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SAUDI ARAMCO OIL COMPANY (Saudi Aramco)YANBU REFINERY INSTRUCTION MANUAL

YRIM No.: 1156!!Revision No.: !!

SUBJECT: YRD Inspection ProgramIssue Date

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Saudi Aramco Loss Prevention Policy

Saudi Aramco will conduct its business in a manner which prevents incidents or accidents which causeloss of life, bodily injury or illness, or damage to property, assets or the environment. As reflected inSaudi Aramcos Corporate Values, the Company will continuously maintain the highest standards ofsafety, security, health and environmental protection. Accordingly, the Company will:

Advise all employees and contractors of their loss prevention responsibilities and regularly

measure their performance

!valuate, identify and eliminate or manage safety ris"s prior to beginning any operation or activity

and continue to review such ris"s, complying with all applicable laws and regulations

Communicate loss prevention objectives and procedures regularly to employees and all affected

parties

#rain employees and provide resources to maintain job competencies, including loss prevention

responsibility and accountability

$esign and construct Company facilities utili%ing recogni%ed best technology and practices to

safeguard property and people

&perate and maintain Company facilities to assure safe operations

'e(uire that contractors, suppliers and others adhere to the Companys loss prevention policies,

procedures and goals

)repare for emergencies and other contingencies and respond promptly and effectively to any

incidents or accidents resulting from operations

'eport all incidents, review performance and communicate progress

)romote off*the*job safety and community awareness, and

'eview and improve the Companys loss prevention program and performance continuously.

Saudi Aramco: [ X ] New Instruction [ ] Complete e!ision [ ] C"an#e [ ] Addition

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1. Purpose & Objective

#he objective of this process is to ensure compliance with all established companyinspection procedures+programs and maintain re(uired level of asset integrity throughoutanbu 'efinery facilities.

2. Owner or Champion: '$ !ngineering -nspection unit is the owner of theseprograms.

3. Applicability

#his comprehensive inspection document contains several inspection procedures+programswhich are applicable to '$ facilities.

. Corporate !"pectations: '$ follows all the guidelines as outlined in SS anual'efer to '$ SS website.

5. Process #escription

#he main objective of this comprehensive inspection programs is to enable '$ inspectionteam to comply with all corporate re(uirement for assets integrity and to highlightdeficiencies observed that re(uire repair or action necessary to prevent further damage tothe e(uipment. Also this document specifies the responsibilities of all '$ personnelpertaining to assets integrity. #he area inspector shall use this document as a supplement tothe plant inspection inde/ 011*SA-)*234. #his document includes a section for eachinspection procedure+program which will include a brief description of theprocedure+program, a list of the related standards and engineering+inspection procedures, atable which specifies the responsibilities and the re(uired documentations and where it willbe filed.

6. $esponsibilities

a% '$ -nspection 5nit Supervisor owns the overall responsibility for implementing theperiodic inspections at anbu 'efinery facilities

b% '$ -nspection 5nit 6ield Supervisor shall provide (ualified inspection personnel toconduct the inspection activities including tests. #he -nspector will e/amine the systemduring the inspection+test and issue a necessary test report per establishedprocedures after successful completion of each inspection+test. #he inspection resultsshall be retained as a record in the -nspection 6iling System.


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c% #he refinery &peration 6oreman is responsible to ensure that all re(uired inspectionprograms are conducted in his plant limit as per inspection schedules.

d% #he Supervising &perator of each unit shall be responsible to ensure that all properwor" permits have been issued.

e% #he Area aintenance+#7- engineer shall be responsible for providing the necessarymanpower and e(uipment 0crane, man lift, scaffolding, etc4 to perform the re(uiredinspection activities and to rectify deficiencies.

% #he Area )rocess !ngineer shall be responsible for preparing and distributing there(uired procedures 0hydrotest procedures, lea" test, shutdown, start up etc4 asre(uired to assist in conducting the inspection activities in accordance with relevantcompany standard, or '$ internal procedures.

g4 #he detail responsibilities of all inspection programs are listed under in each program

7. 'rainin( & Competency

'$ !ngineering -nspection 5nit shall provide re(uired functional training to meet the

competencies re(uired for conducting inspection activities per company established guidelines

and programs. '$ -nspection 5nit is following the corporate training re(uirements to certify '$

inspectors and all re(uired courses and e/ams shall be fulfilled prior to certifying the inspectors.

8. #ocumentation

#he !ngineering -nspection 5nit shall complete, issue and distribute the inspection reportsincluding test information sheets per relevant Saudi Aramco inspection procedures to thearea &perations 6oreman and area &! team. 'ecords of all tests shall be maintained by'$ -nspection 5nit as will be detailed in the documents for each inspectionprocedures+programs.

9.

$eerencesAll relevant references are indicated under each )rocedure+)rogram in this document.

YRD SMS: Inspection Programs E%EMENT & ' #SSET INTE!RITY 'NE(


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)*. +$# List o ,nspection Pro(rams:)- $elie valve installation inspection and testin(:

'efer to SS 8 9. 0'$ !9 124 for more details.

2- ,nternal ,nspection o !/uipments 0'&,% :

Procedure1Pro(ram #escription

-nternal inspection of all static e(uipments such as columns, vessels, drums, storage tan"s,

heat e/changers, reboilers and boilers are conducted by visually inspecting them and by

using ;on*$estructive #esting methods such as agnetic )article #esting, $ye )enetration

#esting and 'adiography #esting for all internal welds, heat affected %one and base metals,

all attachment welds and no%%les. #he internal inspection should also cover the internal

coating, refractory material and the mechanical integrity of the internal elements such as

trays and pac"ing. -n the other hand, the chemical material inside the vessels 0$esiccant,

Sieve, catalyst, etc4 should be inspected by the area process engineer and area operation

supervisor.

