DEP SPECIFICATION

MATERIAL CONTROL AND VERIFICATION FOR

PRESSURIZED EQUIPMENT
Copyright Shell Group of Companies. No reproduction or networking permitted without license from Shell. Not for resale

DEP 31.10.00.10-Gen.

February 2017

ECCN EAR99

DESIGN AND ENGINEERING PRACTICE

DEM1

© 2017 Shell Group of companies

All rights reserved. No part of this document may be reproduced, stored in a retrieval system, published or transmitted, in any form or by any means, without the prior
written permission of the copyright owner or Shell Global Solutions International BV.

This document contains information that is classified as EAR99 and, as a consequence, can neither be exported nor re-exported to any country which is under an
embargo of the U.S. government pursuant to Part 746 of the Export Administration Regulations (15 C.F R. Part 746) nor can be made available to any national of such
country. In addition, the information in this document cannot be exported nor re-exported to an end-user or for an end-use that is prohibited by Part 744 of the Export
Administration Regulations (15 C.F.R. Part 744).

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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
or any part thereof, even if it is wholly or partly caused by negligence on the part of Shell GSI or other Shell Company. The
benefit of this disclaimer shall inure in all respects to Shell GSI and/or any Shell Company, or companies affiliated to these
companies, that may issue DEPs or advise or require the use of DEPs.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, DEPs shall
not, without the prior written consent of Shell GSI, be disclosed by users to any company or person whomsoever and the
DEPs shall be used exclusively for the purpose for which they have been provided to the user. They shall be returned
after use, including any copies which shall only be made by users with the express prior written consent of Shell GSI. The
copyright of DEPs vests in Shell Group of companies. Users shall arrange for DEPs to be held in safe custody and Shell
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.

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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

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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.

1.2 DISTRIBUTION, INTENDED USE AND REGULATORY CONSIDERATIONS

Unless otherwise authorised by Shell GSI, the distribution of this DEP is confined to Shell
companies and, where necessary, to Contractors and Manufacturers/Suppliers nominated
by them. Any authorised access to DEPs does not for that reason constitute an
authorisation to any documents, data or information to which the DEPs may refer.
This DEP is intended for use in facilities related to oil and gas production, gas handling, oil
refining, chemical processing, gasification, distribution and supply/marketing. This DEP
may also be applied in other similar facilities.
When DEPs are applied, a Management of Change (MOC) process shall be implemented;
this is of particular importance when existing facilities are to be modified.
If national and/or local regulations exist in which some of the requirements could be more
stringent than in this DEP, the Contractor shall determine which of the requirements are the
more stringent and which combination of requirements will be acceptable with regards to
the safety, environmental, economic and legal aspects. In all cases, the Contractor shall
inform the Principal of any deviation from the requirements of this DEP which is considered
to be necessary in order to comply with national and/or local regulations.
This DEP is consistent with API RP 578 Material Verification programme for New and
Existing Alloy Piping Systems.

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.

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The Manufacturer/Supplier is the party that manufactures or supplies equipment and

services to perform the duties specified by the Contractor.
The Principal is the party that initiates the project and ultimately pays for it. The Principal
may also include an agent or consultant authorised to act for, and on behalf of, the
Principal.
The word shall indicates a requirement.
The capitalised term SHALL [PS] indicates a process safety requirement.
The word should indicates a recommendation.
The word may indicates a permitted option.
1.3.2 Specific definitions

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.

Fabricator One who fabricates piping systems or portions of a piping system as

defined by ASME B31.3, or process pressure equipment,
instrumentation or machinery.

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.

Level of The specified percentage of the number of components (or weldments

Examination when specified) to be examined in an inspection lot.

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

Material An organization that performs or supervises and directly controls one or

Manufacturer more of the operations that affect the chemical composition or
mechanical properties of a metallic material.

Material Non- A material that does not meet specified requirements.

conformance

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Term Definition

Material An organization that supplies material furnished and certified by a

Supplier material Manufacturer, but does not perform any operation intended to
alter the material properties required by the applicable material
specification. Material Manufacturer and Supplier may be the same
party if the Manufacturer supplies directly to the shop fabricator, field
fabricator, or Principal.

