONENT MARKING SPECIFICATIONS ................................. 25
1. INTRODUCTION
1.1 SCOPE
This DEP specifies requirements and gives recommendations for material control and
verification (MC&V) of alloy and carbon steel that needs to be applied during all phases of a
project or repair/replacement work, to guard against the installation of rogue materials for
pressurized equipment.
Pressurized equipment refers to standard or common types of equipment used in most
assets. Unique or specialized equipment for subsea, pipelines or other parts of the
business are addressed in the DEPs for these specific applications as the material control
and verification requirements in this DEP might not be enough to provide proper controls
and assurance.
This DEP is based on having a procurement system in place that obtains materials and
fabricated equipment from vendors that have been through a review and approval process
similar to that recommended in EEMUA 224.
The material control elements in this DEP apply to bulk and specialty components, and to
fabricated piping and equipment.
This DEP defines the minimum required sample (percentage), elemental analysis
requirements and other verification steps based on the material of construction and the
component type. It includes material traceability to source as part of the process.
This DEP contains mandatory requirements to mitigate process safety risks in accordance
with Design Engineering Manual (DEM) 1 - Application of Technical Standards.
This is a revision of the DEP of the same number dated September 2013; see (1.5)
regarding the changes.
1.3 DEFINITIONS
1.3.1 General definitions
The Contractor is the party that carries out all or part of the design, engineering,
procurement, construction, commissioning or management of a project or operation of a
facility. The Principal may undertake all or part of the duties of the Contractor.
Term Definition
Alloy Material Any metallic material (including welding filler materials) that contain
alloying elements that are intentionally added to enhance mechanical or
physical properties and corrosion resistance, or a combination thereof,
(e.g., Chromium, Nickel, or Molybdenum). The term alloy includes
special grades of carbon steel such as those used in low temperature
(LT) and sour services.
Heat (of A batch of metal made at the same time, that can be traced from its
Material) original constituents and manufacturing process.
Inspection Lot A group of items or materials of the same type from a common source
from which a sample is to be drawn for examination. An inspection lot
does not include items from more than one heat.
Inspection Test A step by step plan outlining special inspection steps that should occur
Plan (ITP) during the fabrication/assembly process.
Lot Size The number of items available in the inspection lot at the time a
representative sample is selected.
Material A documented quality assurance program used to control and verify that
Control and the materials installed on a project meet the requirements.
Verification
Program
Term Definition
MESC Material and Equipment Standards and Code. Provides material and
final product minimum certification requirements and specifications.
Representative One or more items selected at random from the inspection lot that are to
Sample be examined to determine the acceptability of the inspection lot.
Rogue Material Equipment or piping components installed in a specific alloy (or special
carbon steel) system that do not meet the material specification for that
system. This includes welding consumables.
Standard Sample materials for which laboratory chemical analysis data are
Reference available and are used in demonstrating test instrument accuracy and
Materials reliability.
1.4 CROSS-REFERENCES
Where cross-references to other parts of this DEP are made, the referenced section or
clause number is shown in brackets ( ). Other documents referenced by this DEP are listed
in (8).
Section/Clause Change
Title Changed from “Positive Material Identification Program” to
“Material Control and Verification” to better reflect the entire
process.
General Separated which carbon steel components receive PMI and
which receive material verification through traceability.
General Changed the PMI of weld overlay to a surface verification since
the weld procedure is verified at the proper depth.
General Clarified when PMI testing is to be performed.
General Allowed the use of alloy identification instead of element
identification for PMI of “Standard” materials.
Feedback that has been registered in the DEP Feedback System by using one of the above
options will be reviewed by the DEP Custodian for potential improvements to the DEP.
2. GENERAL
1. A material control and verification programme (MC&V) approved by the Principal
SHALL [PS] be in place for the installation of all new components of pressure retaining
equipment and piping.
2. The MC&V programme shall cover the minimum required sample (percentage), the
elemental analysis requirements and other material verification steps contained in this
DEP, based on the alloys of construction and the component type.