#he final bo/ up of static e(uipment in '$ is carried out as per the applicable SA!Ss andSA!)s. #he project inspector will perform the internal inspection for the static e(uipments

which are built by )# along with '$ inspector. $uring #7- and up on re(uest, '$

inspector will perform the internal inspection of static e(uipments prior to signing the final

closure certificate. $eficiencies shall be reported to )#+ '$ aintenance to rectify prior to

signing the final closure certificate.

$eerenced Standards1Procedures

SA!)*

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SA!)*33?= anual 5ltrasonic thic"ness testing

SA!)*

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$esponsibilities:

Activities Assigned to 'emar"

-nspection )#+)-$ )roject inspector shall perform the following activities:

Activities during -nspects the static e(uipment during receiving and storing in

constructionthe yard.

period -nspects the static e(uipment during installation.

-nspects the alignment of static e(uipment.

-nspects the static e(uipment for internal installation.

-nspects and witness the hydrotest and lay up of static

e(uipment if re(uired.

)# )#+)-$+)'&)&;!;# inspects the static e(uipment for final bo/*

)-$ inspectorup and signs the final bo/*up certification.

'$ inspector

-nspection Area -nclude performing the re(uired ;$# test and witnessing

Activities0during inspector hydrotest and lea" test. Additional inspectors will be assigned as#7- and up on needed to assist the area inspector during #7-

re(uest4

aintenance #7- engineer -nclude providing the necessary manpower and e(uipment 0crane,

Activates man lift, scaffolding, etc4 to perform the re(uired #7- activities

For" )ermit Area -nclude providing the necessary wor" permit and initiating

operation deviation letter to postpone the #7-.

supervisor


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)rocedures Area process )repare and distribute the re(uired procedures if re(uired

0hydrotest, lea" engineer to assist in conducting the #7- in accordance with relevant

test, shutdown, company standard, or '$ internal procedures

start*up etc4

-nspect chemical Area process -nspect the internal chemical material 0$esiccant, Sieve,

material engineer + Catalyst, etc4 and provide the re(uired specification if

&peration replacement is needed.

supervisor

#ocumentations:

3. Approved S-S, $rawings, )7-$, SA-C and final bo/ up certification

>. )re*#7- 'eport -ssued by the area inspector

. !(uipment file in the shared folder

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SA!)*>1 !(uipment -nspection Schedule$esponsibilities:

Activities Assigned 'emar"

to

-nspection -nspection Assigns inspector0s4 to carry out e/ternal inspection of all '$facilities.

Activities 5nit

!nsure inspection wor"sheet0s4 are issued to rectify deficienciesreported in

Supervisorthe e/ternal inspection.

Area

!nsure that all e(uipment within his area of responsibility is listed in the !-S

inspectorspecifying inspection intervals as re(uired by SA!)*>1. A schedule oftwo*year e/ternal inspections shall be made available and is updatedregularly.

)erform two*year e/ternal inspection of all e/isting e(uipment within his

area listed in the approved !-S with the corresponding chec"list0s4

perattachments of 11*SA-)*29. Complete individual chec"list forpressure

e(uipment per SA!)*>1, paragraph 9.9.B. 5se the 11*SA-)*29 chec"lists

asreferences only when inspecting piping if not individually listed in the!-S.-nspection of civil structure will be inspected 0every two*year4 bytheassigned civil inspector while electrical e(uipment will beinspected

0annually4 by the assigned electrical inspector.

)repare a detailed on*stream inspection report of the present condition

ofthe e(uipment highlighting the deficiencies observed that re(uire

repair oraction necessary to prevent further damage to the e(uipment and

issue

-FS or @! if re(uired.

'e(uest engineering evaluation if deemed necessary.

5pdate the SA-6 program

aintenan aintena -nclude providing the necessary manpower and e(uipment 0crane, man


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ce lift,

Activates ncescaffolding, etc4 to perform the re(uired inspection activities and rectifythe

!ngineer highlighted deficiencies.

For")ermit Area

-nclude providing the necessary wor" permit and initiating deviation letterto

operation postpone the #7-.

supervisor

#ocumentations:

3. Completed e/ternal chec" list survey

>. -nspection For"sheet highlighting the -nspection 'ecommendations

#he area inspector shall document the above documentations in !(uipment file and-nspection unit shared folder

- ,nspection o Sprin( Support:

Procedure1Pro(ram #escription:

-nspection re(uirement for spring supports for pipes and e(uipment during routine visual e/ternalinspection. -nspections of spring support are re(uired as per 11*SA-)*29. -nspection is re(uired

to e/amine all items related to Spring support such as G IH beam support, beam attachment pin,

hanger attachment, integrity of clamps, eye*bolts 7 hanger rod, spring coil 7 housing, Eot+cold

load positions mar"ed on tap plate, spring coil fully compressed, coating 7 galvani%ing, safety

hoo"s availability, davits 7 lifting lugs in good condition and spring identification. #est results are

reviewed and any defect found shall be sent to Area operation foreman to rectify.


11*SA-)*29 Visual e/ternal inspection procedure

$esponsibilities:


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-nspection )rojects -nspector Assure that all spring supports for new project are wor"ing

Activities during

construction

period

-nspection Area inspector -nclude the following:

Activities Carry visual e/ternal inspection on spring support every

two years. a"e sure all spring mechanism are wor"ing, all parts

are free of corrosion and free of any deficiency

-ssue recommendation for replacement as needed

For" )ermit Area operation -nclude providing the necessary wor" permit and inform

supervisor aintenance to start maintenance activities.

aintenance aintenance -nclude providing the necessary manpower and e(uipment

Activates #echnician 0crane, man lift, scaffolding, etc4 to perform the re(uired

inspection activities and rectify the highlighted deficiencies.