MESC Material and Equipment Standards and Code. Provides material and
final product minimum certification requirements and specifications.

Mill Test A certified document that permits each component to be identified

Report(MTR) according to the original heat of material from which it was produced
and identifies the applicable material specification (including
documentation of all test results required by the material specification).
MTRs are not a substitute for PMI tests.

Positive A physical evaluation or test of a material using an analyzer to confirm

Material that it is consistent with the selected or specified alloy material
Identification designated by the Principal. Evaluations or tests can provide either
(PMI) quantitative information to verify alloy composition in weight percent or
qualitative information that identifies the grade of the material.

Pressure- Items that form the pressure-containing envelope of the operating

Containing components and piping systems. This includes on-line instrumentation
Components up to and including the first isolation valve of off-line instrumentation.

Random Selection process by which choices are made in an arbitrary and

unbiased manner.

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.

Traceability The ability to match an installed component to its source.

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).

1.5 SUMMARY OF MAIN CHANGES

This DEP is a revision of the DEP of the same number dated September 2013. The
changes are too extensive to list individually. The following are the main, non-editorial
changes.

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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.

1.6 COMMENTS ON THIS DEP

Comments on this DEP may be submitted to the Administrator using one of the following
options:

Shell DEPs Online Enter the Shell DEPs Online system at

https://www.shelldeps.com
(Users with access to
Select a DEP and then go to the details screen for
Shell DEPs Online)
that DEP.
Click on the “Give feedback” link, fill in the online
form and submit.

DEP Feedback System Enter comments directly in the DEP Feedback

System which is accessible from the Technical
(Users with access to
Standards Portal http://sww.shell.com/standards.
Shell Wide Web)
Select “Submit DEP Feedback”, fill in the online form
and submit.

DEP Standard Form Use DEP Standard Form 00.00.05.80-Gen. to record

feedback and email the form to the Administrator at
(other users)
standards@shell.com.

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.

1.7 DUAL UNITS

This DEP contains both the International System (SI) units, as well as the corresponding
US Customary (USC) units, which are given following the SI units in brackets. When
agreed by the Principal, the indicated USC values/units may be used.

1.8 NON NORMATIVE TEXT (COMMENTARY)

Text shown in italic style in this DEP indicates text that is non-normative and is provided as
explanation or background information only.
Non-normative text is normally indented slightly to the right of the relevant DEP clause.

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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.

3. MATERIAL CONTROL AND VERIFICATION PROGRAMME MAIN ELEMENTS

1. The elements covered by the MC&V programme for pressurized equipment shall
include the following:
a. Levels of examination, including alloy elements required for PMI;
b. PMI equipment and methods;
c. Materials, components and fabricated assemblies (e.g., pipe spools) subject to
PMI;
d. Marking and identification of components on which PMI has been performed (i.e.,
the stamping and colour coding systems);
e. PMI of welding consumables and gaskets;
f. Material traceability during fabrication and machining, the timing and location of
PMI in accordance with the Inspection and Test Plan (ITP), including transfer of
identification markings (e.g., heat numbers) and colour coding;
g. PMI Inspection reports as defined in (7).
2. The MC&V programme shall include the following controls at both the fabrication and
construction sites:
a. Receipt of Materials – controls for segregation and storage of materials, material
test report validation and PMI and component identification from the
Manufacturers/Suppliers per the scope of this specification.
b. Issue of Materials – Controls for the issue and tracking of materials and
components and welding consumables during fabrication. This includes the
following:
i. Controls during fabrication, such as the segregation of materials, materials
traceability and identification including matching of heat numbers to MTRs
during the fabrication process;
ii. Segregation of tools where applicable to prevent contamination.
c. Surplus Materials – the control and traceability of surplus materials.
d. Rejected Materials – the control and traceability of rejected materials, including
the return and/or replacement.
e. Carbon steel materials – the control and traceability of carbon steel materials
where mill test report verification is the means of verifying the correct material
was installed.
3. The MC&V programme shall include auditable material traceability records including
the following:
a. Transmittal of the records as part of the handover documentation packages;
b. Final field verification on completed systems.