3. The programme shall include MC&V of non-pressure retaining components that are
integral to the pressure equipment.
4. MATERIAL VERIFICATION
4. For weld overlay used to only assure product purity, analysis of the overlay shall be
performed as follows to verify the specified alloy chemical composition and that the
degree of alloy dilution is acceptable:
a. Qualify the weld procedures for overlay per DEP 30.10.60.18-Gen. or
DEP 30.10.60.32-Gen., as applicable
b. During production weld overlay, carry out the following as a minimum:
i. perform PMI on the surface once per shift per welder or operator;
ii. perform PMI including a copper sulphate test on any areas of overlay that
have been ground (e.g., for bundle clearance);
iii. verify the weld overlay thickness.
3. Reports for final products (such as welded fittings) shall include certification of the
base material and a copy of the welding procedure specification (WPS) applied.
4. For final products, if the Manufacturer/Supplier of a semi-finished product and the
Manufacturer/Supplier of the base material are not the same, the report shall consist
of two documents covering both stages of the manufacturing process.
5. A copy of the material certificate may be supplied as long as the
Manufacturer/Supplier has a traceable system of the transfer of data from the original
material certificate to the copy.
6. MATERIAL IDENTIFICATION
6.1 TRACEABILITY
1. Alloy components and carbon steel components per (4.3) shall be traceable to their
source from procurement through final installation as follows:
a. The heat numbers on completed piping spools shall be 100 % verified prior to
release of the spools for painting and/or field installation.
b. The heat numbers shall be copied onto the relevant shop fabrication
isometric/weld map, written on a tag applied to the spool, or hard stamped (when
permitted).
c. Verification of heat numbers and heat number transfer shall be included as a hold
point on the piping Inspection and Test Plan (ITP).
d. The heat number shall be transferred before materials are cut.
e. Verification in the field that the components have been installed per
requirements.
6.2 MARKING
1. All piping bulk materials shall be delivered with the original Manufacturer/Supplier’s
markings and be as follows:
a. Clearly readable.
b. Compliant with the relevant material specification (e.g., ISO, ASTM).
c. Include the Manufacturer/Supplier’s applicable identification symbol, matching the
identification shown on the applicable mill test reports.
d. Be preserved when piping materials are ordered in the blasted and primed
condition (e.g., straight length pipes).
e. Supplemented by markings applied by stock personnel and
Manufacturers/Suppliers (e.g., PO numbers or MESC codes) if needed.
2. All components that require machining shall be traceable through the machining
process by transfer of the heat number to the component.
3. Completed shop fabricated pipe spools shall be fitted with an identification tag
identifying at a minimum the Isometric number and spool number.
8. REFERENCES
In this DEP, reference is made to the following publications:
NOTES: 1. Unless specifically designated by date, the latest edition of each publication shall be used, together
with any amendments/supplements/revisions thereto.
2. The DEPs and most referenced external standards are available to Shell staff on the SWW (Shell
Wide Web) at http://sww.shell.com/standards/.
SHELL STANDARDS
STANDARD DRAWINGS
Nameplate with bracket for vessel and heat exchanger equipment S 10.114
AMERICAN STANDARDS
Material verification programme for new and existing alloy piping API RP 578
systems
Process piping ASME B31.3
Standard specification for alloy-steel and stainless steel bolting for ASTM A193
high temperature or high pressure service and other special purpose
applications
Petroleum, petrochemical and natural gas industries – metallic NACE MR0103
materials resistant to sulfide stress cracking in corrosive petroleum
refining environments
Recommended Practice for colour Coding of Piping Materials PFI ES-22
Issued by: Pipe Fabrication Institute
BRITISH STANDARDS
Specification for colours for identification, coding and special purposes BS 381C
EUROPEAN STANDARDS
INTERNATIONAL STANDARDS
Bulk material
ASTM A193 bolts other than B7/B7M (11) 5 % (3, 12) 5 % (3)
Spiral wound gaskets other than 304SS and 316SS 5 % (10) 5 % (10)
Solid metal, metal jacketed & ring-type joint gaskets 100 % 10 % (1)
Welds
Welds (pressure equipment) 100 % (5, 6) 5 % (8, 9,11)
Welds (repairs) 100 % (5, 6) 5 % (8, 9, 11)
Welds (piping) 100 % (5, 6) 5 % (5, 9, 11)
Weld overlay 100 % (6, 8, 9) 5 % (5, 8, 9, 11)
Weld - dissimilar 100 % (6, 13) 100 % (6, 13)
Pressure relieving equipment
Bellows 100 % 100 %
Body 100 % 100 %
Bonnet 100 % 100 %
Rupture disc 100 % 100 %
NOTES:
1. Examine 10 % of all the purchased components. If any given sample of components has fewer
than 10 items, examine a minimum of one item.