#ocumentations:

#he area inspector shall document the above documentations in:

3. !(uipment file

>. !(uipment file in the shared folder


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3- ,nspection O thermowell:


-nspection is carried out on all thermowell that can be dismantled during plant #7-. -nspectionof all thermowells is conducted as per standard drawing A*11*?3B -nstrument Specification Sheet * #hermowell

A*1

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-nspection Area inspector -nclude the following:

Activities -nspect all thermowells in vibrating services. #hermowells

longer than 2.9 inches re(uired more attention

)erform visual inspection thermowells for crac"s scratch

)erform 5# reading 7 )# on the thermowell during #7-

-ssue recommendation for replacement if re(uired.

For" )ermit Area operation -nclude providing the necessary wor" permit and inform

supervisor maintenance to start maintenance activities.

aintenance aintenance 'emove and re*install the thermowells which shall be mar"ed prior

Activates #echnician to removal. a"e sure they are return to the same locations.

#ocumentations:

@ist of all thermowells inspected during each #7-. #he area inspector shall file this documentation in:

3. !(uipment file


4- 5ydrostatic 'estin( or repaired

components Procedure1Pro(ram

#escription:

Eydrostatic testing of e(uipment and piping is conducted after completing major repair,renovation or alternation and replacement in "ind of e(uipment and piping as per theguideline given the following standards + procedures.


SA!S*A*11? eneral 'e(uirements for )ressure #esting

SA!S*@*391 )ressure #esting of )lant )iping and )ipelines

11*SA-)*1= )ressure #est 'e(uirements

-*111>.31> )ressure #esting Safely

AS!

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AS! oilers and )ressure Vessel Code

; >< ;ational oard of -nspection Code

$esponsibilities:

ActivitiesAssignedto 'emar"

-nspection Area -nclude the following:

Activities inspector 'e(uest and witness pressure testing for all e(uipments+lines which

undergo a repair or alteration that affect the e(uipments+lines

integrity. #he test shall be as per SA!S*@*391 and in accordance with

the fabrication code. As a guideline for boiler hydrotest during #7- or

repair wor", re(uest and witness pressure test as per boiler data

sheet. 6or major repair, the pressure test shall be 3.< J*$). -f no

repair was done, the test shall be up to the $). #his test is re(uired to

chec" tube integrity. 6or shell and tube heat e/changer, re(uest and

witness hydrotest for the shell and another hydrotest for the tubeafter each #7- and before the e/changer is turn to operation.

#hetests shall be as per e(uipment data sheet and fabrication code.

#est media shall be approved by standards. )neumatic test may be

subtitled if water cant be used provided that an approval from

inspection department and loss prevention is granted.

A hydrotest report shall be issued and filed in the e(uipment file for

each pressure test.

)roceduresAreaprocess )repare and distribute the hydrotest procedures to assist in

0hydrotest, engineer conducting the hydrotest in accordance with relevant companyshutdown, standard, or '$ internal proceduresstart*upetc4

For")ermit Area -nclude providing the necessary wor" permit and inform maintenance to


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operation start maintenance activities.supervisor

aintenance

aintenance

)rovide the necessary manpower and e(uipment to performthe

Activates engineer re(uired hydrotest. #he maintenance crew shall be aware of -

re(uirement and well trained to perform the hydrotest.

#ocumentations:)ressure test report for each pressure test which shall be filed in the:

3. !(uipment file


1. An !(uipment -nspection Schedule should beprepared for each group of e(uipments such as columns, drums, heat e/changers, boilers

and storage tan"s indicating the initial #7- and subse(uent #7- intervals. ased on the #7-

findings, the period for the ne/t #7- will be determined by '$ inspection unit and the !-Swill be updated if re(uired. '$ -nspection unit will initiate any revision to the approved !-S

and route it for approval. As re(uired by SA!)*>1, the revised !-S shall be approved by:

3. '$ -nspection 5nit supervisor

>. '$ !ngineering Superintendent

1 !(uipment -nspection Schedule

SA!)*

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)repare &riginal )# + -nspection )# shall prepare and route for approval the !-S for

!-S 5nit supervisor !(uipment built by )#. -nspection 5nit supervisor shall

prepare and route for approval the !-S 6or e(uipment built

by '$ maintenance.

aintaining the Area inspector -nclude filling the approved !-S, initiating any revision to the

!-S approved !-S and updating the SA-6 program.

#ocumentations:

#he Approved !-S shall be filed by the area inspector in:3. !(uipment file located in the -nspection filling room

>. 5pdate the SA-6 program if re(uired

Small 7ipple inspection pro(ram:



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#he small bore piping nipple inspection is intended to monitor the condition of in servicepiping nipple of si%e 3 K inches and smaller. -nternal + e/ternal corrosion and welding defectswill be monitored. !ach piping system will be categori%ed as per the corrosion severity andclassified as per the potential conse(uence on lea"s. ased on corrosion category and pipingclass, the inspection fre(uency will be fi/ed.

#he piping inspection fre(uency is determined from the ;ipple -nspection -ntervals atri/

provided in 13*SA-)*13. #he subse(uent nipple inspection will be adjusted based on the

inspection findings. -nspection fre(uency for injection points shall not e/ceed three years as

stipulated in 13*SA-)*1>.

'adiography testing 0'#4 will be the primary inspection method for the internal or e/ternalcorrosion of the nipple, for all services including cryogenic service. -f welding defects were foundduring the inspection, the acceptance criteria provided in 13*SA-)*13 shall be utili%ed. 5ltrasonic#hic"ness 05#4 inspection shall be utili%ed when '# is not conclusive. -n addition to radiography,# or )# should be used to inspect for crac"s in vibrating services or austenitic stainless steelwelds. Visual inspection should be performed on all pipe nipple systems to determine the needfor replacement or repairs due to e/ternal corrosion, threads not covered by seal weld, vibrationfatigue or possibility of overloading of the nipple.

#he nipple shall be replaced when the retirement thic"ness is reached. #he retirement thic"nessshall be the lower of the minimum thic"ness by code and the structural minimum thic"ness. -f theretirement thic"ness has not been reached but there is metal loss, the remaining life shall becalculated. #he nipple shall be replaced if the remaining life is less than either the ne/t inspectioninterval or the ne/t #7-. -f the piping system cannot be shut down for nipple replacement, temporaryrepair shall be considered until replacement in the ne/t schedule #7-.