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4. MATERIAL VERIFICATION

4.1 ALLOY COMPONENTS AND ALLOY WELDS SUBJECT TO PMI

1. The extent of PMI examination SHALL [PS] be according to the tables in (APPENDIX
A) and (APPENDIX B) according to the following classifications:
a. Standard: Common materials for general corrosion resistance where a smaller
sample size is representative of the Inspection Lot.
b. Full: Higher alloy or specifically selected materials for degradation resistance or
strength requirements where 100% of the components are verified to meet the
requirements of the intended service.
c. Standard: For all grades of Type 304 stainless steel (i.e., 304L, 304, and 304H).
d. Full: For alloy materials other than Type 304 stainless steel, including all grades
of Type 316 stainless steel, for both base material and welds.
Some weld rods have the alloying elements contained in the flux, and do not
meet the alloy specification until welded. PMI of weld metal (e.g., deposited
weld metal or undiluted weld “buttons”) is a permissible alternative to PMI of an
electrode, TIG wire, or wire sample.

4.2 WELDING CONSUMABLE CONTROL AND VERIFICATION

1. Verification and control of welding consumables shall include the following:
a. Controlled storage, handling, quarantining, issuing of welding consumables and
return of unused consumables.
b. PMI of welding consumables based on testing of a heat/lot.
c. Intermediate controls after the consumables have been issued, i.e., before,
during, and after the welding process including inspection and testing, quality
control and assurance measures.
d. Non-conformance identification and marking, tracking and corrective action
measures.
2. When welding is conducted, one electrode or wire sample from each lot or heat of
alloy weld rod shall be positively identified.
a. The remainder of the lot should be compared to the sample to verify that the
markings of the wires/electrodes are correct.
b. Weld rods that have the alloying elements contained in the flux and do not meet
the alloy specification until welded shall require PMI of the deposited weld metal
(e.g., deposited weld metal or undiluted weld buttons).
3. For weld overlay used to provide corrosion protection, analysis of the overlay
SHALL [PS] 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.

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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.

4.3 CARBON STEEL COMPONENTS SUBJECT TO MATERIAL VERIFICATION

1. In Hydrofluoric acid service, carbon steel materials with restricted carbon content and
residual element requirements SHALL [PS] be verified by full (100%) PMI including
material verification by matching heat numbers of components to the mill test reports.
2. An Optical Emission Spectrometer (Arc/Spark) shall be used for PMI of carbon steel
materials with restricted carbon content and residual element requirements in
Hydrofluoric acid service.
3. Materials in the following process services SHALL [PS] be verified by matching heat
numbers of components to the mill test reports:
a. Where Hydrogen Induced Cracking (HIC) resistant material or maximum
hardness levels are specified.
b. Where materials for Wet Hydrogen Sulphide (H2S) services are specified;
c. Where materials with minimum silicon (Si) content critical to corrosion resistance
are specified;
d. Where low temperature enhanced mechanical properties are specified (e.g.,
impact tested material) or drop weight tear tests for pipelines.
4. PMI or material verification for carbon steels in services other than (4.3, Item 3) shall
be as specified by the Principal.
5. Specialty carbon steel (such as impact tested, HIC resistant and for HF service) shall
be stored and fabricated in an area separated from regular grade carbon steel in order
to avoid mixing of materials and welding electrodes.
a. colour coding or unique material tagging shall be applied to specialty carbon steel
materials see (6.3).

4.4 ALTERNATE PMI PROGRAMS

Implementation of an alternative PMI programme that defines the extent of PMI based
on risk might be permitted. Since many of the elements of a PMI programme are DEM1
mandated, an alternate programme would be subject to the approval of the Principal and
the TA1 Principal's Technical Authority (TA1).
For speciality components (e.g., sub-sea blocks), material controls and material
traceability and/or destructive testing can be used in lieu of full PMI if agreed with the
Principal’s Technical Authority (TA1).