2. 1 % representative sample of the total number of tubes from each heat, lot and material
specification of tubes.
3. Examine 5 % of bolts supplied in bulk or two bolts per box, and per heat and lot, whichever is
greater.
a. Bolts to be examined shall be selected randomly by the Principal.
4. One examination per heat of material
5. Examine one spot on every cap pass of every pressure retaining weld or one cap pass per
weld procedure per spool of piping per Table 1.
6. For the buttering welding technique, the extent of PMI to be determined by the Principal.
7. Valve body and bonnet only:
a. Non-standard, high alloy valve trim may be PMId at the discretion of the Principal.
b. PMI testing in the modification shop should be carried out on non-standard, high alloy trim
upgrades such as Alloy 400.
c. Internal bonnets as found on “power seal” type valves are considered internal components
as they typically cannot be accessed by PMI analysers.
8. Take one analysis per weld procedure of the base filler material or overlay finished weld per
shift (e.g., covering a base metal weld or joining the cladding of clad plates), on each major
longitudinal and circumferential weld seam as well as the following:
a. For nozzles and components lined with alloy weld metal overlay, one analysis per nozzle.
b. For sleeve lined nozzles, one analysis for the flange face overlay and one analysis of the
shell tie-in overlay.
c. Alloy Air Cooler Header Boxes: one analysis for each welding procedure used for long
seams, end plates, and nozzles.
d. Machined components: the PMI analysis of the finished machined components.
9. Analyse the base filler metal or final closure weld seams of internally clad or weld overlaid
components at locations determined by the Principal's designated Inspector.
10. Examine 5% of spiral wound gaskets when the windings or ID ring are alloys other than 304,
304L, 304H, 316, 316L or 316H stainless steels.
a. The PMI to be of the area at the ends where there is no filler or, if provided, the inner ring.
11. Equipment and piping fabricated of alloy material (including welds) solely to maintain product
purity (to avoid contamination of the product by corrosion products) is subject to 10% PMI.
a. Equipment and piping fabricated of 304, 304L, 304H or 316, 316L and 316 H solely to
maintain product purity are exempt from PMI unless otherwise specified by the Principal.
12. Examine 100% of B7M bolting for HFA and for sour service (if applicable) for hardness as a
part of the PMI program.
13. Complete PMI on four quadrants of the final closure weld for dissimilar metal welds.
NOTES:
1. The scope of this includes:
a. Venturis (external portion only), level bridles, Coriolis meter, magnetic level, displacer
and other instruments installed in pressure retaining service upstream of the primary
block valve.
b. Only the accessible welds to be tested in the field.
c. Insertion type instruments of alloys higher than 304/316 austenitic stainless.
2. This scope excludes:
a. Insertion type instruments (such as thermowells, annubars, capacitance probes, FCI
flow meters) made of 304/316 austenitic stainless steels because of the low stress level
and standard stainless construction.
b. ,Items that are not pressure retaining.
c. Items that are not in-line instruments upstream of the primary block valve, such as
pressure transmitters.
3. Higher alloy is 321SS, 347SS, all chrome alloys and high nickel alloy.
4. Valve body and bonnet only:
a. Non-standard, high alloy valve trim may be PMId at the discretion of the Principal.
b. PMI testing in the modification shop should be carried out on non-standard trim
upgrades using high alloy material such as Alloy 400 trim.
c. Internal bonnets as found on “power seal” type valves are considered internal
components as they typically cannot be accessed by PMI analysers.