#he nipple shall be replaced when the retirement thic"ness is reached. #he retirement thic"nessshall be the lower of the minimum thic"ness by code and the structural minimum thic"ness. -f theretirement thic"ness has not been reached but there is metal loss, the remaining life shall becalculated. #he nipple shall be replaced if the remaining life is less than either the ne/t inspectioninterval or the ne/t #7-. -f the piping system cannot be shut down for nipple replacement, temporaryrepair shall be considered until replacement in the ne/t schedule #7-.

All pipe nipples that have been identified as having incorrect metallurgy for the piping systemshould be removed and replaced regardless of the remaining wall thic"ness. All alloyreplacement nipples, valves and welds should be evaluated using an approved )ositiveaterial -dentification 0)-4 instrument before installation.


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;ipples which are not braced and subjected to vibration should be ade(uately braced perSA!S*@*1.>.< and Saudi Aramco Standard $rawing A*13 to prevent

future fatigue failure.


13*SA-)*13 Small ;ipple -nspection )rogram

SA!S*@*. ;$# 'eport


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4 shall be filed in the inspection unit filling room.

8- On-Stream inspection o e/uipment and pipin(:


Systematic monitoring program of piping, vessels and tan"s for general loss of wallthic"ness and locali%ed metal loss in critical processes is established and carried outas per the guidelines given in SA!)*33

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construction

Assign #@ locations as detailed in Appendi/ of SA!)*33

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+rocessEn#ineer

$etermine corrosion sectors from processflow diagrams.

Assign corrosion circuits from )7-$s.

!stimate corrosion rates for each piping

corrosion circuit.

Assign #@s to corrosion circuits so that

the (uantity and location will match thee/pected corrosion class.

'eview of corrosion rates greater than 9

mpy or e(uipment with remaining life less

than twice the &S- interval. 'eview of process changes for impact on

&S- )rogram and adjust the #@Ms orintervals as re(uired and determine-nspection interval based on the corrosionrate.

,SI

Coordinator )lanning and running of the &S- )rogram.

-ssue the re(uired &S- progress reports

and &S- #@ overdue reports to the unitsupervisor.

Coordinate for ;$# actions between the area

inspectors and the ;$# technicians.

-ssue report with for circuits where

corrosion rates greater than 9 mpy ore(uipment with remaining life less thantwice the &S- interval to the Corrosion!ngineer

Inspection

-ieldSuper!isor

Assure all plant static e(uipment is

monitored by &S- program.

'eview &S- data with the responsible

area inspector and advise accordingly. Assure &S- program data is being reviewed,

analy%ed, and added to the e(uipment per#7- reports.

Area

Inspector Conduct baseline survey to obtain original

wall thic"ness measurement of new,modified or previously unmonitorede(uipment.

&btain wall thic"ness measurement of the


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monitored plant e(uipment as per &S- duereports and prepare &S- isometric drawingsof added piping and e(uipment.

N./

/ec"nician perform the re(uired 5# reading for the

#@ and record thic"ness

Wor0 +ermit ,peration

Super!isor )rovide the re(uired For" )ermit

aintenance Acti!ities aintenanceEn#ineer

-nclude providing the necessary manpower ande(uipment 0crane, man lift, scaffolding, etc4 to

perform the re(uired inspection activities andrectify the highlighted deficiencies.

#ocumentations:3. &S- isometric drawings.

>. #@ readings.

#he &S- coordinator shall document the above documentations in SA-6 &S- module.

)*- #ead le( survey and monitorin( in plant areas:


$ead leg in the piping system is defined as the piping section where the flow is stagnant,

material has the potential for corrosion and when the length is longer than three times itspipe diameter, or 3.>> m 0? ft4 whichever is less. All dead legs shall be eliminated in the

design stage by modifying the piping system during project review. -f the deal legs cannot be

eliminated at piping system, then '$ inspection 5nit will monitor such dead legs throughthe &n* Stream -nspection 0&S-4 )rogram as per SA!)*33

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-n normal operation, if a piping configuration is suspected to be a dead leg, then the plantprocess engineer and '$ Corrosion engineer should be contacted to evaluate the case anddecide whether it is a dead leg or not. '$ has developed additional reference to help inevaluating the dead leg conditions 0@etter 8 N)*D>*1D4. -f this piping configuration wasconsidered as dead leg, then the following activates will be made:

* #he dead leg will be added to &S- program.

* #he dead leg will be monitored every year for five 094 years.

* After five 094 years of monitoring if no defect is found, then this dead leg can beremoved from &S- program.

* -f we found any metal loss even low corrosion rate, then the dead leg will be "ept in&S- program. -n addition, this dead leg should be targeted for elimination if possible.

Fhen pipe minimum thic"ness 0tm4 is reached, an inspection wor" sheet or logboo"entry shall be issued by area inspector to fi/ deficiency.

$e&erenced Standards1Procedures

SA!S*@*

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R$%&o"%iii'i$%*Activities Assigned to 'emar"

$esign )# 7 new Assure that dead legs are eliminated in the design stage by

Activities project design modifying the piping system during the project review.

reviewer

!ngineering Area process -dentify all lead legs in his plant.

Activities engineer

'$ corrosion )rovide technical assistance to clarify the dead leg criteria and

engineer the addition + removal of dead leg to the &S- program

-nspection '$ inspection -nclude the following:

Activities unit supervisor Eighlight any dead leg, during construction phase, to )# in

order to eliminate it if possible.

Assure that an inspection programs for inspecting dead legs is

established and all dead legs are being inspected and

monitored.

-ssue an -nspection For"sheet or logboo" entry is issued as

needed.

-nspection 6ield 6ield Supervisor shall be responsible for the following:

Supervisor Assure all dead legs are monitored by &S- program or any

other inspection methods.