4.5 ALLOYING ELEMENTS REQUIRED TO BE EVALUATED DURING PMI

1. For the “Full” level of PMI testing, a quantitative alloy assay mode shall determine the
percent by weight of elements in accordance with (APPENDIX C).

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For the “Standard” level of PMI testing, a semi-quantitative material identification

mode is acceptable.

4.6 MATERIALS AND COMPONENTS NOT SUBJECT TO PMI

1. Unless otherwise specified by the Principal, the following materials should not be
subject to PMI:
a. All grades of carbon steel except as specified in (4.3).
b. Internal valve components that are standard from the Manufacturer/Supplier.
c. All standard cast 304 and 316 machinery components.
d. Internal parts of machinery and pumps made of type 304, 316 stainless steel or
brass.
e. Instrumentation as detailed in (APPENDIX B).
f. All cast brass valves.
g. Machinery lube oil systems, hydraulic systems, steam tracing and steam turbine
gland vacuum systems.
h. Standard type 304 and 316 stainless steel spiral wound gaskets.
i. All standard cast 304 and 316 valves.
j. All other materials for both cast and forged valves where the material marking
on both the body and bonnet components are executed in high relief
(stamping or embossing is not considered as high relief) as an integral part of
the component and are not obscured by painting or coating.

4.7 TIMING AND LOCATION OF PMI/VERIFICATION CHECKS

1. PMI, material verification and marking shall be performed during the construction
phase at one of the following stages of the project:
a. During receiving inspection when components or materials arrive at site.
b. Prior to storage in the warehouse or delivery to the on-site fabrication shop or to
the field.
c. At a Manufacturer/Supplier’s facility prior to delivery to the site.
d. At the welding shop prior to dispensing consumables for use.
e. During assembly, machining, or fabrication per the ITP, e.g., at the fabrication
shop.
f. On existing piping at tie-ins of new piping to existing prior to welding in the field.
g. On completed piping systems (including welds), after field installation of pipe
spools at the appropriate stage of turnover of systems (e.g., final punch listing).
2. The PMI or material verification shall be performed prior to the application of paint.

4.8 GENERAL REQUIREMENTS FOR MATERIAL CERTIFICATIONS

The requirements in this section are in addition to the material and final product
minimum certification requirements and specifications in the pertinent MESC and the
applicable DEPs.
1. Mill test reports shall comply with ASME SA-20 and ISO 10474 or EN 10204.
2. The language used in mill test reports shall be English or, if in another language,
accompanied by an endorsed, stamped and dated English translation of the original
report.

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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.

5. EXAMINATION EQUIPMENT/TEST METHOD

1. Alloy analysers used for PMI shall be capable of producing quantitative measurements
(i.e., percentage by weight) for the alloying elements listed in (APPENDIX C).
2. Alloy analysers shall be one of the following technology types (in order of preference):
a. X-ray Tube Equipment (Handheld Analyser)
b. X-Ray Florescence Equipment (Handheld Analyser)
c. Optical Emission Spectrometers (Arc/Spark)
3. The type of analyser and alloy analyser calibration records and results shall be
documented in the PMI Inspection Report.
4. PMI shall be performed by a trained and competent technician.
a. Qualifications of the PMI machine operator, including make and type of PMI
Machine the Operator was trained and has worked with should be submitted for
review and approval by the Contractor.
5. Examination for determining the elements shall not be carried out with sorting methods
such as chemical spot testing or methods that use eddy current, triboelectric testing,
electromagnetic, or thermoelectric tests.
6. Chemical spot testing techniques for dilution such as using copper sulphate to test
areas where grinding has been performed on weld overlay are acceptable.

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.

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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.