AISI 8620 X X X
AISI 4130 X X
1Cr–1/2Mo X X
1-1/4Cr–1/2Mo X X
2-1/4Cr–1Mo X X
2-1/4Cr–1Mo– X X X
1/4V
5Cr–1/2Mo X X
9Cr –1Mo X X X
9Cr-1Mo modified X X X
13Cr–4Ni X X
13Cr–4Ni /CA6NM X X X X
12Cr/CA15 X X X X X
304 (1) X X
308 (1) X X
309 (1) X X
310 (1) X X
316 (1) X X X
317 (1) X X X
321 (1) X X X
347 (1) X X X
405 X X X
410 (2) X X X X
430 X X
Duplex (1) X X X
F6NM X X X
CD4Mcu X X X X
Alloy 20 (1) X X X X X
6 Mo Alloys (1) X X X
Alloy C-276 X X X
Alloy 400 (5) X X X
Alloy 600 X X
Alloy 625 X X X X X
70/30 CuNi X X
Stellites X X X
304L (1, 6) X X X
304H (1) X X X
308L (1, 6) X X X
309L (1, 6) X X X
410S (2) X X X X X
316L (1, 6) X X X X
316H (1) X X X X
317L (1, 6) X X X X
321H (1) X X X X
347H (1) X X X X
Tantalum (3)
Titanium Gr 2 X
Titanium Gr 7 X
Titanium Gr 12 X
Titanium Gr 16 X X
Zirconium (3)
Admiralty brass X X X
Naval brass X X X
Weld Overlayed
Surfaces(to match
specified
chemistry)
CS in HFA Service X X X X
(4)
NOTES: 1. All welds in this metallurgy to have the ferrite controlled to the value specified in the
associated welding DEP (DEP 30.10.60.18-Gen. or DEP 30.10.60.32-Gen.).
a. The sample percentage for ferrite testing to match the same level as the base
material unless a specific sample size / testing rate is given in the welding DEP.
2. 0.5 % to 0.75 % max Ni in base material and <1.1 % Ni for weld deposits. 0.1 % to
0.3 % Al.0.2 % to 0.5 % Ti.
3. Check alloying elements meet the ASTM specification.
4. Carbon steel in HF acid service is limited to the following criteria: Cu + Ni < 0.15 wt%
(C> 0.18 wt%).
a. Where the minimum required carbon is not met, chromium is included in the
formula as: Cu + Ni + Cr < 0.15 wt%.
5. Alloy 400 weld consumables to contain Ti < 2.2 %wt. and Fe < 5 %wt. in Hydrofluoric
acid service.
6. Examination results for the welds to 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.
Component Marking
(1),(2)
Pipe Each length of pipe shall be painted over the entire length with a 12 mm (0.5 in)
to a 40 mm (1.6 in) wide stripe, depending on the pipe size.
Fittings (1),(2) a) Each socket weld fitting, swage or pipe nipple shall be dabbed with a spot
of paint 12 mm (0.5 in) to 25 mm (1 in) in diameter.
b) The entire length of each butt weld fitting shall be painted on the outside
surface with a 12 mm (0.5 in) to 40 mm (1.6 in) wide stripe, depending on
size.
Flanges (1),(2) a) The outer peripheral edge of each flange shall be painted with a spot of
paint on the outer surface.
Plate (1),(2) A stripe shall be painted across from corner to corner.
Valves (1),(2) a) Each welded or flangeless (wafer type) valve shall be dabbed with a spot of
paint 12 mm (0.5 in) to 25 mm (1 in) in diameter.
b) Each flanged valve shall be dabbed with a spot of paint 12 mm (0.5 in) to
25 mm (1 in) in diameter on the top side of one flange.
c) For flanges thicker than 25 mm (1 in), the width of the band may be limited
to 25 mm (1 in).
Bolts (1),(2) Each stud bolt shall be dabbed with a spot of paint on each end.