'eview inspection data with the responsible area inspector

and advise accordingly.

Assure inspection data is being reviewed, analy%ed, and

added to SA-6.

Area inspector + Area inspector + &S- coordinator shall be responsible for the

&S- coordinator following:

!nsure all identified dead legs are monitored by the &n


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Stream -nspection 0&S-4 program as per SA!)*33. $ead leg wor"sheet or logboo" issued by area inspector.


3. !(uipment file


+13 dated >+>B+>113, all dummy legs in the plant, especiallyin hydrocarbon service will be surveyed by the area inspector and any deficiencies will bereported to area operations foreman for remedial action through -FS.


A@!'#*13*11> $eficiency of $ummy leg support elbows

$esponsibilities:


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-nspection Area inspector )erform the re(uired survey and highlight any deficiency to

Activities Area &peration foreman for implementation.

aintenance Area -nclude providing the necessary manpower and e(uipment

Activities aintenance 0crane, man lift, scaffolding, etc4 to perform the re(uired

engineer inspection activities and rectify the highlighted deficiencies.

#ocumentations:

3. $ummy legs survey for each plant.

>. $ummy legs wor"sheet or logboo" issued by area inspector.


3. !(uipment file


)2- Chemical ,njection Point ,nspection:


$ue to the ris" of process lea"s as a result of accelerated or locali%ed corrosion at or near chemical

injection points, an inspection program will be initiated to monitor each chemical injection points.

-njection points include those for injecting corrosion inhibitors, )E control, anti*foam and methanol.

,njection Circuits


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6or the purpose of monitoring, the -njection circuits shall begin at

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#he &S- coordinator shall document the above documentations in SA-6 &S- module

$esponsibilities:

Activities Assigned to 'emar"s

-nspection '$ #he -nspection 5nit Supervisor shall be responsible for:

Activities inspection Assigning inspectors+technicians to gauge pipe wall thic"ness at the

unitinjection point #hic"ness easurement @ocation 0#@4.

supervisor Approve repair, modification or replacement recommendations for the

injection points.

Assure that the &S- inspection program is implemented in '$ facilities.

&S- &n*Stream -nspection 0&S-4 coordinator shall be responsible for:

Coordinator #rac"ing and monitoring all injection points on the &S- drawings.

Eighlighting the areas that are approaching #*min or area of concerns to

the corrosion engineer, the area inspector, and the field supervisor.

Add or delete &S- circuits and update the inspection interval on the SA-6

)rogram as re(uested by corrosion engineer.

Coordinate between ;$# technician and area inspector to perform the

re(uired 5# readings and enter the readings in the SA-6 program

5pdate the &S- drawings.

Corrosion )lant corrosion engineer shall be responsible for:

!ngineer -dentifying all the injection points in the plant 0coordinate with the plant

process engineer in this tas"4.

'eviewing+recommending modifications or replacement of injection

points.

$etermine -nspection interval based on the corrosion rate

!valuate the need to add+delete #@ locations based on the corrosion rate

of the circuits

Coordinate with the area inspector to issue -FS if pipe spools re(uire


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replacement due to internal corrosion

Area )lant inspector shall be responsible for

inspector )erforming visual inspection as per 11*SA-)*29 guidelines.

Verifying the areas that are approaching #*min and issuing repair,

modification or replacement recommendations for review by the corrosion

engineer and the field supervisor and approval by the unit supervisor.

Assure that the &S- inspection program is implemented in his plant and

ma"e sure that all &S- readings are updated in the SA-6 program on

time0no &verdue4

;$# )lant inspector+technician shall be responsible for:

#echnician Verifying the line number and location before ta"ing the readings.

#a"ing the measurements as per the locations identified in this procedure.

'eporting any changes in the isometric drawing to the &S- coordinator.

For" &peration )rovide the re(uired For" )ermit

)ermit supervisor

aint. aintenance -nclude providing the necessary manpower and e(uipment 0crane, man lift,

Activities !ngineer scaffolding, etc4 to perform the re(uired inspection activities and rectify

the highlighted deficiencies.

)- Corrosion ;nder ,nsulation ,nspection and $epairs:


-nsulated e(uipment and piping systems which are susceptible to Corrosion 5nder-nsulation 0C5-4 at '$ shall be identified and chec"ed fre(uently through C5- )rogram.

-nspection fre(uency shall be as per SA!) >1. Susceptible systems shall be carefully

inspected visually. Visual inspection shall identify any sign of damaged insulation,

jac"eting or deviations. -t should be noted that C5- might ta"e place without any sign of it

on the e/ternal surface of the insulation. ;$# may be used in lieu of insulation removal.

ethod and e/tent of ;$# shall be approved by -nspection $epartment.


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Criteria or C;, pro(ram or pipin( systems:

-nsulated piping systems shall be included in C5- inspection program if any of the followingsconditions apply:

)iping systems made of carbon steel and operating temperature between >9P6 0*?PC4and >91P6 03>3PC4.

)iping systems made of carbon steel and operating temperature above >91P6 03>3PC4or below >9P6 0*?PC4 but in intermittent service.

)iping systems made of austenitic stainless steel and operate between 311P6 01?PC4.

)iping located in areas e/posed to mist overspray from cooling water towers.

)iping systems located in areas e/posed to steam vents.

)iping systems e/posed to deluge systems.

)iping systems subject to process spills, ingress of moistures or acid vapors.

$ead legs and protrusions from insulted piping that operates at different temperatures ofthe main line.

Steam traced piping systems that may e/perience tracing lea"s, especially at tubingfittings beneath the insulation.

)iping systems with deteriorated coating and wrapping, damaged insulation cladding, orinsulation that might be damaged by piping vibration.

C;, vulnerable Location or pipin( systems:

#he below specific locations in piping systems susceptible to C5- may be e/posed to C5-more than the rest of the piping systems.