6.3 COLOUR CODING

6.3.1 General
1. colour coding of piping bulk materials shall be applied on alloy or special carbon steel
systems per the scope defined in (4) unless marked as specified in 6.4.1.
a. The box or container shall be colour coded once the PMI sampling results verify
the material markings on the studs and nuts.
2. colour coding shall be the responsibility of the group performing the PMI (e.g.,
Manufacturer/Supplier, warehouse receiving).
3. PMI on pre-fabricated piping spools shall be completed prior to blasting and painting.
The re application of colour coding is not necessary after the components have
been painted.
4. Refer to (APPENDIX F) for piping component marking specifications.
5. Piping components in which identification markings or colour coding are maintained
through pipe spool fabrication may be released for painting as long as all components
have been welded on and all relevant NDE, including PMI, is complete.
a. The spool shall then be tracked by the spool tagging number and isometric.
6.3.2 Colour standard
1. The following colour standards may be applied:
a. Pipe Fabrication Institute - PFI ES-22.
b. British Standards Institution BS 381C.
c. A suitable identification system or colour standard as approved by the Principal.
2. colour coding paint shall be selected to last until fabrication is complete and the spools
are ready for blasting and coating.
3. Paints and markers shall be selected such that they will not cause degradation to the
base material (e.g., no zinc-containing paint/marker on stainless steel base material,
no chloride-containing paint/marker on stainless steel base material).
4. Material Safety Data Sheet (MSDS) or Safety Data Sheet (SDS) documentation and
paint data sheets shall be available for review by the Principal.

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6.4 COMPONENT IDENTIFICATION

6.4.1 General
1. Components on which PMI is performed shall be identified with a PMI indicator stating
the material identification codes applied by means of a low-stress steel stamp (stencil)
or paint/marker as prescribed in this DEP, in accordance with (7.2) and (APPENDIX
D).
2. Vibro-etching may be used for thin wall materials or if the configuration of the
component does not permit stamping.
3. The “PMI” letters shall be circled as shown in the examples in (APPENDIX E).
4. Pressure equipment (e.g., vessel, heat exchanger) subject to PMI shall have a PMI
stamp on the nameplate (Reference standard drawing S 10.114).
a. An additional nameplate for the PMI stamp may be welded on or adjacent to the
code nameplate.
b. Heat exchanger nameplate PMI stamping shall identify the tube side and shell
side separately.
c. Pressure vessel and heat exchanger internals, cladding, and cladding welds shall
be marked with paints or markers identifying the PMI that was performed on each
component, provided sufficient documentation is in place for the PMI of all
components.
5. All piping welds subject to PMI shall be PMI stamped on the final weld pass (where
allowed by code) or next to the weld, applied by means of a low-stress tool.
6.4.2 Material Identification Codes
1. Material identification codes shall be at least 6 mm (1/4 in) high.
2. Material identification codes shall be located below the letters “PMI” within the same
circle as shown in the examples in (APPENDIX E).
3. Material identification codes given in (APPENDIX D) shall be in addition to those
required by the applicable material specification (e.g., ASTM).

6.5 REJECTED MATERIAL

1. Rejected material shall be identified by marking or tagging and segregated from
acceptable material.
2. The Manufacturer/Supplier, shop Fabricator, or field Fabricator, as applicable, shall
submit a non-conformance report (NCR) per the project quality procedures.
3. If an item from a representative sample is rejected, the following additional testing
shall be carried out:
a. Examine 100 % of the remaining components of the lot from which the sample
was taken;
b. Examine 100 % of the same component types from the next delivery from the
same Manufacturer/Supplier;
c. Return the level of examination to the originally specified level if examination of
the next lot does not identify any similar non-conformance.

