PMI PROGRAM REVIEW

Raymond de Weever
May 4, 2009.

Refinery Wide PMI program

PMI program started in June 2004

Twelve (12) process units were PMId:

D1AR, D2AR, D3AR

V3AR
DC1AR, DC2AR
C5AR, C6AR, C7AR
H1AR, H2AR, H3AR

Total locations inspected: 36,811

Out of the 36,811 locations, 3,641 were identified
as non-conformances. This is 9.9% of the total
number of locations that were PMIed. 1,384 were
identified as low grade (3.8%).

Refinery Wide PMI program

The main driver was to confirm the appropriate

material in the following services:

High Temperature Sulfidic Corrosion

High Temperature Hydrogen Attack (HTHA)

That covers 99% of application issues
PMI program was completed in December
2006

Refinery Wide PMI program

The other concern is the correct grade of S.S.
piping

PMI will not identify Carbon content, therefore effort

would be meaningless
With visual inspection stainless steel is easy to
identify vs. carbon steel and alloys, therefore
minimizing the chance of having a complete wrong
material

Refinery Wide PMI program

Refinery Wide PMI program

Current Status:
D1AR:

Except for thirty-four (34) Inconel small bore welds, there is

no other material issues

D2AR:

All low grade non-conformances were removed and repaired

D3AR:

Three (3) non-conformances are monitored (UT, RT). These

non-conformances consist of piping, blinds, flanges and
welds. Address non-conformances in next TA

H1AR:

All low grade non-conformances were addressed in 2006

H2AR:

All low grade non-conformances were addressed in 2007 TA

H3AR:

All low grade non-conformances were removed and repaired

Refinery Wide PMI program

Current Status:
DC1AR:

Sixteen (16) out of one-hundred-thirty-six (136) low grade nonconformances remained to be addressed. These consist of pipings,
welds, blinds and valves. The non-conformances are monitored
(UT, RT)

DC2AR:

All low grade non-conformances were removed and repaired

C5AR:

All low grade non-conformances (5) were submitted for removal

and repair during the 2010 TA

V3AR:

Ten (10) low grade non-conformances remained to be addressed.

Nine (9) have been addressed during the refurbishment. The nonconformances consist of piping, welds, blinds, valves and are
monitored (UT, RT)

C6AR:

All low grade non-conformances were removed and repaired

Refinery Wide PMI program

Starting 2004 Valero Inspection was requesting/
performing 100% PMI of all alloy material
However, as per Valero Specs,

heat numbers were used in order to identify correct

material
Only 10% of welds were to be PMId

Valero Engineering Spec has been modified in

June 2007 to require 100 % PMI of all alloy piping,
welds and components during pre-fab and
installation, in order to eliminate discrepancies.

Refinery Wide PMI program

Re-check all Inco welds on small bore piping for

correct metallurgy
UT/RT low grade materials to determine condition
once a year. Frequency will be increased
depending on findings
Develop a procedure (SP/SOP) to address a check
and balance in order to assure that all PMI issued
are properly identified and repaired during the
TAs
Include step in PSSR checklist requesting
Reliability Engineering & Inspection Managers
sign-off confirming PMI scope completion