All penetrations or breaches in the insulation jac"eting such as dead legs 0vents,

drains, instrument tapping and similar items4, pipe hangers and supports and steamtracing tubing penetrations.

-rregular insulation surfaces such as valves and fittings.

olted*on shoes.

#erminations of insulation at flanges and other piping components.

$amaged or missing insulation jac"eting or when the seams of the insulating jac"etingare located on the top of hori%ontal piping.


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#ermination of insulation in a vertical piping.

Caul"ing that has hardened, has separated or is missing.

ulges or staining of insulation or jac"eting.

@ow points in piping systems that have a "nown breach in the insulation system,including low points in long unsupported piping runs.

Carbon or low*alloy steel flanges, bolting and other components under insulation inhigh*alloy piping systems.

5# measurement windows in the insulation jac"eting.

C;, pro(ram or e/uipment:

-nsulated e(uipment shall be inspected for C5- if any of the following conditions apply:

!(uipment operating between >9P6 0*?PC4 and >91P6 03>3PC4.

!(uipment operating above >91P6 03>3PC4 or below >9P6 0*?PC4, but in intermittent operation.

!(uipment protected by deluge water system.

C5- Vulnerable @ocation for e(uipment:

Some locations of -nsulated vessels and tan"s that are susceptible for C5- may be

e/posed to C5- more than the rest of the e(uipment. !/amples of highly suspect areasinclude, but not limited to the following:

Stiffening rings and insulation support.

Areas around no%%les and man ways.

Areas around protrusions li"e lifting lungs and platforms supports.

Samples of the C5- Vulnerable of corrosion under insulation as described above and

locations of damaged insulation found through visual inspection of the system shall be

inspected by either ;$# or insulation removal. Quantities of inspection samples are as

shown in #able 3. )iping classification is per section =.> of A)-*921. All vessels andtan"s are to be classified as class 3


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'able)

R of locations found with damaged R of locations defined as susceptible

insulation to be inspected by ;$# or locations for C5- on this process to beClass insulation removal inspected by ;$# or insulation removal

3 29R 91R

> 91R

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$esponsibilities:


-nspection '$ inspection -nspection unit supervisor shall be responsible for following:

Activities unit supervisor Assure that an inspection programs for inspection C5- is

established and all susceptible systems for C5- are being

inspected and monitored.

-nspection 6ield Supervisor shall be responsible for the following:

6ield Assure all susceptible systems for C5- are monitored.Supervisor

'eview inspection data with the responsible area inspector and

advise accordingly.

Assure inspection data is being reviewed, analy%ed, and added

to SA-6.

Area inspector Area inspector shall be responsible for the following:

Assure that all identified susceptible systems for C5- are

monitored by the &n Stream -nspection 0&S-4 program as per

SA!)*33

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aintenance aintenance -nclude providing the necessary manpower and e(uipment 0crane,

Activates engineerman lift, scaffolding, etc4 to perform the re(uired maintenanceactivities.

#ocumentations:

3. @ist of Susceptible Systems for C5-.

>. C5- wor"sheet or logboo" issued by area inspector.


3. !(uipment file


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Activities Assigned 'emar"


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to

-nspection Activities '$ inspection -nclude assuring that inspection unit has a (ualified

unit supervisor inspector who can perform thermograph inspection

survey.

-nspection 6ield Assure all susceptiblesystems for damaged

Supervisor insulation are monitored.

'eview inspection data with the responsible

Qualified -nspector and area inspector and

advise accordingly. Assure inspection data is being reviewed,

analy%ed, and added to shared files and

e(uipment file.

'$ Qualified -nclude performing the #hermograph survey and

-nspector report any deficiency.

For" permit Area &peration -nclude providing the necessary wor" permit and

Supervisorinform maintenance to start maintenance activities.

aintenance Activates Area aintenance )rovide technical support as needed!ngineer

)rovide the necessary manpower, material and

e(uipment 0crane, man lift, scaffolding, etc4 to

perform the re(uired maintenance activities.

#ocumentations:

#hermograph inspection survey report. #he inspector shall document this report in:

3. !(uipment file


)3- Cathodic Protection System ,nspection


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'$ &peration+-nspection 5nit will conduct monthly and annually surveys to monitor the

cathodic protection 0C)4 systems as specified in SA!)*

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-n '$, there are two types of rectifiers oil cool and air cool rectifiers. &il cool rectifier isrepresented at $A and air cool rectifier at 5tilities. #hese rectifiers are re(uired two typesof inspection monthly and annually inspections.

onthly inspection:

!ither &perations or aintenance personnel who normally visit the site on a regular

basis for purposes other than those relating to cathodic protection can perform

these procedures.

Chec" rectifiers on a monthly basis and record the output volts and amps.

'ecord the rectifier output data on the attached data sheet.

'eport immediately any abnormal rectifier operation to the -nspection 5nit.

Annual inspection:

'ecord rectifier output volts and amps.

Verify the reading with a portable meter

Visually inspect the cabinet, terminals, and components for any damage.

. -f the oil is dar" or cloudy or appears to be full of suspended particles, it should bereplaced.

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- ?>B.11< Cathodic )rotection onitoring )rocedure

SA!S*J*=11 Cathodic )rotection of -n*)lant 6acilities

SA!)*

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-nspection '$ inspection -nspection unit supervisor shall be responsible for the following:

Activities unit supervisor Assure that an inspection programs for C) is established and being

inspected and monitored.

Area foreman Area foreman shall be responsible for the following:

!nsure that All C) systems are being chec"ed.

!nsure that C) system is in good operating condition.

-nform N) inspection unit for any abnormalities.

!lectrical !lectrical maintenance supervisor shall be responsible for the

maintenance following:

supervisor !nsure that All C) systems are being monthly chec"ed.

!nsure that all electrical technicians "now how to obtain the

rectifier $C Volt+Ampere output readings at the area under his

authority.

-nform '$ inspection unit for any abnormalities.