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7. PMI INSPECTION REPORT

1. The PMI Inspection Report shall be submitted to the Principal and include the
following for each inspection lot examined:
a. Manufacturer/Fabricator's name.
b. Date(s) of testing.
c. Name of person and company performing the test.
d. Method of examination (laboratory or field analyser).
e. Analyser used for the examination.
f. Material specification of the material to be tested.
g. Material Manufacturer/Supplier, MTR number, heat number and lot number, as
applicable.
h. Inspection lot size and number of pieces or items examined.
i. Results of the test and resolution of non-conformance material.
j. Chemical elements verified by PMI and the percentage of the elements in
accordance with (APPENDIX C).
i. Reports downloaded from the alloy analyser are acceptable.
2. For fabricated items with multiple components and welds, the PMI Inspection Report
shall also include the following:
a. Each component receiving PMI by the Manufacturer/Supplier.
b. Each piece of equipment (with item number) receiving PMI by the shop
Fabricator, including a test location map.
c. Each pipe line (with line number and pipe spec, including the spool or fabrication
drawing) showing the locations of PMI by the shop/field Fabricator or field
Constructor.
d. Existing piping PMI results for field welds of new to existing piping.
3. PMI Inspection Reports shall become part of the permanent record included in the
final data package or equipment file folders.

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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

DEP feedback form DEP 00.00.05.80-Gen.

Evaluation of pipeline and pressure vessel steels for resistance to DEP 30.10.02.16-Gen.
hydrogen-induced cracking (amendments/supplements to
NACE TM0284)
Wet H2S requirements for downstream process equipment and piping DEP 30.10.02.17-Gen.
Welding of metals (amendments/supplements to API RP 582) DEP 30.10.60.18-Gen.
Welding of metals, based on ISO standards DEP 30.10.60.32-Gen.
Shell HSSE & SP Control Framework, Design Engineering Manual DEM1
(DEM) 1 – Application of Technical Standards
https://eu001-
sp.shell.com/sites/AAAAA8432/CF/Web/Design Engineering Manual 1 DEM1.aspx

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

A Guide to Risk Based Procurement EEMUA 224

Metallic products - types of inspection documents EN 10204

INTERNATIONAL STANDARDS

Steel and steel products - Inspection documents ISO 10474

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APPENDIX A COMPONENTS SUBJECT TO PMI

Component Full Standard

Piping
Pipe 100 % 10 % (1,11)
Corrosion resistant alloy (CRA) lined or clad pipe 100 % 10 % (1,11)
Fittings 100 % 10 % (1,11)
Valves (7) 100 % 10 % (1,11)
Expansion joints and special items 100 % 10 % (1,11)
Heat exchangers, boilers and fired heaters
Heater tubes 100 % 10 % (1)
Heat exchanger tubes 2 % (2) 1 % (2)
Tubesheets 100 % 10 % (4, 11)
Fittings 100 % 10 % (1, 11)
Solid, jacketed or spiral wound gaskets 100 % 10 % (1)
Expansion joints 100 % 10 % (4)
Non-pressure retaining bundle components: e.g., 10 % (1) 10 % (1, 11)
Baffles, tie-rods, seal strips.
Channels 100 % 10 % (4, 11)
Furnace tube hangers 100 % 10 % (1)
Furnace tube supports 100 % 10 % (1)
Air cooled heat exchanger header plugs and gasket 100 % 10 % (1)
Corrosion resistant alloy (CRA) lined or clad 100 % 10 % (1,11)
components
Pressure retaining components of pressure vessels
Shell 100 % 10 % (4, 11)
Heads 100 % 10 % (4, 11)
Nozzles 100 % 10 % (1, 11)
Fittings 100 % 10 % (1, 11)
Flanges 100 % 10 % (1, 11)
Corrosion resistant alloy (CRA) lined or clad 100 % 10 % (1, 11)
components
Non-pressure retaining components of pressure vessels
Tray components, downcomers, reactor bed 10 % (1) 10 % (1)
internals
Pressure retaining components of machinery
Pump casing 100 % 100 %
Compressor casing 100 % 100 %
Solid, jacketed or spiral wound casing gaskets 100 % 100 %

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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.

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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.