Area electrical Area electrical technician shall be responsible for the following:

technician Conduct the C) rectifier monthly chec" and record output data in

data sheet.

'eport any abnormal rectifier operation to '$ inspection unit.

6orward the rectifier output reading to '$inspection unit on a

monthly basis.

Area operator Area operator shall be responsible for the following:

'eport any abnormal rectifier operation to Area foreman.

-nspection 6ield Supervisor shall be responsible for the following:

6ield Assure all C) systems are monitored.


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Supervisor 'eview inspection data with the responsible electrical inspector

and advise accordingly.

Assure inspection data is being reviewed, analy%ed, and added to

shared files, e(uipment file and SA-6.

Area electrical Area electrical inspector shall be responsible for the following:

inspector Conduct the C) rectifier, junction bo/ and anode bed annually

survey and record output data in data sheets.

'eport any abnormality on the C) rectifier, junction bo/ and

anode bed.

For" )ermit Area operation Area operation supervisor shall be responsible for the following:

supervisor )rovide the necessary wor" permit and inform maintenance to

start maintenance activities.

!ngineering ,'$ corrosion 'eview monthly and annually reports and recommend solutions for

Activities engineer any abnormalities.

aintenance aintenance -nclude providing the necessary manpower and e(uipment 0crane,

Activates engineer man lift, scaffolding, etc4 to perform the re(uired maintenanceactivities.

4- onitorin( o Corrosion onitorin( system 0CS%


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)iping systems are generally subject to both internal and e/ternal corrosion. #he internalcorrosion is considered to be challenging as well as e/pensive in practice. -t has beenobserved that internal corrosion could potentially reduce the pipe wall thic"ness much morethan e/ternal corrosion. -n general, it becomes highly critical to mitigate internal corrosionand reduce the ris" of lea"age in piping system. 6or that, '$ has installed corrosionmonitoring system to monitor internal corrosion and corrosion inhibitor performance insidepiping systems. C&SASC& >T corrosion monitoring assemblies are the CSs, which areinstalled in '$. #his CS is designed to monitor corrosion behavior on line.

C&SASC& >T CS can be installed and retrieved by using the following e(uipments:

3* 'SA retrievers

>* Service valves

T corrosionmonitoring assemblies... safely, without shutdown. ut in order to complete retrieving orinstalling activities safely comply with the below re(uirements:

3* Safe operation re(uires a minimum of > trained operators.

>* $o not use retrieval e(uipment unless you have been trained in its safe operation.

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31* ;ote wind direction prior to starting operations involving ha%ardous products.


Corrosion onitoring &-7

)roject Specification for Corrosion onitoring System

$esponsibilities:


-nspection '$ inspection unit -nspection unit supervisor shall be responsible for the

Activities supervisor following:

Assure that an inspection programs for onitoring of CS

is established and all CSs are being inspected and

monitored.

!ngineering '$ corrosion engineer Corrosion engineer shall be responsible for the following:

Activities Conduct monthly survey through )- system.

'eview monthly and annually reports and recommend

solutions for any abnormalities.

-nform Area 6orman+operation supervisor if there is

any abnormalities or any materials replacement are

needed.

For" )ermit Area 6orman+operation -nclude )roviding the necessary wor" permit and inform

supervisor maintenance to start maintenance activities.

aintenance aintenance engineer -nclude providing the necessary manpower, material and

Activities e(uipment 0crane, man lift, scaffolding, etc4 to perform

the re(uired maintenance activities.

#ocumentations:

3* @ist of CSs at '$.


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>* CSs monthly status reports.

* !(uipment file in the shared folder

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-nspection '$ inspection Assure that the civil inspection program is implemented for all

Activities unit supervisor '$ electrical e(uipment.

civil -nspector )erform !/ternal civil -nspection on all industrial plant civil

structure and &peration Support 6acilities.

'eview maintenance wor" schedule and inspect the

performed civil wor" as needed.

'eport immediately to &perations foreman all deficiencies

which are found during the civil inspection survey through

@og boo" entry or -nspection wor"sheets as needed.

6ollow up with the area maintenance engineer to rectify

these deficiencies.

aintenance Area maintenance 'ectify the reported deficiencies in his area.

Activities engineer

For" )ermit Area operation provide the necessary wor" permit 0as needed4

supervisor

#ocumentations:

3. -ssued civil inspection chec"list

>. -nspection wor"sheets or @og oo" !ntry if needed.

* -nspection unit file room

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Visual civil inspection of plant buildings such as &!, )-, Substations, @ift stations etc shall beconducted as per guidelines given in the civil section of !-S and the below engineeringprocedure.

A concrete database is being created and will be uploaded in the SA-6 system. #he databasewill contain all the e(uipment and piping foundations, footing and sleepers and all fireproofingin the plant. #he concrete foundations will be classified as per the grading given in SA!)*

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-nspection Activities Civil -nspector )erform the e/ternal civil inspection as per the

inspection schedule.

)erform internal inspection for the lift stations

during scheduled #7- or as per operation

re(uest.

For" )ermit Area operation supervisor -nclude providing the necessary wor" permit

and inform maintenance to start maintenance

activities.

aintenance aintenance engineer -nclude providing the necessary manpower and

Activates e(uipment 0crane, man lift, scaffolding, etc4 to

perform the re(uired maintenance activities.

#ocumentations:

3. Civil -nspection 'eport which shall be filed in the inspection filling room and the shared folder

>. 5pdate the SA-6 program.

)8- Concrete ireprooin( and proprietary ire prooin( survey:


6ireproofing on static e(uipment and piping systems shall be considered as insulation.!(uipment furnished with fireproofing shall be inspected for corrosion under fireproofing.

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shall be given more attention during inspection. Any crac" in the fireproofing shall beevaluated to find out if it is indicating any sign of corrosion. -nspection windows might bemade to verify any e/ternal sign of corrosion under fireproofing. -f corrosion is found thenthe fireproofing shall be removed to e/pose all corroded area.

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An annual e/ternal inspection for all electrical e(uipment should be conducted anddeficiencies shall be reported for area operation foreman to rectify. #he internal

inspection of plant e(uipment shall be made as re(uired at installation, upon re(uest

or during scheduled test and inspections 0#7-s4. #he e/ternal inspection of the below

electrical e(uipment in the plant shall be conducted annually:

Conduit systems, cable trays and cable systems for support and continuity.

!nclosures and junction bo/ for covers, conduit seals and drains.

!lectrical !(uipment such as motors for physical damage, oil lea"s, and

overheating.

-ntegrity of the ground grid system and e(uipment grounds.

#he following inspections of all &perations Support 6acilities 0&!, )-,substation, etc4 shall be conducted annually:

!mergency , !/it lighting, !mergency generators and transfer switches

@ighting, @ighting Systems, Fall $evices and $istribution )anels

#ransformers and Switch rac"s

Iunction o/ !nclosures, Cable and Conduit systems

Substations e(uipment

anholes+$uct an"s attery 'ooms and round System


11*SA-)*93 !lectrical -nspection


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39*SA-)*91 -nspection )rocedure for Conduits and Cable seals

39*SA-)*93 -nspection )rocedure for )VC Coated 'igid Steel Conduit

3=*SA-)*33 edium and Eigh Voltage &il Switches

SA!)*3< @ighting

SA!S*)*3>= )ower onitoring and Control System

http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=23&sm=SAES-P-101http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=25&sm=SAES-P-103http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-104http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-107http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-111http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=24&sm=SAES-P-113http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-114http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=23&sm=SAES-P-116http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=23&sm=SAES-P-119http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=23&sm=SAES-P-121http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-123http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-126http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-126http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=25&sm=SAES-P-103http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-104http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-107http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-111http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=24&sm=SAES-P-113http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-114http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=23&sm=SAES-P-116http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=23&sm=SAES-P-119http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=23&sm=SAES-P-121http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-123http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-126http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=22&sm=SAES-P-126http://standards.aramco.com.sa/classic.asp?fol=Saes&cat=0&committee_id=23&sm=SAES-P-101

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$esponsibilities:


-nspection '$ inspection unit 3. Assure that the electrical inspection program is

Activities supervisor implemented for all '$ electrical e(uipment.

!lectrical -nspector >. )erform !/ternal !lectrical -nspection on all

industrial plant electrical e(uipment and &peration

Support 6acilities.

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#echnical Area !lectrical !ngineer )rovide technical support as needed to clarify the

support related standards and to rectify deficiencies

#ocumentations:3* -ssued electrical inspection chec"list

>* -nspection wor"sheets or @og oo" !ntry if needed.

* -nspection unit file room

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$esponsibilities:


-nspection !lectrical -nspector )erforming the #hermography survey and report any

Activities deficiency to the plant foreman. #he inspector

should follow up on rectifying the deficiency by

issuing an -nspection wor"sheet or @og oo" !ntry

item. 5p on completion the inspector should close

the related -FS.

aintenance Area aintenance -nclude providing the necessary manpower and

Activities engineer e(uipment to rectify the deficiency.

For" )ermit Area operation -nclude providing the necessary wor" permit

supervisor

#echnical support Area !lectrical )rovide technical support as needed to clarify

!ngineer the related standards and to rectify deficiencies

#ocumentations:

3* -nfrared camera report

>* -nspection For" Sheet or @og oo" !ntry if needed

#he inspector shall file the above documentations in:

3* Shared folder


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>* -nspection unit file room

oo9 !ntry

'efer to SS 8 9.2

2- 'echnical Alerts 'rac9in( System:


#echnical alerts trac"ing system is implemented as per the guidelines indicated in SA-)*22.#his system should be established to trac" all the technical alerts that are published by S.

Aramco. '$ technical alerts coordinator should assign the alerts to the right team0electrical, mechanical, instrument ...4 to evaluate them and ta"e the re(uired action.


SA-)*22 #echnical Alert -mplementation and #rac"ing )rogram

#echnical Alerts !ngineering Services #echnical Alerts

$esponsibilities:


!stablish technical '$ technical alerts #he system should be implemented according

alerts trac"ing system coordinator + -nspection to SA-)*22

5nit supervisor


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#rac" and update the '$ technical alerts Any new technical alert should be trac"ed.

engineering Services coordinator

#echnical Alerts

!valuate the technical #he assigned team+ unit echanical, electrical, relief valve, piping,

alerts and perform the leader EVAC and instrument.

right action

#ocumentations:

#he technical alerts coordinator shall document the evaluation and action from the assigned team.

N) technical alerts trac"ing system available in the N) shared folder

2- Positive aterial ,dentiication o e"istin( and new material:


-n order to ma"e sure that the material used in fabricating pressure vessels and components,valves are of genuine materials, )ositive material identification tests should be conducted onall new alloy steel materials for new construction, repair and replacement in accordance withthe following !ngineering Standards and inspection procedures.


SA!S*A*>1= )ositive aterial -dentification 11*SA-)*12 )ositive aterial -dentification re(uirements


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$esponsibilities:


-nspection '$ inspection unit Assure that a )- program is developed and implemented

Activities supervisor based on 11*SA-)*12.

'$ Area -nspector -nclude the following:

)erform )- testing.

Verify elements as per table 3 in SA!S*A*>1=.

-nform Area 6orman+operation supervisor if there is any

abnormalities or any materials replacement are needed.

For" )ermit Area -nclude )roviding the necessary wor" permit and inform

6orman+operation maintenance to start maintenance activities.

supervisor

aintenance aintenance engineer -nclude providing the necessary manpower, material and

Activities e(uipment 0crane, man lift, scaffolding, etc4 to perform the

re(uired maintenance activities.

#ocumentations:

3* aterial data sheet.

>* &utput results of reading.



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3* !(uipment file

>* !(uipment file in the shared folder

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