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APPENDIX B PMI FOR INSTRUMENTATION COMPONENTS

Instruments No PMI Standard Full

(10 %) (100 %)
Orifice plate 304/304L and Higher alloy (3)
316/316L SS
Thermowell, other type insertion 304/304L and Higher alloy (1, 2, 3)
type instruments and positive 316/316L SS
displacement meters (analyser
probes, FCI meters and vortex
meters
Instrument tubing including 304/304L and Higher alloy (1, 2, 3)
insertion type 316/316L SS
Control valve (3),(4) Cast 316 SS bulk Higher alloy (3) or all
produced CV Custom Cast
Valve trim Standard trim from the High alloy trim upgrades at
Manufacturer valve modification shops
Displacer, magnetic level 304/304L and Higher alloy (1, 2, 3)
gauges and level chamber 316/316L
SS components and
welds
Coriolis meters 304/304L and Higher alloy (1, 2, 3)
316/316L
SS components and
welds
Fabricated meter runs and 304/304L and Higher alloy (1, 2, 3)
fabricated venturies (pressure 316/316L
retaining parts only) SS components and
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.

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APPENDIX C ALLOYING ELEMENTS REQUIRED FOR PMI

Chemical element (3)

Alloy
C Cr Ni Mo Nb Ti Cu Co Al Zn Sn Pd V
AISI 8630 X X X

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

Super Duplex (1) X X X

SMO 254 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

Alloy 625 LCF X X X X X

Alloy 800 X X X
Alloy 825 X X X X

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Chemical element (3)

Alloy
C Cr Ni Mo Nb Ti Cu Co Al Zn Sn Pd V
90/10 CuNi 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.

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APPENDIX D MATERIAL IDENTIFICATION CODES

Alloy UNS number Material Alloy UNS number Material
Identification Code Identification Code
1¼ Cr ½ Mo K11597 1 CR 430 S43000 430
2¼ Cr 1 Mo K21590 2 CR Duplex S31803 and 2205
S32205
2¼ Cr 1 Mo K31835 2CR V Super Duplex S32750 and 2507
¼V S32760
5 Cr ½ Mo K41545 5 CR Alloy 20 N08020 20
9 Cr 1 Mo S50400 9 CR 6 Mo Alloys N08367 and 6 Mo
N08925
13 Cr-4Ni, or J91540 CA6NM Alloy B2 N10665 B2
CA6NM
12 Cr, or J91150 CA 15 Alloy C-276 N10276 276
CA15
304 S30400 304 Alloy 600 N06600 600
304L S30403 304L Alloy 625 N06625 625
304H S30409 304H Alloy 625LCF N06626 626
308 S30408 308 Alloy 800 N08800 800
308L S30883 308L Alloy 825 N08825 825
309 S30900 309 90/10 CuNi C70600 90/10
309L S30983 309L 70/30 Cu/Ni C71500 70/30
310 S31000 310 Alloy 400 N04400 400
316 S31600 316 Nickel 200 N02200 200
316L S31603 316L Titanium Gr 2 R50400 T-2
316H S31609 316H Titanium Gr 7 R52400 T-7
317 S31700 317 Titanium Gr 12 R53400 T-12
317L S31703 317L Titanium Gr 16 R52402 T-16
321 S32100 321 Zirconium 702 R60702 Z-702
321H S32109 321H Zirconium 705 R60705 Z-705
347 S34700 347 Tantalum R05210 R05210
347H S34709 347H Tantalum 40 % R05240 R05240
Nb
405 S40500 405 Admiralty C44x00 C44x00
Brass x = 3,4 or 5 x = 3,4 or 5
410 S41000 410 Naval Brass C46x00 C46x00
x = 5,6 or 7 x = 5,6 or 7
410S S41008 410S

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APPENDIX E LOCATION OF PMI IDENTIFICATION MARKS FOR PIPING

(EXAMPLES)

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APPENDIX F PIPING COMPONENT MARKING SPECIFICATIONS

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.

Notes: 1. Identifying paint is not applied to the following:

a. inside surfaces of pipe, flanges or fittings;
d. threads;
e. weld bevels;
f. symbols or markings which would obliterate identification;
g. gasket seating surface.
2. Apply colour codes to specialty carbon steels.

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